Sending a steel structure abroad takes more than fabrication: the right design code, execution class, corrosion protection, tolerances, sea packing and on-site erection supervision. The checklist for an export project.
The biggest advantage of steel is that most of the work is done in a controlled workshop and travels to site as ready parts. That advantage is even stronger on export projects: time on the foreign site shrinks. But once parts cross a border, the design code, execution class, coating, tolerances and certification must have been set correctly from the start. Below are the headings we follow on an export project.
1. Design code
The first question is which code the structure is calculated to. In Europe and most export markets, Eurocode 3 (EN 1993) is the basis, with the country's National Annex (wind, snow, seismic parameters) applied. North-American-driven projects may require AISC 360. The code directly drives section sizing, connection design and stability checks, so it must be fixed at contract stage.
2. Execution class
EN 1090-2 divides steel fabrication into four classes, EXC1 to EXC4. The class is set from the structure's consequence class, the load type (static, fatigue, seismic) and the risks involved. Common industrial structures are usually EXC2; bridges and dynamically loaded structures are EXC3. As the class rises, so do the requirements for welder qualification, the share of non-destructive testing, dimensional inspection and traceability. Having the class in writing at the start defines the fabrication plan and the cost.
3. Welding and inspection
Welded joints are made to approved welding procedures (WPS/WPQR), welders are certified to EN ISO 9606 and welding coordination follows EN ISO 14731. Beyond visual inspection, the test plan covers penetrant, magnetic-particle and ultrasonic/radiographic methods at rates tied to the execution class. Reports are filed with the part; on export projects this file is often required for customs and local approval.
4. Corrosion protection
The coating system is chosen from the corrosivity category of the erection site (ISO 12944-2; C2–C5 from rural to coastal, CX for offshore) and the required protection life. Options are hot-dip galvanising (EN ISO 1461), a paint system (ISO 12944-5) or paint over galvanising (duplex). The sea voyage is itself an exposure period; it needs a durable system that will not hide transit damage, plus a site touch-up plan.
5. Tolerances and trial assembly
Because on-site correction is limited, fabrication tolerances are checked to EN 1090-2 and critical connections are trial-assembled in the workshop. For bolted joints, hole positions, base plates and anchor templates are verified beforehand. The aim is for parts to fit first time on the foreign site.
6. Packing and sea logistics
Parts are sized for container or break-bulk transport; long members are planned as flat-rack or out-of-gauge. Securing, stacking and moisture protection account for transport vibration and salt air. Each shipment gets a part list, a weight/volume breakdown, marking and numbering by erection sequence; the certificate of origin and customs paperwork follow from this.
7. Site erection and supervision
Even when erection is done by a local crew, the fabricator's supervisor is on site: the lifting plan, bolt pre-tensioning, temporary bracing and survey checks are their responsibility. The erection method statement and the safety plan are part of the documentation sent.
8. Certificates
- Material certificates: EN 10204 3.1 inspection documents for steel and consumables.
- Fabrication conformity: CE marking and Declaration of Performance (DoP) under EN 1090-1, where the market requires it.
- Welding documentation: WPS/WPQR, welder certificates, NDT reports.
- Coating records: surface preparation, dry film thickness readings, adhesion tests.
In short
Success on an export project is decided by choices made before the first line is drawn: the code, the execution class, the coating category and the scope of certification. When these are clear, fabrication is predictable, site time is short and handover is clean. ÇelikÇ has produced steel structures since 1993 and works under a single responsibility on projects abroad, from design to site erection.