Structural Steel

Prequalification Document (R2)

KIRBY
Structural Steel

Prequalification Document

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INDEX

Introduction … … … … … … … … 4

Market Sectors & Products … … … … … … 6

Vision & Mission Statement … … … … … … 7

Legal Status … … … … … … … … 8

Iso Certificate … … … … … … … … 16

Design and Engineering … … … … … … 17

Piece Monitoring System … … … … … … 19

The Project Structure … … … … … … … 22

General Description of Work Flow Procedures … … 23

Engineering
Design Output
Design Review
Design Validation
Design Changes
Software
RFI‘s
Pre-Production Planning

Example … … … … … … … … … 27

Material Preparation
Identification
Handling, Storage and Stacking
Consumable Storage
Fabrication Drawings
Beam Processing
Beam Preparation Equipment
Plate Processing
Plate Processing Equipment
Assembly
Welding
Curving and Straightening
Non-Destructive Testing
Surface Preparation and Painting
Delivery of Finished Product

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I N D E X (continued)

Attachments … … … … … … … … 32

Process Flow Chart

Change Procedure Flow Chart s
Change Procedure Documentation
Project Quality Plan (Sample)
Inspection and Test Plan (Sample)
PMS Sample Schedules and QC Reports
Welding Procedure Specifications

Organisation Chart … … … … … … … 75

Customer Base … … … … … … … 76

Typical Projects … … … … … … … 78

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Introduction

Kirby Steel Engineering emerged as a natural extension to the ever expanding Kirby steel
fabrication network, as well as in response to the continuous requests from the market and
satisfied customers.

Kirby Steel Engineering complements Kirby Building Systems by providing services and
customized Hot Rolled steel structures to industrial market sectors such as Oil & Gas,
Petrochemical Industry, Heavy Industries, Cement Plants, Aluminium smelters etc…

The company also offers its services, expertise and products in other sectors such as
Commercial sectors where it contributes, alongside its sister company Kirby Building
Systems, in providing a complementary and wider range of products to clients whose projects
may include a combination of heavier structural steel requirements, as well as Pre-engineered
buildings.

Kirby Steel Engineering is managed by a team of professionals with an average experience of

twenty to thirty years experience in the structural steel industry and known to have executed a
number of prestigious and high-profile projects in the GCC and Middle East.

The engineering department uses the latest versions of internationally renowned industry
standard 3D and 2D software for designing as well as drafting.

Kirby Steel Engineering is affiliated to Kirby Building Systems, which in turn is part of Al
Ghanim Industries having the Head Office in Kuwait.

Kirby Building Systems - Kuwait is the premier producer of steel buildings and structures in
the Middle East. In operation since 1976, Kirby maintains a strong reputation for providing
cost effective solutions for buildings manufactured to the highest standards. Kirby’s network
includes 24 offices in the GCC countries (Kuwait, Saudi Arabia, Qatar, Oman, Bahrain and
the UAE), the Middle East, Africa, and the Far East to service customers locally. Kirby
manufacturing facilities produce hundreds of custom made steel buildings each year.

Kirby upholds its position at the cutting edge of the industry due to its commitment to quality
and customer satisfaction. Skilled structural engineers using the very latest in computerized
engineering design and drafting systems permit the selection of the most economical,
accurate and efficient framing and cladding systems.

Kirby’s customer base covers thousands of satisfied clients including General Motors,
AT&T, PepsiCo and Coca Cola , Ministries of Defense, Oil companies and Petrochemical
projects and other key international organizations over the world.

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Alghanim Industries has consistently maintained its position as a leading private sector
trading and industrial group both in Kuwait and the GCC during the past 60 years. It is a
privately owned, professionally managed holding company. The executive management is
composed of professionals with international education and experience in varying areas of
expertise. Overall, with the company’s wholly owned subsidiaries, joint ventures and
associations, Alghanim Industries employs over 12000 men and women from over
40 different countries around the world.

The group’s major areas of activity are trading and distribution of consumer electronics, food
and consumables, automotive vehicles and products, industrial manufacturing, engineering,
technology, travel, shipping and transportation services, advertising, insurance and
contracting.

Furthermore each of Alghanim’s separate businesses employs operating autonomy with its
own general manager, marketing managers and finance managers. Corporate policy matters
remain centrally controlled and direction is provided through strategic business planning
processes, quarterly operating review meetings and long term forecasting.

