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QUALITY ASSURANCE MANUAL

AL’S WELDING & STEEL FABRICATION

222 DOWNIE RD. CHEHALIS, WA 98532 TEL. (360) 740-8020 FAX (360) 740-8826

WWW.ALSWELDING.NET MAIL TO: [email protected]

AL'S WELDING & STEEL FABRICATION, INC.

INTRODUCTION

Al’s Welding & Steel Fabrication, Inc. was began business in September 1989.

Our current facility offers full service structural steel manufacturing in a 32,000 square foot shop, and 3,000 square foot office.

We have

5 – 5 Ton Overhead cranes 2-CNC Pipe Benders for precise bending of handrail

1-CNC Plasma and Flame cutting machine (plate processing) 2500 square foot Spray Booth with overhead crane

We also have our own trucks and trailers for easy deliveries.


OVERVIEW • 35 years of fabricating Category 1 type structures • Annual receipt of approximately 7.2 million • Average employment including management 25+ • Personnel, total years of steel fabrication experience, 140 years QUALIFICATIONS OF KEY PERSONNEL Al Nieman: 35 years structural & miscellaneous steel fabrication, estimating, purchasing and coordination of contracts between the General Contractors and Al's Welding Shane Feeser: Over 12 years experience in detailing, estimating, purchasing and project management David Nieman: 10 years structural & miscellaneous steel fabrication and management Nick Fagernes: 10 years structural & miscellaneous steel fabrication and estimating


OPERATIONS POLICY

Quality at Al's Welding & Steel Fabr. Inc. is an all-hands-on proposition, period. A quality product is possible only if we all live the quality message at all levels, paying attention to all details, spending time on it, hour by hour and day by day. The managers, at all levels, understand that no matter where technology leads us, quality comes from people who care and who are committed. Quality comes from the belief that any process can be made better by constantly improving it a day at a time. Attention to quality can become this organization's mind-set, only if all of its managers as well as its employees live it. We must follow the quality message with passion, persistence and above all consistency. Quality is the most cost effective, least capital-intensive route to productivity We do this by:

• Manufacturing products only from approved shop drawings and procedures, • Insuring that there can be controversy-involving quality vs. production.


QUALITY AND INSPECTION SYSTEM REFERENCES

This manual and controlling procedures meet the interest of the below listed quality requirements. These documents are based on the referenced documents revision level at the time of the contract, unless otherwise stated in the contract. SPECIFICATION NUMBER TITLE ORIGIN AWS/ANSI D1.1 Structural Welding American Welding Code - Steel Society W.A.B.O. 27-13 Welder - Welder Operator Washington Performance Qualifications Association of Standard - Steel Building Officials



PERSONNEL JOB DESCRIPTION

Project Manager/Purchasing Al's Welding & Steel Fabrication Project managers are responsible for procurement of all material and service, establishing material specifications, price, terms and conditions as well as delivery schedules. Shop Foreman The shop foreman is responsible for assignment of personnel to appropriate work, maintain a smooth flow of jobs and material through the shop. Receiving Clerk The receiving clerk is responsible for checking incoming material to verify quality, quantity, proper identification and piece marks. Shop Inspector The shop inspector is responsible for checking the shops' work to make sure it meets specifications as well as grade and dimensional tolerances of the customer's requirements. Fitter Al's Welding & Steel Fabrication fitters are responsible for the proper layout of material per approved shop drawings, including hole locations, size of holes, weld size, procedures and locations. Welder Welders are responsible for performing welding operations in fabrication incorporated into specific structures. All welders at Al's Welding & Steel Fabrication will demonstrate proficiency per W.A.B.O. standards and company welding procedure specifications.


