Ms-Dd-3000-Str-Spe-0001 - rev1-SPECIFICATION FOR FABRICATION

Date : Oct.
13, 2021 CONSTRUCTION SPECIFICATION FOR MS-DD-3000-STR-SPE-0001

FABRICATION AND ERECTION OF STEEL
Rev. : 1 STRUCTURE Page：1 of 48
CONSTRUCTION SPECIFICATION FOR

FABRICATION AND ERECTION OF STEEL STRUCTURE
OWNER: PT. FREEPORT INDONESIA
MANYAR SMELTER PROJECT
PT CHIYODA INTERNATIONAL INDONESIA
1 Issued for Construction Oct. 13, 2021 R.Miguel T.Suzuki T.Moritsuna

0 Issued for Construction Apr. 20, 2021 R.Miguel T.Suzuki T.Okamoto
E Issued for Owner Approval Feb. 26, 2021 R.Miguel S.Okazaki T.Okamoto
Issued for Detailed Engineering
D Feb.16, 2021 R.Miguel S.Okazaki T.Okamoto
(ADE Final)
Rev. Description Date Prepared Reviewed Approved
ALL RIGHTS RESERVED

THIS DOCUMENT WAS PREPARED FOR THE EXCLUSIVE USE OF PT FREEPORT INDONESIA (PTFI) AND CHIYODA GROUP PURSUANT TO THE ENGINEERING,
PROCUREMENT AND CONSTRUCTION AGREEMENT BETWEEN PTFI AND PT CHIYODA INTERNATIONAL INDONESIA. THIS DOCUMENT IS THE PROPERTY OF PTFI,
AND THIS DOCUMENT, DATA AND INFORMATION MAY BE DISCLOSED TO THIRD PARTIES ONLY FOR THE MANYAR SMELTER PROJECT. CHIYODA GROUP SHALL
NOT BE LIABLE FOR USE OR RELIANCE ON THIS DRAWING BY ANY THIRD PARTY NOT UNDER THE DIRECTION OF CHIYODA GROUP, UNLESS OTHERWISE AGREED
IN WRITING.
Date : Oct.13, 2021 CONSTRUCTION SPECIFICATION FOR MS-DD-3000-STR-SPE-0001
Codes and Standard .............................................................................................................5

Project Specification ..............................................................................................................7
Cutting .................................................................................................................................14
Bending ...............................................................................................................................14
Bolt Holes ............................................................................................................................14
General ................................................................................................................................16
Tightening of Bolts...............................................................................................................17
Bolt Length ..........................................................................................................................19

Handling ..............................................................................................................................19
Spare bolt quantity ..............................................................................................................20
General ................................................................................................................................20
Preparation of Base Metal ..................................................................................................21
Assembly .............................................................................................................................21
Welding Consumables ........................................................................................................22
Welding of Attachments and Appurtenances .....................................................................22
Preheat and Inter-pass Temperature..................................................................................23
Welding Procedure ..............................................................................................................24
ALL RIGHTS RESERVED

IN WRITING.
Inspection Tolerances and Corrections for Welding...........................................................26
Non-Destructive Examinations ............................................................................................33
Inspections ..........................................................................................................................35
Tolerances ...........................................................................................................................36
Quality Records ...................................................................................................................41
ALL RIGHTS RESERVED

IN WRITING.
Scope
This specification covers the minimum requirement for materials, supply, detailing,
fabrication, coating, handling, delivery, inspection, testing and site erection of the steel
structures in Manyar Smelter Project
DEFINITION OF TERMS
For the terms used in this specification, the following definitions shall be applied.
PROJECT: Manyar Smelter Project
OWNER: PT Freeport Indonesia (PTFI)
CONTRACTOR: Chiyoda Corporation
FABRICATOR: A successful bidder of the work who receives Purchase Order to
perform all of the obligations under the conditions in the
Purchase Order contract document.
SUBCONTRACTOR: A successful bidder of the work who signs a contract to perform
all of the obligations under the conditions contained in the
contract documents
LANGUAGE
All documents required for submission to the CONTRACTOR shall be in the English
language. This shall include drawings, quality plans, inspection and test plans, test
reports and traceability records, certification and all required records. Translation of
documentation from any other language to English is the responsibility of the Fabricator
and Subcontractor.
STATUTORY REQUIREMENTS
All structural steelwork must comply with the requirements of the relevant local and
national statutory acts, regulations and authorities’ directions.
ALL RIGHTS RESERVED

IN WRITING.
REFERENCES
The requirements contained in the latest editions, as at the date of 4 November 2018,
of the following publications shall form a part of this specification, in the manner and to
the extent indicated herein:
The order of precedence for selecting the minimum design requirements shall be as
follows:
(1) This Specification
(2) Applicable Laws and Regulations
(3) Applicable Local Code and Standards
(4) Owner Specifications
(5) International codes and standards adopted for the project listed hereunder
(6) Vendor standards
(7) Other international codes and standards as required
In the event the design requirements are not consistent, the precedence described above
shall be taken. In case there is deviation to the above precedence, Contractor shall
propose a solution for Owner’s agreement.
Codes and Standard
(1) AWS D1.1 Structural Welding Code - Steel
(2) AISC 360-16 Specification for Structural Steel Buildings
(3) AISC 303 Code of Standard Practice for Steel Buildings and Bridges.
(4) RCSC Specification for Structural Joints Using High-Strength Bolts.
(5) ASTM A36M Standard Specification for Carbon Structural Steel

Note
For Structure steel material, approved JIS material equivalent
to above ASTM list is applicable.
(6) ASTM A53M Standard Specification for Pipe, Steel, Black and Hot-Dipped,
Zinc-Coated, Welded and Seamless
ALL RIGHTS RESERVED

IN WRITING.
(7) ASTM A123M Standard Specification for Zinc (Hot-Dip Galvanized) Coatings
on Iron and Steel Products
(8) ASTM A283M Standard Specification for Low and Intermediate Tensile
Strength Carbon Steel Plates
(9) ASTM A307 Standard Specification for Carbon Steel Bolts, Studs and
Threaded Rod 60000 PSI Tensile Strength
(10) ASTM A325M Standard Specification for Structural Bolts, Steel, Heat Treated,
830 MPa Minimum Tensile Strength
(11) ASTM A563M Standard Specification for Carbon and Alloy Steel Nuts
(12) ASTM A569M Standard Specification for Steel Carbon, Hot-Rolled Sheet and
Strip Commercial
(13) ASTM F436M Standard Specification for Hardened Steel Washers
(14) ASTM F1554 Standard Specification for Anchor Bolts, Steel, 36, 55 and 105-
ksi Yield Strength
(15) ASTM A786 Standard Specification for Hot-Rolled Carbon, Low-Alloy, High-
Strength Low-Alloy, and Alloy Steel Floor Plates.
(16) ASTM A1011 Standard Specification for Steel, Sheet and Strip, Hot-Rolled,
Carbon, Structural, High Strength Low-Alloy, High-Strength with
Improved Formability, and Ultra-High Strength.
(17) ASTM D638 Standard Test Method for Tensile Properties of Plastics.
(18) ASTM A653 Standard Specification for Steel Sheet, Zinc-Coated

(Galvanized) or Zinc-Iron Alloy-Coated (Gal annealed) by the
Hot-Dip Process.
(19) ASTM F959 Standard Specification for Compressible-Washer-Type Direct

Tension Indicators for use with Structural Fasteners, Inch and
Metric Series.
(20) ASTM A792 Standard Specification for Steel Sheet 55% Aluminum-Zinc
Alloy-Coated by the Hot-Dip Process.
(21) AS 1397 Steel sheet and strip—Hot-dip zinc-coated or aluminum/zinc-

coated.
ALL RIGHTS RESERVED

IN WRITING.
(22) AS/NZS 2728 Prefinished/pre-painted sheet metal products for

interior/exterior building applications-performance
requirements.
(23) ASTM D3841 Standard Specification for Glass-Fiber-Reinforced Polyester

Plastic Panels.
(24) JIS G3192 Dimensions, mass and permissible variations of hot rolled steel
sections.
(25) JIS G3101 SS400 Rolled steel for general structure.
Project Specification
(1) MS-DD-3000-CIV-SPE-0001 General Specification for Foundation and Structure Design
(2) MS-DD-3000-CIV-SPE-0104 Construction Specification for Concrete Work
(3) MS-DD-3000-MEC-SPE-0801 General Specification for Painting
(4) MS-DD-3000-PJC-PRO-0901 As-Built Documentation Procedure
(5) MS-DD-3000-PJC-PRO-0013 Technical Deviation Procedure
(6) MS-DD-3000-QUA-PRO-0201 Quality Control Requirements to Subcontractor
(7) MS-DD-3000-QUA-PRO-0006 Non-conformity Management Procedure for Vendor
(8) MS-DD-3000-QUA-PRO-0007 Non-conformity Management Procedure for Site Work
(9) MS-DD-3000-QUA-PRO-0001 Instruction to Vendor for Shop Inspection.
(10) MS-DD-3000-ACT-SPE-0002 Construction Specification for Architecture Material.
Where Fabricator or Subcontractor discovers a discrepancy between two documents that

will affect the fabrication or construction, a technical query shall be raised with the
CONTRACTOR.
All requirements defined in this Specification and the relevant standards are mandatory
and minimum standards, unless a formal request for technical concession has been
submitted by the Subcontractor and accepted by the Contractor and Owner.
ALL RIGHTS RESERVED

