Quality Control System For The Plant Fabrication of Structural Steel

QUALITY CONTROL SYSTEM
FOR THE PLANT FABRICATION OF STRUCTURAL

STEELWORKS
Table of Contents
1. GENERAL .................................................................................................. 3
2. PURPOSE .................................................................................................. 3
3. SCOPE ....................................................................................................... 3
4. REFERENCE DOCUMENTS .......................................................................... 3
5. QUALITY CONTROL AND QUALITY ASSURANCE ........................................ 3
5.1. CONTROL OF DOCUMENTS ..................................................................... 4
6. PROCESS MANAGEMENT ........................................................................... 4
6.1. RECEPTION OF MATERIALS ................................................................... 4
6.2. TRACEABILITY OF STEEL ....................................................................... 4
6.3. MARKING STEELWORK .......................................................................... 4
6.4. HANDLING ............................................................................................. 5
6.5. PRODUCT VERIFICATION....................................................................... 5
6.6. STORAGE, LOADING AND SHIPPING ...................................................... 5
7. FABRICATION ........................................................................................... 5
7.1. SURFACE CLEANING .............................................................................. 7
7.2. FLAME CUTTING .................................................................................... 7
7.3. PUNCHING AND DRILLING .................................................................... 7
7.4. FITTING AND REAMING ......................................................................... 7
7.5. WELDING ............................................................................................... 8
7.6. MOCK UP ASSEMBLY .............................................................................. 8
7.7. PROTECTIVE TREATMENT ...................................................................... 8
8. WELDED CONNECTION ............................................................................. 9
8.1. WELDING PROCEDURE........................................................................... 9
8.1.1. PREPARATION OF PROCEDURE ........................................................ 9

8.1.2. APPROVAL OF PROCEDURES AND PROCEDURE TESTS ....................... 9
8.1.3. AVAILABILITY OF WELDING PROCEDURE SHEETS ............................. 9
8.2. NON-DESTRUCTIVE TESTING OF WELDS ................................................ 9
PWTP2-QA-CR-CON-ARU-0392-B
Quality Control System
For the Plant Fabrication of Structural Steel
Baras Plant
Sitio Rizza Brgy. Pinugay, Baras, Rizal 1
8.2.1. RECORD OF TESTING .................................................................... 9
8.2.2. VISUAL INSPECTION OF WELDS ...................................................... 9
8.2.3. SURFACE FLAW DETECTION ......................................................... 10
8.2.4. ULTRASONIC EXAMINATION ......................................................... 10
8.2.5. ACCEPTANCE CRITERIA AND CORRECTIVE ACTION ......................... 10
9. ACCURACY OF FABRICATION .................................................................. 14
9.1. PERMITTED DEVIATIONS..................................................................... 15
9.1.1. PERMITTED DEVIATIONS IN ROLLED COMPONENTS AFTER FABRICATION

.................................................................................................. 15
9.1.2. PERMITTED DEVIATIONS FOR ELEMENTS OF FABRICATED MEMBERS 16
9.1.3. PERMITTED DEVIATIONS IN PLATE GIRDER SECTIONS .................... 17
10. NON CONFORMANCE PROCEDURE ......................................................... 19
11. DOCUMENTATION ................................................................................. 19
12. ANNEX A ............................................................................................... 20
12.1. WELDER CERTIFICATION ................................................................... 20
12.2. ANNEX B WELDING INSPECTOR ACCREDITATION ............................. 21
12.3. WORK INSPECTION REQUEST (WIR) ................................................. 22
12.4. STRUCTURAL STEEL FABRICATION CHECKLIS ................................... 23
12.5. NON CONFORMANCE REPORT ............................................................ 24
Baras Plant
1. GENERAL
This document consist of processes and operations to provide assurance that finished
steelworks shall conform to the Project Specification in accordance with the
requirements of this guideline.
2. PURPOSE
The purpose of this document is to ensure that fabrications are carried out according
to specifications and in a safe manner.
3. SCOPE
This document covers the processes and quality control in the fabrication of steel
structures requirements for the following buildings:
a) BAF
b) DAF
c) Sludge
d) Genset
e) Chemical Building 1
f) Chemical Building 2
4. REFERENCE DOCUMENTS
a) AWS D1.1 Structural Welding Code, 2015 Edition – Steel

