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RIO TINTO IRON ORE EXPANSION PROJECTS Document Number: SKM-STD-C-009

Standard Specification for Fabrication and Revision: 0

Erection of Structural Steel Issue Date: 25 September 2008

SKM ACN 001 024 095 ABN: 37 001 024 095

P:\SKM_GEN\Deliverables\Specifications\SKM Standard Specs\Civil-Struct-Marine\SKM-STD-C-009 Rev 0 Fabrication & Erection of Structural Steel.doc

CONTENTS

1.0 SCOPE 1

2.0 ABBREVIATIONS 1

3.0 CODES AND STANDARDS 1

3.1 Standard Specifications 2

3.2 Australian Codes and Standards 2

3.3 Statutory Regulations 4

4.0 MATERIALS 5

4.1 General 5

4.2 Certification 5

4.3 Substitution of Sections 6

4.4 Steel Plate 6

4.5 Hot Rolled Sections 6

4.6 Welded Sections 6

4.7 Floor Plate 6

4.8 Hollow Sections 6

4.9 Cold Formed Galvanised Steel Section 6

4.10 Fasteners 6

4.11 Grating 7

4.12 Stairways, Ladders and Handrails 7

5.0 INSPECTION AND TESTING 7

5.1 Material Testing 8

5.2 Weld Testing and Inspection 8

5.2.1 Visual Inspection 8

5.2.2 Non-Destructive Testing, SP Welds 9

5.2.3 Content of Non-Destructive Testing (NDE) Reports 10

5.2.4 Testing of Fatigue Purpose (FP) Welds 10

5.2.5 Representative Sampling 10

5.2.6 Repair of Sub-Standard Welds 10

5.3 Inspection by the Engineer 10

5.4 Inspection During Fabrication 11

5.5 Inspection During Erection 11

5.6 Surface Protection 11

6.0 FABRICATION 11

6.1 General 11

6.2 Shop Drawings 12

6.3 Tolerances 12

6.4 Cutting and Bending 12

6.5 Splices and Joints 12

6.6 Bolt Holes 13

6.7 Tubular Construction 13

6.8 Steel Grating 14

6.9 Purlins and Girts 14

7.0 BOLTING 14

7.1 General 14

7.2 Stainless Steel Bolted Connections 15

7.3 Mild Steel Bolts 15

7.3.1 Commercial and Precision Bolts 15

7.3.2 High Strength Bolted Connections 16

RIO TINTO IRON ORE EXPANSION PROJECTS Document Number: SKM-STD-C-009

Standard Specification for Fabrication and Revision: 0

Erection of Structural Steel Issue Date: 25 September 2008

SKM ACN 001 024 095 ABN: 37 001 024 095

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8.0 WELDING 16

8.1 General 16

8.2 Welding Supervision 17

8.3 Minimum Fillet Weld Size 17

8.4 Preheating 17

8.5 Butt Welds 17

8.6 Procedure and Performance Qualifications for Welding 18

8.7 Weld Materials 18

8.8 Site Welding 18

8.9 Weld Repairs 19

9.0 SURFACE PROTECTION 19

9.1 General 19

9.2 Gilsomastic Paint 19

10.0 MARKING 19

10.1 General 19

10.2 Method 19

10.3 Location 19

10.4 Column Levelling Marks 20

11.0 HANDLING, STORAGE AND DELIVERY TO 20

11.1 Handling and Storage 20

11.2 Delivery to 20

12.0 ERECTION AND ASSEMBLEY 21

12.1 General 21

12.2 Alignment and Fitting 21

12.3 Metal Floor Decking 21

12.4 Floor Grating 22

12.5 Erection Tolerances 22

12.6 Setting Base plates 22

13.0 HANDRAILS 22

13.1 Fabrication and Erection 22

13.2 Surface Protection 23

14.0 MODIFICATION TO STRUCTURAL STEELWORK 23

14.1 General 23

14.2 Modifications and Corrections 23

14.3 Cutting 24

14.4 Holing 24

14.5 Finishing 24

15.0 GROUTING 24

15.1Preparation 24

15.2 Formwork 25

15.3 Grout 25

15.4 Curing 25

16.0 CLEAN UP 25

APPENDICES

Appendix A ?Stainless Steel Fasteners

Appendix B ?Structural Grade Carbon Steel Fasteners

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1.0 SCOPE

This specification covers the requirements for the fabrication and erection of

structural steel and mechanical steelwork, including materials, inspection and

testing, fabrication, bolting, welding, handling, storage, delivery to, erection,

modifications and grouting of base plates.

2.0 ABBREVIATIONS

The abbreviations listed below, where used in this specification, shall have the

following meanings:

AS Australian Standard

SAA Standards Association of Australia

AS/NZS Australian Standard / New Zealand Standard

WTIA Welding Technology Institute of Australia

NATA National Association of Testing Authorities

AINDT Australian Institute of Non Destructive Testing

3.0 CODES AND STANDARDS

The latest revision of the following documents shall form part of this specification

and shall apply wholly or partially as the case may be and as necessary for the

performance of the Work under the Contract.

The contractor shall advise the Engineer in writing of any of the requirements of

this specification that are of a lower standard than the local Standard or the

contractor standard practice.

Local or international standards with requirements equal to or greater than the

Standards nominated herein may be applied with the written approval of the

Engineer.

In the event of inconsistencies between documents, drawings or reference

standards pertinent to the Contract, the more stringent requirements shall apply

unless approved otherwise in writing by the Engineer.

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3.1 Standard Specifications

Specification No. Title

SKM-STD-C-005 Supply and Placement of Concrete

SKM-STD-C-006 Placement of Concrete

SKM-STD-C-007 Anchor Bolts

SKM-STD-C-010 Fabrication & Erection of Structural Steelwork for Marine

Works

SKM-STD-C-011 Surface Preparation, Painting and Galvanising of Steelwork

SKM-STD-G-001 Drawing and Documentation / Data Requirements

3.2 Australian Codes and Standards

Unless otherwise specified or shown, the latest edition of the relevant Australian

Codes and Standards, including but not limited to, the following:

Australian Standard Title

AS 1101 Part 3 - Graphical symbols for general engineering

?Welding and non-destructive examination

AS 1110 ISO Metric hexagon bolts and screws ?Product Grades

A and B

AS 1111 ISO Metric hexagon bolts and screws ?Product Grade C

AS 1112 ISO Metric hexagon nuts

AS 1163 Structural steel hollow sections

AS/NZS 1170 Part 0 ?General principles

Part 1 ?Permanent, imposed and other actions

Part 2 ?Wind actions

Part 4 ?Earthquake loads

AS 1171 Non-destructive testing ?Magnetic particle testing of

ferro-magnetic products, components and structures

AS 1214 Hot-dipped galvanised coatings on threaded fasteners

AS 1237 Plain washers for metric bolts, screws and nuts for

general purposes

AS/NZS 1252 High strength steel bolts with associated nuts and

washers for structural engineering

AS 1275 Metric screw threads for fasteners

AS 1397 Sheet steel and strip ?Hot dipped zinc-coated or

aluminium/zinc-coated

AS 1418 Cranes, hoists and winches

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Australian Standard Title

AS/NZS ISO 14343 Welding Consumables ?wire electrodes, wires and rods

for arc welding of stainless and heat resisting steels ?

Classification

AS/NZS ISO 17633 Welding consumables ?Tubular cored electrodes and

rods for gas shielded and non-gas shielded metal arc

welding of stainless and heat resisting steels ?

