GENERAL SPECIFICATIONS FOR METAL WORKS

FOREWORD

These General Specifications for Metal Works is an excerpt from the Technical Specifications which have been
adopted from the General specifications of the “Institute for Construction Training and Development” of Sri
Lanka, with their permission, for use in the Hulhumalé Project.

The specifications refer to the relevant BS Specifications where necessary.

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8.0 METAL WORKS
DEFINITIONS
BEAD
A single run of weld metal deposited on a surface.

BUTT WELD
A weld in which the weld metal lies substantially within the extension of the planes of the surfaces of
the parts joined or within the extension of the planes of the smaller of the two parts of differing size.
the edges of the metal pieces shall be bevelled or chiselled to the required shape at the throat.

CRATER
A depression left in weld metal where the arc was broken or the flame was removed.

END CRATER
A crater at the end of a weld or at the end of a joint.

FILLET WELD
A weld of approximately triangular cross-section joining two surfaces approximately at right angles to
each other in lap joint, tee joint or corner joint. It is of two types (1) Continuous, (2) Intermittent.

FUSION WELDING
Any welding process in which the weld is made between metals in a state of fusion without
application of pressure.

(a) In fusion welding – The depth to which the parent metal has been fused.

WELD METAL
All metal melted and or made plastic in making a weld and retained in the weld.

8.1 MATERIALS

Materials Standards Remarks

Hot rolled-Mild steel BS 4 Part – 1 To be hot rolled
sections excluding from weldable steel
angles and hollow for structural purposes
sections conforming to BS 4360

Hot-rolled MS hollow BS 4848: Part 2 To be hot rolled from

sections weldable steel for
structural purposes
conforming to BS 4360

Hot-rolled MS angles BS 4848: Part 4 -do-

M.S. bars BS 4360
Steel tubes BS 1775
M.S. plates BS 4360
Galvanized steel sheet BS 2989
Steel plate & Sheet BS 1449: Part 1
Stainless Steel – Tubes BS 3014
Stainless Steel (Plate) BS 1449: Part 2
(Sheet)
( & )
(strip)
Aluminium alloy
Extruded section BS 1161 or BS 1474
Drawn tube BS 1471

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 Plate, Sheet & Strip BS 1470
Cepper alloy
Sections BS 2874
Tubes BS 2871: Part 2
Sheet, Strip & foil BS 2870
Plate BS 2875

Fastenings
Wood screws – Iron BS EN 20898-1
Wood Screws – Brass BS 1210
Bolts, Screws & Nuts BS EN 20898-1
Rivets BS 641 & VS 4620
Or as specified
Expanding Bolts & Nuts As specified
Plugs -do-
Adhesives -do-
Electrodes for manual
are welding BS 639
____________________________________________________________
Note 1: Evidence to show that the steel supplied conforms to the relevant British Standards shall be furnished
to the Officer-in-Charge to his satisfaction. For steel conforming to the specification for Structural
Steel of any other country, the relevant specifications shall be forwarded to the Engineer for prior
approval.

8.2 FABRICATION AND ERECTION – SHOPWORK

8.2.1 PRELIMINARIES
8.2.1.1 QUALITY OF WORK
Metal work shall be fabricated carefully and accurately to ensure compliance with design and
performance requirements, using types and grades of metal as specified for the purpose. The
finished work must be free from distortion and cracks. Proprietory products shall be used to the
recommendations of the manufacturers.

Steel work shall be fabricated and erected by competent, experienced persons and shall generally
conform to B.S 449: Part 2 – “specifications for the use of structural steel in Buildings.”

8.2.1.2 CO-ORDINATION
The work shall be carried out in co-ordination with the work on related building elements and
services. The fabrication/installation drawings showing complete details of the work shall be
furnished by the contractor well in advance for checking by the Officer-in-Charge; necessary
modifications shall be made and sufficient number of corrected copies shall be furnished to the
concerned parties.

8.2.1.3 SAMPLES
Where directed, the contractor shall furnish samples of the components and obtain approval for
the same before proceeding with the fabrication.

