METHOD STATEMENT OF STRUCTURAL STEEL WORK

FABRICATION & ERECTION

 INDEX

CHAPTER CONTENTS PAGE NO.

1.0 SCOPE 3 of 11

2.0 REFERENCE CODES AND STANDARDS 3 of 11

3.0 RESPONSIBILITY 3 of 11

4.0 METHODOLOGY 3 of 11

5.0 QUALITY ASSURANCE / QUALITY CONTROL 10 of 11

6.0 HEALTH, SAFETY AND ENVIRONMENT 10 of 11

7.0 DOCUMENTATION 11 of 11

Air
1.0 SCOPE
This documents cover the Methodology to be followed during Erection of all Steel structures, fabricated at
Vendors Shop like Pipe Rack, Technological Structure, Platforms including Gratings/Handrail, Roof
Trusses, Equipment's Structures etc., at Site. Work Area pertaining to Contract and Project Approved
Drawings/Specification.

2.0 REFERENCE CODES AND STANDARDS

In preparation of this procedure, the following documents in totality or in part shall form the reference document:
a) Structural Steelwork Fabrication: PDRP-8320-SP-0017
b) Structural Steel Design: PDRP-8310-SP-0016
c) Anchor Bolt & Fixings: PDRP-8310-SP-0003
d) Protective Painting System: PDRP-8440-SP-0006
e) General Requirements for Welding PDRP-8440-SP-0018
f) BIS CODES: IS:2062, 800, 801, 802, 816, 819, 822, 919, 1024, 1261, 1323, 1477, 1852, 2074, 7205, 7215,
7307, 7310, 7318, 9595 & Other relevant IS Codes.
g) Other Standards and Codes of Practice.

3.0 RESPONSIBILITY
Following are the responsibilities and reporting structure of Personnel involved in the scope of this Procedure:
Project HOD : Shall be responsible for providing resources for the Implementation of the MS.
Resident Construction: Shall report to Project HOD
Manager : Shall be responsible for providing resources for the Implementation of the MS
Ensure Compliance to Project Specification Fulfill all Required Safety Measures.
Engineer In Charge (Structural): Shall Report to RCM. Shall be responsible for the implementation of this
MS Compliance to Project Specification. Provide adequate resources for Execution of Work.
QA/QC Manager: Shall Report to RCM Shall be responsible for Job carried out as per this MS & ITP. QC
Engineer/Inspector: It shall be the responsibility of the QC Engineer/Inspector to carry out patrol.
Inspection to ensure that all Fabrication work is being carried out as per the requirements of the relevant
Code/Specification, applicable WPS and all Quality MS/Procedure & ITPs to be adhered to.
Structural Engineer/Supervisor: Report to engineer in charge (Structural) & shall be responsible for job carried
out as per this MS.

4.0 METHODOLOGY
4.1 Material
All material shall be procured from approved vendors and confirm to the relevant specification given in PMC
specification. The equivalent or alternative material shall be used after the necessary approval of Deviation request.
If materials test results or certificates are not available shall not be use. All material shall be confirming with
relevant specification by manufacturer's mill certificates, in case of absence of such certificates, test samples shall
be sent to approve laboratories for conformation.
For none confirming laboratory results reports the material shall be Rejected & kept in designated "Non
Confirming area" immediately, until removed from site/fabrication yard.
4.1.1 All structural steel materials shall confirm to the IS 2062 E250A/ E250B as per drawing .
4.1.2 Covered electrodes for metal arc welding of structural steel shall conform to IS 814 & tested as per IS 1608.
4.1.3 Wire electrodes for submerged arc welding of structural steel shall conform to IS 7280. The combination of
wire and flux shall comply with IS 3613.
4.1.4 Filler rods and wires for gas welding shall conform to IS 1278. Filler rods and bare electrodes for gas
shielded arc welding of structural steel shall conform to IS 6419.
4.1.5 Bolt and nuts (including lock nuts) shall conform to IS 1363, IS 1364, IS 1367, IS 3460, IS 3757, IS
6623, IS 6649 and IS 6639 as applicable.
4.1.6 Washers shall conform to IS 5369, IS 5370, IS 5374, IS 6610 and IS 6649 as applicable. Bolts

