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STRUCTURAL SPECIFICATIONS

G10 Structural Steel Framing to Dome and Tree Columns

Project Name: Doha Oasis $ Qatar

Project Number: 3065

C2 Construction Issue Update JR JR 11/04/2014


C1 Construction Issue BB JR 08/11/2013
Revision Revision Detail BY CHK Date
AKT II LIMITED

G10 STRUCTURAL STEEL FRAMING

To be read with Preliminaries/ General conditions.

NB: AKT changes/additions to this NBS Services Specification have been indicated in
italic text.

GENERAL REQUIREMENTS/ INFORMATION

109X CONTRACTORS DESIGN OF ALL STEELWORK CONNECTIONS INDICATED ON


DRAWINGS INCLUDING TREE COLUMN TRUSS CONNECTIONS BUT EXCLUDING
VISUALLY EXPOSED TREE COLUMN CONNECTIONS
Design concept: See Drawings
Design responsibility: Design connections and detail steelwork and connections.
Other responsibilities: Ensure connections fit within envelope defined by
finishes and ceilings.
Structural requirements:
Generally: See Drawings
Design: Complete in accordance with the designated code of practice to satisfy
specified performance criteria.
Connections: reactions as on AKT Drawings, but not less than that required
for robustness purposes to EN 1991 1 7 and through thickness properties of
EN 1993 1.
Fixings to foundations and walls: Contractor design to B50/120
Additional requirements:
Design and production information: provide mark ups of General Arrangement
drawings of locations of weld testing for the Engineers approval.

110X CONTRACTORS TO FINALISE DESIGN OF ALL VISUALLY EXPOSED TREE


COLUMN CONNECTIONS INDICATED ON DRAWINGS AND BASED ON AKT IIs
DESIGN INTENT
Design concept: See Drawings.
Design responsibility: Design connections and detail steelwork and connections.
Other responsibilities: Ensure visually exposed connections are of the highest
standard and to the Engineers satisfaction.
Structural requirements:
Generally: See Drawings
Design: Complete in accordance with the designated code of practice to satisfy
specified performance criteria.
Connections: reactions as on AKT IIs Drawings, but not less than that
required for robustness purposes to EN 1991 1 7 and through thickness
properties of EN 1993 1.
Fixings to foundations and walls: Contractor design.
Additional requirements: Tree column connections are of aesthetic
importance therefore submit details of any changes and final proposals for
Architects approval

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G10 STRUCTURAL STEEL FRAMING

Design and production information: provide mark ups of General Arrangement


drawings of locations of weld testing for design teams approval.

114Y EUROCODES
National Annex: Reference to a Eurocode shall be deemed to include the
appropriate United Kingdom National Annex, and nationally determined
parameters shall apply.
Substitution of alternative design rules for Application Rules: To be agreed
with the Engineer.

115X DESIGN CONSTRAINTS GENERAL


Members forming bracing systems or girders of lattice construction: Unless
detailed or instructed otherwise, position so that their lines of action intersect
at a point.
Bolts:
Diameter (minimum): 20mm.
Number per connection (minimum): two, unless otherwise indicated.
Other requirements: Bolts minimum grade 8.8. Use full depth end plates
where applicable. Adopt non pre loaded bolts to structural members that
may need to be temporarily removed refer to SEs drawings..
Punching of bolt holes: not permitted
Welds: fillet welds minimum 6mm
Other constraints: Refer to SEs drawings.

116 DESIGN CONSTRAINTS STEELWORK TO BE GALVANIZED


Steel grades: Do not use steel downgraded from a higher specification.
Detail design: Avoid details that will increase the risk of initiating liquid
metal assisted cracking (LMAC).
Particular restrictions: None .
Other requirements: None.

120 DRAWINGS AND CALCULATIONS


Information required: All fabrication drawings and calculations for all
connections.
Requirement: Before preparing detailed fabrication drawings, submit:
General arrangement drawings with individual steel members clearly
identified.
Calculations/ selected standard joint detail for major connections.

122Y DOCUMENT SUBMISSION PROCEDURE


Submit three copies of documents at least 15 working days before proposed
commencement of fabrication together with a 3D model. Documents shall
include the Steel Subcontractors name, the date of submission and shall be
signed by the Steel Subcontractor.

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G10 STRUCTURAL STEEL FRAMING

Documents submitted for comment will be reviewed by the Engineer and


assigned one of the following categories:
Category A: Documents so marked by the Engineer mean that fabrication,
manufacture or construction may proceed in accordance with the
submitted drawings. Unless indicated to the contrary on the drawing, work
shall comply with the Contract Documents.
Category B: Documents so marked by the Engineer mean that fabrication,
manufacture or construction may proceed in accordance with the
submitted drawings subject to the Steel Subcontractor taking the necessary
action based on the Engineers comments and all notations added to the
returned drawings. Unless indicated to the contrary on the returned
documents, work shall comply with the Contract Documents. The Steel
Subcontractor shall submit the required number of amended documents to
the Engineer as soon as possible.
Category C: Documents so marked by the Engineer mean that no work shall
be fabricated, manufacturer or constructed. The Steel Subcontractor shall
re submit new documents to the Engineer for review until re submission is
no longer required. Any submission marked C will not be permitted on
site.
The granting of Category A status will be conditional upon submission of all
necessary calculations, certificates, samples, etc, as required in this
specification. Notwithstanding the Engineers comments, the detailed design
carried out by the Steel Subcontractor, materials and construction will remain
the responsibility of the Steel Subcontractor.

125 SPECIFICATION STANDARD


Standard: Comply with latest edition of National Structural Steelwork
Specification (NSSS, CE marking version).
Additional requirements: Comply with the accumulative tolerances envelope
defined on consultants movements and tolerances drawing and the
additional requirements of clauses 181Y and 422Y.
Document availability: For the duration of the work, at fabrication shop
and on site.
References to Engineer in NSSS: For the purpose of this contract, interpret such
references as being to the Engineer.

