Chapter 13.

Steel Fabrication Work

Chapter 13 Steel Fabrication Work

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Chapter 13. Steel Fabrication Work

Table of Contents

1. Generals
2. Materials
2.1. Steel
2.2. Bolts/Nuts
2.3. High-Tension Bolts
2.4. Weld Rods
3. Transportation, Arrangement, and Storage of Materials
4. Preparing Shop Drawings
5. Shop Drawing Inspection
6. Preparing Full-Size Drawings and Molding
7. Inspection of Full-Size Drawings
8. Steel Fabrication
9. Steel Fabrication Inspection
10. Welding
11. Welding Inspection
12. Welding Correction
13. Assembly
14. Assembly Inspection
15. Inspection of Finished Steel Structure
16. Correction of Finished Steel Structure
17. Temporary Assembly
18. Painting
19.Transportation and Field Storage of Steel Structure

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1. Generals
1.1. Start of Construction
(1) In Steel Fabrication Work shall comply with the applicable codes of the JIS & ASTM or equivalent. Other
materials or products shall be approved by the supervisor.
(2) The construction should be started within 3 days from the date of the contract and all administrative
documents required by the responsible person such as construction plans, fabrication plans, fabrication
schedules, field supervisor appointment, and other documents should be submitted.

1.2. Submission of Planning Report of Steel Fabrication Work

The contractor should submit the responsible person the planning report of steel fabrication working in
accordance with relevant drawings upon the start of fabrication.
(1) Shop Drawing Preparation Planning
(2) Full-Size Drawing Planning
(3) Cutting and Welding Mechanics Input Planning
(4) Equipment Arrangement Planning
(5) Machining Location Planning
(6) Quality Control Items and Implementation Planning (for Each Process)
A. Column
B. Crane Girder
C. Roof Truss
D. Eave Girder
E. Roof Girder
F. Wind Girder
G. Others

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(7) Transportation Planning including Marking on Materials (Sub-Materials) and Weight

(8) Temporary and Main Assembly Planning
(9) Welding
A. Improvement Guidelines
B. Welding Guidelines
C. Inspection Guidelines

1.3. Preparing Shop Drawings: The maker should prepare shop drawings in accordance with design
drawings and in the order of work priority, which should not interrupt the following construction and
be subject to the inspection by the responsible person.
1.4. Steel fabrication and assembly for this construction should be performed in accordance with
drawings and others not specified in this specification shall conform to the relevant standards of the
Ministry of Construction and Transportation.
1.5. Construction Status Report: The fabricators should make verbal and/or written report on overall
construction status required by the responsible person such as daily work status, manpower input
status, machinery and tool operational status, construction records, abnormal situations during
construction, and receipt of materials supplied by the company.
1.6. Photo Records: Photo records of steel fabrication should be made for each process, and especially
for the machining of important parts, photo records should be prepared in triplicate to submit to the
responsible person.
1.7. Company-Supplied Materials Management: The contractor should submit the lists of companysupplied materials required for the construction along with sub-material lists to the responsible
person within 7 days before use and manage these materials thoroughly to prevent deformation or
damage when it stacks them for storage, and shall be responsible for all managerial problems in
relation to the supplied materials.

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1.8. Quality Control Tests: Materials procured by the contractor should be tested in accordance with the
quality control test standards of the Company, and the results shall be submitted to the responsible
person.
1.9. Responsibility for Safety Accident: Safety measures should be established and managed to prevent
unexpected accidents during main construction, any accident should be immediately report to the
responsible person of the worksite, and the contractor shall be responsible for all safety accidents.
1.10. Steel fabrication: The contactor should prepare shop drawings for the approval from the responsible
person and then perform cutting and steel fabrication, and any materials in shortage shall be
procured in the contactors expense for re-machining.
1.11. Inspection: The responsible person and the inspector shall perform inspection and let failure items
re-inspected after correction and steel re-fabrication.
1.12. Painting: Remove rust and/or foreign materials from the items completed for inspection through shot
blasting, and then immediately apply antirust paint on them once.
1.13. Transportation of Finished Steel Structure to Field for Erection: Transport the machined materials in
the order of steel frame erection process to the erection field after the confirmation of the
responsible person on the entire marking lists, inspection sheets, and weight and packing lists.
Finished Steel Structure Transportation: Loading and unloading the machined materials shall be
conducted by contract, and the contractor shall be responsible for all defects such as deformation
and damage that occur during the period from machining shops to the completion of unloading and
should correct the defects or make compensation in the contractors expense.
1.14. Section Steel Fabrication: When section steel fabrication is necessary, do it in such a way that the
section steel can withstand various stresses just like the original materials (H-Beams, CT Bards,
etc.).

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1.15. Surplus Material Treatment: When the difference between the weight (gross) of materials for steel
fabrication and the weight (net) of finished materials is within 10% (7%, 5%) of the weight of the
product, 70% of the difference shall be deducted from the contact value based on the market scrap
unit price, and the surplus amount shall be deducted from the contract value when it exceeds 10%
(12%, 15%).
1.16. Non-destructive test and X-ray test for deposition inspection on welded parts shall be performed on
the positions designated by the responsible person, and the following process shall be progressed
after the approval from the responsible person.
1.17. The contractor shall be wholly responsible for any defects such as contact of factory-machined
product with other materials, excess tolerance of bolt holes, and other defects in assembly, and/or
trouble in construction schedule thereby during steel frame erection at the field.
1.18. Oxygen: Oxygen shall be priced based on the contract price for each area.
1.19. Others
Costs for normal temporary assembly, test, and inspection are included in indirect expenses.

2. Materials
2.1. Steel Materials: Steel materials to be used for the construction conform to the below specifications in
accordance with design drawings and a straight figure without any defect or serious rust.
(1) Rolled Steel for Normal Structures ( JIS G 3101 or equivalent.)
Class
1
2

Material
SS 330
SS 400

SS 490

SS 540

Applications
Steel Plates, Flat Steel, Steel Round Bars, and Steel Strips
Steel Plates, Steel Strips, Section Steel, Steel Round Bars, and Flat Steel
Steel Plates, Steel Strips, Flat Steel, and Section Steel with Thickness of 40
mm or Less.
Steel Round Bars of Which Diameter, Side, or Distance to Opposite Side is 40
mm or Less.

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(2) Rolled Steel for Weld Structures ( JIS G 3106 or equivalent.)

Class

Material

Class

SM 520B

SM 520C

Steel Plates, Steel Strips, Flat Steel, and Section Steel with
Thickness of 200 mm or Less
Steel Plates, Steel Strips, and Section Steel with Thickness of 100
mm or Less

Material
SM 490A
(SWS490A)
SM 490B
(SWS490B)
SM 490C
(SWS490C)
SM 490YA
SM 490YB

SM 400A
(SWS400A)
SM 400B
(SWS400B)
SM 400C
(SWS400C)

Applications

SM 570

Applications
Steel Plates, Steel Strips, Flat Steel, and Section Steel with
Thickness of 200 mm or Less
Steel Plates, Steel Strips, and Section Steel with Thickness of 100
mm or Less
Steel Plates, Steel Strips, Flat Steel, and Section Steel with
Thickness of 100 mm or Less
Steel Plates, Steel Strips, Flat Steel, and Section Steel with
Thickness of 100 mm or Less
Steel Plates, Steel Strips, and Section Steel with Thickness of 100
mm or Less
Steel Plates, Steel Strips, and Section Steel with Thickness of 100
mm or Less

(3) TMCP Steel

A. TMCP technology allows saving the amount of steel materials with decrease in the section area of
materials and using steel materials without reduction of standard design strength unlike JIS G 3106 or
equivalent. TMCP steel not only provides excellent heat-resistance property but also improves strength,
tensile strength, and weldability.

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B. According to a sample test performed in cooperation between POSCO Quality Control Department and Korea
Research Council for Industrial Science & Technology (KOCI), TMCP steel with thickness of 40 mm or
greater does not require a decrease in the standard strength as shown in Table 1 unlike normal steel and
thus enables around 10% of reduction in steel materials consumption compared to normal steel materials.
C. Since it is a steel manufacturing process, it is required to prepare a promotion plan for standardization after
obtaining the approval form the Minister of Construction & Transportation (In Japan, TMCP steel for
construction structures will be standardized by JIS).

