welding work appendix c

8/7/2019 Welding Work Appendix C

1/18

Overhead Sign Structures

C - 1

January 2003 DIVISION OF ENGINEERING SERVICESDIVISION OF ENGINEERING SERVICESDIVISION OF ENGINEERING SERVICESDIVISION OF ENGINEERING SERVICESDIVISION OF ENGINEERING SERVICES

Appendix C

Welding Information


2/18

Appendix C - Welding Information

C - 2

January 2003

This page has been left intentionally blank.


3/18

DIVISION OF STRUCTURE CONSTRUCTION

Bridge Construction Records and Procedures Manual B00-08

BRIDGE CONSTRUCTION

BULLETIN

File: BCM180-2.1

WELDING

Approved:_______________________________ Date: June 1, 2000 R. P. SOMMARIVA, Chief Expires: None Division of Structure Construction Supersedes: BCB 180-2 (12-16-96)

Sub jec t : Check l i st for Weld ing Qua l ity Cont r o l

For a l l p ro j ec t s adve r t i s ed a f t e r Apr i l 1997 (and in some cases by addendu m) a section

ent itled "Welding Qua lity Contr ol" was a dded to th e Special P rovisions as well as a revision t o

Section 52-1.08 Reinforcing. Additiona l revisions to both s ections ha ve occurr ed since th at t ime.

The Welding Qu ality Contr ol Section in t he Special P rovisions, su pplement s t he following sections

of th e St an da rd Specifications: Section 49 P iling, Section 52 Reinforcement , Section 55 St eel

Str uctur es, Section 56-1 Overhea d Sign S tr uctur es, Section 75-1.035 Bridge J oint Restr ain er

Un its, an d Section 86-2.04 Sta nda rds, Steel Pedesta ls and Post. Oth er Sections of th e Stan dar d

Specifications will be supplement ed by the welding qua lity control plan wh en r equired. The

welding quality cont rol section also addr esses field and shop welding r equirem ent s.

Att ached ar e checklists t o assist you with under stan ding the r equirements of th e welding quality

cont rol section conta ined in t he cont ra ct Special P rovisions. These checklists include a list of

app licable cont ra ct document s to review and a n outline of th e responsibilities of th e Str uctur e

Represen ta tive, and per sonn el from th e Division of Mat eria ls Engineer ing Testing Ser vice, Office

of Str uctu re Mat eria ls (OSM) dur ing each sta ge of welding. In a ddition t o th e checklist, ther e is a

list of comm only used ter ms an d definitions.

The Str uctur e Represent at ive is responsible for all welding. OSM personnel are ava ilable to

provide advice, guidan ce, review the welding qu ality cont rol plan, a nd per form field and shop

welding QA inspection (refer to BCM 180-4 and BCM 180-9 for a list of OSM contacts and phone

numbers).

E v e n t h o u g h t h e c h e c k l is t s a r e e x t e n s i v e, y o u n e e d t o r e v ie w y o u r C o n t r a c t D o c u m e n t s

fo r t h e l a t e s t s p e c i fi ca t i o n r e q u i r e m e n t s .

Copies of the S tr uctur al Welding Code-Steel (AWS D1.1) ha ve been a ssigned t o every Area

Const ru ction Ma na ger, an d copies of th e St ru ctur al Welding Code, Reinforcing St eel (AWS D1.4),

an d Br idge Welding Code (AWS D1.5) ha ve been as signed to every Senior Br idge Engineer.

Ad d i t i on a ll y, t h e S p e c ia l P r o v is io n s n o w r e q u i r e t h e c o n t r a c t o r t o p r o v i d e t h e S t a t e , a s

pa r t o f t he i r w e l d i ng qua l it y con t r o l p l an , t h e ap p l i cab l e AWS we l d i ng codes fo r t h e

a p p li c a b le y e a r n o t e d i n t h e S p e c i a l P r o v i si on s .

Attachments

C: BCR&P Ma nu al H older s

Consultant Firms

PSt olars ki, OSM

BPieplow, Constr uction P rogram Ma na ger



4/18

WELDING QUALITY CONTR OL CH ECKLIST

Bridge Construction Bulletin 180-2.1 (QC)

Atta chment 1

Sh eet 1 of 2

DEFINITIONS

The following is a list of definitions commonly used within the section Welding

Qua lity Cont rol of the Special Pr ovisions an d elsewhere in th e cont ra ct document s.

Additional definitions can be found in ANSI/AWS A3.0-94 Standard Welding Terms

an d Definitions.

Cer t i fi ed Weld i ng In s pec t o r (CWI) fo r S t a t e P ro j ec t s Inspector certified in

accorda nce with AWS QC1. For St at e projects t he Qua lity Contr ol Inspector will be

a CWI.

FCAW Flu x Cor ed Ar c Weld in g An a rc welding pr ocess u tilizing a t ubu lar

electr ode with th e flux conta ined within t he core. The electr ode is supplied on a r eel

an d is fed continu ously to the welder's gun au tomat ically.

FLUX A ma ter ial used to hinder or pr event th e form at ion of oxides an d oth er

undesirable substances in molten metal and on solid metal surfaces, and to dissolve

or oth erwise facilita te t he r emoval of such substa nces.

GMAW Gas m eta l arc welding u tilizes a ba re or a flux-cored electrode. Gas from

an ext ern al sour ce is used for sh ielding. Norma lly a shop welding process. Often

referr ed to as MIG welding.

Non-Confo rm a nce Re po r t (NCR) A writt en r eport origina ted by OSM which

add resses a d eficiency being perform ed and t he cont ra ct document s not being

fulfilled. The r eport will describe the pr oblem, the location, the Qua lity Contr ol

Insp ector r esponse, the proposed solution, and OSM recomm enda tion.

