METHODOLOGY

4.1 Material
All material shall be procured from approved vendors and confirm to the relevant
specification given in PMC specification. The equivalent or alternative material shall be used
after the necessary approval of Deviation request.
If materials test results or certificates are not available shall not be use. All material shall be
confirming with relevant specification by manufacturer's mill certificates, in case of absence
of such certificates, test samples shall be sent to approve laboratories for conformation.
For none confirming laboratory results reports the material shall be Rejected & kept in
designated "Non Confirming area" immediately, until removed from site/fabrication vard.

• 4.1.1 All structural steel materials shall confirm to the IS 2062 E250A/ E250B as per
drawing .

• 4.1.2 Covered electrodes for metal are welding of structural steel shall conform to IS 814 &
tested as per IS 1608.

• 4.1.3 Wire electrodes for submerged arc welding of structural steel shall conform to IS
7280. The combination of wire and flux shall comply with IS 3613.

• 4.1.4 Filler rods and wires for gas welding shall conform to IS 1278. Filler rods and bare
electrodes for gas shielded are welding of structural steel shall conform to IS 6419.

• 4.1.5 Bolt and nuts (including lock nuts) shall conform to IS 1363, IS 1364, IS 1367, IS
3460, IS 3757,
IS
6623, IS 6649 and IS 6639 as applicable.

4.1.6 Washers shall conform to IS 5369, IS 5370, IS 5374, IS 6610 and IS 6649 as applicable.
Bolts

4.2 Receipt & Storage

4.2.1 Each section shall be marked for identification & each lot shall be accompanied by
MC/IRN. All material shall be from approved manufacturers with proper correlation of
papers.

4.2.2 All section shall be checked, sorted out & arranged by grade & quality in the storage
area.
All material shall be free from surface defect such as pitting, cracks, laminations, twists, etc.
Defective material shall be rejected and kept in designated “Non Confirming Area”
immediately, until removed from site/fabrication yard.

4.2.3 Welding electrodes/consumables shall be kept in the

_store with manufacturing
recommendations as per Procedure No. PDPP-8230-MS-071-0002 for Receipt handling
storage & usage of welding consumables to avoid damping and also stored separately by
quality and lots inside a dry and enclosed room in compliance with IS 9595. Defective
material shall not be used & proper log of the material shall be maintained. All consumables
shall be accompanied with BTC. Electrodes shall be kept perfectly dry to ensure satisfactory
operation and weld metal soundness.

• 4.2.4 All nuts & bolts shall be kept in the storage area as per the size. All nuts & bolts shall
be brought to the site with Manufacturer's test certificate.

• 4.2.5 In case material does not come with its MTC or comes with un-matching MTC
sampling shall be done for the required Laboratory tests for each section. After acceptance of
tests results only the materials can be used.

4.3 Fabrication

Mark the plates as per drawing & erection marking system as per PDRP-8320SP-0017,
Clause No. 9.2 to carry out the cutting operation after proper inspection. All the cutting
operation shall be carried out by Gas Cutting. Grind the cut edges smooth to remove burrs
and slag.
Stack the plates at designated place in the fabrication yard in proper sequence.

• 4.3.1 WAI fabrication work shall be done with the IF-C Drawings & detail fabrication
drawing.

• 4.3.2 Fabrication area shall be levelled before start of fabrication

• 4.3.3 Marking & cutting shall be done as per IF-C drawing. Prior to cutting, all members
shall be properly marked, showing the requisite cut length, width, connection provisions e.g.
location and dimensions of holes, welds, cleat, etc. Marking for cutting shall be done
judiciously so as to avoid wastage or unnecessary joints, as far as practicable. Marking shall
be done by placing members on horizontal supports / pads in order to ensure horizontal and
straight placement of such members. Marking accuracy shall be limited to + 1 mm Cutting
may be affected by shearing, cropping or sawing. Gas cutting will be done by mechanically
controlled torch or manual cutting torch depending on cut length cutting profile.
Shearing, cropping and gas cutting shall be clean, square, free from any distortion & burrs,
and if necessary, the edges shall be ground afterwards, to make the same straight and
uniform.
• 4.3.4 Straightness of all material shall be checked & if required straightening shall be done
to make free from twist. All straightening and shaping to form, shall be done by pressure and
not by hammering. Bending (if required) shall be done by cold process only.