130X GENERAL STEEL SECTIONS AND PLATES


Standard: BS EN 10025.
Grade: S355JR, S355J0, S355J2, S355ML, S355NL
Options: No markings to visually exposed steelwork
Source: Obtain steel from a source accredited to a national or internationally
accepted quality standard.
Other requirements: subgrade to BS EN 1993 10 10/PD6695 1 10.

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G10 STRUCTURAL STEEL FRAMING

132X STEEL Z15 PLATES FOR TREE COLUMN CONNECTIONS WITH


PERPENDICULAR LOADS
Standard: BS EN 10025 & BS EN 10164
Grade: S355JR, S355J0, S355J2, S355M, S355N, S355ML, S355NL
Options: No markings to visually exposed steelwork
Source: Obtain steel from a source accredited to a national or internationally
accepted quality standard.
Other requirements: subgrade to BS EN 1993 10 10/PD6695 1 10 and
Steel EN 10025 3 S355x + EN 10164 Z15

135X HOLLOW STEEL SECTIONS ______


Standard: BS EN 10210 1.
Grade: S355J0H and S355J2H.
Options: No markings to visually exposed steelwork.
Source: Obtain steel from a source accredited to a national or internationally
accepted quality standard.
Other requirements: subgrade to BS EN 1993 10 10/PD6695 1 10.

136Y ERECTION METHOD STATEMENT to be submitted at least 15 working days


before starting erection of steelwork, including details of (with drawings if
necessary):
Method and sequence of erection
Type of cranage
Temporary guys and bracing proposed for use during erection
Prepare erection drawing showing all structural members.
Provide copies to the Engineer
AKT design drawings not to be used as erection drawings.

COLD FORMED MATERIALS

176X PROFILED SHEET FOR SHUTTERING/ COMPOSITE FLOOR SLABS TO


CONTRACTORs DESIGN
Nature of permanent supports: Steel
Manufacturer: Corus or equivalent approved.
Product reference: Comflor 80 with 250thk concrete topping or similar
approved
Material: Galvanized steel sheet to BS EN 10326 S450GD+Z275
Thickness: 1.20mm.
Designation: S450GD+Z275N A C.
Metal accessories: Provided by sheet manufacturer unless otherwise indicated:
edge trims and restraint straps, side and end closure pieces
Finish: As for sheet.
Seam stitching:

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G10 STRUCTURAL STEEL FRAMING

Fixings/ centres: Contractor to submit, sufficient to use decking as a


diaphragm during steelwork erection before concrete is placed and achieve
design strength.

178X FIXING PROFILE SHEET TO STEELWORK TO CONTRACTORs DESIGN


End supports:
Length of sheet bearing onto support (minimum): 50mm or 25mm beyond
the shear connector..
Fixing type/ size: through welding of shear connectors.
Coating applied by manufacturer: None.
Location: In trough of sheet.
Number/ centres of fixings: Contractor to submit, sufficient to use profile
sheet as a diaphragm during steelwork erection.
Distance from end of sheet (minimum): 25mm.
Distance from edge of support (minimum): 25mm.
Side supports:
Width of sheet bearing onto support (minimum): 25mm or 25mm beyond the
shear connector, when shear connectors are used.
Fixing type/ size: Heavy duty powder actuated fixings (e.g. Hilti ENP2 X
ENP 19 L15 nail/Spit SBR14 or equivalent) / Self drilling screws (e.g. SFS
TDC T 6.3 x 38 or equivalent).
Coating applied by manufacturer: None .
Centres of fixings (maximum): 25mm .
Distance from edge of sheet (minimum): 25mm .
Distance from edge of support (minimum): ______ .
Other requirements: None .

FABRICATION

180X NOTIFICATION OF COMMENCEMENT


Notice: Give notice to the Engineer before fabrication is due to start.
Period of notice (minimum): 15 working days.
Before fabricating, ensure that surface condition of steel which is to be coated
complies with requirements for cleaning given elsewhere in this specification.
Ensure that fabrication processes do not cause changes in properties of materials
resulting in non compliance with specified requirements.

181Y FABRICATION TOLERANCES


Tolerances in accordance with BS EN 1090 2 except:
Member length +0mm or 3mm of specified length.
For black, precision of HSFG bolts, holes to be 2mm larger than bolt diameter.
For close tolerance holes drill undersize and ream to 0.5mm larger than
specified bolt size.
Close tolerance bolts only for shop assembly.

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G10 STRUCTURAL STEEL FRAMING

Provide for special tolerances net or slotted holes to the Engineers approval.

182Y STEEL plates sections, flats and hollow sections to comply with BS EN 1993 1
10/PD6695 1 10 and BS EN 10164 for Tree Columns
Shall be new, no sign of detrimental corrosion.
Where free from lamination to BS EN 10160.
Provide manufacturers Test Certificate.

190X MARKING
Identifying and recording materials and components: Submit to the Engineer
details of proposed methods.
Location of marks:
Generally: Visible for checking after erection, but not in faces exposed to
view, subject to approval by architect.
Weathering steel: On surfaces not exposed to open view in the completed
work.
Steel to be blast cleaned, pickled, metal sprayed or galvanized: Marked so that
subsequent treatment cannot obliterate the marking.

195 HARD STAMPING


Usage: Not permitted except as indicated on Drawings.

200 FAYING SURFACES FOR FRICTION GRIP CONNECTIONS


Location: Refer to Drawings.
Steel 25 mm thick or over: Check faying surfaces for deformities that may
reduce slip factor to below design limit.
Remedial measures: Submit proposals.
Preparation/ treatment: Refer to Drawings.

210 END CONNECTIONS


Angle web cleats: Project 10 mm beyond ends of simply supported members.

