STRUCTURAL STEEL

SECTION 15 STRUCTURAL STEEL

1 GENERAL

1.1 SCOPE
Outline description
This section applies to the provision, fabrication, treatment, erection and connection of structural steelwork.

1.2 CROSS REFERENCES

General
Conform to the General requirements worksection.

1.3 STANDARDS
Site copy
Supply and keep on site a copy of AS/NZS 1554, AS 4100.

1.4 ADJOINING ELEMENTS

General
Provide for the fixing of adjoining building elements to be fixed to or supported on the structural steel.

2 QUALITY

2.1 INSPECTION
Notice
Give sufficient notice so that inspection may be made at the following stages:

- Commencement of shop fabrication;

- Commencement of welding procedure tests;

- Commencement of welding;

- Prior to the placement of the root runs of complete penetration butt welds;

- Completion of fabrication prior to surface preparation;

- Commencement of surface preparation prior to protective coating;

- Completion of protective coating prior to delivery to site;

- Steelwork on site prior to erection;

- Completion of erection prior to encasing or fixing cladding;

- Encasing.

Fabrication may proceed

In the absence of any directions to the contrary, after the notice, the Contractor may proceed with his obligations
under the terms of the Contract, but this shall not be construed as implying any approval or negating the
responsibility of the Contractor to complete the work in accordance with all the requirements of the Contract.

2.2 IDENTIFICATION
Marks
Provide suitable and sufficient marks or other means for identifying each member, including bolts and loose
items, and for the correct setting out, location, erection and connection of the steelwork.

Steel grade identification

To AS 4100, clause 14.2.2.

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Connections
Mark connections to distinguish those requiring high-strength bolts from others. Deliver bolts of each size
and type in separate containers suitably identified.

2.3 HANDLING AND STORAGE

Generally
To AS 4100, clause 15.2.2. Handle and store steelwork so as to protect it from damage, including overstress,
distortion, damage to surfaces and applied finishes, contamination by foreign matter, and the like.

Rejection
Steel not handled or stored in an appropriate manner is liable to rejection.

3 MATERIALS

3.1 STEEL TYPE AND GRADE

Standards
Steel shall be of the types and grades shown on the Drawings, to the appropriate material standard, and to
AS 4100, Section 2, or AS/NZS 4600 clause 1.5 in the case of cold-formed sections.

Compliance with standard

For each batch of steel supplied to the Works, provide the manufacturer's Certificate of compliance and
Test certificates.

Independent tests
Alternatively, have the steel independently tested to AS/NZS 3678 or AS/NZS 3679, for compliance with
the chemical composition and mechanical test requirements of the appropriate material standard.

Testing certification
Use NATA registered bodies for testing and certificates unless approved otherwise. In this Section understand
that the word 'certificate' means certificate by NATA registered body, unless approved otherwise.

Rejection
Steel which cannot be shown to comply with the appropriate material standard is liable to rejection.

3.2 BOLTS
High strength bolts, nuts and washers
To AS/NZS 1252.

Lengths and washers for high-strength bolts: Use bolts threaded with length sufficient to prevent threads in
section at interfaces of connected parts of the work. Use washers, flat or tapered as necessary, for each nut
and for each head which is to be rotated.

Commercial mild steel bolts

To AS 1111.

Particular requirements, commercial bolts: Unless otherwise shown or directed, use mild steel drop forged
bolts with hexagon heads and nuts and ISO metric coarse pitch threads. Use bolts threaded length sufficient
to prevent threads in section at interfaces of connected parts of the work. Use washers, circular, clipped, flat
or tapered as necessary, for each nut and for each head which is to be rotated.

Mild steel nuts

To AS 1112.

Mild steel washers

To AS 1237.

Coatings, bolts
Coat bolts, nuts and washers as follows:

- For steelwork to be hot dipped galvanised (GALV) - Hot dipped galvanised.

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- For steelwork to be primed with Special Purpose Primer (IP2) - Hot dipped galvanised.

4 FABRICATION

4.1 FABRICATION
Standard
To AS 4100, Section 14.

Fabrication
Fabricate in an approved workshop unless otherwise specified or permitted.

Cutting
Saw cut ends of hot rolled steel sections, cold formed steel sections and steel tubes. Other sections may be
cut by shearing, cropping or sawing. Do not use hand operated flame cutting tools. Machine flame cutting
may be used for the preparation of edges for welding, but surfaces shall be smooth, uniform, free from fins,
tears, loose scale, slag, rust, grease, paints, any other foreign material and other defects.

