WP001

FABRICATION GUIDANCE
FOR
STEEL STRUCTURE
FOR
PL-TCM PROJECT
OF
TERNIUM MEXICO
FOR REFERENCE
December,
2011
Document No. 11117198 - 2002090 - WP001
HIROSHIMA WORKS
11117198 - 2002090 - WP001
CONTENTS
Page
1.
2.
3.
General................................................................................................................3
1.1
Introduction ....................................................................................................3
1.2
Scope.............................................................................................................3
1.3
Applicable laws and regulations .....................................................................3
1.4
Steel tape measures ......................................................................................3
1.5
Approval of fabrication procedure ..................................................................4
1.6
Engineers in charge and work control ............................................................4
1.7
Control of documents.....................................................................................4
1.8
Storage of documents....................................................................................6
Materials ..............................................................................................................7
2.1
Quality, shape and dimensions ......................................................................7
2.2
Welding materials ..........................................................................................8
2.3
Material test and weldability test.....................................................................8
2.4
Receipt and storage of materials ...................................................................9
Fabrication...........................................................................................................9
3.1
Approval of fabricator.....................................................................................9
3.2
Erection drawings and shop drawings............................................................9
3.3
Full size drawings.........................................................................................10
3.4
Templates and full size rulers ......................................................................11
3.5
Removal of mill scales .................................................................................11
3.6
Marking-off...................................................................................................11
3.7
Cutting and groove face ...............................................................................13
3.8
Bending........................................................................................................13
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Page
3.9
Marking holes...............................................................................................14
3.10 Straightening of materials ............................................................................15

3.11 Assembly .....................................................................................................17
3.12 Safety and health .........................................................................................20
4.
5.
Welding .............................................................................................................22
4.1
General ......................................................................................................22
4.2
Butt welding .................................................................................................24
4.3
Partial penetration welding ...........................................................................25
4.4
Fillet welding ................................................................................................25
4.5
Preparation and assembly ...........................................................................26
4.6
Welding work ...............................................................................................28
Erection marks...................................................................................................29
5.1
General ......................................................................................................29
5.2
Size of erection marks .................................................................................29
5.3
Color of erection marks................................................................................29
5.4
Location of erection marks ...........................................................................29
5.5
Connection and joint parts ...........................................................................29
5.6
Datum point marks.......................................................................................30
5.7
Erection mark system ..................................................................................31
5.8
Examples .....................................................................................................33
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11117198 - 2002090 - WP001
1.
General
1.1
Introduction
This guidance describes how to fabricate structural steel on the basis of
Mitsubishi-Hitachi Metals Machinery Inc.s experience, herein after called as MH, for
the purpose of Terniums fabrication work, and called as Owner. However, this
manual is described according to Japanese code, in general. Fabricator shall
consider the Mexican or American fabrication code appropriately.
If any fabrication method deviating from this specification is customarily used or
there is any point to be improved upon, the method which will produce the best
results shall be agreed upon by all parties concerned.
1.2
Scope
These specifications shall apply to the fabrication work of structural steel.
1.3
Applicable laws and regulations
(1)
Japanese Industrial Standards (JIS)
(2)
Local laws and regulations for :

(a)
Labor safety and sanitation
(b)
Crane safety
(3)
International laws, regulations and standards for steel work
(4)
MH manual Tolerance of Accuracy
1.4
Steel tape measures

Steel tape measures of JIS B 7512 Class 1 shall be used.
Steel tape measures to be used for the same work shall have the least possible
mutual differences.
Before using the steel tape measures at the shop, verify them
against the fabricators standard tape measures to determine their errors.
To
minimize measuring errors, the verification shall be made at dawn on a windless,

cloudy morning or indoors, and the measured values shall be corrected by
atmospheric temperature and the tension of tape measures at measurement.
1.5
Approval of fabrication procedure

The fabricator shall prepare a fabrication procedure describing concretely the
specifications, organization and inspection in accordance with the design drawings
and this specification, and obtain Owners approval thereon before starting
fabrication work.
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1.6
Engineers in charge and work control

The fabricator shall assign engineers responsible for the structural steel work and
clarify their duties and responsibilities.
The fabricator shall perform quality control
so that the work will be carried out properly as per the design documents.
The
fabricator shall also perform intent control of the work to keep its schedule and to
safeguard personnel from hazards.
The fabricator is responsible for guiding its
personnel on the welding methods necessary to obtain good quality, the direction in
which welding should move forward, the sequence and range of welding, how to
reduce residual stress and strain, the sequence of assembly, the necessity of
chipping, and precautions concerning weather.
1.7
Control of documents
Drawings, specifications, manuals and all other documents concerning quality
assurance shall be updated to prevent nonconformities originated in poor control of
documents.
When the fabricator receives the latest drawings and documents from Owner, he
shall sign in the receipt column of the drawing/document dispatch notice, and put
them into his drawing/document control ledger and distribute the documents
promptly to the departments and sections concerned.
The fabricators quality department shall make sure that the drawings and
documents are handled correctly and promptly according to this manual and correct
any imperfections immediately.
1.7.1
Receipt and distribution

The business department of the fabricator shall check the contents of
received documents, enter the necessary information in the
drawing/document control ledger, and promptly distribute them to
departments and sections concerned.
1.7.2
(1)
Storage control
Stamp "COPY" on shop drawings and keep one copy in the order of the
drawing numbers.
(2)
The business department of the fabricator shall receive and store one printed
copy for reviewing fabrication and checking for problematic points in
fabrication.
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(3)
The business department of the fabricator shall receive a reproducible copy,

enter a piece mark, produce the required number of copies, distribute them to
departments and sections concerned, and receive the signed
drawing/document receipt.
(4)
The business, production, and quality assurance departments shall keep one
copy each of design drawings, standards and other necessary documents.
(5)
The reproducible copies of shop drawings shall be kept by the business

department.
(6)
The fabricators production department shall control received drawings,

carefully review problematic points in fabrication with the departments and
sections concerned, and enter into the drawings necessary items and
instructions which should be reflected during fabrication.
(7)
Drawings for the production shop shall be kept and controlled by the
production department of the fabricator so that they will not be stained or
damaged.
If any drawing is stained or damaged severely, promptly replace it
with a reprinted drawing.
Transfer instructions and other information
correctly to the reprinted drawing.

