KUWAIT OIL COMPANY (K.S.C.) STANDARDS PUBLICATION KOC STANDARD FOR STRUCTURAL STEEL WORK - MATERIALS, FABRICATION AND ERECTION DOC. NO. KOC-C-007 I STANDARDS DIVISION I DOC. NO. KOC-C-007 Page 1 of 35 REV. 1 KUWAIT OIL COMPANY (K.S.C.) STANDARDS PUBLICATION KOC STANDARD FOR STRUCTURAL STEEL WORK - MATERIALS, FABRICATION AND ERECTION DOC. NO. KOC-C-007 STANDARDS DIVISION KOC STANDARD FOR STRUCTURAL STEEL WORK - MATERIALS, FABRICATION AND ERECTION DOC. NO. KOC-C-007 ( FORMERL Y 0 75-MH-7002 ) ISSUING AUTHORITY: STANDARDS DIVISION 3 Workmanship 10.4 Steel Pipes 8.7 Fabrication Tolerances WELDING 10. FOREWORD 5 SCOPE APPLICATION TERMINOLOGY 3.1 General 8.6 Electrodes FABRICATION REQUIREMENTS 9.Generally 9.2 Welding Requirements 10.2 List of Standards and Codes 4.1 Conflicts 4.1 General 10.3 Structural Plates 8.1 General 9. TABLE OF CONTENTS Page No.4 Acceptance of Welds .2 Abbreviations REFERENCE STANDARDS AND CODES 4. SAFETY AND ENVIRONMENT BASIC ENGINEERING INFORMATION MATERIALS REQUIREMENTS 8.3 KOC Standard Drawings ENVIRONMENTAL CONDITIONS HEALTH.4 Shop Details 9.6 Erection Markings 9.5 Fabrication Drawings 9.3 Review of Fabrication Drawings 9.5 Structural Bolts 8.1 Definitions 3.2 Structural Shapes 8.2 Connections . 7 Ramps PAINTING IGALVANIZING INSPECTION AND TESTING 14.9 Permissible Deviations MISCELLANEOUS METAL WORK 12.6 Site Welding 1 1.3 Alignment and Fit-up 1 1.8 High Strength Bolts 11.3 Stairways 1 2.4 Spiral Stairways 12.5 Field Holes and Openings 1 1.2 Setting Out 1 1.I General 1 1.7 HSFG Bolted Connections 11.6 Non-destructive Tests QUALITY ASSURANCE PACKING AND MARKING DOCUMENTATION 17. 1 ERECTION REQUIREMENTS 1 1 .2 Work Records and Reports 1 7.1 General 17.2 Steel Flooring 12.1 General 12. KOC-C-007 Page 4 of 35 REV.4 Bracings 1 1.6 Handrails and Toe Plates 12.DOC.2 Quality Plan 14. NO.5 Visual lnspection 14.1 General 14.5 Ladders 12.3 Material and Equipment lnspection 14.4 Shop lnspection 14.3Deliverables ACKNOWLEDGEMENT 35 . Maged M.Akbar Proj.Member Tel. Ahmadi 61 0 0 8 State of Kuwait Task Force Responsible for this Standard The preparation of this Standard has been entrusted by the Standards Technical Committee (STC) t o the Task Force No.Member Tel. No. which are widely used for general structural engineering purposes. . inspection and testing with a view t o achieving safe. 61 197 Mr.Madi Ahmadi Svcs. Standards Division (Chairman. 61 322 Mr.DOC. This KOC Standard has been approved by Standards Division in consultation with the Standards Technical Committee for use throughout the corporate engineering and operational functions of Kuwait Oil Company (K. fabrication.O.S. No. To specify various practical technical requirements of fabrication. Mgmt Div. KOC-C-007 Page 5 of 35 REV. Masood Engg Design Div. . (TF-C/03) comprising of the following members: Mr. Box . welding and erection with a contract.Member Tel. fabrication and erection of structural steelwork within KOC Facilities (Onshore). d. Standards Technical Committee) Loss Prevention Group. KOC P. 1 FOREWORD This document " KOC Standard for Structural Steel Work . reliable and economical construction of structural steelwork. A/Aziz H. erection. 66389 . To provide the basic specifications of applicable materials for weldable. Fabrication and Erection " (KOC-C-007) is intended to address the need for consistent and practical requirements for material selection. 61 407 Mr. To set out minimum requirements t o monitor compliance of material.C) This Standard sets out t o achieve the following objectives :- a. Dept. Feedback as well as any comments or suggestions from the application of this Standard derived at any stage of conceptual design. . fabrication.Team leader/Author Tel. No. b. welding. S.9758. NO. To furnish general technical inputs for developing project specifications and design / construction drawings in order t o ensure a consistent approach for material selection and workmanship in structural steelwork. c. non alloy structural steel and miscellaneous metal work by use of hot rolled sections. No'. field erection or maintenance are encouraged and should be directed to: The Supdt. J. Kumar Standards Div.Materials. engineering.(N) . fabrication and erection including welding. consideration and amendment by Standards Division (if required). Contractor Person or persons. welding. procurement. for general structural and engineering purposes . who prepare the fabrication drawings and/or fabricate the various components of structural steel by connections through welds 1 bolts. APPLICATION The materials and workmanship of structural steelwork shall conform to the requirements of this Standard and the reference standards and codes mentioned herein. inspection. 1 This Standard specifies the basic technical requirements of materials. Compliance with this Standard does not of itself confer immunity from legal or statutory obligations. Any exceptions or deviations from this Standard. hot rolled structural steel shapes and plates etc. Faying Surface The mating surface of a member that is in contact or in close proximity with another member t o which it is t o be joined. firm or company contracted by KOC. and shall not be applicable t o cold formed and light gauge steel sections for any structural work. TERMINOLOGY Definitions For the purposes of this Standard. erection. along with their merits and justifications. NO. shall be brought t o the attention of KOC Controlling Department for their review. Fabricator Person or persons or firm contracted by the Contractor. who are undertaking the execution of the structural steel and miscellaneous metal work related t o engineering. fabrication.DOC. KOC-C-007 Page 6 of 35 REV. This Standard covers only the use of weldable non-alloy. the following definitions apply. testing and painting. painting and galvanizing of Structural Steel and Miscellaneous Metal Work for installation at the KOC onshore facilities within Kuwait. testing. . 1 Friction Grip Connection A bolted connection which transmits shear by frictioh between components. Pressure is not used. Lamellar Tearing Separation in highly restrained base metal caused by through-thickness strains induced by shrinkage of adjacent weld metal. Shielded Metal Arc Welding (SMAW) An arc welding process that produces coalescence of metals by heating them with an arc between a covered metal electrode and the work pieces. Pressure is not used and filler metal is obtained from the electrode. of 0°C J 2 = lmpact energy in Joules at temp. The arc and molten metal is shielded by a blanket of granular. Submerged Arc Welding (SAW) An arc welding process that produces coalescence of metals by heating with an arc between a bare metal electrode or electrodes and the work pieces. or metal granules. KOC-C-007 Page 7 of 35 REV.g. and filler metal is obtained from the electrode and from welding rod. of +20°C JO = lmpact energy in Joules at temp. mi". I*) Minimum Yield Strength (N/mm2) for t 516 mm Symbol for Structural Steel Designated Standard ( e. flux. of . BS EN 10025 ) (*) JR = lmpact energy in Joules at room temp. fusible material on the work pieces.DOC. Steel Designation System (as per BS) Structural steel grades conforming to BS t o be designated as illustrated below : 4 LLL lmpact Properties (J).20°C Weldability The capacity of a metal t o be welded under the imposed fabrication conditions into a specific. suitably designed structure and t o perform satisfactorily in the intended service. NO. at specified temp. Shielding is obtained from decomposition of the electrode covering. . ) Electrode (*) 1 = All flat. symbols E70XX stand for example E7015. NO. vertical. 