SPECIFICATION 830
STRUCTURAL STEELWORK
Copyright MAIN ROADS Western Australia
Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
REVISION REGISTER
Clause
Number
Description of Revision
Authorised
By
Date
Whole
document
Reformatted to corporate branding
guidelines
MPS
02/02/2016
830.02
Updated references
SDSE
02/02/2016
830.03
Added definitions for ACRS,
APLAC MRA, ILAC MRA and NATA.
830.04
Added new clause and included
previous clauses 830.03.02-04 and
830.09
830.05
Added new clause and included
previous clauses 830.10-11
830.06-11
Previous clauses 830.06-08 rewritten
and renumbered as clauses 830.06-11.
Removed previous reference to steel
strength grades. Removed locknut and
stainless steel.
830.08
Added new clause referring to ACRS
certification
830.10
Added new clauses relating to
tolerance in thread and tapping of
galvanised nuts
830.28
Updated Qualifications of Welding
Personnel, Equipment, Welding
Consumables, Welding Procedures,
Inspection and Testing of Welds
830.29
Added new clauses for Responsible
Welding Coordinator and Inspection
830.44
Added new clause for calibration and
validation
830.45
Added new clause for quality records
830.02
References - amendments to
Standards titles AS 1710 and
AS/NZS 1553.1
SDSE
23/9/2008
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Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
CONTENTS
Clause
Page No
GENERAL .................................................................................................................... 5
830.01
Scope ......................................................................................................................... 5
830.02
References ................................................................................................................. 5
830.03
Definitions ................................................................................................................. 7
830.04
Quality Control and Workmanship ............................................................................ 8
PRODUCTS AND MATERIALS ................................................................................... 9
830.05
Storage and Handling ................................................................................................ 9
830.06
Materials and Parts ................................................................................................... 9
830.07
Steel in Plates, Sections and Bars .............................................................................. 9
830.08
Acceptance of Steels in Plates, Sections and Bars...................................................10
830.09
Testing of Steel Plates Greater Than 30 mm ...........................................................10
830.10
Bolts, Nuts and Washers .........................................................................................11
830.11
Acceptance of Bolts, Nuts and Washers..................................................................12
830.12 – 830.20 NOT USED .......................................................................................................12
FABRICATION ........................................................................................................... 12
830.21
General ....................................................................................................................12
830.22
Shop Drawings .........................................................................................................13
830.23
Precamber and Distortions......................................................................................14
830.24
Straightening and Correction of Distortions ...........................................................14
830.25
Cutting and Edge Treatment ...................................................................................14
830.26
Splices ......................................................................................................................15
830.27
Holes for Bolting ......................................................................................................15
830.28
Welding....................................................................................................................15
830.29
Stud Shear Connectors ............................................................................................20
830.30
Bolting......................................................................................................................21
830.31
Holding Down Bolts .................................................................................................22
830.32
Certification of Fabrication ......................................................................................22
830.33 – 830.40 NOT USED .......................................................................................................22
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Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
ERECTION ................................................................................................................. 22
830.41
General.................................................................................................................... 22
830.42
Bolted Joints ............................................................................................................ 23
830.43
Construction Tolerances ......................................................................................... 23
830.44
Calibration and Validation ...................................................................................... 23
830.45
Quality Records ....................................................................................................... 24
830.46 – 830.80 NOT USED....................................................................................................... 24
AS BUILT AND HANDOVER REQUIREMENTS ........................................................ 24
830.81 – 830.90 NOT USED....................................................................................................... 24
CONTRACT SPECIFIC REQUIREMENTS ................................................................. 24
830.91 – 830.99 NOT USED....................................................................................................... 24
ANNEXURE 830A ...................................................................................................... 25
STEEL ITEMS SUPPLIED BY PRINCIPAL ......................................................................................... 25
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Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
GENERAL
830.01
SCOPE
1.
The work under this specification consists of the supply,
fabrication and erection of steel beams, box girders, columns and
associated structural steel work.
2.
Minor steel items, balustrades and traffic barrier
requirements are covered in Specifications 831, 833 and 603
respectively.
830.02
REFERENCES
1.
Australian Standards, MAIN ROADS Western Australia
Standards and MAIN ROADS Western Australia Test Methods are
referred to in abbreviated form (e.g. AS 1234, MRS 67-08-43 or
WA 123). For convenience, the full titles are given below:
2.
All metal fabrication and welding shall comply with the
current edition of the relevant Standard or Code of Practice (including
amendments) specified in the Specifications or nominated on the
Drawings. The requirements of the relevant Standard / Code are
deemed to be the minimum standard applicable, unless otherwise stated
in the Contract Specification.