4.2 Receipt & Storage

4.2.1 Each section shall be marked for identification & each lot shall be accompanied by
MTC/IRN. All material shall be from approved manufacturers with proper correlation of papers.
4.2.2 All section shall be checked, sorted out & arranged by grade & quality in the storage area.
All material shall be free from surface defect such as pitting, cracks, laminations, twists, etc.
Defective material shall be Rejected & kept in designated "Non Confirming area" immediately,
until removed from site/fabrication yard.
4.2.3 Welding electrodes/consumables shall be kept in the store with manufacturing
recommendations as per Procedure No. PDPP-8230-MS-071-0002 for Receipt handling storage
& usage of welding consumables to avoid damping and also stored separately by quality and
lots inside a dry and enclosed room in compliance with IS 9595. Defective material shall not be
used & proper log of the material shall be maintained. All consumables shall be accompanied
with BTC. Electrodes shall be kept perfectly dry to ensure satisfactory operation and weld metal
soundness.
4.2.4 All nuts & bolts shall be kept in the storage area as per the size. All nuts & bolts shall be
brought to the site with Manufacturer's test certificate.
4.2.5 In case material does not come with its MTC or comes with un-matching MTC sampling
shall be done for the required Laboratory tests for each section. After acceptance of tests results
only the materials can be used.
4.3 Fabrication
Mark the plates as per drawing & erection marking system as per PDRP-8320SP-0017, Clause
No. 9.2 to carry out the cutting operation after proper inspection. All the cutting operation shall
be carried out by Gas Cutting. Grind the cut edges smooth to remove burrs and slag.
Stack the plates at designated place in the fabrication yard in proper sequence.
4.3.1 WAI fabrication work shall be done with the IF-C Drawings & detail fabrication drawing.
4.3.2 Fabrication area shall be levelled before start of fabrication
4.3.3 Marking & cutting shall be done as per IF-C drawing. Prior to cutting, all members shall be
properly marked, showing the requisite cut length, width, connection provisions e.g. location
and dimensions of holes, welds, cleat, etc. Marking for cutting shall be done judiciously so as to avoid wastage or
unnecessary joints, as far as practicable. Marking shall be done by placing members on horizontal supports / pads
in order to ensure horizontal and straight placement of such members. Marking accuracy shall be limited to + 1
mm Cutting may be affected by shearing, cropping or sawing. Gas cutting will be done by mechanically controlled
torch or manual cutting torch depending on cut length & cutting profile.
Shearing, cropping and gas cutting shall be clean, square, free from any distortion & burrs, and if necessary, the
edges shall be ground afterwards, to make the same straight and uniform.
4.3.4 Straightness of all material shall be checked & if required straightening shall be done to make free from
twist. All straightening and shaping to form, shall be done by pressure and not by hammering. Bending (if
required) shall be done by cold process only.
4.3.5 Fabrication tolerances shall be maintained as per IFC drawings & IS 7215.
4.3.6 Cutting shall be done after proper marking & checking with IFC drawing. Gas cutting shall be clean,
square, and free from any distortion and burs. All sharp, rough, broken edges and all edges of joints that are
subjected to tensile or oscillating stresses shall be ground by grinding. All edges cut by Oxyacetylene process shall
be cleaned of impurities and slag by grinding prior to assembling. Electrical metal arc cutting or gauging shall not
be allowed. Cutting tolerance shall be (i) ± 1mm for members connected at both ends (ii) ± 3mm elsewhere.
4.3.7 Holes for bolts should not be formed by gas cutting process, if it is formed in any additional case during
erection at site for adjustment of bolt hole then it shall be internally smooth finished by power tools and fabricated
washer is to be provided instead of readymade one. Holes through more than one thickness of material of numbers
and girder flanges shall be drilled after the members are assembled and tightly clamped/bolted together.

