/ SPESIFICATION OF STEEL STRUCTURE / JOB NO : 781502
DOCUMENT NO : GGCP 05-C2-DW-001-PP
DATE :
REV :
SPESIFICATION OF STEEL SRUCTURE

PT PUPUK INDONESIA ENERGI
GRESIK GAS COGENERATION PLAN PROJECT
CONTRACT NO :
PROJECT CODE :
JOB NO :781602
DOC NO :GGCP 05-C2-DW-001-PP
PURPOSE : IFA

CONTRACTOR :
PT PP (Persero) Tbk – DIVISI EPC
REV. NO. / DATE / DESCRIPTION / PREPARED / CHECKED / APPROVED
0 / 3/2/2016 / IFA / DAS / GWN / FP

REVISION CONTROL SHEET

REV. NO. / DATE / DESCRIPTION
0 / Issued for Approval

DISTRIBUTION ORDER

EXTERNAL ISSUE / PT PP (Persero) Tbk - INTERNAL ISSUE
PT PUPUK INDONESIA ENERGI / PROJECT MANAGER / CHIEF ADMINISTRATION
TRACTEBEL / CONNUSA / ENGINEERING MANAGER / CHIEF SHE
CONSTRUCTION MANAGER
PROCUREMENT MANAGER
PROJECT CONTROL MANAGER
SHE MANAGER
QC MANAGER
CHIEF ENGINEERING
CHIEF PROJECT CONTROL

TABLE OF CONTENT

1.GENERAL

2.LANGUAGE AND SYSTEM OF UNIT

3.SRUCTURAL STEEL WORK

3.1. Anchor, Bolts, Nuts and Washers……………………………………………………………………………………………... 4

3.2.Concrete Expanasion Anchor Bolts …………………………………………………………………………………………………….4

3.3.Grouts Works………………………………………………………………………………………………………………………………………4

3.4 Fabrication of Structural Steel………………………………………………………………………………………………………….6

3.5.Erection Of Structural Steel………………………………………………………………………………………………………………… 11

1.GENERAL

The requirements specified below describe the specification of Steel Structure for GRESIK GAS COGENERATION PLANT project at Gresik, East Java, Indonesia

2.LANGUAGE AND SYSTEM OF UNIT

All units of measurement shall be in the metric system. All documents to be submitted shall be written in English

3.SRUCTURAL STEEL WORK

3.1. Anchor, Bolts, Nuts and Washers

Nominal : ASTM A36 for threaded rods and ASTM A307 for headed bolts and for all nuts

High Strength : ASTM A325 For threaded rods and headed bolt. Hardened washers shall be provided with high strength anchor bolts

Anchor Bolt Sleeves

Anchor bolts sleeves shall be made of standardweight steel pipe conforming to ASTM A120 or made of polyethylene plastic.

Plastic Plugs: For anchor bolts with pipe sleeves, provide plastic plugs at top of sleeves.

Column anchor bolts shall be erected to the following tolerance:

Individual anchor bolts : 3mm

Anchor bolt group : 6mm

3.2.Concrete Expanasion Anchor Bolts

Concrete expansion anchors and accessories shall be made of carbon steel with zinc plated finish conforming to U.S. Federal Specification QQ-Z-325c or approved equal. Stainless steel may be used in place of this zinc coated carbon steel.

The materials shall have minimum yield strength of 4220 kg per sq. cm for wedge type anchors, and 3515 kg per sq. cm for sleeve type anchors. The materials shall have minimum tensile strength of 5270 kg per sq.cm for all anchors.

All concrete expansion anchors shall be installed in accordance with the manufacturer’s specsifications and recommendations and the requirements of the specification shall govern. The locations where expansions anchors will be installed and the sizes of these anchors shall be as indicated on Contractor’s design drawings.

3.3.Grouts Works

Grouting equipment shall conform in every respect to requirements of equipmentmanufactures. Instalations of grout shall be strict accordance with the manufactures printed instructions. Wherever requirments for grout and grout installation differ between this specifications and equipment manufactures requirements, equipment manufactures requirements shall apply, subject dor approval by the Owner.

Table 1

Type and Specific Uses of Grout

Type of Grout / Specific Use (Grouting)
  1. Plastic grout (Regular sand and cement grout)
/
  1. Anchors bolts including sleeves and column base plates
  2. Conduit, piping etc. Though concrete floors or walls

  1. Drypack grout
/ Equipment bases where required by manufacturer
  1. General grout work nonshrink grout
/ Bases and support of mechanical and electrical equipment and as dierected by Owner
  1. Prescision grouting nonshrink grout
/
  1. Anchor bolts in drilled holes in concrete
  2. Equipment bases where required by manufacture or subject to high repetitive and dynamic loads.