Non-Des t ru c t i ve Tes t i ng (NDT) Testing or an inspection m eth od which doesnot da ma ge th e element being test ed (e.g. Radiogra phic (RT), Ultr asonic (UT),

Visua l (VT), Magnet ic Par ticle (MT), Liquid P enet ra nt (PT).

P r o c e d u r e Q u a l i fi ca t i o n R e c o r d (P Q R ) Documentation indicating testing was

perform ed to qua lify a WPS.

Qua l ity Assur an ce (QA) This oversight is the prerogative of the Engineer and

will be performed by a State representative.

Qua l it y As s u r an ce In s pec t o r (QA Ins pe c t o r ) The duly designa ted person who

acts for a nd on beha lf of th e En gineer. This person is from OSM an d will inspect t he

welding operat ion a nd wr ite a welding report for the Stat e.

Qua l it y Con t ro l (QC) Responsibility of th e cont ra ctor. As a minimu m, th e

Cont ra ctor sh all perform in spection a nd t esting prior to welding, dur ing welding an d

after welding as specified in th e cont ra ct document s an d additionally as necessar y to

ensur e tha t ma terials an d workm an ship conform to the requirement s of the cont ract

documents.

- 4



5/18

WELDING QUALITY CONTR OL CH ECKLIST


Atta chment 1

Sh eet 2 of 2

Qua l it y Con t r o l In s pe c t o r (QC In s p ec t o r ) The person duly designated by the

cont ra ctor, to perform inspection, test ing, and a ddress welding issues on th e project.

This person sh all be responsible to the cont ra ctor for t he qu ality contr ol accepta nce

or r ejection of ma ter ials, work ma nsh ip, and sh all be cur ren tly cert ified as AWS

Cert ified Welding Inspector (CWI) in conform an ce with t he r equirem ent s in AWS

QC1, Sta nda rd an d Guide for Qua lificat ion of Welding In spectors.

Qua l it y Con t r o l Man ager (QCM) Arepresent ative, employed by the pr ime

cont ra ctor, who is r esponsible directly to th e cont ra ctor for th e qu ality of all field

welding perform ed. This includes the mat eria ls an d work ma nsh ip. The QCM

reviews, approves, and submits all QC documents to the Engineer.

Qua l it y Con t r o l P l an (QCP) o r Wel d i ng Qua l it y Con t r o l P l an (WQCP) A

plan s ubm itted by th e contr actor to the St at e for each item of welding work to be

perform ed. This plan cont ains a ll welding document s requir ed by th e contr act (refer

to the Special Provisions a nd QCP 1). No welding can begin u nt il th is plan is

reviewed by OSM an d a pproved by the St ru ctur e Representat ive.

QCP -1 , QCP -5 an d QCP -7 These forms a re used by OSM and the St ru ctu re

Represen ta tive, as checklists to ensur e th e cont ra ctors Qua lity Contr ol Plan or

Fr actur e Cont rol Plan ar e complete.

SAW An ar c welding pr ocess u tilizing a solid wire electrode th at is fed

au toma tically to th e welding hea d from a reel. A gra nu lar flux is au tomat ically

deposited from a d ispenser onto the m olten weld deposit (norma lly a sh op welding

process).

Res i s t an ce Bu t t Wel d i ng (F l a s h Bu t t Wel d i ng ) A welding pr ocess in which

the necessary h eat is derived from a n a rc or a ser ies of arcs established between th e

bar s being welded prior to pressur e being applied to join th e ends t ogether .

SMAW - Sh ielde d Met al Arc Weld An arc welding process utilizing a solid

electr ode with an out er flux coat ing.

Wel d i ng P roced u r e Spec i fi ca t i ons (WP S) A document providing th e requ ired

welding variables for a specific applicat ion t o assur e repea ta bility by properly

tr ained welders an d welding operat ors.

Weld er s Qu a l i fica t ion Welders m ust be certified for type a nd position of weld

an d weld process. If not certified, tests can be perform ed to qualify the welders.Welders mu st be cert ified an d ap proved by OSM before welding on Sta te pr ojects.

Wel d i ng Qu a l i t y Con t r o l P l an (WQCP) See QCP above.



6/18

WELDING QUALITY CONTROL CHE CKLIST


Attachment 2

Sheet 1 of 6

P RIOR TO BE GINNING ANY WELDING WORK

T h e f oll ow i n g c o n t r a c t d o c u m e n t s s h o u l d b e r e v i e w e d b e f or e s t a r t i n g a n y w e l d i n g

w o r k :

Spec i fi c Refe ren ces :

Sta nda rd Specificat ions Sections:

Section 6-3.02, Testing by Contractor

Sections 49, 52, 55, 56, 75 and 86 (as applicable to th e work)

American Welding Society (AWS) - AWS D-1.1, D-1.4, D-1.5 (appr opriat e year )

AWS D-1.1: Prequalification of WPS, Qualification, an Inspection

AWS D-1.4: Direct But t J oint F igure 3.2, Workma nsh ip, Techn ique, Qualifications an d

Inspection

AWS D-1.5: Figur e 2.4, Work ma nsh ip, Techn ique, Qua lification, Inspection, Welded St eel

Bridge, and F ra ctur e Contr ol Plan

Contr act Plans

Cont ra ct Special P rovisions

Bridge Constr uction Records a nd P rocedures Ma nua lBCM 9-1.1

Section 180 Welding

BCM 145-16

OSM form s QCP 1 & 5 (at ta chment 4)

Before st ar tin g an y welding, th ree item s need to be completed. A pre-weld

meet ing with OSM personnel only, a pre-weld meeting with t he cont ra ctor,

an d th e review an d approval of th e Cont ra ctors Welding Qua lity Cont rol

Plan (WQCP). These an d oth er items a re explained furt her below.

