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STRUCTURALSTEEL

PREQUALIFICATIONDOCUMENT

ASSENT
Al Shafar Steel Engineering
Prequalification Document

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INDEX
Introduction

Al Shafar Group

Quality Policy

Construction & Site Services

Legal Status

10

Branch Office

15

Market Sectors & Products

Registrations

ISO Certifications

17
35

Engineering Capabilities

38

Manufacturing Facility

40

Quality Control & Quality Assurance

49

50

54

General Description of Work Flow Procedures


Engineering
Design Output
Design Review
Design Validation
Design Changes
Software
RFIs
Pre-Production Planning
Example

Material Preparation
Identification
Handling, Storage and Stacking
Consumable Storage
Fabrication Drawings
Beam Processing
Beam Preparation Equipment
Plate Processing
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Plate Processing Equipment


Assembly

Welding
Curving and Straightening
Non-Destructive Testing
Surface Preparation and Painting
Delivery of Finished Product
Attachments

59

Process Control Procedures


Inspection and Test Plan (Sample)
Welding Procedure Specifications
Health Safety & Environment

Our Projects

Organization Chart

..

.. ...

76
77

87

Manpower List

88

Equipment List

93

Our Location Map

95

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Introduction
ASSENT, a member of the long-established AL Shafar Group of Companies, is one of the Middle
East's leading companies in the field of structural steel design, engineering, fabrication, painting and
erection of all types of steel projects.
Having a fully covered and insulated area over 50,000 square-metres, allows ASSENT to be able to
produce a very large volume of fabricated steel, ranging from 8,500 to 10,000 tons per month. This
plant is equipped with the latest technology of CNC, blasting and other types of equipment to ensure
the quality, speed of production accuracy, and proper control.
The Workshop is equipped with four (4) Automatic CNC beams and plates processing lines in an area
of 66m x 180m, for sizing, comprising of :

CNC Beam Sawing Lines


CNC Beam Drilling Lines
CNC Coping Equipment
CNC Plates Processing Lines
CNC Angle Masters
CNC Profiling Machines

All raw material is pre-blast before processing using three (3) automatic blasting machines capable to
of processing 3000 tonnes/month each (total 9000 tonnes/month)
The fabrication area covers an area of 145m x 178m, fully equipped with all necessary welding
equipment, overhead cranes varying from 5 to 15 tonnes in capacity etc In total the facility is
equipped with 89 overhead travelling cranes.
Post-blasting, after fabrication is done through two (2) 10-turbine blasting machines capable of
processing in excess of 8000 tonnes/month
All blasting is done to Sa 2 1/5
All painting is done under controlled conditions under cover in an area of 60m x 145m
An additional area of 72m x 240m has been dedicated to raw material project storage and can
accommodate up to 40,000 tonnes of steel sections
In addition to the production capabilities described above, all the engineering and quality control is
carried out in-house, with the additional independent third party testing of welds, in compliance with
approved specific project ITP (Inspection and Test Plans), undertaken by Internationally Recognised
and Approved Testing Agencies.

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ASSENTs products and services are available for all types of steel projects. The Senior Management
Personnel have a wealth of experience in all areas from high-rise towers to storage sheds; from oil and
gas projects to large-scale commercial buildings; from hangars to showrooms and moreover all types
of prefabricated residential houses, office complexes and labour camps.
ASSENT's quality control and assurance program comply with the international requirement, which
closely governs all engineering, manufacturing and construction standards. We also apply strict health,
safety and environmental policies to safeguard the protection of all employees and subcontractors. We
always work with the aim of having a zero-accident environment.
After sales supports facilities in Abu Dhabi,
ASSENT main facilities are located in Dubai Industrial City, at a convenient location at about 100 km
from Abu Dhabi, and is in a position to provide all necessary after-sales services required within and
around Abu Dhabi area.
Such services include:
Stock of spare parts: In case additional structural members or related accessories, such
items can easily and conveniently be provided on short notice.
Repair facilities: The workshop facilities are within short distance of Abu Dhabi. Any
repairs can be accommodated within the workshop facilities or at the clients premises
depending on the nature of the repairs
Technical support: Can be made available either at Main Dubai Facilities or Abu Dhabi
Office

Satisfy Abu Dhabi regulations concerning Local Agency Requirements


ASSENT is a fully registered Limited Liability company registered in Dubai and fully compliant with
all Legal and Local Agency Requirements of the United Arab Emirates.
Please refer to the Legal Status section of this document for copies of the Industrial License,
Chamber of Commerce Registration and Commercial Register as well as Registrations with other
Authorities.

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Al Shafar Group

A reputation for high quality and reliability


Al Shafar Steel Engineering (ASSENT) is the most recent addition to Al Shafar Group of Companies,
which was established in 1989, and in a period of 20 years has now grown to incorporate a total of 18
companies (including ASSENT), all related to different aspects of the construction and related
manufacturing industries.

Al Shafar Group currently employs approximately 25,000 people overall.


Through its 20 years in existence, Al Shafar Group has earned the respect and loyalty of its repeat
clients such as Government Agencies, Dubai Police and others, through the quality of its products as
well as its transparency and reliability in its business approach.
For additional information on Al-Shafar Group of companies, please visit the web site
http://www.alshafar.com

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Quality Policy
Our Vision
We are confident in our strategies for growth in the Structural Steel Projects
Engineering, Manufacturing, Painting and Erection within the United Arab Emirates
and other Gulf Countries.

Our Mission
Our mission is to be the most effective and respected manufacture of industrial products
by practicing our strategy which is based on improving quality productivity.

Our Quality Policy


To realize our vision and mission we shall exert every effort to achieve the following in
all our activities:

To have a close working relationship with all our Clients / Customers on all aspects of
engineering, quality and service to expedite the contract;

To be aware of the latest technological aspects related to our scope of works and to continually
evaluate this technology and its potential impact on manufacturing capability and company
quality requirements;

To continually strive to satisfy the requirements of our Clients & Customers by completing the
projects in compliance with their specifications, contract and quality requirements;

Gaining the confidence and trust of our supervising bodies, employees, stakeholders,
customers, and the public through strict adherence to all applicable laws, regulations, best
practices, international standard for quality management system ISO 9001:2008;

Continually improving the effectiveness of our Quality Management System through periodic
monitoring and review of its performance and suitability ; and

Protecting our environment by effectively utilizing our resources and reducing / preventing the
pollution that may be associated with ASSENT activities through effective waste management
activities; and

Communicating our Policy to all our employees, stakeholders, partners, customers, interested
parties and the public.

This Policy provides the framework and sets the basis for establishing and reviewing our objectives at
the relevant functions of ASSENT. It will be reviewed periodically for continuing stability and
suitability.

