Infrastructure Steel in Norway; Requirements and Specifications

Transcription

1 Madrid 9. December 2013 Infrastructure Steel in Norway; Requirements and Specifications Kjetil Myhre Chairman ECCS/TC9 Manager Norwegian Steel Association

2 Norwegian Steel Association has promoted the use of steel since 1993

3 EN 1090 EN 1090 Execution of steel structures and aluminium structures EN : Requirements for conformity assessment of structural components (inclusive rules for CE Marking) EN : Technical requirements for steel structures EN : Technical requirements for aluminium structures NB! EN is a harmonised standard (hen)

4 CEN/TC 135 with Norwegian chairman and secretariat Technical committee TC 135 Experts from: Companies Authorities R & D Organizations Consumers Manufacturers Working group WG 1 Working group WG 2 Working group WG 3

5 CE marking EN is a technical spesification and basis for: - Certification of manufacturer s FPC* system - Declaration of Performance (DoP) - CE Marking Time schedule CE Marking: Published in Official Journal (OJ) & start CE-merking: 1. January 2011 Co-existence / transition period: 3,5 years Mandatory CE Merking: 1. July 2014 * FPC = Factory production control

6 CPR & CE Marking New Construction Products Regulation (CPR) Objective: To promote common standards across Europe in order to make trade easier, by CE-marking and declaring the performance of the products

7 CPR & CE Marking New Construction Products Regulation (CPR) The CPD was withdrawn and the full CPR came into force: 1. July 2013 CE Marking is absolute mandatory in EU member states from 1. July 2013 and in Norway from 1. January 2014* (except NS-EN who has the date 1. July 2014) * When there is a harmonised standard where the co-existence period has expired or when there is an ETA

8 Regulations and standards The Planning and Building Act + Regulations on technical requirements including Construction Products Regulation (CPR) Basis of structural design NS-EN National Annexes Projecting standards NS-EN National Annexes Execution standard NS-EN Product and test standards

9 Regulations and standards Additional national standards Norwegian contract standards for execution of building and civil engineering works: NS 8405/7 & 15/17 Specification texts for building, construction & installations: NS 3420 The Norwegian Public Roads Administration: - Manual 025 Standard specification texts for road contracts - Manual 026 Standard specification texts for bridges and quays - Manual 185 Bridge design (Eurocode version) - Manual 122 Cables for suspension bridge Jernbaneverket (Norwegian government s agency for railway services): Technical regulations

10 Eurocodes NS-EN 1993 Design of Steel Structures NS-EN General rules and rules for buildings. NS-EN Steel bridges. NS-EN Towers, masts and chimneys. NS-EN Silos, tanks and pipelines. NS-EN Piling. NS-EN Cane supporting structures. NS-EN to EN refer to the generic rules in NS-EN The rules in parts NS-EN to NS-EN supplement the generic rules in NS-EN NS-EN 1994 Design of composite steel and concrete structures NS-EN General rules and rules for buildings NS-EN Structural fire design NS-EN Bridges

11 Eurocodes NS-EN Design of Steel Structures NS-EN General rules and rules for buildings. NS-EN Structural fire design. NS-EN Cold-formed thin gauge members and sheeting. NS-EN Stainless steels. NS-EN Plated structural elements. NS-EN Strength and stability of shell structures. NS-EN Strength and stability of planar plated structures transversely loaded. NS-EN Design of joints. NS-EN Fatigue strength of steel structures. NS-EN Material toughness and through-thickness properties. NS-EN Design of structures with tension components made of steel. NS-EN Supplementary rules for high strength steel.

12 Eurocode 3 Select proper steel for outdoor climate NS-EN National Annex: Table NA.2(904) Bridges: NS-EN National Annex: Table NA.3(901) Service temperature: -50 C C Note: The lowest service temperature is given in NS-EN /NA.

