Bureau of Bridges and Structures Structural Fabrication … · Welder Qualification Test Report ......

Bureau of Bridges and Structures Structural Fabrication Unit

STRUCTURAL FABRICATION UNIT

V112917

TABLE OF CONTENTS

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MICHIGAN DEPARTMENT OF TRANSPORTATION

Table of Contents

1. Quality Assurance

Structural Fabrication Inspection Flowchart 1

Structural Fabrication Inspection Web Links 2

Structural Fabrication Quality Assurance Guidance Document 3

Materials Quality Assurance Procedures Manual Section 4.05 12

Materials Quality Assurance Procedures Manual Section 4.06 25

2. Request for Information

Structural Fabrication Request for Information Process 36

3. Nonconformance Program

Structural Fabrication Nonconformance Policy 40

Structural Fabrication Nonconformance Process 45

4. Buy America

Structural Fabrication Buy America Guidance Document 53

Buy America Sample Letters 58

5. Welder Qualification

Welder Qualification Program 61

Welder Qualification Field Data Report (Form 1929) 64

Welder Qualification Test Report (Form 0396) – Example 66

6. Material Sampling

Metals Laboratory Sampling Guidance Document 68

Sample Identification (Form 1923) 74

Sample Identification (Form 1923) – Example 75

7. Miscellaneous

Structural Fabrication E-construction Process 76

Structural Fabrication Bookmarking Template 78

8. Forms

Project Folder Checklist (Form 1942) 79

Fabrication Inspection Report (Form 0538) 80

Mill Certification Record (Form 0538D) 81

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v011314

Store Fabrication Inspection Folder

Inspector Notifies MDOT of Deficiencies and Non-Conformance

Notification of Structural Steel Fabrication

MDOT structural steel fabrication inspection flowchart showing high level functions performed by MDOT (Structural Fabrication Unit). After loading, but prior to shipping, the shop inspector stamps all elements and Bill of Lading approved for use. Construction inspector must collect stamped Bill of Lading, visually inspect unloaded elements, accept/reject the elements, and document in Inspector’s Daily Report. Elements that arrive to the project without a Bill of Lading must be rejected. Fabrication Inspection Memo is electronically distributed to the construction office at the end of the project for information only.

MDOT Structural Steel Fabrication Inspection Flowchart

Stock Pile Payment

Figure 1.

Partial Shipment Payment

MDOT Schedules Pre-Fabrication Meeting

TSC Requests Information from MDOT

MDOT Requests Information from Inspector

MDOT Sends TSC Approval Email

Fabricator Notifies Inspector of Partial Shipment

Contractor Requests Payment from TSC

Inspector Notifies MDOT of Partial Shipment

Fabricator Schedules Welder Qualification Testing

Inspector Stamps Elements and Bill of Lading Approved for Use

Fabricator Notifies Inspector of Final Shipment

Inspector Notifies MDOT of Final Shipment

Inspector Stamps Elements and Bill of Lading Approved for Use

Final Shipment Payment

Construction Accepts/Rejects Elements Construction Accepts/Rejects Elements

MDOT Addresses Deficiencies and Non-Conformance

MDOT Issues Fabrication Inspection Memo

MDOT Authorizes Consultant Inspector

MDOT Notifies Fabricator of Assigned Inspector

Fabricator Provides Inspector with Data and Approved Shop Drawings

Inspector Reviews Data and Performs Shop Inspection

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V012418

STRUCTURAL FABRICATION INSPECTION WEB LINKS

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Structural Fabrication

Inspection Web Links

Description This document contains several important links to resources related to structural fabrication inspection for

the Michigan Department of Transportation. Click on the title of each section for the link.

• 2012 Standard Specifications for Construction

This link will take you to a printable/downloadable copy of the MDOT 2012 Standard

Specifications for Construction as well as the Supplemental Specifications for Errata to these

Specifications. These specifications detail all of MDOT’s policies on construction. There are

subsections that are related specifically to structural precast concrete and Structural Steel

inspection.

• Materials Quality Assurance Procedures Manual

This document provides guidance on MDOT’s requirements for performing QA inspections.

• Materials Source Guide

This document describes the acceptance criteria for materials, and should be looked at prior to

the materials being incorporated into a project.

• Forms

All of the inspection forms are stored on this site which can be searched by the form number.

• Bridge Field Services

This site serves as a statewide resource for structures, and contains reference materials for bridge

personnel.

1. Field Manual for Concrete Anchoring

2. Field Manual for Structural Welding

3. Field Manual for Structural Bolting

• Structure Technical Section

This site contains all of the contact information for the Structural Fabrication Unit for which the

inspector is working for. You can also find the current QAI Fabrication Portfolios.

1. MDOT Shop Drawing Review Process

2. 2018 MDOT Structural Steel QAI Manual

3. 2018 MDOT Structural Precast Concrete QAI Manual

• MDOT Buy America Compliance Listing

This site contains a listing of Approved Manufacturers, QPL’s and Tested Stock Suppliers that are

either fully compliant, partially compliant, or do not have any steel/iron in their product as noted

next to each company name. For our use we only need to look at the BA+ or BA- listings.

http://mdotcf.state.mi.us/public/specbook/2012/

http://www.michigan.gov/mdot/0,4616,7-151-9622_11044_11367-207980--,00.html

http://www.michigan.gov/mdot/0,4616,7-151-9622_11044_11367_68095---,00.html

http://mdotjboss.state.mi.us/webforms/WebFormsHome.htm

http://www.michigan.gov/mdot/0,4616,7-151-9623_26663_56139_56173---,00.html

http://www.michigan.gov/documents/mdot/Field_Manual_for_Concrete_Anchoring_490535_7.pdf

http://www.michigan.gov/documents/mdot/MDOT_2017_Structural_Welding_Manual_556963_7.pdf

http://www.michigan.gov/documents/mdot/Field_Manual_for_Structural_Bolting_5_5x8_5pdf_468332_7.pdf

http://www.michigan.gov/mdot/0%2C4616%2C7-151-9623_26663_56139_56173-278981--%2C00.html

http://www.michigan.gov/documents/mdot/MDOT_Shop_Drawing_Review_Process_041513_471762_7.pdf

http://www.michigan.gov/documents/mdot/Structural_Steel_QAI_Manual_611785_7.pdf

http://www.michigan.gov/documents/mdot/Structural_Steel_QAI_Manual_611785_7.pdf

http://www.michigan.gov/documents/mdot/Structural_Precast_Concrete_QAI_Manual_611733_7.pdf

http://www.michigan.gov/documents/mdot/Structural_Precast_Concrete_QAI_Manual_611733_7.pdf

http://www.michigan.gov/mdot/0,4616,7-151-9622_11044_11367-291113--,00.html


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QA GUIDANCE DOCUMENT

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Quality Assurance Guidance Document

Description The purpose of this document is to provide the Michigan Department of Transportation’s (MDOT)

Structural Fabrication Unit guidance to supplement MDOT’s Materials Quality Assurance Procedures

(MQAP) Manual. This guidance document will be used to ensure statewide consistency in performing

quality assurance (QA) verification inspection at fabrication facilities. The Structural Fabrication Unit is

responsible for implementing the Department’s quality assurance program for structural elements

required to be accepted based on “Fabrication Inspection” per MDOT’s MQAP Manual and utilizes

vendors to provide the shop inspection. It is imperative for the quality assurance inspector (QAI) to

completely understand their role and responsibilities when performing QA verification inspection on

MDOT projects to ensure a successful QA program. It is important to note that this document is not

contractual and all project related decisions should be based on the project specifications. This

document is broken down into the following sections:

1. Definitions

2. Contact Information

3. Responsibilities

4. QAI Roles and Responsibilities

5. QAI Frequent Questions and Answers

1. DefinitionsBelow is a list of terms that are significant to this guidance document:

1.1 Contractor The Contractor is responsible for proper completion of all tasks required by the contract.

Subcontractors, including fabricators, erectors, and field painters, may be used by the Contractor,

but the Contractor retains responsibility for all material, operations, and the final product. The

Contractor should permit direct subcontractor interaction with MDOT to expedite the project, but

subcontractors must inform the Contractor of any proposed modifications to contract requirements.

1.2 Design Project Manager (PM) The Design PM can be the Engineer of Record or could be managing a consultant contract where

the consultant is the Engineer of Record.

1.3 Engineer The Engineer can be the Director of the Department of Transportation or the MDOT Construction

Engineer designated by the Director, acting directly or through authorized representatives, who is

responsible for engineering supervision of the construction. The Engineer has the authority to allow

exceptions to contract document requirements.

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1.4 Engineer of Record (EOR) Those preparing the contract documents, including those responsible for the structure’s adequate

design. The Engineer of Record seals and signs the contract plans.

1.5 Fabricator The facility performing such shop activities as cutting, welding, drilling, punching, tying rebar,

tensioning strand, pouring concrete, cleaning and painting of structural steel, etc. The Fabricator also

includes any agents of the Fabricator, such as those who prepare shop detail drawings, perform non-

destructive examinations, paint, etc. In some cases the Fabricator may also be the Contractor, but

the Fabricator is typically a subcontractor.

1.6 Fabrication Inspection The examination by MDOT or the Fabricator of processes and products to verify general

conformance with contract requirements.

1.7 Fabrication Inspection Acceptance The first step in MDOT’s two part acceptance process for structural elements required to be accepted

based on “Fabrication Inspection” per MDOT’s MQAP Manual.

1.8 Field Inspection Acceptance The second step in MDOT’s two part acceptance process for structural elements required to be

accepted based on “Fabrication Inspection” per MDOT’s MQAP Manual.

1.9 Materials Quality Assurance Procedures Manual (MQAP) The formal written document prepared by MDOT that describes the policies and procedures used to

accept materials for incorporation into MDOT projects. The document contains inspection

procedures for fabricated structural precast (prestressed and non-prestressed) concrete, structural

steel, and other structural elements.

1.10 Michigan Department of Transportation (MDOT) The entity (owner) paying the Contractor to fulfill the terms of the contract. MDOT also encompasses

the Engineer who is authorized and responsible for engineering supervision of the construction. The

Engineer is an employee of MDOT; however, MDOT may contract with a professional firm to oversee

the day to day supervision with all critical decisions coming through the Engineer.

1.11 Nonconformance Report (NCR) An alteration in the work or a fabrication error that results in the element not meeting project

specifications. The fabricator generates a NCR submittal after fabrication has begun and their quality

control inspector (QCI) has noted a nonconformance to the project specifications.

Nonconformances are generally defined to be material or workmanship in nature and are further

classified by MDOT to be minor or major. Minor nonconformances can be repaired by the fabricator

without approval of a NCR, whereas major nonconformances require approval of a NCR.

1.12 Precast Concrete Precast concrete is a construction product produced by casting concrete in a reusable form, which is

then cured in a somewhat controlled environment, transported to the construction site, and lifted into

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place. Precast concrete can be either prestressed or non-prestressed. In contrast, cast-in-place (CIP)

concrete is poured into site-specific forms and cured on site.

1.13 Procedure Qualification Record (PQR) A production welding procedure specification (WPS) qualification is based on a procedure

qualification test record (PQR) produced by the Contractor in conformance with required heat input

qualifications and other code requirements. The test is designed to provide assurance that the weld

metal produced by welding in conformance with the provisions of the code must produce weld

metal strength, ductility, and toughness conforming to the code.

1.14 Quality Assurance (QA) Quality assurance (QA) encompasses the activities undertaken by the Owner to verify that the final

product satisfies contract requirements, including verifying that quality control is performed

effectively.