• 4.3.5 Fabrication tolerances shall be maintained as per IFC drawings & IS 7215.

• 4.3.6 Cutting shall be done after proper marking & checking with IFC drawing. Gas cutting
shall be clean, square, and free from any distortion and burs. All sharp, rough, broken edges
and all edges of joints that are subjected to tensile or oscillating stresses shall be ground by
grinding. All edges cut by Oxyacetylene process shall be cleaned of impurities and slag by
grinding prior to assembling. Electrical metal are cutting or gauging shall not be allowed.
Cutting tolerance shall be (i) ‡ 1mm for members connected at both ends (i) ‡ 3mm
elsewhere.

• 4.3.7 Holes for bolts should not be formed by gas cutting process, if it is formed in any
additional case during erection at site for adjustment of bolt hole then it shall be internally
smooth finished by power tools and fabricated washer is to be provided instead of readymade
one. Holes through more than one thickness of material of numbers and girder flanges shall
be drilled after the members are assembled and tightly clamped/bolted together.

Punching may be permitted before assembly, provided the thickness of metal is less than 16
mm and the holes are punched 3 mm less in diameter than the required size and reamed, after
assembly, to the full diameter. Punching shall not be adapted for dynamically loaded
structures.
Holes may be drilled in one operation through 2 or more separable parts and burrs removed
from each part after drilling. No gas cutting holes are permitted. Holes in connecting angles
and plates, other than splices, also in roof members and light framing, may be punched full
size through material not over 12 mm thick, except where required for close tolerance bolts or
barrel bolts.
All matching holes for black bolts shall register with each other so that a gauge of 2 mm less
in diameter than the diameter of hole shall pass freely through the assembled members in the
direction at right angles to such members.
Finished holes shall not be more than 2 mm in diameter than the diameter of the black bolt
passing through them, unless otherwise specifics by PMC Engineer- in - Charge.
Holes for turned and fitted bolts shall be drilled to a diameter equal to nominal diameter of
shank or barrel subject to 1-18 tolerance specified in IS 919 Parts to be connected with Holes
not drilled through all the thickness in one
operation shall be drilled to a smaller size and reamed out after assembly. Where this is not
possible, the parts shall be drilled and reamed separately.
All erection holes where bolts are not used should be plugged by welding.
To facilitate grouting, holes shall be provided in column bases or seating plates exceeding
300 mm in width for the escape of air.
To avoid accumulation of water in gusseted column bases of laced, batten or box type
stanchions, suitably reverse U-type holes shall be provided at the junction of base plate and
column section in the vertical gussets for draining out of any water.

4.3.8 Assembly:
The components shall be assembled and aligned in such a manner that they are neither
twisted nor otherwise damaged and shall be so prepared that the required camber, if any, is
provided. Proper clamps, clips, jigs and other fasteners (bolts and welds) shall be placed in a
balanced pattern it to avoid any distortion in the members and to ensure correct positioning
(i.e. angles, axes, nodes, etc.). Any force fitting / pulling / stretching of members to join them
shall be avoided. Proper care shall be taken for welding shrinkage & distortion so as to attain
the finished dimensions of the structure shown on drawings.

4.3.9 (A) Bolting: All bolts shall be provided such that no part of the threaded portion of the
bolts is within the thickness of the parts bolted together. Washers of suitable thickness shall
be used under the nuts to avoid any threaded portion of the bolt being within the thickness of
parts bolted together. The threaded portion of each bolt shall project through the nut at least
one thread Flat washers shall be circular and of suitable thickness to afford a seating square
with the axis of the bolt. The method of tensioning shall be in accordance with IS 4000 as per
table no.3 & 4 clause 7.2.1 & 7.2.2.
Tensioning of bolts and nuts using a direct tension indication device shall be in accordance
with the manufacturer's instructions and the following procedure. On assembly all bolts and
nuts in the joint shall be first tightened to a 'Snug tight' condition to ensure that the load
transmitting piles are brought into effective contact.
After completing this preliminary tightening to 'Snug-tight' the bolt and nut shall be tensioned
to provide the minimum bolt tension by Torque-wrench & inspection of bolt tensioning shall
be in accordance as per IS 4000 clauses 8.2, note Annexure D. The discipline Engineer shall
be responsible for controlling all the activities related to bolt tightening as per this method
statement.
The concerned foreman shall be responsible for carrying out the actual bolt tightening to the
required torque values as per this method statement under the supervision of discipline
engineer.
OC Inspector shall be responsible for verifying the correct application of this procedure.

