HERA SPECIFICATION FOR THE FABRICATION, ERECTION AND SURFACE TREATMENT OF STRUCTURAL STEELWORK HERA REPORT R4-99

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2 HERA SPECIFICATION FOR THE FABRICATION, ERECTION AND SURFACE TREATMENT OF STRUCTURAL STEELWORK HERA REPORT R4-99

3 HERA For the Fabrication, Erection and Surface Treatment of Structural Steelwork HERA Report R4-99 This specification is in two parts: Part 1: for general application Part 2: Job-specific items requiring consideration Prepared by: G Charles Clifton Date: November 1998

4 Published by: New Zealand Heavy Engineering Research Association Gladding Place PO Box Manukau City New Zealand Phone: Facsimile: ISSN About HERA. The New Zealand Heavy Engineering Research Association (HERA) is a non-profit research organisation dedicated to serving the needs of the metal-based industries in New Zealand. It is the national centre for steel construction, welding, metal fabrication and machining, and promotes the effective and efficient use of steel in structures. HERA s work includes the sponsorship of research and development, the provision of educational, advisory and information services, the dissemination of technical knowledge to specifiers, fabricators and suppliers, participation in the activities of relevant national and international bodies and in the writing of standards and codes of practise. The results of HERA s research are published as reports and technical articles, designed to present the information in a form available for immediate use in design and construction. Acknowledgements. Many people in the industry commented on the draft of this, issued in June, Their input and comments are gratefully acknowledged. In particular, the HERA Structural Engineer would like to thank the following people for their input: Gareth Hancock et.al., Beca Carter Hollings and Ferner Ltd Clark Hyland, SSAS Manager Mike Lake, Lake Engineering Consultants John Little, J H Little and Associates Rod McIntyre, Contracts Manager, Southern Cross Engineering Tony Vos, Courtaulds Coatings (New Zealand Ltd)

5 HERA for the Fabrication, Erection and Surface Treatment of Structural Steelwork CONTENT This comprises nine Sections, covering the following: Part 1 Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Part 2 General: scope and use, definitions, related documents, shop and erection drawings, etc. Standards of Performance Supply of Materials Fabrication Erection Steel Decking Systems Surface Protection Against Corrosion Surface Protection Against Temperature Rise in Fire Inspection of Completed Work Job-Specific Items Requiring Consideration SCOPE AND FORMAT The aim of this is to facilitate the cost-effective fabrication, erection and surface treatment of structural steelwork, to the satisfaction of the client. The is written for compatibility with NZS 3910; ie. for inclusion in a set of Contract Documents between the Principal and the Contractor. The clauses therefore refer to the roles of the three key Persons to the contract, as defined by NZS 3910, ie. the Principal, the Contractor and the Engineer. (Contractor, Contract Documents, Engineer, Person and Principal are defined terms under NZS 3910). In order for the aim of this to be achieved, specialist parties are involved in specific tasks, such as the design engineer, fabricator, erector, etc. The design engineer will generally be the party incorporating this into a set of Contract Documents. The design engineer is not defined by NZS 3910, nor will the design engineer necessarily be the Engineer to the contract, as defined by NZS The other specialist parties involved will typically be sub-contractors and will have their contracts written by the Contractor. These parties are also not defined by NZS Because of this, the contains a set of commentary clauses in which the roles of the design engineer and the sub-contractors are given. These commentary clauses are not part of the and may be deleted, when incorporating the into a set of Contract Documents, by deleting the appropriate column. However, they provide useful information to enable the Contractor to write the contracts for the sub-contractors and it is the HERA Structural Engineer s recommendation that they be retained. If so, then this can be used to enable the writing of the contracts for the subcontractors, by defining the technical requirements for these sub-contractors to follow. However, this will still have to be undertaken by the Contractor in the normal manner, as the commentary clauses are a source of guidance to this and not a mandatory part of it.

6 Part 1 of the is presented in a three-column format, comprising clause, specification and commentary. This is principally a technical. It contains a small number of contractual provisions, each of which has been included for one or more of the following reasons: the provision provides guidance towards a cost-effective outcome on an issue for which many different approaches are currently adopted, often to the detriment of overall economy the provision provides guidance for general contractual application and is considered necessary by HERA for the efficient and effective fabrication, erection and surface treatment of structural steelwork. As previously stated, the commentary does not form part of the, its role being to: (i) Provide a background to appropriate clauses, including references to appropriate sources of additional information. (ii) Provide guidance on the scope of application of appropriate clauses. (iii) Identify particular matters requiring job-specific details to be provided, in accordance with Part 2. (iv) Highlight matters of a contractual nature within this and the reason for their presence in this document. (v) Identifies which party will typically be responsible for undertaking a task, when this party is not defined by the conditions for contract given in NZS Not all clauses contain a commentary Part 2 of this covers various job-specific items requiring consideration. Item 2.1 covers contractual issues relevant to this specification which must be included in the Contract Documents. Item 2.2 covers information required from some sub-contractors when tendering for work covered by this specification. Item 2.3 presents a check list of job-specific items relating back to Part 1 and item 2.4 references further sources of guidance for deriving job-specific details. METHOD OF APPLICATION This is intended to be used, for any given project, in a set of Contract Documents as follows: 1. Part 1 is used as written. 2. Details for the relevant items from Part 2 are developed and included in the Contract Documents or in a job-specific version of Part 2, as directed. AVAILABILITY ON DISKETTE This is also available as a Microsoft Word for Windows 95 file, on a 3.5 inch diskette contained in a pocket on the inside back cover of the report. Two versions are included, namely: 1. Word Version 6; filename is SpecVer6.doc 2. Word Version 7; filename is SpecVer7.doc