4. In case further clarifications are required. Contractor's standards and specifications . as Coating Characteristics ( * * ) Position Code ("1 70. the order of precedence shall be followed as : a.DOC.I In the event of conflicts between this Standard and the standards / codes referenced herein. Kuwait Governmental Rules and Regulations b.1 . E7018 & E7028. 1 3. KOC Technical Specifications c. I 0 Welding Consumables Materials comprising of welding electrodes. 6. the most stringent requirement shall apply. the subject shall be brought t o the attention of KOC Controlling Department.000 psi Tensile Strength ( Min. or other contractual requirements. Safety and Environment ITP Inspection and Test Plan KOC Kuwait Oil Company ( K.1. International codes and standards e. KOC-C-007 Page 8 of 35 REV. overhead and horizontal 2 = Flat and horizontal only ( * * ) 5. wires and fluxes. t o be specified as per AWS classification system with the following notations : For SMAW electrodes.C ) NDE Non-Destructive Examination PQR Procedure Qualification Record QAIQC Quality Assurance IQuality Control WPS Welding Procedure Specification REFERENCE STANDARDS AND CODES Conflicts . 8 = LOWhydrogen Abbreviations HSE Health. This KOC Standard ( KOC-C-007 ) d.S. E7016.2 In general. 6 0 0 0 0 psi Tensile Strength ASTM A325 Specification for Structural Bolts. 1 2 0 / 105 ksi Minimum Tensile Strength ASTM A 4 4 9 Specification for Quenched and Tempered Steel Bolts and Studs ASTM A 4 9 0 Specification for Heat-Treated Steel Structural Bolts.Connections ANSI A1 0. Zinc- Coated. I) AlSC Manual of Steel Construction (Vol. NO.1 Plain Washers ASTM A6/6M Specification for General Requirements for Rolled Structural Bars. Black and Hot-Dipped.1 3 Construction and Demolition Operations . Steel.Working Stress Design AlSC Manual of Steel Construction .DOC.Steel Erection - Safety Requirements API 5L Specification for Line Pipe ASME B18. Allowable Stress Design and Plastic Design AlSC Manual of Steel Construction . Shapes and Sheet Piling ASTM A36/36M Specification for Structural Carbon Steel ASTM A53 Specification for Pipe. KOC-C-007 Page 9 of 35 REV.22. 1 1 List of Standards and Codes The latest edition of the following standards. codes and specifications shall apply: International / National Standards AlSC Specification for Structural Steel Buildings . II) . 1 5 0 ksi Minimum Tensile Strength ASTM A501 Specification for Hot-Formed Welded and seamless Carbon Steel Structural Tubing ASTM A 5 6 3 M Specification for Carbon and Alloy Steel Nuts (Metric) .Load and Resistance Factor Design (Vol. Steel. Welded and Seamless ASTM A1 5 3 Specification for Zinc Coating (Hot-Dip) on iron and Steel Hardware ASTM A 3 0 7 Carbon Steel Bolts and Studs. Plates. Heat-treated. Steel. Metric Series Part 1 : General Grade Industrial Type Metal Flooring. Screws and Nuts - Specification (Metric Units) I S 0 Metric Black Hexagon Bolts. Fabrication and Erection : Hot Rolled Sections . Metric Series : Part 1 : General Grade Code of Practice for Safety in Erecting Structural Frames Structural Use of Steel Work in Building : Part 2 : Specification for Materials. Screws and Nuts - Specification (Metric Units) Specification for Metal Washers for General Engineering Purposes.Steel BS 4 Structural Steel Sections : Part 1 : Specification for Hot-Rolled Sections Specification for The Use of Structural Steel in Building: Part 2 : Metric Units Screwed and Socketed Steel Tubes and Tubulars and for Plain End Steel Tubes Suitable for Welding or for Screwing t o BS 21 Pipe Threads Design and Testing of Steel Overhead Runway Beams I S 0 Metric Precision Hexagon Bolts. l Structural Welding Society . 55. Metric Units High Strength Friction Grip Bolts and Associated Nuts and Washers for Structural Engineering. Walkways and Stair Treads Part 1 : Specification for Open Bar Gratings Use of High Strength Friction Grip Bolts in Structural Steel Work.ASTM B695 Specification for Coatings of Zinc Mechanically Deposited on Iron and Steel ASTM F436 Specification for Hardened Steel Washers ASTM F1554 Specification for Anchor Bolts. and 1 0 5 ksi Yield Strength ASTM F1637 Standard Practice for Safe Walking Surface AWS D 1 . 36. Shape and Mass for Hot Rolled Steel Plates 3 m m Thick or Above Structural Steel I and H Sections -Tolerances on Shape and Dimensions Specification for Structural Steel Equal and Unequal Leg Angles Part 1 : Dimensions Part 2 : Tolerances on Shape and Dimensions Delivery Requirements for Surface Condition of Hot Rolled Steel Plates.Metric Series - Radii under the Head Mechanical Properties of Fasteners made of Carbon Steel and Alloy Steel . Wide Flats and Sections Part 1 : General Requirements Part 2 : Plates and Wide Flats Part 3 : Sections Hot Finished Structural Hollow Sections of Non-Alloy and Fine Grain Structural Steels Part 1 : Technical Delivery Requirements Part 2 : Tolerances. Dimensions and Sectional Properties Welded.Covered Electrodes for Manual Metal Arc Welding of Non Alloy and Fine Grain Steels - Classification Recommendations for Welding of Metallic Materials - Part 1 : General Guidance for Arc Welding Part 2 : Arc Welding of Ferritic Steels Definition and Classification of Grades of Steel Hot Rolled Products of Non-Alloy Structural Steels - Technical Delivery Conditions Specification for Tolerances on Dimensions.Part 1 : Bolts. Screws and Studs BS EN I S 0 1 4 6 1 Hot Dip Galvanized Coatings on Fabricated Iron and Steel Articles . Weather Resistant Weldable Structural Hollow Sections Welding Consumables . Brazed and Soldiered Joints .Symbolic Representation on Drawings General Purpose Bolts and Screws . Fire Proofing of Structural Steel Work KOC-G-002 KOC Standard for Hazardous Area Classification KOC-G-004 KOC Standard for Packing. Standard Details 1 5-30-1 1 1 Standard Platforms and Crossovers Details 1 5-30-1 2 0 Standard Steel Anchor Bolts 15-35-12 Base Plate Detail for Pipe Support .Surface Preparation Specifications SSPC-PA2 Measurement of Dry Coating Thickness w i t h Magnetic Gages 4.2 KOC Standards KOC-C-00 1 KOC Standard for Basic Civil Engineering Design Data KOC-C-027 KOC Standard for Materials and Workmanship . 1 BS EN IS01 2 9 4 4 Paints and Varnishes .DOC. KOC-C-007 Page 12 of 35 REV.Hexagonal Products . Screws and Studs . NO.3 KOC Standard Drawings 15-1 9-1 3 Car Park Shelters .Corrosion Protection of Steel Structures by Protective Paint Systems - Part 1 : General Introduction BS EN IS01 4 7 1 3 Protection Against Corrosion of Iron and Steel in Structures .New Construction KOC Fire & Safety Regulations 4.2.width Across Flats I S 0 888 Bolts.Zinc and Aluminum Coating IS0 272 Fasteners .Nominal Lengths and Thread Lengths for General Purpose Bolts I IS0 4759 Tolerances for Fasteners SSPC-SP Steel Structures Painting Council . Marking and Documentation KOC-G-007 KOC Standard for Basic Design Data KOC-L-025 KOC Standard for Scaffolding KOC-P-00 1 KOC Standard for Painting and Coating of Metal Surfaces . DOC. which may develop surface temperatures of over 80' C (176' F) in exposed metals. All relevant safety requirements of Health and Environment (HE) Guidelines. which are acceptable to KOC. as well as in any other areas within KOC facilities in accordance with Fire and Safety Regulations. by the Contractor. Hot work permits are essential prior t o any field welding in any hazardous areas in compliance with "KOC Standard for Hazardous Area classification" (KOC-G-002) and relevant hazardous area classification drawings. Due regard should be given t o the consistently high levels of solar radiation experienced in Kuwait. HEALTH. while performing the Work within KOC areas. Safety and Environment procedures. . Refer t o KOC Standard for " Basic Design Data " (KOC-G-007) which provides the detailed design information regarding the environmental. KOC Health. Safety and Environment (HSE) Policy and KOC Fire & Safety Regulations shall be adhered to. site and utility supply