Structural Steel Erection Reference Manual

Ironworker Quality Construction Practices Structural Steel Erection International Association of Bridge, Structural, Ornamental and Reinforcing Iron Workers Reference Manual

Ironworkers’ IRONWORKERS’ STANDARDS OF EXCELLENCE IRONWORKERS’ STANDARDS OF EXCELLENCE IRONWORKERS’ STANDARDS OF EXCELLENCE IRONWORKERS’ STANDARDS OF EXCELLENCE IRONWORKERS’ STANDARDS OF EXCELLENCE The purpose of tIhReOIrNonWwOorRkeKrsE’ RStSa’ndSaTrdAsNoDf AERxcDelSleOncFe EisXtCoErLeiLnfEorNceCEthe pride of every Standards of Excellence The purpose of the Ironworkers’ Standards of Excellence is to reinforce the pride of every IRONWORKERS’ STANDARDS OF EXCELLENCE The purpose of tIhReOIrNonWwOorRkeKrsE’ RStSa’ndSaTrdAsNoDf AERxcDelSleOncFe EisXtCoErLeiLnfEorNceCEthe pride of every Ironworker and our commitment to be the most skilled, most productive and safest craft in the The purpose of the Ironworkers’ Standards of Excellence is to reinforce the pride of every Ironworker and our commitment to be the most skilled, most productive and safest craft in the The purpose of the Ironworkers’ Standards of Excellence is to reinforce the pride of every Ironworker and our commitment to be the most skilled, most productive and safest craft in the BThueildpinugrpTorsaedeosf. the Ironworkers’ Standards of Excellence is to reinforce the pride of every Ironworker and our commitment to be the most skilled, most productive and safest craft in the Building Trades. The purpose of the Ironworkers’ Standards of Excellence is to reinforce the pride of every Ironworker and our commitment to be the most skilled, most productive and safest craft in the TBhueildpinugrpTorsaedeosf. the Ironworkers’ Standards of Excellence is to reinforce the pride of every Ironworker and our commitment to be the most skilled, most productive and safest craft in the Building Trades. Ironworker and our commitment to be the most skilled, most productive and safest craft in the Building Trades. Ironworker and our commitment to be the most skilled, most productive and safest craft in the ABusilUdniniognTrIarodnews.orkers, we pledge ourselves to uphold our word, as given through our Collective As Union Ironworkers, we pledge ourselves to uphold our word, as given through our Collective Building Trades. BAusilUdniniognTrIarodnews.orkers, we pledge ourselves to uphold our word, as given through our Collective Bargaining Agreement, and display the professionalism expected of our trade and Union in all aspects As Union Ironworkers, we pledge ourselves to uphold our word, as given through our Collective Bargaining Agreement, and display the professionalism expected of our trade and Union in all aspects As Union Ironworkers, we pledge ourselves to uphold our word, as given through our Collective Bargaining Agreement, and display the professionalism expected of our trade and Union in all aspects eAmspUlonyimonenItroanswexoerkmeprsli,fiwedebpyletdhgeevaoluresselivnegsrationeudpihnoolduroSutranwdoard,saosfEgixvcenllethnrcoeu.gh our Collective Bargaining Agreement, and display the professionalism expected of our trade and Union in all aspects employment as exemplified by the values ingrained in our Standards of Excellence. As Union Ironworkers, we pledge ourselves to uphold our word, as given through our Collective Bargaining Agreement, and display the professionalism expected of our trade and Union in all aspects AemspUlonyimonenItroanswexoerkmeprsli,fiwedebpyletdhgeevaoluresselivnegsrationeudpihnoolduroSutranwdoard,saosfEgixvcenllethnrcoeu.gh our Collective Bargaining Agreement, and display the professionalism expected of our trade and Union in all aspects employment as exemplified by the values ingrained in our Standards of Excellence. Bargaining Agreement, and display the professionalism expected of our trade and Union in all aspects employment as exemplified by the values ingrained in our Standards of Excellence. Bargaining Agreement, and display the professionalism expected of our trade and Union in all aspects Ietmisplouyrmceonmt amsietmxemntptloifiuesdeboyutrhteravianliunegsaingdraskinilelds,ienaocuhraSntdanedvaerrdysdoafyE,xtocepllreondcuec.e the highest quality work It is our commitment to use our training and skills, each and every day, to produce the highest quality work employment as exemplified by the values ingrained in our Standards of Excellence. eItmips louyrmceonmt amsietmxemntptloifiuesdeboyutrhteravianliunegs aingdraskinilelds,ienaocuhraSntdanedvaerrdys doafyE, xtocepllreondcuec.e the highest quality work of our name and consistent with the Collective Bargaining Agreement. It is our commitment to use our training and skills, each and every day, to produce the highest quality work of our name and consistent with the Collective Bargaining Agreement. It is our commitment to use our training and skills, each and every day, to produce the highest quality work of our name and consistent with the Collective Bargaining Agreement. It is our commitment to use our training and skills, each and every day, to produce the highest quality work of our name and consistent with the Collective Bargaining Agreement. It is our commitment to use our training and skills, each and every day, to produce the highest quality work of our name and consistent with the Collective Bargaining Agreement. It is our commitment to use our training and skills, each and every day, to produce the highest quality work oAfsoaunr Inraomnwe oarnkdercomnesmisbtenrt, wI aitghretheetoC:ollective Bargaining Agreement. As an Ironworker member, I agree to: of our name and consistent with the Collective Bargaining Agreement. oAfsoaunr Inraomnwe oarnkdercomnesmisbtenrt, wI aitghretheetoC:ollective Bargaining Agreement. As an Ironworker member, I agree to: of our of our of our of our of our As an Ironworker member, I agree to: As an• IroAnwdhoerkrertommemy bresrp, oI nasgirbeielitioe:s under the Collective Bargaining Agreement for start and quit times, as well • Adhere to my responsibilities under the Collective Bargaining Agreement for start and quit times, as As an Ironworker member, I agree to: well As an• • • • • IroAnwdhoerkrertommemy bresrp, oI nasgirbeielitioe:s under the Collective Bargaining Agreement for start and quit times, as as lunch and break times. Adhere to my responsibilities under the Collective Bargaining Agreement for start and quit times, as as lunch and break times. well • Adhere to my responsibilities under the Collective Bargaining Agreement for start and quit times, as as lunch and break times. Adhere to my responsibilities under the Collective Bargaining Agreement for start and quit times, as aAsllouwncmh yanRdebpreaskenttiamtievse. to handle any disagreements or breaches by refusing to engage in unlawful Allow my Representative to handle any disagreements or breaches by refusing to engage in unlawful as lunch and break times. well • well job job job job job job job job • • aAsllouwncmh yanRdebpreaskenttiamtievse. to handle any disagreements or breaches by refusing to engage in unlawful disruptions, slowdowns or any activities that affect our good name. Allow my Representative to handle any disagreements or breaches by refusing to engage in unlawful disruptions, slowdowns or any activities that affect our good name. • • Allow my Representative to handle any disagreements or breaches by refusing to engage in unlawful disruptions, slowdowns or any activities that affect our good name. Allow my Representative to handle any disagreements or breaches by refusing to engage in unlawful disruptions, slowdowns or any activities that affect our good name. • • Allow my Representative to handle any disagreements or breaches by refusing to engage in unlawful disruptions, slowdowns or any activities that affect our good name. Allow my Representative to handle any disagreements or breaches by refusing to engage in unlawful dRiessruppectitotnhse, Csluoswtodmowern’s oarndanEymapctliovyietire’s trhigaht tasf,fpecrot poeurtygoaond ntoaomlse.as I do my own. • • • Respect the Customer’s and Employer’s rights, property and tools as I do my own. disruptions, slowdowns or any activities that affect our good name. • dRiessruppectitotnhse, Csluoswtodmowern’s oarndanEymapctliovyietire’s trhigaht tasf,fpecrot poeurtygoaond ntoaomlse.as I do my own. • Respect the Customer’s and Employer’s rights, property and tools as I do my own. • Respect the Customer’s and Employer’s rights, property and tools as I do my own. • MReeseptemctythresCpounstsoibmileirty’ staonsdhoEwmpulpoyeevre’rsyrdigahyt;so, uptrfoitpterdtyfoarnwd otorkolasnads fIitdformdyuotywwn.ithout engaging in • • Meet my responsibility to show up every day; outfitted for work and fit for duty without engaging in Respect the Customer’s and Employer’s rights, property and tools as I do my own. • MReeseptemctythresCpounstsoibmileirty’ staonsdhoEwmpulpoyeevre’rsyrdigahyt;so, uptrfoitpterdtyfoarnwd otorkolasnads fIitdformdyuotywwn.ithout engaging in substance abuse. • Meet my responsibility to show up every day; outfitted for work and fit for duty without engaging in substance abuse. • Meet my responsibility to show up every day; outfitted for work and fit for duty without engaging in substance abuse. • Meet my responsibility to show up every day; outfitted for work and fit for duty without engaging in substance abuse. • Meet my responsibility to show up every day; outfitted for work and fit for duty without engaging in substance abuse. Meet my responsibility to show up every day; outfitted for work and fit for duty without engaging in sCuobosptaenrcaeteawbuitshe.the Customer and Employer to meet their statutory, regulatory and contractual Cooperate with the Customer and Employer to meet their statutory, regulatory and contractual substance abuse. • • • • • • • • • • • • • • • • • • • • • • sCuobosptaenrcaeteawbuitshe.the Customer and Employer to meet their statutory, regulatory and contractual responsibilities to maintain a safe, healthy and sanitary workplace. Adhere to my responsibilities under the Collective Bargaining Agreement for start and quit times, as as lunch and break times. Adhere to my responsibilities under the Collective Bargaining Agreement for start and quit times, as as lunch and break times. well Cooperate with the Customer and Employer to meet their statutory, regulatory and contractual responsibilities to maintain a safe, healthy and sanitary workplace. Cooperate with the Customer and Employer to meet their statutory, regulatory and contractual responsibilities to maintain a safe, healthy and sanitary workplace. Cooperate with the Customer and Employer to meet their statutory, regulatory and contractual responsibilities to maintain a safe, healthy and sanitary workplace. Cooperate with the Customer and Employer to meet their statutory, regulatory and contractual responsibilities to maintain a safe, healthy and sanitary workplace. Cooperate with the Customer and Employer to meet their statutory, regulatory and contractual rDeospmonysbibeisltittioeswtormk aininataminaannsearfec,ohnesaisltheyntawndithsatnhietaqruyawliotyr,kprlaocdeu.ctivity and safety of every task that I am Do my best to work in a manner consistent with the quality, productivity and safety of every task that I am responsibilities to maintain a safe, healthy and sanitary workplace. rDeospmonysbibeisltittioeswtormk aininataminaannsearfec,ohnesaisltheyntawndithsatnhietaqruyawliotyr,kprlaocdeu.ctivity and safety of every task that I am assigned. Do my best to work in a manner consistent with the quality, productivity and safety of every task that I am assigned. Do my best to work in a manner consistent with the quality, productivity and safety of every task that I am assigned. Do my best to work in a manner consistent with the quality, productivity and safety of every task that I am assigned. Do my best to work in a manner consistent with the quality, productivity and safety of every task that I am assigned. Do my best to work in a manner consistent with the quality, productivity and safety of every task that I am aDsosigmnyedb.est to help every co-worker return home safe at the conclusion of every shift. Do my best to help every co-worker return home safe at the conclusion of every shift. assigned. aDsosigmnyedb.est to help every co-worker return home safe at the conclusion of every shift. Do my best to help every co-worker return home safe at the conclusion of every shift. Do my best to help every co-worker return home safe at the conclusion of every shift. The •IronwDormkeyrsb’eSstatondhaerldpseovferEyxcoe-lwleonrckeerwrielltuirnncrheoamse tshaefeparitdteh,etchoenpclruosdiuocntiovfiteyvearnydsthieft.craftsmanship of every The Ironworkers’ Standards of Excellence will increase the pride, the productivity and the craftsmanship of every • Do my best to help every co-worker return home safe at the conclusion of every shift. The •IronwDormkeyrsb’eSstatondhaerldpseovferEyxcoe-lwleonrckeerwrielltuirnncrheoamse tshaefeparitdteh,etchoenpclruosdiuocntiovfiteyvearnydsthieft.craftsmanship of