Section 8 Building tolerances and associated repairs Page 1 of 9

Lloyd's Register Rulefinder 2016 - Version 9.26

Lloyd's Register Rules and Regulations - Rules and Regulations for the Classification of Special Service Craft,
July 2016 - Part 3 General Requirements and Constructional Arrangements - Chapter 1 General Regulations -
Section 8 Building tolerances and associated repairs

Section 8 Building tolerances and associated repairs

Parent topic: Chapter 1 General Regulations

8.1 Tolerances - General

8.1.1 Tolerances to be used regarding the acceptability of defects affecting raw materials are to be in
accordance with Pt 3, Ch 1, 8.2 Raw material surface tolerances.

8.1.2 Tolerances to be used for constructional misalignment for all materials are to be discussed
between Owners/Builders and the Surveyor and acceptable Standards agreed subject to the
requirements of this Chapter or National Authority requirements where applicable. The permitted
degree of inaccuracy/misalignment will vary according to whether the defect is:

a. In primary structure.

b. In secondary structure.

c. Aesthetically pleasing.

8.1.3 The requirements in respect of constructional mis-alignment of steel/aluminium craft are to be

found in Pt 3, Ch 1, 8.6 Structural misalignment and fit (steel and aluminium). The requirements for
construction using composite materials are contained in Pt 8, Ch 2 Construction Procedure.

8.2 Raw material surface tolerances

8.2.1 The surface cleanliness of steel/aluminium alloy materials in preparation for painting is to be in
accordance with National or paint Manufacturer's Standards.

8.2.2 Where approved corrosion control coatings are to be used the quality of the surface treatment is
to be in accordance with the grade specified in the approval documents.

8.3 Surface defects

8.3.1 The limits of depth and extent of surface defects on plate, cast or forged materials in relation to
the material plate thickness are shown in Table 1.8.1 Limits of surface defects.

8.3.2 Defects are to be made good by grinding only subject to the plate thickness not being reduced
by more than seven per cent of the nominal thickness or 3 mm whichever is the lower, and the area
involved not exceeding two per cent of the surface area.

8.3.3 When the limits in Pt 3, Ch 1, 8.3 Surface defects 8.3.1 are exceeded, plates may be made good
by weld repair in accordance with the requirements specified in Ch 13 Requirements for Welded

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Construction of the Rules for Manufacturing, Testing and Certification of Materials (hereinafter referred
to as the Rules for Materials.

8.3.4 Where the depth of the deepest imperfection exceeds 20 per cent of the nominal thickness, or
the defective area exceeds two per cent of the total surface area, such areas are to be cropped and
replaced. See Pt 3, Ch 1, 8.5 Part replacement of plates.

8.3.5 Complete removal of the defects is to be verified by suitable non-destructive examination

techniques and after welding the repair is to be proved free from further defects. The complete
removal of defects is to be verified by nondestructive examination in accordance with the
requirements specified in Ch 13 Requirements for Welded Construction of the Rules for Materials.

8.3.6 Care is to be taken in the repair of defects in higher tensile steel, and aluminium alloy materials.
Low hydrogen electrodes with similar properties to the higher tensile steel are to be used with
preheating as necessary. Aluminium alloys are to be heat treated after repair, see Pt 7, Ch 2, 3
Procedures for welded construction.

Table 1.8.1 Limits of surface defects

Normal thickness of material (mm) Maximum permissible depth of defect (mm)

Area affected - Unlimited Area affected 5% of Surface

<8 0,2 0,4

8 to 25 0,3 0,5

25 to 40 0,4 0,6

40 0,5 0,8

Note 1. Defects are to be measured after shot blasting or plate cleaning.

Note 2. The depth of the deepest imperfection is to be considered.

Note 3. Defects not exceeding the limits shown need not be repaired.

Note 4. Where the depth of the defects reduces the material thickness to below the
rolling/forging/casting tolerance (stated in the Rules for the Manufacture, Testing and Certification of
Materials, July 2016) the values of column 2 and 3 will be accepted provided the areas involved do
not exceed 15% and 2% respectively, of the plate/forging/casting surface.

Note 5. Defects exceeding the above limits are to be repaired.

Note 6. Crack-like defects are always to be repaired irrespective of their depth.

8.4 Plate laminations

8.4.1 Plates in which laminations are suspected or detected are to be ultrasonically tested to
determine the full extent of such laminations.

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8.4.2 Where laminations are confined to the plate edge, are less than 300 mm long and whose
penetration is not more than half the plate thickness, then the defect may be chipped or ground out
and rebuilt with weld material.

8.4.3 Where laminations are isolated, located near to the plate surface, and where the total area of the
defect does not exceed two per cent of the surface area of the plate, the defect may be repaired as in
Pt 3, Ch 1, 8.4 Plate laminations 8.4.2.

8.4.4 Defective plate, with defects in excess of those stated in Pt 3, Ch 1, 8.4 Plate laminations 8.4.2
and Pt 3, Ch 1, 8.4 Plate laminations 8.4.3, is to be cropped back and replaced, see Pt 3, Ch 1, 8.5
Part replacement of plates.

8.4.5 Complete removal of the defect is to be verified by non-destructive examination, and after
welding, the repair is to be proved free from further defects.

8.5 Part replacement of plates

8.5.1 When defects exceed the limits laid down in Pt 3, Ch 1, 8.3 Surface defects 8.3.4 and Pt 3, Ch 1,
8.4 Plate laminations 8.4.4 above, the portion of the plate affected is to be cropped and replaced, see
Table 1.8.2 Part replacement of plates.