8.2.1.4 INSPECTION
The Officer-in-Charge shall have access at all reasonable times to all places where the work is being
carried out, and shall be provided by the contractor with all the necessary facilities for inspection
during construction.

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8.2.2 SHOP PREPARATION

8.2.2.1 STRAIGHTNESS

All material before and after fabrication, shall be straight unless required to be of curvilinear form,
and shall be free from twists.

8.2.2.2 CLEARANCES

Care shall be taken to ensure that the clearances specified are adhered to. The erection clearance
for cleated ends of members connecting steel to steel shall be not greater than 2 mm. at each end.
The erection clearance ends of beams without web cleats shall be not more than 3 mm at each end,
but where for practical reasons this clearance has to be increased, the seating shall be suitable
designed.

Where black bolts are used the holes may be made not more than 2 mm greater than the diameter
of the bolts unless otherwise specified.

8.2.2.3 CUTTING
Cutting may be by shearing, cropping, sawing or machine flame cutting. Hand flame cutting may be
adopted subject to the approval of the Officer-in-Charge if thermal cutting is permitted for plates
which will be subjected to dynamic or fatigue loading, the edges shall be machined. In the case of
highly stressed welded joints, thermal cutting shall be controlled to prevent excess hardening.
Sheared or cropped edges shall be dressed to a neat workmanlike finish and be free from distortion
where parts are to be in metal-to-metal contact.

8.2.2.4 HOLING
Holes through more than one thickness of material for members such as compound stanchion and
grider flanges shall where possible be drilled after the members are assembled and tightly clamped
or bolted together. All matching holes for rivets and black bolts shall register with each other so
that a gauge 2 mm less than the required diameter of hole will pass freely through the assembled
members in a direction at right angles to such members.

Finished holes shall be not more than 2 mm larger in diameter than the diameter of the rivet or
black bolt passing through them unless otherwise specified.

When holes are drilled in one operation through two or more separable parts, these parts when so
specified by the Officer-in-Charge, shall be separated after drilling and the burrs removed.

Punching may be permitted before assemble when the thickness of material punched is less than
15 mm. The holes punched shall be 2 mm less in diameter than the required size and reamed after
assemble to the full diameter.

Holes in connecting angles and plates other than splices, as also in roof members and light framing,
may be punched full size through material not over 12 mm thick. This shall not be permitted for
close tolerance or barrel bolts.

Where a connection is subject to impact or vibration or to reversal of stress (unless such reversal is
solely due to wind) or, where for some special reason such as continuity in rigid framing or
precision in alignment of machinery, slipping of bolts is not permissible, then rivets, close tolerance
bolts, high strength friction grip bolts or welding shall be used. Holes for close tolerance and barrel
bolts shall be drilled to a diameter equal to the nominal diameter of the shank or barrel subject to a
tolerance of +0.15 mm and – 0 mm. Parts to be connected with close tolerance bolts or barrel bolts
shall preferably be firmly held together by tacking bolts or clamps, the holes drilled through all the
thicknesses in one operation and subsequently reamed to size. All holes not drilled through all
thicknesses in one operation shall be drilled to a smaller size and reamed out after assembly.

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 Where this is not practicable the parts shall be drilled and reamed separately through hard bushed
steel jigs.

Holes for rivets or bolts shall not be formed by a gas cutting process.

8.2.2.5 FLATTENED ENDS OF TUBES

For welded, riveted or bolted connections, the ends of tubes may be flattened or otherwise formed
provided the methods adopted are such as not to injure or deface the material. The change of section
shall be gradual.

8.2.3 SHOP ASSEMBLE

The component parts shall be assembled in such a manner that they are neither twisted nor
otherwise damaged, and shall be so prepared that the specified cambers if any are provided.
All tubular members shall be sealed so as to prevent the access of moisture to the inside of the
members (see also Clause 9.5.2)

8.2.4 RIVETING
Rivets shall be heated uniformly throughout their length, without burning or excessive scaling, and
shall be of sufficient length to provide a head of standard dimensions. They shall when driven,
completely fill the holes and if countersunk, the countersinking shall be fully filled by the rivet, and
proudness of the countersunk head being dressed off flush if required.