conditions prevailing throughout the KOC facilities. NO. KOC-C-007 Page 13 of 35 REV. 1 15-35-13 Reinforced Base Plate for Pipe Support 15-35-1 4 Anchor Skirt Detail for Pipe Support 15-39-53 Standard Ladder Details 15-39-54 Standard Handrail Details 15-39-55 Standard Circular and Rectangular Platforms - Typical Details 15-39-56 Standard Steel Stair Details 15-39-57 Standard Stiles and Walkways 15-39-58 Standard Car Park Shelters 15-39-59 Typical Sunshade for Mobile Fire Monitor ENVIRONMENTAL CONDITIONS The environmental conditions in Kuwait are severe. t o protect its personnel and surrounding environment during any site work. SAFETY AND ENVIRONMENT The Contractor shall follow the necessary Health. DOC. All materials shall be kept free from dirt. and therefore. KOC-C-007 Page 14 of 35 REV. Mill certificates covering chemical. DIN or equivalent. Structural steelwork shall be designed in the simpler forms of construction for general maintenance.Fireproofing of Structural Steel Work " (KOC-C-027). steel sections manufactured to the specified standard(s) are t o be substituted with sections manufactured in other countries t o different standards. lattice type structures other than towers and roof trusses are not generally acceptable. storing and erecting fabricated components of steelwork. charpy V-notch properties. handling. In case. . free from all defects that impair appearance. Contractor should take into consideration the available facilities for transporting. MATERIAL REQUIREMENTS General All Structural Steel materials shall be new. and the heat treatment data as applicable with heat number of all steel materials shall be submitted by Contractor for KOC approval prior t o fabrication. shipping. 1 BASIC ENGINEERING INFORMATION Structural steelwork shall comply with the relevant technical requirements as specified in " KOC Standard for Basic Civil Engineering Design Data " (KOC-C-001) and shall be designed in accordance with AlSC or BS 4 4 9 along with other applicable British standards. and shall be provided in accordance with " KOC Standard for Materials and Workmanship . Contractor shall submit at the time of inquiry all the technical data in English including geometrical. w i t h the applicable national standards such as JIS. Structural Shapes Structural steel (rolled shapes) shall be in accordance with the requirements of BS EN 10025 Grade S275JR or ASTM A 3 6 or equivalent. NO. and field assembled and erected by bolting at Site. grease and other foreign matter and shall be protected from corrosion. Fireproofing requirements of structural steel shall also be considered for the fire protection of structures. wherever specified by KOC. physical. chemical and mechanical properties of the steel sections proposed. easy access for painting and operation. strength or durability. Structural steelwork shall be generally shop fabricated by welding. and shall conform t o the relevant BS or ASTM standards as referenced in clause 4.2 of this Standard. A 4 9 0 bolts shall not be hot dip galvanized and shall not be used in highly corrosive environments. when designated as Grade 42. nuts. Plates shall have dimensions and tolerances in conformity with BS EN 10029 or ASTM A6. Structural steel pipes.DOC. KOC-C-007 Page 15 of 35 REV. Steel Pipes Structural steel pipes shall conform t o Grade 3 6 as per API 5L. ERW pipes shall be heat treated after welding in accordance with API 5L. and washers shall be mechanically galvanized in accordance with BS EN IS0 1461 or class 5 0 of ASTM B695. Pipes for handrails shall conform to ASTM A53. shall conform API 5L. Steel pipes shall be seamless or submerged arc welded (SAW). BS EN 10034. or t o ASTM A 5 3 Grade B. Grade B. The surface conditions shall conform t o BS EN 10163. General Grade or ASTM A449 with A563 nuts and F436 washers. Grade X42. Structural members shall be supplied with the dimensions and tolerances in conformity with BS 4. High strength friction grip (HSFG) bolts with associated nuts and washers shall comply with the requirements of either BS 4395. 1 Structural steel (hollow sections) shall be in accordance with the requirements of BS EN 10210 Grade S275JOH or ASTM A 3 6 or equivalent. Nuts shall be as per BS EN I S 0 8 9 8 or ASTM A 5 6 3 and washers as per ASTM F436 respectively. Nuts shall be as per BS EN I S 0 898. or electric resistance welded (ERW). Grade B. . Ordinary bolts shall be IS0 metric black bolts with nuts and screws. Structural Plates Structural plates shall be in accordance with BS EN 10025 S275JR or ASTM A 3 6 or equivalent. Part 1.6 or t o ASTM A307.8 or ASTM A325 1 A490. BS EN 1 0 0 5 6 and BS EN 10210 (Part 2) or ASTM A6. Structural Bolts Structural bolts shall be high strength conforming t o either BS 3 6 9 2 Grade 8. NO. High-strength bolts. and strength shall conform t o either BS 41 9 0 Grade 4. All fabricated frames shall be suitably braced and packed t o prevent distortion during transit. For variation of forms. stairways.DOC. ASTM A325 or ASTM A490. ASTM A307.1. Mechanical and chemical properties of bolts and nuts shall be in compliance with BS EN 10025 / BS EN IS0 898. dimensions and tolerances of bolts and nuts refer t o I S 0 272. Ordinary bolts. Electrodes Arc welding electrodes shall be in accordance with AWS as follows: a. Any substitution of shapes and built-up members shown on the KOC approved drawings shall be made only t o expedite the work with full knowledge and prior approval of KOC. All fasteners shall be galvanized when used with galvanized or painted structural steel. IS0 885. ladders. they shall be supported on firm and level ground. KOC-C-007 Page 16 of 35 REV. cages and handrails shall be shop assembled in the largest sections suitable for handling and transporting t o the installation Site. platforms. All frames. For automatic or semi-automatic submerged arc welding (SAW) : F7X- EXXX as per AWS A5. When structures are fabricated or assembled in the open area. For manual shielded metal arc welding (SMAW) : E70XX as per AWS A5.22. IS0 8 8 8 and IS0 4759.17.1. 1 Ordinary steel washers shall comply with BS 4 3 2 0 for Metric Series of bolts or ASME B18. while minimizing site installation wrk. . b. Tapered washers shall be used where appropriate. FABRICATION REQUIREMENTS General The Contractor / Fabricator shall prepare the fabrication drawings and shall be fully responsible for the accuracy of all the shop and / or field details of structural steelwork. and there shall be no settlement of the ground during assembly. nuts and washers shall be hot-dipped galvanized in accordance with BS EN IS0 1461 or ASTM A1 53. NO. column splices. b. 1 Connections . unless otherwise indicated on the drawings. All welding symbols shall conform t o AWS Dl . except as noted on the approved drawings. For main connections : M 2 0 high-strength bolts. Washers parallel or tapered t o suit rolled steel sections being connected. KOC-C-007 Page 17 of 35 REV.Generallv Unless otherwise specified. Splices in structural steel shall be full penetration butt welds and shall be subject t o KOC acceptance. HSFG bolts shall be used for moment connections in structures supporting vibrating or moving loads. All field connections shall normally be bolted at Site during erection. structural steelwork shall be fabricated in the shop. Lock nuts shall be provided for all bolts securing runway beams t o main framing.DOC. Runway beams and structural members t o be periodically removed for maintenance purposes shall be connected t o main framework with bolts BS 3692. Ordinary bolts shall be used for connections of secondary beams. platforms. . All shop connections shall be by welding. All connections shall be made with minimum t w o (2) bolts with minimum bolt sizes as indicated below :- a. where specifically indicated