Fabrication PDF

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Fabrication
Fabrication is the process used to manufacture steelwork components that will, when assembled and joined, form a
complete frame. The frame generally uses readily available standard sections that are purchased from the steelmaker
or steel stockholder, together with such items as protective coatings and bolts from other specialist suppliers.
Although a wide range of section shapes and sizes are produced, the designer may find that the required section size
is not available. In this case, built-up girders may be fabricated from plate. Sections and plate girders may also be
strengthened by stiffening the web or flanges depending upon the load to be carried.
Most modern steelwork fabrication factories have computer aided design and detailing (CAD) which is linked directly
to factory floor computer numerically controlled (CNC) machinery creating a genuine CAD/CAM environment. The
accuracy of the computer generated details being transmitted directly to the computer aided manufacturing (CAM)
machinery increases the quality standards of production
The fact that machinery has taken over from the tape measure means that the frame is produced to high quality
standards which are reflected in the speed and accuracy of steel erection on site. This results in significant benefits
both to the client and main contractor.
CAD/CAM machinery
(Image courtesy of Paddy Wall & Sons)
Design for economic fabrication

There are a number of general "technical" factors to consider in terms of design for economic fabrication that apply to
most building projects. Some relate to the complexity of the particular project, whilst others are specific to the type of
project, e.g. multi-storey, portals, trusses.
Specification
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//www.steelconstruction.info/Fabrication - 16th September 2017
SteelConstruction.info
Conformance with the National Structural Steelwork Specification for Building Construction (NSSS) will reduce
uncertainty. Additional project specific clauses, more demanding tolerances, and additional testing will increase
costs.
Bay size
Diagonal steel bracing Silverstone

(Image courtesy of Kingspan Structural Products)
Structural steelwork prices are influenced by the size of each individual piece (i.e. number of pieces per tonne), which
is largely dependent on bay size. Consider larger bay sizes, where the extra weight due to longer spans may be totally
offset by the reduced price per tonne and the saving in number of columns and related workmanship. Also the
resultant column-free space generally adds value to a project.
Structural steel frames must have the required degree of lateral resistance to wind loads. This can be provided by a
stiff core or by the frame itself - diagonal steel bracing is usually a less expensive solution than moment frames.
Complexity
Modern CNC fabrication equipment can cope with complex individualistic designs but, in general, the more complex
the fabrication the greater the cost. Fabrication is more economic with:
Single square end cuts

One hole diameter on any one piece avoids drill bit changes
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Holes in flanges and webs aligned where possible

Web holes having adequate flange clearance
Rationalised range of fittings for connections
The use of a small range of standard bolts, e.g. M20 grade 8.8 for shear connections
Wherever possible, leave the choice of the connection detail to the steelwork contractor as the type and design of
connections directly influences the total frame cost. Rationalise the range and tonnages of section sizes used.
Complex individualistic designs are going to cost more per tonne, even with modern CNC equipment. If you wish to
keep costs down - keep it simple!
Materials
Avoid mixing steel grades where possible and rationalise the range of section sizes / tonnages used in order to
minimise cost, lead times and factory handling. In general steel grade S355 offers greater economy unless stiffness /
deflection governs the design, in which case S275 should be used.
Tubular steelwork at the National Football Centre

(Image courtesy of Billington Structures Ltd.)
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Ensure that the most appropriate sections are specified for the particular application. I sections are usually most
economical in conventional framing, while tubular sections are a possible alternative for columns and long span
trusses. While tubular sections have a higher first cost than I sections, their lower overall gross weight required to
perform the same function can largely offset this, often with an aesthetic bonus. Asymmetric beams are often used to
reduce the construction depth of floor systems. Steel plate is used to fabricate connections, stiffeners and base plates
and can be used to fabricate economic I sections for longer spans.
Architectural influence
Ensure that unnecessary finishing is not specified and that any applied corrosion resistant coating is appropriate for
the environmental conditions to be encountered. Grinding of welds to improve the appearance of the steel is usually
only required for exposed steel in close proximity to a buildings occupants.
Quality of engineering and documentation
Completeness and accuracy of information are vital for a steelwork contractor to be able to properly assess the work
involved. Where the steelwork is pre-designed, ensure that all member sizes are shown and that the connection forces
are shown or are available. Guidance on identifying the requirements for the production and exchange of accurate,
timely and detailed information for projects involving steelwork is available in BCSA publication no. 45/07.
Further guidance on the design of buildings for economic fabrication is available in:
BCSA publication Steel Buildings, Chapter 11 - Fabrication

The Steel Designers Manual, Chapter 33 - Fabrication
SCI publication P150 Design for Manufacture Guidelines
Guidance on the design for economic fabrication of bridges is available in BCSA publication Steel Bridges, Chapter 7 -
Costs.
Materials and components

Steel sections and plate, structural bolts, welding consumables, light gauge decking and corrosion protection and fire
protection systems are all manufactured to European standards and in many cases are CE marked. In addition to
these materials steel fabrication also needs fabrication equipment (e.g. cutting, sawing, drilling, welding machines
etc.) and software (e.g. for computer controlled machinery).
Sections and plates
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A stockholders external facility