b) ASTM E-165 Test Method for Liquid Penetrant Examination, 2004 Edition.
c) ASTM E-164 Standard Practice for Ultrasonic Contact Examination of
Weldments, 1997 Ed.
d) Sec. 6 “Shop Fabrication and Delivery”, June 15, 2016, Code of Standard
Practice for Steel Buildings and Bridges
5. QUALITY CONTROL AND QUALITY ASSURANCE
The quality control guidelines as presented in the subsequent part of this document
shall be in place in identifying all materials and workmanship from procurement to
delivery and subsequent incorporation into the works. It is essential that monitoring
shall be carried out to ensure performance of materials and workmanship incorporated
into the final works is not inferior to those specified in the design.
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5.1. CONTROL OF DOCUMENTS
The following documents shall be establish and maintain procedures for approval,
issue, and data required for the operation of the quality control. Required
documentation shall include, but may not be limited to, the following:
a) Contract drawings, shop drawings and specifications

b) Welding documentation
c) Purchase orders
d) Delivery Receipt
e) Mill Test Certificates
f) Applicable work inspection and test records
g) Calibration records for measuring and inspection equipment
h) Non-conformity, corrective action, and preventive action reports
All records required by the contract documents shall be available for review by the
Client or his representative.
6. PROCESS MANAGEMENT
6.1. RECEPTION OF MATERIALS
Incoming materials shall be matched against delivery receipt and purchase orders. The
materials shall also be checked if it is comply with the following criterion:
a. Size: conformance to dimensional tolerances
b. Surface condition: the material has no defects
c. Material grade : conformance to A36 steel
Material shall not be used or processed until it has been complied with the above
criterion and approved for use
6.2. TRACEABILITY OF STEEL
All materials delivered shall be check and verify its material specification prior to
incorporate into the work.
All steel to be used in the Works shall have a mill test certificate. Where individual
pieces, lots, and batches are restocked, the identification system shall be maintained.
The material grades of all steel shall bear an identifiable markings of “S36S”, in
corresponding to its material specification.
6.3. MARKING STEELWORK
Individual pieces shall be capable of positive identification at all stages of fabrication.
Completed components shall be marked with a durable and distinguish fabrication

mark in such a way as not to damage the material. Hard stamping may be used, except
where otherwise specified by the Engineer.
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Where areas of steelwork are indicated on the drawings as being unmarked, they shall
be left free of all markings and hard stamping.
6.4. HANDLING
Steelwork shall be bundled, packed, handled and transported in a safe manner so that
permanent distortion does not occur and surface damage is minimized.
6.5. PRODUCT VERIFICATION
The AJF representative shall verify conformance to the contract documents.
The AJF shall define inspection points and inspection record requirements to verify
conformance to the contract documents, including the following:
a) Examination of material for size, conformance to dimensional tolerances, and

surface condition or defects,
b) Examination of assemblies for overall dimensions, and location and orientation
of holes and detail components,
c) Verification that welding is carried out in accordance with the company's
welding standards. This includes visual examination of completed weldments,
d) Examination of surface preparation and coating including coating rhickness.
Any additional inspection requirements noted in the Contract Documents shall be

identified and implemented.
AJF shall provide access to and cooperation with the Clients' designated representative
for inspection of the work as required. Unless specific provisions are included in the
contract documents, such inspections shall be scheduled so as not to impede the
progress of production.
The AJF shall ensure that all verification has been performed in conformance with
contract requirements and this document.
6.6. STORAGE, LOADING AND SHIPPING
AJF shall maintain procedures to ensure that all items are properly prepared, handled,
and/or packaged for storage and shipping to prevent damage to product.
7. FABRICATION
The fabrication of structural steel shall be carried out in a fabrication plant, this allows
the fabricated steelworks and its components in precise and of assured quality.
Generally, the structural steel passes through a series of operation during the course
of its fabrication. The sequence of activities in fabricating the structural steels are
shown in the flowchart below.
Baras Plant
FABRICATION PROCEDURE FLOW CHART
Start
Person in charge:
Plant’s QC Inspector
Return to
Warehouseman Material Inspection NCR
Supplier
Rejected
Accepted
Person in charge:
Foreman
Surface Cleaning NCR
Skilled Worker
Accepted
Rejected
Flame Cutting NCR
Rejected
Punching and Drilling NCR
Rejected
Accepted
Test and
Fitting and Reaming NCR
Full Trace
Accepted
Person in charge:
Foreman Rejected
Welder Welding NCR
Skilled Worker
Accepted
Rejected
Mock up Assembly NCR
Accepted
Person in charge:
Foreman Rejected
Painter Protective Treatment NCR
Skilled Worker
Accepted
Person in charge: Packing and Delivery

