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GENERAL OBSERVATION REPORT Report Number: M7181304.0284 Service Date: 08/14/19 20225 Cedar Valley Rd Ste 110 Report Date: 08/14/19 Lynnwood, WA 98036-6365 425-742-9360 Client Project Pine Street Group LLC WA State Convention Center Expansion Attn: Webb Miller 1600 9th Ave 1500 4th Ave Ste 600 Seattle, WA Seattle, WA 98101-1670 Project No.: M7181304 Services: Special Inspections / Materials Testing Mayes/Terracon Rep.: Lonny Morrison Reported to: Clark Construction Contractor: Clark Construction Report Distribution: See attached distribution list. Reviewed By: __________________________________ __ Timothy G. Beckerle, PE Principal The tests were performed in general accordance with applicable ASTM, AASHTO, or DOT test methods. This report is exclusively for the use of the client indicated above and shall not be reproduced except in full without the written consent of our company. Test results transmitted herein are only applicable to the actual samples tested at the location(s) referenced and are not necessarily indicative of the properties of other apparently similar or identical materials. CT0001, 10-16-13, Rev.10 Page 1 of 1 Permit No.: 6550113-CN Weather: -- Samples: N/A Please find attached field inspection reports from TRC for work performed from 08/05/19 through 08/10/19 at Zhenhua Heavy Industries (ZPMC), Shanghai, CHINA for the above-noted project. To the best of our knowledge, the items inspected today are in conformance with approved plans and specifications.

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Page 1: Client Project - web6.seattle.gov

GENERAL OBSERVATION REPORTReport Number: M7181304.0284Service Date: 08/14/19 20225 Cedar Valley Rd Ste 110 Report Date: 08/14/19 Lynnwood, WA 98036-6365

425-742-9360

Client ProjectPine Street Group LLC WA State Convention Center ExpansionAttn: Webb Miller 1600 9th Ave1500 4th Ave Ste 600 Seattle, WA Seattle, WA 98101-1670 Project No.: M7181304

Services: Special Inspections / Materials Testing

Mayes/Terracon Rep.: Lonny Morrison Reported to: Clark Construction Contractor: Clark Construction

Report Distribution:See attached distribution list.

Reviewed By: ____________________________________ Timothy G. Beckerle, PE

PrincipalThe tests were performed in general accordance with applicable ASTM, AASHTO, or DOT test methods. This report is exclusively for the use of the client indicated above and shall not be reproduced except in full without the written consent of our company. Test results transmitted herein are only applicable to the actual samples tested at the location(s) referenced and are not necessarily indicative of the properties of other apparently similar or identical materials.

CT0001, 10-16-13, Rev.10 Page 1 of 1

Permit No.: 6550113-CN Weather: --Samples: N/A

Please find attached field inspection reports from TRC for work performed from 08/05/19 through 08/10/19 at Zhenhua Heavy Industries (ZPMC), Shanghai, CHINA for the above-noted project.

To the best of our knowledge, the items inspected today are in conformance with approved plans and specifications.

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QUALITY SURVEILLANCE REPORT

Project Name: Washington State Convention Center Expansion Project

Subcontractor: American Bridge Company

Fabricator: Shanghai Zhenhua Heavy Industries (ZPMC)

Date: Monday August 05, 2019 - Dayshift

Report No: 20190805_MTE_TRC_ZPMC_Geng

BACKGROUND:

Mayes Testing Engineers (MTE) Representative Geng Wei (a TRC employee), Quality Assurance Inspector (QAI) was present at the Zhenhua Heavy Industries (ZPMC) in Shanghai China on Monday August 5, 2019. The purpose of the visit was to perform visual observations of American Bridge’s Quality Assurance (QA) and ZPMC’s Quality Control (QC) activities associated with the Fabrication of the Washington State Convention Center Expansion Project.

GENERAL OBSERVATION:

TRC’s QAI performed random inspections of operations associated with cutting, fit-up, preheating and welding of Beams and Columns. In addition, TRC QAI performed general observations of inspection and testing activities conducted by ZPMC’s QC & AB’s QA in Workshop Bays #1, #2, #3, #4 and #5.

1. QA Visual Testing (VT):

During observations in Bay #1, TRC’s QAI noted that visual inspection of the welds in Truss Bottom Chord components identified as #2135043 were being performed by AB’s QA after the welds were accepted by ZPMC’s QC. It was noted that unaccepted welds at the several areas were marked-up to identify areas to be addressed by ZPMC. After correction, the welds appeared to be in compliance with the requirements of AWS D1.1:2010 Table 6.1 based upon random observation by TRC QAI (please see photos #7 & #8 below).

2. Checking of Heat Straightening Temperature: During observations in Bay #3, TRC’s QAI observed that ZPMC’s personnel were performing heat straightening on the Flange/Web in Beam components identified as #2092080 by handheld flame torch to achieve the required profile. The measured heat straightening temperature was determined to 399 oC by the QAI using calibrated infrared thermometer. The result appeared to be in compliance with the requirement of AWS D1.1: 2010 Clause 5.26.2 (please see photos #9 & #10 below).

3. Verification of Stiffener Fit-ups: TRC QAI performed random fit-up checks of Stiffeners to Flanges/Web on Components identified as #3036402 prior to welding. The joint preparation and root opening of weld joints appears to be in compliance with the requirements of approved shop drawings and welding procedure specification. However, many cracked tack welds were observed in the several weld joints of stiffener to Web/Flanges. This same issue was observed four times within this past one week and noted in the TRC’s Daily Reports. QAI informed ZPMC’s QC Quality Manager Luan and AB’s

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Fabrication Superintendent Peter Ferguson of this observations. Subsequent, grinding was performed by ZPMC to remove the cracked tack welds. The QAI was informed by ZPMC’s Quality Manager Luan that the training for the fitters will be conducted tonight (please see photos #11, #12, #13, #14, #15 & #16 below).

4. Witness of QC Performing Ultrasonic Testing (UT): During observations in Bay #1, TRC’s QAI observed ZPMC’s UT Level II Technicians identified as Zhang Lianfu was performing UT on the CJP weld joints in Post components identified as #3107001. Eight (8) welds were tested and were identified as WD057, WD058, WD059, WD060, WD095, WD096, WD097 and WD098. The UT technicians used one (1) different angle probe (70°) to cover the scanned area. No indications of concern were observed. It appeared that the testing process was in accordance with AWS D1.1:2010, Clause 6, Part F (please see photo #17, #18 & #19 below).

5. Improper Joint Preparation: During observations in Bay #1, TRC’s QAI noted that two (2) Plates (P23562) were tacked to the Flanges of Beam identified as #3055004 as CJP welds with a square groove joint preparation with a backing bar. Based upon the information contained in the WPS’s provided for this project, there are no applicable prequalified WPS submitted for this type of weld joint preparation. The QAI informed AB’s QA Tao Ruiwang and ZPMC’s QC Wang Xiangping of this observation. ZPMC’s QC stated that the single bevel groove angle of 45 degrees will be made by grinding all the noncompliant weld joints noted (please see photo #20 & #21 below). This finding was not logged in the Observations and Findings Logs maintained by MTE/TRC because ZPMC and AB’s QA stated that they will track this matter. A similar issue was previously noted in the TRC’s Daily Report (20190802_MTE_TRC_ZPMC_Geng).

6. Verification of Deformed Stiffeners after Replaced: During observations in Bay #1, TRC’s QAI noted that the stiffener plate (P22231) of Beam identified as #2012013 has been replaced with a new plate and re-welded to correct the deformation caused by improper handling. This issue was previously pointed out by ZPMC’s QC after packing. The results appeared to be in compliance with the requirements of AWS D1.1 and Project Dimension Control Plan (please see photos #22, #23, #24 & #25 below).

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PHOTOGRAPHS

1. View of the status of finished products after packing. 2. Overview of in Bay #4.

3. View of fabrication activities in Bay #3. 4. View of fabrication activities in Bay #1.

5. View of dimensional checks by AB’s Surveyor in Bay #1.

6. View of Trusses in trial assembly in Bay #2.

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7. View of VT checks by AB’s QA in Bay #1. 8. Second view of VT checks by AB’s QA in Bay #1.

9. View of heat straightening being applied on the Flange.

10. View of the measured temperature of heated areas at 399 oC.

11. View of the status of stiffeners after fitting. 12. Close-up view of weld joint preparation prior to

welding.

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13. View of cracked tack weld. 14. Second view of cracked tack weld.

15. Third view of cracked tack weld. 16. View of grinding being performed to remove

cracked tacks after QAI pointed out the issue.

17. View of UT being performed by ZPMC’s QC. 18. Second view of UT being performed by ZPMC’s

QC.

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19. View of the marked UT acceptance information on the components.

20. View of the components with improper joint preparation on the components #3055004.

21. Close-up view of the prepared weld joints of square bevel groove with backing bar on the components #3055004.

22. View of the deformed stiffener after packing on the components #2012013.

23. Second view of the deformed stiffener after packing on the components #2012013.

24. View of the status of deformed stiffener after replaced by a new plate.

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25. Second view of the status of deformed stiffener after being replaced by a new plate.

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QUALITY SURVEILLANCE REPORT

Project Name: Washington State Convention Center Expansion Project

Subcontractor: American Bridge Company

Fabricator: Shanghai Zhenhua Heavy Industries (ZPMC)

Date: Tuesday August 06, 2019 - Swing Shift

Report No: 20190806_MTE_TRC_ZPMC_Ding

BACKGROUND:

Mayes Testing Engineers (MTE) Representative Ding Baohua (a TRC employee), Quality Assurance Inspector (QAI) was present at the Zhenhua Heavy Industries (ZPMC) in Shanghai China on the evening of Tuesday, August 06, 2019 to conduct services in association with the fabrication inspection of the Washington State Convention Center Expansion Project. TRC’s QAI performed random inspections of operations associated with cutting, fit-up, preheating and welding of Beams and Columns during the swing shift. TRC QAI performed general observations of inspection and testing activities conducted by ZPMC’s QC & AB’s QA in Workshop Bays #1, #2, #3, #4 and #5. A task for this visit was to perform ultrasonic testing (UT), magnetic particle testing (MT) and conduct visual observations of American Bridge’s (AB) Quality Assurance (QA) and ZPMC’s Quality Control (QC) as they inspect and test the complete joint penetration (CJP) welds. A focus for this QAI is to conduct observations and nondestructive testing of the cruciform type connections in thicker members where lamellar tearing may be a potential concern.

GENERAL OBSERVATION:

TRC’s QAI witnessed AB’s QA perform UT on the CJP cruciform joints of beams and columns. TRC’s QAI observed fifteen (15) components that have CJP cruciform joints in the workshop and under fabrication or testing as indicated in the table below. TRC’s QAI observed that all fifteen (15) components have been repaired due to lamellar defects detected by VT or MT in the intersecting plate of the cruciform connection. UT has been used by ZPMC to detect some of the lamellar defects, but the majority were detected by VT and MT. These components are identified as indicated in the table below:

# Component

ID. Plate No.

Th.

(mm)

Lamellar

Flaws Detected

By

QC UT

Status

QA UT

Status TRC Status

1 1046401 P13147/P18254 61 VT Ok Ok Ok, Green Tagged 5/11/2019

2 1036401 P17223/P13158 102 VT + MT Ok Ok Ok after 4 times repair, Green Tagged 5/28/2019

3 1036402 P17213/P13156 90 UT + MT Ok Ok Ok, Green Tagged 5/28/2019

4 1030002 P17431/P12053 102 MT Ok Ok Ok, Green Tagged 5/21/2019

5 1036405 P14250/P8569 76 VT + UT Ok Ok Ok, Green Tagged 5/23/2019

6 1040001 P18265/P13146 61 UT by TRC Ok Ok Ok after repair, Green Tagged 5/14/2019

7 1030019 P7310/P13114 70 UT by TRC Ok Ok Ok after repair, Green Tagged 5/20/2019

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1. Ultrasonic Testing (UT) Verification of General Joints:

TRC’s QAI performed ultrasonic testing (UT) in accordance with AWS D1.1, Clauses 6, Part F used one (1) shear wave transducer angle (70°) and a longitudinal wave transducer (0°) to cover the scanned areas. The testing was performed on T-joint welds identified as below:

• Component: #3116401. o Stiffener to Flange weld #: WD050, plate thickness: 30 / 58 mm. o Stiffener to Flange welds #: WD064 and WD066, plate thickness: 38 / 58 mm

The above welds were accepted by QC UT technicians. No indications of concern were observed by TRC’s QAI (please see photos #1 & #2 below).