(Image courtesy of Rainham Steel Company Ltd.)
Steel sections and plates are generally manufactured to BS EN 10025-2[1] for open sections, BS EN 10210-1[2] for hot-
finished tubes, and BS EN 10219-1[3] for cold-formed hollow sections. All sections are accompanied by Type 3.1,
product specific CE Inspection documents.
Large orders can be supplied direct from the steel mills, but Steelwork Contractors normally obtain their steel sections
and plates from a steel stockholder. Steel stockholders play a vital part in the steel construction supply chain, ensuring
that the market is supplied with what it needs when it is needed. The industry has an extensive network of depots
serving all parts of the country. The stockholders provide a range of products to the construction industry including
heavy structural sections, plates, light sections, cladding materials, flats, angles. Total stocks held represent about 40
days supply. All BCSA stockholder members have quality management systems such as BS EN ISO 9001[4] in place
supplemented by individual identification systems to ensure full traceability from the steel manufacturer to the
steelwork contractor. The specification and quality controls placed on stockholders by the BCSA Model Specification
for the Purchase of Steel Sections and Plates ensures the quality of steel sections and plate placed on the UK market
by BCSA stockholders.
Bolts
Although the majority of structural bolts are manufactured outside of the European community they are all CE marked
and manufactured to European standards BS EN 14399[5] for preloaded bolts and BS EN 15048-1[6] for
non-preloaded bolts. The exacting quality control requirements placed on European manufacturers and distributors by
the BCSA Model Specification for the Purchase of Structural Bolting Assemblies and Holding Down Bolts ensures the
quality of structural bolts placed on the UK market by BCSA bolt distributors.
Proprietary products
Proprietary products such as some cellular beams, fasteners, purlins, cladding and roofing systems are also available
and can provide novel and cost effective alternative solutions. Many of these are manufactured to either European
product standard or European Technical Approvals.
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(Images courtesy of Kloeckner

Westok)
Coating systems
Paint systems, galvanizing and other protective coatings have developed over the years in response to numerous
technological advancements that have brought improved performance and comply with industrial environmental
legislation. Manufacturers are conscious of their position in the supply chain and the demands by industry for best
service.
Cold-formed sections
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Purlins and side rails on a portal frame

(Image courtesy of Caunton Engineering Ltd.)
Lightweight cold formed steel products are vital components for the majority of steel construction projects. Whether it
is purlins, side rails, walling, channels systems or floor decking systems, these products are ideally suited for most
commercial and industrial applications, while a number of them have been specifically designed for refurbishment
applications.
Fabrication processes
Fully automated saw / drill line

(Image courtesy of Parker Steel)
Advances in quality and productivity in the steel construction sector are largely due to developments in fabricating
machinery. The manufacturers of steelwork fabrication equipment have invested heavily in research and development
to produce the technological advances required by todays steel construction sector. Thanks to this continuous
improvement, sate-of-the-art CNC machinery has been made available from international manufacturers that have
helped the UKs steel construction sector improve productivity to become the envy of the world.
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Preparation
Stockyard
The steel fabrication story begins as the basic sections and plates are delivered to a storage area, or steel stockyard.
Here it is unloaded and stored prior to being moved to the fabrication lines for processing. Fabrication is a rapid
process, and whilst a typical stockyard may contain several thousand tonnes of material, that is only enough to keep
the fabrication lines supplied for a few weeks.
The stockyard
Shot blasting
For many Steelwork Contractors, sections and plates are shot blasted prior to fabrication, although some chose to
carry out the shot blasting after the sections are cut to length. This surface preparation is an important part of the
fabrication process, which is essential to provide a suitably clean finish for welding and subsequently also to produce a
keyed surface ready to accept paint. Shot is fired at the steel. The force of the shot against the surface displaces dirt
and scale, and also indents the steel creating a "rough" surface, approx. 70 microns deep. When paint is sprayed onto
this clean abraded surface it adheres well and provides a longer life for the paint system.
Prefabrication primers can be applied, immediately after blast cleaning, to maintain the reactive blast cleaned surface
in a rust free condition through the fabrication process until final painting can be undertaken.
Shot blasting
Cutting & drilling
In the fabrication factory one of the first operations is to cut the sections to length and profile the plates to the desired
size or shape. This can be done in a number of ways using a range of automated machinery:
Circular saws
Circular saw
(Image courtesy of Kiernan Structural Steel Ltd.)
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Circular Saws are used for cutting to length. Sections are delivered from the stockyard to the machine bed of the saw.
Pre-programming the saw not only ensures that steel is accurately measured and cut to the length required but the
operation is carried out at the most efficient speed for the cutting operation, so reducing wear on the blade.
Saw cutting
Gas or flame cutting
Flame cutting
Gas or flame cutting systems are also used to cut components from steel plate. This process uses a mixture of oxygen
and a fuel gas (propane) to preheat the metal to its 'ignition' temperature; which, for steel, is 700C - 900C (at this
temperature a bright red heat) but this is still well below the materials melting point. A jet of pure oxygen is then
directed into the preheated area instigating a vigorous exothermic chemical reaction between the oxygen and the
metal to form iron oxide or slag. The oxygen jet blows away the slag enabling the jet to pierce and continue to cut
through the material.
Flame cutting
Plasma cutting
Components can also be cut efficiently by plasma arc systems. A fine bore, copper nozzle constricts the arc between
the electrode and the work piece. This increases the temperature and velocity of the plasma emanating from the
nozzle. The temperature of the plasma is in excess of 20,000C and the velocity can approach the speed of sound.
When used for cutting, the plasma gas flow is increased so that the deeply penetrating plasma jet cuts through
material whilst molten material is removed in the efflux plasma.
Plasma cutting
Drilling and punching
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Drilling machine
To allow sections to be rapidly bolted together on site, all holes are pre drilled or punched in the fabrication factory. For
drilling, high speed steel twist bits are used. The rotating bit cuts through the steel and the metal being removed during
the process forms swarf (the curls of metal that spiral off during machining). The swarf travels up the flutes (the helical
grooves), which run up the side of the bit.
Punching can be used where the thickness of the metal is less than the diameter of the hole or in the case of a non-
circular hole its minimum dimension (Note that the 15mm thickness limit for punching mentioned in the video clip
below no longer applies). In the punching process a cutting punch is forced under pressure through the steel into a die
below, so producing a clean, accurately sized, hole. Where fatigue is an issue the holes are punched 2mm undersized
and reamed to the correct diameter.
Drilling and punching
Bending
Where feature steelwork or curved structural steelwork is required, the steel will be sent to a specialist fabricator. Here
through the use of roller bending or press braking equipment, curves and bends can be created. Design
considerations relating to the use of curved members are explained in the Design of Curved Steel (P281), which
covers the theory and also gives examples of curved steel in buildings. Further information can be sourced from well
known bending companies.
Curved steelwork at Hayes Garden Centre