13 NS-EN National Annex: Table NA.3(901): Maximum permitted thickness in mm for bridges

14 NS-EN 1090 EN contains no technical requirements for execution, only rules to demonstrate conformity between the component's properties and the declaration ( CE Marking standard ) The technical requirements are given in NS-EN (steel) and NS-EN (aluminium) These standards cover all types of load bearing structures and single components CE Marking is only for manufacturing, not erection CE Marking is only delivered building site

15 NS-EN Scope Hot rolled, structural steel products up to and including grade S690 Cold formed components and sheeting up to and including grade S700 Hot finished and cold formed stainless steels Hot finished and cold formed structural hollow sections Also custom-made sections manufactured by welding Also grades up to and including S960, if necessary additional requirements are specified. The standard applies to steel structures designed according to relevant parts of Eurocode 3 and 4

16 NS-EN Contents 1 Scope 2 Normative references 3 Terms and definitions 4 Specifications and documentation 5 Constituent products 6 Preparation and assembly 7 Welding 8 Mechanical fastening 9 Erection 10 Surface treatment 11 Geometrical tolerances 12 Inspection, testing and correction

17 Some definitions in NS-EN Execution class a set of requirements specified for the execution of the works as a whole, of an individual component or of a detail of a component Constituent product material and product used for manufacturing a component and which remains as part of it, e.g. structural steel product, stainless steel product, mechanical fastener, welding consumable Component a part of a steel structure (made of constituent products) which may be an assembly of several smaller components

18 5 Constituent products NS-EN : Structural steels Welding consumables Mechanical fasteners Hot rivets Grouting materials Expansion joints for bridges High strength cables, rods and terminations Identification Inspection documents Traceability Steel grade (S355 ) Surface condition

19 6 Preparation and assembly Identification/marking Handling and storage Shearing/cutting Shaping/forming Holing Cut outs Assembly

20 7 Welding Welding plan Welding processes Qualification of welding procedures and welding personnel Preparation and execution of welding Acceptance criteria Welding of stainless steels

21 8 Mechanical fastening Bolting assemblies Preparation of contact surfaces Tightening of bolts Hot riveting Fit bolts Fastening of thin gauge components 1 - mutter 2 - underlagsskive under mutteren når mutteren dreier under stramming 3 - mellomleggsskive 4 - måleinnretning for skruens strekk 5 - avfaset underlagsskive for sammensettingen eller den avfasede mellomleggsskiven 6 - skruehode

22 9 Erection Safety of the works Description of the erection method (design basis) Survey (Site measurements) Supports, anchors and bearings Erection and work at site - Drawings - Marking - Handling and storage - Trial erection - Erection methods

23 10 Surface treatment Preparation of steel Corrosivity categories Galvanizing Sealing of spaces Inaccessible surfaces Repairs after cutting or welding Cleaning after erection ISO :

24 11 Geometrical tolerances Essential and functional tolerances Manufacturing Erection

25 12 Inspection, testing and correction Requirements for inspection and testing included in quality documentation or quality plan as relevant: Constituent products and components Manufacturing Welding Mechanical fastening Surface treatment and corrosion protection Erection

26 Execution classes What is execution class? A set of requirements, given in class, for execution of: The whole construction; A part of the construction; One single component; A group of details; One single detail; This means: A construction may have one or more execution classes (EXC)

27 Execution classes Four execution classes: from EXC 1 to EXC 4 Grade of strictness increase from EXC1 to EXC 4 If class is not specified: applies EXC2 The requirements according to execution classes are summarised in Annex A.3 Guidelines for choosing execution class is given in informative Annex B.

28 Execution classes The criteria for the selection of execution class Designers choose from three different conditions: Consequence Class (CC1 to CC3) - defined in NS-EN 1990 in informative annex B Service Category (SC 1 or SC2) - defined in NS-EN informative Annex B Product Category (PC1 or PC2) - defined in NS-EN informative Annex B

29 Consequences classes = Reliability classes Consequences of failure or malfunction of the structure NB! Particular members of the structure may be designated in the same, higher or lower consequences class than for the entire structure.

30 Service Category (SC) Hazards connected with the use of the structure NB! A structure or part of a structure can contain components or structural details that belong to different service categories.

31 Production categories (PC) Hazards connected with execution of the structure NB! A structure or part of a structure may contain components or structural details that belong to different production categories.