2. Ultrasonic Testing (UT) Verification of Cruciform Joints:

TRC’s QAI performed ultrasonic testing (UT) in accordance with AWS D1.1, Clauses 6, Part F by using three (3) different shear wave transducer angles (70°, 60° & 45°) and a longitudinal wave transducer (0°) to cover the scanned areas. The testing was performed on cruciform joint welds identified as below:

• Component: #2016403. o Flange to intersecting plate weld #: WD035 and WD036, Face A, plate thickness: 102

/ 51 mm. The above welds were accepted by ZPMC’s QC UT technicians. No lamellar indications of concern were observed by TRC’s QAI (please see photo #3 below).

3. Witness of QC Performing Ultrasonic Testing (UT):

TRC’s QAI observed ZPMC’s QC Cao Shengfeng, UT Level II Technician, perform UT testing of CJP T-joint welds on component identified as #3116404. The testing process appeared to comply with the requirements of AWS D1.1-2015, Clause 6, Part F. It was observed that the UT technicians used two (2) different angle probes (60° and 70°) to cover the scanned areas. The QAI observed that four (4) welds were tested and no indications of concern were observed (please see photos #4 & #5 below).

4. Witness of QC Performing Magnetic Particle Testing (MT):

During observations in Bay #1, TRC’s QAI witnessed ZPMC’s MT Level II Technician identified as Li Di was performing MT on the Gusset Plate to Flange welds on component identified as #2105005. The QAI observed that nine (9) welds were tested. The QAI was informed that one (1) linear indication was detected at the end of the weld. ZPMC MT technician instructed the worker to grind out the indication. The area was re-checked by both VT and MT

8 2036406 P17782/P9686 64 UT + MT Ok In process In process

9 2036404 P16773/P17781 64 UT + MT Ok In process

10 2016402 P12762/P12762 76 MT Ok In process

11 2016403 P12763/P12763 51 VT + MT Ok In process In process

12 2036405 P17795/P17796 102 MT + UT Ok In process

13 3030006 P20294/P20295 89 MT Ok Done Done

14 3036404 P8105/P8106 64 MT + UT Ok

15 3036401 P20296/P20297 89 UT + MT In process

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and found to be acceptable after grinding. It appeared that the testing process was in accordance with AWS D1.1-2010, Clause 6, Part C (please see photos #6 & #7 below).

5. Visual Testing (VT) Verification:

TRC’s QAI performed random visual inspection of the welds in Beams components identified as #2095007 and #2098008 after they were accepted by both AB’s QA and ZPMC’s QC Inspectors in Bay #1. The attached green tags were signed by both of parties (QC & QA). No indications of concern were observed. The welds appeared to be in compliance with the requirements of AWS D1.1 table 6.1 (please see photos #8 & #9 below).

6. Verification of Flange Splice Weld Fit ups:

During observations in Bay #3, TRC QAI performed random fit-up checks of Flange and Web splice weld joints on component identified as #3102070 before welding. The fit-up of weld joints appeared to be in compliance with the requirements of approved shop drawing and welding procedure specification (please see photos #10 & #11 below).

7. Verification of Welder Qualification and Welding Parameters:

During a walkthrough of Bay #1, TRC’s QAI observed one (1) Complete Joint Penetration (CJP) welds between the Web splice weld on component identified as #3085003 was being welded by using flux cored arc welding (FCAW) process. TRC QAI verified the welder qualification card for the welding operator identified as Yu Huihui (GG-022). ZPMC’s QC Inspector was present to monitor the welding process. The filler metal of TWE-711H-D (Ø 0.045’’) used was verified by TRC’s QAI, which was satisfactory. The measured interpass temperature was determined to 169 ℃ by TRC’s QAI using an infrared thermometer. The QAI witnessed the checking of the welding parameters by QC. The parameters checked included voltages, currents and travel speed. These checked items were found to follow the approved welding procedure specifications of WPS (please see photos #12 & #13 below).

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PHOTOGRAPHS

1. View of TRC’s QAI performing UT on T-joint welds on component #3116401.

2. View of TRC’s QAI performing UT on T-joint welds on component #3116401.

3. View of TRC’s QAI performing UT on cruciform joint weld on component #2016403.

4. View of ZPMC’s QC performing UT on T-joint welds on component #3116404.

5. View of ZPMC’s QC performing UT on T-joint welds on component #3116404.

6. View of ZPMC’s QC performing MT on component #2105005.

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7. View of ZPMC’s QC performing MT on component #2105005.

8. View of the attached green tag with signatures by QA and QC on the component #2095007.

9. View of TRC’s QAI performing VT on component #2095007.

10. View of fit-ups being performed on component #3102070.

11. View of fit-ups being performed on component #3102070.

12. View of FCAW welding being performed on component #3085003 in Bay #1.

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13. View of QC checks welding parameters in Bay #1.

14. View of grinding being performed in Bay #3.

15. Overview of fabrication activities in Bay #1. 16. Overview of fabrication activities in lay-down

yard.

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QUALITY SURVEILLANCE REPORT

Project Name: Washington State Convention Center Expansion Project

Subcontractor: American Bridge Company

Fabricator: Shanghai Zhenhua Heavy Industries (ZPMC)

Date: Tuesday August 06, 2019 - Dayshift

Report No: 20190806_MTE_TRC_ZPMC_Geng

BACKGROUND:

Mayes Testing Engineers (MTE) Representative Geng Wei (a TRC employee), Quality Assurance Inspector (QAI) was present at the Zhenhua Heavy Industries (ZPMC) in Shanghai China on Tuesday August 6, 2019. The purpose of the visit was to perform visual observations of American Bridge’s Quality Assurance (QA) and ZPMC’s Quality Control (QC) activities associated with the Fabrication of the Washington State Convention Center Expansion Project.

GENERAL OBSERVATION:

TRC’s QAI performed random inspections of operations associated with cutting, fit-up, preheating and welding of Beams and Columns. In addition, TRC QAI performed general observations of inspection and testing activities conducted by ZPMC’s QC & AB’s QA in Workshop Bays #1, #2, #3, #4 and #5.

1. Witness of QC Visual Testing (VT):

During observations in Bay #5, TRC’s QAI noticed that visual inspection of the welds in the Truss Mid Chord component identified as #2025001 were being performed by ZPMC’s QC. However, it was noted that insufficient fillet weld sizes between Gusset Plate (P9112) and Flange of Beam was marked-up by ZPMC’s QC. The measured leg size was determined to be 8.5 mm which is 4 mm smaller than the approved shop drawing (2025001ACR2). The specified fillet weld size is 1/2 inch (12.7 mm). The QAI was informed by ZPMC’s QC that the affected welds will be corrected by welding . It was observed that the other welds were found to be in compliance with the requirements of AWS D1.1:2010 Table 6.1 based upon random observation by TRC QAI (please see photos #7, #8 & #9 below).

2. Verification of FCAW Welding Parameters and Preheat Temperature: During observations in Bay #1, TRC’s QAI observed that ZPMC qualified welder identified as GG-110 was performing flux cored arc welding (FCAW) of the fillet weld joints between Gusset plate and Flange in the Beam components identified as #3114016 in the horizontal position (2F). ZPMC’s QC Inspector was present to monitor the welding process. The measured temperature of preheat was determined to be 121 oC by TRC’s QAI using a calibrated infrared thermometer, which was satisfactory. The QAI witnessed the checking of the welding parameters by QC. The parameters checked included voltages, currents and travel speed. These checked items were found to follow to be in compliance with the approved welding procedure specification of WPS-2018-054 Revision 4 (please see photos #10, #11, #12, #13 & #14 below).

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3. Checking of Heat Straightening Temperature:

During observations in Bay #5, TRC’s QAI observed that ZPMC’s personnel was performing heat straightening on the Web in Column components identified as #3116403 by handheld flame torch to correct the deformation caused by welding. The measured heat straightening temperature was determined to 511 oC by the QAI using calibrated infrared thermometer. The result appeared to be in compliance with the requirement of AWS D1.1: 2010 Clause 5.26.2 (please see photos #15 & #16 below).

4. Verification of Stiffeners Fit-ups: During observations in Bay #5, TRC QAI performed random fit-up checks of Stiffeners to Flanges/Web on Column components identified as #3110003 prior to welding. The fit-up of the weld joints appears to be in compliance with the requirements of approved shop drawings and welding procedure specification (please see photos #17 & #18 below).

5. Witness of QC Performing Ultrasonic Testing (UT): During observations in Bay #3, TRC’s QAI observed ZPMC’s UT Level II Technicians identified as Zhang Lianfu and Cao Shengfeng perform UT on the CJP weld joints in Column components identified as #3066003 after the detected UT indications were repaired. Three (3) welds were tested and were identified as WD007, WD008 and WD012. The UT technicians used one (1) angle probe (70°) to cover the scanned area. No indications of concern were observed, based upon the observations by QAI. It appeared that the testing process was in accordance with AWS D1.1:2010, Clause 6, Part F (please see photo #19 & #20 below).

6. Deformation of Additional Plate: During observations in Bay #1, TRC’s QAI noted that the one (1) additional Plate (P23562) had a big deformation in Truss Mid Chord components identified #3035007 which might be caused by improper handling. QAI informed AB’s Fabrication Superintendent Peter Ferguson and ZPMC’s QC Zhang Ji of this observations. The QAI was informed by ZPMC’s QC Zhang Ji that the affected plate with deformation will be corrected by heat straightening. Later in the day, it was noted that the deformed connection plate was already corrected (please see photos #21, #22, #23 & #24 below). This issue was not logged in the Observations and Findings Log maintained by MTE/TRC since action was immediately taken to correct the matter.

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PHOTOGRAPHS

1. Overview of in Lay-down Yard. 2. Overview of in Bay #3.

3. View of parts components being cut in Bay #3. 4. View of fabrication activities in Bay #1.

5. View of dimensional checks by AB’s Surveyor after trial assembly in Bay #2.

6. Overview of Trusses/Column in trial assembly in Bay #5.

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7. View of the marked VT defects being addressed by ZPMC.

8. View of the found undersize of fillet welds in Bay #5.

9. View of the measured fillet weld size to be 8 mm. 10. View of preheat being applied prior to welding.

11. View of the measured temperature of preheat at 71 oC.

12. View of FCAW welding being performed.

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13. View of FCAW welding parameters checks by ZPMC’s QC.

14. View of the measured welding current at 262.7 amps.

15. View of heat straightening being applied on the Web of Column.

16. View of the measured temperature of heated areas at 511 0C.

17. View of the status of stiffeners after fitting. 18. View of weld joints preparation.

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19. View of UT being performed by ZPMC’s QC. 20. Second view of UT being performed by ZPMC’s

QC.

21. View of the deformed additional plate of Beam #3035007.

22. Second view of the deformed additional plate of Beam #3035007.

23. View of the status of deformed plate after correction. 24. Second view of the status of deformed plate after

being corrected.