Table 1. Comparison of Standard Strength for Design between Normal Steel and TMCP Steel
Category
Standard
Strength for
Design
Fy(kg/)

Thickness
()
40 or Less
40-100

TS 50 Kg Class
Normal Steel

(SM490B)
(PILACW33A)
3,300
3,000
3,300

2/1

1.10

TS 53 Kg Class
Normal Steel

(SM490B)
(PILACW33A)
3,600
3,400
3,600
1.06

2.2. Bolts/Nuts
Refer to Section 3 of Chapter 10 Metallic Materials and Miscellaneous Works in KRAKATAU POSCO Standard
Construction Specifications.

2.3. High-Tension Bolts

Refer to Section 3 of Chapter 10 Metallic Materials and Miscellaneous Works in KRAKATAU POSCO Standard
Construction Specifications.

2.4. Weld Rods

(1) Weld Rods for Manual Welding
Select appropriate weld rods in consideration of the properties and use of the mother materials from the
table below.

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Mother Material

Covering Material
Ilmenite Type
Lime Titania Type

Ductile Steel

High Cellulose Type

High Titanium Oxide
Type

Applications
Normal Structures
Thin Plates, Temporary
Welding
Thin Plates, Steel Pipes

Low Hydrogen Type

Low Hydrogen Type

Flat Welding
Vertical Welding
All Positions
All Positions

Thin Plates, Cosmetic

Welding
Thick Plates, Cosmetic
Welding
High-Tension Steel (50 KG)
High-Tension Steel (55 KG)

Low Hydrogen Type

All Positions

High-Tension Steel (60 KG)

Low Hydrogen Type

High-Tension
Steel

Position
All Positions
Flat Welding
Vertical Welding
Flat Welding
Overhead Welding
All Positions

(2) Weld Rods for Automatic Welding

Weld rods for automatic welding shall conform to the welding regulations of KASS 6 for domestic products.
Type of Mother Material

Rimmed
Steel

Killed Steel
Semi-Killed
Steel

Applications

Thickness

Flux

Remarks

Steel
Plates

SS400
SM400 (Rolled Steel for
Welded Structures)

6 m/m or Less
6 ~ 25m/m

GR50
GR50

NO.36,29
NO.43,36

Steel
Pipes

Piping (Pressurized Piping)

25m/m or Greater
Multi-Layer Welding

GR58
GR50

NO.36
NO.43

Steel
Pipes

Section Steel Fabrication

Pressurized Piping
Mechanical Structures

6 m/m or Less
6 m/m or Greater
Multi-Layer Welding

GR50
GR20
GR50

NO.36,29
NO.36,29
NO.36

SM 490
Normal Structures, Welded
Structures

6 m/m or Less MultiLayer Welding

GR585
GR38

NO.36

High-Tension
Steel

3. Transportation, Arrangement, and Storage of Materials

3.1. Introduction
Since deformation of materials during transportation and storage may interrupt the production of high-quality
products, always pay attention to loading and unloading to prevent any deformation and do not try to transport
unnecessarily long materials.

3.2. Limitation to Length of Materials: In Complex: 17 m or Less, Other Districts: 12 m or Less, Height: 3.5
m or Less

3.3. Transportation: The length of a projected material from the edge of the loading bay should be within 1
m to prevent material deformation during loading, unloading, and transportation. In the event of a

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unavoidable situation (length of 13 m or greater), use an auxiliary trailer for transportation and install
support timbers (95 mm x 90 mm) every 90 cm to prevent deformation.
3.4. Arrangement and Storage
(1) Arrange and store materials by figure (material and thickness for steel plates, section figure for section steel)
and identify different kinds of materials with symbols or colors to prevent confusion during machining.
(2) Place materials on support timbers to prevent contact with the ground and have the interval between the
timbers within 90 cm to prevent damage of materials by foreign materials such as corrosive materials, dirt,
and/or oil.

4. Preparing Shop Drawings

4.1. General
Prepare shop drawings such as reference drawings, detail drawings, and exploded drawings to understand the
dimensions, shapes, quantity, etc. of materials required for steel frame manufacturing, and obtain the approval
from the responsible person and inspectors before the start of machining.
(1) Kinds and Scales of Shop Drawings
Reference Drawings: 1/100 ~ 1/200
Structural Drawings: 1/100 ~ 1/200
Detail Drawings: 1/10 ~ 1/30 (Columns, Beams, Others)
Exploded Drawings: Component diagrams indicating the arrangement of various accessorial steel
components

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4.2. Reference Drawings: Indicate basic dimensions of the building (columns, spacing, beams, floor
height, etc.), standards for connections, and interaction with other constructions.
4.3. Detail Drawings: Indicate the shapes, dimensions, hole locations of all materials and joint figures and
quantity of gusset plates, etc.
4.4. Exploded Drawings: Necessary for steel frame erection at the worksite. Prepare exploded drawings
with entry of material numbers for each process agreed with the responsible person of the worksite
to prevent an error during steel frame erection.

5. Shop Drawing Inspection

Obtain the inspection approval from the responsible person for the finished shop drawings before preparing full-size
drawings, and make corrections when the responsible person points out any error and obtain the approval for the
corrections before preparing full-size drawings.

5.1. Review the kinds and scales of shop drawings.

5.2. Inspect the material, size, length of materials, and various dimensions of the roof, and review the
availability of erection construction.
5.3. Inspect the material, size, length, factors, and pitches of bolts.
5.4. Review layouts and detail drawings of penetrated sections.
5.5. Review the spacing of purlin and girth.
5.6. Review and confirm joint locations in consideration of weight, transportation, and erection equipment.
5.7. Inspect the figure, length, and methods of welding.
5.8. Review the locational relationship among various finishing equipment and temporary facilities.

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6. Preparing Full-Size Drawings and Molding

6.1. Prepare full-size drawings based on the shop drawings with markings of dimensions for cutting, hole
punching, steel fabrication, and assembling of steel materials, and obtain the approval for the fullsized drawings.
6.2. Fabricate holes, gusset plates, and stiffeners through molding by the full-size drawings.
6.3. For solid structures, manufacture main structures by making mockups. The scale for molding shall be
1:5 or greater.

7. Inspection of Full-Size Drawings

7.1. Inspection Methods
Inspection of full-size drawings shall be determined by the scale of the building and processes, and should be
thoroughly performed for the entire processes.
(1) Inspection shall be made based on basic dimensions and marginal error shall be within 1 mm.
(2) Check working points of joints of steel frames.
(3) Review and check the position and dimensions of each steel material, distances from the center of each
column to each side, and distances from the top to the bottom of each beam (stiffeners, tie plate, and base
plate).
(4) Clearance
Check the edges of the roof, flange surface of each beam, tie plates, flange surface of each column, and
beam flanges for clearance.
(5) Check the position of anchor bolts, pitch gauge, and bolt diameter.
(6) Inspect steel strips, section steel, and reference forms.

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(7) Inspect joints at divisions of roof and wall purlins.
(8) Comparison of Steel Tapes: Compare steel tapes with field scales of POSCO. The difference shall be within
1/5,000 per 50 m with 10 kg of tension.
(9) Perform inspection with models and obtain approval.
(10) Check if there is any contact or interference with areas to be remodeled or existing buildings.

8. Steel Fabrication
8.1. Cautions for Steel Fabrication
The responsible person shall take necessary actions after reviewing the followings in advance:
(1) Performance of steel fabrication, production capacity, and amount of contracted projects
(2) Equipment and facilities for steel fabrication, template shop for preparing full-size drawings
(3) Level of fabrication technologies and field work management
(4) Welding technologies, qualified welding technicians, welding equipment, and testing equipment
(5) Product transportation conditions
(6) Overall management system for steel machining

8.2. Steel Fabrication Standards for Steel Tape

(1) Steel tapes to be used for this construction shall conform to JIS Regulations.
(2) Tape comparison shall be made between tapes for field works and those for full-size drawing works, and the
tapes for field works shall be standard.
(3) When you compare tapes, record error every 1 m from 0 to 15 m and every 5 m from 15 m to 50 m.

