You are on page 1of 12

Procedure

M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

Steel Fabrication Procedure


Quality, Environment, Safety and dan Health

Integrated
PT Tekniko Indonesia
Based on International Standard
ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007

REVISION STATUS

May 2 nd,
2015
Dec 11th,
2010
Sept 1st ,
2010
Date

Blasting And Painting Equipment


1

Para 3.6.5, Minimum Ambient Temperature

Issued for Implementation

Revisio
n

Description

NAME

NAME

NAME

NAME

DATE

DATE

DATE

DATE

Prepared by
Production Eng

Reviewed by
Production
Manager

Reviewed by
QA/QC Manager

Approved by
Management Rep.

Page 1 of 11

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

TABLE OF CONTENTS :
Halaman
1.0SCOPE

2.0REFERENCE

3.0 PROCEDURE

4.0 INSPECTION

10

5.0 ATTACMENT

11

Copyright. This document is the property of PT. Tekniko Indonesia and all rights are reserved in respect of it. This
document many not reproduced or disclosed in any manner whatsoever, in whole or in part, without the prior
written consent of PT Tekniko Indonesia. PT Tekniko Indonesia expressly disclaims any responsibility for or liability
arising from the use of this document by any third party. This document is only valid as a controlled document
when there is original stamp "Controlled Copy". And holders of hard copy documents are always checked the
documents to the Document Controller or to the server of HSE Documents

1.0
Page 2 of 11

SCOPE

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

The scope of this fabrication procedure incorporates the activities and


responsibilities of implementation related to steel fabrication work.
Fabrication work is a series of several components assembled into a
single material with gradual implementation to be a form of one of the
types of construction that can be installed into a building form to
complete.

2.0

REFERENCES
ISO 9001: 2008, 7.5 Productions and Service Provision

3.0
3.1

PROCEDURE
Material
1. The quality of the materials shall conform to the standards, owner
specification and drawing required.
2.

in case that material others than those mentioned above are


employed, the quality and type of the materials shall be in accordance
with specification

3. All material supplied by PT. Tekniko Indonesia and shall be used after
Customer accept result for inspection receiving material in PT. Tekniko
Indonesia Workshop.
4. All welding material shall be the same as applicable codes and
approved welder qualification procedure.
3.2Material Inspection Creteria
All material shall be regular configuration and free from deleterious flaws
or heavy rust and shall be accordance with the standard or code. PT.
Tekniko Indonesia shall submit the mill certificate and or test report of all
material such as pipe, beams, bolts and nuts, etc.

Page 3 of 11

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

3.3Shop Drawing
The PT. Tekniko Indonesia

Desain & Engineering shall prepared shop

drawings for each part according to the basic drawing from Customer or
from our Engineering it self. Shop drawing for steel structure fabrication
shall be done and approved by Engineering Department or Customer And
fabrication activities shall be conform to the manufacturing drawing and
fabrication procedure.
3.4

Marking
1. Material identification and or traceability shall consist of a system of
identification that shall be clearly recognizable.
2. Marking shall be done accurately in accordance with shop fabrication
drawing and cutting plan and exactly taking into consideration
allowance for welding and cutting lose.
3. When main material is used make more than one part, the original
identification number will be transfer to each part.
4. After marking, PT. Tekniko Indonesia responsible shall be inspected the
item for the marking dimensional & transfer number.

3.5

Cutting
1. The surface of cutting in any materials shall be vertical to the axis
except where designated on the drawing.
2. The dimension for cutting shall be determined with consideration to
construction and deformation, which may develop during fabrication
and an allowance for finishing work.
3. During cutting process, it shall be carefully executed to prevent a
excess cut. When a excess cut is found it shall be smoothly finished a
grinder to prevent interfere with welding.
4. Un-dimensioned openings on floor plate shall be cut in the field.
5. All cut ends etc shall be dressed in a manner that leaves an acceptable
finish.