215X HOLLOW SECTIONS


Insides of sections: Debris and moisture removed before sealing ends and
openings.
Submit proposals for welding when thickness of section less than 4mm.

220 ACCESS/ VENTILATION HOLES IN BASE PLATES


Base plates larger than 1 m sq: Make 25 mm diameter holes as necessary for
pressure grouting, escape of entrapped air or direct compaction of filling/
bedding material.

225 STEELWORK TO BE GALVANIZED


Cutting, drilling and shop welding: Complete before galvanizing.
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Vent and drain holes: Provide as necessary.


Locations: Submit proposals.
Sealing: If required, proposals to be submitted.

230Y SHOP ASSEMBLY


Check fit, profile and camber before making connections in lattice girders and
trusses that are to be assembled before delivery to site.

231Y ASSEMBLY
Structure to be assembled to BS EN 1090 2.

235 SHOP INSPECTION


Give notice: Before fabricating all exposed steelwork, submit programme of
fabrication for review by the Engineer.
Period of notice (minimum): 10 working days.

WELDING

255 SITE WELDING


Usage: Permitted only where indicated on drawings.
Working conditions: Suitable and safe. Do not weld when surfaces are wet or
when ambient temperature is below 0C.

270 ADDITIONAL WELDS


Welds (including tack welds) not indicated on drawings: Not permitted without
approval.

280X SHEAR CONNECTORS


Connector type: a proprietary type with minimum yield strength of 350 N/mm2
and minimum ultimate tensile strength of 450 N/mm2,15% minimum
elongation, to BS EN ISO 13918
Size/ spacing: Refer to SEs drawings.
Welding method: welders to be certified by the equipment manufacturer or
other recognized authority as competent for the work
Top surface of beam flange to be free from millscale, rust, grease, oil, paint,
and other substances detrimental to welding. Ensure that flange is cleaned
prior to laying decking.
Do not weld studs when the ambient temperature is below 0C.
Procedure trials:.
Trial welding: Before starting, demonstrate suitability of material, equipment
and welding system proposed for welding of studs. Fix not less than ten studs for
testing. During the work, at the beginning of each shift, each welder is to fix
not less than two studs for testing.

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Testing trial weld: Visually inspect; each trail weld is to exhibit full 360C
flash. Subject each trial stud to a 30 bend test; welds must show no sign of
cracking.
Production welds: To be visually free from cracks and lack of fusion and
capable of developing at least the nominal ultimate strength of the studs.
Other requirements: Do not weld shear connectors through more than one layer
of decking.

285 PROPRIETARY SHEAR CONNECTORS CONTRACTOR TO SUBMIT


PROPOSALS
Manufacturer: ______ .
Product reference: ______ .
Coating applied by manufacturer: ______ .
Spacing: ______ .
Method of fixing: ______ .

290Y FINISHED WELDS


Finished welds: Carefully dressed to remove slag without deforming surface of
weld.
Remove burns and sharp edges by grinding
Remove surface laminations, shelling, cracks, crevices, inclusions and other
surface flaws by chipping and/or grinding. If excessive grinding, necessitating
filling or welding is required, obtain Engineers approval before proceeding.
Uneven or oversize welds subject to Engineers approval.

BOLT ASSEMBLIES

300Y BOLTS GENERALLY


Bolts, nuts and washers to BS EN 1090 2.
No deterioration on storage to approval of Engineer.
Heads to point in direction wherever shown on drawings.
Washer to be beneath rotated item.
Nut identification mark to be visible.
Assembly to BS EN 1090 2. Tightening method to Engineer s approval.
Once used, bolt assemblies or parts thereof shall not be re used.
High tensile bolts to be used only with Engineer specific approval.
8.8 grade may be treated only if carried out by bolt manufacturer.

302 NON PRELOADED BOLT ASSEMBLIES CONTRACTOR TO SUBMIT


PROPOSALS
Designation: ______ .
Threading: ______ .
Nuts and washers: To suit grade of bolt, as NSSS, clause 2.3.
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Coating applied by manufacturer: ______ .


Other requirements: ______ .

303 PRELOADED BOLT ASSEMBLIES CONTRACTOR TO SUBMIT PROPOSALS


Designation: ______ .
Coating applied by manufacturer: ______ .

304 PROPRIETARY BOLT ASSEMBLIES CONTRACTOR TO SUBMIT PROPOSALS


Manufacturer: ______ .
Product reference: ______ .

305 PROPRIETARY ANCHORS CONTRACTOR TO SUBMIT PROPOSALS


Manufacturer: ______ .
Product reference: ______ .
Anchor type: ______ .
Material: ______ .

308Y SPACING and distance to edge of concrete or masonry in general to comply with
fixing manufacturer's recommendations for maximum safe static load.

310 ANCHORAGES TO CONCRETE CONTRACTOR TO SUBMIT PROPOSALS


Design standard: As the designated code of practice.
Anchor type: ______ .
Material: ______ .
Coating applied by manufacturer: ______ .
Concrete:
Grade: ______ .
Condition: ______ .
Characteristic resistances of single anchor remote from edge of concrete
(minimum):
Tension: ______ .
Shear: ______ .
Fixing in concrete: ______ .

315Y HOLDING DOWN SYSTEMS CONTRACTOR TO SUBMIT PROPOSALS


Bolts:
Standard: ______ .
Type: ______ .
Grade: ______ .
Diameter: ______ .
Coating: ______ .
Bolt boxes: ______ .
Anchorage: ______ .
Other requirements: ______ .

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325 DIRECT TENSION INDICATORS CONTRACTOR TO SUBMIT PROPOSALS


Standard: To BS EN 14399 9.
Manufacturer: ______ .
Product reference: ______ .
Grade: Appropriate for grade of bolt and nut assembly.
Finish: ______ .
Ancillary components: Washers to BS EN 14399.
Post installation and inspection treatment: Where no further protective coating
is specified, apply a butyl rubber sealing compound to seal measuring gap
around indicators.

