Once the Fabrication file is complete, the fabrication process can start.
2- Material.

2.1 Procurement of Material.The procurement of material is done according to the B.O.Q and the materialSpecifications included in the fabrication file.The materials are procured from certified suppliers.

2.2 Visual inspection

To ensure quality, visual inspection is done on the material to ascertain that is complying with the requirement needed for fabrication, especially on the geometrical and dimensional tolerances.   

 2.3 Mill certificate:    

 All materials are received with Mill test certificates to ensure that adequate type of steel is used.

3- Fabrication.For each part in the project, the major fabrication operations are identified. A"fabrication inspection sheet" is made for it.The fabrication inspector approves each operation; put a check mark, given at this time the permission to proceed to the next operation. Inspectors are responsible for acceptance and rejection of material.During the fabrication, a progress report is made by the workshop chief to evaluate the work progression against the project schedule and take the necessary remedying actions.

4- Welding.

4.1 Welding procedure specification (WPS) and welder qualification. A welding procedure qualification is made to cover the welding operations needed. A WPS is made for each joint according to the AWS.
All our welders are certified from the IRI and have different qualification certificates from other several control desks and institutes.

4.2 Welding inspection and testing.The following examination and testing are made when needed to ascertain a satisfied quality of welds.

4.2.1 Visual test.

Visual examination is made during the fabrication and erection process to assure that all welds comply with the following acceptance standards specified below:

a- There shall be no cracks and inclusions on the surface.

b- There shall be no incomplete fusion.

c- There shall be no incomplete joint penetration in groove welds.

d- Undercut shall not be greater than specified in ASME.

e- The appearance of the weld shall satisfy qualifier.

4.2.2 Penetrate test  The penetrate test is done to discover the following defects:

a- Crack on the surface

b- Porosity when open to surface

c- Slag inclusion.

d- Lack of fusion on the surface.

4.2.3 Other NDT. Other NDT like radiographic test and ultrasonic test are made when required by the Industrial Research Institute (IRI) or other control desks as required by the clients

4.2.3 Welding preparation.The inspector shall ascertain the correctness of the welding joint preparation before the starting of the welding process especially the groove dimension, welding place free from dust, oil and inclusions, alignment of the components in groove welds...

5- Surface Protection.The inspector shall ascertain the quality of work on the followingpoints of inspection:    

5.1 - Surface preparation. Prior to painting, we must do the following works:

a- Sharp edges, comers and weld seams shall be rounded orsmoothened by grinding.
 b- All the deposits of soil, dust, dirt, weld flux and weld spatter must be removed. We use the sandblasting process to do this work. Sand is clean and free from moisture. A visual inspection is made to assure that it is not contaminated.
c- The removing of oil and grease is done by use compressed water and industrial detergent or by using special material recommended by the painting companies.
d- All the defects due to fabrication or lamination must be repaired. After the sandblasting, the component shall be cleaned by air from the sand traces. Then a visual inspection on the surface will did to verify its compliance with the requirement.
If not, the process will be repeated until we reach our objectives.

5.2 Coating condition. Coating application will be done in accordance with manufacturer specification. It will be done under suitable ambient condition of temperature, humidity and dew point temperature. We do the coating process in suitable place where:a- No dusty conditionb- No parallel activity of abrasive blasting carried outc- No parallel activities of cutting, welding or hazardous environment exist.

5.3- Environment Condition.Checking the environment conditions before starting sandblasting and painting is a must.
Our inspector checks the dew point using digital hygrometer and tables .after he measure steel temperature using special thermometer .To prevent moisture condensation during application, surface temperature must be at least 3°C above dew point.   

5.4 Inspection of application equipments.

a- Insure clean air supply

b- The cleanliness of all spray equipment must be verified prior to painting operation.  

5.5 Inspection on coating mixing, application and film thickness.The inspector check correctness of the mixing operation .he must witness that:

a- All the paint components have been added
b- Mixing is done until the paint become smooth, homogeneous.Our inspector assures the way of application:The spray gun should be held between 6 to 8 inches from the surface and
maintained perpendicular to the surface throughout the stroke.
Excessive runs, drips, and other film deficiencies should brushed out.The inspectors verify:1. Anchor profile before painting to assure that is suitable for the kind and thickness of primer used.2. The wet film thickness using special Gauge and the dry film thickness using a special instrument (Elcometer). Adhesion test is done when required by the inspector to ascertain the quality of paint.

d. List of some projects executed:We have worked with several foreign and national companies like Zublin, Ansaldo ,Pirelli ,GEC Alshtom , Polisuis , Holcim ,National cement,..

1. For Zublin ( German Group):  

Project: Libanese University Campus - Hadath    

Works Executed: 

i. Water Tanks with maintenance platforms, spiral stairs ...
ii. 2 underground fuel tanks of diameter 4m and length 18m(200000L)
iii. 4 underground fuel tanks of diameter 2.4m and length 8m(35000L)
iv. 4 underground fuel tanks of diameter 3.8m and length 9m(90000L)

v. Four Chimneys for the boiler of the campus of diameter 1m and height 13m including elbows and accessories with expansion joints ,elbows,....
vi. Ventilation shafts etc.....

vii. Steel Roofs For example: canopy of area 527m² and height 8m
viii. Steel ramps and catwalks.
ix. 6000m of handrails (spiral and straight)
x. Several doors of height 5m and length 11 m-fire rating.
xi. 10 sky lighting roofs of dimensions 5*5m.
xii. Trench covers and different other steel works
xiii. Steel stairs...

2. Pirelli;

Project: Abou Ali Bridge -Tripoli, North Lebanon

3. Polisuis:

Project: Four No.7 - Holcim.We have done for polisius a lot of necessary steel structure works for the Four No. 7

4. Holcim: