BC 1: 2008 Explanatory Notes for BC 1: 2008 1.0 Overview ‘These explanatory notes explain in details the various design procedures which can be adopted during the design stage and their design implications based on the recommendations given in BC 1: 2008. 2.0 Design procedure ‘Tho design procedure is essentially based on the classification approach which consists of both adequacy assessment and reliability assessment of the steel materials to be used in design to BS 5950. The design implication of each class is summarised in Figure I. ‘The differences between adequacy assessment and reliability assessment are given in Table I. Option 1: Certification (BS/EN, APUASTMIAWS, JIS, AS/NZS and GB) Select certified steel materials from Appendix A (6f BC 1: 008) Option 2: Material testing (2on-BSIEN, APIASTMIAWS, JIS, AS/NZS and GB") Engage an accredited laboratory to conduct material testing in accordance to Appendix B Gf BC 1: 2008) and show that the steel materials are in conopliance with all the Design calculation \ relevant requirements given in Seotion 2 (of BC 1: 2006) Reliability assessment Factory production control certification Obtain a validated copy of the valid FPC certificate Manufacturer test certification Obtain an authenticated manufacturer teat certificate (or ite validated copy) and verily the compliance of the steel materials delivered to the specifications Material dslivery stage 38 1~ passing adequacy assessment (certification) and reliability assessment ss 2 ~ passing adequacy assessment (material testing) and reliability assessment 12 3 other than Class 1 and Class 2 Figure I — Classification of alternative steel materials ‘Table I — Comparison of adequacy assessment and reliability assessment Adequacy assessment Reliability assessment 1. Requirements to | Material performance requirements, | Quality assurance requirements, as meet as given in Section 2 (of BC 1: 2008) | given in Section 3 (of BC 1: 2008) 2 Object of Steel materials to be used in design | Both the steel materials and their assessment to BS 5950 in Singapore manufacturers ‘3, Mode of assessment | Certification or material testing Factory production control certification and material test certification © 02-2008 BCA Explanatory Notes 1BC 1: 2008 2.1 Adequacy assessment ‘The first step in the classification approach involves the adequacy assessment, i.e. verification of material adequacy against the material performance requirements given in Section 2 (of BC 1: 2008). Two modes of adequacy assessment are possible, namely certification and material testing, as further explained in 2.1.1 and 2.1.2, respectively. ‘The differences in implementing these two modes of assessment are given in Table II. 2A Certification Certification is the process of rigorous evaluation of the material specifications given in the British/European, American, Japanese, Australian/New Zealand and Chinese material standards, against the essential material performance requirements in Section 2 (of BC 1: 2008). A list of certified steel materials, which contains those materials with their specifications complying with the relevant material performance requirements, is derived for the convenience of the users of BC 1: 2008. ‘The use of any steel material from this list of certified steel materials shall be considered as meeting the relevant material performance requirements given in Section 2 (of BC 1: 2008) and passing the adequacy assessment. Action to be taken by QPs or his representatives: During the design stage, QPs shall select the steel material from the list of certified steel materials given in Appendix A of BC 1: 2008, QPs shall carry out the design and calculation using the design parameters recommended in 4.1 of BC 1: 2008, assuming the materials will be sourced from manufacturers who can meet the quality assurance requirements as well. 21.2 Material testing Material testing is the process of demonstrating the adequacy of non-certified steel materials outside those considered in 2.1.1 during the design stage, through appropriate sample testing and test method as given in Appendix B of BC 1: 2008, Such testing for the purpose of adequacy assessment during the design stage shall not exempt the purchasers from performing the obligatory inspection and testing in accordance with appropriate rogulations during contract execution stage. ‘Test reports from accredited laboratory under the Singapore Laboratory Accreditation Scheme (SINGLAS) or other laboratory accredited under a mutual recognition agreement with SINGLAS are required to prove that such materials are able to comply with all the relevant material performance requirements given in Section 2 (of BC 1: 2008). When the limiting values are not given in Section 2 (of BC 1: 2008), linear interpolation shall be allowed to determine the limiting value for the test parameters of interest. Action to be taken by QPs or his representative: During the design stage, QPs shall engage an accredited laboratory to conduct material sample testing in accordance to Appendix B of BC 1: 2008 and submit a test report containing necessary information (Gee Table IT) to show that the materials are in compliance with all the relevant material performance requirements given in Section 2 of BC 1: 2008. QPs shall carry out the design and calculation using the design parameters recommended in 4.2 of BC 1: 2008, again assuming the materials will be able to meet the quality assurance requirements as well. Explanatory Notes © 02-2008 BCA 2BC 1: 2008 ‘Table II — Comparison of certification and material testing as mode of adequacy assessment Certification Material testing 1. Party to take action BCA (action already taken) QPs (action to be taken) 2. Steel materials covered Certified steel materials, as given in Appendix A (of BC 1: 2008) Any steel materials not listed in Appendix A (of