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(4) Keep the records along with the date, month, year of comparison, weather, humidity, tension, tape number,
etc.
(5) Error shall be measured with 10 kg of tape tension. (Within 1/5000 per 50 m)

8.3. Material Correction: Use mechanical methods such as rollers, press machines, or benders for steel
material correction, and be careful not to give damage to the materials.
8.4. Steel Material Identification: Perform investigation on materials by location to use in accordance with
the specifications and identify those with different materials by symbol and color.
8.5. Marking-Off
(1) Check the material before marking-off and correct deformation areas of the materials, and then carry out
marking-off using a die plate and tools. The number of times to use a die plate shall be within 20.
(2) Machining methods and assembly guidelines should be fully considered for marking-off to prevent an error.
(3) Regular and other measuring devices for marking-off must be inspected to prevent an error.
(4) Marking-off must be applied to the center line or joint areas on cut out surfaces of the die plate (mockup
plate).
(5) Do not use files, drills, or center punches on the outer surface of steel plates and steel materials of SM 490
or higher for bending.
(6) Since welded structures are subject to contraction, marking-off should be performed after welding.
(7) Take inspection from the responsible person and the inspector for marking on important parts after
completion.

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8.6. Cutting
(1) Steel cutting should be performed by the optimum methods including mechanical cutting, gas cutting, and
plasma cutting in consideration of shape and dimensions. The squareness to the axial line of finished
surface shall be within 1.5/1000.
(2) Manual cutting is not allowed except for minor construction.
(3) If there are teeth marks, cutting marks, wave patterns, or slag attachments on cut surfaces, remove them
with a grinder.
(4) Steel cutting dimensions should consider deformation by contraction and finishing.
(5) The precision degree of gas cut surfaces shall be within 100 Ry and notch depth shall be 1 mm or less.
(6) Devices used for cutting are as follows:
Kinds of Steel

Applicable Devices

Angle Steel (t 10)

Die Plate

Angle Steel (t 10)

Angular Cutter

Section Steel
Steel Plate (t 10)
Steel Plate (t 10)

Temporary Plate (Circular Band), Automatic

Gas Cutter
Automatic Gas Cutter
Shearing machines are used in combination.
Gas cutting is principle method for welding.

8.7. Bending
(1) Cold working and hot working methods shall be used for bending. Hot working should not be performed in
blue brittleness state (200 ~ 400) but in red heat state (800 ~ 900). In addition, the temperature
condition shall be in accordance with 8.8 Deformation Correction Standards.
(2) The radius of inner bending in cold working shall be in accordance with the table below:
Table - Radius of Inner Bending in Cold Bending (Refer to the specifications of the Ministry of Construction &
Transportation)

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8.8. Correction of Deformation

(1) In case deformation that has occurred during machining does not guarantee precision of the specified
product, the deformations should be corrected by cold working or hot working (spot heating or line heating)
to prevent damage on the material.
(2) For correction with cold working, use a press or a roller.
(3) For correction with hot working, the temperature should be in accordance with the followings:
Air cooling after heating: 850 ~ 900
Immediate water cooling after heating: 600 ~ 650
Water cooling after air cooling: 850 ~ 900 (The starting temperature for water cooling should be 650 or
lower)

8.9. Friction Surface Treatment

(1) Since friction surfaces require 0.45 or greater slip coefficient and cleanness for fastening, clean surface
should be secured for fastening. If painting is required on a friction surface, however, use zinc primer.
(2) Since mill scales, dust, oil, and paint seriously deteriorate friction force, remove them during steel frame
fabrication or before assembly considering the duration of rust inhibitor.
(3) For base materials, use a flat grinder to remove mill scales around holes for the area, of which diameter
should be twice the diameter of the washers. For splice plates, remove mill scales on the entire surfaces
using a wire brush. If the standard friction surface treatment of the fabrication shop is different from the
above, consult with the inspector and follow his/her instruction.
(4) Inspection of friction surfaces shall be made visually by the product inspector before fastening. If the
performance of the fabrication shop is not sufficient, slip test shall be performed according to the inspectors
instruction for inspection.

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8.10. Hole Punching

(1) Hole punching shall be performed after welding for welded structures.
(2) Use a punching machine for holes with diameter of 13 mm or less and a drill for holes with diameter over 13
mm.
(3) Make rough areas around the holes to punch smooth with a grinder.
(4) The diameter of holes to the diameter of bolts and rivets shall be in accordance with Clause 64 of Standards
for Building Structures.
(5) Hole sizes for anchor bolts are as follows:
Kinds of Bolt
Anchor Bolt (Main
Column)
Anchor Bolt (SubColumn)

Bolt Diameter

Hole Diameter

38 - 80

Bolt Diameter + 9.0

19 - 25

Bolt Diameter + 5.0

8.11. Beveling
Beveling on welded surfaces shall be performed basically with a gas cutting machine. Gouging method may be
used.

8.12. Water-Pressurized Surface

(1) Finish columns, base plates, and column joints evenly with a rotary planar.
(2) Water-pressurized parts should be closely adhered by grinding.
(3) In case of metal touch, joint of columns shall be performed by plasticity in accordance with instructions from
the responsible person. (Plasticity can be omitted according to cutting conditions)
Mechanical Finish: 0.5 , Grinding Finish: 1.0

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9. Steel Fabrication Inspection

9.1. Introduction
Steel fabrication inspection shall be performed for cutting state, finish, shape, and dimensions of various section
plates before main welding, and correction should be made before temporary assembly.
(1) Inspection of Section Steel: Make inspection on cutting state, dimensions of angles and channels, size and
location of bolt holes, deformation, and defects.
(2) Inspection of Gusset Plates, Ribs, and Stiffeners: Make inspection on the state, shape, size and number of
cut surfaces, plate deformation, location of bolt holes, bolt pitch, size and number of holes, and finish of
friction surface.
(3) Inspection of Fabricated Section Steel (WH, WT): Make inspection on deformation of cut materials, size,
improvement state of parts to be welded, number of bolt holes, and finish state.
(4) Inspection of Bending:
Make visual inspection on material damage and deformation by tension.
(5) Inspection of Steel Members Requiring Camber: For fabrication of steel members with camber such as
crane girders and trusses, make precise inspection on the shape, dimensions, and size in advance to
prevent camber steel fabrication.

10. Welding
10.1. General
Welding is a method to assemble a product according to design drawings, and requires full understanding of
shop drawings and works including a variety of knowledge in the selection weld rods, shape of joint, safety rules
for welding, inspection and treatment after welding to complete construction in schedule.

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10.2. Welding Leader

A qualified person having a variety knowledge about welding; always attends welding worksites during welding.

10.3. Welding Workers

Workers with welding technician certificate (Class 1 or Class 2) who have passed a technical evaluation test.
The work ranges are as to Table 9-4.
Table 9-4
Category of Specialty

Object Materials

Thickness of Base Materials (Unit: m/m)

Thin Plate

Steel Plate

6.0 or Less

Medium Plate

Steel Plate

4.5 - 25.0

Thick Plate

Steel Plate

16 or Greater

Thin & Thick Plate

Steel Plate

6.0 or Less, Steel Plate 400 or Less

Medium & Thick Plate

Steel Plate

4.5, 20.0 or Less, Steel Plate 400 or Less

10.4. Kinds of Welding

Welding methods are shown in the chart below. Follow the responsible persons instruction unless otherwise
specified in design drawings.
Electro Slag Welding

SMAW
Welding

Submerged Arc Welding

Consumable
Electrode

Inert Gas Metal Armor Welding

(W/G)
Carbonic Gas Arc
Welding

Non-Gas Arc Welding

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Arc
Welding

Spot Welding
NonConsuma
ble
Electrode

Tungsten Inert Gas Welding (TIG)

Atomic Hydrogen Welding
Carbon Arc Welding

Oxyhydrogen Welding
Gas
Welding

Oxy-Acetylene Welding
Air-Acetylene Welding
Spot Welding

Gas Pressure
Welding
Pressure
Welding

Electric
Resistance
Welding

Dual
Welding

Spot Welding
Projection Welding

Butt
Welding

Forge Welding

Upset Welding
Flash Welding
Tend Seam Welding

(1) Welding methods in the box of the chart above are widely used for steel frame construction.
(2) Gas welding can be used only for steel materials with thickness from 2.3 mm to 4 mm.