Multinational in both outlook and operation, Alghanim Industries has offices in countries that
span four continents. The diverse nationalities of the employees contribute to the company’s
strength and widen its perspective. Alghanim Industries has successfully fused progressive
business procedures, local market place requirements and international resources.

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Market Sectors & Products

The following is an indication, but is not limited to, of the market sectors serviced and the
types of structures undertaken by Kirby Steel Engineering.

The flexibility, expertise and equipment allows the company to customize and provide the
right products or mix of products as required by the clients’ projects.

Market Sectors Structures

Heavy Industries Oil & Gas Pipe Racks

Petrochemical Rectangular Platforms
Aluminum Smelters Circular Platforms
Fertilizer Plants Pipe Supports
Cement Plants Main Workshop Structures
Raw Material Storage
Buildings
Floor Gratings
Staircases
Handrails
Ladders
Temporary Structures

Infrastructure Bridges Steel Bridges

Heavy Duty Building
Power & Desalination Structures
Airports & Seaports Platforms
Railways Equipment Support Structures
Passenger Terminals
Cargo Terminals
Aircraft Hangars

Buildings Segment Residential / Commercial Hi-rise Towers

Shopping Malls Tower Crowns
Leisure Centres Atrium Structures
Multi-storey Car Parks
Roof Structures
Sports Centres

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Vision & Mission Statement

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Trade License - Kuwait

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Commercial License - Kuwait

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Chamber of Commerce – Kuwait

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Commercial Register – Kuwait

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Import License – Kuwait

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Trade License – Ras Al Khaimah - UAE

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Chamber of Commerce – Ras Al Khaimah - UAE

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Commercial Register – Ras Al Khaimah – UAE

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ISO Certificate

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Design and Engineering

Kirby Steel Engineering uses the latest computer software in both Engineering and Design
allowing both activities to be as fully integrated as possible.

All work undertaken in the Engineering / Design Department is closely monitored by the
Engineering Manager who is responsible for ensuring that the design conforms to the clients
requirements and is in accordance with the relevant Design Codes and Regulatory Authority
requirements

The Design / Engineering Department is fully computerized, utilising the latest software
packages to enable them to produce the most economical structures in the shortest time
possible. The software packages most frequently utilised are :

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Design and Engineering Cont…

The Drafting office is also fully computerised and utilises the following main software
packages :

Package Description Specifications / Code

AutoCad Preparation of GA Drawings & N/A
Fabrication Drawings –
Miscellaneous Works
BoCad 3D Modelling – Detailing of N/A
Connections – Automatic
Generation of Fabrication Drawings,
Production & Material Listings
Strucad 3D Modelling – Detailing of N/A
Connections – Automatic
Generation of Fabrication Drawings,
Production & Material Listings

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Piece Monitoring System – What does it do ?

− Maintains a full bill of quantities for each main and sub-assembly

− Establish Production Priorities for each component

− Automatically program each item of steel through the workshop to suit client
requirements and production capacities

− Issue production requirements for each stage of fabrication

− Automatically maintain the independent KIRBY Steel Engineering quality assurance

programme

− Real Time monitoring of production status

Piece Monitoring System—The Advantages

− Each individual piece of steel is dynamically monitored at the stages of production to

assure the client receives all the items on time

− Monitors the effects of design changes etc… to enable the client to incorporate in
their production schedules

− A full set of reports is available under password control in the Web Server. Reports
can be downloaded by the user into spreadsheets, databases etc… for later use

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Piece Monitoring System—How does it work ?

− The project is broken down into units of build-ability or client requirements

− Project programmes are developed using Primavera Project Manager

− Specialised CAD systems used to produce working drawings, also produce their own
bill of materials which is automatically fed into the Piece Monitoring System.

− Drawings produced from other sources are taken off and entered manually.

The PMS automatically reviews the programme, type of fabrication and production
capacities to produce an individual fabrication programme for each item of steel. Full
manual modification control is maintained to allow further requirements to be incorporated

− Production lists are produced for each stage of fabrication and production data re-
entered into the system

− Quality assurance inspection requests are generated automatically by the system and
records maintained

− Full status reports are produced, cross-checked between each function

− The Web Server is automatically updated

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Index to the General Description of Work Flow Procedures

The purpose of the following section is to describe in general each

activity executed during a project.