Splices and joints

Structural members shall be in single lengths unless otherwise required by the Contract or permitted.

Welding of ‘off-cuts’
Do not weld 'off-cuts' or short lengths to make up the required length of any member. Permission may be
given by the Superintendent to join, by one weld, members of long final length, provided written request from
the Contractor is so received.

Fabrication tolerances
To AS 4100 clause 14.4.

Straightness: To AS 4100 clause 14.4.

Straightening methods: Submit proposed methods for approval by the Superintendent.

Beam camber: If beam members have a natural camber within the straightness tolerance, fabricate and erect
them with the camber up.

Machined surfaces: To AS 4100, clause 14.4.4.2.

Temporary connections
Do not locate cleats other than as shown on the shop Drawings without prior permission. Remove
temporary connections on completion and restore the permanent surface.

Holes for bolts

To AS 4100, clause 14.3.5. Do not use flame cutting for any holes.

4.2 WELDING
Standards
To AS 4100, clause 14.3.4, and AS/NZS 1554.

Stud welding
To AS/NZS 1554 Part 2.

Site welds
Do not site weld without prior permission. Wherever possible locate site welds in positions for down
hand welding.

Weld categories
Use SP (structural purpose) category welds to AS/NZS 1554, unless noted otherwise. Use GP (General
Purpose) category welds to AS/NZS 1554 for purlin and girt cleats.

Qualification of welding personnel

Welding operators shall have passed the tests specified in AS 1796 and be in possession of the
appropriate certificate issued by an examining authority specified therein.
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Weld testing
If weld testing by radiographic, ultrasonic or visual examination is called for on the Drawings or specified,
have the tests performed by an independent testing authority, and submit the relevant test report to the
Superintendent, before the tested steelwork is delivered to the site.

Visual inspection
To AS/NZS 1554.1 Clause 7.2, 7.3. VISUALLY EXAMINE 10% of SP welds to Table 6.2.2
of AS/NZS 1554.1.

Radiographic examination: To AS/NZS 1554.1, clause 6.3.

Ultrasonic examination: To AS/NZS 1554.1, clause 6.4.

Weld test failure

If a weld fails a required test, test a further sample of welds in the group at the same rate as the original test
rate, up to a maximum of 100% of the group. If any welds in the second sample fail the test criteria, then
test all the remaining welds in the group, up to 100% of the group, at the Contractor’s expense.

Correction of non conforming welds

To AS/NZS 1554.1, clause 5.8. After correcting a non-conforming weld revealed by a required test, retest
it as specified above under WELD TESTING.

5 ERECTION

5.1 ERECTION
Standard
To AS 4100, Section 15.

Erection tolerances
To AS 4100, clause 15.3.

Beam clearances at each end, maximum: 2 mm for web cleated ends, 3 mm for ends without web cleats.

Anchor bolt position tolerances:

- Deviation of a bolt within a bolt group • 3 mm;

- Deviation between groups • 6 mm;

- Maximum accumulated deviation between groups• 6 mm per 30 m;

- Centre of bolt group off grid - not greater than 6 mm;

- Projection of bolt end + 25 mm, - 5 mm.

Grouting supports
To AS 4100, clause 15.5.

Grout type and strength: Unless shown otherwise on the Drawings, 40 Mpa non-shrink cementitious
proprietary grout.

Bolting
To AS 4100, clause 14.3.6.

6 FINISHES

6.1 SURFACE PREPARATION

Preparation
On completion of shop fabrication, and prior to erection on site and irrespective of any prior application of paint to
the steelwork, clean steelwork as follows:

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- For steelwork to be encased in concrete - to a finish equivalent to Class Sa 1 finish described in AS 1627.

- For steelwork to be hot dip galvanised - clean by suitable preliminary treatment and subsequent acid
cleaning or pickling to produce a clean metallic surface suitable for galvanising.

- For all other steelwork - by abrasive blast, to a standard of finish equal to or better than Class Sa 2-1/2
finish described in AS 1627.

No free silica
Any substance, including sand, containing free silica shall not be used as an abrasive in any blast
cleaning operations.

Reclean
Prior to application of paint, re-clean as specified above any cleaned surfaces left unpainted longer than 4
hours after prior cleaning. Prior to encasement, re-clean as specified above any surface to be encased which
does not have a standard of finish equal to or better than Class Sa 1 of AS 1627.