(B) Sampling: At least three bolts, desirably of the same size (min. length may have to be
selected to suit the calibrating device) and condition as those under inspection shall be placed
individually in a calibrating device capable of indicating bolt tension. A hardened washer
shall be placed under the part turned.

4.3.10 Edge preparation/ bevelling for the fusion faces shall be done for welding as
mentioned in the drawing & as per the approved WPS. The tolerance on limits of gap, root
faces & included angle shall be as per IS: 9595.
Generally no special edge preparation shall be required for members under 8mm thick.

4.3.11 Cleaning: Welding edges & adjacent area of the members (extending up to 20 mm)
shall be thoroughly cleaned of oil, Grease, Scale, Dirt, Rusts, etc. Root gap for welding shall
be free from all foreign materials.

4.3.12 Preheating shall be done as per approved WPS / IS 9595, if required. Preheating shall
be done in such a manner that the parts, on which the weld metal is being deposited, are
above the specified minimum temperature for a distance of not less than 75 mm on each side
of the weld line. The temperature shall be measured on the opposite to that being heated.
However, when there is access to only one face, the heat source shall be removed to allow for
temperature equalization (1 min for each 25 mm of plate thickness) before measuring the
temperature.
The Temple stick or Calibrated Digital Temperature scanner shall be used to measuring the
preheat temperature.

• 4.3.13 Welding: Welding shall be done as mentioned in the drawing & approved WPS.
Adequate protection against rain, dust & strong winds shall be provided during welding
operation. No welding shall be carried out in absence of the mentioned facilities. Electrodes
for manual welding shall comply with IS 814. Weld metal deposited by an automatic or semi-
automatic process will have mechanical properties not less than the minimum specified for
the weld metal deposited by electrodes complying with IS 814. All electrodes shall be
classified, coded or marked in accordance with IS 814. Electrodes shall be packed, stored and
protected from weather effects in accordance with the conditions specified by the
manufacturer. The welding procedure adopted and consumables used shall be specifically
approved vendor list given by PMC/OCL

• 4.3.14 Process of welding shall be as per Project specification/ Approved drawings,

SMAW/GMAW process shall be preferred.