Warehouseman
Foreman
End
The sequence and importance of operation will vary depending on the type of
fabrication required. All these operation are explained briefly in the subsequent parts
of the Section.
Baras Plant
7.1. SURFACE CLEANING
Structural sections from the rolling mills may require surface cleaning to remove mill
scale prior to fabrication and painting. Surface cleaning shall be carried out using blast
cleaning or sand blasting. The method employs the abrasive action of particles that
are projected on to the surface of the steel at high speed by centrifugal impeller to
remove rust, and roughen the surface before applying the coating.
By using shot or slag grits, both of which have an angular profile, surface oxides are
removed and a rougher surface is obtained to provide an adequate key for metal
spraying or special paint.
7.2. FLAME CUTTING
Cutting and shaping of steel shall be carried by flame cutting or burning. In this
method, the steel is heated locally by a pressurised mixture of oxygen and a
combustible gas such as propane, which passes through a ring of small holes in a
cutting nozzle. The heat is focussed on to a very narrow band and the steel melts at
15000°C when a jet of high-pressure oxygen is released through a separate hole in the
centre of the nozzle to blast away the molten metal in globules. The desired cuts are
obtained quickly by this process. However due to a rapid thermal cycle of heating and
cooling, residual stresses and distortion are induced and hence structural sections that
are fabricated using flame cutting are treated specially in the design of structural
steelwork.
Flame-cut edges which are free from significant irregularities shall be accepted without
further treatment except for the removal of dross, otherwise cut edges shall be dressed
to remove irregularities.
7.3. PUNCHING AND DRILLING
Although most of fabrication shops have a wide range of machines, which can form
holes for connection in structural steel works. The punching and drilling of holes will
be done using traditional drilling machine is the radial drill, a manually operated
machine, which drills individual holes in structural steelwork.
In this method, a pin or center punch and hammer to create a small dimple on to the
steel surface where the hole is mark. This gives the tip of your drill bit a place to ride
in as you begin to drill and to avoid the tendency to wander when you first start drilling.
Start drilling hole using the manual drilling machine with a smaller bit and drilling
successively larger holes with your drill bit until you reach the desired diameter of
hole.
For drilling holes larger than 6 mm, a cutting fluid is usually used in lubricating bit to
reduce friction and heat buildup, which makes drilling easier and your bits last longer.
7.4. FITTING AND REAMING
Before final assembly, the component parts of a member are fitted-up temporarily with
bolts or small amount of welds. The fitting-up operation includes attachment of
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previously omitted splice plates and other fittings and the correction of minor defects
found by the inspector.
In bolted work, especially when done manually, some holes in the connecting material
may not always be in perfect alignment and small amount of reaming may be required
to permit insertion of fasteners. In this operation, the holes are punched, 4 to 6 mm
smaller than final size, then after the pieces are assembled, the holes are reamed by
electric or pneumatic reamers to the correct diameter, to produce well matched holes.
7.5. WELDING
The strength of the entire structure depends upon the proper use of fastening
methods. The assemble components is fastened by welding of connection. Welding is
the most common method of shop fabrication of steel structures. In addition to being
simple to fabricate, welded connection considerably reduce the size of the joint and
the additional fixtures and plates
Welding shall be a metal arc process using in accordance with AWS D1.1 as
appropriate, together with other clauses contained in this section, unless otherwise
specifically permitted by the Client.
Welding consumables used shall be chosen to ensure that the mechanical properties
of the weld metal are not less than those required for the parent metal.
7.6. MOCK UP ASSEMBLY
It is necessary to have the fabricated units temporarily assembled at the place of

fabrication before these are dispatched to site for erection. During this operation, the
overall dimensions of the structure including alignment, squareness, camber etc.
should be confirmed. Inadequate or erroneous camber, in fact, introduces huge
secondary stresses in the members instead of eliminating these as originally desired.
Shop assembly also ensures that the open holes drilled in various units are within
tolerable limits.
The assembly shall be accepted with the Client or his representative before it is
prepared for paint application.
7.7. PROTECTIVE TREATMENT
Painting is the principal method of protecting structural steelwork from corrosion.

