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AISC 207-20 PUBLIC REVIEW DRAFT 1

AISC 207-20 Public Review Draft Dated August 30, 2019 Standard for Certification Programs

AMERICAN INSTITUTE OF STEEL CONSTRUCTION

1 2 3 4 5 6

AISC Standard for 7

Certification Programs 8

9 December X, 2020 10

Supersedes the 11

Certification Standard for Steel Fabrication and Erection, 12 and Manufacturing of Metal Components (AISC 207-16) 13

Approved by the Certification Standards Committee 14 15 16 17 18 19

20

21

AMERICAN INSTITUTE OF STEEL CONSTRUCTION 22 130 East Randolph Street, Suite 2000 Chicago, Illinois 60601 23

www.aisc.org 24 25

26


AISC 207-20 Public Review Draft Dated August 30, 2019

AISC Standard for Certification Programs


27 28 29 30

AISC © 2020 31

32 by 33

34 American Institute of Steel Construction 35

36 All rights reserved. This book or any part thereof 37

must not be reproduced in any form without the 38

written permission of the publisher. 39

40 The AISC logo is a registered trademark of AISC. 41

42 Competent design, construction and legal advice should be sought when applying the 43 provisions of this document to a specific construction project or contract document. The 44 publication of this information is not a representation or warranty on the part of the 45 American Institute of Steel Construction, its officers, agents, employees or committee 46 members, or of any other person named herein, regarding performance of contract work or 47

compliance with contract specifications or safety regulations. All representations or 48 warranties, express or implied, are specifically disclaimed. Anyone making use of the 49

information presented in this publication assumes all liability arising from such use. 50

51 Caution must be exercised when relying upon standards and guidelines developed by other 52 bodies and incorporated by reference herein since such material may be modified or 53

amended from time to time subsequent to the printing of this edition. The American 54 Institute of Steel Construction bears no responsibility for such material other than to refer 55 to it and incorporate it by reference at the time of the initial publication of this edition. 56

57 Printed in the United States of America 58

59

60 61

62





PREFACE 63

64 This Preface is not a part of AISC 207-20, AISC Standard for Certification Programs. It is 65 intended for informational purposes only. 66

67 68

This Standard is the result of the deliberations of a balanced committee, the membership of 69 which included engineers, fabricators, erectors, quality control consultants, a code official, 70 a state bridge official, and a general contractor. This Standard is proprietary and has been 71 created for the sole use of the AISC Certification Program as part of its policies and 72

procedures for auditing and certification. 73 This Standard brings together provisions from four individual predecessor standards 74

relating to the four industry segments: steel building fabrication (Chapter 2), metal 75 component manufacturing (Chapter 3), steel bridge fabrication (Chapters 4, 4.I, 4.A, and 76 4.F), and steel erection (Chapter 5) that have been a part of the AISC Certification Program 77 since its beginnings in 1975. A new chapter has been added with requirements for 78 hydraulic metal structures (Chapter 6). Chapter 1 provides general requirements that apply 79 to all industry segments, and Chapters 2, 3, 4, 4.I, 4.A, 4.F, 5, and 6 contain supplementary 80 requirements in addition to those in Chapter 1. 81

82 This Standard was approved by the Certification Standards Committee: 83 84

85 Michael A. West, Chairman Andrew J. Lye

Jack A. Klimp, Vice Chairman Larry A. Martof

Todd Alwood Carol A. Post

Joseph A. Bracken III Gregory F. Rzonca

Theodore L. Droessler Alan T. Sheppard

James K. Hilton Ricky D. Zaske Charles J. Kanapicki Margaret A. Matthew, Secretary

86





TABLE OF CONTENTS 87

GLOSSARY 10 88

CHAPTER 1. GENERAL REQUIREMENTS 17 89

1.1 PURPOSE 17 90 1.2 SCOPE 17 91 1.3 REFERENCES 17 92

1.4 DEFINITIONS 18 93

1.5 MANAGEMENT RESPONSIBILITY 18 94

1.5.1 Policy for Quality 18 95

1.5.2 Quality Management System 18 96

1.5.3 Periodic Management Review 19 97

1.5.4 Responsible Quality Personnel 19 98

1.5.5 Resource Management 20 99

1.5.6 Internal Communication 20 100

1.5.7 Quality Manual 20 101

1.6 CONSTRUCTION DOCUMENT REVIEWAND COMMUNICATION 21 102

1.7 DETAILING 21 103

1.7.1 Detailing Standards 21 104

1.7.1.1 Digital Document Production 22 105

1.7.2 Checking 23 106

1.7.3 Approval of Approval Documents and Release for Fabrication 23 107

1.7.4 Fabrication and/or Installation Documents Supplied by Others 24 108

1.7.5 Management of Detailing 24 109

1.7.6 Detailing Functions 24 110

1.7.7 Subcontract Services 25 111

1.8 CONTROL OF MANAGEMENT SYSTEM DOCUMENTS 112

AND PROJECT DOCUMENTS 25 113

1.8.1 Management System Documents 25 114

1.8.1.1 Quality Management System Documents 25 115

1.8.1.2 Review and Approval 25 116

1.8.1.3 Revision Control 25 117

1.8.1.4 Access 26 118

1.8.1.5 Communication 26 119

1.8.2 Project Documents 26 120

1.8.2.1 Tracking 26 121

1.8.2.2 Revision Control 26 122

1.8.2.3 Access 27 123

1.8.2.4 Communication 27 124



Standard for Certification Programs


1.9 MAINTENANCE OF QUALITY RECORDS 27 125

1.9.1 Retention 27 126

1.9.2 Storage 28 127

1.9.3 Retrieval 28 128

1.10 PURCHASING 28 129

1.10.1 Purchasing Data 28 130

1.10.2 Selection of Subcontractors and Suppliers 28 131

1.10.3 Verification of Purchased Product, Materials, and Services 29 132

1.10.4 Control of Customer-Furnished Material 29 133

1.11 MATERIAL IDENTIFICATION 29 134

1.12 PROCESS CONTROLS 30 135

1.12.1 Welding 30 136

1.12.2 Bolt Installation 31 137

1.12.3 Material Preparation for Application of Coatings 138

1.12.4 Coating Application 139

1.12.51.12.3 Equipment Maintenance 31 140

1.13 INSPECTION AND TESTING 31 141

1.13.1 Assignment of QC Inspections and Monitoring 32 142

1.13.2 Receipt Inspection 32 143

1.13.3 In-Process Inspection 32 144

1.13.4 Final Inspection 32 145

1.13.5 Inspection Records 33 146

1.14 CALIBRATION OF INSPECTION, MEASURING, AND 147

TEST EQUIPMENT 33 148

1.15 CONTROL OF NONCONFORMANCES 34 149

1.15.1 Nonconformance with Management Systems 34 150

1.15.2 Nonconforming Product and Work 34 151

1.16 CORRECTIVE ACTION 35 152

1.17 HANDLING, STORAGE, AND DELIVERY OF PRODUCTS 153

AND MATERIALS 36 154

1.18 TRAINING 36 155

1.19 INTERNAL AUDIT 36 156

CHAPTER 2. BUILDING FABRICATOR REQUIREMENTS 37 157

2.3. REFERENCES 37 158

2.5. MANAGEMENT RESPONSIBILITY 37 159

2.5.4. Resource Management 37 160

2.5.4.1. Buildings, Workspace, Equipment, and Associated Utilities 37 161

2.12 PROCESS CONTROLS 38 162

2.12.3 Material Preparation for Application of Coatings 38 163





2.12.4 Coating Application 38 164

CHAPTER 3. METAL COMPONENT MANUFACTURER REQUIREMENTS 39 165




3.5.4.1. Buildings, Workspace, Equipment, and Associated Utilities 39 169

3.7 DETAILING 40 170 3.7.8 Design Procedure 40 171 3.7.9. Design for Standard Components 40 172

3.7.10 Design for Nonstandard Components 40 173

3.12 PROCESS CONTROLS 174



177

CHAPTER 4. BRIDGE FABRICATOR REQUIREMENTS 42 178

4.2 SCOPE 42 179 4.3 REFERENCES 43 180 4.5 MANAGEMENT RESPONSIBILITY 43 181

4.5.4 Resource Management 43 182

4.5.4.1 Personnel 43 183

4.5.4.2 Buildings, Workspace, Equipment, and Associated Utilities 44 184

4.7. DETAILING 44 185

4.7.8. Preparation of Fabrication, Manufacturing, Erection, and Installation 186 Documents 44 187

4.11 MATERIAL IDENTIFICATION 44 188

4.11.1 Traceability 45 189

4.12. PROCESS CONTROLS 45 190

4.12.2. Bolt Installation 45 191



194

CHAPTER 4.I. SUPPLEMENTAL REQUIREMENTS 195

FOR FABRICATORS OF INTERMEDIATE BRIDGES 46 196

4.I.2. SCOPE 46 197

4.I.5. MANAGEMENT RESPONSIBILITY 46 198

4.I.5.4. Resource Management 46 199

4.I.5.4.1.Buildings, Workspace, Equipment, and Associated Utilities 46 200

4.1.7. DETAILING 46 201

4.I.7.1 Detailing Standards 46 202

4.I.7.6. Detailing Functions 47 203





4.I.12. PROCESS CONTROLS 47 204

4.I.12.6. Laydown/Assembly 47 205

CHAPTER 4.A SUPPLEMENTAL REQUIREMENTS 206

FOR FABRICATORS OF ADVANCED BRIDGES 48 207

4.A.2. SCOPE 48 208

4.A.6. CONSTRUCTION DOCUMENT REVIEWAND COMMUNICATION 48 209

4.A.12. PROCESS CONTROLS 49 210

4.A.12.1 Welding 49 211

CHAPTER 4.F. SUPPLEMENTAL REQUIREMENTS 212

FOR FABRICATORS OF FRACTURE-CRITICAL MEMBERS 50 213

4.F.2. SCOPE 50 214

4.F.5. MANAGEMENT RESPONSIBILITY 50 215

4.F.5.7. Quality Manual 50 216

4.F.7. DETAILING 50 217

4.F.7.1 Detailing Standards 50 218

4.F.10. PURCHASING 50 219

4.F.10.1. Purchasing Data 51 220

4.F.11. MATERIAL IDENTIFICATION 51 221

4.F.12. PROCESS CONTROLS 51 222

4.F.12.1. Welding 51 223

4.F.13. INSPECTION AND TESTING 51 224

4.F.15. CONTROL OF NONCONFORMANCES 51 225

4.F.15.2.Nonconforming Product 51 226

CHAPTER 5. ERECTOR REQUIREMENTS 52 227


5.3.1. Seismic Erection 52 229

5.3.2. Metal Deck Installation Endorsement 52 230

5.3.3. Bridge Erection Endorsement 53 231

5.3.4. Safety 53 232


5.5.2. Periodic Management Review 53 234


5.5.4.3. Erection Tools and Equipment 53 236

5.5.8. Safety Manual 54 237

5.5.9. Policy for Safety 54 238

5.5.10. Responsible Safety Personnel 54 239

5.8. CONTROL OF MANAGEMENT SYSTEM DOCUMENTS 240

AND PROJECT DOCUMENTS 55 241





5.8.1. Management System Documents 55 242

5.8.1.4. Access 55 243

5.8.1.5. Communication 55 244

5.8.2. Project Documents 55 245

5.8.2.1. Tracking 55 246

5.8.2.3. Access 55 247

5.10. PURCHASING 55 248

5.16. CORRECTIVE ACTION 55 249

5.18. TRAINING 56 250

5.19. INTERNAL AUDIT 57 251

5.20. ERECTION PLAN 57 252

5.21. SAFETY PLAN 58 253

5.22. OTHER PROJECT-SPECIFIC REQUIREMENTS 58 254 255

CHAPTER 6. HYDRAULIC METAL STRUCTURES FABRICATOR 256 REQUIREMENTS 60 257

6.2. SCOPE 60 258 6.3. REFERENCES 61 259 6.5. MANAGEMENT RESPONSIBILITY 61 260

6.5.4. Resource Management 61 261 6.5.4.1. Personnel 61 262 6.5.4.2. Buildings, Workspace, Equipment, and Associated Utilities 62 263

6.6. CONSTRUCTION DOCUMENT REVIEW AND COMMUNICATION 62 264 6.7. DETAILING 63 265

6.7.1. Detailing Standards 63 266 6.7.6. Detailing Functions 63 267 6.7.8. Preparation of Fabrication Documents 63 268

6.12. PROCESS CONTROLS 64 269 6.12.1. Welding 64 270 6.12.3 Material Preparation for Application of Coatings 64 271 6.12.4 Coating Application 64 272 273

CHAPTER 6.A. SUPPLEMENTAL REQUIREMENTS FOR FABRICATORS OF 274 ADVANCED HYDRAULIC METAL STRUCTURES 65 275 6.A.3. REFERENCES 65 276 6.A.5. MANAGEMENT RESPONSIBILITY 65 277

6.A.5.4. Resource Management 65 278 6.A.5.4.1. Personnel 65 279

6.A.12. PROCESS CONTROLS 65 280 6.A.12.1. Welding 65 281 6.A.12.2. Bolt Installation 65 282 6.A.12.6. Trial Assembly 65 283 6.A.12.7. Machining 66 284 285





CHAPTER 6.F. SUPPLEMENTAL REQUIREMENTS FOR FABRICATORS OF 286 FRACTURE-CRITICAL MEMBERS OF HYDRAULIC METAL STRUCTURES 67 287

6.F.3. REFERENCES 67 288 6.F.5. MANAGEMENT RESPONSIBILITY 67 289

6.F.5.7. Quality Manual 67 290 6.F.7. DETAILING 67 291

6.F.7.1. Detailing Standards 67 292 6.F.10. PURCHASING 68 293

6.F.10.1. Purchasing Data 68 294 6.F.11. MATERIAL IDENTIFICATION 68 295 6.F.12. PROCESS CONTROLS 68 296

