STANDARD

SPECIFICATIONS FOR
CONSTRUCTION WORKS
2008

Module – 11 – Structural Steel and Coatings

Introduction

The Standard Specifications are published as a series of 21 stand-alone modules each addressing

a single distinct area of the construction process. This stand-alone module 11 is an integral part of

the Standard Specifications.

The purpose of the MoW STANDARD SPECIFICATIONS FOR CONSTRUCTION is to provide the

design professional with a guide for accepted construction practices for Ministry of Works projects.

As an aid to the designer, these Standard Specifications are provided for the inclusion in proposed

development projects for ease, efficiency and cost savings.

The Standard Specifications are not intended to limit the design responsibility of the design

professional. However, they establish a minimum acceptable criterion and/or quality for use within

Ministry of Works projects.

The design professional may increase the requirements of an item contained in the Standard

Specifications to meet job requirements, but when this is done, there should be no reference for

that item on the drawings to the Ministry of Works Standard Specifications and a new specification

should be included with the drawings or project contract documents.

The design professional must review all Standard Specifications to be sure that they are adequate

for the proposed project based on the job site conditions; the design professional is solely

responsible for the designs submitted under his seal.

In order to keep design standards current with changing regulations and improved construction

materials and practices this section will be updated and maintained by the concerned authorities of

the Ministry of Works. Prior to starting a new project, the design professional should contact the

concerned Directorate of the Ministry of Works to verify that he/she has the latest document

revisions.

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Module List
Module
No Module Title
1 Guidance and General Specifications

2 Concrete

3 Earthworks

4 Glass and Glazing

5 Joinery and Carpentry

6 Ironmongery

7 Internal Finishes including Thermal Insulation

8 Painting and Decorating (Internal & External)

9 Metalwork

10 Roofing

11 Structural Steel (and Coatings)

12 Structural Timber

13 Masonry

14 Plumbing and Sanitary

15 Mechanical Installation in Buildings

16 Electrical Installation

17 Sewerage, Pipelines and Pipework

18 Sewerage M&E Works

19 Roadworks

20 Landscaping

21 Dredging, Reclamation and Shoreline Protection

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Table of Contents

CLAUSE DESCRIPTION PAGE

Introduction 1
Module List 2
Table of Contents 3
Foreword 4
1. PART 1 GENERAL 5
1.1 Scope………………………………………………………………………………. 5
1.2 Source Approvals………………………………………………………………… 5
1.3 Testing……………………………………………………………………………... 7
1.4 Submission of Drawings and Method Statements……………………………. 7
1.5 Care and Control of Materials…………………………………………………… 8

2. PART 2 METHODOLOGY AND WORKMANSHIP 9

2.1 General…………………………………………………………………………….. 9
2.2 Bolted Connections………………………………………………………………. 9
2.3 Friction Grip Connections………………………………………………………... 9
2.4 Cambering………………………………………………………………………...10
2.5 Cutting……………………………………………………………………………. 10
2.6 Drilling……………………………………………………………………………..10
2.7 Welding…………………………………………………………………………... 10
2.8 Composite Floors………………………………………………………………...12
2.9 Foundations……………………………………………………………………… 13
2.10 Contractor’s Responsibilities……………………………………………………13
2.11 Erection……………………………………………………………………………14
2.12 As Built Drawings……………………………………………………………….. 14

3. PART 3 SUMMARY 15
3.1 Codes of Practice……………………………………………………………….. 15
3.2 Publications……………………………………………………………………….16

4. PART 4 APPENDICES 17
4.1 Appendix A: Steelwork Coating and Fire Protection………………………… 17

Abbreviations 28

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Foreword

This specification provides the basis for using structural steel in construction. It covers the main

requirements for procurement, fabrication, erection and protective coating of structural steelwork.

This specification must be read in its entirety, as it is structured in order of work-flow, which means

that items or activities appear in several places in the specification corresponding to the

progression of the construction process.

For larger or more complex or specialist projects, a project-specific Particular Specification for

structural steelwork may also be provided.

Absence of clauses for materials and methods does not necessarily signify that they can not be

used. Proposals for use of innovative methods and materials are encouraged and are subject to

review and approval by the Client.

Where the word approved is used in this specification, this means that the Client or Engineer has

been consulted and has confirmed that the item or procedure is acceptable in the specific context

for which approval has been requested.

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1. PART 1 GENERAL

The supply, fabrication and erection of the structural steelwork shall be in accordance
with the general clauses of the National Structural Steelwork Specification for Building
Construction and the clauses of this Specification. In the event of any discrepancies the
clauses of this Specification take precedence over and are in addition to the clauses of
the National Structural Steelwork Specification.

1.1 Scope

This document outlines the requirements related to procurement, fabrication, erection and
protective coatings of structural steelwork which has been designed in accordance with
BS 5950.

All references to Standards and Codes of Practice given hereafter shall be made to the
editions current at the time.

1.2 Source Approvals

1.2.1 Hot Rolled Steel

Steel for hot rolled sections, hot finished structural hollow sections, plates and bars shall
comply as a minimum with the basic specifications of BS EN 10025: Part 1 and BS EN
10210: Part 1. Dimensional properties, tolerances and rolling margins for hot rolled steel
materials shall comply with the following standards:

• plates and bars BS EN 10029

• universal beams, columns, rolled joists, channels and tees BS 4: Part 1
• rolled angles BS EN 10056
• structural hollow sections BS EN 10210: Part 2

1.2.2 Cold Formed Steel

Steel for cold formed welded structural sections shall comply as a minimum with the basic
specification of BS EN 10219: Part 1, and the following standards as applicable:

• Cold formed structural sections in uncoated steel shall be manufactured from strip in
accordance with BS1449: Part 1.
• Cold formed structural sections in zinc pre-coated steel shall be manufactured from
strip in accordance with BS EN 10143.
• Cold formed longitudinally welded hollow sections shall be in accordance with BS
EN 10219: Part 2.
• Purlins, side rails and accessories shall be manufactured from pre-hot-dipped
galvanized mild steel to BS EN 10143 with coating designation Z 275 and a minimum
yield stress of 280 N/mm2.
• All cold formed sections shall be formed by rolling, and not pressing.
• Dimensions and tolerances for cold formed steel materials shall comply with the
following standards:

o Cold rolled sections BS EN 10162

o Cold formed hollow sections BS EN 10219: Part 2

1.2.3 Stainless Steel

Stainless steel for structural purposes shall be grade 316 S31 to PD 970 unless specified
otherwise.

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1.2.4 Consumables

Consumables for use in metal arc welding shall comply with BS EN ISO 14341, BS EN
ISO 2560, BS EN 756, BS EN 757 and BS EN 760 as appropriate.

1.2.5 Structural Fasteners

Structural fasteners shall be in accordance with the following standards:

• Shop and site bolts and nuts in ordinary bolt assemblies shall be grade 4.6 in
accordance with BS 4190 or grade 8.8 or 10.9 in accordance with BS 3692 but with
dimensions, tolerance and threaded length to BS 4190.
• High strength friction grip (HSFG) bolt assemblies shall be in accordance with
BS 4395: Part 2.
• Stainless steel bolts, screws, studs and nuts shall be grade A4-80 to BS EN ISO
3506 unless specified otherwise.
• Holding down bolts in foundations shall be in accordance with BS 7419.
• Cup and countersunk bolts shall be in accordance with BS 4933.
• Metal washers shall be made in accordance with BS 4320 Section 2 and unless
otherwise specified shall be black steel washers to Form E.
• All lock nuts shall be in accordance with BS EN ISO 2320 and BS EN ISO 7042 or
BS EN ISO 7719 as appropriate.
• Where specific coatings are required to fasteners they shall be provided by the
fastener manufacturer and submitted to the Engineer for approval.