Classification

AS/NZS 4854 Welding Consumables ?Covered electrodes for manual

metal arc welding of stainless and heat resisting steels -

Classification

AS/NZS 4855 Welding Consumables ?Covered electrodes for manual

metal arc welding of non-alloy and fine grain steels ?

Classification

AS/NZS 4856 Welding Consumables ?Covered electrodes for manual

metal arc welding of creep resisting steels ?

Classification

AS/NZS 4857 Welding Consumables ?Covered electrodes for manual

metal arc welding of high strength steels ?Classification

AS/NZS ISO 17632 Welding Consumables ?Tubular cored electrodes for

gas shielded and non-gas shielded metal arc welding of

non-alloy and fine grained steels ?Classification

AS/NZS ISO 17634 Welding Consumables ?tubular cored electrodes for gas

shielded metal arc welding of creep-resisting steels ?

Classification

AS/NZS ISO 18276 Welding Consumables ?Tubular cored electrodes for

gas shielded and non-gas shielded metal arc welding of

high strength steels ?Classification

AS/NZS 2717 Welding ?Electrodes ?Gas Metal Arc ?Ferretic steel

electrodes

AS/NZS 1554 Structural steel welding

AS 1579 Arc welded steel pipes and fittings for water and

wastewater

AS 1627 Metal Finishing ?Preparation and Pre-Treatment of

Surfaces

AS 1657 Fixed platforms, walkways, stairways and ladders ?

design, construction and installation

AS 1710 Non-destructive testing ?Ultrasonic testing of carbon and

low alloy steel plate ?Test methods and quality

classification

AS 1789 Electroplated zinc (electro galvanised) coatings on

ferrous articles (batch process)

AS 1796 Certification of welders and welding supervisors

AS 1858 Electrodes and fluxes for submerged arc welding

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Australian Standard Title

AS 1966 Electric arc welding power sources

Part 1 ?Transformer type

Part 2 ?Rotary type

Part 3 ?Plasma arc cutting and welding types

AS 2159 Piling ?Design and installation

AS 2177 Non-destructive testing ?Radiography of welded butt

joints in metal

AS 2207 Non-destructive testing ?Ultrasonic testing of fusion

welded joints in carbon and low alloy steels

AS 2214 Certification of welding supervisors

AS 2812 Welding, brazing and cutting of metals ?Glossary of

terms

AS 2980 Qualification of welders for fusion welding of steel

AS/NZS 3678 Structural steel ?Hot rolled plates, floor plates and slabs

AS/NZS 3679 Structural steel

Part 1 ?Hot rolled bars and sections

Part 2 ?Welded I sections

AS 3990 Mechanical equipment ?Steelwork

AS 4100 Steel structures

AS 4291 Mechanical Properties of Fasteners

AS/NZS 4600 Cold-formed steel structures

AS/NZS 4673 Cold-formed stainless steel structures

ISO Standard Title

ISO 3506.1 & 2 Mechanical Properties of Corrosion Resistant Stainless

Steel Fasteners

International Standards with requirements equal to or greater than the

corresponding Australian Standards may be applied with the written approval of

the Engineer.

3.3 Statutory Regulations

The contractor shall be responsible for compliance of all Works with Australian

Government Acts, By-laws and Regulations, both State and Federal, including but

not limited to:

?Electricity Act Regulations (1945);

?Explosives and Dangerous Goods Act (1961) and Explosives Regulations

(1963);

?WA Electrical Requirements (1995) Particular Specifications;

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?WA Occupational Safety and Health Act (1984);

?WA Occupational Health and Safety Regulations (1996);

?Mines Safety and Inspection Act (1994);

?Mines Safety and Inspections Regulations (1995);

?Transport Operation (Marine Safety) Act (1994);

?Machinery Safety Regulations.

Where Works may be performed outside of Australia, the contractor shall comply

with all applicable International and National Acts, By-laws and Regulations.

4.0 MATERIALS

4.1 General

All materials shall be from an assured source and shall be new and of unused

stock and free from splices for the full length between joints unless otherwise

approved by the Engineer (see Section 6.6). All steel shall be free from rust,

pitting and other defects which are likely to impair either its structural capacity or

the quality of the protective coating system.

4.2 Certification

The contractor shall obtain manufacturer抯 material test certificates or certified

reports of tests made by a NATA certified testing laboratory (or by an overseas

facility which must be acceptable to the Engineer) for all steel plate and sections

demonstrating compliance in all respects with the specified standards. The

manufacturer抯 certificates shall be available at the manufacture抯 workshop upon

request. All such plates and sections shall have clear and distinct marks

identifying the respective grades of steel. The type of certificate required shall be

as follows:

Material Certificate Type

The certificate types shall conform to the requirements of Standard EN 10204

Type 2.2.

Carbon Steel Test Report (with mention of the test results carried out on the

basis of non-specific testing and inspection). Document

validated by the Manufacturer.

Welding

Consumables

Test Report (with mention of the test results carried out on the

basis of non-specific testing and inspection). Document

validated by the Manufacturer.

Fasteners Test Reports shall be in accordance with Appendix A or B,

whichever is applicable.

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All data listed in the certificates and reports shall be shown in SI units, in

accordance with AS 1100 International System of Units (SI) and its application.

Certificates shall be written in the English language and shall be complete,

unambiguous, legible and suitable for electronic scanning. Certificates in other

languages will only be accepted if they are supplied with an endorsed English

translation by an authority approved by the Engineer.

The Engineer will perform random examination of material certificates to check

compliance with these requirements.

4.3 Substitution of Sections

Substitution of structural steel sections or variation of details shown on the

drawings shall not be made without the prior written approval of the Engineer.

4.4 Steel Plate

All steel plate shall be Grade 250 to AS 3678, unless noted otherwise on the

drawings.

4.5 Hot Rolled Sections

All hot rolled sections shall be Grade 300 (i.e. BHP-300 Plus), unless noted

otherwise on the drawings.

4.6 Welded Sections

All standard welded beams (WB) and welded columns (WC) shall be Grade 300 to

AS 3679.2, unless noted otherwise on the drawings (i.e. AS/NZS 3679.2-300).

4.7 Floor Plate

All floor plate shall be Grade 250 to AS/NZS 3678, and shall have a raised pattern

surface (i.e. AS/NZS 3678-250).

4.8 Hollow Sections

All structural hollow sections shall comply with AS 1163. All rectangular and

square hollow sections and circular hollow sections of diameter greater than or

equal to 168.3mm and less than or equal to 457.0mm shall be grade C350 (i.e.

AS1163-C350), unless noted otherwise on the drawings. Other hollow sections

shall be grade C250 (i.e. AS 1163-C250), unless noted otherwise on the drawings.

4.9 Cold Formed Galvanised Steel Section

Cold formed galvanised steel sections shall be formed from Grade 450 hot-dipped

zinc coated steel as specified in AS 1397.

4.10 Fasteners

All bolts, washers and nuts shall comply with the relevant Australian Standards

and where specified shall be supplied with an anti-corrosion treatment comprising

one of the following systems, as specified on the drawings:

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i) Hot-dipped galvanized in accordance with AS 1214, unless noted,

otherwise;

ii) Zinc plated in accordance with AS 1397 where specified on the drawings,

or;

iii) Stainless steel Grade 316 to AS/NZS 4673 bolts, nuts and washers

Strength Classes A4-50 and A4-70 depending on size (unless noted

otherwise), where specified on the drawings.