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QUALITY SURVEILLANCE REPORT

Project Name: Washington State Convention Center Expansion Project

Subcontractor: American Bridge Company

Fabricator: Shanghai Zhenhua Heavy Industries (ZPMC)

Date: Wednesday August 07, 2019 - Swing Shift

Report No: 20190807_MTE_TRC_ZPMC_Ding

BACKGROUND:

Mayes Testing Engineers (MTE) Representative Ding Baohua (a TRC employee), Quality Assurance Inspector (QAI) was present at the Zhenhua Heavy Industries (ZPMC) in Shanghai China on the evening of Wednesday, August 07, 2019 to conduct services in association with the fabrication inspection of the Washington State Convention Center Expansion Project. TRC’s QAI performed random inspections of operations associated with cutting, fit-up, preheating and welding of Beams and Columns during the swing shift. TRC QAI performed general observations of inspection and testing activities conducted by ZPMC’s QC & AB’s QA in Workshop Bays #1, #2, #3, #4 and #5. A task for this visit was to perform ultrasonic testing (UT), magnetic particle testing (MT) and conduct visual observations of American Bridge’s (AB) Quality Assurance (QA) and ZPMC’s Quality Control (QC) as they inspect and test the complete joint penetration (CJP) welds. A focus for this QAI is to conduct observations and nondestructive testing of the cruciform type connections in thicker members where lamellar tearing may be a potential concern.

GENERAL OBSERVATION:

TRC’s QAI witnessed AB’s QA perform UT on the CJP cruciform joints of beams and columns. TRC’s QAI observed fifteen (15) components that have CJP cruciform joints in the workshop and under fabrication or testing as indicated in the table below. TRC’s QAI observed that all fifteen (15) components have been repaired due to lamellar defects detected by VT or MT in the intersecting plate of the cruciform connection. UT has been used by ZPMC to detect some of the lamellar defects, but the majority were detected by VT and MT. These components are identified as indicated in the table below:

# Component

ID. Plate No.

Th.

(mm)

Lamellar

Flaws Detected

By

QC UT

Status

QA UT

Status TRC Status

1 1046401 P13147/P18254 61 VT Ok Ok Ok, Green Tagged 5/11/2019

2 1036401 P17223/P13158 102 VT + MT Ok Ok Ok after 4 times repair, Green Tagged 5/28/2019

3 1036402 P17213/P13156 90 UT + MT Ok Ok Ok, Green Tagged 5/28/2019

4 1030002 P17431/P12053 102 MT Ok Ok Ok, Green Tagged 5/21/2019

5 1036405 P14250/P8569 76 VT + UT Ok Ok Ok, Green Tagged 5/23/2019

6 1040001 P18265/P13146 61 UT by TRC Ok Ok Ok after repair, Green Tagged 5/14/2019

7 1030019 P7310/P13114 70 UT by TRC Ok Ok Ok after repair, Green Tagged 5/20/2019

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1. Rejected UT Indications Missed by QC:

TRC’s QAI performed ultrasonic testing (UT) in accordance with AWS D1.1, Clauses 6, Part F, on T-joint welds identified as WD051 and WD052 on component of #3116401. Two (2) rejectable indications were detected and the details of indications are as described below:

o WD051, with T = 30/58 mm ▪ X = 30 mm, Y= 0 mm, Da = 26 mm, L = 25 mm, d = -5 dB, Class A, 70°

o WD052, with T = 30/58 mm

▪ X = 40 mm, Y = -2 mm, Da = 27 mm, L = 80 mm, d = 0 dB, Class A, 70°. TRC QAI informed both QC and QA of these findings. Subsequently, ZPMC’s QC inspector confirmed the presence of the UT defects identified by MTE/TRC. It appears that these defects were previously missed during the QC testing. The QC stated that the indications will be removed by carbon arc gouging and grinding. The repair area will be verified by both MT and UT after the welding repair (please see photos #1, #2, #3 & #4 below). This finding is logged in the Observations and Findings Log as Item #66.

2. Ultrasonic Testing (UT) Verification of Cruciform Joints:

TRC’s QAI performed ultrasonic testing (UT) in accordance with AWS D1.1, Clauses 6, Part F by using three (3) different shear wave transducer angles (70°, 60° and 45°) and a longitudinal wave transducer (0°) to cover the scanned areas. The testing was performed on cruciform joint welds identified as below:

o Component: #2016403. ▪ Flange to intersecting plate weld #: WD035 and WD036, Face B, plate

thickness: 102 / 51 mm. The above welds were accepted by ZPMC’s QC UT technicians. No lamellar indications of concern were observed by TRC’s QAI (please see photos #5 and #6 below).

3. Witness of QC Performing Ultrasonic Testing (UT):

TRC’s QAI observed ZPMC’s QC Cao Shengfeng, UT Level II Technician, perform UT testing of CJP T-joint weld identified as # WD050 on component identified as #3025008. The testing process appeared to comply with the requirements of AWS D1.1-2015, Clause 6, Part F. It was observed that the UT technicians used two (2) different angle probes (60° and 70°) to cover the limited access areas as much as possible by scanning from two faces (weld sides). The QAI was informed that no indications of concern were observed (please see photos #7 & #8 below).

8 2036406 P17782/P9686 64 UT + MT Ok In process In process

9 2036404 P16773/P17781 64 UT + MT Ok In process

10 2016402 P12762/P12762 76 MT Ok In process

11 2016403 P12763/P12763 51 VT + MT Ok In process In process

12 2036405 P17795/P17796 102 MT + UT Ok In process

13 3030006 P20294/P20295 89 MT Ok Done Done

14 3036404 P8105/P8106 64 MT + UT Ok

15 3036401 P20296/P20297 89 UT + MT Ok

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4. Visual Testing (VT) Verification:

TRC’s QAI performed random visual inspection of the welds in Truss component identified as #2055004 after they were accepted by both AB’s QA and ZPMC’s QC Inspectors in Bay #1. The attached green tags were signed by both of parties (QC & QA). No indications of concern were observed. The welds appeared to be in compliance with the requirements of AWS D1.1 table 6.1 (please see photos #9 & #10 below).

5. Verification of Flange Splice Weld Fit-ups:

During observations in Bay #1, TRC QAI performed random fit-up checks of Flange and Web splice weld joints on component identified as #3021004 prior to welding. The fit-up of weld joints appears to be in compliance with the requirements of approved shop drawing and welding procedure specification (please see photos #11 & #12 below).

6. Verification of Welder Qualification and Welding Parameters:

During a walkthrough of Bay #1, TRC’s QAI observed one (1) Complete Joint Penetration (CJP) welds between the Stiffener and the Flange plate on component identified as #3036402 was being welded by using flux cored arc welding (FCAW). TRC QAI verified the welder qualification card for the welding operator identified as Xue Yuping (GG-215). ZPMC’s QC Inspector was present to monitor the welding process. The filler metal of TWE-711H-D (Ø 0.045’’) used was verified by TRC’s QAI, which was satisfactory. The measured interpass temperature was determined to 172 ℃ by ZPMC’s QC using an infrared thermometer. The QAI witnessed the checking of the welding parameters by QC. The parameters checked included voltages, currents and travel speed. These checked items were found to follow the approved welding procedure specifications of WPS (please see photos #13 & #14 below).

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PHOTOGRAPHS

1. View of TRC’s QAI performing UT on welds WD051 and WD052 on component #3116401.

2. View of screen display of rejected UT indication on component #3116401. Logged as Item #66.

3. View of the longitudinal crack holding MT powder. The crack was initially detected by UT in weld WD052. Logged as Item #66.

4. View of rejected UT indication after it had been removed by carbon air arc gouging on component #3116401. Logged as Item #66.

5. View of ZPMC’s QC performing UT on cruciform joint welds on component #2016403.

6. View of ZPMC’s QC performing UT on cruciform joint welds on component #2016403.

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7. View of ZPMC’s QC performing UT on T-joint weld on component #3025008.

8. View of ZPMC’s QC performing UT on T-joint weld on component #3025008.

9. View of TRC’s QAI performing VT on component #2055004.

10. View of the attached green tag with signatures by QA and QC on the component #2055004.

11. View of fit-ups being performed on component #3021004.

12. View of fit-ups being performed on component #3021004.

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13. View of FCAW welding being performed on component #3036402 in Bay #1.

14. View of QC checks welding parameters on component #3036402.

15. Overview of fabrication activities in Bay #2. 16. Overview of fabrication activities in lay-down

yard.

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QUALITY SURVEILLANCE REPORT

Project Name: Washington State Convention Center Expansion Project

Subcontractor: American Bridge Company

Fabricator: Shanghai Zhenhua Heavy Industries (ZPMC)

Date: Wednesday August 07, 2019 - Dayshift

Report No: 20190807_MTE_TRC_ZPMC_Geng

BACKGROUND:

Mayes Testing Engineers (MTE) Representative Geng Wei (a TRC employee), Quality Assurance Inspector (QAI) was present at the Zhenhua Heavy Industries (ZPMC) in Shanghai China on Wednesday August 7, 2019. The purpose of the visit was to perform visual observations of American Bridge’s Quality Assurance (QA) and ZPMC’s Quality Control (QC) activities associated with the Fabrication of the Washington State Convention Center Expansion Project.

GENERAL OBSERVATION:

TRC’s QAI performed random inspections of operations associated with cutting, fit-up, preheating and welding of Beams and Columns. In addition, TRC QAI performed general observations of inspection and testing activities conducted by ZPMC’s QC & AB’s QA in Workshop Bays #1, #2, #3, #4 and #5.

1. ZPMC’s QC Performing Dimensional Checks:

During observations in Bay #3, TRC QAI noted that ZPMC’s QC was performing the final dimensional checks of bolt holes in three (3) beam components identified as #3095028, #3095032 and #3095031 prior to packing. QAI was informed that the dimensions appear to be in compliance with the approved shop drawing and the project dimension control plan (please see photos #9 & #10).

2. Verification of FCAW Welding Parameters and interpass Temperature: During observations in Bay #1, TRC’s QAI observed that ZPMC qualified welder identified as GG-217 was performing flux cored arc welding (FCAW) in the demand critical weld joint between Stiffener plate (P20503) and Flange in the Column components identified as #3066404 in the vertical position (3G). ZPMC’s QC Inspector was present to monitor the welding process. The measured temperature of interpass was determined to be 169 oC by TRC’s QAI using a calibrated infrared thermometer, which was satisfactory. The QAI witnessed the checking of the welding parameters by QC. The parameters checked included voltages, currents and travel speed. These checked items were found to follow to be in compliance with the approved welding procedure specification of WPS-2018-036 Revision 4 (please see photos #11, #12, #13 & #14 below).

3. Checking of Heat Straightening Temperature: During observations in Bay #1, TRC’s QAI observed that ZPMC’s personnel was performing heat straightening on the Web in Rolled Beam components identified as #3102070 by handheld flame torch to correct the deformation. The measured heat straightening temperature was determined to 302 oC by the QAI using calibrated infrared thermometer. The result appeared to be in compliance with the requirement of AWS D1.1: 2010 Clause 5.26.2 (please see photos #15 & #16 below).

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4. Witness of QC Performing Ultrasonic Testing (UT):

During observations in Bay #1, TRC’s QAI observed ZPMC’s UT Level II Technicians identified as Zhang Lianfu and Cao Shengfeng were performing UT on the CJP weld joints in Column components identified as #3116404 after the detected UT indications were repaired. Two (2) welds identified as WD093 and WD094 were tested. The UT technicians used two (2) different angle probes (70° and 600) to cover the scanned area. One rejectable indication was detected for the second time in weld of WD093. QAI was informed that the rejected weld will be repaired and re-tested by original NDT method. It appeared that the testing process was in accordance with AWS D1.1:2010, Clause 6, Part F (please see photo #17, #18 & #19 below).

5. Magnetic Particle Testing (MT) Verification: TRC’s QAI performed random Magnetic Particle Testing (MT) verification in the welds in Truss components identified as #2035002 which the green tags were signed by both ZPMC’s QC and AB’s QA in Bay #5. Sixteen (16) welds were tested by TRC’s QAI. The details are as follows:

• Connection Plates to Gusset Plates fillet welds of WD045, WD047, WD049, WD051, WD025, WD027, WD029, WD031, WD009, WD011, WD005, WD004 and WD007.

• Gusset Plate to Flanges welds of WD001, WD002 and WD042.

Two linear indications of concern were detected on the fillet welds of WD005 by TRC QAI. Subsequently, the indications were removed by grinding and re-verified by MT after removal. The above noted welds appear to be acceptable in accordance with AWS D1.1, Clauses 6 Part C (please see photos #20, #21, #22 & #23 below). These overlooked linear indications were not logged in the Observations and Findings Log maintained by MTE/TRC since it was immediately addressed.