10.5. Essential Features of Welding Machine

(1) Simple structure; Easy operation.
(2) No high-voltage; Perfect insulation; No danger.
(3) Easy and precise to control welding current; Stable current during welding.
(4) Easy to generate and maintain arc. Current flow in a short time should not be great.

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(5) Temperature increase in use should be small.
(6) Excellent efficiency and power factor.

10.6. Preparations for Welding

(1) Fully understand shop drawings and review the descriptions of works completely.
(2) Check materials to use and study mechanical properties, weldability, and deformation of base material after
welding.
(3) Select appropriate weld rods for welding materials and pay attention to the followings:
A. Consider whether the strength of welding metal satisfy the designers intention: mechanical strength,
performance in high and low temperature, and corrosion resistance.
B. Think about usability and economical efficiency, and select appropriate weld rods since the thickness and
materials to use can vary by structure.
(4) Understand weld joint and groove.
(5) Check whether welding machines and other devices are ready.
(6) Determine welding current, welding order, and welding conditions in advance.
(7) Check if there is paint, oil, or plating in grooves.
(8) Review the necessity of pre-heating and post-heating.
(9) For multi-layer welding, remove slag or spatter after every pass decision and inspect for any defect before
welding.
(10) Use tools for the concentration of main steel members and find a concentration method that allows no
useless residual stress on welded areas by constraint.

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10.7. Welding Postures

Use rotational tools and inspection tools for welding, and basically avoid overhead welding.
(1) Welding Direction
A. Flat Welding Posture: Either direction (forward, backward, left, or right) is OK, but changing the position
(forward, backward, left, and right) of base material during welding should be avoided.
B. Vertical Welding Posture: Either direction (upward or downward) is OK, but changing position (up and
down) of the base material during welding should be avoided.
C. Horizontal and Overhead Welding Postures: Either direction (left or right) is OK, but changing position
(left and right) of the base material during welding should be avoided.
D. Welding of Fixed Pipes: Changing the position of the material during welding should be avoided except
the case of changing horizontal position to vertical position. It is allowed to change a fixed position
(horizontal or vertical) for each layer, but changing up and down or front and rear of a vertically or
horizontally fixed position.

10.8. Selection of Weld Rods

Select weld rods according to the shape of welded joint, material, and welding posture, and based on the
determination of welding current.

10.9. Welding
(1) Basically perform shop welding inside a house and ensure that welding is not affected by wind, snow, and/or
rain for outside welding.
(2) Stop welding when temperature is 0 or less.

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10.10. Cautions for Welding

10.10.1. Since the starting and ending points of weld beads tend to be incomplete, avoid ends, edges, and
corners.
10.10.2 Keep arc depth constant and select proper welding current, welding speed, welding rod control, and
angle of weld rods.
10.10.3. Check if bead formation is sufficient and pay attention to even minor works such as cutting out the first
layer of the front of beads and chipping off the backside to obtain complete welding.

10.11. Kinds of Welding

(1) Butt Welding: It is the principle to apply complete penetration to butt welding.
A. Minimum reinforcement attachment is required for butt welding unless otherwise instructed. The height of
reinforcement attachment shall be within 3 mm for manual welding and 4 mm for submerged automatic
arc welding and semi-automatic welding.
B. Reinforcement attachment does not require finish unless it does not intervene.
C. For welding on both sides, perform welding on the backside after back chipping. Back chipping shall be
performed with arc gouging or air brushing and the depth shall be determined in such a way that the first
layer is removed and deposited metal completely appears.
D. When complete penetration has been obtained by automatic submerged arc welding, back chipping is not
required.
E. In case of welding from the groove side using backing strips, check root clearance and groove angle with
special attention to welding of the first layer, and ensure that sufficient penetration is obtained for the
backing strips.

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F. When the height of base materials are different each other for butt welding, the gradient for plasticity shall
be 1/5. Plasticization is not required when the difference in surface height is 4 mm or less for manual and
semi-automatic welding and 3 mm or less for automatic welding.
(2) Fillet Welding
A. Have the sub-material as closely as possible to the mother materials when doing fillet welding.
B. Embossing of equiangular fillet welding should have no significant difference.
C. The length of intermittent welding shall be the effective dimension plus a value more than twice the fillet
size.
D. The height of reinforcement attachment for fillet shall be within 0.1 S 1 (S is a designated size).
(3) Edge Welding
Edge welding is to weld two or more mother materials on the section by affixing them in parallel. The neck
should be parallel with the mother materials.
(4) Plug Welding
Plug welding is a welding method to join two mother materials by making holes on the mother materials
extended to the surfaces and filling deposited metal in the holes.

10.12. Pre-Heating
Pre-heating shall be performed in accordance with below based on the kind of steel and the thickness of the
plate when required.

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(1) Use a proper gas burner for pre-heating.
(2) Pre-heating shall be applied to materials with a high content of carbon in case of low temperature, high
constraint, and thick plate.

Table 10-16
Main Welding
Steel

Conditions

SM 400
SS 400

SM 490

A. Temperature of worksite is
5 or lower
B. Great Constraint
C. Plate thickness is 25 or
greater
A. Temperature of worksite is
10 or lower
B. Great Constraint
C. Plate thickness is between
25 m/m and less than 38
m/m
Plate thickness is 38 m/m or
greater

Pre-heating
Temperature

50 or Higher

50 or Higher

100 or Higher

Temporary Welding
Pre-heating
Conditions
Temperature
A. Temperature of worksite
is 5 or lower
B. Great Constraint
50 or Higher
C. Plate thickness is 25
or greater
A. Temperature of worksite
is 10 or lower
B. Great Constraint
50 or Higher
C. Plate thickness is
between 19 m/m and
less than 32 m/m
Plate thickness is 38 m/m
100 or Higher
or greater

10.13. Tack Welding

(1) Tack Welding Guidelines
A. Remove moisture, paint, and oil on the welded areas by gas type.
B. Remove rust on the welded areas with a grinder and/or a brush.
C. Remove rust, moisture, paint, and oil on the welded areas by automatic welding with a mill scale wash
primer or a grinder.
(2) Tips for Tack Welding
A. Tack welding shall be performed with an interval of 150 mm or more between cross points of welding
lines.

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B. Tack welding shall be made on the main welding position in case of fillet welding.
C. Edges, corners, main welding parts, starting points, and ending points of the sub-material that have a
problem with machining and strength should be avoided for the location of tack welding.
(3) Weld Rods for Tack Welding
Weld rods for tack welding are same with those for main welding, but weld rods with diameter of 3.34 or 4.04
are used for line tack welding.
(4) The minimum length of tack welding is as follows:
Material Thickness

Minimum Length

Less Than 3.2

30 or Longer

3.2 Less Than 25

40 or Longer

25 or Greater

50 or Longer

Basically, the interval of tack welding shall be 15 ~ 30 times of the plate thickness.
(5) Cautions
A. Tack welding on welded parts of important materials is prohibited. When tack welding on the backside is
inevitable, it should be done on the surface and gouged to the main welding line. In that case, the tack
welded area should be sufficiently welded during the main welding to prevent a welding defect, and
inspected by the responsible person.
B. If tack welding beads remain, gouging is essential to remove remains of tack welding. Pay attention to the
location of tack welding to prevent cutout of the mother material by damage.
C. For tack welding of thick plates (SM 490 and thickness of 25 mm or greater), use low-hydrogen welding
rods in case of SMAW.

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10.14. Generation of Arc

Generate arc on welding plates plus steel materials or welding lines. Ensure that arc strikes do not occur on sub
materials.

10.15. End Tab

Have appropriate number and shapes of end tabs on the both sides for main butt and K-type welding, finish the
start and end of bending with end tabs. The length of end tabs shall be 25 mm or greater. Be careful not to give
damage to the mother material when cutting an end tap after welding.

10.16. Back Chipping: Perform back chipping with arc gouging for dual-axis butt welding. Back chipping
shall be made in such a way that one layer is removed from the surface or pure metal part of the
surface appears with same depth and width.
10.17. Wrap-Around Welding
Finish fillet welded ends with reverse or wrap-around welding.