The requirements for mechanical properties of fasteners are set out in Appendices

A and B.

Refer to Section 7.0 for additional bolting requirements during construction.

4.11 Grating

All grating shall be mild steel, 慦ebforge?F325MPG or 慦eldlok?B60-325

galvanised (or Engineer approved equivalent) unless noted otherwise on the

drawings. All stair treads shall be 慦ebforge?T6 (ex F325MPG) or 慦eldlok?T6

(ex B60-325) galvanised with replaceable non-slip stair tread nosing, or Engineer

approved equivalent. Grating used on dolphins shall be 慦ebforge?F325MSG or

慦eldlok?B60-325 serrated galvanised, or Engineer approved equivalent.

All grating shall be hot dipped galvanised.

4.12 Stairways, Ladders and Handrails

All materials for stairways and ladders shall be in accordance with AS 1657.

All handrails shall be the 慚onowills?handrail system, unless otherwise nominated

or approved by the Engineer.

5.0 INSPECTION AND TESTING

The contractor shall be responsible for all inspection testing and reporting of the

Works specified in this document. Any independent testing authority used shall

have the appropriate NATA certification to carry out the range of testing specified.

All testing for which the contractor is responsible shall be reported directly to the

Engineer. In the event of materials or work being rejected as a result of inspection

or testing, the contractor shall be responsible for the replacement, repair and

further testing of the materials or work.

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5.1 Material Testing

Material certification shall be supplied for all material in accordance with Section

4.2.

The contractor shall be responsible for ensuring that the chemical and mechanical

properties of all steel used in the Works comply with this specification. Chemical

analysis and mechanical testing, including tension, bend, flattening and impact

tests, shall be performed for each batch of steel. Testing shall be performed by

the steel manufacturer or by an approved laboratory. Results shall be presented in

a manner that demonstrates compliance to the requirements of Australian

Standard AS/NZS 3678 (or an approved equivalent International Standard), and

shall be submitted to the engineer when available but before the relevant materials

are incorporated into the works.

The Engineer reserves the right to decide whether or not a plate is considered to

be acceptable and may or may not be used in the Works. The contractor shall

replace all material rejected by the Engineer.

In the event that the manufacturer is unable to produce steel manufacturer抯

certificates in accordance with Section 4.0 when requested by the Engineer,

specimens for testing shall be prepared by the contractor and shall be tested by an

independent NATA registered laboratory, as part of the contractor抯 responsibility.

Testing of specimens shall be carried out in accordance with relevant Australian

Standards.

Where the contractor is unable to produce steel manufacturer抯 certificates for the

through-thickness properties of steel plate 32mm thick or over, or the plate is

manufactured outside Australia, it shall be ultrasonically tested for flaws from both

sides for laminations and other defects in accordance with the requirements of AS

1710 Level 2.

Where the contractor has carried out testing as noted above, they shall issue all

test certificates and reports to the Engineer for approval prior to the tested steel

being used in the Works. The location and extent of inclusions and /or laminations

shall be detailed and sketched in the report.

5.2 Weld Testing and Inspection

The extent of inspection and testing of welds shall be as specified in Sections 5.2.1

and 5.2.2. Where testing levels are less than 100% the Engineer will have the

right to nominate the welds to be tested.

5.2.1 Visual Inspection

Visual inspections of all weld preparation and all welds shall be carried out in

accordance with AS/NZS 1554 except the extent of visual inspection shall be as

follows:

a) visual scanning ?100% of all weld preparations;

b) visual examination ?100% of all welds.

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All visual inspections of welds shall be undertaken by a qualified welding inspector

who has not been involved in the supervision of the welding. Visual inspection

also includes the inspection of the weld preparation.

Should the weld fail the visual inspection criteria as defined in AS/NZS 1554, the

weld shall be rejected and no further non-destructive testing is prescribed until the

condition of the weld is rectified.

5.2.2 Non-Destructive Testing, SP Welds

The following non-destructive testing of welds shall be carried out by the contractor

using an independent NATA registered laboratory. The Engineer shall be advised

that the reports are available for review within ten (10) working days of the test

date.

All NDT Technicians must be fully qualified for the relevant testing to be

undertaken and be qualified to AINDT, PCN or similar. Copies of the technician抯

qualifications shall be made available for review prior to any NDT works being

undertaken.

The testing procedures to be used are:

i) radiographic testing;

ii) ultrasonic testing;

iii) magnetic particle testing.

The extent of testing shall be as follows:

?Shop Welds:

a) 100% of all shop complete penetration butt weld splices for beams

and columns using procedures (i) or (ii) and (iii);

b) all shop complete penetration butt welds, test 10% of the length of

all welds longer than 1000mm or a minimum of 10% (one in ten) of

all other complete or partial penetration welded joints where welds

are less than 1000mm long using procedures (i) or (ii);

c) all critical welds as specified on the drawings and/or noted in the

contract specification, where no procedure is nominated, using

procedures (i) or (ii) and (iii);

d) all shop fillet welds, test 10% of the length of all welds longer than

1000mm or a minimum of 10% (one in ten) of all other shop fillet

welded joints less than 1000mm long using procedure (iii).

?Field Welds:

a) 100% of all field complete penetration butt weld splices for beams or

columns, including using procedures (i) or (ii) and (iii);

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b) 30% of all field complete penetration or partial penetration butt

welds shall be tested using procedure (i) or (ii) and (iii);

c) all critical welds as specified on the drawings and/or noted in the

contract specification, where no procedure is nominated, using

procedures (i) or (ii) and (iii);

d) 10% of all field fillet welds shall be tested using procedure (iii).

The maximum imperfection level for SP welds as determined by testing or

examination shall be limited to L/5 for all plate thicknesses.

5.2.3 Content of Non-Destructive Testing (NDE) Reports

All NDE reports shall contain as a minimum a drawing reference, unique weld

number (as per weld map), welder identification, weld type and exact position of

the test area, full detail of defective area as applicable, statement of compliance

and the name of the Technician and Testing Company.

5.2.4 Testing of Fatigue Purpose (FP) Welds

Unless noted otherwise, FP welds shall be subject to the following testing and

inspection in accordance with the requirements of AS 1554.5:

i) visual scanning 100%;

ii) visual inspection 100%;

iii) magnetic particle testing 100%;

iv) radiographic testing or ultrasonic testing 50%.

5.2.5 Representative Sampling

Where sampling of welded joints is required for non-destructive testing, such

sampling shall be consistent over the duration of shop fabrication and

representative of all types of welded joints, welding procedure specifications

(WPS) and also provide a representative sample of each welder抯 work.

5.2.6 Repair of Sub-Standard Welds

All welds failing to meet the permissible levels of imperfections allowed in

AS/NZS 1554 shall be removed or repaired to the satisfaction of the Engineer, and

then re-tested, along with two (2) extra samples of the same WPS and welder

output either as 10% of the weld length or 10% (one in ten) of all other welded

joints as applicable.

5.3 Inspection by the Engineer

The contractor shall give the Engineer 24 hours notice for inspections nominated

as Witness or Hold points on the contractor抯 ITP, or where the Engineer抯

approval is required for commencement of any stage of the Works.

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5.4 Inspection During Fabrication

During fabrication, the contractor and subcontractor(s) shall permit the Engineer,

or his representative free access to the fabricators?works at all reasonable times

for the purpose of carrying out inspections, and shall afford all necessary facilities

for carrying out such inspections. Items shall be laid out as necessary so that all

parts are accessible for inspection as directed by the Engineer. Any inspection by

the Engineer will not prevent the ultimate rejection of any work or materials in

which defects have been found at any time prior to the completion of the Contract.

