Japanese Architectural Standard Specification JASS 6 (1993) Structural Steelwork Specification for Building Construction Estadlished 1953 Revised 1993 Architectural Institute of Japan©1993 by Architectural Institute of Japan All rights reserved, No part of this book may be reproduced in any form or by any means, without permission in writing from the publisher: AU 5-26-20, Shiba, Minato-ku, Tokyo, Japan Printed in Japan, 1993FOREWORD JASS stands for the Japanese Architectural Standard Specification, estabrished by the Architectural Institute of Japan. Currently it is published in 28 separate volumes, being devided according to type of work. Jass 6, which means volume 6 of JASS, covers structural steelwork for building construction. Ever since the first edition was issured in 1953, it has served as a guideline toward assuring quality of buildings and workmanship by maintaining the standard of building construction methods. The purpose of establishing a standard specification for construction work is to formulate an appropriate construction standard for improving the quality of buildings and rationalizing execution procedures. While compiling the specifications into a system, the following points were taken into consideration: a. The specification is not intended to restrict nor regulate architectural design and engineering work, but what can be standardized without any problem were as much as possible, so as to ensure a minimum standard of building construction workmanship. b. Recent trends in construction techniques have been to concentrate on narrower specializations. Therefore the Specification was formulated with the close co-operation of a number of construction techniques and specialists. Attempt was made to maintain the organic connections among a variety of technical fields, as well as to introduce various specialized techniques to construction practices by means of Specification, ¢. In order to keep up with the progress in technical research and in advances in materials, results obtained by studies were directly linked to practical use, so that such results may be incorporated into the specification as soon as practical and thereby ensure up-to-date construction technology. Since the release of the first edition, a number of new materials and fabrication methods have been developed. With this as a background, the Specification has been revised several times, but the purpose has maintained unchanged. This issue is the first English version, based on the 1993 edition. Although JASS is not a building code as such, it is treated similarly to a building code, indicating how construction work should be carried out. It would not be an overstatement to say that most of the building construction in Japan today is carried out in accordance with JASS. Where special expression is necessary, requirements are expressed as “in accordance with the Special Note”. In order to make this Specification applicable to individual construction, the Special Notes have to be formulized. Section 13, which contains all of the Special Notes from Section 1 through Section 12, is provided for this purpose.It is with greatest pleasure that this English version of JASS 6 is presented, It is hoped that this will assist foreigners in the understanding of structural steelwork for building construction in Japan. Whereever the meaning of this English translation is ambiguous or in contradiction with the original Japanese text, readers are advised to refer the original text of the Specification. ALJ expresses sincerest gratitude to the Kozai Club, Japan Steel-rib Fabricators Association and Japan Steel Constructors Association for the financial assist for editing of the English version, December, 1993 Architectural Institute of JapanLIST OF COMMITTEE MEMBERS Research Committee on Building Materials and Procedure Chairman — Katsuro Kamimura Secretaries Akio Baba Members (Omitted) Sub-committee of Steel Work Chairman Atsuhide Hashimoto Secretaries Kazuhiko Moriya Members Hirofumi Aoki Mitsuru Izumi Kazunori Koshida Tetsuro Matsubara ‘Tomoaki Miyano Tadao Nakagomi Toyokazu Shimizu Atsuo Tanaka Iwao Tsuyama Sunao Nakane Tatsuo Yamashita Takeshi Azuma Mamoru Kimura Takashi Makishi Moriyuki Matsuoka Masanori Mori Masayuki Okamatsu Masaaki Suko Saburo Terakado Kiyoshi Uruno Workingr Group for Editing English Version of JASS 6 Chairman —_Atsuhide Hashimoto Secretaries Kazunori Koshida Members — Tomomi Goto Hirohiko Matsuzaki Hiroshi Onoe Atsuo Tanaka Teruo Kondo Shoichi Nishimura Masaaki Takahashi Kimio Hamano ‘Teruo Kondo Shinji Matsushita Hirohiko Matsuzaki Koji Morita Masaaki Oshima Yoshiaki Tagoku Hiroshi Terunuma Yoshitaka Yabe Takashi Makishi Katsuo Oguni Saburo TerakadoJapanese Architectural Standard Specification JASS 6 (1993) CONTEN’ Section 1 General Provisions 1.1 Scope of Application and Principle - 1.2. Terminology 1.3. General 14 Quality Assurance Section 2 Quality Control 2.1 Scope of Application 2.2. General 2.3. Shop Fabrication - 2.4 Construction-site Work Section 3. Materials 3.1 Steel Products ~ 3.2. High Strength Bolts, Bolts, Studs and Turnbuckle: 3.3. Welding Materials 3.4 Material Test and Weldability Test ~ 3.5 Purchase, Receiving and Storage of Materials: ul Section 4 Fabrication 4.1 Shop Drawing and Full-size Drawing * ul 42. Steel Measuring Tape 12 43 Collation of Length of Measuring Tapes 4.4. Identification of Steel Material after Fabrication: 12 12 45° Marking 12 4.6 Cutting and Machining 13 4.7 Grooving 4 48° Drilling 4 4.9 Treatment of Friction Surfaces 4.10 Straightening of Distortion 15 154.11 4.12 4.13 414 415 4.16 4.17 Bending Assembly « Temporary Assembly Fixing Metal Pins and Rollers. * Maintenance and Inspection of Equipment Safty and Hygiene Section 5 Welding 5.1 5.2 53 54 5.5 5.6 5.7 58 5.9 5.10 SL 5.12 5.13 5.14 Scope of Application 19 Approval of Welding Procedures « 19 Welding Engineer’ 19 Welders" 20 Welding Consumables 20 Confirmation of Joint Preparation and Cleaning of Bace Metal 20 General Conditions for Welding Work: 21 Complete Penetration Weld Fillet Weld Partial Penetration Weld ~ Consumable and Non-consumable Nozzle Electroslag Welding Stud Welding Acceptance Inspection of Weld.“ Repair of Weld « Section 6 High Strength Bolt Fastening 6.1 6.2 63 64 65 High Strength Bolts --- Handling of High Strength Bolts « ‘Assembly of Connection - Tightening of High Strength Bolts ~ Inspection afier Tightening *~ 34 Section 7 Hexagon Bolt Fastening Wd 72 73 Hexagon Bolts « Assembling of Connection and Bolt Tightening Inspection after Tightening -- 38 40 40 Section 8 Anticorrosive Paint 81 Scope of Application8.2. Paint and Painting Methods -- 8.3 Anticorrosive Treatment of Site Welding 8.4 Partial Painting and Repair Painting at Construction Site 8.5 Inspection and Repair =~ kere Section 9 Inspection and Delivery of Products 9.1 Inspection of Products 9.2 Sorting of Members --- 9.3 Transport Plan and Delivery Section 10 Construction-site Work 10.1 Scope of Application -> 10.2 Engineer in Charge and Execution Plan 10.3 Anchorage 10.4 Erection 10.5 Accuracy of Erection 10.6 Site Joining ~ 10.7, Welding Related to Other Work 10.8 Anticorrosive Paint 10.9 Supervision of Safety and Hygiene ~ Section 11 Fireproofing 11.1 Scope and Performance of Fireproofing 34 11.2. Fireproofing Methods and Materials 34 11.3 Inspection and Correction 56 Section 12 Hot-dip Galvanizing 12.1 Type of Hot-dip Galvanizing and Coating Weight ~ + 56 12.2. Members to be Galvanized + 57 12.3. Galvanizing - + 58 12.4 Straightening, Inspection and Repair of Glvanized Members + 58 12.5. Hot-dip Galvanized High Strength Bolt Fastening ~ 59 12.6 Welding of Galvanized Members~ * 61 12,7. Execution of Galvanized Structures - 61 Section 13 Specified Items of Special Notes + 62Appendix 1 Procedure Qualification ‘Test for Submerged Arc Welding: “71 ee Cancellation 3. Procedure Qualification Test for Consumable and Non-consumable Nozzle Electroslag Welding + 16 4 Operator Qualification Test for Stud Welding + 80 5 Joint Preparation Standard for Complete Penetration Weld 83 6 Tolerance Inspection Standard for Steel Structures 103 Commentary-- 123Japanese Architectural Standard Specification JASS 6 (1993) Structural Steelwork Specification for Building Construction Section 1 General Provisions 1.1. Scope of Application and Principle a. This Specification shall be applied, unless otherwise specified, to construction work in which structural steel is used for main structural members of buildings or structures. However, part of this Specification needs not apply to insignificant construction, with special notes. : b. General items common to construction work shall comply with the requirements of JASS 1 General Common Items) c. The provisions of other standards and acts given in this Specification shall have the same effect as this Specification, provided, however, that the provisions of the Specification shall have priority, except for codes or standards on the basis of the Building Standard Law, if these other provisions are different from those of the Specification. 4. In applying the Specification, necessary items shall be determined in accordance with “Specified Items of Special Notes” of Section 13. When necessary items are not specified or when doubts arise, deliberation shall be made with the the Engineer in compliance with JASS 1.1.4 “Doubt”. 1.2. Terminology Terminology used in this Specification is defined as follows : Design documents Design drawings and specifications (including on-site explanatory note of the work and Q & A report for contracting). The Engineer The owner's designated representative, or consignor defined in the “General Conditions of Construction Contract” by SHIKAI RENGO. General Contractor : Contractor mentioned in a construction contract, or nominated agent or representative. Subcontractor :2 JASS6 (1993) A specialist to perform the part of construction work under the contract with a general contractor. Fabricator : Subcontractor responsible for furnishing fabricated steel structures under the contract with a general contractor. Contractors : Parties who undertake construction work, including a general contractor and subcontractors. Fabrication shop : Shop where structural steel is fabricated by a fabricator. Quality assurance : Systematic activities made by contractors to assure that the quality requirements for steel structures are fully satisfied. Quality control : System to economically provide the quality required of steel structures. Design quality : Quality, as a target of construction, which is defined in the design documents and in the matters decided and agreed through deliberation by all parties concerned after contracting. Construction (Product) quality Actual quality of construction, which is performed to comply with design quality, and also is called as attained quality or suitable quality. Approval by the Engineer : Permitting by the Engineer the implementation of the work which is planned by contractors under their own responsibilities. Instructions by the Engineer Inspections to contractors performing the work which is planned by the Engineer under his responsibilities. Deliberation : Contractors shall prepare necessary work plan under own responsibilities for deliberating with the Engineer to select optimum means and methods of the construction, if instructed to do so. Inspection : Inspection means any examination of the work, materials, and equipment at every stage of construction to judge whether they comply with the quality that is shown in design documents, work plan and drawing, and samples. Inspection by the Engineer : Inspection carried out by the Engineer when the work reaches each inspection stage of the process stipulated in design documents.Section 1 General Provisions 3 In-house inspection : Inspection carried out at each process by contractors under their quality control system. ‘Also, the final inspection made by the fabricator prior to delivery to the construction site to assure that fabricated members comply with the design quality and prescribed quantity. Receiving inspection : Inspection to be carried out by the Engineer in accepting structural steel as construction objectives, provides that in-house inspection is done previously. 1.3. General a, Quality control by contractors Contractors shall conduct quality control at all processes to assure that product quality of steel structures is in accordance with the required quality. Contractors shall assign respective engineer or his agent, who is responsible to the quality control under the approval of the Engineer. b. Selection of fabricator (1) Fabricator shall be selected in accordance with the special notes. If no special notes, the fabricator which has satisfactory technique and equipment in scales and details for the work and has effective quality control system shall be nominated by a general contractor for the approval of the Engineer. (2) When suspicion arises about that quality control performance of a fabricator is not satisfactory, the Engineer call for deliberation with all parties concerned to take corrective measure. ¢. Selection of construction methods and submission of documents (1) Ifnot specified in design documents, means and methods of the construction shall be decided by contractors at their own responsibility. (2) The means and methods of construction specified in design documents shall be complied with. If the means and methods are not appropriate in view of site conditions to meet the required design quality, or if there are any better ones than those specified, contractors shall make an alternative construction plan at their own responsibilities for the deliberation with the Engineer. (3) Prior to the start of construction work, contractors shall prepare construction plan, fabrication procedures, erection procedures and schedule of the work for the approval of the Engineer. (4) Construction plan and other documents for approval shall clarify the matters to be implemented upon the contract, including but not limited to the following items Construction Plan 1, General provisions 2. Outline of construction4. JASS6 (1993) Person and company organization in charge of construction ‘Temporary work plan Manpower plan Erection plan Connection plan Quality control, inspection 9. Relation with other work 10. Supervision of safety Outline of Shop Fabrication 1. General provisions Outline of construction Organization of plant Materials Workmanship, welding Quality control, inspection 7. Others Outline of Site Construction 1. General provisions Outline of construction On-site organization Erection work High strength bolt fastening work Welding work 7. Supervision of safety 4. Implementation of receiving inspection ‘Types and methods of receiving inspection shall comply with the special notes. If no special notes, they shall comply with the provisions of Section 9 “Inspection and Delivery of Products.” SIA aD avawy AwaYWN 1.4 Quality Assurance a. Principle of quality assurance (1) A quality assurance program shall be established for the steelwork. (2) To make a quality assurance program effective, both designer and contractors shall perform each work on their own responsibility with mutual cooperation. (3) Design quality shall be guaranteed by a designer, and construction quality shall be guaranteed by contractors respectively. (4) Construction quality is deemed to be assured by quality control for each stage of the work, Therefore, contractors shall maintain an effective quality control system.Section 2 Quality Control 5 b. Design quality The design quality shall consist of design documents and matters agreed through deliberation by all parties concerned after contracting. c. Assurance of construction quality To assure construction quality, four actions listed below shall be performed at each stage. (1) Grasping of design quality (2) Making plan to achieve design quality (3) Performing the work according to the plan, and if required, making quality assurance action (4) Certifying that construction quality fulfills the requirements of design quality. Section 2 Quality Control 2.1. Scope of Application (1) This Section shall cover the shop fabrication and the site work in structural steelworks, and shall be applied to quality control to be implemented by contractors and others at their own responsibility to assure the execution quality of shop fabrication and the site work. (2) Some items in this Section may not be applied only in case that the items are judged not to disturb the quality assurance, considering scale and difficulty of the structural steelwork after deliberating with the Engineer. 