Paints are usually applied one coat on top of another, each coat having a specific
function or use.
The primer is applied directly on to the cleaned steel surface. Its purpose is to wet
the surface and to provide good adhesion for subsequently applied coats. Primers for
steel surfaces are also usually required to provide corrosion inhibition.
The intermediate coats are applied to build the total film thickness of the system. This
may involve application of several coats. The finishing coats provide the first-line
defence against the environment and also determine the final appearance in terms of
gloss, color, etc.
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The procedure for the application of coating is listed below:
COATING APPLICATION PROCEDURE
a) Surface preparation using sand blasting

b) Application of one coat epoxy primer using airless spray
c) Measurement of Wet Film Thickness (WFT) using wet film gauge
d) Curing and drying for 2-3 hours before application of succeeding coating.
e) Application of two (2) coats of epoxy coating using airless spray
f) Measurement of Wet Film Thickness (WFT) using wet film gauge for each
application.
g) Curing and drying for 2-3 hours before application of top coats.
h) Measurement of Dry Film Thickness (DFT) using dry film thickness gauge after
seven (7) days of curing.
The paint coating and its application procedure as listed above shall be depends upon
the approved paint material.
8. WELDED CONNECTION
8.1. WELDING PROCEDURE
8.1.1. PREPARATION OF PROCEDURE
Approved written welding procedures shall be available prior to the

commencement of any welding works.
8.1.2. APPROVAL OF PROCEDURES AND PROCEDURE TESTS
Procedures and tests shall be approved by the Client or his

reprepresentative.
8.1.3. AVAILABILITY OF WELDING PROCEDURE SHEETS
Welding Procedure sheets shall be made available to the welder prior to

the commencement of the work and shall be available to the Client and
Inspector on request.
8.2. NON-DESTRUCTIVE TESTING OF WELDS
8.2.1. RECORD OF TESTING
The test results shall be recorded and be available for inspection by the
Client.
8.2.2. VISUAL INSPECTION OF WELDS
Visual inspection shall be made in accordance with guidance given in Sec.

6 Inspection of AWS D1.1 over the full length of the weld and before NDT
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inspection is performed (see Tables 1.0 and 2.0). Any welds which will be
rendered inaccessible by subsequent work shall be examined in accordance
with Tables 1.0 and 2.0 prior to the loss of access.
8.2.3. SURFACE FLAW DETECTION
Surface flaw detection using liquid penetration test (using dye-penetrant)

shall be conducted in all weld surface as required by Table 2.0.The liquid
penetration test shall be conducted in accordance to the method presented
in Sec. 6.11 NDT of AWS D1.1.
8.2.4. ULTRASONIC EXAMINATION
The ultrasonic examination shall be conducted in the 10% of total welded

joints. The examination shall be carried out in accordance with Tables 1.0
and 2.0 it shall be made in accordance with Sec. 9.28 UT of AWS D1.1.
Examination shall be carried out not less than 16 hours from the time of
completion of the weld to be inspected.
Operators carrying out final ultrasonic examination of the weld shall hold
a current certificate of competence from a nationally recognised authority.
8.2.5. ACCEPTANCE CRITERIA AND CORRECTIVE ACTION
Acceptance criteria, corrective action and re-testing shall be in accordance

with Table 2.0 for components subject to static loading.
Table 1.0 Welds - Scope of Inspection
An excerpt of the requirements of Sec. 6 Inspection of AWS D1.1, 23 rd ed, 2015 is

shown in the table below. This shall not preclude the use of Non- Destructive Testing
outside the limits shown should the results of visual inspection or NDT indicate that a
lapse in quality may have occurred in specific joints
PART A. VISUAL INSPECTION
Prior to Non -Destructive Testing all welds to be visually inspected by a

suitably qualified person
PART B. THICKNESS WHEN NON-DESTRUCTIVE TESTING BECOMES

MANDATORY
(all dimensions in mm)
Weld Type Butt (full, partial penetration and with reinforcing fillets)
Joint Type In-line Tee and Cruciform Corner
Double
sided
Double sided
and
and single
Procedures Single sided Single sided single All
sided plus
sided
backing
plus
backing
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Examples
Design Grade
43/50 t max ≤ 10 1max ≤ 12 1max ≤ 12 1max < 30 1max ≤ 30

