fabrication and quality control of structural steel
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Fabrication definition
Fabrication is the second main process in steel lifecycle after production from mills.
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Difference bet. Q.C & Q.AQuality control: activities used to fulfill requirements
for quality. (ex: calibration)
“Quality control is a process for maintaining standards and not for creating them.”
Quality assurance: activities that do not control quality but establish the extent to which quality will be.(ex: statistical control)
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Main raw materials Standard sections
Plates
Fasteners
Weld electrodes
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Main procedures• Receiving ,
storage, identification and traceability of raw materials.
• Preparation of material.
• Production.• Surface
preparation & protection.
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1.Receiving , storage, identification and traceability of raw materials
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1.Receiving , storage, identification and traceability of raw materials
Color Coding Printed Heat No.
Hard Stamp
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2.Preparation of material
Material is prepared for bolting (in site) or welding (in next stage) by:
Cutting of steel elements.
Edge preparation.
Holes drilling or punching.
Rolling of plates.
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2.Preparation of material
Hole Punching Hole Drilling9
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3.Production Cold forming: using bend machine
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Welding (main process)Factors affecting quality of weld:
1-Proper electrode
2-Welding apparatus
3-Welding method
4-Welding position
5-Edge preparation
6-Control of distortion
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Welding (main process)Possible defects in weld:
1-Lack or incomplete fusion.
2-Inadequate edge preparation.
3-Porosity and gas pockets.
4-Undercut.
5-Slag inclusion.
6-Cracks.
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Non-destructive testsRadiography test(RT): used for small thicknesses to show the defects
inside weld .It uses x-rays and gamma rays.
Ultrasonic test (UT): using ultrasonic waves, used for large thicknesses, it’s faster and easier for judgment and need one technician to be carried out but it needs a certified and qualified technician.
Magnetic Test (MT): using magnet to identify subsurface defect up to 6 mm below surface for A.C current or up to 4 mm below surface for D.C current.
It must be used with materials that have magnetic properties.
Dye penetrant test (PT): used for identifying surface defects or subsurface but open to surface.
As red spot gots wider as defect is deeper.
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MT device Plan of weld
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4.Surface preparation & protection
Methods of preparation:
-Wire brush (manual or automatic)
-Blasting using : - Sand
- Marble
Methods of protection:
-Painting: primer layer followed by another epoxy layer
-Galvanization: for higher protection requirements
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Refrences
Egyptian code of practice for steel construction and bridges.
AISC structural steel building specifications.
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