QCP No. PR.SKM.

2{B
Rcvision No. 0
[TT. SK METALINDO Date l8 Jlnuery 2019
Page

FABRTCATION PROCEDURE FOR STRUCTURAL

FABRICATION PROCEDURE
FOR STRUCTURAL
PR-SKM-248
REV.O

ffi*,6*aT"",,t &st **," ql4"ra fr-,"1t tdi f."*ty.

Prepared By Reviewed By Approved By Authorized Inspector /
QC. Engineer QC. Supervisor QA/QC Manager PJTI/Customer
 QUALITY CONTROL PROCEDURE
P No. R/SKM/248
-sa<31
Fabrication age I of I3
Procedure for Structura! I

TABLE OF CONTENTS

1.0. GENERAL

1.1. Scope

1.2. References

2.0. MATERIAL

2.1. Materials
2.2. Shape
2.3. Material Inspection & Material Control
2.4. Unit of Measurement
3.0. SHOP DRAWING AND FULL SCALE DRAWING

3.1. Shop Drawing

3.2. Full Size Drawing
3.3. Questionnaires or queries
4.0. SHOP FABRICATION

4.1, Fabrication

4.2. Assembling

4.3. Welding and Repair

5.0. SAFETY

6.0. EXAMINATION, TEST AND INSPECNON

7.0. PAINTING

8.0. DOCUMENT APPENDIX

Appendix 1 : Tolerance for Weld Connection

Appendix 2 : Fabrication Tolerances

 NO. IPR/SKM/}4}
QUALIW CONTROL PROCEDURE QCP
-s7<2L
Fabrication age 2 of 13
Procedure for Structural

1.O. GEt{ERAI.
1.1. Scope
This fabrication procedure shall be applied for fabrication of structural steel work
I .2. Refererrces
- All fabrication work shall be performed in accordance with Owne/s Design
drawing, engineering specification and shall subject to standards listed in the QC
Manual. Any changes from this procedure and matters not contained in this
procedure shall be settled upon the Clienfs approval.
- AWS D1.1. Structural Welding Code - Steel.

2.0 MATERIAL
2.L. Materials
The material shall be selected and acceptable for the purpose of which it is intended
to be used and shall be in accordance with the engineers specificatlon and or /
equivalent under the of Clients Engineers approval. Mill certiflcates shall be submitted
for Clienfls review.
2.2. Shapes
All steels to be used shall be in correct shape and dimension according to
specification and approved drawing without any defects or considerable rust and
perfectly true to thickness throughout the whole length.
2.3. Material Inspection and Material Control
For material inspection and control, refer to Quality Control Manual.

3.O. SHOP DRAWING At{D FULL SIiZE DRAWING

3.1. Shop Drawing :

3.1.1. All required shop drawlngs shall be prepared in accordance wtth client's
Design Drawings and specifications and shall have clients engineer approval
prior to proceed fabrication.
3.2. Full Size Drawings :

3.2.1. Full size work shall be performed using metallic tape of the first grade,
whenever necessary.

3.2.3. In full size wor( layout sheet and metallic scale shall be made for marking,
cutting and assembling in accordance with shop drawings. The layout sheet
shall include edge preparation, scallop, cutting and hole diameter and the
scale shall have descriptions of finishing lines, locations of accessoriet and so
on.
3.2.4. The amount of the shrinkage incurred by the welding heat etc, shall be
reflected on the layout sheet and scale.
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 QCP No. PR/SKM/24B
QUALITY CONTROL PROCEDURE
-sa<*t
Fabrication Page 4 of 13
Procedure for Structural

0 Qualrty of gas cutting shall be as follows :

ITEM ALLOWAALE METHOD OF

LIMTT CORRECTION

Main l4ember Up to lmm deep Upto2mm : G

Notches Morethan2mm:W+G
Sub - Member Up to 2 mm deep UPto3mm : -G
More than 3mm:W+G
Roughness of Main Member Below 100 s
surface

Sub - Member Below 200 s

Note : G-Grinding, w-welding

4.t.4. Bending
In principle, bending shall be done mechanically by cold roll at normal
tempemture.
4.1.5 Prebending
In circumstances whereby it is deem necessary for pre-bending the member
where a substantial shrinkage might occur ; e.g. distortion of flanges caused
by fillet welding, then flanges would be pre-bent by means of cold pressing at
normal temperature.
4.1.6 Drilling
a) Drilling of members shall be drilled accurately in accordance with the
marking.
b) Holes shall be made by drills but punching of the holes shall only be
permitted if the plates thickness is12 mm maximum.
c) All burrs shall be removed by grinding.
d) Holes for bolts shall not be more than 2 mm greater in diameter

e) Hole for anchor bolt shall be 5 mm greater than anchor bolt diameter.

