Contents
1.Introduction 1-1 to 1-2
2. Fabrication 2-1 to 2-45
2.1 General 2-1
2.2 Identification 2-2
2.3 Handling 2-3
2.4 Straightening 2-5
2.5 Marking 2-6
2.6 Cutting 2-6
2.6.1 Edge Planning 2-6
2.6.2 Cold Sawing 2-7
2.6.3 Cropping 2-8
2.6.4 Gas Cutting 2-8
2.6.5 Arc Plasma Cutting 2-8
2.7 Holing 2-8
2.7.1 Round Holes 2-9
2.7.2 Oversized Holes 2-10
2.7.3 Slotted Holes 2-10
2.7.4 Punched Holes 2-11
2.7.5 Fitted Bolt Holes 2-11
2.8 Finishing 2-12
2.9 Surface Preparation 2-12
2.10 Painting 2-15
2.11 Deviation 2-16
2.12 Distortion 2-18
2.8.1 Causes of Fabrication Distortion 2-18
2.8.2 Methods on Control of Distortion 2-22
2.8.3 Effect of Design on Distortion 2-30
2.13 Tolerances 2-30
2.14 Safety during Fabrication 2-44
3. Joining 3-1 to 3-31
3.1General 3-1
3.2 Materials 3-1
3.2.1 Mild Steel 3-1
3.2.2 Microalloyed Steel 3-2
3.2.3 Wea ther Resistant Steel 3-3
3.3 Welding 3-3
3.3.1 Weldability of Steel 3-4
3.3.2 Weld Types 3-5
3.3.3 Weld Positions 3-13
3.3.4 Welding Processes 3-14
3.3.5 Weld Defects 3-18
3.3.6 Testing Methods 3-25
3.4 Bolting 3-30
3.4.1 Mild Steel Bolts 3-30
3.4.2 Fit Bolts 3-30
3.4.3 High Tensile Bolts 3-30
4. Erection 4-1 to 4-49
4.1 Introduction 4-1
4.2 Design Considerations 4-1
4.3 Stability Considerations 4-2
4.4 Safe Connection 4-3
4.5 Size and Shape of Components 4-4
4.6 Drawings 4-4
4.7 Site Conditions 4-5
4.8 Dispatch to Site 4-5
4.9 Managing for Safe Erection 4-7
4.10 Site Preparation 4-7
4.10.1 Site Access 4-7
4.10.2 Site Movement 4-8
4.10.3 Storage Areas 4-8
4.11 Delivery, Stacking and Storing 4-9
4.11.1 Planning 4-9
4.11.2 Unloading 4-9
4.11.3 Storing 4-9
4.11.4 Stacking and Destacking 4-10
4.12 Structural Stability 4-11
4.12.1 Assessing the Disturbing Forces 4-11
4.12.2 Principles of Stable Erection 4-11
4.12.3 Methods of Support for Providing Stability 4-12
4.13 Base Fixing 4-20
4.13.1 Initial Considerations 4-20
4.13.2 Setting Out and Pre-erection Survey 4-21
4.13.3 Holding Down and Locating Systems 4-21
4.14 Planning 4-22
4.15 Means of Access and Working Places 4-23
4.16 Lifting and Handling 4-25
4.16.1 Plate Clamps 4-25
4.16.2 Eyebolts 4-26
4.16.3 Wire Rope Slings 4-28
4.16.4 Chain Slings 4-33
4.16.5 Shackles 4-33
4.16.6 Cranes 4-39
4.17 Tolerances 4-45
5. Contracts & Costing 5-1 to 5-11
5.1 Contracts 5-1
5.1.1 Contract for Design and Preparation of Drawing 5-1
5.1.2 Contract for Supply bf Steel 5-1
5.1.3 Contract for Fabrication 5-2
5.1.4 Contract for Erection 5-3
5.2 Costing 5-6