Australian Standards
AS 1100
Technical Drawing
AS 1101.3
Graphical Symbols for General Engineering – Welding
and Non-destructive Examination
ISO Metric Hexagon Bolts and Screws – Product
Grade C – Bolts
ISO Metric Hexagon Nuts – Product Grade C
AS 1111.1
AS 1112.3
AS 1214
AS 1237
AS 1275
AS 1710
AS 1796
AS 2214
AS 2812
Hot-dip Galvanized Coatings on Threaded Fasteners
(ISO Metric Coarse Thread Series)
Plane Washers for Metric Bolts, Screws and Nuts for
General Purposes
Metric Screw Threads for Fasteners
Non-destructive Testing – Ultrasonic Testing of Carbon
and Low Alloy Steel Plate and Universal Sections –
Test Methods and Quality Classification
Certification of Welders and Welding Supervisors
Certification of welding supervisors – Structural Steel
Welding
Welding, Brazing and Cutting of Metals – Glossary of
Terms
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Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
AS 3828
Guidelines for the Erection of Building Steelwork
AS 4100
Steel Structures
AS 5100
Bridge Design
AS 60974.1
Arc Welding Equipment – Welding Power Sources
(IEC 60974-1:2000, MOD)
Australian/New Zealand Standards
AS/NZS 1163
Cold-formed Structural Steel Hollow Sections
AS/NZS 1252
High Strength Bolts with Associated Nuts and
Washers for Structural Engineering
Structural Steel Welding –Welding of Steel
Structures
Structural Steel Welding – Stud Welding (Steel
Studs to Steel)
Welding Cables
AS/NZS 1554.1
AS/NZS 1554.2
AS/NZS 1995
AS/NZS 2980
AS/NZS 3679.1
Qualification of Welders for Fusion Welding of
Steels
Structural Steel – Hot-Rolled Plates, Floorplates
and Slabs
Structural Steel – Hot Rolled Bars and Sections
AS/NZS 3679.2
Structural Steel – Welded I Sections
AS/NZS ISO 3834
Quality Requirements for Fusion Welding of
Metallic Materials
Hot-dip Galvanized (Zinc) Coatings on
Fabricated Ferrous Articles
Welding Consumables – Covered Electrodes for
Manual Metal Arc Welding of Non-alloy and Fine
Grain Steels – Classification
Quality Management Systems – Requirements
AS/NZS 3678
AS/NZS 4680
AS/NZS 4855
AS/NZS ISO 9001
AS/NZS ISO 14171
AS/NZS ISO 14174
AS/NZS ISO 14341
AS/NZS ISO 17632
Welding Consumables – Solid Wire Electrodes,
Tubular Cored Electrodes and Electrode/Flux
Combinations for Submerged Arc Welding of
Non-alloy and Fine Grain Steels – Classification
Welding Consumables – Fluxes for Submerged
Arc Welding and Electroslag Welding –
Classification
Welding Consumables – Wire Electrodes and
Weld Deposits for Gas Shielded Metal Arc
Welding of Non Alloy and Fine Grain Steels –
Classification
Welding Consumables – Tubular Cored
Electrodes for Gas Shielded Metal Arc Welding
of Non-alloy and Fine Grain Steel – Classification
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AS/NZS ISO 18276
Welding Consumables – Tubular Cored
Electrodes for Gas Shielded and Non-gas
Shielded Metal Arc Welding of High-strength
Steels – Classification
Other Standards
WTIA TN03
Welding Technology Institute of Australia,
Technical Note 3, Care and Conditioning of Arc
Welding Consumables
Welding Coordination – Tasks and
Responsibilities
Welding – Calibration, Verification and Validation
of Equipment Used for Welding, including
Ancillary Activities
ISO 14731
ISO 17662
MAIN ROADS Specifications
Specification 603
SAFETY & TRAFFIC BARRIER SYSTEMS
Specification 831
MINOR STEEL ITEMS
Specification 833
BRIDGE BALUSTRADES
Specification 835
PROTECTIVE TREATMENT OF STEELWORK
830.03
DEFINITIONS
1.
The following particular definitions will apply:
2.
ACRS is the Australasian Certification Authority for
Reinforcing and Structural Steels.
ARCS
3.
APLAC MRA is the Asia Pacific Laboratory Accreditation
Cooperation (Mutual Recognition Arrangement).
APLAC MRA
4.
ILAC MRA is the International Laboratory Accreditation
Cooperation (Mutual Recognition Arrangement).
ILAC MRA
5.
ITP is the detailed Inspection and Test Plan(s) for the Works. ITP
6.
MDR is the Manufacturer’s Data Report.
MDR
7.
NATA is the National Association of Testing Authorities
Australia.
NATA
8.
WSP
WSP is the Welding Service Provider.
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830.04
830.04.01
QUALITY CONTROL AND WORKMANSHIP
Workmanship
1.
All work shall be carried out by competent and qualified
personnel under the supervision of experienced and competent
supervisors to fully satisfy the requirements of this Specification.
830.04.02
Provision for Audit Inspection
1.
The Contractor shall lay out and arrange the individual
members or units to be inspected so that identification marks on each
may be readily distinguished and so that each member or unit is
accessible for audit inspection by the Superintendent.
2.
The Contractor shall assist the Superintendent by turning the
members or parts to permit examination of all sides. The Contractor
shall supply all labour, plant, tools and scaffolding required to facilitate
full inspection.
830.04.03
Quality Assurance
The WSP shall:
1.
Be responsible for all quality control and assurance activities
necessary to ensure that the completed Works comply with the specified
requirements.
2.
Provide prior information to the Superintendent in respect of
any proposed subcontract works to enable the Superintendent to assess
and approve their suitability for that work.
3.
Establish and maintain a certified quality management
system to AS/NZS ISO 9001 and AS/NZS ISO 3834 and to ensure that
any Subcontractors comply with this requirement.
4.
Submit a Quality Plan to the Superintendent detailing how
the Quality Assurance requirements are to be applied to each element of
the Works.
830.04.04
Identification Marks
1.