Punching may be permitted before assembly, provided the thickness of metal is less than 16 mm and the holes are
punched 3 mm less in diameter than the required size and reamed, after assembly, to the full diameter. Punching
shall not be adapted for dynamically loaded structures.
Holes may be drilled in one operation through 2 or more separable parts and burrs removed from each part after
drilling. No gas cutting holes are permitted. Holes in connecting angles and plates, other than splices, also in roof
members and light framing, may be punched full size through material not over 12 mm thick, except where
required for close tolerance bolts or barrel bolts.
All matching holes for black bolts shall register with each other so that a gauge of 2 mm less in diameter than the
diameter of hole shall pass freely through the assembled members in the direction at right angles to such members.
Finished holes shall not be more than 2 mm in diameter than the diameter of the black bolt passing through them,
unless otherwise specifies by PMC Engineer — in — Charge.
Holes for turned and fitted bolts shall be drilled to a diameter equal to nominal diameter of shank or barrel subject
 operation shall be drilled to a smaller size and reamed out after assembly. Where this is not possible, the parts
shall be drilled and reamed separately.
All erection holes where bolts are not used should be plugged by welding.
To facilitate grouting, holes shall be provided in column bases or seating plates exceeding 300 mm in width for
the escape of air.
To avoid accumulation of water in gusseted column bases of laced, batten or box type stanchions, suitably reverse
U-type holes shall be provided at the junction of base plate and column section in the vertical gussets for draining
out of any water.
4.3.8 Assembly:
The components shall be assembled and aligned in such a manner that they are neither twisted nor otherwise
damaged and shall be so prepared that the required camber, if any, is provided. Proper clamps, clips, jigs and other
fasteners (bolts and welds) shall be placed in a balanced pattern it to avoid any distortion in the members and to
ensure correct positioning (i.e. angles, axes, nodes, etc.). Any force fitting / pulling / stretching of members to join
them shall be avoided. Proper care shall be taken for welding shrinkage & distortion so as to attain the finished
dimensions of the structure shown on drawings.
4.3.9 (A) Bolting: All bolts shall be provided such that no part of the threaded portion of the bolts is within the
thickness of the parts bolted together. Washers of suitable thickness shall be used under the nuts to avoid any
threaded portion of the bolt being within the thickness of parts bolted together. The threaded portion of each bolt
shall project through the nut at least one thread Flat washers shall be circular and of suitable thickness to afford a
seating square with the axis of the bolt. The method of tensioning shall be in accordance with IS 4000 as per table
no.3 & 4 clause 7.2.1 & 7.2.2.
Tensioning of bolts and nuts using a direct tension indication device shall be in accordance with the
manufacturer's instructions and the following procedure. On assembly all bolts and nuts in the joint shall be first
tightened to a 'Snug tight' condition to ensure that the load transmitting piles are brought into effective contact.
After completing this preliminary tightening to 'Snug-tight' the bolt and nut shall be tensioned to provide the
minimum bolt tension by Torque-wrench & inspection of bolt tensioning shall be in accordance as per IS 4000
clauses 8.2, note Annexure D. The discipline Engineer shall be responsible for controlling all the activities related
to bolt tightening as per this method statement.
The concerned foreman shall be responsible for carrying out the actual bolt tightening to the required torque
values as per this method statement under the supervision of discipline engineer.
QC Inspector shall be responsible for verifying the correct application of this procedure.
(B) Sampling: At least three bolts, desirably of the same size (min. length may have to be selected to suit the
calibrating device) and condition as those under inspection shall be placed individually in a calibrating device
capable of indicating bolt tension. A hardened washer shall be placed under the part turned.
4.3.10 Edge preparation/ bevelling for the fusion faces shall be done for welding as mentioned in the drawing &
as per the approved WPS. The tolerance on limits of gap, root faces & included angle shall be as per IS: 9595.
Generally no special edge preparation shall be required for members under 8mm thick.