Riveted members shall have all parts firmly drawn and held together before and during riveting,
and special care shall be taken in this respect for all single-riveted connections. For multiple riveted
connections, a service bolt shall be provided in every third or fourth hole.

Wherever practicable machine riveting shall be carried out by using machines of the steady
pressure type.

All loose, burned or otherwise defective rivets shall be cut out and replaced before the structure is
loaded, and special care shall be taken to inspect all single-riveted connections.

Special care shall be taken in heating and driving long rivets.

8.2.5 BOLTING
Bolts shall be of sufficient length to have at least one complete thread projecting beyond the outer
face of the nut when tightened up.
Washers shall be provided in all cases. Where necessary, washers shall be tapered or otherwise
suitable shaped to give the heads and nuts of bolts a satisfactory bearing.

In all cases where the full bearing are of the bolt is to be developed, the bolt shall be provided with
a washer of sufficient thickness under the not to avoid any threaded portion of the bolt being
within the thickness of the parts bolted together.

Where a tubular member is drilled to take bolts or studs, provision shall be made to prevent the
access of moisture to the interior of the tube. For example, a transverse sleeve can be inserted
where a bolt passes through a tube, or grommets can be used under the heads and nuts.

8.2.6 WELDING
GENERAL
Steel shall normally be welded by the metal are process conforming to B.S 5136. Other methods
shall be subject to the approval of the Officer-in-Charge.

Welding of stainless steel, aluminium alloys, copper alloys, bronze etc. and brazing shall conform to
the appropriate British Standard where specified, approval and testing of welders, and welding
procedures shall be as per BS 4870, BS 4871 and BS 4872. Surfaces to be welded shall be dry. When

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 rain is falling or during periods of high wind, necessary precautions shall be taken to protect
outdoor welding areas.

Welding shall be so carried out as to ensure that:

(1) Welds will be of good clean metal deposited by a procedure which will ensure
uniformity and continuity of work.

(2) The surfaces of the weld will have an even contour and regular finish and will
indicate proper fusion with the parent metal.

All slag shall be removed after making each run by light hammering followed by wire brushing.

Weld metal shall not be allowed to spatter on surfaces which will be visible in the completed work.

But welds which will be visible in the completed work shall be dressed off smooth and flush with
adjacent surfaces.

8.2.6.1 EQUIPMENT FOR WELDING OF STEEL

EQUIPMENT
The contractor shall be responsible for ensuring that the capacity of welding plant, instruments,
cables and accessories is adequate and suitable for the welding procedure to be used and for
maintaining all welding plant and ancillary equipment in good working order. The contractor shall
also take all necessary safety precautions in connection with the work. All electrical plant in
connection with the work shall be adequately earthed. The welding return lead from the work shall
be adequate in cross section and shall be correctly connected and earthed.

Adequate means of measuring the current shall be available with the welding plant or a portable
ammeter shall be provided.

ELECTRODES
The electrodes used for manual metal are welding shall comply with the requirements of BS 639 or
other appropriate standard with the prior approval of the Officer-in-Charge. Electrodes shall be
selected having regard to the application i.e. joint design, welding position and the properties
required to meet service conditions.

All consumables shall be stored and handled with care and in accordance with the manufacturers’
recommendations. Electrodes filler wires, rods and fluxes that show signs of damage or
deterioration shall not be used.

Covered electrodes shall be stored in their original packets or cartons in a dry place adequately
protected from the effects of the weather. When special protection or other treatment during
storage or immediately prior to use is recommended by the manufacturer of the electrodes, they
shall be treated accordingly.

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8.2.6.2 BUTT WELDS
The details of the angle between fusion faces gap between parts etc. shall be as per BS 5135.
The details for a single V-butt weld (without backing) are given below.
Weld details Welding Thickness Flat position_______
Position Gap Angle Roof
T G X Face
___________________________________________________________________ R___
mm mm mm
Weld from both All 5-12 2 60° 1
sides or one side Positions
only
Over 2 60° 2
12
________________________________________________________________________

The dimensions of the weld preparation may have to be modified for welding in positions
other than flat, in which case they should be the subject of arrangement between the contracting parties.