IN WRITING.
Substitutions of any kind or variations of details as shown on the drawings shall not be
made without the prior approval of the Contractor and Owner. Such approval shall be
obtained prior to execution of the proposed change.
SUBCONTRACTOR RESPONSIBILITIES
(1) It is the Subcontractors responsibility to advise the Contractor in writing of any

requirements of this specification which are of a lower standard than the local Standards,
industry practice and/or Subcontractor’s standard practice.
(2) A copy of this Specification shall be retained by the Subcontractor at the necessary
locations and shall have been read and understood by the Subcontractor’s Management
and Supervisory personnel.
(3) The Subcontractor shall be responsible for ensuring that all materials, fabrication and
erection comply with the requirements of the relevant Standards and the Specifications.
SUBCONTRACTOR PROVIDED DESIGN
(1) Sub-contractor provided design shall comply with MS-DD-3000-CIV-SPE-0001.
(2) The Subcontractor shall only use engineering drawings for fabrication/erection/site works
that have been signed “Approved for Construction” by CONTRACTOR.
(3) The Subcontractor shall prepare Shop and/or Site Drawings incorporating information
including applied standards, fabrication descriptions, dimensions, sizes, tolerances, details
for bolted connections, material take off lists, weld joint preparations and weld
details/symbols etc., for all structural and auxiliary items.
(4) Field welds shall be clearly indicated and appropriately situated to facilitate the least
amount of field welding required.
(5) The Subcontractor shall provide drawings and calculations for all relevant temporary works
including supports, jacking and lifting points, and key erection methods.
ALL RIGHTS RESERVED

IN WRITING.
MATERIALS
(1) All materials shall be new, free from any defects including pitting, flaws and cracks and
have a smooth uniform finish with no loose rust or scale present.
(2) The Subcontractor shall provide materials for welding and fabrication works as per the
Scope of Work.
(3) Structural steel materials used for fabricating steel structure shall conform to the
requirements of ASTM A36 grade 250MPa, A572M Grade 50 (350MPa) or approved JIS
equivalent, unless otherwise approved by CONTRACTOR and OWNER.
(4) Steel materials shall be as specified on drawings, unless a material substitution process
has been approved by the CONTRACTOR.
(5) FABRICATOR shall submit material certificates or mill test reports, for all structural steel
used, except for non-structural members and minor shapes and sections, such as
handrails, ladders, floor panels, stairs, guard posts e.g. Material certificates shall comply
with the ASTM Certificate. All test certificates (i.e. originals and copies) shall be in the
English language and/or supplied with a supporting English translation.
(6) Steels for plates greater than 50 mm thickness shall be fully killed.
(7) Where dissimilar metals come into contact, isolation shall be maintained in accordance with
manufacturer’s specifications. A Polytetrafluoroethylene (TEFLON)
plate/gasket/washer/tape e.g. as applicable can be provided between dissimilar metals to
avoid direct contact. This isolation method shall not be applied between structural
connections plates, High-strength bolts (HSB) or any part joined where the reduction of
friction between metals may impair the strength of the connection without CONTRACTOR
approval.
(8) High-strength bolts conforming to ASTM A325M or equivalent shall be used for connecting
all structural members. Structural bolt conforming to ASTM A307 or equivalent can be used
for connecting specific secondary steel members like girts and purlins and for tertiary steel
like handrails, ladders. All bolts shall have metric thread. Designation of Primary,
ALL RIGHTS RESERVED

IN WRITING.
Secondary and Tertiary Steel shall be in accordance with the Appendix-1 of this
specification.
(9) Washer conforming to ASTM F436M or equivalent. Heavy hex nuts conforming to ASTM
A563M or equivalent.
(10) The minimum bolt diameter for high-strength bolt (HSB) and ordinary strength bolt (OSB)
shall be M16 and M12 respectively. Compliance certificates shall be obtained by the
Fabricator or Subcontractor and kept in traceability records. Certification shall be required
for each batch (diameter and length) of bolts.
(11) Checkered floor plate shall be conforming to ASTM A786, A36. Pattern 4 or 5
(12) Steel grating shall be conforming to ASTM A1011, CS Type B Grade 36
(13) Steel tubes for hand rails shall be conforming to ASTM A53, Type E, Grade B
(14) FRP grating shall be WEBFORGE TYPE G386VGY or equivalent approved
(15) Steel cladding for walls and roofing shall be Lysanght Vendor or equivalent approved as
follows:
• Galvanized and pre-painted Cladding, Spandek (tentative) with Coating COLORBOND Ultra
(pre-painted steel) for Walls of all buildings except as listed below.
• Galvanized and Fluoride coated Cladding, Spandek (tentative) with Coating COLORBOND
XAL or XPD for Roofs of all buildings, Walls of the Smelting process area; Converting
furnace; Anode furnace/anode casting; Jetty/Wharf buildings.
(16) Cladding (walls) for Refinery Tank House shall be GFRP as specified in the Construction
Specification for Architecture Material MS-DD-3000-ACT-SPE-0002.
(17) Translucent Sheeting shall be 1.5mm thick Fiber Reinforced Plastic (FRP) to the same
profile as the adjacent metal sheeting material and comply with ASTM D3841 with a
diffused light transmission of 70%. 25 years for design life is required.
(18) Steel purlin & girts shall be cold formed Z and C sections in accordance with ASTM A1011
Grade 50, Class I for primer or ASTM A653 Grade SS50, Class I for galvanized or G350
ALL RIGHTS RESERVED

IN WRITING.
grade galvanized steel complying with AS1397 or equivalent approved. Painting system
shall be as specified in the General Notes for Steel MS-DD-3000-STR-STA-0001.
(19) Purlin & girts for Refinery Tank House shall be GFRP as specified in the Construction
Specification for Architecture Material MS-DD-3000-ACT-SPE-0002.
(20) Welding electrodes shall be low hydrogen with 480MPa (70ksi) minimum tensile strength
conform to AWS A5.1 or equivalent approved
(21) Shear studs shall conform AWS D1.1 Type B (350MPa minimum yield strength and
450MPa minimum tensile strength) or equivalent approved.
(22) Handrail Elbows material and dimensions shall conform to ASME B16.9 or equivalent.
(23) Hot dip galvanized stair treads 25/32mm thickness as specified in the drawings shall
conform to ASTM A1011 or equivalent approved. Anti-slip stair nosing WEBFORGE
Webgrip or equivalent approved.
(24) Steel checkered plate stair treads shall be 6mm UNO and same pattern of floor plate
conform to ASTM A786, A283, and A36.
(25) Chemical Anchor Bolts shall be HILTI HIT-RE-500 INJECTION WITH HAS-E rod or
equivalent approved.
(26) Shims plates shall be flat and made from steel conform to ASTM A36. Minimum shim
thickness shall be 1.0mm and prepare in a set to stack multiple shims to achieve the
desired thickness as specified in the drawings or contractual documents.
(27) For cast-in anchor bolts material and grout refer to General Specification for Foundation
and Structure MS-DD-3000-CIV-SPE-001 and Construction Specification for Concrete
Work MS-DD-3000-CIV-SPE-0104.
Stainless steel structural components, aluminum floor plate and aluminum structural
extrusions are not anticipated to be used on the project and are not covered in the current
specification.
Material traceability for structural steel is covered by the Instruction to Vendor for Shop
Inspection (MS-DD-3000-QUA-PRO-0001).
ALL RIGHTS RESERVED

IN WRITING.
SHOP DETAILING
(1) Shop drawings for the structural steelwork shall be prepared by Fabricator, showing the
relevant details of each assembly, component and connection, together with information
relative to fabrication, surface treatment and erection, including the following:
 Identification and numbers

 Steel type and grade
 Dimensions of items and tolerances
 Required camber, where applicable
 Fabrication methods including, where applicable, hot or cold forming and post weld
heat treatment
 Location, type and size of welds or bolts, including weld rods and preparation
 Weld categories and bolting categories
 Orientation of members
 Location of temporary connections
 Surface preparation methods and coating system
 Procedures necessary for shop and site assembly, including galvanizing
requirements
 Lifting and support points for handling and transport
 Temporary bracing, if required for handling and transport
 Required fixings for adjoining building elements
 Procedures for erection including temporary bracing
 Identification of approved shop splices
(2) Where rolled sections are to be substituted by welded fabricated sections, acceptance by
the CONTRACTOR shall be obtained.
(3) FABRICATOR shall prepare their shop drawings in according with CONTRACTOR’s
engineering drawings, and shall submit them progressively during the course of the works to
CONTRACTOR for review. Submission of 3D model is required with 2D set of drawings in
PDF format e-file. A bill of quantity listing all materials and fittings used in the fabrication
shall be shown on each related shop fabrication drawing. Shop drawings shall be
accompanied by marking plans showing the position of individual steel members and
components.
(4) Shop drawings shall be submitted and reviewed by the Contractor prior to fabrication.
CONTRACTOR will review shop engineering data and documents developed by
ALL RIGHTS RESERVED