2.2 General (1) Contractors and others shall provide an effective control system for performing quality control, and implement quality control through cooperation and mutual understanding of control systems of counterparts, (2) Plan, execution and inspection of shop fabrication and the site work shall be made on the basis of the construction plan made by general contractor. (3) Adequacy of plan, execution and inspection results shall be certified to the Engineer, if necessary. The records necessary for certification shall be preserved. 2.3. Shop Fabrication (1) Quality Control Organization ‘The fabrication shop shall have a quality control system comprising the following quality control functions. An organization chart of the system shall be submitted. 1) Funetion of confirming design quality and of establishing target quality of6 JASS6 (1993) fabrication 2) Function of implementing plan for realizing design quality 3) Function of achieving quality in compliance with the plan 4) Function of confirming and evaluating execution quality 5) Function of improving production capacity on the basis of data on quality evaluation 6) Function of achieving standardization 7) Function of preventing disqualification 8) Function of preventing reoccurance of disqual (2) Details of Quality Control to Be Implemented 1) Confirmation of design quality Prior to the commencement of the work, the fabricator shall understand precisely the design quality on the basis of contract documents, When the fabricator cannot understand the design quality or questions arise, it shall be confirmed by submitting enquiries. The fabricator shall participate in deliberation with the architect and contractor to decide design quality by taking into account the fabrication conditions, when construction methods or details are determined. The results of the deliberation shall be recorded in minutes of the meetings. 2) Quality control implementation plan Prior to the commencement of fabrication, the fabricator shall plan a quality control implementation method, control items and target values for realizing the design quality, and shall plan countermeasures out of the criteria. If specified, the fabricator shall submit the plan of quality control in which details of plan are described, and shall receive the approval of the Engineer. 3) Quality control implementation and check During the fabrication work, the fabricator shall execute the quality control on the basis of implementation plan, and any deviation from the plan at each process of the work shall be investigated. If abnormalities are found, they shall be corrected immediately and measures for preventing the reocurrence shall be taken after investigating the causes of abnormality occurrence. The fabricator shall deliberate with the Engineer concerning how to treat seriously defective portions. 4) Quality evaluation In-house inspection of products shall be conducted, and product quality shall be maintained and secured by conducting quality evaluation. 5) Quality record/report The results of in-house inspection shall be recorded, and submitted, if necessary, to the Engineer in the form of a report. icationSection 3 Materials 7 2.4 Construction-site Work Quality control of the site work shall follow correspondingly to that of shop fabrication. 3.1. Steel Products Section 3 Materials a. Structural steel products (1) Structural steel products shall have no laminations and be free from harmful internal defects such as hydrogen cracks. (2) Structural steel products shall be in accordance with JIS Standards shown in Table 3.1, and the class shall be specified in accordance with those listed in the table. Table 3.1 Japan Industrial Standards for Structural Steel Products ‘Standard No. Title and Class HS G3101 JIS G 3106 USG3114 JIS G 3350 JIS G 3353 JIS G 3444 JIS G 3466 JIS G 5201 Rolled steels for general structure SS 400 (SS 41), SS 490 (SS 50), SS 540 (SS 55) Rolled steels for welded structure ‘SM 400 A (SM 41 A), SM 400 B (SM 41 B), SM 400 C (SM 41 C) ‘SM 490 A (SM 50 A), SM 490 B (SM 50 B), SM 490 C (SM 50 C) SM 490 YA (SM 50 YA), SM 490 YB (SM 50 YB) SM 520 B (SM 53 B), SM 520 C (SM 53 C) Hot-rolled atmospheric corrosion resisting steels for welded structure SMA 400 AW (SMA 41 AW), SMA 400 BW (SMA 41 BW), SMA 400 CW (SMA 41 CW) SMA 490 AW (SMA 50 AW), SMA 490 BW (SMA 50 BW), SMA 490 CW (SMA 50 CW) SMA 400 AP (SMA 41 AP), SMA 400 BP (SMA 41 BP), SMA 400 CP (SMA 41 CP) ‘SMA 490 AP (SMA 50 AP), SMA 490 BP (SMA 50 BP), SMA 490 CP (SMA 50 CP) Light gauge steels for general structure SSC 400 (SSC 41) Welded light gauge H steels for general structures, ‘SWH 400 (SWH 41), SWH 400 L (SWH 41 L) Carbon steel tubes for general structural purposes STK 400 (STK 41), STK 490 (STK 50) Carbon steel square pipes for general structural purposes STKR 400 (STKR 41), STKR 490 (STKR 50) Centrifugally cast pipes for welded structure SCW 490-CF (SCW 50-CF) (Note : Symbols in parentheses are expressed in conventional ones, notin SI units.)8 JASS 6 (1993) (3) Steel products other than those listed in Table 3.1 shall comply with the special notes. (4) If the yield ratio is specified for steel products, the value shall comply with the special notes. (5) If the carbon equivalent and the cracking parameter are specified in consideration of weldability, the values shall comply with the special notes. (6) If special properties of steel are specified, they shall comply with the special notes. b, Shapes and sizes of structural steel products (1) The shapes and sizes of steel products shall conform to the standards shown in Table ate (2) If particular specifications are required for shapes and sizes of steel products shown in Table 3.2, they shall comply with the special notes. Table 3.2 Standards for Shapes and Sizes of Structural Steel Products ‘Standard No. __ Title WIS G3191 Shape, dimension, weight and tolerance for hot rolled steel bar and bar-in-coil SIS G 3192 Dimensions, mass, and permissible variations of hot rolled sections JIS G 3193 Dimensions, mass, and permissible variations of hot rolled steel plates, sheets and strip MS G3194 Shape, dimension, weight and tolerance for hot rolled flat steel JIS G 3350 Light gauge steels for general structure JIS G 3353 Welded light gauge H steels for general structures JIS G 3444 Carbon steel tubes for general structural purposes JIS G 3466 Carbon steel square pipes for general structural purposes JIS G 5201 Centrifugally cast steel pipes for welded structure JSS* 13 Shapes, dimensions, weight and permissible variations of parallel flange channels “PFC” Note * : Standards of the Japanese Society of Steel Construction (3) The shapes and sizes of light gauge steel and built-up shapes, which have no shape standards, shall comply with the special notes. The allowance shall be in accordance with “Tolerance Inspection Standard for Steel Structure” in Appendix 6. Unless, items not specified in the Standard or need to be specified shall comply with the special notes. 3.2. High Strength Bolts, Bolts, Studs and Turnbuckles (1) High strength bolts, bolts, studs and turnbuckles shall meet the standard specifications given in Table 3.3, and the class shall comply with the special notes.Section 3 Materials 9 ‘Table 3.3 Standard Specifications of High Strength Bolts, Bolts, Studs and Tunbuckles Standard No. Title and Class (Set of high strength bolt) JIS B 1186 Sets of high strength hexagon bolt, hexagon nut and plain washers for friction grip joints Type 2 (A, B); bolt F1OT, nut F10, washer F35 Jss* 109 Sets of Torshear type high strength bolt, hexagon nut and plain washer for structural joints Bolt S1OT, nut F10, washer F35 (Bolt, Nut, Washer) JIS B 1180 | Hexagon head bolts and hexagon head scvews. ‘Type: Ordinary hexagon head bolt Section of material: Steel Strength classification: 4T ‘Type of thread: Metric coarse thread (JIS B 0205) Grade of thread: 6 g (JIS B 0209) Finish level: Medium HSB 1181 Hexagon nuts and hexagon thin nuts Type: Ordinary hexagonal nut ‘Type of shape: Type 1 or Type 2 Section of material: Steel Strength classification: 4T ‘Type of thread: Metric coarse thread (IS B 0205) Grade of thread: 6 H (JIS B 0209) Finish level: Medium JIS B 1251 Spring lock washers No.2 (for general use) JIS B 1256 Plain washers Ordinary round (Stud) JIS B 1198 | Headed Studs (Tumbuckle) | JIS A 5540 | Tumbuckle for building JIS A 5541 Body of tumbuckle for building Type: Separated frame type (ST) or pipe type (PT) JIS A 5542 Bolts of turnbuckle for building ‘Type: Strap bolt(S) or double-end screw bolt (D) Note * : Standards of the Japanese Society of Steel Construction (2) High strength bolts, bolts, studs and turnbuckles, not in accordance with the specifications given in Table 3.3, shall comply with the special notes. (3) Unless otherwise specified, the material quality of anchor bolts shall be $$400 as10 JASS 6 (1993) prescribed in JIS G 3101. The shape and size shall comply with the special notes. 3.3 Welding Materials (1) Welding materials shall meet the standard specifications for class of base metal, sizes and welding conditions for standard products shown in Table 3.4. ‘Table 3.4 Japan Industrial Standards for Welding Materials Standard No. Title : JISZ3211 | Covered electrodes for mild steel SHS Z 3212 | Covered electrodes for high strength steel SS Z 3214 Covered electrodes for atmospheric corrosion resisting steel HS Z 3351 Submerged arc welding wires for carbon steel and low alloy steel MS Z 3352 Submerged arc welding fluxes for carbon steel and low alloy steel SS Z 3312 MAG welding solid wires for mild steel and high strength steel MS Z 3315 Solid wire for CO2 gas shielded arc welding of atmospheric corrosion resisting steel JIS Z 3313 Are welding flux cored wires for mild steel and high strength stee! (2) If welding materials except for those shown in Table 3.4, they shall comply with the special notes. 3.4 Material Test and Weldability Test (1) Standard products of certified materials shown in Table 3.1, Table 3.3 and Table 3.4 need not to be tested, (2) If material test is to be conducted on standard products of certified materials mentioned in the preceding item (1), the test items and testing methods shall comply with special notes. (3) For steel products other than those listed in Table 3.1 of 3.1, material test and weldability test shall be conducted. ‘The material test shall be conducted in accordance with JIS G 0303 General rules for inspection of steel). The weldability testing method shall comply with the special notes. These tests may be omitted if the Engineer approves the steel product based on the results of prior tests. (4) For high strength bolts, bolts, studs and turnbuckles other than those listed in Table 3.3, material test shall be made in accordance with the relevant standards shown in Table 3.3. The test may be omitted if the Engineer approves the materials based on the results of prior tests. (5) For welding materials other than those listed in Table 3.4, material test shall be made in accordance with the relevant standards shown in Table 3.4, The test may be omitted if the Engineer approves the materials based on the results of prior tests,Section 4 Fabrication 1 (6) If steel products other than those listed in Table 3.1 in 3.1 are used, or if special requirements are provided, weldability test shall be conducted. The test may be omitted iff the Engineer approves the steel products based on the results of prior tests. (7) Material and weldability tests shall be conducted at a laboratory approved by the Engineer. 3.5. Purchase, Receiving and Storage of Materials (1) In purchasing materials, a materials supplier which conducts appropriate quality control shall be selected, (2) The class, shape and size of the relevant materials shall be confirmed by the original sheet of the inspection standard certificate. (3) If the original sheet of the inspection certificate of the steel products cannot be obtained, a copy of the certificate may be accepted. ‘The names and signatures of those who guaranteed the relevant steel products and the date of certification shall be shown in the copy. (4) Confirmation shall be made that materials are free from excessive corrosion, harmful surface defects such as surface flaws, and deformation such as bending and distortion. (5) Materials shall be controlled so that those of different standards or defective materials may not be mixed with received products, and shall be stored in good condition. Section 4 Fabrication 4.1. Shop Drawing and Full-size Drawing a. Shop drawing (1) Shop drawings shall be made accurately according to design specifications in the design documents, and shall be approved by the Engineer. (2) The date of approval of shop drawings shall be established by deliberation with the Engineer, (3) Steel structure fabricator shall take responsibility for any discrepancies between shop drawings and design documents caused by mistakes in shop drawings. (4) Shop drawings shall serve as instructions for fabrication and erection instead of the design documents, and the following details shall be contained in principle. i) Steel framing plan, framing elevation, structural members schedule, etc. ii) Detailed shape, dimension, quantity, mark and material quality of steel structural members iii) Shape, dimension, joint code, material quality, etc., of welding and high strength12 JASS6 (1993) bolt connections iv) Auxiliary metallic hardware for M/E items, reinforcing bar insertion hole, temporary metallic hardware, fasteners, etc. (5) Regarding the preceding paragraph iv, the contractor shall have the responsibility of submitting an instruction manual to the steel structure fabricator in sufficient time so as to produce no trouble in the fabrication processes. b. Full-size drawing (1) Full-size drawing work includes the full-size drawing work on the floor and making of spline (ruler) and film (template). Whole or parts of floor drawings may be replaced by the shop drawings, (2) When the floor drawings are required, the schedule, method and scope shall be specified in the special notes. 4.2. Steel Measuring Tape (1) Steel measuring tape for fabrication shall be No. 1 class of JIS B 7512 (steel measuring tape). (2) Steel measuring tapes to be used in each process of shop fabrication shall be checked for error against a standard steel measuring tape in the custody. (3) Tensile force at the time of above-mentioned checking shall be 5 kgf. 4.3. Collation of Length of Measuring Tapes (1) When the length of a steel measuring tape used in steel structure fabrication is collated with that for site construction, method of collation shall comply with the special notes (2) Tensile force at the time of collation shall be 5 kgf. 4.4. Identification of Steel Material after Fabrication (1) Identification of steel products after cutting or assembly shall be made in accordance with “Identification Display Standard of Structural Steel” (JSS I 02-1985) by the Japanese Society of Steel Construction, (2) Abbreviation shall be marked on each steel product for the identification of a construction work name. 4.5. Marking (1) Marking shall be made accurately and clearly on items to be required in subsequent processes referring to shop drawings, or to ruler and template. (2) Punch or drill marks shall not remain on the external surface of high strength steel or mild steel to be bent as long as they are not removed by cutting, punching or welding,Section 4 Fabrication 13 (3) Marking shall be made taking into consideration shrinkage, deformation and finish allowance. 