Each item of structural steelwork shall have its own item
mark number which shall be used on all related schedules and
documents. This mark shall be clearly indicated on all members by
durable identification marks to enable accurate identification on site.
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Mark Number
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PRODUCTS AND MATERIALS
830.05
830.05.01
STORAGE AND HANDLING
Storage
1.
All steel, whether fabricated or not, shall be stored in such a
manner that corrosion is minimised. Generally, storage at least 200 mm
above the ground on timber gluts under cover shall be satisfactory.
Rusted or bent or damaged steel shall be rejected.
830.05.02
Handling and Stacking
1.
Before and after fabrication and during transit and on the Site
all structural steelwork shall be handled and stacked in such a way that it
is not damaged.
2.
All bolts and nuts and washers and plates under 300 mm
maximum dimension and small articles generally shall be packed
separately in watertight containers.
3.
Identification marks as specified in Clause 830.04.04 shall be
stencilled on each package in a conspicuous position.
830.06
TEST CERTIFICATES AND TRACEABILITY
1.
The Contractor shall ensure that all materials or parts
conform with the tests required by the Standards and with other tests
specified in this Specification.
2.
Test certificates showing the results of mechanical tests and
chemical analysis (where applicable) of the material or parts used in the
Works shall be retained by the Contractor, and shall form part of the
MDR.
Certificates
3.
All materials or parts used in the Works shall be traceable to
the Test Certificates. The Contractor shall establish and maintain a
comprehensive system of identification records. Copies of all these
records shall be forwarded to the Superintendent on request, and shall
form part of the MDR.
830.07
STEEL IN PLATES, SECTIONS AND BARS
1.
All materials of steel plates, bars and sections supplied by
New Steel,
the Contractor shall be new and shall conform to the Standards specified Standards
below, unless as varied by this Specification.
2.
Steel shall be identified in accordance with Clause 13 of
Identification
AS/NZS 1163, Clause 12 of AS/NZS 3678, Clause 11 of AS/NZS 3679.1
or Clause 10 of AS/NZS 3679.2, as appropriate. This identification shall
be maintained during all phases of fabrication.
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3.
Steel shall comply with the requirements of the following
standards:
a) Hot-rolled steel bars and sections
AS/NZS 3679.1
b) Hot-rolled steel plates
AS/NZS 3678
c) Hollow sections
AS/NZS 1163
Grade L0
d) Welded I-sections
AS/NZS 3679.2
4.
Structural steel hollow sections with Silicon content greater
than 0.22% shall not be used when steelwork is to be hot dip galvanised
to AS/NZS 4680.
830.08
ACCEPTANCE OF STEELS IN PLATES, SECTIONS AND
BARS
1.
Acceptance of steels for the standards listed in
Clause 830.07 shall be through product certification by ACRS.
2.
In the event of a dispute as to the compliance of the steel
with any of the standards listed in Clause 830.07, the reference testing
shall be carried out by independent laboratories accredited by
signatories to the ILAC MRA or the APLAC MRA. The cost to carry out
the independent testing and the cost for subsequent reporting shall be
borne by the Contractor.
3.
The fabrication of steel shall not commence until the
Superintendent has reviewed and approved the acceptance of
steels in plates, sections and bars by the method in
Clause 830.08(1).
830.09
HOLD POINT
TESTING OF STEEL PLATES GREATER THAN 30 MM
1.
Prior to fabrication, the contractor shall test all plates of
thickness in excess of 30 mm using continuous ultrasonic testing along
all lines where welding shall be carried out and to establish that the
plates are free from laminations and defects. The method of testing
shall be in accordance with AS 1710.
2.
A written report on each line tested shall be forwarded direct
from the NATA registered testing laboratory to the Superintendent within
24 hours of completion of the test. The location and extent of inclusions
and/or laminations shall be detailed and sketched in the report.
3.
The welding of plates with thickness in excess of 30 mm
shall not commence until the Superintendent has reviewed and
approved the acceptance of report described in Clause 830.09(2).
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HOLD POINT
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830.10
BOLTS, NUTS AND WASHERS
1.
All bolts, nuts and washers supplied by the Contractor shall
New
be new and shall conform to the relevant Australian Standards unless as Fasteners,
varied by this Specification.
Standards
2.
The hardness of hot-dip galvanised washers for use with
high strength bolts shall have a hardness of 35-45 HRC.
3.
High strength bolts, with associated nuts and washers, shall
comply with AS 4100. The length of the bolt shall be as shown on the
Drawings, or, if no length is shown, shall be in accordance with the
requirement of AS 4100.
4.
All screw threads shall conform to the ISO coarse pitch
series thread in accordance with AS 1275.
5.
All high strength bolts, nuts and washers shall have the
identification marks as detailed in Clause 1.5 of AS 1252.
Identification
6.
Before the application of corrosion protection, tolerance of
screw threads for:
a)
bolts conforming to AS/NZS 1252 shall be Class 6g; and
b)
bolts conforming to AS 1111.1 shall be Class 8g.
7.
Before the application of corrosion protection, tolerances of
nut threads for:
a)
nuts conforming to AS/NZS 1252 shall be class 6H; and
b)
nuts conforming to AS 1111.1 shall be Class 8H.
8.
The galvanising of fasteners is to be in accordance with
AS 1214. After galvanising, the galvanised nuts shall be tapped
oversize in accordance with AS 1214.