335 SPRING WASHERS


Standard: To BS 4464.

336Y LOCK NUTS


Effective lock nuts to be provided in locations:
- Bolts in tension in all lifting equipment eg. Overhead runway beams to BS2853
section 4.
- Overhead walkways floor panels not subject to high levels of vibration to BS
4592 0 Section B.2.

370 GALVANIZED COATING TO BOLT ASSEMBLIES CONTRACTOR TO SUBMIT


PROPOSALS
Standard: To BS 7371 6.
Galvanizing: Applied by fastener manufacturer. Passivated and lubricated if
no additional coatings are specified. Nuts tapped after galvanizing.
Use/ location: ______ .

375 SHERARDIZED COATING TO BOLT ASSEMBLIES CONTRACTOR TO SUBMIT


PROPOSALS
Standard: To BS 7371 8.
Class: ______ .
Sherardizing: Applied by fastener manufacturer and passivated.
Post treatment: ______ .
Use/ location: ______ .

380 ZINC PLATED FINISH TO BOLT ASSEMBLIES CONTRACTOR TO SUBMIT


PROPOSALS
Standard: To BS EN ISO 4042.
Designation: A ______ .
Zinc plating: Applied by fastener manufacturer. Clear passivated if no
additional coatings are specified. Nuts tapped after plating.
Use/ location: ______ .

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390 SEALED HOLLOW SECTIONS


Holes: Sealed to prevent access of moisture.
Method of sealing: Submit proposal to the Engineer for approval, unless
specified on drawing.

ERECTION

405 OUTLINE METHOD OF ERECTION


Final method of erection to be developed with Contractor..

410 PRE ERECTION CHECKS


Scope: At least 7 working days before proposed erection start date, check the
following:
Foundations and other structures to which steelwork will be attached:
Accuracy of setting out.
Holding down bolts: Position, protruding length, slackness and condition.
Inaccuracies and defects: Report without delay.
Permission to commence erection: Obtain.

415Y ERECTION STEELWORK


Temporary bracing to cause minimum interference to others.
Ensure stability at all times.
Bare lifting chain or chain wrenches not allowed.
Reject any notch damaged steel.
Provide as erected drawings.

422Y TOLERANCES CONSTRUCTION: Notwithstanding BS EN 1090 2, the


following shall be observed:
Upper and lower surface of any truss or element + 10mm taking any specified
cambers into account.
Clear measurements horizontally or vertically necessary to accommodate doors,
windows, services or other facilities as well as dimensions between secondary
structural components shall be + 5mm.
Maximum abrupt change in continuous or jointed surfaces shall be 3mm.
Setting out and Construction Tolerances are not additive refer to BS 5606.
Refer to consultants movements and tolerances drawing for Tolerance
Envelope(s).

425 MODIFICATIONS
Steelwork: Do not modify without approval.
Temporary fabrication/ erection attachments: Contractor to submit proposals.

432X TEMPORARY SUPPORT


Permanent bracing system:
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Vertical: Refer to Drawings.


Horizontal: Refer to Drawings.
Temporary bracing/ restraints: Provide as necessary until permanent bracing
system is complete and sufficiently mature to carry loads and all connections
have been made to the permanent system.
Elements to be supported: To be determined by Contractor.
Forces and moments in temporary supports: make an independent assessment
unless noted otherwise in drawings or specifications.

440 COLUMN BASES


Levels: Adjust using steel shims or folding wedges no larger than necessary.
Location of shims/ wedges: Position symmetrically around perimeter of base
plate. Do not use a single central pack.
Give notice: If space beneath any column base is outside specified limits for
bedding thickness.
Accuracy of erection: Check, and correct errors before filling and bedding
beneath bases and
carrying out other adjacent work.

443 PROPRIETARY FILLING/ BEDDING OF COLUMN BASES


Bedding thickness range: 10 120mm.
Preparation: Concrete surfaces scarified to provide a good mechanical key.
Bolt pockets and spaces beneath base plates: Completely filled with Completely
filled with Fosroc Conbextra HF or similarly approved high strength non
shrink pourable grout for column bases and Fosroc Conbextra GP or similar for
beam connections to RC shear walls and cores..

447 BONDED ANCHORS


Holes: Clean and free from dust at time of installing anchor.
Permeable sleeves: Use in conditions where otherwise the loss of bonding agent
would be unacceptably high.
Other requirements: None .

TESTING

460Y INSPECTION: Permit the Engineer, and/or an independent inspection authority


appointed by the Engineer, to inspect the work at all reasonable times and at
all places where it is being carried out. Provide all facilities, hand tools,
lighting, etc. as necessary to ensure adequate inspection.

462Y COSTS FOR INSPECTION/TESTING:


Costs of all inspection and testing for material, workmanship and protective
coatings to be carried out by the Contractor and the independent Inspection
and Testing Authority to ensure compliance with this specification are deemed
to be included within the Steel Contractors tender sum.
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465X TESTING
Testing: Arrange the following tests. Prepare test pieces as necessary.
Test: Welding, comply with latest edition of National Structural Steelwork
Specification (NSSS, CE Marking version).
Testing authority: Cl. 471Y
Frequency/ Number: as NSSS unless noted otherwise
Level of acceptability: as NSSS unless noted otherwise
Other requirements: None .
Test and examination results: Submit 2 copies immediately they are available.