1. Inform OSM immediat ely after cont ra ct appr oval t ha t welding, including sh op welding, will beper form ed for your pr oject (see BCM 180-4 & BCM 180-9 for a list of OSM cont act p hone

num bers). At th is time, set up an initial meeting with OSM PER SONNEL ONLY to discuss

the welding requirements for the project, an d to plan t he pre-welding meeting with t he

contractor.

2. Condu ct a pr e-welding meeting with t he pr ime cont ra ctor for ea ch type of welding to beperform ed in t he sh op or in th e field for th e cont ra ct (i.e. piles, colum n casin gs, stru ctur al st eel,

reinforcing steel, miscellan eous meta l, etc.). OSM will conduct t his meet ing if you so requ est.

The Resident Engineer, Str ucture Representat ive, Prime cont ractor, QCM, QC Inspector, an y

welding subcontractor, suppliers or fabricators and the NDT firm should attend this meeting.

The St at e should have th eir QA Inspector from OSM present to assist with t he followingdiscussion topics:

a) The su bmitt al an d appr oval process for t he WQCP. Supply and explain OSM form QCP -1(at ta chment 4) to the contr actor. Form QCP-1 is a checklist of th e minimum requirement s

for th e WQCP. The contr act document s may require addit iona l inform at ion to be subm itted

with th e cont ra ctors WQCP beyond th ose listed on form QCP-1.

- 6



7/18



Attachment 2

Sheet 2 of 6

P RIOR TO BE GINNING ANY WELDING WORK (Cont .)

b) Discuss t he a ppropriat e sections of th e AWS code an d cont ra ct documen ts a s th ey perta into th e a ccepta nce an d a pproval process of th e cont ra ctors WQCP (a OSM welding inspector

should cover th is port ion). The WQCP will be reviewed by OSM an d mu st be a pproved by

th e Stru ctu re Representa tive prior t o an y welding in either th e shop or t he field. In order

for t he St ru ctur e Represent at ive to accept t he WQCP, personnel from OSM will have to

review the cont ra ctors WQCP. This accepta nce of the WQCP may r equire OSM personn el

to witness t he welder(s) welding test plat es an d th e test ing of th ose plat es before accepting

th e WQCP. The same is tr ue of the PQR.

c) Remind t he cont ra ctor t o provide adequ at e notice prior t o sta rt ing an y welding work(request one week minimu m a dvance notice). This will allow time to schedu le an OSM QA

Inspector.

d) Inform th e prime contr actor t hey are r esponsible for QC, and th ey must h ire the QCInsp ector (a CWI) and t he NDT firm, un less sta ted other wise in t he Special Pr ovisions (i.e.

AISC Quality Cert ificat ion P rogram , Category Cbr, Major S teel Bridges).

e) Discuss th e frequen cy of inspection, visua l an d N DT, as well as th e frequen cy of the QCMssubmitta l of the QC Inspector an d NDT reports.

f) Est ablish a m eth od to ident ify the welds and lot sizes. This needs to be established fortraceability purposes.

g) Discuss th e pr ocess to ra ndomly select welds to be NDT (see BCM 145-16 for ra ndomselection met hod).

h) Discuss corr ective mea sur es when welding does not conform with AWS or th e cont ra ctdocuments.

i) Discuss OSM agenda items an an y additional r equirements a ddressed in the contr actdocuments.

j) Confirm a ll discussions of each pr e-weld meeting in wr iting an d send a copy to thecontractor.

3. Obta in th ree copies of th e contr actors WQCP. Using form QCP -1 an d th e contr act docum ent s,r e v i e w t h e c o n t r a c t o r s WQ C P a n d e n s u r e t h e s u b m i t t a l i s c om p l et e b e f or e

fo rw ar d i ng t o OSM - t h i s w i ll s ave r ev i ew t i m e . Once the cont ra ctors WQCP is complet e,

s e n d t w o c o p ie s to OSM for their review. OSM will assist the Structure Representative with

th e accepta nce an d app roval of the WQCP. Keep the oth er copy in your project files.

4. If resistan ce but t welding, or a ny other s hop welding is to be perform ed, ensur e OSM hasapproved the welding procedure, performed a shop audit if required, and performed any testing

th at ma y be requ ired t o accept t he welding pr ocess (see BCM 165-10 Ultima te Bu tt Splice).

5. After OSM h as completed th eir r eview, they will notify you by ph one, followed by anacceptance memo (QCP5 for WQCP and or QCP-7 for the Fracture Control Plan, attachment

4) for your pr oject files.



8/18



Attachment 2

Sheet 3 of 6

P RIOR TO BE GINNING ANY WELDING WORK (Cont .)

6. After reviewing OSM accepta nce memo, an d if it is accepta ble, place the sta nda rd st am p5-1.02, on both t he WQCP a nd t he a pproved WPS to be used on t he pr oject. Do no t p l ace

y o u r P E n u m b e r o n t h e WQ C P , t h e WP S , o r t h e a p p r o v a l l et t e r t o t h e c o n t r a c t o r .

7. Send the contractor a letter approving their WQCP and request 7 copies of these approveddocuments.

P R O J E C T R E C O R D S F I L E S

WELDING DOCUMEN TS ARE TO BE FI LED IN CATEGORY 9.