5.5 Inspection During Erection

During erection/installation, the contractor and subcontractor(s) shall permit the

Engineer, or his representative, free access to the Works at all reasonable times

for the purpose of carrying out inspections and shall afford all necessary facilities

for the carrying out of such inspections.

All field bolting and field welding shall be inspected during erection. All field weld

slag shall be removed prior to inspection.

Priming and painting in the vicinity of welds shall not be carried out over any field

welding until they have been tested in accordance with Section 5.2.

No concrete encasing or formwork installation shall be carried out until the

Engineer has inspected and approved the preparation of the steelwork to be

encased.

No grouting may take place until the Engineer has inspected and approved the

preparation of both the steel and concrete.

5.6 Surface Protection

Testing of protective coatings shall be in accordance with the Standard

Specification SKM-STD-C-011 揝urface Preparation, Painting and Galvanising of

Steelwork?

6.0 FABRICATION

6.1 General

All structural steelwork shall be fabricated as shown on the drawings and in

accordance with the requirements of this specification and AS 4100.

Substitutions of structural steel sections or modifications of design details shall

only be made with the written approval of the Engineer.

All members shall be pre-fabricated into sub-assemblies to facilitate field erection.

The maximum size suitable for sub-assemblies shall be subject to approval.

Site fit shall be the responsibility of the contractor. Consideration shall be given to

undertaking trial assembly of sub-assemblies prior to painting, but after abrasive

blasting and any stress relief.

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The steelwork shall be fabricated complete with all necessary temporary brackets,

straps, gussets, cleats, fixings and the like necessary for handling, erection and

assembly of the steelwork.

Temporary fittings, bracings, stiffeners used as fabrication aids in the handling and

erection of steelwork or attachment and support of temporary Works shall be

welded in accordance with this specification. Such temporary fittings may be

allowed to remain in place with the written approval of the Engineer. The

contractor shall submit the type, size and location of all lugs to the Engineer for

approval where the lifting lug exceeds 5t Working Load Limit (WLL).

6.2 Shop Drawings

If directed by the Engineer, the contractor shall be responsible for the preparation

of all shop drawings required for the satisfactory fabrication of steelwork in

accordance with the drawings and specification. Shop drawings shall be prepared

in accordance with CLU-STD-G-001 揝tandard Specification for Drawing and

Documentation / Data Requirements?and shall be submitted to the Engineer for

approval before fabrication commences. Approval of shop drawings by the

Engineer will not relieve the contractor of any responsibility for the accuracy of the

drawings or the fabrication Works there from.

6.3 Tolerances

Tolerances for fabrication of structural steelwork shall be in accordance with AS

4100 unless shown otherwise on the drawings and/or Contract Specification. Such

tolerances are assumed to apply at 20篊.

6.4 Cutting and Bending

All structural steel components shall be plasma or flame cut, sheared or sawn to

the profile as shown on the drawings with the as-cut surfaces and edges in

compliance with AS/NZS 1554. After cutting, all edges shall be ground off to

provide a smooth, even and true profile. Sheared edges to be included in welded

joints shall be ground free of sharp edges.

Preparation of structural tubes for welding shall be in accordance with

AS/NZS 1554.

If members or plates are bent or set, the bends and sets shall be made to the radii

and angles specified and shall be free from hammer marks. Edges of plates to be

bent shall be ground smooth prior to bending.

All plates, gussets, members etc shall have sharp edges and corners rounded and

ground smooth to a minimum radius of 2mm.

6.5 Splices and Joints

Where available stock lengths of steel are shorter than the required length of a

member, splicing by complete penetration full section butt welds is permitted,

unless otherwise noted on the drawings. All splice welds not shown on drawings

shall be approved by the Engineer who shall be notified in writing of the position of

splice weld prior to the joining of the two (2) parts. All such welds shall be

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subjected to 100% ultrasonic or radiographic and magnetic particle testing in

accordance with Section 5.2.

The minimum length of a spliced section component should not be less than six (6)

times the depth of the section or 1000mm, whichever is greater.

Welded splices in compound members shall be staggered, and the component

plates and sections spliced before compounding.

Critical field splices and joints shall be mated in the shop on completion of

fabrication to ensure satisfactory fit when installed.

Should the contractor wish to make field splices and joints, whether bolted or

welded, in addition to those shown on the drawings, or in different locations, such

connections shall be to the written approval of the Engineer in respect to design,

procedure and workmanship.

6.6 Bolt Holes

Unless otherwise noted on the drawings, holes for bolts (except anchor bolts to

footings) shall be not more than 2mm larger in diameter than the bolt which is to be

used. Where paint system SKM-P3 or SKM-P4 is used in accordance with SKMSTD-

C-011, holes for bolts shall not be more than 3mm larger in diameter than the

bolt which is to be used. Where stainless steel bolts are used with grommets, the

hole shall be 2mm larger than the grommet diameter.

Where steelwork is hot dipped galvanised, the contractor shall ensure the zinc

coating thickness within bolt holes does not exceed 200 microns.

Holes in base plates for anchor bolts to footings shall be not more than 6mm

oversize for anchor bolts up to and including 24mm in diameter and not more than

8mm oversize for bolts greater than 24mm in diameter.

Where slotted holes are specified or shown, such holes shall be accurately shaped

with sides smooth, parallel and semi-circular at the ends. Clearance tolerances

shall be as noted above. Length of slotted holes shall be defined as the distance

between centres of drilled or punched holes.

Round or slotted holes in structural steelwork shall not be flame cut. The areas

around holes shall be smooth and free of burrs and fins or other defects which may

prevent solid seating of the contact surfaces.

Punching of holes full size shall be carried out in accordance with AS 4100. Holes

may be punched to at least 3mm undersize and then reamed to full size.

Holes through tubular members shall be lined with sleeves and an external fillet

weld run around the perimeter of the sleeve to seal the gap between the sleeve

and the wall of the tube.

6.7 Tubular Construction

Structural steel tubes and rectangular hollow sections which are to be welded shall

not be sheared, but shall be cut and profiled to fit the shape of the members to

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which they are to be welded. The Contractor shall make appropriate allowances to

ensure match of the mating faces for shop and site splices.

All tubes and hollow sections shall be fully sealed to prevent the ingress of

moisture. Unless noted otherwise, 5mm thick plate shall be used for sealing

purposes, where the members will not be fully sealed in the final fabrication or

erection. All fabricated box sections shall also be fully sealed.

Where galvanising is specified the contractor shall provide all holes in the

members required to ensure adequate venting and no deformation during the

galvanising process. Where galvanised and shown on the drawings, seal weld

and touch up all vent holes, prior to delivery to.

6.8 Steel Grating

Steel grating for floors, walkways, landings and stair treads shall be in sizes

suitable for handling and shall be suitably marked or tagged. The layout of the

panels shall be such as to facilitate their installation and securing in position by the

contractor.

Not withstanding any tolerances nominated by the grating manufacturer, the

contractor shall select, cut and trim each panel so that, when fixed in position, the

maximum difference in vertical level between adjacent edge bars of adjoining

panels shall be not more than 3mm and the maximum horizontal gap between

such edge bars shall be not more than 10mm.

All panels and all openings and recesses in panels for pipes, ducts, and the like,

shall be neatly trimmed all round with a continuous edge piece of at least the same

size as the load bars. All load bars shall be securely welded to the edge pieces.