4.6 Cutting and Machining (1) Cutting of steel products shall be done by the most appropriate method such as machine cutting, gas cutting or plasma cutting, taking into account the shape and size of the steel product. (2) In cutting steel products by gas, automatic gas cutting equipment shall be used in principle. (3) The precision of gas cutting plane at free edge of structural members shall comply with the special notes. If not specified, the standards indicated in Table 4.1 shall be applied. Table 4.1. Roughness and Notch Depth : Roughness Below 1008 Notch depth Below | mm (4) Gas cut surfaces which do not meet the above requirements shall be finished by grinding. (5) Cutting of weld bevel and the accuracy of machined surface shall comply with the requirements in 4.7 “Grooving”. (6) Thickness of steel plate to be sheared shall be not more than 13. mm. When slag or burr is generated on the cut surface, they shall be removed by grinding. (7) Where metal touch is specified in the design documents, the surfaces shall be finished by such machine tools as facing machine or rotary planer so that they fit accurately. The accuracy of the finished plane shall comply with Fig. 4.1 Finished pla approximately 50s UDSI-S/1 000 UD : squareness of axis of finished plane D:: width of finished plane 1 Accuracy of Finished Plane (8) If a machine cutter (cold saw, etc.) which can secure the same accuracy as by using, cutting/forming machine is used, the edges may remain as-cut.14. JASS 6 (1993) (9) For scallop formation, a machining tool or a manual gas cutting machine equipped with attachment shall be used, Forming accuracy shall comply with Table 4.1. If the accuracy prescribed in Table 4.1 cannot be secured, finishing shall be made by grinding. 4.7 Grooving (1) Tolerance for roughness and notch depth of grooving shall comply with Table 4.2 Table 4.2 Tolerance for Roughness and Notch Depth of Groove Surface Roughness ‘Not more than 2008. Notch dept Not more than 2 mm (2) If the roughness and notch depth exceed the prescribed tolerance, the surface shall be corrected by appropriate methods such as weld reinforcing or grinding. (3) Grooving machines shall comply with 4.6 “Cutting and Machining”. 4.8 Drilling (1) Holes for high strength bolts shall be done by drilling. If the joint zones undergo blasting, drilling shall be done prior to blasting, (2) Drilling shall be done in principle for holes for bolts, anchor bolts and reinforcing bars. However, if the thickness of stee! plate is not more than 13 mm, punching may be done. When slag or burr occurs in the hole, they shall be corrected by grinding. (3) Gas drilling may be done for holes, not less than 30 mm in diameter, for anchor bolts, form separators and equipment piping, and holes for metal attachment for equipment, interior and exterior finish work or concrete placement. The roughness of gas drilled holes shall be not more than 100S, and accuracy of hole diameter shall be within +2 mm, (4) The hole diameters to the nominal diameter of high strength bolts, ordinary bolts and anchor bolts shall comply with Table 4,3 Table 4.3 Hole Diameters for High Strength Bolts, Ordinary Bolts and Anchor Bolts (unit : mm) _Type Hole diameter d_[ Nominal diameter di High strength bolt 42.0 27 ee des Oe delice Ordinary bolt I di0.5 ‘Anchor bolt _dit5.0) (5) Diameters for inserting reinforcing bars shall comply with the special notes. If not specified, values shown in Table 4.4 shall be adopted.Section 4 Fabrication 15 Table 4.4 Diameters for Reinforcing Bar Insertion Round bar Bar diameter +10 mm ‘Nominal diameter |D10 D13 D16 D19 _D22 D25 p29 D32 Hole diameter | 21 31 35 38 43 46 Deformed reinforcing bar (6) Hole surfaces shall be at right angle to the member surface, and in the designated positions, Burrs, slag or chips around holes shall be completely removed after drilling. 4.9 Treatment of Friction Surfaces a, Treatment of friction surfaces Methods of treating friction surfaces for high strength bolted connection to secure a slip coefficient not less than 0.45 shall be either spontaneous rust generation or blasting as specified hereunder, Special treatments of friction surfaces other than the methods specified hereunder shall comply with the special notes (1) Spontaneous rust generation Friction surfaces shall be treated by removing mill scales with disc grinder to an extent of more than twice the outside diameter of the washer, and be kept to the open air in which red rust is spontaneously generated (2) Blasting Friction surfaces shall be shot or grit blasted, Friction surface with roughness of not less than 50S shall be secured, and red rust generation is not necessary. b. Remarks for treatment of friction surfaces (1) Floating rust, dust, oil, paint, varnish and welding spatter on friction surfaces and parts of surfaces which are to be in contact with washers shall be removed. (2) There shall be no clamping flaws or irregularities on the friction surfaces. (3) Mill scales may remain on friction surface in cases where light gauge steel of thickness less than 6 mm is used and a design slip coefficient of 0.45/2 (approximately .23) is adopted. Floating mill scales shall be removed. c. Slip test (1) When test for confirmation of slip coefficient is made, the time and method of the tests shall comply with the special notes. (2) When test for confirmation of slip resistance is made, the time and method of the tests shall comply with the special notes. 4.10. Straightening of Distortion (1) Distortion generated during fabrication shall be straightened at room temperatures or by heating (spot heating, linear heating) to the extent that avoids impairing material quality, ifthe specified accuracy of the product is not secured.16. JASS6 (1993) (2) In straightening distortion by heating at room temperature, a press or a roller shall be used. (3) The temperatures at which distortion is straightened by heating shall be in accordance with the following standards ~ When air cooled after heating: 850°C - 900°C When water cooled immediately after heating : 600°C - 650°C . When water cooled after air cooling : g50%C ~900°C provided that the temperature at the start of water cooling is not more than 650°C (4) Materials other than $S400, SM490 shall comply with the special notes, 4.11 Bending (1) Bending shall be carried out at room temperature or by heating, Bending by heating shall be done in red heated condition, and shall not be done in the range of blue brittleness (200°C - 400°C). In this case, temperature shall comply with item 4.10 “Straightening of Distortion”. (2) The inside radius of bending at room temperature shall be not less than twice the plate thickness, as shown in Fig. 4.2 Parts . Notes (Se “| zee Solana totress rg race : “ Beam | Stesg ~ 2 4t | rinsde radius of bending Soe {thickness of material tobe fabricated Others zn oe eee Fig 4.2 Inside Radius of Bending a. General (1) The method and order of assembly and the order of welding greatly affect the accuracy and quality of products. Therefore, they shall be fully examined at the stage of making the outline for fabrication or prior to that stage. (2) In determining the method and order of assembly, examination shall be made in several ways such as by providing prestrains or by dividing into small blocks for assembly and welding, so that distortion and residual stress generated by welding can be minimized. b. Preparation for assembly (1) Structural members shall be checked beforehand for member codes, material qualitySection 4 Fabrication 17 and quantity as well as for damages/stains, corrosion and harmful defects. If there are any abnormalities, members shall be replaced or repaired. (2) Any distortions such as bending or warping of members, shall be straightened before assembly to achieve the prescribed product accuracy. _€. Assembling work (1) Assembling shall be done using surface plates or jigs suitable for the work so as to keep accurately the positions and angles of structural members to be assembled. (2) Backing strips and end tabs shall be provided at the prescribed intervals, so that the space between base metal and such members are eliminated. (3) Presence of surface gap between each members and groove shape in but weld joints shall be checked, and repaired if any inadequacies are found. d. Tack welding (1) Tack welding shall be shielded arc welding or gas shielded arc welding. (2) Welders for tack welding shall be those with qualifications “Basic Class” of JIS Z 3801 or JIS Z 3841 or higher. (3) The selection and storage of welding materials for tack welding shall comply with item 3.3 “Welding Materials”. If shielded are welding is used for tack welding of $8400, SM400 with thickness exceeding 25 mm or steels with tensile strength higher than that of SM490, welding materials with low hydrogen content shall be used. (4) In tack welding, beads having required length and leg length shall be deposited at required intervals, in order to keep the shape during the assembly, transportation and finish welding work, and furthermore in order to avoid cracking of tack welding. The minimum length of a bead for tack welding shall comply with Table 4.5. Short beads shall be avoided. Table 4.5 Length of Bead for Tack Welding (unit: mm) Plate thickness* | Minimum length of bead for tack welding ee Oe eee eae) Pb | 40 (Note *: Greater one of plate thicknesses of tack welded members) (5) Tack welding quality shall be same as that of the final welding. ‘Tack welding shall not be done in grooves. If tack welding of the inside of grooves is inevitable, it shall be done so as to secure the required quality of finish welding. 4.13. Temporary Assembly (1) Whether temporary assembling is necessary or not, and the objective and scope of temporary assembling shall comply with the special notes.18 JASS 6 (1993) (2) Temporary assembling shall comply with the special notes, and an plan of temporary assembling describing methods, measurement and checking items shall be submitted to the Engineer for approval. 4.14. Fixing Metal (1) Among fixing metals such as auxiliary fixings for equipment, and fixings for interior finish and claddings, concrete placement and temporary construction, those to be attached by welding shall be mounted at the correct positions in accordance with shop drawings, and design drawings. (2) Welding of fixing metal shall comply with Section 5 “Welding”, and shall be done so that welding quality equivalent to that of major members may be obtained, 4.15. Pins and Rollers (A) The inside of pin holes of structural members shall be finished smooth by machining after drilling or gas cutting. Unless otherwise specified in design drawings, pin holes shall be at a right angle to the surface of the members. (2) The roughness of contact surface for pin and roller, and the relation between pin diameter and diameter of pin hole shall comply with the special notes, 4.16 Maintenance and Inspection of Equipment (1) Equipment (¢.g., cranes, press machines) for which maintenance and inspection are required by relevant laws shall be maintained and inspected in accordance with the laws. (2) For equipment other than the preceding equipment, a plan of maintenance and inspection describing the inspection period, inspection items and inspection supervisor shall be provided at the fabrication plant, so that the original performance of equipment may be fully maintained and the safe work process is secured. Maintenance and inspection shall be done in accordance with the plan Equipment for which operations are controlled using numerical data, such as NC machines, shall be maintained and inspected so as to keep the prescribed tolerance for the difference between the specified and actual lengths, 4.17. Safety and Hygiene The safety and hygiene supervision at a fabrication shop shall be carried out in accordance with the Labor/Safety/Hygiene Law and the relevant laws concerning the following items: (1) Establishment of supervisory system for safety and hygiene. (2) Improvement in safety for production equipment. (3) Improvement in safety for working methods. (4) Implementation of safety education.Section $ Welding 19 (i) Education of supervisors (i) Safety education of workers engaged in handling dangerous and harmful objects (ii) Qualification of workers and supervisors engaged in works with certain restrictions (5) Health supervision of workers. Section 5 Welding 5.1 Scope of Application This section covers fabrication of major structural steel members and joints for buildings and structures using shielded metal are welding, gas metal arc welding, flux cored arc welding, submerged arc welding and electroslag welding, and also covers stud welding. 5.2. Approval of Welding Procedures (1) Shielded metal arc welding, gas metal arc welding and flux cored are welding may be used without performing welding procedure test, provided that joint preparation is in accordance with the joint preparation standard of design documents or Appendix 5 “Joint Preparation Standard for Complete Penetration Welding” and suitable welding methods and conditions are applied. (2) In case of submerged arc welding or electroslag welding, welding procedure qualification test shall be made in accordance with Appendix 1 “Procedure Qualification Test for Submerged Arc Welding” or Appendix 3 “Procedure Qualification Test for Consumable and Nonconsumable Nozzle Electroslag Welding” for approval of the Engineer. However, if the Engineer approves record of previous welding procedure qualification test, this test may be eliminated. (3) In applying welding methods other than those in items (1) and (2), a method of qualification test shail also be subjected to the approval of the Engineer. 5.3. Welding Engineer (1) A welding engineer shall be assigned for planning, supervising and technical instructing on entire welding work. However, in case of small work, assignment of a welding engineer may be eliminated upon the approval of the Engineer. (2) The welding engineer shall be qualified by the Japan Welding Institute. However, this stipulation shall be disregarded, when the Engineer approves that an assinged welding engineer has full professional knowledge and experience of steel structures, welding metallurgy, welding work and the like, and has the capabilities to plan and manage welding work and supervises the workers.20 JASS 6 (1993) 5.4 Welders a, Manual arc welding and semi automatic arc welding Welders for manual arc welding and semi automatic are welding shall be qualified according to JIS Z 3801 (Standard Qualification Procedure for Welding Technique) and JIS Z 3841 (Standard Qualification Procedure for Semi Automatic Arc Welding Technique), specified for welding position and plate thickness. b. Automatic welding Welders for submerged arc welding, electroslag welding, automatic gas metal are welding and other welding using automatic equipment, shall be those qualified equal to or higher than “Basic Class” of JIS Z 3801 or JIS Z 3841. c. Stud welding Welders for stud welding shall be qualified according to “Operator Qualification Test for Stud Welding” in Appendix 4, specified for welding position and notation of stud. d, Welder qualification test Additional welder qualification test for qualified welders as above shall be made, if mentioned in the special notes. Even if not specified, appropriate ability confirmation test to the qualified welder whose ability is deemed to be doubtful shall be conducted when the Engineer requires it especially. 5.5 Welding Consumables a. Selection of welding consumables Covered electrodes, wires, fluxes, gas, and other welding consumables shall be selected from materials which are appropriate for steel grade of base metal, joint type, joint preparation and welding method, and which conform to JIS (Refer Table 3.4 of 3.3 “Welding Materials”). b. Control of welding consumables Welding consumables shall be stored so that they do not absorb moisture. Welding materials with debonded coating flux, dirt, deterioration, absorbed moisture or heavy corrosion shall not be used. The welding consumables that seems to have absorbed moisture shall be used after drying under the condition according to the specific type of welding materials. 5.6 Confirmation of Joint Preparation and Cleaning of Base Metal a. Confirmation of joint preparation The joint preparation of weld joints shall be according to approved shop drawings, and tolerance of joint preparation and assembly of members shall comply with “Tolerance Inspection Standard for Steel Structure” of Appendix 6. If groove shape does not satisfy the provisions, it shall be corrected before welding, using an approved methodSection 5 Welding 21 b. Cleaning of base metal Finishing of the surface and cut edge of bevel of base metal shall comply with item 4.6 “Cutting and Machining” and item 4.7 “Grooving”. Loose scale, slag, rust, oil and moisture on the surface and the surrounding areas, and other obstacles to welding shall be removed Tight scale and rust-proof coatings may be left unremoved on ordinary groove surface and surrounding areas. 