240k-c2-cs-15-021-c.pdf

R:\103_PROJ_ADMIN\109_ENG DOCS\109.8R_CS\15-Structural\240K-C2-CS-15-021_FabStrct&MiscSteel\240K-C2-CS-15-021-C.doc

SOCIEDAD MINERA CERRO VERDE S.A.A.

CERRO VERDE PRODUCTION UNIT EXPANSION

PROJECT NO. A6CV

FABRICATION OF STRUCTURAL AND MISCELLANEOUS STEEL

CONSTRUCTION SPECIFICATION

DOCUMENT NO. 240K-C2-CS-15-021 REV. C

08 MAY 2012

®

R:\103_PROJ_ADMIN\109_ENG DOCS\109.8R_CS\15-Structural\240K-C2-CS-15-021_FabStrct&MiscSteel\240K-C2-CS-15-021-C.doc

Sociedad Minera Cerro Verde S.A.A. Document No. 240K-C2-CS-15-021 Cerro Verde Production Unit Expansion Revision C Project No. A6CV

FABRICATION OF STRUCTURAL AND MISCELLANEOUS STEEL CONSTRUCTION SPECIFICATION

R:\103_PROJ_ADMIN\109_ENG DOCS\109.8R_CS\15-Structural\240K-C2-CS-15-021_FabStrct&MiscSteel\240K-C2-CS-15-021-C.doc Page 2 of 23

This page is intentionally blank.




TABLE OF CONTENTS

1. GENERAL...................................................................................................................................................... 5 1.1 Summary ..........................................................................................................................................5 1.2 References .......................................................................................................................................6 1.3 Submittals .........................................................................................................................................8 1.4 Quality Control and Quality Assurance ..........................................................................................12

2. PRODUCTS................................................................................................................................................. 13 2.1 Materials .........................................................................................................................................13 2.2 Surface Preparation, Painting, and Galvanizing.............................................................................15 2.3 Connections - General....................................................................................................................15 2.4 Fabrication and Manufacture..........................................................................................................18 2.5 Miscellaneous steel fabrication.......................................................................................................19 2.6 Inspection and Tests ......................................................................................................................21 2.7 Identification and Tagging ..............................................................................................................22 2.8 Preparation for Shipment................................................................................................................22 2.9 Material Tracking ............................................................................................................................23

3. EXECUTION ................................................................................................................................................ 23 4. ATTACHMENTS.......................................................................................................................................... 23




This page is intentionally blank.




1. GENERAL

1.1 Summary

A. Scope of Specification

This specification prescribes the minimum requirements for the labor, material, equipment and services for the design, fabrication, testing, supply and assistance for field installation of steel members, connections, design of connections, detailing, fabrication and delivery of structural and miscellaneous steel.

These facilities The work covered by this specification shall include, but not be limited to the following:

1. Supply, design, detailing, fabrication and delivery of structural and miscellaneous steel.

2. Preparation of shop detail drawings, bar coding, bills of materials, and erection drawings.

3. Engineering, design and detailing of standard and non-standard, bolted or welded connections and splices that are not fully detailed on engineering drawings, and requirements for common and high strength bolts including temporary erection bolts and required erection materials.

4. Supply of leveling plates and shims.

5. Supply of all required connections and splices, components and bolts.

6. Structural and misc. steel surface preparation, priming, or galvanizing, in accordance with the applicable specification listed herein.

7. Field bolt location lists for field bolted connections.

8. Quality control including inspection and testing.

9. Preparation of fabricated steel for shipping, crating, packaging, tagging and loading the steel onto trucks or containers at fabricator's shop and shipping to marshalling area.

B. Work Not Included

The following items do not form part of the scope of this specification:

1. Off-loading of the steelwork at site

2. Erection of structural steel

C. Related Documents

The following documents describe items of related work:

240K-C2-DC-10-002 General Site Conditions Design Criteria

240K-C2-CS-15-012 Grouts

240K-C2-CS-15-022 Erection of Structural Steel

240K-C2-CS-15-024 Metal Decking

240K-C2-ES-55-002 Paint

240K-C2-SD-15-021 Fabrication of Structural and Miscellaneous Steel Supplier Drawing & Data Commitment (SDDC) Form

Coordinate work prescribed by this specification with work prescribed by the above listed specifications.




D. Definitions

Buyer: The party that awards the contract to fabricator. May be the owner or owner's authorized agent.

Fabricator: The party responsible for furnishing structural and miscellaneous steel

Owner: The owner of the proposed structure

Supplier or seller: In the context of this specification it is the party awarded the contract by the buyer. Used interchangeably with: fabricator.

1.2 References

A. The publications listed below form part of this specification to the extent referenced in this specification. If there is a discrepancy between the references and the specifications, the specifications shall govern. Referenced publications shall be the latest revisions and addendum in effect on the date of the Purchase Order, unless otherwise noted. Short titles will be used herein when appropriate. Applicable parts of the referenced publications shall become a part of this specification as if fully included.

ACI American Concrete Institute

301-10 “Specifications for Structural Concrete”

AISC American Institute of Steel Construction

Specification for Structural Steel Buildings- Allowable Stress Design and Plastic Design

Load and Resistance Factored Design Specification for Structural Steel Buildings

Code of Standard Practice for Steel Buildings and Bridges

Allowable Stress Design Specification for Structural Joints Using ASTM A325 or A490 bolts, by the Research Council on Structural Connections

Load and Resistance Factored Design Specification for Structural Joints Using ASTM A325 or A490 bolts, Research Council on Riveted and Bolted Structural Joints.