Figure-l
Spacing tohrance of Hol€s MbnEtcfi of Holes
o, hole o, hole l.B
--"----l
I
tr--
p.r."J
tr
Maximum spacing lol€lance of Holes
Cs Imm

c >2 mm
-
lmm < c s 2mm

-
tcCerltble
-
E rrjccbd
to ba aqrdld *ih llamarS
 CP No. R/SKM/248
QUALIW CONTROL PROCEDURE
-sa<*t
Fabrication Page 5ofl3
Procedure for Structural
4.1.7. Machining
If insuuction of machining is given on the design drawings, the applicable
member sfiall be machined in accordance with machining procedure prepared
specifically after close discussion with the owner. In principle, machining shall
be applied only to the single member and done before assembling.
4,1.8. Edge Preparation or Tapering
Edge preparation & tapering shall be executed by means of gas cutting or
machines. In case of occurrence of notch in groove face shall be smooth and
free from dirt, scale, moisture, ect., before applying welding.
4.2. Assembling :

4.2.1. General
a) Prior to assembling, marks of each part, dimensions and bending degree
shall be checked with shop drawing.
b) Plates and components which are to be welded shall be assembled,
aligned and retained in position for welding to ensure that the dimensions
and tolerance specified are maintained during welding and that the
required shape of the ass€mbly is obtained after welding.
c) In assembling, special care shall be taken in order to avoid misalignment
in direction of plate thickness and bending from joint parts due to angular
distortion. Touch face of the parts to be fillet welded shall be brought
into as close contact as practical.
d) Assembling skid shall be strong enough to remain firmed during
fabrication and be kept horizontally.
e) In case whereby the member is required to be tacked welded to the jig, it
shall be carefully gouged and finished smooth by grinding after
completion of fabrication or welding works.
f) Head mark / ID no. of all member shall be marked permanently by hard
stamp / punch stamp.

4.2.2. fack - welding

a) Tack weld shall be done by SMAW low hydrogen electrodes with
diameters 2.6,3.2 or 4,0 mm.
b) Tack welding for thickness plate under or same 6 mm is 30 mm
maximum length and thickness plate over 6 mm should be 40 mm
maximum length.
c) In case any crack should occur in the part where tack welding has been
applied, it shall be gauged up to the bottom of deposited metal and re-
welded. Apply Penetrant Test to ensure the crack completely removed.
d) Tack welding shall be applied to the reverse side of the back - gauged
part as a rule, however should it not be practical for structural reasons,
the alternative method shall be carefully used in consideration that tack
weld should become part of the first pass of weld.
e) Tack welds shall be deemed to be the same quality as the final welds.
f) Tack welders shall be qualified in accordance with AWS-DI.1
 CP No. PR/SKM/248
QUALITY CONTROL PROCEDURE
-s7<*t
Fabrication Page 6ofl3
Procedure for Structura!

4.3. Welding and Repair :

With the exception of the additional note below, all other references with regards to
welding shall be referred to Quality Control Manual.
4.3,1. End-Tab
For butt weld ( all welding processes ) and fillet weld (SAW process only), the
start and end points of the welded parts shall be installed with end - tabs
which is in possession of the same edge preparation shape as that of the
member. End-tabs shall be gas cut and finished by grinder after completion of
welding. Installation of end - tabs is not required if defects in welding can be
prevented.
4.3.2. Repair

BAS E M ETAL
OEFECT TYPE TOLERAT,'CE UMIT RIPAIR PROCESS
Laminations , entrapped shg Defect ln hngh and Completely remove and weld,
or factory inclusion , gas Defect ln depth grind flush, vlsual, NDT
pockets , etc.
Detected before welding or
during NDT Esting
 qCP ruo. PR/SKM/248
QUALITY CONTROL PROCEDURE
-s7<*t
Fabrication Page 7 of 13
Procedure for Structural