U/S
55 t max ≤ 10 1max ≤ 10 1max ≤ 10 1max ≤ 20 1max ≤ 20
Notation U/S - Ultrasonic Examination
< - Less than
< - Less than or equal to
Weld Type Fillet

Joint Type Lap Tee and Cruciform
Procedures All All
Examples
Design Grade
43/50 Not Mandatory t max ≤ 20

U/S
55 Not Mandatory t max ≤ 15
< - Less than
PART C FREQUENCY OF TESTING OF JOINTS IDENTIFIED IN PART B

First 5 identified joints of each type having
same basic dimensions, material grades and
weld geometry and welded to the same
Connection Shop Welds procedures.
Zones Thereafter 1 in 5 joints of each type
( if the first 5 have complied with Table 2.0 )
Site Welds All identified joints
Traverse butts
in web and
flange plates
As for shop welds in
before assembly
Connection Zones
Member Zones Built up Members Transverse fillet
welds at ends of
cover plates
Longitudinal 0.5 m in each 10 m or part
welds thereof
Note:
Where only partial inspection is required the joints for testing shall be selected on a random basis, but ensuring that
sampling covers the following variables as widely as possible: Joint Type, Material Grade and Welding Equipment.
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DEFINITION OF ZONES AND WELD ORIENTATIONS

< - Less than
Table 2.0 Weld Quality Acceptance Criteria and Corrective Actions
ACCEPTANCE REMEDIAL
REQUIREMENTS ACTION FOR
WELD PARTICULAR (all dimensions in mm) NON-
PARAMETER
TYPE CONDITIONS CONFORMING
(see Note 1 and 5 ) Fig WELDS
(see Note 2)
WELD GEOMETRY
Location All As specified on drawings Repair
Weld Type All As specified on drawings Refer to Engineer
≥ As specified on
Length All Repair
drawings
PROFILE
tb ≥ As drawing
Butt b,c Repair
(Av.50)
Throat
Repair or grind
Thickness
Fillet 1f ≥ As drawing a and MPI after
grinding
Leg Length Fillet 1f ≥ As drawing a Repair
Grind and MPI
Toe Angle All θ ≥ 90° a
after grinding
Cap/Root Bead
(Height or Butt Butt Joint -1 ≤ Cb ≤ 4 b Repair or grind
concavity)
m ≤ As drawing +
Butt Butt Joint 0.25t â‰¤ As drawing d Refer to engineer
+3
Misalignment
m ≤ As drawing +
All Cruciform Joint 0.50t and ≤ As e
drawing + 6
SURFACE DISCONTINUITIES
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U1+ U2 ≤ 0.1t D,e
Longitudinal Weld Repair
(Av.100) And ≤ 2 D,e
Undercut All
U1+ U2 ≤ 0.05t D,e
Transverse Weld
(Av.100) And ≤ 1 D,e
rp ≤ As Repair and double
Single drawing+0.1t(Av.1c00) scope of
Longitudinal Weld c
Root Sided and ≤ As drawing Ultrasonic
Penetration +3 inspection
(lack of)
rp ≤ As
if root is
drawing+0.05t(Av.100)
(lack of) Transverse Weld c inaccessible
and ≤ As drawing
Butt
+2
All Welds d ≤ 3 F
Longitudinal Weld ∑d ≤ 20 in 100 (length) F
Porosity All Repair
∑ d ≤ 10 in 100
Transverse Weld f
(length)
Repair and
Lack of Fusion
All Not Permitted increase MPI
and Cracks
to 100% (Note 4)
H ≤ 3 + As drawing 1 e,g
All Welds ≤ 10 ) if h` < 6 1` g
Slag Lines and
≥ 10 ) g Repair and double
Lack of
All Σ1 ≤ 6t in 200 scope of U/S
Fusion/Root Longitudinal Weld g
(length) Inspection
Penetration
Σ1 ≤ 3t in 200
Transverse Weld g
(length)
Fillet or
Tee, Cruciform, Repair and double
Partial rg ≤ 2(Av 100 ) and a,e
Root Gap Corner and Lap scope of U/S
Pen ≤ 3 a,e
Joints Inspection
Butt
Repair and
increase U/S
Cracks All Not permitted
Inspection to
100%
Refer to Engineer
Tee, Cruciform,
and increase U/S
Lamellar Tears All Corner and Lap Not Permitted (Note 3)
Inspection to
Joints
100%
DIMENSIONAL SYMBOLS DEFINITION OF MEASUREMENTS
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Notes:
1. Where there are two limits for one dimension both shall apply All limits are peak values unless
indicated as average
2. Where a repair is necessary an approved procedure must be used. If on increasing the scope
of inspection, further non-conformances are found, the scope shall be increased to 100% for the
joint type in question.
3. May be accepted up to the limits for slag lines if the joint is subjected to longitudinal shear only.
4. All welds to the same procedure.
5. Abbreviations: Av. 100 or Av.50 indicates the average value over 100mm or 50mm length
≥ Equal or greater than