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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 ASSENT.
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


Petrochemical
Aluminum Smelters
Fertilizer Plants
Cement Plants

Pipe Racks
Rectangular Platforms
Circular Platforms
Pipe Supports
Main Workshop Structures
Raw Material Storage
Buildings
Floor Gratings
Staircases
Handrails
Ladders
Temporary Structures

Infrastructure

Bridges

Steel Bridges
Heavy Duty Building
Structures
Platforms
Equipment Support Structures
Passenger Terminals
Cargo Terminals
Aircraft Hangars

Power & Desalination


Airports & Seaports
Railways

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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Construction & Site Services


ASSENT aims to provide a complete, integrated solution for customers including site installation and
services. We employ a highly qualified construction team, and can provide construction equipment
capable of installing 4,000 tons of steel per month.
ASSENT is part of AL Shafar Group Of Companies, The parent company ASGC (AL Shafar General
Contracting) is a well established and well reputed company in the field of general contracting and
registered and qualified in Steel Erection
Manpower Strength is around 12,000 and equipped with a long fleet of site construction equipments,
cranes, lifting and access equipments and scaffolding.
This gives us clients the privilege of offering our clients very competitive prices for complete package
of supply and erection.

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Trade License

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Chamber of Commerce

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Commercial Register

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Abu Dhabi Commercial License and


Chamber of Commerce Certificate

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Certificate of Office Registration - Kazakhstan

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Abu Dhabi Supreme Petroleum Council

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ADNOC

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TAKREER

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GASCO

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ADCO

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ADMA-OPCO

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ADGAS

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BOROUGE

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FERTIL

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Saudi Aramco

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Qatar Petroleum

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MARAFIQ

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Saudi Electricity Company

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Kuwait National Petroleum Company

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Farabi Petrochemicals

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Ministry of Oil and Gas Oman

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Federal Electricity and Water Authority (FEWA)

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Saudi Basic Industries Corporation (SABIC)

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ISO 9001:2008

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ISO 14001:2004

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OHSAS 18001:2007

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Design and Engineering


The engineering section employs a team of designers and detailing engineers equipped with the
latest and most advanced software for both of these disciplines. All work is closely monitored to
ensure that it conforms to all project specifications and standards.
The engineering department services are available for:
Completing design for statical systems and connections
Composing general-arrangement drawings and
foundation details
Shop drawings
Material take-off
Construction and assembly drawings
Full and close co-ordination with the customer's engineers.
Design proposals and Value Engineering for all types of steel projects

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Design and Engineering Cont


The Drafting office is also fully computerized and utilizes the following main software
packages:
Package
AutoCad

Strucad

Tekla - Xsteel

Description
Specifications / Code
Preparation of GA Drawings &
N/A
Fabrication Drawings
Miscellaneous Works
3D Modelling Detailing of
N/A
Connections Automatic
Generation of Fabrication Drawings,
Production & Material Listings
3D Modelling Detailing of
N/A
Connections Automatic
Generation of Fabrication Drawings,
Production & Material Listings

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Manufacturing Facilities & Equipment


The plant facility is divided into the following areas:

Area Name: Inventory Stock Area


Dimensions: 50m x 172m
Details: Material handling by 2 Nos of Gantry Cranes, 10 ton each.

Area Name: Open yard for Heavy Fabrication


Dimensions: 50m x 172m
Details: Open yard Heavy fabrication and assembly, with Gantry Cranes.

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Area Name: Project Stock Area


Dimensions: 238m x 75m
Details: Handling of material by 15 Nos of over head cranes, each has capacity of 10 tons.

Area Name: Pre-Blasting Area


Details: In feed Conyers - 44m length for feeding the material to pre-blasting through shot blasting
machine, out feed Conyers - 24 m length to feed this material to the CNC beam/plate sizing bays.

Pre-Blasting Machines

Brand: Geitart
Model: GW
2500
Width

(mm)

2500

Height

(mm)

600

Speed

(m/min)

0.6 to 10

Brand: Geitart

Model: GW 2500

Brand: Geitart
Model: GW
2500

Width

(mm)

2500

Height

(mm)

600

Width

(mm)

2500

0.6 to 10

Height

(mm)

600

Speed

(m/min)

Speed

(m/min)

0.6 to 10

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Production Lines
Area Name: Production Line 1
Details: CNC Sizing Bay S01, S02 for fully
automatic cutting, drilling and copying for
Section profiles and plates for Heavy weight
structures.

Heavy Fabrication Bay F01

Heavy Fabrication Bay F02

Length 120m, width 23m equipped with


5 nos x 15 tons capacity over head cranes
2 nos x 30 tons ground trolleys

Length 120m, width 23m equipped with


5 nos x 15 tons capacity over head cranes
2 nos x 30 tons ground trolleys

Production Bay 1 : CNC Machines

Machine: CNC Band Saw


Machine
Brand: FICEP
Model: 1260 LBH
Technical Specifications:
Sawing
capacity
at 90
Sawing
capacity
at 45
Sawing
capacity
at 60
Mitering
angles

(mm)

1250 x
600

(mm)

800 x
600

(mm)

500 x
500

Machine: CNC Drilling Machine


Brand: FICEP
Model: 1203 DF
Technical Specifications:
Web
height
Flange
width
Thicknes
s
Diameter

(mm)

1220

(mm)

510

(mm)

100

(mm)

50

Machine: CNC Thermal Coping


Brand: FICEP
Model: 1201 RC
Technical Specifications:
Volume of
sections to
be
processed
Coping
stroke
Controlled
axes

(mm)

(mm)
(no.)

1220 x
600 x
800
+ 400 / 400
5+1

Machine: CNC Drilling &


Thermal Cutting
Brand: FICEP
Model: TIPO A31
Technical Specifications:
Length
Width
Thickness

(mm)
(mm)
(mm)

6000
3100
130

2 drill heads + 2 thermal cutting


heads

3 axis drilling.

+45/60

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Production Lines
Area Name: Production Line 2
Details: CNC Sizing Bay S03, S04 for fully
automatic cutting, drilling and copying for
Section profiles and plates for Medium weight
structures.

Medium Fabrication Bay F03

Medium Fabrication Bay F04

Length 120m, width 23m equipped with


5 nos x 10 tons capacity over head cranes
2 nos x 20 tons ground trolleys

Length 120m, width 23m equipped with


5 nos x 10 tons capacity over head cranes
2 nos x 20 tons ground trolleys

Production Bay 2 : CNC Machines

Machine: CNC Band Saw


Machine
Brand: FICEP Model: 1260
LBH
Technical Specifications:
Sawing
capacity
at 90
Sawing
capacity
at 45
Sawing
capacity
at 60
Mitering
angles

(mm)

1250 x
600

(mm)

800 x
600

(mm)

500 x
500
+45/60

Machine: CNC Drilling Machine


Brand: FICEP Model: 1203 DF
Technical Specifications:
Web
height
Flange
width
Thicknes
s
Diameter

(mm)

1220

(mm)

510

(mm)

100

(mm)

50

3 axis drilling.