In the as welded conditions the weld face shall be proud of the surface of the parent metal, the butt
weld shall be built up so that the thickness of reinforcement at the centre of the weld shall be not
less than 10% of the size of the butt weld nor more than 3 mm. See fig. 9/1. Where a flush surface is
require, the butt weld shall be first built up as specified above and then dressed flush. When no
dressing is to be carried out, the permissible weld profile shall either be as specified or as directed.

(a) FULL PENETRATION BUTT WELDS

Full penetration single V, U, J, bevel or square butt welds shall be completed by
depositing a sealing run of weld metal on the back of the joint; else where these or other
butt welds are to be welded from one side only, backing material may be used except
where it is agreed between the Officer-in-Charge and the contractor that, by the adoption
of an approved special method of welding, full penetration will be obtained without the
use of backing material.

Note:- It should be noted that under fatigue conditions backing material

may be undesirable.

Backing material shall consist of another steel part of the structure, or of material
approved by the Officer-in-Charge. Where backing material is employed, the joint shall be
arranged in such a way as to ensure that complete fusion of the parts to be joined is
readily obtained.

In all complete penetration butt welds which are to be welded from both sides, the
particular welding procedures which allow this to be done without back gouging shall be
adopted; but where complete penetration cannot be achieved, the back of the first run
shall be gouged out by suitable means to clean sound metal before welding is started on
the gouged out side.

(b) PARTIAL PENETRATION BUTT WELDS

Partial penetration butt welds shall not be allowed unless specially designed in
which case, the weld shall have a throat thickness not less than that specified.

8.2.6.3 FILLET WELDS

A fillet weld as deposited shall be not less than the specified dimensions clearly indicated as throat
thickness and/or leg length as appropriate, taking into account the use of deep penetration
processes or partial penetration. The effective length of a fillet weld designed to transmit loading
shall be not less than 50 mm nor 6 times its leg length.

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 For concave fillet welds, the actual throat thickness shall be not less than 0.7 times the specified leg
length. For convex fillet welds, the actual throat thickness shall be not more than 0.9 times the
actual leg length.

Where the specified leg length of a fillet weld at the edge of a plate or section is such that the
parent metal does not project beyond the weld, melting of the outer corner or corners which
reduces the throat thickness, shall not be allowed.

8.2.6.4 PREPARATION OF JOINT FACES

If preparation or cutting of the material is necessary, this shall be done by shearing, chipping,
grinding, machining, thermal cutting, thermal gouging or machine gas cutting. Edges shall be left
free of slag. When shearing is used, the effect work hardening shall be taken into account and
precautions shall be taken to ensure that there is no cracking of the edges.

FUSION FACES
The preparation of fusion faces, angle of bevel, root radius and root face shall be to the required
accuracy.

Fusion faces and adjacent surfaces shall be free from cracks, notches or other irregularities which
might be the cause of defects or would interfere with the deposition of the weld.

Fusion faces and the surrounding surfaces for a distance of at least 12 mm shall be free from heavy
scale, moisture, oil, paint or any other substance which might affect the quality of the weld or
impede the progress of welding. This is particularly important when a controlled hydrogen welding
process is used.

8.2.6.5 ASSEMBLY FOR WELDING

Parts to be welded shall be assembled such that the joints to be welded are easily accessible and
visible to the operator. Welding shall be done in the flat position whenever practicable.

Jigs and manipulators shall be used where practicable so that the welding can be carried out in the
most suitable position.

(a) ALIGNMENT OF BUTT JOINTS

The root edges or root faces of butt joints shall not be out of alignment by more than 25%
of the thickness of the thinner material for material up to and including 12 mm thick, or by
more than 3 mm for thicker material. For certain applications and welding processes closer
tolerances may be necessary.

(b) FIT UP OF PARTS JOINED BY FILLET WELDS

The edges and surfaces to be joined by fillet welds shall be in as close contact as possible
since any gap increases the risk of cracking, but in no case shall the gap exceed 3 mm.