every Ironworker throughout North America. This commitment will improve work place conditions, increase work The Ironworkers’ Standards of Excellence will increase the pride, the productivity and the craftsmanship of every Ironworker throughout North America. This commitment will improve work place conditions, increase work The Ironworkers’ Standards of Excellence will increase the pride, the productivity and the craftsmanship of every Ironworker throughout North America. This commitment will improve work place conditions, increase work oTphpeoIrrtounwitioersk,earnsd’ ShetalpndmaradinstaoifnEoxucrewlleangcees,wbeilnleifnitcsreaansdestthaendparrideo,fthlievipnrgo.dIunctaivdidtiytioand, ththeeSctraanfdtsamrdasnoshfiEpxocfelelevnecrye Ironworker throughout North America. This commitment will improve work place conditions, increase work opportunities, and help maintain our wages, benefits and standard of living. In addition, the Standards of Excellence The Ironworkers’ Standards of Excellence will increase the pride, the productivity and the craftsmanship of every Ironworker throughout North America. This commitment will improve work place conditions, increase work TophpeoIrrtounwitioersk,earnsd’ ShetalpndmaradinstaoifnEoxucrewlleangcees,wbeilnleifnitcsreaansdestthaendparrideo,fthlievipnrgo.dIunctaivdidtiytioand, ththeeSctraanfdtsamrdasnoshfiEpxocfelelevnecrye wIroilnlwheolrpkeorurthsirgonuagthooryutemNpolrotyherAsmcoemricpale.teTthiesircpormojmecitms oenttimwiel,loinmbpurdogvet wiotrhknopliancjeuriceosnodritaioccnisd,enintsc.rease work opportunities, and help maintain our wages, benefits and standard of living. In addition, the Standards of Excellence will help our signatory employers complete their projects on time, on budget with no injuries or accidents. Ironworker throughout North America. This commitment will improve work place conditions, increase work opportunities, and help maintain our wages, benefits and standard of living. In addition, the Standards of Excellence IwroilnlwheolrpkeorurthsirgonuagthooryutemNpolrotyherAsmcoemricpale.teTthiesircpormojmecitms oenttimwiel,loinmbpurdogvet wiotrhknopliancjeuriceosnodritaioccnisd,enintsc.rease work opportunities, and help maintain our wages, benefits and standard of living. In addition, the Standards of Excellence will help our signatory employers complete their projects on time, on budget with no injuries or accidents. opportunities, and help maintain our wages, benefits and standard of living. In addition, the Standards of Excellence will help our signatory employers complete their projects on time, on budget with no injuries or accidents. opportunities, and help maintain our wages, benefits and standard of living. In addition, the Standards of Excellence IwnilalchceolrpdoanucresiwgnitahtoAryrtiecmlepXloXyeVrsI,cSoemcptiloente1t5heoifr tphreojIencttesrnoantitoimnael,Cononbsutidtguetitown,itchhnaorgiensjumriaeysboer apcrecfiderernetds.against any In accordance with Article XXVI, Section 15 of the International Constitution, charges may be preferred against any will help our signatory employers complete their projects on time, on budget with no injuries or accidents. wInilalchceolrpdoanucresiwgnitahtoAryrtiecmlepXloXyeVrsI,cSoemcptiloente1t5heoifr tphreojIencttesrnoantitoimnael,Cononbsutidtguetitown,itchhnaorgiensjumriaeysboer apcrecfiderernetds.against any member for violations of the Ironworkers’ Standards of Excellence, including, but not limited to the following In accordance with Article XXVI, Section 15 of the International Constitution, charges may be preferred against any member for violations of the Ironworkers’ Standards of Excellence, including, but not limited to the following In accordance with Article XXVI, Section 15 of the International Constitution, charges may be preferred against any member for violations of the Ironworkers’ Standards of Excellence, including, but not limited to the following rIneaascocnosr:dance with Article XXVI, Section 15 of the International Constitution, charges may be preferred against any member for violations of the Ironworkers’ Standards of Excellence, including, but not limited to the following reasons: In accordance with Article XXVI, Section 15 of the International Constitution, charges may be preferred against any member for violations of the Ironworkers’ Standards of Excellence, including, but not limited to the following Irneaascocnosr:dance with Article XXVI, Section 15 of the International Constitution, charges may be preferred against any member for violations of the Ironworkers’ Standards of Excellence, including, but not limited to the following reasons: member for violations of the Ironworkers’ Standards of Excellence, including, but not limited to the following reasons: member for violations of the Ironworkers’ Standards of Excellence, including, but not limited to the following reaso•ns: Taking a job referral and not reporting to work, • Taking a job referral and not reporting to work, reasons: reaso•ns: Taking a job referral and not reporting to work, • Failing pre-employment qualifications and/or • Taking a job referral and not reporting to work, • Failing pre-employment qualifications and/or • Taking a job referral and not reporting to work, • Failing pre-employment qualifications and/or • DTaiskcihnagragejdobforrefexrcraelssainvde naobtsernepteoeritsimng. to work, • Failing pre-employment qualifications and/or • TDaiskcihnagragejdobforrefexrcraelssainvde naobtsernepteoeritsimng. to work, • Failing pre-employment qualifications and/or • TDaiskcihnagragejdobforrefexrcraelssainvde naobtsernepteoeritsimng. to work, • Failing pre-employment qualifications and/or • Discharged for excessive absenteeism. • Failing pre-employment qualifications and/or • Discharged for excessive absenteeism. • Failing pre-employment qualifications and/or Fines• forDthisechfiarrsgteodffeonrsexscheaslslivbeanboselnetsesetihsman. One Hundred Dollars ($100.00) or no more than one (1) day’s pay, Fines for the first offense shall be no less than One Hundred Dollars ($100.00) or no more than one (1) day’s pay, • Discharged for excessive absenteeism. Fines• forDthisechfiarrsgteodffeonrsexscheaslslivbeanboselnetsesetihsman. One Hundred Dollars ($100.00) or no more than one (1) day’s pay, including fringe benefits and working assessments of eight (8) hours. Fines for the first offense shall be no less than One Hundred Dollars ($100.00) or no more than one (1) day’s pay, including fringe benefits and working assessments of eight (8) hours. Fines for the first offense shall be no less than One Hundred Dollars ($100.00) or no more than one (1) day’s pay, including fringe benefits and working assessments of eight (8) hours. Fines for the first offense shall be no less than One Hundred Dollars ($100.00) or no more than one (1) day’s pay, including fringe benefits and working assessments of eight (8) hours. Fines for the first offense shall be no less than One Hundred Dollars ($100.00) or no more than one (1) day’s pay, including fringe benefits and working assessments of eight (8) hours. Fines for the first offense shall be no less than One Hundred Dollars ($100.00) or no more than one (1) day’s pay, Mincelmudbienrgs fhrainvginegbbeneenfitfsoaund wguoirlktyinogfaassseescsmonedntosfofefnesieg,hftin(8e)s hsohuarlls.be no less than Five Hundred Dollars ($500.00) Members having been found guilty of a second offense, fines shall be no less than Five Hundred Dollars ($500.00) including fringe benefits and working assessments of eight (8) hours. iMncelmudbienrgs fhrainvginegbbeneenfitfsoaund wguoirlktyinogfaassseescsmonedntosfofefnesieg,hftin(8e)s hsohuarlls.be no less than Five Hundred Dollars ($500.00) or no more than one (1) week’s pay, including fringe benefits and working assessments of forty (40) hours. Members having been found guilty of a second offense, fines shall be no less than Five Hundred Dollars ($500.00) or no more than one (1) week’s pay, including fringe benefits and working assessments of forty (40) hours. Members having been found guilty of a second offense, fines shall be no less than Five Hundred Dollars ($500.00) or no more than one (1) week’s pay, including fringe benefits and working assessments of forty (40) hours. Members having been found guilty of a second offense, fines shall be no less than Five Hundred Dollars ($500.00) or no more than one (1) week’s pay, including fringe benefits and working assessments of forty (40) hours. Members having been found guilty of a second offense, fines shall be no less than Five Hundred Dollars ($500.00) or no more than one (1) week’s pay, including fringe benefits and working assessments of forty (40) hours. Members having been found guilty of a second offense, fines shall be no less than Five Hundred Dollars ($500.00) Morenmobmerosrehathvaingobnee(n1)fowuenedk’gsupilaty,oifncaluthdirndgofrffinengseeb,efnineefistshaanldl bweornkoinlgesasstsheasnsmOenetsTohfofuosratynd(4D0)olhloaursrs(.$1,000.00) Members having been found guilty of a third offense, fines shall be no less than One Thousand Dollars ($1,000.00) or no more than one (1) week’s pay, including fringe benefits and working assessments of forty (40) hours. oMrenmobmerosrehathvaingobnee(n1)fowuenedk’gsupilaty,oifncaluthdirndgofrffinengseeb,efnineefistshaanldl bweornkoinlgesasstsheasnsmOenetsTohfofuosratynd(4D0)olhloaursrs(.$1,000.00) and no more than two (2) week’s pay, including fringe benefits and working assessments of eighty (80) hours. Members having been found guilty of a third offense, fines shall be no less than One Thousand Dollars ($1,000.00) and no more than two (2) week’s pay, including fringe benefits and working assessments of eighty (80) hours. Members having been found guilty of a third offense, fines shall be no less than One Thousand Dollars ($1,000.00) and no more than two (2) week’s pay, including fringe benefits and working assessments of eighty (80) hours. Members having been found guilty of a third offense, fines shall be no less than One Thousand Dollars ($1,000.00) and no more than two (2) week’s pay, including fringe benefits and working assessments of eighty (80) hours. Members having been found guilty of a third offense, fines shall be no less than One Thousand Dollars ($1,000.00) and no more than two (2) week’s pay, including fringe benefits and working assessments of eighty (80) hours. Members having been found guilty of a third offense, fines shall be no less than One Thousand Dollars ($1,000.00) Aanndynmoemobrertfhoaunntdwgou(i2lt)ywoefetkh’esapfaoyr,eminecnlutidoinegdfrviinogleatbioenseftihtsreaen(d3w) toimrkeinsgwaisthseinssamtehnretseo(f3)eiygehatryp(e8r0i)odhomuarsy. also be Any member found guilty of the aforementioned violations three (3) times within a three (3) year period may also be and no more than two (2) week’s pay, including fringe benefits and working assessments of eighty (80) hours. aAnndynmoemobrertfhoaunntdwgou(i2lt)ywoefetkh’esapfaoyr,eminecnlutidoinegdfrviinogleatbioenseftihtsreaen(d3w) toimrkeinsgwaisthseinssamtehnretseo(f3)eiygehatryp(e8r0i)odhomuarsy. also be expelled from the Local Union subject to the approval of the General Executive Board. Any member found guilty of the aforementioned violations three (3) times within a three (3) year period may also be expelled from the Local Union subject to the approval of the General Executive Board. Any member found guilty of the aforementioned violations three (3) times within a three (3) year period may also be expelled from the Local Union subject to the approval of the General Executive Board. Any member found guilty of the aforementioned violations three (3) times within a three (3) year period may also be expelled from the Local Union subject to the approval of the General Executive Board. Any member found guilty of the aforementioned violations three (3) times within a three (3) year period may also be expelled from the Local Union subject to the approval of the General Executive Board. Any member found guilty of the aforementioned violations three (3) times within a three (3) year period may also be IexapceklnleodwflerodmgetthheisLroecsaploUnsniiboinlitsyubanjedctptloedtghe mapypwroovradl toof dthoetGheensaemrael.Executive Board. I acknowledge this responsibility and pledge my word to do the same. expelled from the Local Union subject to the approval of the General Executive Board. e I x a p c e k l n l e o d w f l e r o d mg e t t h h e i s L r o e c s a p l o U n s n i i b o i n l i t s y u b a n j e d c t p t l o e d t g h e e ma p y p wr o o v r a d l t o o f d t h o e t Gh e e n s a e mr a e l . E x e c u t i v e B o a r d . I acknowledge this responsibility and pledge my word to do the same. I acknowledge this responsibility and pledge my word to do the same. I acknowledge this responsibility and pledge my word to do the same. I acknowledge this responsibility and pledge my word to do the same. I acknowledge this responsibility and pledge my word to do the same. of our of our of our worthy worthy worthy worthy worthy worthy worthy worthy well well