WELD METAL
DEFECT TYPE REPAIR PROCESS
Arc strike Crdd6 or blemishes caused by arc strikes shall be grind to a srnooti
contour & checked b eosure soundness, checked by NDT ( MPI or
DP ).
Cracks in rrelds ( Including Asc€rtain extent of crack by MPI , DP or o$er equally pcsitive
tack Yreld and base metal ) means , remove the crack and sound metal by carbon arc gouging
or grinding 50 mm beyond each end and re-weld, revisual & reMPI
or DP.
O/edap and Ej(cgstve Remove excess metal by grinding or carbon arc gouging and re
Convexlty weld.

Excessive Concavlty, C.ate. , Prepare surfaces by grinding or carbon arc gouglng and depcit
undersizes welds, Undercutslng additbnal weld metal
Excessive Weld Poro6ity, Remove Unacceptable portion by grinding oI carbon arc gouging
Excessive Slag Inclusion and and re-weld, re-vbual, re-NDT
Incomplete fusion

Note : Any re-weld or additional weld shall use original WPS

4.3.3. Straightening of distortion

a) Distortion generated during fabrication shall be straightened at room
temperatures or by heating ( Spot heating, linear heating )

b) The temperature at which distortion is straightened by heating shall be in

accordance with the following standards ( Refer to AWS D1.1
Paragraph 8.5.5 ) :
- When heat straightenang method are used, the maximum temperature
of heated areas shall not exceed 650 oC.
- Accelerated cooling of steel above 315 oC shall be prohibited.

5.0. SAFETY
5.1. Safety shall be strictly observed at all time during fabrication process, especially for
lifting, welding and cutting.
5,2. Close visual inspection for the lifting equipment and accessories, grinding / welding
machine and connection the LPG hose.
5.3. Extreme case shall be taken and I or removed from the fabrication area.
5.4. Tool box meeting to be conducted prior to started the job every day.

6.0. EXAMIilATION , TEST AND II{SPECTION

6.1. Material's
a. All raw material's shall be backed up by and conform to their relevant mill
ceftificates and standard specification.
 QUALITY CONTROL PROCEDURE
P No. R/SKM/248
-sa<*1
Fabrication a9e 8 of 13
Procedure for Structural

b. Compare the mill certificate to marking on raw material's prior cutting execution.
if
In case the material's doubt. may be the material's should be tested
mechanically.
6.2. Welding
a. Generally all wdding works shall conform to American weldirg Society AWS
D1.1, and design requirements including but not limited to where explicitly
specified otherwise.
b. For welding tolerances of steel structure, refer to appendix 1.
c. All spatter deposit and slag shall should be removed completely from the whole
of the weld surface area, except some tightly adhering spatter is allowed,
d. Non-Destructive test should be performed accordance to the Project
specification

6.3. Dimensional
a. Dimensional checks shall be conducted at stages before, during and after the
manufacturing process.
b. For dirn€nsional tolerances of steel structure, refier to appendix 2.

7.O. PAIilTING
Refer to Painting Procedure

8.0. DOCUMENTAPPENDIX
Appendix 1 : Tolerance for Weld Connection
Appendix 2 : Fabrication Tolerance
 PNo R/SKM/248
QUALITY CONTROL PROCEDURE
-s7<*1
Fabrication Page 9 of 13
Procedure for Structural

APPENDIX - 1
TOLERANCE FOR WEID CONNECTION

ITEM FTGIJRE TOLERANCE

1. Gap of fillet welding 2mm

The size should be increased by

_rd
I

2. Gap oflap joints 2mm

The size should be increased by
r----------l___l n
I

3. Gap ofthe backing lmm

strip -lA
-l
.

4. The plate at the butt 1.5 mm for t 15 mm

weldingjoint 2mm for> 15 mm to 30 rm
i 3mm for t> 30 mm
_lA
"t" is the thickness ofthe material with
-l the smaller thickness .

