Engineering Construction and Erection Company LLC Technical Procedure for Fabrication and Welding of Structural Steel Client: M/S. AL EZZ CO LLC Document: ECE/FP/002 Rev. No.:0 Contract NO. : ECE/262 Prepared by: QA Dep.Technical Procedure for Fabrication and Welding of Structural Steel FE CONTENTS 1.0 SCOPE 2.0 DEFINITIONS 3.0 GOVERNING STANDARDS 4.0 MATERIAL CERTIFICATION 5.0 MARKING FABRICATED STEEL 6.0 FABRICATION 7.0 WELDING 8.0 SHOP ASSEMBLY 9.0 PLATFORMS, WALKWAYS, STAIRWAYS & LADDERS 10.0 TOLERANCES 11.0 INSPECTION 1of 9 ECE/FP/002 Rev. No.0Technical Procedure for Fabrication and Welding of Structural Steel +E SCOPE This Procedure establishes the principles to be followed by ECE in the fabrication structural steelwork and the performance requirements of all operations necessary to complete this work. This Procedure is to be read in conjunction with the Scope of Works as outlined in this document. DEFINITIONS * ECE - ENGINEERING CONSTRUCTION AND ERECTION COMPANY LLC * QA/QC Engineer - QUALITY ASSURANCE / QUALITY CONTROL « ITP - INSPECTION AND TEST PLAN * QCF - QUALITY CONTROL FORMATS * ENGINEER — A DULY DESIGNATED INDIVIDUAL WHO ACTS FOR THE OWNER. GOVERNING STANDARDS 3.1 General Except where otherwise stated, the works shall be in accordance with the relevant AWS D1.1: 2015 Standard. This should include, but not be limited to those identified. Except as modified by the requirements specified herein or the details on the drawings, work included in the Procedure shall conform to the applicable provisions of these publications. 3.2 Document Precedence if conflicting requirements occur in the documents; the order of procedure shall be: @ AWS D1.1: 2015 @ The Contract Documents 3.4 Documentation by Contractor The following documentation shall be forwarded to the Engineer. - Inspection and Test Plan. - Welding Procedure. 20f 9 ECE/FP/002 Rev. No.: 0Technical Procedure for Fabrication and Welding of Structural Stee! FE Welders Qualification Certificates. Material Certificates. Non-destructive Examination Records. Painting / galvanizing Records. Dimensional Inspections Records. Release Certificates MATERIAL CERTIFICATION 4.1 General All material for fabrication shall be clearly stamped / marked with the manufacturers’ numbers and cross-referenced fo the certified material Receiving Inspection report (MRIR). MTC's from the manufacturer shall show the heat / batch number and mechanical and chemical properties derived from testing of the steel. Material received without certificates shall be quarantined, pending completion of the above. 4.2 Mill Test Certificate (MTC) Copies of all Mill Test Certificates covering the chemical and physical properties As BS EN 10204 / Clause 3.1 is the min. requirements of the steel to be used in the work shall be fumished to the Engineer on request and records shall be kept for inspection. 4.3 Units of Measurement alll steelwork plates/sections/members/bolts, shall be metric units. MARKING OF FABRICATED STEEL alll marking of steelwork shall comply with the following requirements and shall be subject to the agreement of the Engineer. - Each piece of steel work shall be distinctly marked by hard stamping and shall include orientation marks for ease of erection. FABRICATION 6.1 General All fabrication shall be carried out in a workmanlike manner generally in accordance with the applicable AWS D1.1: 2015 Clause 5. 30f9 ECE/FP/002 Rev. 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APF 6.2 Cutting Plates, members, brackets and other steel work shall be cut in compliance with ECE Fabrication drawing which contains all dimension details clearly. - All edges shall be smooth profiled, flattened and equalized unless otherwise shown on the design drawings or agreed by the Engineer. - The end of tubular or hollow sectians shall be profiled to fit the Snape of the members to which they connect, and shall not be sheared or flattened unless otherwise shown on the design drawings or agreed by the Engineer. 6.3 Punching and Drilling of Bolt Holes - The bolt holes clearance shall not exceeds 3 mm regardless of hole size/dimension. - Oversized and slotted holes for high strength bolts will not be permitted unless shown on the design drawings or otherwise agreed by the Engineer. 6.4 Machined Surfaces Rockers, rollers or hinge gearing sets shall be machined fo the radii shown on. the design drawings, with the axis of rotation at right angles to the direction of the motion of the structural members which they support. Machining tolerances shall be as shown on the design drawings. 6.5 Splicing in Members - All structural members shall be single lengths, except where splices are shown ‘on the design drawings, or where the Engineer has given prior written approval. 6.6 Boxed Members - A butting edges shall be connected and sealed with a continuous welds - Weld reinforcement ground flush only when shown in the drawings - Stiffeners and other details that will be enclosed within the box members shall be subject to inspection by the Engineer before the closure plates are welded into place. 