Procedure tests (PQR) shall be carryout in accordance with IS 7307. The test weld shall be
held at ambient temperature for a minimum period of 72 hours prior to testing and shall be as
per IS 7307. The selection of Low
Hydrogen Electrodes shall be as follow:
A) All butt weld having thickness more than 13 mm thick.
B) All base plate welding.
C) Moment connections & others as per drawings. Sequence of welding,
• As far as practicable, all welds shall be made in a sequence that will balance the applied
heat of welding while the welding progresses and to minimize distortion.
• The direction of the general progression in welding on a member shall be from points where
the parts are relatively fixed in position with respect to each other towards points where they
have a greater relative freedom of movement.
• All splices in each component part of a cover plated beam or built up member shall be made
before the component part is welded to other component parts of the member.
• Joints expected to have sufficient shrinkage shall be welded before joints expected to have
lesser shrinkage.
• Welding shall be carried continuously to completion with correct number of runs.
• Welding Procedure: After the fusion faces are carefully aligned and set with proper gaps,
the root pass of butt joints shall be executed properly so as to achieve full penetration with
complete fusion of the root edges. On completion of each run welding slag shall be removed.
Any visible defect shall be removed to sound metal. All full penetration welding shall be
completed by chipping/gouging to sound metal & then depositing a seal run of weld metal on
the back of the joints. Care shall be taken to avoid any kind of movement of the components,
shocks, vibrations to prevent occurrence of weld cracks. All welds shall be visually checked
for its completeness. Welding approval shall be taken before start of the subsequent activities.
• Welding procedure qualifications & Welder performance qualifications shall be carried out
as per IS - 7307
& IS - 7310 respectively.
• In joints connected by fillet welds, the minimum sizes of single run fillet welds or first run
shall conform to requirements of IS 813 & IS 816. Fillet welds shall be made with two or
more passes.
• Visual inspection: All finished welds shall be visually inspected. The following types of
welds' defects and faults shall be inspected.
•
• Weld defects occurring at the surface such as blow holes, exposed porosity, infused welds,
etc.
• Surface cracks in the weld metal or in the parent metal adjacent to it.
• Damages to the parent metal such as undercuts, burning, overheating etc.
Profile defects such as excessive convexity or concavity, overlapping, unequal leg lengths,
excessive reinforcement, incompletely filled grooves, excessive penetration beads, root
grooves, etc.
• Distortion due to welding i.e., local shrinkage, camber, bowing, twisting, rotation, wariness
etc.
• Liner eccentric, angular, and rotational misalignment of parts.
• Dimensional errors: The size of the specified weld may be slightly over but not under.
Welds not complying with the above acceptance requirements and as specified by IS codes,
shall be corrected in part or whole either by removing and replacing or as follows: Excessive
convexity: Reduce to size by removal of excess weld metal.
• Shrinkage cracks: Defective to be removed up to sound metal and in parent plates and
craters re-welded with confirming the method of Dye penetration test.
• Under cutting: Additional weld to be deposited.
• Improperly fitted: Welding to be cut and edges suitably prepared and parts misaligned parts
re-welded.
• Members distorted b: Member to be straightened by mechanical means or by the heat of
welding careful application of limited amount of heat.
• In removing defective parts of a weld, gouging, chipping, oxygen cutting or grinding shall
not extend into the parent metal to any substantial amount beyond the depth of weld
penetration, unless cracks or other defects exist in the parent plates. The weld or parent plates
shall not be undercut in chipping, grinding, gouging or oxygen cutting.
• NDT/Repair of weld shall be carried out in accordance with IS 822Bolting & Splicing shall
be done in accordance with the IS 800 & IF-C drawings.
•
• All primer application members shall be shop painted. Painting shall be done in accordance
with Project Specification Standard for Protective painting systems Doc no. PDRP-8440-SP-
0006
• Only visually inspected fabricated items shall be sent to blasting shop.
• Welds shall not be painted or otherwise observed until they have been inspected, approved
& accepted.
• 4.3.15 Non Destructive Testing of Welds: -

• 4.3.15.1 TEL shall carry out final inspection of all welds in accordance with IS 15326.

• 4.3.15.2 All welds shall be visually inspected in accordance with IS 15326 before any non-
destructive testing. (NDT) is performed. Any welds that will be rendered inaccessible by
subsequent work shall be examined prior to loss of access. QC & welder shall ensure visual
inspection of the relevant types of welds. All full penetration welds shall be radio graphed or
Ultrasonic tested as per requirement of project specification or approved ITP.
• 4.3.15.3 Non-destructive testing of welds shall be applied to the relevant joint types. The
weld thickness and frequency of testing of joints requiring NDT is in accordance with
applicable Indian Standards.

• 4.3.15.4 Magnetic particle inspection (MPI)/ Dye penetrant inspection (DPI) shall be carried
out in accordance with IS 15326. Final surface flaw detection shall be carried out not less
than 16 hours from time of completion of the weld to be inspected. Where a welding
procedure requires an inspection after initial weld runs before further welding is performed,
such inspection may be carried out when the weld metal has cooled to ambient temperature.
A suitable qualified person for surface flaw detection of welds may be a welding inspector or
a. welder who holds a current certificate of competence in surface flaw detection of the
relevant types of work, from a nationally recognized authority.