IN WRITING.
FABRICATOR only to check that design intention is properly reflected. These shall be
issued for review not less than two weeks prior to commencement of fabrication unless
otherwise specified in the Contract.
(5) When the surface of the bolt head or nut or the surface of the steel forms with inclination of
1:20 or more, using of tapered washers shall be indicated in the shop fabrication drawings.
(6) FABRICATOR shall furnish the drawings for field erection and installation work.
(a) Identification mark in the assembly drawings shall be the same with that shown on the
marking plans. For details of the identification marks, refer to Section 15.
(b) Quantities, diameters and lengths of permanent bolts and other fasteners shall be
indicated.
(c) A detailed specification for field welding shall be furnished.
GENERAL PREPARATION
(1) Steel materials delivered to the shop shall be placed on wooden sleepers so that the steel is
not in direct contact with ground.
(2) Precautions shall be taken during fabrication so that excessive stress is not induced in any
part of the work.
(3) Prior to marking, deformed material shall be rectified without affecting the mechanical
properties of the material. Deformations shall be rectified either by a mechanical method, or
by limited local heating of the deformed material to not higher than 650 degree Celsius and
reforming it.
(4) All fabrication operations, including welding, shall be carried out and completed where
practicable in covered fabrication workshops.
ALL RIGHTS RESERVED

IN WRITING.
CUTTING, BENDING AND BOLT HOLES
Cutting
(1) The minimum length of a section adjacent to a splice weld shall be not less than six (6)
times the depth of the section, or 1000 mm (whichever is the lesser), unless approved by
the CONTRACTOR.
(2) Steel material may be cut by either a mechanical method, such as sawing, shearing, or
grinding, or by thermal method, such as automatic gas cutting or plasma cutting or by a
combination of the two methods.
(3) Deformations and burrs resulting from cutting work shall be corrected and ground smooth
with the surrounding material.
(4) After cutting, all edges shall have a smooth, even and true profile.
(5) Sheared edges to be included in welded joints shall be ground free of sharp edges.
Bending
(1) Steel materials shall be bent at ambient temperature or by limited local heating of the
material to not higher than 650 degree Celsius.
(2) Bending, where possible, shall be transverse as to the direction of rolling material
manufacture.
(3) Bending of plates or material shall not cause cracks, rips or tears to the material.
(4) Bend radii shall be in accordance with the relevant standard or material manufacturer's
specifications.
Bolt Holes
(1) Bolt holes shall be drilled or punched. Burrs around the holes shall be removed by
grinding to achieve a smooth and even surface.
(2) Holes in steel plates over 12mm thick shall be drilled.
ALL RIGHTS RESERVED

IN WRITING.
(3) Bolt holes shall be formed to the tolerance as shown in Figure-1.
(4) Diameter of standard holes for bolts (other than for anchor bolts) shall be as per AISC
360, section J3.2.
(5) Diameter of holes for anchor bolts shall be as specified in the engineering drawings.
Hardened washers conforming to ASTM F436 Type-1 and included in the anchor bolt set
can be used for oversized holes conforming to AISC Table J3.3M. Square, rectangular or
round plate washer furnished from ASTM A36 plate for larger oversized holes shall be as
specified in the engineering drawings. Plate washers where specified in the engineering
drawings shall be supplied by FABRICATOR.
(6) Holes in base plates for anchor bolts to footings shall be as shown on the Drawings and
may be flame cut, subject to approval by the CONTRACTOR.
(7) Where slotted holes are specified or shown, such holes shall be accurately shaped with
sides smooth and parallel.
(8) Holes may be punched to at least 3 mm undersized and then reamed to full size. If holes
are punched in steel, which is to be galvanized, the holes shall be punched at least to 3
mm undersized and shall be reamed to full size.
Figure-1
BOLT HOLE TOLERANCES
Spacing Misalignment
±2
mm
±2
mm C
C ≤ 1 mm : Acceptable
1 mm < C ≤ 2 mm : To be adjusted with Reamer
2 mm < C : To be rejected
ALL RIGHTS RESERVED

IN WRITING.
HIGH-STRENGTH BOLT
General
(1) All bolts shall be hot dip galvanized and additionally painted within the Acid Plant (Gas
Cleaning Area), Refinery, Jetty and specific structures within the ETP identified in the
design drawings. Refer to the General Notes for Steel MS-DD-3000-STR-STA-0001. Zinc
plated bolts are not acceptable.
(2) A tension calibrator shall be used where bolts are to be installed in pretensioned joints
and slip-critical joint to confirm the conditions described in the section 7.1 of the
Specification for Structural Joints Using High-Strength Bolts (RCSC). As well as a
required testing of a representative sample shall be conducted in accordance with the
section 7.2 of the above specification.
(3) Installation method for Snug-Tightened Joints shall be in accordance with the section 8.1
of the Specification for Structural Joints Using High-Strength Bolts (RCSC).
(4) Installation method for pretensioned joints and slip-critical joints shall be in accordance
with the Specification for Structural Joints Using High-Strength Bolts (RCSC) section 8.2.2
where the Calibrated Wrench method is applied or section 8.2.4 where the Direct-
Tension-Indicator (DTI) method is applied.
(5) Bolts classes shall be as specified in the design drawings. Unless specified otherwise, all
bolted joints should be made using high strength bolts, nuts and washers. The use of 12
or 16 mm diameter high tensile nuts and bolts is permitted for fastening cold formed purlin
and girt members. Shouldered high tensile girt bolts are acceptable if minimum diameter
at 12 mm is maintained. These bolts are to be galvanized.
(6) High-strength bolts shall be carefully selected for grade, size, and length in accordance
with instructions on the erection drawings or identification mark lists prepared by the
FABRICATOR.
ALL RIGHTS RESERVED

IN WRITING.
(7) Each bolted connection shall contain at least two (2) bolts, unless stated otherwise on the
drawings.
(8) At least one washer shall be placed under the bolt head or nut.
(9) Bolted parts shall solidly seat together across the whole faying surface when assembled
and shall not be separated by gaskets or any other compressible material. When
assembled, all joint surfaces, including those adjacent to the bolt heads, nuts and
washers shall be free of scale, burrs, dirt, drilling or cutting lubricant and other foreign
material that will prevent solid seating of the parts. Contact surfaces shall be free of oil,
paint (except primer coat), lacquer or rust inhibitor.
(10) After erected structural steel work has been aligned and inspected, the erection
SUBCONTRACTOR shall start the tightening high-strength bolting.
(11) When bolts, nuts, and washers are handled during transporting, storing or for other
purpose, threads and coated surfaces shall be properly protected. Bolts, nuts, and
washers shall be kept free from dust, moisture, contamination, and rusting.
(12) When the bolt holes in connecting steel components are misaligned by 1 mm or more, a
reamer shall be used to make the holes match. Refer to Figure 1 above.
Tightening of Bolts
General
(1) High strength bolts shall be tightened to the snug-tight condition as a minimum.
(2) High strength bolts shall be tightened to achieve the minimum pretension specified in
AISC Table J3.1M for end plate moment connections, hanging type connections, splices
of columns and beams and any other connection subjected to vibration or fatigue as
indicated in the engineering drawings.
(3) High strength bolts shall be tightened to achieve the minimum pretension specified in
AISC Table J3.1M for Slip-Critical joints identified in the engineering drawings.
ALL RIGHTS RESERVED

IN WRITING.
(4) When the surface of the bolt head or nut and the surface of the steel forms an inclination
of 1:20 or more, tapered washers shall be used to make the contact tight.
(5) Bolts shall be tensioned by tightening the nut. Only where unavoidable, may the bolt head
be tightened with approval of CONTRACTOR. Erector subcontractor can submit a method
statement to obtain approval for the case where the tightening of the bolt is performed by
turning of the head.
(6) When all bolts in a joint have been tightened to the specified requirement, a mark shall be
made to indicate this is complete to avoid possible double tightening.
(7) Once bolting has been tightened, it shall not be re-used for any purpose. For pre-
tensioned bolted connections, should these bolts be loosened for any reason, they shall
be replaced. Re-tightening of bolts is not permitted.
(8) Bolts shall be tightened progressing systematically from the center to the free edges of
the joint.
Snug Tight Joint
Snug-tightened joint is a condition that exist when all of the connected plies in a
connection have been pulled into a firm contact by the bolts in the join and all of the bolts
in the joint have been tightened sufficiently to prevent the removal of the nuts without the
use of a wrench. The snug tightened condition is attained with a few impacts of an impact
wrench or the full effort of an ironworker using an ordinary spud wrench to bring the plies
into firm contact.
SUBCONTRACTOR shall demonstrate to CONTRACTOR his method will sufficient to

achieve that snug tight condition.
As QC/QA needs to document and mark on the field for easy visual check.
ALL RIGHTS RESERVED