Machine: CNC Thermal Coping


Brand: FICEP Model: 1201 RC
Technical Specifications:
Volume of
sections to
be
processed
Coping
stroke
Controlled
axes

(mm)

(mm)
(no.)

1220 x
600 x
800
+ 400 / 400
5+1

Machine: CNC Punching&


Thermal Cutting
Brand: FICEP Model: TIPO
B251
Technical Specifications:
Length
Width
Thickness
Punching
Thickness
Drilling
Thickness
Plasma
Thickness
Thermal
Cutting
Thickness

(mm)
(mm)
(mm)
(mm)

6000
2540
100
25

(mm)

130

(mm)

60

(mm)

130

1 drill + 1 thermal cutting + 1


punching + 1 plasma

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Production Lines
Area Name: Production Line 3
Details: CNC Sizing Bay S05, S06 for fully
automatic cutting, drilling and copying for
Section profiles and plates for Medium weight
structures.

Medium Fabrication Bay F05

Medium Fabrication Bay F06

Length 120m, width 23m equipped with


5 nos x 10 tons capacity over head cranes
2 nos x 20 tons ground trolleys

Length 120m, width 23m equipped with


5 nos x 10 tons capacity over head cranes
2 nos x 20 tons ground trolleys

Production Bay 3 : CNC Machines

Machine: CNC Band Saw


Machine
Brand: FICEP Model: 1260
LBH
Technical Specifications:
Sawing
capacity
at 90
Sawing
capacity
at 45
Sawing
capacity
at 60
Mitering
angles

(mm)

1250 x
600

(mm)

800 x
600

(mm)

500 x
500
+45/60

Machine: CNC Drilling Machine


Brand: FICEP Model: 1203 DF
Technical Specifications:
Web
height
Flange
width
Thicknes
s
Diameter

(mm)

1220

(mm)

510

(mm)

100

(mm)

50

3 axis drilling.

Machine: CNC Drilling Machine


Brand: FICEP Model: 1203 DF
Technical Specifications:
Web
height
Flange
width
Thicknes
s
Diameter

(mm)

1220

(mm)

510

(mm)

100

(mm)

50

3 axis drilling.

Machine: CNC Punching&


Thermal Cutting
Brand: FICEP Model: TIPO
B251
Technical Specifications:
Length
Width
Thickness
Punching
Thickness
Drilling
Thickness
Plasma
Thickness
Thermal
Cutting
Thickness

(mm)
(mm)
(mm)
(mm)

6000
2540
100
25

(mm)

130

(mm)

60

(mm)

130

1 plasma + 1 punching

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Production Lines
Area Name: Production Line 4
Details: CNC Sizing Bay S07, S08 for fully
automatic cutting, drilling and copying for
Section profiles and plates for pipes structures
and Light weight structures.

Production Bay 4 : CNC Machines

Machine Name: CNC Angle Processing Machine


Brand: FICEP Model: A 164
Technical Specifications:
Angles 410 M/mm2
Punching Diameter

(mm)
(mm)

160 x 160 x 19
32

Machine Name: Press Brake


Brand: Gizelis S.A. Model: G. Bend 3290
Technical Specifications:
Bending Force
Width
Thickness

(tons)
(mm)
(mm)

290
3100
12

Machine Name: CNC Pipe Processing Machine


Brand: HGG Model: SPC 1000-6t
Technical Specifications:
Length
Weight

(mm)
(ton)

20000
2.5

Machine Name: Shearing Machine


Brand: Gizelis S.A. Model: G. Cut CNC 3010
Technical Specifications:
Width
Thickness

(mm)
(mm)

3100
12

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Production Lines
Area Name: Production Line 5
Built Up Assembly Line
Dimensions:48m x 75m
Details: Specialist workshop for heavy /
medium assembly of built-up Girders / Columns /
Trusses and Boxes
Fully automated using hydraulic jacks system
and gantry automatic welding lines.

Production Bay 5 : CNC Machines

Machine Name: Built Up Assembly Machine


Brand: CMM Model: BWF 2000

Machine Name: Plate Cutting Machine


Brand: ESAB Quantity: 3

Technical Specifications:

Technical Specifications:

Web height
Flange width
Length
Speed

(mm)
(mm)
(mm)
(m/min)

2000
700
18000
0.3 to 6

Length
Width

(mm)
(mm)

28000
4000

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Area Name: Post-Blasting


Dimensions: 238m x 18m
Details: 115m in feed Conyers & collecting this material from all fabrication bays to post blast before
painting.
60m out feed Conyers to feed this material to the painting area.

Brand: Geitart
Width

(mm)

Model: CM 3100

Brand: Geitart

Model: CM 3100

3000

Width

(mm)

3000

(mm)

1500

(m/min)

0.6 to 4

Height

(mm)

1500

Height

Speed

(m/min)

0.6 to 4

Speed

Area Name: Painting Area


Dimensions:120m x 20m (nos x 3)
Details: Equipped with 5 nos over head cranes
10 ton capacity each, CNC ground trolley for
swift movement.
Each Bay is having 1 x 10 tons ground trolley

Machine Name: Spray Painting Machine


Brand: Graco Model: NXT Xtreme King 70:1

Painting Bay 1

Painting Bay 2

Painting Bay 3

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Area Name: Generators Area

Details:
Machine Name: Generator
Brand: Caterpillar
Model: 500 kVA
Model: 365 kVA
Model: 455 kVA
Model: 410 kVA

Quantity: 3
Quantity: 3
Quantity: 3
Quantity: 1

Area Name: Gas Station Area


Details:
Argon
CO2
Oxygen
Acetylene

CO2 tanks, Argon Tanks

Tank
Tank
Racks
Racks

4500 kg
3
2

100 nos of gas outlets for 100 MIG Welding Machines


every shift

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Quality Control & Quality Assurance


Meeting the essential requirement of ISO 9001:2008
ASSENT has established and implemented ISO 9000 based procedures and has a complete
ISO compliant QA Manual that includes all the following procedures:

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

Microsoft Office
Primavera / Microsoft Project
Autocad
Strucad
Tekla - Xsteel
Staad Pro
Master Key
ProKon
PMS system

General Office
Planning
2D Drafting
3D modeling and drafting
3D modeling and drafting
2D & 3D Design
Connections Design
Connections Design
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 ASSENT produce a full Bill of Quantities
during the "3 D" modelling phase of the drafting cycle. This information is transferred to the
Stru M.I.S evolution Software Program where the pre-determined priority ratings for each
Sub-structure are automatically assigned to the individual item
This allows the Stru M.I.S evolution Software Program 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 Stru M.I.S evolution Software Program 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 Stru M.I.S evolution Software Program 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 Stru M.I.S
evolution Software Program 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 Stru M.I.S evolution Software
Program 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 ASSENT 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 Stru M.I.S
evolution Software Program.
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 Stru M.I.S evolution Software
Program.