6.2 PAINTING
Coating systems
Apply the paint coating systems (including both decorative and protective coatings) shown on the Drawings.

Australian paint approval scheme

The paint specification references stated below refer to Australian Paint Approval Scheme (APAS)
published specifications.

Priming
Prime as follows:

- Special Purpose Primer (IP2) - Paint steelwork (except where galvanised or to be encased in concrete)
with a two-pack inorganic ethyl silicate zinc primer to APAS 2908 depositing a minimum of 75 microns
dry film thickness on the substrate applied in one coat.

Drying time
Carry out painting, unless otherwise specified, within 4 hours of cleaning and allow 24 hour drying time
before re-coating and 72 hour drying time before commencing delivery to site.

Unpainted areas
Do not paint contact surfaces of high strength friction-grip bolted connections, surfaces against which
concrete is to be poured, and surfaces within 50 mm of locations where "field welds" are required.

Column bases
Where steel columns have encased bases, extend the priming of the shaft 25 mm below the top of the encasing.

After erection
On completion of bolting or site welding, clean with a wire brush or other acceptable methods, bolts,
damaged areas of paint and galvanising and areas previously specified to remain unpainted, to an
equivalent standard specified, then treat as follows:

- For prime painted steelwork - feather any existing paint to a fine edge. Repaint cleaned areas with
primer specified above, overlapping existing paint by 25 mm minimum.

- For galvanised work (GALV)- apply one coat of 50 microns dry film thickness of an approved single
pack epoxy zinc rich paint to APAS 0014/1 made by a manufacturer approved by APAS to
manufacture that product.

Approved paint manufacturer

Use paints made by a Manufacturer approved by the APAS to manufacture the paint. Use the same brand of
paint for subsequent touch-up and additional coats.

Paint gauge
Upon request provide the Superintendent with an approved thickness gauge such as an 'Elcometer' for
use in testing paint thicknesses.
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6.3 GALVANISING
Structural sections
To AS/NZS 4680 and HEAVY DUTY GALVANISED COATINGS worksection requirements.

Threaded fasteners
To AS 1214.

Distortions
If any member is distorted during the galvanising process, submit the proposed method of straightening
to the Superintendent.

Components in contact with concrete

Passivate galvanised surfaces to be cast into or in contact with concrete by dipping in 0.2% sodium
dichromate solution.

Coating quality
The zinc coating shall be free from lumps, blisters, gritty areas, uncoated spots, acid and black spots, dross,
flux and other imperfections.

Site welding
Grinding of edges: Permitted.

Weld areas: Reinstate coating.

Site coating reinstatement

Extent: Areas damaged by transport, site welding, site flame cutting, site handling, or erection.

- Size of area to be repaired: Relevant to the size of the article and the conditions of service.

Method: Wire brush or mechanically buff the surface. Apply zinc-rich primer to 150 m dry film thickness.
Stipple edges of the primed area.

- Paint standard: To APAS-0014/1 or APAS-2916.

- Surface preparation: To AS 1627.2 and Grade St 2 to AS 1627.9.

7 PERFORMANCE CRITERIA ELEMENTS

7.1 PERFORMANCE CRITERIA ELEMENTS

Responsibility
Take responsibility for the design and construction of all performance criteria elements specified or shown on
the drawings, and comply with parameters specified. Supply to the Superintendent, a certificate from a
practicing Structural Engineer to the effect that the design complies with the parameters specified and that the
design has received an independent check for compliance with the structural provisions of the Standard
Building By-laws. Supply to the Superintendent, on request, a copy of engineering calculations in support of
the Structural Engineer's certificate.

Incompatibility
Include for the following where the design details of the performance criteria element(s) are incompatible
with the rest of the structure:

(i) Any redesign and/or redocumentation required to any or all parts of the structure.

(ii) Amendment/alteration to any or all parts of the structure including amendment/alteration to associated
internal and external finishes.

(iii) Any delays occurred caused by redesign, redocumentation or amended/altered construction

requirements or procedures.

Satisfactory redocumentation: Any redesign and/or redocumentation necessary to comply with the foregoing
shall be to the satisfaction of the Superintendent. A decision of the Superintendent in regard to the necessity
for any redesign and/or redocumentation shall be binding in respect of this clause.
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