6. Deformation of Packed Components: During observations in packing storage of finished products, TRC’s QAI noted that deformation was observed on the Flange of Beam identified as #2052034 and angle beam (a1186) in Beam component identified as #2056415. This deformation might be caused by improper handling after packing. QAI informed AB’s Fabrication Superintendent Peter Ferguson of this observations. He stated that the affected components with deformation will be corrected before shipment (please see photos #24, #25, #26, #27 & #28 below). This issue was not logged in the Observations and Findings Log maintained by MTE/TRC since AB will be tracked this matter.

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PHOTOGRAPHS

1. Overview of packing storage. 2. Second overview of packing storage.

3. Overview of Trusses/Column in trial assembly in Bay #5.

4. View of the status of components after packing in Bay #2.

5. View of dimensional checks by AB’s Surveyor after trial assembly in Bay #2.

6. Overview of fabrication activities in Bay #3.

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7. View of component being milled in Bay #3. 8. View of preheat being applied prior to welding in Bay

#1.

9. View of the dimensional checks by ZPMC’s QC. 10. Second view of the dimensional checks by ZPMC’s

QC.

11. View of FCAW welding being performed. 12. View of the measured temperature of interpass at

169 oC.

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13. View of FCAW welding parameters checks by ZPMC’s QC.

14. View of the measured welding current at 190.5 amps.

15. View of heat straightening being applied on the Web of Beam.

16. View of the measured temperature of heated areas at 302 0C.

17. View of UT being performed by ZPMC’s QC. 18. Second view of UT being performed by ZPMC’s

QC.

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19. View of the marked information of UT detected indication.

20. View of random MT verification being performed by QAI.

21. Second view of random MT verification being performed by QAI.

22. View of the detected linear indications.

23. View of the detected MT indications were removed by grinding.

24. View of the deformed Flange in the Beam #2052034 after packing.

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25. Second view of the deformed Flange in the Beam #2052034 after packing.

26. View of the deformed angle steel in the Beam #2056415 after packing.

27. Second view of the deformed angle steel in the Beam #2056415 after packing.

28. View of the deformed Flange after packing.

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QUALITY SURVEILLANCE REPORT

Project Name: Washington State Convention Center Expansion Project

Subcontractor: American Bridge Company

Fabricator: Shanghai Zhenhua Heavy Industries (ZPMC)

Date: Thursday August 08, 2019 - Swing Shift

Report No: 20190808_MTE_TRC_ZPMC_Ding

BACKGROUND:

Mayes Testing Engineers (MTE) Representative Ding Baohua (a TRC employee), Quality Assurance Inspector (QAI) was present at the Zhenhua Heavy Industries (ZPMC) in Shanghai China on the evening of Thursday, August 08, 2019 to conduct services in association with the fabrication inspection of the Washington State Convention Center Expansion Project. TRC’s QAI performed random inspections of operations associated with cutting, fit-up, preheating and welding of Beams and Columns during the swing shift. TRC QAI performed general observations of inspection and testing activities conducted by ZPMC’s QC & AB’s QA in Workshop Bays #1, #2, #3, #4 and #5. A task for this visit was to perform ultrasonic testing (UT), magnetic particle testing (MT) and conduct visual observations of American Bridge’s (AB) Quality Assurance (QA) and ZPMC’s Quality Control (QC) as they inspect and test the complete joint penetration (CJP) welds. A focus for this QAI is to conduct observations and nondestructive testing of the cruciform type connections in thicker members where lamellar tearing may be a potential concern.

GENERAL OBSERVATION:

TRC’s QAI witnessed AB’s QA perform UT on the CJP cruciform joints of beams and columns. TRC’s QAI observed fifteen (15) components that have CJP cruciform joints in the workshop and under fabrication or testing as indicated in the table below. TRC’s QAI observed that all fifteen (15) components have been repaired due to lamellar defects detected by VT or MT in the intersecting plate of the cruciform connection. UT has been used by ZPMC to detect some of the lamellar defects, but the majority were detected by VT and MT. These components are identified as indicated in the table below:

# Component

ID. Plate No.

Th.

(mm)

Lamellar

Flaws Detected

By

QC UT

Status

QA UT

Status TRC Status

1 1046401 P13147/P18254 61 VT Ok Ok Ok, Green Tagged 5/11/2019

2 1036401 P17223/P13158 102 VT + MT Ok Ok Ok after 4 times repair, Green Tagged 5/28/2019

3 1036402 P17213/P13156 90 UT + MT Ok Ok Ok, Green Tagged 5/28/2019

4 1030002 P17431/P12053 102 MT Ok Ok Ok, Green Tagged 5/21/2019

5 1036405 P14250/P8569 76 VT + UT Ok Ok Ok, Green Tagged 5/23/2019

6 1040001 P18265/P13146 61 UT by TRC Ok Ok Ok after repair, Green Tagged 5/14/2019

7 1030019 P7310/P13114 70 UT by TRC Ok Ok Ok after repair, Green Tagged 5/20/2019

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1. Witness of QC Performing Magnetic Particle Testing (MT):

During observations in Bay #1, TRC’s QAI witnessed ZPMC’s MT Level II Technician identified as Wang Wei was performing MT on the Connection Plate to Flange welds on component identified as #3055002. The QAI observed that four (4) welds were tested. The QAI was informed that two (2) linear indications were detected at the ends of the weld. ZPMC MT technician instructed the worker to grind out the indication, the area was re-check by both VT and MT and found to be acceptable after grinding. It appeared that the testing process was in accordance with AWS D1.1-2010, Clause 6, Part C (please see photos #1, #2 & #3 below).

2. Witness of QA Performing Ultrasonic Testing (UT): TRC’s QAI observed AB’s UT Level II Technician identified as Yang Yun perform UT on the CJP Flange splice welds on component identified as #3085004. The UT was performed after the welds were accepted by ZPMC QC. The QAI was informed that three (3) butt joint welds of the component were tested by QA and no indications of concern were observed. It appeared that the testing process was in accordance with AWS D1.1:2010, Clause 6, Part F (please see photos #4 and #5 below).

3. Ultrasonic Testing (UT) Verification of General Joints:

TRC’s QAI performed ultrasonic testing (UT) in accordance with AWS D1.1, Clauses 6, Part F used one (1) shear wave transducer angle (70°) and a longitudinal wave transducer (0°) to cover the scanned areas. The testing was performed on T-joint welds identified as below:

• Component: #3107001. o Tube splice welds #: WD057, WD058, WD059, WD060, WD097 and WD098,

plate thickness: 30 / 62 mm. The above welds were accepted by both QA and QC UT technicians. No indications of concern were observed by TRC’s QAI (please see photos #6 & #7 below).

4. Ultrasonic Testing (UT) Verification of Cruciform Joints:

TRC’s QAI performed ultrasonic testing (UT) in accordance with AWS D1.1, Clauses 6, Part F by using three (3) different shear wave transducer angles (70°, 60° and 45°) and a longitudinal wave transducer (0°) to cover the scanned areas. The testing was performed on cruciform joint welds identified as below:

• Component: #2016403. o Web to intersecting plate weld #: WD037 and WD048, plate thickness: 102 / 51

mm.

8 2036406 P17782/P9686 64 UT + MT Ok In process In process

9 2036404 P16773/P17781 64 UT + MT Ok In process

10 2016402 P12762/P12762 76 MT Ok In process

11 2016403 P12763/P12763 51 VT + MT Ok In process In process

12 2036405 P17795/P17796 102 MT + UT Ok In process

13 3030006 P20294/P20295 89 MT Ok Done Done

14 3036404 P8105/P8106 64 MT + UT Ok

15 3036401 P20296/P20297 89 UT + MT Ok

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The above welds were accepted by ZPMC’s QC UT technicians. No lamellar indications of concern were observed by TRC’s QAI (please see photos #8 below).

5. Verification of Stiffener Plate Fit-ups:

During observations in Bay #3, TRC QAI performed random fit-up checks of the Stiffener Plate to Beam joints on component identified as #3112023 prior to welding. The fit-up of weld joints appears to be in compliance with the requirements of approved shop drawing and welding procedure specification (please see photos #9 & #10 below).

6. Verification of Heat Straightening Temperature:

During observations in Bay #1, TRC’s QAI observed that ZPMC’s personnel perform heat straightening on the Flange Plate in Beam identified as #3086402 by handheld flame torch to correct the deformation caused by welding. The measured heat straightening temperature was determined to 515 ℃ by ZPMC’s QC using a calibrated infrared thermometer. The result appeared to be in compliance with the requirement of AWS D1.1: 2010 Clause 5.26.2 (please see photos #11 and #12 below).

7. Verification of Welder Qualification and Welding Parameters:

During a walkthrough of Bay #1, TRC’s QAI observed one (1) Complete Joint Penetration (CJP) weld between the Flange splice joints on component identified as #3101035 was being welded by using flux cored arc welding (FCAW). TRC QAI verified the welder qualification card for the welding operator identified as GG-233. ZPMC’s QC Inspector was present to monitor the welding process. The filler metal of TWE-711H-D (Ø 0.045’’) used was verified by TRC’s QAI, which was satisfactory. The measured interpass temperature was determined to 155 ℃ by ZPMC’s QC using an infrared thermometer. The QAI witnessed the checking of the welding parameters by QC. The parameters checked included voltages, currents and travel speed. These checked items were found to follow the approved welding procedure specifications of WPS (please see photos #13 & #14 below).

PHOTOGRAPHS

1. View of ZPMC’s QC performing MT on component #3055002.

2. View of MT linear indication detected by QC on component #3055002.

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3. View of MT indication being removed by grinding on component #3055002.

4. View of AB’s QA performing UT on component #3085004.

5. View of AB’s QA performing UT on component #3085004.

6. View of TRC’s QAI performing UT on T-joint welds on component #3107001.

7. View of TRC’s QAI performing UT on T-joint welds on component #3107001.

8. View of TRC’s QAI performing UT on cruciform joint welds on component #2016403.

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9. View of fit-ups being performed on component #3112023.

10. View of fit-ups being performed on component #3112023.

11. View of heat straightening being applied on the flange plate on component #3086402.

12. View of the measured temperature of heated areas at 515℃ in Bay #1.

13. View of FCAW welding being performed on component #3101035 in Bay #1.

14. View of QC checks welding parameters on component #3101035.

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15. Overview of fabrication activities in Bay #1. 16. Overview of fabrication activities in Bay #3.

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QUALITY SURVEILLANCE REPORT

Project Name: Washington State Convention Center Expansion Project

Subcontractor: American Bridge Company

Fabricator: Shanghai Zhenhua Heavy Industries (ZPMC)

Date: Thursday August 08, 2019 - Dayshift

Report No: 20190808_MTE_TRC_ZPMC_Geng

BACKGROUND:

Mayes Testing Engineers (MTE) Representative Geng Wei (a TRC employee), Quality Assurance Inspector (QAI) was present at the Zhenhua Heavy Industries (ZPMC) in Shanghai China on Thursday August 8, 2019. The purpose of the visit was to perform visual observations of American Bridge’s Quality Assurance (QA) and ZPMC’s Quality Control (QC) activities associated with the Fabrication of the Washington State Convention Center Expansion Project.

GENERAL OBSERVATION:

TRC’s QAI performed random inspections of operations associated with cutting, fit-up, preheating and welding of Beams and Columns. In addition, TRC QAI performed general observations of inspection and testing activities conducted by ZPMC’s QC & AB’s QA in Workshop Bays #1, #2, #3, #4 and #5.

1. Packed Finished Products:

TRC QAI noted that a total of one hundred and twenty-six (126) packages of finished product had been packed for the next shipment. Green tags with signatures of both QA and QC were attached to the all products visible (please see photos #3, #4 &#5 below).

