Steel Fabrication Method Statement

7/24/2019 Steel Fabrication Method Statement

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ABRICATION METHOD

STATEMENT

Document Number : W-

17

Date : 15.07.2011Revision : 02Page : 1/13

FABRICATION MT!OD "TATMNT

ATA# N$INRIN$ CON"TR%CTION

TRAD INC. CO.

Rev.00

P&e'a&e( B) A''&ove( B)

"ign

ABRICATION METHOD

STATEMENT


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1.0

TAB* OF CONTNT"

"COP OF +OR# ,

2.0 PRO$RAMM ,

3.0 MATRIA*"

3.1 MATRIA* "%PP*- ,

3.2 MATRIA* IDNTIFICATION AND TRACABI*IT- ,

3.3 RA+ MATRIA* T"TIN$ 5

,.0 MT!OD "%NC OF T! +OR# 5

,.1 FABRICATION 5

,.2 FABRICATION PROC"" 0

,.2.1 C%TTIN$ P*AN" 0

,.2.2 MAR#IN$ 0

,.2.3 C%TTIN$ 7

,.2., "TRAI$!TNIN$ 7

,.2.5 BNDIN$ 7

,.2. !O*" 1

,.2.7 NOTC!" 2

,.2. A""MB*- 10

,.2. BO*TIN$ 10

,.2.10 +*DIN$ 10

,.2.10.1 D$ PRPARATION IN"PCTION 10,.2.10.2 FIT%P A""MB*- 10

,.2.10.3 BAC#IN$ "TRIP IN"PCTION 11

,.2.10., +*DIN$ PROC"" 11

,.2.10.,.1 T-P OF +*DIN$ PROC"" 11

,.2.10.,.2 *CTROD" 1

,.2.10.,.3 PR!AT AND INTRPA"" TMPRAT%R 1

,.2.10.,., "%NC OF +*DIN$ 4CONTRO* OF

DI"TORTION AND "!RIN#A$ 2

,.2.10.,.5 6I"%A* AMINATION OF +*D" 2

,.2.11 PROCD%R FOR B%I*T %P $IRDR" / BAM" 1013

,.2.11.1 PRPARATION OF MATRIA* 10

,.2.11.2 FIT%P A""MB*- 11

,.2.11.3 +*DIN$ PROC"" 11

,.2.12 NOND"TR%CTI6 T"TIN$ 4NDT 12

ABRICATION METHOD

STATEMENT


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4.2.12.1$NRA* R%IRMNT OF 6I"%A* IN"PCTION


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3.2. Mate&ia8 I(entii;ation an( T&a;ea


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ll steel material shall be straight and free from bends or twists. $f the sections are distorted or

twisted during transit, storage etc. they shall be straightened andor flattened by straightening

machine at ambient temperature, though minor bends may be corrected by limited heating under

super-ision.

ABRICATION METHOD

STATEMENT


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Date : 15.07.2011

Revision : 02Page : /13

4.2.+ Ben(ing

The bending of plates and sections to specially required shapes shall be done on appropriate

machine.

4.2.6 !o8es

%unching and or drilling shall be done accurately as per the drawings and burrs remo-ed effecti-ely.

:here se-eral parts are to be connected to -ery close tolerances, such parts shall be first

assembled, tightly clamped together and drilled through. ll holes shall be minimum 1.+mm larger

than the sie of the bolt. The holes shall be drilled reamed within the allowable limits specified in

%roect specs. ;oles for bolts shall not be formed by a gas cutting process e5cept in special case

with specific permission of the customer.

4.2.< Not;>es

The ends of all oints, beams and girders shall be cut truly square unless required otherwise and oist

flanges shall be neatly cut away or notched where necessary, the notches being 'ept as small as

possible.

4.2.= Asse?


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ABRICATION METHOD

STATEMENT


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4.2.> Bo8ting

ll bolt and nuts shall be used as per appro-ed shop drawing and contract specification. nchor boltand nuts shall be as per specification.