9.
Unless otherwise shown on the Drawings, nuts other than
those for high strength bolts shall be “normal” size. The strength grade
of normal nuts to be associated with each strength grade of the bolt,
U-bolt or other threaded component shall be as follows:
Grade of Bolt, U-bolt,
etc
Strength Grade of
Nut
4.6
5
5.8
5
8.8
8
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10.9
10
10.
Unless shown otherwise on the Drawings, the following
types of washers shall be used:
a)
with precision bolts – bright metal washers, normal series;
and
b)
with commercial bolts – black metal washers, normal
series.
11.
screws.
Washers are generally not required under socket head cap
830.11
ACCEPTANCE OF BOLTS, NUTS AND WASHERS
1.
Acceptance of bolts, nuts and washers for the standards
listed in Clause 830.02 shall be through test certificates that state that
the bolts, nuts and washers comply with all the provisions of the
appropriate standards listed in Clause 830.09. These test certificates
shall be provided by the manufacturer or bolt importer and these
certificates shall be supported by test reports from an independent
laboratory accredited by signatories to the ILAC MRA or the
APLAC MRA. Alternatively, the test certificates with supporting test
reports can be provided by the testing laboratory on behalf of the
manufacturer, importer or customer.
2.
The installation of bolts, nuts and washers shall not
commence until the Superintendent has reviewed and approved
the acceptance of bolts, nuts and washers by the method in
Clause 830.11(1).
830.12 – 830.20
HOLD POINT
NOT USED
FABRICATION
830.21
GENERAL
1.
All structural steelwork shall be fabricated as shown on the
Drawings and in accordance with the requirements of AS 4100 and
AS/NZS 1554.1 (SP quality) except as varied by this Specification.
2.
The steelwork shall be fabricated where applicable with all
necessary temporary brackets and straps and gussets and cleats and
fixings and lifting eyes and the like necessary for erection and assembly.
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830.22
SHOP DRAWINGS
1.
The Contractor shall prepare shop drawings for the
fabrication of all members.
2.
Shop drawings shall show details of fabrication which are not
explicit in the Drawings. Details required include dimensions, angles
and weld preparation details and any contract specific requirements
specified in Clauses 830.91 to 830.99.
3.
The details shown on the shop drawings shall be consistent
with the Drawings and shall comply with the following:
a)
the marking plan shall show the location of each part in the
structure;
b)
shop drawings shall conform to AS 1100;
c)
welding and cutting definitions shall conform to AS 2812;
d)
welding symbols shall conform to AS 1101.3;
e)
complete information regarding the location, type, size and
extent of all welds shall be clearly shown on the shop
drawings. These shop drawings shall clearly distinguish
between shop and field welds;
f)
joints or groups of joints in which it is especially important
that the welding sequence and technique of welding be
carefully controlled to minimise shrinkage stresses and
distortion shall be noted on the shop drawings. Joints where
no welding is permitted shall also be clearly indicated. Weld
lengths specified on the Drawings shall be the required
effective lengths;
g)
each member shall be clearly identified with the
identification marks shown on the Drawings. Each type of
component shall be further identified to readily distinguish it
from all other types; and
h)
for assemblies, all associated bolting, accessories and/or
joining details shall be shown on the shop drawings.
4.
Four copies of the shop drawings, certified by the Contractor
as complying with the above requirements, shall be submitted to the
Superintendent 7 working days before fabrication commences.
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5.
Variations of details shown on the shop drawings shall not
be made without resubmission of appropriately amended shop drawings
at least 7 working days before fabrication of any affected component of
the Works.
6.
The Contractor shall be responsible for the correctness of
the shop drawings. Acceptance of the shop drawings by the
Superintendent shall not relieve the Contractor of any responsibility.
830.23
PRECAMBER AND DISTORTIONS
1.
The Contractor shall be aware that the specified construction
tolerances require making due allowance for pre-camber and distortions
due to fabrication and erection processes and for careful matching of
angles and dimensions at field joints.
2.
The Drawings show pre-camber allowance for dead load.
The Contractor shall allow for all other aspects of the construction
method affecting pre-camber.
830.24
STRAIGHTENING AND CORRECTION OF DISTORTIONS
1.
All plates shall be flattened and all sections shall be
straightened and made free from twist before any work is done on them
to ensure assembled surfaces are flat within specified tolerances and
adjacent surfaces are in close contact throughout. The methods
adopted for such flattening and straightening shall be such as not to
damage or mark the material. Heating of plates and all sections shall
not be permitted unless written approval is obtained from the
Superintendent prior to any heat application.
830.25
CUTTING AND EDGE TREATMENT
1.
Steelwork shall be cut only by sawing, thermal cutting,
abrasive water jet cutting or laser cutting. After cutting, cut edges shall
be ground to remove burrs, dross and slag, and to clean up any
roughness (including gouge marks and unintentional bevel).
2.
Unless required otherwise for welding, or where shown
differently on the Drawings, any surfaces produced by cutting shall be
finished square (unless a bevelled edge is called for) and smooth and
true to the required dimensions.
3.
Ends of web stiffener plates shall be cut and finished to fit
snugly and uniformly to girder flanges unless otherwise shown on the
Drawings.
4.
Cut edges shall be finished as specified in AS 4100.