Welding
All welding operations are carried out in accordance with ASSENTs approved welding
procedures by independently qualified welders.
All procedures and welder qualifications are in accordance with AWS D 1.1 (2010) as well as
British standard BSEN 15614-1:2004 and BSEN 287-1:2004.
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 (2010) 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 Stru M.I.S evolution Software Program.

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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 650C
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(2010) acceptance standards used for determining the acceptability of the weld.
The results of all NDT examinations are entered on the Stru M.I.S evolution Software
Program.
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%) shall not exceed 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 stripe-coating 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. 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 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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SAMPLE DOCUMENTATION ONLY

PROCESS CONTROL PROCEDURE


Document No. ASSENT-QMS-P09

Revision 01

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1.0 PURPOSE
The purpose of this procedure is to identify and define the steps to be taken for
controlling and monitoring the workmanship, fabrication and surface preparation
activities in order to meet the specified quality requirements
2.0 SCOPE
This procedure outlines the responsibilities, method to control workmanship and
fabrication activities to achieve the required quality during the fabrication of all
structural steel products.
3.0 TERMS AND DEFINITIONS
ASSENT

Al Shafar Steel Engineering L.L.C

QC

Quality Control

ITP

Inspection and Test Plan

WPS

Welding Procedure Specification

PQR

Procedure Qualification Record

NDE

Nondestructive Examination (Third Party Testing)

4.0 RESPONSIBILITIES
4.1

QA Manager
To develop and implement the management of the Quality Procedures which will
govern the standard of quality on the contract

4.2

Material Control Engineer


Ensures that applicable procedures for procurement of material, receipt, checking
quality of material coordinating with QC Engineer, storage and issue of material,
comply with the Contract requirements.

4.3

QC Engineer
Commissioning and overseeing third party inspection services (NDT) and ensuring
that all relevant shop floor inspections and checks are conducted and documented.
Coordinating inspection of purchaser supplied materials. Coordinating the collation
and storage of all project specific quality records and documentation;

4.4

QC Inspector
To ensure that all welding and fabrication activities which are undertaken conform to
the approved procedures, and to notify the QC engineer of any non-conformances. To
conduct patrol inspections to monitor the welding parameters, consumables and
techniques being used are in accordance with the approved procedures to conduct
visual and weld dimensional checks for conformance to requirements.
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4.5

Dimensional Checker
To ensure that the overall dimensions of a specific piece or item of a structure comply
with those stated on the drawing.

4.6

Fabrication Workshop Supervisor


To compile and issue cutting schedules in conjunction with the Project Coordinator
and Drawing office. Verify that all cutting schedules are completed and all the items
listed are within the specified tolerances. Deploy the workforce for maximum
efficiency and ensure the standard of workmanship meets requirements. Raise orders
to purchase in conjunction with the Materials Controller to ensure adequate stock
levels are maintained.

4.7

Discipline Foreman (Cutting Fabrication Welding Painting)


Each discipline foreman is directly responsible to the Fabrication Workshop
Supervisor. They are responsible for the level of workmanship, shop floor
organization and control of their individual discipline.

5.0 PROCEDURE
5.1 Identification
5.1.1 Traceability of Steel
All steels materials received, ex-mils or from Merchants stock, shall have a valid
material (Mill) certificate
The material shall be received into stock with the manufacturers heat number marked
on to the item, this heat number traceability shall be maintained on cutting list for
each item.
5.1.2

Fabrication/Shop Drawings
The fabrication / shop drawings shall be prepared by our in-house drafting department
all drawings shall be checked and signed as Checked by ASSENT Draughts men for
accuracy prior to issue to the Client for Approval, if contractually required
Fabrication & Shop drawings shall show all the necessary details and dimensions to
enable fabrication of components to proceed, and will be controlled in accordance
with the Document Control Procedure "ASSENT-QMS-P01"
A latest controlled copy of fabrication / shop drawings shall be issued to the
Fabrication Workshop Supervisor and QC Engineer.

5.2 Marking
5.2.1 All Steel material received into stock shall be marked with the manufactures heat
number ref Material Control Procedure "ASSENT-QMS-P16".
5.2.2 All material used in the fabrication shall maintain full traceability.
5.2.3 The Fabrication Supervisor shall make a requisition to the Material Control Engineer
for material to be issued to Fabrication Shop, by means of beam and plate cutting
schedules.
5.2.4 Steel sections will be marked prior to cutting and shaping as detailed in the fabrication
drawings and cutting schedules.
5.2.5 QC Inspector shall randomly check individual parts to ensure correct marking prior to
cutting, shaping or drilling and sign the cutting schedule to record his check
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5.3 Cutting and Shaping, Bending and Bolt Holes


5.3.1 Beams will be cut in accordance with Beam Cutting Schedule.
5.3.2 Cutting and shaping of steel may be carried out by shearing, sawing, grinding,
machine flame cutting except that where machine flame cutting is impractical, hand
flame cutting may be used.
5.3.3 Deformation and burrs resulting from cutting shall be corrected and ground smooth.
5.3.4 Where cutting surfaces are required to transfer compressive loads by bearing (e.g.
column on base plates), they shall be milled to provide an adequate bearing surfaces.
5.3.5 Holes may be made by drilling and punching. Slotted holes shall be made by one of
the following methods:
Punch in one operation
Formed by drilling two holes and completed by gas cutting and grinding
5.3.6 Holes in steel plates over 10 mm thick shall be drilled. The diameter of the holes for
bolts (other than anchor bolts) shall not exceed nominal bolt diameter by more than
1.6 mm unless otherwise specified by Client.
5.3.7 Tolerance of the holes shall be in accordance with the approved drawings and Clients
specifications.
5.4 Machining
The thickness of elements shown on the drawings as requiring machining shall mean the
minimum thickness after the machine operation.
5.5 Dressing
Cut edges shall be dressed to remove burrs, dross and irregularities. Holes shall be
dressed as required to remove burrs and protruding edges.
Sharp edges shall be dressed, but a 90 deg. rolled, cut, sheared or machined edge is
acceptable without further treatment.
5.6 Assembly
5.6.1 General
All components shall be assembled in a manner such that they are not bent, twisted or
otherwise damaged. (Ref Inspection and Test Plan ASSENT-QMS-18). Drifting of
holes to align the components shall be permitted, but must not cause damage or
distortion to the final assembly.
5.6.2

Curving and Straightening


When it is necessary to curve or straighten components, one of the following methods
may be used (or as stated in the project specifications):
Mechanical means, taking care of indentations or change of cross sections;
The local Application of heat, ensuring that the temperature is carefully
controlled, by using crayon type temperature stick and does not exceed 650
deg. Centigrade;
These operations will be monitored and recorded by the Quality Control Engineer or
Inspector After curving or straightening, welds within the area of curving or
straightening shall be visually inspected. Welds which are to be subject to Nondestructive Examination shall have these tests carried out after curving or
straightening.
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5.7 Welding
5.7.1 General
All welder qualification certification and weld controls will be in accordance with
Weld Control "ASSENT-QMS-21".
The size of all structural fillet welds shall be as stated on the approved fabrication
drawings, all welds shall be dressed smooth, free from porosity, cracks, holes and
finished to match adjacent surfaces.
All pre-qualified WPS shall be made available to the Client for his review and
approval prior to commencement of welding activities or new WPS with PQR carried
out if no current qualification is available for the required process.
5.7.2

Preparation of Base Metal


Preparation of base metal shall be in accordance with the approved WPS. Surfaces
and edges to be welded shall be free from loose scale, slag, rust, grease, and any other
foreign matter.
Joint surfaces shall be free from laminations and tears. NDE shall, if a project
requirement shall be carried out on weld preparation to ensure no laminations are
present prior to welding.
Preparation of edges by gas cutting shall, wherever practicable, be done by a
mechanically guided torch.