Ironworker Quality Construction Practices Structural Steel Erection Reference Manual International Association of Bridge, Structural, Ornamental and Reinforcing Iron Workers

Apprenticeship and Training Department and National Fund Mission Statement The mission of the Ironworkers Apprenticeship and Training Department is to ensure that our contractors and employers have union Ironworkers with the skills, knowledge, and training necessary to be safe on the job site, competitive in the workplace, and satisfied in their careers. We accomplish this mission by providing training and training materials, leadership, accreditation, and certification in order to uphold union values and the principles of service and professionalism. We stand for: Unionism Safety Leadership Service Integrity Professionalism These manuals are provided to you to assist in your training and educate you concerning the importance of safety on the job. It is important for you to fully understand that your employer and other employers on the job site are first and foremost responsible for creating a safe environment. The National Training Fund and IMPACT are not responsible for the formulation of employer safety policies or maintenance of safety on the job site. The content in these manuals is intended for the sole use of the National Training Fund, IMPACT, and signatory employers, and should not be construed to imply that no other hazards or hazard- ous conditions may be present in your workplace. The training guidelines and information pro- vided in these manuals are not intended to comply with any federal, state, or local statutes per- taining to workplace training or safety and health requirements. Copyright 2018. International Association of Bridge, Structural, Ornamental and Reinforcing Iron Workers, AFL-CIO, Washington, DC. All rights reserved. No portion of this document may be reproduced without the express written permission of the copyright holder.