Guillotined plates shall be cut to an oversize sufficient for the correct
dimensions to be achieved after edge finishing. Where galvanising is
specified, the edge surface preparation shall conform to the
requirements of this Specification.
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5.
Unless shown otherwise on the Drawings, all corners on cut
edges shall be rounded to a radius of approximately 1.5 mm, except
where such edges are subsequently to be welded. Rolled edges need
not be rounded provided the corners have a similar radius.
830.26
SPLICES
1.
The location of any splices required in the flanges or webs of
the box girder, additional to those shown on the Drawings, shall be
suitably staggered and away from zones of high stress (typically not
within 1 m of beam bolted splice connection points and located near the
contraflexure points away from pier centrelines) as approved by the
Superintendent.
830.27
HOLES FOR BOLTING
1.
All bolt holes shall be drilled to a diameter 2 mm larger than
the diameter of the bolt unless otherwise shown on the Drawings.
2.
Drilled holes shall be cylindrical and perpendicular to the
face of the member. Drilling shall be done by mechanical means.
830.28
WELDING
830.28.01
General
1.
All welding shall comply with AS/NZS 1554.1 or
AS/NZS 1554.2 as appropriate. All welding shall be category SP
(Structural Purpose) in accordance with AS/NZS 1554.1.
830.28.02
Qualifications of Welding Personnel
830.28.02.01 Welder
1.
Welding shall only be carried out by welders meeting the
requirements of Clause 4.12.2 of AS/NZS 1554.1.
2.
Not less than 10 working days prior to planned
commencement of welding, the following information on each welder
shall be provided to the Superintendent:
a)
documentary evidence of the qualification/certification
currently held;
b)
trade training background;
c)
duration of employment with current employer;
d)
nature of current employment duties; and
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Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
e)
3.
documentary evidence confirming each welder is qualified
for each welding procedure that they shall apply to the
Works.
The WSP shall:
a)
maintain records clearly identifying the welders to each
completed weld, weld repair and/or fabricated
assembly/unit. All records shall be available to the
Superintendent; and
b)
on completion of the welding work, a weld map showing the
welds completed by each welder shall be part of the MDR.
830.28.02.02 Responsible Welding Coordinator
1.
All welding shall be carried out under the supervision of the
Contractor's Responsible Welding Coordinator who shall meet the
requirements of Clauses 4, 5 and 6 of ISO 14731.
2.
Not less than 10 working days prior to commencement of
welding, the WSP shall identify the Responsible Welding Coordinator
who shall be responsible for the coordination of all operations in respect
of the welding work. The WSP shall provide to the Superintendent
details of the Responsible Welding Coordinator’s qualifications,
certification and experience. The Responsible Welding Coordinator
shall have delegated authority to deal directly with the Superintendent on
all issues relating to the welding work, including:
a)
welding procedure management;
b)
welding quality management;
c)
inspection and testing activities; and
d)
sign-off of completed work.
830.28.02.03 Welding Inspector
1.
All welding work shall be inspected by a suitably qualified
Welding Inspector in accordance with Clause 7.2 of AS/NZS 1554.1, and
who holds a current WTIA Welding Inspection Certification, either as a
Welding Inspector, Senior Welding Inspector or as a Comprehensive
Welding Inspector.
2.
Not less than 10 working days prior to commencement of
welding, the WSP shall identify the Welding Inspector who shall be
responsible for the inspection of the welding work. The WSP shall
provide to the Superintendent details of the Welding Inspector’s
qualifications, certification and experience.
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830.28.03
Equipment
1.
Welding equipment and plant shall conform to AS 60974.1
and AS/NZS 1995, and shall be maintained at all times in good
condition. It shall be of an appropriate type for the intended purpose and
shall only be used in the circumstances and in the manner
recommended by the manufacturer for size of electrodes, currents,
voltages, speeds of travel, position of welding and fixtures and jigs shall
be as laid down for the particular class of work.
2.
Where a machine or a method is not of a conventional type,
the machine or method shall be used in the welding procedure
qualification.
3.
Where welding is required to be done in conditions of a high
risk of electric shock the welding equipment shall be fitted with a Voltage
Reduction Device (VRD).
4.
The WSP is required to maintain a list of essential equipment
and their capacities in accordance with Clause 9.2 of AS/NZS ISO 3834
Part 3.
830.28.04
Welding Consumables
1.
All welding consumables to be used in welding procedures
and for the Works shall comply with the relevant Standards. Electrodes
used for manual welding shall conform to AS/NZS 4855. Tubular cored
electrodes used for gas shielded and no-gas shielded metal arc welding
of non-alloy and fine grain steels shall conform to AS/NZS ISO 17632.
Tubular cored electrodes used for gas shielded and no-gas shielded
metal arc welding of high-strength steels shall conform to
AS/NZS ISO 18276. Solid wire electrodes, tubular cored electrodes and
electrode/flux combinations for submerged arc welding of non-alloy and
fine grain steels shall conform to AS/NZS ISO 14171. Fluxes for
submerged arc welding shall conform to AS/NZS ISO 14174. Wire
electrodes for gas shielded metal arc welding of non-alloy and fine grain
steels shall conform to AS/NZS ISO 14341.
2.
The WSP shall produce and implement procedure’s for
storing, handling, identification and the use of welding consumables, in
particular hydrogen controlled electrodes, in compliance with the
recommendations in WTIA TN03.