1.15 Quality Assurance Inspector (QAI) MDOT’s representative that is responsible for duties specified in the MDOT MQAP, with the authority to

accept work that meets contract requirements.

1.16 Quality Control (QC) The activities undertaken by the Contractor/Fabricator to ensure a product is provided that meets

contract requirements.

1.17 Quality Control Inspector (QCI) A qualified employee of the Fabricator who performs inspection as defined by the Fabricator’s

Quality Control Plan.

1.18 Quality Control Plan (QCP) The formal written document prepared by the Fabricator and reviewed by a certification agency

(AISC, NPCA, PCI, etc.) that describes the policies and procedures used to verify that fabricated

structural precast (prestressed and non-prestressed) concrete, structural steel, and other structural

elements will satisfy the contract requirements.

1.19 Request for Information (RFI) Requests by the Fabricator seeking additional information or proposing alternate material, fabrication

method, or inspection method for the structural element.

1.20 Spot Inspection The random examination of the Fabricator’s processes or products for verification of conformance

with contract requirements.

1.21 Structural Fabrication Unit MDOT’s specialized QA unit that is responsible for implementing the Department’s QA program for all

structural elements required to be accepted based on “Fabrication Inspection” per MDOT’s MQAP.

1.22 Welding Procedure Specification (WPS) Is a formal written document describing welding procedures, which provides direction to the welder

or welding operators for making sound and quality production welds as per the code requirements.

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The purpose of the document is to guide welders to the accepted procedures so that repeatable

and trusted welding techniques are used.

2. Contact Information The Structural Fabrication Unit can be contacted by phone or email. QAI’s are required to bring urgent

matters to the appropriate contact person by phone and then immediately follow up by email for record

and attach all applicable supporting documentation to the email. All other matters are required to be

submitted via email and then a call, if needed, can be setup. The Structural Fabrication Unit’s email

resource is shown below:

[email protected]

3. Responsibilities

3.1 Team Effort

3.1.1 The Contractor, Fabricator, and MDOT will approach quality control and quality assurance

as a team effort to facilitate accurate and timely construction.

3.1.2 All parties will cooperate and maintain open lines of communication so that problems can

be quickly addressed and resolved.

3.1.3 The QAI’s verification does not relieve the Fabricator from the responsibility to perform the

required testing and inspection and produce a product satisfying the contract.

3.2 Fabricator

3.2.1 Provide quality control to ensure that the finished product meets or exceeds contract

requirements.

3.2.2 Develop and implement a QCP that reflects a commitment to quality and describes the

quality control activities that will be employed on each project.

3.2.3 Provide MDOT with a copy of the QCP.

3.2.4 Submit shop drawings to MDOT for review with weld procedure specification (WPS) and

supporting procedure qualification record (PQR), as applicable.

3.2.5 Provide structural precast concrete Material Source List (MSL) prior to the prefabrication

meeting.

3.2.6 Provide qualified QCIs who report to personnel responsible for quality control as defined by

the QCP.

3.2.7 Provide MDOT with an accurate notification before beginning work in the shop and all

production scheduling as required by the contract requirements.

3.2.8 Present all material for the QAI’s acceptance in a manner that will allow a thorough

inspection of components and assemblies.

3.2.9 Provide the QAI full access to shop facilities where the work is being stored, fabricated, or

assembled.

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3.2.10 Provide the QAI with all approved shop drawings, NCRs, RFIs, MDOT Welder Qualification

test reports, WPSs, QC reports, material certifications/test reports, NDE reports,

personnel/plant certifications, equipment calibration reports, and all other applicable

documents in a timely manner as required by the contract requirements.

3.2.11 Keep the QAI informed prior to performing in-process repairs, NCRs (if applicable), QC

inspection activities, and pending nondestructive examination (if applicable).

3.3 MDOT

3.3.1 Monitor the Fabricator’s control of the operations and verify conformity of the work with the


3.3.2 Keep the Fabricator’s QCP confidential.

3.3.3 Observe fabrication (either on a schedule or at random) and perform testing of materials

and fabricated elements as necessary to confirm the effectiveness of the Fabricator’s QCP.

3.3.4 MDOT has the right to observe all phases of the work, from initial receipt and preparation of

raw materials through prestressing, tying steel, fresh concrete testing, placing concrete,

testing cylinders, repairs, burning and cutting, welding, nondestructive testing, cleaning,

coating, shipping, and any other activities deemed appropriate by MDOT.

3.3.5 The frequency and nature of QA inspection will vary with the type of structure, experience

of the Fabricator, strength of the Fabricator’s QC organization, and other similar factors

that affect the quality of work.

3.3.6 Verify that production quality and fabrication processes generally satisfy contract

requirements, including the QCP.

3.3.7 Accept materials and fabricated elements that satisfy the contract requirements.

3.3.8 Notify MDOT when fabricator ships elements for projects, and specify if the shipment is the

final shipment for the project.

3.3.9 Submit project file to MDOT within one week of final shipment of elements.

3.3.10 MDOT will not waive items that are contractual obligations of the Fabricator and will not

accept material that does not conform to the contract requirements. However, based on

experience and knowledge of the specific situation, the Engineer may accept materials

and elements that are not in conformance with the contract and may allow material

substitutions. See the following two documents for more information:

MDOT Structural Fabrication RFI Process

MDOT Structural Fabrication Nonconformance Policy

3.3.11 MDOT will not direct the Fabricator’s work. However, MDOT should advise the Fabricator to

discontinue any operation that would result in noncompliance with the contract.

3.3.12 MDOT will direct all official communications to the Fabricator’s quality control or

management as determined in the prefabrication meeting.

3.3.13 MDOT will not convey directives or personal judgements about overall shop quality or

concerns about employee competence to production personnel.

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3.3.14 MDOT will not publish, copy, or distribute any proprietary information, documents, or forms

received from the Fabricator for any purpose other than the contractual needs of MDOT.

3.4 Prefabrication Meetings Prefabrication meetings facilitate effective quality control and quality assurance and are conducted

by MDOT’s Structural Fabrication Unit prior to the start of fabrication and preferably after shop

drawings have been approved. The Structural Fabrication Unit, QAI, Fabricator, and QCI must be

present, whereas the Engineer and Contractor should be present to ensure a team effort to facilitate

accurate and timely construction. Quality assurance and quality control contact information will be

shared during this meeting to ensure effective and timely communication.

4. QAI Roles and Responsibilities

4.1 Qualifications of the QAI Qualification requirements of the QAI is covered in the MDOT MQAP Manual for the type of inspection

required.

4.2 Equipment Requirements of the QAI Equipment requirements of the QAI is covered in the MDOT MQAP Manual for the type of inspection

required.

4.3 Scheduling The scheduling of inspection and other QA functions can have a significant impact on the project.

The QAI must follow these guidelines:

4.3.1 Coordinate with the QCI for anticipated production scheduling to anticipate timing and

staffing needs. Discuss the progress of the work with appropriate fabrication personnel

designated during the prefabrication meeting.

4.3.2 Schedule inspections in a timely manner to facilitate fabrication progress, especially if

multiple shifts are used.

4.3.3 Discuss with the Structural Fabrication Unit whether additional presence in the shop is

required.

4.3.4 Document problems with scheduling inspection, including inaccurate information from

fabrication personnel and production delays.

4.4 Role of the QAI

4.4.1 Perform verification tests, measurements, inspection, or observations to ensure that

fabricated elements conform to the contract requirements. Although the QAI does not

perform the QC work, some QA activities may duplicate a portion of the QC activity for

verification purposes.

4.4.2 If there are questions about a requirement or level of quality, contact the Structural

Fabrication Unit and, if appropriate, alert the Fabricator.

4.4.3 Conduct consistent inspections based on the contract requirements and obtain assistance

from the Structural Fabrication Unit as needed.

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4.4.4 Be familiar with the QCP to better understand the QC operations of the shop.

4.5 Responsibilities of the QAI See subsection 3.3 above for a list of QAI responsibilities.

4.6 Interaction with the Fabricator QCI

4.6.1 Verify the effectiveness of the QCI’s evaluation of the work.

4.6.2 Perform verification inspection after the QCI has completed their inspection and testing in

accordance with the Fabricator’s QCP. However, serious problems noted at any time or

stage of fabrication must be immediately pointed out to the QCI.

4.6.3 Though QA inspection may include all aspects of fabrication, the QAI must not supersede

QC, which is the responsibility of the Fabricator. If QC is not accomplishing its role then the

Structural Fabrication Unit, Engineer, Contractor, and Fabricator must determine the

necessary corrections.

4.7 Interaction with Fabricator If the Fabricator’s inquiries involve design questions, material substitutions, alternate fabrication

methods, or items that are beyond the authority of the QAI, refer them to MDOT’s Structural

Fabrication Request for Information Process. If the Fabricator’s inquiries involve fabrication or material

nonconformance questions, refer them to MDOT’s Structural Fabrication Nonconformance Reporting

Process. Do not direct the fabricator.

4.8 Interpretation of the Contract Review contract requirements and seek guidance from the Structural Fabrication Unit if the QAI has

questions. Do not direct the Fabricator.

4.9 Fabrication Observation

4.9.1 Establish a pattern of regular and frequent observations during the progress of work to

verify satisfactory workmanship without delaying production or missing critical operations.

4.9.2 Coordinate verifications with the QCI and accomplish them with minimal additional

material handling by the Fabricator and with as little interference with the work in process

as possible.

4.9.3 Though there are not designated points during fabrication when the suitability of materials

must be checked, problems should be discovered and addressed as early as possible.

4.9.4 Provide narrative record keeping in accordance with applicable sections of the MQAP

manual.

4.10 Nonconforming Materials and Workmanship See MDOT’s Structural Fabrication Nonconformance Policy and MDOT’s Structural Fabrication

Nonconformance Reporting Process for more information.

4.11 Final Acceptance of the Work Acceptance of structural elements must be in accordance with MDOT’s MQAP Manual.

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5. QAI Frequent Questions and Answers The purpose of this section is to provide answers to frequently asked questions to ensure consistency and

alignment.

5.1 Fabricating without Approved Shop Drawings The QAI must notify the Structural Fabrication Unit immediately if the Fabricator is working without

MDOT approved shop drawings. Approved shop drawings are required prior to stamping elements

approved for shipping.

5.2 Inspecting Approved Repair Plans QAI must have the approved repair plan in hand prior to performing QA verification inspection of the

repair. Verification inspection also includes confirming that production and QCI have the approved

repair plan. If production and QCI do not have the approved plan then the QAI must notify them

that they are required to have the approved plan in hand during all aspects of the repair. If the

Fabricator begins working on the repair without the approved plan then the QAI must notify the

Fabricator of their observation in writing immediately and carbon copy the Structural Fabrication. The

Structural Fabrication Unit will notify the Engineer and Fabricator that the repair is recommend to be

rejected.

5.3 Stamping Elements Approved for Use QAI must have approved shop drawings prior to stamping any element approved for use. Elements

proposed to be shipped by the Fabricator that are not in general conformance with the approved

shop drawings must not be stamped. The only exception is if a nonconformance report (NCR) has

been approved by MDOT. Approved NCRs are to be used in conjunction with approved shop

drawings for acceptance. If elements are not in conformance with the approved shop drawings

then they are not to be stamped approved for use by the QAI. If requests for information (RFI) have

been approved by MDOT for the project then they must be incorporated into the shop drawings, if

applicable, prior to shipping.