▶▶TABLE OF CONTENTS List of Tables ........................................................................................ Acknowledgements ............................................................................ Preface .................................................................................................. ▶▶SECTION 1: Introduction to Steel Erection ix xi xv 1.1 1.2 1.5 1.8 1.15 1.18 1.22 1.25 2.1 2.2 2.5 2.8 2.12 2.15 2.16 3.1 3.2 3.6 UNIT 1: History of Iron and Overview of Structural Steel Ironwork .. Objective 1: Early History of Iron .................................................. Objective 2: The Transition from Iron to Steel ............................. Objective 3: The Evolution of Structural Steel for Building Use Objective 4: Riveting ........................................................................ Objective 5: Planning and Scheduling ........................................... Objective 6: A Brief Overview of Structural Steel Erection ........ Objective 7: The Structural Steel Ironworker ................................ General Safety For Structural Steel Erection ....................... Objective 1: Basic Safety .................................................................. Objective 2: Personal Protective Equipment (PPE) ..................... Objective 3: JHAs and Safety Meetings ......................................... Objective 4: First Aid and Fire Safety ............................................ Objective 5: Substance Abuse ......................................................... Objective 6: Safety Data Sheets (SDSs) .......................................... Tools and Equipment for Structural Steel Erection ............ Objective 1: Basic Hand Tools ........................................................ Objective 2: Power Tools ................................................................. UNIT 2: UNIT 3: Table of Contents iii

UNIT 4: UNIT 5: Unloading, Handling, and Storing Structural Steel Materials .. 4.1 Objective 1: Unloading, Sorting, Dressing Out, and Storing Structural Steel ........................................................................... 4.2 Objective 2: Safely and Appropriately Unloading Structural Steel ........................................................................... 4.9 Structural Connections ......................................................... 5.1 Objective 1: Structural Connection Types and Fastening Methods.. 5.2 UNIT 6: Erecting Columns and Beams ............................................... 6.1 Objective 1: Anchor Bolts and Column Base Plates .................... 6.2 Objective 2: Rigging Columns ........................................................ 6.6 Objective 3: Erecting Columns ....................................................... 6.9 Objective 4: Erecting Beams ........................................................... 6.11 Objective 5: Column and Beam Splicing ....................................... 6.18 Objective 6: Bracing ......................................................................... 6.21 Objective 7: Topping Out ................................................................ 6.23 Installing Joists, Joist Girders, and Trusses .......................... 7.1 Objective 1: Steel Joists .................................................................... 7.2 Objective 2: Connecting Bar Joists ................................................. 7.5 Objective 3: Joist Girders and Joist Girder Connections ............. 7.7 Objective 4: Erecting Joists and Joist Girders ............................... 7.9 UNIT 7: Objective 3: Layout Instruments Objective 4: Welding Machines Objective 5: Rigging Equipment .................................................... 3.14 ...................................................... 3.18 ..................................................... 3.23 ▶▶SECTION 2: Erecting Structural Steel Objective 5: Bridging Objective 6: Trusses ....................................................................... 7.12 .......................................................................... 7.14 iv Structural Steel Erection

UNIT 8: Plumbing and Aligning Structural Steel .............................. Objective 1: Plumbing and Aligning Structural Steel .................. Objective 2: Plumbing and Spacing Welded Structures .............. Objective 3: Detailing Structural Steel ........................................... Bolting Up of Structural Steel ............................................... Objective 1: Bolts and Accessories ................................................. Objective 2: Bolt Lengths ................................................................. Objective 3: Tension and Torque .................................................... Objective 4: Installation of Bolts ..................................................... Objective 5: Methods Used to tension bolts ................................. Objective 6: Preinstallation Verification Testing of Bolts ............ Objective 7: Inspecting Bolts .......................................................... Handling and Installing Metal Deck .................................... Objective 1: Decking ........................................................................ Objective 2: Preparation .................................................................. Objective 3: Installation ................................................................... Handling and Installing Sheeting ......................................... Objective 1: Types of Sheeting ........................................................ Objective 2: Preparation .................................................................. Objective 3: Accessing Work Areas and Materials to Install Sheeting ...................................................................... Objective 4: Installing Sheeting ...................................................... Objective 5: Solar Air Heating Systems ......................................... Introduction to Structural Steel Erection and Detail Drawings . Objective 1: Structural Steel Erection and Detail Drawings ....... Objective 2: Common Views Used in Structural Steel Drawings ... Objective 3: Elevations ..................................................................... Objective 4: Symbols and Abbreviations ....................................... 8.1 8.2 8.8 8.10 9.1 9.2 9.11 9.22 9.24 9.28 9.34 9.36 10.1 10.2 10.4 10.8 11.1 11.2 11.5 11.7 11.12 11.18 12.1 12.2 12.4 12.6 12.8 UNIT 9: UNIT 10: UNIT 11: UNIT 12 Table of Contents v

UNIT 13: Objective 5: Welding Symbols ........................................................ 12.19 Objective 6: Piece Marks ................................................................. 12.24 Objective 7: Structural Steel Shapes and Notation Sequences .... 12.26 Reading Structural Steel Blueprints ..................................... 13.1 Objective 1: Reading Structural Steel Erection and Shop Detail Drawings ........................................................ 13.2 ▶▶SECTION 3: Erecting Other Structures UNIT 14: UNIT 15: Erecting Bridges ..................................................................... 14.1 Objective 1: History of Bridge Construction ................................ 14.2 Objective 2: How Bridges Work ..................................................... 14.4 Objective 3: Bridge Types ................................................................ 14.7 Objective 4: Steps in Erecting a Bridge .......................................... 14.17 Erecting Towers ...................................................................... 15.1 Objective 1: Types of Towers ........................................................... 15.2 Objective 2: Uses of Towers ............................................................. 15.4 Objective 3: Procedures for Erecting Towers ................................ 15.11 Objective 4: Tensioning Guy Wires and Cables ........................... 15.18 Objective 5: Erecting Communications Towers ........................... 15.20 Objective 6: Safety Concerns, Standards, and Regulations ......... 15.25 Erecting Wind Turbines ......................................................... 16.1 Objective 1: History of Wind Turbines .......................................... 16.2 Objective 2: Types and Basic Parts of Wind Turbines ................. 16.3 Objective 3: Blades and Rotation Control ..................................... 16.7 Objective 4: Erecting Wind Turbines ............................................. 16.9 Objective 5: Wind Turbine Maintenance ...................................... 16.22 UNIT 16: vi Structural Steel Erection

UNIT 17: Erecting Clear Span and Modular Structures ...................... 17.1 Objective 1: Clear Span Structures ................................................. 17.2 Objective 2: Modular Structures ..................................................... 17.7 UNIT 18: UNIT 19: Erecting Amusement Park Structures Objective 1: History of Amusement Parks Objective 2: History of the Roller Coaster Objective 3: Erecting an Amusement Park Ride .......................... 18.6 Objective 4: Ride Inspections and Maintenance .......................... 18.11 Composites and Structural Erection .................................... 19.1 Objective 1: Composite Construction Materials .......................... 19.2 Objective 2: Working with Composites on the Job Site ............... 19.6 Objective 3: Procedures for Fabricating Composites ................... 19.10 Objective 4: Procedures for Repairing Composites ..................... 19.18 Glossary ................................................................................................... G.1 .................................. 18.1 .................................... 18.2 .................................... 18.4 Table of Contents vii

viii Structural Steel Erection

3.1 Common Hand Tools Used by Ironworkers ......................................... 3.2 Other Welding Safety Considerations ................................................... 3.3 Safe Working Load in Tons for Screw Anchor Shackles....................... 5.1 Shear Connection Fastening Methods .................................................. 5.2 Moment Connection Fastening Methods ............................................. 7.1 Camber for Standard Types of Joists ..................................................... 9.1 High-Strength Bolt Dimensions ............................................................ 9.2 Maximum Tensile Strengths of ASTM A325 and A490 Bolts ............. 9.3 Suggested Bolt Lengths – 3⁄4\" Diameter Bolts ........................................ 9.4 Suggested Bolt Lengths – 7⁄8\" Diameter Bolts ........................................ 9.5 Suggested Bolt Lengths – 1\" Diameter Bolts ......................................... 9.6 Estimating Bolt Lengths .......................................................................... 9.7 Turn-of-Nut Method Required Turns ................................................... 9.8 DTI Gaps Allowed ................................................................................... 12.1 Steel Erection Drawing Symbols and Abbreviations ............................ 12.2 Nine Elements of an Assembled Welding Symbol ............................... 12.3 Welding Symbols and Applications ....................................................... 12.4 Notation Sequences of Structural Steel Shapes ..................................... 13.1 Structural Steel Drawings Summary ...................................................... 3.2 3.19 3.24 5.3 5.4 7.4 9.4 9.5 9.12 9.15 9.18 9.21 9.29 9.31 12.8 12.20 12.22 12.31 13.2 LIst of Tables ix ▶▶LIST OF TABLES

x Structural Steel Erection

The International Association of Bridge, Structural, Ornamental and Reinforcing Iron Workers, AFL-CIO, wishes to express its sincere gratitude and appreciation to the following individuals, companies, and associations for their efforts which made the development of this manual possible. Special Acknowledgements A special thanks to photographer John Robinson, author of Spanning the Straight: Building the Alfred Zampa Memorial Bridge, for permission to use several of his photographs. We would like to offer a special thanks to Mike Relyin from Local 25 in Detroit for arranging the use of the majority of the drawings for this training package. We would like to thank CENTRIA Architectural Systems for granting permission to use videos from their training modules. We would also like to offer a special thanks to the following individuals for acquir- ing some of the photographs used in this manual: John Bosworth, Bosworth Erectors Bryan Brady, Local 40/361 Kaye Brazier, Local 55 Neil Conley, Local 7 Michael Durant, Local 7 Jack Gavett, Local 229 Terry Gildon, Local 21 Fiore Grassetti, Local 7 Patty Kosta, District Council of Northern New Jersey Frank Marsh, Local 401 Neal J. McKelligan, Local 7 Jose Naranjo, Local 229 Ed Penna, Local 405 Mike Relyin, Local 25 Acknowledgements xi ▶▶ACKNOWLEDGEMENTS