1.2.6 Shear Studs

Proprietary shear studs used in composite construction shall be in accordance with

BS 5950: Part 3.1 and shall be the headed type with the following properties after being
formed:
2
• Minimum yield strength 350 N/mm
2
• Minimum ultimate tensile strength 450 N/mm
• At yield elongation of 15% on a 5.65√So gauge length, as given in BS EN 1002: Part
1.

1.2.7 Protective Treatments

Protective treatment materials shall comply with the requirements of the following
standards:

• Chilled iron shot and grit for blast cleaning shall be in accordance with BS EN ISO
11124.
• Surface coatings shall be in accordance with the guidance given in BS EN ISO
12944, BS EN ISO 14713 and/or specialist advice.
• Sherardized coatings shall be in accordance with BS 4921.
• Composition of zinc in galvanizing baths shall be in accordance with BS EN ISO
1461.
• Lightweight gauge metalwork shall be galvanized by the hot-dip process as specified
in BS 3083 or BS EN 10143.

1.2.8 Surface Condition

The surface condition of steel for fabrication shall be in accordance with the following
standards:

• Steel surfaces when used shall not be more heavily pitted or rusted than Grade C of
BS EN ISO 8501: Part 1.

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 • Surface defects in hot rolled sections, plates, wide flats, round and square bars
revealed during surface preparation which are not in accordance with the
requirements of BS EN 10163 for quality of finished steel, shall be rectified
accordingly.
• Surface defects in hot rolled hollow sections revealed during surface preparation
which are not in accordance with the requirements of BS EN 10210: Part 1 shall be
rectified accordingly.

1.3 Testing

The Contractor shall perform tests and provide test certificates, or obtain and submit test
certificates from the manufacturers, for the materials to be used in the work.

The tests shall include the following, in accordance with BS EN 10025, BS EN 10210:
Part 1, BS EN 10219: Part 1 and BS EN 10160 as appropriate:

• Chemical analysis
• Tensile strength tests
• Impact tests
• Bend tests
• Lamination tests

The tests shall be carried out by an approved testing authority and notice shall be given
of the intended execution of any such tests.

If any sample fails a test the consignment it represents may be rejected in part or in
whole.

If necessary, additional tests shall be carried out by Inspection Authority selected by the
Engineer in the event of apparent discrepancy between submitted certificates and actual
condition of the supplied material.

1.4 Submission of Drawings and Method Statements

The Contractor may amend the responsibilities of the Contractor defined in these
Specifications, subject to the prior notification and approval of the Engineer.

The Contractor shall submit for approval four initial copies of each fabrication drawing
produced by Contractor and subsequently four prints and one electronic copy of the
approved shop drawings for retention by the Engineer. Materials shall not be ordered nor
fabrication commenced until shop drawings are approved. Such approval shall not relieve
the Contractor from any of his obligations and responsibilities under the contract.

In submitting drawings and erection procedures for approval, the Contractor shall allow
sufficient time for review, comment, checking and re-submission as agreed with the
Engineer.

The Contractor shall submit, as a minimum, the following information on or with the
fabrication drawings:

• position of all plates, sections, stiffeners, welds, bolts, holes, shear connectors and
temporary attachments including type, size and orientation;
• length of plates and sections with a specified and calculation-supported allowance
for shrinkage and curvature caused by the method of fabrication, wherever such
deviations may become critical for building tolerances;
• cambers which should allow for the pre-cambers given in the Contract Drawings;
• grades of structural materials and connectors.

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 The Contractor shall maintain and submit a record of the source of all plate, section, bolt
and welding consumables, including test certificates.

At least 6 weeks prior to erection, the Contractor shall submit an erection method
statement which shall include the following information:

• health and safety statement including procedures relating to safe working practice;
• sequence of programme for erection of steelwork and execution of protective coating
systems, including drawings detailing crane and steelwork positions during erection,
lifting tackles, temporary props, supports and bracing;
• details of stationary lifting arrangements (tower cranes) including calculations
relating to allowable ground pressures for crane supports;
• details of mobile lifting equipment including details of ground surface preparation in
crane operation areas;
• procedures for site bolting, welding and corrosion protection;
• calculations relating to all props, supports and bracing required to maintain the
stability of steelwork at all stages of erection;
• details of access to be provided for erection, bolting, welding, corrosion protection
and inspections by the Contractor’s Quality Personnel representatives and the
Engineer.

1.5 Care and Control of Materials

1.5.1 Handling, Storage and Protection of Materials

• Steelwork shall be bundled, packed, handled and transported in a safe manner so

that permanent distortion does not occur and surface damage is minimised.
• All lifting tackle shall carry a current test certificate.
• Suitable packings, lashings, lifting harnesses, nylon slings, rubber protected chains
and chocks, etc. shall be used.
• Fabricated components shall be stacked clear of the ground, kept clean and
supported in such a manner as to avoid permanent distortion. If possible,
accumulation of water from rain or condensation shall be avoided.
• Freshly applied surface coatings shall be protected from damage. ' Wet paint'signs
and protective barriers shall be provided where necessary. Surfaces adjacent to
those being coated shall be protected.
• Early degradation of coatings by blistering, peeling, flaking, cracking, lack of
adhesion, etc. shall be made good by complete removal, preparation and
reapplication of all coats, as instructed.
• Inadequate dry film thickness or surface defects due to adverse weather may,
depending on the type of paint, be remedied by rubbing down and applying further
coat(s), as instructed.
• Mechanical damage to coatings shall be made good by local cutting back of
coatings, preparation and reapplication of all coats to leave a neat, continuous and
flat finish.
• Where damage to coatings or subsequent surface preparation has exposed bare
metal, it must be thoroughly cleaned and primed within two hours.
• Consumables stored in the contractors works and on site shall be kept in a
controlled atmosphere, in accordance with BS EN 1011: Part 1.

1.5.2 Fabricated Material Control & Delivery

• Every component which is to be individually assembled or erected shall be allocated

a unique erection mark. Members which are identical in all respects may have the
same erection mark. Individual pieces shall be capable of positive identification at all
stages of fabrication.
• Completed components shall be marked with a durable and distinguishing erection
mark in such a way as not to damage the material. Hard stamping may not be used.

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 Marks shall be placed, where possible, in positions where they will be visible in
storage and after erection.
• All steel shall have a test certificate reference so that its properties are known and
can be verified.

2. PART 2 METHODOLOGY AND WORKMANSHIP

2.1 General

• All parts shall be cut, shaped and assembled to ensure accurate erection.
• Proprietary components, where used, shall be to manufacturers’ recommendations,
and to the satisfaction of the Engineer.
• The ends of structural sections shall be cold sawn or machined except where special
permission is granted for hot sawing.
• All plates and sections shall be true to form and free from twists, accurately
straightened, planed or shaped as necessary.
• Where material lengths are incorrect, the extension of members by welding on
additional material will not be permitted.
• End connections of beams shall not have more than 2 mm clearance at each end,
but cleats may project a maximum of 6 mm beyond the beam.
• Columns with ends not in direct bearing shall be fabricated to the accuracy required
by Clause 7.2.2. of the National Structural Steelwork Specification, i.e. out of
squareness not exceeding (depth of section)/300.
• Columns intended to be in direct bearing shall be fabricated to the accuracy required
by Clause 7.2.3. of the National Structural Steelwork Specification i.e. out of
squareness not exceeding (depth of section)/1,000.

2.2 Bolted Connections

• Bolts shall be threaded only over the length of shank which is outside the parts
bolted together i.e. bearing must be made on unthreaded shank.
• The bolt shall protrude by at least two complete threads and not more than four
complete threads beyond the outer face of the tightened nut.
• Bolt holes shall not be distorted or enlarged by the use of drifts.