6.7 Connections = In general, shop connections shall be welded and field connections shall be bolted, unless otherwise shown on the drawings. All bolting and welding shall conform to steel structures specifications. - Unless otherwise noted, only one butt joint connection for each steel assembly (Either tubular or non-tubular members) shall be allowed per each 10 meters length of the member. 6.8 Shop Errors Fabrication errors or potential errors resulting from incorrectly detailed components are to be reported immediately to the Engineer. The Engineer will consider the action required for correction or modification of the work. Should corrections be necessary, written instructions will be given to the Contractors to carry out such work to the account of the responsible party. 4of9 ECE/FP/002 Rev. No.:0Technical Procedure for Fabrication and Welding of Structural Steel FPF 6.9 Inspection during Fabrication During fabrication, the Contractor shall permit the Engineer or the nominated representative free access to the Fabricators Works at all reasonable times for the purpose of carrying out inspections. Units shall be laid out and fabricated as necessary so that all parts are accessible for final inspection before transportation to the site. Where steel has been inspected by the Engineer at the shop, before being delivered to the site, such inspection shall not relieve the Contractor of the responsibility for the correctness of the fabricated steel. WELDING - All welds should conform the Welding procedure Specification arranged by ECE QA/QC Engineer. - All welds shall be general purpose (GP) unless noted otherwise on the approved drawings. - All welds shall be made with the appropriate grade of electrode suitable for the grade of steel being welded. Welds shall be thoroughly chipped to remove slag and shall be the full size specified and/or as shown on approved drawings, - Unless otherwise noted, all butt welds shall be complete penetration butt welds and where possible, shall be Single V but! welds except that in the 25 mm base plate or higher thickness the welds shall be Double V and made with low hydrogen electrodes. Over reinforcement of butt welds and pronounced bumps shall be of 3mm maximum Height. Subject to the Engineer's approval. Beams, flange plates, web plates and cord members of long trusses may be butt welded in the shop to form any long lengths required provided that such splices in the member, in the case of compound members, the splices in the individual units shall be staggered by not less than 40 mm weld length As shown in (annex 1- Fig. B) - Unless otherwise noted, all built up H-Sections with an 8mm web thickness or less shall be welded by SAW process for only one side of each T-Joint vice-versa as shown in (annex 1 Fig. C), since the other side shall be intermittent Fillet weld by not less than 40 mm weld length of FCAW process; in the case of higher web thicknesses the two-sided corner of each T-oint shall be welded by SAW continuous weld. The Fillet weld size should comply with (Annex 1 - Fig. A) -To enable complete assemblies to be erected, site welding of individual members attached to main shop fabricated pieces shall be permitted as indicated on the Engineer's /fabrication drawings. The individual members shall be welded to their main components at ground level. - Adequate mobile welding facilities shall be provided for this operation. - Site welding may be used. All relevant details and procedures must be approved by the Engineer before site welding can commence. - Qualification of welding procedures and personnel shalll be carried out. Sof 9 ECE/FP/002 Rev. No.0Technical Procedure for Fabrication and Welding of Structural Stee! FPF Weld procedures shall be approved and personnel shall be qualified prior to commencing welding on structural steel or components. Documentary evidence of personnel qualifications shall be submitted to the Engineer for review prior to fabrication. - Unless noted otherwise on the drawings an attached Annex-2 shall be followed to provide a general purpose clarification of the commonly used joint details / schemes illustrated by welding symbols SHOP ASSEMBLY Sections of the fabricated steelwork shall be shop assembled when specified on the drawings. During shop assembly, drifting of misaligned holes shall not be permilied. Misaligned holes shall be drilled and reamed to a larger size and larger bolls fitted, subject to the agreement of the Engineer. PLATFORMS, WALKWAYS, STAIRWAYS AND LADDERS The platforms, stainways and ladders and associated attachments shall conform to: Fixed platforms, walkways and ladders - design, construction and installation and the following requirements. 9.1 General All decking shall be firmly fixed to the supporting steelwork. Shop fixings shall be welded and field connections shall be bolted unless otherwise shown on the drawings. Bolts or other fixings on the surfaces of platforms, londings and walkways shall be countersunk flush with the surfaces. 