5.7 General Conditions for Welding Work a. Shape of weld Finished weld shape shall comply with “Tolerance Inspection Standard for Steel Structure” of Appendix 6. There shall be no harmful defects likely damage the quality of joints such as crack, incomplete penetration, slag inclusion and blow holes in weld joints. b. Electric current/voltage/others Welding shall be done under the control of a welding engineer. Appropriate welding current, are voltage, welding speed, gas flow, and interpass temperature shall be selected c. Welding position ‘A work stand or a positioner shall be installed so that shop welding may be carried out with suitable welding position. 4, Preheating If required to achieve sound welding, preheating shall be carried out taking the following into consideration : (1) Chemical composition of steel (2) Thickness of steel plate (3) Conditions of restraint of weld (4) Temperature of steel (5) Heat input during welding (6) Hydrogen content of weld metal e. Welding sequence (1): In assembling of parts of members, welding sequence shall be such as minimizing welding distortion and shrinkage. If welding distortion and shrinkage are likely to affect the adequacy, welding sequence and method of minimizing of distortion and shrinkage shall be taken into full consideration. (2) Ifhigh strength bolts and welding are combined for jointing, welding shall be done in full consideration of the welding distortion of the contact surfaces of bolting and heat input to high strength bolts22 JASS 6 (1993) f. Run-off plates Run-off plates shall be used at both ends of a groove weld joint, so that sound welds with full throat thickness are ensured. However, other appropriate methods may be used with prior approval of the Engineer. Run-off plates need not be removed unless required by the special notes, g. Temperature, weather, others (1) When the ambient temperature is below 0°C, welding shall not be done, unless the base metal shall be preheated to at least 36°C within the range of 100 mm from a joint and maintained with this minimum temperature during weld. (2) When welding in strong wind, wind shield shall be provided. When welding on a tainy day or under high moisture, even if indoors, welding shall be done after confirming that moisture is not present on both surfaces of base metal. Semi-automatic gas metal arc welding shall not be done in wind speeds of 2 m/s or more, unless wind shield is provided, h. Cleaning of welds (1) Slag detrimental to welding shall be removed. (2) When defects such as crack are found during welding, subsequent welding shall be done only after the defect is completely removed. (3) When crack is generated in tack welding during or before final welding, the final welding shall be done only after completely removing the cracked portion. (4) Slag shall be removed from completed welds. The weld and vicinity shall be cleaned. Spatter shall be removed with brushing or the like. Tightly adherent spatter on the surfaces other than contact surfaces of high strength friction bolts may be left unremoved, 5.8 Complete Penetration Weld a. Complete penetration weld In complete penetration welds, the full plate thickness shall be completely welded. b. Back gouging When welding is done from both sides of plates, back gouging shall be done to the extent that sound weld metal appears, prior to the root pass of that side. For submerged arc welding, back gouging may be eliminated if sufficient penetration is confirmed by welding procedure qualification test and the approval of the Engineer is obtained. c. Steel backing In the use of steel backing, enough root gap shall be secured, and the steel backing shall be fitted closely, so that sound penetration at the root can be achieved. The material of steel backing shall not impair weldability.Section § Welding 23 4. Butt joints with different plate thicknesses When the plate thickness of members at butt joints is different, welding shall be done so that the weld surface slopes smoothly from the thinner plate to the thicker plate. When the surface level difference due to the difference of plate thickness exceeds 10 mm, as shown in Fig. 5.1(a), or when members are subjected to low stress and high cycle fatigue like a crane girder, the thicker plate shall be chamfered to have an inclination of 1/2.5 ot less, and shall have the same height as the thinner plate at the groove. When both sides welding with back gouging is applied for flange plates of beam column connection of the column, which detail is likely to happen in the column of SRC (steel reinforced concrete) structure, as shown in Fig.5.1 (b), only reinforcing fillet weld may be applied without chamfering, even if the difference of plate thickness exceeds 10 mm. One-side welding with steel backing for the above case shall be subjected to the approval of the Engineer. ae Alignment of outside surface 1c pao 4) To provide a taper previously Alignment of z inside surface ee ear} ‘To provide a taper after weld fa taper is removed, ether ofthe above a) oF b) Deit shall be applied alignment of (a) An example of removing a taper (b) An example of not removing a taper outside and (when flange thickness is varied in (when flange thickness of beams is inside Tong-span beams) different in the direction X and Y in the surfaces beam-through type connection of stel- (alignment of reinforeed concrete construction) plate center) Fig. 5.1 Example of Butt Joints with Different Plate Thicknesses e. Reinforcing fillet weld Fillet welds to reinforce groove welds in T-joints s quarter of plate thickness but not more than 10 mm. f. Reinforcement of weld ‘The height of reinforcement of weld in complete penetration weld shall comply with “Tolerance Inspection Standard for Steel Structure” of Appendix 6. Excessive reinforcement all be applied with the size equal to a24. JASS 6 (1993) of weld and marked irregularity of butt joint weld surfaces shall be avoided, as stress concentration is likely to happen. 5.9 Fillet Weld a. Tolerance of fillet weld size The tolerance of fillet weld size shall comply with “Tolerance Inspection Standard for Steel Structure” of Appendix 6. The difference of leg length of equal leg fillet weld shall not be excessive. b. Fixing of parts The parts to be joined by fillet welds shall be brought in a close contact. The tolerance of fit-up for Tjoint and lap joint shall comply with “Tolerance Inspection Standard for Steel Structure” of Appendix 6. When fit-up cannot be fully secured in assembly, the size of the fillet weld shall be increased by the size of the gap. When the gap in T-joints exceeds the allowable tolerance of “Tolerance Inspection Standard for Steel Structure” of Appendix 6., complete penetration weld shall be conducted in making the groove. c. Effective weld length The weld length indicated in design drawings and specifications means the effective weld length. The weld length of fillet weld shall be the effective length plus double of nominal jum weld length The minimum weld length of fillet weld shall be more than ten times of nominal fillet size and not less than 40 mm, e. Reinforcement of weld For fillet weld, convex profile shall be avoided as possible, and the height of reinforcement of weld shall comply with “Tolerance Inspection Standard for Steel Structure” of Appendix 6. f. Boxing Boxing shall be done smoothly for the ends of fillet weld, 5.10. Partial Penetration Weld a. Partial penetration weld Partial penetration weld shall be done so as to secure the prescribed penetration. Partial penetration weld may be done only when approved by the Engineer. b, Weld reinforcement The height and shape of weld reinforcement shall comply with item f of 5.8 “Complete Penetration Weld”. c. Effective throat Effective throat shall be depth of groove less 3 mm for all joint preparations. However, ifSection $ Welding 25 confirmation test is made for grooves such as single V and the approval of the Engineer is obtained, decrease of 3 mm need not be applied. 5.11 Consumable and Non-consumable Nozzle Electroslag Welding a. Welding position Welding position shall be vertical. In case of inclined welding, the approval of the Engineer shall be given by the joint welding procedure qualification test or previous execution record. b. Prevention of distortion Welding distortion and shrinkage stress shall be minimized. c. Treatment of start/end areas of weld The start/end areas of the weld shall be completely removed after welding’ from base metal, with the assistance of copper or steel run-off plates. 4. Interruption of welding Welding shall not be interrupted. If interrupted by accident, the zone of stop and restart welding shall be inspected. If there would be defects, the defects shall be completely removed and repair welding shall be done. e. Backing strip Copper backing or steel! backing shall be fitted closely to avoid gap between backings and base metal, 5.12 Stud Welding (1) Unless otherwise specified, stud shall be of suitable design for arc welding to steel members directly with the use of automatically timed stud welding equipment, and shall be applied in flat position, (2) The power supply for stud welding shall be a exclusive one, When the power supply for stud welding is used in combination with other power supply, totally required capacity shall be provided. 5.13 Acceptance Inspection of Weld a. Inspection for surface defects and profiles Inspection method for surface defects and weld profiles, and acceptance criteria shall comply with the special notes. If not specified, they shall comply with the following provisions: (1) Inspection items and acceptance criteria shall comply with “Tolerance Inspection Standard for Steel Structure” of Appendix 6. (2) Inspection for surface defects and weld profiles shall be spot visual inspection with random sampling by more than 10% of the total number or total length, Weld portions,26 JAS 6 (1993) which are visually deemed deviating from the limit allowance, shall be measured with suitable tools. (3) Welds passed by inspection shall be accepted, including remaining welds in the lot. For items not passed by inspection, additional inspection shall be made for the remaining total number by use of suitable tools, and welds which did not pass the inspection shall be identified, (4) The welds which did not pass the inspection shall be repaired or reinforced by suitable methods b. Internal defects of complete penetration weld (1) Unless otherwise specified, the inspection method for internal defects of complete penetration welds shall be ultrasonic test. The test method shall comply with “Standard for the Ultrasonic Inspection of Weld Defects in Steel Structures” by the Architectural Institute of Japan. (2) Acceptance criteria of welds shall comply with the special notes. If not specified, the inspection method shall comply with 7.2.1(1) “A Case in Which Tensile Stress Acts on Weld Zone” of “Standard for the Ultrasonic Inspection of Weld Defects in Steel Structures” by the Architectural Institute of Japan. (3) Extent of ultrasonic test shall comply with the special notes. If not specified, all complete penetration welds shall be subjects of inspection (4) Ultrasonic test shall be spot inspection. The method of counting the number of welds and sampling method shall comply with the special notes. If not specified, the following methods shall be used. When a defect is clearly identical to be a weld crack, a sampling method shall be specified upon agreement between the Engineer and the Fabricator. i) Method of counting welds The method of counting welds is given in Table 5.1,Section 5 Welding 27 Table 5.1. Method of Counting Weld Bead Number ‘Column to | Panel of box type | Complete Part Column to beam | column joint | column, complete | penetration weld of joint (box type penetration weld of | cross column column) comer joint stiffener ze lt A weld 1 weldx 2 = 3 or Counting xz ie oS method T = a tee a aa Tweld 1 weld a 1 weld x2 Weld length of 300 mim shall be T weld asa rule Total 2 welds 4 welds ‘When weld length is | 2 welds of stiffener, number of 1800 mm, it shall be | 1 weld of beam welds a eal erama art oweldexd flange When fractions are | Weld lengih of less than 150mm, _| stiffener is short. | they shall be | But weld line is included in adjacent | discontinued, it shall Remarks welding line. be counted as 1 When fractions are | weld. 150. mm or more, they shall be ii) Inspection lot Welds of not over 300 shall constitute one inspection lot. An inspection lot shall be constituted of similar part of structure, Accordingly, a column to beam joint, a column to column joint, a weld of stiffener or diaphragm, and a weld of corner joint shall constitute individual inspection lots. However, the part with welds of 100 or less may constitute an inspection lot, together with parts in which welding method, welding position, groove preparation and the like are similar. In addition, each section shall constitute its inspection lot separately. If the number of welds of one inspection lot exceeds 300, the inspection lot shall be divided for each story or for each division of work. For field welding, each story or each division of work shall constitute an inspection lot. This is because if each section constitute an inspection lot, the construction schedule may be delayed by inspection of all welds of a rejected lot.28. JASS 6 (1993) iii) Sampling Sampling of 30 welds for every inspection lot shall be made in a reasonable way. iv) Acceptance criteria of a lot When the sample of 30 welds contain one or less rejection, the lot shall be accepted. When rejections are four or more, the lot shall be rejected. If rejections in the samples are more than one but fewer than four, additional 30 samples shall be taken from the same lot and inspected. When the total number of rejections of all 60 samples are four or less, the lot shall be accepted. If total rejections number five or more, the lot shall not be accepted. vy) Treatment of lots Lots passed the inspection shall be accepted. For a rejected lots, inspection shall be made of all the remaining welds. Rejected welds shall be repaired and reinspected, ¢. Inspection of stud welds (1) The inspection of height and inclination shall be done after welding as follows: i) Constitution of a lot and sampling ‘The inspection of height and inclination of studs after welding shall be conducted in terms of one stud per lot. In this case, 100 studs or the number of studs welded on one major structural member, whichever smaller, constitute one lot. For sampling of one stud to be inspected, the stud longer or shorter in length than the others, or with greater inclination shall be selected from one lot. ii) Acceptance criteria Suitable measuring devices shall be used for inspection. The acceptance criteria shall comply with the limit allowance specified in “Tolerance Inspection Standard for Steel Structure” in Appendix 6, When inspected studs are accepted, the lot in which they are included shall be accepted. iii) Treatment of lot Lots passed the inspection shall be accepted. For a lot rejected according to ii) above, two additional studs of the same lot shall be inspected, and if the two studs are accepted, the lot shall be accepted. If one or both of the two studs are rejected, all studs of the lot shall be inspected. (2) Stud blow bending inspection shall be conducted as follows: i) Constitution of lot and sampling Stud blow bending inspection shall be made of one stud per lot. In this case, 100 studs or the number of studs welded on one major structural member, whichever smaller, shall constitute one lot. ii) Acceptance criteria If crack or other defect does not occur in the weld at the bending angle of 15 degrees, the lot shall be accepted.Section 5 Welding 29 iii) Treatment of lot Lots passed the inspection shall be accepted. For a lot rejected according to ii) above, two additional studs of the same lot shall be inspected. If the two studs are accepted, the lot shail be accepted. If one or both of the two studs are rejected, all studs of the lot shall be inspected. (3) Studs rejected according to (1) and (2) above, shall be repaired and reinspected in accordance with item d of 5.14 “Repair of Weld”. 