32 Execution classes EN Table B.3 Recommended matrix for determination of execution classes

33 Execution classes EN Table B.3 Recommended matrix for determination of execution classes Static Medium S355

34 Execution classes Guidance: Actual construction types. A rough classification: EXC1 Small houses, warehouses, agricultural buildings, nurseries, quays. Welded and non-welded structures with simple fabrication EXC2 Homes, offices, commercial buildings, halls, institutional buildings, harbor facilities, towers, masts, small road bridges and footbridges EXC3 Larger road and railway bridges, crane structures, large buildings with huge crowds, large tribunes, sports arenas... EXC4 Nuclear facilities, extraordinary designs. As for EXC3 but with particularly large impact, high utilization by fatigue and complex fabrication conditions.

35 New proposal: Annex in EN If the required execution class for components or details is different from that applicable to the structure, then the components or details shall be clearly identified.

36 New proposal: Annex in EN NOTE The National Annex may specify the choice of execution class in terms of types of components or details. The following is recommended: If EXC1 is selected for a structure, then EXC2 shall apply to the following types of component: a) welded components manufactured from steel products of grade S355 and above; b) welded components essential for structural integrity that are assembled by welding on the construction site; c) welded components of CHS lattice girders requiring end profile cuts; d) components with hot forming during manufacturing or receiving thermic treatment during manufacturing.

37 Table A.3 Requirements to each EXC

38 Requirements for welding Welding in general (7.1) Quality requirements in accordance with EN ISO 3834: EXC1: Part 4 "Elementary quality requirements"; EXC2: Part 3 "Standard quality requirements"; EXC3 and EXC4: Part 2 "Comprehensive quality requirements". Requires a welding plan prepared for the work

39 EXC NS-EN : Table 14 Technical knowledge of the welding coordinator (RWC). Structural carbon steels Steels (steel group) Reference standards Thickness (mm) t 25 a 25 < t 50 b t > 50 EXC2 S235 to S355 (1.1, 1.2, 1.4) EN , EN , EN EN , EN , EN EN , EN B S C c S420 to S700 (1.3, 2, 3) EN , EN , EN EN , EN EN , EN S C d C EXC3 S235 to S355 (1.1, 1.2, 1.4) EN , EN , EN EN , EN , EN EN , EN S C C S420 to S700 (1.3, 2, 3) EN , EN , EN EN , EN EN , EN C C C EXC4 Alle Alle C C C a Column base plates and endplates 50 mm. b Column base plates and endplates 75 mm. c For steels up to and including S275, level S is sufficient. d For steels N, NL, M and ML, level S is sufficient.

40 EXC National approved Welding Coordinator and IIW competence Steels (steel group) Reference standards Thickness (mm) t 25 a 25 < t 50 b t > 50 S235 to S355 (1.1, 1.2, 1.4) EN , EN , EN EN , EN , EN EN , EN Nivå2 eller IWS Nivå 3 eller IWT IWE c EXC2 S420 (1.3, 2.1) S420 to S700 (1.3, 2, 3) generelt EN , EN , EN EN , EN EN , EN Nivå 3 eller IWT IWT Nivå 3 eller IWE d IWE d IWE S235 to S355 (1.1, 1.2, 1.4) EN , EN , EN EN , EN , EN EN , EN Nivå 3 eller IWT IWE IWE EXC3 S420 (1.3, 2.1) EN , EN , EN S420 to S700 (1.3, 2, 3) EN , EN EN , EN Nivå 3 eller IWE IWE IWE IWE EXC4 Alle Alle IWE IWE IWE a Column base plates and endplates 50 mm. b Column base plates and endplates 75 mm. c For steels up to and including S275, level S is sufficient. d For steels N, NL, M and ML, level S is sufficient.

41 NS EN Quality requirements & NDT of welds Qualifying for execution. The first 5 welds with new WPS must always meet the following requirements: - The quality level B (ISO 5817) - NDT shall be double of the values in Table 24 - Minimum length to be inspected is 900 mm - If inspection gives non conforming results, a new set of five joints shall be tested - After acceptable result the manufacturing shall meet: - EXC1 quality level D - EXC2 quality level C (partly level D) - EXC3 quality level B - EXC4 quality level B + (additional requirements) - The extent of supplementary NDT shall meet Table 24.