466Y TESTING: (FOR CRITICAL JOINTS WHICH REQUIRE ADDITIONAL INSPECTION:


ALL TREE COLUMN JOINTS)
Testing: Arrange the following tests. Prepare test pieces as necessary.
Test: Welding, comply with latest edition of National Structural Steelwork
Specification (NSSS, CE Marking version).
Testing authority: Cl. 471Y
Frequency/ Number: as NSSS unless noted otherwise
Level of acceptability: as NSSS unless noted otherwise
Other requirements: None .
Test and examination results: Submit 2 copies immediately they are
available.

470X SITE TESTING OF ANCHORS TO MASONRY AND CONCRETE OF UNKNOWN


STRENGTH
Standard: To BS 5080.
Preliminary tests: ______ .
Proof tests: ______ .
Test results: Report failures and seek instructions.

471Y INSPECTION AND TESTING AUTHORITY


All inspections and tests to be carried out by an independent NAMAS
Accredited or other laboratory approved by the Engineer.

475 PRODUCTS
Steel: Submit test certificates.

480Y DEFECTIVE WORK


As soon as possible after any part of the work or any materials are known or
suspected to be defective, submit proposals to the Engineer for further testing,
inspection or replacement and obtain instructions.

PROTECTIVE COATINGS
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501Y SAMPLES, MOCKUPS, PROTOTYPES, QUALITY BENCHMARKS AND TESTING


Submit the following information at tender stage:
Provide technical data including inspection proposals, workmanship and
application methods, touching up proposals, testing data, material
properties including generic descriptions of all products to be used.
Provide details of spray equipment that the Contractor proposes to use for
factory applied finishes including capacities and pressure levels for
review.
Provide details of all site applied painting techniques that the Contractor
proposes to use including touching up specifications for review.
A statement of compliance with this Specification.

505Y QUALITY OF FINISH


Take extra care to ensure finished work of highest visual quality.
Only items totally free from any contaminating matter affecting life or
durability of coatings shall be deemed clean.

510 SURFACES NOT TO BE COATED


Location: ______ .
Other requirements: ______ .
Any surfaces within 150mm of areas to be site welded.
Contact surfaces of high strength friction grip bolted connections.
Portions of steel members in contact with concrete.
Mask over top flangers where through deck connectors to be welded where studs
occur.

510X SURFACES NOT TO BE COATED


Any surfaces within 150mm of areas to be site welded.
Contact surfaces of high strength friction grip bolted connections.
Portions of steel members in contact with concrete.
Mask over top flanges where through deck connectors to be welded where studs
occur.

515Y OPERATIVES must be appropriately skilled and experienced in the use of


specified materials and methods of application.

520Y COATING MATERIALS


Wherever possible, to be from one manufacturing batch. Where more than one
batch is to be used, keep separate, allocate to distinct parts or areas of the work,
and inform the Engineer accordingly.
Use according to manufacturers instructions.
Use in accordance with any relevant local Environmental Protection Act and
apply systems to meet the requirements of the Solvent Emissions Directive:
Directive 2004/42/EC or equivalent.

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Check that all coating materials to be used are recommended by their


manufacturers for the particular surface and conditions of exposure, and that
they are compatible with each other.

521 ALTERNATIVE MANUFACTURERS


Short list of manufacturers: Obtain coating materials from one only of the
following: International Protective Coatings
Selected manufacturer: Submit details and obtain the Engineers approval
before ordering materials.

523 COMPATIBILITY OF SHOP PRIMER WITH SITE APPLIED INTUMESCENT


COATING
Intumescent coating: Refer to M61 .
Primer: Compatible with coating under general and fire conditions.
Manufacturers recommendations and test evidence: Submit before priming.
Include fire test data to BS 476 20 and 21, or BS EN 1363 1 and BS EN
1365 2, 3, and/ or 4 as appropriate.

526Y PREPARATION MATERIALS AND ANCILLARIES


Types recommended by their manufacturers and the protective coating
manufacturer for the surfaces being prepared.

527Y MAINTENANCE PROCEDURE


The maintenance procedure for the outer decorative paint finishes for the
internal/external exposed areas are to be confirmed by International Protective
Coatings (or other Paint Supplier approved by the Engineer) who shall provide
the Engineer, on request, a written maintenance specification to be adopted at
the end of the anticipated life expectancy period.

535X INSPECTION OF COATING WORK


Work in progress: Permit coating manufacturer to inspect and take samples of
products. (Do not comply with directions or requests given by coating
manufacturer unless and until confirmed by Engineer)
Notice: Give notice of dates for:
Start of surface preparation and coating.
Coated members or components leaving the works.
Period of notice (minimum): 5 working days.

540Y HANDLING AND STORING COATED STEELWORK


Use methods and equipment, which will minimise chafing, chipping and other
damage to coated components.
Ensure an adequate drying/curing period for each coat before handling.
Use suitable packings, lashings, lifting harnesses, nylon slings, rubber protected
chains and chocks, etc.

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Stack coated components clear of the ground, separated by timber chocks, and
so that ponding does not occur.
Where galvanized do not store in damp or badly vented conditions, guard
against white rust.
Where the finished coat is to be shop applied, extreme care and attention
should be taken during transportation and erection to ensure the finished
surface remains undamaged. Allowance should be made for bubble wrap
protection or similar during this process.

545Y PROTECTION
Protect freshly applied surface coatings from damage.
Exhibit Wet Paint signs and provide protective barriers where necessary.
Protect surfaces adjacent to those being covered.
Ensure all surfaces to be painted are dry, clean and free of any dirt, oil, grease
or other combination, including any zinc salts.
Where an epoxy zinc rich primer has been specified the applied primer must
have a minimum zinc dust pigment content of 80% by mass of the dry film
and comply with requirements specified by ISO 3549.