The contractor shall prepare shop drawings detailing all penetrations required in

the flooring panels and all reinforcement required.

Penetrations to floor panels shall be cut and fabricated in the shop prior to hot dip

galvanising.

6.9 Purlins and Girts

Purlins and girts shall be continuous members, supplied and erected in

accordance with the Manufacturer抯 specification, complete with laps at splices

where required and central or double rows of bridging where shown.

7.0 BOLTING

7.1 General

Structural steelwork shall be bolted as shown on the drawings. All bolts, washers

and nuts shall comply with the relevant Australian Standards.

Unless specified otherwise, all bolted joints shall be made using Grade 8.8 high

strength bolts, nuts and washers.

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The length of bolts shall be selected so that the threaded portion of the bolt shall

project through the nut a minimum two (2) threads and a maximum of 10 mm when

fully tightened and so that the nut can be fully tightened without reaching the end

of the thread.

Where bolted end cleats are used, they and the member to which they are

connected shall receive the full specified treatment before assembly.

Bolted connections subject to vibration and/or heavy loads shall be fitted with lock

nits approved by the Engineer. Such bolted connection may include but not be

limited to: platform support, walkways, conveyors, steelwork and secondary

steelwork.

7.2 Stainless Steel Bolted Connections

All bolts, nuts and washers used offshore below deck level shall be stainless steel

316 (minimum Grade A4) fitted with lock nuts unless shown otherwise on the

drawings.

All stainless steel bolts shall have rolled threads and be:

A4-70 For bolts less than or equal to M20

A4-50 For bolts greater than M20

All stainless steel bolts and nuts assembled with lock nuts shall have threads

treated with a nickel-based anti-seize compound. Stainless steel bolts assembled

into ferrules shall have 慙octite Threadlocker 243?or a similar approved removable

thread locking compound applied to the threads when installed, in accordance with

the Manufacturer抯 written instruction.

Stainless steel bolts shall be tightened to the correct torque using a torque wrench

in accordance with the Manufacturer抯 specification. Tightening torques shall take

into account lubrication of threads and nyloc nuts.

Where joint configurations include acetal grommets and/or neoprene spacers,

stainless bolts shall be tensioned such that joint integrity is achieved without

damage to acetal grommets and neoprene spacers.

7.3 Mild Steel Bolts

All mild steel bolts, washers and nuts shall be hot-dipped galvanised in accordance

with AS 1214.

7.3.1 Commercial and Precision Bolts

Commercial bolts may be used for field connections for handrails, cold formed girts

and purlins, stair treads, handrails, doors and window framing. Commercial bolts

are indicated on the drawings as 4.6/S in accordance with AS 1111, Clause 5.1.

Nuts and washers shall be compatible with the bolts used and members joined.

The length of bolt shall be selected so that the threaded portion of the bolt shall

project through the nut for a minimum of two (2) threads and a maximum of 10mm

when fully tightened.

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7.3.2 High Strength Bolted Connections

High strength bolted connections shall be bearing-type (TB), unless otherwise

shown and shall be made in accordance with the provisions of AS 4100.

All bolts indicated on the drawings as 8.8/TB or 8.8TF may be tightened by the

direct-tension indication method or 揚art Turn?method specified in AS 4100. Bolts

tensioned using the direct-tension indication method shall be installed with a

galvanised load indicating device under the element (nut or bolt head) not turned in

tightening. The flat side of the load indicating washer shall be placed against the

steelwork with the protrusions facing towards the bolt head or nut, as appropriate.

Bolts installed by the direct-tension indication method shall be tightened in

accordance with AS 4100.

The contractor抯 proposed methods for bolt tightening shall be submitted to the

Engineer for approval. The tensioning of bolts using torque wrenches is not

permitted, except for stainless steel bolts.

One (1) flat round hardened steel washer shall be used under the nut for each

bolted connection except that if the bolt is turned during tightening then two (2)

washers shall be used, one under the nut and one under the bolt head. The bolt

may be turned only if the nut is not accessible and where the bolt may be turned

without interference or friction from bolt holes or steelwork.

Unless otherwise specified, bolts used on bevelled surfaces shall be provided with

bevelled washers which shall provide full bearing to the head and the nut.

8.0 WELDING

8.1 General

Welding shall be carried out strictly in accordance with the requirements of

AS 1554 unless specifically stated otherwise on the drawings. All welding shall be

carried out conforming to either GP (General Purpose) or SP (Structural Purpose)

categories as defined in AS 1554.1 or FP (Fatigue Purpose) as defined in

AS1554.5. The categories shall be used for the following purposes:

i) GP ?handrails, guards, minor brackets carrying light fittings, electrical

cable trays, etc;

ii) SP ?all structural connections including all bracing and cleat connections;

iii) FP ?connections subject to high levels of fatigue loading.

All stainless steel welds shall be category 18, Grade III as defined in AS/NAZ

1554.6 unless noted otherwise.

The finished surface profile of all welding shall be smooth and free from sharp

edges or crevices that would be detrimental to the performance of the structure or

to the protective treatment. All slag and weld splatter shall be thoroughly removed,

and the weld surface shall be replaced, repaired and ground as directed by the

Engineer to achieve the requirements of the standard Specification SKM-STD-C-

011 揝urface Preparation, Painting and Galvanising of Steelwork?

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Undercutting shall be minimised to T/10 or 1mm maximum and weld toes shall

blend evenly with the parent plate.

8.2 Welding Supervision

Welding for Category GP, SP and FP shall be carried out under the supervision of

a welding supervisor complying with AS 1554.1 (or AS 1554.5), Section 4.12.1.

The welding supervisor shall hold appropriate certificates in accordance with

AS 1796 and/or AS 2214.

The appointment of a Welding inspector by the Engineer will not relieve the

Contractor of the responsibility to adequately supervise and control the quality over

all work carried out either in the workshop or on Site.

Notwithstanding the provisions of AS/NZS 1554, the sole authority for final

determination of quality and acceptance of welds will be the Engineer.

8.3 Minimum Fillet Weld Size

Unless otherwise shown on the drawings, the minimum weld size between

adjoining components, touching components, edges and faying surfaces shall be a

continuous fillet weld, Category SP, with a leg length as listed below:

i) 6mm for plates less than 16mm thick;

ii) 8mm for plates equal to or greater than 16mm thick and less than 32mm

thick;

iii) 10mm for plates greater than or equal to 32mm thick.

The plate thickness refers to the thinner of the elements being welded. In the case

of one (1) of the components having less thickness than 6mm, the fillet weld size

shall equal the thickness of the thinnest material.

8.4 Preheating

Preheating and inter-pass temperature control shall be performed in accordance

with AS 1554.1, Section 5.3.

8.5 Butt Welds

Run-on and run-off strips shall be used for butt welds and shall be removed on

completion of the weld and the attachment weld ground square and/or flush.

Backing strips will only be permitted if it is impossible to back gouge the root runs

or if full penetration cannot be achieved from one side. Permanent backing strips

are not permitted unless otherwise shown on the drawings.

Preparation of edges for butt welding shall be carried out by grinding, machining,

planning, machine flame cutting or plasma cutting. Manual flame cutting shall only

be carried out with the approval of the Engineer; however, surfaces to be

incorporated into welds shall then be ground.

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Welds shown on the drawings as 慍P?are complete penetration butt welds. For

慍P?welds, the contractor shall determine the most appropriate complete

penetration butt weld detail for each particular location and submit the details to

the Engineer for approval.