Index

− Engineering

− Software

− RFI’s

− Pre Production Planning

− Example

− Identification

− Handling Storage and Stacking

− Fabrication Drawing

− Beam Processing

− Plate Processing

− Assembly

− Welding

− Curving and Straightening

− Non Destructive Testing

− Surface Preparation

− Delivery of Finished Products

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Engineering
All Technical information received from the client such as drawings, project specifications,
bills of quantity, agreed scope of work and any other pertinent information is forwarded to
the Design Department who review all relevant documentation to establish the design
parameters. Any clarifications and requests for information are communicated to the
client in writing.

Should circumstance arise were the requested information is not available then the Design
Department clearly detail any and all assumptions they have made. This information is
forwarded to the client.

Design Output

The design output is expressed in the following formats :

− Computer generated calculations prepared on propriety software

− Design sketches containing all the necessary information to allow drafting to generate
general arrangement drawings

The General Arrangement drawing package shall consist of but not be limited to:

− Anchor Bolt Layout

− Roof Framing Plan
− Elevations
− Connection Details (if requested)

Design Review

During the Design Sketch and calculation stage, the activities of the individual designer are
monitored by the Design Department Supervisor

On completion of the calculations the designer details in writing all parameters used in
the calculation, the Design Supervisor verifies that the design parameters are correct as
per contract documentation.

Should the contract require the formal submittal of the design calculations to the client then
the Design Supervisor forwards the package to the Engineering Manager for Approval.

All General Arrangement drawings developed from design sketches are reviewed by the
drafting department for drawing accuracy and signed as checked then the package is
forwarded to the Design Department for review by the Designer against his design sketches
to determine if they have been correctly interpreted. The design package is then forwarded
to the client for review and comment.

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Design Validation

All design packages, as detailed in the contractual requirements are forwarded to the client
for review comment and approval prior to the start of fabrication. Should any comments or
status codes be applied to the submitted design package other than approved, these comments
are addressed and another submittal is made to the client. This process is repeated until the
design is acceptable to the client.

Design Changes

When a change or modification to the design is required, the originator of the change
documents the required modification and forwards written instructions to the relevant
departments. Depending on the source of the change notice, the information is transmitted as
follows :

− Internal Change notice Information to be forwarded to the Design Supervisor for

review and action

− External (Client) notice Information to be forwarded to the Design Supervisor for

review and action

All change notices either in the form of commented drawings or written instructions are filed
in the Project File for future reference.

Software

KIRBY Steel Engineering has standardized the computer software used in order to ensure
compatibility with clients and other third parties involved in the project:

− Microsoft Office General Office

− Primavera / Microsoft Project Planning
− Autocad 2D Drafting
− Strucad 3D modeling and drafting
− Bocad 3D modeling and drafting
− Staad Pro 2D & 3D Design
− Master Key Connections Design
− ProKon Connections Design
− PMS system Production Tracking & Monitorng

RFI ‘ s

If during the review, engineering design, or drafting cycles, additional information or

clarifications are required, a formal RFI is raised and issued to the client. The issue and
return of the RFI is recorded.

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Pre-Production Planning

On award of the contract the Planning Department review the overall structure to establish
the following :

− Overall production requirements per week and month

− Sequence of contract execution in order to support the clients program
− Priority for each sub structure
− Engineering and Drafting planning
− Procurement planning

The 3D modeling & drafting systems utilized by KIRBY Steel Engineering produce a full
Bill of Quantities during the "3 D" modelling phase of the drafting cycle. This information is
transferred to the piece monitoring system where the pre-determined priority ratings for each
Sub-structure are automatically assigned to the individual item

This allows the Piece Monitoring System to automatically generate a detailed (item by item)
production program which is then grouped together to give the daily production requirements
for all fabrication activities.

Due to the modular format of the Piece Monitoring System the individual module and the
relevant information required to control a specific activity can be downloaded onto the
computer system of any associate company. This allows them to conduct their area of the
operation in parallel with the overall project requirements.

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Example
Material Preparation

The relevant material preparation modules of the Piece Monitoring System is forwarded to
the relevant departments and all the production scheduling information downloaded.

The engineering department also issues the plates and beam shafts drawings in the format
required to program the CNC equipment used in the material preparation.

As the material is processed in accordance with the production schedule, the Piece
Monitoring System is regularly updated by the computer system controlling the CNC
equipment or by manual entry periodically through the shift. This updated information
allows monitoring the progress of the contract piece by piece.

This example is applicable to each individual stage of the fabrication process.