42 NS EN Quality requirements & NDT of welds

43 Specifications and documentation NS-EN requires 1 Execution Specification + 2 Constructor's Documentation

44 Documentation 1 Execution Specification All necessary information and technical requirements for execution 2 The constructor's documentation - Quality plan and documentation - Welding plan - Erection works and safety plan - Inspection plan - Execution / AS-built documentation

45 Execution Specification The engineer should draw up the Execution Specification! - So that the load bearing capacity, stability and functionality are met. The steel contractor must ensure that the Execution Specification meets the requirements of EN and eventually supplement with the missing. The steel contractor is responsible!

46 Execution Specification NS-EN requires Execution Specificaton = Necessary information and technical requirements for execution incl. procedures for alterations shall consider the following items when relevant: a) additional information, as listed in A.1; b) options, as listed in A.2; c) execution classes, see 4.1.2; d) preparation grades, see 4.1.3; e) tolerance classes, see 4.1.4; f) technical requirements regarding the safety of the works, see and 9.2.

47 Execution Specification

48 Execution Specification

49 NS-EN Requirements for conformity assessment of structural components

50 NS-EN Contents 1 Scope 2 Normative references 3 Terms, definitions and abbreviations 4 Requirements 5 Evaluation methods 6 Evaluation of conformity 7 Classification and designation 8 Marking Annex A (informative) Guidelines for preparation of the component specification Annex B (normative) Assessment of factory production control Annex ZA (informative) Clauses of this European Standard Addressing the provisions of EU

51 CE marking of products CE marking comprises all types of: - Load bearing steel components and kits - Unique components Although fabricated steel components are generally bespoke, being one-offs or to a limited number typically of less than 10 identical items this may be series or nonseries production. From 1. July 2014: Mandatory in the EU and EFTA member countries

52 Definitions in NS-EN Component specification document or documents giving all necessary information and technical requirements for manufacturing the structural component Design brief documents containing all information necessary to perform a structural design of the component, considering its intended use Structural characteristics properties of the component connected with its ability to function satisfactorily under the influence of the actions it is subject to (the performance characteristics are load bearing capacity, fatigue strength, resistance to fire and deformation at serviceability limit state)

53 How to evaluate conformity? EN specifies the performance characteristics That shall be declared by the manufacturer or supplier The general principles of evaluation of conformity is the use of - Initial Type Testing (ITT) - Factory Production Control (FPC).

54 How evaluate conformity? The basis of ITT is: - A manufacturer develops a product (a prototype) to demonstrate its properties in relation to the performance characteristics. - The manufacturer starts to produce the new product, and representative samples from new production are tested to determine that the production methods used can produce consistent products.

55 Initial type testing (ITT) ITT is needed - at the start of production of a new product, - the use of new constituent products - at the start of a new or modified method of production if this would affect a characteristic subject to evaluation - if production is changed to a higher Execution Class.

56 Initial type testing (ITT) Example: - A manufacturer develop a preliminary welding procedure specification (pwps); - Based on the pwps, the manufacturer carries out a welding procedure test, which is subjected to destructive and nondestructive tests (NDT). The results are recorded in a welding procedure qualification record (WPQR); - The WPQR is used to support application of the WPS in practice and the qualification of other WPS to be used in production within a defined range of essential variables, e.g material type/thickness, joint types, welding position etc.

57 Initial type testing (ITT) - The WPS can be used in a variety of specific welds which differs slightly from the initial type test. - This is an example of the allowance in EN for extended use of ITT to other situations within a "family". - The range of qualification allowed in the welding standards defines how big the family may be, which in terms of parent materials is done using steel groups cited in EN Table 14: S235 to S355 (1.1, 1.2, 1.4) S420 to S700 (1.3, 2, 3)

58 Factory production control, FPC Factory production control (FPC) is needed to establish that a manufacturer can produce conforming product in regular ongoing production. The FPC system shall consist of written procedures, regular inspections and tests and/or assessments and the use of results to control the component s constituent products, equipment, the production process and the manufactured component.

59 Factory production control, FPC A FPC system conforming to the requirements of EN ISO 9001 and made specific to the requirements of EN shall be considered to satisfy the requirements. The results of inspections, tests and assessments stated in the manufacturer`s FPC system shall be recorded. The action to be taken if control values or criteria are not met shall be recorded and retained for the period specified in the manufacturer s FPC procedures. The assessment of FPC shall be as Annex B.