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(Image courtesy of Kloeckner Westok)
Section bending
Section bending
(Image courtesy of Barnshaw Section Benders Ltd.)
Steel can be curved by roller or section bending. This process involves progressive bending of a section through a set
of bending rolls that are shaped to the cross section of the bar. On each pass through the rolls, more bend is created
and the process is repeated until the desired curvature is achieved. Pulling units are used on most beam sections
curved on the x-x axis (the strong way). This is used to maintain the cross section of the web during bending
Section bending
Plate bending
Plate bending is similar to section bending but the bending rolls are horizontal and are longer. Plate is fed in flat and on
each pass through the rolls, more curvature is introduced and the process is repeated until the desired curvature is
achieved.
Plate bending
Tube bending
Tube bending is carried out in a similar way to section bending. Generally, a tube is stronger than its equivalent size
beam so, to bend it, more force is required. During bending the outer profile of the tube is supported by sets of
machined rolls.
Tube bending
Press breaking
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A wide variety of shapes can be formed from profile cut or sheared plates. Sometimes these shapes are required at
12metres long (or more). To achieve this a Press Breaking process is used to press the steel along its entire length.
Press breaking
Tee splitting
Flame cutting is used to make tee sections from beams. This involves the use of a burning torch on a trolley
arrangement that runs up the beam until the cut is completed. The beam can be cut centrally; off-centre or the flanges
can be trimmed. The Tee section needs to be straightened after splitting, this is due to the stress being released after
the cut.
Tee splitting
Profiling of tubular sections
In addition to the standard fabrication processes common to all structural elements, tubular sections may require
profile-shaping or saddling. Profile-shaping is required where the end of a tubular section has to fit the contour of a
curved surface on a circular hollow section main member. This type of connection can be most commonly seen on
tubular trusses
Profiling tubes
Welding
Main article: Welding
Welding is a core activity in the fabrication factory; it is used to prepare joints for connection on site and for the
attachment of other fixtures and fittings. Different welding techniques are used for different activities within the
fabrication factory.
Essentially, the welding process uses an electric arc to generate heat to melt the parent material in the joint. A
separate filler material supplied as a consumable electrode also melts and combines with the parent material to form a
molten weld pool. The weld pool is susceptible to atmospheric contamination and therefore needs protecting during
the critical liquid to solid freezing phase. Protection is achieved either by using an inert shielding gas, by covering the
pool with an inert slag or a combination of both actions. As welding progresses along the joint, the weld pool solidifies
fusing the parent and weld metal together. Several passes or runs may be required to fill the joint or to build up the
weld to the design size
Assembly and welding requires skilful operatives and will generally be the largest element of the fabrication costs.
Welding requires the steelwork contractor to have in place a welding quality management system to BS EN ISO
3834[7] under the control of a Responsible Welding Coordinator. CE marking of fabricated steelwork to BS EN
1090-1[8] requires the steelwork contractor to have in place a certified Factory Production Control system in line with
BS EN 1090-1[8] which is supported by the European standard for Execution of steelwork, BS EN 1090-2[9].
Manual Metal Arc welding (MMA)
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MMA or Shielded metal arc welding is used to temporarily join or tack weld components during fabrication prior to full
strength welding. Shielded metal arc welding employs a "Stick" type electrode covered with a flux coating. The
electrode is brought into contact with the work piece and an electric arc between the electrode tip and the work piece
is struck. The flux coating on the welding rod is heated to a gas and liquid. This shields the molten puddle from the
atmosphere, hence its name - Shielded metal arc welding.
Manual Metal Arc welding (MMA)
Metal Active Gas welding (MAG)
MAG Welding
Metal Active Gas (MAG) is used for continuous welding. MAG welding employs a continuous solid wire electrode
carrying current. This is supplied by a power source and fed through a "Gun" by a roller wire-feeder. An arc is struck
between the continuous metal electrode and the steel work piece this effectively melts the two together. The molten
weld pool is protected from atmospheric oxidation by a gas shield (formed from an Argon and Carbon Dioxide
mixture).
Metal Active Gas welding (MAG)
Submerged Arc Welding (SAW)
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Minimal PPE required for SAW welding