5.14 Repair of Weld a, Repair of defective welds during fabrication (1) The procedure for repair of defective welds shall be given in a fabrication procedure and approved by the Engineer. (2) If it is observed that weld crack is not restricted, or crack of base metal occurs, the start of crack shall be reported to the Engineer for approval of a repairing method for the defect. (3) When many nonconformities are found during welding work, the cause shall be investigated prior to repair, and countermeasures to prevent recurrence shall be taken. b. Repair of welds rejected at acceptance inspection (1) All welds rejected because of bad appearance, incorrect size or internal defects at acceptance inspection shall be repaired and reinspected. (2) Repair of rejected welds shall be done after deliberation with the Engineer. When there is no particular instruction, repair shall be done according to the following: c. Repair method Unless instructed by the Engineer for item a and item b, repair shall be made in accordance with the following. For all repairing work, appropriate preheating shall be applied, if necessary, and repair welding shall be done with interpass temperature control (1) For undercutting or excessive concavity, preparation of surfaces shall be done, if necessary, and deposition of additional weld metal shall be done not to shorten the weld length too much to avoid deterioration and shall be finished by grinding as necessary. (2) Overlap or excessive reinforcement of weld shall be removed by grinding carefully. (3) Pits shall be removed by are gouging or grinding and then repair welded. (4) Surface crack shall be removed by gouging 50 mm beyond each end of the crack after confirming the extent of crack, then finished into a bilge shape and rewelded. (5) For internal defects such as slag inclusion, insufficient penetration, lack of fusion and blow hole, the position of the defect shall be marked based on the non-destructive inspection record, and the actual position shall be confirmed by arc gouging. The portion of the defects shall be removed by gouging 20 mm beyond each end of the defect approximately finished into a bilge shape, and rewelded. For the defect which30 JASS 6 (1993) shows crack unmistakably, the portion shall be removed by gouging 50 mm beyond its each end. d. Repair of stud weld (1) A new stud, if rejected at acceptance inspection, may be welded in the areas of 50 mm to 100 mm adjacent to the original area in licu of repair and replacement. However, where the adjacent areas does not have enough room for the new stud, or when defects reach the base metal, rejected studs shall be removed and the surface of base metal shall be repair welded and finished flush by grinding prior to welding the replacement stud (2) Studs which have been bent to the angle of 15° by blow bending inspection may be left bent, as long as any defect is not generated. Section 6 High Strength Bolt Fastening 6.1 High Strength Bolts a. High strength hexagon bolts (1) Sets of high strength hexagon bolts Sets of high strength hexagon bolts for friction grip joints (hereinafter referred to as “high strength hexagon bolts”) shall conform to the standards set out in JIS B 1186(Sets of high strength hexagon bolt, hexagon nut and plain washers for friction grip joints) shown in Table 6.1. Table 6.1 Class and grade of high strength hexagon bolts Combination of grades according Class of sets to mechanical properties of component parts Class according to Class according to | mechanical properties | _ torque coefficient Bot__| Nut Washer 7 1 Class 2 imam Pap aesaccaal F1OT F1O beh (2) Length of high strength hexagon bolts In order to determine the required bolt length, the value shown in Table 6.2 should be added to the grip (that is, the total length of all connected material, exclusive of washers), and the nearest size shall be selected from those shown in the attached Table 1(Nominal bolt length) of JIS B 1186. If the length does not turn out to be a Smm unit, it shall be rounded off to the nearestSection 6 Hith Strength Bolt Fastening 31 ‘5mm unit, that is, 2 shall be rounded down and 3 shall be rounded up to make a Smm_ unit. Table 6.2 Length added to the grip (High strength hexagon bolt) ‘Nominal bolt size M12 MI6 M20 M22 M2. b. Torshear type high strength bolts (1) Sets of Torshear type high strength bolts Sets of Torshear type high strength bolts for structural joints(hereinafter referred to as “Torshear type high strength bolts”) are manufactured in conformity with Table 6.3, JSS 11-09(Sets of Torshear type high strength bolt, hexagon nut and plain washer for structural joints), which shall comply with the provisions of Notification No.1795 of the Ministry of Construction, 25 30 35 40 45_ Length added to the grip, in mm ‘Table 6.3 Grade of Torshear type high strength bolts Combination of grades acccording to mechanical properties of component parts Bolt ‘Nut Washer S10T F10 ears: Note* : Marking “S101 (2) Length of Torshear type high strength bolts of a bolt is recognized to be used as Marking “PLOT In order to determine the required Torshear type high strength bolt length, the value shown in Table 6.4 should be added to the grip (that is, the total length of all connected material, exclusive of washer), and the nearest size shall be selected from those shown in the attached table 1(Nominal bolt length) of JSS. 1-09. If the length does not turn out to be a Smm unit, it shall be rounded off to the nearest Smm unit, that is, 2 shall be rounded down and 3 shall be rounded up to make a $ mm unit.32, JASS 6 (1993) Table 6.4 Length added to the grip (Torshear type high strength bolt) ee Length added to the grip, in mm coca Mioneae see ees M20 30 . M22 35 M24 sistas 6.2 Handling of High Strength Bolts a. Delivery High strength bolts shall be delivered to a construction site in unopened complete packages. At the time of delivery, the packing style, appearance, bolt size and lot number shall be confirmed, b. Receiving inspection at construction site (1) Confirmation of inspection certificates High strength bolts shall be delivered with the inspection certificates issued by the manufacturer. The bolts shall be checked against the inspection certificates to confirm that they conform to the purchase order. (2) Confirmation inspection of initial bolt tension of high strength hexagon bolts using the torque control method Use of high strength hexagon bolts to be tightened using the torque control method shall be in accordance with item b.(3) “Confirmation and inspection of initial bolt tension of Torshear type high strength bolts” of 6.2 “Handling of High Strength Bolts”. (3) Confirmation inspection of initial bolt tension of Torshear type high strength bolts i) For Torshear type high strength bolts, five sets per representative lot from every manufacturer and of nominal size shall be randomly selected, and confirmation inspection shall be made of the initial bolt tension of the bolts. ii) When the inspection is carried out at normal temperatures (10°C to 30°C), confirmation shall-be made that the average value of the initial bolt tension of the five sets of bolts satisfies the value prescribed in Table 6.5 The prescribed values at temperatures between °C and 60°C (except normal temperature) shall be those shown in Table 6.6.Section 6 Hith Strength Bolt Fastening 33 Table 6.5 Initial bolt tension at normal temperatures ‘Average value of initial bolt | tension, in ket en ‘Nominal bolt size M16 11,000 ~ 13,300 a M20 17,200 ~ 20,700 M22 21,200 ~ 25,600 M24 24,700 ~ 29,800 Table 6.6 Initial bolt tension at temperatures other than normal temperatures. ‘Average value of initial bolt tension, in kgf 10,600 ~ 13,900 16,500 ~ 21,700 20,500 ~ 26,800 800 ~ 31,200 23,800 ~ 31,200 ‘Nominal bolt size iii) When the average of five sets of bolts does not satisfy the prescribed value, 10 sets of bolts shall be randomly selected from the same lot, and confirmation inspection according to the preceding item shall be conducted again, iv) After obtaining the average value of initial bolt tension of 10 sets of bolts, the value shall be compared with the foregoing prescribed values, and acceptance or rejection of the lot shall be determined only by the results of the reinspection. v) If the results of reinspection do not satisfy the prescribed values, the complete lot with the relevant nominal size shall be replaced. vi) The bolt tension meter and tightening instrument to be used for i have the required properties and be correctly adjusted. ¢. Handling at the construction site (1) High strength bolts shall be divided by size, length and lot number, and shall be stored in a place free from rainwater and dust or other possible contaminants, and with little temperature variation, (2) In transportation and tightening, high strength bolts shall be handled carefully to prevent thread damage. Torshear type high strength bolts shall be handled carefully to prevent pin tail damage. ection shall 6.3 Assembly of Connection a, Assembling accuracy of joint parts (1). Special attention shall be paid to achieve a tight fit of the joint parts. Distortion, warping and bending in the joint part of the connected member, and34. JASS 6 (1993) bending of the splice plate, etc. shall be corrected with care taken not to damage the friction surface. (2) If the joint surface of the member is uneven, it shall be treated in accordance with Table 6.7. Table 6,7 Measures to be taken in the case of uneven joint surfaces Degree ofunevenness__| _-Measures Not larger than | mm |__No treatment required Larger than 1mm | __To insert fillers (3) The filler plate material may be SS400, regardless of the material of the connected member. Both sides shall be treated as friction surfaces. b. Correction of bolt holes (1) When staggered bolt holes on overlapped plates are out of alignment by not more than 2mm, the holes may be corrected by reaming. (2) When staggered bolt holes on overlapped plates are out of alignment by more than 2 mm, the disposition shall be decided through deliberation of the safety of the joint part with the Engineer. c. Temporary hexagon bolts for assembling Tightening of temporary hexagon bolts in assembling structural members shall comply with item g of 10.4 “Erection”. 64 Tightening of High Strength Bolts a. Tightening of high strength hexagon bolts (1) Tightening work in general i) Tightening procedure of high strength bolts shall be preliminary tightening, marking and full tightening at every group of connections, so that the specified bolt tension in site shown in a Table 6.8 may be obtained. Tightening shall be done by torque control method or turn-of-nuts method. Tightening by other methods shall comply with the special note. Table 6.8 Specified bolt tension in site of high strength bolts Grade of Nominal Specified bolt tension of bolt bolt size _ | high strength bolt, in tf Mi2 6.26 M6 17 ‘ FIOT. M20 cae! M22 22.6 M24 : 26.Section 6 Hith Strength Bolt Fastening 35 ii) Tightening of high strength bolts shall be done by rotating nuts with washers placed under the bolt head and nut, after confirming the soundness of bolts. iii) As each washer and nut, which constitute a set,has a surface and a back, special care shall be taken against upside-down use at the time of inserting a bolt into the joint part. (see Fig. 6.1) O ALB ‘The surface with the symbol mark ‘The surface with inside chamferring is the outer surface ofthe nut, is the outer surface of the washer. Fig. 6.1 Contact surface of nut and washer iv) Tightening of high strength bolts shall be made in sequence(see Fig. 6.2) in which care is taken to achieve a tight fit of joint parts, and in the three steps described below: preliminary tightening, marking and full tightening. } 1 group of bolts o> Tightening sequence Tightening of bolts shall be done from the center outwards, Fig. 6.2 Tightening sequence of bolts36. JASS 6 (1993) v) Tools for tightening and inspecting high strength bolts, such as a torque wrench and a bolt tension meter, shall be correctly adjusted to the accuracy of +3% (2) Preliminary tightening i) The preliminary tightening of every joint and every group of bolts shall be done in the sequence shown in Fig.6.2, immediately after the insertion of bolts for full tightening. ii) Tightening shall be done to the torque values shown in Table 6.9 using a preset- type torque wrench or an electric impact wrench . Table 6.9 Torque values for preliminary tightening Nominal Torque values for ___ bolt size preliminary tightening, in kgf-cm MI2 | ‘Approx. 500 MI6 ____ Approx. 1,000 M20, M22 Approx. 1,500 M24 Approx. 2,000 (3) Marking After preliminary tightening, a mark running through the bolt, nut, washer and member shall be made on each bolt(see Fig. 6.3). Fig. 6.3. Marking (4) Full tightening i) Full tightening using the torque control method shall be done using tightening tools adjusted, so that the specified bolt tension in site may be obtained. The adjustment of tightening tools shall be made everyday, in principle, prior to tightening work. ii) Full tightening using the turn-of-nut method shall be done by rotating the nut through 120°(M12 : 60") after the completion of preliminary tightening. When the bolt length exceeds five times the nominal bolt size, the amount of nut rotation shall comply with the special note. b. Tightening of Torshear type high strength bolts (1) Tightening work in generalSection 6 Hith Strength Bolt Fastening 37 i) Tightening of Torshear type high strength bolts shall be done by rotating nuts with washer placed under the nut, after confirming the soundness of the bolts. ii) As each washer and nut, which constitute a set, has a surface and a back, special care taken against upside-down use at the time of inserting a bolt into the joint part(see Fig. 6.1). iii) Tightening of Torshear type high strength bolts shall be made in sequence (see Fig, 6.2) in which care is taken to achieve a tight fit of joint parts, and in the three steps described below: preliminary tightening, marking and full tightening. iv) Tools for tightening and inspecting Torshear type high strength bolts, such as a torque wrench and a bolt tension meter, shall be correctly adjusted to the accuracy of 43%, (2) Preliminary tightening i) The preliminary tightening of every joint and every group of bolts shall be done in the sequence shown in Fig.6.2, immediately after the insertion of bolts for tightening. ii) Tightening shall be done by rotating nuts to the torque values shown in Table 6.9 using a preset-type torque wrench or an electric impact wrench. (3) Marking After preliminary tightening, a mark running through the bolt, nut, washer and member shall be made on each bolt(see Fig, 6.3). (4) Full tightening i) Full tightening shall be done using tools exclusively for Torshear type high strength bolts, and tightening shall be done until the pin tail ruptures. ii) When tightening tools exclusively for Torshear type high strength bolts cannot be used due to a difficult tightening position, these bolts shall be replaced by high strength hexagon bolts, and tightened using the torque control method or the turn-of- nut method. 