4.2.10 +e8(ing

:elding procedure qualifications and welders and welding operators performance qualification test

shall be made in accordance with ?( "* $(/ or rele-ant (T standards.

4.2.10.1 (ge P&e'a&ation Ins'e;tion

The edges or surfaces of parts to be oined by welding shall be uniform, smooth and cleaned from all

foreign materials such as moisture, slag, oil, grease, paint, scale or rust. "dge preparation shall be

-erified for proper groo-e angle and root face dimensions. :elding groo-e dimensions shall be

inspected as per shop drawings under tac'7welded condition prior to welding. The allowable

misalignment of adoining plates to be butt7welded shall be in accordance with :( @1.1or ?(7"*7

$(/.

4.2.10.2 Fit9' Asse?


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ABRICATION METHOD

STATEMENT


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Date : 15.07.2011Revision : 02Page : /13

@uring welding wor', the most appropriate arc length, angle and welding speed shall be

maintained so that welding defects shall be a-oided and arc energy requirements are satisfied. &illet weld terminating at the end of members shall be returned continuously around the corner for

a distance of not less than twice the sie of the weld.

(urfaces of butt oints required to be flush shall be finished so as not to reduce the thic'ness of the

inner base metal or weld metal than 1mm or +B of the thic'ness whiche-er is the smaller not lea-e

reinforcement that e5ceed 1mm. ll reinforcement shall blend smoothly into the plate surfaces with

transition areas free from undercut.

#hipping and gouging shall be used, pro-ided grinding follows them.

$n the case of multi layer welding, slags and spatters on each completed bead shall be remo-ed

prior to the start of welding for the following layer.

ll craters shall be filled to the full cross section of the welds.

4.2.10.4.1 T)'e o +e8(ing P&o;ess

ll :elding acti-ities shall be carried out as per the appro-ed :elding procedure specification.

The following :elding %rocess used in &abrication wor's

$) A ) %rocess

(: %rocess

: %rocess

(: %rocess

4.2.10.4.2 8e;t&o(es

The electrodes used for welding shall be of suitable type and sie depending upon specifications of

the parent materials, the method of welding, the position of welding and quality of welds desired.

;owe-er, only low hydrogen electrodes 8"


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4.2.10.4.3 P&e>eat an( Inte&'ass Te?'e&at9&e

%reheating of abo-e 6+ degree # shall be applied for o-er 3=mm thic' of (3++F, F/, F2 and !2

steel plate by means of o5y7 acetylene flame or non7carboniing li'e G%). Hniform heating of the

surface e5tending up to a distance of three times the thic'ness of the plate on either side of the plate

shall be obtained. %reheating minimum 1


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Temporary lugs, braces and clips shall be welded in connection with :%( and these shall be

remo-ed without damaging the base metal and the area ground flash and smooth.

4.2.11 PROCD%R FOR B%I*T %P $IRDR" / BAM"

,.2.11.1 P&e'a&ation o Mate&ia8

ar'ing of steel shall be done in accordance with the shop drawings and cutting plan. aterialcutting shall be carried out by gas. "ither by pug cutting or #*# machine to cut the plates to the

required sies. The dimensions and shape of the edges to be oined by welding shall be chec'ed as

per appro-ed drawing specification. (urfaces and edge preparation shall be free from loose scale,

slag, grease, paint and other foreign matter. "dge preparation shall be -erified for proper groo-e

angle and root face dimensions. Foint surfaces shall be free from fins and tears.

4.2.11.2 Fit9' Asse?


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ll non7destructi-e testing shall be performed as per appro-ed agency as per the contract in

accordance with the requirements of the applicable standards and proect specifications.