6.F.12.1. Welding 68 297 6.F.13. INSPECTION AND TESTING 69 298 6.F.15. CONTROL OF NONCONFORMANCES 69 299

6.F.15.2. Nonconforming Product 69 300

301





302

GLOSSARY 303

304 The terms listed below are to be used in addition to those in the AISC Code of Standard 305

Practice for Steel Buildings and Bridges, hereafter referred to as the Code of Standard 306 Practice; some commonly used terms are repeated here for convenience and marked with 307 an†. 308

309 AASHTO. The American Association of State Highway and Transportation Officials. 310

AISC.† American Institute of Steel Construction. 311

Approval documents.† The structural steel shop drawings, erection drawings, and 312 embedment drawings, or, where the parties have agreed in the contract documents to 313 provide digital model(s), the fabrication and erection models. A combination of 314 drawings and digital models also may be provided. 315

Approved construction documents. Those construction documents approved by the 316 building official as part of the building permit issuance process. 317

AREMA.† The American Railway Engineering and Maintenance of Way Association. 318

ASNT. The American Society for Nondestructive Testing. 319

Assembly. Two or more components joined to make a part or product that can be the final 320 item or that join to other components. Joining methods include welding, bolting, 321

pressure fit, molding and adhesion. 322

ASTM.† American Society for Testing and Materials. 323

AWS.† American Welding Society. 324

Calibration. The process of comparing the measurements of a device of known accuracy or 325 standard to determine if the difference is acceptable when compared to the desired accuracy. 326

Checker. A person in a detailing organization who, because of experience and ability, has 327 advanced successfully to a position of responsibility with the ability to perform the final 328

verification of shop drawingsfabrication and erection documents without direct 329 supervision. 330

Checking (of shop drawings, digital models, and erection drawings fabrication documents 331

and erection documents). A detailed review of all sketches and dimensions on shop 332 drawings, digital models, and erection drawingsthe fabrication documents and erection 333 documents by a qualified checker other than the original detailer. Checking is performed 334

to ensure that the fabrications and erection documents have accurately and completely 335 transferred the information from the contract documents. Checking will compare the 336

shop drawings, digital models, and erection drawings fabrication documents and 337 erection documents to design documents, specifications, and project requirements. 338 During checking, the checker shall verify: that include, but are not limited to: 339 (a) Geometry. 340

(b) Use of the correct connections. 341 (c) Proper notes are included. 342





(d) Proper material usage. 343 (d)(e) Shop bills contain all required information. 344 (e)(f) UseAssignment of appropriate and complete welding symbols. 345 (f)(g) Use of pProper coatings and preparation. 346

(h) Proper representation on erection drawings, including the notation of any necessary 347 instructions and depiction of details necessary to conduct the work in the field 348

(i) All information is clearly presented and in compliance with the Code of Standard 349

Practice requirements. 350

(g)(j) All steel included in the contract documents has been detailed. 351

Coating. Coatings may include paint, powder coatings, galvanizing, metalizing, Teflon, 352 and electro-deposited metals. 353

Component. A bridge- or transportation-related item that contract documents stipulate to 354 be obtained from an AISC Certified Bridge and Highway Metal Component 355 Manufacturer and that is not covered by the AISC Bridge Fabricator Certifications. A 356

component may be entirely produced by the manufacturer, or comprised of 357 subassemblies and parts from subcontractors and suppliers, assembled by the 358

manufacturer. A finished component may ship as a single piece or multiple elements, 359 and may require field assembly or adjustment, based upon installation instructions 360 provided by the manufacturer. 361

Construction documents. Written, graphic and pictorial documents prepared or assembled 362 for describing the design (including the structural system), location, and physical 363

characteristics of the elements of a building necessary to obtain a building permit and 364 construct a building. See also approved construction documents. 365

Contract documents.† The documents that define the responsibilities of the parties that are 366

involved in bidding, fabricating and erecting structural steel. These documents normally 367 include the design documents, the specifications and the contract. 368

Corrective action. The action or actions undertaken to identify and eliminate the root cause 369 of a service or process nonconformance to prevent its recurrence. Corrective action is 370 not the repair or rework of identified nonconforming product or process to meet 371 specified requirements. 372

Corrective measure. The measure taken to bring a nonconforming product or process into 373 conformance with specified requirements. 374

Customer furnished material. Material or products that the fabricator, erector or 375 manufacturer receives from the customer directly for incorporation into their work. 376

Detailer. See steel detailer. 377

Detailing. The function that produces shop drawings, digital models, and erection framing 378 (or installation) drawings fabrication and erection (or installation) documents from 379 contract documents. 380

Design documents.† The design drawings, or where parties have agreed in the contract 381 documents to provide digital model(s), the design model. A combination of drawings 382 and digital models also may be provided. 383





Design drawings.† The graphic and pictorial portions of the contract documents showing 384 the design, location and dimensions of the work. These documents generally include, 385 but are not limited to, plans, elevations, sections, details, schedules, diagrams and notes. 386

Design model,† A dimensionally accurate 3D digital model of the structure that conveys 387 the structural steel requirements given in Code of Standard Practice, Section 3.1, for the 388

building. 389

Documentation (documented). Material that provides information or evidence. 390 Documentation may include written instructions, drawings, models, diagrams, charts, 391

photographs, electronic media, specifications, and references to or excerpts from 392 appropriate technical standards and codes. 393

Documented procedure. A procedure that is established, documented, implemented and 394 maintained. The documentation provides information about how to perform an activity 395 or process consistently. Documentation shall contain: 396 (a) The purpose of the procedure 397 (b) Process definition that includes steps required for completion 398 (c) Assignment of responsibility for performance 399 (d) Assignment of responsibility for review, revision, and/or approval of the procedure 400 (e) Identification of records that are generated 401

(f) For inspection activities, frequency of observations or inspections and how those 402 observations or inspections are documented 403

Documented training. Training in which there is a record of the course outline, a record of 404

who attended, the date it was given, and the instructor who provides the training. 405

Embedment drawings.† Drawings that show the location and placement of items that are 406 installed to receive structural steel. 407

Erection. The process of assembling individual members into a structural steel building or 408 bridge in accordance with all contract documents. 409

Erection documents.† The erection drawings, or where the parties have agreed in the 410 contract documents to provide digital model(s). the erection model. A combination of 411 drawings and digital models may also be provided. 412

Erection drawings.† Field-installation or member-placement drawings that are prepared by 413 the fabricator to show the location and attachment of the individual structural steel 414 shipping pieces. 415

Erection model.† A dimensionally accurate 3D digital model produced to convey the 416 information necessary to erect the structural steel. This may be the same digital model as 417 the fabrication model, but is not required to be. 418

Erection plan. The documentation of major resources and activities anticipated to be 419 needed in performance of the work as it is affected by the conditions and requirements 420 of one singular project. 421

Erector.† The entity that is responsible for the erection of the structural steel. 422

Executive management. The highest ranking official(s) in the company, e.g., CEO, 423 President, General Manager, Owner, etc. Executive management has full authority in 424





final decision making for all aspects of the quality management system and safety 425 management system. 426

Fabrication. The process of preparation and assembly of individual parts into a shipping 427 piece in accordance with all contract documents. This includes all operations performed 428 in the production and shipping of the product (e.g., assembly, drilling, sawing, milling, 429

and thermal and mechanical cutting). 430

Fabrication documents.† The shop drawings, or where parties have agreed in the contract 431 documents to provide digital model(s), the fabrication model. A combination of 432 drawings and digital models may also be provided. 433

Fabrication model.† A dimensionally accurate 3D digital model produced to convey the 434 information necessary to fabricate the structural steel. This may be the same digital 435

model as the erection model, but is not required to be. 436

Fabricator.† The entity that is responsible for detailing (except in Section 4.5 of the Code 437 of Standard Practice) and fabricating the structural steel. 438

Installation documents. The installation drawings, or where the parties have agreed in the 439 contract documents to provide digital model(s), the installation model. A combination 440 of drawings and digital models may also be provided. 441

Installation drawings. Field-installation or member placement drawings that are prepared 442 by the manufacturer to show the location and attachment of the individual manufactured 443 components. 444

Installation model. A dimensionally accurate 3D digital model to show the location and 445 attachment of the individual manufactured components. 446

Key position. Executive management and positions in the fabricator’s, manufacturer’s or 447 erector’s quality management system that manage detailing, purchasing, quality 448 assurance, quality control, fabrication processes, erection, project management, and the 449 erector’s safety functions. 450

Management systems. See safety management system and quality management system. 451

Manufacture (manufacturing, manufactured). The process of designing, producing, testing 452

and assembling components by the manufacturer. 453

Manufacturer. The entity that manufactures components. 454

Manufacturing documents. Documents, drawings, or where parties have agreed in the 455

contract documents to provide digital model(s), the manufacturing model that illustrates the 456

manufacturing of components for production. 457

Manufacturing model. A dimensionally accurate, 3D digital model produced to convey the 458

information necessary to manufacture components. 459

MTR. Mill test report as defined in Section 14 of ASTM A6. 460

Nonconformance. Attributes of materials, consumables, fabricated or manufactured 461 product (in-process or final), erected members, or processes that do not meet contract, 462 regulatory, or internally defined requirements. 463





NDT. Nondestructive testing (nondestructive examination). 464

Objective evidence. Data supporting the existence or verification of something. Records, 465 statements of fact, or other information that are relevant to the audit criteria and 466

verifiable. In this context, it is evidence of whether the quality management system is 467 functioning properly. Objective evidence may be obtained through: 468 (a) Observation of the performance of a task or physical products 469 (b) Measurements 470

(c) Tests 471 (d) Review of a record, document or procedure 472 (e) The result of an interview with one or more employees about their duties or 473

performance of a task 474

Owner.† The entity that is identified as such in the contract documents. 475

Owner’s designated representative for construction.† The owner or the entity that is 476

responsible to the owner for the overall construction of the project, including its 477 planning, quality and completion. This is usually the general contractor, the construction 478

manager or similar authority at the job site. 479

Owner’s designated representative for design.† The owner or the entity that is responsible 480 to the owner for the overall structural design of the project, including the structural steel 481

frame. This is usually the structural engineer of record. 482

Procedure. See documented procedure. 483

PQR. Procedure Qualification Record as defined by AWS A3.0M/A3.0. 484

Quality assurance (QA). That part of quality management focused on providing confidence 485 that quality requirements will be fulfilled. For the purposes of this program, Quality 486 assurance is the planned system of documented procedures and organizational 487 requirements developed and implemented for the purpose of measuring and assuring 488 compliance with customer requirements and providing confidence that quality goals are 489 achieved. Quality assurance encompasses such areas as compliance with project 490 specification requirements, compliance with referenced standards and achievement of 491 customer service objectives. Specific functions included in quality assurance are: 492

o Determination of quality criteria 493 o Establishment of a plan to monitor quality including assignment of quality control 494

(inspection) 495 o Determination of acceptance criteria 496

o Determination of QC personnel qualifications 497 o Oversight (periodic monitoring) of QC activities 498

o Summarizing and reporting quality conformance measures to management 499

The foregoing definition is solely applicable to this Standard. It is mutually exclusive of 500 other definitions for the term quality assurance that are found in other AISC 501 publications, such as the Specification for Structural Steel Buildings. 502

Quality control (QC). Controls and inspections implemented by the fabricator or erector, 503

as applicable, to ensure that the material provided and work performed meet the 504 requirements of the approved construction documents and referenced standards. 505





Quality control records. Documents that report the results of inspections mandated by the 506 documented procedures and the contract documents. 507

Quality manual. A document stating the quality policy and describing the quality 508

management system. 509

Quality management system. A system to establish policy, objectives, plans and resources 510 to direct and control an organization with regard to quality. 511

Quality record. A document that provides objective evidence of activities performed or 512

results achieved. 513

RCSC.† Research Council on Structural Connections. 514

Repair. Action taken on a nonconforming product to make it acceptable for the intended use. 515

Registered design professional. An individual who is registered or licensed to practice his/ 516

her respective design profession as defined by the statutory requirements of the 517 professional registration laws of the state or jurisdiction in which the project is to be 518 constructed. 519

Released for fabrication. Status of the work as described in AISC Code of Standard 520 Practice Section 4. 521

Rework. Action taken on a nonconforming product to make it conform to the requirements. 522

RFI.† A documented request for information or clarification generated during the 523 construction phase of the project. 524

Safety management system. A system to establish policy, goals, plans and resources to 525 identify and document hazards and their elimination, mitigation or isolation related to 526 the safety and health of employees and third parties, and to eliminate property and 527

equipment damage that may be caused by unsafe acts or unsafe conditions. Safety 528 management systems only apply to erectors. 529

Safety manual. A document stating the safety policy and describing the safety management 530 system of the erector’s organization. 531

Safety plan. The identification and documentation of specific hazards related to a singular 532 project and the means and methods to be used to eliminate, mitigate or isolate those 533

hazards. 534

Shop drawings.† Drawings of the individual structural steel shipping pieces that are to be 535 produced in the fabrication shop. 536

Specifications.† The portion of the contract documents that consists of the written 537

requirements for materials, standards and workmanship. 538

SSPC.† The Society for Protective Coatings, which was formerly known as the Steel 539 Structures Painting Council. 540

Steel detailer.† The entity that produces the approval documents. 541

Structural engineer of record.† The licensed professional who is responsible for sealing 542 the contract documents, which indicate that he or she has performed or supervised the 543

analysis, design, and document preparation for the structure and has knowledge of the 544 load-carrying structural system. See also registered design professional. 545





Structural steel.† Elements of the structural frame as given in AISC Code of Standard 546 Practice Section 2.1. 547

Structural steel buildings and other structures. Buildings and other structures designed, 548

fabricated and erected in accordance with the AISC Specification for Structural Steel 549 Buildings. See AISC Specification Section A1. 550

Subcontractor. A firm that performs a portion of the fabricator’s, manufacturer’s or 551 erector’s contract work, such as fabrication, erection, detailing, coating application, 552 inspection or consulting services. 553

Supplier. A firm that supplies materials (including, but not limited to, mill materials, 554 process supplies, welding consumables, coatings and process machinery) and completed 555 purchased product (including, but not limited to, fasteners, decking, joists and 556

proprietary buy-out items) needed to fulfill the contract requirements. 557

Training. See documented training. 558

Verification. The confirmation through objective evidence that the quality management 559 system requirements have been met. 560