546Y REMEDIAL WORK: (IN PRINCIPLE) SUBJECT TO DETAILED METHOD


STATEMENT FROM PAINT SUPPLIER
Early degradation of coatings by blistering, peeling, flaking, cracking, lack
of adhesion, etc. must be made good by complete removal, preparation an
reapplication of all coats, as instructed.
Inadequate dry film thickness or surface defects due to adverse weather
may, depending on the type of paint, be remedied by rubbing down and
applying further coat(s), as instructed.
Mechanical damage to coatings must be made good by local cutting back of
coatings, preparation and reapplication of all coats to leave a neat,
continuous and flat finish, overlapping existing by 30mm.
Any painted areas mechanically damaged in transit or following erection
damage to be hand or power tool cleaned to St2 (ISO 8501 1). Touch up
damaged areas with a suitable primer coat followed by specified top coat to
meet original works d.f.t. Adhere to International Protective Coatings
recommendation re appropriate method of application. External exposed
steelwork will require two coats.
For Intercure 99 Any painted areas mechanically damaged in transit or
following erection are to be mechanically cleaned to SSPC SP11 with light
abrading of intact Intercure 99 up to 50mm from damaged area to provide
a feathered edge. Repair by reinstating the original specification by brush,
multiple coats may be necessary to achieve required dry film thickness.
Where there has been significant damage to an individual steel
sections(s)following transit or erection then the exposed steel must be
vacuum blasted to Sa 2.5.before reinstating the original coating system.
For Interfine 979 Any painted areas mechanically damaged in transit or
following erection are to be hand or power tool cleaned to St3(ISO 8501

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1).Touch up damaged areas with 1 coat of Interplus 356 @ 80 100 microns


dft.
For C4 environment then apply a further coat of Interseal 670HS @ 80
microns dft followed by Interfine 979 @ 100 microns dft.
For C5 environment then apply two further coats of Interseal 670HS @ 80
microns dft per coat followed by Interfine 979 @ 100 microns dft.
For Interfine 979 Where there has been significant damage to an
individual steel section(s) following transit or erection then apply an
overall coat of Interfine 979 at a minimum of 75 microns dft.
Where damage to coatings or subsequent surface preparation has exposed
bare metal, it must be thoroughly cleaned and primed within two hours.
Re execute any work undertaken with non approved or untested material.
All remedial work to Engineer approval.

550 POST GALVANIZING INSPECTION


Inspector: Submit, on request, evidence of training and competence in visual
inspection for liquid metal assisted cracking.
Components requiring additional inspection:
Procedure PGI 2A: none .
Procedure PGI 2B: none .
Timing: Before erection of steelwork or application of other coatings.
Action in event of non compliance:
Submit: Full records of all post galvanising inspections, drawing attention to
any erected components that are required to be quarantined.
Procedure PGi 3: Carry out on all quarantined components, and submit
report.
Sites of suspected defects: Remove zinc coating by grinding back to bright
metal for a distance of not less than 50 mm around each defect and from a
similar area on opposite face of member and inspect.
Remedial actions: Submit proposals.

560Y CONTROL SAMPLES


For exposed steelwork requiring a decorative finish the Contractor shall
arrange for two samples of each type of steel section exposed (UB, CHS,
fabricated box section) approximately 1m long or with the Engineers
agreement an alternative suitable piece of steel coated and welded in
accordance with the specification in advance of the main works.
Following approval by the Design Team this sample shall be kept at works
and used as reference to establish consistency of finished work during the
course of the Works and will be a point of reference re quality of finish to
be achieved.

PROTECTIVE COATING SYSTEMS

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600Y ANTICIPATED LIFE TO FIRST MAINTENANCE (ACCORDING TO ISO 12944 5)


The ISO 12944 standard is intended to assist engineers and corrosion experts in
adopting best practice in corrosion protection of structural steel at new
construction. It is progressively superseding regional standards to become a truly
global benchmark in corrosion control.

It has been assumed that the first major maintenance painting would be carried
out for reasons of corrosion protection once the coating has reached Ri3 as
defined in ISO 4628 3 Designation of degree of rusting, which refers to a
coating system where 1% of the surface area has broken down so that rust has
broken through. Based on this pre condition, the durability of a coating system
may be expressed in terms of 3 ranges:

Low 2 to 5 years
Medium 5 to 20 years
High More than 20 years

It needs to be clearly understood that the durability of a paint system i.e. how
long will it last before requiring a first major maintenance is not a "guarantee
time". Durability is a technical consideration that can help the Employer set up
a maintenance programme. A guarantee time is a consideration that is the legal
subject of clauses in the administrative part of the contract. The guarantee time
is usually shorter than the durability range. There are no rules that link the
two periods of time. It is important to note that the durability range does not
mean that it will not be necessary for localised touching up of the corrosion
during this period.

For this project, given the life period of 60 years the durability should be
specified as high and therefore in excess of 20 years. The nature of the structure
is such that minimal maintenance should be a key criterion in the selection of
the coating system increasing the thickness of coating can increase the
durability. A cost check for the best balance between initial costs of the coating
system against cost of maintenance should be carried out.

610 GALVANIZING TO CHEMICALLY CLEANED STEEL


Use/ location: ______ .
Preparation: Chemical cleaning.
Galvanizing: To BS EN ISO 1461.
Minimum mean coating thickness: 85 micrometres.

620 GALVANIZING TO BLAST CLEANED STEEL


Use/ location: ______ .

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Preparation: Blast cleaning to BS EN ISO 8501 1, preparation grade Sa2 1/2


using chilled angular iron grit grade G24 to give a coarse surface profile,
followed by chemical cleaning.
Galvanizing: To BS EN ISO 1461.
Minimum mean coating thickness: 140 micrometres.

638(A) INTERNAL NON EXPOSED STEELWORK


Two pack fast curing epoxy zinc phosphate protective finish compliant
coating
Use/Location : All internal non exposed steelwork including
steelwork
that is partially embedded in concrete (C2
environment as per ISO 12944 2 classification)
Paint Manufacturer : International Paint Ltd
Shop Preparation : Blast clean to Preparation Grade Sa21/2 (ISO
8501 1: 1988).