IN WRITING.
Pretensioned and Slip Critical Joints
High Strength Bolts in Pretensioned and Slip-Critical joints shall be tightened to achieve
the minimum pretension specified in AISC J3.1M. The Calibrated Wrench method or the
Direct-Tension-Indicator (DTI) conforming to ASTM F959 shall be used to reach the
required pretension.
Bolt Length
The required bolt length shall be determined by adding the value shown in Table-1 to
the grip (i.e., the total thickness of all connected material including tapered washers if
used, but excluding standard washers) except that the length of torque controlled bolts
shall be determined in accordance with the manufacturer’s specification as approved by
CONTRACTOR.
Table-1
LENGTH TO BE ADDED TO THE GRIP
ASTM A325M
Bolt Size w/one washer
M16 26 mm
M20 30 mm
M22 32 mm
M24 36 mm
Note: The length determined by this table should be adjusted to the next bolt length
size.
Handling
When handling bolts, nuts, and washers for transporting, storing, or other purposes,
precautions shall be taken so that the threads and surfaces will not be damaged. Bolts,
nuts, and washers shall be kept from dust, moisture contamination, and rusting.
ALL RIGHTS RESERVED

IN WRITING.
Spare bolt quantity
FABRICATOR shall supply spare bolt quantity in addition to net quantity. Spare for field
bolts including washers and nuts shall be 5% for high-strength bolts and ordinary
structural bolts.
WELDING
General
(1) AWS D1.1 shall apply to all welding of structural steelwork, unless otherwise specified.
(2) Welds shall be made only by qualified welders, tack welders, and automatic welding
machine operators as specified in AWS D1.1.
(3) All welding procedure specifications and pre-qualification records (WPS & PQR) shall be
submitted to CONTRACTOR for approval prior to the commencement of any works. The
suggested form showing the information required in the procedure specification is given in
Appendix-1. When a WPS and PQR are classified prior to use in accordance with AWS
D1.1, the qualification test may not be required.
(4) Except when the written evidence of a previous qualification test is accepted by
CONTRACTOR, the joint welding procedure to be used shall be qualified prior to use in
accordance with AWS D1.1.
(5) Welding shall not be done when the ambient temperature is below -18 degrees Celsius
without preheat; when surfaces to be welded are wet or exposed to rain, snow, or high
winds; nor when the welders are exposed to inclement conditions.
(6) The sizing and lengths of welds shall not be less than those specified in the Standard
Drawings and detailed drawings, nor they shall be substantially in excess of those
requirements without the approval of CONTRACTOR and OWNER.
(7) Unless noted otherwise in the drawings the weld access holes to facilitate welding
operations shall be in accordance with ASIC-360 specification, section J1.6.
ALL RIGHTS RESERVED

IN WRITING.
Preparation of Base Metal
(1) Surfaces and edges to be welded shall be free from loose scale, slag, rust, grease, paint
and any other foreign matter except that mill scale which withstands vigorous wire brushing
may remain.
(2) Joint surface shall be free from fins and tears.
(3) Preparation of edges shall be by planning or machine flame cutting or plasma cutting.
(4) For shear stud welding, at the location of each steel stud, the parent metal shall be cleaned
of all foreign material and mill scale, with the rust ground off for a radius equal to the radius
of the stud plus 10mm. Shear studs shall be positioned as shown in the design drawings
with a maximum variation of 25mm as specified in AWS D1.1, Clause 7.4.5, Spacing
Requirements.
(5) It is not required to remove the backup plate unless specified in the engineering drawing.
In this case back up plate shall be entirely seal welded.
Assembly
(1) Those parts to be joined by filler welds, and separations between faying surfaces of lap
joint and or butt welds landing on a backing shall be brought into as close contact as
practicable. The gap between faying surfaces of a lap joint shall not exceed 2.0 mm.
(2) Those parts to be joined by groove welds shall be brought into correct alignment.
(3) Those members to be welded shall be held in the correct position by bolts, clamps, wedges,
guy lines, struts or other suitable devices, or by tack welds until welding has been
completed. The use of jigs and fixtures is recommended where practicable.
(4) Suitable allowances shall be made for warpage and shrinkage.
(5) Tack welds which are integrated to the structural welding of the joint shall be subject to the
same quality requirements as the final welds.
(6) In assembling and joining parts of a structure of build-up members and in welding
reinforcing parts to members, the procedure and sequence shall be carefully selected to
minimize distortion and shrinkage.
ALL RIGHTS RESERVED
IN WRITING.
Welding Consumables
(1) All Filler metal that has been removed from its original packaging shall be handled so that
it does not absorb moisture. Electrodes which are wet shall not be used. Low-Hydrogen
electrodes shall be dried in accordance with the manufacturer’s instructions before being
used. After being issued, electrodes shall be kept in a quiver, stainless steel box or any
other suitable container which will prevent them from becoming damp.
(2) Welding consumables shall be matched with steel type and used within the welding
parameter ranges specified by the manufacturer.
(3) Welding consumables shall be capable of producing welds with strength, ductility and
notch toughness properties at least equal to the requirements of the base material
welded.
(4) Welding consumables shall be pre-qualified to standards.
(5) Welding consumables shall be supplied with product conformance/batch test certification.
Welding of Attachments and Appurtenances
(1) Attachments to steelwork may consist of cleats, gussets, brackets etc. that are structural in
nature for connection of either primary, secondary or tertiary steelwork. Appurtenances to
primary steelwork may also consists of brackets, bolts, C or U electrical brackets/fittings,
light fittings, lubrication lines, pneumatic lines etc. that are generally required for the support
of services (electricity, controls, hydraulics, air, water, signage etc).
(2) Attachments/appurtenances shall not be placed within 40 mm of a flange or web edge,

unless the attachment is shown on the drawings.
(3) Temporary or permanent attachments shall be subject to the same material and welding
requirements as the item to which they are attached.
ALL RIGHTS RESERVED

IN WRITING.
Preheat and Inter-pass Temperature
(1) Prior to welding, the base metal shall be preheated as required to the applicable
temperature shown in Table-2.
Table-2
MINIMUM PREHEAT AND INTERPASS TEMPERATURE
Thickness of The Thickest

Part at Point of Welding (t)
Welding Process
t ≤ 20 mm 20 mm < t ≤ 38 mm < t ≤
38 mm 50 mm
Shield metal-arc welding with other None* 65 °C 110 °C
than low-hydrogen electrodes
Shield metal-arc welding with other None* 10 °C 65 °C
than low-hydrogen electrodes,
submerged arc welding, gas metal
arc welding, flux cored welding
*Where the base metal temperature is below 0 degree Celsius, the base metal shall be
preheated to least 20 degrees Celsius and that temperature shall be maintained during
welding.
(2) Minimum preheats used for all production welding and welding procedure qualifications,
shall be at least the value stipulated in the approved welding standard, and/or the material
manufacturer recommendations. Preheat temperatures shall be referenced on the WPS.
(3) The maximum inter-pass temperature shall not exceed the maximum value recommended
for each individual material thickness by the material manufacturer/approved standard or
250°C, whichever is less.
(4) The pre-heating temperature must extend over a distance at least equal to the thickness
of each part of the weld, and more than 75 mm both locally and in advance of the welding
of each run.
ALL RIGHTS RESERVED

IN WRITING.
Welding Procedure
General
(1) Arc strikes outside the weld zone shall not be permitted. Repairs due to arc strikes are to
be completed and arc strikes shall be completely removed, ground smooth with the base
metal and NDTs carried out to confirm the affected area is crack free.
(2) Before marking the subsequent welding pass, all slag shall be removed and adjacent
base metal shall be brushed clean.
(3) Groove welds shall be terminated at the ends of joints in a manner that will ensure sound
welds.
(4) Steel backing, if used, shall be made continuous to the full length of the weld. It is not
required to remove the backup plate unless specified in the engineering drawing. In this
case back up plate shall be entirely seal welded.
(5) Extension bars and run-off plates, if used, shall be removed after completion of the weld,
and the cut surfaces shall be ground smooth with the surrounding material.
(6) All butt welds shall be qualified complete penetration butt welds, unless noted otherwise.
(7) Square edge butt joints shall not be used except for material equal or less than 6 mm
thick. The beveling of the plates, width of the land and root opening, or spacing for
square edge plates, shall be adequate to assure full penetration.
(8) Butt welds in sections 25 mm or more in thickness shall be made with low hydrogen
electrodes.
(9) All fillet welds shall be minimum 6 mm continuous unless noted otherwise.
(10) Seal welds shall be a minimum of 4 mm fillet welds.
(11) Welds shall be continuous around the perimeter of the parts being joined to provide a
sealed joint.
(12) Cleanliness shall be maintained throughout welding. All stubs, rods, flux, slag and other
foreign materials shall be removed from the structure.
ALL RIGHTS RESERVED