6.5. Inspection after Tightening a. High strength hexagon bolts (1) Torque control method i) After the completion of tightening, all bolts shall be visually inspected for the amount of nut rotation from the marks made after preliminary tightening. ii) Fora group of bolts in which remarkable discrepancy is found in the amount of nut rotation, the propriety of tightening torque values shall be checked for all bolts by tightening nuts additionally with the use of a torque wrench. iii) High strength hexagon bolts with average torque value within 10% at the receiving inspection, shall be accepted. iv) Bolts tightened to the torque values over the aforementioned range shall be38. JASS 6 (1993) replaced. For a group of bolts tightened in which insufficient or incomplete tightening is found, all bolts in the group shall be inspected and tightened to the required torque values. (2) Turn-of-nut method i) After the completion of tightening, whether or not the required amount of nut rotation from the marks made after preliminary tightening is achieved shall be confirmed by visual inspection. ii) High strength hexagon bolts with nut rotation of 120" 30°(MI2 : 60°, -0°+30°) after the preliminary tightening shall be accepted. iii) Bolts tightened over the aforementioned range shall be replaced. Bolts with insufficient nut rotation shall be tightened to the required nut rotation level. b, Torshear type high strength bolts i) The rupture of pin tails shall be confirmed for all bolts for which tightening is completed. While at the same time, whether or not there is washer rotation with nut or bolt rotation, and the nut rotation amount shall be visually inspected by reference to marks made after the preliminary tightening. Bolts where abnormalities are not found shall be accepted. ii) For a group of bolts in which remarkable discrepancy is found in the nut rotation amount, the nut rotation amount of all bolts in the group shall be measured and the average rotation angle shall be calculated, iii) Bolts with the average rotating angles of $30" shall be accepted. Rejected bolts shall be replaced with new ones. iv) Insufficiently tightened bolts shall be retightened after confirming their soundness. c. Replacement of bolts When there is bolt rotation with nut and washer rotation of high strength hexagon bolts, or there is washer rotation with nut and bolt rotation of Torshear type high strength bolts, or if discrepancy is found in the nut rotation amount, the set shall be replaced by a new one. . Prohibition of re-use of high strength bolts High strength bolts which were once used shall not be used again Section 7 Hexagon Bolt Fastening Hexagon Bolts The Building Standards Law prescribes that hexagon bolt fastening cannot be generally applied except for structures with maximum eaves height of not more than 9 m, span of not more than 13 m and total floor area of not more than 3,000 m*. Therefore, hexagon boltSection 7 Hexagon Bolt Fastening 39 fastening is limited to relatively insignificant structures. a, Hexagon bolts, nuts and washers (1) The quality of hexagon bolts, nuts and washers shall comply with the special note. If not specified, hexagon bolts shall be 4T of JIS B 1180 (Hexagon head bolts), nuts shall be 4T of JIS B 1181(Hexagon nuts) and washers shall be plain washers of JIS B 1256(Plain washers). The finishing level shall be the medium level or above. Table 7.1_ Mechanical properties of hexagon bolts irade according to mechanical properties aT Stamping 4 Tensile strength, in kgffmm* ‘over 40 __Hardness, in HB 105 ~ 229 (2) The combination of hexagon bolts and nuts shall comply with Table 7.2, where nuts with a tensile strength higher than that prescribed in Table 7.2 may be used. Table 7.2 Combination of hexagon bolts and nuts Grade of hexagon bolts aT Grade of nuts 47 b. Length of hexagon bolts The hexagon bolt length shall be indicated as the nominal bolt length as shown in the Appendix table of JIS B 1180, and selected so that not less than three thread turns project beyond the nut after tightening in accordance with the grip(that is, the total length of all connected material, exclusive of washers)(see Table 7.3). Table 7.3 Length added to the grip ees, Length added to the grip, in mm Single nut Double nut _ Mi2 Not less than 20 Not less than 27 MI6___|_Notless than 26 | __Not less than 36 M20 Notless than 30__| Not less than 42 M22 Not less than 35 | _ Not less than 48 M24 Not less than 37 Not less than 5140. JASS 6 (1993) c. Washers A washer shall be used under each bolt head and nut, 7.2. Assembling of Connection and Bolt Tightening a. Bolt holes Bolt hole diameters shall comply with item (4) of 4.8 “Drilling”, b. Bolt tightening Bolts shall be properly tightened with the use of a hand wrench or an impact wrench. c. Nut locking ‘Nuts shall be prevented from loosening after tightening by means of a spring washer or other locking device. 4. Correction of misaligned bolt holes Bolt holes with misalignment of not less than 0.5 mm in overlapping plates during assembly shall not be corrected by reaming, but by fitting a splice plate. 7.3. Inspection after Tightening a. Inspection After completion of bolt tightening, inspection shall be made of all bolts for the following: (J) Bolts not of the prescribed quality (2) Bolts not of the prescribed size (3) Nuts with no locking device (4) Bolts which are not tightened to the required torque or loose (5) Bolts over-tightened b. Handling of defective bolts (1) Bolts not of the prescribed quality or size shall be replaced by those of prescribed quality or size. (2) Nuts with no locking device shall be fitted with locking device. (3) Bolts which are not tightened to the required torque or are loose shall be tightened correctly. (4) Bolts over-tightened shall be replaced.Section 8 Anticorrosive Paint 41 Section 8 Anticorrosive Paint 8.1 Scope of Application (1) This Part concerns anticorrosive paint on steel frames to give them long-term rust resistance. The classification and scope of paint shall comply with the special notes, (2) Temporary anticorrosive paint to prevent stains due to rust generated during the construction period shall comply with the special notes. 8.2. Paint and Painting Methods a. Surface cleaning of substrate (1) Surface cleaning of substrate shall be done without fail prior to painting. (2) Surface cleaning of steel substrate shall be done in accordance with Class 1 B or Class 2 of Classification of Surface Cleaning of Steel Substrate shown in Table 8.1, and the selection shall comply with the special notes. If not specified, it shall be done in accordance with Class 2. If etching primer (long-term exposure type), zinc-rich primer or epoxy resin primer is applied, the surface cleaning of substrate shall be done in accordance with Class | B. Table 8.1 Classification of Surface Cleaning of Stee! Substrate Classification of surface cleaning Surface cleaning method Class 1 | A [When phosphate chemical conversion coating is applied B_| When blasting is done ‘ Class 2 When cleaning is done primarily by power tools together with hand tools (Note) * : Usually not applied to steel frame (3) The surface cleaning of galvanized steel substrate shall comply with Surface Cleaning of Galvanized Substrate shown in Table 8.2, and the selection shall comply with the special notes.42 JASS 6 (1993) Table 8.2 Classification of Surface Cleaning of Galvanized Substrate a —| Time required Procedure cose Caan Class 2 for subsequent (chemical conversion | (etching primer coating) | (degreasing) | soos coating) E Removal of stains and _| Remove stains and deposits with wire brush or cloth — deposits : Heating after clean Removal of | with alkalescent Geo Clean with] ee grease degreasing agent or solvent clean with solvent : ‘After phosphate aoa chemical conversion cy conversion _| Teatment or chromate — — conduct the treatment | chemical conversion i} capac treatment, wash with | water and dry 7 : Brash or spray coating | | of etching primer (JIS More than 2 Etching primer K35633, Class 2, short- hours coating ce | term exposure type) | Within 8 hours (coating amount : 0.05 kg/m) (Note) * : Usually not applied to steel frame b. Painting (1) Anticorrosive paint shall be selected from paints shown in Table 8.3 taking into account the top coating, and shall be specified. The number of paintings shall comply with the special notes.Section 8 Anticorrosive Paint 43 Table 8.3 Types of Anticorrosive Paints Service condition and substrate surface a Common {Harsh condition Paints Standard condition _| such as exposure Steel |Galvaniz-|Steel [Galvaniz~ surface led steel surface led steel surface | _|surface Antisomonve pint or general 5 5694 Cia 1 oe z Red lead anticorrosive paint__| JIS K 5622 Class 1 Class2|_O a - Lead suboxide anticonosive |< x 5695 classi cass2} O | - | - . paint d é Basic lead chromate anticorrosive paint JIS K 5624 Class 1 Class 2] O ms - Ce eee isk ses Clee | Chaz) |= 7 paint ss = a - : t ine chromate anticorosive [yee ago; AB oe = paint : Red lead-zine chromate O anticorrosive paint ———_—_—_—(|JISK 5628 Ol |: : Plumbic acid calcium aa = Z anticorrosive paint Chlorinated rubber primer JIS K 5639 i 7 OF oO 2 component type epoxy resin z primer for metallic substrate ASS 18 M-101 -{|°] 2 2 component type thick film epoxy resin primer for metallic | JASS 18 M-106 ae - @: fe} substrate : Zine-rich primer JASS 18 M-103 = = O° = JIS K 5633 Class 2,tong- |_| |G 2 Etching primer {erm exposure type US K 5633 Class I,shor- | _ [| _ O term exposure type Note * : If chlorinated rubber is applied directly to the steel surface, corrosion is liable to grow. Therefore, itis necessary to apply it on zine-rich primer.44. JASS 6 (1993) (2) The cleaned steel! surface becomes activated and easily corroded. Therefore, painting shall be applied immediately after cleaning. (3) Painting work shall be done in a suitable condition and uniformly. (4) Painting work shall be suspended under the following conditions: i) When the air temperature at painting place is under 5°C or when the relative humidity is over 80%, ii) When water droplets or dust are likely to adhere to the painting due to snow, rain, strong wind or dew condensation during the painting or before the paint is dry. iii) When the steel temperature is high (over 50°C) under strong sunshine, and bubbles. are liable to generate on the paint. (5) Portions on which paint is not applied are as follows: i) Site welding portions and portions within 100 mm of both sides of weld, and parts which would impede ultrasonic test ii) Friction surface of parts to be joined by high strength bolts (6) The following portions shall not be painted. If painted, they shall comply with the special notes. i) Portions embedded in concrete ii) Portions to be contacted by pins and rollers, or portions machine-finished as rotating or sliding surfaces. iii) Portions of surfaces in contact assembled. iv) Inside portions to be sealed. (7) Portions on which fireproof covering is applied shall be treated in accordance with a. Surface Cleaning (2) of 11.2 Fireproofing Methods and Materials. 8.3 Anticorrosive Treatment of Site Welding If rust is expected to grow on weld surface between shop fabrication and site welding, anticorrosive treatment which gives no obstacles to welding shall be applied after completely removing stains such as oil. The treatment method shall be discussed with the Engineer. 8.4 Partial Painting and Repair Painting at Construction Site Unpainted portions such as connection and damaged portions of painting shall undergo Substrate Surface Cleaning Class 2, and immediately be applied with the same anticorrosive painting as applied at the shop. 8.5. Inspection and Repair a, Inspection of painting Cleaned and painted surfaces shall be inspected in the shop, When inspection at the construction site permits the omission of shop inspection, it shall comply with the specialSection 9 Inspection and Delivery of Products 45 notes. b. Method of inspection (1) Inspection shall be visual inspection. (2) Detailed inspection such as that for painting thickness shall comply with the special notes. Measuring method, measuring period, measuring portion, number of inspections and judgement shall comply with the special notes. ©. Repair of painting (1) Conspicuous defects on painting shall be removed, and repainted (2) Painted portion short of prescribed thickness shall be given additional painting. Section 9 Inspection and Delivery of Products 9.1 Inspection of Products a, General items (1) Products shall be inspected both in-house and at receiving in accordance with item 9.1 b. “In-house Inspection” and item 9.1.c. “Receiving Inspection”. (2) Product inspection here means inspection of shop fabricated structural members. If not specified, inspection shall cover dimensional accuracy, connections, external and internal defects of welds, stud welds, tightness of high strength bolts, auxiliary metallic hardware and completed amount. Among the above-mentioned inspection items, those related to the relevant construction shall be made. (3) For the above inspection, the items, methods, quantity, acceptance and rejection standard and execution period not prescribed in this Part, shall comply with the special notes, (4) The fabricator shall offer help for the receiving inspection. The fabricator shall take responsibility for defects found at the receiving inspection, (5) Dimensional accuracy inspection shall comply with the provisions of Appendix Table 4 “Products” in Appendix 6 “Tolerance Inspection Standard for Steel Structures” to ensure that the product has the prescribed dimensions. (6) Inspection of the connection zone shall be made for members to be joined at the site by high strength bolts and welding. This inspection shall comply with the provisions of Part 5 “Welding”, Part 6 “High Strength Bolt Fastening”, and Part 10 “Construction- site Work” (7) Visual inspection shall be made of member surfaces, cut planes, connection by high strength bolts, surface defects of welds and stud welds. Inspection shall comply with the provisions of Part 4 “Fabrication”, Part 5 “Welding” and Part 6 “High Strength Bolt46. JASS 6 (1993) Fastening”. : (8) Defective portions found as a result of product inspection shall be repaired immediately. As for the treatment of seriously defective portions, deliberation shall be held with the Engineer. (9) Products to be painted shall be painted, in principle, after completion of inspection, b. In-house inspection (1) In-house inspection of shop fabricated members shall be made. The results shall be recorded and showed at the request of the Engineer. (2) The results of in-house inspection of dimensional accuracy shall be recorded in a list of inspection records as a difference between a measured size and the prescribed size. If not specified, inspection items shall cover the length of column, height of story, length of bracket, depth of column, depth of bracket, and length and depth of beam as prescribed in Appendix 6 “Tolerance Inspection Standard for Stee! Structures”. This inspection shall apply to all products. c. Receiving inspection (1) Receiving inspection shall be made after in-house inspection. (2) Receiving inspection of dimensional accuracy shall comply with the following items. i) Inspection methods, if not specified, shall be checked for a list of in-house inspection records of item 9.1 b. (2) of this Part. ii) In determination of acceptance or rejection of dimensional accuracy by papers, if not specified, dimensional accuracy shall be accepted when the ratio exceeding the control allowance to the total measurement numbers in each inspection item is less than 5%, and the ratio exceeding the limit allowance is 0%. iii) Inspection of each product shall comply with the special notes. (3) Inspection of connections, if not specified, shall comply with the provisions of item 9.1. a. 6) of this Part. (4) Visual inspection of member surfaces, cut planes and connection by high strength bolts, if not specified, shall comply with the provisions of 9.1 a. (7) of this Part. (5) Receiving inspection of weld part, if not specified, shall comply with the following items : i) Inspection of weld surface defects shall comply with item a, of 5.13 “Receiving Inspection of Weld”. ii) Inspection of weld internal defects shall comply with item b. of 5.13 “Receiving Inspection of Weld”. iii) Inspection of stud welds shall comply with item c. of 5.13 “Receiving Inspection of Weld”. (6) Inspection of shop fastened high strength bolts, if not specified, shall comply with item 6.5 “Inspection after Tightening”.Section 10 Construction-site Work 47 (7) Inspection of completed amount shall be for the quantity of members fabricated out of the number of members contracted. 9.2 Sorting of Members (1) Member code drawing shall be made. (2) Member code shall be marked clearly on each member so that no troubles will occur at the time of erection. (3) Structural assemblies exceeding 5 tons shall be clearly marked with the weight. Truss or other members difficult to determine the center of gravity, shall be clearly marked with the center of gravity position to prevent accidents. (4) The erection procedure shall be checked against a list of delivered members, codes and quantity. 