5.7.3

Assembly
The parts to be jointed by fillet welds, separation between facing surfaces of lap joints
and butt welds, shall be in line with approved WPS.
The parts to be jointed by groove welds shall be brought into correct alignment.
The members to be welded shall be held in the correct positions by bolts, clamps,
wedges, guy lines, struts or other suitable devices, or by tack welds until welding has
been completed. The use of jigs and fixtures is recommended where practicable.
Suitable allowances shall be made for war page and shrinkage.
In assembling and joining parts of a structure of built-up members and in welding
reinforcing parts to members, the procedure and sequence shall be exercised to
minimize distortion and shrinkage.
Dimensional check for the assembly before welding shall be carried out by the
Dimensional Checker, and these inspections will be recorded on the form (Form #
ASSENT-QMS-P17F04) further to this inspection the work will be monitored by
inspection on a continuous basis through random patrol inspections recorded on form
Daily Patrol Inspections (Form # ASSENT-QMS-P17F05)

5.7.4

Electrodes and Automatic Coils


Electrodes and automatic Coils shall be procured, stored, issued and controlled in
accordance with ASSENTs procedure Welding Consumable Control ASSENTQMS-P22".
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5.7.5

Preheat and Interpass Temperature


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

5.8 Inspection
These activities shall be controlled in accordance with procedure of Inspection and
Testing "ASSENT-QMS-P18" and governed by the Test and Inspection Plan
All items forming part of the welded assemblies will be checked for freedom from
distortion and straightness, dimensional accuracy and conformity to the drawings and for
compliance with project specifications and ITP to ensure that the manufacturing process
is correctly implemented.
NDE inspection of welds shall be carried out in accordance with the requirements stated
in the project specifications and ITP
On completion of welding and testing, final inspection of assembled pieces shall be
made by QC Engineer or nominee prior to being dispatched for blasting and painting.
The results and report numbers of all inspections carried out during fabrication shall be
recorded in the fabrication check-list (Form # ASSENT-QMS-P17F02)
5.9 Surface Preparation, and Painting
All surface preparation, pruning and top coating, will be in accordance with the
ASSENT s procedure of Paint Control " ASSENT-QMS-23".
6.0 RETENTION PERIOD OF RECORDS:
Record

No.

Retention Period

NDT Request and Report Log


Fabrication Check List
Release for Painting

ASSENT-QMS-P17F01
ASSENT-QMS-P17F02
ASSENT-QMS-P17F03

One Year
One Year
One Year

Daily Dimensional Control Reports


Patrol Inspection Reports
Daily Painting Inspection Report
Plate Sizing & Cutting Check List

ASSENT-QMS-P17F04
ASSENT-QMS-P17F05
-----------

One Year
One Year
One Year
One Year

Beam cutting Schedule

------

One Year

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WPSWELDINGPROCEDURESSPECIFICATIONS
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Environment, Health & Safety


ASSENT EHS STATEMENT
ASSENTs Environment, Health and Safety (EHS) Policy and Management System is
committed to:
Develop, implement and manage Environmental, Health and Safety policies and
work processes at all ASSENT facilities.
Provide a safe and healthy work place and environment, to avoid injury or damage
to our employees, contractors, visitors and the public, the environment and
company assets.
Comply with applicable EHS regulatory requirements at each location.
Audit EHS activities at regular intervals at each facility to monitor its effective
implementation and to take corrective actions, wherever required.
Create a proactive EHS culture through awareness, training and motivation, to
achieve continual improvement in EHS performance.

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List of Current Projects by ASSENT


PROJECT TITLE

END USER

ROLE

WesternRangeDSO
IronOreSMPP

ArcelorMittal

SUBCONTRACTOR

LR2RefineryProject

LaffanRefinery
CompanyLimited2

SadaraDesalination
Plant

Marafiq

SUBCONTRACTOR

AbuDhabiPlaza

Aldar

SUBCONTRACTOR

AlZourNorthPower
Plant

HHI

SUBCONTRACTOR

BHSLinkBridge
Backbone
CMTExpansion

LouvreAbuDhabi

DubaiAviation
EngineeringProjects
Corporation
DubaiAviation
EngineeringProjects
Corporation
Tourism
Development&
InvestmentCompany

SUBCONTRACTOR

SUBCONTRACTOR

SUBCONTRACTOR

SUBCONTRACTOR

WesternRangeDSO
IronOreBuildings

ArcelorMittal

SUBCONTRACTOR

RasAbouFontas2
DesalinationPlant

QatarElectricityand
WaterCompany

SUBCONTRACTOR

KOCTelemetry
Project

KuwaitOilCompany

SUBCONTRACTOR

SSAGS

Shell

SUBCONTRACTOR

WestQurna1

ExxonMobil

SUBCONTRACTOR

BadraOilFiled

Gazprom

SUBCONTRACTOR

Rabigh2

SaudiAramco

SUBCONTRACTOR

SCOPE OF WORK

SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL
SUPPLY&
FABRICATIONOF
STRUCTURALSTEEL

TONNAGE

3,300

4,500

1,200

12,000

9,400

585

1,900

3,500

1,800

800

1,096

3,200

10,000

4,500

12,000

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List of Completed Projects by ASSENT