JOB DESCRIPTION OF PLANT MANAGER POSITIONS

President/Operations Manager/Production Manager: Establishes the market goals, fabrication philosophy, approve formal operating and quality system procedures and determines company direction and growth. Supervises and coordinates the activities of the project manager(s), and quality assurance manager. Responsible for staffing these management positions and the approval of equipment and machinery acquisitions requested by these department managers. Supervises the activities of all shop and field production functions. The President is also responsible for the staffing of production personnel as well as scheduling of shop and field activities. He/she is also responsible for maintenance and procurement of machinery and equipment. Quality Assurance Manager: Responsible for the establishment and implementation of quality system that controls and monitors plant activities to assure that the contractual requirements and applicable codes and specifications are incorporated and those deliverable items are in compliance. Responsible, also for the training and supervision of the assistant and qualified weld inspectors and the coordination of inspection by outside inspection companies. Reports directly to the President who has the authority to "shop work". Sales and Marketing Manager: Provides initial company contact with customer representatives. Responsible for securing bids and quotes and participation in the estimating process. Provides market visibility and sales presence. Reports directly to the President. Finance: Responsible for the administration of the accounting function, including: accounts payable, accounts receivable, payroll, contract billing, preparation of balance sheets, profit and loss statements and the preparation of job cost analysis. Reports directly to the President. Purchasing: The project manager is responsible for the selection of suppliers, and the preparation of procurement documents required for purchasing the materials and services, which are required. Project manager's report directly to President.


EMPLOYEE JOB DESCRIPTIONS

President: Responsibilities include general supervision of all Al's Welding day to day operations, billing, purchasing, estimating, contract negotiations, and disbursement and scheduling of work in the shop. Sec/Treasurer: Responsibilities include maintaining all financial records of Al's Welding, paying bills, and payroll. Shop Foreman: Coordinates work in the shop and assigns work to shop personnel. Supervises all discipline of shop personnel. Quality Control: Is responsible for maintaining records of inspections, weld procedures, and welder's certification. QC shall also see that applicable guidelines are met for quality of welds and fit up. Estimating: Is responsible for pricing all work that is done by Al's Welding. Detailing: Responsibilities include providing shop drawings and material take-off for estimating as well as filing and maintaining records of shop drawing submittals. Welders, Fitters and Shop Laborers: All duties as determined by the shop Foreman or the President. The following personnel are responsible for quality control:

President: Al Nieman Project Manager: Shane Feeser Shop Foreman: David Nieman Cost Estimating: Nick Fagernes Safety Officer: David Nieman Sec/Treasurer: Janete Nieman Quality Control: Al Nieman Detailing: Independent Detailers


QUALITY ASSURANCE MANUAL

TABLE OF CONTENTS

SECTION TITLE PAGE(S) 1.0 Purpose 1 2.0 Scope 1 3.0 Responsibility 1 4.0 General Management Policy Statement 1 - 2 5.0 Quality Planning 2 6.0 Document Control 2 - 3 7.0 Purchasing 3 - 4 8.0 Receiving Inspection 4 9.0 Packaging & Shipping 4 10.0 Manufacturing Control 4 11.0 Non-Conforming Material Control 4 12.0 Calibration Control 4 13.0 Raw Material & Furnished

Goods Storage 5 14.0 Part Marking 5 15.0 Data Retention 5 16.0 Detail Shop Drawings 5 - 6 17.0 Storage & Control of

Weld Consumables 6


1.0 PURPOSE This manual defines the general methods used to ensure product quality of contact deliverable items, which have been manufactured, fabricated, and/or assembled by Al’s Welding & Steel Fabr. Inc. Specific responsibilities, work and instructions are Contained in the Quality Assurance Procedures for the disciplines defined herein. Activities affecting quality include: designing, purchasing, fabricating, handling Shipping, receiving, storing, cleaning, erecting, installing, inspecting, testing, operating, Maintaining, repairing and modifying. 2.0 SCOPE The methods defined in this manual are applicable to all departments within Al’s Welding and will be used to: a) control the quality, and b) adherence to customer specification of all contract deliverable items. 3.0 RESPONSIBILITY The Al’s Welding Quality Assurance Department is responsible for the compliance and enforcement of the requirements stated herein.