7 PART 1 SPECIFICATION FOR THE FABRICATION, ERECTION AND SURFACE TREATMENT OF STRUCTURAL STEELWORK Clause 1. GENERAL 1.1 SCOPE AND USE This covers the fabrication, erection and surface treatment of structural steel for buildings and the welding of headed shear studs onto the building structural steelwork This forms part of the Contract Documents It is assumed, in writing this, that the design engineer is responsible for incorporating this into the Contract Documents for given project. 1.2 OTHER DOCUMENTS Read this in conjunction with the other Contract Documents NEW ZEALAND BUILDING CODE Refer to the following New Zealand Building Code clauses and approved document paragraphs for the criteria and/or methods that must be used to establish compliance with the Code. B1/VM1 Structure- General 2.0 Loadings 5.0 Steel F5 Construction and demolition hazards 1.3 DEFINITIONS The commentary for The Contractor is the Person with overall responsibility for relates to this section as a construction of the building, so named in the Contract whole, rather than being Documents and as defined by NZS specific to one of the subclauses. For this reason, it is The Engineer is the Engineer to the contract as defined by NZS 3910 presented as a series of items The Principal is as defined by NZS denoted (i), (ii), etc Person is as defined by NZS (i) The Persons defined in The Contract Documents and Drawings are as defined by NZS contd to are as defined in NZS 3910, in order that this can form part of the Contract Documents. When carrying out work covered by this, various parties which are not formally part of the contract between the Principal and Contractor will have specific tasks to perform, on behalf of one of the Persons defined in to These parties are stated in (ii) to (v) below. Whenever this applies to a clause in this, the party or parties typically responsible for undertaking the task(s) is/are given in the commentary to that clause. (ii) The design engineer is responsible for design of the structure(s) covered by this, in accordance with NZS 3404 Clause (iii) The construction reviewer

8 1.4 RELATED DOCUMENTS Documents which relate to this are: contd. AS/NZS 1111 ISO metric hexagon commercial bolts and screws AS/NZS 1112 ISO metric hexagon nuts, including thin nuts, slotted nuts and castle nuts AS 1214 Hot-dip galvanised coatings on threaded fasteners AS/NZS 1252 High strength steel bolts with associated nuts and washers for structural engineering AS 1397 Steel sheet and strip hot-dipped, zinc-coated or aluminium/zinc-coated AS/NZS Structural steel welding Part 1: welding of steel structures. AS Structural steel welding Part 2: stud welding (steel studs to steel) AS/NZS Structural steel welding Part 5: welding of steel structures subject to high levels of fatigue loading AS 1627 Code of practice for the preparation and pretreatment of steel surfaces prior to protective coating Parts 1-10 AS/NZS 1650 Hot dipped galvanised coatings on ferrous articles AS 1897 Electroplated coatings on threaded components (metric coarse series) AS 2105 Inorganic zinc rich paint AS/NZS 2312 Guide to the protection of iron and steel against exterior atmospheric corrosion NZS 3404 Steel structures standard Part 1: steel structures standard Part 2: commentary AS Organic zinc rich primers is responsible for review of the structure(s) covered by this, in accordance with NZS 3404 Clause (iv) The fabricator is responsible for fabrication of the structural steelwork. In this, the fabricator is also assumed to be responsible for applying protective coatings against corrosion and for the erection of the structural steelwork. Variations to these roles should be noted in item 1.1, Part 2 of this. (v) The stud welder is responsible for the welding of shear studs to structural steel members, unless noted otherwise in item 1.1, Part 2 of this. Such a variation may arise where shear studs are welded to the beams prior to delivery on-site; this would often be done by the fabricator. Wherever practicable, this refers to the relevant provisions from related standards and other documents, rather than repeating them herein. Writers of Contract Documents incorporating this should note that smaller firms, especially, may not have all these documents available inhouse and should offer firms the opportunity to view these documents, at their premises, notifying firms of this opportunity through inclusion of such a statement in Part 2. All these documents can be viewed at HERA Information Centre and are available, on loan, to HERA Members. For further guidance on welding related issues, refer to the on the Structural Steel Welding Standard AS/NZS 1554, published by the WTIA as WTIA TN11.