5.4 Welder Qualification Testing See MDOT’s Welder Qualification Program for all welding information.

5.5 As-Built Shop Drawings The Fabricator is required to submit as-built shop drawings to MDOT for historical purposes. All

approved RFIs that are incorporated into the project must be added to the shop drawings and

submitted to MDOT for review and approval. Very minor changes toward the end of fabrication must

be documented and submitted as as-built shop drawings to the QAI prior to shipping. The Structural

Fabrication Unit can provide more guidance on a project by project basis as to what constitutes a

shop drawing revision and what is considered an as-built.

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MATERIALS QUALITY ASSURANCE PROCEDURES MANUAL

Partial Document October 2018 Edition In accordance with the 2012

Standard Specifications for Construction

CONSTRUCTION FIELD SERVICES DIVISION

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Materials Quality Assurance Procedures Manual 2012

4.05

4.05 STRUCTURAL STEEL FABRICATION

4.05.01. Scope

A. This structural steel fabrication inspection procedure should be used to aid the quality assurance inspector (QAI) in interpreting and enforcing the contract for structural steel elements. Fabrication inspection includes the time from verifying materials used for fabrication through loading for shipping to the construction site.

4.05.02. Reference Documents

A. QAI must have a thorough knowledge of the following references:

1. The following sections of the MDOT Standard Specifications for Construction (MDOT SSC) as modified by supplemental specification 12SS-001A – Errata, as applicable:

Section 104 Control of the Work Section 105 Control of the Materials Section 707 Structural Steel Construction Section 711 Bridge Railings Section 716 Shop Cleaning and Coating Structural Steel Section 906 Structural Steel Section 908 Miscellaneous Metal Products Section 915 Bridge Coating Systems

2. The following special provisions, as applicable:

12SP-105A Source of Steel and Iron (Buy America) 12SP-707A Special Provision for Structural Steel and Aluminum Construction 12SP-707B Special Provision for Fracture Critical Members 12SP-707C Special Provision for Modular Expansion Joint System 12SP-707F Special Provision for Structural Steel Construction Revisions

12SP-716A Special Provision for Shop Cleaning and Coating Structural Steel Revisions

12SP-906B Special Provision for Structural Steel Revisions

3. Structural Steel QAI Manual

4. AASHTO/American Welding Society (AWS) D1.5:XXXX, Bridge Welding Code (as modified by 12SP-707A, Structural Steel and Aluminum Construction), hereafter called AWS D1.5

5. Construction Field Services Division (CFS) Materials Source Guide (MSG)

6. MDOT Structural Fabrication Quality Assurance Guidance Document

7. MDOT Welder Qualification Program

8. MDOT Structural Fabrication Unit E-Construction Process

9. Prefabrication meeting minutes (if available)

B. QAI must be familiar with the following references:

1. AWS 2.4:XXXX, Symbols for Welding and Nondestructive Testing

2. AWS A3.0:XXXX, Standard Welding Terms and Definitions

3. MDOT Structural Fabrication Request for Information Process

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4.05


5. MDOT Structural Fabrication Nonconformance Process

6. Applicable SSPC specifications

7. Applicable coating test methods

8. Applicable ASTM and AASHTO specifications

9. MDOT Accident Prevention Plan

4.05.03. Qualifications, Responsibilities, Duties, and Equipment

A. Qualifications of the QAI – QAI performing the fabrication inspection must possess the following active qualification:

1. AWS Certified Welding Inspector (CWI)

B. Responsibilities of the QAI – QAI performing the fabrication inspection is not permitted to make changes to the contract and has the following responsibilities:

The Contractor, Fabricator, and MDOT will approach quality control and quality assurance as a team effort to facilitate accurate and timely construction. QAI’s verification does not relieve the Fabricator from the responsibility to perform the required testing and inspection to produce a product satisfying the contract. Though QA inspection may include all aspects of fabrication, the QAI must not supersede QC, which is the responsibility of the Fabricator. If QC is not accomplishing its role then the Structural Fabrication Unit, Engineer, Contractor, and Fabricator must determine the necessary corrections.

QAI is the responsible party, representing the Engineer, who performs quality assurance verification inspection on the element after quality control (QC) inspects and approves the item of work. The QAI must be at the fabrication facility at all times during fabrication as required by the inspection procedure stated below. If issues arise, it will be at the Engineer’s discretion whether to increase the level of QA inspection.

It is the Engineer’s responsibility to engage the Engineer of Record (EOR) when making structural decisions. The Engineer is also responsible for following internal MDOT procedures for review and approval of shop drawings, fabrication procedures, request for information (RFI), nonconformance reports (NCR), and for professional decision making on fabrication problems that arise. The Engineer relies on the Structural Fabrication Unit to manage and assist when appropriate. The Engineer has the prerogative for holding a prefabrication meeting with the Fabricator to discuss and clarify the contract plans and specifications. The Engineer is the responsible party who ensures MDOT’s fabrication QA program is followed for inspection and acceptance of the element.

Fabrication should proceed only with approved shop drawings. However, if the Fabricator must proceed prior to receipt of approved shop drawings (performing work at their own risk), ensure that the Structural Fabrication Unit is aware of this activity and await instruction on how to proceed. If the Engineer permits the work to proceed without approved shop drawings, proceed with basic QA functions using the non-approved shop drawings. Later, verify notes against approved drawings. Notify the Structural Fabrication Unit immediately if fabrication is not in conformance with the approved shop drawings.

C. Duties of the QAI – QAI performing the fabrication inspection has the following duties:

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4.05

1. QAI must thoroughly understand the contract.

2. QAI must verify steel material certifications show compliance with Buy America contract requirements.

3. QAI must be proficient in testing welders, sampling materials, verifying material traceability, and inspecting welds and coating systems.

4. QAI must be proficient in writing reports and using computers.

5. QAI must notify the Engineer if production begins before approved shop drawings are on the shop floor and provided to the QAI.

6. QAI must communicate all concerns through QCI or whomever the Fabricator directs during the prefabrication meeting.

7. QAI must communicate with QCI to obtain the work schedule.

8. QAI must follow MDOT’s Structural Fabrication E-Construction Process for closing out fabrication inspection file.

D. Deficiencies on Local Agency Projects – MDOT’s QAI must notify the Structural Fabrication Unit if they observe fabrication or inspection deficiencies on local agency program (LAP) projects. The Structural Fabrication Engineer will report the deficiencies via email to the Engineer that is responsible for construction oversight of the local agency project and carbon copy the applicable CFS and Design Division LAP Engineers.

E. Inspection Facilities and Access – Facilities for the QAI must be provided by the Fabricator per contract. QAI must have access to all parts of the work at all times. The authority and general duties of the QAI are specified in Section 104.01.D and E of the MDOT SSC.

F. Inspection Equipment – QAI will be furnished with the following items by the Engineer:

1. Contract (MDOT SSC, special provisions, standard plans, special details, plan sheets, etc.)

2. Approved shop drawings (provided by Fabricator)

3. Access to MDOT’s Fabrication Inspection & Construction System (FICS)

4. MDOT shop approval stamp

QAI must provide the following inspection equipment:

1. Computer with high speed internet access

2. Cell phone with camera

3. Flashlight

4. Fillet weld gauges

5. Undercut gauges

6. Instrumentation for measuring voltage and amperage

7. Temperature measuring devices capable of covering the range from 0°F to 1650°F

8. Dry film thickness gauges

9. Wet film paint thickness gauge

10. Surface roughness comparator gauge

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11. Extra course replica tape for measuring blasted steel surface profile

12. SSPC book of pictorial blast standards

13. Temperature and humidity measuring instruments

14. Measuring devices (200 foot and 20 foot steel tape and calipers)

15. Straightedge and levels

16. Safety equipment

17. Other as needed for the project

4.05.04. Inspection Procedure

A. Prefabrication Meeting – Prefabrication meetings facilitate effective quality control and quality assurance on the project and are conducted by MDOT’s Structural Fabrication Unit prior to the start of fabrication and preferably after shop drawings have been approved. The Structural Fabrication Unit, QAI, Fabricator, and QCI must be present, whereas the Engineer and Contractor should be present to ensure a team effort to facilitate accurate and timely construction. Quality assurance and quality control contact information will be shared during this meeting to ensure effective communication.

B. Fabrication Inspection – Structural steel must be fabricated in accordance with the MDOT SSC and contract. Fabrication inspection must be performed as shown below:

1. Structural steel fabrication inspection consists of verifying compliance with the approved shop drawings, contract, and approved NCRs. RFIs must be incorporated into the approved shop drawings for the QAI to inspect to.

2. An approved Materials Source List (MSL) is provided to the QAI by the Engineer so that the QAI knows what materials are being incorporated into the project and what the basis of acceptance is. The MSL is used to track material sampling by the QAI and to foster communication with QC to ensure all required sampling and testing occurs in a timely manner to prevent impacts to the project schedule. It is the Fabricator’s responsibility to notify the QAI when materials are available for sampling.

3. QAI begins by inspecting materials that will be used in the fabrication process and ensures they are being stored correctly, tagged for traceability purposes, and are in conformance with the contract. Next, the QAI inspects the Fabricator’s operations to ensure the condition of the equipment and work area for conformance to the contract.

4. MDOT’s Accident Prevention Plan states, “MDOT employees shall not engage in any act which would endanger another employee or themselves”. QAI must notify the Engineer immediately if work conditions exist that are not safe. If the level of inspection diminishes below what is specified in this QA procedure, due to safety concerns, then the element will not be approved for use.

C. Before Welding – Below is a checklist for the QAI to use for fabrication inspection prior to the start of welding. The actual steps and their exact sequence will depend upon the type of structure, the method of erection, and the qualifications of the welders who are to do the work.

1. Verify mill test reports match the base metal for conformance with the specifications. Verify that QC is maintaining traceability of all materials to such degree that the heat number of each piece of steel that is used in the project can be tracked to its location in the structure. Obtain from the Fabricator, if necessary, the shipping records,

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storage locations, and scheduling for each piece of steel that they intend to use in connection with the assigned contract. Examine each piece of steel as it is received at the shop to see that it has no uncorrected defects, kinks, or bends resulting from improper handling while in the mill or shop or in transit from mill to shop. Verify that the material from the mill meets ASTM A6.

2. Verify all welders are MDOT qualified (see MDOT’s Welder Qualification Program) and have appropriate fracture critical qualification, if applicable. Require requalification or supplementary welder tests if there are concerns. MDOT’s SSC requires that all tack welders, welders, and welding operators are active MDOT qualified welders for the welding process, plate thickness, and position prior to welding.

3. Verify that the welding procedure specification (WPS) and welding sequences are agreed to and understood by QAI, QC, and Fabricator prior to welding. All WPSs are required to be reviewed and approved by MDOT’s Structural Fabrication Unit. Contract require all WPSs to be qualified by a procedure qualification record (PQR) prior to welding. This qualification requirement is inclusive of all types of welds (butt welding, fillet welding, seal welding, plug welding, etc.). MDOT does not recognize prequalified AWS welding procedures, but we do accept properly documented evidence of previous PQRs that have not expired. See the contract for WPS and PQR requirements. The Fabricator is required to post approved WPS’s at each welding station.

4. Make a general examination of the structural steel and verify the quality of fabrication. Pay attention to the plate edge preparation, which would affect control over welding. Notify QC of any observed deficiencies before weld joint fit up is complete so they can correct any deficiencies.