BC 1: 2008) manufactured to material standards which are current and confirmed, regardless of the country or region of origin 3. Condition to pass the assessment QPs are to select steel materials from the list of cortified steel materials given in Appendix A (of BC 1: 2008) QPs are to engage an accredited laboratory to conduct material testing in accordance to Appendix B (of BC 1: 2008) and show that the steel materials are in compliance with all the relevant requirements given in Section 2 (of BC 1: 2008) Class 2, if also pass the reliability assessment, 4, Class of material, if pass the assessment Class 1, if also pass the reliability assessment 5. Class of material, if fail the assessment Class 3, and review design Class 8, and review design 2.2 Reliability assessment ‘The second step in the classification approach involves the reliability assessment, ie. verification of material reliability against the quality assurance requirements given in Section 8 (of BC 1: 2008). Reliability assessment to ensure the steel materials are manufactured under stringent quality assurance system shall meet the quality assurance requirements given in Section 8 (of BC 1: 2008). It shall be noted that failure in the reliability assessment shall result in the downgrading of material class to Class 3. Notes on the implementation of reliability assessment, namely factory production control certification and manufacturer test certification are given in 2.2.1 and 2.2.2. Implementation of reliability assesement are summarised in Table IV. 221 Factory production control certification ‘The manufacturers shall have a factory production control (FPC) system attested by an independent third- party certification agency acceptable to or recognised by BCA (see Annex B for the list of certification agencies acceptable to BCA and a sample of FPC certificate). Valid FPC certificates issued by the certification agency upon successful first and annual inspections shall bbe produced by the manufacturers as an indicator of a FPC system acceptable to BCA. General requirements on FPC are given in 8.1 (of BC 1: 2008). It shall also be noted that:- - 180 9001 certificate for quality management system is complimentary, however, it is regarded as insufficient to demonstrate reliability of the FPC system for manufacturers in a production environment; - _ FPC certificates shall form the acceptable indicator for an attested production control system in manufacturing a particular type of steel materials (see Section 2 of BC 1: 2008 for the nine types of steel materials and a sample FPC certificate in Annex B of these notes); FPC certificates to manufacture BS EN steel materials under the European Union Construction Directives or API Monograms, both which are already widely recognised in the Buropean market and the oil and gas industry respectively, shall be considered ‘acceptable in lieu’. The FPC system of such manufacturers in manufacturing the particular type of steel materials shall be considered already attested. © 02-2008 BCA Explanatory Notes 3BC 1: 2008 Action to be taken by QPs or his representatives: Upon confirmation of the source of the steel materials, QPs shall evaluate the validated copy of the valid FPC certificate, obtained either directly from the manufacturer or through the stockist or trader. ‘The document mentioned shall also be made available for subsequent inspection by BCA, if required, 222 Manufacturer test certification ‘The manufacturers shall issue an authenticated test certificate for every batch of steel materials delivered as a form of quality assurance on the steel materials. ‘Mandatory information on test results (as per 8.2.5 of BC 1: 2008) corresponding to different type of steel materials is summarised in Table IIL. Tt shall also be noted that:- - use of the test results of feedstock materials, if any, shall be clearly indicated; + actual quantity of steel materials purchased from the stockist or trader shall be clearly indicated and the validated copy of the authenticated test certificate corresponding to the steel materials delivered shall be given to the purchaser. ‘Table III — Mandatory test results to be indicated on manufacturer test certificate ‘Type of steel materials Mandatory test results «Steel plates = Yield strength? * Hot rolled sections + Tensile strength? = Hollow sections = Elongation after fracture? * Steel for cold forming! + Impact energy + Chemical content!, based on ladle or product analysis, of| carbon, sulphur, phosphorous, silicon, manganese, copper, chromium, molybdenum, nickel, aluminium, niobium, titanium, vanadium, nitrogen and any other element intentionally added * Carbon equivalent value computed based on equationt: CHV 00) = 40+ 2M, HCE+HMO+BV , %Cu+ HN: 6 5 5 + Non-preloaded bolting + Yield strength (bolts) eal + Tensile strength (bolts) * Preloaded bolting assem Elongation after fracture (bolts) ‘+ Hardness (bolts, nuts and washers) Proof load stress (nuts) + Chomical content, based on product analysis, of carbon, sulphur and phosphorous (bolts and nuts) = Welding consumables = Yield strength Tensile strength "Elongation after fracture Impact energy Explanatory Notes 02-2008 BCA, 4BC 1: 2008 ‘Type of steel materials Mandatory test results «Profiled steel sheets «Yield strength * Tensile strength intentionally added * Chemical content, based on ladle or product analysis, of carbon, sulphur, phosphorous, silicon, manganese, copper, chromium, molybdenum, nickel, aluminium, niobium, titanium, vanadium, nitrogen and any other element + Stud shear connectors «Yield strength = Tensile strength "Elongation after fracture Action to be taken by QPs or his representatives: Upon confirmation of the source of steel materials, QPs shall evaluate sample copy of manufacturer test certificate, obtained directly from the manufacturer or through the stockist or trader. Upon delivery of the steel materials to the site, QPs to inspect and confirm that all the mandatory information are indicated on the actual certificate. The document shall also be made available for inspection by BCA, if required. ‘Table IV — Comparison of implementation of factory production control certification and manufacturer test certification in reliability assessment Factory production control (EPC) certification Manufacturer test certification QTC) 1, Requirements to Factory production control, as given ‘Manufacturer test certificates, as meet in 8.1 (o£ BC 1: 2008) and attestation | given in 8.2 (of BC 1: 2008) checklist. 