on the drawings. main bracing. For secondary connections : MI 6 ordinary bolts. purlins.8 or equivalent. shall be provided under each nut. the Contractor shall comply with the following: Generally. main beam-to-column. Grade 8. light bracings. For ladder cages : MI 2 ordinary bolts. Friction type connections shall be provided for crane girder. crane brackets and all beams carrying equipment loads except as noted on the approved drawings. All strength welds shall be continuous fillet welds of minimum six (6) m m size (leg length). Main connections shall include main beam-to-beam. Gusset plates and stiffeners shall be minimum 10 m m thick. NO.I or BS EN 22533. and bolting may be used if shown specifically on the design drawings. Butt welds shall be used. High-strength bolts shall be used for all main bearing type and moment connections. crane girder supports and wherever specifically indicated. railings and similar members. Welded end plates shall be minimum 1 2 m m thick. c. All columns shall be welded t o the base plates and at the column splices unless noted otherwise on the drawings. unless otherwise specified. drilled. . The review and approval of fabrication drawings by KOC does not. Crane rails shall have staggered joints. except in steel base plates or where otherwise specified. If crane girders are t o be spliced. Beam t o column connections shall be arranged t o facilitate erection without the tilting of columns. except angle columns. sizes. Holes shall be clean cut without torn or ragged edges. For bolts not exceeding 2 4 m m diameter (inclusive). along the runway beam. location of hardware fastenings. the beam set-back shall not exceed 1 2 mm. shall be milled t o bear on base plates and at the contact surfaces of column splices. shop and field splices. Fabrication drawings shall indicate for KOC review. methods of assembly. Where seated connections are used. however. Bolt holes shall be cut. holes shall be not more than 2 m m greater in diameter than the bolt. if any. holes shall be not more than 3 m m greater in diameter than the bolt. or punched at right angles t o the surface of the metal and shall not be made or enlarged by burning. information about materials. Holes should be perfectly circular and not oblong. rails shall not be spliced at the same points. All beams with moving loads shall have a pair of 10 m m thick stop angles bolted on the flange at each end. joint preparation and weld procedures. welding details. relieve the Contractor of his responsibility t o furnish the materials and construction in full compliance with the project drawings and the requirements of this Standard. and for bolts over 2 4 rnm diameter. Fabrication shall commence only after KOC has completed the review and informed the Contractor in writing t o proceed with the work. The beam web shall be connected with a side clip t o the column. the bottom flange of the beam shall be connected t o the seat angle. A t any seated connections.Review of Fabrication Drawings The Contractor shall submit all fabrication drawings w i t h shop and field connection details t o KOC for review. exact cut lengths. Shop Details All columns. all details of fabrication. mid-rail. toe plate. Fabrication Drawings As a part of fabrication procedure. Where the shop attachment of handrail assembly t o platforms is limited by shipping constraints. beam and bracing. and post shall be supplied in shop fabricated assemblies for field bolting or welding to platform steel t o minimize the field work. the web shall be stiffened with stiffeners t o match the stiffeners in the bolster above the beam. shall be shop assembled including posts. field fastened with 6 m m diameter self tapping screws at each end of panel and one at middle of panel at each intermediate support. A bolt list specifying the number. the index may be included t o the erection plan. grip and ordered length of connector for each connection shall be furnished by the Contractor . Large span welded trusses shall be detailed with splice connection t o the largest possible section for ease of shipping. Horizontal bracing shall be connected t o both column and beam where the inside face of the column is used as a working point. where convenient. type of connector. size. Vertical bracing shall be connected t o both beam and column at the intersection of column. handrail. including circular platforms. Camber shall be provided for trusses of span exceeding 30 m and wherever indicated on the drawings. both straight and bent sections of top rail. mid-rail and toe plate t o the maximum extent permitted by shipping limitations. Removable floor plates shall be fastened with M I 2 bolts. On small jobs.DOC. Removable sections of handrail shall be provided with posts at each end of the removable section for bolted connection t o supporting clip. horizontal bracing in plane of the beams shall be connected t o both beams. Each structure shall have an index sheet for the steel details. Open grid flooring shall be attached t o the supporting members with the saddle type clips. KOC-C-007 Page 19 of 35 REV. All platforms. preferably on the reproductions of the approved project or construction drawings. stiffener length shall be one-half of the nominal depth with the top milled. NO. 1 A t equipment support beams with bolsters. When the center of a column is used as a working point with beams framing t o the flange and the web of the column. the Contractor shall prepare the erection plans with erection marks shown thereon in letters of at least 3 m m high. KOC-C-007 REV. flatness and verticality of members and built-up members. a separate bills of material shall be furnished by the Contractor. b. All unsymmetrical beams. All columns shall have the mark painted "North" or "East" on the outside face of the flange. camber. The suffixes like "R" or "L" for opposite hand marks shall not be used. straightness. All members shall be marked "Top" where the member may be erected inverted. This listing shall be divided into categories and tiers as below :- a. . e. Fabrication Tolerances The tolerances for materials (rolled sections & plates) shall be in accordance with relevant standards as mentioned in clause 8. Otherwise. Beam t o beam connections. shall be in compliance with BS 5 9 5 0 Part 2 or AWS D l . 1 1 Fabricator. Erection Marking The Contractor / Fabricator shall be responsible t o furnish an erection marking system identifying all members for KOC review prior t o fabrication. preferably "North" or "East". A summary of all field connectors by size and length shall also be included.DOC. All marks shall be painted on the steel in legible fashion. Bracing t o column connections. squareness. each piece shall have a different mark. girders. tolerances for other features like length. I . Beam marks shall be painted on beams at the same end as they are shown on the plan view of the framing plan.0 of this Standard. or trusses. with letters and numerals of minimum 40 m m high. A bill of material in standard format shall be the integral part of each fabrication drawing(s) listing all material and fittings with weight(s) of each member summarizing into actual "weighing up" of the structure. Column splices. NO. d. Where a member is shipped in t w o or more pieces. Beam t o column connections. Bracing t o beam connections. c. shall have a direction painted on one end. However. All vertical bracings shall be marked with paint on the lower end. All SMAW electrodes t o be used shall be low hydrogen with E70 filler metals for fabrication of structural steel work. Workmanship All structural welds shall be made in accordance with the sizes and types of welds (fillet.Irequirements and submit t o KOC for approval at least one (1) month in advance before commencing fabrication works.Records of all these qualification tests and certificates of qualification of personnel shall be maintained for the period of fabrication work. welding wires.I.DOC. . Structural fabrication shall generally be made by manual shielded metal arc welding (SMAW) with E7OXX electrodes. However. 