PROJECT TITLE

END USER

ROLE

MaadenAlumina
Refinery

Maaden

SUBCONTRACTOR

ShahGasPKG2

AlHosnGas

SUBCONTRACTOR

RumailaField

BritishPetroleum

SUBCONTRACTOR

BoosterStation171

KuwaitOilCompany

SUBCONTRACTOR

QusahwiraField

ADCO

SUBCONTRACTOR

ShahGasPKG1

AlHosnGas

SUBCONTRACTOR

ArcelorMittal

SUBCONTRACTOR

HajrElectricity
Company

SUBCONTRACTOR

AlHosnGas

SUBCONTRACTOR

EMAL

SUBCONTRACTOR

MaekKazatompron

SUBCONTRACTOR

RRE7Expansion

TAKREER

SUBCONTRACTOR

ShahGasPKG4

GASCO/AlHosngas

SUBCONTRACTOR

BOROUGEIIIO&U

BOROUGE

SUBCONTRACTOR

BabThamama

ADCO

SUBCONTRACTOR

SouthYoloten

Turkmengas

SUBCONTRACTOR

MaadenRollingMill

Maaden

SUBCONTRACTOR

RRE1Expansion

TAKREER

SUBCONTRACTOR

GasSweetening

QatarPetroleum

SUBCONTRACTOR

TheOneTower

AlMazroei

SUBCONTRACTOR

RRE3

TAKREER

SUBCONTRACTOR

BoosterStation132

KuwaitOilCompany

SUBCONTRACTOR

SoharII&BarkaIII

OmanPowerand
WaterCompany

SUBCONTRACTOR

WesternRangeDSO
IronOre
QurayyahPower
Plant
ShahSulphurStation
andPipeline
GreenAnodePlant&
RoddingShop
AktauDesalination
Plant

SCOPE OF WORK

FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL
FABRICATIONOF
STRUCTURALSTEEL

TONNAGE

5,000
900
400
5,000
3,500
900
760
12,750
5,300
4,000
170
1,300
9,400
12,550
6,400
8,000
8,000
17,500
4,150
1,000
7,550
4,500
200

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Sample Projects
ProjectName:BoosterStation132
Location:Kuwait
Client:KuwaitOilCompany
EPCContactor:SKEngineering&Construction

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ProjectName:GasSweeteningFacilities
Location:Qatar
Client:QatarPetroleum
EPCContactor:Petrofac

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ProjectName:QurayyahPowerPlant
Location:SaudiArabia
Client:HajrElectricityCo.
EPCContactor:SamsungC&TCorporation

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ProjectName:SouthYolotenFieldDevelopment
Location:Turkmenistan
Client:Turkmengas
EPCContactor:Petrofac

ProjectName:LouvreMuseum
Location:UAE
Client:TourismDevelopmentInvestmentCompany
EPCContactor:WaagnerBiro

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ProjectName:Borouge3Utilities&Offsites
Location:UAE
Client:BOROUGE
EPCContactor:HyundaiEngineering&Construction

ProjectName:ShahGasDevelopmentPkg4
Location:UAE
Client:AlHosnGas
EPCContactor:SamsungEngineering

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List of Projects Executed by ASSENT Senior Management


ASSENT is a recent addition to Al-Shafar Group of Companies, but has the advantage of a Senior
Management Members who have a large experience in the structural steel fabrication business in the
Middle East and in particular, the UAE and GCC countries, in all major market sectors and in
particular the Oil & Gas and Petrochem Sectors.
As an indication of the background and experience of the management in these fields, we are pleased
to attach the list of projects been executed by ASSENTs Senior Management Team
S1

ProjectTitle

Client

EndUser

Location

SteelTonnes

Year

YansalebOlefin

TechnipItaly

SABIC

Saudi

9,200

2006

CommonSulphurProject

AlJaberEnergy

QatarGas

Qatar

4,800

2006

TaweelahExtensionGAS
TrubineBuilding

SiemensPower

AbuDhabi

800

2006

RGX6RASGASOnshore
ExpansionTrain6&7

RASGAS

Qatar

13,832

2006

OGDIII

Arabian
Construction
Co.
Chiyoda
TechnipJoint
Venture
Bechtel

GASCO

AbuDhabi

21,400

2005

DCA

DubaiCivil
Aviation

Dubai

2,500

2005

DCA

DubaiCivil
Aviation

Dubai

6,500

2005

SDMiddleEast

DubaiCivil
Aviation

Dubai

4,000

2004

GroupFive

DubaiCivil
Aviation
JGC

Dubai

1,000

2005

AbuDhabi

2004

Dubai

828

21,000

2004

Dubai

4,250

2004

13

DubaiAirportExpansion
PhaseIIDutyFree
Expansion
DubaiAirportExpansion
PhaseIICargoMega
Terminal
DubaiAiportExpansion
PhaseII
CargoMegaTerminalULD
Structure
DubaiAiportExpansion
OhaseIICUC
SoharRefineryProject

AX149StructuralSteel
worksforthe
DubaiAirwing
MalloftheEmirates
Develop
WP4150SnowCentre
UmmAlNarIWPP

AbuDhabi

4,300

2004

14
15

AmranCementPlant
ArzewDesalinationPlant

Yemen
Algeria

1,340
450

2004
2004

16
17

KestrelBoilerSupports
SaharaMallInterchange

Dubai
Sharjah

450
170

2004
2003

18

Sajja/DhaidInterchange

Sharjah

290

2003

9
10

11

12

JGC

DarAl
Handasah
AlNabodah
LaingO'
Rourke
Arabian
Construction
Co.
IHI
HitachiZosen
CMI
AthenaSA/
NCTC
ChinaHarbor
Engineering

Dept.ofCivil
Aviation
Govt.ofDubai
MallofEmirates

IWPP

ArmantCement
Algeria
Government
DUBAL
Governmentof
Sharjah
Governmentof
Sharjah

Page 84 of 95

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STRUCTURALSTEEL

PREQUALIFICATIONDOCUMENT

Location

SteelTonnes

Year

19

KestrelProjectPhaseII

DUBAL

DUBAL

Dubai

8,500

2003

20

GasMeteringSkids

AlderlyFZE

ARAMCO

80

2003

21

AlUdiedPackage4Hangar

QatarACC

QatarMOD

Saudi
Arabia
Qatar

400

2003

22

GAMCOHangar

GAMCO

AbuDhabi

2,000

2003

23

SharjahCement

AlHamed
Development
&
Construction
IHI

Sharjah

1,250

2001

24

AbuDhabi

550

2001

Ruwais

1,450

2000

AbuDhabi

3,000

1999

KSA

2,500

1999

KSA

850

ADNOC

AbuDhabi

1,200

1999

ADCO

AbuDhabi

1,440

1999

31

AlBateenAirbase
SidecoGen.
MW2273
Contracting
RuwaisUpgradingFacilities TechnipAbu
Dhabi
AlTaweelahA2Power
Arabian
Station
Construction
Co.
HawiyahGasPlant
JGC
Corporation
AramcoR&DLaboratory
JaffarAl
HamoodEst.
OGD2Package1,2,3,4,5
Technip/
Bechtel
ASABGasGather&Inj
Mannesmann
Project
DemagAG
TD48DCAExpansion
HMRJV

Dubai

16,500

1998

32

CodorProjectPipeRack

AlstomPower

Dubai

1,125

1998

33

CMIBelgium

Dubai

805

1998

34

CodorProjectBoiler
Supports
RaslafanQatarGas

Qatar

1,400

1997

35

OmanLNGBuilding

Oman

800

1997

19
20

KestrelProjectPhaseII
GasMeteringSkids

8,500
80

2003
2003

21
22

AlUdiedPackage4Hangar
GAMCOHangar

QatarMOD
GAMCO

Dubai
Saudi
Arabia
Qatar
AbuDhabi

400
2,000

2003
2003

SharjahCement
DMW Dubai

Sharjah
AbuDhabi

1,250
550

2001
2001

Ruwais

1,450

2000

AbuDhabi

3,000

1999

25
26

27
28
29
30

23
24
25
26

ProjectTitle

Client

WilliamHare
Ltd.
BhawanEngg.
Co.
DUBAL
AlderlyFZE

QatarACC
AlHamed
Development
&
Construction
SharjahCement
IHI
AlBateenAirbase
SidecoGen.
MW2273
Contracting
RuwaisUpgradingFacilities TechnipAbu
Dhabi
AlTaweelahA2Power
Arabian
Station
Construction
Co.