WPS. Welding procedure specification as defined by AWS A3.0/A3.0M.561

562





563

CHAPTER 1 564

GENERAL REQUIREMENTS 565

566

1.1. PURPOSE 567

The purpose of this Standard is to confirm to owners, the design community, the 568 construction industry, and public officials that those who adhere to the 569 requirements in this Standard have the personnel, organization, experience, 570 documented procedures, knowledge, equipment and quality commitment to 571

perform fabrication, manufacturing, and/or erection as described in this Standard. 572 573

1.2. SCOPE 574

The requirements in this Standard shall apply as follows: 575

(a) Chapters 1 and 2 shall apply to building fabricators, who fabricate and supply 576 the structural steel frames for buildings. 577

(b) Chapters 1 and 3 shall apply to metal component manufacturers, who 578

manufacture components that include bracing not designed for primary loads 579 (diaphragms, cross frames, and lateral bracing); camera, light, sign, and signal 580

support structures; bridge rail; stairs; walkways; grid decks; drains; scuppers; 581 expansion joints; bearings; ballast plates; and mechanical movable bridge 582 equipment. Manufacturers of camera, light, sign, and signal support structures; 583 high mast light towers; bridge rail; complex expansion joints; high load multi- 584 rotational (HLMR) bearings; and mechanical movable bridge equipment shall 585

also be required to meet specific supplemental requirements to this Standard. 586 (c) Chapters 1 and 4 shall apply to bridge fabricators, who fabricate and supply 587

steel highway or railroad bridges. 588 (d) Chapters 1 and 5 shall apply to erectors. 589 (e) Chapters 1 and 6 shall apply to hydraulic metal structure fabricators. 590

In Chapters 2 through 6, only those subsections that are supplementary to Chapter 591 1 are indicated. 592

The Glossary is an integral part of this Standard. Nonmandatory Commentaries are 593 provided for background, and the user is encouraged to consult them. 594

595

1.3. REFERENCES 596

The reference documents and standards necessary to make personnel aware of 597

work requirements shall be consistent with the requirements of existing contract 598 documents and shall be readily available to those who need them. 599

The ability to work to and meet the requirements of the latest edition of the 600





following documents shall be demonstrated: 601

(a) ANSI/AISC 303 Code of Standard Practice for Steel Buildings and Bridges 602 (b) RCSC Specification for Structural Joints Using High-Strength Bolts 603 (c) Selected ASTM Standards for Structural Steel Fabrication, as published for 604

AISC, or equivalent content 605 (d) AWS A2.4 Symbols 606

(e) AWS A3.0M/A3.0 Terms and Definitions 607 (f) AWS D1.1/D1.1M Structural Welding Code—Steel 608

609 1.4. DEFINITIONS 610

As used in this Standard, the words shall or will denote a mandatory requirement. 611 The word should denotes a guideline or recommendation. The words may or can 612 denote an opportunity to make a choice. 613

614 1.5. MANAGEMENT RESPONSIBILITY 615

1.5.1. Policy for Quality 616

Executive management shall ensure that the policy for quality is understood, 617 implemented and maintained. The policy for quality shall include: 618

(a) A commitment to quality that includes a commitment to meet the 619 requirements in contract documents. 620

(b) A quality management system that provides a framework for establishing, 621 communication and reviewing quality goals. 622

Executive management shall establish goals to improve quality. Goals shall be 623 measurable and documented through objective evidence. As quality goals are 624 achieved, new goals shall be set that demonstrate commitment to continuous 625 improvement. 626

627

628

1.5.2. Quality Management System 629

The quality management system shall satisfy all of the requirements of this 630 Standard and the requirements of the contract documents and referenced 631 standards. The quality management system shall include a quality manual, 632 documented procedures, and records as required by this Standard. The quality 633 management system must address both quality control and quality assurance as 634 defined in the Glossary of this Standard. 635

636

Commentary: New quality goals can be a new level of achievement of a

previous goal, or a new goal that has not been previously identified.

Commentary: The extent of the quality management system documentation

can differ from one organization to another due to the size of organization, the

type of activities, and the complexity and interaction of processes.

Requirements may be satisfied in a single document called the quality manual

that may incorporate separate documents by reference.





1.5.3. Periodic Management Review 637

Executive management shall conduct periodic review of the quality management 638

system at planned intervals, but annually at a minimum. Management review shall 639 encompass, assess and report the following, at a minimum: 640

(a) A summary of previous management reviews. 641 (b) Results of any internal and external audits conducted since the previous 642

management review. 643 (c) An assessment of customer feedback and feedback mechanisms, identifying 644

opportunities for improving quality. 645 (d) An assessment of product or work nonconformances. Both the number and 646

severity of nonconformances shall be assessed. 647 (e) An assessment of process nonconformances, including compliance with the 648

documented procedures comprising the quality management system. 649 (f) An assessment of the effectiveness of the corrective actions taken. 650 (g) An assessment of the results of equipment maintenance and preventive 651

maintenance, including the adequacy of equipment resources. 652

(h) An assessment of the adequacy of the training program with respect to the 653 levels of qualification required. 654

(i) An assessment of any proposed or required modifications to the quality 655 management system. 656

The management review record shall include the decisions and actions required for 657 implementation of: 658

(a) Improvement of the effectiveness of the quality management system and its 659 processes 660

(b) Improvement of product quality 661 (c) Resource needs 662

Records from management reviews shall be maintained in accordance with the 663 documented procedure as required in Section 1.9. 664

1.5.4. Responsible Quality Personnel 665

Executive management shall designate a management representative for quality 666 who shall report directly to (or be a part of) executive management. The 667 designated management representative for quality may perform other functions 668 within the company, provided that those functions do not conflict with the quality 669 responsibilities. The designated management representative(s) shall have the 670

ability, responsibility and authority to: 671

(a) Ensure that documented procedures needed for the quality management systems 672 are established, implemented, and maintained in accordance with this Standard. 673

(b) Report to executive management on the performance of the quality 674

management system and any need for improvement. 675 (c) Communicate with external parties on matters relating to the quality 676






1.5.5. Resource Management 678

Resources necessary to comply with the contract documents shall be available, 679

and procedures for resource management must be documented. Resources are 680 both personnel and non-personnel. The qualification requirements, responsibility, 681 authority, and the interrelation of functional positions that manage, perform, and 682 verify work affecting quality shall be defined as required in Section 1.5.3 and in 683

the industry-specific chapters. Other provisions relating to personnel are found 684 elsewhere in the Standard. See Sections 2.5.4, 3.5.4, 4.5.4, 4.1.5.4, and 5.5.4.2, 685 and 6.5.4.2 for non-personnel, industry-specific resource requirements.Resources 686 shall include, but are not limited to, the resources described in the following. 687 Personnel performing defined functions shall have the required qualifications and 688

the ability to successfully perform the function. 689 690

691

692 693

1.5.6. Internal Communication 694

Executive management shall ensure that appropriate communication processes are 695

established and that communication takes place on a regular basis regarding the 696 effectiveness of management systems. 697

1.5.7. Quality Manual 698

The quality manual shall include a page showing the current revision date and the 699

name and location of the facility or organization. 700

The quality manual shall include or incorporate by reference the following 701

documents at a minimum: 702

(a) Documented statements of a quality policy and quality objectives as required 703 by this Standard. 704

(b) Documented procedures established for the quality management system. 705

(c) Documents needed by the organization to ensure the effective planning, 706 operation, and control of its processes. 707

(d) Organizational chart describing the interrelationship of functional positions 708

that affect quality. 709 (e) Job descriptions outlining and describing responsibilities, authority, required 710

Commentary: Objective evidence of qualification may be demonstrated

through biographies, resumes, documented training, and individual licenses or

certifications. Personnel may be assigned to more than one function, provided

they are qualified and able to perform fully the duties of each position.

User Note: See Sections 2.5.4, 3.5.4, 4.5.4, 4.I.5.4 and 5.5.4 for nonpersonnel

industry-specific resource requirements.





qualifications, and activities for key positions. 711 (f) Qualification evidence for individuals in key positions/functions. 712 (g) Equipment list. 713 (h) Facility plan (not applicable to erectors). 714

Executive management shall define additional documented procedures, drawings 715 or other documents that are required beyond the minimum requirements set by 716 this Standard to meet the needs of the organization and its customers. 717

The highest ranking member of executive management shall sign and date the 718

quality manual. 719

720

1.6. CONSTRUCTION DOCUMENT REVIEW AND COMMUNICATION 721

A documented procedure shall be developed for contract and project specification 722

review. The procedures shall require these reviews for each project, and the 723 review shall begin no later than the acceptance of responsibility for performing 724 the work. Records of this review shall be maintained in accordance with the 725

documented procedure as required in Section 1.9. 726 727 728

1.7. DETAILING 729

Section 1.7 does not apply to erectors. 730 731

1.7.1. Detailing Standards 732

The fabricator or manufacturer shall prepare and use detailing standards 733

Commentary: Executive management determines the level of detail in the

quality manual and procedures. At a minimum, these documents should be

detailed enough to adequately describe the quality management system used to

assure the end work meets the required quality.

Commentary: Ideally, the review should begin during the project estimation

or bid process.

The review should identify, plan for and record the specific project

requirements. The documented procedure should provide for review of the

contract documents and referenced standards to ensure awareness of the

contract requirements.

Evidence of contract review may take the form of technical summaries, sign-

offs, schedules, change orders, and allocation of adequate resources, as well as

development of an erection plan and a safety plan as applicable. Such evidence

should indicate consideration of pertinent Sections of this Standard and other

critical project requirements that, if missed, will have a major impact on project

quality.





describing technical preferences and requirements. These standards shall show 734 special information required on advance bills such as allowances for cuts, camber, 735 or supplementary requirements. The detailing standards shall include how bills of 736 material are prepared which, at a minimum, include: 737

(a) Sizes and quantities 738 (b) Appropriate specification references 739 (c) Special ordering information 740 (d) Any allowances or tolerances 741

The detailing standards shall describe the fabricator’s or manufacturer’s methods 742 of drawing layout, including, but not limited to: 743

(a) Sections and views. 744

(b) Title block information. 745 (c) The method of designating shipping sequences. 746 (d) The piece marking system. 747 (e) Commonly used shop abbreviations. 748 (f) Fabricators: Showing bolt placement lists (including bolt type and installation 749

requirements). 750 (g) Fabricators: Information required on weld symbols including any special NDT 751

requirements. 752 (h) Manufacturers: If applicable, illustrate information to be included on weld 753

symbols and the preferred way to designate surface preparation and coating 754 requirements. 755

(i) Fabricators: The detailing standards shall describe the method for: 756

(i) Selection of connection type, connection geometry and connection 757 material. 758

(ii) Detailing holes, fasteners, washers, cuts and copes. 759

(iii) Assignment of appropriate and complete welding symbols (shop and field 760 welds). 761

(iv) Selecting bolt installation method (for shop-installed bolts). 762

(v) Showing surface preparation (including specification of surface finish). 763

(vi) Designating coating requirements (including coating materials and dry 764

film thickness). 765

(vii) Showing any necessary special instructions to fabricate and erect the steel. 766

1.7.1.1 Digital Document Production 767

For digital fabrication, manufacturing, erection, and installation documents, the 768 documented procedure for producing these documents shall identify the data, 769 variables, graphics, calculating formulas, and other output that are checked to 770 determine that the software is functioning correctly. 771

772





1.7.2. Checking 773

The fabricator or manufacturer shall develop a documented procedure to provide 774 for checking of all fabrication and erection documents. shop, installation and 775 erection framing drawings and to describe the method used to release shop 776 drawings for fabrication. The documented procedure for checking of these 777 documents shop and erection framing drawings and installation drawings shall 778 describe the method used by the fabricator , manufacturer or its subcontractor to 779 perform and record the final check of drawings to ensure compliance with 780 contract documents before release. Records shall provide means for identification 781 of the individual checker who performed the final check of each 782 documentdrawing. 783

For computer-generated shop drawings and digital models, the documented 784 procedure shall identify the data, variables, graphics, calculating formulas, and 785

other output that are checked to determine that the software is functioning 786 correctly, and shall include provisions for verifying accuracy of input. 787

When detailing is performed by a subcontractor, the documented procedure shall 788

define the extent of review required by management and the extent of checking 789 required of received documents detailing products before release. 790

The documented procedure for checking shop drawings, digital models, and 791 erection framing drawings fabrication and erection documents shall include 792 comparing those documents and models them to project requirements. that 793 include at a minimum: 794

(a) Geometry 795 (b) Use of the correct connections 796 (c) Proper notes 797 (d) Proper material usage 798

(e) Assignment of complete welding symbols 799 (f) Proper coatings and preparation 800 (g) Proper representation on erection framing drawings, including the notation of 801

any necessary instructions and depiction of details necessary to conduct the 802 work in the field 803

1.7.3. Approval of Approval Documents and Release for Fabrication 804

A documented procedure shall be developed for the approval of approval 805 documents, and shall describe the method used to document owner approval of 806 approval documents released for fabrication, whether produced in-house or 807 through a subcontractor. 808

809

810

Commentary: Such methods may include signatures, stamps, logs, files or

lists.

See the AISC Code of Standard Practice for an elaboration of the process of

approval of approval documents.