2. Object of ‘The manufacturers of steel materials | The steel materials assessment 3. Certificate to be produced by the manufacturers ‘A valid factory production control (FPO) certificate issued by certification agency acceptable to or recognised by BCA "A sample test certificate + An authenticated test certificate containing complete information for every batch of steel materials delivered 4, Valid coverage of the certificate ‘The production control and quality assurance provided by the ‘manufacturer in producing the particular type of steel materials Quality assurance on the particular batch of steel materials delivered Condition to pass the assessment QPs are to evaluate the certificate*, ‘upon confirmation of source of materials + @Psare to evaluate the sample certificate*, upon confirmation of source of materials + QPs are to evaluate the actual certificate’, which shall also specify the actual quantity of steel materials delivered “Validated copy of certificates shall be available for inspection © 02-2008 BCA Explanatory NotesBC 1: 2008 Factory production control | Manufacturer test certification (EPO) certification (urc) 6. Class of material, if pass both aseessments Class 1, ifpass the adequacy assessment through certification; Class 2, if pass the adequacy assessment through material testing fail at least one of the two assessments 7. Class of material, if | Class 3 2.3 Summary of design procedure Necessary actions to be taken by QPs and BCA during the various stages in the overall design procedure are summarised in Table V and Table VI. Table V— Actions to be taken by QPs and BCA for Class 1 steel materials Stage QPs BCA 1, Design calculation Select only certified steel materials from Appendix A of BC 1: 2008 Assume* materials to be Class 1 and adopt design parameters from 5.1 of BC 1: 2008 Submit the necessary design calculation as per normal ‘Evaluate and approve the submission 2, Material procurement Confirm the source of steel materials Obtain a validated copy of the valid FPC certificate Obtain a sample of manufacturer test certificate to ensure all mandatory information can be provided Keep copy of above document for inspection Check the certificate, if necessary Appoint a certification ‘agency to inspect the manufacturer (optional) 3. Material delivery Obtain an authenticated manufacturer test certificate (or its validated copy) and verify the ‘compliance of the steel materials delivered to the specifications Keep copy of above document for inspection Check the certificate, if necessary * Tt shall be noted that QPs can only assume that the materials will be Class 1 during the design calculation stage; it is therefore extremely important that QPs perform the necessary follow-up actions during the material procurement and delivery stages to confirm the materials to be Class 1 Explanatory Notes 6 © 02-2008 BCA.BC 1: 2008 ‘Table VI — Actions to be taken by QPs and BCA for Class 2 steel materials Stage QPs BCA 1, Design calculation = Engage an accredited laboratory to «Evaluate and approve the conduct sample material testing in submission accordance to Appendix Band show |» Request for test report that the steel materials are in from an independent compliance with all the relevant inspection agency requirements given in Section 2 (optional) = Assume* materials to be Class 2 and adopt design parameters from 5.2 of BC 1: 2008 = Submit a copy of the test report and the necessary design calculation as per normal 2, Material procurement |* Confirm the source of steel materials |* Check the certificate, if * Obtain a validated copy of the valid necessary FPC certificate + Appoint a certification = Obtain a sample of manufacturer test | ##eney to inspect the certificate to ensure all mandatory manufacturer (optional) information can be provided = Keep copy of above document for inspection 3. Material delivery ‘= Obtain an authenticated "Check the certificate, if manufacturer test certificate (or its necessary validated copy) and verify the compliance of the steel materials delivered to the specifications "Keep copy of above document for inspection It shall be noted that QPs can only assume that the materials to be Class 2 during the design calculation stage; it is therefore extremely important that QPs perform the necessary follow-up actions during the material procurement and delivery stages to confirm the materials to be Class 2 3.0 Alternative procedure In lion of the adequacy and reliability assessments recommended in 4.1 and 4.2 (of BC 1: 2008), a material performance-based assessment based on rigorous material testing and control might be appropriate, subject to case-by-case approval from BCA (under clause 4.4 special case of BC 1: 2008). If approved, the steel materials concerned may be treated as Class 2 materials if their adequacy and reliability can be guaranteed through rigorous control and testing plans of the materials delivery to site. As a minimum, such assessment shall include: + 100% material visual inspection and non-destructive testing to verify manufacturing tolerances; = 100% destructive testing for all batches and heat numbers (see Table III for tests required); = test reports from accredited