EndUser

SharjahCement
DMW Dubai
GASCO
AbuDhabiWater
&
Electricity
SaudiAramco
SaudiAramco

DubaiCivil
Aviation
DubaiAluminum
Co.
DubaiAluminum
Co.
QatarGas
OmanLNG
DUBAL
ARAMCO

GASCO
AbuDhabiWater
&
Electricity

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STRUCTURALSTEEL

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ProjectTitle

Client

27

HawiyahGasPlant

JGC
Corporation
JaffarAl
HamoodEst.
Technip/
Bechtel

28

AramcoR&DLaboratory

29

OGD2Package1,2,3,4,5

30
31

ASABGasGather&Inj
Project
TD48DCAExpansion

Mannesmann
DemagAG
HMRJV

32

CodorProjectPipeRack

AlstomPower

33

CMIBelgium

34

CodorProjectBoiler
Supports
RaslafanQatarGas

35

OmanLNGBuilding

WilliamHare
Ltd.
BhawanEngg.
Co.

Location

SteelTonnes

Year

SaudiAramco

EndUser

KSA

2,500

1999

SaudiAramco

KSA

850

ADNOC

AbuDhabi

1,200

1999

ADCO

AbuDhabi

1,440

1999

Dubai

16,500

1998

Dubai

1,125

1998

Dubai

805

1998

Qatar

1,400

1997

Oman

800

1997

DubaiCivil
Aviation
DubaiAluminum
Co.
DubaiAluminum
Co.
QatarGas
OmanLNG

Page 86 of 95

STRUCTURALSTEEL

PREQUALIFICATIONDOCUMENT

Organization Chart

Page 87 of 95

STRUCTURALSTEEL

PREQUALIFICATIONDOCUMENT

Manpower List Category: Staff

ASSENTOFFICESTAFF
Department
Executive'sOffice

Operations

Finance

HR&Administration

SalesandEstimation

ProjectManagement

Engineering

Designation
ManagingPartner
ExecutiveAssistant

GeneralManager

FinanceManager
ChiefAccountant
Accountants

HR&AdminManager
HRExecutive
PRO
Receptionist
DocumentController
TransportinCharge
CampBoss

GeneralSalesManager
AreaSalesEngineer
EstimationEngineer
SteelDetailer
MarketingExecutive
Sales&MarketingAssistant

ProjectsDirector
ContractsManager
ProjectManagers
ProjectEngineers
SiteEngineer
ConstructionManager
QuantitySurveyor
DocumentController

EngineeringManager
DesignEngineer
SteelDetailers
SteelCheckers

Number Total

1
2

1
1

3
5

2
8

1
10

1
16

20

Page 88 of 95

STRUCTURALSTEEL

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IT

Procurement

Inventory&Warehouse

Production

CNCProgrammer
DocumentController

ITManager
ITEngineers
AttendanceOfficer

ProcurementAuditor
Sr.ProcurementOfficer
ProcurementExecutive
ProcurementOfficer
CustomCoordinator

Inventory&WarehouseManager
MaterialPlanner
MaterialExpeditor
StoreForeman
Storekeepers
StoreClerk

HeadofProduction
ProductionEngineer
AssistantEngineer(MPS)
WeldingForeman
CNCProgrammers
CNCForeman
ProductionCoordinator
MPSSupervisor
MPSChargehand
MPSForeman
Blasting&PaintingForeman
BlastingForeman
PaintingSupervisor
PaintingForeman
FabricationForeman
ErectionForeman
SiteFormean
PreparationForeman
OfficeClerk
Chargehand
ErectionChargehand
DocumentController

1
2

1
2
1

1
1
1
1
1

1
1
2
1
8
1

1
2
1
9
2
1
1
1
1
1
1
1
3
3
15
1
1
1
1
8
1
1

36

14

57

Page 89 of 95

STRUCTURALSTEEL

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Facilities/Maintenance

QA/QC

PrintingArea

HSE

Dispatch/Delivery

OfficeStaffTotal

FacilityManager
MaintenanceManager
MaintenanceSupervisor
MaintenanceForeman
MaintenanceEngineer
ElectricalForeman

QA/QCManager
QCEngineers
QCInspector(Painting)
DocumentController

PrintingOfficer

HSEManager
SafetySupervisor
SafetyOfficer
Asst.SafetyOfficer
SiteHSEOfficer
CompanyNurse

DispatchSupervisor
DispatchClerk
DriverHeavyTruck
Driver
DocumentController
DispatchForeman

1
1
1
3
1
3

1
4
2
2

1
1
1
2
1
3

1
1
3
10
3
1

10

9
196

Page 90 of 95

STRUCTURALSTEEL

PREQUALIFICATIONDOCUMENT

Manpower List Category: Labor

ASSENTWORKSHOP
Designation
Asst.Safetyofficer
Asst.Fabricator
Asst.Maintenance
Asst.SprayPainter
Asst.SteelErector
Asst.Storekeeper
BlastingOperator
CAGWelder
Chargehand
Clerk
CNCMachineOperator
CraneOperator
DieselMechanic
DimensionalInspector
DispatchChargehand
DispatchClerk
DispatchQC
Electrician
FabricationChargehand
Fabricator
ForkliftDriver
ForkliftOperator
Gardener
GasCutter
Helper
Housekeeping
IndustrialWiringTechnician
LandSurveyor
MachineOperator
MachineOperatorBlasting
MaintenanceElectrician
MaintenanceTechnician
Mason
MaterialClerk
Materialhandler
MechanicalHelper
MechanicalTechnician
MaintenanceChargehand

Number
1
22
6
1
2
1
1
1
15
7
35
22
1
22
2
1
1
9
1
170
1
1
1
1
252
1
1
1
2
1
1
1
8
2
1
19
2
1

Page 91 of 95

STRUCTURALSTEEL

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MigWelder
Mixer
OfficeBoy
Painter
PaintingInspector
Plumber
QCDocumentController
QCInspector
RadialDrillOperator
Rigger
SecurityGuard
ShearingOperator
SprayPainter
SteelErector
SteelErectorChargehand
Storekeeper
TackWelder
TeamLeader
Technician
TouchupPainter
Welder
WeldingChargehand
WeldingInspector
WorkshopTotal