• 4.3.13.5 Ultrasonic inspection shall be carried out in accordance with IS 15326.

Examination shall be carried out not less than 16 hours from time of completion of the weld
to be inspected, or not less than 40 hours in the case of butt welds thicker than 40mm.
Operator carrying out final ultrasonic examination shall hold a current certificate of
competence for the relevant types of work, from a nationally recognized authority.

4.4 Surface Preparation:-

Surface preparation for steel structure is listed in Project Specific Standard for Protective
Painting system Doc no.
PDRP-8440-SP-0006.
• Part Nos./ Heat Nos./ Identification no. shall be marked by hard punch on a corner of the
structure / Assembly.
• The temperature & humidity parameters shall be ensured as per the specifications (Max
Humidity level 85% & Temp Ambient). A moisture separator unit shall be mounted on the
compressors hose line so that compressors air shall be free from moisture and oil.
The surface preparation of the fabricated materials shall be carried out by blasting, power
tool-cleaning techniques to meet the required specific surface preparation/ roughness as per
Sa 2½ or SSPC-SP-IO. Also procedure and degree of surface preparation are shown in
project specific standard for protective painting system Doc no. PDRP-8440-SP-0006
• The surfaces where the approach by blasting nozzle is difficult, cleaning by power tool
would be done to achieve the necessary surface profile.
• The surface preparation by blasting shall meet the requirements of Sa 2½ as per ISO 8501-1
shall be inspected and recorded in approved format. Only dr./ blast cleaning techniques shall
be employed and abrasives shall be re-usable steel grit or mixture of iron and steel grit. A
non-metallic blast abrasive, i.e. aluminium oxide or garnet shall be used when abrading
stainless steel surfaces.
• Compressed air to be used for surface preparation shall be filtered free of oil and moisture.
Only trained operators shall carry out the Surface preparation activity after wearing adequate
personal protective equipment.
• In case of Structures / Plates, after completing the Surface preparation on one side, the job
shall be turned and surface preparation shall be carried out on the other side.
• After shot/grit blasting and just prior to paint application, all dust & blasting residues shall
be removed from the material surfaces by brushing and blowing down using clean dry air.
• Items shall be inspected for correct profile using profile gauge / comparator - ISO 8501 - 1
after completion of surface preparation. Surface profile shall be uniform to provide good key
to the paint adhesion.
• Surface of steel structures if to be fire-proofed with concrete or mortar covering shall not be
painted.

4.5 Shop Painting:-

• Painting system for steel structure is listed in project specific standard for protective
painting system Doc no. PDRP-8440-SP-0006. Only qualified applicator shall be deployed
for painting works. The primer coat shall be applied over completely dry surfaces with airless
spray in a manner so as to ensure a continuous and uniform film without "holidaying". The
primer coat shall be air-dried and shall have a required dry.
Film thickness after drying:
• Dry film thickness (DFT) readings shall be taken using a non-destructive dry film thickness
instrument capable of storing the readings. Sufficient readings shall be taken covering each
coat prior to application of the following coat to ensure the correct required DFT.
• Steel surfaces shall not be painted within a suitable distance of any edges to be welded if the
paint specified would be harmful to welders or impair the quality of welds.
• Welds and adjacent parent metal shall not be painted prior to deslagging and final
inspection approval.
• Primer or first coat of paint shall be applied within 4 hours of surface preparation.

4.6 Packing Transportation Delivery:-

A) After final shop acceptance by TPIA/PMC, and marking of drawing and component
number, the items shall be packed and loaded for transportation.
B) Packing must be adequate to protect items against warping during loading and unloading.
Proper lifting devices shall be used for loading, in order to protect items against warping.
C) Slender projecting parts shall be braced with additional steel bars, before loading, for
protection against warping during transportation.
d) During transportation any damaged happens, that should be re-fabricated at site before
erection.