laboratory; and + a material assessment report from an independent expert consultant, © 02-2008 BCA “Explanatory Notes 7BC 1: 2008 Annex A List of non-certified steel materials This list only covers non-certified steel materials manufactured to standards given in Appendix A of BC 1: 2008. Each material in this list is non-certified because of at least one or more of the following reasons: - A rena eo ew Strength: Out-of-range Ductility: Inadequate/Unspecified ‘Toughness: Inadequate/Unspecified Hardness: Inadequate/Unspecified Chemical composition: Non-permitted/Unspecified Manufacturing tolerance: Non-permitted/Unspecified Manufacturing process: Rimming steel Manufacturing process: Quenched & tempered steel Not applicable to structural use Al Non-certified British/European steel materials Material standard | Specification Specification 1. Steel plates 2 See = ees = S620QLi = 8335 + Be BSEN 10025-2:2004 [= E360 ma = S185 [= sep0qL_| = S690QLi = 845030 = $8909 = $8909 = S800QL + $800QL = S800QLi BSEN 10025-6:2004 [+ Ss90QLi Pseengll _ = S050e = $9609 +See. = $9600 2. Hot rolled sections a = E205 a. = 8335 ,2 #335 __i BS EN 10025-2:2004 [+ 360 BSEN 10025-2:2004 | = 360 _1 = S185 22 an * 845050 : 'S600MC BS EN 10025-6:2004 500g BS EN 10149.2:1996 'S650MC = S500QL. * aE = S500QLi - = $550Q, BS EN 10326:2004 = S5506D = S550QL, = S550QLi Explanatory Notes © 02-2008 BCA 8BC 1: 2008 A2~ Non-certified American steel materials Material standard | Specification Material standard | Specification 1._Stoel plates ASTM A 606-2001 . 7A = 83255 =B ASTMA792-2006a [+ $8275 ASTMA 285-200307) | 8 = 85 340 *D ASTM A 875-2006 + SS 330 ASTM A 514-2005 : = ST 2305 = 50 = ST 250L Sten taemeemae = 55 + ST 2551 - = 440 = ST 255. ASTM A 573-2005 ao ASTM A 1003-2005 = ST 275H = 60 = ST275L ASTM A 871-2001 +e SSrsior 2. Hot rolled sections an rs ‘+ HSLA 480 ASTM A 529.2005 a = HSLA-F 480 s + HSLA-F 550 '3._ Hollow sections = HSLAS 310 API 5L-2004 = PSLI + HSLAS 340 TA * HSLAS 380, ASTM A 53-2007 4 = HSLAS 410 * HSLAS 450 ‘ASTM A 268-2005a | * ASTM A 1011-2007 HISIAS a0 ASTM A 333-2005 : * SS 275 = 88310 ASTMA 425-1995(04) [+ = SS 340) maar * SS 380 +B = 8S 410 ASTM A 500-2007 a a8 =D = 88 550 ASTMA 501.2007 tA 5._ Non-preloaded bolting assemblies ASTM A 595-2006 : ASTM A 198-2007 : ala 1 : = Ib 2 ete I ASTM.A 194.2007 3 = UT 6 ‘ASTMA 847-2005 . "8 4, Steel for cold forming Bere Se Ronen i008 . ASTMA563-2007a [+ 853.B 75550 6._ Preloaded bolting assemblies ASTM A 308.2006 = 8558 "ASTM A 193-2007 7 Renta ce a0? = ASTM A 194-2007) + 2H © 02-2008 BCA ‘Explanatory Notes 9BC 1: 2008 ee A3 Non-certified Japanese steel materials Material standard | Specification Material standard | Specification 1._ Steel plates = STRB00 a = STici90 Sato + STK640. JIS G 8101: 2004 Se Gagne ae + STRR&OD Lee = STRR«90 = SMA005, BIS G 3475: 1996 pope 318 G 3106: 2004 SM4008 © SMi000 4._Steel for cold forming + SMA400AW7 = 5550 = SMAd00AP + $8400 i JIS G 3101: 2004 2 Sain = SMAsO0BP = SS540 JIS G 3114: 2004 + SMAdo0CW = SMA400A = SMA400CP JIS G 3106: 2004 = SMA008, = SMAA90AW = SM400 + SMAdQ0AP + SMAs00AW = SMABT0P SMAAO0AP. = SHY 685 = SMA4o0BW JIS G 3128: 1999 + SHY 68587 = SMAd00BP SHY G85NS, JIS G 3114: 2004 + SMAA000W7 = SPHC = SMA400CP JIS G 8131: 2005 SPHD + SMAd90AW SPHE + SMAASOAP. * SPHTT + SMAB70P : = SPHT2 JIS G 3136: 2005 + SNAO0A JIS G 3132: 2005 ~ Sere = SPHT 4 1 SGHe + SGH340 JIS G 3136 2005 + SN400A = SGHa00 2, Hot rolled sections + SGH4s0 = S350 + 80190 ao © SGH540 = SCC + 88490 see + S8540 JIS G 3302: 2005 Seoi0 = SGCDI 2. Shiau = SGCD2 JIS G 5106: 2004 = SMa008. = SM400C. 2 Ln + Sa0s40 + SMAs0oAW = SMA4O0AP 2 SGCA00) + SGC440 + SMA4ooBW + SGC490 + SMAd00BP Satie JIS G 3114: 2004 + SMAdo0CW = SMAs00CP 2 2660: * CGH + SMAA90AW seccay + SMA490AP = COCR = SMABTOP: JIS G 8812: 2005 See {IS G 3136: 2008 + SN400A + 6GC440 3,_ Hollow sections * CGC490 = oacari JIS G 3444: 2006 + STK290 . SeLRe = STK400 TTS ASITE ZONE Bxplanatory Notes © 02-2008 BCA 10BC 1: 2008 _———— ee Material standard | Specification Material standard | Specification = SeLio0 8._ Profiled steel sheets + SGLH490 ae = scacc + SGLH540 ee = SGCH BIS G 3302: 2005 = SGCDi = SGLCD = sacbe * SGLCA00 = SGCD3 = SGLC440) p = SGC5q0 + SGLC490 4 = SGLHC * SGLC570 a = SGLH400 = CGLCC, © SGLH440 = CGLCD, * CGLC400. 2 SGLIL90 JIS G 5322: 2005 aecie = SGLH540 JIS G 8921: 2005 = SGLCC = CGLCA90. = CaLCs70 Lt * SGLC400 2.8prt * SGLG440 JIS G 3352: 1979 = SDP2 = SDP en * SGLC570 Ad Non-certified Australian/New Zealand steel materials Material standard | Specification Material standard | Specification 1. Steel plates “AGN RT ASINZS 1594-2002 | +7490 N, RF ora 2, Hot rolled sections ASINZS 1694-2002 | « = 350 ASINZS 1679.1-1996 [+ 800 2 GA 220 Se ASINZS 1696-1998 FCA 260 4, Stool for cold forming = OW 800 AS 1597-2001 + 6500 + 300 = 6550 ASINZS 3678-1996 [= 350 + 5-490N oF A = 400 ee + 7-430 N, R, +450 ora, © 02-2008 BCA Explanatory Notes ulBC 1: 2008 _——— A.5 Non-certified Chinese steel materials Material standard | Specification Material standard | Specification 1, Steel plates = Q300A a oir 3908 = Q1957, QA208, = Q215AP 24208 = Q215AzZ a * Q215BF 0 GBIT 700-2006 = Q215BZ 38 = Q2a5aF 45 = Q235A7, see en 45Mn2 an 278M = Q275AZ wMnb, =a ae : = Q345A in GBIT 1591-1994 + Bes 20Cr = 420A a 35Cr 2. Hot rolled sections 40Cr = Qi05F 45Cr = Q1957 50Cr = Q215AP 3805: = Q215AZ 12CrMo = Q215BF GBIT 8162-1999 «aart 700-2006 Tg2i6Bz OCH = Q235AF '35CzMo = Q2a5Az, 42C:Mo = guEr 12CeMov : 12CrIMo¥ = Q275Az, '38CrMoAl = Q205A 50CrVA GBIT 1591-1994 1 Gada 20CMn = Q390A. 206/MnSi = Q420A '30CxMnSi 3, Hollow sections 35CrMnSiA_ IEF 20GMaT, + eieez 30CMa = Q215AF = Q215AzZ * s eat = 12CeNid + CHER = 40CeNiMOA GBIT 700-2006 = Q235AF oe © Q2554Z 4. Steel for cold forming = Q235BF = Quer Tearsar TeaisaF = Q215. = Q275AZ GBIT 700-2006 215BF = Q275 Bz, = Q235AF GBIT 1591-1994 = Q205A = Q235BF