IN WRITING.
(13) Welding shall not be carried out on wet surfaces. Welding operations shall be fully
protected from the elements.
(14) Anti-spatter compounds may be used only with the approval of the CONTRACTOR.
These shall not be used in or near to the weld zone.
(15) Arc craters must be filled in unless being incorporated into the next weld.
(16) All faying joints/surfaces shall be seal welded unless noted otherwise.
(17) Joints to be welded after painting shall be masked with the joint to be free of
contaminants. Their area to be welded shall be masked for a width of 100 mm.
(18) Where tack welds are to be incorporated into the final weld, they shall be made by a
qualified welder to a qualified procedure.
(19) Where tack welds are used, that are not to be incorporated into the final weld, they shall
be removed, such that the joint preparation satisfies the requirements of the relevant
WPS.
(20) Site welding shall not be permitted without approval by CONTRACTOR or where
indicated on the Drawings. All site welds shall comply with the same standards as apply
for shop welding and shall be subject to the level of inspection and non-destructive test
specified in the section 11.9.
(21) Where site welding is to be employed to complete the fabrication, the Subcontractor shall
plan the assembly of steelwork in sections, which shall permit a maximum amount of
welding to be completed on the ground. The Subcontractor shall plan the work in a
manner to limit the amount of overhead welding.
(22) Welds on hand rails exposed to contact by personnel shall be ground smooth.
(23) All tubular and boxed members shall be fully seal welded, except where member is to be
hot dipped galvanized.
(24) Repair, chipping, or grinding of welds shall be done without any gouging, grooving, or
reduction in the base metal thickness.
ALL RIGHTS RESERVED

IN WRITING.
Weld Quality
(1) The welding shall be done in the flat position whenever practicable.
(2) The classification and size of electrodes, electrode-arc length, voltage, and amperage
shall be specially selected to suit the thickness of the materials being welded, type of
grove, welding position, and other circumstances relevant to the work.
(3) The root pass shall be sufficiently large to prevent root cracking.
(4) When welding in the vertical position, the progression of all passes shall be upwards.
(5) The root of groove welds with no backing plate shall be gouged back and re-welded to
produce sound metal fusion throughout the entire cross section.
(6) The size of reinforcement on butt and fillet welds shall not be greater than that allowed in
the relevant standard. Excess reinforcement shall be removed and the weld surface
repaired to a compliant state.
(7) Weld cap and toes shall transition smoothly with the parent plate and shall not develop a
notched profile.
(8) Final acceptance of the weld and fabrication finish shall consider the requirement for
surface treatment e.g. weld spatter, weld slag, notches, burrs, surface breaking gas
pores and notches at the toes of welds shall not be allowed.
Inspection Tolerances and Corrections for Welding
(1) QC/QA will be done by qualified and certified welding inspector.
(2) The CONTRACTOR reserves the right to inspect and test any and all items of structural
steelwork, at any stage of supply and fabrication.
(3) The Fabricator or Subcontractor shall at all times facilitate inspection and testing by the
CONTRACTOR and OWNER or appointed delegate, and/or Inspector. During fabrication,
the Subcontractor shall permit the CONTRACTOR and OWNER free access to the
Fabricator’s works at all reasonable times for the purpose of carrying out inspections.
ALL RIGHTS RESERVED

IN WRITING.
(4) Should all additional tests requested by the CONTRACTOR (over and above the specified
extent of testing) be proven to be compliant/conforming, the Subcontractor shall be entitled
to reimbursement of all costs from the CONTRACTOR.
(5) The Subcontractor shall provide a minimum of 48 hours notice in writing for HOLD points
requiring CONTRACTOR inspection.
Base Metal
Prior to welding, all base metal surfaces shall be inspected visually. Any notches or other
defects that are found shall be repaired by grinding them out and depositing additional
weld metal at the defect with a low-hydrogen electrode not exceeding or 4 mm in
diameter, (observing the applicable requirements of Subsection 9.6.2) and grinding the
completed weld smooth and flush with the adjacent surface to produce a workmanlike
finish.
In the repair and determine of limits of internal defects visually observed on sheared or
oxygen cut edges and caused by entrapped slag or refractory, deoxidization products, gas
products, gas pockets, or weld porosities, the amount of metal removed shall be the
minimum necessary to remove the defect or to determine that the permissible limit shown
in Table-3 is not exceeded.
Table-3
Description of Discontinuity Repair Required
Any discontinuity 25 mm in length or less None -- need not be explored
Any discontinuity over 25 mm in length and None -- need not be explored
3 mm maximum depth
Any discontinuity over 25 mm in length with Removed – need not weld
depth over 3 mm but not greater than 6mm
Any discontinuity over 25 mm in length with Completely removed and weld.
depth over 6 mm but not greater than 25 Aggregated length of welding
mm shall not exceed 20% of plate
edge length being repaired.
Any discontinuity over 25 mm in length with Follow the procedure specified in
depth greater than 25 mm AWS D1.1 (2015), section
5.14.5.1 Acceptance Criteria.
ALL RIGHTS RESERVED

IN WRITING.
Assembly Tolerances
(1) The alignment, groove angle, root opening, and cleanliness of the surface to be welded
shall be inspected prior to welding for compliance with the tolerances shown in Table-4.
(2) The dimensions of the cross section of a welded joint which vary from the specified
dimension by more than the tabulated tolerances in Table-4 shall be reported to
CONTRACTOR for his directions.
Table-4
Tolerance (mm)
Item Figure Root not Gouged
gouged
Separation of fillet w
elded joint
(Note 1) 5.0 --
Separation or faying
surface of lap joint
and butt joint on a 2.0 --
backing
Misalignment at butt
welded joint 3 or t/10 whichever
t
(Note 2) Smaller
Root face of joint Not

± 2.0 limited
Root opening without

backing ± 2.0 + 2.0
(Note 3) - 3.0
Root opening with

backing + 6.0 --
(Note 3) - 2.0
Groove angle of joint
+ 10°
- 5°
ALL RIGHTS RESERVED

IN WRITING.
Notes:
(1) Parts to be joined by fillet welds shall be brought together as closely as practicable. If
the separation is 1.5 mm or greater, the size of the fillet weld shall be increased by the
amount of the separation. If the gap cannot be closed sufficiently during straightening
and in assembly to meet this tolerance, a maximum gap of 8.0 mm is acceptable
provided a sealing weld or suitable backing material used to prevent a melt through.
(2) In correcting misalignment, the mating parts shall not be drawn into a greater slope
4:100.
(3) Root opening wider than these tolerances but not greater than the thickness of the
thinner part may be built up by welding to acceptable dimensions.
Dimensional Tolerances
The dimensional tolerances of welded structural members shall be within the values
specified in Section 14.
Weld Profiles
(1) Welds shall be free from excessive undercuts, insufficient throat, overlaps, insufficient leg,
or excessive reinforcement. Dimensional tolerances for these defects shall be in accordance
with AWS D1.1. Visual Inspection acceptance criteria shall also be in accordance with AWS
D1.1.
(2) Defective portions of the weld shall be removed without any substantial removal of the base
metal. Additional weld metal shall be deposited in defective position to compensate the
deficiency in size using an electrode preferably smaller than that used in marking the original
weld, and preferably not more than 4.0 mm in diameter. Defective or unsound welds or base
metal shall be corrected either by removing and replacing the entire weld, or as follows:
(a) Overlap or excessive convexity:
Reduce by removal of excess weld metal.
(b) Insufficient throat of weld or crater, undersize weld, under cutting:
ALL RIGHTS RESERVED

IN WRITING.
Make additional welds.
Remove and re-weld.
(c) Excessive weld porosity, excessive slag inclusions, incomplete fusion:
Remove and re-weld.
(d) Cracks in weld or base metal:
Remove the crack and sound metal 50 mm beyond each end of crack and re-
weld.
(3) Welds shall be free from excessive undercuts, insufficient throat, overlaps, insufficient leg,
or excessive reinforcement. Dimensional tolerances for these defects shall be in accordance
with AWS D1.1. Visual Inspection acceptance criteria shall also be in accordance with AWS
D1.1.
(4) Defective portions of the weld shall be removed without any substantial removal of the base
metal. Additional weld metal shall be deposited in defective position to compensate the
deficiency in size using an electrode preferably smaller than that used in marking the original
weld, and preferably not more than 4.0 mm in diameter. Defective or unsound welds or base
metal shall be corrected either by removing and replacing the entire weld, or as follows:
(a) Overlap or excessive convexity:
(b) Insufficient throat of weld or crater, under size weld, under cutting:
Make additional welds.
Remove and re-weld.
(c) Cracks in weld or base metal:
Remove the crack and sound metal 50 mm beyond each end of crack and re-
weld.
ALL RIGHTS RESERVED

IN WRITING.
Distortion and Shrinkage
(1) Members distorted by welding shall be straightened by mechanical means or by carefully

supervised application of a limited amount of localized heat. The temperature of heated
area shall not exceed 650 degrees Celsius (a dull red color).
(2) In assembling and joining parts of the structure or built-up members and in welding
reinforcing parts to members, the procedure and sequence should be such as to minimize
distortion, shrinkage and restraint.
(3) As far as practicable, all welds shall be deposited in a sequence that will balance/evenly
distribute the applied heat of welding, as the welding progresses.
(4) The Fabricator/Subcontractor shall conduct suitable NDT to confirm restrained joints
satisfy the requirements of the relevant standard.
(5) Notwithstanding the above, the completed component shall satisfy the tolerance
requirements of this specification and any project specified tolerances
Post Weld Heat Treatment
(1) Post weld heat treatment of members is to be shown on the drawings.
(2) Post weld heat treatment procedures are to be submitted to the CONTRACTOR for
approval prior to commencement of the works and shall describe support details and
thermal couple placement. At the completion of the treatment, temperature records are to
be submitted to the CONTRACTOR to demonstrate compliance with the standard.
(3) Structural components that undergo post weld heat treatment shall have final NDT
undertaken following the completion of the post weld heat treatment.
(4) No heating or welding shall be performed on stress-relieved items unless accepted by the
CONTRACTOR.
Shop Splice Weld
(1) Material for structural members and plates shall be supplied in full stock lengths.
ALL RIGHTS RESERVED