(8)
The quality assurance department shall keep received drawings and use
them for inspection during and after fabrication.
If they find any problematic
points or points to be checked, they should mark them immediately on their

drawings.
(9)
The business department shall collect the drawings used at the shop after
completion of fabrication and store them until completion of field erection.
1.7.3
(1)
Control of revised drawings

When the fabricators business department receives revised drawings, it shall
stamp "COPY" on them.
When drawings are superseded, stamp "COPY" on
the revised drawings, and sign the drawing/document receipt.

(2)
The fabricators business department shall transfer revised places correctly to

the reproducible copies it has kept, reproduce the necessary copies, stamp
"REVISED" on them and distribute them to the departments and sections
concerned.
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(3)
Mark with color revised places on revised drawings to call attention to the
revision.
(4)
If old drawings include necessary instructions, transfer the instructions

correctly to the revised drawings.
(5)
The fabricators business department shall promptly retrieve old drawings,

stamp them "ABOLISHED" or "OBSOLETE", and dispose of them.
1.7.4
Storage period
Unless otherwise specified, the drawings and documents shall be stored until
completion of field erection.
1.7.5
Control of other documents

Prior to the start of the work, the fabricator shall provide the latest editions of
various applicable codes and standards (JIS, AWS, etc.) which will not be
supplied by Owner.
1.8
Storage of documents
The fabricator shall store the erection drawings, shop drawings, rulers for full size
drawing and templates until Owner instructs him to discard them or for one year
from the final shipment of products, whichever is earlier.
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2.
Materials
2.1
Quality, shape and dimensions

The quality, shape and dimensions of materials shall conform to JIS standards
applicable to the materials described in design documentation and shall be free of
harmful defect and excessive rusting.
Unless otherwise specified in a drawing, or approved by MH, steel materials shall
not be forged or welded to obtain the required length.
If weld cracking can have serious results, steel materials conforming to the following
specifications shall be used.
Steel material specifications to prevent weld cracking
Steel materials specifications
ASTM A36
1. Carbon contents (C)
0.18% max.
2. Manganese contents (Mn) (T = thickness)

For A36
T 19 mm
19 mm < T 64 mm
64 mm < T
For A572 grade 50
T 9.5 mm
9.5 mm < T
ASTM A572
Grade 50
0.18% max.
Not specified
0.80 to 1.20%
0.85 to 1.20%
0.50 to 1.35%
0.80 to 1.35%
3. Manganese/carbon ratio (Mn/C)
4.0 min.
6.5 min.
4. Carbon equivalent
0.30% max.
0.42% max.
Si
C eq.= C +
24
Mn
+
Ni
+
40
Cr
+
Mo
+
V
+
14
(C, Si, Mn, Ni, Cr, Mo, V contents :%)

5. V-notch Charpy absorbed energy on 0 C
Not specified
6. Columbium contents (Nb)
Not specified
20/1000% max.
7. Vanadium contents (V)
Not specified
20/1000% max.
8. Columbium + vanadium contents (Nb + V)
Not specified
20/1000% max.
5kgfm 0C
min.
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2.2
Welding materials
All welding materials shall be carefully selected so that they will be optimum for the
type and size of the base metal and other welding conditions, and shall be approved
by Owner.
2.3
Material test and weldability test

Material test can be omitted for materials with JIS certificates by means of mill test
reports.
Unless otherwise specified, materials without mill test reports shall be
subjected to material test and weldability test.

If the same type of material was subjected to the weldability test with satisfactory
results, the weldability test of the material may be omitted upon Owners prior
consent.
2.4
Receipt and storage of materials

(1)
Receipt of materials
Materials shall be inspected when they are received at the shop, and rejected
materials should not be used.
Materials shall be rejected and not used if they have a harmful defect, are
deformed, do not have the required dimensions or thickness, or have excessive
rust.
(2)
Control and storage of materials

Materials shall be classified by shape and quality, and shall be carefully
controlled and stored so that no confusion will occur.
During storage, the
materials shall be fully protected from mud, oil, paint, dirt and rusting by water
and acid.
To prevent deformation when materials are piled, do not allow
excess force to be imposed on materials on the bottom.
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3.
Fabrication
3.1
Approval of fabricator
Before starting fabrication, the fabricator shall submit to Owner a document
including all information concerning his experience, designers, workers, research
and test equipment, etc., and obtain Owners approval on it.
3.2
Erection drawings and shop drawings
3.2.1 Erection drawings

(1)
The fabricator shall prepare erection drawings in

accordance with MHs design documents and obtain Owners approval of
them.
(2)
The erection drawings shall include the marks of each member necessary for
erection and a bolt list of the required bolts, to facilitate erection.
If the bolt list is prepared separately from erection drawings, obtain Owners
prior approval.
(3)
There shall not be any repetition of erection marks in the erection drawings.
(4)
Marks shall be given to show the direction in which members shall be erected.
3.2.2 Shop drawings

(1)
The fabricator shall prepare shop drawings including the detailed shapes,
dimensions, names, erection marks and other necessary data of structural
steel members to be fabricated, and obtain Owners approval thereon before
starting fabrication.
(2)
Full size drawings may be prepared for such portions which cannot be
expressed in shop drawings.
Be sure to inspect these portions with the full
size drawings.
(3)
The developed length of a member to be bent shall be the length of the

neutral axis.
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(4)
In preparing the shop drawings, check the following items and look into
workability at the shop and ease of work at field erection.
3.3
(a)
Dimensions and cross-sectional shapes
(b)
Erection marks
(c)
Relative positions of parts
(d)
Reference lines of members
(e)
Details of connection of members
(f)
Types of steel materials to be used
(g)
Type, class, bolt diameter and length of high strength bolts
(h)
Welding symbols and nondestructive test symbols of welding
(i)
Type, class, bolt diameter and length of bolts
(j)
(The degree of smooth machine finish for bearing joints)
(k)
(Camber dimension)
Full size drawings

Full size drawings shall be drawn and inspected in accordance with shop drawings.
Based on the full size drawings, templates and rulers shall be provided.
Prior to full size drawings, steel tape measures to be used for fabrication shall be
checked against the tape measures for full size drawings and the standard tape
measure of the shop to determine errors.
The steel tape measures for fabrication
shall be used after correcting the errors.