Qu0ss = Q2T5AF = Q3458 Explanatory Notes 2 (© 02-2008 BCA,BC 1: 2008 Annex B List of certification agencies acceptable to BCA Certification agencies in this list are considered acceptable to BCA. FPC certificate issued by any agency in this list is an attestation of a reliable FPC system adopted by the manufacturer in manufacturing a particular type of steel material. American Bureau of Shipping (ABS) ‘American Petroleum Institute (API) Bureau Veritas (BV) Det Norske Veritas (DnV) Germanischer Lloyd Lloyd's Register ‘Moody International Nippon Kaiji Kyokai (ClassNK) ‘TOV Rheinland See Figure II for a sample of FPC certificate required and the mandatory information to be indicated, © 02-2008 BCA Explanatory Notes 13BC 1: 2008 ® Factory Production Control Certificate to BC 1:2008 In compliance with the Factory Produstion Control requirements of ‘the Building and Construction Autherity, Singapore. This is to certify that the Factory Production Control system of: © Name of the manufacturer in the factory located at: © Address of factory has been assessed under the Factory Production Control requirements of BC 1:2008 and conforms toits requirements for the production of List of product standards and, if appropriate: + slaridard for manufacturing tolerances (cee Appendix A of BC 1:2008) e ‘additional provisions to which the product conforms particular conditions applicable to the use of the product (addendum sheet if necessary) Conditions and period of validity, where applicable This certificate is only valid when: Certificate no: BCI-1294.56789 Firstissue date: 21 February 2008 Currentissue date: 21 February 2008 @ Expiry date: 20 February 2011 7 Name and address ° fame and pdsition of the certification on behalf of agency name of the certification agency Figure II — Mandatory information, as numbered, for BC 1: 2008 FPC certificate (sample) Explanatory Notes © 02-2008 BCA. 4Use of Alternative Steel Materials to BS 5950 Presented by: Chiew Sing-Ping Nanyang Technological University (On behalf of: The Building and Construction Authority Content (1) = Overview — Alternative steel materials — Anew design guide = Major concerns = Adequacy — Reliability = Material performance requirements — Basic requirements — Additional requirements — Material-specific requirements — Certified steel materials Content (2) = Quality assurance requirements = Factory production control — Manufacturer test certificate — Implementation = Design procedures — Material classification — Design recommendations — Special case = Conclusions Alternative steel materials (1) ‘Alternative’ in Singapore's context... = not manufactured to BS/EN, but available = ASTM/API/AWS, JIS, AS/NZS, GB = not covered in BS 5950 by default = widely available, e.g. chinese steel materials = use to BS 5950 = design guidance neededA new design guide Objectives: * To allow wider choice of steel materials to achieve greater economy * To ensure product conformity, quality and traceability in materials from various sources Features: + allow the use of adequate & reliable alternative steel materials to ensure public safety + optimize the use of alternative steel materials (e.g. use full design strength) to make design more competitive + address the long-standing material quality and discrepancy problems facing the industry Major concerns... 2 major concerns over the ‘alternative’... = Adequacy Ability to meet material performance requirements = Reliability Ability to meet quality assurance requirements Hence... we only want steel materials which are both adequate and reliable! Adequacy Material performance requirements: = Essential requirements on the mechanical, physical, chemical, dimensional and/or other relevant properties of alternative steel materials = Derived based on relevant BS/EN = Material-specific, i.e. different sets of requirements for 9 different categories of steel materials Reliability Quality assurance requirements: = Requirements for the manufacturers to provide sufficient assurance to ensure the compliance of the alternative steel materials with their nominal specifications 2 new mandatory requirements to ensure ‘quality products from quality mills’:- — Factory production control (FPC) ~ Manufacturer test certificate (MTC)Material performance requirements = Basic requirements = Other requirements = Material-specific requirements = Certified steel materials Other requirements (1) Additional requirements: = Z-properties — through thickness deformation properties m= CEV — carbon equivalent value = Impurity level — sulphur & phosphorous content = Manufacturing process = Manufacturing tolerances Basic requirements Basic requirements: = Strength — ability to carry load = Ductility — ability to undergo permanent deformation without loss of strength = Toughness — ability to absorb damage without fracture = Weldability — ability to transfer load Other requirements (2) Z-properties = through thickness deformation properties measured by reduction of cross-sectional area upon specimen failure in tensile test = due to anisotropy of mechanical properties in steel products = as general guide to lamellar tear resistance in flat productsOther requirements (3) Z-properties : S,-S, = % reduction of area, Z =—*—"* x 100% 5S, = original area; S$, = area after fracture = e.g. 225 refers to 25% reduction in cross- sectional area upon tensile failure m= higher Z value indicates better resistance to lamellar tearing Other requirements (5) Carbon equivalent value [_cev imit or stee pates Grede (MPa) [_CEV limit (%4) = generally, higher limits of 235 040 CEV for higher grade 275 044 steels which contain 355 on ; 420 052 more alloying elements i O35 60" 050 (see the table on right for example 550" 083 = CEV limit for steel plates, % by a 08s mass, based on ladle analysis) = quails eee Other requirements (4) Carbon equivalent value = empirical measure of hardening tendency of heat-affected zone (HAZ) which promotes crack formation %Mn = %Cr +%Mo+ %V . YNi+ %Cu Setee eee deer cce 6 6 1S ™ a significant indicator of weldability Other requirements (6) Impurity level = non-metallic impurities, esp. sulphur & phosphorous, are source of brittleness in structural steel = high impurity level leads to lamellar tearing & low formabilityOther requirements (7) Impurity level - Sulphur content Other requirements (8) Impurity level - Phosphorous content ‘Maximum sulphur content (% by mass, ladle analysis) ia | ieees asa] ae a eee eo ae ee Other requirements (9) Manufacturing process = manufacturing process decides the metallurgical behavior & performance = deoxidation method — rimming steel linked with internal voids is not permitted = QST steel — quenched & tempered steel with lower ductility & formability is restricted to plates and hot-rolled sections only Other requirements (10) Manufacturing tolerances = deviations from nominal dimensions & mass must be well within tolerances to assure member resistance & constructability = dimensions — direct impact on sectional properties, hence structural resistance = mass — theoretical amount of steel material to prevent deliberate under-sizingOther requirements (11) | Material-specific requirements (1) | Manufacturing tolerances for sections 9 categories of materials:- 1. Steel plates ae Tolerance (%) 2. Hot rolled sections Hot-rolled sections | Hollow sections 3. Hollow sections “Thickness 4. Steel for cold forming Commer | Ce wee s. Non-preloaded bolting assemblies aaere 6. Preloaded bolting assemblies erall dimension ; (eg. depth, width, leg £2% £1% 7. Welding consumables Tength, lameter) 8. Profiled steel sheets mee rex cea 9. Stud shear connectors Material-specific requirements (2) Material-specific requirements (3) Steel mates [strength] ouctity]Toughness| Chemical, |Manfectina}| oes E.g. requirements for steel plates:- Steal ates hot oe (across various performance indicators) aedareion | a |i | oy |v [Nantes secon sel fr preess = Rimming steel not permitted ‘en probaded 8 Heer, = Yield strength: 235 ~ 690 MPa preadedobing| ¥ | ¥ . Process = Min elongation: 15 % (< 460 MPa); 10 % (> 460 MPa) Welding pealaeesjeas alhweld | = Min toughness: 27 J at 20°C faiatiacia a = Tolerances: -5, +10 % (thickness) Potied sed Ty ’ | meconing = Max carbon content: 0.26 % (based on ladle analysis) Gudstex | —y | > connectors ‘The complete sets of requirements are given in Sectio’ ~ of this design guideMaterial-specific requirements (4) E.g. requirements for strength:- (across various types of steel materials) Type of steel materials | Yield strength (MPa) Steel plates 235 ~ 690 Hot rolled & hollow sections oe Steel for cold forming & profiled steel sheets eee Certified steel materials (1) = Material standards of steel materials commonly available in Singapore were evaluated rigorously against the material performance requirements = Allist of certified steel materials was produced for the 9 categories of steel materials Note: The complete list is given in Appendix A of this design guide Most commonly, used BS/EN, ASTM/API/AWS, JIS, AS/NZS & GB steel materials are adequate and included in this list Certified steel materials (2) e.g. Certified Chinese (GB) steel plates Any combination of steel grades manufactured to:- Certified steel materials (3) e.g. Non-certified Chinese (GB) steel plates Steel grades manufactured to:- GB/T 700-2006 | GB/T 1591-1994 | GB/T 4171-2000 | GB/T 4172-2000 Q2358z/CZ/0TZ | Q295B (Q295GNH/GNHL | Q235NHC/NHD/ Q275BZ/CZ/DTZ | Q345B/C/D/E | Q345GNH/GNHL | NHE Q3908/C/D/E | Q390GNH Q295NHC/NHDY aes cassiicnnoy Q460C/D/E HE Q46ONHD/NHE GB/T 700-2006 ] GBT 1591-1994 | GB/T 4171-2000 | GBT 4172-2000 Qu9sFy/Z 295sKz Nil (all certified) | Nil (al certified) qaisaryazy | Q3asne BFY/BZ! ga90ne Qea5Aryazy | Q420K BP Q275AF/AZ* with manufacturing tolerances in accordance with GB/T 709-2006 Reasons of not being certified: 1 Out-of-range yield strength 2 Untested toughness 3 Rimming steelOther non-certified materials a JIS G3101 (SS400, $S490, etc.) a JIS G3444 (STK400, etc.) = JIS G3466 (STKR400, etc.) = ASTM A500 Factory production control (1) Responsibility of manufacturers Proper factory production control (FPC) system in place, and 1uditable by independent third-party certification agencies or Procedures (QP), written instructions (WI) and inspection lans (ITP) on all processes and equipments which, iy and personnel whose work can affect qualty In — equipments* (calibration, maintenance, etc) = personnel — product testing* = product marking* — non-conforming products * Material-specific, depending on the relevant material performance requirements Factory production control (2) Factory production control (FPC) certificate: * Attestation of factory production control system (ISO 9001 QMS is complimentary but not sufficient) Issued by an independent third-party international certification agency* on the basis of:~ ~ Fits inspection after receiving and analyzing the complete set of quality manuals from the Factory = Annual inspection (surveillance/assessment) * The agency must be:- seer acceptable t BCA (e.g. Bureau Veritas, TUY Rheinland Det Norske Vertas, Lloyd's Register, Germanischer Lloyd, Moody Intemational, etc); ~ or recognized by BCA (e.g. Joint BCA/SSSS or Singapore-based eSuhenen boys OS apo Manufacturer test certificate (1) Responsibility of Manufacturers Substantiate the testing and inspection to ensure the compliance with nominal specifications by issuing an authenticated test certificate for every batch of products delivered Provide sufficient information for QPs to assess and control the material during fabricationManufacturer test certificate (2) Manufacturer test certificate (MTC): = Quality assurance on the product delivered = Asa minimum, MTC