1 WELDING General Welding shall be carried out in compliance with all requirements specified in AWS D 1 . KOC-C-007 Page 2 1 of 35 REV. All butt welds shall be full penetration welds and shall be made 'in t w o or more passes such that filler material is deposited over the whole thickness of the joint. NO. Welding Requirements All items of electrodes. All welding shall be performed in areas protected from rain. when used by a qualified welder or welding operator using qualified welding procedures. wind and air- borne dust and sand. l or BS EN 1011. butt or groove) as shown on the project or fabrication drawings. Welders shall be pre-qualified and approved by KOC through Welder Qualification tests as per AWS D l . submerged arc welding (SAW) with F7X-EXXX electrodes may be used for automatic or semi-automatic welding of long runs of welds for built-up sections and crane girders. All fillet welds shall be minimum 6 m m equal leg size unless otherwise noted. Contractor shall prepare the Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) as per AWS D l . All welding work shall be carried out by the skilled and qualified welders. fluxes and welding equipment shall be capable of producing sound and satisfactory welds. and shall be finished smooth and flushed by grinding.0 of this Standard. if not t o be included in the final welds of the welded joint.3. welds shall be stress relieved in accordance with AWS D l . KOC-C-007 Page 22 of 35 REV.13 If post-weld heat treatment is required. 1 Suitable joint details for full penetration welds shall be selected based on the thickness of the base metals such that it will not cause lamellar tearing due t o weld shrinkage.I.DOC. 10.1 2 If joined by fillet welds. No welding shall be done on wet surfaces.14Welding inspection and testing shall be in conformity with the relevant section of AWS D l . Partial penetration groove welds shall not be allowed. All temporary assembly attachments shall be removed by flame cutting or gouging a minimum 3 m m above the surface of the base material.3.3. If the separation is more than 1. not otherwise structurally welded. the leg of the fillet weld shall be increased by the amount of root opening.3. All welds shall be deposited in a sequence which will minimize distortion and shrinkage.Iand shall meet the requirements as specified in clause 14. All structural tubular members shall be connected w i t h full penetration groove welds as shown on the drawings or in accordance w i t h AWS pre- qualified tubular joints. 10. the parts shall be brought as close as practicable t o a separation distance for root opening not exceeding 5 m m (3116").10Any paint on surface adjacent t o joints t o be welded shall be thoroughly removed t o expose clean steel within 50 m m from each side of the outside lines of welds. . taking care so that base metal is not damaged. shall be provided along all faying surfaces. Seal welds except for building. t o 3 m m (118") minimum size. 10. All tack welds shall be carried out by qualified welders and/or weld operators and shall be subject t o the same quality requirements as the final welds as specified in AWS D l .1 1 Structural parts t o be welded shall be properly prepared and shall be firmly held in position prior t o welding t o avoid warping and buckling.6 m m (1/ I 6") or greater.I. 10. 10. Tack welds may be used judiciously t o retain the parts in alignment during welding and shall be removed.Section 3.3. NO. MPI or radiographic) as specified in clause 14. All miscellaneous materials like erection bolts. buckling or other damage to any of the structural members. ERECTION REQUIREMENTS General Prior t o erection. equipment and scaffolding t o execute the erection work as per the KOC approved method statements and erection drawings. .DOC. when the results are found t o be satisfactory after random checks and tests in accordance with clause 14. NO. KOC-C-007 Page 23 of 35 1 REV. all such welds shall be repaired or replaced by the Contractor at no cost t o KOC. b. all fabricated parts of structures shall be transported safely by the Contractor from the fabrication yard t o the installation Site without any visible abrasion. Routine repairs should not need case by case approval t o proceed. The repaired welds. gas pockets. d. 1 Acceptance of Welds Welds shall be examined by visual inspection for inadequate penetration. depending on the types. The Contractor shall submit repair procedure(s) t o KOC for review and shall commence rectification of defective welds only after obtaining KOC approval t o proceed with the work. shall be tested for soundness as per methods of testing (UT. slag inclusions. Welds that do not conform t o the project or fabrication drawings. and shall comply with the relevant ASTM 1 BS standards as referenced in clause 4. If these or any other defects are found. washers. Any weld that impairs the safety of the member or structure. black bolts. undercutting and improper weld geometry.0 of this Standard. c. incomplete fusion. high-friction grip bolts with nuts. Welds shall be deemed t o be acceptable. Welds that do not conform t o AWS D l . shims. load indicator washers. burned-through areas.0 of this Standard. distortion.Iand this Standard. which in the opinion of KOC are detrimental t o the integrity of the structure. bending. tools. KOC has the right t o reject any weld under the conditions as below :- a. The Contractor shall provide all labor.. wedges and leveling plates shall be furnished by the Contractor as necessary t o facilitate proper alignment and correct fit-up.2 of this Standard. Welds that have caused distortion and shrinkage of the adjoining members. However. Minor misfits shall be remedied by means of drifting. free from defects and shall be regularly tested as per the Factory Acts. The Contractor shall be responsible t o familiarize with all existing services above and below ground and shall take all necessary precautions t o ensure that no damage will occur thereto during execution of the Work. and it shall be confirmed that the structure(s) shall be in place within the permissible deviations as specified in BS 5950 Part 2 or AISC. and modern techniques & lifting equipment(s) shall be utilized. plumbing. chipping or cold cutting of the members as necessary. Members shall not be permanently fixed before checking their correct positions and alignments. ANSI A10. lifting and fixing shall be KOC approved.13 for steel erection shall be adhered t o for all safety requirements. The test certificates shall be always available at Site for inspection by KOC. The method of handling.DOC. they shall be rectified t o a practical and satisfactory solution subject t o KOC approval. Setting out shall be carried out for all column bases and column tops for accurately positioning. Alignment and Fit-up All structural members shall be erected in a sequential order which shall ensure safety as well as speedy progress of work. moderate reaming. Setting Out Before commencing erection of any major structures. They shall be in sound condition. If any major misfits and misalignments of members occur due t o fabrication errors. that part of structural work or the individugl affected members shall be removed and replaced by the new members. NO. KOC-C-007 Page 24 of 35 REV. grinding. No props or supports shall be attached or affixed to such services. . aligning and leveling of all other members of structures in accordance with KOC approved fabrication drawings and to KOC satisfaction.1 