The positions of gussets and bolt holes near the joints of members to be assembled
by welding shall be marked after completion of welding to avoid shrinkage due to
the effect of welding heat.
For members which can easily be marked directly from
shop drawings using steel tape measures, full size drawings may be omitted.
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11117198 - 2002090 - WP001
3.4
Templates and full size rulers

(1)
Be sure to use a steel sheet (t=0.29 mm or over) or synthetic resin sheet

(t=0.105 mm or over) as template material.
(2)
Mark the template dimensions, bolt diameter, pitch, quantities of holes and edge
distance according to the full size drawing.
(3)
Using a full size ruler (steel band of 0.4 mm thick and 18 to 25 mm wide) on the
full size drawing, accurately copy bolt positions, pitches and cutting positions.
(4)
Marking accuracy shall not be greater than 0.5 mm.
(5)
For gusset plates, rib plates and base metal which will not be fitted at right
angles, templates for inspecting the fitting angles shall be prepared in addition to
member templates.
(6)
If members can easily be marked from shop drawings, preparation of templates

and full size rulers may be omitted.
3.5
Removal of mill scales

Prior to fabrication, steel materials shall be carefully cleaned free of slag, moisture,
dirt, rust, oil, paint and other foreign matters.
However, tight mill scales which
cannot be removed with a wire brush may be left as they are.

If the specification requires, the inside and outside surfaces of steel plates shall be
cleaned of mill scales by shot blast, etc., prior to fabrication and rolled shapes shall
be phosphatized.
3.6
Marking-off
3.6.1 General
(1)
Before starting the marking-off, inspect the rulers and templates for damage
and deformation.
(2)
Put weights on rulers and templates so that they will fit closely to the steel
material to prevent transferring errors at marking-off.
(3)
Markings shall be clearly and properly treated so that they will not disappear
before they are needed in the subsequent process.
(4)
If it is necessary to guarantee a marking accuracy of not greater than 0.5 mm,

use a scriber.
In general cases, marking pens and marking strings shall be such that
marked-off lines are not greater than 0.8 mm.
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(5)
High-strength steel and mild steel to be bent shall not be given indentations
with a punch or chisel.
(6)
Before starting marking-off, inspect the steel material for quality and size and
check it for bend, damage and any other defects.
can be used after straightening.
A strained steel material
However, an excessively strained steel
material shall be rejected.

(7)
Main members shall be given extra length to compensate for shrinkage due to
heat effect along the length.
Marking-off for built-up columns and beams shall be done after completion of
building-up to ensure accurate length and width.
3.6.2 Marking-off on steel plates

(1)
Templates to be used for marking-off of steel plates shall have a maximum

length of about 3 m, and shall not be made of extremely elastic material.
(2)
Marking-off of long members shall be done using rulers and steel tape
measures.
(3)
For members which will be cut before marking-off, datum line or datum point
per shape and plate shall be determined beforehand.
3.6.3 Marking-off on shapes and pipes

(1)
Mark off hole positions on the flange of the angle and channel along the
gauge line from the back (the intersection point of the flange faces).
(2)
The marking-off datum line on the flange of an H-shape shall be the center
line of the web.
(3)
Mark off hole positions in the web of an H-shape and channel, measuring
from one-half of the height of the web or from the outside surface of one
flange.
(4)
When marking off pipes, the datum lines connecting both ends of a pipe
obtained using jigs shall be made to agree with the datum lines of the
templates.
(5)
The four centers on the circumference of a pipe shall be at one-fourth of the

actual length of the circumference from the datum line mentioned above.
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3.7
Cutting and groove face

(1)
Take into account shrinkage of steel material due to cutting and welding.
(2)
Accurately shear or gas cut steel material.

finished.
The cut and groove faces shall be
Deformation caused by cutting shall be properly straightened.
High-strength steel material shall not be sheared.

(3)
Before cutting, remove loose rust, oil and grease from the surface of steel
material.
For steel material to be primed, the primer coat shall be less than 20
m as the target.
(4)
Unless otherwise specified, all cut edges shall be finished accurately to right
angles.
(5)
Use an automatic gas cutter for gas cutting.
If it is difficult to use an automatic
gas cutter, obtain Owners prior approval and use a manual gas cutter.
(6)
When cutting thin or long members, heat them uniformly on both sides of their
width, or cool with water to prevent thermal strain.
(7)
All notches caused by gas cutting shall be finished with a grinder after build up
welding.
(8)
3.8
Strain caused by cutting shall be straightened.
Bending
(1)
Use a press machine or bending roller to bend steel material in a cold state.
To bend steel material in a hot state, heat it linearly or overall and then bend it
with a press machine.
(2)
For bending in a hot state, heat steel material to about 900C.
Do not impose
external force to steel material at temperatures of about 200 to 400C.

High-strength steel should be heat treated only by a method approved by Owner.
(3)
Heat-treated steel shall be bent in a cold state.

If such material is bent in a hot state, provide heat treatment again or take other
measures, if required.
(4)
The minimum curvature radius of the inside surface of a plate to be bent in a cold
state shall be 1.5 times the plate thickness.
If the curvature radius is less than
that, the plate shall be bent in a hot state.