Ron Repmann, District Council of Northern New Jersey Dan Slavin, Local 787 Wayne Worrall, Local 771 Some of the images and information in this training package were also provided by or derived from materials available through the OSHA Training Institute Edu- cation Center under OSHA Harwood grant #46F3-HT13. Organizations A.C. Dellovade (Peter Dellovade) American Institute of Steel Construction (AISC) www.aisc.org Applied Bolting Technology (Chris Curven) www.appliedbolting.com Canadian Institute of Steel Construction (CISC) www.cisc-icca.ca Centria www.centria.com Construction Lifters www.constructionlifters.com The Crosby Group (Brad Beal) www.thecrosbygroup.com Flexospan www.flexospan.com Hilti Corporation (Chris Gill) www.hilti.com Hytorc (Joe Paul) www.hytorc.com Ironworker Employers Association of Western Pennsylvania (Bill Ligetti) www.iwea.org Klein Tools www.kleintools.com National Association of Tower Erectors www.natehome.com Nucor-Vulcraft Group www.vulcraft.com xii Structural Steel Erection

Patent Construction Systems www.pcshd.com Research Council on Structural Connections (RCSC) www.boltcouncil.org Spider, a division of SafeWorks, LLC www.spiderstaging.com Steel Deck Institute (SDI) www.sdi.org Steel Joist Institute (SJI) www.steeljoist.org Steel Structures Technology Center (Bob Shaw) www.steelstructures.com Strongwell Corporation (Ed Balaban) www.strongwell.com Torc Up (Jacki Counterman) www.torcup.com TurnaSure, LLC (Rich Brown) www.turnasure.com White Construction www.whiteconstruction.com Individuals Harvey C. Swift, IMPACT Assistant Director of Education and Training Kevin Bryenton, President,District Council of Ontario Dane Bowers, Apprenticeship Coordinator, Local 340 Ray Simpson, Local 700 Lee Worley, Apprenticeship Coordinator, Local 29 Jeff Norris, Apprentice Coordinator, Local 720 Dick Zampa, Apprenticeship Director, Ironworker District Council & Vicinity Jim Gallik, Apprenticeship Coordinator, Local 3 Greg McClelland, Ironworkers Workers’ Compensation Program (California) Kenny Waugh, IMPACT Director of Industry Liaison Rick Sullivan, IMPACT Director of Education and Training Acknowledgements xiii

Apprenticeship and Training Department/Safety Department Michael L. White, Executive Director of Apprenticeship and Training Ed Abbott, General Organizer Frank Piccione, Apprenticeship and Training Department Frank Migliaccio, Executive Director of Safety and Health General Officers, The International Association of Bridge, Structural, Ornamental and Reinforcing Iron Workers, National Training Fund, and IMPACT Eric M. Dean, General President, IABSORIW Ronald J. Piksa, General Secretary, IABSORIW Bernie Evers, General Treasurer, IABSORIW Lee Worley, Executive Director of Apprenticeship and Training, IABSORIW Kevin Hilton, CEO, IMPACT xiv Structural Steel Erection

TThhisttrraaiiniingppaacckkaaggeeisisdedseigsingendedforfourseusbeybyotbhotthetIhroeniwroonrwkeorkinesrtrinucstrourcatnodr satnud- dsteundte. nDt.epDenepdeingdionng thone ctohuersceo, uthrseer,e tahrerfeouareorfofiuvre porimfivareypcroimparoynecnotms tphoant ewnitlsl btheaut swedilldbuerinugsetdhedculraisnsgrotohme calnadsssrhoopmseasnsdionshsopf tsheissicoonusrsoef. Ththiessecocuormsep. oTnheenstes acoremsphonwentisnatrheesfhoollwowniingtfihgeufroel.lowing figure. The following is a brief description of each component of this package. The following is a brief description of each component of this package. Reference Manual – The Reference Manual is the heart of the training package RanedfecroentcaeinMs alnl oufatlh–e cTohneteRntefoerreinfcoermMatniounalthise tIhroenhweoarkt eorfstuhde etnrat ineiendgsptoaclkeargne adnudrincgonthtaisincsouarllseo.fThtheeincfonrtmenationr isnpforermseantieodninthaeuinroitnowfoinrskterrucstiuodnenfotrmneaetdwsitho loebajrenctidvuersinangdthsuisppcourtrisneg. mThaeteriinaflo. rTmoastuiopnpoirst pthresceonntetdenitnpraesuenittedofininthsteruRcetfieorn- feonrcme aMt awniuthalo, bthjecrteivaerseapnhdotsougprpaoprhtsin, gdrmawatienrgisa,l.sTafoetsyuptipos,rtanthdeoctohnetreintfoprmesaetniotend. iThnethremRaeyferaelsnocebeMaangluoasls,atrhyedrefianreinpghkoetyogtrearpmhss,frdormawtihnegsu,nsiatsfe.tWyhtiepns,fiarnsdtgoivtheenr, ignlofosrsamraytwioonr.dTshaeprpeemaraiynablsoldbeinatghleosRseafreyrednefcienMingankueayl.terms from the units. When first given, glossary words appear in bold in the Reference Manual. The student should use the Reference Manual to: 1. Read the appropriate sections before classroom presentations. 2. Take notes in during class. Preface xv ▶▶PREFACE

Th3e. studAenstwsehroAulsdsigunsemtehnetRSehfeertenqcuesMtioansualntdo:for other reference. 41.. RSteuadytfhoeraupnpitrotepsrtisa.tesectionsbeforeclassroompresentations. Stu2d. enTtaWkeonroktebsoionkd–urThinge cwlaosrsk.book contains student assignment sheets that are required for each unit of instruction in the Reference Manual. These assignment 3. Complete assignments. sheets are required to be completed by the student. 4. Study for unit tests. The workbook may also contain skill performance exercises. When included, they SarteudreqnutirWedoarksbpoaortko–ftThheecowuorrskeb.oThokepcoenrftoarinmsaanscseigenxmerecnisteshaeretsusredqubiyretdhetostbue- cdoemntpslteotedebvyeltohpecseturtdaeintm. andatory skills. They are also used by the instructor to evaluate that these minimum skills have been satisfactorily demonstrated. The workbook may also contain skills performance exercises. Unless identified as oWphtieonalp, preorpforriamtea,nbcleuexperrincitsews ailrlebreqinucirluedeads pwairtht otfhtehSetcuoduernste.WTohrekpbeorofkorfmoranucse einxecrlcaissersooarme udsisecdubssyiothnes,sctoumdepnletstitnogdaesvsieglnopmceenrttsasinheestse,notriaplesrkfoilrlsm. ance exercises. WInhsternuacptporropGruiaitde,eb–luTheprisingtusiwdiellisbfeoirnicnlustdreudctwoirthusteheonStluy.dIetnctoWntaoirnksbgoeonkerfoarlaunsde isnpecliafiscsrionofomrmdaistciounssaionndss,ucgogmesptlieotnins gonashsoigwnmtoetnetaschshtehetsc,opuersrefoursminagnctheeepxaecrckiasgees,. oArlsuonintctelustdse.d are the unit tests, the skill performance exercises, the answers to the assignment sheets, and the answers to the unit tests. Instructor Guide – This resource contains general and specific information and sThugeguesntitotnestosnarheouwsetdo toeadcehtetrhme icnoeuirfsethuessintugdtehnet phacskacghei.eIvteadlstoheinucnluitdkens oawnslwedegres toobjaelcltoivfetsh.eThuneituansistigsknimllsentetsstsheaertestahnedskteisllts.performance exercises. The instructor must observe each student performing the skills required in the performance exer- The unit tests are used to determine if the student has achieved the unit cises, and record the results in the student’s course record. knowledge objectives. When applicable, essential skills are tested through the use oDfVpDerf–orThmaenDcVeDexiesrdciesseigansesdestsombenuts.edThbyetihnestirnusctrtourctmoru.ThsteobDsVerDvecoenactahinsstucdlaesns-t proeorfmorsmliidnegptrheesesnktilaltsiorenqsufiorerdeainchthuenpiteorfoirnmstarnucetieoxne.rThciseseanprdersecnotardtiothnes rmesauyltaslsino tinheclsutduedevnidt’esocosuegrsmeernetcsoardn.d Internet links to additional related information. When appropriate, the DVD will contain blueprints and other supplemental resources that Instructor Resources – These resources are designed for the instructor to use in the instructor can use during classroom presentations. preparing for and presenting the course. Classroom slide presentations are provided for each unit of instruction. When appropriate, other resources that may be provided include: videos or video clips, related Internet links, blueprint files, and other THE COURSE SYLLABUS supplemental resources for instructional use. For each course there must be a course syllabus. A template syllabus is available from the Apprenticeship and Training Department for each course. The syllabus THE COURSE SYLLABUS serves as a design document for a course, provides information about the course, Fanodr eisactyhpcicoaullryseg,ivthenerteomthuestIrboenwaocrokuerssetusydlelanbtsuos.nAthtemfirpsltadteaysyolflacblauss.isAasvyalillabules fcraonmintchluedAeptphreefnotlilcoewshinipg ianfdorTmraitnioing: Department for each course. The syllabus serves as a design document for a course, provides information about the course, • Course title and description and is typically given to the ironworker students on the first day of class. A syllabus can• incluCdoeutrhse foblljoewctinvegsinformation: •• CDoeusrcsreiptittiloenaonfdthdestcarigpettioanudience and course prerequisites •• CLoeunrgstehoabnjedcstcivheesdule of the course •• DLeoscartipiotnioonfotfhethceotuarsgeet audience and course prerequisites xvi Structural Steel Erection viii Reinforcing Concrete for Ironworkers