Ensure adequate surface profile.

Shop Primer : Intercure 200

Dry Film Thickness : 75 microns nominal


Colour : Red, Buff
Special Requirements : Maximum VOC: 200 grms/kg
Volume Solids: 67%
System SED Solvent Content : 38.1 gms per sq.m.
Contractor to ensure compatibility of protective primer and intumescent coating
(as specified by the Architects M61 specification)

638(B) INTERNAL NON EXPOSED STEELWORK


Two pack high solids epoxy zinc protective finish compliant coating
Use/Location : All internal non exposed steelwork including
steelwork
that is partially embedded in concrete (C2
environment as per ISO 12944 2 classification)
Paint Manufacturer : International Paint Ltd
Shop Preparation : Blast clean to Preparation Grade Sa21/2
(ISO 8501 1: 1988).

Ensure adequate surface profile.

Shop Primer : Interzinc 52

Dry Film Thickness : 75 microns nominal


Colour : Grey
Special Requirements : Maximum VOC: 152 grms/kg
Volume Solids: 59%
System SED Solvent Content : 48.7 gms per sq.m.

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Contractor to ensure compatibility of protective primer and intumescent coating


(as specified by the consultants intumescent specification)

640(A) INTERNAL EXPOSED STEELWORK


Two pack high solids polyaspartic primer/finish compliant coating
Use/Location : All internal exposed steelwork as required
required in a
C2 environment as per ISO 12944$2 classification.
Paint Manufacturer : International Paint Ltd
Shop Preparation : Blast clean to Preparation Grade Sa2.5
(ISO 8501 1 : 1988).
Ensure adequate surface profile
Shop Primer : Intercure 99
Dry Film Thickness : 150 microns minimum
Colour : As required
Special Requirements : VOC: 153 gms/kg
Volume Solids : 80%
System SED Solvent Content : 37 gms per sq/m.

- Anticipated life to first major maintenance: 20 years


(The figure above is not warranted, it is strictly for guidance purposes only)
- Contractor to ensure compatibility of protective primer and intumescent coating
(as specified by the consultants intumescent specification)

643(B)EXTRERNAL EXPOSED AND SEMI EXPOSED STEELWORK


Two pack high solids polyaspartic protective primer finish compliant coating
(for high architectural finish), non fire rated
Use/Location : All external exposed steelwork including semi
exposed areas in a C3 Enviroment as per ISO 12944 Classification to provide
20 years Life to First Major Maintenance.
Paint Manufacturer : International Paint Ltd
Shop Preparation : Blast clean following fabrication to Grade Sa2.5
(ISO 8501 1
1988).A surface profile of 50 75 microns is
recommended
Shop Primer : Intercure 99
Dry Film Thickness : 200 microns nominal
Colour : As required
Special Requirements : VOC: 153 gms/kg
Volume Solids: 80%
- System SED Solvent Content : 49 gms per Sq.m.
- Contractor to ensure compatibility of protective primer and intumescent coating
(as specified by the consultants intumescent specification)

PREPARATION FOR PAINTING

710X OFFSITE PREPARATION AND PAINTING


Working area: Covered and properly lit, heated and ventilated.
Sequence of working: Select from the following and submit proposals:
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Fabricate, blast clean, prime. This route must be adopted when applying
Intercure 99 for either external or internal exposed steelwork.
Blast clean, fabricate, remove flash rust with a light overall sweep blast,
prime.
Blast clean, apply weldable prefabrication primer, fabricate, prime.
Prefabrication primer (option 3): Type recommended by manufacturer of post
fabrication primer.
Thickness of post fabrication primer coat: May be reduced if and as
recommended by manufacturer.
Surfaces inaccessible after assembly: Apply full treatment and coating system
including, if necessary, local application of site coatings.
If a prefabrication primer is to be used apply a suitable product recommended
by International Paint Ltd.

720Y BLAST CLEANING FOR PAINTING


Ensure that steel complies with Sa 2.5 (ISO 8501 1 1998) at time of blasting
as follows:
Dry blasting: Initial rust grade A or B.
Blast clean to the specified Sa 2.5 preparation grades. Use abrasive of suitable
type and size, free from contamination by fines, water and oil. Remove
abrasive residues.

725X MANUAL CLEANING OF NEW STEELWORK (only when blast cleaning is


deemed impractical or impossible)
Only when specifically approved.
Preparation: Remove fins, burrs, sharp edges, weld spatter, loose rust and loose
scale.
Surface finish: Clean but unpolished to BS EN ISO 8501 1, grade St 2.
Finishing: Thoroughly degrease and clean down. Remove any consequent
rusting back to grade St 2. Prime without delay.

730 PREPARATION FOR SITE WELDING OF SHOP PAINTED STEELWORK


Method: Select from the following:
Mask weld areas immediately after blast cleaning and before coating
steelwork. If paint system comprises more than one coat, step each coat 30
mm back from edge of preceding coat and away from masked areas. Remove
masking immediately before welding.
Prepare and paint steelwork including weld areas. Grind off to bare steel
around each weld area immediately before welding.

735X TREATMENT OF SITE WELDED JOINTS IN PAINTED STEELWORK


Preparation: After welding, and without delay, vacuum blast all weld areas to
a minimum standard of Sa 2.5(ISO 8501 1 1988).
Prime without delay and apply further coatings to the weld areas to match the
surrounding painted areas.
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736 TREATMENT OF SITE WELDED JOINTS IN GALVANIZED STEELWORK


Preparation: After welding, and without delay, remove scale and weld spatter
from weld areas. Remove traces of rust. Wash with clean water and allow to
dry.
Coating: Reinstate using one of the methods given in BS EN ISO 1461, clause
6.3.