5. Root gap back Manual arc welding 0 < 4mm

chipping Submerged arc welding 0 < Imm
Gas shielded arc semi automatic welding
0< 3mm
Non gas shielded arc semi automatic
welding 0 < 3mm

6. Root gap
Submerged arc welding 0 I mm
( with backing strip ) Manual arc welding , gas shielded arc
semi automatic welding , non gas scaled
arc semi automatic welding
-.1 L 0 2mm
A
 QUALITY CONTROL PROCEDURE
CP No. PR/SKM/248
-sa<*t
Fabrication age I0 of 13
Procedure for Structural I'

ITEM FIGLIRE TOLERANCE

7. Root face Non gas shielded arc s€mi automatic

welding , manual arc welding , gas
shielded arc semi automatic welding .

With back strip

-2 lrnm
Without back strip
-2 2mm
Submerged arc welding
I lmm

8. lncluded angle o +t0

c ,a
(I -0

c{ c{

9. Minimum filla ri Min : Refer to Table 5.8 Clause

weldingsize(L) 5.14 AWSDl.l - 2006
Note :

L:teg t ength (I
e: Convexity of filla
welding size

l0 . Maximum convexity of W 5/16" (8 mm),

the fillet welding
(w)
Max e = l/16" (2 mm)
(e)
Note
W 5/16" (8 nnn) to l" (25 mm),
:
(r) Max e = 1/8" (3 mm)
L:Irg t ength
W = Width of weld W l" (25 mm),
face or individual Max e = 3/16" (5 mm)
surface bead

I l. reinforcement ofthe Max +3 mm

butt welding (e)
--e
 QUALITY CONTROL PROCEDURE CP No. PR/SKM/248
-sa<*t
Fabrication I

1lof13
iP age
Procedure for Structural I

TTEM FIGURE TOLERANCE

12. Undercut t< 25.4 (e= 1mmany lengh )

(e : 2 mm accumulaled length
of 50 mm in any 305 mm
length )

t 25.4 ( e = 2 mm any length )

13. Unevenness ofbead el<2.5mm(L25mm)

(el, e2) .' e2<5mm(Ll50mm)
:*

l ,l
 QUALITY CONTROL PROCEDURE QCP No. PR/SKM/248
-s7<*1
Fabrication
Procedure for Structural
Page l2ofl3

APPENDIX -2
FABRICATION TOTERANCE

ITEM FIGURES TOLERANCE

I Distance from erd or Lt L2 L1 orL2:*2.0mm

connection bolts hole
to gusset plate II III
( 11, 12)
p].at€

2 Distance from end or C€n!.. linc Bolstcr LlorL2:+2.0mm

connection bolts hole lt__ I
to bolster r
( 11, 12) LI L2

3 Bolster I t S.t bolt H:+1.5mm

(H, L, I) L : + 2.0mm
| :+1.0mm

4. Perpendicularity of eM e1 : + D/100 and 2 mm or

plate to beam (e1), aZ less
and flatness of end
phte (e2)
e2 : max. 0.5 mm
unevenness

5. Distance from center l:+1.5mm

of the member to
center of the bolt hole
of gusset plate ( I ) E
I

6. Beam length (L) L:t3mm

L
 QUALITY CONTROL PROCEDURE
CP No. PR/SKM/248
-s7<*1
Fabrication Page l3ofl3
Procedure for Structural

ITEM FIGURES TOLERANCE

7. EendirE or defiection For beam : 1/1000 and 'e' is

(e/L) max.+10mm,-0mm
L For cdumn : 1/1500 and 'e'
ismax.+5mm,-0mm

8. Angle at column to
1/300, or e1 and e2
beam connection L
( el/L e2ll ) : 3 mm or less
.l
I (El.1.tic{)

9. Floor hight column H :+3mm

length ( Hl, H2, H )
Lll
L2 H1,H2:+3mm
Project length of
11, 12: +3mm
bracket ( 11, L2 ) LI

10. Center to center E1,e2:+3mm

disEnce of andpr bolt
hde ( el, e2 ) -t: I
!
'----T----_

I l. Perpendicularity of El, e2 : + D/100, d1100

base plate to column
center line ( el, e2 ) 900 EI I ard 3 mm or less

I
It

12. Center to center PI P1 :+1mm

distance of bolt holes P2:*2mm
( Pl, P2)

Y2