IN WRITING.
(2) The only welded spliced joint permitted will be as shown on the CONTRACTOR drawings,
otherwise written approval is required by the CONTRACTOR. Where additional shop
splices are intended or required by the Subcontractor (FABRICATOR), these shall be
considered a design change and the following actions shall be required:
(a)FABRICATOR to initiate a Technical Query (TQ) or similar applicable figure for the
Shop Splice location.
(b)CONTRACTOR to approve TQ with certain guidelines, which has been agreed with
OWNER and shared with FABRICATOR.
(c) FABRICATOR to reflect the splices in their Shop Engineering documents.
(3) Where permitted, shop splice welds shall be complete penetration butt welds, ground to a
condition of blended flush, followed by 100% RT or UT testing.
(4) Multi-plate, compound members that require shop splice welds in the components shall
have the individual component plates and sections shop splice welded before assembly.
These shop splice welds shall be staggered by not less than 60mm.
(5) Unless otherwise shown, make column splices between 500 mm and 800 mm above
finished floor level.
(6) Field splices and joints shall be pre-assembled in the shop on completion of fabrication to
ensure satisfactory fit when installed on site.
(7) The location of shop and field splices shall be clearly shown on the “As Built” Drawings.
ALL RIGHTS RESERVED

IN WRITING.
Non-Destructive Examinations
Visual Examination/Inspection shall be completed on all structures. The structure shall

pass the criteria for Visual Examination prior to NDT. Non-Destructive Examinations shall
be performed in accordance with AWS D1.1, unless otherwise specified, and the following
frequency for welding point:
Structural Structural Non-Structural

Primary Member Secondary Member Tertiary Member
Shop Weld
- Butt/corner weld UT 10 % UT 10% N/A
- Fillet weld MT 5 % N/A N/A
Field Weld
- Butt/corner weld UT 100 % UT 10% N/A
- Fillet weld MT 25 % MT 10% N/A
Notes:
1. UT means Ultrasonic Testing and MT means Magnetic Testing.
2. L means leg lengths of weld.
3. Lifting Lugs required for erection of steel structure blocks or modules are
considered safety key items. If Lifting Lugs are required, the following NDE shall
be applied:
- Visual examination 100%

- CJP/Butt welds UT 100%
- Fillet welds MT 100%
All welding shall be visually and NDT inspected after a minimum of 24 hours has passed
following completion of the welding. The NDT of quenched and tempered steel fabrication
and highly restrained joints, sensitive to lamellar tearing shall be UT tested following a
minimum of 24 hours after completion of welding. Final inspection of welding subject to
post weld hear treatment shall be undertaken after completion of the treatment.
(1) All weld slag, flux residues and spatter shall be removed prior to inspection.
ALL RIGHTS RESERVED

IN WRITING.
(2) The Subcontractor shall perform all NDT and material testing using an accredited
laboratory, having accreditation to the relevant classes of test and is independent of the
Fabrication Contractor.
(3) Repair welds shall be retested for the length of the repair with 100% visual examination,
100% MT for fillet and 100% MT and UT for butt welds. This retesting and repair shall be
carried out at the Subcontractors expense and is not considered as part of the extent of
testing.
(4) In any group of steelwork tested, if 10% or more of a weld type proves defective, the level
of NDT for the methods prescribed in the above table shall be increased to 100% for the
welds already completed.
(5) All NDTs shall be documented in NDT reports. NDT reports shall be clearly presented and
contained reference to the unique weld number, date of test, name of approved
technician, material grade and dimensions, description of product, weld type, reference
standard for NDT testing and interpretation, type and extent of NDT, including the detail of
the test area (being length and position), name of testing company and a statement of
compliance.
(6) The CONTRACTOR reserves the right at all times to nominate any particular weld/welds
to be included within the extent of welds which are the tested and to nominate the extent
and type of NDT to be used.
(7) The OWNER and/or CONTRACTOR reserves the right at all times to have the testing
cross examined/checked by a third party NDT Company.
(8) Where welds of greater than one (1) meter in length are examined, defect evaluation shall
be made for a unit length of one (1) meter.
(9) The prescribed extent of NDT shall be regularly spread in equal proportions of time, weld
size and type, welders, and coverage of all fabrication components/ subassemblies.
Where it is observed by the CONTRACTOR that a regular spread of testing has not been
conducted, the CONTRACTOR may instruct the Subcontractor to conduct additional
ALL RIGHTS RESERVED

IN WRITING.
testing over and above the entire project extent, to suitably cover subassemblies. This
testing shall be at the Subcontractors expense.
(10) Where a defect is discovered, NDT shall be extended to identify the full extent of the
defect, for the purpose of weld rectification, at the Subcontractors expense.
INSPECTIONS, TOLERANCES AND CORRECTIONS
Inspections
The requirements of this specification are considered the OWNER's minimum for
inspection, examination and testing. The CONTRACTOR may, at his discretion, elect to
increase the quantity of testing and inspection for a particular component. The
Subcontractor shall carry out all testing requirements specified unless prior written
approval is received from the CONTRACTOR for a reduction in scope.
(1) The Subcontractor that shall record all inspections and testing data in a format approved
by the CONTRACTOR.
(2) The Subcontractor shall prepare and submit an inspection and test plan (ITP). This
inspection and test plan shall be approved by the CONTRACTOR prior to commencing
the work.
(3) Inspection and testing shall be done in such a manner as to avoid or minimize delays to
the work.
(4) All field bolting and field welding shall be inspected by the CONTRACTOR’S
Construction/ Fabrication/ Welding Supervisor during erection.
(5) Priming and painting in the vicinity of welds shall not be carried out until after inspection
by the Contractor’s Construction /Fabrication/Welding Supervisor.
(6) Give a minimum of 24-hour notice so that hold point inspections by the CONTRACTOR may
be made at the following stages:
 Procurement of materials, certification, heat numbers;

 Commencement of shop fabrication;
 Inspection of welder qualifications;
ALL RIGHTS RESERVED
IN WRITING.
 Commencement of welding (weld procedures, welder qualifications, weld

numbers);
 Prior to placement of root runs of complete penetration butt welds;
 Completion of fabrication prior to surface preparation;
 Surface preparation prior to protective coating;
 Completion of protective coating prior to delivery to site;
 Steelwork on site prior to erection;
 Tensioning of bolts in pre-tensioned and slip-critical joints;
 Completion of erection prior to encasing, field painting or fixing cladding;
 Column bases prior to grouting;
 Commencement of concrete encasing. All fabricated materials shall be
inspected at the shop prior to shop painting or galvanizing. All inspection
and approval shall be documented and mark at the steel.
Tolerances
(1) The tolerances specified herein apply to individual members or units and shall not be
interpreted as permitting a cumulative error over the whole or part of any structure.
(2) Sag or lateral bow of fabricated sections shall not exceed 1/1000 of the member length to
a maximum of 15 mm total.
(3) The width or depth of the fabricated sections shall not deviate from that specified by more
than 3 mm.
(4) Welded end plates and web cleat angles shall be free from such distortion as will prevent
the connected faces from being in full contact when bolted snug tight.
(5) Abutting flanges supporting a rail or forming a running surface, or intended to perform a
similar operational function, shall be fitted up such that misalignment does not affect in the
joint’s required function.
(6) Out of tolerance fabricated steel members and assemblies shall be rectified to the
satisfaction of CONTRACTOR.
Straightness
Structural members consisting of a single rolled shape shall be straight within the
appropriate tolerances allowed by the standards or codes specified in this Specification.
ALL RIGHTS RESERVED

IN WRITING.
Built-up structural members fabricated by bolting and welding shall be straight within the
tolerances listed in Table-5.
Table-5
TOLERANCES FOR STRAIGHTNESS
Item Length Tolerance

Column L ≤ 14,000 d ≤ L / 1000 or 10
(whichever is smaller)
L > 14,000 d ≤ 10 + (L – 14,000) / 1,000

All L1 / 1,000
Girder and beam where there All L / 1,000
is no specified camber or
sweep
Girder and beam from All + 6.0
specified camber + L / 500 (Max 19 mm)
+ p / 1,000
Whichever is greater
Where, L = total length (mm)
d = deviation from straight (mm)
L1 = length between points which are to be laterally supported (mm)
P = distance from nearest end (mm)
Length
Members without ends finished for contact bearing, may have a variation from the
detailed length not greater than the following tolerances:
L ≤ 9,000 : d ≤ 2.0
L > 9,000 : d ≤ 4.0
Where, L = total length (mm)
d = deviation from straight (mm)
ALL RIGHTS RESERVED