3.1 The Quality Assurance program shall provide for the planning and accomplishment of activities affecting quality under suitable controlled conditions. Controlled conditions include the use of appropriate equipment and assurance that prerequisites for the given activity have been satisfied. The program shall also provide for any special control test equipment, processes, tools and skills to attain the required quality, and for verification of quality.

3.2 The program shall provide for indoctrination and training, as necessary of

personnel performing activities affecting quality to assure that suitable proficiency is achieved and maintained.

4.0 General Management Policy Statement This quality policy requires not only a complete understanding of customer requirements and specifications and a system to ensure their incorporation, but exceeds the traditional quality definitions by working quality as a continuous effort to improve or exceed our customer’s expectations, a way of life in every department and task, and in every Al’s Welding employee.

Finally, in order to create proven value for customers and employees, we here at Al’s Welding adhere to the principle that quality and cost of quality are a sum, not a


difference. Partners, not adversaries. We believe that the way to make our product quicker and cheaper is to make it better. 5.0 QUALITY PLANNING

5.1 Contract Quality Review

The review of contract requirements containing specific quality requirements, against RFQ requirements are the responsibility of the designated project manager. 5.2 Subcontract Vendor/Suppliers

Items contracted by Al’s Welding quality clauses disallow subcontracting, shall not be subcontracted, without WRITTEN customer approval. When contractually specified, only customer approved special processors shall be utilized. 5.3 Quality Planning Procedure

A project specific Quality Plan will be developed by the Al’s Welding Project Manager, based on contract, engineering drawing and specification requirements, to assist in planning, receiving, inspection and in process inspections. 5.4 Quality Planning Documentation

Quality planning may be manifested in designated manufacturing and quality operation procedures and work instructions, hereafter referred to as “Travelers”, as the need arises. 5.5 Pre-Fab Meeting

A “Prior to Fabrication” meeting per project shall be convened to ensure all departments are knowledgeable of contract requirements. This can take place during the weekly production meetings, if convenient.

6.0 DOCUMENT CONTROL

Drawing and specification used to control the fabrication, processing and assembly of contract deliverable items will be controlled and documented in accordance with the following, and entered on the Al’s Welding Drawing Index and Status Log:

6.1 Document Control Requirements

At a minimum, Al’s Welding will specify: (1) Departmental responsibilities, (2) Required forms, (3) A specific procedure for the control and recall of drawings and specification, (4) Instructions for the control of obsolete drawings and/or specifications, and (5) Drawing and specification special marking instructions.


6.1.1 All shop drawings received from approved detailers will get a cursory review prior to submitting for approval and a second cursory review prior to release to shop for fabrication. NOTE: See Al’s Drawing procedure for tracking.

6.2 Quality Assurance Records

Records that furnish documentary evidence of quality shall be specified, prepared and maintained. Records shall be legible, identifiable and retrievable. Records shall be protected against damage, deterioration or loss. Requirements and responsibilities for record transmittal, retention, distribution, maintenance and disposition shall be pre-established and documented.

7.0 PURCHASING

7.1 Purchasing Responsibility

Project Management is responsible for the purchasing of all materials, services and processing of contract deliverable items. Purchasing is accomplished by the Project Manager or as directed by the Project Manager. At a minimum, purchasing requirements will consist of: Material or process name Specification title Specification revision level Specification exceptions or additions Quantities Sizes Identification marking requirements Certification requirements 7.2 Policy Statement

It is the policy of Al’s Welding to obtain all materials and services required to conform to customer contract requirements. Al’s Welding uses a standard ordering form as the purchase order (with project number or name) for purposes

of confirmation of the procurement of materials and services to support fabrication or AISC project, or the procurement of same.

8.0 RECEIVING INSPECTION

Inspection of raw materials, standards, processing or manufacturing of raw materials, detail sub-assemblies or assemblies will be accomplished and documented to the level required by contract and as specified by Al’s Welding Receiving Inspection Procedure.

