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

3. 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

4. Main raw materials Standard sections Plates Fasteners Weld electrodes 4

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

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

7. Color Coding Printed Heat No. Hard Stamp 7

8. 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

9. 2.Preparation of material Hole Punching Hole Drilling 9

10. 3.Production Cold forming: using bend machine 10

11. 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

12. 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

13. 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

14. MT device Plan of weld 14

15. 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

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