Identification

All material received either from the mill or merchants stock is inspected on receipt for:

− Completeness of order
− Compliance with Purchase Order requirements
− Transport Damage
− Identifiable to valid mill certificate

As the material is processed through the preparation stage of the fabrication process the heat
number of the individual piece is logged onto the cutting schedule against its unique position
/ item number. This information is then transferred to the Piece Monitoring System
providing material trace-ability for each individual piece back to the mill certification

Handling, Storage and Stacking

Steel plates and sections are either delivered to the preparation facility on a JIT basis or
stored and stacked in a KIRBY Steel Engineering designated area. All material is stored and
stacked in such a manner as to prevent distortion twisting or bending.

Consumable Storage

All welding rods painting and blasting material are stored in accordance with the
anufacturer's recommendations.

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Fabrication Drawings

Material preparation drawings are issued to the Preparation Facility in electronic format and
are identified by phase substructure and cutting schedule.

The assembly drawings are issued either in electronic format or paper copy again they are
identified by phase substructure and assembly schedule

Beam Processing

During the cutting operation each beam is marked with it's item / position number to allow
identification and trace-ability through the rest of the fabrication process.

After the beam has been marked and cut, and depending on the requirements, the beam is
either moved directly to the transit lay-down area or processed thorough the CNC drill
station.

Beam Preparation Equipment

Please refer to the list of equipment attached.

Plate Processing

Plates are processed using various methods depending on thickness contract requirements and
end usage

If the thickness of the plate is 12 mm or less, the plates can be sheared to the required size,
however the end usage and contract requirements are also considered before work is detailed
to these machines.

Once the plate has been cut to the correct size and shape the final operation is producing the
holes. This can be done either by drilling or punching. Again thickness, hole dia, and
contract requirements are considered before allocating the work to the various machines

During the cutting operation, each plate is marked with it's item / position number to allow
identification and trace-ability through the rest of the fabrication process.

All cut edges can be dressed to remove burrs, dross and irregularities. Holes are dressed
as required to provide a smooth contoured surface.

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Plate Processing Equipment

Please refer to the list of equipment attached.

Once the preparation of the material has been completed the material is then ready for
assembly.

Assembly

When the material has passed it's inspection, it is released to the assembly / welding yard
were it is segregated in the lay down yard prior to release to assembly.

The material is assembled in accordance with the fitting schedule issued by Piece Monitoring
System.

The material is assembled in accordance with the fabrication drawings in such a manner that
they are not bent, twisted or otherwise damaged, and any deformation is within the stated
tolerances.

All items, after assembly, are fully dimensionally checked, any deviations are corrected
immediately.

The results of the dimensional check are logged onto the Piece Monitoring System.

Welding

All welding operations are carried out in accordance with KIRBY Steel Engineering’s
approved welding procedures by independently qualified welders.

All procedures and welder qualifications are in accordance with AWS D 1.1

During the welding operation all welders are continually monitored to ensure that the welding
parameters, as detailed in the relevant procedure, are adhered to and that the level of
workmanship is maintained.

All items, after completion of welding are visually inspected against the requirements of
AWS D 1.1 for compliance. Any visual discontinuity is marked and repaired immediately.
Only when the item has been fully passed and accepted will it be released to blasting and
painting

All welding inspections are entered onto the piece monitoring system.

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Curving and Straightening

When it is necessary to curve or straighten components one of the following methods may be
used:

− Mechanical - taking care not to cause indentations or changes in cross section

− Local Application of Heat - ensuring that the temperature does not exceed 650°C

Non-Destructive Testing

Non destructive testing is carried out in accordance with the contract requirements, all NDT
inspections are conducted by an independent 3rd party specialist company with AWS D1.1
acceptance standards used for determining the acceptability of the weld.

The results of all NDT examinations are entered on the Piece Monitoring System.

Surface Preparation and Painting

The surface preparation / blast cleaning produces the required anchor pattern and cleanliness
level as detailed by the paint manufacturer to ensure paint adhesion to the surface.

The Painting Inspector carries out profile checks at the start of each blasting run to ensure
that the required profile and cleanliness levels are met.

All material once blasted are primed within 4 hours to prevent rust bloom.

The painting operation is conducted ony if the following conditions are met:
(as specified by the paint manufacturer)

− The surface temperature shall be at least 3 degrees centigrade above the dew point and
the Relative Humidity (RH%) 40% and 85%.