9 AS Site testing of protective coatings Part 3: determination of dry film thickness NZS 3910 Conditions of contract for building and civil engineering construction. NZS 4711 Qualification tests for metal-arc welders AS/NZS 9002 Quality systems model for quality assurance in production installation and servicing AS/NZS HB62 Safe erection of steelwork BS Coatings for fire protection of building elements Part 1: code of practice for the selection and installation of sprayed mineral coatings BS Coatings for fire protection of building elements Part 2: code of practice for the use of intumescent coating systems to metallic substrates for providing fire resistance ISO 2063 Metallic and other inorganic coatings: thermal spraying: zinc, aluminium and their alloys WTIA Flame cutting of steels, WTIA Technical Note 5 WTIA Health and safety in welding, WTIA Technical Note 7 IPENZ/ACENZ The briefing and engagement of consultants Documents listed in clause and cited in the clauses which follow are deemed to form part of this. However, this takes precedence when it is at variance with the cited document Documents listed in clause refer to their latest issue complete with amendments that are current at the time of preparing the Contract Documents Acts which relate to this are: Building Act 1991 Health and Safety in Employment Act 1992 Dangerous Goods Regulations, Flammable Liquids Acts listed in include any amendments that are current at the time of preparing the Contract Documents. 1.5 EXISTING STRUCTURES When matching new steelwork to existing structures and where stated in Part 2 of this, the Contractor shall verify specified dimensions against site measurements, prior to fabrication and report discrepancies to the Engineer contd. When carrying out cutting or welding operations on existing structures, appropriate precautions shall be taken to minimise the risk of fire. Unless more stringent requirements are specified in Part 2 of this, appropriate precautions to be taken, when red-hot or molten metal could contact combustible material, shall comprise: (i) One hand held fully charged fire extinguisher or operational fire hose to be immediately accessible at all times, and (ii) All non-essential combustible materials, dust etc. to be cleared away before welding or cutting takes place. HERA can advise on the current status of documents and acts. The fabricator is the party that would undertake this check. Discrepancies that could affect the design capacity or constructability would need to be reported back to the design engineer. Either in Part 2 of this or elsewhere in the Contract Documents, the following must be specified: the parties responsible for ascertaining the risk of fire the precautions to be taken to reduce this risk to an acceptably low level, if the default requirements specified herein are not deemed adequate. The details required will vary from job to job; contact HERA for further advice where necessary.

10 1.6 CONTRACT PROGRAMME Progress this work in accordance with the Contract Documents. The Contract Documents should include a procedure for payment on additional work. For work covered by this, payment in accordance with agreed rates is the preferred solution. HERA Report R4-96 Structural Steelwork Estimating Guide, provides suitable rates to use. 1.7 SHOP AND ERECTION DRAWINGS Where required by Part 2 of this, the Contractor shall supply the Engineer with one set of shop and erection drawings for review prior to fabrication. Allow two working days for review Discrepancies between the interpretation of the design concept and the Contract Documents, as presented in these drawings, and the requirements of the Engineer shall be noted by the review and shall be resolved prior to fabrication commencing. 1.8 HEALTH AND SAFETY All work covered by this must be undertaken in accordance with the requirements of the Health and Safety in Employment Act (see section herein) and the Contractor s health and safety workplan (see item 2, section 2.1, Part 2 herein) Any party undertaking work, in accordance with this, which introduces hazards on site shall comply with and the requirements of item 3, section 2.1, Part 2 herein Where the elimination or isolation of on-site hazards is not possible, appropriate and effective equipment, clothing and work practices shall be used to minimise these hazards Health and safety practices for welding should be in accordance with WTIA Technical Note STANDARDS OF PERFORMANCE 2.1 GENERAL All work shall be performed in accordance with this, The fabricator will typically be responsible for preparation of the shop and erection drawings. Shop and erection drawings will not be required on many small and uncomplicated projects, however they do facilitate accurate and trouble-free fabrication and erection. The design engineer should consult with a fabricator or with HERA, prior to compiling the Contract Documents, if in doubt as to their need for a specific project. This will require liaison between the fabricator and Contractor and/or the Engineer. The provisions of and are particularly applicable to the following: stud welder, for on-site stud welding (section 4.8) erector (section 5) paint applicator (section 7) applicator of fire protection material (section 8) The hazard of fire from welding or cutting is covered in above. WTIA Technical Note 7 supersedes NZS 4781 with regard to the scope of work covered by this.