2.3 Friction Grip Connections

• High-strength friction grip bolts shall be fitted in accordance with BS 4604: Part 2.
• Faying surfaces of friction grip joints shall be immediately masked after blast
cleaning and before coating surrounding areas to protect from contamination and
deterioration.
• If paint system comprises more than one coat, each coat shall be stepped 30 mm
back from the edge of the preceding coat and away from masked areas.
• Immediately before bolting, masking shall be removed. Faying surfaces shall be
checked as free from adhesive, and cleaned with solvent if necessary.
• After final tightening of bolts, and inspection of joints:

o Uncoated areas including bolts shall be thoroughly degreased and cleaned.

o Primer shall be applied without delay.
o The full shop coating specification shall be applied.
o Where direct tension indicators are used, measuring gaps shall be sealed to
prevent ingress of moisture.

• Load-indicating washers

o Load-indicating washers shall be installed in accordance with the manufacturer’s

recommendations.

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 o The load indicator protrusions should be oriented against the bolt head
o The bolt head shall not be allowed to rotate against the protrusions

• The unit shall be tightened until the average gap is as indicated in the table below.

Table 1 – Load Indication Fitting for Friction Grip Connections

Load Indicator BS 4395
Fitting Metric Series
Under Bolt Head General Grade Part 1 Higher Grade Part 2
Black Finish Bolts 0.4 mm Max 0.5 mm Min 0.4 mm
All plating 0.4 mm Max 0.5 mm Min 0.4 mm

2.4 Cambering

Unless shown otherwise in the Contract Drawings, cambering shall be a smooth

continuous curve. Selection of a curving or straightening process shall be agreed with the
Engineer prior to execution.

2.5 Cutting

• Flame-cut edges which are free from significant irregularities shall be accepted
without further treatment except for the removal of dross; otherwise cut edges shall
be dressed to remove irregularities.
• Sniping of stiffeners at the root radii of rolled members shall be avoided wherever
possible. Stiffeners shall be cut to the required profile to fit closely into all such radii,
and seal welded in accordance with the welding requirements hereafter.

2.6 Drilling

Bolt holes shall be drilled, punching is not allowed. Slotted holes shall be formed by
drilling two holes and completed by cutting. Holes in components shall be shown to the
following sizes.

For ordinary bolts and preloaded (HSFG) bolts:

• not exceeding 24 mm diameter, 2 mm greater than the bolt diameter

• greater than 24 mm diameter, 3 mm greater than the bolt diameter

For holding-down bolts:

• 6 mm greater than the bolt diameter, or with sufficient clearance to ensure that a
bolt, whose adjustment may cause it to be out of perpendicular, can be
accommodated through the base plate.
• Where cope holes are required to allow completion of butt welding they shall be of
adequate size to allow fillet welding to seal the connection, while still allowing full
accessibility for subsequent painting.

2.7 Welding

2.7.1 Site Welding

In all cases precautions are to be taken so that the welding current does not damage
components it passes through and adequate return earth connections are made local to
the area being welded.

Welding shall not be permitted during inclement weather, unless adequate protective
measures are taken.

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2.7.2 Welders

• Welders employed on the work shall be tested to BS EN 287: Part 1 and Part 2, but
in the case of welders engaged on fillet welding only, BS 4872: Part 1 is an
acceptable alternative.
• Welder testing shall be witnessed and certificates endorsed by an independent
Inspection Authority. Copies of certificates for all welders shall be supplied to the
Engineer and the welder of any joint shall be shown to be qualified for the position
and type of weld proposed.
• Welding shall be carried out under the supervision of a competent welding
technologist and the test pieces shall be tested in accordance with BS EN ISO
15614: Part 1.
• Documentation shall be maintained to enable welds to be traced to the welder who
made them.
• The Engineer has the right to instruct the Contractor to suspend any welder whose
performance is deemed unsatisfactory.

2.7.3 Welding Methods

• Welding of steels to BS EN 10025 and BS EN 10210: Part 1 shall be metal arc

process in accordance with the requirements of BS EN 1011: Part 1.
• Fillet welds shall be continuous to form a complete seal where two members join.
Gaps at joints to be fillet welded shall not exceed 1 mm average (measured over 1 m
or length of weld, whichever is smaller) and 2 mm maximum.
• Butt welds shall be full penetration welds. Butt welds in flanges and webs shall be
dressed flush by grinding in the direction of stress.
• Run-on/run-off plates shall be used during butt welding. No temporary backing strips
shall be permitted.
• Penning of welds will not be permitted.
• Welding electrodes shall be of matching chemical composition to the parent metal in
compliance with BS EN ISO 2560, and shall give a weld deposit with mechanical
properties not less than the minimum specified for the parent metal.
• Hydrogen-controlled electrodes shall be used for butt welding of steel over 25 mm
thick.

2.7.4 Weld Testing

Finished welds shall comply with Section 6 of API Standard 1104. Defective welds shall
be cut out, remade and retested until approved.

For surface flaw examination, magnetic particle inspection (MPI) shall be used. If MPI is
impractical, dye penetrant inspection (DPI) can be used in accordance with the
recommendation given in BS EN 571: Part 1, with the permission of the Engineer.

The Contractor shall ensure that the welding processes are maintained to an accepted
standard which is generally suitable for structural steelwork. The Engineer shall check
that any additional project specific requirements for non-destructive testing (NDT) of
welds are clearly specified in the Particular Specification. BS 5950: Part 2, Annex A may
be used as a reference for identifying critical welds which require additional inspection.
Further details regarding scope of inspection, record of testing, visual inspection of welds
and surface flaw inspection can be provided if required.

2.7.5 Visual Inspection of Welds

• Visual inspection shall be made in accordance with guidance given in BS EN 970

over the full length of all welds. Such inspection shall be performed before any
required NDT inspection.
• A suitably qualified person for visual inspection of welds may be a welding inspector
or a welder who can provide evidence of having been trained and assessed for
competence in visual inspection of the relevant types of welds.

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2.7.6 Radiography Testing

Site-welded joints shall be inspected by radiography in accordance with Section 8 of API

Standard 1104. Initially 100% of each butt weld shall be inspected. At the discretion of the
Engineer, the number of inspections may subsequently be reduced.

2.8 Composite Floors

2.8.1 Stud Welding

• Shear studs shall be through deck welded on site following erection of the profiled
steel decking.
• Top surfaces of beam flange shall be free from mill-scale, rust, grease, oil, paint, and
other substances detrimental to welding. Flanges shall be cleaned prior to laying
decking.
• Studs shall not be welded if the deck is wet.
• The minimum distance from sheet edge to the hole made in a sheet by welding shall
be 25 mm.
• Before starting, suitability of materials, equipment and welding system proposed for
welding of studs shall be demonstrated. Not less than ten studs shall be fixed for
testing. Each trial weld shall exhibit full 360 degrees 'flash'
. Each trial stud shall be
subjected to a 30 degree bend test; welds must show no sign of cracking. Test
results shall be retained for the Engineer’s inspection.
• Production welds shall be visually free from cracks and lack of fusion and capable of
developing at least the nominal ultimate strength of the studs. 2% of all studs shall
be bent to 15 degrees to the vertical, to ensure continuing weld adequacy. Bent
studs are not required to be re-straightened.

2.8.2 Decking

• Floor decking shall be fixed (during layout) to the beams to ensure no gaps between
beams and deck, fixed by shot-firing or self drill-tap screws.
• Profiled decking shall be galvanized steel.
• Personnel shall not walk on the decking until after it has been fixed to the steel
beams. After fixing, access to the decking shall be via crawling boards. Any
damaged sheeting shall be replaced entirely at the Contractors expense. Delays in
delivery of new sheets will not be considered as grounds for an extension of the
contract period.
• The Contractor shall ensure that no moisture is trapped between the beams and
decking, and provisions shall be made for boiling off any moisture prior to stud-
welding.
• Joints in the decking shall be prepared to the manufacturer' s recommendations (by
taping or mechanical fixing) to prevent grout leakage.
• Decking sheets are to be clean and free of all traces of grease or mould oil
contamination. The Contractor shall de-grease the decking to the satisfaction of the
Engineer.
• Spacers for reinforcement shall be steel or concrete, in accordance with the
Concrete Specification. The use of plastic spacers is not permitted.
• All ferrules shall be removed prior to placing the reinforcement or concrete.