8.2.6.6 TACK WELDS

Tack welds shall be not less than the throat thickness or leg length of the root run to be used in the
joint and shall be subject to the same welding conditions as those specified for the root run. The
length of the tack weld shall not be less than four times the thickness of the thicker part or 50 mm
whichever is the smaller.

Where a tack weld is incorporated in a welded joint its shape shall be suitable for incorporation in
the finished weld and it shall be cleaned and fused thoroughly with the final weld. Cracked, broken
or otherwise defective tack welds shall be removed before final welding.

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8.2.6.7 IDENTIFICATION

When specified by the Officer-in-Charge adequate means of identification, either by an

identification mark or other record, shall be provided to enable each weld to be traced to the
welder (s) by whom it was made.

8.2.6.8 INSPECTION & TESTING

The Officer-in-Charge shall have access to the contractor’s work at all reasonable times, and the
contractor shall provide him with all facilities necessary for inspection during manufacture and on
completion.

Welds showing cavities or in which the weld metal tends to fall over the parent metal without
proper fusion shall be cut our and re-weided to the satisfaction of the Officer-in-Charge. Care shall
be taken to avoid under cutting of the base metal along the weld edges and where serious
undercutting occurs the reduction shall be made good to the satisfaction of the Officer-in-Charge.

Where specified for important works, radiographic or ultrasonic testing procedures shall be carried
out to the satisfaction of the Officer-in-Charge.

Finished welds and adjacent parts shall be protected with clean boiled linseed oil after all slag has
been removed.

Welds shall not be painted or otherwise obscured until they have been accepted by the Officer-in-
Charge.

Quality of Welds

Welds joints shall be free from defects that would impair the service performance of the
construction.

8.2.6.9 CORRECTION OF FAULTY WELDS

Where welds do not comply with the requirements of the Clauses above, the defective portions
shall be cut over they shall then be rewelded and reinspected in accordance with this standard.
Where serious undercutting of the base metal along the weld edges is noticed, the education shall
be made good to the satisfaction of the Officer-in-Charge.

8.2.7 MACHINING OF BUTTS, CAPS, AND BASES

Stanchion splices and butt joints of compression members dependent on contact for the
transmission of compressive stresses, shall be accurately prepared to butt so that the permitted
stress in bearing is not exceeded nor eccentricity of loading created which would induce secondary
bending in the members. Stanchion caps and bases shall be prepared in a similar manner to the
above, and where this is obtained by machining, care shall be taken that any attached gussets,
connecting angles or channels are fixed with such accuracy that they are not reduced in thickness
by more than 2 mm.

8.2.8 SLAB BASES AND CAPS

Slab bases and slab caps, except when cut from material with true surfaces, shall be accurately
machined over the bearing surfaces and shall be in effective contact with the end of the stanchion.
A bearing face which is to be grouted direct to a foundation need not be machined if such face is
true and parallel to the upper face.

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 To facilitate grouting, holes shall be provided where necessary in stanchion bases for the escape of
air.

8.2.9 MARKING
Each piece of steel work shall be distinctly marked before delivery in accordance with a marking
diagram, and shall bear such other marks as will facilitate erection.

8.2.9 PAINTING

All surfaces which are to be painted, oiled or otherwise treated shall be dry and thoroughly cleaned
to remove all loose scale and loose rust; all other steel worked shall be given one coat of red oxide
of iron paint at the earliest possible opportunity. During the process of erection and subsequently
until the work is completed the contractor shall maintain these protective coats.

Shop contact surfaces need not be painted unless specified. If so specified, they shall be brought
together while the paint is still wet.

Surfaces not in contact, but inaccessible after shop assembly, shall receive the full specified
protective treatment before assembly. This does not apply to the interior of sealed hollow sections.

All faces to be riveted or bolted together shall be painted before assembly.

In the case of surfaces to be welded, the steel shall not be painted or metal coated within a suitable
distance of any edges to be welded if the paint specified or the metal coating would be harmful to
welders or impair the quality of the welds.

Welds and adjacent parent metal shall not be painted prior to de-slagging, inspection and approval.