Table 2

Grout Components and Products

Type of Grout / Cement / Aggregated / Admixture (If used) / Mixing Water / Grout Product
  1. Plastic grout
/ a.1 Portland cement, ASTM C150
Type II or unless otherwise indicated / a.2.2 Grout 75 mm thick or less Fine aggregate ASTM C33
a.2.2 Grout thicker than 75 mm fine aggregate, ASTM C33, or coarse aggregate, Size No.7 or 8, ASTM C33 / Conforming to ASTM C494, Type A water-reducing admixtures; and containing chloride not more than 1% by weight (use only if reviewed by the Owner) / a.4 Clean, portable and free form injurious of oil, acid, salt, alkali, organic matter and other deleterio us substances / Not specified
  1. Drypack grout
/ Same as item a.1 / Fine aggregate ASTM C33 / ---- / Same as Item a.4 / Not specified
  1. General grout work nonshrink grout
/ Manufacture’s standards (this grout shall not contain oxidizing and gas producing agents, catalysts, inorganic accelerators and chlorides ASTM C109 / Same as Item a.4 / Not specified
  1. Prescision grout
/ Manufacturer’s standars (this grout shall not contain any metallic aggregates, oxidizing and gas producing agents, catalysts, and more than 300 ppm chloride)ASTM C109 / Same as Item a.4 / Not specified

Table 3

Property Requirement for Placed Grout

Type of Grout / Cement / Aggregated / Admixture / Mixing Water / Grout Product
  1. Plastic grout
/ 250 kg/cm2 at days unless otherwise specified / Plastic with maximum slimp 125 mm for grout 75 mm thick or less; and maximum slump 75 mm for grout thicker than 75 mm / No requirement / No requirement / No visible bleedings
  1. Drypack grout
/ 350 kg/cm2 at 28 days unless otherwise specified / Stiff with hand shaping work ability and no measurable slump / No expansions / Not more than 1.0 % / No bleeding
  1. General grout work nonshrink grout
/ 600 kg/cm2 at 28 days ASTM – C109 / Flow able, 35-45 cm lateral flow 22o-30o C / Not more than 0.4% at 7.14 or 28 days CRD621 / No Shrinkage / No bleeding
  1. Prescision grout
/ 800 kg/cm2 at 28 days ASTM – C109 / Flow able, 35-45 cm at 22o-30o C with time of efflux not more than 30 second. ASTM 1107 / Not more than 0.4% at 7.14 or 28 days CRD621 / No Shrinkage / No bleeding

3.4.Fabrication of Structural Steel

Provide ne fabrication materials which conform to the specifications indicated and are the types specificiedec=xpect that substitutes will be allowed if the Supplier obtains Owners permission prior to fabrication.

Have certified mili test reports for steel material confirming that chemical and mechanical properties conform to the applicable ASTM or other material specifications and make them available for inspector’s review. Have certificates of compliance for bolts, nuts, washers, filler material, shear connectors, welding electrodes, and the other material specifications and make than available for inspectors review.

Table 4

Material For Structural Steel Work

Item No. / Utilization / ASTM Standards Unless Noted
Rolled beams, bars channels, plates and angles, bracing, structural steel / A36
JIS G3101 SS40
Plate girders / A36
JIS G3101 SS400
A572 Grade 50
A588 Grade 46
A588 Grade 42
Column / A36 or JIS G3101 SS400
A572 or A588
Covers plates / A36 OR JIS G3101 SS400
A572 Grade 50
A588 Grade 50
Column base plates and splice plates / A36 or JIS G3101 SS400
Connection bolts / A325, A490, or A307
Welding / AWS D1.1
Round tubular bracing / A53
Square and rectangular tubing / A500 Grade B or A501
Castings / A27 Grade 65-35 or
A148 Grade 80-50
Forgings / A668 Classes C, E and F
Shear connerctors / A106

Table 5

Aditional Requirements For Structural Steel Material

Material Item / Standards / Additional Requrements
  1. Low Sulfur High Strength Steel (for plates over 12 mm in thickness when shown on)
/ ASTM A588 Grade A or B or A572 Grade %0 with special process ( such as vacuum degassing). /
  1. The Sulfur content of the steel shall be 0.01% maximum, and the sulfides shall be in globular form.
  2. The steel shall have the following properties in through-thickness direction.
b.1 Reduction of area under tensile test shall be 25% minimum
b.2 The yield and tensile strengths shall not be less than 75% of specified strengths of original A588 or A572.
For plates thicker than 56 mm, yield test shall be perfomed with test specimens conforming to ASTM A370 Figure 5 for 12 mm dia specimens
  1. The steel shall be 100% ultrasonically tested, per ASTM A572 Level 1 for plate thickness of 19 mm and greater, and level II for plate thickness less than 19 mm dia circle, and scanning shall be continued over 100% of the plate surface.
  2. The steel shall Be tested for charpy V-notch impact, In accordance with ASTM A370 with frequency (P) indicated in ASTM A673; and shall meet the following requirements:
Direction Charpy Value (Mills-lateral Expansions at 0o C
Longitudinal 70
Transverse 60
Through- 30
Thickness
  1. Use : Where indicated, especially for plates loaded or stressed in through-thickness direction