4.7 Erection :

• Before start of erection all crane & Hydra & other lifting equipment's shall be ensured of
having proper test certificates so that it can work safely for the required load of the member.
• Storing & Handling shall be done to avoid excessive stress & any damage.
• The erection clearance for cleated ends of members shall be not greater than 2 mm at each
end. The erection clearance at ends of beams without web cleats and end plates shall be not
more than 3 mm at each end. Erection tolerances as per IS 12843.
• Proper safety precautions shall be taken before & during the erection work each worker
shall be trained for precaution taken for erection jobs.
• The framework must be sufficiently braced to prevent wind damage.
• Steelwork shall be hoisted and erected in position carefully, without any damage to itself,
other works and injury to workmen.
• During erection, the steelwork shall be securely bolted or fastened. Wherevernecessary
temporarily braces shall be provided for all loads to be carried by the structure during
erection, including those due to erection equipment and its operation.
• All field assembly and welding shall be executed in accordance with the requirements for
shop assembly and welding. A hole for all erection bolts where removed after final erection
shall be plug weld.
Alternatively, erection bolts may be left and secured.
• A specific erection scheme with methodology shall be submitted to PMC. In case of
criticality of structures, equipment etc., the erection scheme shall be submitted separately.
• During high wind velocity, ghai rope (wire rope sling) will be tied up at the column top at
the time of erection and full tightening of bolts & nuts in structural members after erection.
• Erection inspection the structure shall be checked by the area In-Charge/QC for the
following including finish grade such as levelness, plumb-ness, etc. (Member installed,
dimensional c heck, grade of bolt and size, bolt tightening, paint repairs) A punch list shall be
Prepared by the TEL Engineer.

4.8 EIT-UP & WELDING:-

The component parts shall be aligned without any damage / twist and proper clamps, clips.
Jigs and fasteners shall be so placed to avoid any distortion in the nos. and ensure correct
position. Proper care shall be taken for welding shrinkage and distortion so as to attain the
finished dimension of the structure as shown on the drawings.
Fit-up shall be made as per approved drawing using qualified welder. Upon clearance of fit-
up by QA/OC & Inspection authority, all welding shall be done using approved welding
procedure specification in accordance with IS: 7307 or ASME section IX / project
specification and other relevant codes. Necessary arrangement is made to provide no of
welding sets of required quantity, consumables, cutting and grinding equipment with
requisite accessories, equipment and material required for carrying out the job. Edge
preparation for welding is done as per the dimensions/ details in the drawing. Welding edge
and adjusting area and the gaps between the members shall be thoroughly cleaned of all oil,
grease, scale and rust and made completely dry before welding starts. Welding shall be
carried out continuously o completion with correct no. of runs. It is preferable to have two
nos. of runs (min). On completion of each run, all slag and Spatters shall be removed and
wire brushing & light chipping shall clean the weld & adjusting base metal. Visible defects
such as cracks, cavities and other deposition faults, if any shall be removed to sound metal
before depositing subsequent run of Weld. All full penetration butt welds shall be completed
by chipping to solid metal and then depositing a seal runs of weld metal on the back of joints.
While welding is in progress, care shall be taken to avoid any kind of movement of the
components, shocks. Vibrations to be prevent occurrence of weld cracks.

4.9 INSPECTION & TESTING OF WELD:-

The method of inspection shall be according to the relevant applicable codes & standards and
to be carried out during all stages of fabrication & erection, to check the conformity with the
relevant specifications and IS codes / standards. Defects & faults occurring at the surface
such as blow holes, exposed porosity, unfused welds, surface cracks in the weld metal etc,
profile defects like excessive convexity or concavity, overlapping, incomplete filled grooves
excessive penetration heads root grooves etc. Distortion due to welding (i.e) local
shrinkage, camber, bowing, twisting, rotation etc. & other dimensional errors, eccentric
angular & rotational miss.
minimum inspection check points as follows:

PRIOR To Fabrication
Checking of structural steel material supplied by contractor / manufacturers test certificates /
testing (as applicable)
Welding filler material approval / qualification manufacturing test certificates / documents
Testing, if any
WPS / PQR / WPQ (Welder's Performance qualification)

FABRICATION ACTIVITIES SHOP

Dimensional and fit-up checks
Visual check for welding primer application painting material
Surface preparation (Blasting), Shop painting (Visual & DFT)