2.8.3 Temporary Propping

• All propping for concrete work shall comply with the Concrete Specification.
• Where required by the design the Contractor shall provide, install and maintain
propping of all slabs as required until the design strength of the concrete has been
reached. Propping shall be in accordance with the deck suppliers’ recommendations
and shall be capable of transferring all loads to the ground or floors below without
overstressing any part of the structure. A full method statement shall be submitted
and approval shall be obtained from the Engineer before installation.

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 • Propping shall not be removed until the concrete in the slabs has achieved the
design strength. The propping shall be progressively lowered in bays between
columns to ensure the loads taken by the propping are transferred uniformly to the
composite construction.

2.9 Foundations

2.9.1 Holding Down Bolts

• The Contractor shall position the holding down bolts and sleeves in accordance with
the Contractor' s Foundation Plan. The ends of bolts shall be held and linked by cast
steel sections.
• Holding down bolts shall be protected by bituminous paint to the unthreaded parts
before casting in, and all exposed parts and nuts shall be recoated after grouting and
tightening.
• Holding down bolts shall be hand spanner tight when the base plates are grouted,
and fully tightened at least 7 days after grouting to a controlled torque as specified by
the Engineer.
• Bolts shall be cast into foundations, using templates to ensure accurate positioning
to the required line and level, within cylindrical pockets (sleeves). Anchor plates shall
incorporate welded ' stops'to prevent bolt rotation during tightening.
• Neither bolts nor pockets shall be in contact with steel reinforcing bars. Immediately
after concreting in, all bolts shall be 'waggled'to ensure free movement within the
pocket.

2.9.2 Grouting

• All grout and grouting shall comply with the Concrete Specification.
• The Contractor shall notify the Engineer if the space beneath any column base is
less than 15 mm or more than 50 mm, and await his instructions before grouting
under any bases of the structure concerned.
• Bedding operations shall not commence until a sufficient number of columns,
trusses, beams, bracings and ties have been properly lined, levelled, plumbed and
finally assembled.
• Immediately before grouting, pockets and spaces under the base plates shall be
thoroughly cleaned and excessive moisture removed.
• Bolt pockets shall be filled with neat cement grout, just fluid enough to pour.
• Spaces under base plates shall be filled as follows:

o depth not exceeding 25 mm – Neat cement grout, just fluid enough to pour.
o depth between 25 mm and 50 mm – Mortar of 1:2 cement : fine aggregate, just
fluid enough to pour. The mortar shall be tamped as filling proceeds.
o In all cases care shall be taken to ensure that no pockets of air are trapped under
base plates. In larger base plates grout holes of appropriate size and location
shall be provided.
o In all cases a shrinkage compensating additive shall be incorporated in the
material in accordance with manufacturer' s recommendations.

• Grout or mortar shall have a minimum 28-day strength of 50 N/mm2. Packs shall be
protected by grout to a minimum thickness of 50 mm.

2.10 Contractor’s Responsibilities

• The Contractor shall inspect the prepared foundations and holding down bolts for
position and level not less than seven days before erection of steelwork starts. In the
event of any discrepancies found which are outside the permitted maximum
deviations, these shall be reported to the Engineer and the necessary remedial work
shall be carried out before erection commences.

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 • Accuracy of position and levels of foundations and holding down bolts shall be as
specified in the National Structural Steelwork Specification for Building Construction.
• It should be noted in particular that the permitted deviations for foundations and
foundation bolts are:

o Clause 9.4.1 – the maximum deviations of foundation level from exact level are
+ 0 mm and - 30 mm;
o Clause 9.4.3 – the maximum deviation of foundation bolt from exact location is
20 mm in any direction horizontally and + 25 mm or - 5 mm vertically at shaft tip.

These are total deviations from the exact locations due to setting out inaccuracies as well
as construction allowance. Note also the required bolt movement in the location tube of
25 mm minimum in all directions from the central position.

2.11 Erection

2.11.1 Approvals

The erection sequence and procedure shall be submitted for Engineer’s approval at an
agreed time period prior to erection including the details of lifting plant and other
machinery. Prior to use, all lifting equipment shall be certified by an authorized third party
to be safe for use on site.

2.11.2 Contractor’s Responsibilities

Until the steelwork is accepted, the Contractor shall provide and maintain setting out lines
and datum levels within or immediately adjacent to the Works. Before grouting under
column bases (or casting-in bases) the Contractor shall check the accuracy of the
steelwork erection and any errors shall be corrected.

The Contractor shall

• Achieve the design level of base plates during erection of columns, and steel plate
packs or shims of appropriate thickness shall be used. It is not allowed to support
base plates from levelling nuts.
• Be entirely responsible for stability of the steelwork during erection and shall arrange
for all temporary guying, bracing and supports, together with any additional tackbolts
necessary for structure stability until final bolting up. Use of tack welds shall be
limited to an indispensable minimum.
• Assemble all parts as shown on the drawings and shall accurately position, plumb-
line and level the work. Drift pins shall only be employed to align component parts
and must not distort the work.
• Accurately erect the steelwork within the tolerances outlined in National Structural
Steelwork Specification and BS 5950: Part 1. In the event of discrepancy, the
following tolerances take precedence:

o Ensure that setting out/plan dimensions do not exceed ± 12 mm overall building

dimensions, or ± 5 mm in any one bay;
o Ensure that levels do not exceed ± 5 mm for truss and beam support plates, ± 10
mm stanchion base plates;
o Ensure that stanchions are not out of plumb by more than 0.1% of height for
stanchions and vertical axis of truss girders, or 6 mm overall;
o Ensure that after erection, straightness, bow or out-of-squareness shall be not
more than the rolling tolerances given in appropriate British Standards.

2.12 As-Built Drawings

The contractor shall produce all As-Built drawings before hand over, and format size and
number shall be as specified in the contract.

Page 14
3. PART 3 SUMMARY

3.1 Codes of Practice

Reference Title

BS 4: Part 1 Structural steel sections. Specification for hot-rolled

sections
BS 1449: Part 1 Steel plate, sheet and strip. Carbon and carbon-
manganese plate, sheet and strip
BS 2989 Specification for continuously hot-dip zinc coated and iron-
zinc alloy coated steel
BS 3083 Specification for hot-dip zinc coated and hot-dip
aluminium/zinc coated corrugated steel sheets for general
purposes
BS 3692 ISO metric precision hexagon bolts, screws and nuts.
Specification
BS 4190 ISO metric precision hexagon bolts, screws and nuts.
Specification
BS 4320 Specification for metal washers for general engineering
purposes. Metric series
BS 4395: Part 1 Specification for high strength friction grip bolts and
associated nuts and washers for structural engineering.
General grade
BS 4395: Part 2 Specification for high strength friction grip bolts and
associated nuts and washers for structural engineering.
Higher grade bolts and nuts and general grade washers
BS 4604: Part 1 Specification for the use of high strength friction grip bolts
in structural steelwork. Metric series. General grade
BS 4604: Part 2 Specification for the use of high strength friction grip bolts
in structural steelwork. Metric series. Higher grade (parallel
shank)
BS 4872: Part 1 Specification for approval testing of welders when welding
procedure approval is not required. Fusion welding of steel
BS 4921 Specification for sherardized coatings on iron or steel.
BS 4933 Specification for ISO metric black cup and countersunk
head bolts and screws with hexagon nuts
BS 5950 Structural use of steelwork in building
BS 7419 Specification for holding down bolts
PD 970 Wrought steels for mechanical and allied engineering
purposes. Requirements for carbon, carbon manganese
and alloy hot worked or cold finished steels
BS EN 287: Part 1 Qualification test of welders. Fusion welding. Steels
BS EN 287: Part 2 Approval testing of welders for fusion welding. Aluminium
and aluminium alloys
BS EN 571: Part 1 Non-destructive testing. Penetrant testing. General
principles
BS EN 756 Welding consumables. Solid wires, solid wire-flux and
tubular cored electrode-flux combinations for submerged
arc welding of non alloy and fine grain steels. Classification
BS EN 757 Welding consumables. Covered electrodes for manual
metal arc welding of high strength steels. Classification
BS EN 760 Welding consumables. Fluxes for submerged arc welding.
Classification
BS EN 970 Non-destructive examination of fusion welds. Visual
examination
BS EN 1011: Part 1 Welding. Recommendations for welding of metallic
materials. General guidance for arc welding
BS EN 10002: Part 1 Tensile testing of metallic materials. Method of test at
ambient temperature