10.18 Welding of High-Tension Steel

50 kg or 55 kg class high-tension steel can be welded in normal conditions, but require special attention to the
followings since alloy components are contained.
(1) hour of pre-drying at 300 ~ 400 is required since low hydrogen type weld rods are used.
(2). Since low hydrogen type weld rods generate air bubbles at the start and joint of beads, generate arc a little
bit earlier before welding.
(3) Clean the inside of bevel and other areas to be welded before welding.

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(4) Since wide weaving may cause deterioration of tension strength and air holes, maintain the width within
three times the diameter of the weld rod.

10.19. Defects of Welded Parts and Defect Prevention

(1) Fish Eye
Defects

Causes

Fish eye is a fish-eye-looking

brominated piece occurring on
a plate surface at tension or
bending test for deposited
metal. When hydrogen exists
supersaturated in the field
during solidification, it rapidly
gathers in a certain area and
form a large hydrogen
pressure to cause fracture.

A. Weld rod drying is

not sufficient.
B. Large amount of
hydrogen are
melted.

Preventive Measures
A. Dry weld rods properly.
B. Use low hydrogen-type weld
rods.
C. Perform pre-heating and postheating.
D. Slow down welding speed and
avoid rapid cooling.

(2) Bead Form Defects and Defect Preventive Measures

Defects

Causes

A. Welding angle is narrow.

B. Welding speed is not
appropriate.
C. Welding current is low.
Welding Defects

Mixture of Slag

Undercutt

Defect Preventive Measures

A. Increase welding angle or widen
root interval. Use a weld rod of
which the diameter is appropriate
for the welding angle.
B. Keep welding speed appropriately
to prevent slag from proceeding.
C. Move the welding flow to a level
that does not harm slag
encapsulation.

A. Removal of slag of the front

layer is unstable.
B. Welding speed and/or
angle is inappropriate.
C. Welded form is bad.

A. Remove slag properly.

B. Maintain a proper angle and
perform welding continuously with
an appropriate method.
D. Make the length of arc proper.

A. Current is too high.

B. Welding speed and/or
angle is inappropriate.
C. Arc is too long.
D. Weld rod is improper.

A. Lower current.
B. Pay attention to welding rod
operation.
C. Make arc length appropriate.
D. Select an appropriate welding rod.

Overlap

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Overlap

Bad Bead Form

(Uneven width, height,
and/or waveform of
bead)

A. Current is not appropriate.

B. Welding speed is inappropriate.
C. Welding rod selection is
inappropriate.
D. Overheated welding area.

A. Increase current.
B. Increase welding speed.
C. Select an appropriate welding
rod.

A. Current is not appropriate.

B. Welding speed is inappropriate.
C. Welding rod selection is
inappropriate.
D. Overheated welding area.

A. Use a proper current level.

B. Operate the welding rod at a
proper speed in such a way that
slag enters into the welded
material in half way.
C. Select a proper welding rod.
D. Avoid overheating at the welded
area.

(3) Welding Cracks and Defect Preventive Measures

Defects

Transverse
Crack

Longitudinal Crack

Causes

Defect Preventive Measures

A. Hardness of the joint is too high.

A. Change the welding order.

B. Mother material with too much

amount of sulfur was used.

B. Use a low hydrogen type

welding rod.

C. Joint angle is too narrow.

C. Make the angle of weld grove

appropriate.

D. Cooling speed of deposited metal

is too bad.

D. Perform pre-heating and postheating.

E. Drying of welding rods is

insufficient.

E. Dry enough.

F. Too much hydrogen in arch

atmosphere.

F. Use a low hydrogen type

welding rod or perform preheating and post-heating.

G. Excess carbon has been applied

to the alloy metal of the mother
material.

G. Lower current level and

welding speed, and make bead
thinner. Use a low hydrogen
type welding rod if it is hard to
prevent cracks.

Root Crack

Sulfur Crack

Sulfur Bent
End
Crack

Longitudinal
Crack
Bead
MillCrack
Root
Crack

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(4) Air Bubble and Pit Defects and Defect Preventive Measures
Defects

Pit (Mouth opened to

outside)
Blow Hole
(Inside)

Deposited
Metal

Longitudinal Section
A cavity formed by
welded metal trapped in
hydrogen or gas during
cooling of the metal.

Causes

Defect Preventive Measures

A. Too much hydrogen or carbon

monoxide in arc atmosphere.

A. Use a low hydrogen type

welding rod.

B. Weld metal zone cooling speed

is too rapid.

B. Slow down cooling speed by

weaving or pot-heating.

C. Oil, paint, or rust is attached to

the joint area.

C. Clean the joint area.

D. The welding rod or joint area is

wet.

D. Use well dried welding rods and

materials.

E. The length of arc or current level

is not appropriate.

E. Make arc a little bit longer.

(5) Ice-Flower Like Structure and Defect Preventive Measures

Defects

Causes

Defect Preventive Measures

Ice-Flower
Structure

A. Welded part cooling speed is too

high.
Longitudinal
Section

Deposited
Metal

A unique structure that

occurs in welded areas.
It usually contains many
micro-blow holes and
fine particles of refractory
material between the
crystals. Ice flower like
structure is often created
by rapid cooling.

B. Too much carbon sulfide in the

mother material.

A. Perform pre-heating and postheating.

B. Select the mother material
properly.

C. Mixture of slag.

C. Use a welding rod with much

carbonic acid and light slag.

D. A large amount of dissolved

hydrogen.

D. Use a low hydrogen type

welding rod.

10.20 Deformation Types and Prevention of Residue Stress

(1) Types of Deformation
A. Vertical Contraction: Frequently seen in butt welding. When the distances are larger between roots, the V
crack appears bigger than the X crack.

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B. Horizontal Contraction: The vertical contraction is comparatively smaller than the horizontal contraction.
This is because the parent material is preventing the contraction of the bead.
C. Rotation Deformation: Rotation deformation contracts following the progress of welding. Of the direction
in which welding is in process, the front side crack, which is not welded, will rotate.
D. Angle Deformation (Horizontal Bending Deformation): A deformation which appears on the right angle of
the weld and differs depending on whether it is restrained or not.
E. Vertical Bending Deformation: Happens in cases of excessive vertical contraction and occurs when the
weld is separated from the middle of a section, like it is with T or I shape assembly parts.
F. Buckling Distortion: Especially in welding of thin plates, buckling distortion occurs and ruins the exterior of
the structure.
(2) Prevention of Deformation and Residual Stress
A. Reduce the amount of heat as much as possible.
B. Avoid concentration of heat.
C. Reduce the side wall angle and the amount of deposited metal as much as possible.
D. Increase welding speed.
E. Make sure the process of welding is correct
F. Use preheating.

10.21 Safe Operation

The causes of accidents in welding work and preventive measures are as follows:

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Category

Causes

1. Electric Shock

A. Using a holder of which the charging

part is exposed.
B. Touching the core of the welding rod
with hands.
C. Contact with cable of which cover is
damaged.

2. Optical
Disorder

A. Using a lens with poor light-shielding

performance.
B. Arc entering into an eye.

Preventive Measures
A. Use an insulative holder.
B. Use a arc preventive device for arc
welders.
C. Wear insulative boots and gloves.
D. Apply insulation tape immediately to
damaged parts.
A. Use the appropriate No. of lightshielding lens for arc current.
B. Use a light-shielding plate or a tent.
C. Prohibit access by unauthorized
persons.

3. Toxication

A. Inhaling welding gas for a long time.

A. Provide appropriate ventilation.

B. Use a protection mask.
C. Pay a special attention to zinc and
lead welding.

4. Burn

A. Scattered spatter.
B. Contact with preheated mother
material.

A. Wear heat-resistant apparatuses.

B. Put things in order.

5. Explosion

A. Cable inflames nearby combustible

material.
B. Spatter scattered to paint.

A. Use wires with proper size for current

capacity.
B. Do not place a combustible material
around welding worksite.

11. Inspection of Welded Parts

11.1 Inspection Methods
(1) Verification of Welder
A The welder must be verified for government-approved certificates of qualification.
B. The welder must present a photo and copies of certificates. The welder must be checked whether he/she
is wearing a mark which shows that he is qualified.
(2) Checking Welded Materials
A. Check whether deformation by welding has been taken into consideration and enough space has been
left for the finishing part.