− Visual checks on the surface shall be carried out to ensure none of the following point
exist oil, grease, dirt, loose paint, rust and other surface contamination.

− There is protection from adverse weather conditions, such as wind that may blow
sand, or other foreign bodies on the painted surface or it may disrupt the paint pattern
or cause dry spray.

− Paint Strip shall be applied to all welds and corners if required.

− Primers, intermediate coats and top coats shall be contrasting colours, if more than
one application is required to achieve the required film thickness, then the same
colour should be used. But reference to Client's specifications must be made before
implementation.

− Finished coatings shall be free of runs, drips, dry spray etc. Areas that are cracked,
damaged or below minimum thickness shall be repaired in prior to dispatch

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All defective areas are to be cleaned with solvents, detergents or clean water as required

All repair areas blast cleaned to the metal surface, with the edges being feathered back at
least 50 mm beyond the clean metal surface. For areas less than 1000 mm2, brush coating
may be acceptable, but with reference to Client's specifications , areas greater than 1000 mm2
the paint shall be applied as to the original specification.

Painted items shall be handled with proper care so that damage to the paint is minimised.

Structural steel items shall not be handled until paint has thoroughly dried.

Care shall be taken to avoid abrasions and other damage.

Nylon / Canvas slings shall be used for handling the coated steelwork or when steel slings are
to be used, they shall not be choked with wood to avoid / limit contact with coated steelwork.

Delivery of Finished Product

Each piece of steelwork shall be distinctly marked with Item No and bar code before dispatch
in accordance with the fabrication drawing . Steelwork shall be stacked on timbers in order to
provide easy handling

All attachments and fittings shall be securely attached. Loose plates and smaller items shall
be either boxed or wired together and then wired to larger parts.

Floor plates shall be bundled for shipment

Bolts, Nuts and Washers shall be packed in strong bags with the Nuts and Washers assembled
on the Bolts.

The client should be informed of the time of delivery and delivery notes shall accompany all
deliveries.

The sequence of shipment shall be such as to expedite erection and minimise field handling
of material

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Attachments

i. KIRBY STEEL ENGINEERING Process Flow Chart & Description

ii. KIRBY STEEL ENGINEERING Change Control Procedure & Description

iii. KIRBY STEEL ENGINEERING Steel Sample Project Quality Plan

iv. KIRBY STEEL ENGINEERING Steel Sample Inspection & Test Plan

v. “P M S” Sample Schedules & Q C Reports

vi. KIRBY STEEL ENGINEERING Welding Procedures

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KIRBY STEEL ENGINEERING Change Procedure

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KIRBY STEEL ENGINEERING Change Procedure

The attached logic chart details the standard method adopted by KIRBY STEEL
ENGINEERING for processing changes. This procedure may be amended to reflect ndividual
contract requirements.

Note: P = Project Management Team

FW = Fabrication Workshop

SAMPLE DOCUMENTATION ONLY

PROJECT QUALITY PLAN

Document No CGP-PQP-204
Revision 0

15-9-01 0 Douglas Bevan Henry Nasr Henry Nasr

Date Revision Author Review Approval

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SAMPLE DOCUMENTATION ONLY

PROJECT QUALITY PLAN

Document No. CGP-PQP-204

Revision 0

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SAMPLE DOCUMENTATION ONLY

INDEX

1.0 Purpose

2.0 Scope

3.0 References

4.0 Definitions

5.0 Responsibilities

6.0 Procedure

6.1 Contract / Tender Review

6.2 Document Control and Quality Records
6.3 Procurement Procedure
6.4 Material Control
6.5 Identification and Tractability
6.6 Process Control
6.7 Inspection and Testing
6.8 Control of Inspection Measuring and Testing Equipment
6.9 Non Conforming Product Control
6.10 Corrective and Preventative Action
6.11 Material Handling Storage and Delivery
6.12 Audit Procedure
6.13 Training

7.0 Exhibits

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SAMPLE DOCUMENTATION ONLY

1.0 Purpose

The purpose of this Standard Project Quality Plan is to outline the applicable
procedures to be used for the execution of a project in conformance with KIRBY
STEEL ENGINEERING Quality system.

2.0 Scope

This procedure is applicable to all contracts where the generation of a specific Project
Quality Plan is not called for by the client.

3.0 References

KIRBY STEEL ENGINEERING's Quality Management System.