Manual of Steel Construction, Allowable Stress Design/Load and Resistance Factor Design, 13th Edition 2005

AISI American Iron and Steel Institute

Specifications for the Design of Cold Formed Structural Members

API American Petroleum Institute

API-650 Welded Steel Tanks for Oil Storage, Eleventh Edition

AREMA American Railway Engineering and Maintenance-of-Way Association

Manual for Railway Engineering, 2010 Edition

ASCE American Society of Civil Engineers

ASCE 7-05 (ASCE7) Minimum Design Loads for Buildings and Other Structures




ASME American Society of Mechanical Engineers

ANSI/ASME B30.11-2010

Monorails and Underhung Cranes

ASTM American Society for Testing and Materials

A1 Standard Specification for Carbon Steel Tie Rails

A6/A6M Standard Specification for General Requirements for Rolled Steel Plates, Shapes, Sheet Piling, and Bars for Structural Used

A36/A36M Standard Specification for Structural Steel

A53 Standard Specification for Pipe, Steel, Black and Hot Dipped Zinc-Coated Welded and Seamless

A153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

A123 Standard specification for Zinc (Hot Dip Galvanized) Coatings on Iron and Steel Products

A307 Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength

A325 Specification for High-Strength Bolts for Structural Steel Joints

A325M Standard Specification for High-Strength Bolts for Structural Steel Joints (Metric)

A490 Standard Specification for Heat Treated Steel Structural Bolts, 150 ksi Minimum Tensile Strength

A490M Standard Specification for High-Strength Steel Bolts Classes 10.9 and 10.9.3, for Structural Steel Joints (Metric)

A500 Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

A501 Standard Specification for Hot Formed Welded and Seamless Carbon Steel Structural Tubing

A563 Standard Specification for Carbon and Alloy Steel Nuts

A563M Standard Specification for Carbon and Alloy Steel Nuts (Metric)

A572/A572M Standard Specification for High Strength Low Alloy Columbiun Vanadium Steel of Structural Quality

A759 Standard Specification for Carbon Steel Crane Rails

A786/786M Standard Specification for Rolled Steel Floor Plates




A992/A992M Standard Specification for Steel for Structural Shapes for use in Building Framing.

E329 Standard Practice for Use in the Evaluation, Testing and Inspection Agencies Used in Construction

F436 Standard Specification for Hardened Steel Washers

F436M Standard Specification for Hardened Steel Washers (Metric)

F844 Standard Specification for washers, steel, plain, (flat) unhardened for general use.

F959 Standard Specification for Compressible Washer Type Direct Tension Indicators for Use with Structural Fasteners

AWS American Welding Society

D1.1 Structural Welding Code

QC1 Standards and Guide for Qualification and Certification of Welding Inspectors

ICBO International Conference of Building Officials

International Building Code (IBC), 2006 Edition

MSHA Mine Safety and Health Administration

NAAMM National Association of Architectural Metal Manufacturers

AMP-510 Metal stairs manual, Fifth edition

ICC International Code Council

International Building Code (IBC), 2006 Edition

OSHA Occupational Safety and Health Administration

CFR 1910D: Occupational Safety & Health Standards – Walking – Working Surfaces, Code of Federal Regulations

SJI Steel Joist Institute

Specification for Open Web Joists

1.3 Submittals

A. For submittals, refer to PO (Purchase Order)/ Contract and the following provisions:

B. General

1. Supplier shall prepare and submit schedules for detailing, fabricating, and delivering the steel. Supplier shall update schedules weekly.

2. Buyer’s Expeditor will be present full time in the Fabricator’s shop to monitor the progress of fabrication and to ensure that fabrication is progressing in accordance with the agreed schedule. Buyer’s Expeditor will report to the Buyer weekly and assist in communications between the Fabricator and Buyer for progress reporting and resolving issues.




3. Supplier shall submit the documents specified on the Supplier Drawing and Data Commitment form.

4. Supplier shall submit to the Buyer the following documents prior to start of fabrication:

a. Quality Control Program and Inspection Procedures

b. Sample engineering calculations for each type of fabricator-engineered connection

c. Checked erection and shop fabrication drawings

d. Welding Procedure Specification

e. Welding Procedure Qualification Records

f. Welders Qualification Records

C. Connection Design and Detailing

1. For complex structures which require special seismic connection detailing to AISC 341, the Fabricator shall submit evidence of successful completion of previous projects that the Fabricator has designed and detailed special seismic connections to the requirements of AISC 341.

2. Where evidence of previous experience to AISC 341 cannot be provided to the Buyer’s satisfaction, the Fabricator shall retain a specialist connection design and detailing firm from a short list provided by the Buyer.

3. A representative from the specialist connection design and detailing firm shall be in the Fabricator’s shop full time during the fabrication of any complex seismic connections to interpret the shop drawings and check that the work is fabricated in accordance with the details provided.

4. Submit engineering calculations for each type of the fabricator designed connections for review by the Buyer before starting shop drawings. Calculations shall be stamped and signed by a professional engineer registered in Peru.

5. Buyer reserves the right to audit the fabricator’s ability to successfully perform connection design and detailing. If technical problems are encountered, the buyer may assign connection design and detailing to a third party North American specialist connection design and detailing firm.

6. Lead Connection Design Engineer

a. Fabricator shall have 1 Lead Connection Design Engineer (LCDE) who will oversee the overall connection design to ensure consistency and eliminate any duplication of effort.

b. Each LCDE will submit his or her qualifications and proof of professional engineer registration in Peru for review and approval by the Buyer.

c. Additional connection design engineers may be utilized, provided one connection design engineer is responsible for the connection design for a complete structure.

d. Each LCDE shall stamp the connection design drawings and erection drawings for their respective contract areas with their Peru professional engineer stamp.

e. Each LCDE shall be in the Fluor Vancouver office for the first 6 months of the detailing phase of the work. During this time the LCDE and Buyer will work together to plan the work, prepare the conceptual connection designs and coordinate the start of shop drawing review.