4.3.11 Cleaning: Welding edges & adjacent area of the members (extending up to 20 mm) shall be thoroughly
cleaned of oil, Grease, Scale, Dirt, Rusts, etc. Root gap for welding shall be free from all foreign materials.
4.3.12 Preheating shall be done as per approved WPS / IS 9595, if required. Preheating shall be done in such a
manner that the parts, on which the weld metal is being deposited, are above the specified minimum temperature
for a distance of not less than 75 mm on each side of the weld line. The temperature shall be measured on the
opposite to that being heated. However, when there is access to only one face, the heat source shall be removed to
allow for temperature equalization (1 min for each 25 mm of plate thickness) before measuring the temperature.
The Temple stick or Calibrated Digital Temperature scanner shall be used to measuring the preheat temperature.
4.3.13 Welding: Welding shall be done as mentioned in the drawing & approved WPS. Adequate protection
against rain, dust & strong winds shall be provided during welding operation. No welding shall be carried out in
absence of the mentioned facilities. Electrodes for manual welding shall comply with IS 814. Weld metal
deposited by an automatic or semi-automatic process will have mechanical properties not less than the minimum
specified for the weld metal deposited by electrodes complying with IS 814. All electrodes shall be classified,
coded or marked in accordance with IS 814. Electrodes shall be packed, stored and protected from weather effects
in accordance with the conditions specified by the manufacturer. The welding procedure adopted and consumables
used shall be specifically approved vendor list given by PMC/IOCL
4.3.14 Process of welding shall be as per Project specification/ Approved drawings, SMAW/GMAW process
shall be preferred.
Procedure tests (PQR) shall be carryout in accordance with IS 7307. The test weld shall be held at ambient
temperature for a minimum period of 72 hours prior to testing and shall be as per IS 7307. The selection of Low
Hydrogen Electrodes shall be as follow:
a) All butt weld having thickness more than 13 mm thk.
b) All base plate welding.
C) Moment connections & others as per drawings. Sequence of welding,
• As far as practicable, all welds shall be made in a sequence that will balance the applied heat of welding while
the welding progresses and to minimize distortion.
• The direction of the general progression in welding on a member shall be from points where the parts are
relatively fixed in position with respect to each other towards points where they have a greater relative freedom of
movement.
• All splices in each component part of a cover plated beam or built up member shall be made before the
component part is welded to other component parts of the member.
• Joints expected to have sufficient shrinkage shall be welded before joints expected to have lesser shrinkage.
• Welding shall be carried continuously to completion with correct number of runs.
• Welding Procedure: After the fusion faces are carefully aligned and set with proper gaps, the root pass
of butt joints shall be executed properly so as to achieve full penetration with complete fusion of the root
edges. On completion of each run welding slag shall be removed. Any visible defect shall be removed to
sound metal. All full penetration welding shall be completed by chipping/gouging to sound metal & then
depositing a seal run of weld metal on the back of the joints. Care shall be taken to avoid any kind of movement
of the components, shocks, vibrations to prevent occurrence of weld cracks. All welds shall be visually checked
for its completeness. Welding approval shall be taken before start of the subsequent activities.
• Welding procedure qualifications & Welder performance qualifications shall be carried out as per IS - 7307
& IS - 7310 respectively.
• In joints connected by fillet welds, the minimum sizes of single run fillet welds or first run shall conform to
requirements of IS 813 & IS 816. Fillet welds shall be made with two or more passes.
• Visual inspection: All finished welds shall be visually inspected. The following types of welds' defects and
faults shall be inspected.
• Weld defects occurring at the surface such as blow holes, exposed porosity, infused welds, etc.
• Surface cracks in the weld metal or in the parent metal adjacent to it.
• Damages to the parent metal such as undercuts, burning, overheating etc.
Profile defects such as excessive convexity or concavity, overlapping, unequal leg lengths, excessive
reinforcement, incompletely filled grooves, excessive penetration beads, root grooves, etc.

• Distortion due to welding i.e., local shrinkage, camber, bowing, twisting, rotation, wariness etc.
• Liner eccentric, angular, and rotational misalignment of parts.
• Dimensional errors: The size of the specified weld may be slightly over but not under. Welds not
complying with the above acceptance requirements and as specified by IS codes, shall be corrected in part or
whole either by removing and replacing or as follows: Excessive convexity: Reduce to size by removal of
excess weld metal.
• Shrinkage cracks: Defective to be removed up to sound metal and in parent plates and craters re-welded
with confirming the method of Dye penetration test.
• Under cutting: Additional weld to be deposited.
• Improperly fitted: Welding to be cut and edges suitably prepared and parts misaligned parts re-welded.
• Members distorted by: Member to be straightened by mechanical means or by the heat of welding careful
application of limited amount of heat.
• In removing defective parts of a weld, gouging, chipping, oxygen cutting or grinding shall not extend into
the parent metal to any substantial amount beyond the depth of weld penetration, unless cracks or other defects
exist in the parent plates. The weld or parent plates shall not be undercut in chipping, grinding, gouging or
oxygen cutting.
• NDT/Repair of weld shall be carried out in accordance with IS 822.
• Bolting & Splicing shall be done in accordance with the IS 800 & IF-C drawings.
• All primer application members shall be shop painted. Painting shall be done in accordance with
Project Specification Standard for Protective painting systems Doc no. PDRP-8440-SP-0006
• Only visually inspected fabricated items shall be sent to blasting shop.
• Welds shall not be painted or otherwise observed until they have been inspected, approved & accepted.
4.3.15 Non Destructive Testing of Welds: -
4.3.15.1 TEL shall carry out final inspection of all welds in accordance with IS 15326.
4.3.15.2 All welds shall be visually inspected in accordance with IS 15326 before any non-destructive testing
(NDT) is performed. Any welds that will be rendered inaccessible by subsequent work shall be examined prior to
loss of access. QC & welder shall ensure visual inspection of the relevant types of welds. All full penetration
welds shall be radio graphed or Ultrasonic tested as per requirement of project specification or approved ITP.
4.3.15.3 Non-destructive testing of welds shall be applied to the relevant joint types. The weld thickness and
frequency of testing of joints requiring NDT is in accordance with applicable Indian Standards.
4.3.15.4 Magnetic particle inspection (MPI)/ Dye penetrant inspection (DPI) shall be carried out in accordance
with IS 15326. Final surface flaw detection shall be carried out not less than 16 hours from time of completion of
the weld to be inspected. Where a welding procedure requires an inspection after initial weld runs before further
welding is performed, such inspection may be carried out when the weld metal has cooled to ambient temperature.
A suitable qualified person for surface flaw detection of welds may be a welding inspector or a. welder who holds a
current certificate of competence in surface flaw detection of the relevant types of work, from a nationally
recognized authority.
4.3.13.5 Ultrasonic inspection shall be carried out in accordance with IS 15326. Examination shall be carried out
not less than 16 hours from time of completion of the weld to be inspected, or not less than 40 hours in the case of
butt welds thicker than 40mm. Operator carrying out final ultrasonic examination shall hold a current certificate of