1.7.4. Fabrication and/or Installation Documents Shop Drawings Supplied by 811 Others 812

When the fabricator or manufacturer receives fabrication or installation 813 documents shop drawings from others (i.e., the owner or an outside entity), a 814 documented procedure shall define the method of receipt, revision and control of 815 those documentsdrawings. 816

817

818 819

1.7.5. Management of Detailing 820

The fabricator’s or manufacturer’s staff shall manage detailing. Responsibilities 821 for detailing management shall include: 822

(a) Overseeing the production of fabrication, manufacturing, erection, and 823 installation documents shop and erection drawings, including the work of 824 subcontractors 825

(b) Communicating with owners’ representatives for design 826 (c) Scheduling 827 (d) Developing and maintaining company detailing standards and documented 828

detailing procedures 829 (e) Transmittals related to obtaining approval from the owner’s designated 830

representative for design or construction 831 (f) Coordinating and incorporating construction requirements 832 (g) Training of employed detailers and checkers 833

Qualification requirements for detailing management personnel shall include 834 experience in detailing and checking shop and erection framing drawings that 835 have been approved for a variety of structures representative of projects the 836 fabricator or manufacturer provides. 837

The fabricator or manufacturer shall determine and describe methods to 838

demonstrate competence of detailing management personnel. 839

Detailing management shall be familiar with the requirements of pertinent codes 840 and specifications. 841

1.7.6. Detailing Functions 842

Personnel who perform detailing or checking of shop, manufacturing and erection 843 drawings shall have experience in drawing projects similar to the projects the 844 fabricator or manufacturer provides and shall have knowledge of applicable 845 material specifications and of mill rolling practices as they affect the detailing of 846 structural steel. 847

Detailers in training shall work under the supervision of a trained detailer or 848 checker. 849

Commentary: Refer to AISC Code of Standard Practice Section 4.5 for

further elaboration.





A qualified checker shall check all documents drawings before release for 850 fabrication. Qualification requirements for checkers shall be defined and 851 documented and include training and experience in connection selection. 852 Demonstrated competency of employed and subcontracted individuals performing 853

final checks shall be documented by detailing management. 854

855 856

1.7.7. Subcontract Services 857

Subcontractors may be used for the following functions: detailing, connection 858 shop standards, delegated connection design as applicable; checking of shop, 859 manufacturing, and erection drawings; and training of detailers and checkers. The 860 fabricator or manufacturer shall define and document the qualification and 861

selection process for choosing subcontractors. 862 863

1.8. CONTROL OF MANAGEMENT SYSTEM DOCUMENTS 864

AND PROJECT DOCUMENTS 865

1.8.1. Management System Documents 866

A documented procedure shall be developed to control quality management system 867

documents. 868

1.8.1.1. Quality Management System Documents 869

Documents covered by this Section shall include, but not be limited to, the quality 870

manual, the safety manual as applicable, and any documented procedures. 871

1.8.1.2. Review and Approval 872

Documents shall be reviewed and approved by the same function and authority 873 level that authorized the original document. 874

The function and authority levels that have responsibility for review and approval 875 of internal standards and documented procedures shall be designated. Revisions to 876 the quality manual and other quality management system documents shall be 877 reviewed for adequacy and approved by the same function and authority level that 878 authorized the original document. 879

The documented procedure for document and data control shall describe the 880 frequency and requirements for review and updating, and establish a method to 881 identify changes. 882

1.8.1.3. Revision Control 883

Commentary: Detailers and checkers should be assigned on the basis of

qualification, evidenced by experience, training and education.

Qualification standards and certifications granted by recognized industry

organizations, such as the National Institute of Steel Detailing, Inc. (NISD),

can be used as a basis for qualification.





Revisions shall be clearly identifiable and there shall be a method for monitoring 884 and identifying the latest revision. 885

Revisions shall be reviewed for adequacy and approved by the same function and 886 authority level that authorized the original document. 887

Documents shall remain legible and easily identifiable. 888

1.8.1.4. Access 889

Documents shall be available and readily accessible to all personnel responsible 890

for performing functions affecting the quality of the completed work. 891

1.8.1.5. Communication 892

Changes and revisions shall be clearly communicated to all personnel responsible 893 for performing functions affecting the quality of the completed work. 894

1.8.2. Project Documents 895

A documented procedure shall be developed to control project documents. 896 Documents covered by this Section shall include, but are not limited to, contract 897 documents, revised contract documents, RFIs, and fabrication, manufacturing, 898 erection, and installation documentsshop drawings, erection drawings, and RFIs. 899

1.8.2.1. Tracking 900

Contract documents and changes to the contract documents, including, but not 901 limited to, revised contract documents, change orders, and RFIs, shall be tracked. 902

Tracking information shall indicate, at a minimum, date of receipt, summary of 903 issue, and ultimate disposition of the change, including distribution of the final 904 decision to the appropriate parties. 905

The documented procedure shall define methods for receipt and documentation of 906 owner and general contractor requirements and fabricator-originated changes as 907 they occur throughout the fabrication and detailing process. Requirements may be 908 received in original contract documents; in subsequent telecommunications, 909 letters, transmittals related to product requirements; and in change orders or 910 contract addenda. 911

The documented procedure shall require records (e.g., logs, files or master lists) 912 that show receipt of change data, incorporation, issue, and distribution of 913 approved and revised approval documents to all necessary departments and 914 personnel at the fabricator's facility and necessary external organizations, 915

subcontractors or suppliers. 916

1.8.2.2. Revision Control 917

For project documents that the fabricator, erector or manufacturer produces, 918 revisions shall be clearly identifiable and there shall be a method for monitoring 919





and identifying the latest revision. 920

The documented procedure shall include provisions to prevent inadvertent use of 921 obsolete documents. 922

Documents shall remain legible and easily identifiable. 923

924

1.8.2.3. Access 925

Documents shall be available and readily accessible to all personnel responsible 926 for performing functions affecting the quality of the completed work. 927


Changes and revisions shall be clearly communicated to all personnel responsible 929 for performing functions affecting the quality of the completed work. 930

931 1.9. MAINTENANCE OF QUALITY RECORDS 932

A documented procedure shall be developed for the maintenance of quality 933

records that provide for record identification, collection, storage and retrieval, 934 retention, and disposition. 935

936

937

1.9.1. Retention 938

Quality records shall be subject to an established retention policy. The 939 documented procedure for the control of quality records shall contain provisions 940 for the disposition of the records at the end of the retention period. 941

942

Commentary: Quality records commonly include items such as:

(a) Certificates of conformance (b) Corrective action requests (c) Drawing logs (d) Equipment maintenance records (e) Inspection records (f) Internal and external quality management system and safety

management system audits

(g) Mill and consumable purchase orders

(h) MTRs (i) NDT reports (j) Personnel certifications (k) Records or summaries of nonconformance reports (l) Revisions to the contract documents (m) RFIs and related documentation

(n) Subcontractor and supplier evaluations (o) Training records

Commentary: The retention and disposition procedure should consider the

AISC Code of Standard Practice and contract and legal requirements.





943

1.9.2. Storage 944

Quality records shall be stored in a manner that minimizes damage, deterioration 945

or loss. 946

1.9.3. Retrieval 947

Quality records shall be accessible in a reasonable time frame. 948 949

1.10. PURCHASING 950

A documented procedure shall be developed to ensure that subcontractors and 951 suppliers provide contracted services and materials conforming to project 952 requirements. 953

1.10.1. Purchasing Data 954

Purchasing documents shall clearly describe subcontracted work, purchased 955

materials, and services ordered in written purchasing documents. This information 956 shall include, but shall not be limited to: 957

(a) The type of service, material, class, grade, and other unique identification 958 (b) The project specifications, design documentsdrawings, applicable ASTM 959

specifications, process requirements, and inspection instructions and any 960 witness points 961

(c) Delivery instructions and date 962 (d) Required quality reports, certified test reports, and certificates of compliance/ 963

conformance of purchased materials 964

Commentary: It should be noted that ASTM specifications often include 965 ordering information that the purchaser should be aware of when placing an order. 966

1.10.2. Selection of Subcontractors and Suppliers 967

Subcontractors and suppliers shall be evaluated and selected on the basis of their 968 ability to meet subcontract requirements, the management system requirements, 969 the requirements of this Standard, and the requirements of the approved 970 construction documents and referenced standards. 971

A documented procedure shall be developed that describes how the certified 972 company conducts initial and ongoing evaluation of all subcontractors and 973 suppliers. 974

Management shall determine: 975

(a) Evaluation criteria 976 (b) Reevaluation interval 977

(c) Personnel involved in the evaluation process 978

Subcontractors and suppliers shall be evaluated via an audit or documented 979 acceptable past experience. As a minimum, quality of the final products and 980





timely, proper delivery of services or products shall be part of the evaluation. 981

The documented procedure for the selection of subcontractors for fabrication, 982 manufacturing or erection shall include a provision that requires that these entities 983 have current AISC Certification for the type of work that is being subcontracted. 984

The procedure shall also include provisions for obtaining approval to retain a 985 subcontractor who is not certified on a project-specific basis from the owner, 986 owner’s designated representative for design, and the owner’s designated 987 representative for construction, when certification is required in the contract. 988

989

990

991

992

993

1.10.3. Verification of Purchased Product, Materials, and Services 994

The documented procedure for verification shall identify the activities necessary 995 for ensuring that purchased products, materials and services meet project 996 requirements. Purchasing documents, subcontractor and supplier qualification 997 records, and records of the periodic evaluation of subcontractors and suppliers 998 shall be maintained as required by Section 1.9. 999

1.10.4. Control of Customer-Furnished Material 1000

If materials are furnished by the customer, the organization shall verify, store, and 1001

maintain materials in an appropriate fashion. Customer-furnished material shall 1002 be protected to prevent use for other than its intended purpose. Any such product 1003 that is lost, damaged, or otherwise unsuitable for use shall be recorded and 1004 reported to the customer. 1005

1006 1.11. MATERIAL IDENTIFICATION 1007

A documented procedure shall be developed for the identification of material. 1008 Records that provide a basis for material identification shall be maintained as 1009 defined for quality control records. 1010

Structural steel material shall be identified as stated in the AISC Code of Standard 1011 Practice, unless otherwise noted in the contract documents. 1012

Welding consumables shall be identified in accordance with the appropriate AWS 1013 specification. 1014

Coating materials (excluding metallic coating) shall be identified on the container 1015 by, at a minimum, color (pigment description and federal standard number, or 1016

manufacturer’s number), lot/batch number, ID/stock number, quantity of coating 1017

Commentary: This provision of the Standard requires a documented procedure for the selection of subcontractors and suppliers. In general, subcontractors that

are fabricators, component manufacturers, and erectors are required to be certified when subcontracted to a certified entity. However, situations may arise

in which a certified entity is not able to subcontract with another certified entity. In cases such as this, the documented procedure needs to address how the certified entity obtains approval to employ a noncertified subcontractor.





in container, date of manufacture, date of expiration, and manufacturer’s name 1018 and address. 1019

Metallic coatings shall be identified by composition and the appropriate ASTM 1020 specification, including hot dip or mechanical galvanizing and metallizing. 1021

Fasteners shall be stored in containers clearly identified by type, grade, size, and 1022

lot number(s). 1023

Material traceability to corresponding MTRs is necessary only when specifically 1024

required by contract. The fabricator or manufacturer shall develop a documented 1025 procedure to maintain traceability, when required, of materials from the point of 1026

receipt and throughout the course of fabrication. 1027 1028

1029

1.12. PROCESS CONTROLS 1030

Documented procedures shall be developed for the fabrication, manufacturing, 1031 and erection processes necessary to produce a consistent, acceptable level of 1032 quality of the completed work in accordance with applicable codes and project 1033 requirements. 1034

Regardless if these processes are routinely performed, effective implementation of 1035 the following documented procedures is required as a minimum. 1036

1037

1038

1039

1040

1041

1.12.1. Welding 1042

A documented procedure shall be developed for welding. 1043

The documented procedure for welding shall address the development and 1044 management of: 1045

Commentary: MTRs, manufacturer’s test reports, certificates of conformance

for base materials, fasteners, welding consumables, and coatings provide

material identification. In the absence of specific contract requirements, these

records usually constitute sufficient evidence that the product satisfies material

order requirements.

For traceability, the marking method may identify material type and grade or

use a method that provides traceability through piece, assembly or group

numbering.

Commentary: This section requires documented procedure(s) for those

fabrication, manufacturing, and erection processes that affect quality. In

addition to the processes listed in this section, other processes include but

are not limited to: drilling, sawing, reaming, milling, thermal and

mechanical cutting, cambering, straightening, and assembly.





(a) WPSs 1046 (b) Preheat requirements 1047 (c) PQRs 1048 (d) Storage (including ovens), handling, (including ovens) and identification 1049

requirements for welding consumables 1050 (e) Welder, welding operator, and tack welder qualifications and qualification test 1051

records in accordance with appropriate AWS requirements 1052 (f) Welder, welding operator, and tack welder performance records—to provide 1053

objective evidence that the “period of effectiveness” has not been exceeded 1054

and satisfactory performance is consistently achieved 1055 (g) Traceability of welds to the welders who produce them, as applicable 1056

WPSs shall be in close proximity to and used by the welders, welding operators, 1057 or tack welders. 1058

1.12.2. Bolt Installation 1059

A documented procedure shall be developed for bolting. The procedure shall meet 1060 the requirements of the RCSC Specification for Structural Joints Using High- 1061

Strength Bolts and the requirements of approved construction documents and 1062 referenced standards. The documented bolting procedure shall include storage, 1063

pre-installation verification, installation, and inspection of fastener assemblies. 1064

1.12.3. Material Preparation for Application of Coatings 1065

The documented procedure for material preparation shall support achievement of 1066 cleanliness and surface profile required by coating manufacturer 1067 recommendations, product data sheets, and contract documents, as applicable. 1068

1.12.4. Coating Application 1069

The documented procedure for coating application shall support achievement of 1070 proper application and curing of coatings in accordance with manufacturer 1071 recommendations, product data sheets, and contract documents, as applicable. 1072

1.12.5.1.12.3. Equipment Maintenance 1073

The documented procedure for equipment maintenance shall, at a minimum, 1074

define the evaluation of and preventive maintenance for equipment necessary to 1075 meet product or work quality and delivery requirements. 1076

1077 1.13. INSPECTION AND TESTING 1078

A documented procedure shall be developed to ensure that the completed work 1079

meets the requirements of the contract documents. 1080

The procedure shall define receipt, in-process, and final inspection of work 1081 furnished for a project. Work determined during inspection and testing to be 1082 nonconforming shall be addressed following the Nonconformance Procedure 1083 required in Section 1.15. 1084

Comment [MM1]: Sections 1.12.3 and 1.12.4

have been removed here and moved into Chapters 2, 3, 4, and 6.