IN WRITING.
Shapes
The tolerances for shapes of structural members consisting primarily of a single rolled
shape shall be in accordance with the specifications or codes specified in the Project
Specification. Tolerance for built up members shall be in accordance with Table-6.
Other
Tolerances for other fabricated members shall be in accordance with Figure-2 and Table
7.
Dimensional Checking
(1) The Subcontractor shall provide personnel, equipment and instruments necessary to
monitor and control dimensions and tolerances.
(2) Measurements of dimensions shall be continuously checked during fabrication for

individual members, before fit-up of sections and subassemblies, to ensure conformance
with the nominated dimensions and tolerances of both individual components and the fully
fabricated and erected assembly.
(3) The Subcontractor shall set out all primary datum points on the structure, using accepted
engineering surveying techniques consistent with achieving the tolerances required.
(4) The Subcontractor shall perform a final survey by a Licensed Surveyor on all shop
subassemblies that have field erection interfaces, to confirm dimensions per the drawings
and specifications.
Correction
(1) Defective members shall be corrected before shop painting in accordance with the
applicable provisions of this specification.
ALL RIGHTS RESERVED

IN WRITING.
Table-6
TOLERANCE FOR SHAPES OF BULIT-UP MEMBERS
1/2B±E B 1/2B±E B
T’ T’
C C A
A
T T
1/2B±E 1/2B±E
TOLERANCES (Unit: mm)

Section (A) Depth (B) Fig. Width (T+T’) (E) (C)
Normal Over Under Over Under Flanges Web off Max. Depth at
size Theo- Theo- Theo- Theo- Out of Center, any Cross-
retical retical retical retical Square, Max Section Over
Max. Theoretical
300 and 3 3 6 5 6 5 6
smaller
Over 300 8.0 8.0
Figure-2
TOLERANCE FOR ANGLE OF BEAM TO COLUMN
Column Column
l l
l1 l2
Beam Beam
Elevation Plan
l1 ≤ l/ 300 and l2 ≤ l / 300 and
l1 ≤ 3 mm l2 ≤ 3 mm
ALL RIGHTS RESERVED

IN WRITING.
Table-7
TOLERANCES FOR FABRICATED MEMBER
Item Figure Tolerances

Flatness of girder A / 150 and B / 150
web d
d
A
D
B
Out-of-straightness of d 13mm with due regard to

intermediate stiffener any members which
D D frame into them
Out-of-straightness of D ≤ 1,800 d ≤ 6mm
bearing stiffener D > 1,800 d ≤ 13mm
D
d
Offset of stiffener t: Thickness of stiffener
from theoretical
t
centerline
D
ALL RIGHTS RESERVED

IN WRITING.
Handrail
In addition to the inspections already prescribed herein, handrails shall be visually

inspected in accordance with the tolerances shown in Table-8.
Table-8
TORELANCES FOR HANDRAIL
Item Figure Tolerances

(mm)
Straightness d d ≤ 10 mm
of Handrail d
(Top Rail)
“d” is the deviation from

straightness of the handrail
in each 5 m.
Straightness d d ≤ L / 300
of Handrail
(Mid-Rail and L
Toe Plate)
“d” is the deviation from
straightness in the spacing
between two handrail posts.
Anchor Bolt
The dimensions of all anchor bolt holes for equipment on steel structures shall be
measured and reported to CONTRACTOR.
Quality Records
(1) All quality control records and results of all examinations and testing are to be
progressively compiled into a Material Data Record (MDR) and forwarded to the
CONTRACTOR on completion of the works. The MDR shall be available for progressive
inspection, review and approval by the CONTRACTOR throughout the works.
ALL RIGHTS RESERVED

IN WRITING.
(2) Quality control records shall be maintained in the SUBCONTRACTOR’s office. These
records shall include as a minimum of following information:
a) The current approved version of the Quality Plan for the project.
b) All quality records as agreed with the CONTRACTOR.
c) Weld maps and traceability sheets. These sheets shall be initialed and dated as each
weld is completed, inspected and tested.
d) The results and report numbers of all test reports.
(3) Material and weld repair records shall detail accepted repair procedures and detailed
written reports of repairs with acceptance of repair results by the CONTRACTOR,
including weld repair NDT reports.
PROTECTIVE COATING AND MARKING
(1) Structural steel excluding bolt coating and surface preparation shall be in accordance
with the requirements in MS-DD-3000-MEC-SPE-0801.
(2) All bolts shall be hot dip galvanized unless otherwise noted and additionally painted
where required as specified in the General Notes for Steel MS-DD-3000-STR-STA-0001.
(3) All fabricated sections shall be clearly identified in accordance with FABRICATOR’s
marking procedure subject to prior approval by CONTRACTOR and OWNER.
(4) Steelwork coating systems shall be deemed to include painting, galvanizing, and fire
protection coatings included in the scope of this Section.
(5) Protective coating shall provide durability (design life) of 25 years.
(6) Protective coatings, including repairs to damaged coatings, shall be in accordance with
specification MS-DD-3000-MEC-SPE-0801.
(7) Steelwork shall have sharp edges and corners rounded and ground smooth to a
minimum radius of 2 mm to promote adherence of protective coating in these critical
areas.
(8) Friction surfaces shall not have paint top coat only zinc coat;
ALL RIGHTS RESERVED

IN WRITING.
(9) Where structural steelwork is specified to be hot dipped galvanized, it shall be designed
with adequate venting and drainage for the galvanizing process.
(10) Where members are partially concrete encased, extend the priming 25 mm into the
surface to be encased.
(11) Do not handle or transport steel members until the paintwork is dry. Protect the paintwork
from damage during transport and handling.
(12) Before site painting clean the steelwork to remove any foreign matter or contamination
of the primed surface.
(13) The SUBCONTRACTOR shall prepare and submit a marking procedure to the
CONTRACTOR for approval.
(14) All material used on fabrications shall be clearly marked to facilitate traceability
throughout all fabrication stages. This may be by paint marker, weatherproof bar code
or other approved method.
(15) Where permanent marking is required, low stress rounded stamps may be used.
(16) Each element shall have an item mark, which shall be shown on the shop drawing
marking plans.
(17) Provide suitable and sufficient marks or other means for identifying each member, and
for the correct setting out, location, erection and connection of the steelwork. Mark bolted
connections to show the bolting category.
(18) If unidentified material is found on the fabrication, the Subcontractor shall be responsible
for the removal of the material to the satisfaction of the CONTRACTOR at no extra cost.
(19) Markings shall be transferred to “As Built” traceability records prior to coating operations
and this operation may be subject to CONTRACTOR’S verification and sign off prior to
coating operations commencing. This stage shall be controlled by the ITP
documentation.
(20) All fabricated steelwork, before leaving the fabricator’s shop, must be clearly identifiable,
providing the following information as a minimum:
ALL RIGHTS RESERVED

IN WRITING.
1. Order/Contract Number.
2. Item or mark Number.
3. Shop Drawing Number
(21) The location of lifting points shall be prominently marked with yellow paint on large
components.
(22) Handrail and walkway grating are not subject to the traceability documentation provisions
in this Specification.
TRANSPORTATION HANDLING AND STORAGE
(1) Care shall be taken when transporting fabricated materials to ensure they are not
damaged or become deformed.
(2) Fabricated structural steel work found damaged shall be fully repaired or replaced prior
to erection. Damage caused by handling during transportation shall be either replaced
or repaired by the Subcontractor at the Subcontractor’s expense, including protective
coatings.
(3) Fabricated materials shall be stacked clear of the ground and be self-draining.
(4) Prior to erection, the surfaces of structural steel sections that are connected by high-
strength bolts shall be cleaned of any sand, dust, grease deposits and other foreign
matter.
(5) Steelwork shall be provided with ready means for lifting and handling including suitable
lugs or slings as required.
(6) Bolts, nuts and washers shall be transported, stored and handled in a manner that will
prevent damage, contamination, corrosion, or loss of the lubricant. Bolts, nuts, washers
and other small items shall be delivered to site in suitable bags or containers, which shall
be clearly labeled identifying the size and quantity.
(7) Each metal surface having a workshop applied protective coating shall be protected from
physical or chemical damage in a manner approved by the Contractor.
ALL RIGHTS RESERVED

IN WRITING.
(8) Shop fabricated items such stairs, ladders, columns, beams e.g. shall be shipped in the
largest dimension suitable for handling and transportation.
ERECTION
(1) The structural steel frame shall be positioned and safely secured by means of temporary
bracing during erection.
(2) Temporary bolts and temporary welds made for erection purpose shall be sufficiently
strong to withstand all erection loads.
(3) Unless otherwise specified in the construction drawings, the temporary bolts on welded
connections need not be removed.
(4) All structural steel work shall be aligned and then inspected. The tolerances for erection
and tilt in columns are shown in Table-9.
(5) All structural steel work shall remain aligned during bolting and welding work.
(6) All anchor bolts at column bases shall be tightened immediately after alignment of
structural steel work.
(7) Ladders, lugs and hooks welded to structures for the purpose of erection in accordance
with the construction drawings shall not be removed, unless otherwise specified or
requested.
(8) The SUBCONTRACTOR shall erect, fix, adjust and maintain all members in their
intended vertical and lateral alignment and level.
(9) When major steelwork members are lifted they are to be slung or supported in such a
manner as to prevent undue distortion or flexing of the member during lifting operations.
(10) It is permissible to partially assemble structures before lifting into position providing all
necessary precautions are taken to prevent distortion, flexing or undue stresses in the
structure during lifting operations.
(11) Additional members used to facilitate erection shall be affixed in a manner which does
not weaken or deface permanent steelwork.
ALL RIGHTS RESERVED