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B. Welded part machining should be checked for machine processing and automatic gas cutting.
(3) Keeping of Welding Rods
In handling the welding rod, make inspections and take care not to use deteriorated or wet covering
material.
(4) Checking Welding Process
Try to reduce angle deformation to the minimum. When constructing a part with excessive welds, check not
to weld one section at a time but to weld in such a way that materials are welded evenly.
(5) Welded Part Inspection before Welding
Make inspection on the gap between materials, welded part angle, distance between roots, and cleaning of
welded parts.
(6) Inspection During Welding
Check the welding procedure, welding rods, differentiation of uses, diameter of the welding rod, suitability of
the voltage, cleaning between layers, and double-edge welding position.
(7) Inspection after Welding
A Check both sides of the weld, size, attachment size, plans for the size, UNDER CUT OVERLAP pitching,
the existence of mold, and cleaning condition of the SLAG.
B. The welded part angle of the sub-material, distance between roots, each layer and overlap process are
inspected and measured through specific pages. The cleaning of the exterior, and double-edge cutting is
examined through the naked eye.

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Chapter 13. Steel Fabrication Work

(a) Welded Angle

Welding
Method

Category
Welded Angle

Permissible Tolerance Range

Refer to standard specifications for machinery.

Root Gap

Manual
Automatic

K Type: 2m/m or less, L Type: 1m/m + 3m/m

0.6m/m or less

Bead Gap

Manual
Automatic

1.0m/m
0.6m/m

(b) Inspection and Correction of Welded Parts

Defects
Slag Mixture, Blow
Holes, Bad Bead,
Cracks

Inspection Methods

Treatment

r-RAY Inspection
JIS Z 3104

Remove welding defects with gouging

and perform re-welding.

Undercut, Overlap,
Wrong Bend, Pin Holes

Visual Inspection

Perform repair welding and grinding

finish
Perform repair welding after gouging.

Thickness of Layer in
Excess or Shortage

Various Inspection
Methods

Perform repair welding and grinding

finish.

11.2 Non-Destructive Inspection

(1) Ultrasonic Test
In the following major welds, it should be operated 100% on the ones which are marked with FULL
PENETRATION.
A. Main Column
- Welded Area at Joint of Low Column and Upper Joint (A)
- Welded Area of Upper and Lower Flanges of Column and Truss Joining Bracket (B)
B Crane Girder
- Joint of Upper and Lower Flanges and End Plate (C)
C. Main Truss
- Welded Area of Middle Member of Truss and Upper and Lower Flanges (F)

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(2) Radioactive Ray Inspection

In the following major welds, it should be performed 100% on the ones which are marked with FULL
PENETRATION.
A. Main Column
- Butt Joint Area of Flange (D)
B. Crane Girder
- Butt Joint Area of Flange and Web (E)
C. Judgment Criteria for Nondestructive Welding Inspection
- In case of failing the nondestructive inspection, an additional test of units, two times that of the faulty
ones, should be made. The cost is for the operator to manage.

(3) Exterior Inspection

A. Examine whether the bead is uniform or examine the height and unevenness of the bead.
B. Check for mixing of SLAG or cracks in the bead.
C. Check that penetration towards the parent metal is small and that no OVERLAP or UNDERCUT exists.
D Check whether the start, end and the joint of the bead is in good condition.
E Check if the dimensions of the welded parts are in accordance with regulations (Length of Leg, Height of

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Bead, Thickness of Neck)

12. Correction of Welding

12.1 Transfiguration due to welding can be modified through the PRESS or the heating-cooling method.

When using the heating-cooling method, be careful not to arouse transformation of the material.
12.2 Air bubbles in the inner part should be revised using methods such as GOUGING and perform re-

welding.
12.3 Defects such as shortages in length through the naked eye should be repair-welded and treated with

GRINDER.

13. Assembling
13.1 Generals
(1) In assembling, check tools needed for the assembling process(surface plate, cramp, JAKC, etc) to secure
the accuracy of assembling.
(2) Before assembling steel materials, check the height and levelness of the assembling table to prevent any
errors.
(3) Parts which are rusty or impossible to paint after assembling should be checked beforehand and be coated
with paint.
(4) Other materials should be coded to prevent confusion in assembling.
(5) Temporary welding should avoid short bend and follow Number 4 of 10-16 of this specification.

14. Assembling Inspection

14.1 Usually the finish parts are left unassembled as before the welding. Examination of the distance
between roots, angle of end opening, end opening side, usage of the double-sided cover, trimming
condition of the weld, and cracks between temporary welds should be made.

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Chapter 13. Steel Fabrication Work

(1) Front Opening of Butt Welding

(2) Front Opening of Butt Welding (w/ Back Support Plate)

Provide proper contact.

Back Support Plate
Maintain the root gap accurate.
14.2 After completing temporary adhesive work, inspect important dimension (length, width, height, etc.)
of product before formal welding.

15 Inspection of Finished Steel Structure

15.1 Preparation of Inspection Report
Its purpose is to examine the measurements of the metal and the finishing of products before entering the site.
After writing out the examination sheet, present it to the administrator and inspector for checking and approval.

Owner
Incoming
Construction
Name
Part Name

Construction
No.
Material

Table 1.1 Inspection Report

Drawing
No.
Test No.

Quantity

Machine
No.
Inspection
Items

Issued on DD/MM/YY
Inspected on DD/MM/YY
Inspection
Place

15.2 Standard Dimensions

Executed for the examination of the iron frame measurement and finishing of the steel structure. The
measurements should be followed as stated in table 1.2 and be examined by and administrator and inspector
for approval.

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Table 1.2 Standard Dimensions
Block

Item

Location

Tolerance ()

Main
Column

Length of Base Plate

Anchor Bolt
Direction of Anchor Bolt

Length of Each Side (A)

Central Distance of Bolt Hole
Check diagonal direction of bolt

- 2 = A = +4
2.0
2.5

Length (Overall Length)

Floor-to-Floor Height
Bending rate to Overall
Length
Width of Flange

Main Axis, Column

Width of Flange
Height of Web

H Section Steel, Column

Main Axis, Column
H Section Steel, Column

3
2
H = 500 + 300
H = 500 5

Joint Bracket Direction

Check slope, horizontal and

vertical length

2.0
4.0

Column

Girder

Length (Overall Length)

Height of Girder
Width of Flange
Bending rate to Overall
Length
Flange Squareness
Direction

Main Axis
H Section Steel
Check end areas.

Length (Overall Length)

BEAM

2.0
2.0
/1500
2.0

2.0
2.0
3.5
2.0
/1000
1.5

2.0

Beam Height
Bending rate to Overall
Length

2.0
/1000
3.5

Web corridor

15.3 Inspection Methods

(1) Accept and check the inspection sheet.
(2) Visually check the shape, and inspect bending and deformation of the material using a steel iron wire.
(3) Measure each dimension (Span, Floor-to-Floor Height, Angle, Projection, and Material Dimensions)
(4) Measure division dimensions (Various Beams and Girders).

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(5) Joint Inspection
A. Check the number of rivets, bolts, and fastening status.
B. Exterior Inspection (Refer to the terms of welding for the conditions of the welded sides and other welds).
C. Welding Worksite Inspection
D. State of finished surface (Removal of rust, Deformation by impact of cleaning)
E. Hole Inspection (Holes on Steel Frame, Duct Holes, Holes Made during Construction)
F. Check the adhesion of temporarily constructed steel frames.

15.4 Processes after Inspection

(1) According to the responsible person and the inspectors instructions, recheck the faulty parts.
(2) Check the faulty parts of the welds and write out the checked sections and re-weld the examined parts.
(3) Rework the parts which are impossible to amend and have them rechecked for approval.