1085 When inspecting less than 100% of the work, the procedure shall describe the 1086 sampling plans for each type of inspection. The plans will adjust the level and 1087 frequency of inspection at any time the required level of quality is not met. 1088

1089

1.13.1. Assignment of QC Inspections and Monitoring 1090

Qualification requirements for QC inspectors shall be defined and documented as 1091 required in Section 1.5.4. 1092

1093

1094

Production personnel may be assigned to QC inspection duties under the following 1095 conditions: 1096

(a) They are knowledgeable in proper inspection methods and acceptance criteria 1097 specified for the material or products they are inspecting and hold the required 1098 certification as applicable. 1099

(b) They are aware of their responsibilities and are given time to perform them. 1100 (c) They inspect other’s work. 1101 (d) Their inspections are monitored by qualified quality control personnel. 1102

1103

1.13.2. Receipt Inspection 1104 Materials received shall be compared to the purchase order requirements and other 1105 receiving documents. The receiver shall identify the material and quantity and 1106 check for visible shipping damages. The receiver shall inspect shapes and plates for 1107 obvious deviations from the project requirements. 1108

1109

1.13.3. In-Process Inspection 1110

Materials shall be inspected before the work begins. The fabricator, manufacturer, 1111

or erector shall employ in-process inspection plans and practices for specified 1112 process requirements and inspection acceptance criteria that are not verifiable at 1113

final inspection or for which final inspection can hinder subsequent work. In-1114 process inspection is appropriate for processes including, but not limited to, 1115 welding, bolting, coating surface preparation, and coating application, as 1116 applicable. 1117

Compliance with documented process control procedures shall be monitored.1118

1119

1.13.4. Final Inspection 1120

Final inspection shall be conducted. QC inspectors qualified and responsible for 1121

Commentary: QC inspectors should be assigned on the basis of qualification,

evidenced by experience, training and education. Qualification standards and

certifications granted by recognized industry organizations can be used as a

basis for qualification.





final inspection shall perform the final inspection of structural steel products and 1122 metal components prior to delivery in the case of fabrication, or after the 1123 completion of work in the case of erection. 1124

1.13.5. Inspection Records 1125

The inspection procedure shall indicate what records and marks are used to 1126 document inspections. In-process inspections shall be verifiable until the final 1127

inspection of the piece. 1128

Final inspections shall be documented. The quality records produced shall be filed 1129 and retained as defined in the procedure required by Section 1.9. Inspection 1130 records shall clearly show what was inspected, the result of the inspection, and 1131 who performed the inspection. 1132

1133 1.14. CALIBRATION OF INSPECTION, MEASURING, AND 1134

TEST EQUIPMENT 1135

A documented procedure shall be developed to calibrate and maintain inspection, 1136

measuring and testing equipment. The procedure shall define equipment 1137 calibration frequency. However, the volt/amp meters used to verify compliance 1138 with WPS parameters (may be welding machine volt and amp meters or auxiliary 1139 volt/amp meters) shall be calibrated at a minimum every 12 months, unless a 1140 more frequent interval is required. The documented procedure shall include 1141 provisions for: 1142

(a) A unique identifier for each piece of equipment. 1143 (b) An equipment list. 1144 (c) Service use for each piece of equipment, including the required precision for 1145

the types of inspections, measurements or tests made. 1146 (d) Calibration or adjustment instructions in accordance with the manufacturer’s 1147

recommendations. 1148 (e) Frequency of calibration or adjustment. 1149 (f) Tracking calibrations, adjustments and repairs. 1150 (g) Storage and handling of inspection, measuring, and test equipment to maintain 1151

accuracy and fitness for use. 1152 (h) Identification of standards or certified equipment having a known valid 1153

relationship to recognized standards used to calibrate each listed piece of 1154 equipment. Where such standards do not exist, the basis used for calibration 1155 shall be documented. 1156

(i) The action to be taken when equipment does not meet the calibration 1157 requirements. This action includes disposition of the measuring device and an 1158 evaluation of the impact to product that was measured using the device. 1159

(j) Method of preventing inadvertent use of uncalibrated equipment where 1160

calibration is required. 1161

1162 Commentary: Calibration is a process in which an instrument or piece of

equipment’s accuracy is compared with a known and proved standard. When a variation exists, a determination is made to adjust, repair, replace, or accept the

instrument or piece of equipment as is.





1163

1164

1165

Calibration or adjustment history shall be available. 1166

Rented or borrowed equipment must be accompanied by a valid calibration 1167 certificate and is subject to the requirements of this Section. 1168

For equipment that is damaged, dropped, knocked over or functioning improperly, 1169 the documented procedure shall include provisions for prominently marking or 1170 tagging such equipment to preclude usage and removing the equipment from 1171 service until it can be recalibrated, adjusted, or repaired. 1172

Whenever the accuracy of inspection, measuring and test equipment is in question, 1173 proactive calibration shall occur, regardless of manufacturer’s recommendations. 1174

The precision required of any piece of equipment shall be sufficient to satisfy the 1175 acceptance standards of the project specifications or industry standards. 1176

1177

1178 1179 1180 1181 1182 1183 1184 1185 1186 1187 1188 1189 1190

1.15. CONTROL OF NONCONFORMANCES 1191

A documented procedure shall be developed to identify and control 1192 nonconformances. 1193

1.15.1. Nonconformance with Management Systems 1194

A nonconformance related to the performance of the management system shall 1195 be documented to the detail level described by the documented procedure. These 1196

nonconformances may be identified by the management systems during external 1197 audits or by internal audits. 1198

1.15.2. Nonconforming Product and Work 1199

The documented procedure for nonconforming product and work shall provide for 1200 identification, documentation, evaluation, treatment of nonconforming product 1201

Commentary: Calibration or adjustment history records include:

● evidence that the calibration was performed and traceable to a national

or international standard,

● identification of the equipment that was calibrated,

● who performed the calibration,

● the date of the calibration,

● the date the calibration expires or the next calibration is due.

The calibration record should also include evidence of any adjustments that

were performed during the calibration process.





and work, and notification of the relevant functions concerned. Nonconforming 1202 product and work may also be identified in a quality inspection report. These 1203 reports, when received, become quality inspection records. The procedure shall 1204 provide for the disposition of quality inspection records. 1205

Nonconforming product and work shall be clearly marked as soon as practical 1206 after it is discovered. Records shall be kept of the pieces affected, the nature of 1207 the nonconformance, the treatment selection, authorization, and reinspection 1208 results if applicable. 1209

The treatment of nonconforming work may include: 1210

(a) Redesign and rework, as approved by the responsible party, and as required in 1211 the contract documents 1212

(b) Repair, as approved by the responsible party, and as required in the contract 1213

documents 1214 (c) Use as-is, as approved by the responsible party, and as required in the contract 1215

documents 1216 (d) Scrap 1217

If the treatment is rework or repair, the result will be inspected per project 1218 requirements, as well as per the quality control process. 1219

1.16. CORRECTIVE ACTION 1220

A documented procedure shall be developed for corrective action to improve 1221 quality. Any corrective action taken shall be to the degree appropriate to the 1222 magnitude of problems and commensurate with the risks to quality. The 1223 documented procedure shall include periodic review of records or summaries of 1224

nonconformances and of internal and external quality audit reports for 1225 determination and initiation of corrective actions. The corrective action procedure 1226

shall address these steps: 1227

(a) Document a corrective action request (CAR) that includes the 1228

nonconformance to be addressed by the corrective action and the requirement 1229 that has not been met. The corrective action procedure shall define the 1230

functional positions authorized to issue a CAR and initiate the corrective 1231 action process. 1232

(b) Assign responsibility and establish a time frame for the response to a CAR. 1233 (c) Investigate and document the scope of the nonconformance, root causes, 1234

corrective measures taken, and list the actions to be taken to prevent 1235 recurrence. 1236

(d) Communicate the corrective action request and resolution to executive 1237 management and appropriate members of the organization. 1238

(e) Follow up the corrective action taken with periodic monitoring to assure the 1239

corrective action is implemented and is effective. 1240

Corrective action shall be applied when: 1241





(a) There is a nonconformance that is repetitive in nature as identified by 1242 periodically reviewing nonconformance reports or summaries for negative 1243 trends. 1244

(b) Process nonconformances are found during the internal and external quality 1245

audits indicating that the quality management systems may not be 1246 implemented and functioning as stated in the quality manual. 1247

(c) Nonconformance with the quality management system is found during the 1248 day- to-day execution of the system. 1249

(d) Nonconformance is unacceptable as determined by management. 1250 (e) A customer complaint has been investigated and corrective action has been 1251

determined necessary. 1252 1253

1.17. HANDLING, STORAGE, AND DELIVERY OF PRODUCTS 1254

AND MATERIALS 1255

Products and materials shall be stored, loaded and shipped to avoid damage and 1256 deterioration as required by the AISC Code of Standard Practice. Products and 1257 materials shall be protected to prevent use in other than its intended purpose. Any 1258 such material that is lost, damaged, or otherwise unsuitable for use shall be 1259 recorded and reported as appropriate. 1260

1261 1.18. TRAINING 1262

Personnel responsible for functions that affect quality, including, but not limited 1263 to, project managers, field/shop supervisors, detailers, inspectors, welding 1264 personnel, fitters, painters, riggers, signal persons, and crane operators, shall 1265 receive appropriate initial and periodic documented training. Training records 1266 shall be controlled in the same manner as quality records. Personnel providing 1267 training shall have appropriate training or experience in the subject they are 1268 teaching. Training course outlines include the subject and the key points. 1269

1270

1271

1.19. INTERNAL AUDIT 1272

In accordance with a documented procedure, an internal audit of each section of 1273

the quality management system shall be performed at least once a year to evaluate 1274 the compliance and the effectiveness of implementation. Different parts of the 1275

management systems may be audited at different times and different frequencies, 1276 as long as all sections of the management systems are audited annually. 1277

The management representative or a qualified individual, independent of the 1278 function being audited, shall perform the audit and produce a written record of the 1279

audit result from each section. 1280

Internal audit records shall be controlled in the same manner as quality records. 1281

Commentary: Evaluation of trainee comprehension of course material and documentation of successful completion is desirable.





CHAPTER 2 1282

BUILDING FABRICATOR REQUIREMENTS 1283

1284

This chapter addresses building fabricator requirements and applies as required in 1285 Section 1.2. 1286 1287 This chapter is organized as follows: 1288 1289 2.3. References 1290 2.5. Management Responsibility 1291

1292 2.3. REFERENCES 1293

The ability to work to and meet the requirements of the latest edition of the 1294 following documents shall be demonstrated: 1295

(a) ANSI/AISC 360 Specification for Structural Steel Buildings 1296

(b) ASTM F3125 Standard Specification for High Strength Structural Bolts, Steel 1297 and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) 1298 Minimum Tensile Strength 1299

1300 1301

2.5. MANAGEMENT RESPONSIBILITY 1302


2.5.4.1 Buildings, Workspace, Equipment, and Associated Utilities 1304

A fabrication facility shall consist of areas and buildings that provide space for 1305 the routine functions considered to be part of steel fabrication. The work areas and 1306 buildings (including housekeeping, ventilation and clean air supply, and electrical 1307 supply) shall be conducive to achieving consistent quality work. The fabricator 1308 shall have under their control the equipment and software necessary to perform 1309 fabrication and inspection consistent with the contract documents. 1310

Commentary: The fabricator should also have the following references

available as applicable:

(a) ANSI/AISC 341 Seismic Provisions for Structural Steel Buildings (b) ANSI/AISC 358 Prequalified Connections for Special and Intermediate

Steel Moment Frames for Seismic Applications

(c) AWS D1.4/D1.4M Structural Welding Code—Reinforcing Steel (d) AWS D1.8/D1.8M Structural Welding Code—Seismic Supplement (e) SSPC Steel Structures Painting Manual, Volume I, Good Painting Practice (f) SSPC Steel Structures Painting Manual, Volume II, Systems and

Specifications





1311



The documented procedure for material preparation shall support achievement of 1314 cleanliness and surface profile required by coating manufacturer recommendations, 1315 product data sheets, and contract documents, as applicable. 1316



1321





CHAPTER 3 1322

METAL COMPONENT 1323

MANUFACTURER REQUIREMENTS 1324

1325

This chapter addresses metal component manufacturer requirements and applies as 1326 required in Section 1.2. 1327 1328 This chapter is organized as follows: 1329 1330 3.3. References 1331 3.5. Management Responsibility 1332 3.7. Detailing 1333

1334 1335

3.3. REFERENCES 1336


(a) ANSI/AISC 360 Specification for Structural Steel Buildings 1339 (b) AASHTO/ASTM standards applicable to the component manufacturer’s 1340

product and/or contract documents (for verification purposes) 1341 (c) SSPC Steel Structures Painting Manual, Volume I, Good Painting Practice 1342

(d) SSPC Steel Structures Painting Manual, Volume II, Systems and Specifications 1343

1344 1345




A manufacturing facility shall consist of areas and buildings that provide space 1349 for routine functions considered part of component manufacturing. Work areas 1350 and buildings shall be conducive to achieving consistent work quality. The 1351 manufacturer shall have under their control the equipment and software necessary 1352 to perform manufacturing and inspection consistent with the specifications and 1353

standards applicable to the work. 1354



(a) AWS D1.2 Structural Welding Code—Aluminum (b) AWS D1.3 Structural Welding Code—Sheet Steel (c) AASHTO/AWS D1.5M/D1.5 Bridge Welding Code

(d) AWS D1.6 Structural Welding Code—Stainless Steel





1355 3.7 DETAILING 1356

3.7.8. Design Procedure 1357

Where component design is provided by the manufacturer, the design process 1358 shall be defined by a documented procedure. The procedure shall describe steps in 1359

the design development, review and verification phases of the process. The 1360 procedure shall: 1361

(a) Define methods for determining component product requirements from 1362 contract documents, customer and industry input, regulatory and code 1363 requirements, and similar component designs. 1364

(b) Define a design review process to identify and propose solutions for 1365 nonconformances with product requirements. Identify the individuals 1366 responsible and keep records of the design review process. 1367