5. Check the fitting of joints that are to be welded, including dimensions of root face, angle of bevel, cleanliness, match marks, alignment of parts to be joined, and uniformity and size of root openings. Recheck root faces and angles of bevel because trimming and re-beveling of plate edges is sometimes performed during fitting. Check the prepared weld joint edges for evidence of possible undesirable internal defects such as laminations in the steel plate. Make dimensional checks of all critical measurements to assure a proper fit in the field.

6. Check the fixture, clamping, and pre-cambering arrangements used in the fabrication assembly setup for adequacy. Make certain tack welds are made by MDOT qualified welders and the welds are small, smooth, and of specified quality. Verify that runoff tabs or extension plates are in place to ensure complete welding beyond the plate edges.

D. During Welding

1. Verify all welding is being performed using the approved WPS and sequences (if applicable) and electrodes are used with suitable currents and polarity for the positions the electrodes are intended to be used. Refer to the approved WPS for all details of performing the weld in question.

2. During inclement weather, ensure that suitable windbreaks or shields are provided and welding is not performed on surfaces that are wet, exposed to rain or snow, or if a heavy fog is present. Check the ambient and steel temperatures at the start of welding and during welding to determine if the specified preheat and interpass temperature requirements are being observed. Use temperature-indicating crayons or other equivalent means to check these temperatures.

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3. Check to make certain the correct electrodes (type and size) are available and are properly dried to prevent porosity and hydrogen cracking in the final welds. Low-hydrogen electrodes are susceptible to these types of defects if they are exposed to the atmosphere beyond the recommended limits. If electrodes and fluxes have been improperly stored or exposed to humidity in excess of the recommended limits, notify QC that reconditioning or rejection is required per the contract.

4. Intermittently observe the technique and performance of each welder to verify the approved WPS and suitable techniques are being followed. Inspect important or unique joints multiple times to ensure all weld passes meet project specifications. Arrange for the welder or the foreman to notify the QAI when such inspections at various stages may be made. Report any unusual or excessive distortion during welding to QC. Verify all corrective measures are being followed as approved by the Engineer to ensure the Fabricator’s methods minimize locked-in stresses.

5. Verify the welding arc is only struck in the joint or other area on which metal is to be deposited and not at random locations on the base metal outside of the prepared joint. Arc strikes cause physical and metallurgical stress risers and can change the mechanical properties of the steel at isolated locations. These changes can result in fatigue failures. Verify that approval by the Engineer has been given to the Fabricator prior to ground bars, clips, or ties being welded to the base metal. Approval for such welding is only given by the Engineer when unavoidable. When steel ground bars are used instead of ground clamps to carry the welding current to the base metal, make certain the ground bars are carefully welded to the base metal at a runoff tab or securely clamped to any area where all mill scale has been removed. Verify the grounding lead is as close to the point of welding as is practical.

6. Inspect root passes with special care because it is very important the first weld materials deposited in the root of a multiple pass weld is properly performed. Closely examine the root pass in important complete joint penetration welds, such as flange and web butt welds, t-joint, and corner joints to verify a sound pass that is free from cracks, inclusions, and lack of fusion.

7. Verify the root pass and every subsequent weld pass is cleaned with a wire brush and chipping hammer to thoroughly remove slag between weld passes to avoid inclusions. Ensure defects and substandard workmanship in any weld pass be removed by chipping or gouging before subsequent passes of metal are deposited. Peening or consolidating of weld metal by hammering is not permitted without the approval of the Engineer. Under conditions of very severe restraint, minimize weld cracking by acceptable techniques such as a cascade build-up sequence. Avoid any interruptions in the welding of a critical joint other than those necessary to change electrodes and quickly clean the slag from each pass before the next pass is deposited.

8. Verify the Fabricator is not creating re-entrants or local areas with high residual stresses in highly stressed parts of primary members. Where beam flanges do not match well at butt welded splices, the Fabricator should deposit the weld metal in such a way as to provide a smooth transition between the parts being joined. Verify that temporary fitting aids, such as plates and angles, are not applied at highly stressed locations and that temporary tack welds are not allowed.

9. Check all members to verify the welds are of proper size and length, are being made in the proper location to conform to the approved shop drawings, and are performed in such a manner as to produce weld metal conforming to the contract. To determine whether the weld metal is being deposited in such a manner as to penetrate well into the root of a joint without producing excessive slag inclusions or porosity, a field test may be conducted by making a T-joint with a fillet weld on only one side of the stem

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of the T. This joint can be broken open easily for visual examination. If welds are to be ground smooth and flush for any reason, verify grinding is performed so grinding marks are not left transverse to the direction of the main stress in a member. Verify welds are not being over ground so as to produce a "dished" surface. Verify the ends of welds are being ground smooth after runoff tabs are removed.

10. Identify with paint (do not steel stamp) each splice of primary member with the symbol of the welder doing the work. If two welders work on such a splice, show the symbol of each and record, in writing, the work each welder performed.

11. Record progress of fabrication on MDOT Form 0538. Include the dates that the work was completed and pertinent remarks regarding problems encountered and corrective action taken.

E. After Welding

1. Verify welds are cleaned of slag and weld spatter so they can be given a thorough final examination. Verify the surfaces of the welds are reasonably smooth and of suitable contour without evidence of undercut, overlap, excessive convexity, insufficient throat or leg size, unfilled craters at the ends of welds, or other defects in excess of the limits prescribed by the contract. Refer to the contract for the appearance of welds containing these various kinds of defects. Ensure all scars and defects, such as undercutting or remnant portions of tack welds and other scars that are left after the removal of temporary fitting and erection clips are corrected to be within the tolerances specified.

2. Check the storage, loading, blocking, and handling of the welded members to avoid distortion or structural damage. Verify braces or lugs are not welded to the members.

3. Verify the final camber and required curvature (or sweep) of all girders after all fabrication steps have been completed by observing QC perform their inspection. The Engineer will notify the QAI if they are required to perform QA inspection using the appropriate MDOT forms. Any members that measure out of tolerance must be noted for corrective action and rechecked after the correction has been made.

F. Non-Destructive Testing (NDT) - Is the responsibility of the Fabricator per the contract. QAI verifies the NDT requirements of the contract are correctly performed and documented. Knowledge of the principles and procedures of NDT is essential for QAI to verify QC during NDT.

Ensure the required visual test (VT), penetrant test (PT), magnetic particle test (MT), ultrasonic test (UT), and radiographic test (RT) inspections are performed and documented as required in the contract. Verify that the weld surface and adjacent plate surfaces are in satisfactory condition prior to non-destructive testing (NDT).

Verify NDT QCIs are ASNT Level II or III by reviewing certification records.

Check the performance of NDT QCIs at frequent intervals to verify approved procedures are being used, all weld joints to be tested are examined in accordance with contract and results are recorded. QAI should witness NDT of all critical splices. Collect all NDT reports generated and submit to the Engineer with the final documentation package.

Verify QC identifies locations of all rejected welds. Observe the excavation defects and the use of MT inspection to verify no part of the defect remains. Verify that the Fabricator follows all approved weld repair plans.

Perform VT after blast-cleaning the base metal for weld surface defects, weld finish, and edge and hole finish requirements.

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1. NDT Inspection Methods

a. Visual testing (VT) inspection of weldments must be in accordance with the contract.

b. Penetrant testing (PT) inspection of weldments must be in accordance with the contract.

c. Magnetic particle testing (MT) inspection of weldments must be in accordance with the contract.

d. Ultrasonic testing (UT) inspection of weldments must be in accordance with the contract.

e. Radiographic testing (RT) inspection of weldments must be in accordance with the contract.

2. Interpretation - The interpretation of all NDT is the responsibility of the Fabricator's QC personnel. QAI is responsible for reviewing all of the Fabricator's interpretations and calling any disagreements to the attention of the Engineer. The Engineer's interpretation is final and they may also call for additional testing to further explore a discrepancy.

G. Inspection of Shop Cleaning and Coating Fabricated Steel - QAI is responsible to verify that QC is being effective and enforcing all cleaning and coating contract requirements. All MDOT steel bridge contracts specify a high technology coating system. Most steel bridges are completely shop coated (i.e. primer, intermediate, and top coat) by the Fabricator. The essential phases of inspecting a coating system is summarized below:

1. Environmental Conditions – Contract include specific controls on environmental conditions (e.g. temperature, humidity, cleanliness, air movement, shading, etc.). These conditions must be strictly enforced.

2. Coating Materials - All paints must be carefully mixed, thinned, and handled in accordance with the manufacturer’s specifications. Verify QC is recording all batch numbers used for comparison to the certification documents. Verify the color numbers of the top coat for conformance to the approved shop drawings.

3. Cleaning and Coating Equipment - High technology coating systems employ the most sophisticated blast cleaning and spray painting equipment developed. A thorough knowledge of their operation and use is required by the QAI. QAI is responsible for evaluating the performance of the equipment prior to the coating of the structural steel. If any of the equipment is operating outside of the specification limits the coatings will not be properly applied and may fail (peeling) at some time after application.

4. Steel Surface Conditions - All grinding, weld repairs, and fabrication steps must be completed before blast cleaning and painting. Any remedial work performed after coating may be grounds for rejection of the coating system. The steel must be free of all traces of grease and oil before blast cleaning is performed.

5. Surface Preparation – Verify QC is monitoring surface cleanliness and surface profile using specialized equipment per the contract.

6. Coating Application - QAI must verify that the proper techniques of applying the high technology coating systems is being performed. Improper application techniques may "appear" to give acceptable results, but will lead to a greatly reduced performance life and possibly an early coating failure (blistering and peeling). QAI must verify QC is monitoring all environmental conditions before and during the

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coating process. Corrective actions must be taken on each coat of the painting system before the next coat is applied. Ensure that approved coating repair procedures are followed.

7. Documentation - Documentation of an approved coating on structural steel is comprised of the QC test reports on the coating evaluations and environmental conditions as well as a certificate of compliance from the paint manufacturer. MDOT coating systems are in a Qualified Products List found in the MDOT MSG. The certificate of compliance attests that the painting materials supplied are the same as those submitted to MDOT for acceptance testing.

8. Handling, Storage, and Repair - QAI must verify all contract for handling, storage, and repair of shop painted steel are strictly followed. All paint damages during handling and loading by the Fabricator must be repaired using approved procedures prior to QAI's approval for shipping.

4.05.05. Suggested Radiographic Testing Procedures

A. Radiographic testing (RT) inspection of weldments as required by the contract must be performed in accordance with the applicable welding code as modified by the contract. The following procedure is a suggested format that meets the requirements of most MDOT contracts.

1. Fabricator must furnish a satisfactory viewer and darkroom facility for developing and viewing the radiographic film and also provide shop space and time for all radiographic work. All safety precautions as required must be followed and enforced by the Fabricator.

2. See the contract for RT inspection requirements. All joints must be free of dirt, scale, grease, etc. prior to inspection. Flange splices must be ground flush on both sides and webs ground flush at the area to be RT (one side). The direction of grinding must be perpendicular to the length of the weld. All runoff tabs or other appendages must be completely removed before RT inspection.

3. Radiographs must be taken and interpreted by experienced and qualified technicians or radiographers as approved by the Engineer. The radiographic film and a report of the technician's interpretation must be submitted to the Engineer for their final approval before the weld is accepted. The film type must be fine grain Class I or Class II. Dimensions must be a minimum of 4.5 inches by 17 inches. Areas too large to be RT inspected on one film will require additional exposures. Limit web shot film size to 15 inches and flange shot film size to 16 inches. Either x-rays or gamma rays may be used to produce radiographs. Double lead screens must be used to back the film. Screens may be either pure lead or antimony lead with a maximum of 6 percent antimony. Tin coated lead foil or fluorescent screens must not be used. If RT inspection discloses defective welds, the defective portions must be removed and the material re-welded. Additional films must be taken of all repaired welds at the expense of the Fabricator and then submitted to the Engineer for approval.

