8.steel Structure Work

OMRON HEALTHCARE VIETNAM FACTORY PROJECT

CONSTRUCTION METHOD AND QUALITY CONTROL PLANNING For STEEL STRUCTURE WORK

OBAYASHI VIETNAM CORPORATION BINH DUONG – VSIP II SITE OFFICE 2007

Project Manager

Site Manager

Building Engineer

CONTENTS 1- GENERAL 1.1 Scope 1.2 Alteration 2- OUTLINE OF PROJECT 2.1 General parameters 2.2 Steel structure parameters 3- MATERIAL SPECIFICATION 4-SITE PREPARATION 5- METHOD OF ERECTION 6- QUALITY CONTROL 6.1 Members 6.2 Connection 6.3 Alignment 6.4 Adjustment of bracing 6.5 Roofing and wall cladding 6.6 Final inspection 7-STEEL COLUMN BASE TREATMENT 8- MEASUREMENT OF SAFETY 9-SCHEDULE 10-DOCUMENT ATTACHMENT 　10.1 Erection schedule 10.2 Erection method drawings 10.3 List of Tools and Equipment 10.4 Working Procedure for MAXSEAM Panels 10.5 Inspection and Control Form 10.6 Grouting mortar catalog

1- GENERAL 1.1 Scope This Construction Method and Quality Control Planning shall be applied to steel structure erection work. Based on the design and specification, this document provides a proper procedure and management of the structure erection work. 1.2 Alteration This Construction Method and Quality Control Planning may be subject to change or alter due to its revision. In that case, corrected or adjusted requirements shall prevail after its official written approval. 2- OUTLINE OF PROJECT 2.1-General parameters: * Name of the project: OMRON HEALTHCARE VIETNAM FACTORY * Location: 28 Road No. 2, VSIP II, Ben Cat Dist., Binh Duong Province. * Client: OMRON HEALTHCARE MANUFACTURING VIETNAM Co., Ltd * Design: OBAYASHI VIETNAM CORPORATION * Contractor: OBAYASHI VIETNAM CORPORATION * Construction period: June 08th 2007 to November 23rd 2007 * Land area: 38,369.1 m2 * Building area: 6,538.57 m2 2.2-Steel structure parameters:

• Factory main structure: • Office main structure:

3- MATERIAL SPECIFICATION

No.