(5)
To bend pipes and shapes into an arc, use specific bending rollers to prevent
harmful deformation in the cross-sectional dimension.
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(6)
If shapes are bent into a small radius, cut a flange or web.
(7)
It is recommended that the external edges of a plate to be bent into a large

curvature should be partially cut off with a grinder, etc.
(8)
If bolt holes or member joints are to be marked off near the bend of a member,
mark them off after bending.
(9)
The developed length of a member to be bent shall be the length of the neutral
axis.
(10) The bending accuracy shall be inspected with angle gauges and rulers.
For
long members, calculate an offset from the reference line connecting the
member ends.
3.9
Making holes
(1)
In principle, drill holes for high strength bolts and other bolts for general uses.
If
plate thickness is not greater than 13 mm, holes may be sheared.

(2)
Hole diameters (D) to the nominal diameters (d) of high strength bolts and other
bolts shall be as shown below.
(Unit:
Type of bolt
Hole dia. (D)
High strength bolts
(3)
mm)
Applicable range
d + 1.5
d 16
d + 2.0
24 d 20
Bolts
d + 0.5
Anchor bolts
d + 5.0
Check punch marks given at finish marking-off, and make holes at right angles to
the surface of member.
Thoroughly remove burrs and chips from the holes.
(4)
Holes in erection joints shall be made in such positions as to compensate for

shrinkage during fabrication at the shop in order to secure the dimensional
accuracy of the product.
If the construction or configuration of a product does
not allow for an accurate estimate of shrinkage, holes shall be re-marked and
made in the final work stage.
(5)
For making holes in long members, it is advisable to use a girder type radial drill.
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(6)
For many parts of the same size such as gussets and splice plates, stack-drilling
using a gauge plate with bush, or drilling without marking by means of a jig is
recommended.
(7)
When many holes are sheared in a relatively small member, consider

straightening the member after the holes are made.
(8)
When a manual tool such as an electric drill or air drill is used, take proper
measures to ensure that holes be drilled at right angles to the surface of the
member.
(9)
When holes are made with a punching machine, check the accuracy of the
punch and mortar and the accuracy of the machine beforehand.
The standard
tolerance for punches and mortars of the nominal diameters (d) of bolts shall be
as follows.
When
d 10, +1.2 mm.
When 10 <
d 25, +1.6 mm.
3.10 Straightening of materials

Strain, twisting and bending of materials shall be straightened by methods which will
not impair the strength of the materials.
Strain of plates shall be removed with a press machine. Strain of shapes shall be
removed with a beam bender.
3.10.1
(1)
Do not use an extremely deformed material.
General
High-strength steel and heat-treated steel shall be straightened cold.
The
other steels may be straightened hot.

(2)
Strain of steel materials shall be straightened after receipt, taking into account
the product and fabrication accuracies.
It is not necessary to straighten materials which will be cut into small pieces.
(3)
If an H-shape, in which holes will be made automatically is bent, straighten it

to within the following accuracy before making holes.
Columns specially
L/2000 and not greater than 3mm
L/1000 and not greater than 5mm
requiring accuracy
Other members
where, L : Length of member
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(4)
Small members such as gusset plates and splice plates which are gas cut or
sheared on four edges shall be inspected for flatness after cutting and
straightened with a press machine.
(5)
A bent flange of I-shape shall be straightened with a press machine or

bending roller in a cold state.
Local straightening may be done in hot state
by linear heating, etc.

If a flange is not at right angles to the web, straighten it with a press machine
with specific dies or by linear heating.
For a rolled H-shape, it is advisable to make adjustments at the joints.
(6)
Cutting and welding methods and an order of cutting and welding which will
minimize strain shall be employed.
3.10.2
Cold straightening
(1)
The flatness of steel plate materials shall be straightened with a roller leveler.
(2)
When correcting the flatness of steel plate materials, do not damage the
surface by hammering or otherwise.
(3)
For straightening with a press machine, use specific dies which fit the shape
of the member to be straightened.
(4)
To straighten a bent flange of I-shape, use a specific roller straightener or a

specific press machine, and straighten the flange with care not to deform the
web.
(5)
Cold straightening is recommendable from the standpoint of securing the final

dimensional accuracy of parts.
3.10.3
(1)
Hot straightening
Local angular deformation may be straightened in a hot state by linear
heating.
(2)
The flatness of panels which have sagged due to welding around four sides
shall be straightened by spot heating.
(3)
The heating temperature of hot straightening shall be such as not to impair

the quality of steel material.
It shall be about 900C for mild steel.
50 kg/mm2 high-strength steel shall be heated to an appropriate temperature

and then cooled with air down to less than 650C, and again cooled with
water.
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(4)
SM570 and SMA570 materials shall not be heated or cooled with water.
Materials other than heat-treated steel may be heated up to 650C and then
cooled with air.
(5)
Hot straightening is accompanied with shrinkage.
When cutting members, a
shrinkage allowance shall be estimated and included in the length of members.

The heating temperature and heating range shall be carefully planned and
controlled to secure the accurate length of straightened members in hot state.
3.11 Assembly
3.11.1
(1)
General
Members shall be assembled at the shop to the maximum allowable size for
land and marine transportation and for handling limits with cranes at the site.
Sub-assemblies shall be planned carefully to ensure a high efficiency of
erection at the site.
(2)
The fabrication range at the shop shall be so planned as to minimize adjusting

points and adjusting amounts during erection at the site.
(3)
Members which are difficult to join at the site shall be joined at the shop as
much as possible.
(4)
Accuracy shall conform to the specification of MHs "Tolerance of Accuracy

manual.
(5)
Assembly jigs shall be used, wherever necessary, to minimize errors in the

dimensional accuracy of shop assembled products.
(6)
The accuracy of members joined shall conform to the specifications of MHs

"Tolerance of Accuracy" manual.
Efforts shall be made to increase the
accuracy of parts as far as possible to improve the accuracy of final products.