4. The interpretation of all radiographic films must be furnished to the Engineer by the Fabricator. The interpretation report must be submitted on a form as approved by the Engineer. Should the Engineer question the interpretation of the radiographic film by the technician, or should the Fabricator question the interpretation of the Engineer, a joint review will be made. The Engineer’s final interpretation will govern.

5. All radiographs must be positively identified by the Fabricator in accordance with AWS D1.5. Identification lettering of radiographs must be placed on the source side along

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with the penetrometers. Lettering of repairs must show an "R" and the number of the repair, and must be placed next to the weld identification.

B. Standard Radiographic Identification Layout - (numbers refer to diagram above)

Explanation State structure number and control section.

Fabricator's initials and shop contract number.

Penetrometers. Use penetrometers for nominal thickness of each plate, but penetrometer for thicker plate not to exceed penetrometer for thinner plate by more than ten.

Weld Identification. Identification should identify the exact location of the weld in relation to piece number and location.

Location Letters. Placement of location letters is necessary to relate the location of questionable areas or defects should repair be necessary. More location letters must be added in the event more than one shot is required.

Tight fitting steel edge blocks must have a thickness equal to or greater than the thickness of the weld on all weld ends.

Lead “V” must be placed at edge to delineate the top edge on the radiograph. Additional identification may be used as required. All lead numbers and penetrometers must be placed on the source side of the plate being radiographed.

The use of "blocks" as illustrated is required. The use of these edge blocks will give a better picture of the top and bottom edges and are especially useful when the limits of the film are being crowded (e.g. one shot on a 16 inch flange).

4.05.06. Reports

A. The Engineer may require a periodic status report from the Structural Fabrication Unit; therefore, all reports are required to be completed in a timely and orderly manner using

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MDOT’s Fabrication Inspection & Construction System (FICS). Make entries as soon as possible after an event or conversation to ensure accuracy. Number the reports consecutively until completion of the work, with the last report noted “final”.

B. QAI must complete an accurate and detailed account of fabrication for the project. The report must include a discussion of fabrication progress for all aspects of the work. It is intended to be a detailed record of the status of fabrication and should include number of elements fabricated, documentation of specification and procedure compliance as well as documentation of conflicts, repairs, and other problems or discussion which could affect the project in anyway. If force account work is taking place, document each day that the work occurs in the shop and which elements are being worked.

C. Documentation is not a substitute for appropriate dialogue with the Fabricator, but should provide a record of important discussions. In some cases, the QAI is more familiar with the events or issues and therefore should review and comment on draft copies of the Structural Fabrication Unit’s correspondence.

D. Reports must be assembled into one fabrication inspection portable document format (PDF) file and stored in MDOT’s ProjectWise document storage program per MDOT’s Structural Fabrication Unit’s E-Construction Process. The Engineer will receive a fabrication inspection memorandum from the Structural Fabrication Engineer after fabrication inspection is complete. The memorandum is for informational purposes and is not used for acceptance.

E. Below is a list of various MDOT reports/forms and a brief description of their purpose and use requirement. Similar forms can be used in place of the standard MDOT form if noted below.

1. Project Folder Checklist (Form 1942) – This form must be completed by QAI for each project. The checklist is placed on top of the fabrication inspection folder when the project is complete.

2. Fabrication Inspection Report (Form 0538) – This form must be completed by QAI on a weekly basis for each project and should contain a clear and brief narrative of the work performed over the reporting period and keep emotions of personal feelings out. The report must contain the following information: Weather conditions, elements worked on, work activity, non-conformances, shipping, force account work (rare), and anything else deemed important by the QAI.

3. Mill Certification Record (Form 0538D) – This form is completed by the QAI during the fabrication of a bridge. An entry is made for each girder in the bridge and the actual mill certification heat numbers for every plate used in fabricating the girder are recorded in an orderly sequence (including beams, cover-plates, webs, flanges, splice plates, etc.). A notation is made when the corresponding mill certification has been received and checked by the QAI.

4. Sample Identification (Form 1923) – This form must be submitted when material sampling is required on a project. QAI must completely fill out the form and keep a copy in the fabrication inspection folder.

5. Welder Qualification Field Data Report (Form 1929) – This form is submitted with each test of a welder, welding operator, or welding procedure when weld testing is required. All the available parameters requested on the form must be completed since the approvals issued from these tests are conditional for the variables tested.

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4.05.07. Stockpile Payment

A. This stockpile payment section directs the QAI on the requirements when stockpile payment inspection is requested by the Structural Fabrication Unit. The QAI must perform the following steps:

1. Verify plate/rolled material is traceable to the mill certifications and meets ASTM A6 (if applicable);

2. Verify fabricated material meets approved shop drawings (if applicable);

3. Verify stockpile quantity and include quantity in report;

4. Verify material is labeled for MDOT use only;

5. Verify material is correctly stored and protected from the elements; and

6. Provide a report summarizing the inspection and provide adequate photos that represent the general condition of the elements, how they’re being stored, mill markings or piece marks, and mill certifications for plate/rolled material if applicable.

4.05.08. Acceptance

A. The Fabricator is required to provide the QAI with a minimum of five (5) copies of the Bill of Lading for each shipment. QAI will stamp each copy of the Bill of Lading with the MDOT “Approved for Use” stamp and will retain one copy for their records. It is the Fabricator’s responsibility to distribute the remaining copies of Bill of Lading to the following individuals:

1. QAI

2. Engineer

3. Fabricator

4. Contractor

5. Trucking company

The Bill of Lading is required to contain, at a minimum, the following information:

1. Shipping date

2. Description of cargo (quantity, element size, weight, etc.)

3. Element unique piece mark

4. MDOT project location (route, cross road/river, and city)

5. MDOT project information (structure number, control section, and job number)

6. Manufacturer’s name and address

B. Acceptance consists of the following two-part process:

1. Fabrication Inspection Acceptance: Structural elements must be inspected by the QAI after they are loaded for shipping. If the structural elements meet the contract requirements, the QAI will stamp them “Approved for Use”. The elements must be stamped “Approved for Use” prior to shipping. Additionally, the QAI must stamp at least five copies of the Bill of Lading that is prepared by the Fabricator. The approval

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stamp is for use by the Department and does not relieve the Contractor of their responsibility to meet contract requirements.

2. Visual Inspection (VI) Acceptance: The Engineer must collect one copy of the stamped Bill of Lading and use it to verify the delivered structural elements. Additionally, the Engineer must verify that the elements are stamped and visually inspect them for signs of damage that may have occurred as a result of shipping and handling. This visual inspection should be documented in the field inspector’s daily report.

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4.06 LIGHTING, SIGNAL, AND SIGN SUPPORT STRUCTURE FABRICATION

4.06.01. Scope

A. This lighting, signal, and sign support structure fabrication inspection procedure should be used to aid the quality assurance inspector (QAI) in interpreting and enforcing the contract for highway structures. Fabrication inspection includes the time from verifying materials used for fabrication through loading for shipping to the construction site. The following lighting, signal, and sign support structures are included in this inspection procedure:

1. Traffic sign support structures:

a. Cantilever b. Truss c. Dynamic message sign d. Bridge sign connections e. Steel column breakaway

2. Tower lighting unit

3. Traffic signal mast arm pole and mast arm

4.06.02. Reference Documents

A. QAI must have a thorough knowledge of the following references:

1. The following sections of the MDOT Standard Specifications for Construction (MDOT SSC) as modified by supplemental specification 12SS-001A – Errata, as applicable:

Section 104 Control of the Work Section 105 Control of the Materials Section 707 Structural Steel Construction Section 810 Permanent Traffic Signs and Supports Section 819 Electrical and Lighting

2. The following special provisions, as applicable:

12SP-105A Source of Steel and Iron (Buy America) 12SP-707A Special Provision for Structural Steel and Aluminum Construction 12SP-707F Special Provision for Structural Steel Construction Revisions

12SP-716B Special Provision for Coating of Galvanized Lighting, Signal, Sign, and Miscellaneous Support Structures

12SP-810A Special Provision for Anchor Bolt Inspection and Reporting and Payment Schedule for Overhead Support Structures

12SP-810B Special Provision for Traffic Signal Mast Arm Pole and Mast Arm (Trunkline)

12SP-906B Special Provision for Structural Steel Revisions

3. Structural Steel QAI Manual

4. American Welding Society (AWS) D1.1:XXXX, Structural Welding Code – Steel (as modified by 12SP-707A, Structural Steel and Aluminum Construction), hereafter called AWS D1.1

5. Construction Field Services Division (CFS) Materials Source Guide (MSG)

6. MDOT Structural Fabrication Quality Assurance Guidance Document

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7. MDOT Welder Qualification Program

8. MDOT Structural Fabrication Unit E-Construction Process

9. Prefabrication meeting minutes (if available)

B. QAI must be familiar with the following references:

1. AWS 2.4:XXXX, Symbols for Welding and Nondestructive Testing

2. AWS A3.0:XXXX, Standard Welding Terms and Definitions

3. MDOT Structural Fabrication Request for Information Process


5. MDOT Structural Fabrication Nonconformance Process

6. Applicable SSPC specifications

7. Applicable coating test methods

8. Applicable ASTM and AASHTO specifications

9. MDOT Accident Prevention Plan

4.06.03. Qualifications, Responsibilities, Duties, and Equipment

A. Qualifications of the QAI – QAI performing the fabrication inspection must possess the following active qualification:

1. AWS Certified Welding Inspector (CWI)

B. Responsibilities of the QAI – QAI performing the fabrication inspection is not permitted to make changes to the contract and has the following responsibilities:

The Contractor, Fabricator, and MDOT will approach quality control and quality assurance as a team effort to facilitate accurate and timely construction. QAI’s verification does not relieve the Fabricator from the responsibility to perform the required testing and inspection to produce a product satisfying the contract. Though QA inspection may include all aspects of fabrication, the QAI must not supersede QC, which is the responsibility of the Fabricator. If QC is not accomplishing its role then the Structural Fabrication Unit, Engineer, Contractor, and Fabricator must determine the necessary corrections.

QAI is the responsible party, representing the Engineer, who performs quality assurance verification inspection on the element after quality control (QC) inspects and approves the item of work. The QAI must be at the fabrication facility at all times during fabrication as required by the inspection procedure stated below. If issues arise, it will be at the Engineer’s discretion whether to increase the level of QA inspection. It is the Engineer’s responsibility to engage the Engineer of Record (EOR) when making structural decisions. The Engineer is also responsible for following internal MDOT procedures for review and approval of shop drawings, fabrication procedures, request for information (RFI), nonconformance reports (NCR), and for professional decision making on fabrication problems that arise. The Engineer relies on the Structural Fabrication Unit to manage and assist when appropriate. The Engineer has the prerogative for holding a prefabrication meeting with the Fabricator to discuss and clarify the contract plans and specifications. The Engineer is the responsible party who ensures MDOT’s fabrication QA program is followed for inspection and acceptance of the element.