1

2

3

Components

Built-up

Hot Rolled

Cold Formed

Plates≦6mm thick Plates＞6mm thick

Specifications

Minimum Strength

ASTM A570 Grade 50 Type 1

Fy = 34.5 kN/cm2

ASTM A572 Grade 50 Type 1

Fy = 34.5 kN/cm2

Tubes

JIS-G3466 Grade 50 Type 1

Fy = 32.5 kN/cm2

Channels

EN-10025 S355JR

Fy = 35.5 kN/cm2

Channels

JIS-G3101-SS400

Fy = 24.5 kN/cm2

Beams

JIS-G3101-SS400

Fy = 24.5 kN/cm2

Painted

ASTM A607 Grade

Fy = 34.5 kN/cm2

PreGalvanized

ASTM A653 SS50 Class 1 G90

Fy = 34.5 kN/cm2

4

Exterior Wall & Roof Panel

ASTM A792 Grade 50B: Coating AZ150

Fy = 34.5 kN/cm2

5

Mezzanine Deck Panel

ASTM A653 SS50 Class 1 Coating G60

Fy = 34.0 kN/cm2

6

Interior Liner Panel

ASTM A792 Grade 50B: Coating AZ150

Fy = 34.5 kN/cm2

Rods

TCVN-1765-75 CT38 or higher grade

Fy = 37.2 kN/cm2

Angles

TCVN-1765-75 CT38 or higher grade

Fy = 37.2 kN/cm2 Fy = 37.2 kN/cm2

7

X-Bracing

8

Anchor Bolts

TCVN-1765-75 CT38 or higher grade

High Strength Bolts

2 ASTM A325 M Type 1 Hot D Ft = 30.3 kN/cm Galvanized Fu = 72 to 83 kN/cm2

9

10

Machine Bolts

DIN 933 Class 4.6/4.8 Yellow Chromate

Ft = 13.3 kN/cm2 Fu = 40.0 kN/cm2

4. SITE PREPARATION Stock yard must be prepared before unloading of steel structure materials. (see attached layout plan) All steel structure materials are carefully checked and loaded to ensure safe delivery and to avoid shortages. Materials are packaged and can be unloaded by use of heavy duty Fork-lift or by crane. At the time of unloading, materials should be checked by both Obayashi engineer and Zamil engineer responsible with the Bill of Materials or Packing List. Any shortages must be reported to Zamil Steel immediately by official letter. Materials should be laid out in order. The layout will depend on size of building and site conditions. Use timber blocks between bundles or members for ease of handling. 5. METHOD OF ERECTION Phase 1: ANCHOR BOLT SETTING Step 1: Marking for boundary line of starting column on footing Step 2: Check and adjust position of starting column-rebar if necessary. Step 3: Set form for starting column and support them carefully. Step 4: Marking for bolt-group-center line on side of form. Step 5: Set template with anchor bolts. The template position is higher than concrete surface level. Marking line of bolt-group-center and each bolt must be matched on the template. Adjust position of the template according to marking line on footing by plum bob. Step 6: Welding diagonal supporting bar to column rebar and anchor bolt. Step 7: Check position of anchor bolt again. Step 8: Protect bolts head by masking tape Step 9: Cast concrete for starting column Step10: After casting concrete, re-check anchor bolt position. Adjusting the template if necessary.

Phase 2: STRUCTURE ERECTION Step 1:

• Set up 2 side columns of braced bay (between Grid 4 and Grid 5), including • •

• • • •

•

bracing beams. Erect interior columns (along grid C1-4 and C1-5) with temporary bracing. Tighten anchor bolts and nuts sufficiently to prevent columns from rocking. Assemble rafter components of Grid 4 on the ground into connection. Install all bolts in rafter splices to proper tension, using turn-off- nut method and torque wrench. Raise the first assembled rafter on top of column by cranes. Install bolts of rafter through column connection and tighten to snug position. Secure all temporary, wire ropes bracings, plumb and align the column and rafter before releasing the crane.

Step 2:

• Using same procedure to assemble other parts of the rafter of Grid 5 (A – F). • • •

Place it on top of interior columns. Bolt to column connections and tighten. Secure temporary bracings.

Step 3:

• Assemble the rafter of Grid 6 (same as the first erected rafters). Connect and

•

• •

•

Step 4:

• • •

bolted to column splices. The crane has to keep holding the rafter in position until sufficient purlins ( 1/3 of total purlins at that area ) have installed to provide rigid support for the bay. The crane can release if having temporary bracing cables for both sides at interval of maximum 10 m. Continue erecting the next rafters of the brace bay. Completing purlins, flange braces, roof bracings. Plumb and align before proceeding to erect the next bays. After checking the alignment and square-ness, tighten again anchor bolts, column connection, girts bolts, and eave strut bolts to required tension by torque wrench. Continue erecting columns rafters for the next bays, using same procedure described in Step 1. Complete installation of purlins and girts. Complete roof angle bracings, and all secondary members.

Step 5:

• Fabrication and installation of MAXSEAM roofing panels. (See attached “Erection Procedure for Maxseam roof Panel”) Step 6:

• Install wall panels, downspouts and gutters. •

Complete trims and accessories.

6. QUALITY CONTROL - Inspection is necessary at all steps of erection process, from the times materials are first received until the structure is completely installed. - Inspection during the erection process shall be continuous in order to prevent the occurrence of possible damage and to require the maintenance of high standard workmanship. Inspection shall include members, painting, connection, alignment, bracings, roofing and wall cladding, equipment and false work. 6.1. Members - Inspection members for damage due to mishandling or careless storage. - Make sure that each member is placed in its proper position in the structure and that fillers, shims, and washers required for the type of connection are properly used. - Prevent abuse of material by bending, straining, or heavy pounding by sledges. - Inspect the accuracy of match-marked connections. - Check the painting work. - After finishing the painting work, all steel members shall be checked to make sure that small area of steel members is painted. 6.2. Connection a/ Anchor bolts: - Check the tolerance of dimensions between anchor bolts to meet the required tolerance (5mm). - Check the tightness of anchor bolts to meet the require forces. b/ Bolts connection: - The supervisor has to assure himself that the wrenches used are calibrated properly so that bolts are tightened the proper amount. Also the proper lengths of bolts shall be checked. - After connecting, all bolts shall be tightened to obtain the required tension values • Using turn-off nut method: Tighten more120o+/-30o for bolt diameter >12mm, tighten more 60o-0+30o for bolt diameter = 12mm. • Torque wrench: the actual value must be within the recommended value +/5_10%. - Every connection point shall be inspected with the inspection record that is made by the team leader, with the confirmation of Obayashi responsible engineers and Site Manager.