Parts to be encased in concrete shall not be painted or oiled. See also clause 15.1.

8.3 ERECTION – SITE WORK

8.3.1 PLANT AND EQUIPMENT

The suitability and capacity of all plant and equipment used for erection shall be to the satisfaction
of the Officer-in-Charge.

8.3.2 STORING AND HANDLING

All structural steel at the site shall be stored and handled so that members are not subjected to
excessive stresses, damage deformation etc.

8.3.3 PERMISSION
The erection of steel work shall be started only after obtaining the permission of the Officer-in-
Charge.

8.3.4 SETTING OUT

The positioning and leveling of all steel work, the plumbing of stanchions and the placing of every
part of the structure with accuracy shall be in accordance with the approved drawings and to the
satisfaction of the Officer-in-Charge.

8.3.5 SECURITY DURING ERECTION

The work may be erected in suitable units as may be directed by the Officer-in-Charge. Fabricated
members shall be lifted at such points as will avoid the deformation or excessive stress in members.

The structures or part of it placed in position shall be secured against overturning or collapse by
suitable means.

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 During erection the work shall be securely bolted or otherwise fastened and if necessary
temporarily braced, so as to make adequate provision for all erection, stresses and conditions,
including those due to erection equipment and its operation. Neither riveting, permanent bolting
nor welding shall be done until proper alignment has been obtained.

8.3.6 MODIFICATION TO FABRICATION

Modification to fabricated steel work which would involve cutting, welding etc. must not be made
without the prior approval of the Officer-in-Charge.

8.3.7 PAINTING AFTER ERECTION

All surfaces to be painted shall be dry and thoroughly cleaned from all loose scale and rust.

The specified protective treatment shall be completed after erection. All rivet and bolt heads and
site welds after deslagging shall be cleaned. Damaged or deteriorated paint surfaces shall first be
made good with the same type of paint as the shop coat. Where specified, surfaces which will be in
contact after site assembly shall receive a coat of paint (in addition to any shop priming) and shall
be brought together while the paint is still wet.

Where the steel has received a metal coating in the shop, this coating shall be completed on site so
as to be continuous over any welds and site rivets or bolts. Protection may be completed by
painting on site in lieu of metal coating subject to the approval of the Officer-in-Charge. Bolts which
have been galvanized or similarly treated are exempted from this requirement.

Site painting should not be done when humidity is such as to cause condensation on the surface to
be painted. Please also see clause 15.8

8.3.8 BEDDING OF STANCHION BASES AND BEARING OF BEAMS AND GIDERS ON STONE, BRICK OR
CONCRETE (PLAIN OR REINFORCED)
Bedding shall be carried out with Portland cement grout or mortar or fine concrete.

For multi-storied buildings this operation shall not be carried out until a sufficient number of
bottom lengths of stanchions have been properly line, leveled and plumbed and sufficient floor
beams are in position.

Whatever method is employed, the operation shall not be carried out until the steel work has been
finally leveled and plumbed, the stanchion bases being supported meanwhile by steel wedges and
immediately before grouting the space under the steel shall be thoroughly cleaned.

The belt holes and space beneath column base plates shall be filled with grout or mortar of
specified below.

a. Space not deeper than 25 mm neat cement slurry to as thick a consistency as possible
and pured under a suitable pressure head.
b. Spaces between 25 mm and 50 mm deep; A mortar of cement and fine aggregate in
the proportion of 1.1, just fluid enough to pour, poured under a suitable head and
tamped as filling proceeds.
c. Spaces over 50 mm deep: A damp dry mortar of cement fine aggregate 1:2 well
tamped against properly fixed forms as filling proceeds.

8.7 ALUMINIMUM FRAMED SLIDING GLASS DOORS

These shall be made of extruded Aluminium alloy sections anodized to Grade AA 25 as per BS 1615
or as specified mechanically jointed and erected and finished conforming in all respects to BS 5286.

8.8 ALUMINIUM WINDOWS

These shall be made of extruded aluminium alloy sections anodized to Grade AA 25 as per BS 1615
or as specified, mechanically jointed, erected and finished conforming in all respects to BS 4873.

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