9.2 Floor Grating Floor gratings shall be as specified on the approved drawings. Gratings shall be furnished to be continuous over two spans, or more where practicable. Grating panels shall be banded. Longitudinal and cross bars in ‘adjacent sections shall be in line when erected end to end. Where removable grating is required, the maximum grating panel shall be normally 1500 mm x 1200 mm wide. TOLERANCES Tolerances for shop fabricated steel shall comply with the relevant requirements of AWS D1.1: 2010, unless specified otherwise on the design drawings. The deviation in pian position of a column shall not exceed 10 mm from its specified position at any point. 6of 9 ECE/FP/002 Rev. No.:Technical Procedure for Fabrication and Welding of Structural Steel FE 11.0 INSPECTION Welding of shop fabricated structural steel and field welding shall be subjected to Non Destructive Tests (NDT) as follows: 1- Visual inspection of 100% of all welds shall be performed. 2. All welds of all thicknesses range to be tested by 10% of Liquid (Dye) penetrant test (LPT) 3. Any additional tests can be carried out by a third party based on the contract documents and/or based on the Engineer requirements. Table | give Us initial guide to major methods for the nondestructive examination of welds. or jable tm inspection Equipment [Enables ‘Advantages |Limitations |Remarks Method Required Detection of | | Visual Magnifying Surface flaws- |Low cost. Applicable to ||Should always lass cracks, Can be surface Ibe the primary Weld sizing porosity, applied while defects only. method of gauge unfilled craters, work isin Provides no inspection, no Pocket rule slag inclusions _|process, permanent |matter what Straight edge _Warpage, ‘permitting record. Jother ‘Workmanship underwelding, correction of |techniques are standards ‘overwelding, faults. required, poorly formed Gives |Is the only } beads, lindication of "productive" ‘misalignments, incorrect ype of improper fitup procedures. linspeetion, | Is the Inecessary function of leveryone who in any way ‘contributes to the making of the weld. Radiographic Commercial Interior ill X-ray X-ray or |macroscopie indications i 1g inspection is gamma units flaws-cracks, larerecorded angles of —_required by ‘made porosity, blow on film, gives exposure, many codes especially for holes, lapermanent — operating and inspecting nonmetallic record. equipment, __|specifications. 7of 9 ECE/FP/002 Rev. No.: 0Technical Procedure for Fabrication and Welding of Structural Stee! FF welds, inclusions, __|When viewed and |Useful in castings and incomplete root on a interpreting qualification forgings. penetration, {fluoroscopic indications. _jof welders and |Film and |screen,alow- Requires welding [processing | ‘cost method safety processes. facilities. |burnthrough. of internal _ precautions. [Because of Fluoroscopic | inspection _Not generally cost, its use viewing | suitable for should be equipment. | fillet weld limited to , inspection. those areas | |where other methods wi ? {fot provide thie {assurance |required. Special Excellent for Simpler to use Applicable to (Elongated commercial detecting ‘than ferromagnetic defects parallel equipment, _ surface radiographic materials ‘tothe Magnetic {discontinuities |inspection. only. magnetic field powders - dry [especially Permits Requires skill |may not give or wet form; surface cracks. [controlled in |pattern; for may be ‘sensitivity, interpretation this reason the ‘fluorescent for ‘Relatively of indications |field should be ‘viewing under low-cost. and lapplied from lultraviolet method, recognition of |two directions | irrelevant [at or near right patiems. _jangles to each Difficult to other. use on rough. i surfaces. Commercial Surface cracks Applicable to Only surface [In thin-walled kits not readily |magneticand defects are __|vessels will containing visible to the nonmagnetic detectable. _[reveal leaks fluorescent or unaided eye, materials. Cannot be __jnot ordinarily dye penetrants Excellent for Easy to use. used located by and locating leaks Low cost. effectively on usual air tests. developers. in weldments. | hot irrelevant ‘Application assemblies, [surface ‘equipment for iconditions |the developer. (smoke, slag) |A source of |may give 80f9 ECE/FP/002 Rev. No.:0Technical Procedure for Fabrication and Welding of Structural Steel FE ultraviolet misleading ‘light -if indications, ‘method is used. /Special ‘Surface and | Very ‘Requires high |Pulse-echo [commercial ‘subsurface sensitive. __|degree of skill jequipment is equipment, flaws including Permits ‘in interpreting {highly either of the those too small probing of — pulse-echo developed for |Auorescent | [pulse-echo or to be detected joints (patterns, |weld | transmission [by other inaccessible [Permanent inspection wn YPC. methods. to record is not .purposes...._ Standard Especially for radiography. readily ‘The reference detecting i ‘obtained. ‘transmission- patterns for subsurface | | type interpretation lamination-like equipment lof RF or video |defects. simplifies "patterns. pattern linterpretation where it is | applicable, 12.0 ATTACHMENTS Annex -1: Fillet weld sizes, Built up and intermittent welds configuration. = Annex.-2: a general purpose joint details. 9of 9 ECE/FP/002 Rev. 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