The actual value of tension or torque moment of every bolt in the connection shall be shown on the record.

Bolt diameter

Bolt Tension Required (Table 1) Min- tension

D mm 12.7 15.9 19.0 22.2 25.4 28.6 31.7 35.0 38.1

N KN 53 84 125 173 226 249 317 378 459

Recommended Torque M N.m 136 271 481 773 1153 1437 2027 2658 3526

6.3. Alignment - After the first bay (braced bay) is erected, the columns shall be made plumb and the rafters shall be straight. - After completing the erection of main frames the alignment check shall be done again, before continuing the erection of the successive bays. The tolerance of column plumb must be within the value of 1/500 of column height, but can not be more than25mm. The tolerance of Rafter alignment (from straight rafter - line) must be within the value of 1/300 of Span. -After completing the erection of main frames, the final check of alignment (plumbing and straightness) for the all columns and rafters of whole building shall be done. 6.4. Adjustment of bracing - Adjustable diagonal bracing is fixed after all parts of the structure are in place. - In bolted structures having diagonal bracing, wall bracings are adjusted after the columns are plumbed, and roof bracing are adjusted when rafters are in straight line. 6.5. Roofing and Wall cladding Check sequence of roof panels on roof. Check correct starting- end position of roof and wall panels. Check right screws using. All screws must be perpendicular to panels, and rubber washer thickness must be from 1.00 to 1.20mm.

(See attached “Erection Procedure for Maxseam roof Panel”)

6.6. Final Inspection After completing all trims and accessories, a final inspection of the building shall be done: All bracings in position and tightened. All bolts in place and high strength bolts tightened to correct tension value. Check that roof and gutters are clear of debris and ferrous metals. Check improper drilled screws. Check opening for joinery. Touch up any damaged paint. 7. STEEL COLUMN BASE TREATMENT Procedure a. Cleaning of concrete column top surface. b. Marking centerline of steel column. c. Leveling mortar base (using high grade mortar G150 ) at middle of 4 anchor-bolts with the same level of bottom of column-base-plate. d. Checking level of column. e. Grouting mortar for column base. (Sika- grout 212-11: see attached catalog)

8. MEASUREMENT OF SAFETY ●Each

workers shall be physically qualified to perform the duties to which he is assigned. ●Workers shall always wear hard helmets, shoes, uniforms and gloves. ● Workers shall wear safety belts. ●Goggles, face masks shields or helmets are required for scaling, grinding, cutting, and welding operations. ●Maintenance of machines used in the erection work shall be done properly. ●Setting of safety rope on Roof when carry out the roofing work. ●Setting of signboard, and barricade by ropes around working area, do not permit any person without duty to enter the working area. ●The crane condition (including machine parts, wire rope) must be checked everyday. ●Safety meeting shall be done everyday before starting work. ●Scaffoldings shall be arranged properly. ●Daily cleaning shall be done everyday.

9. SCHEDULE 10. DOCUMENTATION ATTATCHED

LIST OF BASIC ERECTION EQUIPMENTS The following items are basic equipments for erecting xxx project. LIFTING EQIPMENT, ROPES AND LINES. 1. 2. 3. 4.

01 No. of 45 MT Crane 01 No. of 20 MT Crane 04 Nos. of 12 MT Crane Assorted Slings in various size and Length. 5. Steel guy lines for temporary bracing. 6. Manila Ropers for hand lines. ELECTRICAL EQIPMENTS 1. 2. 3. 4. 5. 6. 7. 8. 9.

Welder Machine Extension Leads and pigtails. Heavy Duty Drill ½”. Heavy Duty Drill ¼”. Heavy Duty Screw gun w/Hex Sockets. Electric Nibbler. Electric Shear. Angle Grinder. Concrete Drill.