Page 15
 BS EN 10025 Hot rolled products of structural steels
BS EN 10029 Tolerances on dimensions, shape and mass for hot rolled
steel plates 3 mm thick or above
BS EN 10056 Specification for structural steel equal and unequal leg
angles
BS EN 10143 Continuously hot-dip metal coated steel sheet and strip -
tolerances on dimensions and shape
BS EN 10160 Ultrasonic testing of steel flat product of thickness equal or
greater than 6 mm (reflection method)
BS EN 10162 Cold rolled steel sections. Technical delivery conditions.
Dimensional and cross-sectional tolerances
BS EN 10163 Delivery requirements for surface condition of hot-rolled
steel plates, wide flats and sections
BS EN 10210: Part 1 Hot finished structural hollow sections of non-alloy and fine
grain steels. Technical delivery requirements
BS EN 10210: Part 2 Hot finished structural hollow sections of non-alloy and fine
grain steels. Tolerances, dimensions and sectional
properties
BS EN 10219: Part 1 Cold formed welded structural hollow sections of non-alloy
and fine grain steels. Technical delivery requirements
BS EN 10219: Part 2 Cold formed welded structural hollow sections of non-alloy
and fine grain steels. Tolerances, dimensions and
sectional properties
BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel
articles. Specifications and test methods.
BS EN ISO 2320 Prevailing torque type steel hexagon nuts. Mechanical and
performance properties
BS EN ISO 2560 Welding consumables. Covered electrodes for manual
metal arc welding of non-alloy and fine grain steels.
Classification
BS EN ISO 3506 Mechanical properties of corrosion-resistant stainless-steel
fasteners
BS EN ISO 7042 Prevailing torque type all-metal hexagon nuts. Property
classes 5, 8, 10 and 12
BS EN ISO 7719 Prevailing torque type all-metal hexagon nuts, style 1.
Property classes 5, 8 and 10
BS EN ISO 8501: Part 1 Preparation of steel substrates before application of paints
and related products. Visual assessment of surface
cleanliness. Rust grades and preparation grades of
uncoated steel substrates and of steel substrates after
overall removal of previous coatings
BS EN ISO 11124 Preparation of steel substrates before application of paints
and related products
BS EN ISO 12944 Paints and varnishes. Corrosion protection of steel
structures by protective paint systems
BS EN ISO 14341 Welding consumables. Wire electrodes and deposits for
gas shielded metal arc welding of non alloy and fine grain
steels. Classification
BS EN ISO 14713 Protection against corrosion of iron and steel in structures.
zinc and aluminium coatings. Guidelines
BS EN ISO 15614: Part 1 Specification and qualification of welding procedures for
metallic materials

3.2 Publications

National Structural Steelwork Specification for Building Construction.

API 1104: Welding of Pipelines and Related Facilities

Page 16
4. PART 4 APPENDICES

4.1 Appendix A: Steelwork Coating and Fire Protection

Surface preparation and painting shall be carried out in accordance with good practice,
generally but not exclusively laid down in such publications as BS 6150 ‘Code of Practice
for Painting of Buildings’, BS EN 12944 ‘Paints and varnishes. Corrosion protection of
steel structures by protective paint systems’, BS 7079 ‘Preparation of Steel Substrates
Before Application of Paints and Related Products’, BS EN ISO 8501 to 8504
‘Preparation of Steel Substrates Before Application of Paints and Related Products’.

Where the surface preparation or coating requirements of this specification differ from
those of the approved manufacturer, the manufacturer' s requirements shall take
precedence, subject to the approval of the Engineer.

All references to Standards and Codes of Practice shall be made to the editions current
at the time.

4.1.1 Materials

4.1.1.1 Approved Systems

Coating systems proposed shall have a verifiable track record for use in climates similar
to Bahrain.

The upper and lower limits provided for the Nominal Dry Film Thickness (NDFT) indicate
the minimum requirements for time to first maintenance of 10 years and 15 years
respectively. Where an upper limit is not provided, the time to first maintenance is
expected to be more than 10 years and less than 15 years.

The durability requirements for the project shall be defined in the contract documents.

Water-based coatings are preferred. Where water-based formulations are not available,
preference shall be given to “high solids” systems that contain low fractions of volatile
organic compounds.

Coatings containing lead or chromate based pigments will not be approved.

4.1.1.2 Decorative Coatings

Decorative coatings for steel shall meet the requirements of the following coating systems
listed in Table 2 below:

Note: Decorative paint coatings shall only be applied to steel intended to be installed in
air-conditioned environments.

Table 2 – Coating System for Decorative Coating

System ID Primer Topcoat NDFT m
System 1 Alkyd Alkyd 80-160
System 2 Acrylic Acrylic 120-160
System 3 Epoxy Poly-urethane 120-160

4.1.1.3 Protective Coatings

Protective coatings shall meet the requirements of the following coating systems listed in
Tables 3, 4 and 5 below:

Page 17
 Note: Protective coating systems are defined based on the expected exposure condition.
The exposure conditions are based on those described in BS EN ISO 12944-2 as follows:

• E1 equivalent to BS EN ISO 12944-2 (C3)

• E2 equivalent to BS EN ISO 12944-2 (C4)
• E3 equivalent to BS EN ISO 12944-2 (C5-M)

Exposure condition E1 shall apply to the interiors of non-air-conditioned buildings in

urban areas.

Table 3 – Coating System for Protective Coating – Exposure Class E1

System ID Primer Topcoat NDFT m
System 1 Alkyd Alkyd 160-200
System 2 Acrylic Acrylic 160-240
System 3 Epoxy Epoxy 160-240
System 4 Epoxy Poly-urethane 160-240

Exposure condition E2 shall apply to the exteriors of buildings in urban areas greater than
1,000 m from the coast and the interior of buildings containing swimming pools, or
chemical processing facilities.

Table 4 – Coating Systems – Exposure Class E2

System ID Primer Topcoat NDFT m
System 1 Acrylic Acrylic 240
System 2 Epoxy Poly-urethane 240-320
System 3 Epoxy-Zn-R Poly-urethane 200-320
System 4 Ethyl-silicate Poly-urethane 200-320
Zn-R

Exposure condition E3 shall apply to the exteriors of all buildings less than 1,000 m from
the coast and the interior of buildings containing almost permanent condensation or high
pollution levels. Minimum coating thickness shall be as in Table 5 below:

Systems denoted by * shall only be applicable to applications where UV exposure is not

expected.

Table 5 – Coating Systems – Exposure Class E3

Primer Topcoat NDFT m
System 1* Epoxy - 400
System 2* Epoxy- Epoxy 300-500
Zn-R
System 3* Ethyl- Epoxy 240-320
silicate
System 3 Epoxy-Zn-R Poly-urethane 240-320
System 4 Ethyl-silicate Poly-urethane 240-320
System 5 Epoxy Zn-R Epoxy- 200
siloxane

4.1.1.4 Galvanizing

Hot dip galvanizing shall be in accordance with the requirements of BS EN ISO 1461.