2. Visual Testing (VT): During observations in Lay-down Yard, TRC’s QAI performed random visual inspection of the welds in Truss Top Chord components identified as #2055004 after the welds were accepted by both ZPMC’s QC and QA. No indications of concern were observed. The welds appeared to be in compliance with the requirements of AWS D1.1:2010 Table 6.1 (please see photos #9, #10, #11 & #12 below).

3. Verification of FCAW Filler Metal and preheat Temperature: During observations in Bay #1, TRC’s QAI observed that ZPMC qualified welder identified as GG-022 was performing flux cored arc welding (FCAW) in the CJP weld joint between Stiffener plate (P16289) and Flanges in the Column components identified as #3010002 in the vertical position (3G). It was noted that preheat was applied prior to welding by handheld flame torch and the measured temperature of preheat was determined to be 121 oC by TRC’s QAI using a calibrated infrared thermometer, which was satisfactory. Meanwhile, the filler metal of TWE-711H-D (Ø0.045’’) used was verified by QAI as well and found to be in compliance with the approved welding procedure specification of WPS-2018-036 Revision 4 (please see photos #13, #14 & #15 below).

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4. Verification of Stiffeners Fit-ups:

TRC QAI performed random fit-up checks of Stiffeners to Flanges/Web on Beam Components identified as #3085006 prior to welding. The fit-up of weld joints appears to be in compliance with the requirements of approved shop drawings and welding procedure specification (please see photos #16 & #17 below).

5. Checking of Heat Straightening Temperature: During observations in Bay #1, TRC’s QAI observed that ZPMC’s personnel was performing heat straightening on the Gusset Plate (P21988) in Beam components identified as #3114014 by handheld flame torch to correct the deformation caused by welding. The measured heat straightening temperature was determined to 438 oC by the QAI using calibrated infrared thermometer. The result appeared to be in compliance with the requirement of AWS D1.1: 2010 Clause 5.26.2.

6. Witness of QC Performing Ultrasonic Testing (UT) of Base Metal: During observations in Bay #1, TRC’s QAI witnessed ZPMC’s UT Level II Technician identified as Zhang Lianfu was performing UT on the base metal of rolled shapes by using a straight beam probe prior to fabrication. Four (4) shapes with the thickness of flanges greater than 1 ½ inches had been tested and were identified as W14X257, W14X311 and W14X342 (2 pieces). Many discontinues of concern were detected by ZPMC’s QC on the Flanges of W-shape identified as W14X342 with heat number of 68048 (please see photos #18, #19, #20 & #21). QAI was informed by ZPMC’s QC that this W-shape will be scrapped.

7. Base Metal Damage: During observations in Bay #1, TRC’s QAI observed base metal damage caused by improper cutting on the Gusset Plate (P21988) in Beam components identified as # 3114014. The damages was cut through the whole thickness of plate. This issue was correctly identified as being noncompliant with the code criteria by ZPMC’s QC at the time of observation by QAI. QAI was informed by ZPMC’s QC that the damaged area will be repaired by welding and grinding, and the repaired areas will be verified by both UT and MT after correction (please see photos #22 & #23 below). This was not logged in the Observations and Findings Log maintained by MTE/TRC.

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PHOTOGRAPHS

1. View of finished products being packed in Lay-down Yard.

2. View of finished products being packed in Bay #2.

3. View of the status of Trusses and Beams after packing.

4. Second view of the status of Trusses and Beams after packing.

5. Third view of the status of Trusses and Beams after packing.

6. Overview of fabrication activities in Bay #3.

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7. View of fabrication activities in Bay #1. 8. View of the dimensional checks by ZPMC’s QC.

9. View of the status of truss after green tagged. 10. View of the attached green tags with signatures by

both QA and QC on the component.

11. View of the measured fillet weld size to be 25mm. 12. View of the acceptable weld profile.

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13. View of preheat being applied prior to welding. 14. View of the measured temperature of preheat at 121

0C.

15. View of the filler metal of TWE-711H-D (Ø0.045’’) used.

16. View of the status of stiffeners and gusset plates after fitting.

17. View of the weld joints preparation prior to welding. 18. View of UT being performed by ZPMC’s QC on the

rolled shapes prior to fabrication.

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19. Second view of UT being performed by ZPMC’s QC on the rolled shapes prior to fabrication.

20. View of the UT detected indication.

21. View of the information of W-shape with UT defects.

22. View of base metal damaged caused by improper cutting.

23. Close-up view of the cutting damage.

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QUALITY SURVEILLANCE REPORT

Project Name: Washington State Convention Center Expansion Project

Subcontractor: American Bridge Company

Fabricator: Shanghai Zhenhua Heavy Industries (ZPMC)

Date: Friday August 09, 2019 - Swing Shift

Report No: 20190809_MTE_TRC_ZPMC_Ding

BACKGROUND:

Mayes Testing Engineers (MTE) Representative Ding Baohua (a TRC employee), Quality Assurance Inspector (QAI) was present at the Zhenhua Heavy Industries (ZPMC) in Shanghai China on the evening of Friday, August 09, 2019 to conduct services in association with the fabrication inspection of the Washington State Convention Center Expansion Project. TRC’s QAI performed random inspections of operations associated with cutting, fit-up, preheating and welding of Beams and Columns during the swing shift. TRC QAI performed general observations of inspection and testing activities conducted by ZPMC’s QC & AB’s QA in Workshop Bays #1, #2, #3, #4 and #5. A task for this visit was to perform ultrasonic testing (UT), magnetic particle testing (MT) and conduct visual observations of American Bridge’s (AB) Quality Assurance (QA) and ZPMC’s Quality Control (QC) as they inspect and test the complete joint penetration (CJP) welds. A focus for this QAI is to conduct observations and nondestructive testing of the cruciform type connections in thicker members where lamellar tearing may be a potential concern.

GENERAL OBSERVATION:

TRC’s QAI witnessed AB’s QA perform UT on the CJP cruciform joints of beams and columns. TRC’s QAI observed fifteen (15) components that have CJP cruciform joints in the workshop and under fabrication or testing as indicated in the table below. TRC’s QAI observed that all fifteen (15) components have been repaired due to lamellar defects detected by VT or MT in the intersecting plate of the cruciform connection. UT has been used by ZPMC to detect some of the lamellar defects, but the majority were detected by VT and MT. These components are identified as indicated in the table below:

# Component

ID. Plate No.

Th.

(mm)

Lamellar

Flaws Detected

By

QC UT

Status

QA UT

Status TRC Status

1 1046401 P13147/P18254 61 VT Ok Ok Ok, Green Tagged 5/11/2019

2 1036401 P17223/P13158 102 VT + MT Ok Ok Ok after 4 times repair, Green Tagged 5/28/2019

3 1036402 P17213/P13156 90 UT + MT Ok Ok Ok, Green Tagged 5/28/2019

4 1030002 P17431/P12053 102 MT Ok Ok Ok, Green Tagged 5/21/2019

5 1036405 P14250/P8569 76 VT + UT Ok Ok Ok, Green Tagged 5/23/2019

6 1040001 P18265/P13146 61 UT by TRC Ok Ok Ok after repair, Green Tagged 5/14/2019

7 1030019 P7310/P13114 70 UT by TRC Ok Ok Ok after repair, Green Tagged 5/20/2019

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1. Witness of QC Performing Magnetic Particle Testing (MT):

During observations in Bay #1, TRC’s QAI witnessed ZPMC’s MT Level II Technician identified as li Di was performing MT on the Connection Plate to Flange welds on component identified as #2016403. The QAI observed that eight (8) welds were tested. The QAI was informed that one (1) linear indication was detected at the end of the weld. ZPMC MT technician instructed the worker to grind out the indication, the area was re-check by both VT and MT and found to be acceptable after grinding. It appeared that the testing process was in accordance with AWS D1.1-2010, Clause 6, Part C (please see photos #1 & #2 below).

2. Witness of QC Performing Ultrasonic Testing (UT):

TRC’s QAI observed ZPMC’s QC Zhang Nianfu, UT Level II Technician, performed UT testing of CJP butt joint welds on component identified as #3101035. The testing process appeared to comply with the requirements of AWS D1.1-2010, Clause 6, Part F. It was observed that the UT technicians used two (2) different angle probes (60° and 70°) to cover the scanned areas. The QAI observed that three (3) welds were tested and no indications of concern were observed (please see photos #3 & #4 below).

3. Witness of QA Performing Visual Inspection (VT):

During a walkthrough of Bay #1, TRC QAI observed that visual inspection of welds of the component identified as #2095013 was being performed by AB’s QA Inspector identified as Tao Ruiwang. The welds were compliant with AWS D1.1-2010, Clauses 6, Part F, Table 6.1 based upon random observation by TRC’s QAI (please see photos #5 & #6 below).

4. Ultrasonic Testing (UT) Verification of General Joints:

TRC’s QAI performed ultrasonic testing (UT) in accordance with AWS D1.1, Clauses 6, Part F used two (2) shear wave transducer angle (70° and 60°) and a longitudinal wave transducer (0°) to cover the scanned areas. The testing was performed on butt joint welds identified as below:

• Component: #3090005. o Flange splice welds #: WD123 and WD124, plate thickness: 57 mm. o Web splice weld #: WD125, plate thickness: 36 mm.

The above welds were accepted by both QA and QC UT technicians. No indications of concern were observed by TRC’s QAI (please see photo #7 below).

5. Ultrasonic Testing (UT) Verification of Cruciform Joints:

TRC’s QAI performed ultrasonic testing (UT) in accordance with AWS D1.1, Clauses 6, Part F by using three (3) different shear wave transducer angles (70°, 60° and 45°) and a longitudinal wave

8 2036406 P17782/P9686 64 UT + MT Ok In process In process

9 2036404 P16773/P17781 64 UT + MT Ok In process

10 2016402 P12762/P12762 76 MT Ok In process

11 2016403 P12763/P12763 51 VT + MT Ok In process In process

12 2036405 P17795/P17796 102 MT + UT Ok In process

13 3030006 P20294/P20295 89 MT Ok Done Done

14 3036404 P8105/P8106 64 MT + UT Ok

15 3036401 P20296/P20297 89 UT + MT Ok

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transducer (0°) to cover the scanned areas. The testing was performed on cruciform joint welds identified as below:

• Component: #2036404. o Flange to intersecting plate weld #: WD080, plate thickness: 102 / 64 mm.

The above weld was accepted by ZPMC’s QC UT technicians. No lamellar indications of concern were observed by TRC’s QAI (please see photos #8 below).

6. Verification of Gusset Plate Fit-ups:

During observations in Bay #3, TRC QAI performed random fit-up checks of the Gusset Plate to Flange joints on component identified as #3015003 prior to welding. The fit-up of weld joints appears to be in compliance with the requirements of approved shop drawing and welding procedure specification (please see photos #9 & #10 below).

7. Verification of Heat Straightening Temperature:

During observations in Bay #3, TRC’s QAI observed that ZPMC’s personnel perform heat straightening on the Flange Plate in Beam identified as #3016402 by handheld flame torch to correct the deformation caused by welding. The measured heat straightening temperature was determined to 451 ℃ by ZPMC’s QC using a calibrated infrared thermometer. The result appeared to be in compliance with the requirement of AWS D1.1: 2010 Clause 5.26.2 (please see photos #11 and #12 below).

8. Verification of Welder Qualification and Welding Parameters:

During a walkthrough of Bay #1, TRC’s QAI observed one (1) Complete Joint Penetration (CJP) weld between the Flange splice joints on component identified as #3102070 was being welded by using flux cored arc welding (FCAW). TRC QAI verified the welder qualification card for the welding operator identified as Su Zhandou (GG-312). ZPMC’s QC Inspector was present to monitor the welding process. The filler metal of TWE-711H-D (Ø 0.045’’) used was verified by TRC’s QAI, which was satisfactory. The measured preheat temperature was determined to 117 ℃ by ZPMC’s QC using an infrared thermometer. The QAI witnessed the checking of the welding parameters by QC. The parameters checked included voltages, currents and travel speed. These checked items were found to follow the approved welding procedure specifications of WPS (please see photos #13 & #14 below).