9.0 PACKAGING AND SHIPPING


Packaging methods, materials and marking requirements will be defined by contract and will be shown on the Quality traveler or designated document. If there are not contractual requirements, Al’s Welding will utilize the best commercial practices as defined by the applicable American Society for Testing and Materials (ASTM) packaging specification.

10.0 MANUFACTURING CONTROL

Manufacturing controls will be adequate to control the fabrication, processing and assembly of contract deliverable items.

11.0 NON-CONFORMING MATERIAL CONTROL

Specific instructions for documentation and control of non-conforming material control shall be in accordance with contract requirements and/or as specified in Al’s Welding “Non-Conforming Material Control Procedure”.

12.0 CALIBRATION CONTROL

Measuring, test equipment and equipment used by Al’s Welding to determine acceptance or rejection of production items will be subject to periodic maintenance and calibration, and entered on the master list of Al’s Welding Calibrated Tools.

12.1 Comparison Standard

Calibration of equipment and tools will be by direct comparison to standards, which are traceable to the National Institute of Standards Technology (NIST).

13.0 RAW MATERIAL AND FURNISHED GOODS STORAGE

Raw material intended for incorporation into contract deliverable items, and finished goods (deliverable items), will be controlled in accordance with the “Raw Material and Furniture Goods Storage” Procedure.

14.0 PART MARKING

Part marking identification will be controlled in accordance with contract and engineering drawing requirements as provided by detailed instructions in the Al’s Welding “Part Marking Procedure”.

15.0 DATA RETENTION

Unless otherwise defined by contract, all Purchase Orders, Manufacturing, Inspection, Test and Certification Report will be kept on file and available for customer review for a minimum of seven (7) years.

16.0 DETAIL SHOP DRAWINGS

16.1 Policy Statement


Al’s Welding details the design drawings for shop use with the intent of supplementing the AISC standard manual. The detailer shall be familiar with the AISC Codes, steel detailing specifications, shop practice and field erection procedures. 16.2 Training of Detailing personnel is under direct supervision of the Engineering department head. 16.3 Detailing shall be responsible for producing all shop and erection drawings as required by the contract. It shall be the drafting department responsibility to produce copies of shop drawings for Approval. Upon receipt of contract drawings Detailing shall record date of arrival, contractors name, job title, and number of addendum’s received. Drawings will clearly note any special instructions. Detailing shall be done per AISC latest addition and per contract documents. Welding symbols per AWS a2.4-93. Upon completion of shop drawings, the number of copies required by the specifications will be printed and forwarded to the General Contractor (GC) for review. When approved shop drawings are received back from GC, Detailing will so note in the log book. They will review the drawings and make any corrections as noted by the Architect or GC. When completed, the drawings will be passed onto the President for review who will then initial and pass them onto purchasing for ordering material. 16.4. Detailing Standards 16.4.1 All drawings must show Material Specification 16.4.2 Drawings must show customer, job name & item description

16.4.3 Purchasing will then be able to track material for specific jobs as to mill

test reports (main material, weld electrodes, bolts, etc.) 16.4.4 Drawing must show any specification that is not standard

Al’s Welding considers the following to be standard:

a. Steel ASTM A36 b. Pipe ASTM A53 c. Tube ASTM A500 d. Bolts A307 e. Paint STD Shop Coat (Red Oxide)

16.5 Organization Chart - Detailing

17.0 STORAGE AND CONTROL OF WELD CONSUMABLES

Weld consumables will be controlled and stored as provided in detailed instructions in the American Welding Society ANSI/AWS D1.1, “Structural Welding Code – Steel”.