9.3 Transport Plan and Delivery (1) Transport plan shall be prepared to suit the erection plan, and shall be based on the laws and regulations concerned. (2) In delivery, full consideration shall be taken to prevent damage of products, and packages during transport, (3) For bolts and other small items, the contents of packages containing such items shall be clearly displayed. Section 10 Construction-site Work 10.1 Scope of Application Construction-site work here means the work required for the erection of steel structures, such as sorting of members delivered to the site, site assembly, erection and joining of members. It shall also mean the construction work related to the preceding work 10.2. Engineer in Charge and Execution Plan a. Engineer in charge The general contractor at the construction site shall appoint an engineer in charge of steel structure erection (hereinafter called “engineer in charge”), and the responsibilities of the engineer in charge shall be clarified. The engineer in charge shall make efforts to satisfy the quality and performance requirements shown in design literature, by overseeing various works related to steel structure erection48. JASS 6 (1993) b. Preparation of execution plan The engineer in charge shall prepare a execution plan and accept the approval from the Engineer. 10.3 Anchorage a. Function of anchor bolts Anchor bolts shall be divided into A type (load bearing bolt) and B type (non load bearing, bolt). Ifnot specified, B type shall be adopted. b. Shape, size and quality of anchor bolts The shape, size, and quality of anchor bolts shall comply with the special notes. If not specified, B type anchor bolts shall be 4-M20, 25d in anchoring length, with 180° U-bend at the tip. c. Supporting and embedding of anchor bolts The method of supporting and embedding of anchor bolts shall comply with the special notes. If not specified, A type shall be supported by steel frame. B type shall be supported by a form. 4. Care for anchor bolts Anchor bolts shall be protected by vinyl tape, vinyl chloride pipe or cloth to prevent thread damage, rusting and bending during the period from setting to erection of steel structures. €. Support of base plate (1) The supporting method of base plate shall comply with the special notes, If not specified, the construction method shall be partial mortar base for erection and grouting. after installation. (2) The concrete surface adjacent to mortar shall be executed so that mortar and concrete may be unified by removing laitance and fully conducting grain raising, (3) The strength of mortar shall comply with the special notes. If not specified, the cement-to-sand mixing ratio of mortar shall 1:2 (volume percent). (4) Mortar shall be cured for more than three days by the time of erection of steel structure. (3) Mortar to be used for grouting of remaining gap shall be nons! £. Fastening of nuts (1) Nuts shall be fastened so that the tension force of anchor bolts becomes uniform after the correction of plumb. Locking of nuts shall comply with the special notes. If not specified, locking shall be by double nuts except where nuts are embedded in concrete. (2) Tightening torque and fastening method of anchor bolts shall comply with the special notes. If not specified, nuts shall be turned 30° after preliminary tightening g. Accuracy of anchor bolts (1) Position of anchor bolts ink mortar.Section 10 Construction-site Work 49 After hardening of the concrete, the position of anchor bolts shall be measured. If not specified, the position shall comply with Appendix 6 “Tolerance Inspection Standard for Steel Structures”. (2) Projecting height of anchor bolts ‘The projecting height of bolt shall comply with the special notes. If not specified, it shall be standard practice that three threads project, even when double nuts are provided. (3) Mortar levelness i) Levelness of finished mortar shall be inspected prior to erection of columns. The accuracy of levelness of the finished surface shall comply with Appendix 6 “Tolerance Inspection Standard for Steel Structures”, ii) The size of mortar shall be 200 mm x 200 mm square, or more than 200 mm in diameter. iii) The coating thickness of mortar shall be more than 30 mm and less than 50: mm. 10.4 Erection a. Erection plan The erection plan shall be prepared in terms of erection order, erection machinery and sorting method in consideration of building scale, shape, site and process. It shall be confirmed that framework in the process of erection is safe against fixed load, live load, wind load, earthquake load, snow load and impact load of erection machinery. It shall also be confirmed that such loads do not impair the quality of structures. b. Erection machinery Erection machinery shall be selected by taking into account the maximum load, working, range and working efficiency. It shall be confirmed that erection machinery and structural members, frames and roadbed on which erection machinery is installed, are safe against wind load, earthquake load and impact load during operation. c. Delivery and sorting (1) Receiving of products In receiving products, products shall be checked against the fabricator’s invoice so as to confirm quantity of products and whether there is any deformation or damage. (2) Handling of products Products shall be protected from deformation or damage by placing them in suitable positions, If deformation or damage occurs, it shall be rectified prior to erection. 4. Site assembling In site assembling, suitable frames or jigs shall be used to secure the dimensional accuracy of members. Joining shall be made in accordance with item 10.6 “Site Joining”. ¢. Equipment and tools for erection50. JASS 6 (1993) Wire rope, shackles and hooks shall be used correctly within the range of allowable load. Ifany damage of these devices is found by periodic inspection, they shall be replaced. f. Correction of plumb (1) When force is given for correction of plumb, the portion where force is given shall be cured, and be prevented from damage of members. (2) In structures which have diagonal braces and turbuckles, correction of plumb shall not be done using these braces. (3) Correction of plumb shall be made so as to satisfy the provisions of 10.5 “Accuracy of Erection”. (4) When wire rope is used for prevention of framework collapse, it may also be used for correction of plumb. g. Fastening of temporary bolts Temporary bolts are used for assembling of structural members in erection work prior to full fastening or welding, to prevent deformation or collapse of framework caused by unexpected external force. Bolts shall be used as temporary bolts. ‘Temporary bolts shall constitute approximately one third of the total number of bolts used and shall not number less than two. They shall be located in a balanced distribution and be tightened. For composite and combination joining, temporary bolts shall constitute approximately half of the total number of bolts used and shall not number less than two. As for temporary bolts to be used for erection piece in weld joining, all number of them shall be clamped. When these are not applied, the safety of connection against wind, earthquake and snow loads shall be examined, and appropriate measures taken,Section 10 Construction-site Work 51 (column joint) (girder join (gusset plate joint) (composite joint) girder bolts shal be located ina balanced distibuion Fig. 10.1 Constitution for a group of temporary bolts, column| weld zone erection piece oi Fig. 10.2 Temporary bolts for erection pieces 10.5 Accuracy of Erection a, Measurement (1) In measuring the accuracy of erection, the influence of temperature shall be taken into account. Measurement shall be done when the influence of temperature on the whole framework, steel measuring tape and tools becomes minimum, (2) A standard steel measuring tape complying with the provisions of item 4.2 “Steel Measuring Tape” shall be used. Measurement shall be made at prescribed tensile load and correction made for temperature, b, Accuracy of connection The accuracy of connection, if not specified, shall comply with Appendix Table | “Fabrication and Assembling”, Appendix Table 2 “High Strength Bolts” and Appendix Table 3 “Welding” of Appendix 6 “Tolerance Inspection Standard for Steel Structures”, c. Accuracy of erection The accuracy of erection, if not specified, shall comply with Appendix Table 552 JASS 6 (1993) “Construction Site” of Appendix 6 “Tolerance Inspection Standard for Steel Structures”. 10.6 Site Joi a. Joining by high strength bolts Prior to fastening of high strength bolts at the site, a high strength bolt fastening plan that specifies the type of bolts, control method of axial force and execution procedure shall be prepared in accordance with 6 “High Strength Bolt Fastening”. Execution and work control shall be carried out according to the plan. b. Site welding Prior to site welding, an execution plan that specifies the control system, welding methods, welders, welding equipment, welding materials, welding execution, inspection and repair shall be made in accordance with 5 “Welding”. Execution and work control shall be carried out according to the plan. If welding methods other than those given in design literature are employed, the approval by the Engineer shall be required. (1) Control system The engineer in charge shall be appointed in advance, and division of work and his responsibility shall be clarified. Systematic control shall be made according to the plan. (2) Welding Method Site welding, if not specified, shall be manual are welding, gas shielded arc semi- automatic welding or self-shielded arc semi-automatic welding and stud welding (3) Welders Welders for site welding shall be in accordance with item 5.4 “Welders”, and shall have enough knowledge and experience in welding at construction site. When additional tests of ability are made, they shall comply with the special notes. (4) Welding equipment and materials Welding equipment shall be suitable for site welding, and the operation of welding equipment shall be mastered by welders. The selection and control of welding materials shall comply with item 5.5 “Welding Materials”. (5) Welding Site welding, if not specified, shall comply with of 5.6 “Confirmation of Joint Preparation and Cleaning of Base Metal”, 5.7 “General Conditions for Welding Work”, 5.8 “Complete Penetration Weld” and 5.9 “Fillet Weld”. Site welding procedure shall be determined in consideration of the influence of weld distortion on accuracy of erection. (6) Inspection and repair Inspection and repair of site welds, if not specified, shall comply with items of 5.13 “Receiving Inspection of Weld” and 5.14 “Repair of Weld”. c. Joining by boltsSection 10 Construction-site Work 53 If not specified, joining by bolts shall be carried out in accordance with 7 “Hexagonal Bolt Fastening”, 4. Composite joint For composite joints in which webs are joined by high strength bolts and flanges by welding, high strength bolts shall be fastened first followed by welding. e. Combination joint For combination joining by both high strength bolts and welding, high strength bolts shall be fastened first followed welding. £, Welding of steel structures in extension, rebuilding, repairing or alteration In extension, rebuilding, repairing or alteration of buildings, if welding is applied to steel structure of the existing building, the condition surrounding the building shall be examined in advance on the instruction of the Engineer, and the weldability of the existing steel structure shall be confirmed. 10.7 Welding Related to Other Work a. Welding in incidental work In incidental work, when metallic hardware and/or other materials are welded to steel structure members at the site, welding shall not be done in such a method that may damage the base metal. In such welding onto steel structures, examination shall be made in regard to the type of steel and welding method, and the advanced approval of the Engineer shall be obtained, b, Welding of deck plates When deck plates are welded onto steel structural members, a suitable welding method shall be adopted according to the usage of deck plate. The floor construction using deck plates has the following three types: (1) Composite slab construction of deck plate and conerete (2) Slab construction using the deck plate as formwork (3) Slab construction using the deck plate itself as structural member In any case mentioned above where the deck plate is welded onto the steel structural members, the deck plate shall, contact closely to the girder and, unless otherwise specified, arc-spot welding (puddle welding) shall be done in the case of (1) in order to bear the in-plane shear force which is transmitted from floor slab. In the cases of (2) and (3), are-spot welding or fillet welding shall be done in order to avoid the scatter of plates by strong wind and gust. c. Welders A welder shall be, in principle, a qualified welder of at least the “Basic Class” of welders specified in 5.4 “Welders”. However, a welder engaged in stud welding shall be a qualified welder specific in the clause c. of 5.4 “Welders”, and a welder engaged in arc-spot welding54 JASS 6 (1993) (puddle welding) shall be a qualified welder of the basic class specified in JIS Z 3801 “Standard Qualification Procedure for Welding Technique”. 10.8 Anticorrosive Paint a. Painting of portions joined at site shall be made after the completion of welding inspection, with the specifications corresponding to painting at construction site. b. Painting shall comply with 8 “Anticorrosive Pai 10.9 Supervision of Safety and Hygiene Supervision of safety and hygiene at the site shall comply with the Building Standards Law, the Contractors Law, the Labor Law, the Labor/Safety/Hygiene Standards Law, Safety Rules for Crane, the Fire Services Act, the Road Traffic Act, dangerous objects regulations, the Technical Standards for Electric Equipment, and other related laws and regulations. Supervision shall be performed without fail. Section 11 Fireproofing 11.1 Scope and Performance of Fireproofing The scope and performance of fireproofing shall comply with the special notes. 