NOTE: To limit duplication and confusion, the Structure Representative may want to use a cross-

referen ce system with th e oth er pr oject r ecord cat egories (ensur ing records can be easily

au dited). For example, corr espondences are filed in Cat egory 5. If th e issue is welding,

the Str ucture Represent ative shall file th e documen t in Category 9 a s described in t he

Const ru ction Man ua l Section 3-01-2 Cat egory 5, Gen era l Corr espondence.

The following is a suggested list for filing welding documents.

1. The WQCP will be submit ted for each item of work for wh ich welding will be perform ed in t heshop an d field (i.e. piles, str uctur al steel, reba r, etc.). The WQCP sh all conform to the

requ iremen ts of th e Special Pr ovisions and sh all include, as a m inimum , the items listed on

form QCP-1. R e m e m b e r , w e l d in g i s n o t a l lo w e d u n t i l t h e W QC P i s a c c e p t e d b y O S M

a n d a p p r o ve d b y t h e S t r u c t u r e R e p r e s en t a t i v e. Ea ch approved copy of the contr actor s

WQCP is to be filed in Category 9 "Welding" along with forms QCP-1, QCP-5 and QCP-7 if

required.

2. Str ucture Representat ives an d th eir Assistant s sha ll file th eir reports/diaries in Cat egory 45an d 46 respectively. If welding item work is included within t he r eport, one of two things sh allha ppen: write a sepa ra te report , or place a copy of th e report in cat egory 9. The welding report

sha ll include: location an d t ype of welding work, am ount of production, welder, QC I nspector,

QA Inspector, equipment , comm ent s or observa tions ma de by eith er t he QC or QA Inspectors

an d any other pertinent informa tion.

3. OSM welding inspection r eport s ar e to be filed in Ca tegory 9. All oth ers ins pection r eportsfrom OSM should be filed in th eir appr opr iate Ca tegory as outlined in th e Const ru ction

Manual.

4. If you receive an OSM Non-Conformance Report (NCR) it is to be filed in Category 9, alongwith the documentation showing what corrective action was taken (repairs and re-inspectionsof the non-conformance work). I t i s t h e S t ru c t u r e Rep r es en t a t i ve s r e s pon s ib i l it y t o

e n s u r e t h e n o n -c o n fo r m a n c e w o r k i s c or r e c t e d a n d a d d i t io n a l t e s t in g a n d i n s p e c t i on

i s p e r f or m e d p e r t h e c o n t r a c t d o c u m e n t s ( O SM w i ll o n ly a s s is t i n t h e r e i n s p e c t io n

w h e n r e q u e s t e d a n d i n st r u c t e d a s t o t h e a c c e p t a n c e c r i t er i a ).

5. Cont ra ctors QCM is to subm it th eir welding report to th e En gineer within 7 da ys following theperform an ce of an y welding. The En gineer sha ll review th e report for completen ess and ens ur e

th e welding was foun d t o be satisfactory. The completed rep ort is to be filed in Cat egory 9.

- 8



9/18



Attachment 2

Sheet 4 of 6

P RO J ECT RE CO RD F I LES (CO NT.)

6. Copies of all welding correspondences are to be filed in Category 9 (reference ConstructionManual 3-01-2).

7. Test r esults of all field and shop welding ar e to be filed in Ca tegory 9.8. The cont ra ctor sh all fur nish t o th e Engineer a Cer tificate of Complian ce for all welding an d

electr odes used, a s requ ired by the cont ra ct docum ent s an d in accorda nce with Section 6-1.07

Certificates of Compliance of the Standard Specification and Section 8 of the Special

Pr ovisions. These certificat es sha ll be filed within Ca tegory 9 with r eferen ce to the a ppropria te

section within th e pr oject files.

DURING WELD P RODUCTION

1. Make ar ra ngements so an OSM welding inspector is present a t t he job site or t he shop on t hefirst day of welding (if th e first day is not possible, then th e next a vailable day - the key is to

provide OSM adequa te notice). If welding is being perform ed in t he sh op, OSM should be

informed by a Notice of Mat eria ls To Be Used (Form CE M 3101). This will ens ur e thewelding for your project gets off to a good beginnin g an d th e QC Insp ector ha s a clear

un derst an ding of the QA Inspectors r ole and expecta tions.

2. OSM is responsible for assisting th e Str uctur e Represent at ive with QA inspection on t heproject. OSM is responsible for welding QA at t he fabrication shop. Every effort sha ll be made

to ensur e a r epresen ta tive from OSM is present dur ing production welding; however, if OSM is

not available, the St ructur e Representa tive an d/or th e Assistant St ructur e Represent at ive

sha ll provide QA inspection a nd docum ent t heir findings in t heir da ily report s. The following

items sh ould be discussed with a n OSM inspector before t he pr e-weld meeting with th e

cont ra ctor. This discussion should be done in th e event a QA Inspector is not a vailable during

production welding.

a) Verify the contr actor is providing QC inspection a nd u sing th e app ropriat e AWS code,Contr act Special Provision, an d Sta nda rd Specificat ion t o evalua te th e weld an d weld

procedur e. The cont ra ctor is to provide a sufficient n um ber of QC Inspectors to perform th e

inspection pr ior t o, dur ing, and a fter welding. The inspection inter val of each welders work

sha ll not lapse more th an 30 minutes, as stipulated in th e contr act documen ts.

b) Verify the welder is listed with in th e appr oved WQCP an d is qualified an d was a ccepted byOSM to perform th e specified weld. For examp le, if the WP S calls for SMAW in t he vertical

position, mak e sur e th e welder is qualified to perform SMAW in th e vertical position. Note:

the AWS code specifically disallows a vertical downward progression of welding.

c) En sur e th e welders a re following the a pproved WPS. Item s easily verified, include: correctbase m eta ls, fit u p, joint deta ils (such as bevel angle an d r oot openin g), weld process, weld

position, electr ode type an d size, tra vel speed, volta ge and a mp set tings, preh eat an d

interpass temperature, cleaning/slagging between each weld pass, number of weld passes,

an d ensur ing the welder is placing a string bead an d not a weave weld. The QC Inspector

should also verify and record t hese item s daily.