≤ Equal or less than
Σ Sum of
9. ACCURACY OF FABRICATION
This section deals with the accuracy of fabrication of structural steel sections.
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9.1. PERMITTED DEVIATIONS
9.1.1. Permitted Deviations In Rolled Components After Fabrication
Permitted deviations in rolled components after fabrication given in Table

3.0
Table 3.0 Permitted Deviations in Rolled Components after Fabrication
Item Component Deviation

1 Cross Section after Fabrication In accordance with the tolerances
specified in AISC as appropriate.
2 Squareness of Ends Not Prepared
for Bearing
Plan or Elevation of End

3 Squareness of Ends Prepared for
Bearing
Plan or Elevation
4 Straightness on Both Axes
Δ = L/1000 or 3mm whichever is the

greater
5 Length
Length after cutting, measured on the

centre line of the section of angles.
6 Curved or Cambered
Deviation from intended curve or

camber at mid-length of curved
portion when measured with web
horizontal.
Deviation = L/1000 or 6mm
whichever is greater
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9.1.2. PERMITTED DEVIATIONS FOR ELEMENTS OF FABRICATED MEMBERS
Permitted deviations for elements of fabricated members are given in Table

4.0
Table 4.0 Permitted Deviations for Elements of Fabricated Members

1 Position of Fittings
Fittings and components whose

location is crucial to the force path in
the structure, the deviation from the
intended position shall not exceed Δ.
2 Position of Holes
The deviation from the intended

position of an isolated hole, also a
group of holes, relative to each other
shall not exceed Δ
3 Punched Holes
The distortion caused by a punched

hole shall not exceed Δ
Δ = D/10 or 1mm whichever is the

greater
4 Sheared or Cropped Edges of
Plates or Angle
The deviation from a 90° edge shall

not exceed Δ
5 5 Flatness
Where bearing is specified, the

flatness shall be such that when
measured against a straight edge not
exceeding one metre long, which is
laid against the full bearing surface in
any direction, the gap does not exceed
Δ
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9.1.3. PERMITTED DEVIATIONS IN PLATE GIRDER SECTIONS
Permitted deviations in plate girder sections are given in Table 5.0
Table 5.0 Permitted Deviations in Plate Girder Sections

1 Depth
Depth on centre Line
2 Flange Width
Width of Bw or Bn
3 Squareness of Section B Flange width
Out of Squareness of Flanges.
Δ
Δ=B/100 or 3mm
whichever is greater
4 Web Eccentricity
Intended position of web from one

edge of flange.
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5 Flanges B Flange width
Out of flatness
Δ = B/100 or 3mm whichever is the

greater
6 Top Flange of Crane Girder w = Rail width + 20 mm
Out of flatness where the rail seats.
7 Length
Length on centre line
8 Flange Straightness
Straightness of individual flanges
Δ = L/1000 or 3mm whichever is the

greater
9 Curved or Cambered
Deviation from intended curve or

camber at mid-length of curved
portion, when measured with the
web horizontal.
Deviation = l/1000 or 6mm whichever is

the greater
10 Web Distortion gauge length = web depth
Distortion on web depth or gauge

length.
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Δ = d/150 or 3mm whichever is the
greater
11 Cross Section at Bearings
Squareness of flanges to web
12 Web Stiffeners
Straightness of stiffener out of plane

after welding.
Δ = d/500 or 3mm whichever is greater

13 Web Stiffeners
Straightness of stiffener in plane

after welding.
Δ = d/250 or 3mm whichever is greater
10. NON CONFORMANCE PROCEDURE
All variations after the work has started shall be accompanied by a Non-Conformance
Report (NCR), traceable throughout the entire process and signed off by the inspector.
Please refer to Sec. 12.5 for the template of non-conformance report.
11. DOCUMENTATION
The inspector shall secure the following documents during the fabrication such as
contract drawings, inspection report, fabrication checklist, mill certificates, detail and
erection drawings, welding records, test report, and photos as required.
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12. ANNEX A
12.1. WELDER ACCREDITATION
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12.2. ANNEX B WELDING INSPECTOR ACCREDITATION
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12.3. WORK INSPECTION REQUEST (WIR)
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12.4. STRUCTURAL STEEL FABRICATION CHECKLIS
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12.5. NON CONFORMANCE REPORT
NOTE:
Photos of non-complying components and its rectified or rejected components shall be
included on this document for proper documentation of this report.
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QUALITY CONTROL SYSTEM