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Fabrication should proceed only with approved shop drawings. However, if the Fabricator must proceed prior to receipt of approved shop drawings (performing work at their own risk), ensure that the Structural Fabrication Unit is aware of this activity and await instruction on how to proceed. If the Engineer permits the work to proceed without approved shop drawings, proceed with basic QA functions using the non-approved shop drawings. Later, verify notes against approved drawings. Notify the Structural Fabrication Unit immediately if fabrication is not in conformance with the approved shop drawings.

C. Duties of the QAI – QAI performing the fabrication inspection has the following duties:

1. QAI must thoroughly understand the contract.

2. QAI must verify steel material certifications show compliance with Buy America contract requirements.

3. QAI must be proficient in testing welders, sampling materials, verifying material traceability, and inspecting welds and coating systems.

4. QAI must be proficient in writing reports and using computers.

5. QAI must notify the Engineer if production begins before approved shop drawings are on the shop floor and provided to the QAI.

6. QAI must communicate all concerns through QCI or whomever the Fabricator directs during the prefabrication meeting.

7. QAI must communicate with QCI to obtain the work schedule.

8. QAI must follow MDOT’s Structural Fabrication E-Construction Process for closing out fabrication inspection file.

D. Deficiencies on Local Agency Projects – MDOT’s QAI must notify the Structural Fabrication Unit if they observe fabrication or inspection deficiencies on local agency program (LAP) projects. The Structural Fabrication Engineer will report the deficiencies via email to the Engineer that is responsible for construction oversight of the local agency project and carbon copy the applicable CFS and Design Division LAP Engineers.

E. Inspection Facilities and Access – Facilities for the QAI must be provided by the Fabricator per contract. QAI must have access to all parts of the work at all times. The authority and general duties of the QAI are specified in Section 104.01.D and E of the MDOT SSC.

F. Inspection Equipment – QAI will be furnished with the following items by the Engineer:

1. Contract (MDOT SSC, special provisions, standard plans, special details, plan sheets, etc.)

2. Approved shop drawings (provided by Fabricator)

3. Access to MDOT’s Fabrication Inspection & Construction System (FICS)

4. MDOT shop approval stamp

QAI must provide the following inspection equipment:

1. Computer with high speed internet access

2. Cell phone with camera

3. Flashlight

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4. Fillet weld gauges

5. Undercut gauges

6. Instrumentation for measuring voltage and amperage

7. Temperature measuring devices capable of covering the range from 0°F to 1650°F

8. Dry film thickness gauges

9. Wet film paint thickness gauge

10. Surface roughness comparator gage

11. Extra course replica tape for measuring blasted steel surface profile

12. SSPC book of pictorial blast standards

13. Temperature and humidity measuring instruments

14. Measuring devices (200 foot and 20 foot steel tape and calipers)

15. Straightedge and levels

16. Safety equipment

17. Other as needed for the project

4.06.04. Inspection Procedure

A. Prefabrication Meeting – Prefabrication meetings facilitate effective quality control and quality assurance on the project and are conducted by MDOT’s Structural Fabrication Unit prior to the start of fabrication and preferably after shop drawings have been approved. The Structural Fabrication Unit, QAI, Fabricator, and QCI must be present, whereas the Engineer and Contractor should be present to ensure a team effort to facilitate accurate and timely construction. Quality assurance and quality control contact information will be shared during this meeting to ensure effective communication.

B. Fabrication Inspection – Structural steel must be fabricated in accordance with the MDOT SSC and contract. Fabrication inspection must be performed as shown below:

1. Structural steel fabrication inspection consists of verifying compliance with the approved shop drawings, contract, and approved NCRs. RFIs must be incorporated into the approved shop drawings for the QAI to inspect to.

2. An approved Materials Source List (MSL) is provided to the QAI by the Engineer so that the QAI knows what materials are being incorporated into the project and what the basis of acceptance is. The MSL is used to track material sampling by the QAI and to foster communication with QC to ensure all required sampling and testing occurs in a timely manner to prevent impacts to the project schedule. It is the Fabricator’s responsibility to notify the QAI when materials are available for sampling.

3. QAI begins by inspecting materials that will be used in the fabrication process and ensures they are being stored correctly, tagged for traceability purposes, and are in conformance with the contract. Next, the QAI inspects the Fabricator’s operations to ensure the condition of the equipment and work area for conformance to the contract.

4. MDOT’s Accident Prevention Plan states, “MDOT employees shall not engage in any act which would endanger another employee or themselves”. QAI must notify the Engineer immediately if work conditions exist that are not safe. If the level of inspection diminishes below what is specified in this QA procedure, due to safety concerns, then the element will not be approved for use.

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C. Fabrication Inspection – Cantilever sign support, tower lighting unit, and traffic signal mast arm pole and mast arm structures must be fabricated in accordance with the MDOT SSC and contract. Welders must be qualified in accordance with MDOT’s Welder Qualification Program prior to welding on structures. Visually inspect flanges using a straight edge for flatness to assure that full contact of flanges is obtained in an unbolted relaxed condition. Inspect structural elements for straightness, flange bolt hole alignment, and horizontal truss member camber per the contract. Truss Sign Supports Only – Witness the bolting and vertical horizontal truss sections to ensure proper alignment and bolt tightening procedures (truss sign supports only) per the MDOT SSC.

D. Before Welding – Below is a checklist for the QAI to use for fabrication inspection prior to the start of welding. The actual steps and their exact sequence will depend upon the type of structure, the method of erection, and the qualifications of the welders who are to do the work.

1. Verify mill test reports match the base metal for conformance with the specifications. Verify that QC is maintaining traceability of all materials to such degree that the heat number of each piece of steel that is used in the project can be tracked to its location in the structure. Obtain from the Fabricator, if necessary, the shipping records, storage locations, and scheduling for each piece of steel that they intend to use in connection with the assigned contract. Examine each piece of steel as it is received at the shop to see that it has no uncorrected defects, kinks, or bends resulting from improper handling while in the mill or shop or in transit from mill to shop. Verify that the material from the mill meets ASTM A6.

2. Verify all welders are MDOT qualified (see MDOT’s Welder Qualification Program) and have appropriate fracture critical qualification, if applicable. Require requalification or supplementary welder tests if there are concerns. MDOT’s SSC requires that all tack welders, welders, and welding operators are active MDOT qualified welders for the welding process, plate thickness, and position prior to welding.

3. Verify that the welding procedure specification (WPS) and welding sequences are agreed to and understood by QAI, QC, and Fabricator prior to welding. All WPSs are required to be reviewed and approved by MDOT’s Structural Fabrication Unit. Contract require all WPSs to be qualified by a procedure qualification record (PQR) prior to welding. This qualification requirement is inclusive of all types of welds (butt welding, fillet welding, seal welding, plug welding, etc.). MDOT does not recognize prequalified AWS welding procedures, but we do accept properly documented evidence of previous PQRs that have not expired. See the contract for WPS and PQR requirements. The Fabricator is required to post approved WPS’s at each welding station.

4. Make a general examination of the structural steel and verify the quality of fabrication. Pay attention to the plate edge preparation, which would affect control over welding. Notify QC of any observed deficiencies before weld joint fit up is complete so they can correct any deficiencies.

5. Check the fitting of joints that are to be welded, including dimensions of root face, angle of bevel, cleanliness, match marks, alignment of parts to be joined, and uniformity and size of root openings. Recheck root faces and angles of bevel because trimming and re-beveling of plate edges is sometimes performed during fitting. Check the prepared weld joint edges for evidence of possible undesirable internal defects such as laminations in the steel plate. Make dimensional checks of all critical measurements to assure a proper fit in the field.

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6. Check the fixture, clamping, and pre-cambering arrangements used in the fabrication assembly setup for adequacy. Make certain tack welds are made by MDOT qualified welders and the welds are small, smooth, and of specified quality. Verify that runoff tabs or extension plates are in place to ensure complete welding beyond the plate edges.

E. During Welding

1. Verify all welding is being performed using the approved WPS and sequences (if applicable) and electrodes are used with suitable currents and polarity for the positions the electrodes are intended to be used. Refer to the approved WPS for all details of performing the weld in question.

2. During inclement weather, ensure that suitable windbreaks or shields are provided and welding is not performed on surfaces that are wet, exposed to rain or snow, or if a heavy fog is present. Check the ambient and steel temperatures at the start of welding and during welding to determine if the specified preheat and interpass temperature requirements are being observed. Use temperature-indicating crayons or other equivalent means to check these temperatures.

3. Check to make certain the correct electrodes (type and size) are available and are properly dried to prevent porosity and hydrogen cracking in the final welds. Low-hydrogen electrodes are susceptible to these types of defects if they are exposed to the atmosphere beyond the recommended limits. If electrodes and fluxes have been improperly stored or exposed to humidity in excess of the recommended limits, notify QC that reconditioning or rejection is required per the contract.

4. Intermittently observe the technique and performance of each welder to verify the approved WPS and suitable techniques are being followed. Inspect important or unique joints multiple times to ensure all weld passes meet project specifications. Arrange for the welder or the foreman to notify the QAI when such inspections at various stages may be made. Report any unusual or excessive distortion during welding to QC. Verify all corrective measures are being followed as approved by the Engineer to ensure the Fabricator’s methods minimize locked-in stresses.

5. Verify the welding arc is only struck in the joint or other area on which metal is to be deposited and not at random locations on the base metal outside of the prepared joint. Arc strikes cause physical and metallurgical stress risers and can change the mechanical properties of the steel at isolated locations. These changes can result in fatigue failures. Verify that approval by the Engineer has been given to the Fabricator prior to ground bars, clips, or ties being welded to the base metal. Approval for such welding is only given by the Engineer when unavoidable. When steel ground bars are used instead of ground clamps to carry the welding current to the base metal, make certain the ground bars are carefully welded to the base metal at a runoff tab or securely clamped to any area where all mill scale has been removed. Verify the grounding lead is as close to the point of welding as is practical.

6. Inspect root passes with special care because it is very important the first weld materials deposited in the root of a multiple pass weld is properly performed. Closely examine the root pass in important complete joint penetration welds, such as pole to base plate and splices to verify a sound pass that is free from cracks, inclusions, and lack of fusion.

7. Verify the root pass and every subsequent weld pass is cleaned with a wire brush and chipping hammer to thoroughly remove slag between weld passes to avoid inclusions. Ensure defects and substandard workmanship in any weld pass be removed by chipping or gouging before subsequent passes of metal are deposited. Peening or

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consolidating of weld metal by hammering is not permitted without the approval of the Engineer. Under conditions of very severe restraint, minimize weld cracking by acceptable techniques such as a cascade build-up sequence. Avoid any interruptions in the welding of a critical joint other than those necessary to change electrodes and quickly clean the slag from each pass before the next pass is deposited.

8. Verify the Fabricator is not creating re-entrants or local areas with high residual stresses in highly stressed parts of primary members. Verify that temporary fitting aids, such as plates and angles, are not applied at highly stressed locations and that temporary tack welds are not allowed.

9. Check all members to verify the welds are of proper size and length, are being made in the proper location to conform to the approved shop drawings, and are performed in such a manner as to produce weld metal conforming to the contract. To determine whether the weld metal is being deposited in such a manner as to penetrate well into the root of a joint without producing excessive slag inclusions or porosity, a field test may be conducted by making a T-joint with a fillet weld on only one side of the stem of the T. This joint can be broken open easily for visual examination. If welds are to be ground smooth and flush for any reason, verify grinding is performed so grinding marks are not left transverse to the direction of the main stress in a member. Verify welds are not being over ground so as to produce a "dished" surface. Verify the ends of welds are being ground smooth after runoff tabs are removed.

