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Fabrication definition Fabrication is the second main process in steel lifecycle after production from mills. 2

Difference bet. Q.C & Q.A Quality 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) 3

Main raw materials Standard sections Plates Fasteners Weld electrodes 4

Main procedures Receiving, storage, identification and traceability of raw materials. Preparation of material. Production. Surface preparation & protection. 5

1.Receiving, storage, identification and traceability of raw materials 6

Color Coding Printed Heat No. Hard Stamp 7

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. 8

2.Preparation of material Hole Punching Hole Drilling 9

3.Production Cold forming: using bend machine 10

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 11

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. 12

Non-destructive tests Radiography 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. 13

MT device Plan of weld 14

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 15

Refrences China code of practice for steel construction and bridges. AISC structural steel building specifications. 16