SITE VISIT (KKB FABRICATION YARD)

During the factory visits at 16th, 23rd & 29th March 2011, the progress was mainly on cutting for the
previous month. For month March the major work had been focus on the assembly and fit- up for the
girders. It had been total of 10 girders fitted into shape but not fully complete fabricate during the 23 rd
March site visit and the last visit for March at 29th, the girders of 30 nos already been fitted in shape and 6
nos were completed with the fillet joints flange to web.

The work sequence for the steelworks:

1. Surface preparation
2. Prime coating
3. Cutting
4. Jointing (transverse weld-flange to flange)
5. Fitting/ fit up (Assembly)
6. Jointing (flange & web)
7. Painting & coating application

We had discussed the work sequence for item 1. Surface preparation to item 4. Jointing (welding) Flange
to Flange at the QA/QC report no. 6 and this report will discuss on the assembly part of the girders for the
last 2 visiting.

16th March 2011

The major progress of KKB still focuses on the cutting and jointing progress. None of the fit-up or
assembly work been carried out. They had been finish cutting for the steel girder’s flange (Top &
Bottom) and web during end of February. The stiffness, bracing and splice plate had taken a lot of time on
cutting and preparation for the jointing for this month.

Bottom plate of slide guide bearing were ready to sent

to site for installation

Flame cutting for the equal angle

 Rough surface after
welding

Welding for transverse

flange jointing Goughing

Ensure 100% joint

fusion & remove the
discontinuities of the
root pass after gouging
Welding transverse wed in progress and each weld run-off plate stacking and ready for testing at Johor.
(Professional Testing services Sdn. Bhd.)

Name: Bantin Anak

Sadan
StampsNo:QW-46

Name :
Tingga Ak
Medang
Stamp
No. QW-
51
Name : Muncheng
Anak Milu
Tamp No. QW-01

Each run-off plate prepared for testing purpose marked with the name of qualified welder from KKB.
23rd March 2011

This visiting had shown us the great progress of the steel girders, it finally fitted into shape. The total of
10 girders been fitted up by spot weld only. The fillet weld for connection web to top and bottom flange
was not completed yet.

All the equal angle, stiffeners & splice plates were completed cutting and drilling.
29th March 2011

During the visiting with the Hart Builders and representative of JKR, the visit was focus on the progress
of the fabrication of steel girders. The girders with temporary tack weld ready for the flange to web joint
are around 24 nos and completed jointing of flange to web are 6 nos.
The testing for Non destructive testing, radiographic testing was planned to perform at the early of April
prior delivery to site.
Completed fillet weld

Fillet weld (Flange to

web joints

Stacking after
temporary tack
weld

Girders in shape
ready for jointing
 Welding for flange
and web

ASSEMBLY FOR STEEL GIRDER

Clamps

web

flange

Hanged or clamps the web to the assembly point for fit-up. The web was plated horizontal / laid in flat
and support by the vertical square steel case as temporary support during welding.

Adjusted the web into position, suitable allowance for the weld connections shall check by welding
section before weld started.
 Gusset

With the exception of longitudinal web to flange welds and longitudinal stiffeners to web welds, all
stiffeners, gusset plate, or any other detail material welded to girder webs shall be a minimum of 300 mm
from the web butt welds.
The welding sequence outlined in the procedure specification shall be such as to avoid needless distortion
and shrinkage stresses in accordance.

A fully automatic single-pass submerged arc used to connect the flange plates to the web plates, unless
the fabricator has special welding fixtures capable of supporting the flange in a horizontal plane while
centering the web on the flange and simultaneously welding both sides of the web to flange connection.
Removal of the slag, rough weld, weld spatter shall be ground smooth prior to painting work
Factory visit of KKB Fabrication yard on 29th March 2011