31
4
2
35
2
2
1
2
2
22
10
1
1
46
1
1
6
1
1
2
200
1
6
998

Page 92 of 95

STRUCTURALSTEEL

PREQUALIFICATIONDOCUMENT

Equipment List
YEAROF
PURCHASE

QTY

SAWCAPACITY1250X600mm(max),80x
10mm(min)

2009

1203DF

SECTIONLENGTH(250018000)MM,WEB
HEIGHT(801220)MM,FLANGEHEIGHT(42
510MM)

2009

FICEP

1201RC

SECTIONLENGTH(250012000)MM,WEB
HEIGHT(801220)MM,FLANGEHEIGHT(42
600MM)

2009

FICEP

TIPOA31

PROCESSPLATETHICKNESS(10
130MM),MINIMUMWORKPIECESPECIFICATION
L=200,W=150

2008

FICEP

TIPOB251

PROCESSPLATETHICKNESS(625MM),MINIMUM
WORKPIECESPECIFICATIONL=200,W=150

2009

ESAB

EXA5000

2009

ESAB

EXA4500

2009

FICEP

A164

2008

FICEP

A206

SN

EQUIPMENT

MAKE

MODEL

CNCBEAM
SAWING

FICEP

1260LBH

CNCBEAM
DRILLING

FICEP

CNCBEAMCOPING

4
5
6
7
8
9

CNCPLATE
PROCESSING

CNCANGLE
PROCESSING

801

2011

HGG

SPC1000

PUNCHSTROKELENGTH=40MM,PUNCHING
POWER=800KN,MAXTHICKNESS=20MM

2009

CNCSHEARING

GIZELIS

GCUT3010

CUTTINGTHICKNESS(610MM)

2010

CNCBENDING

GIZELIS

GBEND3290

BENDINGTHICKNESS610MM)

2010

SIMCO

Z3050X16/1

2009

2010

2009

2009

WEBHEIGHT2502000MM,WEBTHICKNESS6
40MM,FLANGEHEIGHT150600MM,FLANGE
THICKNESS680MM

2010

FICEP

11

CNCPROFILING
SPC1000

19
20
21
22
23
24
25
26
27
28

PROCESSANGLEDIMENSIONS(40X40X4)
(200X200X20)MAXDIAOFHOLE=32MM

2009

10

18

CUTTINGTHICKNESS(8100MM)

PUNCHSTROKELENGTH=40MM,PUNCHING
POWER=800KN,MAXTHICKNESS=20MM

CNCHYDRAULIC
PUNCHPRESS

12
13
14
15
16
17

CAPACITY

SIMCO

RD5016

LAROSA

Z3050X16/1

LAROSA

Z3050X16/1

CNCBUILTUP
SECTION

CMM

BW2000

PREBLASTING

GIETART

AGW2500

BLASTINGWITH6WHEEL

2009

POSTBLASTING

GIETART

AGCM3100

BLASTINGWITH10WHEEL

2009

CATERPILAR

3046PRM

365KVA

2008

CATERPILAR

C15_PRM

500KVA

2008

CATERPILAR

500

500KVA

2008

CATERPILAR

LC6

500KVA

2008

SULLAIR

3710

150160PSI

2010

COMPAIR

L3710

11BAR,37KW,3000RPM

2010

RADIALARM
DRILLINGMAC

GENERATOR

COMPRESSOR
DRYER

50MMPLATETHICKNESSDRILLING

SULLAIR

030BAR(REFERIGERANT134A)

2010

COMPAIR

DC150AX

1620BAR(REFERIGERANT134A)

2010

230/400415/500V,60%DUTYCYCLE
56/32(43)/26A,100%DUTYCYCLE43/25/20A

2009

120

CUT11/2"(38MM),SEVERS13/4"(45MM)
,60%DUTYCYCLE90AMP

2010

29

MIGWELDING

ESAB

MIG402C

30

PLASMAMACHINE

ESAB

POWERCUT
1600

Page 93 of 95

STRUCTURALSTEEL

PREQUALIFICATIONDOCUMENT

YEAROF
PURCHASE

QTY

CO2ANDARGONAT5BAR

2010

LHF400

400V,340W,.90P.F,35%D.S=400A/36V,60%
D.S=315A/33V,100%D.S250A/30V

2010

83

LINCOLN

200iDC

220V/1/50/60HZ+/10%IP21S/F

2010

60

GOLDSTAR602

20590AMPDC,OPENCIRCUITVOLTAGE
(71),IP=21M,INPUTAMP51A/3PHASE

2010

415V/50HZ,80A/64A

2010

415V/50HZ,74A/67A

2009

SN

EQUIPMENT

MAKE

MODEL

31

GASMIXING
MACHINE

SHARJAH
OXYGEN

ESAB

32

ARCWELDING

33

CAPACITY

34

GOUGING
MACHINE

MILLER

35

SUB ARC

LINCOLN

36

SUB ARC

ESAB

IDEALARC
DC600
LAF1000DC

37

OVERHEADCRANE
(5TON)

ABUS

SINGLEGIRDERCROSSTRAVEL19065MM,HOIST
WORKING7200MM

2009

10

38

OVERHEADCRANE
(10TON)

ABUS

SINGLEGIRDERCROSSTRAVEL19070MM,HOIST
WORKING7770MM

2009

61

39

OVERHEADCRANE
(15TON)

ABUS

SINGLEGIRDERCROSSTRAVEL22070MM,HOIST
WORKING7700MM

2009

14

40

ELECTRICTOLLEY
(10TON)

WUXI

F21E1BTX

10TON,8HOURBACKUP36VOLT

2009

41

ELECTRICTOLLEY
(30TON)

WUXI

F21E1BTX

16TON,8HOURBACKUP75VOLT

2009

42

ELECTRICTROLLEY
CHARGER

WUXI

DF4860D11

36VCHARGING

2009

43

ELECTRICTROLLEY
CHARGER

WUXI

DF4860D11

75VCHARGING

2009

13

44

SPRAYPAINTING
MACHINE

EXTREME

GRACO60:1

220CC(900)PUMP

2009

15

45

THREADING
MACHINE

RIDGID

1224

1/2"2"

2010

GRINDER41/2"

MAKITA

GA5010

2010

90

GRINDER41/2"

DEWALT

D28143

2011

100

GRINDER7"

MAKITA

GA7020

2010

70

GRINDER7"

DEWALT

D28413

2011

100

46
47
48
49
50
51
52
53

GRINDER7"

DEWALT

D28495

2011

18

DIEGRINDER

MAKITA

GD800C

2011

40

DIEGRINDER

DEWALT

DW887

2011

70

DIEGRINDER

DEWALT

DW28886

2011

20

Page 94 of 95

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PREQUALIFICATIONDOCUMENT

Our Location Map

Page 95 of 95