Complete penetration butt weld symbols shown on the drawings are indicative of

design preference. The contractor may submit alternative complete penetration

butt weld details for the approval of the Engineer.

The size of cap (reinforcement) on butt welds shall not be greater than shown in

AS 1554.1, Table 6.2. Excess cap shall be ground to the required profile and shall

be free of surface breaking weld defects and gas holes.

8.6 Procedure and Performance Qualifications for Welding

For all weld categories, the contractor shall develop and submit to the Engineer for

approval, welding procedures and procedure qualification records designed to

produce welds in accordance with the requirements of the weld process and

intended duty prior to the commencement of Work.

In addition to the above requirements, the contractor shall document the applicable

welding procedure specifications including non-destructive examination, test

material certificates, test consumable certificates and destructive testing where

required.

All welders shall be certified and/or qualified in accordance with the relevant part of

AS 1554. The contractor shall submit copies of all certificates and/or qualification

records to the Engineer for approval prior to commencement of Work.

8.7 Weld Materials

Hydrogen controlled electrodes shall be mandatory for SP Category welding.

Electrodes shall be E48XX, except that E55XX (low hydrogen) shall be used for

welding Grade 450 steel, unless otherwise approved by the Engineer.

Electrodes to be furnished by the contractor for welding shall conform to,

standards listed in Section 3.2.

All consumables employed for the Works shall be supplied with batch certificates

in accordance with Section 4.2.

Tack welds shall be made with the same type of electrode that is used for

depositing the root pass, unless the tack weld is removed prior to welding.

8.8 Site Welding

Site welding shall not be permitted except where shown on the drawings or

specifically approved by the Engineer.

The contractor shall plan the Work as far as possible to limit the amount of

overhead welding.

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8.9 Weld Repairs

Where it is necessary to repair welds that have failed the inspection criteria, the

contractor shall submit a repair procedure to the Engineer for approval prior to

commencing the Work.

9.0 SURFACE PROTECTION

9.1 General

All steelwork shall be painted or galvanised as specified on the drawings in

accordance with Standard Specification SKM-STD-C-011.

For galvanised steelwork, the contractor shall ensure that adequate drainage holes

are incorporated prior to dispatch for galvanising. Drainage holes shall be detailed

on the shop drawings. No holes shall be created with an oxyacetylene torch under

any circumstances.

9.2 Gilsomastic Paint

Gilsomastic paint, which contains asbestos material bound into the paint matrix,

has been applied as a protective coating on some existing steelwork at the Cape

Lambert facilities. Wherever Gilsomastic paint is identified on steelwork which is to

be welded or modified, the requirements of SKM-SMP-002 揝afety Management

Plan?and Hamersley Iron Procedure DO-OH-C0023 揥elding Structures Coated

with Gilsomastic Paint? shall be followed.

10.0 MARKING

10.1 General

All fabricated structural steel members shall be distinctly marked in accordance

with the marking diagram before being despatched to Site.

10.2 Method

The mark numbers shall be painted, using a stencil, on the member in oil paint and

shall also be stamped on the member using rounded stamps in such a manner that

the strength of the member is not affected.

Where the size of the member is such that the mark number cannot be stamped

on the member it may be stamped on a 1.5mm thick metal tag which shall be

securely fastened to the member by 12 gauge (minimum) wire.

All mark numbers shall consist of 15mm high characters as a minimum.

10.3 Location

All beams shall be marked on the top face at the North or East end.

All columns shall be marked on the North face approximately 200mm above the

base plate, or bottom end.

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Horizontal bracing shall be marked at the North or East end.

Vertical bracing shall be marked at the bottom.

10.4 Column Levelling Marks

All columns shall be provided with legible levelling marks, scribe lines or centre

marks to facilitate the checking of vertical accuracy in two (2) directions at right

angles and the horizontal accuracy during erection. Marks and scribe lines shall

show the true theoretical centre line of the column.

11.0 HANDLING, STORAGE AND DELIVERY TO

11.1 Handling and Storage

All steelwork shall be handled and stored without overstress or deformation. It

shall be stored clear of the ground in such a manner so as to avoid collection of

water. Bolts, nuts and washers shall be supplied in grit-free containers and stored

in water-tight premises. Buried, damaged, corroded or otherwise unserviceable

bolts shall not be used.

Lifting studies shall be prepared and submitted for approval prior to lifting any

element weighting 20t or more.

11.2 Delivery to

All steelwork shall be delivered to in a condition conforming to the requirements of

the drawings and specifications. The Engineer and the Contractor will inspect

steelwork delivered to ensure it is undamaged and stored correctly.

Damaged materials or components shall be replaced unless the contractor is given

the Engineer's written consent to repair and erect them.

Signature of delivery dockets is not an acceptance that the items have been

delivered free of damage.

Care shall be taken during delivery, off-loading, stacking and erection so protective

coatings are not damaged. Damaged areas shall be made good by the contractor

to a quality consistent with the specified coating.

Responsibility for steelwork shall remain with the contractor until erected,

inspected and accepted by the Engineer.

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12.0 ERECTION AND ASSEMBLEY

12.1 General

Unless otherwise shown on the design drawings, shop drawings and/or erection

drawings, erection of structural steel shall conform to AS 4100. Note however that

consideration must be given to the alignment of mechanical components and this

may be more onerous than the requirements of AS 4100.

All temporary bracing, supports and guys shall be designed and erected to take

care of all loads to which a structure may be subjected during erection, including

wind forces, mass of materials and equipment and stresses due to operation of

equipment. Such bracings, supports and guys shall be left in place so long as may

be required for safety.

In multi-storey structures, permanent fixing shall be carried out progressively,

following as closely as practicable behind erection. Unless otherwise agreed,

erection shall not continue more than three (3) levels above the last permanently

bolted or welded level.

Erection planning shall minimise the 憌orking at heights?risk in accordance with

the safety requirements.

12.2 Alignment and Fitting

Each part of the structure shall be properly aligned before completing field

connections.

All members in completed frames shall be true to line and free from bends, twists

and open joints. At assembly, all joints shall achieve face contact before full bolt

torque is reached.

Fitting-up bolts and drift pins shall not be used to bring improperly fabricated

members and parts into place, thus causing strain on bolts in the finished work.

Drift pins shall not be driven with such force as to deform adjacent metal.

No packing, shimming, or wedging will be permitted to correct imperfect work,

unless so directed by the Engineer.

All shop errors shall be reported and the proposed method of correction shall be

submitted for review. Minor mis-fitting may be remedied and corrected by reaming

or slight cutting as directed by the Engineer.

Damage caused by handling during erection shall be reported. Corrective

measures shall be completed as directed by the Engineer.

12.3 Metal Floor Decking

Floor plate units shall be adjusted to final position and brought to proper bearing

on the supporting members before being permanently fastened.

Floor plate units shall be fastened to supporting members by 20mm diameter plug

welds spaced at a maximum of 300mm centres at intermediate supports and

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200mm centres at end and side supports unless otherwise noted. There shall be a

minimum of three welds at each side of each unit.

12.4 Floor Grating

The extent of floor grating and stair treads shall be as nominated on the drawings.

Grating shall be cut and strengthened as required to suit services and equipment

penetrations. All such openings shall be neatly trimmed and banded.