The minimum coating thickness for steel work exposed to air-conditioned interiors of
buildings or interior spaces where the exposure condition is E1 – as defined above – shall
be in Table 6 below:

Page 18
 Table 6 – Galvanized Coating System – Exposure Class E1
Article Thickness Mean coating
thickness m
6 mm 85
3 mm to < 6 mm 70
1.5 mm to < 3 mm 55
< 1.5 mm 45

The minimum coating thickness for exterior steelwork where the exposure condition is E2
– as defined above – shall be as in Table 7 below:

Table 7 – Galvanized Coating System – Exposure Class E2

Article Thickness Mean coating
thickness m
6 mm 85

The minimum coating thickness for exterior steelwork where the exposure condition is E3
– as defined above – shall be as in Table 8 below:

Table 8 – Galvanized Coating System – Exposure Class E3

Article Thickness Mean coating
thickness m
6 mm 115
3 mm to < 6 mm 95
1.5 mm to < 3 mm 70

4.1.1.5 Fire Protection Coatings

The requirements for fire-protection shall be defined in the Particular Specification.

Coating systems for the provision of fire-protection shall be limited to the systems listed in
Table 9 below.

Table 9 – Fire Protection Coating System

System ID Primer Fire Protection Coating
1
System 1 Ethyl silicate Zn-R Thin film intumescent
System 2 Epoxy Zn-R Intumescent epoxy mastic
2
System 3 Ethyl silicate Zn-R or Lightweight concrete
Epoxy Zn-R
System 4 Ethyl silicate Zn-R or Fire protection boards/
Epoxy Zn-R casings3
System 5 Ethyl silicate Zn-R or Concrete4
Epoxy Zn-R

Notes:

1 Thin intumescent coatings shall only be used in domestic/commercial internal

applications. They shall not be used for external or industrial type projects unless
approved by the Engineer
2 Lightweight concretes shall generally comply with the Concrete Specification and shall
be proprietary mixes based on vermiculite or similar lightweight materials with a
proven fire rating when tested in accordance with BS 476
3 Due to longer-term durability issues, fire-protection systems based on protection
boards or casings shall be applicable for internal applications only
4 Concrete shall comply with the Concrete Specification and shall provide a minimum
cover of 50 mm to the element it is protecting. Where installation is external, the

Page 19
 concrete shall be coated with a protective coating rated to Class 1 for flame spread
when tested in accordance with BS 476 Part 7.

The required fire rating shall be defined in the contract documents.

4.1.2 Approval of Systems

The Contractor shall submit details of the proposed coating systems for approval by the
Engineer. Submittals shall include:

• Technical data for all materials including but not limited to the following:

o nominal recommended coating thickness

o surface preparation requirements
o manufacturer approved application methods
o available colours
o over-coating intervals

• Samples of the proposed coating system

o A verifiable track record for the coating system for use in climates similar to
Bahrain.

For fire rated systems, test certificates indicating the performance of the material when
testing in accordance with the requirements of BS 476 shall be provided.

Materials shall be sourced from a single manufacturer.

Materials shall not be procured until they have been approved. Such approval shall not
relieve the Contractor from any obligations and responsibilities of the contract.

4.1.2.1 Alternative Systems

The Contractor shall be entitled to submit alternative systems for approval. Alternative
systems shall meet the durability requirements of the approved systems. Their
performance shall be documented and evidence shall be submitted for approval by the
Client.

4.1.3 Handling, Storage and Protection of Materials

4.1.3.1 Safety

Hazards associated with the handling and storage of materials shall be defined and
control measures identified and included in the Contractor’s method statements.

Safe handling practices shall be adhered to at all times. Personnel shall be trained in the
safe handling, and storage or materials.

• Control of Volatile Organic Compounds

Materials shall be stored, prepared and applied in well ventilated areas. Where
adequate ventilation is not practically achievable, painters shall be provided with
suitable respiratory devices to prevent ingestion of vapours.

• Fire Safety

Materials shall be stored away from potential ignition sources. Smoking shall be
prohibited on sites where flammable materials are being stored or applied.

Page 20
 Fire hazards shall be assessed and controls defined in the Contractor’s method
statements.

4.1.3.2 Storage

All materials shall be stored in a secure air-conditioned area. Unless other temperatures
are indicated in the manufacturer’s instructions or specified elsewhere, coating materials
shall be stored at temperatures above + 3°C and under + 30°C. Materials shall only be
taken to site as required by planned coating operations. Containers shall remain sealed
until the contents are prepared for use.

Partly used containers may be re-sealed and used later unless otherwise advised by the
manufacturer. Partly used containers shall be clearly marked.

Steelwork protected by only prefabrication primer shall not be stored outside for more
than 21 days.

If damage has exposed parent metal, local re-blasting may be required to prepare the
steel for remedial coating. The maximum time lag between cleaning steel and applying
primer shall not be more than two hours.

4.1.3.3 Shelf Life

Materials shall not be used beyond their specified shelf life.

When any mixed 2 pack material has exceeded its pot life it should be discarded
irrespective of its apparent condition.

Labelling and date stamps:

All containers shall be clearly identifiable and shall be machine labelled with the following
information:

o Manufacturer’s name
o Material name
o Mass/Volume of contents of container
o Date of Manufacture
o Expiry date or expected shelf life
o Batch and/or production number
o Material’s hazard classification (if applicable)
o Recommended storage temperature

4.1.4 Methodology and Workmanship

4.1.4.1 Approvals

• Method Statements

The Contractor shall submit detailed method statements for the coating work. The
submittal shall include but not be limited to the following:

o Technical data sheets and material safety data sheets (MSDS) for all products
proposed
o Details of proposed surface preparation methods and materials
o Details of proposed application methods
o Details of equipment to be used
o Details of Personal Protective Equipment required
o Details of safe handling controls
o Methods for protecting finished coatings during transport and erection on site
o Details of fire safety controls
o Nominated safety officers

Page 21
 • Inspection and Test Plan

The Contractor shall submit an Inspection and Test Plan (ITP) that details quality
and safety hold points and inspections for all stages of the works including surface
preparation, materials preparation and application as detailed in the method
statements.

4.1.4.2 Preparation

• Cleaning

Accumulated dirt, grease and soluble salts shall be removed and the steelwork
cleaned in accordance with BS 7079. Dry bristle brushing shall normally be
adequate for accumulated dirt. Soluble salts shall be removed by fresh water
washing.

• Preparation of Welds/Edges

Sharp edges shall be rounded or chamfered. All burrs from holes shall be removed
prior to blasting.

All welds shall be free of undercutting, craters and splatters. Splatters shall be
removed by suitable methods prior to blast cleaning.

• Blast Cleaning

All surfaces shall be blast cleaned with to a minimum standard of Sa 2½ (ISO 8501:
Part 1). Surface profile shall be in accordance with recommendations from the
coating manufacturer.

For galvanized elements, the surface shall be prepared by sweep blast, cleaned to
surface roughness “fine (G)” in accordance with ISO 8503: Part 2.

Abrasives based on silica-containing materials shall not be used.

After blast cleaning all dust and debris shall be removed by vacuum cleaner or oil
free compressed air and brush. Freedom from residual surface contamination shall
be checked by pressing the adhesive side of transparent adhesive tape onto the
cleaned surface and on removal examining it for adherent rust, scale or dust.

• Cleaning Prior to Hot Dip Galvanizing

All steel articles shall be cleaned by acid pickling to remove mill scale, oils and other
protective films prior to hot dip galvanizing.

• Safety

Personnel involved in surface preparation shall be trained to a recognized standard

and shall wear the appropriate Personal Protective Equipment that shall include but
not be limited to:

o Eye protection
o Hearing protection
o Respiratory protection

Areas where surface preparation works are carried out shall be clearly demarcated
with warning signs/barriers. Access to the work site during surface preparation shall
be limited to those carrying out the works.