(7)
In assembly work, carefully check the tack welded position and angle of joined
members so that there will occur no necessity to cut off welded members for
correction.
(8)
If any defect is found, remove it by a method approved by the person

responsible for fabrication and Owner.
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(9)
If any defect or nonconformity occurs, carefully analyze it and take proper

measures to prevent its recurrence.
Whenever a nonconformity or irregularity occurs, the fabricator shall submit to
Owner a report describing it and preventive measures to be taken.
(10) Only persons qualified for the basic class of the Welders Performance
Qualification according to JIS Z 3801 "Standard Qualification Procedure for
Welding Technique" or equivalent shall be employed to do tack welding.
3.11.2
(1)
Assembly of columns and beams

The line connecting the centers in the top and bottom end cross-sections of a
column shall be the column virtual center line and shall be used as the datum
line for fitting beam joints, brackets, etc.
(2)
When assembling columns, the center line of the holes in the beam joint, or
those in the column joint, is used as the datum line.
For this purpose, beam
joints to be welded to columns should have accurately beveled edges, and

there shall be no misalignment among members.
(3)
When assembling I-shapes such as beams, use a proper jig to fit and tack
weld the flange to the web so that the welded flange will intersect the web
exactly at right angles.
3.11.3
(1)
Built-up members
Assembly of materials
(a)
Assemble materials into the required shape.

Accurately fit flanges to webs, tack weld them and fit ribs for adjustment,
if necessary.
(2)
(b)
After tack welding, carry out welding on rotating and inclined jigs.
(c)
After welding, carry out straightening.
Assembly of columns
(a)
After steel materials have been assembled, do finish markings, taking

into account shrinkage allowances, and tack weld brackets and beams.
Also tack weld gussets and brackets for horizontal braces and beams.
Check marking-off on column top and bottom ends and each joint after
straightening.
11117198 - 2002090 - WP001
(b)
The joint between two columns shall be decided after temporarily

mounting the upper column fitted with parts on the completed lower
column.
(c)
Punch line center marks as datum points on the four sides of the base
plates.
Give datum point marks on the first tier of columns.
Measure the
datum point marks not from the base plates but from the first floor
beam top surface.
(d)
(3)
Mark off the column center lines on all the sides.
Assembly of beams
(a)
For beams to be built-up by welding, assemble materials in the same

manner as the columns.
For girders, assemble materials including
beams and brackets to be welded to columns.

(b)
After assembly of materials, carry out finish markings in the same

manner as on the columns, and tack on weld stiffeners, ribs, gussets
and plates.
(c)
After completion of welding, recheck the finish marking along the length
and gas cut both ends of the girder which will be the brackets to
columns.
(4)
Assembly of braces
(a)
Members to be built up by welding shall be assembled in the same

manner as columns and beams.
(b)
Braces shall be cut from shapes with a hand saw or gas cut and
finished.
Braces which will shrink lengthwise when ribs and brackets are welded
to them shall have a shrinkage allowance to be cut at both ends after
completion of welding in the same manner as beams.
11117198 - 2002090 - WP001
3.11.4
(1)
Temporary assembly
If it is necessary to determine a deflection of a large structural member, the
member shall be temporarily assembled under the same supporting
conditions as when erected on the site.
(2)
Temporary assembly to assure the dimensional accuracy of members shall be

performed if it is required because of geographical conditions on the erection
site or for any other reasons.
In this case, one plane of the structure may be
temporarily assembled on the ground and supported at many points.

(3)
If temporary assembly is performed under the same supporting conditions as

erection on the site, drift pins and fit-up bolts shall be installed into more than
one-third of the holes in the joints to ensure safety.
(4)
For measuring dimensions of temporarily assembled structures, be sure to

use steel tape measures verified for erection.
3.12 Safety and health

(1)
Shop fabrication shall be carried out in an environment which ensures personnel

safety and health in accordance with the laws for labor safety and sanitation, the
laws for protecting workers from pneumoconiosis and other relevant laws and
regulations.
(2)
The operators of drills and facing machines shall not wear gloves or aprons.
Workers who will use hammers shall not wear gloves.
(3)
All persons who will perform welding, gas cutting, arc air gouging, etc. and be
exposed to harmful rays, shall wear safety goggles.
(4)
Persons who will perform arc welding, semi-automatic welding, grinding, rust
removal, cutting, etc. and be exposed to cutting chips and dust, shall wear
dustproof goggles or dustproof masks.
(5)
Before cutting and welding, carefully inspect the surroundings, especially the
reverse side of the area to be worked on, to make sure that there is no
flammable object.
(6)
Welding, gas cutting and painting work in a narrow or poorly ventilated place
shall be performed only after gas concentration is measured and safety is
confirmed.
11117198 - 2002090 - WP001
(7)
Only qualified persons shall be employed to perform gas cutting and

straightening by heating with a gas burner.
(8)
Persons who replace grinder grinding stones and/or adjust dies in the press
machine shall have gone through special training given by the fabricator, etc.
(9)
If a gas collective supply unit is installed at the work place, a chief responsible
for the unit shall be appointed from qualified gas welding work chiefs.
(10) The gas cutting equipment shall be inspected for leakage before work to ensure
safety.
The safety device shall be inspected once a day to ensure proper functioning.
(11) Be sure to inspect fabrication machines before use to ensure safety.
Before
inspecting a machine, stop it and turn off the power switch.

Take proper measures to prevent any third person from switching it on.
(12) Persons who will weld and cut metal with an arc welder shall have gone through
special training given by the fabricator, etc.
11117198 - 2002090 - WP001
4.
Welding
4.1
General
(1)
Welding plan and control

(a)
Welding methods, welding machines and welding materials to be used shall

be appropriate for the mechanical properties and weldability of base metals
and the sizes and shapes of welding grooves.
(b)
Welding shall be performed in flat position, wherever possible.
(c)
Select the shapes of welding grooves and a welding sequence which will
minimize welding strain.
Avoid excessive constraint and extreme stress
concentration.
(d)
Welding shall be performed in an environment protected from wind and

moisture.
(e)
The working environment shall always be kept in good order to ensure sound
welding.
(2)
Approval of shop
The shop which will perform welding shall obtain Owners approval according to
international standards for quality control and quality assurance throughout the
entire fabrication process.
(3)
Approval of welding procedure

The welding procedure qualification test shall be performed and the procedure
shall be approved by Owner.
This test may be omitted if Owner accepts the
previous test results of the same procedure.