11 the related documents to this and the qualifying requirements of the Contract Documents. 2.2 CONSTRUCTION REVIEW All stages of fabrication and erection shall be reviewed in accordance with NZS 3404 Clause The extent of review shall be nominated by the Engineer, taking into account the factors identified in NZS 3404 Part 2 Clause C These requirements shall form part of the Contract Documents The extent of inspection of each component of construction shall be determined in accordance with section 9 of this The person responsible for review of the weld procedure sheets shall be nominated in Part 2 of this. 2.3 MATERIALS Certification shall be provided to the Engineer for steels in accordance with NZS 3404 Clause and for fasteners and welding consumables in accordance with NZS 3404 Section FASTENERS Bolts, nuts and washers shall comply with, and be installed to, the requirements of NZS 3404 Sections 2 and TOLERANCES Tolerances for holding down bolts, columns, beams and other members shall comply with Section 15 of NZS 3404 Part Unless stated otherwise in Part 2 of this, the Contractor shall be responsible for placement of holding down bolts and other structural components cast into the concrete. 3. SUPPLY OF MATERIALS 3.1 STRUCTURAL STEEL Structural steel shall comply with NZS 3404 Clause WELDING CONSUMABLES Welding consumables shall comply with AS/NZS and NZS 3404 Clause STEEL SHEAR STUDS Steel shear studs shall comply with AS BOLTS, NUTS AND WASHERS Bolts, nuts and washers shall comply with the standards listed in NZS 3404 Clauses or Bolts, nuts and washers forming a permanent part of an exterior structure subject to a protective coating shall be galvanised. Property class 4.6 or 8.8 bolts, nuts and washers shall be galvanised to AS The design engineer will typically undertake this task. Note (4) to Clause of NZS 3404 requires the weld procedure sheets to be approved and the person to do this shall be nominated in Part 2 of this. The construction reviewer will typically receive this material on behalf of the Engineer. These components will usually be supplied by the fabricator. 3.5 STEEL DECKING SYSTEMS Steel tray decking systems shall be manufactured from G550 galvanised steel coil, to AS 1397, with a Z200 zinc layer. A thicker layer of zinc is available, if required. 4. FABRICATION The fabrication part of this could be summarised as simply stating fabrication shall be to NZS 3404 Section 14. However, the greater level of detail provided herein is more desirable, in order to maximise the likelihood of compliance with these provisions.

12 4.1 WORKMANSHIP Fabrication procedures shall comply with NZS 3404 Clause REJECTION OF A FABRICATED ITEM This shall be considered in accordance with NZS 3404 Clause SURFACE FINISH Surface finishes of as-supplied steel shall comply with the appropriate material standard specified in NZS 3404 Clause Surface finishes of cut edges shall comply with NZS 3404 Clause Rust grade on as-supplied steel shall not exceed Grade C to AS 1627 Part IDENTIFICATION Throughout the fabrication, the grade of steel shall be identified in accordance with NZS 3404 Clause TOLERANCES Tolerances for fabricated steelwork shall comply with NZS 3404 Clause 14.4, unless specified otherwise in Part 2 of this Architecturally exposed structural steelwork (AESS) may need more stringent controls on cross section tolerances than those specified in NZS 3404 Clause Particular members requiring this shall be identified in the Contract Documents as AESS members, along with the tolerances required for these members contd Lifting slings or cradles for lifting AESS members shall be constructed so as to minimise damage to the steel surface and to any surface coating applied prior to erection. 4.6 CUTTING Cutting shall comply with NZS 3404 Clause This clause specifies three different applications for surface finish roughness, namely normal, fatigue or yielding regions. Lower roughness values are required for the latter two applications. Locations where the fatigue or yielding region requirements apply must be specified in the Contract Documents or drawings. Requirements for AESS members that are additional to this may be necessary for aspects of fabrication, delivery, erection and components with concrete backing. Suitable provisions for inclusion in the Contract Documents are given in HERA Design Guides Volume 2, HERA Report R4-49, Section 17, Clause 9. These provisions could be incorporated into Part 2 of this, where required. With regard to cross section tolerances, compliance with AS/NZS or AS/NZS will be suitable for hotrolled sections or for welded I-sections, respectively. Solutions can include nylon lifting strops or lagged chains. 4.7 WELDING OF STRUCTURAL STEEL See section 8 for inspection Welding shall comply with the standards listed in NZS 3404 of completed work, including Clause weld testing

13 4.7.2 For the welding of structural steel, welding personnel shall be qualified in accordance with Clause 4.11 of AS/NZS or AS/NZS , as appropriate. Details of qualifications shall be submitted to the Engineer, prior to commencement of welding on that project by that person. 4.8 WELDING OF STEEL SHEAR STUDS TO STEEL For the welding of steel shear studs to steel, welding personnel shall be qualified in accordance with Clause 4.1 of AS For the welding of steel shear studs to steel, the Contractor shall provide a producer statement to the Engineer that the procedural control procedures of Clauses 4.1 and 4.2 of AS have been complied with The steel surface onto which shear studs are to be welded shall be free of paint, oil, loose or thick scale, slag, dirt and, where necessary, moisture After the welding of steel studs to steel, the Contractor shall remove the arc shields from the base of the studs and leave the surface to which the studs have been welded clean and tidy. 4.9 HOLING The formation of holes for bolted construction shall comply with NZS 3404 Clause The construction reviewer will typically receive these details on behalf on the Engineer. The stud welder will be the party supplying the producer statement; typically to the construction reviewer. If the stud welding equipment being used is capable of delivering dependable welds in damp or wet conditions, then the restriction on moisture is not required. For more details, see the HERA Steel Design and Construction Bulletin (HERA DCB) Issue 22. This task will usually be performed by the stud welder. Locations where holes are not permitted to be produced by full size punching because of seismic requirements (NZS 3404 Clause ) or fatigue requirements (NZS 3404 Clause 10.9) must be specified in the Contract Documents or drawings BOLTING The table in is principally a repeat of NZS 3404 Table It is included herein because of confusion in the industry over the correct bolt category to specify in practice. In bearing type connections, the normal condition is to have the threads included in the shear plane. To achieve the threads excluded condition requires careful control on bolt lengths and direction of installation Bolting procedures shall comply with NZS 3404 Clauses and Notation of bolting categories. Bolting Bolt Bolt Tension Tensioned Category Standard Property Method Joint Type Class 4.6/S AS/NZS snug tight bearing 8.8/S AS/NZS snug tight bearing 8.8/TB AS/NZS full tension bearing 8.8/TF AS/NZS full tension friction In bearing type connections, where the thread position relative to the shear plane is to be controlled: N threads included in shear plane X thread excluded from the shear plane 4.11 CRANE RAILS The following details shall be given on the Drawings or in the Contract Documents: Guidance on specifying these items will be given in HERA DCB Issue 47, December