competence for the relevant types of work, from a nationally recognized authority.
4..4 Surface Preparation:-
Surface preparation for steel structure is listed in Project Specific Standard for Protective Painting system Doc no.
PDRP-8440-SP-0006.
• Part Nos./ Heat Nos./ Identification no. shall be marked by hard punch on a corner of the structure / Assembly.
• The temperature & humidity parameters shall be ensured as per the specifications (Max Humidity level 85% &
Temp Ambient). A moisture separator unit shall be mounted on the compressors hose line so that compressors air
shall be free from moisture and oil.
The surface preparation of the fabricated materials shall be carried out by blasting, power tool-cleaning techniques to
meet the required specific surface preparation/ roughness as per Sa 2½ or SSPC-SP-IO. Also procedure and degree of
surface preparation are shown in project specific standard for protective painting system Doc no. PDRP-8440-SP-0006

• The surfaces where the approach by blasting nozzle is difficult, cleaning by power tool would be done to
achieve the necessary surface profile.
• The surface preparation by blasting shall meet the requirements of Sa 2½ as per ISO 8501-1 shall be
inspected and recorded in approved format. Only dr./ blast cleaning techniques shall be employed and
abrasives shall be re-usable steel grit or mixture of iron and steel grit. A non-metallic blast abrasive, i.e.
aluminum oxide or garnet shall be used when abrading stainless steel surfaces.
• Compressed air to be used for surface preparation shall be filtered free of oil and moisture. Only trained
operators shall carry out the Surface preparation activity after wearing adequate personal protective equipment.
• In case of Structures / Plates, after completing the Surface preparation on one side, the job shall be turned and
surface preparation shall be carried out on the other side.
• After shot/grit blasting and just prior to paint application, all dust & blasting residues shall be removed
from the material surfaces by brushing and blowing down using clean dry air.
• Items shall be inspected for correct profile using profile gauge / comparator — ISO 8501- 1 after completion
of surface preparation. Surface profile shall be uniform to provide good key to the paint adhesion.
• Surface of steel structures if to be fire-proofed with concrete or mortar covering shall not be painted.
4.5 Shop Painting:-
• Painting system for steel structure is listed in project specific standard for protective p ainting system Doc
no. PDRP-8440-SP-0006. Only qualified applicator shall be deployed for painting works. The primer
coat shall be applied over completely dry surfaces with airless spray in a manner so as to ensure a
continuous and uniform film without "holidaying". The primer coat shall be air-dried and shall have a
required dry.
Film thickness after drying:
• Dry film thickness (DFT) readings shall be taken using a non-destructive dry film thickness instrument
capable of storing the readings. Sufficient readings shall be taken covering each coat prior to application of
the following coat to ensure the correct required DFT.
• Steel surfaces shall not be painted within a suitable distance of any edges to be welded if the paint specified
would be harmful to welders or impair the quality of welds.
• Welds and adjacent parent metal shall not be painted prior to deslagging and final inspection approval.
• Primer or first coat of paint shall be applied within 4 hours of surface preparation.
a) After final shop acceptance by TPIA/PMC, and marking of drawing and component number, the items
shall be packed and loaded for transportation.
b) Packing must be adequate to protect items against warping during loading and unloading. Proper lifting devices
shall be used for loading, in order to protect items against warping.
C) Slender projecting parts shall be braced with additional steel bars, before loading, for protection against
warping during transportation.
d) During transportation any damaged happens, that should be re-fabricated at site before erection.
4.7 Erection :-
a) Before start of erection all crane & Hydra & other lifting equipment's shall be ensured of having proper
test certificates so that it can work safely for the required load of the member.
b) Storing & Handling shall be done to avoid excessive stress & any damage.
c) The erection clearance for cleated ends of members shall be not greater than 2 mm at each end. The erection
clearance at ends of beams without web cleats and end plates shall be not more than 3 mm at each end. Erection
tolerances as per IS 12843.
d) Proper safety precautions shall be taken before & during the erection work each worker shall be trained for
precaution taken for erection jobs.
e) The framework must be sufficiently braced to prevent wind damage.
f) Steelwork shall be hoisted and erected in position carefully, without any damage to itself, other works and
injury to workmen.