8.6 Structural misalignment and fit (steel and aluminium)

8.6.1 For the requirements for the alignment and structural continuity of joints, see Pt 6, Ch 2
Construction Procedures and Pt 7, Ch 2 Construction Procedures.

8.6.2 Table 1.8.3 Structural misalignment and fit (steel and aluminium), Table 1.8.4 Structural
misalignment and fit (steel and aluminium) and Table 1.8.5 Structural misalignment and fit (steel and
aluminium) define the minimum limits of accuracy required to be achieved in the various welded joint
designs. When these values are not achieved, the defects are to be discussed and agreed by the
Builder and the Surveyor before remedial action is taken.

8.6.3 Welding defects are generally to be dealt with in accordance with Ch 13 Requirements for
Welded Construction of the Rules for Materials. Limits for weld undercut and remedial action to be
taken depend on plate thickness and are to be discussed and agreed by the Builder and the Surveyor
prior to commencement of repairs.

8.7 Post welding plate deformation

8.7.1 Post welding plate deformation for steel and aluminium alloy construction is to be limited, see
Table 1.8.6 Plate deformation limits and Figure 1.8.1 Measurement of plate deformation.

8.7.2 Deformation outside the limits of Figure 1.8.1 Measurement of plate deformation is to be faired
by local heating or the plating renewed.

8.7.3 Local heating of steel is not to exceed 900oC (red heat) when flame straightening is employed.

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8.7.4 Local heating of aluminium alloys is not to be carried out. All repairs are to be by renewal of
plating.

Table 1.8.2 Part replacement of plates

Shell, strength deck, tank top, top and bottom strakes

Parts to be replaced Elsewhere
of longitudinal bulkheads

End and corner of plate 1000 x 1000 1000 x

300
AxB
Side of plate 1000 x 300 1000 x
300

Insert 1000 x 300 1000 x

300

Line of plate replacement to be not less than 100 from extreme edge of defect.

All dimensions are in mm.

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Note 1. All dimensions are Note 4. Dimensions in millimetres:

minimum.
x = 50
Note 2. Rolling direction of
d = 1,5 x plate thickness with minimum 6 and maximum
replaced plate to be the same
20
as that of the parent plate.
r = 75 minimum
Note 3. Minimum distance
from outermost defect to line of
weld 100 mm.

Table 1.8.3 Structural misalignment and fit (steel and aluminium)

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Joint Location Acceptable Remedial action

dimensions
(mm)

Fabricated a>
a 0,03 x Reject
frames 0,03 x

Beams, girders
and
longitudinals

Butt welded
face flats a 0,03W a>
Reject
primary (max 6 mm) 0,03W
structure

Secondary a 0,04W a>

Reject
structure (max 8 mm) 0,04W

Obtuse angle a>t

a t 1/2 Reject
fillet weld 1/2

Repair by welding or
d 0,1t 1
d> grinding depends on
All areas (max 0,8
0,1t 1 thickness t 1 in
mm)
accordance with 8.3

d 0,1t
d>
All areas (max 0,8 As above
0,1t
mm)

Table 1.8.4 Structural misalignment and fit (steel and aluminium)

Joint Location Permitted Remedial action

misalignment

a (mm) a (mm)

0,25t 1 Increase weld leg length by a

to 0,5t
1 (t 1

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max =
5 mm)
< 0,25t 1 (a 0,5t 1 Vee material to +/45o. Fit
max = 1 mm) to t 1 (t backing strip and weld. Remove
All areas
1 max backing strip and complete weld.
(Continuous
= 15
fillet weld)
mm)

a > t 1 Realign and replace

0,25 to Increase weld lengths by 50%

0,5t 1
(t 1
max =
3 mm)
All areas
(intermittent < 0,25t 1 0,25t 1 Continuous weld
weld) to 0,5t
1 (t 1
max =
5 mm)
a > t 1 As for continuous weld above

Strength a t 2/3 t 2/3 Increase weld leg length of

members at welds by 10%
1/2

Others a t 2/2 a>t Realign

2/2

Higher tensile a t 3/3 a>t Realign

steel joint in 3/3
designated
critical areas

Strength a 0,15t 1 a> Realign

members (max 3,0 mm) 0,15t 1

Others a 0,2t 1 (max a> Realign

3,0 mm) 0,2t 1

All areas a in a t 1 Build one side of butt until a in

accordance accordance with weld
with weld procedure.
procedure a >t 1 Cut back 150 mm and fit insert
(max plate
10

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mm)

Table 1.8.5 Structural misalignment and fit (steel and aluminium)

Joint Location Acceptable Remedial action

dimensions (mm)

All 1 40 mm Adjust to suit

All 2 20 mm Adjust to suit

All 1 > 50 mm 1 < 30 Treat as an insert

mm

All 2 20 mm 2 < 15 Adjust to suit

mm

Increase weld leg

All a 1,0 a<5
length by actual a

All a 1,0 a5 Adjust to suit

Strength a 0,15t 1 (max 3,0 a>

Reject
members mm) 0,15t 1

Other a 0,2t 1 (max 3,0 a > 0,2t Reject

mm) 1

All For angle or tee a > 0,2t

Reject
longitudinal a 0,2t 1 1

For offset bulb a > 0,2t Reject

longitudinal a 0,2t 2 2

Table 1.8.6 Plate deformation limits

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Position s/t p/s

in 0,6L amidship 80 1/100

> 80 1/75

Remainder all 1/50

where
s = stiffener spacing, in mm

t = plating thickness, in mm
p = panel deflection, in mm

Figure 1.8.1 Measurement of plate deformation

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