11.2 Fireproofing Methods and Materials a. Surface cleaning (1) Rust, oil and dust shall be removed from the surface of steel frames so as to secure proper adhesion of fireproofing materials. (2) Whether or not anticorrosive paint is to be applied to steel frames shall comply with the special notes. The selection of painting materials shall also comply with the special notes. b. ‘Type of fireproofing (1) The method and materials of fireproofing shall be selected from the types shown in Table 11.1, and shall be specified.Section 11. Fireproofing 55 Table 11.1 Types of Fireproofing Application of fireproofing materials] Fireproofing materials Placing method Plastering method Spraying method Winding method “Concrete Light weight concrete * Metal lath mortar Metal lath pearlite mortar * Rockwool spraying* Rockwool wet spraying Mortar spraying Plaster spraying Silica and alumina type mortar Ceramic fiber blanket Boarding method + Autoclaved inorganic fiber silicate boards ALC (autoclaved lightweight aerated conerete) panels + Fire-resistant gypsum board + Extruded cement panels «Precast concrete panels Concrete block Masonry method + Lightweight concrete block a - Stone, brick Membrane method “Rockwool acoustic board ‘Composite construction method Combination of various materials and method. Note * ; For rockwool spraying, there are the dry method for industrial mixing and the semi-dry method for field mixing. c. Storage and care of materials (1) In storing materials at the site, care shall be taken in loading them on pallets and covering to prevent water absorption, contamination and other damage. (2) Materials shall be used within the prescribed period of storage. d. Execution (1) Materials and methods prescribed by the special notes shall be used in accordance with the conditions prescribed by the Minister of Construction. (2) Placing of concrete shall conform to JASS 5, and mortar plastering shall conform to JASS 15. (3) Fireproofing shall be applied immediately after surface cleaning. (4) For places exposed to rain, suitable care such as sheet covering shall be taken to prevent damage of fireproofing. (5) If dust is liable to scatter, appropriate countermeasures such as sheet covering or wearing of dust mask shall be taken.56 JASS 6 (1993) 11.3 Inspection and Correction a. Inspection items and methods shall comply with the special notes. If not specified, inspection and correction shall comply with the following (1) In case of plastering or spraying i) Fireproofing thickness shall be confirmed by a pin for each unit area of 5 m*. ii) Fireproofing thickness and bulk specific gravity shall be measured by taking up a core by spraying method. The measuring frequency of each portion shall be once, in principle, for every floor and for every floor area of 1,500 m’, and the number of cores taken shall be 5 per measurement. For a building with total floor area of less than 1,500 m:, the measuring frequency shall be more than twice, (2) In the case of winding method, boarding method, masonry method, or membrane method The thickness and bulk specific gravity shall be confirmed at delivery. The measuring frequency shall be once, in principle, for every floor and for every floor area of 1,500 m®, and the number of cores taken shall be 3 per measurement, For a building with total floor area of less than 1,500 m’, the measuring frequency shall be more than twice. b. When fireproofing is not accepted, correction shall be made by additional covering or recovering. Section 12 Hot-dip Galvanizing 12.1 Type of Hot-dip Galvanizing and Coating Weight (Note: Regarding hot-dip galvanized structures, refer to “Manual of Hot-dip Galvanized Structures for Building” of the Japanese Society of Steel Construction.) (1) The type of hot-dip galvanizing (hereinafter called “galvanizing”) and coating weight shall comply with Table 12.1. Table 12.1 Type of Galvanizing and Coating Weight Classification by application Standard | Type | Code on “Shapedsteel plate HDZ55__| More than 550 “High-strength hexagonal head bolt | [mz 55 | More than 550 Boltnut eee (ee (eZ 35 Wee [aes tan 350% ‘Anchor bolt z HDZ35__| More than 350Section 12 Hot-dip Galvanizing 57 (2) The coating weight of shapes and plate of less than 3.2 mm in thickness shall comply with the special notes. 12.2. Members to be Galvanized a, Maximum size of members ‘The maximum size of members shall be that which permits galvanizing at one time taking into’account the size of the galvanizing bath. b. Combination of plate thickness of members to be galvanized The combination limit of plate thickness of members to be galvanized shall comply with Table 12.2. ‘Table 12.2. Combination Limit of Welded Plate Thickness of Members to be Galvanized Plate thickness [Maximum value t to t: t b t b ti (mm) (mm) 9 21 16 37 28 60 mn 10 24 7 39 32 70 "1 26 18 40 36 5 2 28 19 42 40 85 fia 3 30 20 45 45 95 14 32 2 50 50 100 15 35 25 55 (Note : Refer to the figure for t and t) c. Shape and size of members (1) The cross section of the member to be galvanized shall be symmetrical as far as possible, (2) Members with closed cross section, ¢.g., box structure or pipe structure, shall be provided with openings at both ends for flowing in and out of zinc and air, (3) Web plate thickness “tr” of built-up H shape shall be more than 1/100 of the depth “D” and not less than 9 mm, (4) When the depth of built-up H shape is more than 600 mm, stiffeners with thickness of: over 9 mm shall be provided at intervals within one and a half times the depth. (5) Scallop with radius of over 40 mm shall be provided at portions where zine is likely to build up, such as at stiffeners. (6) Light gauge members shall have plate thickness of over 3.2 mm, If member with plate thickness under 3.2 mm is used, it shall comply with the special notes, d. Welding (1) For the fillet weld of steel plate to be mounted to members, full-circumferential welding shall be applied.58 JASS 6 (1993) (2) When overlapped plates are welded, full-circumferential fillet welding shall be applied, and the area of overlap shall be less than 400 cm’. (3) When discontinuous welding is necessarily applied, it shall comply with the special notes. The minimum welding length shall not be less than 50 mm, e. Bending The radius of curvature in cold bending of members shall be more than three times the plate thickness. £. Finishing Prior to galvanizing, welding slag shall be completely removed by blasting or jet chisel. Spatter shall also be completely removed. 12.3. Galvanizing Galvanizing shall be done at a JIS authorized plant, 12.4. Straightening, Inspection and Repair of Galvanized Members a, Straightening Distortion generated by galvanizing shall be straightened by means of press, roller or jack. In straightening, the galvanized surface shall be protected from damage by means such as placing wood. Straightening by heating shall not be applied. b. Inspection ‘This inspection shall be applied to in-house inspection and receiving inspection by the constructor. (1) Inspection of galvanizing shall comply with the special notes. If not specified, judgment shall be made by appearance, and inspection points shall comply with Table 123. ‘Table 12.3 Details and Standard of Inspection Item Object OF Inspection standard inspection ae There shall not be the portion Appearance | U"sslva All exceeding the diameter of 2mm. _ inspection | Flaw/Ash inclusion members | There shall not be harmful. Die wear on friction surface There shall be not exist. (2) When test of coating weight is made, inspection shall comply with the special notes. ©. Repair Correction of galvanized portion judged defective by inspection shall comply with the special notes. If not specified, correction shall be made according to Table 12.4Section 12 Hot-dip Galvanizing 59 Table 12.4 Repair of Galvanized Surface Defect rae Repair method a ~ When defects are scattered, zinc rich paint (containing more than 90% Ungalvanized | metallic zinc) shall be applied in not less than two coats, after portionflaw | thorough cleaning of base material by wire brush. When defective portion is extensive, galvanizing shall be done again. ‘Ash inclusion _| File or sand the surface smooth i a Die wear on Die wear generated on the edge of bolt hole and of friction surface shall friction surface | _be removed by file. 12.5 Hot-dip Galvanized High Strength Bolt Fastening If hot-dip galvanized high strength bolts are used, fastening work shall be supervised by a person qualified by the Technical Institute of Hot-dip Galvanized High Strength Bolts. a. Hot-dip galvanized high strength bolts Hot-dip galvanized high strength bolts (hereinafter called “galvanized high strength bolts”) shall be approved by the Ministry of Construction according to Article 38 of the Building Standards Law. The set of galvanized high strength bolts shall consist of one hot-dip galvanized high strength hexagonal head bolt, one hot-dip galvanized high strength hexagonal nut and two hot-dip galvanized high strength plain washers, as shown in Table 125. ‘Table 12.5 Type and Grade of Galvanized High Strength Bolts Grade by mechanical properties of components to be fastened Type of a set Type by mechanical] ‘Type by torque ae a Sone property coefficient value ee Type | A FST FI0 F35 b, Length of galvanized high strength bolts The standard length of galvanized high strength bolt shall be the tightening length plus the length shown in Table 12.6, and the nearest size shall be selected from among those shown in Appendix Table 1 (Standard Size) of JIS B 1186. When the length is short by a unit of 5 mm, 2 shall be rounded down and 3 shall be rounded up to make aS mm unit,60 JASS 6 (1993) ‘Table 12.6 Length to Be Added to Tightening Length (unit : mm) ‘Nominal diameter of bolt__| Length to be added to tightening length M16 M20 M22 See Mae c. Hole diameter for bolts Hole diameter for galvanized high strength bolts shall comply with Table 12.7. ‘Table 12.7 Hole Diameter for Galvanized High-strength Bolts (unit : mm) Nominal diameter of bolt_[Nominal axial diameter (d)|_Hole diameter for bolts M16 16 175 M20 20 22.0 M22 2 24.0 M21. | 24 26.0 4. Treatment of friction surface (1) Friction surfaces shall be lightly blasted after galvanizing, and surface roughness shall be more less than 50S. (2) The range of blasting of friction surface shall comply with Fig, 12.1 Approx, twice washer Some $ mm r = [ism (fees, T Fe8lpteing Range of Poe Fem [PS splice plate = for: ADDYOX. 5am : Range oF spice Some oie Flange zone Plate Wea ome 5 mm Fig. 12.1 Example of Range of Blasting (3) When treatment other than blasting is to be applied to friction surface, the method shall be specified. In this case, slip test shall be done, and it shall be confirmed that the following equation is satisfied : (Slip load >1.2 x design bolt tensile strength x 0.4 x number of friction surface x number of bolts) A test piece equivalent to the actual situation shall be used for the slip test, and the test shall be done after the lapse of more than 24 hours after assembly. In an unavoidableSection 12 Hot-dip Galvanizing 61 case, a standard test piece may be used. e. Assembly of connection (1) Correction of bolt holes shall comply with item b. of 6.3 “Assembly of Connection” The bore corrected bolt hole shall be coated with zine rich paint. (2) When there exists gap at connected part, its treatment shall comply with item b. of 6.3 “Assembly of Connection”. Friction surface of both sides of filler plate shall be treated after being galvanized. f. Tightening of galvanized high strength bolts (1) Tightening of galvanized high strength bolts shall be done in three stages of preliminary tightening, marking and full tightening, by turn-of-nut method. (2) Preliminary tightening of galvanized high strength bolts shall be done by nut rotation to the torque value shown in item a. (1) of 6.4 “Tightening of High Strength Bolts” after confirming the fixing of members. (3) After preliminary tightening, a mark running through the bolt, nut, washer and member shall be made, (4) Full tightening shall be done by nut rotation of 120° from the preliminary tightening point. When the length of a bolt exceeds five times the nominal diameter, the nut rotation shall comply with the special notes. g. Inspection after tightening (1) Alll fully fastened galvanized high strength bolts shall be inspected visually for nut rotation angle from the preliminary tightening mark. (2) Galvanized high strength bolts with nut rotation angle within + 30° of the prescribed angle, shall be accepted. Bolts with nut rotation angle exceeding 30° from the preliminary tightening mark, shall be replaced. Nuts short of the prescribed angle, shall be tightened to the required angle. (3) Bolts, nuts and washers which rotate together, shall be replaced. (4) Galvanized high strength bolts once used shall not be used again. 12.6 Welding of Galvanized Members Galvanized members shall not be welded. In an unavoidable case, the method and pretreatment shall comply with the special notes. 12.7. Execution of Galvanized Structures a, Handling of members Handling of galvanized members shall be done taking care to avoid damage to the galvanized surface. b. Storage (1) Galvanized members shall be stored with adequate ventilation by placing dividers62 JASS 6 (1993) between members. (2) Galvanized high strength bolts shall be classified by type, diameter, length and lot number, and stored in a clean dry place with little temperature fluctuation, c. Erection (1) Joining of members prior to correction of plumb shall be done using temporary bolts. ‘Temporary bolts shall constitute one third of the total number of bolts used and number not less than two, so that the safety of the framework may be secured, Bolts for temporary fastening shall be tightened so that the surfaces mate completely. (2) In correcting plumb, care shall be taken to avoid damage of the galvanized surface. (3) Damage of the galvanized surface in handling of members and erection, shall be repaired in accordance with item c of 12.4 “Straightening, Inspection and Repair of Galvanized Members”. Section 13 Specified Items of Special Notes 1 General Provisions Special notes Ttems to be Tiems not specified shall Part « item specified, | Hem needed for special notes | (oN ae Te TASS without fail meee ciraaet specification 11 Scope of Item excluding its application | Application in this specifications and Principal | a | 1.3 General b. Appointment of steel- structure fabricator 4. ‘Type and point in receiving inspection 2 Quality Control Special notes Items to be Tiems not specified shall Partsitem | “specified | Hem needed for special notes | corny with this JASS 6 without fail Gee ean specification 2.3 Shop Fabrication 2,2) Submission of quality control planSection 13 Specified Items of Special Notes 63 3. Materials Special notes : Tems to be Ttems not specified shall eid ee a. special notes | comply with this JASS 6 without fail eee specification 31 Steel Type of | Products structural | a. 2-6) steel b.2).@) Steel products other than + Yield ratio + Special performance those shown in Table 3.1 Carbon equivalent and composition for weld crack sensitivity Shape and size Shape and size of steel products for which shape standard does not exist Allowance not found in Appendix 6 “Tolerance Inspection Standard for Stee! Structures” ‘Type of Strength Bolts,| high | Bolts, Studs | strength | and bolts, bolts, | Turnbuckles studs and (Ds 2), 8) tumbuckles - High strength bolts, bolts, studs and turnbuekles other than those shown in Table 3.3 Material quality of anchor bolts ‘Shape and size of anchor bolts ae eae 3.3 Welding Welding materials other than Materials (2) those shown in Table 3.4 3.4 Material | - Test items of materials test Testand | and testing methods Weldability Weldability test Test (2)~(6)64 JASS 6 (1993) 4 Fabrication Special notes Tiems to be : Tims not specified shall Partsitem | “specified | emneeded for special notes | ory ‘with this JASS 6 without fail in case of operation specification 4.1 Shop ~ Implementation, time, Drawing and method and details of fll- Full-size size drawing on the floor Drawing b.@) Es 43 Collation of “Implementation and method Length of of collation of length of Measuring ‘measuring tapes Tapes (1) 4.6 Cutting and | __ Machining (3) - Accuracy of gas-cut surface of free edges of members 48 Drilling (5) “Hole diameter for reinforcing bar 49 Treatment ‘Treatment of special friction of Friction surface Surface + Implementation, time and a(1) method of slip coefficient test b. (1), 2) - Implementation, time and ‘method of slip bearing force test : 4.10 Straightening temperatures Straightening for products other than those of Distortion of $8400, SM490 4) = 4.13 Temporary implementation, objective Assembly (1) and scope of temporary assembly 4.15 Pins and Roughness of surface in Rollers contact with pins and rollers Q) « Diameter of pin and diameter of pin holeSection 13 Specified Items of Special Notes 65 5 Welding Special notes : ae Tiems to be Items not specified shall Part + item, specifed. | Hemnceded for special notes | coro with this TASS 6 —_| without fail Reena specification 34 Welders “Implementation of additional a test of welder qualification fae 5.7 General ~ Cutting of end tabs Condition for Welding Work : | 3.12 Stud Welding method and position Welding (1) - : 3.3 “Inspection for surface defects ‘Acceptance and welding accuracy Inspection of Inspection for internal defects Weld of complete penetration weld a()~(4) | b.~(4) | 6 High Strength Bolt Fastening Special notes, Tiems to be Items not specified shall Partvitem | 1 Gined | emneeded for special notes | ih this JASS 6 without fail Bore Pane specification 64 Tightening ~ Tightening methods other of High than torque contro! method Strength Bolts and turn-of-nut method a()i) + Nut rotation angle where bolt (4) ii) length exceeds 5 times of the nominal diameter 7 Hexagonal Bolt Fastening Special notes : Items to be . | Items not specified shall ee specified | Hem needed for special notes | conty with this JASS 6 wun | ___it ease of operation specification 7.1 Hexagonal Bolts a (1) Quality of bolts, nuts and washers