7. Connection Design Process

a. Conceptual connection designs will be reviewed before the fabricator starts detailed connection design and preparation of shop drawings.

b. The review of conceptual connection designs will include confirmation of parametric calculation methodologies and development of standard connections for the following:

Standard beam shear connections

Simple beam end connections (including axial forces)

Standard splices

Typical moment connections

Common vertical bracing joint configurations

Common horizontal bracing joint configurations

Unique connections

c. Buyer and Owner construction team members will participate in the review of conceptual connection designs to provide input as to their impact on erection and their efficiency in the field.

d. Wherever possible, bolted field connections will be utilized. Field welding will be avoided unless absolutely necessary. If field welding is required, down-hand welding with backing bars will be utilized.

e. Where beam and girder connections are not detailed on the drawings, the connection shall be of the strength specified for Framed Beam Connections of the Manual of Steel Construction, 13th Edition, of AISC, and shall support no less than the reaction of the uniform load capacity of each particular beam or girder in relation to its size and span. The connection, however, shall in no case be less than ½ of the maximum shear capacity of the member, or loads indicated on the design drawings. The minimum length of a connection shall be determined using the maximum number (n) rows of field bolts compatible with the flange cope(s) and the T-dimension of the member.

f. Standard connections, as shown in parts 9 – 15 of the AISC Manual of Steel Construction, 13th Edition, shall be used. Unless noted otherwise, connections are to be designed to be consistent with Type 2 construction as defined by AISC.

g. Standard connection shall use 22 mm (7/8 inch) diameter A325 bolts. For heavily loaded connections, 28 mm (1 1/8 inch) diameter A490 bolts shall be used.

D. Drawings

1. Submit shop drawings, bills of material (including field bolt lists) and erection drawings for review by the Buyer before starting fabrication. Submit data for review in accordance with the Specification - Instructions for Use: “Supplier Drawing and Data Commitment Form”. Supplier is responsible for the adequacy of connections and the accuracy of fabrication and erection fitup.

2. Review of shop drawings by Buyer shall be for the purpose of confirmation of intent and agreement with general methods and arrangements only. Review shall not constitute verification of dimensions or quantities nor engineering performed by the suppliers.

3. Provide shop drawings for every member and piece mark, showing weld, number of bolts, nuts, washers, connecting materials.




4. All erection drawings, shipping lists and documents shall be prepared in two languages on the same document - English and Spanish. Shop detail drawings shall be prepared in English and the language of the shop, if the language of the shop is not English.

5. All drawings will be issued in SI (metric) units.

6. Shop drawings shall show clearly the specification and grade of steel to be used and grade of electrode to be used.

7. Provide for sufficient erection clearances on shop details.

8. Surface preparation and shop applied coatings, including areas to be masked shall be noted on the shop drawings.

9. Show the general arrangement of the work on erection drawings. Identify every member by a piece-mark, position and indicate field-welding and drilling. Show the PO Number and Engineering Drawing Number on both, erection diagrams and shop fabrication drawings. Identify on the shop fabrication drawings the pay class of each piece mark.

10. Provide bolt lists with summaries to show quantities, sizes and lengths. Include 15 percent extra quantities for each size and length, but in no case fewer than 2 bolts. List separately temporary bolts that are supplied for erection only.

11. Submit calculations for all connections (other than standard connections) for review, in advance of the related shop drawings.

12. Final Erection Diagrams shall be stamped and signed by a Professional Engineer registered in Peru.

13. Fabricator shall affix a blank shop drawing review stamp, provided by the Buyer, to each shop drawing before submitting them.

14. Erection and shop fabrication drawings shall be submitted to the Buyer for review in an electronic format (Adobe Acrobat pdf files).

15. Fabricator shall make arrangements with a print shop in Vancouver to print 1 set of shop and erection drawings at Fabricator’s expense each time shop drawings are submitted. This print shop will receive the shop drawings electronically from the Fabricator, print them and deliver the prints to Fluor Structural group. Erection drawings to be printed on 22” x 34” paper, shop drawings on 11” x 17” paper and illegible shop drawings on 22” x 34” paper.

16. As a result of the review, the Buyer will assign a grade of A, B or C to each shop drawing. The meaning of each grade is:

Grade Meaning

A No comments made by Buyer during review, fabrication may proceed.

B Comments made by Buyer during review but fabrication may proceed if the fabricator does not disagree with the comments.

C Comments made by Buyer during review must be resolved and shop drawings must be resubmitted for review before fabrication can proceed.

17. Only shop drawings that are grade B or C will be returned via the Buyer’s Project Online (POL) system.

18. Buyer will provide a transmittal to the Fabricator showing the review grade of each drawing. Grade B and C drawings will be available on POL.




19. After review is complete, Fabricator shall submit Certified for Construction (CFC) shop drawings on CD to the Buyer. Buyer will post these PDF files to POL so that all team members have access to the most up-to-date steel shop drawings four weeks after review.

20. Fabricator shall submit a drawing index of all CFC drawings in Excel format. The drawing index shall be updated by the Fabricator weekly. The Buyer will post this index to POL so that all team members have access to the most up-to-date information.

E. MTRs (Material Test Reports)

1. Submit certified material test reports two weeks after receipt of materials to verify that materials meet applicable specifications.

2. Fasteners and fastener list shall be shipped prior to the first shipment of fabricated steel for each release. The manufacturer’s test certificates and each lot number shall be indicated clearly on each container shipped, so inspectors can check lot numbers against test certificates received at the job site.

F. Subcontracted items

Scope and procedure qualification records for purchased items subcontracted by Supplier shall be reviewed by Supplier for content and contract compliance before submittal to Buyer’s Representative for approval.

G. Record Documents

1. One set of reproducible final erection drawings, shop fabrication drawings and field bolt lists shall be submitted to Buyer before shipment of steel. A shipping list (including total weight of release and weight of shipment), a bolt list, and one set of final erection drawings shall precede the first shipment of each release.