Page 22
 Access to the work site for other personnel shall only be upon a clearly defined
signal as defined in the Contractor’s Safety Management Plan.

• Period Between Surface Preparation and Coating

The period between surface preparation and coating shall be kept to the minimum
that is practically achievable. Where periods between surface preparation and
coating may be sufficient for the preparation grade to change (e.g. by formation of
rust), temporary protection such as pre-fabrication primers or adhesive films shall be
provided.

Further preparation will be required prior to coating application.

4.1.4.3 Galvanizing

• Galvanizing of steelwork shall be carried out after fabrication is complete in

accordance with BS EN ISO 1461.
• Steelwork required to be galvanized shall be pickled in dilute hydrochloric acid,
washed, fluxed and stoved, and then coated with zinc by dipping in a bath of molten
zinc. Components shall be immersed in the bath only for a period sufficient to attain
the temperature of the bath, and shall be withdrawn at a speed which ensures that
2
the coating of 610 g/m of surface is achieved (85 microns minimum DFT).
• Components shall be covered evenly on all surfaces and shall be free from pin
holes, lumps of galvanizing materials and all other defects.
• Items described as heavily galvanized shall be grit blasted prior to galvanizing and
shall receive a minimum coating of 1,000 g/m2 of surface (140 microns minimum
DFT).
• Before application of the specified paint treatment, galvanized steelwork shall be
cleaned, degreased and etch primed.
• All damaged galvanizing surfaces and all edges exposed by cutting, drilling or
welding after galvanizing shall be treated with two coats of sprayed metallic zinc in
accordance with manufacturer specification, prior to restoring of paint system.
• Contact between galvanized steel members and aluminium surfaces or between
galvanized and ungalvanized steel members shall be prevented by means of
approved insulating washers and grommets.

4.1.5 Application

4.1.5.1 General

Prior to and during the application, the Contractor shall verify coating materials to ensure:

• conformity of the container label with the specified product description

• no skin formation
• no irreversible settling
• usability under the given site conditions

Where viscosity modification is required it shall be made in strict accordance with the
manufacturer’s recommendations.

4.1.5.2 Safety

Personnel involved in surface preparation shall be trained to a recognized standard and

shall wear the appropriate Personal Protective Equipment that shall include but not be
limited to:

• Eye protection
• Hearing protection (as applicable)
• Skin protection (gloves or barrier cream as appropriate)
• Respiratory protection

Page 23
4.1.5.3 Shop Coating

Where fabrication methods allow, all coating shall be completed in a dedicated coating
facility.

All completed coatings shall be protected from damage during storage and during
transport to the site.

4.1.5.4 Site Coating

Where fabrication methods do not allow shop coating or where touch-ups or final coats
on connections are required, site coating shall be allowed.

Containment shall be provided to ensure abrasive used for blast cleaning and coating
overspray is contained local to the works.

The containment shall also offer the area of any works adequate protection from rain and
wind.

Ideally the containment should be able to control the local environment to the ambient
conditions detailed in this specification throughout the preparation and painting
operations and including the initial drying and curing of the applied paints.

4.1.5.5 Ambient Conditions

Coating application should only be carried out when good atmospheric conditions and
clement weather prevail.

The surfaces to be treated shall be safely accessible and well illuminated.

Coating should not be undertaken:

• When the air temperature falls below the lower drying or curing limit of the coating
• During fog or mist conditions or when rain is imminent
• When the surface to be painted is wet with condensation or when condensation can
occur during the initial drying period of the coating
• When the amount of moisture likely to be deposited on the surface by condensation
or rain immediately after coating, may have a harmful effect on the coating
• When the ambient temperature falls below 10°C
• When substrate is below 10°C
• When the relative humidity rises above 85%.
• When the ambient temperature is less than 3°C above the dew point
• When the substrate or ambient temperatures are above 40°C
• When wind-borne dust may have a harmful effect on the coating.

In order to determine whether or not a surface is wet, the steel temperature should be
measured using a surface temperature thermometer and the dew point calculated after
measurement of humidity with a hygrometer. Coating application should not take place
when steel temperature is less than 3°C above the dew point.

4.1.5.6 Mixing

All components of the coating materials shall be prepared strictly in accordance with the
manufacturer’s printed requirements.

Mixing equipment shall be clean and dry and not contaminate the materials in any way.

4.1.5.7 Pot Life

Coatings shall not be used beyond the pot life specified by the manufacturer or when it is
obviously thickening.

Page 24
4.1.5.8 Application Methods

All coatings shall be applied in accordance with the requirements of the manufacturer.

Where concrete is used for fire protection, installation shall be in accordance with the
Concrete Specification.

Coating application methods shall include but not be limited to the following:

• Brush
• Roller
• Trowel
• Airless spray

The application method shall be determined in accordance with the manufacturer’s

recommendations and any other factors that may affect the suitability of a particular
method. The application method shall be included in the method statement submittal for
review by the Engineer.

All application equipment shall be cleaned at the commencement of painting and shall be
kept clean during the painting operation, using the cleanser specified for the particular
paint. Brushes stored in thinners shall be well worked out to remove thinners before use.

4.1.5.9 Coating Thickness

All materials shall be applied at the manufacturer’s recommended thickness, but the
completed coating system must meet the minimum dry film thickness defined in the
project specification.

Unless agreed otherwise, individual dry film thicknesses of less than 80% of the nominal
dry film thickness are not acceptable.

Stripe coats shall be applied to all welds, lap joints, plate edges, corners, sharp edges,
and any other edges where spray application of the overall coating system may prove
difficult resulting in low dry film thicknesses.

Wet film thickness gauges shall be used regularly to check adequate wet material is
applied meet the recommended application rates for each coat.

4.1.5.10 Testing

The type and frequency of testing shall be identified in the inspection and test plan.
Testing shall include but not be limited to:

• Surface comparator testing (if particular profile is required by coating manufacturer)

• Wet film thickness testing
• Dry film thickness testing
• Pull-off testing
• Spark testing

During application wet film thickness of each coat shall be checked with a wheel or comb
gauge used in accordance with BS EN ISO 2808.

After each coat has dried, check total accumulated film thickness using a magnetic or
electromagnetic meter.

Average dry film thickness shall be at least specified thickness over any square metre
and no reading to be less than 75% of the specified thickness.

Top coat dry film thickness shall be sufficient to give an even, solid, opaque appearance.

Page 25
 Measurements to be independently witnessed.

Check meter against standard shims and recalibrate regularly against a smooth steel
reference plate.

4.1.5.11 Period between Over-coating

Over-coating periods shall be strictly in accordance with the paint manufacturer’s printed
requirements.

Surfaces to be over-coated shall be clean and dry and prepared as required by the
manufacturer.

4.1.5.12 Colour of Coats

To enable clear identification of coats, the primer, intermediate and top coats shall be of
different shades subject to the opacity of the final coat.

The final coat colour shall be defined in the contract documents.

The colour shall be as defined in the contract documents at the end of the warranty
period.

4.1.5.13 Special Requirements

• Connections:

Where fabricated items are to be subsequently welded on site, the coating system
shall not be applied within 150 mm of the weld.

Where steelwork is galvanized, the galvanizing shall be removed from the weld area
to provide a minimum of 75 mm clearance from the weld.

• HSFG bolt connections:

Coatings shall be carefully selected to ensure that the friction factor does not affect
the ability of the connection to perform as designed.

Friction type bolted connections shall be blast cleaned to Sa 2½ in accordance with

ISO 8501: Part 1 with an agreed roughness. The friction surfaces can be coated with
a material with a suitable friction factor.

