MODULE 502:

STEELWORK FABRICATION AND

ERECTION
Engr. R. A. Olushola SANNI
[Link].(Civil), SMCE, MESC, [Link]., MICE, MIStructE, FNIStructE, MNSE

Presented At:

STRUCTURAL STEELWORK DESIGN

ORGANISED BY:
AT
NIStructE SECRETARIAT
5, AKINHANMI STREET, SURULERE, LAGOS

THURSDAY 29 – FRIDAY 30 AUGUST

2019

MODULE 502: STEELWORK FABRICATION AND ERECTION

MODULE 502: STEELWORK FABRICATION AND ERECTION
 NISTRUCTE – STRUCTURAL STEELWORK DESIGN – 29-30 AUGUST 2019

MODULE 502 – STEELWORK FABRICATION AND ERECTION

Engr. R. A. Olushola SANNI
1.0 INTRODUCTION

Steel structures derive their competitive advantages from the virtues of

prefabricated components, which can be assembled speedily at site.

Unlike concreting, which is usually a wet process conducted at site, steel is

produced and subsequently fabricated within a controlled environment. This
ensures high quality, manufacture offsite with improved precision and
enhanced speed of construction at site.

The efficiency of fabrication and erection in structural steelwork dictates the

success of any structural steelwork project. It is therefore imperative that
structural engineers must be conversant with all aspects of structural steelwork
including “fabrication and erection” processes.

Design standards, such as the BS 5950, give design rules that are valid only if
strength, dimensional accuracy and freedom from defects are within
presumed limits. The performance of a structure required by regulations will
also only be achieved when construction is within presumed limits.

In summary the sequence of events leading to the realization of any steelwork

project is as follows:

1. Preparation of Steelwork Tender Documents consisting of Structural

Drawings, Steelwork Specifications, Contract Terms and Tendering
Instructions.
2. Tendering Process and Selection of Steelwork Sub-Contractor
3. Construction of Foundation (By Others) which incorporates the Holding-
Down System for the Steelwork
4. Preparation of Steelwork Shop Drawings (for fabrication and erection) and
Approval by the Structural Designer
5. Fabrication of Steel Components in Workshop with regular Shop Inspection
Visits by Structural Designer
6. Shipping of fabricated components to site and storing in designated areas
for subsequent erection process
7. Checking and Confirmation (in writing) of Correctness of Holding-Down
bolts by Steelwork Erector preparatory to commencement of erection
8. Erection of “Anchor” fully braced bays
9. Complete Steelwork Erection with regular site inspection by the Structural
Designer
10. Aligning of Erected Steelwork and final grouting of holding-down bolts
11. Touching up painting of damaged painted areas
12. Application of finishing coat of paint and installation of cladding, etc.

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 NISTRUCTE – STRUCTURAL STEELWORK DESIGN – 29-30 AUGUST 2019

2.0 PREPARATION AND APPROVAL OF SHOP DRAWINGS

The required accuracy in steel fabrication and erection is higher than that
required in concrete construction.

Therefore shop drawings including holding-down bolts layout, column layouts,

beam layouts, connection details at joints should be prepared with due
accuracies.

The shop drawings should be checked by the Structural Designer to ensure

total compliance with the design drawings.

In the case where the Steelwork Contractor is given the responsibility to design
the connections between the steel components, the Structural Designer must
check the adequacy of the joint design and calculations by the steel
fabricator.

It is very important that the critical elevations of bolts, top of steel (T.O.S)
beams be shown on the fabrication drawings and properly coordinated with
the supporting concrete elements.

Adequate attention must be paid to limitations to the means of transportation

to site – by break-cargo shipping, in containers, on lorry beds, etc. so that
proper splice joints can be included and detailed appropriately.

Approval of fabrication drawings by the Structural Designer can be done in

various stages – (“Not Approved”, “Approved As Noted” and “Approved”) but
all the drawings must achieve the “Approved” status before they can be used
for fabrication on the shop floor.

Only shop drawings with the “Approved” status should be used during
fabrication.

At this stage, the erection drawings should also be checked and approved by
the Structural Designer.

3.0 FABRICATION PROCEDURE

Structural steel fabrication is best carried out in the workshop that is

adequately equipped with facilities to achieve the desired quality of
workmanship. However, in some cases steelwork fabrication is also carried out
at the construction site. In such cases, all the necessary material handling and
fabrication tools must be provided.