14 (i) The material and section profile (ii) The resilient seating to be used between the crane rail and the crane runway girder (iii) The fastening system to be used between the crane rail and the crane runway girder (iv) The method of joining individual lengths of crane rail Until then HERA can provide specialist advice on each item. Joining can be either by bolting or welding; specialist details are required in each instance Length of individual crane rails shall be not less than 3 metres Tolerances for crane rails shall be as follows: (i) Horizontal distance apart of crane rails across the building shall be accurate to within 3 mm of the specified distance. (ii) Difference in elevation between crane rails across the building shall not exceed 5 mm. (iii) Difference in plan and elevation at joints between adjacent crane rails shall not exceed 0.5 mm. (iv) All points along each crane rail shall be within 3 mm of their specified location in plan and elevation On completion of the crane rail erection, the Contractor shall supply the Engineer with a plot showing the actual position, to within 0.5mm, of each crane rail, throughout its length, with respect to its theoretical position. 5. ERECTION The erection part of this could be summarised as simply stating erection shall be to NZS 3404 Section 15. However, the greater level of detail provided herein is considered more desirable, in order to maximise the likelihood of compliance with these provisions. 5.1 WORKMANSHIP Erection practices and procedures shall comply with SAA/SNZ HB 62 and with NZS 3404 Clause REJECTION OF AN ERECTED ITEM This shall be considered in accordance with NZS 3404 Clause STARTING TIME Start erection when approval is given by the Contractor or by the Engineer, whomever has the appropriate authority. 5.4 DELIVERY, STORAGE AND HANDLING These shall comply with NZS 3404 Clause ASSEMBLY AND ALIGNMENT Assembly and alignment shall comply with NZS 3404 Clause TOLERANCES Tolerances for erected steelwork shall comply with NZS 3404 Clause BASEPLATES AND HOLDING DOWN BOLTS Enlargement or other site rectification of holes in baseplates is not permitted, without the approval of the Engineer Holding down bolts and other structural components to be cast into concrete shall be checked for correct location by a surveyor prior to concrete placement Components from shall be secured to prevent their movement during concrete placement. While this is a non-technical item, it is included to clarify an important issue, as to when erection may commence. The design engineer will have to be involved in this decision. A good solution is to have the fabricator supply preassembled holding down bolt cages for casting into the concrete.

15 5.7.4 Drilled-in holding down bolts shall not be substituted for cast-in holding down bolts without the approval of the Engineer Bending or displacement of holding down bolts is not permitted. 5.8 GROUTING AT SUPPORTS Grouting at supports shall be in accordance with NZS 3404 Clause Unless specified otherwise in Part 2 of this, grouting at supports shall be undertaken by the Contractor Unless specified otherwise in Part 2 of this, the grout used shall be a cement-sand grout, containing an approved non-shrink additive, and having a minimum compressive strength of 30MPa at 28 days, or alternatively shall comprise a dry pack of 1:2 cement : sand mortar, hammered in tight to ensure the complete filling of space beneath the steelwork Beach sand shall not be used in the grout or mortar specified in STEEL DECKING SYSTEMS 6.1 STORAGE AND HANDLING Steel decking shall be handled and stored in accordance with the written requirements of the decking manufacturer In all instances, decking shall be stored clear of the ground and protected from the weather When lifting long lengths or bundles of decking, use multiple lifting points and use nylon strops. 6.2 SUPPLY AND INSTALLATION contd. The decking placer shall be responsible for supply of all end caps, closure strips, edge forms and hanger tabs specified in the Contract Documents Decking shall be installed and fixed in accordance with the written requirements of the decking manufacturer Temporary propping shall be provided, where necessary, to support wet concrete and/or construction loads in accordance with the manufacturer s written instructions. The design engineer will need to be involved in this decision Typically the construction reviewer will approve the nonshrink additive on behalf of the Engineer. Beach sand contains unacceptably high chloride ion concentrations, which will cause excessive corrosion of the underside of the baseplate. The former requirement is to prevent local buckling of the decking cross section and the latter is to prevent local damage to the decking. The design engineer must decide the method for forming around slab edges and deck openings and specify the supply of proprietary components to achieve this. Either in Part 2 of this or elsewhere in the Contract Documents, the party responsible for supply of support to the decking at openings or cut edges not detailed in the Contract Documents or drawings should be stated, along with the method of payment for this additional work. Responsibility for supply of temporary propping should be stated in Part 2 of this. This could be either the Contractor or the party responsible for laying the decking. Who is to supply this must be specified in Part 2. The design engineer (typically) will specify the location of