g) During erection, the steelwork shall be securely bolted or fastened. Wherever necessary temporarily braces
shall be provided for all loads to be carried by the structure during erection, including those due to erection
equipment and its operation.
h) All field assembly and welding shall be executed in accordance with the requirements for shop assembly
and welding. A hole for all erection bolts where removed after final erection shall be plug weld.
Alternatively, erection bolts may be left and secured.
i) A specific erection scheme with methodology shall be submitted to PMC. In case of criticality of
structures, equipment etc., the erection scheme shall be submitted separately.
j) During high wind velocity, ghai rope (wire rope sling) will be tied up at the column top at the time of
erection and full tightening of bolts & nuts in structural members after erection.
k) Erection inspection the structure shall be checked by the area In-Charge/QC for the following including
finish grade such as levelness, plumb-ness, etc. (Member installed, dimensional c heck, grade of bolt
and size, bolt tightening, paint repairs) A punch list shall be Prepared by the TEL Engineer.
4.8 FIT-UP & WELDING:-
The component parts shall be aligned without any damage / twist and proper clamps, clips. Jigs and fasteners shall
be so placed to avoid any distortion in the nos. and ensure correct position. Proper care shall be taken for welding
shrinkage and distortion so as to attain the finished dimension of the structure as shown on the drawings.
Fit-up shall be made as per approved drawing using qualified welder. Upon clearance of fit-up by QA/QC &
Inspection authority, all welding shall be done using approved welding procedure specification in accordance with
IS: 7307 or ASME section IX / project specification and other relevant codes. Necessary arrangement is made to
provide no of welding sets of required quantity, consumables, cutting and grinding equipment with requisite
accessories, equipment and material required for carrying out the job. Edge preparation for welding is done as per
the dimensions/ details in the drawing. Welding edge and adjusting area and the gaps between the members shall
be thoroughly cleaned of all oil, grease, scale and rust and made completely dry before welding starts. Welding
shall be carried out continuously o completion with correct no. of runs. It is preferable to have two nos. of runs
(min). On completion of each run, all slag and Spatters shall be removed and wire brushing
& light chipping shall clean the weld & adjusting base metal. Visible defects such as cracks, cavities and other
deposition faults, if any shall be removed to sound metal before depositing subsequent run of Weld. All full
penetration butt welds shall be completed by chipping to sound metal and then depositing a seal runs of weld
metal on the back of joints. While welding is in progress, care shall be taken to avoid any kind of movement of the
components, shocks. Vibrations to be prevent occurrence of weld cracks.
4.9 INSPECTION & TESTING OF WELD:-
The method of inspection shall be according to the relevant applicable codes & standards and to be carried out
during all stages of fabrication & erection, to check the conformity with the relevant specifications and IS codes /
standards. Defects & faults occurring at the surface such as blow holes, exposed porosity, unfused welds, surface
cracks in the weld metal etc, profile defects like excessive convexity or concavity, overlapping, incomplete filled
shrinkage, camber, bowing, twisting, rotation etc. & other dimensional errors, eccentric angular & rotational miss.
minimum inspection check points as follows:
PRIOR TO FABRICATION
Checking of structural steel material supplied by contractor / manufacturers test certificates / testing (as applicable)
Welding filler material approval / qualification manufacturing test certificates / documents
Testing, if any
WPS / PQR / WPQ (Welder's Performance qualification)