QUALITY ASSURANCE PROCEDURES

TABLE OF CONTENTS

SECTION TITLE PAGE(s) Receiving Inspection Part Marking Procedure Calibration Control Welding Machines Nonconformance Material Control Nonconformance Definitions Welding Consumables Control Coating Inspection


RECEIVING INSPECTION

Receiving inspection will be performed by a Al's Welding designated Quality Control person or by Production personnel, on all detail parts, raw materials and special processes such as heat treating, plating, and non-destructive testing. Records of inspection(s) performed and copies of certification(s) will be kept on file in a file Al's Welding Job Number/Name designated file. EXTENT OF INSPECTION: Review Packing Slip/Bill of Lading against Al's Welding Purchase Order

Project Manager review of Certificate of Compliance or Physical and Chemical Mill Test Reports (CMTR's) Conduct dimensional inspections as required (record by Al's Welding QC when required by contract) Transit damage Quantity Identify, route, control and store received material Signify by signature and date when receipt complete

When "Best Shop Practice" and material requirements have not been customer specified, Production shall: Review Packing Slip/Bill of Lading against Al's Welding Purchase Order Inspect for transit damage Check quantities RAW MATERIAL Raw material shall be received and released for production by signature acceptance of the receiving copy of the Purchase Order. Raw material shall be stored in a Project Manager/ Production Supervisor designated area capable of providing protection to the extent required for the material to be stored. Material will be identified to provide Al's Welding Job Number traceability. (See Pg 6 2B) FINAL GOODS Final goods awaiting shipment (or pickup) will be stored in a Project Manager/Production Supervisor designated area.


Final goods awaiting shipment, and not requiring customer inspection, will be wrapped, protected and identified to the customer part number and purchase order. Handling, storage, cleaning, packaging, shipping and preservation of items shall be controlled to prevent damage or loss, and to minimize deterioration.

PART MARKING PROCEDURE

When required, part marking will be accomplished in accordance with contract requirements, or as specified below: Part mark handwritten, legible, size as required permanent or non-permanent markers ("non-bleed through" if finish is required) as follows on structural steel. Mark columns in bottom web with direction position as specified on drawing. EXAMPLE: 47A "South" Mark beans and trusses on left end in web. Mark details; small letter precedes the drawing number. EXAMPLE: a47


QUALITY ASSURANCE PROCEDURE

CALIBRATION CONTROL-WELD MACHINES

1.0 Purpose

To establish a procedure for the calibration of Al's Welding welding machines.

2.0 Definitions

Calibration: The comparison of equipment of unknown accuracy to a measurement standard of known accuracy. In order to detect, correlate, report or eliminate by adjustments, any variation in the accuracy of the equipment being tested. Traceability: The ability to relate individual measurement results through an unbroken chain of calibration. (i.e., NIST, NBS) Accuracy: The extent to which the measured value of a quantity agrees with the accepted value. Tolerances: The permitted amount of deviation from the exact value specified.

3.0 Responsibilities

The QA Manager or an appointed designee will develop and provide the documents and procedures required to support the requirements described herein. The QA Manager will determine calibration requirements for Al's Welding welding machines in accordance with project documents and requirements. The QC Department shall accomplish, document and maintain all records of physical calibration or sub-contracting. The QA Manager is responsible for the implementation and execution of the systems required in the administration of calibration control. The QA Manager shall develop audit procedures and checklists, and administer and direct scheduled audits for calibration control compliance.

4.0 Uncalibrated Equipment

Any welding machine that is uncalibrated may be used for reference only, and shall be identified as "Reference Only".


5.0 Rod Oven Thermostat

Calibration shall be per manufacturer instructions, which are on file in the office, and shall be entered onto the master list of calibrated tools. The thermostat shall be calibrated at the same interval as the weld machines (annually).

NON-CONFORMING MATERIAL CONTROL

Materials, details, sub-assemblies or assemblies that do not comply with customer contracted requirements will be identified as "discrepant" by notation on the part, and when physical size allows, segregated from the production list. Specified instructions for the documentation and control of nonconforming material control are in accordance with contract requirements and/or as specified in the following: A. When obvious rework (i.e., undersize or missing holes) Disposition:

"Drill per print", or oversize condition: plate is 2x2x1-1/2, SB 1x2x1-1/2 Disposition: "cut to 1" length". Inspector will disposition as required.