(4)
Welding procedure manual

The fabricator shall prepare a welding procedure manual which includes, but is
not limited to, the following information:
- Steel materials and welding materials to be used
- Type of welding machine
- Welding current, arc voltage and welding speed
- Type of joint
- Shape of groove, preheating and welding sequence
- 22 Q:_Spec11117198-2002090-WP001 Ternium Fab.SS22-weld.doc
11117198 - 2002090 - WP001
Prevention of strain and straightening method
- Safety, inspection, repair and engineer in charge

- The outlined history of the instructor
- Welders list and welding experiences of welders
(5)
Welders qualifications
(a)
Arc and gas welding

Welders shall be skilled experts who have engaged in welding of this type of
structural steel for more than six (6) months continuously and have passed
the test according to JIS Z 3801 "Standard Qualification Procedure for
Welding Technique" in the required position for the specific plate thickness, or
have an equivalent qualification certificate issued within one (1) year by NK
(Nippon Kaiji Kyokai), AB (American Bureau of Shipping) or Lloyd.
(b)
Semi-automatic arc welding

Welders shall be skilled experts who have engaged in welding of this type of
structural steel for more than six (6) months continuously and have passed
the test according to JIS Z 3841 "Standard Qualification Procedure for
Semi-automatic Arc Welding Technique" in the required position for the
specific plate thickness, or have an equivalent qualification certificate issued
within one (1) year from NK, AB or Lloyd.
(c)
Tack welding
Welders shall be those qualified by test for basic class or higher according to
JIS Z 3801 or
JIS Z 3841 or equivalent.
(6)
Welding materials
(a)
Welding materials of JIS standard specified in design documents shall be

used.
(b)
Store welding materials at a designated dry place in good order.
(c)
Appoint a person responsible for the drying box of dry welding materials and
note his name on the drying box.
(d)
The drying box shall indicate the identifications of welding materials being
dried in it.
11117198 - 2002090 - WP001
(e)
The drying temperature, time, holding temperature, time allowed to be left

outside, and redrying of welding materials shall comply with welding material
manufacturers recommendations.
(f)
The fabricator shall deliver the welding materials required by welders, using a
welding material delivery slip.
(g)
The welder shall return the remainder of the welding material with the welding
material delivery slip to the welding material controller.
The controller shall
weigh the returned welding material and enter the weight on the welding
material delivery slip.
(h)
Handle the welding materials carefully.
Do not use electrodes which have
covering flux peeled off, are damaged or deteriorated, have become dirty or
moist, or are extremely rusty.
(i)
If electrodes are suspected to contain moisture, be sure to dry them before

use.
4.2
Butt welding
(1)
General
(a)
Butt welded joints are classified into butt joints, corner joints and tee joints.
(b)
The throat depth of butt welds shall not be less than the thickness of base
metal.
If the thicknesses of base metals to be joined differs one from the
other, the throat depth shall not be less than the thickness of the thinner base
metal for butt welds, and shall not be less than the thickness of the thinner
base metal to be butted for tee and corner joints.
(c)
Any type of butt welded joints shall have full penetration throughout the cross
section.
(d)
One-side welds made by using backing strip can be regarded as butt welds
as long as full penetration is secured by proper method.
(2)
Reinforcement of weld
Unless otherwise specifically stated, butt welds shall have minimum weld
reinforcement.
11117198 - 2002090 - WP001
(3)
Reinforcing fillet weld

A fillet weld of more than one-fourth of the thickness of the base metal to be
butted shall be added to the tee and corner joints for reinforcement.
If
one-fourth of the thickness of the base metal exceeds 10 mm, the thickness of
the fillet weld may be 10 mm.
(4)
Back chipping
Butt joints shall be welded from the top side and then welded from the reverse
side after back chipping.
If full penetration is secured by using a backing strip,
the weld may be done from only the top side.

(5)
Backing strip
A backing strip shall be fitted in close contact to the base metal.
The backing
strip fitting procedure test shall be performed and the test results shall be
submitted to Owner for approval.
4.3
Partial penetration welding
(1)
Unless indicated in the design documents, partial penetration welding shall not
be performed.
(2)
Partial penetration welded joints are classified into butt joints, corner joints and
tee joints.
(3)
Partial penetration welding shall be performed carefully to secure the required

penetration.
4.4
Fillet welding
(1) Size of fillet weld
A fillet weld shall not be thicker than the thickness of the thinner base metal.
(2) Difference in leg lengths
There shall not be an extreme difference in the leg lengths of an equal leg fillet
weld.
(3) Length of fillet weld
The length of weld given in design documents shall be an effective length.
The
effective length of a fillet weld shall be more than 10 times its size and not less
than 40 mm.
The length of a fillet weld shall be the effective length plus more
than twice its size.
11117198 - 2002090 - WP001
(4)
Reinforcement of weld
The reinforcement of fillet weld shall not be greater than 0.1S + 1 mm (S : the
size of fillet weld).
(5)
Treatment of starting and terminal points

Provision shall be made to ensure sound welds at the starting and terminal
points of fillet welds.
4.5
Deposit sufficient beads at the corners for this purpose.
Preparation and assembly
(1)
Preparation
(a)
If steel materials of different qualities are mixed, identify them with color or by
another appropriate method.
(b)
If any steel material is bent or deformed and does not come in close contact
with its counterpart, straighten it beforehand.
(c)
To avoid harmful damage, the specified areas in design documents and the
areas which are liable to defect during fabrication shall not be marked off with
a chisel, indentation or center punch.
(d)
Weld edges shall be smoothed by automatic gas cutting or finishing by a

proper method.
Manual gas cutting shall be used only when the other
methods are unusable, and the cut surfaces shall be carefully finished.
(e)
Nonconformities such as a clearance between two plates to be joined,

improper groove angles, or inaccurate root openings which could cause a
harmful effect on the welding, shall be repaired by build-up welding or any
other method.
(f)
In tee and corner joints, care shall be taken to prevent lamination cracking in
the base metal.
(2)
Assembly
(a)
Use a properly leveled support and jigs suitable for assembly work and
maintain an accurate mutual position and angle for steel pieces.
If a jig is
inevitably welded to a member, take proper measures to minimize the heat