740X BOLTED JOINTS (OTHER THAN FRICTION GRIP JOINTS)


Steelwork to be shop painted: Apply full shop specification to joint faces.
Steelwork to be erected with mill finish then site painted: Before erection,
prepare and prime joint faces and allow to dry.
Bolted joints in externally exposed steelwork:
Immediately before assembling, apply a further coat of primer and bring
surfaces together while still wet.
After assembling and before applying site coatings, seal crevices to bolts and
joint perimeters with a compatible sealant noting compatibility requirement
of any subsequent intumescent paint.

745 FAYING SURFACES OF FRICTION GRIP JOINTS


Protection: Immediately after blast cleaning and before coating surrounding
areas, mask faying surfaces to protect from contamination and deterioration.
Paint systems comprising more than one coat: Step each coat 30 mm back
from edge of preceding coat and away from masked areas.
Removal of protection: Immediately before bolting, remove masking. Check
faying surfaces are free from adhesive. Clean with solvent if necessary.

750 FRICTION GRIP JOINTS IN SHOP PAINTED STEELWORK


Post assembly treatment of bolts and surrounding areas: After final tightening
of bolts and inspection of joints:
Thoroughly degrease and clean uncoated areas including bolts.
Prime without delay.
Apply full shop coating specification.
Direct tension indicators: Seal measuring gap to prevent ingress of moisture.

755 UNCOATED FASTENERS


Treatment: After steelwork erection and before applying site coatings,
thoroughly degrease and clean. Without delay, coat to match adjacent shop
painted areas.

760 GALVANIZED FASTENERS


Treatment: After steelwork erection and before applying site coatings,
thoroughly degrease and clean. Etch prime.

765 SITE PREPARATION OF SHOP PAINTED STEELWORK


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Preparation: Touch in shop coats, as necessary, and allow to dry. Before


applying site coats (when specified), abrade surfaces or wash down or both, as
recommended by paint manufacturer.

770 SITE PREPARATION OF GALVANIZED SURFACES FOR PAINTING


Preparation: Thoroughly degrease. Remove white corrosion products. Wash off
and allow to dry before applying etching wash or primer.

PAINTING

805Y FINISHES GENERALLY


Once applied the finish should not in any way slump, flow, crack, flake, split,
sag, pit, bubble, blister, float, effloresce, craze, shrink, break, wrinkle, crinkle,
yellow, chalk, fade, discolour, powder, stain, bleed or lose its finish or gloss in
any way taking full account of the extremes of all atmospheric and
environmental conditions specified for the service life specified.
Thinners shall not be added to paint to change in any way its constitution or
consistency unless agreed by Paint Manufacturer.
All finishes should be durable, of uniform texture and colour and should be
resilient.
All finishes should be uniform in texture, colour and appearance within the
limits of the agreed samples and without irregularities or distortion. Finish
coatings shall match the colour and gloss of the agreed control samples.
There shall be an interval of at least 24 hours between successive coats of
painting or as recommended by Paint Manufacturer.
The external aesthetic performance of the polysiloxane material is critical to
its choice and the manufacturer must be able to show over 10,000 hours quv
resistance with a gloss retention of above 50% as measured over this time
period.
On request evidence to be shown that after 28 days weathering in a C5 1
environmental the polysiloxane when subjected to a 3/8th inch mandrel bend
test, in accordance with ISO 1519, will show that no cracking/disbondment
has occurred.
Specular gloss levels for Intercure 99 polyaspartic and Interfine 979 acylic
polysiloxane at 60 degrees to the vertical will be typically 85 units as specified
and shall be measured in accordance with BSEN ISO 2813.
Epoxy Polysiloxanes are explicitly not approved.

810X ENVIRONMENTAL CONDITIONS


General requirements prior to starting coating work:
Surfaces: Unaffected by moisture or frost.

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Steel temperature: At least 3C above dew point, with conditions stable or


improving, and not high enough to cause blistering or wrinkling of the
coating.
Relative humidity: Below 85%.
No exterior painting in inclement weather.
Take all necessary precautions including restrictions on working hours,
providing temporary protection and allowing extra drying time, to ensure that
coatings are not adversely affected by climatic conditions before, during and
after application.
Application of coatings will be taken as an acceptance by the Contractor of the
suitability of surfaces and conditions within any given area.

815 COATINGS
Surfaces to be coated: Clean, dust free and suitably dry. Previous coats to be
adequately cured.
Multiple coats of same material: Use different tints to assist checking of complete
coverage.
Penultimate coat: Colour recommended by paint manufacturer to suit top coat
colour.
Finish required: Smooth and even, of uniform thickness and colour, free from
defects.

820 FILM THICKNESS


Wet film thickness: During application, check thickness of each coat with a
wheel or comb gauge used in accordance with BS EN ISO 2808.
Accumulated dry film thickness: After each coat has dried, check total
accumulated film thickness.
Method: Magnetic or electromagnetic meter.
Number and position of measurements: As directed.
Validation: Measurements to be independently witnessed.
Meter calibration: Check against standard shims and recalibrate regularly
against a smooth steel reference plate.
Average dry film thickness:
At least specified thickness over any square metre.
No reading to be less than 75% of specified thickness.
Top coat dry film thickness: Sufficient to give an even, solid, opaque
appearance.

825Y STRIPE COAT


- Stripe coating is to be carried out by brush for such items as welds, sharp edges
and corners of flanges, nuts and bolt heads and areas that are difficult to access.
Brush application of Intercure 99 stripe coat is to be carried out prior to the
full application of the specified coating by spray. Engineer to be informed when
stripe coating has been completed for inspection.

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- Where the Interfine 979 acrylic polysiloxane system has been specified then
stripe coating will be carried out for each coat in the system by brush
application prior to the full application of the specified coating. Engineer to be
informed when stripe coating has been completed for inspection.

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