60 Assessment of FPC The tasks for the initial assessment are given in Table B.1 Tasks related to execution work - General: Inspection and evaluation of execution resources (premises, personnel and equipment), in particular: - Evaluation of competence of personnel (and job descriptions) - Inspection and evaluation of the control system for checking conformity, and procedures for handling any nonconformity. - Check that the factory and the welding plant meet the requirement with regard to equipment (testing and calibration)

61 Assessment of FPC Assesment of tasks related to structural design work: - General: Inspection and evaluation of design resources (premises, personnel and equipment), in particular: - Evaluation of competence of personnel (and job descriptions) - Evaluation by samples that relevant equipment and resources e.g. procedures for hand calculations and/or computer equipment and computer programs for the work are available and functional. - Evaluation of procedures for structural design including control procedures to secure that conformity is obtained.

62 Essential performance characteristics The first 6 are material properties & geometrical data (mandatory to declare) The next 4 (blue text) are structural characteristics Tolerances on dimensions and shape Weldability Fracture toughness Reaction to fire Emission of radioactivity and Release of cadmium. Durability Load bearing capacity Fatigue strength Resistance to fire Deformation at serviceability limit state

63 Example: declaration of essential characteristics Essential characteristics Performance Harmonised technical specification Tolerances on dimensions and shape EN , tolerance class 1 EN : A1: 2011 Weldability EN , S275JR & S355JR EN : A1: 2011 Fracture toughness/impact resistance S275JR & S355JR 20C) EN : A1: 2011 Load bearing capacity NPD EN : A1: 2011 Fatigue strength NPD EN : A1: 2011 Resistance to fire NPD EN : A1: 2011 Reaction to fire Class A1 (steel only) EN : A1: 2011 Release of cadmium and its NPD EN : A1: 2011 compounds Radioactivity NPD EN : A1: 2011 Durability Surface preparation according to EN , Preparation grade P3. Surface painted according to EN ISO EN : A1: 2011

64 Eksample: Declaration of Performance

65 CE marking and labelling The manufacturer or his authorised representative established within the EEA is responsible for the affixing of the CE marking. The CE marking symbol affix shall be in accordance with directive 93/68/EC and shall be shown on the component or may be on the accompanying label, the packaging or on the commercial documentation. The CE marking consists of the initials "CE" and regulated information.

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68 Eksample: CE mark

69 Main harmonised steel product standards Harmonised standard (hen) Description Available date Start coexistens/ Start CE marking End coexistens/ Mandatory CE merking EN Steel sections and plates Nov /09/ /09/2006 EN Hot finnished hollow sections Apr /02/ /02/2008 EN Cold formed hollow sections Apr /02/ /02/2008 EN Preloadable bolts Mar /01/ /10/2007 EN Non-preloadable bolts Apr /01/ /10/2009 EN Fabricated structural steelwork Oct /01/ /07/2014

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71 How to ensure conformity of steel System 2+: system for production control FPC, controlled by a Notified Body The Notified Body issues a certificate to the manufacturer that gives the right to CE Mark The notified body carries out regular inspections to confirm the certificate The Notified Body checks the system, not the component It is the manufacturer's responsibility to deliver components that conform to the declaration, which refers to the component specification and standards.

72 NS-EN Intervals between inspections after the initial surveillance Execution classes EXC1 and EXC Intervals between inspections of manufacturer's FPC after the ITT (years) EXC3 and EXC The frequency of inspection may be increased if there is: a) new or changed essential facilities; b) change of responsible welding coordinator; c) new welding processes, type of parent metal and the associated welding procedure qualification record (WPQR); d) new essential equipment.

73 CE marking, the process Here is a procedure leading to CE marking: A - Identify the Execution class(es) including steel materials B - Identify the performance characteristics to be declared C - Perform Initial Type Testing (and ev. ITC) D - Establish a system for production control, FPC E - Certification of FPC by a Notified Body. F - Make a Declaration of Performance G - Affixing the CE mark

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75 Examples: FPC and Welding Certificate

76 Thank you Any questions?