Grating sections shall be fastened using standard proprietary clips fixed using

thread-cutting fasteners. Clips are to be installed to the Manufacturer抯

specification. Clips are to be installed at 500 nominal centres. A minimum of four

(4) fasteners are required per panel. Main bars and cross bars of adjacent

sections shall be in line.

Any requirement to re-lift grating shall require an approved Permit to lift to be

issued by the Engineer and appropriate solid barricading to be in place, in

accordance with the Project Safety Management Plan.

12.5 Erection Tolerances

Erection tolerances shall be in accordance with AS 4100. Note however that

consideration must be given to the alignment of mechanical components and this

may be more onerous than the requirements of AS4100.

Unless otherwise shown, runway beam and rail tolerances for overhead cranes

shall not exceed those given in AS 1418.1.

12.6 Setting Base plates

Base plates shall be set and shimmed to correct positions and elevations shown

on the drawings and shall be subject to review after placing and plumbing and

aligning the first lift. Errors shall be corrected before proceeding further.

13.0 HANDRAILS

13.1 Fabrication and Erection

Handrails shall conform to the requirements of AS 1657. Handrails shall be

慚onowills?type or similar approved and shall consist of stanchions, top rail, mid

rail and kick plate unless otherwise shown on the drawings.

The layout of the handrails and kick plates shall be fully detailed by the contractor.

The shop details shall indicate the layout of the stanchions, details of their

attachment to the supports, the run of the rails and kick plates, location of closure

bends between the top and mid rails and of special bends and the method of

securing kick plates. Special bends are defined as bends having a radius of less

than 125mm on the centreline of the rail.

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Particular attention shall be paid to the run of the handrail at the top and bottom of

each stair flight. Sudden offsets in the line of the stanchions requiring

unnecessary bends will not be permitted.

All joints in handrailing shall be complete penetration butt welds. Welds

connecting handrailing to stanchions and stanchions to the supporting steelwork

shall be 6mm fillets, unless otherwise detailed on the drawings.

The following general requirements for handrails shall apply unless noted

otherwise on the drawings:

i) handrails shall be fabricated as detailed on the drawings and delivered to

for bolting into place;

ii) rails shall be welded on to stanchions. Where rail connections between

stanchions cannot be avoided, an internal backing sleeve shall be used;

iii) kick plates shall be welded unless otherwise noted. Welds shall be a full

seal weld;

iv) generally stanchions shall be bolted to structures. Stanchions to dolphins

shall be welded into place;

v) welds on handrails shall be fully sealed and ground smooth;

vi) where handrails are continuous at changes of direction, stanchions shall

not be located more than 500mm from the direction change.

13.2 Surface Protection

Handrails, stanchions and kick plates shall be hot dipped galvanised and painted

in accordance with Standard Specification SKM-STD-C-011, 慡urface Preparation,

Painting and Galvanising of Steelwork?

CHS top and mid rails on the wharf and access jetty shall also be galvanised

internally.

14.0 MODIFICATION TO STRUCTURAL STEELWORK

14.1 General

No modification shall be made without the prior written approval of the Engineer.

Such fabrication and sub-assembly as may be necessary shall conform to the

requirements of this specification.

14.2 Modifications and Corrections

Procedures and methods for modifications and for corrections shall be submitted

to the Engineer for approval.

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14.3 Cutting

Site cutting shall be wherever possible by a mechanical process. Where flame

cutting is necessary an allowance shall be left for grinding of ragged edges to

ensure a smooth finish.

14.4 Holing

Holes for bolts shall be drilled. Burning of such holes will not be permitted.

Correction of misaligned holes may be achieved by reaming or, subject to approval

by the Engineer, by filling badly misaligned holes with welded plugs or weld metal,

grinding flush and re-drilling correctly.

14.5 Finishing

Wherever remedial Work has been carried out, the affected area shall be cleaned,

burrs, slag and weld spatter removed and the paintwork made good in accordance

with Standard Specification SKM-STD-C-011, 慡urface Preparation, Painting and

Galvanising of Steelwork?

15.0 GROUTING

15.1 Preparation

Prior to the erection of steelwork, the concrete surface under the base or bearing

plate shall be given a scabble finish. All defective concrete and laitance shall be

removed from the concrete surface to be grouted by chipping or other approved

means. The resulting surface shall be rough and free of oil, grease, dirt and loose

particles. The underside of steelwork to be grouted shall also be clean of all dust,

oil, dirt and loose material prior to erection.

Polystyrene material used for foundation bolt blockouts shall be dissolved using a

product such as d-Limonene or similar approved. All residues shall be removed.

Temporary shims or wedges which are designated to be removed after grout has

hardened shall be coated with a thin coat of grease to facilitate removal.

Prior to beginning grouting, the concrete surface shall be saturated with water for a

minimum of six (6) hours. Just before grouting, all free water shall be removed

from the surfaces, keys and sleeves which are to be grouted.

Grouting procedures shall ensure the placement of grout under the entire surface

of the base or bearing plate avoids any possibility of air pockets or voids by

sufficient compaction.

Grouting procedures shall be submitted for approval by the Engineer prior to the

commencement of any grouting.

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15.2 Formwork

Formwork shall be made from materials of adequate strength and shall be securely

anchored and shored to withstand the grout pressure under working conditions.

It shall be sufficiently water tight to prevent leakage and shall be caulked where

necessary.

Adequate clearances shall be provided between formwork and structural

steelwork, to allow the proper placement of the grout.

15.3 Grout

Grout shall be a non-shrink pre-mixed cementitious product of approved, standard

manufacture such as MBT Masterflow 870 or similar Engineer approved. Grout

shall be mixed, placed and cured in accordance with the grout manufacturer抯

instructions. Grout shall be non-staining and shall be suitable for the intended

purpose.

The average compressive strength of the grout at 28 days, standard cured shall

not be less than 70MPa, based on 50mm cubes prepared from grout of the same

consistency at which it was placed.

After initial set of the grout has taken place, the formwork shall be removed and

the excess grout cut away, leaving a full 45 degree chamfer smooth and neatly

finished. The chamfer shall extend from the underside of base plate level to the

top of concrete. All structural steelwork shall be cleaned of all grout on or above

the base plates and any damage to paintwork shall be repaired. Levelling devices

such as shims shall not be removed.

15.4 Curing

Sources of vibration which may cause settlement, bleeding or bond failures shall

be eliminated until the grout has set.

After the grout has sufficiently hardened, the grout shall be damp cured

continuously for a minimum period of three (3) days. Surrounding objects such as

steel base plates, directly in contact with grout, shall be wrapped or covered in

hessian bagging and maintained wet during the entire curing period.

At completion of the wet curing, all exposed grout shall be sealed by the

application of an approved curing compound.

16.0 CLEAN UP

The Work and work-area shall be left clean and tidy on completion and all surplus

materials and equipment removed from the Site.

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APPENDIX A

STAINLESS STEEL FASTENERS

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Erection of Structural Steel Issue Date: 25 September 2008

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TESTING OF IMPORTED STAINLESS STEEL FASTENERS

1.0 PURPOSE

The purpose of the following procedure is to verify compliance of Grade A4-50 and

A4-70 Stainless Steel Corrosion Resistant Fasteners imported into Australia using

PMI, hardness and tensile testing methods.

2.0 SCOPE

This scope covers testing on a statistical basis with the relevant Australian and

ISO Standards for physical properties of all Stainless Steel Grade A4-50 & A4-70

Bolts, Nuts and Washers.