All plant and equipment shall be of sufficient capacity and suitable for the loads and sizes of the structures or their parts t o be erected. all foundations including anchor bolts shall be checked for accuracy. If the safety of any part of structural work is in doubt due t o these misalignments and misfits or the solutions outlined by the Contractor are not acceptable t o KOC. Banding of field cut-outs (piping. cleaned of burrs or rough edges and countersunk. whenever specified. Site Weldinq Site welding. shall be full penetration welds unless noted otherwise. Hardened washers shall be provided as recommended by the manufacture of the load indicator washers. HSFG bolts shall be tightened t o required tension using "coronet" load indicator washers or approved equivalent.0 of this Standard. conduit. No burning or punching shall be allowed unless otherwise authorized.) shall be done as per the details shown on the drawings. equipment penetration etc. All field connections shall be with minimum t w o (2) Nos. if necessary. Field Holes and Openings Field holes required t o be made shall be drilled. Such bracing(s) shall remain in place t o maintain the safety and stability of the structures until completion of erection and installation of permanent bracing systems. All welds. M 2 0 bolts. except fillet welds. . shall be carried out in accordance with the details shown on the fabrication drawings after setting out and aligning the members t o their positions and providing the field connections.Bracings Adequate numbers of temporary guys and bracings shall be provided wherever necessary t o withstand all loads including erection load during erection. No site welding shall be done on structural steelwork after surface preparation or painting has been carried out unless specifically permitted by KOC. and HSFG bolts shall be supplied in accordance with clause 8. unless otherwise specified. Openings in gratingslopen grid floorings and floor plates not indicated on the drawings shall be cut and banded by the Contractor. HSFG Bolted Connections All connections using high-strength friction grip bolts shall comply with the requirements of BS 4 6 0 4 Part 1 or AISC. Crane(s) and heavy equipment shall not be erected on the structure. until permanent bracing systems (vertical and horizontal) with tie members are fixed t o the structure. . servicing and maintenance as indicated on the drawings. oil. steel flooring shall be of open grid type and should be hot dip galvanized. Permissible Deviations The erection tolerances of steel framed structures shall comply with BS 5950 Part 2 or AISC. stairways or ladders with specific attention t o escape routes in the event of fires. Headroom clearance at all platforms shall not be less than 21 5 0 m m considering the presence of electrical fittings and all other obstructions thereon. scale. Walkways shall be of open grid type and shall be provided with handrails and toe plates. checker plate flooring should be considered for safety where any chance of spillage exists from upper level t o lower or equipment. The tightening shall be achieved by using a normal podger spanner or up t o a point where a power wrench starts t o impact. MISCELLANEOUS METAL WORK General Platforms shall be provided at locations above grade levels as operating floors and/or for access t o equipment and their appurtenances for operations. dirt.DOC. KOC-C-007 Page 26 of 35 REV. Minimum width shall be not less than 1 0 0 0 m m for operating platforms and access around equipment(s).2 t o 12.6 of this Standard. shall be interconnected by walkways.l Contact surfaces shall be free of paint or other applied finish. High Strength Bolts High strength bolts.8 shall be tightened enough t o ensure that adequate contact is achieved between the parts assembled. However. Platforms shall be installed in the form of either open grid or solid checker plate steel flooring with stairways and ladders for access and exit. Platforms. Grade 8. NO. Steel Floo- Normally. and shall be protected with handrails and toe plates as generally detailed in the clauses 12. burrs or other defects. Walkways shall not be less than 7 5 0 m m in width. if provided at various levels and around different items. loose rust. unless otherwise indicated on the drawings.5 m2 of floor plate. The maximum rise in a single flight of stairs shall be limited t o 3 0 4 0 mm or 1 6 risers without landing. if possible. . Unsupported edges shall be stiffened with a 6 0 m m x 1 0 m m butt strap. Stairs shall have minimum 2 4 0 m m tread width and maximum 1 9 0 m m riser height. NO. All stairs on the same platform or in the same building should preferably be arranged with same slope. However. KOC-C-007 Page 27 of 35 REV.2.DOC. Floor panel shall be limited t o span (L) having deflections not more than Ll200 or 1 0 mm. Generally.3 of this Standard Stairways Stairways shall be provided for access t o platforms serving equipment which requires regular and frequent operational attendance or rapid escape or access in the event of an emergency. In some special cases. Checker floor plates shall be attached t o the supporting frames with countersunk bolts. Stairways shall be arranged with the angle of slope between 30" t o 38" t o the horizontal. Drainage holes of 1 2 m m diameter shall be provided for every 1. 1 Open grid flooring shall be serrated rectangular type. Checker floor plates shall have raised pattern t o provide a non-slip surface and shall be minimum 6 m m thick excluding the pattern. up t o 45" may be provided subject t o KOC approval. Open grid flooring shall be attached t o the supporting steelwork with clips or by other effective means approved by KOC. stairs shall be provided with at least 7 5 0 m m minimum clear width between stringers. and shall have handrails continuous with platform handrails. Holes or cut-outs in panels shall be stiffened around with welded strips prior t o galvanizing. Steel flooring shall be provided t o the extent as indicated on the project drawings and shall comply with all details shown on the KOC standard drawings listed in clause 4. The minimum length of landing shall be 1200 mm. main access and escape stairs shall have at least minimum clear widths of 1000 m m and 1200 m m respectively between stringers. whichever is smaller. with a minimum of one (1) hole per panel. with load bearing bars 3 0 m m deep x 5 m m thick @ 3 0 mm centers with 1 0 m m twisted cross bars @ 1 0 0 m m centers in transverse direction. Grade A and ASTM F436. Anchor bolts shall be ASTM A307 or ASTM F1554. All ladders shall be generally vertical. All treads at stairs and landings shall have full width anti-skid checker plate nosing. treads shall be made with 25mm deep x 5 m m bearing bars @ 3 0 m m c/c with 1 0 m m diameter twisted bars @ 1 0 0 m m c/c in transverse direction. NO. Type 1 respectively. the slope shall be not more than 15" t o the vertical. c. an emergency escape from a platform which is alread) served by a stairway . KOC-C-007 Page 28 of 35 REV. Nuts and washers shall be in conformity with ASTM A563.2 of this Standard. depending on the diameter and height of the structures.2. For stair widths of 1 0 0 0 m m and 1 2 0 0 mm. Spiral Stairways Spiral stairways shall be generally provided t o the circular structures like vessels and tanks for access t o platforms. All spiral stairways shall be provided with handrails in accordance w i t h KOC Standard drawing 15-39-54. treads shall follow the same requirements given in clause '1 2. Stairways shall be fabricated in accordance with KOC standard drawings 15-39-54 and 15-39-56. access t o locations where no platforms are provided. access t o all platforms not served by a stairway . Structural steel shall conform t o ASTM A36. Ladders Fixed ladders shall be provided for a. but their use is subject . Treads of stairs and landings shall have full width anti-skid checker plate nosing.DOC. Stair widths shall be at least minimum 1 0 0 0 m m between stringers and slope shall be decided on the basis of number of landings. 