(Image courtesy of Mabey Bridge Ltd.)
For welding long pieces of steel together to fabricate structural sections, submerged arc welding is used. In
Submerged arc welding a power current is applied to a continuous wire electrode. This is generally much larger
diameter than in MAG welding. The arc is struck when the wire electrode contacts the work piece. Protection of the
weld is provided by slag, formed by the action of the arc on a powder covering the whole weld reaction area. The arc is
"Submerged" under the powder.
Submerged Arc Welding (SAW)
Non Destructive Testing (NDT)
Non destructive testing is carried out to ensure that welds are free from unacceptable defects such as cracks and
inclusions. The main NDT techniques are magnetic particle inspection (MPI), and ultrasonic testing. MPI utilises a
magnet and a magnetic liquid on the surface of the weld, and ultrasonic testing involves sending sound waves through
the weld and interpreting the resulting echo pattern on an oscilloscope
Non Destructive Testing (NDT)
Coating
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Coating application in the fabrication factory

(Image courtesy of Hempel UK Ltd.)
The application of paint coatings or hot dip galvanizing to the steelwork is carried out (if required) at the end of the
fabrication process. Paint coating systems are generally applied in the fabrication factory to reduce site activity times
and make significant cost savings. In addition to adding any aesthetic finish specified by architects, coatings are also
widely used to provide corrosion protection, and fire resistance in the case of intumescent coatings.
Coating application
Generally, the emphasis for buildings is on simple systems that are easy to apply involving spray application after
automatic blasting. Many fabrication facilities have internal atmospheres that enable the steel to be blast cleaned
before fabrication and surface coated afterwards. In such cases, the weld areas would require further surface
preparation before coating, and components that are not too bulky can be re-blasted by passing them through the
automatic blasting machine on a conveyor. Larger components would have to be manually blasted. To minimize this
double handling, it makes economic sense to keep some components with no welding as these would not require re-
blasting before coating application.
Access for painting is difficult for double angle or double channel members and these types of elements have now
been largely superseded by using Square Hollow Section (SHS) / Rectangular Hollow Sections (RHS) members that
reduce the painted area and provide fewer locations for corrosion traps to form.
Accuracy
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Modern steel fabrication involves the manufacture of large and often complex welded assemblies of rolled steel
products. High temperature processes are used to make the steel products, to form the components and to join them
together, so dimensional variation resulting from distortion is inherent and unavoidable.
Dimensional variation is significant in a number of ways, for it involves structural steelwork manufactured remote from
the site, civil engineering works at the site, and sometimes even precise mechanical components. These interface with
each other and yet their precision varies from the high accuracy of mechanical components to the approximation
inherent in placing concrete.
For each new project, the steelwork contractor will assess the design to determine how best to undertake the
fabrication to control dimensions and achieve the required accuracy of steel fabrication to ensure proper fit-up and
assembly at site.
A thorough understanding of the causes of fabrication distortion, and experience in the control and correction of
distortion allows the Steelwork Contractor to work within standard fabrication tolerances, such as those defined in the
NSSS. For particularly complex fabrications, trial erection can be carried out to ensuring that fit-up and geometry can
be achieved at site, so reducing the risk of delays in erection or damage to protective treatment. However, with the
much-improved accuracy achieved by automated fabrication procedures, the need for trial erection has been much
reduced.
Handling and transportation
Handling steelwork in the factory

(Image courtesy of Mabey Bridge Ltd.)
The means of handling and manipulating steelwork within a Steelwork Contractors factory has developed over time to
suit their particular operations. However, it generally involves the use of computer controlled conveyor systems and
overhead gantry cranes running on either rails on the floor, or crane girders attached to the steel frame of the
fabrication factory. Steel elements may be picked up using chains or strops, or temporary lifting brackets can be
welded on to facilitate the use of hooks. BCSA have published several health & safety guides to assist steelwork
contractors with the handling and transportation of steelwork, including:
Health and Safety in the Workshop for Employees: A Guide for Steelwork Contractors,
Guide to Work at Height during the Loading and Unloading of Steelwork
There are three regimes for the transportation of steelwork on the UK road network:
Normal loads
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Abnormal loads
Special order
Normal loads
Vehicles with rigid vehicle length less than 18.65 m, width less than 2.9 m, gross weight less than 44 tonnes, with no
axle weight over 11.5 tonnes, and overall height less than 4.95 m can travel anywhere at any time, except where the
route includes an underbridge with weight restriction or an over-bridge with height restriction. In the case of
transportation of bridge girders, rigid vehicle length is usually the girder length. Although the height limit is 4.95 m, the
trailer bed is usually about 1.7 m high so that leaves only 3.25m for the load above.
Abnormal loads
Transporting steelwork by road

