1 SPECIAL TOPICS IN STEEL STRUCTURES – STR 654 STEEL STRUCTURE ERECTION By Hazem M. Ramadan October 13 1 Hazem M. Ramadan Associate Professor, Steel Structures and Bridges Structural Engineering Department Cairo University CONTENTS Field Bolts Connections Field Welded Connections Quali Inspection Testing Plan [ITP] Inspector Check List Cladding Erection October 13 2
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SPECIAL TOPICS IN STEEL STRUCTURES – STR 654
STEEL STRUCTURE ERECTION
By
Hazem M. Ramadan
October 13 1
Hazem M. Ramadan
Associate Professor, Steel Structures and BridgesStructural Engineering DepartmentCairo University
survey ongoing work› Inspector shall mark the bolts after they are snugged and
after they are tightened
October 13 9
after they are tightened› If any nut or bolt head is turned using the job inspecting
torque, all bolts in the connection should be tested accordingly
Turn of Nut Method› Egyptian Code
A- FIELD BOLTS CONNECTIONSFriction Bolts Tightening Methods
α = 90o + t + d
t is thickness of connected parts (mm), d is the bolt diameter ( mm).
› AISC
October 13 10
Eng.Ahmed
Stamp
Eng.Ahmed
Rectangle
6
Torque Wrench› The toque wrench shall be calibrated [Certificate] before
A- FIELD BOLTS CONNECTIONSFriction Bolts Tightening Methods
› The toque wrench shall be calibrated [Certificate] beforeusage in the presence of the inspector
› Torque values must be determined from tables or equationsmentioned in the approved Code
› The rotation between the bolt and the nut need not begreater than the Turn of the Nut rotation value
October 13 11
› At least three complete fastener assemblies shall be testedfor each combination of bolt length, diameter, grade, …etc
› The calibrated wrench must be re-used to re-torquepreviously tightened bolts.
Torque Wrench› If there are several bolts in a single connection minor
A- FIELD BOLTS CONNECTIONSFriction Bolts Tightening Methods
› If there are several bolts in a single connection, minorseparation is acceptable at the beginning.
› After tightening of subsequent bolts, the separation shalldisappear, leaving the tension in the first bolt less thanrequired.
› Hardened washers shall be installed under the element to beturned in tightening
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turned in tightening.› Several cycles may be necessary to ensure all bolts reach the
torque established for the day.
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Torque Wrench Types› Manual or Hydraulic in accordance to the project nature
A- FIELD BOLTS CONNECTIONSFriction Bolts Tightening Methods
› Manual or Hydraulic in accordance to the project nature.
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Torque Wrench› Egyptian Code
A- FIELD BOLTS CONNECTIONSFriction Bolts Tightening Methods
gyp
Ma = k d T
Ma is the applied torque.
k is a coefficient (about 0.2).
d is the bolt diameter.
T is the bolt pretension force.
October 13 14
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Direct Tension Indicator› The DTI with protrusion
compressed onl indicates that
A- FIELD BOLTS CONNECTIONSFriction Bolts Tightening Methods
compressed only indicates thatenough tension was applied at sometime.
› Specified tension is assured only ifthe bolts are systematically snuggedand tightened.
› Tightening of individual bolts withDTI shall not be accomplished in a
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DTI shall not be accomplished in asingle continuous operation.
Tension Control (Sheared Off Head)› The sheared-off splined end only indicates that enough
A- FIELD BOLTS CONNECTIONSFriction Bolts Tightening Methods
p y gtorque was applied to fracture the break neck.
› Specified tension is assured only if the bolts aresystematically snugged and tightened.
› Tightening to final tension and shearing the break neckshall not be accomplished in a single continuousoperation
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operation.
› The use of specific and proper lubricant.
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Bolts have to conform to the contract documents (ensure that the proper bolt grade is used)
A-FIELD BOLTS CONNECTIONSGeneral Procedure
Steel contact surfaces have to be free of dirt, dust, mill scale or any other foreign material
Ensure solid contact between the contact surfaces
Verify bolt installation method in accordance with specifications
Receipt of fasteners:
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p
Test certificate.