IN WRITING.
(12) During erection, the use of excessive force will not be allowed. Light drifting necessary
to draw holes or align multiple components is permitted, however no damage shall be
caused to the structure as a result.
(13) Drifting to match incorrectly placed holes shall not be permitted. Holes that are badly
punched or drilled shall be reamed out to accept a bolt of larger diameter if approved.
Otherwise the holes shall be reamed out, plug welded, tested and re-drilled to the sizes
shown on the Drawings.
(14) Prior to commencement of erection of a structure on site a proposed sequence of

erection for each structure shall be submitted for review by the CONTRACTOR.
(15) The Subcontractor shall carry out a craneage study in which the nature of the site
conditions and access shall be taken into account. Cranage and spreader beams shall
be designed by the Subcontractor and approved by CONTRACTOR prior to use
positioned at load points as necessary.
(16) Before final bolting or welding, erected structures are to be checked dimensionally for
line, level, alignment and plumb. Erected structures are to be re-checked for line, level,
alignment and plumb after final bolting or welding.
(17) Steel shims and packers shall be supplied as required to undertake any other
adjustments and corrective measures necessary to ensure that the finished position of
the steelwork is within the required tolerance of the position shown or inferred on the
Drawings.
(18) Do not attach cleats without prior approval except as shown on shop drawings.
(19) Provide for thermal movements during erection.
(20) Unless approved by CONTRACTOR the pouring of grout will not proceed if the
temperature of the base plate or pedestal surface exceed 32°C. Mitigation measures can
be implemented if required, such as sheltering from the sunlight and keep the grout
material cool using cold water for mixing. Recommendations given by the grout
manufacturer shall be considered.
ALL RIGHTS RESERVED

IN WRITING.
Table-9
TOLERANCES FOR ERECTION
Item Figure Tolerance

Tilt in d d ≤ H / 500
column or
25 mm
H whichever
is smaller
STEEL FLOORING
(1) Steel Flooring shall be installed and fixed flat or slope as specified in drawing by using
approved devices and procedure.
(2) The method for fastening grating shall be as specified on the design drawings. A
minimum of two fasteners per panel shall be used at each support, with a minimum of
four per panel. The fasteners shall be supplied with 5% extra to cover losses.
(3) All cut floor plate or grating openings requiring toe plate protection or banding shall be
installed as required on the design drawings.
(4) Fabricator shall prepare and submit floor paneling layout drawing for CONTRACTOR
review.
(5) Floor plate shall be 6 mm thick unless noted otherwise on the Drawings and shall have
a raised angular pattern.
(6) Checker Plate Flooring shall not be used at the outdoor environment. In case there is a
necessity for checker plate to be installed outdoors, CONTRACTOR shall seek
approval from OWNER and to include a method of providing an anti-slip surface when
it is wet.
(7) The top surface at butting edges of adjacent plate shall not misalign by more than 2
mm. Floor plate fasteners shall not project above the top face of the floor by more than
2mm.
ALL RIGHTS RESERVED
IN WRITING.
Appendix-1 CLASSIFICATION OF STRUCTURAL STEEL
Primary Structural Steel
Primary Steel shall be defined as structural elements (members and their connections)
essential for the overall stability and integrity of the structure. Primary steels are following
items but not limited to:
• Main Frame Columns
• Main Frame Trusses
• Girders
• Beams
• Vertical Braces and Horizontal Braces
Secondary Structural Steel
Secondary Steel shall be defined as structural elements (members and their connections)
critical to the local integrity of the Installation and/or equipment. Secondary steels are following
items but not limited to:
• Floor Joists
• Building Girts and Purlins
• Equipment-Bearing Supports and Skid Framing
• Stanchions and Pipe Support Beams
• Mezzanines and Misc. Platforms
• Vessel Platforms
• Monorails, Jib Cranes, Davits,
• Pipe & cable tray supports
• Maintenance Padeyes
• Stair towers
Tertiary Steel
Tertiary steel shall be defined as all outfitting steelwork not essential to the global or local
stability of the structure but providing a functional installation, safe working environment and
allowing safe access. Tertiary steels are following items but not limited to:
• Floor Plate (checkered plates and flat plates)

• Grating
• Handrails
• Stairs
• Ladder and Ladder Cages
• Safety Gates
• Supports for HVAC ducts and refrigerant pipes, service water pipes and electrical conduits for
building services.
ALL RIGHTS RESERVED

IN WRITING.

Ms-Dd-3000-Str-Spe-0001 - rev1-SPECIFICATION FOR FABRICATION

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ms-Dd-3000-Str-Spe-0001 - rev1-SPECIFICATION FOR FABRICATION

Uploaded by

Copyright:

Available Formats

Date : Oct.

13, 2021 CONSTRUCTION SPECIFICATION FOR MS-DD-3000-STR-SPE-0001

CONSTRUCTION SPECIFICATION FOR

OWNER: PT. FREEPORT INDONESIA

MANYAR SMELTER PROJECT

PT CHIYODA INTERNATIONAL INDONESIA

1 Issued for Construction Oct. 13, 2021 R.Miguel T.Suzuki T.Moritsuna

ALL RIGHTS RESERVED

Codes and Standard .............................................................................................................5

Bolt Length ..........................................................................................................................19

ALL RIGHTS RESERVED

Inspection Tolerances and Corrections for Welding...........................................................26

Non-Destructive Examinations ............................................................................................33

Quality Records ...................................................................................................................41

ALL RIGHTS RESERVED

ALL RIGHTS RESERVED

Codes and Standard

(1) AWS D1.1 Structural Welding Code - Steel

(2) AISC 360-16 Specification for Structural Steel Buildings

(4) RCSC Specification for Structural Joints Using High-Strength Bolts.

(5) ASTM A36M Standard Specification for Carbon Structural Steel

ALL RIGHTS RESERVED

(13) ASTM F436M Standard Specification for Hardened Steel Washers

(18) ASTM A653 Standard Specification for Steel Sheet, Zinc-Coated

(19) ASTM F959 Standard Specification for Compressible-Washer-Type Direct

(21) AS 1397 Steel sheet and strip—Hot-dip zinc-coated or aluminum/zinc-

ALL RIGHTS RESERVED

(22) AS/NZS 2728 Prefinished/pre-painted sheet metal products for

(23) ASTM D3841 Standard Specification for Glass-Fiber-Reinforced Polyester

(25) JIS G3101 SS400 Rolled steel for general structure.

(1) MS-DD-3000-CIV-SPE-0001 General Specification for Foundation and Structure Design

(2) MS-DD-3000-CIV-SPE-0104 Construction Specification for Concrete Work

(3) MS-DD-3000-MEC-SPE-0801 General Specification for Painting

(4) MS-DD-3000-PJC-PRO-0901 As-Built Documentation Procedure

(5) MS-DD-3000-PJC-PRO-0013 Technical Deviation Procedure

(6) MS-DD-3000-QUA-PRO-0201 Quality Control Requirements to Subcontractor

(7) MS-DD-3000-QUA-PRO-0006 Non-conformity Management Procedure for Vendor

(8) MS-DD-3000-QUA-PRO-0007 Non-conformity Management Procedure for Site Work

(9) MS-DD-3000-QUA-PRO-0001 Instruction to Vendor for Shop Inspection.

(10) MS-DD-3000-ACT-SPE-0002 Construction Specification for Architecture Material.

Where Fabricator or Subcontractor discovers a discrepancy between two documents that

ALL RIGHTS RESERVED

(1) It is the Subcontractors responsibility to advise the Contractor in writing of any

SUBCONTRACTOR PROVIDED DESIGN

(1) Sub-contractor provided design shall comply with MS-DD-3000-CIV-SPE-0001.

ALL RIGHTS RESERVED

ALL RIGHTS RESERVED

(12) Steel grating shall be conforming to ASTM A1011, CS Type B Grade 36

(14) FRP grating shall be WEBFORGE TYPE G386VGY or equivalent approved

ALL RIGHTS RESERVED

ALL RIGHTS RESERVED

 Identification and numbers

ALL RIGHTS RESERVED

(c) A detailed specification for field welding shall be furnished.

ALL RIGHTS RESERVED

CUTTING, BENDING AND BOLT HOLES

(2) Holes in steel plates over 12mm thick shall be drilled.

ALL RIGHTS RESERVED

(3) Bolt holes shall be formed to the tolerance as shown in Figure-1.

ALL RIGHTS RESERVED

ALL RIGHTS RESERVED

ALL RIGHTS RESERVED

Snug Tight Joint