(Image Courtesy of Mabey Bridge Ltd.)
Certain vehicles that exceed the above normal limits are covered by a section of the Road Traffic Act 1988, entitled
Road Vehicles, (Authorisation of Special Types) (General) Order. The latest Order is SI 2003 No.1998[10]. The
letters STGO, which are displayed on the tractor unit of most abnormal loads, are an abbreviation for this section of
the Act.
There are three categories of STGO vehicles, each with different weight limits, but all three have a maximum vehicle
length of 30m and width of 5m. Each police authority on the planned route has to be notified at least 2 days in
advance, and it is also necessary to notify bridge owners on the route if the weight exceeds 44 tonnes.
Often the police will not insist on escorting loads that are long and not wide as these cause far fewer manoeuvrability
problems. Even with wide loads the number of times the police insist on escorting them has reduced since the
Department of Transport introduced the 'Code of Practice: Lighting and Marking for Abnormal Load Self escorting
vehicles incorporating Operating guidance[11]. Where the police do insist on escorting loads, the notification / escort
arrangements must be separately agreed with every police force en route. It is not unknown to be taken so far by one
force then held for hours if the next force has an emergency that intervenes. Some forces also have restrictions on the
timing of escorted loads, so delivery from works to site can be unpredictable, which may have implications in the
timing of critical lifts.
Special order
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If the vehicle and load to be moved fall outside the STGO categories it is still possible to move, but approval must be
gained from the Highways Agency (or the Scottish Executive or Welsh Assembly Government) in the form of a VR1
Permit or a Special Order. All details of the load must then be notified to the Highways Agency, together with precise
dispatch and delivery points. At least three months should be allowed between the first application for such a permit or
order and the anticipated date of the actual movement.
A Special Order details the approved route and must be followed exactly. Special Orders are usually valid for 6
months. The specified notice must be given to each police region for the actual movement and to the relevant bridge
owners on the route.
Clearly it is advantageous for designers to consider transportation when determining element sizes, and preferably
limit the length and width of elements such that they comply with the normal load rules. However, transportation of
larger fabrications is commonplace under the abnormal load rules, and specialist bridgeworks fabricators are
experienced in the movement of very long girders using special orders.
Further guidance on the transport of steelwork by road is available in GN 7.06
Specification
National Structural Steelwork Specification (6th Edition)
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It is important that the steelwork specification (and accompanying drawings) for a project should express clearly the
particular requirements for a structure and, where standards allow options and alternatives, which additional
requirements apply. Failure in clarity will lead to extra provisions for risk and extra costs in resolving queries. The
project specification should also avoid over-specification - requiring unnecessary quality and excessively tight
tolerances will lead to higher costs. The project specification should generally follow recognized industry standards,
such as the National Structural Steelwork Specification, and the Specification for Highway Works[12].
Quality management
The steel construction industry and supply chain are able to call upon members of the BCSA and their inherent
qualities of competency and professionalism, all demonstrated by among other things, the following:
BCSA membership assessment requirements

Register of Qualified Steelwork Contractors for Bridgeworks (RQSC)
Steel Construction Certification Scheme (SCCS)
CE Marking
Steel Construction Sustainability Charter (SCSC)
Steel Construction Building Information Modelling (BIM) Charter
BCSA Steelwork Contractor membership
The BCSA membership assessment and RQSC for Bridgeworks requirements are more than just registers of
companies selected from a tick list. Each company only qualifies for inclusion on the lists after being assessed by
specialists who check financial, technical, and health & safety resources as well as track record and employed
personnel. The assessments are carried out annually with a physical factory inspection every three years. The result is
three criteria:
Categorisation of the company in terms of the work it can execute technically