Preface xvii ix • Length and schedule of the course • • • • • • Description of materials the Ironworker will need and/or receive • Location of the course • Information about the instructors • Description of materials the ironworker will need and/or receive • Description of the course assignments and tests Description of the course grading criteria Information about the instructors Description of the course assignments and tests Description of the course grading criteria Attendance criteria A course syllabus template is available from the Apprenticeship and Training De- partment for each course taught by Ironworker instructors. You will need to adapt • Attendance criteria this syllabus to meet the needs of your course. In most situations, all you need to do is to adjust the course schedule to meet the scheduled days and times for your course sessions.

xviii Structural Steel Erection

▶ SECTION 1 INTRODUCTION TO STEEL ERECTION UNITS 1-5



▶ HISTORY OF IRON AND OVERVIEW OF STRUCTURAL STEEL IRONWORK UNIT 1 ▶ OBJECTIVES After completion of this unit, you should be able to describe the historical use of iron and the basic roles and responsibilities of structural Ironworkers. This knowl- edge will be evidenced by correctly completing the assignment sheet and by scoring a minimum of 70% on the unit test. Specifically, you should be able to: 1. Describe the early history of iron 2. Describe the transition from iron to steel 3. Describe the evolution of structural steel for building use 4. Discuss the history and process of riveting 5. Describe the basic process of planning and scheduling a structural steel project 6. Describe the basic process of erecting structural steel 7. Describe the roles and responsibilities of the structural steel Ironworker Each of these objectives will be covered in the pages that follow. Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.1 UNIT 1

▶▶OBJECTIVE 1: EARLY HISTORY OF IRON Iron, as the very name Ironworkers suggests, has an important role in the history of ironwork, and in the history of the Ironworkers’ union. Iron was used in the early construction of bridges, and its use led to the development of steel and ultimately to modern-day steel skeleton structures, including skyscrapers. Note: The workers who erected skeleton skyscrapers were and still are called Ironworkers. Most of them had previous experience working on bridges. They were accustomed to working at significant heights and were not afraid of going higher. By 1896, The International Association of Bridge and Structural Ironworkers was established. The name has changed twice since then. First, the name was The International Association of Bridge, Structural, and Ornamental Ironworkers. The name is currently The International Association of Bridge, Structural, Ornamental and Reinforcing Iron Workers. The origins of The International Association of Bridge, Structural, Ornamental and Reinforcing Iron Workers is discussed in depth in the “History of the Iron Workers Union” course. The development of iron as a structural building material was gradual: in 1619 Dud Dudley, an Englishman, devised a method for converting coal into coke. Nearly a century later, another Englishman, Abraham Darby, developed the first commer- cially viable process for smelting iron at a foundry in Coalbrookdale, England. Even with these advances, however, iron remained unsuitable for bridge construction. Reliable sources of cast iron were difficult to obtain, and the brittle quality of the material precluded its use in tension. Since cast iron could only be used in compres- sion, it was only useful in the form of an arch (which is always in compression). It was not until the end of the 18th century, with the increased viability of wrought iron (a superior iron which could be used in either compression or tension), that iron was employed as a major structural material, particularly to replace timber columns in industrial buildings. Although wrought iron chains were used for sus- pension bridges in China and India as early as the first century, the full potential of iron as a construction material could not be realized until a method for reducing the carbon content of cast iron was devised and a practical solution for rolling large amounts of it into wrought iron was found. 1.2 Structural Steel Erection UNIT 1

Both method and solu- tion were discovered in the 1780s, when an English navy agent and iron dealer named Henry Cort devel- oped the “puddling pro- cess” for reducing carbon in cast iron and patented “grooved mills” to produce large amounts of wrought iron. As a result, iron was used more and more as a structural material. The beginning of this trend can be seen in the construction of the iron bridge spanning the River Severn near Coalbrookdale (Figure 1.1). Its completion in 1779 marked the end of the era in which stone and timber were the dominant building materials. Figure 1.1 Cast Iron Bridge Near Coalbrookdale Iron Buildings The first person to use iron as a building material for the exterior of a building was Daniel D. Badger. He erected the first iron structure ever seen in America in Boston in 1842. This structure made use of a cast-iron front, which does not affect the height or structural design of a building. Until the introduction of elevators, the number of floors in commercial buildings was gener- ally limited to five. In order to admit more light, the windows on lower stories were taller than windows on upper floors. Because cast-iron fronts were sepa- rate from the structure or frame of buildings, they did not affect elevator-limited designs. Figure 1.2 shows one of Badger’s cast iron building fronts. Figure 1.2 Cast Iron Building Front Erected in Albany, N.Y. by Badger for J. Kidd Because it lacks high tensile strength, cast iron was not capable of long spans. As a result, it was used in single window units, with the repetition of units creating the visual effect of the front. The windows tended to be sash windows, two-over-two windows, or made of wood or iron. This was characteristic of the cast-iron con- struction industry, even in its final development in the 1870s. Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.3 UNIT 1

The advantage of cast iron, and later of steel, was that its great strength enabled the builder to reduce the thickness of the walls and thereby enlarge the interior. Because space was, and still is, expensive, this was a great advantage over conven- tional thick masonry walls. Other advantages of iron, often used as selling points by those promoting its use in buildings, included its being a good conductor (which made it safe during thun- derstorms), as well as its being incombustible, light, economic, durable, and capable of prefabrication. Indeed, early cast iron structures are recognized today both as the forerunners of the steel-framed skyscraper and as early examples of prefabrication and modular design. 1.4 Structural Steel Erection UNIT 1

▶▶OBJECTIVE 2: THE TRANSITION FROM IRON TO STEEL At the end of the nineteenth century, steel struggled for precedence over iron as iron had over wood and masonry at the end of the eighteenth century. Steel had been used for centuries, but its high cost had limited its use mainly to the manu- facturing of tools. The first major turning point came in 1855 when Henry Bessemer patented a pro- cess for making steel cheaply and in large quantities. His solution was the “converter” (see Figure 1.3). The basic idea of the process was that crude pig iron (cast iron that had been poured into rough molds) was heated until it was molten. A blast of air was then blown through the molten metal, which helped to burn off impurities and carbon. This left a “pure” iron to which the correct proportion of carbon could be added, mixed, and poured out as liquid steel. Figure 1.3 Bessemer’s Early Steel Converter The Bessemer method of manufacturing steel has since been supplanted by other tech- niques, but its contribution to the development of steel should not be underestimated. With it, steel was slowly and tentatively adopted as a construction material for bridges (and even- tually buildings). Between 1874 and 1883, three steel bridges debuted: the Eads Bridge in St. Louis, Missouri (Figure 1.4), the Figure 1.4 Eads Bridge in St. Louis, Missouri Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.5 UNIT 1

Glasgow Bridge in Glasgow, Missouri (Figure 1.5), and perhaps most importantly, the Brooklyn Bridge in New York (Figure 1.6). Brooklyn Bridge The Brooklyn Bridge repre- sents an enormous advance over every previous struc- ture, regardless of type. In an era without skyscrapers, the height of its towers (275 feet above high water level) in comparison to other structures was so great that they were terrifying for some people to look upon. Figure 1.7 illustrates the height difference between the bridge’s towers and sur- rounding structures. Figure 1.5 First All Steel Bridge (Glasgow, Missouri–1879) The bridge also incorpo- rated many important innovations in suspension bridge work. Its suspension system consists of four steel wire cables made up of parallel wires formed into a circular shape. These cables carry a much longer span than any bridge previously built, with a mid-river clearance under the span of 133 feet, and they stand as the first example of the application of steel wire to bridge construction. The outsides of the cables were wrapped with steel wire for protection against the weather, while galvanizing was also used for the first time in this bridge as a means of protecting wire. Figure 1.7 Stone Towers of the Brooklyn Bridge Figure 1.6 Brooklyn Bridge 1.6 Structural Steel Erection UNIT 1