4.0 Definitions

KIRBY STEEL ENGINEERING KIRBY STEEL ENGINEERING

ITP Inspection and Test Plan

5.0 Responsibilities

As Detailed in the procedure

6.0 Procedure

6.1 Contract / Tender Review

6.1.1 All Tender Enquiry's Shall Be:

− Logged as received and assigned a Tender Number

− Reviews shall be carried out by Senior Management

− The contract shall be priced by engineering

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SAMPLE DOCUMENTATION ONLY

6.2 Document Control and Quality Records

6.2.1 Project Filing System

On the award of a contract, a contract specific identification number shall be allocated

by the Engineering Manager, and a Project File shall be generated All the in-coming
and out-going documents related to their project will be logged in the Project File.

On completion of the project, the Project files shall be filed for a minimum of 1 year.
After which they may be disposed of, at the discretion of Senior Management

6.2.2 Drawing Receipt Approval and Issue

All drawings received by KIRBY STEEL ENGINEERING relating to a specific

project shall be acknowledged and a copy of the acknowledgement shall be filed in
the project file

All drawings as detailed in the contract shall be issued to the client for approval

After approval Fabrication drawings shall be generated and issued to the relevant
personnel

Their issue and return shall be recorded in the Issue register maintained by the Head
of Drafting or his designated nominee.

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SAMPLE DOCUMENTATION ONLY

6.2.3 Quality Records

The QC Engineer shall maintain the following records: -

− Material Certification
− Goods Inwards Inspection Reports
− Plate / Beam Cutting Schedules
− Consumable Certification (Electrodes, Paint, Bolts etc)
− Fabrication Check Lists
− NDE Reports if applicable
− Welders Qualifications
− Welders Records
− Weld Procedure Specifications
− Procedure Qualification Records
− Painting Release Forms
− Painting Inspection Reports
− Dimensional Check Reports
− Final Inspection Reports
− Copies of Delivery Notes
− QC Fabrication Drawings

On completion of a Project the quality records relating to the project shall be

correlated by the QC Engineer into a Project Data Book. The quality records shall
consist of:

− Material Certification Data Book

− Plate / Beam Cutting Schedules Data Book
− Fabrication Check Lists Data Book
− NDE Reports if applicable Data Book
− Painting Release Forms Data Book
− Painting Inspection Reports Data Book
− Final Inspection Reports Data Book
− Copies of Delivery Notes Forwarded with each delivery
− QC Fabrication Drawings Data Book
− Bolt Certification Data Book
− Paint Certification Data Book

On completion of the project the quality records will be archived for the minimum of
one year

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SAMPLE DOCUMENTATION ONLY

6.2 Procurement Procedure

6.3.1 BOQ

The Engineering Manager through his designated nominee shall ensure that a BOQ is raised
for each project.

The Stores shall check the BOQ against the stock lists and raise the necessary requisition
orders for the balance material

The Commercial Director shall review the requisitions for cost quantity and technical
accuracy; if the requisition is acceptable he shall approve it and forward it to Procurement
who shall raise the order.

6.4 Material Control

6.4.1 Material Receipt

All material ordered by and delivered to KIRBY STEEL ENGINEERING shall be inspected
by the Goods Inwards Inspector in accordance with the relevant Work Instructions and
Procedures.

6.4.2 Traceability

Material trace-ability shall be maintained by heat number, which shall be logged on the
material cutting schedule against the relevant piece number.

6.4.3 Electrodes

All electrodes shall be inspected upon receipt, stored in accordance with KIRBY STEEL
ENGINEERING procedures and their issue, return and baking (if required) shall be recorded
by the Rod Storeman.

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6.4.4 Paint

Paint shall be inspected upon receipt in accordance with KIRBY STEEL

ENGINEERING's procedures; the paint shall be stored in the designated area, used
within its shelf life and rotated through the stores on a first in first out basis.

6.5 Identification and Trace-ability

All material shall be marked with its Project Number and position / piece number at
the material preparation stage.

The material heat numbers shall be logged on the Cutting schedule.

6.6 Process Control

6.6.1 Trace-ability of steel

All steel material shall have a valid mill certificate and the material shall be identified
to the mill certificate

6.6.2 Fabrication / Shop Drawings

All in house drawings shall be checked for accuracy before issue

The drawings shall contain all the necessary details for production to fabricate the
item.

Certain contracts may require specific information to be included on the drawing, the
head of drafting shall be informed of these requirements

6.6.3 Marking

All items shall be marked with their Project Number and their position / piece number
as detailed on the cutting schedule, at the preparation stage.