FOR THE PLANT FABRICATION OF STRUCTURAL

4. REFERENCE DOCUMENTS .......................................................................... 3

5. QUALITY CONTROL AND QUALITY ASSURANCE ........................................ 3

5.1. CONTROL OF DOCUMENTS ..................................................................... 4

6. PROCESS MANAGEMENT ........................................................................... 4

6.1. RECEPTION OF MATERIALS ................................................................... 4

6.2. TRACEABILITY OF STEEL ....................................................................... 4

6.3. MARKING STEELWORK .......................................................................... 4

6.4. HANDLING ............................................................................................. 5

6.5. PRODUCT VERIFICATION....................................................................... 5

6.6. STORAGE, LOADING AND SHIPPING ...................................................... 5

7.1. SURFACE CLEANING .............................................................................. 7

7.2. FLAME CUTTING .................................................................................... 7

7.3. PUNCHING AND DRILLING .................................................................... 7

7.4. FITTING AND REAMING ......................................................................... 7

7.5. WELDING ............................................................................................... 8

7.6. MOCK UP ASSEMBLY .............................................................................. 8

7.7. PROTECTIVE TREATMENT ...................................................................... 8

8. WELDED CONNECTION ............................................................................. 9

8.1. WELDING PROCEDURE........................................................................... 9

8.1.1. PREPARATION OF PROCEDURE ........................................................ 9

9.1. PERMITTED DEVIATIONS..................................................................... 15

9.1.1. PERMITTED DEVIATIONS IN ROLLED COMPONENTS AFTER FABRICATION

11. DOCUMENTATION ................................................................................. 19

12. ANNEX A ............................................................................................... 20

12.1. WELDER CERTIFICATION ................................................................... 20

12.2. ANNEX B WELDING INSPECTOR ACCREDITATION ............................. 21

12.3. WORK INSPECTION REQUEST (WIR) ................................................. 22

12.4. STRUCTURAL STEEL FABRICATION CHECKLIS ................................... 23

12.5. NON CONFORMANCE REPORT ............................................................ 24

a) AWS D1.1 Structural Welding Code, 2015 Edition – Steel

5. QUALITY CONTROL AND QUALITY ASSURANCE

a) Contract drawings, shop drawings and specifications

6.1. RECEPTION OF MATERIALS

6.2. TRACEABILITY OF STEEL

6.3. MARKING STEELWORK

Individual pieces shall be capable of positive identification at all stages of fabrication.

Completed components shall be marked with a durable and distinguish fabrication

6.5. PRODUCT VERIFICATION

The AJF representative shall verify conformance to the contract documents.

a) Examination of material for size, conformance to dimensional tolerances, and

Any additional inspection requirements noted in the Contract Documents shall be

6.6. STORAGE, LOADING AND SHIPPING

Flame Cutting NCR

Person in charge: Packing and Delivery

7.2. FLAME CUTTING

7.3. PUNCHING AND DRILLING

7.4. FITTING AND REAMING

7.6. MOCK UP ASSEMBLY

It is necessary to have the fabricated units temporarily assembled at the place of

7.7. PROTECTIVE TREATMENT

Painting is the principal method of protecting structural steelwork from corrosion.

COATING APPLICATION PROCEDURE

a) Surface preparation using sand blasting

8.1. WELDING PROCEDURE

8.1.1. PREPARATION OF PROCEDURE

Approved written welding procedures shall be available prior to the

8.1.2. APPROVAL OF PROCEDURES AND PROCEDURE TESTS

Procedures and tests shall be approved by the Client or his

8.1.3. AVAILABILITY OF WELDING PROCEDURE SHEETS

Welding Procedure sheets shall be made available to the welder prior to

8.2. NON-DESTRUCTIVE TESTING OF WELDS