FIELD ERECTION ACTIVITIES

Alignment & levels

Fit-up
Field welding Grouting
Final Painting

INSPECTION & TEST DOCUMENTS

Review test and Inspection documents

4.10 Grouting :-

• Grouting shall be done as per Grouting Specification-PDRP-8310-SP-0012. Type of grout

shall be used for major steel structures as per specification & drawing requirement. For type
grout, surface preparation, grout preparation, mixing, placing, curing and testing shall be in
accordance with manufacturer's written instruction.
• Prior to positioning of structural columns / girders / trusses over the pedestals/ columns/
brackets, all laitance and loose material shall be removed by wire brush & chipping. The
bearing concrete surfaces shall be sufficiently levelled hacked with flat chisels to make them
rough, cleaned & made thoroughly wet. Thereafter, the structural member shall be erected,
aligned & plumbed maintaining the base plates / shoe plates at the levels shown in the
drawings, with necessary shims/ pack plates /wedges.
• The thickness of grout shall be as per the approved civil drawings.

4.11 Check List –

1. Preparation of check list location & axis wise

2. All check list items shall be completed mentioning date of completion.
3. Check list incorporating PMC/Client comments are to be Verified by PMC/Client.

4.12 Final painting :-

Final painting shall be done as per Doc. PROTECTIVE PAINTING SYSTEM PDRP-8440-
SP-0006.
• The shop-coated surfaces shall be rubbed down thoroughly with emery / abrasive paper to
remove dust, rust, other foreign matters and degreased, if required in accordance with IS
1477, as applicable, cleaned with warm fresh water and air dried. The portions from where
the shop coat has peeled off shall be touched up and allowed to dry. Special care shall be
taken to cover all the crevices, corners, edges etc.
• The over coat of paint shall be applied after the first coat is hard dry or manufacture's
recommendation to be followed.

5.0 QUALITY ASSURANCE /QUALITY CONTROL

Quality control of fabrication & erection will be as per quality plan and corresponding
Inspection Test Plan.
Format of records as appended to this procedure will be maintained for erection.
• Following shall be checked while carrying out the job.
• Fabricated member shall be checked for measurement/ dimensions from drawings.
• Foundation bolts must be true to vertical position. Their location, orientation shall be
checked and must be matching with column base plate hole. Check shall be carried out for
condition of the thread before erection of structure.
• To provide proper support /bracing to sections /members and other components in position
during erection.

6.0 HEALTH, SAFETY AND ENVIRONMENT

• Safety aspects shall comply with IS: 7205 for necessary safety & adhere to safe erection
practices and guard against hazardous as well as unsafe working conditions during all stages
of erection.
• During erection, the steel work shall be securely bolted or otherwise fastened and when
necessary, temporarily braced/ guyed to provide for all loads to be carried by the structure
during erection till the completion, including those due to the wind, erection equipment & its
operation etc.
• No permanent bolting or welding shall be done until proper alignment has been achieved.
Proper access, platform and safety artangement shall be provided for working and inspection,
whenever required.
• Area shall be cordoned off during erection activity.
• Qualified and experienced engineers / supervisor, safety officers must be available during
entire period of crection and alignment of structures.
• All workers engaged shall be experienced and well trained for the specific job including
medically fitness for height work.
• All required PPE would be used by all people engaged for the job.
• Where workers on a construction site are exposed to vertical drops of 6 feet or more, TEL
shall provide fall protection in one of three ways before work begins:
• Placing guardrails around the hazard area,
• Providing personal fall arrest systems for each employee. Safety nets must be inspected for
wear, damage, and other deterioration at least once a weck, and after any occurrence which
could affect the integrity of the system.
• Defective nets shall not be used, and defective components must be removed from service.
• Objects which have fallen into the safety net, such as scrap pieces, equipment, and tools,
must be removed as soon as possible from the net.

7.0 DOCUMENTATION

The following document needs to be maintained and submitted.

• Material Inspection and acceptance report
• Release Note
• Paint application records including record showing surface preparation
• Fit up record, welding record, NDT record
• Bolt tightening reports
• Grouting reports
• Alignment records