Module 4: Installation & Site Work 

Reading Architectural Drawings & Specifications

Precise interpretation of technical documents forms the foundation of successful metalwork installation. Modern construction relies on three key documentation types:

Shop Drawings serve as the metal fabricator's bible, containing exact dimensions, material specifications, and connection details that bridge design intent with physical execution. Students learn to cross-reference these with architectural elevations, identifying potential clashes between structural steel and MEP systems before they reach the jobsite. Building Information Modeling (BIM) has revolutionized this process - we train participants in navigating 3D models using Navisworks, identifying interference points through clash detection, and extracting accurate quantities via BIM takeoffs.

Compliance forms the non-negotiable framework for all installations. The Americans with Disabilities Act (ADA) dictates critical parameters for handrail heights (34"-38"), graspability dimensions, and stair nose profiles. For structural elements, the International Building Code (IBC) governs seismic bracing requirements, fireproofing standards for steel columns, and wind load calculations for curtain walls. Case studies demonstrate how a 1/4" deviation in balcony railing spacing can fail inspection, emphasizing why millimeter-level precision matters in code-compliant metalwork.

On-Site Fabrication & Adjustments

Real-world installation demands adaptive problem-solving when theoretical designs meet physical realities. Tolerance management becomes an art form - we teach techniques like laser-aligned shimming to compensate for concrete slab unevenness, and thermal expansion gap calculations for aluminum cladding systems. A common challenge involves field-fit modifications, where students practice plasma-cutting adjustment notches in steel beams or re-drilling bolt patterns using magnetic base drills when as-built conditions differ from drawings.

Heavy component handling requires specialized rigging expertise. The module covers:

• Below-the-hook device selection (spreader beams vs. plate clamps)

• Load dynamics calculations for swinging metal panels during tower crane lifts

• Fall arrest systems for workers installing high-level steelwork

• Temporary bracing protocols for unsecured structural members

Participants conduct practical exercises with certified riggers, learning to interpret load charts and establish exclusion zones during critical lifts.

Quality Control & Inspection

Robust inspection protocols separate professional installations from amateur work. The curriculum emphasizes non-destructive testing (NDT) methods:

Dye Penetrant Inspection (DPI):

• Cleaner application to weld surfaces

• 10-30 minute dwell time for capillary action

• UV fluorescent or visible dye comparison

• Classification of linear vs. rounded indications per AWS D1.1

Ultrasonic Testing (UT):

• Calibration using IIW-type reference blocks

• Identification of lack-of-fusion defects in thick steel connections

• Angle beam techniques for fillet weld examination

• Data recording for traceability

When defects surface, students learn remediation hierarchy:

1. Grind-and-repair for surface flaws

2. Butter-and-repass welding techniques

3. Complete removal and rewelding for critical defects

4. Engineering evaluation for non-conforming but serviceable conditions

The module concludes with mock inspections where participants must:

• Identify improperly torqued high-strength bolts

• Spot inadequate weld profiles

• Recognize galvanizing discontinuities

• Document findings with digital reporting tools

This hands-on approach ensures graduates can deliver installed metalwork that meets both aesthetic expectations and rigorous performance standards.