(c) Define methods to identify, document, evaluate and approve design changes 1368

before implementation. Keep records of all documents. 1369 (d) Describe a means for validating the function of the resulting component with 1370

respect to intended uses and identified component requirements. Identify 1371 individuals responsible and keep records of the validation process. 1372

3.7.9. Design for Standard Components 1373

For products that are standard components not specific to any one project, the 1374

manufacturer shall have on file and available to the customer a set of design 1375 calculations reviewed and prepared and sealed by a registered design professional 1376 to signify that the designed product meets the current applicable code 1377 requirements for its intended use. Any design tables or design processes published 1378

with the product literature shall also be reviewed and stamped by a registered 1379 design professional. Manufacturing documentsShop drawings for these 1380

components shall include a statement that the component details are based on 1381 designs that have been reviewed and stamped by a registered design professional 1382 and are on file with the manufacturer. 1383

3.7.10 Design for Nonstandard Components 1384

For products that are job specific, the manufacturer shall retain the services of a 1385 registered professional to prepare and seal the site-specific design of the 1386

component. The registered professional shall also review the manufacturing 1387 documents shop drawings produced for the component and verify their 1388 consistency with the design. The results of this review shall be indicated on the 1389 component manufacturing documents shop drawings. 1390



The documented procedure for material preparation shall support achievement of 1393





cleanliness and surface profile required by coating manufacturer recommendations, 1394 product data sheets, and contract documents, as applicable. 1395



1400

1401





CHAPTER 4 1402

BRIDGE FABRICATOR REQUIREMENTS 1403

1404

This chapter addresses bridge fabricator requirements and applies as required in Section 1405 1.2. 1406 1407 This chapter is organized as follows: 1408

4.2. Scope 1409 4.3. References 1410 4.5. Management Responsibility 1411 4.7. Detailing 1412 4.11. Material Identification 1413 4.12. Process Controls 1414 1415

1416 4.2 SCOPE 1417

This Standard establishes three categories of bridges: simple, intermediate and 1418 advanced. Fabricators producing intermediate bridges, advanced bridges, or 1419 fracture-critical members shall be required to meet supplemental requirements in 1420 Chapters 4.I, 4.A and 4.F, as applicable. 1421

Bridge Category Descriptions: 1422

Simple bridges consist of unspliced rolled sections. 1423

Intermediate bridges are those that require a high level of fabrication expertise, 1424 including, but not limited to, techniques for geometric control, bending, 1425 curving, welding, and handling. 1426

1427

1428 Advanced bridges are more complex bridge structures than simple or intermediate bridges, 1429 and they require a higher level of fabrication expertise. 1430

Commentary: Common examples of intermediate bridges include:

(a) A rolled beam bridge with field or shop splices, either straight or with a

radius over 500 ft

(b) A built-up I-shaped plate girder bridge with constant web depth (except

for dapped ends), with or without splices, either straight or with a radius

over 500 ft

(c) A built-up I-shaped plate girder with variable web depth (e.g., haunched),

either straight or with a radius over 1,000 ft

(d) A truss with a length of 200 ft or less that is entirely or substantially

preassembled at the certified facility and shipped in no more than three

subassemblies





1431

4.3 REFERENCES 1432


(a) AASHTO/AWS D1.5M/D1.5—Bridge Welding Code 1435 (b) ASTM F3125 Standard Specification for High Strength Structural Bolts, Steel 1436

and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) 1437 Minimum Tensile Strength 1438

1439 1440

4.5 MANAGEMENT RESPONSIBILITY 1441


4.5.4.1. Personnel 1443

In addition to the requirements in Section 1.5.4, the following additional 1444 qualification requirements shall apply: 1445

(a) For production and QA management functions, at least five years steel 1446 fabrication experience or training 1447

(b) For QC and purchasing management functions and for detailing checkers, at 1448 least three years steel fabrication experience or training 1449

The fabricator shall have the following personnel on staff or available under 1450 contract, that are certified in accordance with the fabricator’s NDT program: 1451

(a) At least one Certified Level III NDT administrator for each NDT method 1452 performed in the shop 1453

(b) At least one Certified Level II technician for each NDT method performed in 1454

Commentary: Common examples of advanced bridges include:

(a) Tub or trapezoidal box girders (b) Closed box girders (c) Large or non-preassembled trusses (d) Arches (e) Bascule bridges

(f) Cable-supported bridges (g) Moveable bridges (h) Bridges with a particularly tight curve radius



(a) AASHTO/NSBA S4.1 Steel Bridge Fabrication QC/QA Guide Specification

(b) Chapter 15 of the AREMA Manual for Railway Engineering





the shop 1455

1456 1457

The fabricator shall have documented procedures for certifying and updating NDT 1458 personnel employed by the fabricator. Alternately, the fabricator’s documented 1459 procedures shall describe how they review the methods and/or written practice of 1460 contractors as suitable to subcontract to their organization. 1461

The fabricator shall have enough AWS Certified Welding Inspectors (or other 1462 personnel as permitted by AWS D1.5, “Inspection Personnel Qualification”) to 1463 monitor all shifts on which welding is performed. 1464

The fabricator shall have a competent welding technician on staff. The welding 1465 technician shall have extensive knowledge and experience with or education in 1466

welding processes, procedures, and equipment and with the development, 1467 preparation, qualification and execution of welding procedure specifications. 1468


A fabrication facility shall consist of areas and buildings that provide space for 1470 the routine functions considered to be part of steel fabrication. The work areas and 1471 buildings (including housekeeping, ventilation and clean air supply, and electrical 1472 supply) shall be conducive to achieving consistent quality work. The fabricator 1473 shall have under their control the equipment and software necessary to perform 1474 fabrication or manufacturing and inspection consistent with the contract 1475 documents. 1476

1477 4.7. DETAILING 1478

4.7.8. Preparation of Fabrication and Erection DocumentsShop Drawings and 1479 Erection Drawings 1480

Any fabrication and erection documents shop drawings, digital models, erection 1481 framing drawings, and manufacturing drawings shall incorporate all contract 1482

requirements, specifications, codes, and relevant standards to adequately procure 1483 materials, and , fabricate and erect the structure. or manufacture the component, 1484 and erect the structure or install the component. To ensure this, a documented 1485 procedure for preparation of these documents shop drawings, erection framing 1486 drawings, or manufacturing drawings shall be developed, which describes: 1487

(a) How project requirements are reviewed and incorporated 1488

(b) How the fabricator coordinates, proposes changes, and tracks information with 1489 the general contractor or owner (e.g., change orders and RFIs), and how the 1490 associated resolutions are tracked and controlled 1491 1492

4.11. MATERIAL IDENTIFICATION 1493

Commentary: ASNT Recommended Practice No. SNT-TC-1A provides

guidelines for employers to establish in-house certification programs for the

qualification and certification of nondestructive testing personnel.





4.11.1. Traceability 1494

The fabricator’s documented procedures for identification of material and for 1495 material traceability shall include provisions for maintaining heat and MTR 1496 identity material throughout the fabrication process. 1497

1498 4.12 PROCESS CONTROLS 1499

4.12.2 Bolt Installation 1500 1501

The documented procedure for bolting shall meet the S4 supplementary 1502 requirement for rotational capacity testing as required by ASTM F3125/F3125M. 1503


The documented procedure for material preparation shall support achievement of 1505

cleanliness and surface profile required by coating manufacturer recommendations, 1506 product data sheets, and contract documents, as applicable. 1507


The documented procedure for coating application shall support achievement of 1509

proper application and curing of coatings in accordance with manufacturer 1510 recommendations, product data sheets, and contract documents, as applicable. 1511

1512





CHAPTER 4.I 1513

SUPPLEMENTAL REQUIREMENTS FOR 1514

FABRICATORS OF INTERMEDIATE BRIDGES 1515

1516

This chapter addresses supplemental requirements for fabricators of intermediate 1517 bridges and applies as required in Section 4.2. 1518 1519 This chapter is organized as follows: 1520 1521 4.I.2. Scope 1522 4.I.5. Management Responsibility 1523

4.I.7. Detailing 1524 4.I.12. Process Controls 1525 1526

4.I.2 SCOPE 1527

Eligible fabricators shall have either: 1528

(a) Supplied plate girder spans with field splices for highway or railroad bridges 1529 within the last five years, or 1530

(b) Established a documented training program for the purpose of communicating 1531 intermediate bridge work functions to the work forces, and demonstrated 1532 capability to fabricate intermediate bridges. Training shall include detailing, 1533 purchasing, and project management functions. 1534

1535

1536

4.I.5. MANAGEMENT RESPONSIBILITY 1537

4.I.5.4. Resource Management 1538

4.I.5.4.1 Buildings, Workspace, Equipment, and Associated Utilities 1539

Equipment shall include automatic, mechanized or semiautomatic welding 1540

equipment. 1541

4.I.7. DETAILING 1542

4.I.7.1. Detailing Standards 1543

The detailing standards shall define the fabricator’s method for presenting 1544

information on shop assembly (blocking) drawings. 1545

4.I.7.6. Detailing Functions 1546

Detailing personnel shall have an understanding of bridge geometry, including, 1547

Commentary: Users of this Standard are encouraged to evaluate fabricator capability

on a project-specific basis.





but not limited to, vertical and horizontal alignment, cross-slope, and roadway 1548 transitions. 1549

4.I.12. PROCESS CONTROLS 1550

4.I.12.6. Laydown/Assembly 1551

The fabricator’s documented procedure for shop assembly of field connections 1552 shall include, at a minimum, the following items: 1553

(a) Provisions for control of assembled dimensions for both vertical and 1554

horizontal geometry 1555 (b) Provisions for control of accuracy of drilling and reaming of field connections 1556

(c) Documented procedures, including reference drawings, for match-marking 1557 shop-assembled pieces 1558

(d) Provisions for assuring the accuracy of numerically controlled equipment, if 1559 contract documents permit the use of such equipment in lieu of physical 1560 assembly 1561

1562

1563





CHAPTER 4.A 1564


FABRICATORS OF ADVANCED BRIDGES 1566

1567

This chapter addresses supplemental requirements for fabricators of advanced bridges 1568 and applies as required in Section 4.2. 1569 1570 This chapter is organized as follows: 1571 1572 4.A.2. Scope 1573

4.A.6. Construction Document Review and Communication 1574 4.A.12. Process Controls 1575 1576

4.A.2 SCOPE 1577


(a) Supplied advanced bridges for highway or railroad applications within the last 1579 five years, or 1580

(b) Supplied intermediate bridges for highway or railroad use, established a 1581

documented training program for the purpose of communicating advanced 1582 bridge work functions to the work forces, and demonstrated capability to 1583

fabricate advanced bridges. 1584

Fabricators of advanced bridges shall also meet the supplemental requirements of Sections 1585

4.I.5, 4.I.7 and 4.I.12. 1586 1587

1588

4.A.6 CONSTRUCTION DOCUMENT REVIEW AND COMMUNICATION 1589

The fabricator’s documented procedure shall include a process for communicating 1590 with individuals in the fabricator’s organization, the general contractor, and the 1591 owner regarding special fabrication-related requirements for advanced bridges, 1592 including: 1593

(a) Shop assemblies 1594 (b) Dimensional control and verification 1595 (c) Welding 1596 (d) NDT 1597 (e) High-performance materials 1598 (f) Erection considerations 1599 (g) Other atypical or special job requirements 1600

Commentary: Users of this Standard are encouraged to evaluate fabricator capability

on a project-specific basis.





Decisions made in the process of these communications shall be recorded, 1601 approved by the appropriate parties (if applicable), and the record shall be 1602 distributed to the appropriate parties. This distribution shall be controlled in 1603 accordance with Sections 1.6 and 1.8. 1604

1605

Commentary: High-performance materials are designated with an HPS such 1606

as A709 HPS 50W, A709 HPS 70W, and A709 HPS 100W. High-1607

performance materials may also be contract specific materials not addressed 1608

by AWS D1 welding codes. 1609

1610

4.A.12. PROCESS CONTROLS 1611

4.A.12.1. Welding 1612

The fabricator’s documented procedure for welding shall include a distortion 1613 control program. 1614

1615





CHAPTER 4.F 1616


FABRICATORS OF FRACTURE-CRITICAL MEMBERS 1618

1619

This chapter addresses supplemental requirements for fabricators of fracture-critical 1620 members and applies as required in Section 4.2. 1621 1622 This chapter is organized as follows: 1623 1624 4.F.2. Scope 1625 4.F.5. Management responsibility 1626 4.F.7 Detailing 1627 4.F.10 Purchasing 1628 4.F.11. Material Identification 1629 4.F.12. Process Controls 1630 4.F.13. Inspection and Testing 1631 4.F.15. Control of Nonconformances 1632 1633

4.F.2. SCOPE 1634


(a) Supplied fracture-critical members in accordance with AWS D1.5 within the 1636 last five years, or 1637

(b) Established a documented training program for the purpose of communicating 1638 fracture-critical work functions to the work forces, and demonstrated 1639 capability to fabricate fracture-critical members. 1640

4.F.5. MANAGEMENT RESPONSIBILITY 1641

4.F.5.7. Quality Manual 1642

The quality manual shall include or reference a written fracture control plan 1643

meeting the requirements of AWS D1.5. 1644

4.F.7. DETAILING 1645

4.F.7.1. Detailing Standards 1646

The detailing standards for preparation of bills of material shall include whether 1647

the material is to be used for fracture-critical applications. 1648

The detailing standards for the fabricator’s fabricationshop and erection 1649 documentsframing drawings shall define the manner of identifying fracture-1650 critical welds. 1651

4.F.10. PURCHASING 1652





4.F.10.1. Purchasing Data 1653

The fabricator’s written purchasing documents shall identify material to be used 1654

for fracture-critical applications. 1655

4.F.11. MATERIAL IDENTIFICATION 1656 The fabricator’s documented procedures for identification of material and for 1657 material traceability shall include provisions for maintaining heat and MTR identity 1658 of fracture-critical material throughout the fabrication process. The procedure shall 1659 address how fracture-critical material is identified at receipt and throughout 1660 fabrication by unique mill piece or plate number. Further, the procedure shall also 1661 address how consumables purchased for fracture-critical welding are identified. 1662