B. When rework can be accomplished per a customer approved rework procedure, rework in accordance with the applicable approved procedure.

C. When rework is required, and no customer approved standard rework

procedure exists, and controlled and inspected operations are required, submit for Project Manager rework disposition, using Al's Welding Fax Memo form, and label: "Non-Conformance Report".

Rework shall be controlled per contract requirements as flowed down by the Project Manager. When the determination has been made that rework is not possible. Al's Welding nonconformance report may be sent to the customer for disposition, or if it is felt by Project Management that a deviation from the contract could suffice, submit the Memo form labeled: "Request for Assistance". In either case, customer disposition is required.

NON-CONFORMANCE DEFINITIONS

Repair: Customer authorized documented deviation from design, shop drawing and/or procedure or specification.

Rework: Documented, unplanned activity to bring an item into compliance

without deviation from design, shop drawing and/or specification or procedure.


Scrap: The physical removal or alteration and special identification of non-conforming items from production, to discard or prevent use in production lots.

WELDING CONSUMABLES CONTROL

SHIELDED METAL ARC WELDING (SMAW) SMAW COATED ELECTRODES Electrodes for SMAW processes will conform to:

a) ANSI/AWS A5.1, Specification for Mild Steel Covered Arc Welding Electrodes, or

b) ANSI/AWS A5.5, Specification for Low Alloy Steel Covered Arc

Welding Electrodes

ANSI/AWS A5.1 Electrodes - Must be purchased in hermetically sealed containers. If or when the seal is broken, the rods must be oven dried for a minimum of two (2) hours at 475 degrees F. +/- 25 degrees F. prior to use. ANSI/AWS A5.5 Electrodes - Must be purchased in hermetically sealed containers. If or when the seal is broken, the rods must be oven dried at 750 degrees F. +/- 50 degrees F. for a minimum of one (1) hour.

COATED ELECTRODES ATMOSPHERIC EXPOSURE REQUIREMENTS After the container seal is broken, or after electrodes have been removed from the drying oven in accordance with the above paragraphs, the electrode exposure to atmosphere shall not exceed the values shown in AWS D1.1 for the specific electrode classification listed. GAS METAL ARC/FLUX CORED ARC WELDING (GMAW & FCAW) GMAW/FCAW ELECTRODES AND SHIELDING Electrodes and shielding for GMAW and FCAW for producing welds with minimum specified yield of 60,000 PSI or less shall conform to the following:

ANSI/AWS A5.18, Specification for Carbon Steel Filler Metals for Gas Shielded Arc Welding, or ANSI/AWS A5.20, Specification for Carbon Steel Electrodes for Flux Cored Arc Welding


MINIMUM YIELD STRENGTH REQUIREMENT Weld metal having a minimum specified yield strength greater than 60,000 PSI shall conform to the following: Electrodes and shielding for GMAW shall meet ANSI/AWS A5.28,

Specification for Low Alloy Steel Filler Metals for Gas Shielded Arc Welding. Electrodes and shielding gas for FCAW shall meet ANSI/AWS A5.29, Specification for Low Alloy Steel Electrodes for Flux Cored Arc Welding.

GMAW/FCAW ELECTRODE/SHIELDING MINIMUM CERTIFICATIONS

Al's Welding will purchase GMAW/FCAW electrodes and shielding material with Certifications of Conformance certifying that the electrodes will meet the requirements of classification or grade per the requirements above of this procedure and include typical chemical and physical test results.

SHIELDING GAS

Gasses or gas mixture(s) for shielding in GMAW or FCAW shall be of a welding grade having a dew point of minus forty degrees (-40 degrees F.) or lower.

When requested by customer contract, engineering or specification, Al's Welding will furnish proof of compliance by: a) Gas manufacturer's Dew Point Certification

b) Independent laboratory test results traceable to the gas

intended for use in contract deliverable items.