Page 4 of 11

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

3.6

Welding
2

Welding is a metal splicing in metallurgy by using heat and pressure, with


or without filler metal having a melting point that is almost the same. All
welding shall be performed in accordance with the requirement of ASME
SECTION IX. (as per API 650 clause 5.2.1.1 & clause 7.2.1)
1. Welders who perform arch welding shall qualified by having met the
requirements of the project specification and or approved welder
qualification procedure.
2. All shop connections shall be welded unless otherwise noted on the
design drawing
3. All welds shall be continuous along edges of connected part unless
otherwisw note on the drawing.
4. Welding shall not be performed when the surface on the base metal is
wet due to rain, etc, or during strong wind. However, welding may be
performed when the welder and weld are satisfactorily protected and
suitable measures have been taken with respect tho the base metal.
5. Welding shall not be performed when the ambient temperature is less
than 0.
6. Slag and spatter shall be removed after the completion of welding
7. When a manual weld is made from both sides, back gouging shall be
performed before making the weld on the backside, when required by
contract document.
8. When making a weld from one side only, special care shall be taken to
produce a satisfactory welding of the root portion by using backing or a
backing strip on the other side.
9. Field connections shall be bolted whenever pissible unless otherwise
note on the design drawing
10.All welds shall be visually inspected to the requirements of applicable
code.

Page 5 of 11

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

3.7
2

Blasting and Painting


1. Agitator :
An equipment used to mix paint material and thinner in paint pot
continuously in order to keep paint viscosity same.
2. Paint Viscosity Index:
A stable paint viscosity at a certain temperature.
3. Zahn Cup :
An equipment used to measure paint viscosity before use.
4. Keane - Tator Surface Profile Comparator :
An equipment used to measure the profile surface of abrasive material
visually.
There are three types of this equipment based on type of blasting material,
those are : Keane-tator for sand, grit and shot abrasive.
The use of this equipment should be together with lighted magnifier.
5. Wet Film Thickness ( WFT ) :
Thickness of painting in wet condition.
6. Dry Film Thickness ( DFT ) :
Thickness of painting in dry condition.
7. Paint Material Specific Gravity :
Gravity of paint material in painting pot (The unit is Kg/Litre). The
equipments to measure the specific gravity are measuring glass and the
balance.

Page 6 of 11

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

8. Dry Time :
Time needed to have the dry and/or hard condition of paint material at a
certain temperature.
9. Air Humidity :
Water contained in the surrounding air.
10.

Semi auto blasting

Autoblasting machine by using steel grit or steel shot.


11. Mesh.
Filter to determine the size of grain during sand pot filling process on
manual blasting.
It is also used to separate the litter from blasting sand.
12.

Elcometer Adhesion Tester.

Equipment to test the stress strength of paint material, which already


painted to the product having the contact surface about 1/5 square inch.
(Measuring Adhesion by Tape Test) ASTM D 3359.
13. Taseto.
Weldable paint used in site weld area for rust prevention during
transportation.

Page 7 of 11

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

3.8

Painting Process
1. Check paint material to be used, it must be as per clients specification.
2. Mix paint material smoothly following the direction on data sheet provided
by paint

manufacture. The mixture may use both viscosity index and

specific gravity system.


3. Pour paint material mixed to the paint pot by using fine sieve 80 mesh
filter.
4. To avoid the sediment of paint material, paint pot to be completed with
agitator to mix
5.

paint material inside paint pot continuously.

Check air pressure inside paint pot. Air pressure inside paint pot should
refer to paint data

sheet in which the pressure for each paint material

should be different.
6. Check air humidity at the area where painting work is conducted by using
hygrometer and compare the actual air humidity with humidity allowed by
paint material data sheet. Painting work shall not be carried out if humidity
is over 85%, rain or snow (except indoor work).
7. Check material temperature by using surface temperature thermometer
and room temperature at the location where material to be painted by
using thermometer. Compare with temperature allowed by paint material
data sheet. Painting work shall not be carried out if temperature surface
are below 5C, over 50C, and below dew point plus 3C.
8. Make sure that the area where painting work is conducted free from
blasting dust and heavy wind, the surface of material clean and dry by
sweeping and/or blowing up with compressor wind, and the un-painted
area is cover with paper tape / masking tape.
Page 8 of 11