Classification of the company in terms of the maximum size of contract it should handle
Safety Schemes in Procurement (SSIP) minimum health and safety criteria
The assessments provide clients with an easy way to pre-qualify steelwork contractors for buildings and bridges
before contracts are tendered. This ensures that the successful steelwork contractor has the special skills to suit the
project, and helps the client to fulfill the regulatory duty only to use competent contractors.
The categories of work are general and the precise scope of work demanded by each project will differ. Thus, the first
priority for competent contractors is to ensure that the scope of work can be safely undertaken with the resources of
know-how, manpower, equipment and finance at their disposal. For this purpose two checklists of competences are
available:
Normal scope of competence for activities that steelwork contractors should be competent to undertake with
their own personnel
Special scope of competence for activities that steelwork contractors should be able to manage using
specialist subcontractors as necessary
Having checked at tender stage what a project demands, steelwork contractors should warn their clients if they are
unable to undertake any of the normal activities, and their clients should check beforehand whether a steelwork
contractor is willing to undertake any of the special activities.
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The BCSA membership assessment also include the stage 1 health and safety assessment and gives members
mutual recognition of the Safety Schemes in Procurement (SSiP).
A separate Register operates to cover bridgeworks. Highways England includes in its Specification for Highway
Works[12] a requirement that only firms listed on the Register of Qualified Steelwork Contractors for Bridgeworks
(RQSC) for the type and value of work to be undertaken will be employed for the fabrication and erection of
bridgeworks.
Steelwork contractors can be sourced according to the required project Class and Category on
www.steelconstruction.org/directories
Steel Construction Certification Scheme
The Steel Construction Certification Scheme (SCCS) is a wholly owned subsidiary of The BCSA and provides a
Quality Management Systems certification service for steelwork contracting organisations. SCCS has developed
additional certification and monitoring services for the steelwork contractors with integrated or separate Environmental
and Health & Safety management systems.
Quality Management System Certification (QM)
Quality management systems operated by the certified contractors are formally assessed to ensure compliance with
the requirements of BS EN ISO 9001[4]. Each certificate is valid for three years during which period SCCS conducts
interim surveillance audits to monitor continued compliance with the certified management system.
Environmental Management System Certification (EM)
Environmental management systems operated by the certified contractors are formally assessed to ensure
compliance with the requirements of BS EN ISO 14001[13]. Each certificate is valid for three years during which period
SCCS conducts interim surveillance audits to monitor continued compliance with the certified management system.
Occupational Health and Safety Management System Certification (HSM)
Occupational health & safety management systems operated by the certified contractors are formally assessed to
ensure compliance with the requirements of BS OHSAS 18001[14]. Each certificate is valid for three years during which
period SCCS conducts interim surveillance audits to monitor continued compliance with the certified management
system.
CE Marking and Factory Production Control (FPC)
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CE marking is an audited and tested declaration that a product meets specific public safety requirements and
specifications throughout the supply chain, and is legal requirement of the Construction Products Regulation[15]. SCCS
provide certification of factory production control, bolting and welding systems to enable companies to carry out CE
marking.
FPC systems operated by the certified steelwork contractors are formally assessed to ensure compliance with the
requirements of:
BS EN 1090-1[8] for structural steel
BS EN 14399-1[16] for high strength structural bolting assemblies
BS EN 15048-1[6] for non-preloaded structural bolting assemblies
Each certificate is valid for three years during which period SCCS conducts interim surveillance audits to monitor
continued compliance with the certified FPC system.
National Highway Sector Schemes (NHSS)
SCCS has been accredited by UKAS to carry out assessments against:
NHSS 3 [17] The stocking and distribution activities for mechanical fasteners
NHSS 19A[18] For corrosion protection of ferrous materials by industrial coatings
NHSS 20[19] The execution of steelwork in transportation infrastructure assets
Each certificate is valid for three years during which period SCCS conducts interim surveillance audits to monitor
continued compliance with the certified NHSS.
Steel Construction Sustainability Charter
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The objective of the Sustainability Charter (SCSC) is to develop steel as a sustainable form of construction in terms of
economic viability, social progress and environmental responsibility. BCSA has three levels of status in the Charter i.e.
Member, Silver and Gold, the status achieved depends on the number of points scored following audit. BCSA requires
Charter Members to formally declare to operate in sustainable ways that work towards: adding value to clients and
stakeholders; optimising the eco-efficiency of steel construction life cycle; promoting resource and energy efficiency in
steel construction through reuse and multi cycling; operating in a healthy, safe and environmentally sound manner;
promoting respect for people and communities associated with steel construction; having high ethical standards;
implementing sustainable development by constructive dialogue and enhancing knowledge of sustainability to share
with and promote others in. the steel construction supply chain also to implement. Benchmarking key performance
indicators (KPIs) are being developed by the BCSA, not only to measure the progress of sustainable development in
steel construction but to demonstrate genuine commitment.
Steel Construction Building Information Modelling (BIM) Charter
BIM model
(Image courtesy of S.H.Structures Ltd.)
The UK Governments requirement for Level 2 BIM on all central government projects means the construction industry
wants to know which suppliers are BIM compliant. BCSA steelwork contractors are now able to demonstrate
compliance with Level 2 Building Information Modelling (BIM) with the launch of the Steel Construction BIM Charter,
and can now be certified against the requirements of both PAS 91[20] and PAS 1192-2[21] as outlined below.
Compliance with PAS 91[20] section 4.2 table 8, and specifically that:
The company has the capability of working within a project using a Common Data Environment as described
in PAS 1192-2[21].
The company has a documented policy, systems and procedures to achieve Level 2 BIM maturity as defined
by PAS 1192-2[21].
The company has the capability of developing and delivering or working to (depending upon the role(s)) a BIM
Execution Plan (BEP) as described in PAS 1192-2[21].
The company has arrangements for training employees in BIM related skills and assessment of their
capabilities.
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Compliance with the supply chain assessment requirements outlined in PAS 1192-2[21] and specifically defined in
sections:
6.4 Suppler BIM assessment form