4.F.12. PROCESS CONTROLS 1663

4.F.12.1. Welding 1664

The fabricator’s documented procedure for welding shall include: 1665

(a) PQRs for fracture-critical WPSs 1666 (b) Fracture-critical provisions for welding procedure qualification, preheat, and 1667

storage of consumables 1668

4.F.13. INSPECTION AND TESTING 1669

The fabricator’s documented procedure shall include provisions for inspection of 1670

fracture-critical welds. 1671

4.F.15. CONTROL OF NONCONFORMANCES 1672

4.F.15.2. Nonconforming Product 1673

The fabricator’s documented procedure shall include provisions for critical and 1674

noncritical repairs of fracture-critical welds in accordance with AWS D1.5. 1675 1676

1677





CHAPTER 5 1678

ERECTOR REQUIREMENTS 1679

1680

This chapter addresses erector requirements and applies as required in Section 1.2. 1681 1682 This chapter is organized as follows: 1683 1684 5.3. References 1685 5.5. Management Responsibility 1686 5.8. Control of Management System Documents and Project Documents 1687 5.10. Purchasing 1688 5.16. Corrective Action 1689 5.18. Training 1690 5.19. Internal Audit 1691 5.20. Erection Plan 1692 5.21. Safety Plan 1693 5.22. Other Project-Specific Requirements 1694

1695 1696



(a) ANSI/AISC 360 Specification for Structural Steel Buildings 1700 (b) ASTM F3125 Standard Specification for High Strength Structural Bolts, Steel 1701

and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) 1702 Minimum Tensile Strength 1703

5.3.1. Seismic Erection Endorsement 1704

For the erection of structures requiring the use of ANSI/AISC 341 Seismic 1705

Provisions for Structural Steel Buildings, the erector shall have available and 1706 demonstrate the ability to work to and meet the requirements of: 1707

(a) ANSI/AISC 341 Seismic Provisions for Structural Steel Buildings 1708 (b) AWS D1.8/D1.8M Structural Welding Code—Seismic Supplement 1709

5.3.2. Metal Deck Installation Endorsement 1710

When the erector’s work includes the installation of metal deck, the erector shall 1711

have available and demonstrate the ability to work to and meet the requirements 1712 of ANSI/SDI QA/QC Standard for Quality Control and Quality Assurance for 1713 Installation of Steel Deck. Instructions for metal deck installation shall be 1714 provided in the erection plan and the safety plan. 1715

(a) AWS D1.3/D1.3M Structural Welding Code—Sheet Steel 1716





5.3.3. Bridge Erection Endorsement 1717

For the erection of bridges, the erector shall have available and demonstrate the 1718

ability to work to and meet the requirements of: 1719

(a) AASHTO/AWS D1.5M/D1.5 Structural Welding Code—Bridge Welding Code 1720

1721

5.3.4. Safety 1722

The erector shall provide access to OSHA Part 1926 Safety and Health 1723 Regulations for Construction, or the appropriate state equivalent, to employees 1724 and others who require access to this information to perform their scope of work. 1725

1726 5.5. MANAGEMENT RESPONSIBILITY 1727

5.5.2. Periodic Management Review 1728

Executive management shall conduct periodic review of the safety management 1729 system at planned intervals, but annually at a minimum. The management review 1730 shall encompass the following, at a minimum: 1731

(a) A brief summary of applicable previous management reviews. 1732 (b) Results of any internal and external audits conducted since the previous 1733

management review. 1734 (c) An assessment of customer feedback and feedback mechanisms, identifying 1735

opportunities for improving safety. 1736 (d) An assessment of product nonconformances. Both the number and the severity 1737

of product nonconformances shall be assessed. 1738 (e) An assessment of process nonconformances, including compliance with the 1739

documented procedures comprising the safety management system. 1740 (f) An assessment of the results of equipment inspections, including the adequacy 1741

of equipment resources. 1742 (g) An assessment of the adequacy of the training program with respect to the 1743

levels of qualification required, as appropriate. 1744 (h) An assessment of any proposed or required modifications to the safety 1745


Records from management reviews shall be maintained according to the record 1747

retention policy. 1748


5.5.4.3. Erection Tools and Equipment 1750

The erector shall have under their control the tools and equipment necessary to 1751

Commentary: The erector should also have the AASHTO/NSBA S10.1 Steel

Bridge Erection Guide Specification available as applicable.





perform the work, and the tools and equipment shall be maintained at the level 1752 necessary to produce the required quality. 1753

5.5.8. Safety Manual 1754

The highest ranking member of executive management shall sign and date the 1755

safety manual. The safety manual shall contain the following information at a 1756 minimum: 1757

(a) Safety policy statement 1758

(b) Identification of the individual responsible for the safety management system 1759 (c) Safety and health inspections 1760 (d) Incident investigation 1761

(e) Hazard prevention and control 1762

(f) Safety and health training 1763 (g) Personal protective equipment 1764 (h) Hazard communication 1765 (i) Lockout/tagout procedure 1766 (j) Respiratory protection 1767 (k) Fall protection 1768

5.5.9. Policy for Safety 1769

Executive management shall be responsible for training employees on the policy 1770

for safety as well as for implementation and ongoing maintenance. The policy for 1771 safety shall include: 1772

(a) A commitment to safety that includes, at a minimum, a commitment to meet 1773 federal and/or state requirements for construction safety 1774

(b) A safety management system that provides a framework for establishing, 1775 communication and reviewing safety goals 1776

(c) A commitment to safety training 1777

Executive management shall establish safety goals. Goals shall be measurable and 1778 documented through objective evidence. As safety goals are achieved, new goals 1779 shall be set that demonstrate commitment to continuous improvement. 1780

1781

5.5.10. Responsible Safety Personnel 1782

Executive management shall designate a management representative for safety 1783 who shall report directly to (or be a part of) executive management. The 1784

designated management representative for safety may perform other functions 1785 within the company, provided that those functions do not conflict with the safety 1786 responsibilities. The designated management representative(s) shall have the 1787 ability, responsibility, and authority to: 1788

Commentary: New safety goals can be a new level of achievement of a

previous goal or a new goal that has not been previously identified.





(a) Ensure that documented procedures needed for the safety management systems 1789 are established, implemented, and maintained in accordance with this Standard. 1790

(b) Report to executive management on the performance of the safety 1791 management system and any need for improvement. 1792

(c) Communicate with external parties on matters relating to the safety 1793 management system. 1794

5.8. CONTROL OF MANAGEMENT SYSTEM DOCUMENTS AND 1795

PROJECT DOCUMENTS 1796

5.8.1. Management System Documents 1797

5.8.1.4. Access 1798

The safety management system documents shall be available and readily 1799 accessible to all personnel affected by the safety management system. 1800


Changes and revisions to the safety management system documents shall be 1802

clearly communicated to all personnel affected by the safety management system. 1803

5.8.2. Project Documents 1804

5.8.2.1. Tracking 1805

A transmittal system shall be established to record the distribution of project 1806 information to steel erection personnel, subcontractors, and suppliers. 1807

Transmittals shall indicate the status of approval and release for erection. 1808

5.8.2.3. Access 1809

The safety plan shall be available and readily accessible to all personnel affected 1810 by the safety management system. 1811

1812 5.10. PURCHASING 1813

The information included in purchasing documents shall include safety data sheets. 1814 1815

5.16. CORRECTIVE ACTION 1816

Any corrective action taken shall be to the degree appropriate to the magnitude of 1817

problems and commensurate with the risks to erection safety. The documented 1818 procedure shall include periodic review of records or summaries of 1819 nonconformances and of internal and external safety audit reports for 1820

determination and initiation of corrective actions. 1821

Corrective action shall be applied when: 1822

(a) Process nonconformances are found during the internal and external safety 1823 audits indicating that the safety management system may not be implemented 1824 and functioning as stated in the safety manual. 1825





(b) Nonconformance with the safety management system is found during the day- 1826 to-day execution of the system. 1827

1828 5.18. TRAINING 1829

The requirements in Section 1.18 shall additionally apply to personnel responsible 1830

for functions that affect safety. 1831

Safety training shall include weekly safety training talks and an initial safety 1832 orientation for each employee. 1833

Safety training shall include the requirements of OSHA 1926, as applicable. 1834 1835 1836 1837 1838 1839 1840 1841 1842 1843 1844 1845 1846 1847 1848 1849 1850 1851 1852 1853 1854 1855 1856 1857 1858 1859 1860 1861 1862 1863 1864 1865 1866 1867 1868 1869 1870 1871

Commentary: The safety plan described in Section 5.21 is an integral

component of safety training.

OSHA provides minimum requirements for training in the following Subparts:

(a) General Safety and Health Provisions (OSHA Subpart C) (b) Occupational Health and Environmental Controls (OSHA Subpart D) (c) Hazard Communication (d) Personal Protective and Life-Saving Equipment (OSHA Subpart E)

(e) Respiratory protection (f) Fire Protection and Prevention (OSHA Subpart F) (g) Signs, Signals and Barricades (OSHA Subpart G) (h) Tools—Hand and Power (OSHA Subpart I) (i) Welding and Cutting (OSHA Subpart J) (j) Electrical (OSHA Subpart K) (k) Scaffolding (OSHA Subpart L) (l) Fall Protection (OSHA Subpart M) (m) Motor Vehicles, Mechanized Equipment and Marine Operations

(OSHA Subpart O) (n) Steel erection (OSHA Subpart R)

(o) Connector training (p) Multiple Lift Rigging Training (q) Stairways and Ladders (OSHA Subpart X) (r) Toxic and Hazardous Substances (OSHA Subpart Z) (s) Cranes and Derricks in Construction (OSHA Subpart CC) (t) Aerial lift Training (u) Qualified Rigger Training (v) Qualified Signal Person Training (w) Certified Crane Operator Training

It is the responsibility of the erector to maintain current editions of all

reference documents and regulations incorporated into this Standard, as

well as any replacement or additional references that become relevant

subsequent to the initial publication of this Standard.





1872 1873

5.19. INTERNAL AUDIT 1874

The requirements in Section 1.19 shall additionally apply to the safety 1875 management system. 1876

1877

5.20. ERECTION PLAN 1878

The erector shall prepare an erection plan for every project. The erection plan, in 1879 whole or in part, may be described graphically or in text. The erection plan shall 1880 include the following information as appropriate for the project: 1881

(a) Project name and location. 1882 (b) Indication of access for material delivery and equipment delivery, including 1883

lay-down, shake-out, and field-assembly areas. 1884 (c) Sequence of erection. 1885 (d) Dimensions and locations of cranes or other lifting equipment. 1886 (e) Required site conditions for the crane location and confirmation of adequate 1887

base support for the crane. 1888 (f) Sizes, model names or numbers, and capacity charts for lifting equipment. 1889

(g) Information regarding the heaviest lift and its radius; the longest radius and 1890 its lift weight; and the boom configuration for each at every location of the 1891

lifting equipment. 1892 (h) Indicate critical lifts, if any, and include the critical lift protocol or procedure. 1893

(i) Requirements for multi-lift rigging. 1894 (j) Types of slings to be used and, if more than one type, the locations in which 1895

they will be used. 1896 (k) Rigging information for atypical lifts (weight, geometry, center of gravity, 1897

etc.) such as slings and hardware, rated lifting beams, beam clamps 1898 (including catalog cuts), as applicable to the lift. 1899

(l) Designation of crane paths from position to position, indicating load travel 1900

paths, swing restrictions, and personnel exclusion zones. 1901 (m) Designation of space required for field assembly prior to erection. 1902

(n) Identification of special fastening sequences and/or methods. 1903 (o) Identification of special or atypical connections. 1904

(p) Traffic control notes. 1905 (q) Identification of specification requirements for erection, such as plumbing 1906

tolerances smaller than those stipulated in the AISC Code of Standard 1907 Practice. 1908

(r) The stability of the structure and individual members during erection shall be 1909 checked in accordance with AISC Code of Standard Practice Section 7.10.3. 1910

(s) Falsework requirements and corresponding design calculations. 1911 (t) Jacking layout and jacking procedure. 1912 (u) Notation of special problems due to overhead restrictions, underground 1913

utilities, barriers to crane tail swing, etc. 1914





The erection plan shall be reviewed before the start of erection by the erector’s 1915 project management team and be available to all employees assigned to the 1916 project. All revisions shall be approved by the site superintendent and 1917 communicated to affected personnel at the time of the revision. 1918

1919 5.21. SAFETY PLAN 1920

The erector shall prepare a safety plan for every project. 1921

A safety plan shall consider known or reasonably anticipated hazards relating to 1922

the project site and construction activities. The safety plan shall include a pre-task 1923 analysis for each steel erection activity that occurs on the project site, a list of all 1924 hazardous materials in the control of the erector at the project site, an emergency 1925

evacuation plan, and requirements for regularly scheduled safety inspections. 1926

The safety plan shall include the following information as appropriate for the 1927 project: 1928

(a) Project name and location 1929 (b) The erector’s emergency contacts on site and off site 1930 (c) Medical services available on site, contact information for emergency 1931

services, and emergency evacuation procedures 1932 (d) Fall protection requirements that differ from those in the safety manual 1933 (e) Required personal protective equipment 1934 (f) Protection for openings and perimeters 1935 (g) Special procedures required, such as, but not limited to, lockout/tagout, 1936

confined space training, and lead exposure mitigation 1937 (h) Special training required 1938 (i) Requirements for work attire 1939 (j) Information as provided to the erector regarding other hazardous materials 1940

onsite 1941

The safety plan shall be reviewed before the start of erection by the erector’s 1942 project management team and be available to all employees assigned to the 1943

project. All revisions shall be approved by the individual responsible for the 1944 safety management system and communicated to affected personnel at the time of 1945 the revision. 1946

1947

1948

5.22. OTHER PROJECT-SPECIFIC REQUIREMENTS 1949

In accordance with OSHA Subpart R, the AISC Code of Standard Practice, and 1950

the contract documents, prior to the start of erection, the erector shall have 1951 documentation or other evidence that required site conditions have been met. 1952

Commentary: The safety plan is an integral component of the safety training described in Section 5.18.