effect on the base metal.
After use, carefully chip off the jig and finish the
area smoothly.
11117198 - 2002090 - WP001
(b)
If fit-up bolt holes are made in material for assembly, determine how to treat
these holes after they become unnecessary and obtain Owners approval
thereon.
(c)
Give appropriate pre-strain or constraint to the members to be joined by

welding to reduce deformation and take into account shrinkage during welding
so that sub-assemblies will maintain accurate dimensions and shape.
(d)
The root opening for butt welding should be kept as accurately as possible to
prevent incomplete penetration and burn through.
It is desirable that a
backing strip come in close contact with a base metal and that two plates to
be fillet welded come in close contact with each other.
(e)
In principle, runoff tabs of the same shape as a joint shall be fitted to both
ends of a butt weld and a partial penetration weld to ensure a sound weld.
In
the case of fillet welds, use runoff tabs similar to those of butt welds or box the
ends.
(3)
Tack welding
(a)
Make minimum necessary tack welds.

final welds shall be free of defect.
Tack welds which will become part of
If a tack weld which will become part of
final weld has cracking, chip it off down to the root.

(b)
The standards of tack welds are shown below.
Do not make tack welds on
the ends and corners of joints and the start and terminal points of final welds
susceptible to stress and defect.
Leg length
Rod dia.
Length Pitch
7 mm & over
4 mm
50 300 mm
Up to 7 mm
3.2 mm
40 250 mm
(c)
Remarks
Tack welding of butt
welds shall be done on
reverse side.
Low hydrogen electrodes shall be used for tack welding of steel materials with
2
nominal tensile strength of 50 kg/mm or over and of thickness of 25 mm or

over.
In the case of submerged arc automatic welding, the thickness shall be
12 mm or more.
11117198 - 2002090 - WP001
4.6
Welding work
(1)
(a)
Preparation
Welding shall be made, as far as possible, in flat position, using appropriate
jigs.
(b)
Store welding materials in a dry storage room at all times.
Be sure to dry
materials in a drying box before they are used.

(c)
Before welding, thoroughly clean the surfaces to be welded free of moisture,

slag, rust, paint, loose mill scale and any other foreign matter which will
harmfully affect the welding work.
(d)
(2)
(a)
Use spatter deposit preventive agent around the surfaces to be welded.

Welding work
Use welding materials suitable for the type of welding machine, the type and
thickness of steel and the environment in which welding will be done, and
select appropriate welding conditions such as welding current, arc voltage,
welding speed, gas flow, etc. so that sound welds will be obtained.
(b)
Move arc correctly along a weld line.
(c)
If a weld and high strength bolts are used in one place, separate the weld
from the high strength bolts properly so that the high strength bolts will not be
loosened by the welding heat.
(d)
Butt welds shall be made under proper conditions to ensure full penetration.
(e)
Take proper measures to minimize welding deformation and shrinkage, and

select the welding sequence
carefully, so that sub-assemblies will maintain
accurate dimensions and shape.

(f)
Weave the electrode carefully to ensure full penetration and prevent blowhole,
slag inclusion, undercut, unequal leg lengths, overlap and other welding
defects.
(g)
The width of weaving shall be less than 3 times the diameter of the electrode.
11117198 - 2002090 - WP001
(3)
(a)
Workmanship
The surface of welds shall be smooth and regularly waved.
The size and
length of a weld shall not be less than the design dimensions.
A size and
length slightly exceeding the design dimensions is acceptable, but excessive

deposit or irregular surface profile is unacceptable.
(b)
Craters at the start and terminal points of beads shall be properly treated.
Cut off runoff tabs carefully so as not to damage the base metal and weld,
and finish the surface smoothly with a grinder.
If the base metal is damaged,
build up and finish the weld smoothly.

(c)
The welds should not include any harmful defect.
(d)
Remove spatters with a wire brush and/or other suitable means.
(4)
Preheating
Depending on the type and thickness of material, the temperature of base metal
and welding method, perform proper preheating as shown in the following tables.
(a)
The Architectural Institute of Japans "Technical

Recommendations for Steel Construction for Buildings, Part 1 Guide to
Steel-rib Fabrications"
Preheating standard for SMAW and GMAW (multi layer welding)
Thickness (mm)
Kind of steel
SS400
SM400
t<25
No preheating
38t50
25t<38
(1)(2)
No preheating
60 C10C
SMA400
SM490
No preheating
SMA490
SM490Y
SM520
SM570
SMA570
60C10C
(1)
(1)
(1)
(2)
60C10C
100C10C
(1)
(1)
60C10C
100C10C
(1)
120C10C
(1)
Notes :
(1)
When low hydrogen electrode is used.
(2)
When electrodes other than low hydrogen electrodes are used.
(3)
The area to be preheated shall be 10 cm on either side from the center

of the weld line.
The preheating temperature shall be measured 5 cm
from the weld line.
(1)
11117198 - 2002090 - WP001
(b)
(5)
(a)
AWS
(American Welding Society)
Kind of steel
Welding
material
ASTM A36
and
A572 Gr50
SMAW
(Low hydrogen)
SAW
GMAW
FCAW
Plate thickness
(mm)
Preheating ( C)
Min.
Max.
Inter-layer
temp.(C)
19
205
19< t
38
10
205
205
38< t
64
66
205
205
107
205
205
64< t
Atmospheric temperature and weather

Welding work shall not be performed when the atmospheric temperature is
lower than 0C.
If base metal 100 mm from the weld line is heated to a
temperature of 36C or over, welding can be done even at an atmospheric

temperature of 0C to -25C.
(b)
If wind is strong, provide a wind shield to protect arc against the wind.
On a
rainy or highly humid day, check the top and reverse surfaces to be welded for
moisture, even when welding is performed indoors.
11117198 - 2002090 - WP001
5.
Erection marks
5.1. General
All members shall have erection marks clearly indicated according to the following
instructions. However, fabricator can apply his own erection marking system after
getting Owners approval, nonetheless instructions herein. If erection marks are hand
written or punched on cut face of ends of members for stack storage, Owners prior
approval shall be obtained. The specification is not applicable to the erection marks
according to the bar code system and their indications.
5.2
Size of erection marks

An erection mark shall be at least 4 cm square and stenciled on a member.
For hand
writing, obtain Owners prior approval.