16 6.2.4 When the deck laying is completed, the installed decking shall be left in a clean and tidy condition. 7. SURFACE PROTECTION AGAINST CORROSION 7.1 STEELWORK SURFACE PREPARATION The extent of steelwork surface preparation for the protective coating selected under clause 7.2 below shall be determined in accordance with AS/NZS 2312 Section 5 and shall follow the requirements of the relevant standard or standards listed therein. 7.2 APPLICATION OF PROTECTIVE COATING Paint systems shall be selected in accordance with Section 7 of AS/NZS contd Paint systems shall be applied in accordance with Section 8 of AS/NZS Galvanising process shall be in accordance with Clause 6.2 of AS/NZS 2312 and AS/NZS Metal spray coatings shall be applied in accordance with Clause 6.3 of AS/NZS 2312 and ISO QUALITY ASSURANCE For steelwork in external environments or in aggressive internal environments, applicators shall have in place formal written quality assurance (QA) procedures appropriate to the scope of work under this contract, details of which shall be submitted with the tender During the course of the contract, where necessary the Engineer shall be given access to the QA certification records from for verification purposes. 7.4 UNPAINTED SURFACES Do not paint: Interior enclosed steelwork, unless nominated elsewhere in the Contract Documents to be painted. Faying surfaces of bolted joints of category 8.8/TB or 8.8/TF temporary propping in the Contract Documents or drawings. The extent of steelwork surface preparation required depends on the specific surface protection system chosen. For many paint types, this is specified in the relevant standard referenced from AS/NZS 2312 Appendix C. For paint types not covered therein, consult the paint manufacturer s written specification. It is typically the role of the design engineer to specify the appropriate system. HERA provides generic guidance on this through a range of sources, such as section 9 of HERA Report R4-96 or HERA DCB Issue 41. Careful consideration should be given to this choice, to avoid overexpensive specification of surface treatment for corrosion protection. The advice of a reputable coatings supplier or coatings consultant can be very useful in selecting an appropriate paint system. It is preferred that applicators have in place a QA system which has been certified by an organisation accredited under JAS-ANZ, as this provides independent verification of the adequacy of such a system. This will only be necessary when the Engineer (construction reviewer) is part of the QA process. With regard to painting of the faying surfaces of bolted joints, the area of significant bearing contact extends a

17 (see herein) Within 75mm of locations to be welded subsequent to painting. Surfaces to be fully encased in concrete, except as noted in below. Surfaces onto which shear studs are to be welded Where steel is only partly encased in concrete, then extend priming at least 100mm into the concrete encasement area. radius of 2d f from the centre of the bolt hole. An alternative to not painting the whole contact surface is to not paint within 1.5d f from the edge of any bolt hole, where d f = bolt diameter. (The faying surfaces are the steel surfaces in contact with each other in a bolted connection). Faying surfaces may be painted with a single coat of inorganic zinc silicate paint (system MP1-A from AS/NZS 2312) as an alternative to being left unpainted. Where the steel is in an external environment or in an aggressive internal environment, a non-conductive barrier coat should be used. More guidance on painting the interface between steel and concrete inagressive environments is to be given in HERA DCB Issue 47, December SITE REPAIR All damaged areas shall be repaired to match the workshop applied coating thickness, quality, surface finish and colour Areas of weld damage are to be given the extent of steelwork surface preparation specified through clause 7.1 above. Reapply the original paint system as specified. 7.6 PAINTING AND WELD INSPECTION Welds shall not be painted until the weld inspection required from section 9.1 has been completed. 8. SURFACE PROTECTION AGAINST TEMPERATURE RISE IN FIRE 8.1 STEELWORK SURFACE PREPARATION For sprayed mineral coating, steelwork surface preparation shall be in accordance with Section 6 and, where necessary, Section 7 of BS For intumescent paint, steelwork surface preparation shall be in accordance with Clause 6.2 of BS APPLICATION OF PRODUCT Sprayed mineral coating shall be applied in accordance with Section 10 of BS and any additional written requirements of the coating manufacturer Intumescent paint shall be applied in accordance with Clauses 6.2 and 6.3 of BS and any additional written requirements of the paint manufacturer. 8.3 QUALITY ASSURANCE Applicators shall have in place formal written quality assurance (QA) procedures appropriate to the scope of work under this contract, details of which shall be submitted with the tender. It is preferred that applicators have in place a QA system which has been certified by an organisation accredited under