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PHOTOGRAPHS

1. View of ZPMC’s QC performing MT on component #2016403.

2. View of ZPMC’s QC performing MT on component #2016403.

3. View of ZPMC’s QC performing UT on flange spice weld on component #3101035.

4. View of ZPMC’s QC performing UT on web spice weld on component #3101035.

5. View of AB’s QA performing final VT on component #2095013.

6. View of AB’s QA performing final VT on component #2095013.

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7. View of TRC’s QAI performing UT on butt joint welds on component #3090005.

8. View of TRC’s QAI performing UT on cruciform joint weld on component #2036404.

9. View of fit-ups being performed on component #3015003.

10. View of fit-up checks being performed on component #3015003.

11. View of heat straightening being applied on the flange plate on component #3016402.

12. View of the measured temperature of heated areas at 451℃ in Bay #3.

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13. View of FCAW welding being performed on component #3102070.

14. View of preheat being perform prior to welding on component #3102070.

15. Overview of fabrication activities in Bay #2. 16. Overview of fabrication activities in lay-down

yard.

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QUALITY SURVEILLANCE REPORT

Project Name: Washington State Convention Center Expansion Project

Subcontractor: American Bridge Company

Fabricator: Shanghai Zhenhua Heavy Industries (ZPMC Nan Tong Base)

Date: Friday August 09, 2019 - Dayshift

Report No: 20190809_MTE_TRC_ZPMC_Geng

BACKGROUND:

Mayes Testing Engineers (MTE) Representative Geng Wei (a TRC employee), Quality Assurance Inspector (QAI) was present at the Zhenhua Heavy Industries (ZPMC) in Nan Tong China on Friday August 9, 2019 under the presence of AB’s Fabrication Superintend Peter Ferguson. The Nan Tong base of ZPMC is located approximately two and half hours far away from Chang Xing Island in Shanghai by car. The purpose of the visit was to perform visual observations of painting progress and American Bridge’s Quality Assurance (QA) and ZPMC’s Quality Control (QC) activities associated with the blasting and painting application of Zone 2 for the Washington State Convention Center Expansion Project.

GENERAL OBSERVATION:

TRC’s QAI performed random inspections of operations associated with blasting and painting of Beams and Connection Plates. In addition, TRC QAI performed general observations of inspection activities conducted by ZPMC’s QC & AB’s QA in Blasting shop, Painting shop and Lay-down Yard.

1. Products Painting Progress:

A quick meeting was initiated by AB’s Fabrication Superintendent Peter Ferguson under the presence of Smith Emery, ZPMC’s Coating Inspector, Paint Manufacture Representative and TRC. ZPMC’s Coating Inspector reported the Painting/Blasting progress of Zone 2 components were summarized as below:

• A total three hundred and thirty-four (334) beams and two hundred and ninety-two (292) connection plates were scheduled to be painted in Nan Tong Base #1.

• A total two hundred and thirty-eight (238) Beams had been blasted by the end of this shift. • A total one hundred and sixty-four (164) Beams had been completed primer application. • A total sixty-eight (68) Beams had been accepted and green tagged by both QA and QC. • The remaining of ninety-six (96) Beams and two hundred and ninety-two (292) connection

plates were still waiting for blasting and painting application.

TRC QAI was informed ZPMC’s QC that the completion date of all painting works was scheduled for August 23, 2019.

2. Observations of Painting Shop: During observations in paint shop. TRC’s QAI noted that ZPMC’s personnel were performing paint repairs/touch-up by using a roller at the low dry film thickness (DFT) locations and where the paint defect removal areas. It was noted that the environmental conditions were checked and compliant by ZPMC’s Coating Inspector prior to repair (please see photos #1, #2, #3, #4, #5, #6, #7, #8 & #9 below). The results were recorded as below:

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DT: 31 oC, WT: 26 oC, RH: 67%, Td: 24 oC, Ts: 34 oC. The paint batch number of primer was recorded as below:

TNEMEC 27WB: Part A: HH2018120010. Part B: HH20190300001.

3. Visual observations of Painted components:

During observations in Lay-down Yard, TRC’s QAI observed that many of the Beams had primer applied and placed on the jig with wood protection. TRC QAI was informed by AB’s QA that all Beams had been accepted by both parties (QA and QC). A random visual inspection of the primer coating was performed by TRC’s QAI in the accessible areas. The observations of concerns were as follows:

• The surface of several beams was sanded by sandpaper to correct the unacceptable appearance (brush marks), where the color of primer was different with the remaining areas due to the areas were not touched-up (please see photos #12 & #13 below).

• The color of primer at the support areas in Beam identified as # 2131030 was different with the remaining areas (please see photo #14 below).

• No primer applied on the connection areas (faying surface) (please see photo #15 below). • Holiday/rust was observed at inside of all bolt holes (please see photo #16 below).

TRC QAI was informed by ZPMC QC that the sanded areas will be touched-up later, and according the requirements of the approved RFI #1218, no primer is required at the connection areas and inside of all bolt holes for zone 2, but the mentioned FRI #1218 was not available for review by the QAI.

4. Witness of QA and QC Checks Blasting: TRC QAI witnessed AB’s QA was performing inspections of total thirty-three (33) Beams after sand blasting and blew the dust away under the presence of TENMEC Technical Representative and ZPMC’s QC. The observations of inspection and testing were as follows:

• The blasting cleanliness of Sa 2.5 was not achieved at the several small areas that were marked-up by both QA and QC for re-blasting (please see photos #20, #21 & #22 below).

• The deformed angle steel in Beam identified as #2145002 was observed, which might be caused by improper handling (please see photo #28 below).

• Structure steel damaged (notches & scratches) on the several beams after blasting (please see photos #25, #26 & #27 below).

• No salt testing was carried out (no required). • The blasting surface profile was verified by using ISO profile comparator. The results

appear to be defined as medium.

QAI was informed that the deformed angle steel will be corrected, and notches/scratches will be removed by grinding, and the marked unacceptable blasting cleanliness areas will be re-blasted prior to primer application. Later in the day, it was noted that the re-blasting was carried out by ZPMC.

5. Calibration of Dry Film Thickness Gauge: TRC QAI noted that no DFT gauges and calibration foils were available to neither AB’s QA or ZPMC’s QC. After talking with AB’s QA and ZPMC’s QC, TRC’s QAI was informed that the DFT’s of green tagged components were checked by using TENMEC Technical Representative’s DFT gauge. However, it was noted that the DFT gauge used was calibrated on the standard zero

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plate without the use of foils. This is not an approved method to correctly calibrate the DFT gauge to ensure the accuracy of the measurements. AB’s Fabrication Superintendent Peter Ferguson explained that it will be acceptable if only one set of equipment used for inspection if it is done correctly. Based upon the observations of DFT calibrations, AB’s Peter Ferguson requested that total sixty-eight (68) green tagged components be re-checked by ZPMC and QA after the DFT gauge is calibrated correctly. Later in the day, it was observed that one DFT gauge and one set of calibration foils were borrowed by ZPMC’s QC from the another department.

6. Random DFT Measurements Checks: TRC QAI performed random Dry Film Thickness (DFT) checks of all green tagged components in the Lay-down Yard by using the QAI’s calibrated DFT instrument. A total of 204 measurements were taken. A minimum reading of 151 microns was detected, a maximum reading of 356 microns (single reading) was detected, and the average of the measured DFT of readings is 227 microns. The average of DFT readings appear to be meet the requirements of project specification specified minimum of 150 microns (please see photos #29, #30 & #31).

PHOTOGRAPHS

1. View of painting shop. 2. Second view of painting shop.

3. Third view of painting shop. 4. View of TENMEC paint products used.

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5. View of grinding being performed by sandpaper. 6. View of paint repairs being applied by roller.

7. View of environmental condition checks by ZPMC’s QC.

8. View of the measured steel temperature to be 34 0C.

9. View of base metal (holiday). 10. View of the status of components after green tagged.

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11. Second view of the status of components after green tagged.

12. View of the acceptable profile.

13. View of the steel of surface after sanding of the unacceptable appearance.

14. View of the different colors of primer at the support areas.

15. View of no primer applied at the connection areas. 16. View of no primer applied inside of bolt holes.

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17. View of the status of components after blasting. 18. Second view of the status of components after

blasting.

19. View of blasting checks by ZPMC’s QC and AB’s QA.

20. View of the marked the unacceptable blasting cleanliness.

21. Second view of the marked the unacceptable blasting cleanliness.

22. Third view of the marked the unacceptable blasting cleanliness.

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23. View of the acceptable blasting cleanliness. 24. View of the achieved blasting profiles of medium.

25. View of structure steel damages (scrapes). 26. View of structure steel damage (notches).

27. View of structure steel damages (scratches). 28. View of the deformed angle steel.

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29. View of the measured DFT reading of 234 microns. 30. Second view of the measured DFT reading of 230

microns.

31. Third view of the measured DFT reading of 266 microns.

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QUALITY SURVEILLANCE REPORT

Project Name: Washington State Convention Center Expansion Project

Subcontractor: American Bridge Company

Fabricator: Shanghai Zhenhua Heavy Industries (ZPMC)

Date: Saturday August 10, 2019 - Swing Shift

Report No: 20190810_MTE_TRC_ZPMC_Ding

BACKGROUND:

Mayes Testing Engineers (MTE) Representative Ding Baohua (a TRC employee), Quality Assurance Inspector (QAI) was present at the Zhenhua Heavy Industries (ZPMC) in Shanghai China on the evening of Saturday, August 10, 2019 to conduct services in association with the fabrication inspection of the Washington State Convention Center Expansion Project. TRC’s QAI performed random inspections of operations associated with cutting, fit-up, preheating and welding of Beams and Columns during the swing shift. TRC QAI performed general observations of inspection and testing activities conducted by ZPMC’s QC & AB’s QA in Workshop Bays #1, #2, #3, #4 and #5. A task for this visit was to perform ultrasonic testing (UT), magnetic particle testing (MT) and conduct visual observations of American Bridge’s (AB) Quality Assurance (QA) and ZPMC’s Quality Control (QC) as they inspect and test the complete joint penetration (CJP) welds. A focus for this QAI is to conduct observations and nondestructive testing of the cruciform type connections in thicker members where lamellar tearing may be a potential concern.

GENERAL OBSERVATION:

TRC’s QAI witnessed AB’s QA perform the UT on CJP cruciform joints of beams and columns. TRC’s QAI observed fifteen (15) components that have CJP cruciform joints in the workshop and under fabrication or testing as indicated in the table below. TRC’s QAI observed that all fifteen (15) components have been repaired due to lamellar defects detected by VT or MT in the intersecting plate of the cruciform connection. UT has been used by ZPMC to detect some of the lamellar defects, but the majority were detected by VT and MT. These components are identified as indicated in the table below:

# Component

ID. Plate No.

Th.

(mm)

Lamellar

Flaws Detected

By

QC UT

Status

QA UT

Status TRC Status

1 1046401 P13147/P18254 61 VT Ok Ok Ok, Green Tagged 5/11/2019

2 1036401 P17223/P13158 102 VT + MT Ok Ok Ok after 4 times repair, Green Tagged 5/28/2019

3 1036402 P17213/P13156 90 UT + MT Ok Ok Ok, Green Tagged 5/28/2019

4 1030002 P17431/P12053 102 MT Ok Ok Ok, Green Tagged 5/21/2019

5 1036405 P14250/P8569 76 VT + UT Ok Ok Ok, Green Tagged 5/23/2019

6 1040001 P18265/P13146 61 UT by TRC Ok Ok Ok after repair, Green Tagged 5/14/2019

7 1030019 P7310/P13114 70 UT by TRC Ok Ok Ok after repair, Green Tagged 5/20/2019

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1. Witness of QC Performing Ultrasonic Testing (UT):

TRC’s QAI observed ZPMC’s QC Cao Shengfeng and Zhang Nianfu, UT Level II Technicians, perform UT testing of CJP T-joint welds on component identified as #3066404. The testing process appeared to comply with the requirements of AWS D1.1-2015, Clause 6, Part F. It was observed that the UT technicians used three (3) different angle probes (70°, 60° and 45°) to cover the scanned areas. A total of eight (8) T-joint welds of the component were tested by QC. The QAI was informed that one (1) rejectable indication was detected in the weld identified as WD130 on this component by UT (please see photos #1 & #2 below).