shall contain:- — Information of manufacturer — Reference details ~ Material specifications = Information for traceability — Test results (for e.g. minimum 13 elements for chemical composition) — Authentication = If purchase from stockist/trader: — MTC must be validated by stockist/trader — Exact quantity supplied must be clearly indicated in the MTC Implementation (1) Quality manufacturer Quality product Factory production control (FPC) Manufacturer test certificate (MTC) Implementation (2) Responstiiy of Requrements Manufacturer Certification agency* Esabich wren procedures | rst &.annal ‘Facon, Jeni pocesen equpment | suvelane and and personel wich atect | inepecny ance of control (FPC) quality FPC certificate 2. Manufacturer Issuance of authenticated test certificate | MTC (validated by stockist / ee (rc) trader) *Independent third-party international certification agency acceptable to or recognized by BCA (Lloyd's Register, Bureau Veritas, TUV Rheinland, Det Norske Veritas, Germanischer Lloyd, Moody International, etc.) Material classification (1) Design based on classification approach:- = Adequacy assessment against material performance requirements — Certification or Material testing = Reliability assessment against quality assurance requirements — Factory production control (FPC) and Manufacturer test certification (MTC)Material classification (2) Adequacy assessment: = Certification — The rigorous evaluation exercise to derive a list of certified materials for BS/EN, ASTM/API/AWS, JIS, AS/NZS & GB OR... = Material testing ~ Sample testing on non-certified materials (other than BS/EN, ASTM/API/AWS, JIS, AS/NZS & GB) to demonstrate adequacy of the materials and to confirm design parameters Material classification (4) Steel materials to BS 5950 Kev: in Singapore —> pass se Fal (by material testing) Class 3 Material classification (3) Reliability assessment: = Factory production control (FPC) — The materials shall be delivered with FPC certificate issued by an independent certification agency recognized or acceptable to BCA AND... = Manufacturer test certificate (MTC) — The materials shall be delivered with MTC furnished with essential information (see design guide) & authenticated by the manufacturer/stockist/trader Material classification (5) Information on the 3 classes:- = Class 1 — normal use to BS 5950 ~ only certified steel materials with acceptable QA can achieve Class 1 status = Class 2 — normal use to BS 5950 with 10% higher material factors ~ non-certified steel materials can only achieve Class 2 status at most = Class 3 — restricted (non-structural) use to BS 5950 with severely downgraded design strengths (es .g. 170 MPa for steel Plates) — materials which fail to meet QA requirements will be downgraded to Class 3 straightawayDesign recommendations (1) Design recommendations: = Design parameters are provided for alternative ie oe to be used in accordance with meg. — design strength for structural steel — recommended combination of bolting assemblies — design equation for stud shear connectors Design parameters vary across different material classes Design recommendations (3) Class 2 materials: = Factored strength, i.e. strength given in the respective material standards divided by a factor (a, = %/1.1 < U,/1.3), for all structural steel = Lower design strength for bolts, welds and stud shear connectors as compared to Class 1 materials Design recommendations (2) Class 1 materials: = Unfactored strength, i.e. strength given in the respective material standards, for all structural steel (plates, sections & cold-forming steel) = Design parameters for bolts and welds recommended by the respective national standards = Design parameters for stud shear connectors recommended by HKSC2005 Design recommendations (4) Class 3 materials: = Maximum design strength downgraded to 170 N/mm for non-structural use only ye m Use of bolts, welds and stud shear are not allowed NOTE: Detailed design recommendations are given in Section 5 of this design guideClause 4.4 Special case = An alternative design procedure, on case-by- case approval from BCA, the material may be treated as Class 2 if its adequacy and reliability can be guaranteed through rigorous material testing and control plan. Such written plan should comprise at least 100% visual inspection and non-destructive testing, 100% destructive testing for all batches/heat numbers, test reports from accredited laboratory and material assessment report from expert consultant. Significance of Clause 4.4 = An interim measure for key industry players to adjust and switch to the new requirements = To cater for existing on-going projects and stockpiles of alternative steel materials = Not an escape route to by-pass new requirements Implications of Clause 4.4 = QP has to propose & monitor a very rigorous material control plan subject to BCA’s approval = Possible change in class of materials from Class 1 to Class 2 = QP has to review & redo design m= Less quality-conscious manufacturers can still continue to supply materials In short, QP still has to shoulder the quality problem and damage caused by lesser manufacturers are not addressed directly. Conclusion (1) Need for a new design guide = wider choice of materials from diverse sources = availability of alternative steel materials not covered in BS 5950 by default = requirements & recommendations neededConclusion (2) Material performance requirements = minimal performance indicators to ensure the material adequacy = material-specific, varies across 9 categories of materials = certified materials - adequacy verified against the requirements through rigorous evaluation, qualify as Class 1 materials if QA requirements are also met Conclusion (3) Quality assurance requirements = to address & tackle the quality issues directly = 2 new aspects of QA requirements: « FPC - Factory