Construction of the bridge began in 1869, under the design of John A. Roebling. Although Roebling died that same year, work continued under the direction of his son, Washington A. Roebling. By April of 1877, the first of the suspension wires had been strung from anchorage to anchorage over the tops of the towers and the wide expanse of the river. Wire by wire, the cables grew until the last wire was added in October of the following year. After about fourteen years of continuous labor, the bridge, which consists of a single deck totaling eighty-six feet in width and divided to provide for two elevated railroad tracks, two trolley car tracks, a single lane roadway beside each trolley track, and a central foot walk of fifteen feet, opened to pedestrians and road vehicles in May of 1883 (Figure 1.8). By September of that same year, shuttle train service was put into operation. Through train service fol- lowed in 1908. Figure 1.8 Brooklyn Bridge on Its First Day Open – 150,000 People Traveled Across Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.7 UNIT 1

▶▶OBJECTIVE 3: THE EVOLUTION OF STRUCTURAL STEEL FOR BUILDING USE With advances in elevators in the late nineteenth century, architects began designing taller buildings. These buildings were usually limited to ten stories – the practical limit for a building with solid masonry walls. The walls, as necessary, became thinner at an average rate of about four inches to a story. Even with a ten story building, the brick piers at the first floor would be four feet thick from front to back. The dilemma for architects was how to design build- ings taller than ten stories while maintaining inte- rior space on the lower floors and structural integ- rity throughout. Major William Le Baron Jenney, owner of a Chicago firm specializing in large win- dow openings and glass areas, developed a solution to the problem with the construction of the Home Insurance Building in Chicago in 1884 (Figure 1.9). Jenney’s great solution and discovery was “skel- eton” construction. In skeleton construction, a steel skeleton, or cage, consisting of columns, girders, and beams is erected first. The rest of the building (i.e., exterior walls, floors, partitions, and roof) is then hung on this skeleton. This discovery upset the five-thousand-year-old custom of supporting buildings on enclosing walls of frame or masonry. Following the success of the Home Insurance Building, which was the first building made with a structural steel frame and thereby the world’s first skyscraper, there was a demand for taller and taller office buildings. Some of the first buildings to use steel skeletons were Chicago’s Reliance Building (Figure 1.10) and Carson Pirie Scott store, and the Guaranty Building in Buffalo, New York (Figure 1.11). Figure 1.9 The Home Insurance Building 1.8 Figure 1.10 Reliance Building Structural Steel Erection UNIT 1

Rolled Structural Steel Shapes With the demand for taller buildings and the advent of skeleton construction came an increased willingness to use steel, which was being used more and more for bridges, but met with resistance as a material for buildings. Part of the problem was that the shapes that were available at the turn of the century simply were not strong enough to form the columns of build- ings. Flat plates, angles, and channels could be put together to make columns that were strong enough, but these were costly. Charles Schwab, organizer and president of Bethlehem Steel Company, devised a solution. Schwab constructed the nation’s first mill for roll- ing wide-flanged shapes (Figure 1.12). Figure 1.11 Guaranty Building The mill was very successful, and rolled structural shapes (Figure 1.13) became the answer to designers’ dreams. They permitted maximum flexibility of design, and offered then (as now) the strongest, most versatile, and most economical material avail- able to the construction industry. Steel’s uniformity in strength, dimensional stability, and durability unaffected by alternate freezing and thaw- ing makes it the preferred building material for sky- scrapers. As rolled structural steel shapes became widely used, costs came down and buildings went up – higher and higher. Figure 1.12 Mill Rolling Flanged Shapes Figure 1.13 Steel Rolled Into Structural Shapes Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.9 UNIT 1

Figures 1.14-1.25 show some other structures, both old and new, made possible by the development of steel as a building material. Figure 1.14 Building Under Construction in Erie, PA in 1910 Figure 1.15 Building Under Construction in Lincoln, NE in 1910 Figure 1.16 Koppers Building, Pittsburgh, PA 1.10 Structural Steel Erection UNIT 1

Figure 1.17 Structural Building Under Construction Figure 1.18 Toronto (Canada) Figure 1.19 High Rise Under Construction Dominion Tower Number 1 (Erection Begun in 1964; Completed in 1966) Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.11 UNIT 1

Figure 1.20 Structural Building Figure 1.22 Structural Building with Figure 1.21 CN Tower (Toronto) Replica Concrete Parking Garage 1.12 Structural Steel Erection UNIT 1

Figure 1.23 Golden Gate Bridge Figure 1.24 St. Louis Arch Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.13 UNIT 1

Figure 1.25 World Trade Center Towers Erected by Members of Locals 40, 361, 466, and 580. Destroyed During a Terrorist Attack on September 11th, 2001. 1.14 Structural Steel Erection UNIT 1

▶▶OBJECTIVE 4: RIVETING No history of steel erection is complete without a brief discussion of riveting. Although rivets (Figure 1.26) have been replaced by bolts in new steel construction, some structures built during the early 1900s are still standing and still have their original rivets. What this means is that there are many areas where repair and mainte- nance jobs may require rivets, so a knowledge of riveting is essential for Ironworkers. Riveting was a demanding task. In addition to the hazards of falling, rivet crews (Figure 1.27) were exposed to extreme heat, noise, and con- stant pneumatic tool impact. Riveting required Ironworkers with excellent hand-to-eye coordi- nation and dexterity. A good riveting crew was highly valued, and usually consisted of three or four Ironworkers: the heater, the catcher, the bucker-up, and the riveter. The heater’s tools included long, slender tongs (Figure 1.28), a hand-operated blower, and a forge (Figure 1.29). The heater’s duties were to place rivets in the forge and heat them until they were red hot and malleable. The size and length of the round stock used to form the rivets was determined by the connection being riveted. Figure 1.28 Tongs Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.15 Figure 1.26 Rivets Figure 1.27 Rivet Crew Figure 1.29 Hand-Operated Forge UNIT 1

Using tongs, the heater retrieved a rivet from the forge and pitched it, while still red hot, to the catcher. The catcher caught the hot rivet in a catch can, which is shaped like an inverted cone with a handle (Figure 1.30). Catchers had to have great balance and hand-to-eye coordination. To miss a rivet, as occasionally happened, was extremely dangerous (just imagine a red hot steel rivet falling from the sky). Figure 1.30 Catch Can Once the hot rivet was caught, the catcher knocked it against the steel work to remove scale, and then inserted it into its prepared hole. The bucker-up usually worked off of a temporary work platform hung by ropes, called a float. Once the hot rivet was inserted into the hole, the bucker-up pressed the rivet into place with a dolly bar and held it there while the rivet head was formed on the other end by the riveter. The riveter, also on a float, used a pneu- matic hammer to pound the red hot end of the rivet flat against the steel while the bucker-up held it in place and absorbed the rapid succession of shocks from the stroke of the hammer on the other side (Figure 1.31). Once the rivet was hammered to the point of tight iron, the process would start again at the next hole. Safety and Riveting Figure 1.31 Bucking Up 1.16 Structural Steel Erection One of the things that made riveting so dangerous was that, at the turn of the twentieth century, there were no standards for construction safety. Today, with the establishment of safety rules by the International, employers, and federal, state, and provincial governments, the frequency of accidents has been greatly reduced and safety has become a top priority. Earlier in the century, however, most employers viewed the tremendous dangers of Ironwork as part of the cost of doing business. It was generally believed that there was no safe way to erect iron and that accidents were inevitable. Some Ironworkers UNIT 1

even romanticized the danger, adopting a dare- devil attitude demonstrated in their nickname of the time: “Cowboys of the Sky.” Figures 1.32–1.35 show Ironworkers at the turn of the twentieth century working in dangerous con- ditions and apparently unconcerned about their safety. Figure 1.33 Early Connector Making a Point Figure 1.34 Early Ironworkers Not Tied Off Figure 1.32 Early Connector Waiting for a Piece Figure 1.35 Early Ironworker Perched Precariously Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.17 UNIT 1

▶▶OBJECTIVE 5: PLANNING AND SCHEDULING To eliminate unnecessary delays, re-handling of materials, and rework, detailed and careful planning and scheduling in advance of a project, as well as on the job site (Figure 1.36), is required. This is usually done by the Ironworker foreman, but knowledge of what goes into planning and scheduling a structural steel project allows all Ironworkers to know and accomplish their jobs better. It can also help Ironworkers decide if they would like to be foremen in the future. Figure 1.36 Planning on a Structural Job Site Planning is the act of developing a sequence of events to accomplish part or all of a project. Scheduling is the process of attaching times and dates to the events iden- tified during the planning process. Planning and scheduling activities may begin years before the first column is erected, and they continue every day on the job. Planning and scheduling are achieved through teamwork; the superintendent or project manager, the general foreman, the Ironworker foreman, the fabricator, and inspectors must all work together to plan and schedule a project. To ensure that a project is accomplished according to that plan and schedule requires the full cooperation of all of the Ironworkers involved, as well as of the Ironworker erection company, project construction management, and the project owner. Architects and engineers are also involved in the planning of a project. 1.18 Structural Steel Erection UNIT 1