FABRICATION ACTIVITIES SHOP

Dimensional and fit-up checks
Visual check for welding primer application painting material
Surface preparation (Blasting), Shop painting (Visual & DFT)

FIELD ERECTION ACTIVITIES

Alignment & levels
Fit-up
Field welding Grouting
Final Painting

INSPECTION & TEST DOCUMENTS

Review test and Inspection documents

4.10 Grouting :-
a) Grouting shall be done as per Grouting Specification-PDRP-8310-SP-0012. Type of grout shall be used for
major steel structures as per specification & drawing requirement. For type grout, surface preparation, grout
preparation, mixing, placing, curing and testing shall be in accordance with manufacturer's written instruction.
b) Prior to positioning of structural columns / girders / trusses over the pedestals/ columns / brackets, all
laitance and loose material shall be removed by wire brush & chipping. The bearing concrete surfaces shall be
sufficiently levelled hacked with flat chisels to make them rough, cleaned & made thoroughly wet. Thereafter,
the structural member shall be erected, aligned & plumbed maintaining the base plates / shoe plates at the
levels shown in the drawings, with necessary shims/ pack plates /wedges.
c) The thickness of grout shall be as per the approved civil drawings.
4.11 Check List :-
1. Preparation of check list location & axis wise
2. All check list items shall be completed mentioning date of completion.
3. Check list incorporating PMC/Client comments are to be verified by PMC/Client.
4.12 Final painting :-
Final painting shall be done as per Doc. PROTECTIVE PAINTING SYSTEM PDRP-8440-SP-0006.
• The shop-coated surfaces shall be rubbed down thoroughly with emery / abrasive paper to remove dust,
rust, other foreign matters and degreased, if required in accordance with IS 1477, as applicable, cleaned with
warm fresh water and air dried. The portions from where the shop coat has peeled off shall be touched up
and allowed to dry. Special care shall be taken to cover all the crevices, corners, edges etc.
• The over coat of paint shall be applied after the first coat is hard dry or manufacture's
recommendation to be followed.

5.0 QUALITY ASSURANCE / QUALITY CONTROL

Quality control of fabrication & erection will be as per quality plan and corresponding Inspection Test Plan.
Format of records as appended to this procedure will be maintained for erection.
• Following shall be checked while carrying out the job.
• Fabricated member shall be checked for measurement/ dimensions from drawings.
• Foundation bolts must be true to vertical position. Their location, orientation shall be checked and must be
matching with column base plate hole. Check shall be carried out for condition of the thread before erection of
structure.
• To provide proper support /bracing to sections /members and other components in position during erection.

6.0 HEALTH, SAFETY AND ENVIRONMENT

• Safety aspects shall comply with IS: 7205 for necessary safety & adhere to safe erection practices and guard
against hazardous as well as unsafe working conditions during all stages of erection.
• During erection, the steel work shall be securely bolted or otherwise fastened and when necessary,
temporarily braced/ guyed to provide for all loads to be carried by the structure during erection till the
completion, including those due to the wind, erection equipment & its operation etc.
• No permanent bolting or welding shall be done until proper alignment has been achieved.
• Proper access, platform and safety arrangement shall be provided for working and inspection,
whenever required.

• Area shall be cordoned off during erection activity.

• Qualified and experienced engineers / supervisor, safety officers must be available during entire period of
erection and alignment of structures.
• All workers engaged shall be experienced and well trained for the specific job including medically fitness for
height work.
• All required PPE would be used by all people engaged for the job.
• Where workers on a construction site are exposed to vertical drops of 6 feet or more, TEL shall provide fall
protection in one of three ways before work begins:
• Placing guardrails around the hazard area,
• Providing personal fall arrest systems for each employee. Safety nets must be inspected for wear, damage, and
other deterioration at least once a week, and after any occurrence which could affect the integrity of the system.
• Defective nets shall not be used, and defective components must be removed from service.
• Objects which have fallen into the safety net, such as scrap pieces, equipment, and tools, must be removed
as soon as possible from the net.
7.0 DOCUMENTATION
The following document needs to be maintained and submitted.
• Material Inspection and acceptance report
• Release Note
• Paint application records including record showing surface preparation
• Fit up record, welding record, NDT record
• Bolt tightening reports
• Grouting reports
• Alignment records