production control (mills to be audited by certification agency & FPC certificate is required) * MTC - manufacturer test certificate (must contain sufficient information for QP to control material during delivery) Conclusion (4) Material classification = involves adequacy & reliability assessments = divides materials into 3 classes — Class 1, Class 2 & Class 3, which are subject to different design recommendations Final Remarks = Guide is blind to ‘country of origin’, and all steels are allowed and treated the same, including BS/EN steels = The actual properties and performances of the steel material is more important = To raise the ‘quality bar’ in the steel construction industry based on ‘trust and shared-responsibility’ amongst all key stakeholdersWards Sustainable Construction using High Strength Concrete & Materials Use of Alternative Steel Materials for Construction Richard Liew Ph.D, PE Associate Professor National University of Singapore | | Problems with Alternate Stee! Materials Steel materials come from countries such as China, Europe, Japan & Australia, etc. Sections are manufactured to the respective national standards. Mechanical properties may differ slightly from the specifications in the BS.Design Guide on Use of Alternative Steel Standards under study = America - ASTM, API © Japan — China — = Australian / New Zealand — AS/NZS JIS GB Comparison of Structural steels [Buctity - Elongator [reac toughross- Cray V._waldeby- fede ea tsissverath (AP) oer £0 mm (4) |notsh eneay absob at 10°C) |Cogy > [SEN [55 0023 Gade SBN a zl 3 ire) [ast [A992 Grede 346 0] See FEE =: EE] (aL BL Grade XS 3 25 elt O43] (ASINTS —[3670-Grade SOUS Sees 2 1 EaeA) [ca [Grade 3545 305 2 ai 0.0] Wis [sx 4900. 325 7 2 0.44]Design Guide Salient Features Allow design procedures to be based on BS, with appropriate parameters to account for the difference in the manufacturing standards on the steel materials & =-- © Design Guide on Use yd he of Alternative Steel : e Rte. materials to BS 5950 rh 2 @o bagviteleds © Recommendations to ae & ensure product conformity, quality and traceability in steel materialsa Classifications Alternative steel materials shall be classified into 3 classes, based on verification against material performance and quality assurance requirements. Issues © Strength and mechanical properties (Coupon tests) Dimension tolerance (affect section properties) = Plate -6% k « Hollow section -10% [bee » Mass tolerance ? % (e.g. ASTM A6-2007 > -2.5%) © Chemical Contents (weldability) © Duetility (Charpy impact test, bend test)Typical Mill Certificate tlds Cp) aL A ‘AWGMER N/R LILZHOU RON AND STEBLCO.LTD 4 Fa RE cm QUALITY Seknsrencinoy ‘are ease i t [atsn. oases, enaranne. porest aaa oR are $ER Eh: : Manufacturer production control _ certificates m™ The manufacturer shall produce a cert icate issued by an independent third-party certification agency acceptable to or recognized by BCA as an attestation of the manufacturer production control system in meeting the requirements given in 3.1. The purchaser shall obtain a validated copy of such certificate directly from the manufacturer or through the stockistManufacturer test certificates | The manufacturer shall produce an authenticated test certificate as an additional layer of quality assurance on the alternative steel materials delivered. s The purchaser shall obtain such certificate directly from the manufacturer or a validated copy of such certificate through the stockist. In both cases, the quantity of steel materials supplied to the purchaser shall be clearly indicated. = Class 1 — Steel mills are audited to have manufacturing production control certificate = If no manufacturing production control certificate available, .....Hangar Structures fetes rb ele dak) fee cieteeekeBuilt-up box and H sections by Q345 steel plates are i provided where stresses are most critical, while rolled sections are provided for the less stresses segments. fexvig sic)Air Show Exhibition Centre Steel plate materials from steel mill certificates Min, Country Range of plate ieee fora a Tensile oforigin | thickness (mm) hea a Strength (MTons) | ara) | Sarl 30, 25,20 : 25, 608.049 | 335 485 China] 16,15,12,10,8,6.5, | Igearse | 345 oy Korea 50, 40 92.966 351 550 50,40,25 310.546 | 397 529 12,10 102.07 | 430 535 Total tonnage: 2977385 mechanical test results for Q345B steel : = p04) tox =] tem Tested Number of ] Viedstrength | Tensile | ereentage (Thickness) Heat No Test Coupons (MPa) ‘Strength (MPa) | Elongation (%) p8813-4mm | 61108908 z e122 5152 2 esas—amm | 6108518 3 32 3673 2aa 3 a 5130856 i 2735 5519 3 a a 62108527 3 67 598 2a 5 | pa7ai-sem | 61100803 3 2299 3429 2a 110080502 6 | ossei-smm| 0 1 ans 5658 25 110080506 2 5 ° 1 aus 3499 236 — 110080508 8 5 ° 1 ans sma 23 170080508 9 5 ° 1 99 5374 256 6110090507 w| os Q 1 a5 5308 267Resistance to brittle fracture & The Charpy V-notch impact test energy at 20°C temperature are greater than 27J indicating sufficient notch toughness of Q345 steel to be used for the Air Show project Ductility & tensile elongations of the steel plates are greater than 15%. Bent test results (plates are bent through 180° without fracture) indicate sufficient ductility of Q345 steel WELDABILITY @ For this project, the maximum carbon content of Q345 steel does not exceed 0.24%. The maximum sulphur content does not exceed 0.05% and the maximum phosphorus content does not exceed 0.05%. = The steel is a low carbon structural steel suitable for structural application.Measurement of Plate Thickness Site measurement of plate thickness In Hint - Original Plate Thickness Point 1 Point 2 Point 3 60 60 60 60 8.0 81 81 8.1 12.0 13.0 13.2 133 20.0 20.0 20.0 200 700 a0 a0 wa Conclusion In reality, itis not the standard that the material is certified to pass but the actual product, its properties and performance that matter!