10. Identify with paint (do not steel stamp) each splice with the symbol of the welder doing the work. If two welders work on such a splice, show the symbol of each and record, in writing, the work each welder performed.

11. Record progress of fabrication on MDOT Form 0538. Include the dates that the work was completed and pertinent remarks regarding problems encountered and corrective action taken.

F. After Welding

1. Verify welds are cleaned of slag and weld spatter so they can be given a thorough final examination. Verify the surfaces of the welds are reasonably smooth and of suitable contour without evidence of undercut, overlap, excessive convexity, insufficient throat or leg size, unfilled craters at the ends of welds, or other defects in excess of the limits prescribed by the contract. Refer to the contract for the appearance of welds containing these various kinds of defects. Ensure all scars and defects, such as undercutting or remnant portions of tack welds and other scars that are left after the removal of temporary fitting and erection clips are corrected to be within the tolerances specified.

2. Check the storage, loading, blocking, and handling of the welded members to avoid distortion or structural damage. Verify braces or lugs are not welded to the members.

3. Verify the final camber and required curvature (or sweep) of all members after all fabrication steps have been completed by observing QC perform their inspection. The Engineer will notify the QAI if they are required to perform QA inspection using the appropriate MDOT forms. Any members that measure out of tolerance must be noted for corrective action and rechecked after the correction has been made.

G. Non-Destructive Testing (NDT) - Is the responsibility of the Fabricator per the contract. QAI verifies the NDT requirements of the contract are correctly performed and documented. Knowledge of the principles and procedures of NDT is essential for QAI to verify QC during NDT.

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Ensure the required visual test (VT), penetrant test (PT), magnetic particle test (MT), ultrasonic test (UT), and radiographic test (RT) inspections are performed and documented as required in the contract. Verify that the weld surface and adjacent plate surfaces are in satisfactory condition prior to non-destructive testing (NDT).

Verify NDT QCIs are ASNT Level II or III by reviewing certification records.

Check the performance of NDT QCIs at frequent intervals to verify approved procedures are being used, all weld joints to be tested are examined in accordance with contract and results are recorded. QAI should witness NDT of all critical splices and pole to base connection. Collect all NDT reports generated and submit to the Engineer with the final documentation package.

Verify QC identifies locations of all rejected welds. Observe the excavation defects and the use of MT inspection to verify no part of the defect remains. Verify that the Fabricator follows all approved weld repair plans.

Perform VT after blast-cleaning the base metal for weld surface defects, weld finish, and edge and hole finish requirements.

1. NDT Inspection Methods

a. Visual testing (VT) inspection of weldments must be in accordance with the contract.

b. Penetrant testing (PT) inspection of weldments must be in accordance with the contract.

c. Magnetic particle testing (MT) inspection of weldments must be in accordance with the contract.

d. Ultrasonic testing (UT) inspection of weldments must be in accordance with the contract.

e. Radiographic testing (RT) inspection of weldments must be in accordance with the contract.

2. Interpretation - The interpretation of all NDT is the responsibility of the Fabricator's QC personnel. QAI is responsible for reviewing all of the Fabricator's interpretations and calling any disagreements to the attention of the Engineer. The Engineer's interpretation is final and they may also call for additional testing to further explore a discrepancy.

H. Inspection of Shop Cleaning and Coating Fabricated Steel - QAI is responsible to verify that QC is being effective and enforcing all cleaning and coating contract requirements. All MDOT structures require hot-dip galvanizing (HDG) and may be coated using a high technology wet coating system or dry system per the contract. HDG must be inspected to verify conformance to the applicable ASTM and contract. The essential phases of inspecting a coating system is summarized below:

1. Environmental Conditions - Contract include specific controls on environmental conditions (e.g. temperature, humidity, cleanliness, air movement, shading, etc.). These conditions must be strictly enforced.

2. Coating Materials - All paints must be carefully mixed, thinned, and handled in accordance with the manufacturer’s specifications. Verify QC is recording all batch numbers used for comparison to the certification documents. Verify the color numbers of the top coat for conformance to the approved shop drawings.

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3. Cleaning and Coating Equipment - High technology coating systems employ the most sophisticated blast cleaning and spray painting equipment developed. A thorough knowledge of their operation and use is required by the QAI. QAI is responsible for evaluating the performance of the equipment prior to the coating of the structural steel. If any of the equipment is operating outside of the specification limits the coatings will not be properly applied and may fail (peeling) at some time after application.

4. Steel Surface Conditions - All grinding, weld repairs, and fabrication steps must be completed before blast cleaning and painting. Any remedial work performed after coating may be grounds for rejection of the coating system. The steel must be free of all traces of grease and oil before blast cleaning is performed.

5. Surface Preparation - Verify QC is monitoring surface cleanliness and surface profile using specialized equipment per the contract.

6. Coating Application - QAI must verify that the proper techniques of applying the high technology coating systems is being performed. Improper application techniques may "appear" to give acceptable results, but will lead to a greatly reduced performance life and possibly an early coating failure (blistering and peeling). QAI must verify QC is monitoring all environmental conditions before and during the coating process. Corrective actions must be taken on each coat of the painting system before the next coat is applied. Ensure that approved coating repair procedures are followed.

7. Documentation - Documentation of an approved coating on structural steel is comprised of the QC test reports on the coating evaluations and environmental conditions as well as a certificate of compliance from the paint manufacturer. MDOT coating systems are in a Qualified Products List found in the MDOT MSG. The certificate of compliance attests that the painting materials supplied are the same as those submitted to MDOT for acceptance testing.

8. Handling, Storage, and Repair - QAI must verify all contract for handling, storage, and repair of shop painted steel are strictly followed. All paint damages during handling and loading by the Fabricator must be repaired using approved procedures prior to QAI's approval for shipping.

4.06.05. Reports

A. The Engineer may require a periodic status report from the Structural Fabrication Unit; therefore, all reports are required to be completed in a timely and orderly manner using MDOT’s Fabrication Inspection & Construction System (FICS). Make entries as soon as possible after an event or conversation to ensure accuracy. Number the reports consecutively until completion of the work, with the last report noted “final”.

B. QAI must complete an accurate and detailed account of fabrication for the project. The report must include a discussion of fabrication progress for all aspects of the work. It is intended to be a detailed record of the status of fabrication and should include number of elements fabricated, documentation of specification and procedure compliance as well as documentation of conflicts, repairs, and other problems or discussion which could affect the project in anyway. If force account work is taking place, document each day that the work occurs in the shop and which elements are being worked.

C. Documentation is not a substitute for appropriate dialogue with the Fabricator, but should provide a record of important discussions. In some cases, the QAI is more familiar with the events or issues and therefore should review and comment on draft copies of the

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Structural Fabrication Unit’s correspondence.

D. Reports must be assembled into one fabrication inspection portable document format (PDF) file and stored in MDOT’s ProjectWise document storage program per MDOT’s Structural Fabrication Unit’s E-Construction Process. The Engineer will receive a fabrication inspection memorandum from the Structural Fabrication Engineer after fabrication inspection is complete. The memorandum is for informational purposes and is not used for acceptance.

E. Below is a list of various MDOT reports/forms and a brief description of their purpose and use requirement. Similar forms can be used in place of the standard MDOT form if noted below.

1. Project Folder Checklist (Form 1942) – This form must be completed by QAI for each project. The checklist is placed on top of the fabrication inspection folder when the project is complete.

2. Fabrication Inspection Report (Form 0538) – This form must be completed by QAI on a weekly basis for each project and should contain a clear and brief narrative of the work performed over the reporting period and keep emotions of personal feelings out. The report must contain the following information: Weather conditions, elements worked on, work activity, non-conformances, shipping, force account work (rare), and anything else deemed important by the QAI.

3. Sample Identification (Form 1923) – This form must be submitted when material sampling is required on a project. QAI must completely fill out the form and keep a copy in the fabrication inspection folder.

4. Welder Qualification Field Data Report (Form 1929) – This form is submitted with each test of a welder, welding operator, or welding procedure when weld testing is required. All the available parameters requested on the form must be completed since the approvals issued from these tests are conditional for the variables tested.

4.06.06. Stockpile Payment

A. This stockpile payment section directs the QAI on the requirements when stockpile payment inspection is requested by the Structural Fabrication Unit. The QAI must perform the following steps:

1. Verify plate/rolled material is traceable to the mill certifications and meets ASTM A6 (if applicable);

2. Verify fabricated material meets approved shop drawings (if applicable);

3. Verify stockpile quantity and include quantity in report;

4. Verify material is labeled for MDOT use only;

5. Verify material is correctly stored and protected from the elements; and

6. Provide a report summarizing the inspection and provide adequate photos that represent the general condition of the elements, how they’re being stored, mill markings or piece marks, and mill certifications for plate/rolled material if applicable.

4.06.07. Acceptance

A. The Fabricator is required to provide the QAI with a minimum of five (5) copies of the Bill of Lading for each shipment. QAI will stamp each copy of the Bill of Lading with the

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MDOT “Approved for Use” stamp and will retain one copy for their records. It is the Fabricator’s responsibility to distribute the remaining copies of Bill of Lading to the following individuals:

1. QAI

2. Engineer

3. Fabricator

4. Contractor

5. Trucking company

The Bill of Lading is required to contain, at a minimum, the following information:

1. Shipping date

2. Description of cargo (quantity, element size, weight, etc.)

3. Element unique piece mark

4. MDOT project location (route, cross road/river, and city)

5. MDOT project information (structure number, control section, and job number)

6. Manufacturer’s name and address

B. Acceptance consists of the following two-part process:

1. Fabrication Inspection Acceptance: Structural elements must be inspected by the QAI after they are loaded for shipping. If the structural elements meet the contract requirements, the QAI will stamp them “Approved for Use”. The elements must be stamped “Approved for Use” prior to shipping. Additionally, the QAI must stamp at least five copies of the Bill of Lading that is prepared by the Fabricator. The approval stamp is for use by the Department and does not relieve the Contractor of their responsibility to meet contract requirements.

2. Visual Inspection (VI) Acceptance: The Engineer must collect one copy of the stamped Bill of Lading and use it to verify the delivered structural elements. Additionally, the Engineer must verify that the elements are stamped and visually inspect them for signs of damage that may have occurred as a result of shipping and handling. This visual inspection should be documented in the field inspector’s daily report.

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V011717

REQUEST FOR INFORMATION PROCESS

PAGE 1 of 3



Request for Information Process

Description The purpose of this document is to provide the Michigan Department of Transportation (MDOT) with

statewide consistency managing and responding to a structural fabrication request for information (RFI).

MDOT’s Structural Fabrication Unit is responsible for implementing the Department’s quality assurance

program for structural elements that are required to be accepted based on “Fabrication Inspection” per

MDOT’s Materials Quality Assurance Procedures (MQAP) manual. MDOT utilizes vendor inspectors to

provide shop inspection for these structural elements. When information is requested, it is important for

MDOT to quickly respond to a RFI submittal in order to keep the project moving forward. This document is

broken down into the following sections:

1. Request for Information

2. RFI Report

3. RFI Submittal Process

4. Innovative Contracting

1. Request for Information Request for information is defined to be a request by the Fabricator seeking additional information or

proposing an alternate design, material, fabrication method, or inspection method for the structural

element. The Fabricator typically generates RFI submittals before shop drawings are produced, but they

are sometimes submitted after fabrication has begun. A RFI submittal is not to be confused with a

nonconformance report (NCR) that is defined to be an alteration in the work or a fabrication error that

results in the element not meeting project specifications. Each unique request should be submitted on a

separate RFI for housekeeping purposes.