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 NISTRUCTE – STRUCTURAL STEELWORK DESIGN – 29-30 AUGUST 2019
Fabrication on site may be inevitable where there is very high cost of
transportation, difficulty in transportation of large members and high excise
duty on products from workshops. However, the level of sophistication of
equipment on site and lower environmental controls are less compared to
workshop facilities. In addition, the skill of personnel on site also tends to be
lower, hence the quality of the finished product tends to be lower.

Fabrication of steelwork carried out in workshop is more precise and of assured

quality compared with site-fabricated components. It is also efficient in terms
of cost, time and quality.

Structural steel passes through various operations during the course of its
fabrication. Generally, the sequence of activities in fabrication shops is as
shown below:

The Structural Designer must visit the fabrication workshop regularly to inspect
the process of fabrication and give instructions for corrections where
necessary. The guiding document is the quality provisions contained in the
Steelwork Specification.

All the welds must be inspected for defects so that corrections can be
effected before the members are shipped to site. The following is a guide to
inspection of welds:

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 NISTRUCTE – STRUCTURAL STEELWORK DESIGN – 29-30 AUGUST 2019

4.0 STEELWORK TOLERANCES

Tolerances of steelwork construction can be addressed under the following
areas: mill tolerances, fabrication tolerances and field or erection tolerances.

1. Mill Tolerance
Mill tolerance usually only affects the mill producing the steel sections and
the steel fabricator placing the order.

Fabricators often use details that reduce the impact of most mill tolerances
on the fabricated components.

2. Fabrication Tolerance
Section 7 of BS 5950-2:2001 specifies the limits for cross-section, straightness
and curvature, length and squareness of ends and flatness for full contact
bearing.

The deviation of a built-up member from a straight line drawn between

adjacent points of subsequent effective lateral restraints shall not exceed
3mm or L/100 whichever is the greater (where L is the distance between the
restraints in mm).

The length of a member measured on centre line of the section or on the

corner and an angle should be within the specified length + or – 3mm.

The tolerance for squareness of ends to the longitudinal axis should be +/-
depth/300 and +/-depth/1000 for members not finished for full contact
bearing and finished for full contact bearing respectively.

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 NISTRUCTE – STRUCTURAL STEELWORK DESIGN – 29-30 AUGUST 2019
3. Erection Tolerances
Erection of members, especially beam members, on fixed columns will be
very difficult if the specified tolerances are not maintained.

The column position at the base level should not deviate from the specified
position by 5mm along either of the principal setting out axes.

The deviation of column at any level shall not exceed the greater of 5mm
or 1/600 of the storey height over the actual positions of the column at the
level immediately below.

Members, other than columns, shall not deviate more than 5mm from the
specified position. The level at the top of the beam shall be within +/-10mm
of the specified level.

It is advisable for the fabricators not to reach even the limits specified
above, as sometimes the erection will be very difficult even if the
fabrications are done for the limits stated above.

5.0 STEELWORK ERECTION

Steelwork erection is the process by which the fabricated structural members
are assembled together to form the skeletal structure. The erection process
requires considerable planning in terms of material delivery, material handling,
member assembly and member connection.
It would be very useful to request the Steelwork Erector to submit a Method
Statement to the Structural Designer for its vetting and approval before the
erection works commence on site.
It is also very important to request a written confirmation that the interface
between the steel and foundation has been inspected and found acceptable
by the steelwork erector before commencing erection works.
Proper planning of material delivery would minimize storage requirements and
additional handling from the site storage, particularly heavy items.
Before erection, the fabricated materials should be verified at site with respect
to mark numbers, key plan and shipping list.
The structural components received for erection should be stacked in such a
way that erection sequence is not affected due to improper storing.
Care should be taken so that structural components should not come in
contact with earth or accumulated water. The stacking should be such that
erection marks and mark numbers on the components are visible easily and
handling do not become difficult.

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 NISTRUCTE – STRUCTURAL STEELWORK DESIGN – 29-30 AUGUST 2019
The steelwork erection is the most important activity in the realization of the
building project. Therefore, the Structural Designer should inspect the
fabricated components and make sure that the fabrications have been done
within the acceptable tolerances.
Generally the sequence of activities involved in steelwork erection is given
below:

5.1 Bracings
During the entire erection period, the steelwork should be securely
bolted and fully braced. This is to take care of the stresses from erection
equipment or the loads carried during erection. In addition, adequate
provisions to resist lateral forces and wind loads during erection should
be made.
Erection process should start with a fully braced bay. Other parts of the
structure can then proceed outwards from the erected bay.
5.2 Erection Tolerances

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