The Heat Number shall be transferred to the cutting schedule and logged against the
items position piece number.

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6.6.4 Cutting Shaping Bending and Bolt Holes.

Beams plates and sections shall be cut in accordance with their cutting schedules

Cutting may be done by shearing, sawing, grinding and machine cutting. Hand flame
cutting may be allowed if all other methods are impractical.

Holes may be made by drilling or punching and slotted holes made by a combination
of drilling punching and cutting. All tolerances shall be in accordance with the
contract requirements as detailed on the ITP

6.6.5 Assembly

All components shall be assembled in a manner such that they are not bent, twisted or
otherwise damaged.

6.6.6 Curving and Straightening

When it is necessary to curve or straighten components, this may be done by

mechanical means or the local application of heat

6.6.7 Welding

All welding shall be in accordance with the requirements of AWS D1.1

When required by contract all applicable welding procedures shall be submitted to the
client for approval

Pre Qualified welding procedures shall be used unless specifically stated in the
contract documentation.

The preparation and fit up of all parent metal shall be in accordance with the
requirements of AWS D1.1 and the approved welding procedure.

6.6.8 Electrodes and Automatic Coils

Electrodes and automatic coils shall be procured, stored, issued and controlled in
accordance with KIRBY STEEL ENGINEERING's procedure

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6.6.9 Preheat and Interpass Temperature

Minimum Preheat and Interpass Temperature shall be exercised as detailed in the

approved WPS.

6.6.10 Inspection

These activities shall be controlled in accordance with procedure KIRBY STEEL

ENGINEERING Inspection and Testing procedures. And governed by the Test and
Inspection Plan

6.6.11 Surface Preparation, and Painting

All surface preparation, priming and top coating, will be in accordance with the
KIRBY STEEL ENGINEERING' procedure of Paint Control

6.7 Inspection and Testing

6.7.1 Inspection and Test Plan

KIRBY STEEL ENGINEERING standard Inspection and Test Plan shall be adhered
to unless a project specific Inspection and Test Plan is required by the contract in
which case the QA Manager shall draft, submit for approval and issue the relevant
Project Specific Inspection and Test Plan.

6.7.2 Receipt Inspection

All incoming material shall be checked by the Goods Inwards Inspector for
conformance to KIRBY STEEL ENGINEERING's requirements.

6.7.3 In-process Inspection and Testing

All stage inspections shall be carried out by the designated inspection personnel and
the findings reported to the QC Engineer.

6.7.4 Non-destructive Examination

The QC Engineer shall call up such NDT as required (10% MPI + Radiography of
Splice Welds. KIRBY STEEL ENGINEERING normal in-house requirement) to
ensure the quality of KIRBY STEEL ENGINEERING's fabrication.

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6.7.5 Records

Records of all inspections shall be filed with the QC Engineer as objective evidence
of the inspection.

6.8 Control of Inspection Measuring and Testing Equipment

All inspection Measuring and testing equipment utilised by KIRBY STEEL

ENGINEERING shall maintain a current calibration status that is traceable back to
the national standards at all times

6.9 Non Conforming Product Control

6.9.1 Non-conformance of Procured material

If purchased material is found not to conform to KIRBY STEEL ENGINEERING's

requirements, then the material shall be returned to the supplier. The materials
controller shall inform the supplier for the reason for rejection and the supplier may
re-supply material that conforms to KIRBY STEEL ENGINEERING's requirements
or the Materials Controller shall inform procurement who shall place the order with
an alternate supplier.

6.9.2 Non-conformance during Production

When a Non-conformance is noted during production the Inspector shall quarantine

the material and an NCR shall be raised.

The QC engineer shall evaluate the Non-conformance and decide on the relevant
course of action to correct the non-conformance.

Should corrective action be outside the specification requirements then a concession

request shall be forwarded to the client for their recommendation and approval.

Rejected material shall be removed from the production area and either down graded
or scraped

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6.10 Corrective and Preventative Action

6.10.1 Customer Complaints

The QA manager shall record investigate and respond to any formal complaint from
the client.

6.10.2 Quality System Deficiencies

When a deficiency is identified in the Quality System, then the deficiency shall be
reviewed against the relevant procedure. Should it be found necessary to amend the
procedure this shall be done in accordance with Procedure Preparation Style and
Format procedure and the eview and issue procedure as detailed in the Quality
Manual.