15.5 Standards for Accuracy

Dimension

Figure

Tolerance

A. Length (L)

B. Bend

D/L = 1/1000

C. Height (H)

H < 400 2
400 < H < 1000
: H/200
H 1000
5

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Chapter 13. Steel Fabrication Work

Dimension

Figure

Tolerance

D. Width (B)

E. Slope of
Flange at Joint
(e)

B200
eB/100
B200
e<2

F. Bending of
Flange at Joint
(e)

b100
eb/100
b100
e1

G. Eccentricity
(e)

e2

H. Angle of
Customized
Steel Frame

1/500
3 or less

I. Web Strength
(el/H, e2, B)

1 / 150

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Chapter 13. Steel Fabrication Work

Dimension

Figure

Tolerance

J. Hole (Pitch)

K. Difference in
Hole Center (e)

L. Separation of
Rivet Head from
Center (e/d)

1/5

M. Rivet Head
Gap

Gap O

N. Gap between
Members Joined
with HighTension Bolt

O. Gap of Butt
Welding

e5

P. Gap of Dual
Welding
(e)

Q. Misalignment
of Groove (P)
Welded Parts (e)

t15 : 1.5
15 t 30
: t/10
t30 : 3

R. Root Gap (for

Bottom
Chipping) (a1,
a2)

a1 = 3 or less
a2 = 4 or less

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Chapter 13. Steel Fabrication Work

Dimension

Figure

Tolerance

S. Root Gap
(for Back
Support) (a)

+5
-0

T. Root Surface
(a)

a3 mm1 mm
a3 mm2 mm

U. Side Wall
Angle (a1, a2)

-O
+ 10

V. Gap with
Bottom Support
Steel

W. Fillet Welding
Size (s)

+3
-O
-0.1 S is acceptable for
10% or less of welding
length.

X. Overlap for
Butt Welding

Max: + 4.0 m/m

Min: + 0.5 m/m

Y. Undercut (e)

Depth of undercut: 0.05 t

or 0.5mm or less

Z. Bead Surface
Treatment

A) Difference of elevation
of bead surface: 2.5 mm /
150 mm of welding length
B) Difference in bead
width: 5 mm or less per
150 m/m of welding
length

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Chapter 13. Steel Fabrication Work

16. Correction of Finished Steel Structure

16.1 Introduction
As it is the final inspection of the manufactured product, check the materials, shape, measurements, welding
state, deforming of materials, and bolt holes related to the product.

16.2 Correction of Deformation

Materials with defects in 1.1.2 should be modified with GAS CUTTING heating, cooling modification,
GRINDING, or other appropriate methods. For materials which cannot be modified should be re-manufactured.

16.3 Correction of Welding Defects

Inner blow holes, welding defects, and cracks should be completely blown through gouging and be re-welded

17. Temporary Assembling

17.1 For the best quality management, the following subjects should be inspected to prevent unfitting
materials in the construction of an iron frame product.
(1) For the temporarily assembled parts, make sure to clean the contacting parts and inspect the distance
between welds, adhesion of layers, measurements, the position of the BOLT HOLE, and repaired parts. Any
faulty parts should be revised and inspected by the administrator to prevent any problems in the process of
construction.
(2) Temporary assemblage should be taken place according to the administrator especially transport of loaded
material, separable to 1 PIECE or more materials according to its characteristics(CRANE GIRDER, pillar,
truss, etc.) and in the making of the HOPPER type, work only following the administrators orders and modify
the faulty parts of the examined parts.

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Chapter 13. Steel Fabrication Work

18. Paint
18.1 Surface Preparation
Applying paint, the surface shall be prepared as required by SSPC - SP6, commercial blast cleaning.

18.2. Primer Coating

(1) Applicable Primer
Use an explosion-proof and fast-dry type wash primer with no rust after a three month or longer beach
exposure test and a thinner compatible with the wide and fast dry type wash primer.
(2) Coating Method
Since various wash primer products (explosion-proof type) such as two-component type, three-component
type, and mixture type exit by manufacturer, it is important to fully understand the method of use before
coating to obtain the maximum film coating effect.

18.3 Paint Quality

(1) Paint to be used in the construction should be of a manufacturer that can produce products conforming to
ASTM Standards or an equivalent.
(2) Paint Quality
(3) Anticorrosive Paint: ASTM
A. Repair painting (15%) shall be applied to welded areas, cut areas and areas requiring repair painting
immediately with anticorrosive or antirust paint after surface preparation.
B. Epoxy Primer (Shop Primer)
Epoxy primer to for the prevention if rust of corrosion shall be immediately coated after shop blasting and
used after sufficient consultation with paint maker about the mixture of diluted solution and agitation state
based on the following paint specifications and the approval from the responsible person.
a) Color: Flat Grey, Reddish Brown
b) Component: 2 Component Epoxy Primer (Excellent Anticorrosion, water-proof, salt water resistant,

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chemical resistant properties)
c) Specific Gravity: 1.30kg/
d) Solid Volume Ratio: 38%
e) Dry Membrane Thickness: 35/1 Time(the inside), 50/1 Time(the outside)
f) Coating Amount: 10.85/ (Theoretical Coating Rate)
g) Number of Coating Time: Once (Spray)
h) Interval for Re-coating: 24 Hours or Longer
C. Oil Paint: ASTM
a) Color: Designated Color (Color of primer, intermediate, and top coat should be distinguished)
b) Number of Coating Time: 70/2 Time(the inside), 100/2 Time(the outside)
D. Acid Resistant Paint
Paint used at acid and gas generating places should conform to the following paint specifications, and
color, mixture of dilution solution, and agitation state should be approved from the responsible person
after sufficient consultation with the paint manufacturer.

(a) Zinc Primer (Base Coating)

Color: Flat Grey/Green
Component: Inorganic silica and zinc containing etching primer
(chemical resistant, heat resistant, anticorrosive, antirust primer)
Solid Volume Ratio: 62%
Dry Membrane Thickness: 60 (10.3 M2/L)
Coating Amount: 10.3M2/L 0.90 9.27M2/L (0.108 L/M2)
Number of Coating Time: Once (Spray)

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Interval for Re-coating: 24 HR

(b) Epoxy Resin Coat (for Intermediate Coating)

Color: Flat Red/Yellow
Component: 2 Component Type Epoxy Polyamide (abrasion resistant, acid resistant, and salt
water resistant coat)
Solid Volume Ratio: 48%
Dry Membrane Thickness: 40 (12.0 M2/L)
Coating Amount: 12.0M2/L 0.90 10.8 M2/L(0.093L/M2)
Number of Coating Time: Once (Spray)
Interval for Re-coating: 8 Hours

(c) Epoxy Enamel Coat (For Top Coating)

Color: Gloss (Designated Color)
Component: 2 Component Epoxy Polyamide Enamel Coat (Abrasion Resistant, Chemical
Resistant, and Anticorrosive Coat)
Solid Volume Ratio: 40 ~ 42 %
Dry Membrane Thickness: 40 (10.3 M3/L)
Coating Amount: 10.3M2/L 0.90 9.72 M2/L(0.108 L/M2) 0.108 2 0.216 L/M2
Number of Coating Time: Twice (Spray)
Interval for Re-coating: 8 Hours

d) Tests for selection and control of the above mentioned coats shall be in accordance with ASTM
Standards.
E. Heat Resistant Paint

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a) For Base Coating
Color: Silver, Grey
Component: Natural Drying Type Ceramic Paint Added with Inorganic Zinc
Heat Resistance Temperature: 600
Solid Volume Ratio: 30 ~ 33 %
Dry Membrane Thickness: 30 / 1 Time
Number of Coating Time: Once (Spray)
Drying Time: Set-to-Touch 1 Hour, Dry-to-Hard 8 Hours

Type
Set to Touch
Semi Hard
Minimum
Maximum

5 C
60 Minutes
3 Hours
48 Hours
6 Months

20 C
30 Minutes
2 Hours
24 Hours
6 Months

30 C
10 Minutes
1 Hour
12 Hours
6 Months

40 C
5 Minutes
45 Minutes
8 Hours
6 Months

Interval for Re-coating: In Shortest Time after 8 Hours

Others: In case of an exposed outside worksite, base/intermediate/top coating should be able to
prevent the occurrence of rust.

b) For Intermediate and Top Coating

Color: Silver
Component: Natural Dry Type Ceramic Coat
Heat Resistance Temperature: 800
Solid Volume Ratio: 30 ~ 32 %
Dry Membrane Thickness: 25
Number of Coating Time: Twice (Spray)
Drying Time: 48 Hours
Interval for Re-coating: In Shortest Time after 5 Hours

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Others: Rust or water spot by the spread of silver dust should not be generated after
intermediate and top coating.

c) Others
Substrate treatment level and coating thickness maintenance should be confirmed by the
responsible person to secure coating quality.
Heat resistant thinner should be used for dilution, and cleaning of substrates and coating devices.