SHOP CONTROLS

- Welders shall use only those consumables which they have personally obtained

- All stubs or remnants of electrodes will be discarded - Electrodes found to be uncontrolled will be discarded

COATING INSPECTION PURPOSE: To ensure that the required coating specifications are met. TOOLS: Calibrated dry film thickness meter. Calibrated dry film thickness shims


INSPECTION SEQUENCE: Inspection often begins with a pre-job conference at which the ground rules are set. The inspector is responsible for witnessing, verifying, inspecting and documenting the work at various points. The following points will be reviewed along with the appropriate instruments used for each. 1. Pre-Surface Preparation Inspection 2. Measurement of Ambient Conditions 3. Evaluation of Compressor (Air Cleanliness) and Surface Preparation Equipment 4. Determination of Surface Preparation Cleanliness and Profile 5. Inspection of Application Equipment 6. Witnessing Coating Mixing 7. Inspecting Coating Application 8. Determination of Wet Film Thickness 9. Determination of Dry Film Thickness 10. Evaluating Cleanliness Between Coats 11. Pinhole and Holiday Testing 12. Adhesion Testing 13. Evaluating Cure NOTE: Each of the above steps are explained in detail and are contained in the Steel Structures Painting Councils, Volumes 1 & 2: "Good Painting Practices" and "Systems and Specifications". RESPONSIBILITIES: A pre-coating review of the contract specifications using

the above sequence shall be conducted. All results of any inspection shall be thoroughly

documented in writing to verify that the specified requirements have been met. Future maintenance or the removal of a failed coating system may be dependent on the factual reporting of every phase of the work.

BOLT INSTALLATION PROCEDURE

AL'S WELDING POLICY: Shop bolting will consist of two types of bolted joints.

a) Loose to slip b) Snug tight

All other bolted joints will be field installed.


DEFINITION:

a) Loose to slip: tighten with wrench only enough for shipping assembled. Final tightening, per contract specification, to be done in the field.

b) Snug Tight: tightness that exists when the plies of the joint are in firm contact. A few impacts of an impact wrench or the full effort of a man using an ordinary spud wrench attains this.

HIGH STRENGTH BOLT INSTALLATION PROCEDURE

1.0 Purpose

The purpose of this procedure is to ensure that faying surfaces are properly prepared and proper bolts are installed and tightened as required by approved shop drawings and the applicable specifications.

2.0 Scope

This procedure shall only apply to permanent high strength bolts installed in the fabrication shop.

3.0 Procedure

3.1 Faying surfaces shall be prepared per contract specifications.

3.1.1 Burrs exceeding 1/64 inch, which may prevent solid seating of connecting members, shall be removed by grinding.

3.1.2 Connections required to be "No Paint" shall be free of loose mill scale, dirt

or other foreign material.

3.1.3 Connections required to be "Painted" shall be cleaned to the required SSPC Specification and painted per contract specifications. Paint shall be allowed to properly cure prior to assembly and bolt installation.

3.1.4 Bolted connections classified as being Slip Critical Faying Surfaces shall

meet the following:

a. For non-painted joints, all paint, including any inadvertent overspray, shall be excluded from areas closer than one bolt diameter, but not less than one inch, from the edge of any hole, and all area within the bolt pattern.

b. Joints specified to be painted shall be blast cleaned and coated with a paint which has been qualified as Class A or B in accordance with The Research Council on Structural Connections Using ASTM A325 or A490 Bolts, Appendix A. Class A or B coatings include those coatings which provide a mean slip coefficient not less than 0.33 or 0.50 respectively. The coating manufacturer shall


provide certified test reports that the product meets this requirement.

3.1.5 Galvanized surfaces shall be galvanized per ASTM A123 and shall be free

of drips or excess globs of zinc, which would prevent solid seating of the connecting members. Galvanized surfaces shall be roughened by hand wire brushing.

3.2 The slope of connecting surfaces shall not exceed a slope of 1:20 with respect

to a plane normal to the bolt axis. If the slope exceeds this requirement, tapered washers shall be used.