18 8.3.2 During the course of the contract, where necessary the Engineer shall be given access to the QA certification records from for verification purposes. 8.4 FIRE PROTECTION AND WELD INSPECTION Welds shall not be obscured with fire protection material until the weld inspection required from section 9.1 has been completed. 9. INSPECTION OF COMPLETED WORK 9.1 WELD INSPECTION The extent of independent weld inspection shall be as specified in accordance with Appendix D of NZS 3404, except that: When applying Table D1 to an extent of Non Destructive Examination (NDE) less than 100%, the frequency of inspection shall be not less than 1 in 5 for each type of component or 0.5m in each 10m length of weld, whichever is appropriate The extent of independent weld inspection required and the qualification of the welding inspector shall be given in Part 2 of this, including the extent of additional inspection required if weld defects are found during inspection. Payment for independent welding inspection shall be specified in Part 2. JAS-ANZ, as this provides independent verification of the adequacy of such a system. This will only be necessary when the Engineer (construction reviewer) is part of the QA process This extent will be specified by the design engineer. Guidance on determining the frequency of inspection of welds in welded connections for a specific project is given in HERA DCB Issue 44, June The article referenced in the commentary to provides guidance on this issue. Payment will be either by the Principal or the Contractor depending on the wishes of the client Repair of defective welds shall be in accordance with Clause 5.8 of AS/NZS or AS/NZS INSPECTION OF BOLTED CONNECTIONS Independent inspection of bolted connections shall be undertaken by the Engineer Inspection shall be to Clause of NZS 3404, with the extent of inspection of a given sample of joints determined in accordance with Clause C15.4 of NZS and the frequency of inspection (ie. the number and frequency of visits to site) determined by below and stated in Part 2 of this 9.3 INSPECTION OF FABRICATED AND ERECTED STEELWORK Independent inspection of fabricated and erected steelwork shall be undertaken by the Engineer The extent of independent inspection of fabricated and erected steelwork shall be determined in accordance with Clause C1.6.3 of NZS and Appendix 1 of The Briefing and Engagement of Consultants. This extent of inspection shall form part of the Contract Documents. 9.4 SHEAR STUD WELDING INSPECTION Shear studs shall be inspected in accordance with Clause 6.1 of AS and studs which fail this test shall be replaced. In terms of payment for weld inspection, it is recommended that the Principal pay for inspection of the specified minimum number of welds and that the fabricator pay for additional inspection required due to defective welds being found. Typically, the construction reviewer will perform this task. Guidance on determining the frequency of inspection of bolts in bolted connections for a specific project is given in HERA DCB Issue 46, October Typically, the construction reviewer will perform this task. In addition to these tests, prequalification testing of studs is required as specified in herein In addition to the requirements of 9.4.1, at locations specified The design engineer should

19 prior to commencement of construction, further studs shall be inspected by one of the following means: (1) Either 1% of the studs shall be subject to the 15 bend test specified in AS Clause 6.1, or (2) 50% of the studs shall be ring tested in accordance with the provisions of the HERA Steel Design and Construction Bulletin (HERA DCB) Issue Defective studs from clause above shall be replaced and further studs tested, until the number of studs tested satisfactorily equals the number involved in 9.4.2(1) or 9.4.2(2) The testing called for in clause shall be undertaken, on behalf of the Engineer 9.5 INSPECTION OF APPLIED PROTECTIVE COATING AGAINST CORROSION A specification for the extent and frequency of inspection shall be produced, by the applicator and to the approval of the Engineer, in accordance with AS/NZS 2312 Clause 11.3 and Section 12, and with AS , prior to application of any coating, and that specification shall form part of the Contract Documents contd. determine these locations and should specify them in the Contract Documents. HERA DCB Issue 44 is included in the specification in this instance, rather than in the commentary, because it contains the requirements for ring testing which are not included in AS This testing will typically be undertaken by the construction reviewer or by an independent inspector. Clause 11.3 of AS/NZS 2312 lists the items to be considered in preliminary discussions and leads into preparation of the coating specification, covered by AS/NZS 2312 Section 12. Recommended extent of nondestructive testing for coating dry film thickness are given in Clause 1.7 of AS For painting of most structural steel members, these requirements can be summarised as follows: 1. Readings shall be taken every linear metre along each flat face of the member 2. One reading shall be taken across each flat face less than 300mm in width and readings at 300mm centres shall be taken across each flat face greater than 300mm in width. 3. Each reading shall consist of one point reading, where this reading is satisfactory (see 4. below). Where the reading is suspect, the mean of three separate gauge readings, taken within an area of 12mm diameter, shall be recorded. 4. No one point reading should be less than 80% of the specified minimum coating thickness. However, where three