  1. Tubular members
2.1. Round Tubular Bracing
2.2. Rectangular or square tubing / ASTM A53 of the following type and grade:
  1. Type E or S, open- hearth or basic oxygen steel only, with Sulphur content not exceeding 0.05%).
  2. Grade B only (2,460 kg/cm2 yield)
ASTM A500 Grade B or A501 / Use standard, extra strong or double extra strong weight.
For tubular framing
  1. High-Strength Bolts
/ AISC specification for Structural Joints Using ASTM A325 /
  1. Bolts and Nuts : Use the following materials unless otherwise indicated.
a.1 For bolt size through 22mm diameter, use A325 Type I steel.
a.2 For other size bolts, use steel as indicated in the bid document.
  1. Washers
A325bolts one washer under the head or nut whichever is the clement turned in tightening.
  1. Shoulder bolts for slotted sliding connections
4.1 Bolts
4.2 Nuts / ASTM A325, Type I
ASTM A563, Grade C / 22mm diameter shank; grip length of bolt shall equal the thickness of the mated parts plus two 3 mm thick washers plus 3 mm. Bolt threads shall be 19 mm diameter and the length shall equal the thickness of two nuts plus 6mm
Two required per bolt.
  1. Washers
/ ASTM F436 / Two 22 mm diameter washers required. One washer under the bolt head and one under the nut.
  1. Castings
/
  1. ASTM A27, Grade 65-35
  1. ASTM A148, Grade 80-50
/ Use for all castings under otherwise indicated
Use only whre high-strength steel castings are required.
  1. Forgings
/ ASTM A668, Classes C / Use for all forgings unless otherwise indicated
  1. Stock material
/ As specified in item 1 through 10 / Mill test reports for applicable material, shall ordinarily constitute sufficient record, but separate tests may be required on my pieces selected from any shipment.
  1. Crane rails-weigh 50kg/m or more (lighter rails shall conform to manufacturer standards)
/ ASTM A1, No. 1, rails with carbon content 0.67-0.82% or manufacturers standards meeting the same requirements /
  1. Length : Standard 12 m, subject tolerances of ASTM A1.
  2. Size : As indicated on the design drawings
  3. End drilling; Three holes each end, spaced to suit specified joint bars and as required for tight end joints.
  4. Marking: As specified in ASTM A1.

  1. Crane Rail Accessories
  1. Joint bars
/ As indicated
ASTM A3 / Accessories shall be as made by, or as furnished by, one of the rail manufacturers indicated in item 9 in accordance with their Standard Specifications for rail accessories, for the specified rails and in accordance with the requirements of this item 10.
Low-carbon steel, with 6 holes and with size and shape of of bars and spacing of holes as required for tight end joints.
  1. Bolts and Nutes
/ ASTM B325 and ANSI B18.2 / Heat-treated, with finished hexagon heads in accordance with ANSI B18.2.
  1. Spring Washers
/ AREA Specification for Spring Washers / Alloy Steel with one washer for each bolt.
  1. Rail Clips
/ ASTM A36 or better / Shall be “Tight Fit” type, made of pressed steel plate with reversible steel filters and 2 holses each clip.

Connections

For shop connections provide bolted or equivalents welded connections.

For field connections, provide bolted connection unless shown otherwise on the design drawings. Field welded connections are permitted only where shown on the desigm drawings or specifically authorized by the owner.

Use Friction type bolted connections with ASTM A325 bolts.

Where required by magnitude of reactions or space considerations, use ASTM A490 bolts. Install ASTM A325 bolts with hardened washer under bolt head and nut.

Bolts conforming to ASTM A 307 may be used for girts, purlins, doors, window framing, and for fabrications, assembly, and erection at the jobsite. The number of each size of loose nuts, bolts, washers, and fittings furnished for field erections shall be 5 percent more than the numbers indicated as required on the drawings.

Use the Turn-of-Nut Tightning or Calibrated Wrench Tighening method, as specified in the AISC” Specification for structural Joints Using ASTM A325 Bolts”.

Unless specials protection against corrosions is provided by other means, the interior of any hollow member, wether a structural hollow section or fabricated member, shall be sealed so as prevent the ingress of moisture.

Fabrications Tolerances

Unless specified otherwise, the fabrication and assembly tolerance on all dimensions shall follow JIS G3192. Holes For connections shall be aligned as specified.

The tolerance on cross-sectional dimensions of rolled sections after fabrication shall be as specified JIS G3192

Unsless otherwise specified, the tolerance on cross –sectional dimensions of built-up section shall also comply with the relevant clauses of JIS G3192.

3.5.Erection Of Structural Steel

Erect structural steel in accordance with the AISC Code Of Standard practice and the AISC Specification for Design, Fabrication and Erection of Structural Steel for Buildings.

Erections Tolerences

Set steelwork accurately to the estabilished lines angle grades and erect is plumbed and leveled such that the deviations in all completed work are within the tolerance limits and meet the requirements as specified in the AISC Code of Standard Practice in the following subsection of this specification. Rections tolerance shall not be accumulative but fabrication and erection tolerances are accumulative.

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