2. The fabricator shall submit as a minimum the following documents to the Buyer for record purposes:

a. One reproducible set of final erection drawings in English and Spanish and shop detail drawings in English.

b. Records of quality control inspection test reports requested by the Buyer.

c. One set of final engineering calculations for each type of fabricator-designed connection sealed and signed by the responsible professional engineer registered in Peru.

d. Records of calibration and re-calibration performed on the tools and equipment used by the fabricator during the work.

1.4 Quality Control and Quality Assurance

A. Requirements

1. Supplier shall be solely responsible for quality control of all materials and workmanship.

2. Fabricator shall establish a shop Quality Control (QC) program to perform inspection and testing to assure conformance with contract requirements. Fabricator’s QC program and inspection system shall be submitted in writing to the Buyer in sufficient detail to delineate those items to be inspected and the manner of inspection. The QC program shall completely describe all fabrication quality control activities contemplated, including provisions for adequate documentation of the Fabricator’s performance of such quality control and inspection.

3. Additional quality control program requirements may be outlined on the Purchase Order/Contract.




4. Fabricator’s QC program shall be subject to the Buyer’s approval before commencement of work.

5. Buyer’s Quality Assurance (QA) representative will audit the Supplier’s Quality Control program on a periodic basis. Fabricator’s QC representative shall cooperate fully with the Buyer’s QA representative and give the Buyer’s QA representative full and unrestricted access to the Fabricator’s records and facilities used for the fabrication work.

6. Supplier shall be certified by the AISC Quality Certification Program (AISC, 13th Edition). Supplier shall maintain fabrication plant certification in AISC Category II – Complex Steel Building Structures during the fabrication work.

7. Certified mill test reports, which include heat numbers or other identification, shall be submitted for steel to be used in the work. Such mill test reports shall show that the steel conforms to this specification.

8. Welding procedures and individual welders shall be qualified in accordance with the requirements of AWS D1.1.

9. A copy of each prequalified welding procedure intended to be used in the work shall be submitted before the start of welding.

10. A certificate of qualification shall be submitted for each welder, welding operator, and tacker employed on the work.

11. Inspection and Quality Control Reports shall be submitted to Buyer’s QA representative on the same day the tests are made. Each Test Report shall have a definite statement indicating compliance or noncompliance with the specifications. The fabricator's inspectors shall be qualified and certified as AWS Certified Welding Inspectors in accordance with AWS D1.1 or AWS QC1 or shall be trained and working under the supervision of an AWS Certified Welding Inspector.

12. Supplier's certificate stating conformity of the welding filler materials to this specification shall be submitted to the Buyer’s Representative.

13. Supplier's certification stating conformity of bolts, nuts, and washers to this specification shall be submitted to the Buyer’s Representative.

14. Supplier’s certification stating conformity of shear connector studs to this specification shall be submitted to the Buyer’s Representative.

15. There may be more than one supplier on the project. The detailing concepts coming from different sources are to be matched. Where steel members connected to each other are supplied by different fabricators, the connection details shall be coordinated by each fabricator through the Buyer’s Representative or the Prime Supplier (if applicable) to ensure proper match.

2. PRODUCTS

2.1 Materials

A. Use only new materials.

B. Structural steel wide flange shapes, including WT shapes shall conform to ASTM A992/A992M, unless noted otherwise. All other structural shapes, plates and bars shall be in accordance with ASTM A36/A36M, unless noted otherwise.

C. High strength bolt assembly- shall consist of a LeJeune or equal Tension Control (Twist Off) structural bolt, a heavy hex nut and a hardened flat circular washer. All bolts shall conform to ASTM A325, except otherwise specified on design drawings. Bolt/Nut/Washer shall conform to




ASTM F1852, Type 1. High strength heavy hex head structural bolts may substitute for Tension Control (Twist Off) bolts in the following connections:

Removable members where specified on design drawings.

Where designed bolt size is larger than 28mm (1-⅛ inches).

Where space is restricted to permit use of installation tool for Tension Control (Twist Off) bolts.

Where LeJeune bolts or equal are unavailable in quantities required by Project.

Classified areas where use of electric tools is not permitted.

D.Standard bolt assembly- shall consist of one heavy hex head structural bolt conforming to ASTM A307, Grade A, one heavy hex head nut conforming to ASTM A563, Grade A, and one hardened washer conforming to ASTM F436.

E.D. Structural tubing shall conform to ASTM A500, Grade B, unless noted otherwise

F.E. Steel pipe shall conform to ASTM A53, Type E or S, Grade B. (use type S for railing)

G.F. Anchor bolts shall conform to ASTM A36 or ASTM A307 Class C unless noted otherwise.

H.G. Crane rails shall conform to ASTM A1 or ASTM A759, as applicable, unless noted otherwise.

I.H. Checkered plate – ASTM A786, pattern 4 or 5 and ASTM A36. (Four way safety plate, 6mm (¼ inch) thick excluding height of raised pattern)

J.I. Welded steel bar grating- ASTM A569 - Welded steel , plain surface, 32mm ( 1-¼ inch ) by 5mm ( 3/16 inch ) bearing bars at 30mm ( 1-3/16 inches) O.C., cross bars at 100mm ( 4 inches) O.C. All sloping and outdoor grating shall be serrated. Heavier grating type shall be used in limited areas as indicated on drawings.

K.J. Safety Grip Walkway Channel

Preformed, hot dip galvanized, ASTM A525, G-90, 30” wide, 11 gauge, as manufactured by Fisher & Ludlow (SHUR GRIP walkway channel, part number SW16115-G) or Engineer approved equal. End bearing length of any panel must be at least 2 ½”.

L.K. Grating Clamps

Grating clamps shall be reusable type, as manufactured by Hilti, FCM grating clips,E.P.I., Pittsburgh, PA; G-Clips, as manufactured by Gratins Specialty Co., New Orleans, LA; Grate-Fast, as manufactured by Struct-Fast, Inc., Wellesley Hills, MA; or an approved equal. Entire assembly to be painted or stainless steel. Clamps shall be of the size required for the thickness of grating.