3.0 REFERENCES

AS1815.1 ?2002 Mechanical Materials ?Rockwell Hardness Test (HRA)

AS1817.3 ?2003 Mechanical Materials ?Vickers Hardness Test (HV10)

AS1391 ?2005 Metallic Materials ?Tensile Testing at Ambient

Temperature

ISO 3506 .1 & 2 Mechanical Properties of Corrosion Resistant Stainless

Steel Fasteners

All other standards referenced in those listed here which are relevant to the

dimensional, chemical and mechanical properties of stainless steel fasteners.

4.0 DEFINITIONS

?definitions shall be as shown in the above referenced Standards;

?PMI ?Positive Material Identification via Spectrographic Chemical Analysis.

5.0 PROCEDURE

5.1 Location

All testing shall be carried out in Australia by a NATA certified facility, or equivalent

facility approved by the Engineer.

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5.2 Frequency

For bolts, the frequency of hardness and tensile testing shall be one (1) bolt per

1000 per batch. Where smaller batch quantities (less than 1000) are involved, one

(1) unit per batch shall be tested. Where smaller quantities of different grades are

involved (ie Gr A4-50, A4-70 etc), as one (1) unit per grade shall be tested.

Nuts, bolts and washers shall be PMI tested (via Spectrographic Chemical

Analysis) at a frequency of one unit per batch, regardless of the batch size.

5.3 Traceability

All bolts, nuts and washers shall be traceable to batch numbers by a suitable

means of identification such as tagging or colour coding.

5.4 PMI, Hardness and Tensile Testing Requirements

5.4.1 Bolts

Hardness testing shall be conducted on bolts in accordance with AS 1815.1 ?

2002 (Rockwell HRA) and AS 1817.3 ?2003 (Vickers HV10). The test shall be at

the threaded end face of the bolt opposite to the head.

The bolt threaded end face shall be ground flat and three (3) Rockwell (HRA) tests

conducted at the mid-radius position at 120 degree intervals.

Using the same bolt, conduct three (3) Vickers (HV10) tests also at the mid-radius

position at 120 degree intervals between the sites of the Rockwell tests.

The bolt shall then be tensile tested, recording the following data:

?yield (0.2% PS and 0.5% PS);

?tensile strength;

?percentage elongation;

?percentage reduction of area.

The Rockwell and Vickers hardness test results should also be recorded for each

bolt.

5.4.2 Nuts

Nuts shall be subject to PMI and Proof Load testing. Proof load testing shall be

carried out at the same frequencies as bolts (as shown at 5.2).

5.4.3 Washers

Washers shall be subject to PMI testing only.

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5.5 Compliance

Using the above method, where the chemical properties or hardness and tensile

values fall outside the specified ranges, the entire batch (from which the sample

came) shall be rejected, physically identified, quarantined, and shall not be used.

5.6 Abstract

Research into the correlation of hardness to tensile values for Austenitic stainless

steels has revealed only limited Rockwell data. Therefore there is a need to better

correlate the Rockwell values and Vickers values against the tensile test results for

each bolt tested. This would allow eventual dropping of tensile testing while the

Vickers or Rockwell testing would continue giving reliable indications of tensile

values.

The intent of this testing regime is to establish accurate, reliable data showing unit

compliance from known suppliers and manufacturers without ongoing high levels

of tensile testing.

Once a level of confidence has been established via these quality control

measures, testing frequencies may be reduced at the Engineer抯 discretion. In the

event of a change in supplier or manufacturer, the above testing regime will be reinstated

until satisfactory results are consistently returned.

RIO TINTO IRON ORE EXPANSION PROJECTS Document Number: SKM-STD-C-009

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Erection of Structural Steel Issue Date: 25 September 2008

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APPENDIX B

STRUCTURAL GRADE CARBON STEEL FASTENERS

RIO TINTO IRON ORE EXPANSION PROJECTS Document Number: SKM-STD-C-009

Standard Specification for Fabrication and Revision: 0

Erection of Structural Steel Issue Date: 25 September 2008

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TESTING OF IMPORTED STRUCTURAL GRADE FASTENERS

1.0 PURPOSE

The purpose of the following testing methodology is to verify compliance on a

statistical basis with the relevant Australian and ISO Standards for physical

properties of Structural Grade Fasteners imported into Australia.

2.0 SCOPE

This scope covers all Structural Grade Bolts, Nuts and Washers.

3.0 REFERENCES

AS 1252 ?1996 High-Strength steel bolts with associated nuts and washers

for structural engineering.

AS 4291.1 ?2000 Mechanical properties of fasteners made of carbon steel

and alloy steel. Part 1: Bolts Screws and Studs.

AS 4291.2 ?1995 Mechanical properties of fasteners. Part 2: Nuts with

Specified Proof Load Values ?Coarse Thread.

AS1815.1 ?2002 Metallic materials ?Rockwell Hardness Test.

AS1817.3 ?2003 Metallic materials ?Vickers Hardness Test.

AS 1391 ?2005 Metallic materials ?Tensile testing at ambient temperature.

All other standards referenced in those listed here which are relevant to the

dimensional and physical properties of Structural Grade Fasteners used in

Australia.

4.0 DEFINITIONS

Definitions shall be as shown in AS 1252.

5.0 PROCEDURE

5.1 Location

All testing shall be carried out in Australia by a NATA certified facility, or equivalent

facility approved by the Engineer.

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5.2 Frequency

The frequency of testing shall be one (1) per 1000 units per batch for nuts,

washers and bolts. Where smaller batch quantities (less than 1000) are involved,

one (1) unit per batch shall be tested. Where smaller quantities of different grades

are involved (ie Gr 8.8, Gr 10.9, Gr 12.9 etc), one (1) unit per grade shall be

tested.

5.3 Traceability

All bolts, nuts and washers shall be traceable to batch numbers by a suitable

means of identification such as tagging or colour coding.

5.4 Hardness Testing

5.4.1 Bolts

Hardness testing in accordance with AS 4291.1 is acceptable in lieu of tensile

testing only when testing is conducted on a flat machined surface at the mid-radius

position of the shank, one diameter back from the threaded end of the bolt.

The Vickers test (HV) shall be the accepted method for hardness testing of bolts.

5.4.2 Nuts

Hardness testing using the Rockwell scale in accordance with AS 4291.2 Section

8.2 is acceptable except where inconsistencies are found in which case the

Vickers method shall be the referee test.

5.4.3 Washers

Hardness testing on the flat of the washer using the Rockwell scale in accordance

with AS1252 ?1996 Section 4 is acceptable except where inconsistencies are

found in which case the Vickers method shall be the referee test.

5.5 Compliance

Using the above methods, where the hardness values fall outside the specified

range, the entire batch shall be rejected unless the supplier is able to demonstrate

compliance via tensile, wedge and proof load testing on samples from the same

batch. This applies equally to bolts, nuts and washers. In all cases Galvanising

shall be removed and a clean, flat surface prepared prior to hardness testing.

Where batches are rejected, they shall be physically identified, quarantined, and

shall not be used.

All imported structural grade fasteners shall meet the requirements of AS 1252-

1996.

5.6 Abstract

The intent of the above testing regime is to establish accurate, reliable data

showing unit compliance from known suppliers and manufacturers. Once a level

of confidence has been established via these quality control measures, testing

frequencies may be reduced at the engineer抯 discretion. In the event of a change

RIO TINTO IRON ORE EXPANSION PROJECTS Document Number: SKM-STD-C-009

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in supplier or manufacturer, testing frequencies will be increased until satisfactory

results are consistently returned.

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