6.11 Material Handling Storage and Delivery

6.11.1 Before and After Fabrication

All material shall be stacked in such a manner as to minimise damage and distortion.
The material during fabrication shall be laid out clear of the ground and in such a
manner as to acilitate inspection

6.11.2 After Painting

All painted material shall be stacked in bundles, with wooden strips in between
adjacent members these bundles shall then be metal strapped before loading. All
lifting operations of painted steel shall be done with nylon / canvas slings so as to
minimise damage. Paint touch-up is acceptable before dispatch.

6.11.3 Delivery of Finished Product

All items shall be marked with their item number as detailed on the erection drawings

All loose items shall be securely fastened, bundled or bagged before dispatch.

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6.12 Audit Procedure

The QA Manager or his designated nominee shall carry out periodic audits of the
quality system to access its effectiveness and the level of compliance to the Quality
Management Procedure.

6.13 Training

While it is not generally KIRBY STEEL ENGINEERING's policy to employ then

train personnel but to employ already trained personnel. Should the need for training
of personnel be identified then this training shall be accomplished in one of the
following manners

− Verbal Instruction
− Tool Box Talks
− Work Instructions
− In House Training
− Training Agency (outside the Company)

7.0 Exhibits

Inspection and Test Plan

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Organisation Chart

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Customer Base

Kuwait United Arab Emirates

Snamprogetti/Equate National Food Co.
Al Hamra / MOD System Construct
Jahra Mega Warehouse Choithram & Sons
PIC/Kuwait Fertilizer Plant System Construct
Public Warehousing Sharjah Airport
RECAFCO System Construct
Kuwait Co.for Processing Plant C Fawaz Al Khateeb
Ministry of Defence Orion Engineering
TOYO Sheikh Saleh Bin Ham.
Kuwait Airways Corporation (KAC) Abu Dhabi Municipality
Ahmadi Governorate Gulf Erection / EMC
Kuwait Free Trade Zone System Construct
Coca Cola Boskin Factory
Kuwait Oil Co. Dubai Municipality
National Guard
Bahrain
Qatar Jawid Textile Mill
Al Jaber Engg. Manama Textiles
J.G.C. Daewoo Desalination Project
Qapco/Snamprogetti Rolls Royce / Chrysler
Qatar Clay Bricks Co. Bahrain Airport Service
Naseer Enterprise
NBKS Saudi Arabia
Qatar Steel Co. (QASCO) Ministry of Defence, S.A.
Al Madar Cont. Trdg. Al Owaidah / Ministry of Awkahf
NADA
Oman Al Othman Agri Products
Khimji Textile Mill Al-Othaim Central Warehouse Pro.
Oman Ceramics Ministry of Education
Qurum Contractors Sahara Building Cont.
Steel Service Centre Hussain Bakri Gazzaz & Partners
Raysyt Cement Co. Nesma & Al Fadel Cont. Co.
Al Turki Trdg. Cont. Co.
Yemen Saudi BinLaden Group
Canada Dry TADCO
Yemen Co. For Ind. Invest. Ltd. Saudi National Guard
H.S.A. - (YCFM)

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Customer Base – Ctd.

Syria Jordan
Rubi Eco. Group Jordan Royal Airforce
Deiri Group International Arabian Dev. Co.
Arab Agri. Mfg. Co.
Granada Ceramic Ind. Egypt
Arab Brothers
Lebanon Inglen
Sukom Misr Al Amria
Liban Lait Sal Al Safadi Group
Misr Al Amria
Sudan
Sudan Railway Corporation Tanzania
Coldair P.B. Power / Rolls Royce

Ethiopia Libya
H'rena Pvt. Ltd. F.L. Smidth
Summit Partners Alimaz
Burayu Spring
Sri Lanka
Vietnam Industrial & Commercial dev. Co.
Indochina Ceramics Factory Complex/Star Packaging
American Standard Cotton Line
Triumph International
Nestle Korea
Toforby Corporation
Bangladesh
Spinning Mill/Silver Line Composite Romania
Al Muhaidib & Sons
Pakistan
Adam Motor Co./Car Plan Cambodia
Manitel / Pochentong Airport
Guam
S.H. Behbehani

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Typical Structural Steel Projects

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Typical Structural Steel Projects

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Typical Structural Steel Projects

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Typical Structural Steel Projects

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Typical Structural Steel Projects

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