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

9. Use Painting Personal Protective Equipment (PPE), before painting work.


10. Do the paint spraying throughout the material according to the airless
spray direction layer by layer until the required WFT achieved.
11. When paint material is dry as specified drying time, the thickness of paint
is measured by using DFT gauge with reference to SSPC standard (if any
other requirement from client, it should be followed accordingly). Its spot
measurement consists of an average of trigeange readings makes to
another.
12. If painting work to be applied more than 1 coat , check coating interval
with paint material data sheet. Check the coating surface dry condition by
finger before next coating. Clean and rub the painting surface with sand
paper before next coating. Repeat the steps on point 7.4.1. up to 7.4.11.
13. Stencile the punch mark of each material by using paint marker stenciled
Mark.
3.9

Condition Blasting And Painting


1. Surface preparation shall be in accordance the project specification.
2. Prior to blast cleaning, contamination shall be removed from steel
surfaces, oil and grase shall be removed by solvent cleaning.
3. Prior to blast cleaning, weld defct shall be repaired, sharp edges and
flames cut edges shall be reduced by grinding and welds shall be smooth
and free of all weld slag and weld spatter.
4. Surface to becoated and painting shall be free of all visible dust, oil, grease
and other surface contaminants. All surface shall be thoroughly dried prior
to pinting.
5. All coated and painting material shall be in a thoroughly mixed condition at
the time of application and shall be thinned only accordance with the
manufacturer instruction.

Page 9 of 11

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

6. Primer coating shall be applied as soon as possible after cleaning the


surface.
7. Coating shall be applied by spraying, brushing, roller or others suitable
method depending on the kind of paint, surface and material to be painted,
circumstances of working area and recommendations by the paint
manufacturer.
8. Before the application of the next coat, the surface shall examined for
damage and contamined areas. Where coating have been damaged, all
damaged and loosely adhering coating shall be removed and repaired with
the original specified paint system.
4.0

INSPECTION
1.

Inspection Receiving Material


Inspection required to checking the dimension of shapes after material
arrived. The length and material specification should meet the specified
requirements. Those with non conformity should be identified with marking
to prevent from abuse.
The steel material shall be deem to have passed inspection to comply with
standard, code and accordance to material certificate.

2.

Visual and Dimensional Check


Visual check conducted to check and ensure there is no significant defect
caused any stage of fabrication which has performed

by QA/ QC

Department.
Dimensional check accordance to standart and tolerance of size, length
according to drawing and specification by QA/ QC Department.
4.1

Packing and Trasportation


1.

Packing performed after all process of fabrication and painting has been
finished. All

document required to submit the material such as packing

list and delivery note shall be prepared prior delivery materiall to the job
site.
Page 10 of 11

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

2. The transportation of fabricated steel structure from the painting shop or


fabrication shop to the job site shall be carried out by trailer with items
adequately loaded and secured to prevent/minimize transit damage.
3. Steel structural members shall be shipped in the order erection, being
check against their steel member lists.
4. In shipping good care shall be taken to prevent rusting, demage and injury
during transit. Necessary protection shall be provided so that the painted
surface and the unpainted surface may not be injured. Small items shall be
properly packed ant the contents of each package shall be clearly
indicated.

4.2

INSPECTION
1.

Inspection Receiving Material


Inspection required to checking the dimension of shapes after material
arrived. The length and material specification should meet the specified
requirements. Those with non conformity should be identified with
marking to prevent from abuse.
The steel material shall be deem to have passed inspection to comply
with standard, code and accordance to material certificate.

2.

Visual and Dimensional Check


Visual check conducted to check and ensure there is no significant defect
caused any stage of fabrication which has performed

by QA/ QC

Department.
Dimensional check accordance to standart and tolerance of size, length
according to drawing and specification by QA/ QC Department.
5.0

ATTACHMENT

Page 11 of 11

Marking & Cutting Report, Doc No. PT. Tekniko Indonesia-001


Dimensional Report, Doc No. PT. Tekniko Indonesia -002

Procedure
M0-MLK3-034 Rev. 02
Integrated
PT Tekniko Indonesia

Page 12 of 11

Welding Report, Doc No. PT. Tekniko Indonesia -003


Control List Fabrication Status, Doc No. PT. Tekniko Indonesia -004
Painting Report, Doc No. PT. Tekniko Indonesia -005