6.5 Supplier information technology (IT) assessment form
6.6 Supplier resource assessment form
The certification process requires companies to carry out an online assessment, which is then followed up by an onsite
audit. Certified companies are provided with a comprehensive document summarising the companys BIM capability,
which they can then provide to the supply chain.
The BCSAs online directories mean clients and main contractors can see which companies have been assessed
against the BIM Charter, with the Charter providing a simple way to prequalify steelwork contractors as BIM
compliant.
Health and safety
Automated sawing & drilling machine
Working on construction sites means that lots of people and equipment have to be provided with temporary access
especially for working at height. The steelwork is pre fabricated in factories which significantly reduces the on site
work especially the work at height as the steel components only need to be assembled.
The use of automated and semi-automated multi-function machines that cut, drill and mark the steelwork reduces the
number of people involved in the process and the need to handle the steel i.e. turning and repositioning is reduced.
These processes also reduce the risk of error and the need for re work to take place on site where even minor
alterations may need lots of additional access or plant and equipment to be mobilized.
Generally the fabricated item moves through the production area until completed and then stored. On construction
sites the equipment (often temporary) has to be brought to the final position of the item and then moved each time, all
of which increases risk of incidents as lots more moving and repositioning needs to take place.
Working within a factory eliminates any health and safety issues concerned with adverse weather conditions and
production can continue. This also gives additional advantage for longer hours of production including night shift work
if necessary, all of this in a controlled environment with no disruption to the local communities.
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Pedestrian access and egress is controlled by permanent marked routes which are separate from the vehicular routes.
Loading and unloading of steelwork is carried out in designated areas with the appropriate access and lifting
equipment.
The systems used to programme the production of fabricated steelwork mean that the work can be packaged, this
enables the deliveries to site to be managed in such a way that offloading can be direct to the final position. This
reduces site storage and minimizes lifting and handling where most risks of incidents and injuries can be presented.
24 / 27
References
1. BS EN 10025-2:2004, Hot rolled products of structural steels. Technical delivery conditions for non-alloy
structural steels, BSI
2. BS EN 10210-1:2006, Hot finished structural hollow sections of non-alloy and fine grain steels. Technical
delivery requirements, BSI
3. BS EN 10219-1:2006, Cold formed welded structural hollow sections of non-alloy and fine grain steels.
Technical delivery requirements, BSI
4. 4.04.1 BS EN ISO 9001:2015, Quality management systems Requirements, International Organization for
Standardization
5. BS EN 14399-1:2015, High-strength structural bolting assemblies for preloading (Various Parts). BSI
6. 6.06.1 BS EN 15048-1:2016, Non-preloaded structural bolting assemblies. General requirements. BSI

7. BS EN ISO 3834:2005, Quality requirements for fusion welding of metallic materials (Various Parts). BSI
8. 8.08.18.2 BS EN 1090-1:2009+A1:2011, Execution of steel structures and aluminium structures. Requirements

for conformity assessment of structural components, BSI
9. BS EN 1090-2:2008+A1:2011, Execution of steel structures and aluminium structures. Technical
requirements for steel structures, BSI
10. Road Vehicles (Authorisation of Special Types) (General) Order, 2003, Statutory Instruments 2003 No.
1998, The Stationery Office Limited
11. Code of Practice Lighting and Marking for Abnormal Load Self escorting vehicles incorporating Operating
guidance, 2016, (Publications Code PR152/15 ), Highways England
12. 12.012.1 Manual of Contract Documents for Highway Works (MCHW). Volume 1: Specification for Highway
Works. Series 1800 Structural Steelwork. August 2014, TSO
13. BS EN ISO 14001:2015 Environmental management systems - Requirements with guidance for use, BSI
14. BS OHSAS 18001:2007, Occupational health and safety management systems. Requirements, BSI
15. Construction Products Regulation (EU) No. 305/2011 of the European Parliament and of the Council of 9
March 2011, Official Journal of the European Union L88/5 4.4.2011
16. BS EN 14399-1:2015, High-strength structural bolting assemblies for preloading. General requirements, BSI
17. NHSS 3: National Highways Sector Schemes for Quality Management in Highway Works, 3. The Stocking
and Distribution Activities for Mechanical Fasteners, UKAS, Issue 1 (9001:2015), July 2016
18. NHSS 19A: National Highways Sector Schemes for Quality Management in Highway Works, 19A. For
corrosion protection of ferrous materials by industrial coatings. UKAS, Issue 3 (9001:2015), June 2017
19. NHSS 20: National Highways Sector Schemes for Quality Management in Highway Works, 20. The
Execution of Steelwork in Transportation Infrastructure Assets, UKAS, Issue 2 (9001:2015), December 2016
20. 20.020.1 PAS 91:2013 Construction prequalification questionnaires, BSI
21. 21.021.121.221.321.4 PAS 1192-2:2013 Specification for information management for the capital/delivery phase of
construction projects using building information modelling, BSI
Resources
National Structural Steelwork Specification (6th Edition), Publication No. 57/17, BCSA 2017
Steel Buildings, 2003, (Publication No. 35/03), BCSA
Chapter 9: Welding
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Chapter 10: Bolting

