SITE VISIT (KKB FABRICATION YARD)

During the factory visits at 16th, 23rd & 29th March 2011, the progress was mainly on cutting for the previous month. For month March the major work had been focus on the assembly and fit- up for the girders. It had been total of 10 girders fitted into shape but not fully complete fabricate during the 23rd March site visit and the last visit for March at 29th, the girders of 30 nos already been fitted in shape and 6 nos were completed with the fillet joints flange to web.

The work sequence for the steelworks:

1. Surface preparation2. Prime coating3. Cutting4. Jointing (transverse weld-flange to flange)5. Fitting/ fit up (Assembly)6. Jointing (flange & web)7. Painting & coating application

We had discussed the work sequence for item 1. Surface preparation to item 4. Jointing (welding) Flange to Flange at the QA/QC report no. 6 and this report will discuss on the assembly part of the girders for the last 2 visiting.

16th March 2011

The major progress of KKB still focuses on the cutting and jointing progress. None of the fit-up or assembly work been carried out. They had been finish cutting for the steel girder’s flange (Top & Bottom) and web during end of February. The stiffness, bracing and splice plate had taken a lot of time on cutting and preparation for the jointing for this month.

Bottom plate of slide guide bearing were ready to sent to site for installation

Flame cutting for the equal angle

Welding for transverse flange jointing

Rough surface after welding

Goughing

Ensure 100% joint fusion & remove the discontinuities of the root pass after gouging

Welding transverse wed in progress and each weld run-off plate stacking and ready for testing at Johor. (Professional Testing services Sdn. Bhd.)

Each run-off plate prepared for testing purpose marked with the name of qualified welder from KKB.

Name: Bantin Anak SadanStampsNo:QW-46

Name : Muncheng Anak MiluTamp No. QW-01

Name : Tingga Ak MedangStamp No. QW-51

23rd March 2011

This visiting had shown us the great progress of the steel girders, it finally fitted into shape. The total of 10 girders been fitted up by spot weld only. The fillet weld for connection web to top and bottom flange was not completed yet.

All the equal angle, stiffeners & splice plates were completed cutting and drilling.

29th March 2011

During the visiting with the Hart Builders and representative of JKR, the visit was focus on the progress of the fabrication of steel girders. The girders with temporary tack weld ready for the flange to web joint are around 24 nos and completed jointing of flange to web are 6 nos. The testing for Non destructive testing, radiographic testing was planned to perform at the early of April prior delivery to site.

Fillet weld (Flange to web joints

Girders in shape ready for jointing

Completed fillet weld

ASSEMBLY FOR STEEL GIRDER

Hanged or clamps the web to the assembly point for fit-up. The web was plated horizontal / laid in flat and support by the vertical square steel case as temporary support during welding.

Adjusted the web into position, suitable allowance for the weld connections shall check by welding section before weld started.

flange

web

Clamps

Welding for flange and web

With the exception of longitudinal web to flange welds and longitudinal stiffeners to web welds, all stiffeners, gusset plate, or any other detail material welded to girder webs shall be a minimum of 300 mm from the web butt welds.

Gusset

The welding sequence outlined in the procedure specification shall be such as to avoid needless distortion and shrinkage stresses in accordance.

A fully automatic single-pass submerged arc used to connect the flange plates to the web plates, unless the fabricator has special welding fixtures capable of supporting the flange in a horizontal plane while centering the web on the flange and simultaneously welding both sides of the web to flange connection.

Removal of the slag, rough weld, weld spatter shall be ground smooth prior to painting work

Factory visit of KKB Fabrication yard on 29th March 2011