5.3
Color of erection marks

In principle, erection marks shall be written with white paint or in light color.
color is designated by the Owner, observe it.
If the
If white marks are not suitable for a
building or structural steel, another color may be used upon Owners prior approval.
5.4
Location of erection marks

Erection marks shall be painted at conspicuous locations on all members under the
same rule.
In principle, two erection marks shall be given on a member; one on the side facing
west from east of the plant or facing north from south of the plant and another on the
top surface.
The erection marks on all members shall be located about one (1) m from the
members left end.
If any member is finish coated at the shop, the location of erection marks on such
member shall comply with the instructions herein unless otherwise specified.
5.5
Connection and joint parts

Erection marks should not be given to splice plates, clip angles, etc., unless otherwise
noted by Owner.
These parts shall be shipped fixed on intended members with not
less than two (2) temporary bolts or wire so that they will not damage other members.
The dispatch list and packing list shall clearly indicate that members are fitted with
splice plates or clip angles to prevent them from being lost.
- 29 Q:_Spec11117198-2002090-WP001 Ternium Fab.SS29-erection mark.doc
11117198 - 2002090 - WP001
5.6
Datum point marks

The first tier of columns shall be marked with
2FL Floor Level
datum points using a center punch for the

measurement of levels during erection at site.
The datum points shall be measured from the
FL+1,000
Datum point
upper floor level.

The floor level shall be indicated with
established level such as FL, GL, EL.
The Line center, as a working point, shall be
marked on the top surface of base plates using
a center punch.
The datum points and the line center shall be
marked circle with paint.
Line center
11117198 - 2002090 - WP001
5.7
Erection mark system

C
Column
Horizontal Brace
X
Numerical line
Serial No.
Alphabetical
line
Brace line
Stage No.(omitted
for single story
building)
Stage No., story No.
Girder
SC
Secondary Column
SC
Intersecting line
Serial No.
Girder line
Secondary column
line
Beam
Purlin
P
Serial No.
Serial No.
Block No.
Vertical Brace
Furring strip
(girt)
F
Serial No.
Serial No.
Brace line
Line
11117198 - 2002090 - WP001
FP
Floor plate
FP
Stair
S
Serial No.
Serial No.
Joist
HR
Handrail for floor
HR
Serial No.
Serial No.

SR for handrail for stairs
Truss
Ladder
L
Serial No.
Serial No.
Line
WG
Wind Girder
WG
Serial No
Line
11117198 - 2002090 - WP001
Examples
Column : 1CA2
Joint
2CA2
(1)
2CA2
5.8
(2) Girder : 3GA1, 3G1A
3G1A
3GA1
A
1
3FL
(3) Beam : 3B1, 3B2
B
3B1
3B2
A
1
3FL
1CA2
1CA2
11117198 - 2002090 - WP001
(4)
Vertical Brace : 3VA3
4FL
3VA3
3FL
A Line
(5)
Horizontal Brace : 33
B
33
A
3FL

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FABRICATION GUIDANCE

Document No. 11117198 - 2002090 - WP001

11117198 - 2002090 - WP001

Applicable laws and regulations .....................................................................3

Steel tape measures ......................................................................................3

Approval of fabrication procedure ..................................................................4

Engineers in charge and work control ............................................................4

Quality, shape and dimensions ......................................................................7

Welding materials ..........................................................................................8

Material test and weldability test.....................................................................8

Receipt and storage of materials ...................................................................9

Erection drawings and shop drawings............................................................9

Full size drawings.........................................................................................10

Templates and full size rulers ......................................................................11

Removal of mill scales .................................................................................11

Cutting and groove face ...............................................................................13

-1Q:_Spec11117198-2002090-WP001 Ternium Fab.SS01-Cont.doc

11117198 - 2002090 - WP001

3.10 Straightening of materials ............................................................................15

Butt welding .................................................................................................24

Partial penetration welding ...........................................................................25

Fillet welding ................................................................................................25

Preparation and assembly ...........................................................................26

Welding work ...............................................................................................28

Size of erection marks .................................................................................29

Color of erection marks................................................................................29

Location of erection marks ...........................................................................29

Connection and joint parts ...........................................................................29

Datum point marks.......................................................................................30

Erection mark system ..................................................................................31

-2Q:_Spec11117198-2002090-WP001 Ternium Fab.SS01-Cont.doc

11117198 - 2002090 - WP001

Applicable laws and regulations

Japanese Industrial Standards (JIS)

Local laws and regulations for :

Labor safety and sanitation

International laws, regulations and standards for steel work

MH manual Tolerance of Accuracy

Steel tape measures

against the fabricators standard tape measures to determine their errors.

minimize measuring errors, the verification shall be made at dawn on a windless,

Approval of fabrication procedure

-3Q:_Spec11117198-2002090-WP001 Ternium Fab.SS03-gene.doc

11117198 - 2002090 - WP001

Engineers in charge and work control

The fabricator shall perform quality control

The fabricator is responsible for guiding its

Receipt and distribution

-4Q:_Spec11117198-2002090-WP001 Ternium Fab.SS03-gene.doc

11117198 - 2002090 - WP001

The business department of the fabricator shall receive a reproducible copy,

The reproducible copies of shop drawings shall be kept by the business

The fabricators production department shall control received drawings,

If any drawing is stained or damaged severely, promptly replace it

with a reprinted drawing.

Transfer instructions and other information

correctly to the reprinted drawing.

If they find any problematic

points or points to be checked, they should mark them immediately on their

Control of revised drawings

When drawings are superseded, stamp "COPY" on

the revised drawings, and sign the drawing/document receipt.

The fabricators business department shall transfer revised places correctly to