830.28.05
Welding Procedures
1.
Welding procedures for all fillet and butt welds, or any
combination of either, shall be proven qualified by the WSP, who shall
submit to the Superintendent a schedule of all proposed welding
procedure qualifications, not less than 10 working days prior to the
planned commencement of welding work to which the procedures shall
apply.
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
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2.
Prior to the commencement of any welding procedure
where the essential variables vary outside the limits specified in
Table 4.11(A) of AS/NZS 1554.1, the Contractor shall submit to the
Superintendent a copy of the new procedures proven qualified by
the WSP.
HOLD POINT
3.
Suitable run-on and run-off tabs shall be used for all butt
welds. The tabs shall have the same thickness and preparation as the
parts to be joined. Each weld pass shall terminate at least 20 mm
beyond the edges of the parts to be joined. Welds shall be continuous
for the full length.
4.
All welding for the work shall be shown in a detailed Welding
Procedure Sheet in accordance with AS/NZS 1554.1. Each welding
procedure shall be qualified by way of test pieces and/or assemblies in
accordance with AS/NZS 1554.1.
5.
Test pieces and/or assemblies shall represent the actual
conditions in the work in regard to location, weather, environment,
geometric arrangement, plate thickness, joint preparation and equipment
and be of a minimum size recommended by AS/NZS 1554.1, but of
adequate size to carry out all testing.
6.
The Superintendent shall be given at least 3 working days
notification of the time and place where the welding and testing of all test
pieces and/or assemblies shall be carried out.
7.
The WSP shall obtain any test and/or Inspection Certificates
from a laboratory with appropriate NATA registration, with all relevant
results shown and a statement that the results comply with
AS/NZS 1554.1.
8.
The WSP shall develop and maintain a document control
procedure for all welding documentation including welding procedure
specifications, procedure qualification records, welder qualifications and
supporting documentation.
830.28.06
Cleaning of Finished Welds
1.
All run-on and run-off tabs shall be removed after the joint
has cooled and the ends of the welds shall be finished smooth and flush
with the faces of the abutting parts.
2.
Slag shall be removed from completed welds. The weld and
adjacent base material shall be cleaned by brushing or other suitable
means to remove spatter and foreign material. Welded joints shall not
be painted until after the welds have been inspected and tested in
accordance with Clause 830.28.07.
3.
Where butt welds form part of a faying or contact surface,
the surfaces of the butt welds shall be dressed in accordance with
Clause 5.12 of AS/NZS 1554.1.
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
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830.28.07
Inspection and Testing of Welds
1.
Inspection of welds shall be carried out in accordance with
AS/NZS 1554.1. The WSP shall produce an Inspection and Test Plan
(ITP) for all welding work, which shall contain the necessary elements
and hold points to ensure the completed welding work complies with
AS/NZS 1554.1 and Clause 14 of AS/NZS ISO 3834 requirements. The
WSP shall submit ITPs to the Superintendent not less than 10 working
days prior to commencement of the welding work.
2.
The WSP shall ensure that testing of all welds is carried out
in accordance with AS/NZS 1554.1. Test Certificates issued by a NATA
registered laboratory shall be available to the Superintendent and shall
be part of the MDR. The testing procedures to be used are:
a)
visual scanning;
b)
visual inspection;
c)
radiographic testing;
d)
ultrasonic testing;
e)
magnetic particle inspection;
f)
dye penetration testing;
g)
hardness testing; and
h)
microstructure replica examination.
3.
The extent of testing and inspection of welds shall generally
be in accordance with the recommendations in Table 7.4 of
AS/NZS 1554.1, but also as follows:
a)
visual inspection of all weld preparations prior to welding;
b)
inspection of all weld quality using testing procedures
830.28.07.2.(a) and (b);
c)
testing of all full strength butt weld splices in tension and
compression using testing procedure 830.28.07.2.(c);
d)
for all other butt welds test 10% of the length of all welds
longer than 1 m and one in twenty of all welds which are less
than 1 m long using a combination of testing procedures
830.28.07.2.(c) and (d);
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Contract No: xxxx/xx Contract Name
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Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
e)
10% of fillet welds tested using testing procedures
830.28.07.2.(e) and/or (f); and
f)
testing procedures 830.28.07.2.(g) and (h) shall be used
where directed by the Superintendent.
4.
The Contractor shall allow for all labour and plant required to
lay out and arrange items for inspection and testing and carry out any
necessary weld preparation including allowance for lost production time.
5.
All repaired welds shall be retested and for welds tested
under Clause 830.28.07.3.(d) above, retest three non-overlapping
samples each 10% of the length of all welds longer than 1 m and retest
three in twenty of all welds which are less than 1 m long using a
combination of testing procedures 830.28.07.2.(c) and (d). All repairing
and retesting defective welds and additional testing shall be at no cost to
the Principal.
6.
The WSP shall only employ or contract Australian Institute
for Non Destructive Testing (AINDT) certified NDT operators and
qualified procedures.
830.28.08
Non-conforming Welds
1.
Any welds not meeting the requirements of this Specification
shall be rejected. The WSP shall document all NCRs and shall submit
proposals to the Superintendent for correcting defective welds. All
corrective work shall be in accordance to AS/NZS 1554.1.
2.
Repairing or correcting defective welds and any additional
work or material required to repair defective welds shall be at no cost to
the Principal.