Lot number.
Accessories (nuts and washer) of same type
Proper storage
Get only the number of bolts for each shift.
Tension measuring device.
A-FIELD BOLTS CONNECTIONSGeneral Procedure
g
Reaming of poorly aligned holes.
Record major misalignment.
Exclude corroded or dirty bolts.
Fastener assemblies shall demonstrate an installation tension 5% higher than min. required tension.
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Bolts shall be brought to a snug-tight position.
Begin snug-tightening at the most rigid part of the connection and progress to the free edge.
After snug-tightening, full tightening to proceed similarly.
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Continuous surveillance by inspector.
Tension higher than specified is not a reason for rejection.
A-FIELD BOLTS CONNECTIONSGeneral Procedure
g p j
HSB must not be re-used.
Bevel washers are required if the surface of connected parts slopes more than 5% (1:20).
At splice location, bolts are to be tightened from the center outwards.
HSB b ti ht d b t r i ith r th t r th
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HSB may be tightened by turning either the nut or the head, provided a washer is used at the tightening end.
HSB must never be replaced by ordinary bolts.
All bolts (100%) must be checked at splice locations.
Specify codes and standards to be followed for fieldwelding
B-FIELD WELDED CONNECTIONS
welding
Weld procedure specifications must be submitted andapproved
Welders must be qualified
Non prequalified joints need to be qualified by testing
All ld b f h ldi d
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All welders must be aware of the welding procedurespecifications
Contact surfaces shall be cleaned prior to welding
Eng.Ahmed
Stamp
Eng.Ahmed
Typewriter
This is only in case of (HEX) head Bolts Round Plane Head Bolts Need to be tightened from the nut side.
Eng.Ahmed
Typewriter
Otherwise it will fail
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Welded parts shall be aligned complying with thetolerances specified in the mentioned codes and
B-FIELD WELDED CONNECTIONS
pspecifications
Specify weather and environmental conditions whenfield welding is not allowed
Weld consumables shall be purchased, stored, dried,and used according to the specifications
October 13 21
g p
Preheat shall be applied when applicable as perspecifications
Field painting / touch up shall be performed
A quality control plan should be prepared and carefullyfollowed:
C- QUALITY CONTROL
Erection method statement
Inspection and Testing Plan (ITP)
Erection inspection check list (EICL)
Procedures & inspection forms as stated in the ITP
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Bolt tightening procedure
Paint touch up procedure
Site organization chart including dedicated safetyofficer and Quality Control engineer
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D- INSPECTION TESTING PLAN
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E- INSPECTOR CHECK LIST Review and understand erection procedure Review false work and traffic plan E l f b Ensure complete survey of superstructure by an
independent surveyor Check alignment and levels of bearings Check anchor bolt locations Check surface finish of concrete. Minor grinding /
chipping may be required Check required shims for level adjustment
October 13 24
Check required shims for level adjustment Ensure pockets are fully grouted with an approved grout
material (where required) Check temperature when grouting according to supplier
requirements
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F- CLADDING ERECTION Preparation Touch up any paint damage of the steel
structure prior to erecting the cladding. Install the base angle (in case side cladding
extends to the ground). Use temporary supports (if sag rods are not
used or not sufficient to get the side girts inhorizontal position.
Prepare erection tools Lay down the roof panels on the roof (make
sure of the applied load)
October 13 25
pp )
F- CLADDING ERECTION Installation of cladding Use chalk line to mark the position of the
girts on the cladding.girts on the cladding. Make sure that the wall sheeting is
straight and connect it to the top purlin,base angle, and side girts.
Install the roof sheeting as per theprearranged sequence in the drawings
Bead mastic should be carefully installedbetween the cladding layers.
October 13 26
g y
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F- CLADDING ERECTION Important Notes Stay away from high
corrugationscorrugations. Brush off any metal chips. Workers should use soft
footwear to avoid damagingthe cladding.
Walk on the sheet valleys incontact with the purlins