F. Fire Retardant Paint

a) Scope to Apply
Fire retardant paint shall be applied to steel structures in accordance with ASTM Standards.
b) Fire Retardant Specifications
To be in accordance with ASTM Standards
c) Materials: Materials to use should be confirmed for performances at the quality test performed by
G. Tar Epoxy Paint
a) Scope to Apply
Paint shall be applied to the inside surfaces of eave gutters and valley gutters for rain drainage.
b) Physical Properties
- Components: 2 Component Type Polyimide Cure Epoxy Paint (Film Type Paint with Excellent
Water-Proof, Oil Resistant, and Chemical Resistant Properties
- Color: Black and Brown
- Solid Volume Ratio: 48%
- Specific Gravity: 1.2 0.05 (20)

c) Coating Specifications
- Dry Film Thickness: 150/Time X 2 Times

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- Number of Coating Time: Twice (Brush / Roller)
- Theoretical Coating Rate: 6.4 M2/L (Based on 75/ Time)
- Working Conditions: Ambient Temperature 5 - 35, Relative Humidity 80% or Less

18.4 Cautions for Painting

(1) Places to Avoid Painting
A. Friction Surfaces of High-Tension Bolts
B. Parts in contact with or mounted in concrete structures
C. Crane Rails
D. Pin Roller Contacting Surfaces
E. Areas for field welding and areas adjacent to machines (within 100 mm) should not be painted.
a) Paint should be stored at a place where there is no direct sunray and once opened paint containers
should be used all on that day.
b) Use brushes, sprays, guns, or rollers for painting and be careful to prevent uneven color, brush
marks or paint remains on surfaces during work.
F. Galvanized steel materials
a) ASTM A53, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and
Seamless.
b) ASTM A123, Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
Products.
c) ASTM A153, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware.

18.5 Execution of Surface Preparation Work

(1) Restrictions concerning surface preparation and protective measures:
A. In case of rain or bad weather, surface preparation shall not be carried out outdoors.

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B. When the substrata surface is wet, preparation shall not be carried out.
C. When the relative humidity is 85% or higher, surface preparation shall not, in principle, be carried out.
D. When surface preparation is carried out in dark locations (inside of tanks, etc.), use lighting equipment by
means of which the extent of rust removal from the surface can be seen.
E. When blast cleaning is to be carried out at the job site, appropriate protective measures shall be taken to
ensure prevention of adverse effect of dust on adjacent work or environmental pollution in the
surrounding area.
F. No surface preparation is carried out during the night.

18.6 Weather Conditions for Painting Work

(1) In the event of rainy weather, painting should be avoided in the following cases:
(2) There is possibility of snowfall or dew concentration before the completion of curing and drying;
(3) Wind speed is 3 m/s during outside work;
(4) The temperature at the workplace is 5 or lower or there is possibility of the attachment of foreign materials
to painting.
(5) Restrict concerning painting when the relative humidity is 85 % or more.

18.7 Coating thickness management standards

(1) Coating thickness shall be classified into 2 types: average coating and minimum coating. (New painting and
maintenance painting)
A. Average coating shall be 80% or more of the standard coat.
B. Minimum coating shall be 70% or more of the standard coat.
a) Average coating : Average coating of the measured parts
b) Minimum coating : Minimum coating of the measured parts
(2) The coating thickness shall be measured based on the following criteria:

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(New painting and maintenance painting)
A. Criteria of selecting measuring points
Painted Area(m)

Measuring

Coating Thickness Standards

Point

Less than 100

2 or more

100 or more ~ Less than 1000

4 or more

1000 or more ~ Less than 3000

6 or more

3000 or more ~ Less than 5000

8 or more

5000 or more ~ Less than 10000

10 or more

10000 or more

14 or more

Measured value of all points shall be 70%

or more of the standard coat, and the
average value of each part shall be 80%
or more.

Check visually, and concentrate the

thickness measuring on the most
vulnerable parts.

Number of point : 1 measuring point of the measured surface

18.8 Drying and Others

(1) Drying at a clean place for 4 days or longer is required after painting.
(2) Surface preparation Class 1 (Shot Blast) is required for painting on materials.
18.6.3. Inspect damage on painting after transportation and before erection, and carry out re-painting at the
field, if required.

18.9. Identification of Materials (Steel Members) after Painting

(1) Generals
Mark on the materials competed with painting but not identified for weight, material number and location
(row number) with paint easy to identify or stamping that does not give a negative effect to the strength of
the materials.
(2) For main columns, trusses, and back girders of lattice structures, mark the erection number, weight, and
indication of each row on the central position of the materials with paint easy to identify.
(3) For base plates, crane girders, and wind girders, mark weight (except base plates), erection number, etc. on
the central position of the materials.
(4) For other materials, the central, top, and bottom positions of the materials should be indicated according to

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the instruction of the responsible person, if necessary, and all fabricated materials should be marked
erection number.

19. Transportation and Field Storage of Finished Steel Structure

19.1. Generals
- Transportation of products the field shall be made for those competed with the final inspection of the
responsible person and the inspector in the order of field erection work and after appropriate measures for
the prevention of deformation. Attention should be paid to unloading at the field to prevent deformation and
storage at the field shall be made in the order steel frame erection according to the prepared plan.

19.2. Transportation (Loading and Unloading)

(1) Sub-materials with possibility of loss during loading, unloading, and transportation such as splice fillers,
liners, plates, and other section steel should be transported in boxes or fastened to main materials with bolts
for transportation.
(2) Projected parts of main materials that are subject to deformation during transportation such as brackets and
gusset plates should be contained in boxes to prevent deformation.
(3) Sustain timers should be installed every 1,800 mm for each layer to prevent deformation during
transportation and loading factor shall be equal to or lower than the values in the following table:
Type

Ultra-High
Buildings

Normal
Buildings

Factory
Buildings

Gymna
siums

Steel Plants,
Power
Plants

Steel Pipe
Structures

Average
Loading
Factor

75

70

60

65

80

50

Remarks

Stack
Structures

1. Product neck: 3 m or Less

2. Height: 4 m or Less (G.L Top of Material)
3. Length: 12 m or Less

(4) Fasten common bolts ( 16) to splice plates and gusset plates to prevent separation during transportation.
(5) Prepare protection measures when using wire ropes or hooks for loading / unloading.
(6) Use shock absorbing materials to prevent damage on coating by contact between materials.
(7) Do not use steel wires when attaching sub materials to main materials for transportation.

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(8) Ensure that there is no unnecessary room when loading materials to prevent rolling.
(9) Not painted parts or parts that have possibility of getting rust such as areas around bolts during
transportation or storage should be protected with vinyl or protection covers from rain and snow.
(10) Unloading Materials
Be sure that no material deformation occurs by impact during unload of materials and follow the instruction
of the responsible person for positions and locations of unloading and storage of large-sized materials.

19.3 Field Storage

(1) Field Storage Method
Store materials laid down on the ground with support of sustain timbers at a position more than 30 cm away
from GL. Place sustain timbers every 1,200 mm for each layer to prevent deformation during field storage
and avoid stacking in 3 layers or higher. Ensure that stored materials are free from harmful foreign matters
such as salt and dirt and avoid long-term field storage.
Material Carrying-in and Storage Order
Material carry-in shall be made in accordance with the order of erection work and procedure below, and field
storage shall be performed in consultation with the field representative and the responsible person as
planned.

(2) Material Carry-in Order

A. Material carry-in shall be made in accordance with the order agreed with the responsible person of the
field.
B. If it is not the case above, carry-in order is as follows:
(a) Main Columns
(b) Crane Girders
(c) Roof Trusses
(d) Back Girders

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(e) Wall Bracings
(f) Purlin Eaves Girders, Roof Bracings
(g) Wind Girders
(h) Sub-Columns

(i) Etc

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