830.29
830.29.01
STUD SHEAR CONNECTORS
General
1.
Stud shear connectors and stud welding shall comply with
the requirements of AS/NZS 1554.2 except as varied by this
Specification.
830.29.02
Responsible Welding Coordinator
1.
All welding shall be carried out under the supervision of the
Contractor’s Responsible Welding Coordinator who shall be qualified in
accordance with Clause 4.12 of AS/NZS 1554.1 and meets the
requirements of Clauses 4, 5 and 6 of ISO 14731.
830.29.03
Operator Qualification
1.
Operators shall be qualified in accordance with Section 4.3
of AS/NZS 1554.2.
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
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830.29.04
Welding
1.
After stud welding, all beams shall comply with the
tolerances given in Clause 830.43 "Construction Tolerances". Quality
control for all stud welding shall be maintained in accordance with
AS/NZS 1554.2.
830.29.05
Distortion
Testing
1.
The testing of welded studs shall be in accordance with
AS/NZS 1554.2. In addition, the Superintendent shall select an
additional five per cent of the remaining studs which shall also be tested.
All other studs shall be ring tested.
830.29.06
Inspection
1.
Inspection of welds shall be carried out in accordance with
AS/NZS 1554.2. The WSP shall produce an inspection and Test Plan
(ITP) for all welding work, which shall contain the necessary elements
and hold points to ensure the completed welding work complies with
AS/NZS 1554.2 and Clause 14 of AS/NZS ISO 3834 requirements. The
WSP shall submit ITPs to the Superintendent not less than 10 working
days prior to commencement of the welding work.
830.29.07
Correction of Defective Stud Welds
1.
Any stud welds not meeting the requirements of
AS/NZS 1554.2 shall be rejected. Repairs to defective welds, except
where allowed for in AS/NZS 1554.2, shall not be allowed.
830.30
BOLTING
1.
All bolts, nuts and washers are to be hot-dip galvanised
General
unless otherwise noted. Use one nut only to each bolt. Project the
threaded portion of the bolt a minimum of one thread and a maximum of
five threads through the nut. Use washers, tapered where necessary, to
give nuts and bolts satisfactory bearing. All nuts and washers in each
joint shall face in one direction and away from the general view.
2.
The following types of bolts with their tightening procedures
are designated on Structural Drawings when required:
Types of
Bolts
4.6/S, 8.8/S, 8.8/TF, 8.8/TB, 8.8X/TF and 8.8X/TB
Where 8.8 bolts are designated, the washers and nuts shall also be
hardened as for the bolt.
Where 8.8X bolts are designated, the thread portion of the bolt shall be
kept outside the shear plane of the parts being joined.
3.
The tightening of bolts shall be carried out to the following
procedures according to the grade of bolt:
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
Bolt
Tightening
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Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
830.31
a)
bolting procedure 4.6/S refers to commercial bolts of
strength grade 4.6 manufactured to AS 1111.1, tightened
using a standard wrench to a snug-tight condition; and
b)
bolting procedure 8.8/S refers to any bolt of strength grade
8.8 tightened using a standard wrench to a snug-tight
condition in the same way as for procedure 4.6/S. The bolts
used shall be high strength structural bolts of grade 8.8 to
AS/NZS 1252.
HOLDING DOWN BOLTS
1.
All holding down bolts shall, wherever applicable, be welded
into a cage to ensure accurate placement. Bolts, nuts, washers and
cage assemblies shall be hot-dip galvanised to give a coating of zinc of
not less than 85 microns thick.
830.32
CERTIFICATION OF FABRICATION
1.
Prior to dispatch of work from the shop the Contractor
shall provide the Superintendent with certification that each item
fabricated conforms to the requirements of the Drawings and the
Specification.
830.33 – 830.40
HOLD POINT
NOT USED
ERECTION
830.41
GENERAL
1.
Where applicable, erection procedures shall comply with the
requirements of AS 3828. The erection sequence assumed in the design
is shown on the Drawings.
2.
Upon completion of erection all temporary bracing shall be
removed and holes plugged and steel made good.
3.
During erection, no steel shall be cut or heated or welded or
drilled. Drifting may only be used for bringing parts into position and not
to match unfair holes or enlarge holes or distort metal.
4.
Permanent bolting of the box girder shall not be carried out
until the correct alignment and level has been obtained including any
pre-camber allowance necessary.
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
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830.42
830.42.01
BOLTED JOINTS
General
1.
Unless otherwise shown on the Drawings, all bolts and nuts
for field joints shall be High Strength Friction Grip Bolts, complying with
AS/NZS 1252 Grade 8.8.
830.42.02
Bolt Installation and Tightening
1.
High Strength Bolts shall be installed and tightened in
accordance with AS 4100 and all bolts shall be installed and tightened in
accordance with procedures detailed in the Drawings.
830.43
CONSTRUCTION TOLERANCES
1.
Measurements of length shall be checked with a standard
steel measuring tape or band corrected to a standard temperature of
20°C.
2.
The Contractor shall allow in the fabrication of the girders for
all weld distortion so that on completion of erection the dimensions of the
fabricated members shall be correct within the tolerances specified in
AS 4100 and in addition shall not exceed the following:
a)
Deviation from flatness and straightness of all
exposed plate surfaces and edges
(or from specified surface in the case of curved
surfaces).