10/18



Attachment 2

Sheet 5 of 6

DURING WELD P RODUCTION (CONT.)

d) Review th e appr opria te AWS code to ensu re welding i s n o t d o n e when the ambienttem pera tu re is too low, when sur faces ar e wet or exposed to wind, or when welders ar e

exposed to inclement conditions (see the a ppropria te AWS Code un der workm an ship or

technique).

e) En sure backing plates, if shown in t he WPS, are tight a gainst th e base metal or rebar (itmight be n ecessary to grind down only the bar deforma tions t ha t int erferes with the tight

fit, n ot t he core a rea of th e reinforcing steel). The Special Pr ovisions, for ba r r einforcement ,

requ ires th e backing plate to be a flat plate. Ba cking plat es ar e not to be removed for

ra diogra phing. If th e backing plat e is for welding a colum n casing refer to BCM 180-6 an d

BCM 180-7.

f) En sur e the electr odes ar e properly stored. For SMAW electrodes, once the her met icallysealed cont ain er is opened, or a fter electrodes ar e rem oved from dr ying or st ora ge ovens,

th e electr ode exposur e to th e atm osphere sh all not exceed th e times sta ted in t he AWS code

(typically 4 hours m aximu m). For F CAW electrodes, th ey shall be stored in clean an d dry

condit ions a t a ll times.

g) En sur e the welder does not ma ke an y erran t a rc strike (conta ct between th e electr ode andth e base meta l outside th e weld a rea). If an erra nt str ike does occur, t he ma terial is subject

to rejection, but confer with OSM first .

h) Verify NDT an d destr uctive testing, when requ ired, is being perform ed properly an inaccorda nce with th e Special Pr ovisions a nd other cont ra ct document s (OSM ma y be of

assistan ce in this regard).

i) Keep an eye on t he production a nd failure r ate. A dram at ic increase in pr oduction a nd adrop in th e failure ra te genera lly result in non-conforma nce with th e WPS.

3. Obta in th e QCM welding reports with in 7 days or as specified by th e contr act docum ent s,following perform an ce of an y welding. Review th is report with t he a ssista nce of OSM to

deter mine if th e cont ra ctor is in conforma nce with t heir WQCP. Except for st eel piling, th is

report mu st be reviewed and a writt en r esponse a pproving or r ejecting the r eport must be

retu rn ed to the contr actor with in 7 days (your time frame m ay var y, read your Special

Pr ovisions). For piling, this review time will be specified in th e Contra ct Special P rovisions.

4. Review all report s regar ding NDT, destr uctive test ing, an d rad iograp hing. As described in thecontr act documents, all report s sha ll have the a ppropriate signat ur e of the reviewer. For

radiographs - the NDT technician, the person performing the review and the QCM shall sign

these r eports. The reviewers na me sha ll be clearly printed or t ype written next to their

signat ur e. If th ey ar e not, retur n them to the QCM.

5. All radiogra phic envelopes sha ll have clear ly writt en on th e out side the n am es of the: QCM,NDT firm, radiographer, date, contract number, complete part description, and include the

weld num bers or a r eport n umber a s detailed in the WQCP. In addition, all inner leaves shall

ha ve clearly written on t hem t he pa rt description a nd include weld numbers, as det ailed in th e

WQCP.

- 10



11/18



Attachment 2

Sheet 6 of 6

WELD ACCEP TANCE

1. Ther e ar e different form s of NDT (VT, UT, RT, MT, and P T) th at ma y be perform ed on weldelement s, but t he cont ra ctors QC In spector will always perform a visua l inspection (VT) and

write up a daily report. The cont ractor is responsible to ensure a ll necessary a nd r equired

NDT is perform ed. The cont ra ctor is a lso responsible to ensu re a ll welding fulfills th e

requirement of th e contr act documen ts a nd t he appr opriate AWS codes. It is the En gineers

prer ogative t o perform QA inspection. If the QC In spector ident ifies a defect it is t o be noted inth e welding report a long with th e corrective action tak en. If th e QA Inspector identifies a

defect, a Non-Conform an ce Report will be writt en a nd given to th e Str uctur e Represent at ive

that day. T h e s e r e p o r t s a r e n o t t o b e g iv e n t o t h e c on t r a c t o r . I t is t h e S t r u c t u r e s

R e p r e s e n t a t i v e s r e s p o n s i b i li t y t o n o t i fy t h e c o n t r a c t o r i n w r i t in g a n d e n s u r e t h e

d e f ec t is r e p a i r e d a n d a n y a d d i t io n a l t e st i n g is p e r f or m e d a n d e v a l u a t e d . I n f or m

O S M o f t h e r e p a i r a n d r e q u e s t a n i n s p e c t io n o f t h e r e p a i r e d w e ld .

2. Welds can be accepted if both th e Contr actors QC a nd OSM QA Insp ectors find t he weldingqua lity to be accepta ble by visua l inspection a nd/or NDT, in accorda nce with th e appr opriate

AWS code.

3. In a ddition to th e inspection, the cont ra ctor sh all fur nish t o th e engineer, in accordan ce withSection 6-1.07 Certificate of Compliance, of the Standard Specifications and Section 8 of the

Special Provisions, a Certificate of Compliance for each item of work for which welding was

perform ed. This certificate shall stat e tha t a ll of the ma terials an d workm ansh ip incorporated

in th e work , and a ll requ ired test s an d inspections of th is work , have been perform ed in

accorda nce with th e details shown on the plans, an d the r equirements of th e Stan dar d

Specifications a nd th e Special Pr ovisions.