On most ironworking projects, the primary planning and scheduling activities involve developing a detailed job schedule and/or timeline for the project. For struc- tural projects, this schedule includes items such as sequencing of delivery of mate- rials, location and storage of materials, sequencing of erection, and access to the project. The planning and scheduling steps the Ironworker foreman follows in order for his or her structural crew or gang to get the work done include the following: 1. Reviewing work area drawings and specifications, if available and appropriate 2. Conducting a pre-job walk-though of the job site 3. Determining the erection or installation sequence, and creating an erection plan 4. Identifying the required materials to complete the work, and determining when they will be needed and should be scheduled to arrive and where they should be unloaded and stored (see Figure 1.37 for a pre-planned unloading, storing, and erection sequence) 5. Identifying the required tools and equipment (including safety equipment) to complete the work, including the type and capacity of crane or cranes required Figure 1.37 Unload, Shake Out, and Erect by Sequence Diagram Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.19 UNIT 1

6. Creating a pick list (Figure 1.38) that establishes the order in which pieces will be hoisted (“picked”) by the crane to be placed at the designated point on the structure Tuesday pick list: 1) Bay 1 (West Bay) 2nd floor 1C1 3C3 2C1 4C1 6B1 6B4 6B2 7B1 7B5 7B7 9B3 12D3 x2 10DH1 10DJ1 x2 3) Bay 1 (West Bay) roof 1C2 4C2 2C2 5C1 J2 8B5 8B3 10G1 9B2 10X47 J1 x4 10A1 x2 Figure 1.38 Sample Pick List 2) Bay 2 (East Bay) 2nd floor 3C1 5C2 7B3 6B3 7B2 12D1 12D2 7B6 7B4 4) Bay 2 (East Bay) roof 3C2 3C4 8B4 8B2 8B1 9B4 x2 8B6 8B7 9B1 1.20 Structural Steel Erection UNIT 1

7. Devising a critical lift plan for any lift that exceeds 75% of the rated capacity of the crane or derrick or that requires the use of more than one crane or derrick (Figure 1.39) 8. Scheduling work activities (weekly and daily) 9. Determining the needed crew size and mix Figure 1.39 Tandem Crane Lift 10. Assigning work tasks to crew members 11. Reviewing plans and schedules with supervisor(s) and crew members 12. Coordinating work with other trades working on the project Once these preparations are completed, Ironworkers begin erecting the steel struc- ture, following both blueprints (drawings) and the foreman’s directions. Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.21 UNIT 1

▶▶OBJECTIVE 6: A BRIEF OVERVIEW OF STRUCTURAL STEEL ERECTION The erection of structural steel will be addressed in great detail in other units, but some of the basic information concerning it is covered below. Foundations In structural steel erection, the foun- dations come first. These are placed deep down in the excavation, where the steelwork begins. Reinforcing Ironworkers place and tie reinforc- ing steel and anchor bolts in foot- ings and piers, while steel base plates (Figure 1.40) are usually placed on the concrete. Leveling plates, level- ing nuts, and/or shims are used to distribute the load. When a building will be excep- tionally tall, however, it takes more than base plates to distribute load. Grillages (Figure 1.41) are then put on top of the foundation to achieve even greater distribution of the load. Structural Members The members that you will encounter most frequently during your ironworking career are col- umns, beams, girders, and trusses. Columns are vertical members that transfer the load to the ground. They are generally made of W-shapes and are equipped with holes and connection pieces for splicing them together and for joining other members. When erecting the steelwork, members are connected with high-strength bolts or by welding. Figure 1.40 Steel Base Plate Figure 1.41 Grillage 1.22 Structural Steel Erection UNIT 1

The term “beam” describes most horizontal members except trusses and joists. Beams transfer the load of all floors to the columns and, at the same time, tie the columns together to form a rigid frame. Girders are extra heavy beams that are usu- ally the main beam extending between columns. They carry the load from smaller intermediate beams. A truss is a horizontal member that acts like a beam, but is made up of many pieces with openings in between, and is specially engineered to give maximum strength with minimum weight. Trusses are often used to span large spaces such as lobbies and auditoriums. General Erection Process The first part of the actual erection process is the arrival of needed materi- als. The steel members to be used are trucked in from a fabricating shop or a storage yard (Figure 1.42) according to a careful schedule meant to get every piece to the job site exactly when needed. When the steel arrives, Ironworkers unload it and sort the members, which are clearly marked to show their places in the structure. Ironworkers also assemble the heavy equipment (e.g., cranes and derricks) that helps them hoist and move structural steel. The Ironworkers then begin to place the members in their appropriate posi- tions. Figure 1.43 shows Ironworkers carefully chok- ing (hitching) a beam to raise it to its proper loca- tion in a structure. Figure 1.42 Storage Yard Figure 1.43 Choking a Beam Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.23 UNIT 1

When the beam is nearly in place, Ironworkers in the rais- ing gang use a spud wrench (a combination pin, lever, and wrench) to line up the holes in the beam. Figure 1.44 shows a connector aligning a hole. When the holes are lined up, the connector puts in enough bolts to secure the joint temporarily. The bolting gang then installs permanent high-strength bolts, which are impacted to the proper tightness by workers using a pneumatic, electric, or hydraulic wrench. Figure 1.44 Connector Using a Spud Wrench to Align Holes Finally, the steel framework goes up. Of course, there is far more to erecting steel structures than just these steps out- lined above. You will learn more about these steps, and erecting steel structures as a whole, in later units. 1.24 Structural Steel Erection UNIT 1

▶▶OBJECTIVE 7: THE STRUCTURAL STEEL IRONWORKER Structural steel Ironworkers work in many areas of construction. Steel frames sup- port bridges, steel towers carry communications lines, and steel reinforces homes built in hurricane zones. Structural Ironworkers in many locals also participate in building bridges, wind turbines, clear span and modular structures, and amuse- ment parks. In general, the major roles and responsibilities of the structural steel Ironworker include, but are not limited to, the following: • Following all applicable safety rules and regulations under the employer’s safety program (see Unit 2) • Using the right tools and equipment to make sure the job is done right the first time (see Unit 3) • Unloading, handling, and storing structural steel materials (see Unit 4) • Making structural connections (see Unit 5) • Erecting columns and beams (see Unit 6) • Erecting joists, joist girders, and trusses (see Unit 7) • Plumbing and aligning structural steel (see Unit 8) • Bolting up structural steel (see Unit 9) • Handling and installing metal decking (see Unit 10) • Handling and installing sheeting (see Unit 11) • Reading structural steel drawings (see Units 12 and 13) Structural Ironworkers in many locals will also do some or all of the following: • Erecting bridges (see Unit 14) • Erecting towers (see Unit 15) • Erecting wind turbines (see Unit 16) • Erecting clear span and modular structures (see Unit 17) • Erecting amusement park structures (see Unit 18) • Erecting composites (see Unit 19) Unit 1 — History of Iron and Overview of Structural Steel Ironwork 1.25 UNIT 1

1.26 Structural Steel Erection UNIT 1

▶ GENERAL SAFETY FOR STRUCTURAL STEEL ERECTION UNIT 2 ▶ OBJECTIVES After completion of this unit, you should be able to follow safety guidelines and procedures when erecting structural steel. This knowledge will be evidenced by correctly completing the assignment sheet and by scoring a minimum of 70% on the unit test. Specifically, you should be able to: 1. Describe and apply basic safety measures 2. Use required personal protective equipment 3. Describe job hazard analyses and procedures of safety meetings 4. Describe first aid and fire safety requirements 5. Describe signs of substance abuse and identify available resources 6. Interpret Safety Data Sheets (SDSs) Each of these objectives is covered in the pages that follow. Unit 2 — General Safety For Structural Steel Erection 2.1 UNIT 2

▶▶OBJECTIVE 1: BASIC SAFETY Structural steel Ironworkers often do their work while balancing on narrow metal beams high above the ground. In the past, they relied on their own equilibrium and good luck to keep them from falling. Now, workers protect themselves by using guardrails, by being tied off according to safety rules and regulations, and by wear- ing safety equipment like harnesses and lanyards. Examples of some of the sorts of safety equipment used by contemporary Ironworkers can be seen in Figure 2.1. Figure 2.1 Contemporary Ironworkers Using Safety Equipment Even with the safeguards of protective equipment in place, however, ironworking is still one of the most dangerous jobs in the field of construction. To succeed in the job, an Ironworker must not only be comfortable with great heights, but also be conscious of safety. Safety is in fact the most important aspect of the ironworking trade. In part due to the efforts of The International Association of Bridge, Structural, Ornamental and Reinforcing Iron Workers, the focus in construction has shifted from how quickly a project can be completed, regardless of personal injury to a worker, to whether or not a project can be completed with no accidents, injuries, or fatalities. It is difficult today to find a job, regardless of size, that does not place a heavy emphasis on safety. Owners, Ironworkers, and sub-contractors all recognize the importance of safety. The importance of safety is also highlighted throughout this manual and its cor- responding training curriculum: not only is a general introduction to steel erection safety provided in this unit, issues of safety are discussed as they apply to subjects throughout this and other manuals and courses. 2.2 Structural Steel Erection UNIT 2