+3 mm in 2 m straight
edge in any direction
b)
Length of beam
+5 mm
c)
Deviation from specified alignment at points of
support
+5 mm
d)
Deviation from specified alignment elsewhere
+10 mm
e)
Deviation from specified profile measured along
edge of box girder
+10 mm
f)
Maximum permitted angular rotation of any crosssection relative to its specified location
0.6
830.44
CALIBRATION AND VALIDATION
1.
The WSP be responsible for the appropriate calibration or
validation of measuring, inspection and testing equipment used for
assessing the quality of the construction. ISO 17662 is to be used as
the guideline document.
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
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830.45
QUALITY RECORDS
1.
All records specified as part of the MDR shall be retained by
the WSP for a minimum period of 5 years.
830.46 – 830.80
NOT USED
AS BUILT AND HANDOVER REQUIREMENTS
830.81 – 830.90
NOT USED
CONTRACT SPECIFIC REQUIREMENTS
830.91 – 830.99
NOT USED
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
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Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
ANNEXURE 830A
STEEL ITEMS SUPPLIED BY PRINCIPAL
Description
Number
Location
Time of Availability
(Weeks after
Commencement of
Contract)
Suppliers’ yard
Fabricators’ yard
(Delete Annexure if not applicable – refer Guidance Notes)
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
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SPECIFICATION 830 GUIDANCE NOTES
DELETE THESE GUIDANCE NOTES FROM FINAL DOCUMENT AFTER USING FOR
REFERENCE
All edits to downloaded TDP documents shall be tracked (most word processing
software allows this to be done automatically). Deletions shall be struck through e.g.
example. Insertions shall be in italics e.g. example. If all information relating to a clause
is deleted then the clause number should be retained and the words "NOT USED"
should be inserted.
The proposed documents with tracked changes shall be submitted to the Project
Manager for review, prior to printing the final batch of documents. When this final
printing is carried out, the tracked changes option is to be turned off.
The Custodian of this specification is the Structures Design and Standards Engineer.
1.
PRINCIPAL SUPPLIED STEEL (Clause 830.91)
1.1
If there are to be Principal Supplied Items, insert Clause 830.91 and
complete Annexure 830A.
1.2
If the Principal is to pre-supply steel:
Annexure 830A is provided for listing Principal supplied items such as pre-supplied
rolled steel beams. The description should include identification with items shown on
the drawings as well as the length and weight and whether items are fabricated with
shear studs, bolt holes etc. or unfabricated. The location may need to be changed to
suit arrangements made.
1.3
Note that the last column in Annexure 830A should be deleted if the
paragraph on timing in Clause 830.91 is included unaltered.
1.4
Clause 830.06 should generally be retained unless the Contract is for
erection only.
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
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CONTRACT SPECIFIC REQUIREMENTS TO ADD OR DELETE
The following clauses are to be placed under the CONTRACT SPECIFIC
REQUIREMENTS as required.
830.91
SUPPLY OF STRUCTURAL STEEL BY THE PRINCIPAL
1.
The Principal shall make available free of charge to the
Contractor structural steel as listed in Annexure 830A.
2.
The Contractor shall provide for all cranage, handling and
loading and a means of transport for the structural steel.
Handling
3.
The structural steel will be available at the commencement of Timing
the Contract.
4.
The Contractor shall supply all other material in accordance
with the Specification necessary for fabricating, connecting and
supporting the structural steel.
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
Associated
Materials
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Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
SPECIFICATION AMENDMENT CHECKLIST
Specification 830 – STRUCTURAL STEELWORK
Revision No: ______
Project Manager: Name: _______________Signature: _____________Date:________
Checked By: Name: _______________Signature: _______________Date:________
Contract No: _______Contract Description: __________________________________
ITEM
SIGN
OFF
All changes/amendments must be shown in Tracked Change mode until
DESCRIPTION
Note:
approved.
Project Manager has reviewed Specification and identified
1.
Additions and Amendments.
CONTRACT SPECIFIC REQUIREMENTS addressed? –
2.
Contract specific materials/products/clauses added? (Refer
Specification Guidance Notes for guidance).
Any unlisted Materials/Products proposed and approved by the
3.
Project Manager? – if “Yes” provide details at 16.
Standard Clauses amended? – MUST SEEK approval from
4.
Manager Commercial.
5.
Clause deletions shown as ‘NOT USED’.
Appropriate INSPECTION & TESTING parameters included in
6.
Spec 201 (Test Methods, Minimum Testing Frequencies
verified).
ANNEXURES completed (Refer Specification Guidance Notes).
7.
HANDOVER and AS BUILT requirements addressed.
8.
Main Roads QS has approved changes to SMM.
9.
Project Manager certifies completed Specification reflects intent
10.
of the design.
Completed Specification – independent verification arranged by
11.
Project Manager
12.
Project Manager’s review completed.
SPECIFICATION GUIDANCE NOTES deleted.
13.
TABLE OF CONTENTS updated.
14.
FOOTER updated with Document No., Contract No. and
15
Contract Name.
Supporting information prepared and submitted to Project
16
Manager.
Further action necessary:
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
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Specification 830 Structural Steelwork – 04/10141 Issued 02/02/2016
Signed:
Document No: Dxx#xxxxx
Contract No: xxxx/xx Contract Name
(Project Manager) Date: _______________
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