2. Witness of QC Performing Magnetic Particle Testing (MT):

During observations in Bay #5, TRC’s QAI witnessed ZPMC’s MT Level II Technician identified as Li Changtao was performing MT on the Connection Plate to Flange welds on component identified as #2055007. The QAI was informed that two (2) linear indications were detected at the end of the weld. ZPMC MT technician instructed the worker to grind out the indication. The area was re-check by both VT and MT and found to be acceptable after grinding. It appeared that the testing process was in accordance with AWS D1.1-2010, Clause 6, Part C (please see photos #3 & #4 below).

3. Ultrasonic Testing (UT) Verification of General Joints:

TRC’s QAI performed ultrasonic testing (UT) in accordance with AWS D1.1, Clauses 6, Part F used two (2) shear wave transducer angle (70° and 60°) and a longitudinal wave transducer (0°) to cover the scanned areas. The testing was performed on T-joint welds identified as below: • Component: #2076402.

o Stiffener to Web welds #: WD095 and WD105, plate thickness: 33 / 76 mm. The above welds were accepted by both QA and QC UT technicians. No indications of concern were observed by TRC’s QAI (please see photo #5 below).

4. Ultrasonic Testing (UT) Verification of Cruciform Joints:

TRC’s QAI performed ultrasonic testing (UT) in accordance with AWS D1.1, Clauses 6, Part F by using three (3) different shear wave transducer angles (70°, 60° and 45°) and a longitudinal wave transducer (0°) to cover the scanned areas. The testing was performed on cruciform joint welds identified as below: • Component: #2036404.

o Flange to intersecting plate weld #: WD089, plate thickness: 102 / 64 mm.

8 2036406 P17782/P9686 64 UT + MT Ok In process In process

9 2036404 P16773/P17781 64 UT + MT Ok In process Done

10 2016402 P12762/P12762 76 MT Ok

11 2016403 P12763/P12763 51 VT + MT Ok In process In process

12 2036405 P17795/P17796 102 MT + UT Ok In process

13 3030006 P20294/P20295 89 MT Ok Done Done

14 3036404 P8105/P8106 64 MT + UT Ok

15 3036401 P20296/P20297 89 VT + UT Ok

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The above weld was accepted by ZPMC’s QC UT technicians. No lamellar indications of concern were observed by TRC’s QAI (please see photos #6 below).

5. Verification of Welder Qualification and Welding Parameters:

During a walkthrough of Bay #1, TRC’s QAI observed one (1) Completed Joint Penetration (CJP) weld between the Web and Stiffener joints on component identified as #3114016 was being welded by using flux cored arc welding (FCAW). TRC QAI verified the welder qualification card for the welding operator identified as Yu Huihui (GG-022). ZPMC’s QC Inspector was present to monitor the welding process. The filler metal of TWE-711H-D (Ø 0.045’’) used was verified by TRC’s QAI, which was satisfactory. The measured preheat temperature was determined to 132 ℃ by ZPMC’s QC using an infrared thermometer. The QAI witnessed the checking of the welding parameters by QC. The parameters checked included voltages, currents. These checked items were found to follow the approved welding procedure specifications of WPS (please see photos #7 & #8 below).

6. Verification of Flange and Web Plate Splice Welds Fit-ups:

During observations in Bay #3, TRC QAI performed random fit-up checks of the Flange and Web Plate splice welds on component identified as #3066001 prior to welding. The fit-up of weld joints appears to be in compliance with the requirements of approved shop drawing and welding procedure specification (please see photos #9 & #10 below).

7. Verification of Heat Straightening Temperature:

During observations in Bay #1, TRC’s QAI observed that ZPMC’s personnel perform heat straightening on the Flange Plate in Beam identified as #3035004 by handheld flame torch to correct the deformation caused by welding. The measured heat straightening temperature was determined to 355 ℃ by ZPMC’s QC using a calibrated infrared thermometer. The result appeared to be in compliance with the requirement of AWS D1.1: 2010 Clause 5.26.2 (please see photos #11 & #12 below).

8. TRC UT Verification Tracking Sheet:

Please see the details in the below summary table.

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# Comp.

ID. IP No.

Weld

No.

Flange/

IP

Thickness

(mm)

Fabrication

Stages

UT (Welds) Lamellar

Flaws

(IP)

detected

by

ZPMC

UT

Status

AB UT

Status

TRC

UT

Status

Straight

Beam

UT of

Plate

Before

Welding

Straight

Beam

UT of

Plate

After

Welding

TRC UT Initial Within

t/4 of

The

Base

Metal

Details of Indication

TRC UT After

Repairs Remarks

R0 R1 R2 Results Test

Date Result

Test

Date

1 1046401

P13147

WD65 102/61 Completed ACC / / / Done Done Done

Not tested ACC

Comply 5/1/2019 N/A N/A N/A

Date of Green Tag: 5/11/2019

WD226 102/61 Completed REJ ACC / / Done Done Done Comply 5/1/2019 N/A N/A N/A

WD62 102/61 Completed ACC / / / Done Done Done Comply 4/26/2019 N/A N/A N/A

WD64 102/61 Completed ACC / / / Done Done Done Comply 4/25/2019 N/A N/A N/A

P18254

WD63 102/61 Completed REJ ACC / / Done Done Done

Not tested ACC

Comply 5/1/2019 N/A N/A N/A

WD70 102/61 Completed REJ ACC / / Done Done Done Comply 5/1/2019 N/A N/A N/A

WD227 102/61 Completed ACC / / VT Done Done Done Comply 4/26/2019 N/A N/A N/A

WD85 102/61 Completed REJ ACC / Done Done Done Comply 4/26/2019 N/A N/A N/A

2 1036401

P13158

WD43 102/102 Completed ACC / /

MT + UT Done Done Done

Not tested ACC

Two indications 4/29/2019 Yes X1=350 mm, Y1=+20 mm, D=96 mm, L=12 mm, d=+10 dB, 60°. Comply 5/24/2019

WD43, WD44 Repaired four times 5/19/2019, 5/20/2019, 5/21/2019 and 5/22/2019. UT Ok after repair #4 on

5/24/2019

Completed ACC / / Done Done Done 4/29/2019 No X2=610 mm, Y2=+50 mm, D=96 mm, L=25 mm, d=+7 dB, 60°. Comply 5/24/2019

WD44 102/102 Completed ACC / / MT + UT

Done Done Done Two indications

4/29/2019 No X1=235 mm, Y1=+50 mm, D=99 mm, L=10 mm, d=-2 dB, 70°. Comply 5/24/2019

Completed ACC / / Done Done Done 4/29/2019 No X2=550 mm, Y2=+20 mm, D=100 mm, L=15 mm, d=+10 dB, 60°. Comply 5/24/2019

WD45 102/102 Completed ACC / / Done Done Done Comply 4/27/2019 N/A N/A N/A

WD46 102/102 Completed REJ ACC / Done Done Done Comply 4/27/2019 N/A N/A N/A

P17223

WD31 102/102 Completed REJ ACC / VT + MT

Done Done Done

Not tested ACC

Comply 4/30/2019 N/A N/A N/A

WD32 102/102 Completed REJ ACC / Done Done Done Comply 4/30/2019 N/A N/A N/A

WD33 102/102 Completed ACC / / / Done Done Done Comply 4/27/2019 N/A N/A N/A

WD34 102/102 Completed ACC / / / Done Done Done Comply 4/29/2019 N/A N/A N/A

3 1036402

P17213

WD45 102/89 Completed REJ ACC / UT + MT

Done Done Done

Not tested ACC

Comply 5/14/2019 N/A N/A N/A

UT OK

WD64 102/89 Completed REJ ACC / Done Done Done Comply 5/14/2019 N/A N/A N/A

WD47 102/89 Completed ACC / / / Done Done Done Comply 5/12/2019 N/A N/A N/A

WD48 102/89 Completed ACC / / / Done Done Done Comply 5/12/2019 N/A N/A N/A

P13156

WD46 102/89 Completed ACC / / / Done Done Done

Not tested ACC

Comply 5/14/2019 N/A N/A N/A

WD65 102/89 Completed ACC / / / Done Done Done Comply 5/14/2019 N/A N/A N/A

WD66 102/89 Completed REJ ACC / UT + MT

Done Done Done Comply 5/14/2019 N/A N/A N/A

WD67 102/89 Completed REJ ACC / Done Done Done Comply 5/14/2019 N/A N/A N/A

4 1030019

P13114

WD31 114/70 Completed ACC / / UT

Done Done Done

Not tested ACC

Two indications 5/3/2019 No X1= 80 mm, Y1= +35, D=7 mm, L= 105 mm, d= -12 dB, 45°, 2 leg. Comply 5/21/2019

Date of Green Tag: 5/20/2019. WD31, WD33, WD25 R1 5/21/2019

Completed ACC / / Done Done Done 5/3/2019 No X2= 190 mm, Y2=+ 20, D=3 mm, L=35 mm, d= -10 dB, 45°, 2 leg Comply 5/21/2019

WD33 114/70 Completed ACC / / UT Done Done Done One indication 5/3/2019 No X=275 mm, Y=+30, D= 6.2 mm, L=25 mm, d= -2 dB, 45°, 2 leg Comply 5/21/2019

WD35 114/70 Completed ACC / / / Done Done Done Comply 5/3/2019 N/A N/A N/A

WD36 114/70 Completed ACC / / / Done Done Done Comply 5/3/2019 N/A N/A N/A

P7310

WD25 114/70 Completed ACC / / UT Done Done Done

Not tested ACC

One indication 5/6/2019 No X=25 mm, Y=+18, D=2.8 mm, L=25 mm, d= -2 dB, 45°, 2 leg Comply 5/21/2019

WD30 114/70 Completed ACC / / / Done Done Done Comply 5/6/2019 N/A N/A N/A

WD27 114/70 Completed ACC / / / Done Done Done Comply 5/6/2019 N/A N/A N/A

WD28 114/70 Completed ACC / / / Done Done Done Comply 5/6/2019 N/A N/A N/A

5 1036405

P14250

WD27 102/76 Completed REJ ACC / VT + UT

Done Done Done

Not tested ACC

Comply 5/17/2019 N/A N/A N/A

Date of Green Tag: 5/23/2019

WD28 102/76 Completed ACC / / Done Done Done Comply 5/17/2019 N/A N/A N/A

WD29 102/76 Completed ACC / / / Done Done Done Comply 5/16/2019 N/A N/A N/A

WD30 102/76 Completed ACC / / / Done Done Done Comply 5/17/2019 N/A N/A N/A

P8569

WD47 102/76 Completed ACC / / / Done Done Done

Not tested ACC

Comply 5/20/2019 N/A N/A N/A

WD48 102/76 Completed ACC / / / Done Done Done Comply 5/19/2019 N/A N/A N/A

WD49 102/76 Completed REJ ACC / / Done Done Done Comply 5/18/2019 N/A N/A N/A

WD50 102/76 Completed ACC / / / Done Done Done Comply 5/18/2019 N/A N/A N/A

6 1040001

P18265

WD49 95/61 Completed ACC / / UT Done Done Done

Not tested ACC

One indication 5/9/2019 No X=130 mm, Y=+32, D= 89 mm, L=25 mm, d= +6 dB, 60°, 1 leg Comply 5/21/2019

Date of Green Tag: 5/14/2019. WD49 R1 5/21/2019

WD52 95/61 Completed ACC / / / Done Done Done Comply 5/9/2019 N/A N/A N/A

WD48 95/61 Completed REJ ACC / / Done Done Done Comply 5/8/2019 N/A N/A N/A

WD53 95/61 Completed ACC / / / Done Done Done Comply 5/8/2019 N/A N/A N/A

P13146

WD55 95/61 Completed ACC / / / Done Done Done

Not tested ACC

Comply 5/12/2019 N/A N/A N/A

WD59 95/61 Completed ACC / / / Done Done Done Comply 5/12/2019 N/A N/A N/A

WD54 95/61 Completed ACC / / / Done Done Done Comply 5/9/2019 N/A N/A N/A

WD58 95/61 Completed ACC / / / Done Done Done Comply 5/9/2019 N/A N/A N/A

7 1030002 P17431

WD47 89/102 Completed ACC / / MT

Done Done Done Not

tested ACC Comply 5/23/2019 N/A N/A N/A

Date of Green Tag: 5/21/2019 WD49 89/102 Completed REJ REJ ACC Done Done Done Comply 5/23/2019 N/A N/A N/A

WD46 89/102 Completed REJ ACC / / Done Done Done Comply 5/21/2019 N/A N/A N/A

Page 64: Client Project - web6.seattle.gov

Page 5 of 9

# Comp.

ID. IP No.