P R O J E C T CL OS E O UT

1. The locat ion of all splices need to be sh ow on th e as build dra wings per BCM 9-1.1.2. Met with t he OSM repr esent at ive to confirm a ll NCR an d an y oth er deta ils ar e resolved before

accepting t he pr oject.



12/18

RE INFOR CING STEEL CHECKLIST

Bridge Construction Bulletin 180-2.1 (D-1.4)

Attachment 3

Sheet 1 of 4

P RIOR TO BE GINNING ANY WELDING WORK

The following item s ar e in addition to th ose listing in Atta chment 2 and a re int ended t o assist you

with t he insp ection of reinforcing steel welding on your project. Ther efore, b e fo r e s t a r t i n g a n y

wel d i ng , r ev i ew t h e s ec t i on en t i t l ed P r i o r t o Beg inn i ng an y Wel d i ng Work w i t h i n t h e

Wel d i ng Qu a l i t y Con t r o l Check l i st (a t t ach m e n t 2 ).

Spec i fi c Refe ren ces :

Sta nda rd Specificat ions Sections:

52-1.08B, Butt Welded Splices

52-1.08D, Qualifications of Welding and Mechanical Splices

Str uctu ra l Welding Code - Reinforcing Steel, AWS D1.4 (appr opriate year)

Welding Pr ocedure Qua lificat ion

Welder Qualification

Direct Butt J oints - Figure 3.2

Inspection

An a pproved WQCP is requir ed before a ny welding is allowed. Review th e requirem ent s outlined

in form QCP-1, cont r act documen ts a nd AWS D-1.4. AWS D 1.4 does not provide for prequ alified

welds; th erefore, a ll WPSs a nd welders m ust be qualified by testin g. You will need a copy of the

PQR for ea ch WPS th at will be used on t he pr oject a nd t he qua lification test for t he welder(s). The

PQR a nd t he welder qua lification t est mu st be witnessed by either a lab appr oved by OSM or by

OSM personnel. This should be discussed at t he meeting with the OSM representat ive and also

related t o the cont ra ctor a t t he pr e-welding meeting.

P R O J E C T R E C O R D S F I L E S

In a ddition t o those items listed in Att achmen t 2, th e following items a lso need t o be filed inCategory 9 for reinforcing steel welding:

1. The cont ra ctor's QCM and OSM QA report s. These report s sha ll also include th e followinginform at ion when reba r welding and NDT is being performed:

a) Evidence showing a t least 25% of all butt welds were ra diograph ed by the Contr actor.b) Evidence the Contr actor evalua ted t he r esults, corr ected deficiencies, ra diograp hed

repaired welds and radiographed additional welds as required (review your Special

Pr ovisions for specific deta ils on a dditional test ing requ iremen ts wh en welds ar e rejected).

c) If more th an two repairs of any weld ar e required, the Cont ractor must submit a r epairplan deta iling th e problem a nd t heir pr oposed solut ion. This will prevent excessive heat

dam age t o the r einforcing steel in t he vicinity of the weld (heat affected zone).

2. A summa ry sheet recording when r adiographs were submitted t o and r eviewed by OSMpersonn el and t he r esponse to th e cont ractor.

3. Test r eports of destr uctive testing per form ed for resista nce butt welds. OSM will review th etesting and perform QA.

- 12



13/18



Attachment 3

Sheet 2 of 4

DURING WELD P RODUCTION

In a ddition t o Att achmen t 2, th e following items sha ll also be reviewed by the St ru ctu re

Representat ive an d/or t heir Assista nt:

1. Preheat and interpass temperatures. Ensure th e proper temperatures are being used for thegra de of steel or Ca rbon Equ ivalent (CE) being used. Refer t o th e your Special Pr ovisions, an d

AWS D-1.4-92 table 5.2 or contact OSM personnel.

2. Bar alignmen t is with in a llowable toleran ces. For exa mple, AWS D-1.4-92 Section 4.2.3 sta tes,for ba r s No. 10 or sm aller th e a llowable offset is 1/8 inch. Additiona lly, Section 52-1.08 of the

Sta nda rd Specificat ions st at es, the deviation in alignmen t of reinforcing bars a t a welded splice

sha ll not be more t ha n 1/4 inch over a 3-1/2 foot length of bar.

3. When specified, a m inimu m of 6 inches on eith er side of the welded splice is covered with aninsu lated wr appin g to cont rol the r at e of cooling after welding is complete. The m eth od of

protecting th e weld ar ea from h eat loss sha ll be addr essed in the approved WQCP.

4. Ran domly select welds to be ra diogra phed (for th e r an dom selection pr ocess, see BCM 145-16).Verify ra diograp hs a re being ta ken on at least 25% of th e ra ndomly selected pr oduction lot. If

welds or r adiogra phs a re r ejected, verify additional welds ar e being ra diogra phed a nd r e-shots

of the repa ired welds are t aken in accordan ce with t he Special Provisions.

5. Verify test s ar e being perform ed properly in accordan ce with t he Special Provisions and oth ercontract documents (assistance from OSM is required). Radiographs are to be taken at zero

degrees from th e top of the weld an d per pendicular to th e root of th e weld as sh own below.