20 9.5.2 For steelwork in external environments or in aggressive internal environments, painting inspectors shall hold Certified Coatings Inspector certification from the Certification Board for Inspection Personnel (CBIP) or an equivalent qualification acceptable to the CBIP. Details of qualifications/certification shall be submitted to the Engineer, prior to commencing application of the protective coating Painting inspectors shall undertake the requirements of AS/NZS 2312 Clause 11.4 to INSPECTION OF SURFACE INSULATION AGAINST TEMPERATURE RISE IN FIRE Inspection of sprayed mineral coatings shall be to Clause 10.9 of BS The party responsible for undertaking this inspection shall be nominated in the Contract Documents Inspection of intumescent paints shall be to Clause 9 of BS The party responsible for undertaking this inspection shall be nominated in the Contract Documents Inspectors of intumescent paints shall hold Certified Coatings Inspector certification from the Certification Board for Inspection Personnel or an equivalent qualification acceptable to CBIP. Inspectors of sprayed mineral coatings should hold such a certification. Details of qualifications/certification shall be submitted to the Engineer, prior to commencing application of the surface insulation material. readings are averaged to produce a point reading, an individual reading may be less than 80% of the specified minimum coating thickness. The construction reviewer will typically receive these details on behalf of the Engineer. The construction reviewer will typically receive these details on behalf of the Engineer.

21 PART 2 JOB-SPECIFIC ITEMS REQUIRING CONSIDERATION 2.1 Contractual Items Relevant to This which must be Included in The Contract Documents. Item 1. The relationship of the work covered by this to the contract programme. Relevant Clause Numbers The Contractor s Health and Safety Workplan Prior to commencing work, any party bringing hazards onto the site shall inform the Contractor of: the nature of these hazards the measures that have been put in place to minimise these hazards the procedures that have been put in place for dealing with emergencies 5. The Contractor s Quality Plan this must incorporate the requirements of clauses to of this , Information Required from Specific Sub-Contractors when Tendering for Work Covered by This. Item 1. From applicators of protective coatings against corrosion: a copy of the procedures proposed to be used for steelwork surface preparation and for protective coating application. where relevant, a copy of the formal written QA procedures appropriate to the scope of work. 2. From applicators of surface protection against temperature rise in fire: a copy of the procedures proposed to be used for steelwork preparation and for product application. a copy of the formal written QA procedures appropriate to the scope of work. Relevant Clause Numbers Part 2 - continued

22 2.3 Check List of Job-Specific Items The following is a check list of items for which job-specific details are to be provided for use as part of this. Not all items listed below will require specific consideration for any one job. The check list gives the clause, topic and clause number(s). Clause Topic Clause Number(s) 1. GENERAL 1.1 Role of parties undertaking tasks in accordance with 1.3 this. 1.2 Relevant documents available for viewing Contractor (fabricator) to check existing measurements Fire risk from welding in existing structures Method of payment for additional work to the programme Shop drawings Hazards on site STANDARDS OF PERFORMANCE 2.1 Extent of construction review Extent of inspection of components Person to approve weld procedure sheets Responsibility for placing of hold-down bolts SUPPLY OF MATERIALS 3.1 Supply of steel decking with other than the Z200 layer FABRICATION 4.1 Surface finish roughness Variations in tolerances Architecturally exposed structural steelwork which members it applies to - what standard of finish is required 4.4 Restrictions on punching holes full size Nominate bolting categories Details for crane rails ERECTION 5.1 Authority to approve start of erection Who is to grout hold-down bolts? Composition of grout 5.8.3

23 Part 2 continued Clause Topic Clause Number(s) 6. STEEL DECKING SYSTEMS 6.1 Manufacturer s written requirements for handling and 6.1, 6.2 storage to form part of. 6.2 Supports to cut edges Manufacturer s written requirements for installing and fixing decking to form part of 6.4 Supply and placement of temporary propping SURFACE PROTECTION AGAINST CORROSION 7.1 Paint system to be used QA system of applicator, where required Treatment of faying surfaces of bolted connections SURFACE PROTECTION AGAINST TEMPERATURE RISE IN FIRE 8.1 Manufacturer s written requirements to form part of QA system of applicator INSPECTION OF COMPLETED WORK (These items should be included in the Contractor s Quality Plan; see item 5, section 2.1, Part 2 herein) 9.1 Frequency and extent of weld inspection in welded connections 9.2 Frequency and extent of bolt inspection in bolted 9.2 connections 9.3 Extent of independent inspection of fabricated 9.3 and erected steelwork 9.4 Extent of additional inspection of welded shear studs Inspection of paint systems for corrosion Qualifications of paint inspectors (where relevant) Inspection of fire protection systems party responsible - scope of inspection 2.4 Further Sources of Guidance for Deriving Job-Specific Details The following check lists should also be consulted when deriving job-specific details, to ensure that no information necessary to the successful completion of the contract is overlooked. (1) For design data and details - Clause of NZS 3404

24 Part 2 - continued (2) For fabrication - Clause C14.6 of NZS 3404 (3) For erection - Clause C15.7 of NZS 3404 (4) For welding - Appendix E of AS/NZS Many items in (1)-(4) above will have been covered by section 2.1 above and Part 1 of this, however the above lists are a useful reminder to the design engineer in regard to design data (especially (1)) and the requirements for more unusual applications (eg. applications involving complex joints, unusual steels).