3.3 Bolts installed shall be of the proper type, grade, size, manufacturer, origin,

and finish as required by contract specifications. If required, bolt identity shall be traceable by lot number or other approved means.

3.4 Bolt tensioning.

3.4.1 Turn Of the Nut Method:

a. Prepare faying surfaces as required in 3.1 above.

b. Install the proper size and type bolts as required by the approved shop

drawings. A hard flat washer shall be placed under the element to be turned usually the nut.

c. Tighten all of the bolts in the connection to a snug tight condition,

beginning with the most rigid area of the connection and progressing systematically to the free edge. Snug tight is defined as the tightness which exists when all plies of the joint are in firm contact. A few impacts of an impact wrench, or the full effort of a man using an ordinary spud wrench may attain this. After all bolts have been brought to the snug tight condition, mark the element to be turned and the adjacent surface with a non-permanent mark such as soap stone or lumber crayon in order to verify the required rotation listed below.


TABLE 1

DISPOSITION OF OUTER FACE OF BOLTED MEMBER Bolt Length Both faces normal

to bolt axis One face normal to bolt axis and other Sloped not more than 1:20 (beveled washer not used)

Both faces sloped not more than 1:20 from normal to bolt axis (beveled washer not used)

Up to 4 Diameters 1/3 Turn 1/2 Turn 2/3 Turn Over 4 Diameters and Less Than 8 Diameters

1/2 Turn 2/3 Turn 2/3 Turn

Over 8 Diameters But Not Exceeding 12 Diameters

2/3 Turn 5/6 Turn 1 Turn

Tolerances: < 1/2 Turn = + 30 Degrees ≥ 2/3 Turn = + 45 Degrees

3.4.2 Direct Tension Indicator Type Fastener:

a. Twist off type high strength bolts shall be installed per the bolt manufacturer's instructions.

b. High strength bolts using load indicator washers shall be installed per the

manufacturer's instructions.

3.5 Verification and Inspection

3.5.1 Immediately prior to beginning the bolt installation, verify by use of 3 samples tested in a Bolt Tension Indicator (Skidmore) that the method of bolt tensioning to be used will achieve the minimum bolt tension required for the size and type bolts being used.

3.5.2 For bolts installed by the Turn Of The Nut Method, inspect the installation at

each connection by observing the installation process and/or verifying the required rotation given in Table 1 by noting the temporary marks placed on the turned element and adjacent surface.

3.5.3 For bolts installed by the Direct Tension Indicator Method, twist off type,

verify that the calibrated tip has been twisted off by the special installation wrench.

3.5.4 For bolts installed by the Direct Tension Indicator Method, load indicating

washers, verify that the washers have been installed per the manufacturer's


instructions, and that the gap between the LIW and the flat washer is within the manufacturer's published tolerances.

PROCEDURE FOR CALIBRATING OF TAPE MEASUERS

All non-Stanley tapes will be checked with Stanley tape #33-425 by appropriate personnel for conformance to specification as supplied by the Stanley Tool Corp. The tape will only be used for the calibration of shop tapes. All tapes will be checked periodically, upon notice of any excessive ware. Tapes that do not pass will be discarded. Procedure will be to lay tapes side by side on a long table and visually inspect to see that tape conforms to master tape.

MATERIAL TRACEABILITY

1. Job number along with the letter "S" will be transferred to all usable drops. 2. When bundles are broken, job number will be added to all remaining pieces. 3. All material not marked will be considered scrap and will be disposed of accordingly. 4. When using material for jobs other than designated jobs, written documentation will

be provided to the office for proper filing.

DOCUMENTATION SHALL INCLUDE: a. Material Type and Section

b. Quantity

c. Old Job Number

d. New Job Number


WELDER IDENTIFICATION

1. Jeb Arvin WABO 2. Mark Fagerness WABO 3. Nick Fagernes WABO 4. Jon Harader WABO

5. Mark Hite WABO

6. Michael Banks WABO

7. Jesse Mann WABO

8. David Nieman WABO .

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