M.L. Stair Treads

Stair treads shall be ASTM A569 metal serrated grating with perforated or checker plate standard nosings. The tread shall be fabricated from serrated, welded grating having 32mm (1-¼ inches) by 5mm (3/16 of an inch) bearing bars at 30mm (1-3/16) inch centers, and cross bars at 100mm (4-inch) centers unless noted otherwise on drawings. A standard nonslip nosing shall be provided on the grating at the head of stairs.

N.M. Bolting material shall be U.S. origin raw material. Bolts, nuts and washers shall be manufactured by Buyer approved manufacturers using materials and methods in accordance with ASTM specifications, and shall bear the manufacturer's markings. Fill material shall have traceable mill test.

O.N. Direct tension indicators (load indicator washers) when specified shall be manufactured to ASTM F959 by J & M Turner, Inc., or Buyer approved substitute.




P.O. Low hydrogen welding electrodes with a tensile strength of 70 ksi shall be used. Electrodes shall be compatible with the welding process and with the materials being welded.

Q.P. Material or work that does not meet the requirements of the drawings and specification shall be repaired or removed and replaced solely at the Supplier's expense.

R.Q. Nuts for high strength bolting: ASTM A563, Grade DH.

S.R. Washers: Hardened round washers shall be manufactured to ASTM F436 and must show manufacturer's mark. Washers for use with short slotted or oversized holes on over 1-inch diameter A490 bolts must also be 5/16 of an inch or thicker.

T.S. Headed studs (shear connectors): ASTM A108 headed stud, Type B.

U.T. Plate Girder flanges shall be limited to 50mm (2 inches) in thickness maximum.

2.2 Surface Preparation, Painting, and Galvanizing

A. Surface preparation for painting and galvanizing of structural steel shall be in accordance with 240K-C2-ES-55-002 Paint Equipment Standards. Bolt surface preparation and finish shall match the connected steelwork.

B. Structural steel shall remain unpainted in the following areas:

1. Where concrete and steel are in contact.

2. At contact areas to be field-welded.

3. Crane rails.

4. Surfaces of friction-type connecting connections(unless primed with Buyer approved primer).

5. As noted on drawings.

C. Touch-up coatings damaged during material handling or trial assembly.

D. Galvanizing of the structural steel, if so noted on the design drawings, shall be in accordance with the appropriate specifications. Bolts, nuts, and washers should be zinc coated under the supervision of the bolt manufacturer. Zinc coating should be either mechanically deposited to ASTM B695 Class 50 or by hot dip to ASTM A153. Zinc coating shall be undertaken on Type I A325 bolts only. Mechanically deposited galvanizing of fasteners is recommended for its superior uniformity of coating thickness.

E. Hot dip galvanized bolts should have the nuts tapped oversize after galvanizing. Mechanically galvanized nuts should be tapped oversize before galvanizing. In both cases, the nuts must be supplied lubricated (refer to ASTM 563, Section 4.8). A wax type lubricant that is visually identifiable is recommended such as Johnson's #140 or equal. In order to be certain that the nuts can be tightened without either seizure of the nut or stripping, there shall be a turn test on at least 2 samples from every lot shipped as described in Section 6.3 of ASTM A325. The supplier is required to supply the wax with the materials.

2.3 Connections - General

A. Shop fabricated connections shall be welded whenever possible or high-strength bolted bearing type connections (Type N) using A325 or A490 bolts. Members with shop-bolted connections shall be assembled to the same tolerances as shop-welded members. Shop-bolted connections shall be tightened “snug tight”.

B. Bolted connections for primary structural members shall be made with minimum ¾ 7/8of an inch diameter high strength bolts conforming to ASTM A325 or A490 in bearing type connections with threads included in the shear plane unless noted otherwise as slip-critical (friction-type)




connection. The design and assembly of high strength bolted connections shall be in accordance with AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts. High strength bolted connections Connections bolted with A490 bolts shall be indicated clearly on the erection drawings.

C. For the odd areas where High Strength Tension Control (Twist Off) bolts are unsuitable and substituted by high strength heavy hex head slip-critical connections, tighten bolts by either of the following:

1. Turn-of-nut method

2. Direct tension indicating devices (preferred)

3. Job calibrated wrench method

D. For job calibrated wrench method, wrench calibration shall be checked at least once each working day to ensure accuracy. For turn-of-the-nut method, match-mark nut and bolt before final tightening to provide visual means of noting nut rotation. For DTI method, use the indicating devices as directed by the manufacturer and in accordance with Paragraph 8.d.4, Direct Tension Indicator Tightening, of the Specification for Structural Joints using ASTM A325 or A490 Bolts, as approved by the Research Council on Structural Connections and endorsed by AISC and in accordance with ASTM F959. Inspection to check tension as well as snug-tightness of plies. AISC specified slip-critical allowable based on surface conditions shall be used. Connection material subjected to tension forces shall be checked for prying action.

E. Bolted connections for secondary members, (such as purlins, girts, and stair framing) may be made with ¾ of an inch diameter machine bolts as bearing type connections (type N) conforming to ASTM A307 with the following exceptions. Bolts for stair bracing, handrails, and toe plates shall be ⅝ of an inch in diameter, conforming to ASTM A307 unless noted otherwise.

F. Gusset plates and connection materials shall be a minimum of 10mm (⅜ of an inch) thick.

G. Beam-splice connections are not permitted unless shown on the design drawings.

H. Where a beam connection is required to carry moment, design the connection for 100 percent of the moment capacity of the smaller connected member, as a minimum.

I. High strength bolts shall not be reused.

J. When member reactions or loads are shown on the drawings, they shall be used for the connection design.

K. Steel components designated as removable shall be marked as such, and their connections shall be detailed accordingly.