In accordance with the AISC Code of Standard Practice and contract documents, 1953 the erector shall have documentation or other evidence that the required 1954 information in AISC Code of Standard Practice Section 7.10 has been provided. 1955

1956

Commentary: The specific requirements are found in OSHA Subpart R

1926.752 a, b and c; OSHA 1926.755 b; and the AISC Code of Standard

Practice Sections 7.2 and 7.3.





CHAPTER 6 1957

HYDRAULIC METAL STRUCTURES 1958

FABRICATOR REQUIREMENTS 1959

This chapter addresses hydraulic metal structures fabricator requirements and applies as 1960

required in Section 1.2. 1961

This chapter is organized as follows: 1962

6.2 Scope 1963 6.3 References 1964 6.5 Management Responsibility 1965 6.6 Construction Document Review and Communication 1966 6.7 Detailing 1967 6.12 Process Controls 1968

1969 6.2. SCOPE 1970

This Standard establishes two categories of hydraulic metal structures: 1971

standard and advanced. 1972

Fabricators producing standard hydraulic metal structures shall be required to 1973

meet the requirements in Chapter 6 and may be required to meet supplemental 1974

requirements in Chapter 6.F. 1975

Fabricators producing advanced hydraulic metal structures shall be required 1976

to meet the requirements in Chapter 6 and the supplemental requirements in 1977

Chapters 6.A. and 6.F. 1978

Hydraulic Metal Structure category descriptions: 1979

Standard hydraulic metal structures are those that do not require 1980 sophisticated measures such as specialized equipment and techniques for 1981 geometric control, machining, welding and handling. 1982

Commentary: Common examples of standard hydraulic metal structures 1983 may include: 1984 (a) sluice gates 1985 (b) knife gates 1986 (c) spillway gates 1987 (d) bulkheads and stop logs 1988 (e) needle beams 1989 (f) lock culvert valves 1990

1991

Advanced hydraulic metal structures are those requiring sophisticated 1992

measures in fabrication and erection, particularly with regard to size, 1993





curvature, plate thickness, distortion, machining, fabrication access, 1994

geometric tolerances, and constraint conditions. 1995

Commentary: Common examples of advanced hydraulic metal structures 1996 include: 1997

(a) miter gates 1998

(b) vertical lift gates 1999

(c) roller gates 2000

(d) hoisting gates 2001 (g) bonneted gates 2002 (h) sector gates 2003 (i) submersible Tainter gates 2004

2005


The ability to work to and meet the requirements of the latest edition of the 2007

following documents shall be demonstrated: 2008

(a) ANSI/ASNT CP-189 Standard for Qualification and Certification of 2009 Nondestructive Testing Personnel, or 2010

(b) ASNT-TC-1A Recommended Practice No. SNT-TC-1A Personnel 2011 Qualification and Certification in Nondestructive Testing 2012

(c) ASTM F3125 Standard Specification for High Strength Structural Bolts, 2013 Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 2014 MPa) Minimum Tensile Strength 2015

2016

Commentary: The fabricator should also have the following references 2017

available as applicable: 2018

UFGS 05 59 20 Fabrication of Hydraulic Steel Structures 2019

AWS D1.2/D1.2M Structural Welding Code—Aluminum 2020

AWS D1.3/D1.3M Structural Welding Code—Sheet Steel 2021

AASHTO/AWS D1.5 Bridge Welding Code 2022

AWS D1.6 Structural Welding Code—Stainless Steel 2023

2024



6.5.4.1. Personnel 2027

The following qualification requirements shall apply: 2028

(a) For production and QA management functions, at least five years 2029

fabrication experience or training 2030





(b) For QC and purchasing management functions and for detailing checkers, 2031

at least three years fabrication experience or training 2032

The fabricator shall have the following personnel on staff or available under 2033

contract that are certified in accordance with the fabricator’s NDT program: 2034

(c) At least one Certified NDT Level III for each NDT method performed in 2035

the shop 2036

(d) At least one Certified NDT Level II for each NDT method performed in the 2037 shop. 2038 2039

The fabricator shall have documented procedures for certifying and updating 2040 NDT personnel employed by the fabricator. Alternately, the fabricator’s 2041 documented procedures shall describe how they review the methods and/or 2042 written practice of contractors as suitable to subcontract to their organization. 2043

2044

Commentary: ASNT Recommended Practice No. SNT-TC-1A provides 2045 guidelines for employers to establish in-house certification programs for the 2046 qualification and certification of nondestructive testing personnel. 2047 2048

The fabricator shall have an individual on staff that has knowledge and 2049

experience with: 2050

(a) welding processes, procedures, welding equipment, welder performance 2051

qualifications, and 2052

(b) development, preparation, qualification, and execution of welding 2053

procedure specifications. 2054

In addition, the fabricator shall have AWS Certified Welding Inspectors (or 2055

other personnel as permitted by AWS D1.1, “Inspection Personnel 2056

Qualification”) available to monitor all shifts on which welding is performed. 2057

6.5.4.2. Buildings, Workspace, Equipment, and Associated Utilities 2058

A fabrication facility shall consist of areas and buildings that provide 2059

adequate space for the routine functions considered to be part of hydraulic 2060

metal structure fabrication. The work areas and buildings (including 2061

housekeeping, ventilation and clean air supply, and electrical supply) shall be 2062

conducive to achieving consistent quality work. The fabricator shall have 2063

under their control the equipment and software necessary to perform 2064

fabrication and inspection consistent with the contract documents. 2065

Equipment shall include automatic, mechanized, or semiautomatic welding 2066

equipment. 2067

6.6 CONSTRUCTION DOCUMENT REVIEW AND COMMUNICATION 2068





The fabricator’s documented procedure shall include a process for 2069

communicating with individuals in the fabricator’s organization, the general 2070

contractor, and the owner regarding special fabrication-related requirements 2071

for hydraulic metal structures, including: 2072

(a) Shop assemblies 2073

(b) Dimensional control and verification 2074

(c) Welding 2075

(d) NDT 2076

(e) High-performance materials 2077

(f) Erection and installation considerations 2078

(g) Other atypical or special job requirements 2079

Decisions made in the process of these communications shall be approved by 2080

and distributed to the appropriate parties. This distribution shall be controlled 2081

in accordance with Sections 1.6 and 1.8. 2082

Commentary: High-performance materials are designated with an HPS such 2083

as A709 HPS 50W, A709 HPS 70W, and A709 HPS 100W. High-2084

performance materials may also be contract specific materials not addressed 2085

by AWS D1 welding codes. 2086

2087 6.7. DETAILING 2088

6.7.1. Detailing Standards 2089

The detailing standards shall define the fabricator’s method for presenting 2090

information on shop assembly (blocking) documentsdrawings or other 2091

fabrication documents. 2092

6.7.6. Detailing Functions 2093

Detailing personnel shall have an understanding of geometry, machining 2094

methods and finishes, dimensioning formats, final tolerances, and materials 2095

related to the fabrication of the type of hydraulic projects the fabricator may 2096

undertake. 2097

6.7.8. Preparation of Fabrication Documents 2098

Any fabrication documents shall incorporate all contract requirements, 2099

specifications, codes, and relevant standards to adequately procure materials 2100

and fabricate the structure. To ensure this, a documented procedure for 2101

preparation of fabrication documents shall be developed, which describes: 2102

(a) How project requirements are reviewed and incorporated 2103

(b) How the fabricator coordinates, proposes changes, and tracks information 2104

with the general contractor or owner (e.g., change orders and RFIs), and 2105





how the associated resolutions are tracked and controlled 2106

2107 6.12. PROCESS CONTROLS 2108

6.12.1. Welding 2109

The documented procedure for welding shall include welding of dissimilar metals. 2110

WPSs and supporting PQRs shall be available for the dissimilar metals to be 2111

joined, including those not addressed by AWS D1 welding codes. 2112


The documented procedure for material preparation shall support achievement of 2114 cleanliness and surface profile required by coating manufacturer recommendations, 2115 product data sheets, and contract documents, as applicable. 2116



2121





CHAPTER 6.A 2122

SUPPLEMENTAL REQUIREMENTS 2123

FOR FABRICATORS OF 2124

ADVANCED HYDRAULIC METAL STRUCTURES 2125 2126

This chapter addresses supplemental requirements for fabricators of advanced hydraulic 2127

metal structures and applies as required in Chapter 6. 2128


6.A.3. References 2130 6.A.5. Management Responsibility 2131 6.A.12. Process Controls 2132

6.A.3. REFERENCES 2133

The ability to work to and meet the requirements of the latest edition of ASTM 2134

F3125/F3125M Standard Specification for High Strength Structural Bolts shall 2135

be demonstrated. 2136

2137

6.A.5. MANAGEMENT RESPONSIBILITY 2138

6.A.5.4 Resource Management 2139

6.A.5.4.1 Personnel 2140

The fabricator shall have AWS Certified Welding Inspectors present to 2141

monitor all shifts on which welding is performed. Alternate qualifications 2142

described in AWS D1.1 “Inspection Personnel Qualification,” are not 2143

permitted for fabricators of advanced hydraulic metal structures. 2144

6.A.12. PROCESS CONTROLS 2145

6.A.12.1. Welding 2146 The fabricator’s documented procedure for welding shall include provisions for 2147 distortion control. 2148

6.A.12.2. Bolt Installation 2149 The documented procedure for bolting shall meet the S4 supplementary 2150 requirements for rotational capacity testing as required by ASTM 2151 F3125/F3125M Standard Specification for High Strength Structural Bolts. 2152

6.A.12.6. Trial Assembly 2153

The fabricator’s documented procedure for trial assembly of field 2154





connections shall include, at a minimum, the following items: 2155

(a) Provisions for control of assembled dimensions 2156 (b) Provisions for control of accuracy of drilling and reaming of shop 2157 connections 2158

(c) Documented procedures, including reference drawings, for match-2159

marking shop-assembled pieces 2160

(d) Provisions for assuring the accuracy of numerically controlled 2161

equipment, if contract documents permit the use of such equipment in 2162

lieu of physical assembly 2163

6.A.12.7. Machining 2164 A documented procedure shall be developed for machining, whether it is 2165 performed by the fabricator or a subcontractor. 2166

2167





2168

CHAPTER 6.F 2169

SUPPLEMENTAL REQUIREMENTS 2170

FOR FABRICATORS OF FRACTURE-CRITICAL 2171

MEMBERS 2172

OF HYDRAULIC METAL STRUCTURES 2173

2174

This chapter addresses supplemental requirements for fabricators of fracture-critical 2175

members of hydraulic metal structures and applies as required in Chapter 6. 2176


6.F.3. References 2178

6.F.5 Management Responsibility 2179 6.F.7. Detailing 2180 6F.10. Purchasing 2181 6.F.11. Material Identification 2182 6.F.12. Process Controls 2183 6.F.13. Inspection and Testing 2184 6.F.15. Control of Nonconformances 2185

6.F.3. REFERENCES 2186

The ability to work to and meet the requirements of the latest edition of 2187 AASHTO/AWS D1.5M/D1.5 Bridge Welding Code shall be demonstrated. 2188

6.F.5. MANAGEMENT RESPONSIBILITY 2189

6.F.5.7. Quality Manual 2190

The quality manual shall include or reference a written fracture control plan 2191

(FCP). 2192

6.F.7. DETAILING 2193

6.F.7.1. Detailing Standards 2194

The detailing standards for preparation of bills of material shall include how 2195

fracture-critical members (FCM) are identified in bills of material. FCM shall 2196

be individually identified. 2197

Commentary: Materials like castings, stainless steel, aluminum, and steels 2198

other than ASTM A709 do not have properties specified for meeting the 2199

requirements of FCM. 2200





The detailing standards shall define the manner of identifying fracture-critical 2201

welds. 2202

6.F.10. PURCHASING 2203

6.F.10.1.Purchasing Data 2204

The fabricator’s written purchasing documents shall identify material to be 2205

used for fracture-critical applications. 2206

Commentary: Purchase orders no longer need to specify killed steel and 2207

prohibit mill repairs because it is now covered in ASTM A709. Purchase 2208

orders for fracture-critical material should reference the applicable 2209

requirements in ASTM A709. 2210

If non-ASTM A709 material is specified for FCM, the owner’s representative 2211

for design should indicate which properties and test methods are required. 2212

Fracture-critical specific Charpy V-notch testing is not required in the 2213

specification of some materials. Without a published specification or 2214

supporting testing or research, the specifier should define these requirements 2215

for other materials like castings, stainless steel, or aluminum. 2216

6.F.11. MATERIAL IDENTIFICATION 2217

The fabricator’s documented procedures for identification of material and for 2218

material traceability shall include provisions for maintaining heat and MTR 2219

identity of fracture-critical material throughout the fabrication process. The 2220

procedure shall address how fracture-critical material is identified at receipt 2221

and throughout fabrication by unique mill piece or plate number. Further, the 2222

procedure shall also address how consumables purchased for fracture-critical 2223

welding are identified. 2224

2225

6.F.12. PROCESS CONTROLS 2226

6.F.12.1. Welding 2227

The fabricator’s documented procedure for welding shall include: 2228

(a) Fracture-critical provisions for welding procedure qualification, preheat, 2229

and storage of consumables 2230

(b) Provisions for the creation and implementation of a FCP. The FCP shall 2231

be in accordance with the requirements of AWS D1.5M/D1.5 Bridge 2232

Welding Code, “AASHTO/AWS Fracture-Control Plan (FCP) for 2233

Nonredundant Structures” with the following modifications: 2234

(1) All instances of the word “bridge” shall be replaced with “hydraulic 2235

structure.” 2236

(2) The first sentence of the section, Certification and Qualification, shall 2237





be omitted. 2238

2239

6.F.13. INSPECTION AND TESTING 2240

The fabricator’s documented procedure shall include provisions for inspection 2241

of fracture-critical welds. 2242

6.F.15. CONTROL OF NONCONFORMANCES 2243

6.F.15.2. Nonconforming Product 2244 The fabricator’s documented procedure shall include provisions for critical 2245 and noncritical repairs of fracture-critical welds in accordance with AWS 2246 D1.5. 2247