This post explains the necessary inspections and testing required during the Erection (Installation) of structural steel works. This is only a summary, and a fully customizable ITP with the required checklist in Word format can be downloaded from the link given at the bottom.
Click Here for the ITP for Structural Steel Works Fabrication.
WHAT IS STRUCTURAL STEELWORK
Structural steel is one of the most important materials in the construction industry. It is used in many structures — in fact, heavy structures like buildings, factories, bridges, etc.
Structural steelwork involves reshaping and fabrication of steel through cutting, bending, and assembling into the required structural shapes.
WHAT IS AN INSPECTION AND TEST PLAN (ITP)
Inspection and Test Plans and checklists are integral parts of quality management systems — not only in construction but in almost every industry where Quality Management Systems (QMS) are implemented.
They are considered master documents through which various parameters and activities of a process are monitored and recorded. These records later play a vital role during verification and auditing.
In construction, where numerous trades and activities must be completed — such as structural, finishes, façade, electrical, mechanical, and plumbing works — preparation and implementation of different ITPs form a crucial part of the project quality management system.
To read more about ITPs and how to prepare one, CLICK HERE and refer to the last picture in this post for a quick understanding of an ITP’s structure and how to align it with your project requirements.
INSPECTION AND TEST PLAN FOR STRUCTURAL STEEL WORKS
SECTION 1 – DOCUMENTATION REVIEW
This section outlines the review and approval process for all necessary documents prior to commencing structural steel works on-site.
Key documents include:
- Approved drawings and typical details
- Material specifications
- Welding procedures and welder qualification details
- Inspection checklists and quality control forms
- Method Statement
Proper review of these ensures that fabrication and erection proceed as per approved standards
SECTION 2 – INSPECTION OF INCOMING MATERIALS
This section addresses the inspection of materials used for structural steel elements, including beams, columns, girders, and plates.
Points to verify:
- Materials Angles, T-sect, beams, flats, plates, bolts, nuts, welding rods) etc. conform to approved specifications
- Mill/Test certificates are reviewed and approved
Materials are stored as per the required guidelines and standards to prevent damage or corrosion
This section focuses on inspections to be carried out before the Erection process begins to ensure all prerequisites are met and materials are ready for production. It also details inspection requirements for different structures, such as Foundations and other structures (Columns, Beams, Girders and Bracings) in two different sections
SECTION 3 – PRE-ERECTION INSPECTION – MATERIALS & WELDERS
This section covers the inspection of all pre-fabricated materials and the review of welders’ qualifications
SECTION 4 – PRE-ERECTION INSPECTION – FOUNDATIONS
Checks include:
- Check on benchmarks
- Check on the casting of foundations
- Check for levels and distances of foundations
SECTION 5 – PRE-ERECTION INSPECTION – COLUMNS, BEAMS, GIRDERS & BRACINGS
- Check on the base plate and the HSFG bolt area
- Check on templates.
- Check for column pieces
- Check for packer plates
- Check on painting
- Check for stubs welded on columns.
These checks help ensure accuracy, consistency, and readiness before welding or assembly starts.
SECTION 5 – FABRICATION IN PROGRESS INSPECTION
During fabrication, continuous inspection ensures that the process meets quality and safety standards.
Checks typically include:
- Check for preheating before welding where required
- Check for fit-up of joints to ensure alignment and correct gaps
- Check for assembly of welding parts
- Check for tack welding
- Check for general welding
- Check for post-weld heat treatment
These inspections help prevent defects and ensure that welded joints meet structural and quality requirements.
SECTION 6 – ERECTION IN PROGRESS INSPECTION
During erection, a thorough inspection ensures that the erection is carried out as per the approved drawings and other applicable details.
Checks include:
- Check on column erection.
- Check on the alignment of columns.
- Check for the erection of horizontal beams, girders and vertical bracings
- Check bolting
- Check on the locking of the packer plates.
- Check for the erection of the second column.
- Check on the erection of interconnecting members.
- Check on welders
- Check on welding materials
- Check for preheating.
- Check for fit-up of joints.
- Check for assembly of welding parts.
- Check for post-weld heat treatment
These inspections ensure conformity to design requirements and readiness for delivery or erection.
SECTION 7 – POST ERECTIONC INSPECTION
After erection, thorough inspection ensures that the finished work meets specifications, approved drawings and all other applicable details.
Checks typically include:
- Check on columns and other members
- Check on the weld surface & Size.
- Check on welding
- Testing of welds
- Check for repair of faulty welds.
- Check for re-weld and retest
- Check on tolerances
- Check on grouting
- Check on painting
CONCLUSION
This Inspection and Test Plan (ITP) for structural steel erection ensures that all erection activities are carried out in accordance with approved drawings, project specifications, and relevant codes. By defining clear hold points, witness points, and surveillance requirements, the plan provides a structured approach to monitor alignment, bolting, welding, stability, and overall installation quality.
Proper documentation, timely inspections, and coordination among the contractor, consultant, and quality team help prevent non-conformances and ensure that the erected steel structure meets the required safety and performance standards. When followed diligently, this ITP supports safe execution, quality workmanship, and successful completion of steel erection works.
Click here to understand what an ITP is and prepare one
Sign up to download the full customizable Structural Steel Erection ITP and checklist for erection and grouting in Word format. Allowable tolerance for erection is also included
Refer to this picture to learn tips on how to customize the ITP depending on the Project Requirements