L. Connections shall have a minimum of 2 bolts.

M. Double angle members shall have bolted fillers spaced in accordance with AISC Specifications, 13th Edition.

N. Tubular and pipe member’s connections: Connections for tubular members shall be designed and fabricated in accordance with AWS D1.1. All welds shall be sealed. Connections eccentricities shall not exceed the values shown on drawings. As a minimum, welding of truss web members to truss chords shall be either continuous fillet weld with a throat size equal to web member wall thickness or complete penetration welded.

O. Column Connections

1. Design column base plate connection as welded and column field splices as bolted unless noted otherwise. The splice location shall be approved by Buyer.




2. Finishing of column base plates shall be in accordance with section M2.8 of the 2005 AISC Specification for Structural Steel Buildings.

P. Bracing Connections

1. Design bracing to resist the forces shown on the buyer's drawings. Where forces are not shown, then design as outlined below.

a. X-bracing: Design x-bracing as tension bracing. Design connections for 50 percent of the tension resistance capacity of the member.

b. K-bracing: Design k-bracing and single bracing members in a structure level as compression bracing. Design connections for 100 percent of the compression resistance capacity of the member.

c. Make bracing connections with minimum of 2 bolts per line along the longitudinal axis of the member.

d. Fasten horizontal bracing to intermediate beams to eliminate sag, and connect cross bracings at the intersection point with one bolt for angles and two bolts for tees.

e. Vertical bracing and knee bracing shall have gusset plates on column centerlines, unless indicated otherwise on drawings.

f. Vertical bracing at the intersection of a column, beam and brace, gussett plate shall be connected to both, the beam and the column. The work point shall be at the intersection of the column and beam centerlines.

g. For connection of vertical braces to nominal beams 300mm ( 12 inches) or larger, the working point may be at the intersection of a horizontal line 125mm ( 5 inches ) below the top flange when the brace is above the beam and above the bottom flange, when the brace is below the beam and the centerline of the bay. See engineering drawings for other details.

h. Design connection materials members, plates and angles with due consideration to eccentricities included by offsets from the working line of the bracing system. When eccentricities result in bolts being subject to tension forces, design shall include the effects of prying in connection design.

i. Bracing connections shall be reviewed and approved by Buyer’s Representative before fabrication.

Q. Welding

1. Welding, including procedures, appearance, and quality of welds, and methods for correcting welding work, shall be in conformance with AWS D1.1 and prequalified procedures accepted by Buyer.

2. Temperature of base metal to be welded shall conform to minimum preheat and interpass temperatures outlined in AWS D1.1 for the appropriate welding process and steel specification.

3. Minimum size of fillet welds shall be per Table J2.4 of AISC Manual of steel Construction 13th Edition, but no smaller than 5mm (3/16 of an inch), except as otherwise shown or noted on the design drawings.

4. Assemble and weld built-up sections by methods that will produce true alignment of axis without warp.

5. Butt welds in tension and compression flanges of Fabricated Plate Girders when the flanges are a 345 MPa (50,000 psi) yield point steel shall be heat stress relieved in the




area of the butt weld before the flange is welded to web. The width of the heated band on each side of the greatest width of finished weld shall not be less than two times the maximum material thickness. The stress relieving shall consist of heating the band to a mean temperature range between 590 and 650ºC (1100 and 1200ºF) and holding this heat for one hour for each inch of thickness up to 50 mm (2”) thick, over 50mm (2”) thick heat for 2 hours plus 15 minutes for each additional inch over 50 mm (2”) thick. The rate of heating and cooling shall be 205ºC (400ºF) per hour divided by maximum thickness in inches at weld. The furnace may be opened at 315ºC (600ºF) in still air. The fabricator shall ensure a tight fit of the girder web plate to the top flange prior to welding. Fabricator shall make records charting: heat treatment showing time and date, piece mark, location, thickness and duration of heat treatment.

R. Splices

1. Columns shall be 1-piece, without splices, except as otherwise shown on the drawings. Splices desired for convenience of Supplier shall be subject to acceptance by Buyer’s Representative.

2. Top and bottom chords of trusses and sway frames shall be 1-piece, without splices, except as may otherwise be shown on the drawings. Splices desired for the convenience of Supplier shall be subject to acceptance by Buyer’s Representative.

2.4 Fabrication and Manufacture

A. Fabrication methods shall follow the best accepted practice within the industry and shall be in accordance with the AISC Specification for the Design, Fabrication and Erection of Structural Steel for Buildings.

B. Fabrication shall be performed in a professional manner. Even though structurally sound, poor workmanship on prefabricated items shall be cause for rejection where appearance is a justifiable consideration.

C. Rolled material shall be in accordance with the tolerances specified in ASTM A6. Straightening shall be done by methods that will not injure or weaken the material.

D. Buyer shall approve in writing any substitutions in material or member size.

E. The size of assembled pieces of structural steel may be limited by the permissible weight and clearance dimensions of transportation. The Supplier shall provide field connections for such conditions. These connection details and locations, which shall be designed to minimize field work, shall be approved by Buyer. Preassemble structural steel items in the shop to the greatest extent possible so as to minimize splicing and field assembly.

F. Beams, except cantilever, shall be fabricated with the natural mill camber in the up position. Other camber shall be as called for on the drawings and shall be done in an approved manner.

G. Welding sequence and procedures shall be such as to minimize distortion and shrinkage. Where required by the drawings, welded assemblies shall be stress relieved by heat treating.

H. Clearly mark and match-mark components for erection at site.

I. Materials shall be delivered in the sequence shown on the erection shop drawings accepted by Buyer. When such sequence is not indicated, deliver materials in accordance with AISC Code of Standard Practice for Steel Buildings and Bridges.

J. Handle materials in a manner that will not cause overstress, warp, twist, or other damage.

K. Take precautions to prevent damage to protective coatings on surfaces of materials.

L. Store and protect materials at the site from damage, deterioration, and corrosion.




M. Where the physical truss and bracing end connection interfaces are located away from the working point of the intersecting members, the connecting materials shall be designed for the force system operating at the interface. The design shall include the effects of prying. The Buyer’s Representative will review and approve truss and bracing end connections.