1 Headroom clearance over stairs shall be minimum 21 5 0 m m measured at the nose of a tread. b. Field connections shall be bolted with ASTM A325 bolts.2. Treads for stairs and landings shall be galvanized open grid flooring to the sizes indicated on the drawings.2 of this Standard. for stairs having 7 5 0 m m width. However. If inclined ladders are t o be provided. Grade 36. Stairs and landings of stairways shall be galvanized open grid flooring to the sizes indicated on the drawings and shall follow the same requirements given in clause 12. but not across the entrance t o platforms by stairs and ladders. Handrails shall be fabricated in accordance with details shown on KOC Standard drawing 15-39-54.1 m minimum but not exceeding 2. Toe plates shall be provided along all edges protected by handrails. and shall be laid over a smooth surface of . and shall be of solid checker plates with raised anti-skid patterns. Safety bars shall be provided where ladders start close t o the edge of an elevated platform. Intermediate platforms shall be provided t o avoid change of inclination within a flight. Safety cage shall be circular shape in plan with a radius ranging from minimum 3 4 0 m m t o maximum 3 8 0 m m as applicable. Ramps or inclines shall have slopes not more than 15" and should never exceed 20" from the horizontal. if made of steel. Handrails shall be provided for stairways and all landings. Handrails and Toe Plates Handrails shall be provided for safety around edges of all platforms and walkways which are 5 0 0 m m or more above ground or any operating ievel. at openings in flooring around equipment.l to KOC approval. KOC-C-007 Page 29 of 35 I REV. Ladder shall be provided with safety cage. NO. Handrails shall be made of either steel sections (equal angles) or pipes and shall be fixed t o steel posts (equal angles) or tubular sections by bolts or by welding. Ramps Ramps. Ladder rungs shall be fitted into holes in the stringers and secured by welding.0 m or more above ground or platform level. when ladder height is 5. Changes in inclination of ladders shall not be allowed. Safety cage shall start in that case from a height of 2. shall be provided with adequate width at emergency escapes in hospitals and buildings. Ladder width shall be not less than minimum 3 8 0 m m but not more than 4 6 0 m m for ease of climb.-- DOC. Side access ladders shall be preferred t o front access. Checker plate shall be minimum 8 m m thick excluding the raised patterns. Toe plate upstand shall be not less than 1 0 0 mm. Handrail posts shall be spaced not more than 1 8 0 0 m m with railing height not less than 110 0 m m with at least one mid-railing.4 m maximum from the ground or platform level. Ladders shall be fabricated in accordance with the details shown on KOC Standard drawing 15-39-53. sags. ladders. stiles. All surface preparation and shop coating application shall be carried out by the Contractor in compliance with KOC Standard KOC-P-001. walkways including open grid flooring. steel beams and appurtenances shall be hot dip galvanized in accordance with BS EN IS0 1461. The areas of contact surface for friction type connections (HSFG) in crane girders and girder supports. handrails. KOC reserves the right of independent inspection of the material and workmanship at all times t o assure conformance t o the project drawings. thin spots. All bolts. Care shall also be taken t o prevent damage t o the coated surfaces during handling and transportation. approved fabrication drawings. Painting shall be excluded from the areas within 5 0 m m of joints t o be field welded. INSPECTION AND TESTING General Contractor shall perform at all stages of the Work. and other friction type connections with high- tensile bolts. cages and safety guards shall be hot dip galvanized in accordance with BS EN IS0 1461. 1 and this Standard. All steelwork for platforms. t o meet fully the requirements of fabrication. If any fabrication or welding is done after shop painting. shall not be painted. all the responsibilities and duties of inspection and testing through his qualified and KOC approved inspectors.thoroughly compacted base. welding and erection as laid down in AWS D l . However. Painted surfaces shall be free from pinholes. damaged areas of coating shall be re-blasted and recoated.5 of this Standard. and shop painted or galvanized in accordance with KOC Standard for "Painting and Coating of Metal Surfaces -New Construction" (KOC-P-001). standards and specifications . runs. All steelwork for valve pits and trenches including checker plates cover. nuts and washers shall be galvanized as specified in clause 8. stair treads. PAINTING I GALVANIZING All structural steel including miscellaneous metal items shall be prepared. dirt inclusions and other evidence of poor workmanship. The quality plan shall consist of the following: a) lnspection and Test Plan (ITP) The ITP shall list the sequence of all inspection and testing activities. as deemed appropriate. the acceptance criteria. The Contractor shall keep the mill certificates and shop material test reports of all approved materials t o be used or used in the fabrication work available for KOC inspection whenever needed. during assembly. 1 referenced in clause 4. in the plan. monitoring (M). inspection. assembly. surveillance (S). reviewing (R). The approved quality plan shall be strictly adhered to throughout the entire fabrication.2 of this Standard. Shop lnspection Shop fabrication inspection and tests shall be performed by the Contractor in accordance with ITP prior t o assembly. Quality Plan Contractor shall prepare and submit a detailed quality plan for KOC approval prior to implementation. KOC may additionally employ the services of inspectors. and packing for shipment in a chronological order. b) Pre-inspection Meeting (PIM) PIM shall be held by the Contractor with KOC before commencing of the fabrication work. Care shall be taken t o ensure that no damage or harmful sand or water ingress occurs. t o witness the required inspection and testing of materials and workmanship after getting proper advance notice from the Contractor. during welding and after welding t o ensure that materials and workmanship shall meet the requirements of this Standard and approved drawings. and testing period. During the PIM the Contractor and KOC will review and finalize the mark-up of the ITP. The plan shall include inspection & testing of fabrication.DOC. the governing code and whether a document or report is produced for each activity. showing the frequency of control. All equipment t o be used for site welding and field erection shall be inspected t o ensure compliance with the KOC Fire and Safety Regulations. Material and Equipment lnspection All materials shall be inspected from time to time for safe keeping and shall be properly laid out on wooden supports clear of the soil and shall be covered with plastic sheets. confirm the requirements for witnessing (W). NO. . assembly. KOC-C-007 Page 31 of 35 REV. acceptance criteria and personal qualifications. 