Weld

No.

Flange/

IP

Thickness

(mm)

Fabrication

Stages

UT (Welds) Lamellar

Flaws

(IP)

detected

by

ZPMC

UT

Status

AB UT

Status

TRC

UT

Status

Straight

Beam

UT of

Plate

Before

Welding

Straight

Beam

UT of

Plate

After

Welding

TRC UT Initial Within

t/4 of

The

Base

Metal

Details of Indication

TRC UT After

Repairs Remarks

R0 R1 R2 Results Test

Date Result

Test

Date

WD50 89/102 Completed REJ REJ ACC / Done Done Done Comply 5/21/2019 N/A N/A N/A

P12053

WD53 89/102 Completed REJ ACC / / Done Done Done

Not tested ACC

Comply 5/22/2019 N/A N/A N/A

WD61 89/102 Completed REJ ACC / / Done Done Done Comply 5/22/2019 N/A N/A N/A

WD52 89/102 Completed REJ REJ ACC / Done Done Done Comply 5/23/2019 N/A N/A N/A

WD62 89/102 Completed REJ ACC / / Done Done Done Comply 5/22/2019 N/A N/A N/A

8 2036406

P17782

WD68 102/64 Completed ACC / / / Done In progress

ACC ACC

Comply 7/26/2019 N/A Only Face A

WD69 102/64 Completed ACC / / / Done In progress Done Comply 7/25/2019 N/A

WD72 102/64 Completed REJ ACC / / Done In progress

WD73 102/64 Completed REJ ACC / / Done In progress

P9686

WD76 102/64 Completed REJ ACC / / Done In progress

ACC ACC

Comply 7/26/2019 N/A Only Face A

WD77 102/64 Completed REJ ACC / / Done In progress Done Comply 7/23/2019 N/A

WD84 102/64 Completed REJ ACC / UT + MT Done In progress

WD85 102/64 Completed REJ ACC / Done In progress

9 2016402

P12762

WD35 102/76 Completed REJ ACC / MT

Done ACC (after

replacing the

plate)

WD40 102/76 Completed REJ REJ ACC Done

WD38 102/76 Completed ACC / / / Done

WD39 102/76 Completed ACC / / / Done

P12762

WD49 102/76 Completed REJ ACC / MT

Done ACC (after

replacing the

plate)

WD50 102/76 Completed REJ ACC / Done

WD45 102/76 Completed ACC / / / Done

WD46 102/76 Completed ACC / / / Done

10 2036404

P16773

WD88 102/64 Completed REJ ACC / UT + MT

Done Done

ACC ACC

Comply 7/19/2019 N/A

WD89 102/64 Completed REJ REJ R3 ACC Done Done Comply 8/10/2019 N/A

WD84 102/64 Completed REJ REJ ACC / Done Done Comply 7/11/2019 N/A

WD85 102/64 Completed REJ REJ ACC / Done Done Comply 7/11/2019 N/A

P17781

WD80 102/64 Completed REJ ACC / UT + MT

Done Done

ACC ACC

Comply 8/09/2019 N/A

WD81 102/64 Completed ACC / / Done Done Comply 7/22/2019 N/A

WD76 102/64 Completed REJ REJ R3 ACC / Done Done Comply 7/15/2019 N/A

WD77 102/64 Completed REJ ACC / / Done Done One indication 7/18/2019 Yes X=140 mm, Y=+10, D= 9.7 mm, L=25 mm, d= -2 dB, 45°, 2 leg Comply 8/02/2019

11 2016403

P12763

WD35 102/51 Completed REJ ACC / VT

Done In progress ACC (after

replacing the

plate)

ACC

Comply 8/07/2019 N/A These two indications are not Rejectable since flaws are not within the ¼ T zone per AWS D1.1, Table 6.2, This flaw is being report for informational purposes only.

WD36 102/51 Completed REJ REJ ACC Done In progress Comply 8/07/2019 N/A

WD39 102/51 Completed REJ REJ ACC / Done In progress

WD40 102/51 Completed REJ ACC / / Done In progress

P12763

WD49 102/51 Completed ACC / / MT

Done In progress

Not tested ACC

Not rejectable indication 7/30/2019 No X=230 mm, Y=+25, D= 59.7 mm, L=120 mm, d= +7 dB, 70°, 1 leg

WD50 102/51 Completed REJ REJ ACC Done In progress Not rejectable indication 8/01/2019 No X=235 mm, Y=+26, D= 59.8 mm, L=115 mm, d= +13 dB, 70°, 1 leg

WD45 102/51 Completed REJ ACC / / Done In progress

WD46 102/51 Completed REJ ACC / / Done In progress Comply 7/31/2019 N/A

12 2036405

P17795

WD90 102/102 Completed REJ ACC / MT + UT

Done In progress

ACC

WD91 102/102 Completed REJ ACC / Done In progress

WD94 102/102 Completed REJ ACC / / Done In progress

WD95 102/102 Completed REJ ACC / / Done In progress

P17796

WD78 102/102 Completed REJ ACC / MT + UT

Done In progress

ACC

WD79 102/102 Completed REJ ACC / Done In progress

WD82 102/102 Completed REJ ACC / / Done In progress

WD83 102/102 Completed REJ ACC / / Done In progress

13 3030006

P20294

WD25 57/89 Completed ACC / / MT

Done Done Done

Not tested ACC

Comply 7/5/2019 N/A

WD26 57/89 Completed ACC / / Done Done Done Comply 7/16/2019 N/A

WD28 57/89 Completed ACC / / / Done Done Done Comply 7/16/2019 N/A

WD29 57/89 Completed ACC / / / Done Done Done Comply 7/5/2019 N/A

P20295

WD22 57/89 Completed ACC / / MT

Done Done Done

Not tested ACC

Comply 7/17/2019 N/A

WD23 57/89 Completed ACC / / Done Done Done Comply 7/17/2019 N/A

WD19 57/89 Completed ACC / / / Done Done Done Comply 7/8/2019 N/A

WD20 57/89 Completed ACC / / / Done Done Done Comply 7/8/2019 N/A

Page 65: Client Project - web6.seattle.gov

Page 6 of 9

# Comp.

ID. IP No.

Weld

No.

Flange/

IP

Thickness

(mm)

Fabrication

Stages

UT (Welds) Lamellar

Flaws

(IP)

detected

by

ZPMC

UT

Status

AB UT

Status

TRC

UT

Status

Straight

Beam

UT of

Plate

Before

Welding

Straight

Beam

UT of

Plate

After

Welding

TRC UT Initial Within

t/4 of

The

Base

Metal

Details of Indication

TRC UT After

Repairs Remarks

R0 R1 R2 Results Test

Date Result

Test

Date

14 3036404

P8105

WD84 102/64 Completed REJ REJ ACC MT

ACC

WD85 102/64 Completed ACC / / WD79 102/64 Completed ACC / / / WD80 102/64 Completed REJ ACC / /

P8106

WD66 102/64 Completed ACC / / MT

ACC

WD67 102/64 Completed REJ ACC / WD70 102/64 Completed ACC / / / WD71 102/64 Completed ACC / / /

15 3036401

P20296

WD21 102/89 Completed REJ ACC / VT + UT

ACC

WD22 102/89 Completed ACC / /

WD25 102/89 Completed REJ ACC / /

WD26 102/89 Completed REJ REJ ACC /

P20297

WD19 102/89 Completed REJ ACC / MT + UT

ACC

WD20 102/89 Completed ACC / /

WD15 102/89 Completed REJ ACC / /

WD16 102/89 Completed ACC / / /

Note: Comp. ID=Component identification; IP=Insert Plate; WI= Welding in progress; REJ=Reject; ACC=Accepted; R0= Initial test; R1=Test after 1st time repair; R2=Test after 2nd time repair: = UT and MT of the welds have been tested by TRC QAI and satisfactory results were found by TRC.

Page 66: Client Project - web6.seattle.gov

Page 7 of 9

PHOTOGRAPHS

1. View of ZPMC’s QC performing UT on T-joint welds in Bay #1.

2. View of the rejected UT weld WD130 by ZPMC’s QC on component #3066404.

3. View of ZPMC’s QC performing MT on T-joint welds on component #2055007.

4. View of ZPMC’s QC performing MT on T-joint welds on component #2055007

5. View of TRC’s QAI performing UT on cruciform joint weld on component #2036404.

6. View of TRC’s QAI performing UT on T-joint welds on component #2076402.

Page 67: Client Project - web6.seattle.gov

Page 8 of 9

7. View of FCAW welding being performed on component #3114016.

8. View of measured of the preheat temperature at 132 ℃ in Bay #1.

9. View of fit-ups being performed on component #3066001.

10. View of fit-ups being performed on component #3066001.

11. View of heat straightening being applied on the web plate on component #3035004.

12. View of the measured temperature of the heated areas at 355 ℃ in Bay #1.

Page 68: Client Project - web6.seattle.gov

Page 9 of 9

13. View of welding being performed in Bay #1. 14. View of cutting being performed in Bay #1.

15. View of grinding being performed in Bay #3. 16. Overview of fabrication activities in Bay #2.

17. Overview of fabrication activities in Bay #1. 18. Overview of fabrication activities in Bay #3.

Page 69: Client Project - web6.seattle.gov

Report Date:Service Date:Report Number:

Task:

M7181304.028408/14/1908/14/19

20225 Cedar Valley Rd Ste 110Lynnwood, WA 98036-6365425-742-9360

Distribution List

Distribution Page

(1) Pine Street Group LLC, Webb Miller

(1) American Bridge Company, Jared Carlson

(1) American Bridge Company, Jim Thornton

(1) American Bridge Company, Josh Ishibashi

(1) American Bridge Company, Patrick Ryan

(1) American Bridge Company, Peter Ferguson

(1) American Bridge Company, Ryan Ferguson

(1) American Bridge Company, Tyler Zak

(1) Clark Construction Group LLC, Chris Donovan

(1) Clark Construction Group LLC, Colin Reed

(1) Clark Construction Group LLC, Fausto Figueroa

(1) Clark Construction Group LLC, Ryan Fiesta

(1) Clark Construction Group LLC, Scott Howland

(1) Donald B. Murphy Contractors, Inc., Bryce Niekamp

(1) Donald B. Murphy Contractors, Inc., Mihir Bharmal

(1) Garco Construction Company, Casey Stulc

(1) Garco Construction Company, Dan Fishburn

(1) Garco Construction Company, Dave Long

(1) Garco Construction Company, Greg Everson

(1) Garco Construction Company, Jesse Galaviz

(1) Garco Construction Company, Matthew Recknagel

(1) Garco Construction Company, Melissa Meidinger

(1) Garco Construction Company, Mike Herlihy

(1) Lewis Builds, Daniel Tunacik

(1) Lewis Builds, Joshua Van Kirk

(1) Lewis Builds, Kirk Highberger

(1) Magnusson Klemencic Assoc, James Stephens

(1) Magnusson Klemencic Assoc, Thomas Meyer

(1) Mayes Testing Engineers, Inc, Lisa McDuffy

(1) Mayes Testing Engineers, Inc, Michael Mayes

(1) Pine Street Group LLC, Crystal Ng