N. Crane rail joints shall be staggered at least 3.7m (12 feet) on opposite sides of the runway and shall be at least 0.9m (3 feet) from crane girder joints.

O. Use of elements with mispunched or misdrilled holes is not allowed without prior approval of Buyer.

P. Do not shop splice members without the prior written approval of Buyer. When approved, shop splices shall develop 100 percent of the capacity of the member. NDE (Nondestructive Examination) for shop splicing shall be at the discretion of Buyer and at the expense of the fabricator.

Q. Keep field-welded connections to the minimum number practical. Provide erection clips required for field-welded connections.

R. Do not prime or finish paint joints to be field-welded.

S. Connections are to be symmetrical. One-sided connections require specific approval of Buyer. At skewed connections, bend connection angles and plates in a heated condition, and avoid cracking or other damage. Slotted or oversized holes shall not be used unless noted on the design drawings. When oversized or slotted holes are noted on the design drawings, they shall be sized in accordance with Table 1 of AISC Specification for Structural Joints using ASTM A325 or A490 bolts.

T. In new work, A307 bolts or high-strength bolts used in bearing-type connections shall not be considered as sharing the stress in combination with welds. Welds, if used, shall be proportioned to carry the entire stress in the connection. High-strength bolts proportioned for slip-critical connections may be considered as sharing the stress with the welds.

U. Composite beam connections shall be overdesigned by 60 percent as compared to similar noncomposite beams.

V. Bracing members shall be fabricated with a draw of 1.5mm (1/16 of an inch) per 3m (10 feet) of length with a maximum draw of 3mm (⅛ of an inch).

W. When directed by Buyer, certain fabricated pieces will be trial-assembled in shop at fabricators expense to ascertain that field assembly will have proper fit and no rework.

X. The deviation of crane girder straightness (sweep and camber) shall not exceed 9.5mm (⅜ of an inch), plus or minus, with a maximum rate of change of 6.4mm (¼ of an inch) in 6.1m (20 feet).

Y. All bearing stiffeners shall be milled at the bearing edges. The fabricator shall ensure a tight fit to flanges prior to welding.

2.5 Miscellaneous steel fabrication

A. Handrails (Process Buildings/Structures)

Handrails shall conform to OSHA Part 1910, Subpart D. Fabricate from pipe as shown on design drawings, with closed ends, heated and bent smoothly without distortion. Return ends of wall mounted rails to wall. Provide smooth continuous transition around turns and bends. Miter, weld, and grind smooth where exposed.

1. Horizontal Load

Must withstand a horizontal concentrated 90kg (200-pound) load with a top rail height of 1070mm (42 inches).




2. Toe Plate

Provide bar 100mm (4 inches) by 6mm (¼ of an inch) at platform handrails.

B. Corner Guards

Fabricate from 100mm x 100mm x 6mm (4-inch by 4-inch by ¼ of an inch) angle, with 12mm (½ inch) diameter by 100mm (4-inch) nelson stud anchors at 400mm (16 inches) O.C. (maximum), unless shown otherwise on design drawings.

C. Grating Assemblies

1. Fabricate from rolled steel shapes and grating as shown, providing for bolted connections unless otherwise shown and approved on shop drawings.

2. Grating shall be removable unless otherwise specified on the design drawings. Where grating is specifically indicated on the drawings as removable, the maximum weight of one section of grating shall be limited to 68 Kg (150 pounds). All other sections shall be limited to a maximum weight of 135 kg (300 pounds).

3. Grating shall be secured to the supporting steel beams by removable grating clamps. Two clamps per panel shall be used at each support with a minimum of 4 per panel. The clamps shall be supplied with 5 percent extra to cover losses. Clamp installation shall be done by the Erector.

4. Joints in floor panels perpendicular to the span of grating shall only occur over support members.

5. Notching of bearing bars at supports to maintain elevation is not permitted.

6. Openings dimensioned on the design drawing shall be cut and banded in the shop. Undimensioned openings shall be cut in the field.

D. Floor Plate Assemblies

1. Fabricate from rolled steel shapes and floor plate as shown, providing for bolted connections unless otherwise shown and approved on shop drawings.

2. Floor plate shall be field welded to steel supporting members, except floor plates indicated as removable on the design drawings.

3. Removable floor plates shall be secured with flush, counter-sunk bolts. The bolts shall be supplied by the fabricator with 5 percent extra to cover losses.

4. Joints in floor plates shall only occur over supports.

5. Openings dimensioned on the design drawings shall be provided by the Fabricator. These openings should be cut and banded in the shop. Undimensioned openings shall be cut in the field by others.

6. Drain holes 14mm (9/16-inch) diameter shall be provided for each 2 square meters (20 square feet) of area, with a minimum of 1 hole per panel.

E. Edge and Curb Angles

Fabricate from steel angles as shown on design drawings.

F. Grating Tread Stairs, and Checkered Plate Tread Stairs

1. Stringers and Framing: Conform to ASTM A36.

2. Treads and Landings: Checkered plate or grating as indicated on the drawings.

3. Nosings: Integral with treads and landings.




4. Safety Nosings: Type 120, 75mm (3 inches) wide, as manufactured by Wooster Products, Inc., or an approved equal

G. Construct steel frame assemblies of channels, plates, rolled sections, or combinations thereof to sizes shown. Accurately square, miter, butt or cope, and full-weld joints. Grind welds smooth that shall be exposed in finished work.

H. Galvanize fabrications, where noted, in accordance with ASTM A386

2.6 Inspection and Tests

A. Perform shop tests and inspections in accordance with the approved Inspection and Test Plan. The Buyer reserves the right to designate an Independent Testing Agency to inspect, sample and test steel materials/ fabrication of structural steel as required by the Buyer. Failure to detect any defective material/fabrication work shall not in any way prevent rejection when any such material/fabrication work is discovered, nor shall it obligate the Buyer for final acceptance.