1.l. and base metals and other discontinuities in the welding. and all deficiencies. surface inclusions and undercutting. Non-destructive Tests Non-destructive examinations (NDE) of structural welds. equipment. magnetic particle (MP).I. faults or bad practices shall be corrected as soon as possible. Section 6 and shall be accepted based on Part D. Visual inspection shall be aided by a strong light. Fillet welds shall be inspected by MP or DP tests as per Part A.Welds shall be inspected regularly by the Contractor 1 Fabricator according to AWS requirements with respect t o technique. All welds shall be subject t o random visual inspection according t o Section 8. Visual Inspection All structural steel welding shall be subjected t o close visual inspection by the qualified welding inspectors of the Contractor as the work progresses. Location of the spot testing shall be determined by KOC. All full penetration welded corner and T-joints used in beam column connections shall be inspected by ultrasonic tests in accordance with the thickness schedule as per Table I : Table I : Tests for Weld Length Thickness of Thinnest Section to be Welded Weld Length to be Tested by UT (%I 1 Over 5 0 mm (2") 20 2 5 0 mm (2") to 25 mm (1 "1 5 3 Less than 25 mm ( I " ) 0 All full penetration butt welds used in splicing members shall have visual inspection and shall also be inspected by non-destructive tests. whenever required. Section 8 of AWS D l . dye penetrant (DP) or radiography tests to evaluate the soundness of weld metal for the integrity of structural welded connections and critical joints. shall be conducted by means of ultrasonic (UT). In particular. either by ultrasonic or radiographic tests as follows:- . Testing shall be in random spots and as per AWS D l .1 5 of AWS D l . main structural welds shall be examined after thorough cleaning for faults such as lack of fusion. Miscellaneous steel welding shall also be visually inspected as per ITP as specified. magnifiers or such devices which are helpful t o detect visually cracks in welds. Ultrasonic tests shall be carried out on the entire length of butt weld including the webs as per Part C. .). shall be in SI units unless otherwise specified. if found t o be unsatisfactory and unacceptable.DOC. data sheets. The Contractor shall demonstrate compliance by providing a copy of the accredited certificate or its quality manual.I. Welds. Auto Cad etc. units of measurement.7 of AWS D 1 . Verification of the Contractor quality system is normally part of the pre-qualification procedure and is. All dimensions.I. Section 6 of AWS D l . data sheets. All calculations shall be submitted in approved and widely used software(s) agreed upon by KOC.4 of this Standard and shall be repaired as per Section 3. Welds shall be acceptable. one language shall be English. shall be subjected t o the requirements of clause 10. b. Section 6 of AWS D l . when they are found t o be satisfactory meeting all the requirements of visual inspection and the specified tests in accordance with relevant sections of AWS D l . PACKING AND MARKING For packing and marking of materials. refer t o " KOC Standard for Packing. (Nominal bore pipe sizes t o be generally mentioned in inches ).) shall be provided with electronic files in the approved and widely used software ( M S Word. physical constants etc. 1 a. Marking and Documentation " (KOC-G-004). therefore. Excel. not detailed in the core text of this Standard.It o assure the soundness of weld metal. specifications etc. instructions. DOCUMENTATION General All correspondence. Radiographic tests shall be made by one spot radiograph per 5 0 0 m m (20") of butt weld including radiographs on the flange sections of the beam w i t h a minimum one radiograph per welded connection in accordance with Part B. All documents (text.I. In case of dual languages. QUALITY ASSURANCE The Contractor shall operate a quality system preferably based on I S 0 9 0 0 0 series of standards t o satisfy the requirements of this Standard. drawings or any other written information shall be in English language. KOC-C-007 Page 33 of 35 REV. NO. Material safety data sheets for paintslgalvanizing and safety precautions t o be taken. Welder qualification test records. lnspection and nondestructive examination (NDE) records. handling. Repair procedures.2 ContractorIFabricator shall submit the relevant calculations for any splice connections by boltslwelds t o KOC for review. materials and connections. As-built drawings. dimensions. (For review only) j. erecting and painting the structural steel. built-up sections. e. Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR). 17. as per KOC regulations. 17. girders. welding. trusses.3 All equipment and machinery. erection markings and bill of materials for all fabricated items. Inspection and test plan (ITP) and QAIQC procedures. 17.17. if necessary. whenever required. connection details including bolt sizes and lengths. d. associated with cutting. Erection plans including list of equipment and tools t o be used. b. m. bracings. I. Structural analysis and design calculations for all frames. type of welds and weld lengths with shop and field weld symbols.2 All test results and certificates of materials required for satisfactory execution of the Works shall be submitted t o KOC for review and approval within the stipulated period as specified in the Contract documents. f. All relevant information shall be set out on a Site Record for fabrication and erection within 2 4 hours of carrying out a specific work. . Fabrication drawings showing member sizes and exact cut lengths. connections and support structures. k.2. (For approval) h. but is not limited t o the following only: a. Weld quality surveillance records. Deliverables 1 Contractor shall submit the necessary documents as a minimum to KOC for review and acceptance as given below. c. Certified mill test and shop test reports for all steel materials specified.2 Work Records and Reports 17. elevations and details outlining sizes.2.4 All inspection reports including NDE tests shall be submitted t o KOC for review and acceptance within 7 2 hours of completion of tests. transporting. shall have the latest fitness test reports certifying that they are in good working conditions and shall be submitted t o KOC for further inspection.2. Designlconstruction drawings of plan.1 Contractor shall operate a detailed recording and reporting system on all aspects of structural steelworks including inspection and testing. 17. g. primary and secondary load bearing members.3. (For approval & mark-up) i.2. Proj. Emam (Insp. Mohd. Supdt. This KOC Standard for " Structural Steel Work . & Corr. Gen.) Member Mr.Member Tel. NO. . Supdt. Ali H. Dept. Engg.Team IeaderIAuthor Tel. 6 1 3 2 2 Mr. Supdt. No. Svcs. Supdt. Transport & Plant Dept. Fabrication and Erection " has been prepared b y the Task Force (TF-Cl03) comprising of the following members: Mr.) Deputy Chairman Mr.Akbar Proj. Dept. 6 1 4 0 7 Mr. MAJOR PROJECTS GROUP OPERATIONS GROUP (N&W) Gen. Maged M.Supdt. Gen.Materials. Dept. Gen. Dept. Gen. & Facilities Div.) Member Mr. 6 6 3 8 9 . AI-Ali (Gen. Hill (Opn. Supdt. . Mgmt. & Supp. J. Proj. Khalid S. Drill. Supdt. M g m t Div. Kumar (Standards Div. Henry S. Supdt. Supdt. Fire & HSE Dept. Opn. Supdt. Mohammad llyas (Standard Div. Dept.Member Tel. No.(N&W) Gen. Svcs. Svcs.Member Tel.Madi Ahmadi Svcs. Engg. Div. Engg. Insp. Dept. Proj. AIAziz H. (El Gen. 6 1 1 9 7 Mr. Dept. M&EO Dept.(N) . No. Kumar Standards Div. DRILLING OPERATIONS GROUP DIVIDED ZONE GROUP Gen. . No. S. Opn Dept.I DOC. Svcs. Opn. Baba (Standards Div. S. Dept. Dept.(N&W) INDUSTRIAL SERVICES GROUP LOSS PREVENTION GROUP Gen. Supdt. Supdt.& Corr. Supdt. Dept. Dept. KOC-C-007 Page 35 of 35 REV. Engg. S&E) Member The draft of this Standard has been circulated t o the KOC user departments for their review and responses were received from the following:- ENGINEERING GROUP OPERATIONS GROUP (S&E) Gen. Ahmadi Svcs. Masood Engg Design Div.) SecretaryIMember Dr.(S&E) Gen. Mgmt.) Chairman Mr. Dept. Svcs. 1 ACKNOWLEDGEMENT This Standard has been approved b y the Standards Technical Committee (STC) consisting of the following:- Mr.(S&W) Gen.(S&E) Gen. Supdt. Proj. Proj.