TOP

SOURCE SOURCE

WELD

0

BAR 45

90

BACKING PLATE

ROOT

SIDE VI E W E ND VIE W



14/18



Attachment 3

Sheet 3 of 4

WELD ACCEP TANCE

The Cont ra ctor should be encour aged to subm it rad iogra phs in a timely man ner . This will allow

th e Contr actor th e opportu nity to ma ke corr ections if necessar y before t he work pr ogresses t oo far.

Since the qua lity of th e welding and t he ra diograp hing is the r esponsibility Contr actor, the

Cont ra ctor m ay choose to continu e the work without wa iting for OSM review and comm ent . If so,

th e contr actor proceeds at h is own r isk an d should be inform ed in writing.

The following item s an d th ose in Atta chment 2 need to be obta ined before a ccepting a ny

reinforcing st eel welding.

1. The contractor shall evaluate the radiographic film and the weld for acceptability and makean y necessar y repair t o the weld and perform additiona l testing per t he contr act document s if

required.

2. All radiogra phs, a pproved, reshot an d/or r ejected by th e QC Inspector, mu st be r eviewed byOSM. When the film is delivered to the Stru ctu re Representat ive, the Stru ctur e

Representat ive should prepar e a cover memo (atta ch to the ra diograph film) requesting areview by OSM personn el. Before sending your memo an d th e film, check with your local OSM

office for direction a nd proper send ing inst ru ctions. On th e memo, please include th e Str uctur e

Represen ta tives nam e, telephone num ber an d fax nu mber. Ea ch piece of film shall include the

cont ra ctors na me, dat e of radiogra ph, na me of NDT firm, initia ls of th e ra diogra pher , contr act

num ber, part n umber, an d weld num ber. The letter R and r epair num ber shall be placed

directly after th e weld nu mber t o designat e a ra diograph of a r epaired weld.

3. OSM personn el will review radiographs submitted by th e contr actor and phone the r esults tothe St ru ctu re Representa tive within seven (7) calendar days after th e review or a s stat ed in the

cont ra ct docum ent s. A writt en report will follow with in 10 work ing days. To ensu re a

complete review of the cont ra ctors QC in spection, t he r adiograph s of welds rejected by th e

cont ra ctors QC Insp ector will be reviewed by OSM. OSM will report t heir findings or th erejections to th e Stru ctur e Represent at ive as inform at ion only. These findings will be report ed

as either:

a) Reviewed film a nd int erpreta tions su bmitted by the Contr actor a re consistent with th eOffice of Stru ctur al Ma ter ials findin gs."

Or

b) "Reviewed film a nd int erpreta tions su bmitted by the Contr actor are inconsistent with th eOffice of Str uctur al Mat erials findin gs and we recomm end t he Contr actor review the QC

procedures cur rent ly in use."

4. The Structure Representative can accept welds if both the QC Inspector and the QA Inspectoragree th e welding qua lity is a ccepta ble by visual inspection a nd N DT in accordan ce with AWS

D1.4.

- 14



15/18



Attachment 3

Sheet 4 of 4

WELD ACCEP TANCE (Con t . )

5. In a ddition to th e inspection, th e contr actor sha ll furn ish to the E ngineer, in accorda nce withSection 6-1.07 Certificate of Compliance, of the Standard Specifications and Section 8 of the

Special Provisions, a Certificate of Compliance for each item of work for which welding was

perform ed. This certificate shall stat e tha t a ll of the ma terials an d workm ansh ip incorporated

in th e work , and a ll requ ired test s an d inspections of th is work , have been perform ed in

accorda nce with th e details shown on the plans, an d the r equirements of th e Stan dar d

Specifications a nd th e Special Pr ovisions.

P R O J E C T CL OS E O UT

1. The locat ion of all splices need to be sh ow on th e as build dra wings per BCM 9-1.1.2. Met with t he OSM repr esent at ive to confirm a ll NCR an d an y oth er deta ils ar e resolved before

accepting t he pr oject.



16/18

CONTRACTOR'S QCP SUBMITTAL FOR WELDING

To: , Resident Engineer Date of this Submittal: ,

Tel. No.: , Fax No.: ,

From: , Contract No.: ,

Welding Firm: NDT Firm: ,

Materials to be Welded: Struct. Steel Misc. Rebar Col. Casings H-Piles Pipe Piles

NDT Required : RT UT MT Visual Only

Specifications : D1.1 (yr) D1.4 (yr) D1.5 (yr) D1.6 (yr)

Our Quality Control Plan for welding to be performed on the subject contract is submitted for your review and approval.

The items checked below are submitted herewith.

QCP ITEMS TO BE SUBMITTED AS A MINIMUM SUBMITTED N/A For R.E. Use

1. Organization Chart showing all QC Personnel & their duties.

2. Name & Qualifications of Quality Control Manager (QCM).

3. QC Inspectors - Provide copy of current AWS CWI Certification and eye exam

for each Inspector to be used in the work # of submittals ,

4. Names & Qualifications of Asst. QC Inspectors Provide current AWS Assoc.

CWI Certification or resume. # of submittals ,

5. Procedure Manual of NDT firm: certified personnel, NDT equipment, test

procedures, calibration methods, methods and frequencies of tests, safety

procedures and report forms to be used.