*on7destructi-e Testing shall be performed as follows

(l.*o. @escription

Eisual

$nspection

*@T TJ%"

HT T %T

1

aw material plate

thic'ness +0 mm and

abo-e

100B K K K

2&ull penetration butt

welds100B K K K

3%artial %enetration butt

weld100B K K K

4 ll fillet weld 100B K K K

K %roect (pecification

third party $nspection agency shall be engaged as independent and appro-ed testing and

inspection agency to carry out the HT and %T on :eldments. 8$f there is proect specification9

4.2.12.1 $ene&a8 Re@9i&e?ent O 6is9a8 Ins'e;tion

:eld Eisual inspection shall be carried by &abrication "ngineers or certified :elding $nspector as

per ?(7"*7$(/ standard for e5ternal defects li'e, surface porosity, under cut, e5cess penetration,

o-er laps, lac' of penetration or incomplete fusion and fillet sies.

4.2.12.2 $ene&a8 Re@9i&e?ents O *i@9i( Penet&ant Testing 4PT

Giquid %enetrant Testing procedures shall be in accordance with (T " 16+ or rele-ant ?(7"*7

$(/ (tandard.This test shall be carried during the welding process while bac' gouging. The

e-aluation of indications and the acceptance criteria shall be in accordance with (ec.E$$ @i-.1 ("

code or rele-ant "*7$(/ standards.

ABRICATION METHOD

STATEMENT


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4.2.12.3 $ene&a8 &e@9i&e?ents o Magneti; Pa&ti;8e Testing 4MT

agnetic particle Testing procedures shall be in accordance with (T " , :( @ 1.1 or

rele-ant ?(7"*7$(/ (tandard. The e-aluation of indications and the acceptance criteria shall be in

accordance with (T " , :( @ 1.1 or rele-ant ?(7"*7$(/ (tandard . $ndependent testing

authority %$ reports shall be obtained for fillet welds.


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4.2.12.4 $ene&a8 Re@9i&e?ents O %8t&asoni; a?ination 4%T:

The ultrasonic Testing of plates for lamination shall be in accordance with ( 43+ and HT of ?utt

oint shall be in accordance with (T " 164, :( @ 1.1 or rele-ant ?(7"*7$(/ (tandard.

$ndependent testing authority HT reports shall be obtained for all butt oints.

+. DIMN"IONA* IN"PCTIONThe fabricated steel structure shall be inspected in accordance with respecti-e appro-ed fabrication

drawings and specification. /-er all length, orientation, diagonal measurement and all other

dimensions shall be -erified and recorded. $f dimensions are not with required tolerance the member

shall be corrected prior to further process. ll dimensions shall be recorded in appro-ed format.

100B -isual inspection shall be carried out for e5ternal defects. T! uality staffs shall conduct

the final inspection and re-iew all inspection reports and prepared as inspection and test plan 8$T%9.

6. PROTCTION

.1 "!OT B*A"TIN$ 4"9&a;e P&e'a&ation

brasi-es for blast cleaning shall be clean, dry and free of any constituent. (ilica sand shall not be

used. (urface preparation shall be in accordance with $(/ =+01701 and technical data sheet of

specified paint. brasi-e shall be of steel grit and shot in the ratio of


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The painted structures after fabrication shall be protected from further damage during

transportation. The materials will be loaded on to the trailers using timber supports and separators

and secured properly to pre-ent any damage to the material while transportation to site. &abricated

items will be deli-ered loose. inor fabricated items, which are not li'ely to be subect to permanent

deformation during handling operations 8i.e. bracing etc9 maybe bundled or hoped. (mall items 8i.e.

bolts, loose, cleats etc9 will be pac'ed in cratesdrums or loaded on pallets.

=. IN"PCTION AND T"T P*AN

ppro-ed $nspection and test plan shall be implemented during each and e-ery stage of fabrication,

to ensure the wor' is carried out with full compliance drawings and specification. The $nspection and

appro-ing parties as per $T% shall ensure the quality of wor' at e-ery le-el.

Steel Fabrication Method Statement

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