HAND TOOLS. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Socket Wrench ¾” or 1” drive with asst. Sockets. Open ended wrenches assorted imperial size. Spud wrenches 15/16” opening up to 1-1/8” Crescent wrench – ½”. Pipe wrench. Screw drivers Standard and Philips. Aviation snip – Left and right. Vice grips. Pop rivit puller 4bl Sedge hammer. Hacksaw frame and blades. Wood saw. Spirit level and plumb – bob. Chalk line. Steel measuring tapes 30m and 8m. Utility knife. Staple applicator. Oxy-Acetylene cutting outfit. Welding hood. Hard hats. 21.Safety belts – Bolt bags. 22. Broom. 23. Masonry drill bits 12mm. 24. Extension ladders. 25. Step Ladders. 26. Scaffolding System. 27.Hilti gun, cartridges and nails

TOOLS AND TACKLES

No. Machinery 1 2 3 4 5 6 7

Item

Portable Rollformer Portable Air Compressor Seamer Electric Hydr １ alic Engine Unit Diesel Engine Unit Uncoiler Crimper

Tools 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Combination Wrench Allen key Set Strap Wrench 18" Screw Driver Adjustable Wrench 24" Wrench Sweeping Broom Stapler for insulation Mastic Gun (Silicon) Goggles Fire Extinguisher Nibbler Cutting Snip 10" Hack Saw C Clamps various size Electricextension 50M Screw Gun Drill machine Grinder (small) Nylon Rope Riveter (heavy duty) Venier Caliper (digital) Vice Grip 8" Utility Knife Line Man's Pliers 8" Long Nose Pliers 6" Side Cutter 8" Digital tester (VOM) First Aid Kit Plastic tarpaulin cover 8mx10m Plastic Galoon 20 litter Feller Gauge mm 3 Claw Mechanical Puller small Hydraulic Jack 20 tons Level Scow Bar 1m length Electric soildering Iron 100 watts Oiler Ball Pien Hammer (medium) Torch Tape 8 meters Tape 30 meters Tape 5 meters

Unit 　

Q'ty 　

Part Number/Made in

Set Pcs Pcs Pcs Pcs Pcs Pcs

1 1 2 1 1 2 2

# 38624 # 051394 567B604050005 86541 405DAC38/12H USA USA

　

　

　

Set Set Pc Pcs Pc Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Mett Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Set Pcs Can Set Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs Pcs

2 2 1 8 1 2 3 15 8 45 2 1 6 3 4 4 21 1 1 750 2 1 8 12 2 2 6 1 1 4 4 1 1 1 1 1 1 1 1 1 2 2 5

Stanley Kingtony Stanley Goodman USA Stanley Vietnam 　 China 　 　 Makita Stanley Italy Vietnam Vietnam Makita Makita Makita Vietnam Stanley Mitutoyo Stanley Stanley Stanley Stanley Stanley Koritsu Vietnam Vietnam Vietnam China Japan Japan Stanley Vietnam Czech India Stanley Vietnam Stanley Stanley Stanley

　

TOOLS AND TACKLES No.

Item

Unit Q'ty

Part Number/Made in

Support 1 2 3 4 5 6 7 8 9 10 11

Scaffolding 1.5 meters Bracing for scaffolding Platform for scaffolding Jack for scaffolding Wheel for scaffolding Spreader bar Stair for scaffolding Extension Cord (Cable 3x16+1x10) Electrical box Stand Conveyor Roof Panel Carridge

Safety 1 2 3 4 5 　

Safety Clothers Universal Harness (1008833 size M) Rope Lanyard 2m with G) Safety rope (14mm Polyamide Rope) Helmet 　

　

　

　

Pcs Pcs Pcs Pcs Pcs Pcs Pcs Mett Gox Pcs Pcs

40 40 20 12 12 2 40 100 1 25 30

Hung Cuong Co.Ltd Hung Cuong Co.Ltd Hung Cuong Co.Ltd Hung Cuong Co.Ltd Hung Cuong Co.Ltd ZSV Hung Cuong Co.Ltd Korea Vietnam ZSV ZSV

　

　

　

Pcs Pcs Pcs Pcs Pcs 　

30 17 17 4 16 　

France France France France Vietnam