Chapter 11: Fabrication
Chapter 15: Specification and Quality
Design for Manufacture Guidelines (P150), 1995, SCI
Steel Bridges: A practical approach to design for efficient fabrication and construction, 2010, (Publication no.
51/10), BCSA
Chapter 4 Bolting
Chapter 5 Welding
Chapter 6 Accuracy
Chapter 7 Costs
Allocation of Design Responsibilities in Constructional Steelwork, 2007, (Publication no. 45/07), BCSA
Model Specification for the Purchase of Steel Sections and Plates, 2011, BCSA
Model Specification for the Purchase of Structural Bolting Assemblies and Holding Down Bolts, 2011, BCSA
Health and Safety in the Workshop for Employees: A Guide for Steelwork Contractors, 2009, (Publication no.
49/09), BCSA
Guide to Work at Height during the Loading and Unloading of Steelwork, 2007, (Publication no. 43/07), BCSA
Normal scope of competence, BCSA
Special scope of competence, BCSA
Design of curved steel (P281), 2001, SCI
Hendy, C.R.; Iles, D.C. (2015) Steel Bridge Group: Guidance Notes on best practice in steel bridge
construction (6th Issue). (P185). SCI
Guidance Note 4.02 Weld procedure tests
Guidance Note 5.01 Weld preparation
Guidance Note 5.02 Post-weld dressing
Guidance Note 5.03 Geometrical tolerances
Guidance Note 5.04 Plate bending
Guidance Note 5.05 Marking of steelwork
Guidance Note 5.06 Thermal cutting of structural steels
Guidance Note 5.07 Straightening and flattening
Guidance Note 5.08 Hole sizes and positions for preloaded bolts
Guidance Note 5.09 The prefabrication meeting
Guidance Note 6.01 Control of weld quality and inspection
Guidance Note 6.02 Surface inspection of welds
Guidance Note 6.03 Sub-surface inspection of welds
Guidance Note 6.04 Hydrogen / HAZ cracking and solidification cracking in welds
Guidance Note 6.06 Visual inspection after welding
Guidance Note 7.06 Transport of steelwork by road
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Further reading
Steel Designers Manual (7th Edition), 2012, Chapter 33 - Fabrication, The Steel Construction Institute.
See also
Welding
Accuracy of steel fabrication
CE marking
Corrosion protection
Steelwork specification
Health and safety
External links
Safety Schemes in Procurement (SSIP)
Steel Construction Certification Scheme (SCCS)
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SteelConstruction.

Design for economic fabrication

Diagonal steel bracing Silverstone

Single square end cuts

Holes in flanges and webs aligned where possible

Tubular steelwork at the National Football Centre

Quality of engineering and documentation

BCSA publication Steel Buildings, Chapter 11 - Fabrication

Materials and components

Sections and plates

A stockholders external facility

(Images courtesy of Kloeckner

Purlins and side rails on a portal frame

Fully automated saw / drill line

Cutting & drilling

Gas or flame cutting

Drilling and punching

Drilling and punching

Curved steelwork at Hayes Garden Centre

(Image courtesy of Kloeckner Westok)

Profiling of tubular sections

Main article: Welding

Manual Metal Arc welding (MMA)

Manual Metal Arc welding (MMA)

Metal Active Gas welding (MAG)

Metal Active Gas welding (MAG)

Submerged Arc Welding (SAW)

Minimal PPE required for SAW welding

Submerged Arc Welding (SAW)

Non Destructive Testing (NDT)

Non Destructive Testing (NDT)

Coating application in the fabrication factory

Handling and transportation

Handling steelwork in the factory

Transporting steelwork by road

Further guidance on the transport of steelwork by road is available in GN 7.06

National Structural Steelwork Specification (6th Edition)

BCSA membership assessment requirements

BCSA Steelwork Contractor membership

Categorisation of the company in terms of the work it can execute technically

Steel Construction Certification Scheme

Quality Management System Certification (QM)

Environmental Management System Certification (EM)

Occupational Health and Safety Management System Certification (HSM)

CE Marking and Factory Production Control (FPC)

BS EN 1090-1[8] for structural steel

BS EN 14399-1[16] for high strength structural bolting assemblies

BS EN 15048-1[6] for non-preloaded structural bolting assemblies

National Highway Sector Schemes (NHSS)

SCCS has been accredited by UKAS to carry out assessments against:

NHSS 19A[18] For corrosion protection of ferrous materials by industrial coatings

NHSS 20[19] The execution of steelwork in transportation infrastructure assets

Steel Construction Sustainability Charter

Steel Construction Building Information Modelling (BIM) Charter

6.4 Suppler BIM assessment form

Health and safety

Automated sawing & drilling machine

6. 6.06.1 BS EN 15048-1:2016, Non-preloaded structural bolting assemblies. General requirements. BSI

8. 8.08.18.2 BS EN 1090-1:2009+A1:2011, Execution of steel structures and aluminium structures. Requirements

20. 20.020.1 PAS 91:2013 Construction prequalification questionnaires, BSI

Chapter 10: Bolting

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