6. Certifications for Level II NDT Technicians. # of submittals ,

7. Methods and frequencies of NDT Inspections.

8. List of Visual Insp. Tools (weld gages, tempstiks, lights, etc.).

9. Procedures frequencies and extent of Visual Inspections.

10. Method of tracking and identifying weld joints & welders.

11. Daily Production & Inspection Log of Welds by QC Inspector.

12. Action Plan for reporting non-conforming welds.

13. Prequalified WPS (PQR not required). # of submittals ,

14. WPS' requiring PQR testing. (PQR tests Must be State Witnessed)

# of submittals & tests ,

15. Standard Weld Repair Procedures.

16. Electrode & Shielding Gas Certs. for each weld process. # of submittals ,

17. Welder Qualifications for each process & position that each welder will

perform. (Must be State Witnessed) # of submittals ,

18. Sample Certificate of Compliance form to be used.

19. One copy each of applicable AWS Welding Codes

20. Other

QCM Signature:__________________________ _____________________________ (Printed Name)

Form METS QCP-1 rev.4 Bridge Construction Bulletin 180-2.1

Attachment 4Sheet 1 of 3- 16



17/18

METS LETTER OF TRANSMITTAL

REVIEW OF CONTRACTOR'S WELDING QUALITY CONTROL PLAN

To: , Resident Engineer Date of this Transmittal:

Tel. No.: Fax No.:

From: , Branch Chief Contract No.:

Date of Receipt (R.E.): Date of Receipt (METS):

The Contractor's Quality Control Plan Submittal #: Rev. # has been reviewed.

QCP substantially complies with specification requirements and approval is recommended.

QCP needs to be resubmitted and unacceptable (reject) items corrected as per comments.

(See attached QCP5-NC for Non-Conforming Item Comments)

General Contractor: Contractor's QCM:

Welding Firm: NDT Firm:

Materials to be Welded: Struct. Steel Misc. Rebar Col. Casings H-Piles Pipe Piles

NDT Required : RT UT MT Visual Only

Specifications : D1.1 (yr) D1.4 (yr) D1.5 (yr) D1.6 (yr)

QCP ITEMS REVIEWED COMPLIESDOESNT

COMPLYN/A

1. Organization Chart showing all QC Personnel & their duties

2. Name & Qualifications of Quality Control Manager (QCM)

3. QC Inspector-AWS CWI Certification and eye exam for each. # of submittals

4. ASST QC Inspector - AWS CAWI Certification for each. # of submittals

5. Procedure Manual of NDT firm: certified personnel, NDT equipment, test

procedures, calibration methods, methods and frequencies of tests, safety procedures

and report forms to be used.

6. Certifications for Level II NDT Technicians # of submittals

7. Methods and frequencies and extent of NDT Inspections

8. List of Visual Insp. Tools (weld gages, tempstiks, lights, etc.)

9. Procedures frequencies and extent of Visual Inspections

10. Describe method of tracking and identifying weld joints and welders production

11. Daily Production & Inspection Log for Welds for use by QC Inspector

12. Action Plan for reporting non-conforming welds

13. Prequalified WPS (PQR not required) # of submittals

14. WPS' requiring PQR tests. # of submittals

15 Standard Weld Repair Procedures

16. Electrode & Shielding Gas Certifications for each process # of submittals

17. Welder Qualifications # of submittals

18. Sample Certificate of Compliance form to be used

19. Other :

METS REVIEWER: Date Review Completed:

Form METS QCP-5 rev. 4 file: Loc: XX.20. A or B

Bridge Construction Bulletin 180-2.1

Attachment 4

Sheet 2 of 3



18/18

CONTRACTOR'S FRACTURE CONTROL PLAN (FCP) SUBMITTAL FOR WELDING

To: ,Resident Engineer Date of this Transmittal:

Tel. No.: Fax No.:

From: , Branch Chief Contract No.:

Date of Receipt (R.E.): Date of Receipt (METS):

The Contractor's Fracture Control Plan Submittal #: Rev. # has been reviewed.

FCP substantially complies with specification requirements and approval is recommended.

FCP needs to be resubmitted and unacceptable (reject) items corrected as per comments.

(See attached QCP7-NC for Non-Conforming Item Comments)

General Contractor: Contractor's QCM:

Welding Firm: NDT Firm:

Specification: D1.5 (yr )

FRACTURE CONTROL PLAN (FCP)

ITEMS TO BE SUBMITTED AS A MINIMUMCOMPLIES

DOESNT

COMPLYN/A

1. Base Metal used meet the project and code requirements

2. Consumable meet the requirements of heat or lot testing by the manufacturer

3. Weld metal strength and ductility conform to tables 4.1 or 4.2

4. Weld metal toughness meets table 12.1 requirements or the undermatching yield

strength of a minimum toughness of 25ft-lb @ -20F.

5. WPS requiring PQR test (according to section 12.7). # of submittals:

6. Prequalified WPS (PQR not required) (According to section 12.7.1)

# of submittals:

7. Base metal repair procedure

8. Tack weld procedures (According to section 12.13). # of submittals:

9. Lead QC name, qualifications, and resume. Work history needs to show a

minimum of 3 years experience in steel bridge fabrication inspection.

10. NDT methods, personnel qualifications, eye exams, frequency of testing, reports

to be used, and written practice of NDT firm. (see Sec. 12.16.1.2-5)

11. Electrode & Shielding Gas Certs. for each weld process and base metal

combination. # of submittals:

12. Welder Qualifications for each process & position that each welder will perform.

Welder Qualification tests shall be within 6 months of FCM work and shall be

qualified by both mechanical (bend) and radiograph tests according to section 12.8.2

and 5 Part B. # of submittals:

13. Daily Production & Inspection Log of Welds by Lead QC Inspector

14. Noncritical Repair Welding Procedures such as surface discontinuities. Nocritical

repair WPS shall meet the requirements of Section 12.17.2 and 12.17.2.1

15. Critical Repair Welding Procedures (According to Section 12.17.3).

16. Other:

METS REVIEWER: Date Review Completed:

Form METS QCP-7 FCP rev. 4 File Location: XX.20.A or B

Bridge Construction Bulletin 180-2.1

Attachment 4

Sheet 3 of 3


welding work appendix c

Documents