4.1.5.14 Re-work

Where testing indicates that the coating does not meet the requirements defined in the
contract documents, the coating shall be made good by complete removal of all coats,
preparation of the surface and re-application of the coating system in accordance with the
contract documents.

Where localised repairs are required, the coating shall be made good by local cutting-
back of the coating, preparation of the surface and re-application of the coating system in
accordance with the contract documents.

4.1.6 Reference Documents

4.1.6.1 Standards

Reference Title

BS 476 Fire tests on building materials and structures

BS 5950 The structural use of steelwork in buildings
BS 6150 Painting of buildings. Code of practice

Page 26
 BS 7079 General introduction to standards for preparation of steel
substrates before application of paints and related
products
BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel
articles. Specifications and test methods
BS EN ISO 2808 Paints and varnishes. Determination of film thickness
BS EN ISO 8501 Preparation of steel substrates before application of paints
and related products. Visual assessment of surface
cleanliness
BS EN ISO 8502 Preparation of steel substrates before application of paints
and related products. Tests for the assessment of surface
cleanliness
BS EN ISO 8503 Preparation of steel substrates before application of paints
and related products. Surface roughness characteristics of
blast-cleaned steel substrates
BS EN ISO 8504 Preparation of steel substrates before application of paints
and related products. Surface preparation methods
BS EN ISO 9002 Quality systems. Model for quality assurance in production,
installation and servicing
BS EN ISO 12944 All parts Paints and varnishes. Corrosion protection of
steel structures by protective paint systems
BS EN ISO 14713 Protection against corrosion of iron and steel in structures.
Zinc and aluminium coatings. Guidelines

4.1.6.2 Publications
rd
Fire protection for structural steel in buildings, 3 Edition, (2004),
Association for Specialist Fire Protection, UK
ISBN 1 870409 22 1

Spray coatings for the protection of structural steel – Part 1: Technical guidance note for
the mechanical retention of sprayed mineral coatings based upon the requirements of BS
8202: Part 1: 1993, Association for Specialist Fire Protection, UK
ISBN 1 870409 11 6

Page 27
Abbreviations
ACB Air Circuit Breakers EMC Electromagnetic Compatibility
ACOP Approved Code of Practice EPDM Ethylene-propylene-diene-monomer
ACRIB Air Conditioning and Refrigeration Industry copolymer
Board FA Fresh Air
ADCM Acoustic Doppler Current Meters FBA Factory Built Assembly
AFMA Australian Fisheries Management Authority FRP Fibre Reinforced Polymer
AGMA American Gear Manufacturers’ Association FSC Forest Stewardship Council
AISI American Iron and Steel Institute GANA Glass Association of North America
AS Acceptance Strength GGBS Ground Granulated Blast-furnace Slag
ASTA Association of Short-circuit Testing GMS Galvanized Mild Steel
Authorities GRC Glass Reinforced Cement/Glass Reinforced
ASTM American Society for Testing Materials Concrete
ATS Automatic Transfer Switch GRP Glass Reinforced Plastics
AWS American Welding Society HCFC Hydrofluorocarbons
BASEC British Approval Service for Electric Cables HDPE High Density Polyethylene
BOCA Building Officials and Code Administrators HEPA High Efficiency Particulate Air
BRE Building Research Establishment Ltd. HFC HydroFluoroCarbon
BS British Standards HPL High Pressure Laminate
BSRIA Building Service Research and Information HPPE Higher Performance Polyethylene
Association HRC High Rupturing Capacity
CBR California Bearing Ratio HSE Health and Safety Executive
CCTV Close Circuit Television HSFG High Strength Friction Grip
CECOMAF Comité Européen des Constructeurs de HV High Voltage
Matériel Frigorifique HVCA Heating and Ventilating Contractors’
CENELEC Comité Européen de Normalisation Association
Electrotechnique ICBO International Conference of Building Officials
CFC Chlorofluorocarbons IGCC Insulating Glass Certification Council
CIBSE Chartered Institution of Building Services IGE/UP Institution of Gas Engineers – Utilization
Engineers Procedures
CHW Chilled Water IP Ingress Protection
CI Cast Iron ISAT Initial Surface Absorption Test
CLW Cooling Water ISO International Standard Organization
CM Current Margin / Communication cable ITP Inspection Testing Plan
CMP Communication cable (Plenum) KD Kiln Dried
CP Code of Practice kVA Kilovolt Ampere
CPC Circuit Protection Conductor LCD Liquid Crystal Display
CPT Cone Penetration Testing LED Light Emitting Diode
CRS Categorised Required Strength LPG Liquid Petroleum Gas
CRT Cathode Ray Tube LS0H Low Smoke Zero Halogen
CRZ Capillary Rise Zone LSF Low Smoke and Fume
CT Current Transformer LV Low Voltage
c(UL) Underwriters Laboratories Incorporated MCB Miniature Circuit Breaker
(Canada) MCC Motor Control Centre
DEO Defence Estate Organisation MCCB Moulded Case Circuit Breakers
DFT Dry Film Thickness MDF Medium Density Fireboard
DI Ductile Iron MDD Maximum Dry Density
DIN Deutsches Institut für Normung MDPE Medium Density Polyethylene
DPC Damp Proof Course MEP Mechanical Electrical Plumbing
DPDT Differential Pressure, Differential MICC Mineral Insulated Copper Covered Cable
Temperature MIO Micaceous Iron Oxide
DS Durability Strength MMI Man Machine Interface
DVR Digital Video Recorder MOD Ministry of Defence
DW Ductwork Specification MS Micro-silica
EA Exhaust Air MSDS Material Safety Data Sheet
ECMA European Computer Manufacturers MSRPC Moderate Sulphate Resistance Portland
Association Cement
EA Exhaust Air N Nitrogen
ECMA European Computer Manufacturers NDFT Nominal Dry Film Thickness
Association NEMA National Electrical Manufacturers’ Association
ECR Extra Chemical Resistant NFPA National Fire Protection Association
EIA Environmental Impact Assessment/ NRC Noise Reduction Coefficient
Electronic Industries Alliance NS Norwegian Standard

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O/D Outside Diameter
ODP Ozone Depletion Potential
OFS Oil Fired (Appliance/Equipment) Standard
OFTEC Oil Firing Technical Association
O&M Operation and Maintenance
OPC Ordinary Portland Cement
PD Published Documents
PE Polyethylene
PFA Pulverised Fuel Ash
PFC Power Factor Correction
PM Project Manager
PTFE Polytetrafluoroethylene
PVC Polyvinylchloride
PVC-u Unplasticised Polyvinylchloride
PWTAG Pool Water Treatment Advisory Group
QA/QC Quality Assurance/Quality Control
RA Return/Recycled Air
RCCD Residual Current Circuit Breaker
RCD Residual Current Device
R&D Research and Development
REFCOM Register of Companies Competent to handle
refrigerants
RPM Reinforced Plastic Mortar
RPZ Reduced Pressure Zone
RTD Resistant Temperature Detector
RTR Reinforced Thermosetting Resin
SA Supply Air
SBCCI Southern Building Code Congress
International (Incorporated)
SDR Standard Dimension Ratio
SIS Swedish Institute of Standards
SP Super-plasticizing
SPDT Single Pole Double Throw
SRPC Sulphate Resistance Portland Cement
SS Structural Strength
SSPC Steel Structures Painting Council
TIA Telecommunication Industry Association
TRA Trussed Rafter Association
UL Underwriters Laboratories Incorporated
ULPA Ultra Low Penetration Air
UP Unsaturated Polyester Resin
UPS Uninterruptible Power Supply
UTP Unshielded Twisted Pair
UV Ultra Violet
VC Vitrified Clay
VR Video Recorder
WBP Weather and Boil Proof
W/C Water Cement Ratio
WIS Water Industry Specification
WP Water Proofing
WRAS Water Regulations Advisory Scheme
XLPE Cross Linked Polyethylene

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