B. Buyer’s QA / QC (Quality Assurance / Quality Control) Representative shall have reasonable access to Supplier's work place. Additional testing of welds shall be at the discretion of QA / QC Representative and shall apply to Supplier as well as other Suppliers.

C. Buyer reserves the right to remove test specimens from any portion of the work to verify the quality of the welding. Supplier, at own expense, shall repair or replace any base metal or filler metal found to be defective. Method of repair shall be approved by the Buyer.

D. NDE

Generally, NDE, methods, acceptance criteria, and additional requirements shall be as follows:

1. Visual Examination

a. Visual examination procedures shall be in accordance with AWS D1.1.

b. Supplier shall visually inspect all completed welds.

2. NDT Examination

a. The minimum extent of NDT (Mag. part, ultrasonic, radiographic, etc.) inspection shall be as follows:

(1) Full penetration welds 100 percent

(2) Partial penetration welds 50 percent

(3) Fillets welds 25 percent

b. Inspection of welds on dynamically loaded structures will be as noted on the design drawings.

c. Buyer shall reserve the right to request any other method of NDE for any corrective work performed by Supplier or in course of the work.

3. Buyer reserves the right at any time before final acceptance of the structural steel work to reject any portions of the work not in conformance with specified requirements. Buyer has sole authority to issue directives concerning defective structural steelwork.

4. Supplier shall provide inspection personnel with safe means of access to materials and facilities involved in the quality assurance and control work. Supplier also shall provide facilities normally on hand as required to assist in the quality assurance and control work.

5. Structural steel fabrication may be inspected and tested during all phases.

6. Verification shall be made of the type and quality of materials, and compliance of fabrication with design, size, and weight of members and assemblies. Attention shall be




given to milling of contact bearing surfaces and sheared sections, and to filleting of re-entrant cuts.

7. Bolted connections shall be inspected and tested in accordance with the recommendations of AISC Specification for Structural Joints using ASTM A325 or ASTM A490 Bolts, as approved by the Research Council on Structural Connections.

8. Testing Agency shall meet and follow the requirements of ASTM E329, Recommended Practice for Inspection and Testing Agencies for Concrete, Steel, and Bituminous Materials as used in Construction, including but not limited to Sections 3.2.3 through 3.2.7 under Responsibilities and Duties.

9. No peening, caulking or filling shall be permitted in repairing cracks, pin holes/blow holes.

10. Defective welds shall be repaired per AWSD1.1 by machining, grinding, chipping, or gouging and in such a manner that the base metal is not nicked or gouged.

2.7 Identification and Tagging

Piece-Marking System:

A. Steel stencil each erection piece mark number on the left-hand end as detailed. Mark the erection diagram in the corresponding "in place" position.

B. Piece-mark galvanized members using 1 of the following methods:

1. Metal tags stamped with the mark number and seal-welded to the member.

2. Mark numbers steel-stenciled on the member before galvanizing.

3. Mark numbers shall be at least 0.625 inch (15mm) high and shall be stamped or stenciled deep enough so that they will be legible after galvanizing.

2.8 Preparation for Shipment

A. Materials shall be delivered in the sequence needed for erection. Deliver materials in accordance with AISC Code of Standard Practice for Steel Buildings and Bridges. Typically, Loose base plates, steel embedded in concrete, first tier columns and framing for all its levels (including stairs and handrails), second tier columns and its framing, etc.

B. Include shipping/bar coding lists with each shipment of steel.

C. Two copies of the master shipping/bar coding list shall be transmitted by the Supplier in a waterproof package with each shipment of steel. An electronic copy in excel format shall be uploaded to POL the same day the steel is released for shipping.

D. Bolts required for erection of each package shall be shipped prior to the first shipment of fabricated steel for each unit or structure. All nuts, bolts and washers to be packaged in metal keg containers. NO EXCEPTIONS.

E. Mark each shipping piece as specified.

F. Bundle the fabricated steel for shipment in a manner that facilitates direct loading from transport trailers to the ship and off loading from the ship to transport trailers. Load small pieces in shipping containers.

G. Load containers, crib cars and trucks so that they can be unloaded readily and continuous drainage can occur. It is imperative that the Fabricator protect the steel and shop applied coating during transit.

H. Sizes of fabricated pieces shall be as large as practical, considering clearances and capacities of railroad cars, trucks and shipping containers.




I. Protect exposed threaded parts from damage during shipping.

J. Include paint for touch-up.

2.9 Material Tracking

A. General

As soon as shop drawings are grade A or B and the comments are incorporated, the fabricator shall submit an Excel spreadsheet which lists each piece together with its WBI, AISC section name, length, weight and pay class for the Buyer to load into the Buyer’s material management system, MatMan. The fabricators will assign a unique MatMan mark piece number to each piece based on a template provided by the Buyer.

B. Shipment

Each shipment of steel will be assigned a "Ship Group" within the Expediting Module of MatMan and will be tracked and reported on, accordingly. These ship groups are housed within each respective Purchase Order, and the status of important milestones is reported by Expediting. These milestones include such important steps as:

Drawings Issued

Detail Drawings Received

Fabrication Completed

Inspection Released

In Transit, Received, etc.

C. 2D “QR” bar coding will be implemented for structural steel. After the fabricator has submitted the piece mark list, the Buyer will provide bar code labels to the fabricator for each package. The bar code numbers will be a product of MatMan, applied by the vendor/fabricator, and used from readiness-to-ship through issuance to erectors at site.

D. Shipping lists as Excel spreadsheets that can be loaded into MatMan will be provided with each shipment. Shipping list will include the MatMan mark piece numbers. Logistics will use the data from these shipping lists to generate the required paperwork.

3. EXECUTION

Not applicable.

4. ATTACHMENTS

Not applicable.

End of Specification