The Structural Fabrication Unit is responsible for coordinating the RFI review process and should provide a

timely response or acknowledgement (explanation, decision, request for additional information, or

estimate of time needed to evaluate) within three business days after receiving the RFI submittal. The

Structural Fabrication Unit will distribute all RFIs that are design related to the Design PM for their

disposition and then the Design PM is responsible for engaging other MDOT areas, as applicable

(Roadside Development, Geometrics, etc.). MDOT will consider alternate fabrication methods or

configurations, materials, or inspection procedures proposed by the Fabricator provided the alternative

will result in improving or equaling the expected performance, maintenance, and longevity of the

structure; however, approval of a RFI may be contingent on a reduction in the contract unit price.

Contract modification due to approval of a RFI by the Fabricator requesting alternate material,

fabrication method, inspection method, or anything else that is not determined by the Engineer to be an

extra will be at no additional cost or time extension to MDOT. RFIs are resolved by providing an

appropriated response on the RFI form.


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2. RFI Report A RFI is generated by the Fabricator. The Fabricator is required to submit the RFI to MDOT as discussed in

Section 3 of this document.

MDOT has developed a standard Request for Information (Form 0558) form that should be used by the

Fabricator. Use of the form is recommended to facilitate a faster review process. RFIs submitted for

review are required to include, at a minimum, the following information:

• Follow MDOT’s file naming convention as shown on the RFI form;

• MDOT project information (structure number, control section, job number, project location, and

element mark);

• RFI number in ascending order for each project (resubmittals use a different RFI number);

• Clearly state what information is being requested or what is being proposed;

• Clearly state the required specifications if an alternate is being proposed;

• Include drawings (contract plan, sketches, etc.), numerous high resolution photos, product data

sheets, etc.;

• Indicate the urgency of a reply.

Approval of a RFI does not waive the contractual requirement to provide shop drawings prior to the start

of fabrication, nor is it sufficient information to allow MDOT’s quality assurance inspector (QAI) to stamp

elements approved for use. If the Fabricator elects to use an approved RFI then they need to

incorporate the RFI into the shop drawings for MDOT’s review and approval prior to the start of

fabrication. MDOT’s QAI is instructed to inspect using approved shop drawings and approved NCRs only.

The Fabricator is also required to obtain the Contractor’s acceptance of any contract modifications that

alter the finished product.

3. RFI Submittal Process Listed below is MDOT’s structural fabrication RFI submittal process:

1. Fabricator names RFI file per MDOT’s file naming convention shown on Form 0558.

2. Fabricator must send RFI to Structural Fabrication Unit and carbon copy the Engineer and

Contractor. All correspondence to the Structural Fabrication Unit must be sent using the following

email resource:

[email protected]

3. Structural Fabrication Unit distributes RFI to QAI and Design PM (if applicable) and begins

reviewing.

4. Design PM distributes RFI to other areas (e.g. Geometrics, Load Rating, Roadside Development),

as applicable, and provides all comments to Structural Fabrication Unit.

5. Structural Fabrication Unit provides response on RFI form via email to Fabricator and carbon

copies the Engineer, Contractor, Design PM, and QAI.

http://mdotcf.state.mi.us/public/webforms/public/0558.pdf

mailto:[email protected]


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6. QAI places final RFI form and correspondence in the fabrication inspection file that will be stored

in ProjectWise.

4. Innovative Contracting The request for information process described above applies to Design-Bid-Build projects. This section will

discuss subtle changes required to successfully submit RFIs for innovative contracting such as Design-Build

projects. Design-Build is an innovative construction method that pairs the Engineer of Record (EOR) with

the Contractor. The main difference between a Design-Build and a Design-Bid-Build project is that the

EOR on the Design-Build team is required to completely review and approve the RFI submittal prior to

MDOT’s review. Once the Design-Build team is satisfied with the submittal, the MDOT Design-Build Project

Manager (Design Build PM) acts as the MDOT RFI coordinator and distributes the submittal to the

Structural Fabrication Unit for review. The Structural Fabrication Unit returns any comments to the Design

Build PM. Once satisfied, the Structural Fabrication Unit stamps “Approved” on the RFI form. The Design

Build PM must be included on all correspondence related to a RFI, therefore Section 3 (RFI Submittal

Process) must be revised to reflect this for Design-Build projects.

Michigan Department of Transportation

0558 (01/18) REQUEST FOR INFORMATIONRFI #

To be completed by the fabricator and submitted to the Structural Fabrication Unit. Naming Convention: 0558 SN-CS-JN Fabricator RFI#.pdf

GENERAL INFORMATION FABRICATOR / LOCATION CONTROL SECTION

JOB DESCRIPTION JOB NUMBER

RFI SUBJECT STRUCTURE #

DATE

INFORMATION REQUEST

MDOT RESPONSE

Approved RFI, if implemented by the Fabricator, must be incorporated into the shop drawings and approved by the Engineer prior to the start of fabrication.

BBS Approval Block

• Submit to the Structural Fabrication Unit and cc the Contractor and Engineer.

Clear Form

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V101915

NONCONFORMANCE POLICY

PAGE 1 of 5



Nonconformance Policy


statewide consistency in addressing material and fabrication nonconformance issues with structural steel

and structural precast concrete elements. MDOT’s Structural Fabrication Unit is responsible for

implementing the Department’s quality assurance program for fabrication inspection and utilizes vendor

inspectors for inspection of structural steel and structural precast concrete elements at nationwide

fabrication facilities. When nonconforming material or fabrication issues are discovered the Structural

Fabrication Unit immediately notifies the Project Engineer (hereafter referred to as Engineer) overseeing

the construction project of the deficiencies. It is the Engineer’s responsibility to reject or accept

nonconforming elements with consideration of imposing a negative price adjustment in accordance with

subsection 104.04 of the MDOT Standard Specifications for Construction. Bridge Field Services is available

to provide technical support to the Engineer when additional guidance is needed. Guidelines are

provided in this document for the Engineer and Structural Fabrication Unit to use when determining if a

price reduction is warranted. When a price reduction is warranted, the Structural Fabrication Unit

provides the recommended amount to ensure statewide consistency and alignment. Below is a list of the

structural elements inspected for acceptance by the Structural Fabrication Unit for which this document

applies (see contract documents for project specific information):

Structural steel for bridges (plate, rolled, hollow structural shape, bridge tube railing, steel deck

grating, modular expansion joints, castings, forgings, etc.);

Highway structures (sign structures, tower lighting units, mast arm traffic signals, DMS, etc.);

Structural precast concrete (prestressed concrete beams, spun concrete poles, sound wall

panels/posts, MSE wall panels/posts, etc.);

Precast concrete three-sided, arch, and box culverts (span lengths 20 feet and greater measured

parallel to the roadway centerline).

This document does not address fabricated elements cast by the contractor on the project site or non-

structural precast concrete (concrete pipe, manhole, etc.).

1. Control of Materials The service life of a highway is dependent upon the quality of the materials used in its construction as well

as the method of construction. Therefore, it is critical to ensure the materials incorporated into the work

meet the project specifications. Control of materials is discussed in subsection 105 of the MDOT 2012

Standard Specifications for Construction (hereafter referred to as Standard Specifications) with

information on approval of materials in subsection 105.05 and nonconforming materials in subsection

105.08. The Engineer may inspect materials that the contractor will incorporate into the work at any time

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and at any place during the preparation, storage, and use of the materials. The Engineer will perform

inspections of the materials, including sampling and testing, in accordance with the methods required by

the contract to determine if the material is approved for use. Approval of materials is discussed in the

Department’s Materials Quality Assurance Procedures Manual (MQAP).

2. Nonconforming Materials – Acceptable and Unacceptable Use It is the Department’s intent to discourage the use of nonconforming materials from being incorporated

into the work even if they are found acceptable for use. Subsection 105.08 of the Standard

Specifications gives the Engineer the authority to either reject nonconforming materials or to allow the

nonconforming materials to remain in place. If materials are found to be unacceptable before or after

placement into the work, the Engineer may reject the materials, and the contractor must remove the

materials from the site at no cost to the Department. Materials that have been tested and approved at

their source or otherwise previously approved, but have become damaged or contaminated before use

in the project, are also subject to rejection by the Engineer.

Materials that are nonconforming, but determined by the Engineer to be acceptable for use may be

subject to a negative price adjustment. To ensure consistency in the decisions made for acceptance of

nonconforming material or workmanship, it is recommended the Engineer involve Bridge Field Services

before finalizing any decision. This communication will help keep the applicable technical sections of the

Bureau of Field Services informed about contractor or material problems that may require specification

changes, a Bridge Field Services Advisory, or discipline of a contractor. Additionally, this communication

will aid in the consistent treatment of nonconforming materials statewide. The Bureau of Field Services is

available to provide technical support if the Engineer has any questions regarding the acceptance or

rejection of nonconforming materials. It is the Engineer’s responsibility to determine whether a

nonconforming material is acceptable for use; however, Bridge Field Services can assist with

recommendations.

2.1 Determining if Nonconforming Material can be Incorporated into the Work Good engineering judgment is required when making decisions on nonconforming materials. The

Engineer may choose to approve nonconforming materials, allow them to be incorporated into

the work, and impose a negative price adjustment. When making the decision to direct the

contractor to remove and replace the materials versus leave the materials in place, it is important

to consider the following:

Safety;

Long-term consequences on quality and durability;

Implications on the structural element’s life cycle costs, service life, serviceability, and

maintenance;

Environmental and aesthetic considerations;

Impacts on the project’s traffic, staging, and construction timeframes;

Future costs associated with maintenance.

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2.2 Determination of Price Reductions After the Engineer has decided to allow nonconforming materials to remain in place, the

Structural Fabrication Unit will carefully evaluate each situation in deciding whether to

recommend a price reduction. The goal is to achieve statewide consistency in administering

price reductions for nonconforming materials that are allowed to remain place. The purpose of

the price reduction is to facilitate an environment that encourages the contractor to incorporate

materials meeting contract specifications and to make it fair for all contractors.

Results of retests and related quality tests should be considered. The following list includes some

examples of the types of factors the Structural Fabrication Unit will consider when deciding if a

price reduction is warranted:

Has the contractor been conscientious to provide quality by carefully controlling materials

and construction operations?

Has the contractor been proactive and made good use of quality control (QC) data to

maintain and improve quality?

Did the contractor notify the Engineer of materials that needed to be tested in a timely

manner to ensure the test results would be reported prior to the materials being

incorporated?

Did the Engineer process the test results within the industry accepted timeframe so the

contractor could make process or materials corrections?

Upon becoming aware of a materials quality problem, has the contractor responded

quickly to correct it?

Is the nonconforming test an isolated incident or a recurring situation?

How does the nonconforming test compare to the rest of the project data:

o Have material test results been well within specification requirements or

consistently at the very limit of what is acceptable?

o How many tests are nonconforming versus how many tests have passed?

o How far out of specifications is the nonconforming test?

2.3 Nonconforming Structural Precast Concrete If the Engineer has decided to accept nonconforming material and it is determined that a

negative price adjustment is warranted then the final step is for the Structural Fabrication Unit to

determine a recommended price reduction. The following guidelines provide a list of common

nonconformance issues related to the structural precast concrete industry and are intended to

aid the Structural Fabrication Unit in determining the recommended price reduction. The goal of

these guidelines is to provide consistent price reductions independent of the type of project or

project office location.

The Engineer must justify and document the incorporation of any nonconforming materials into

the work. The Structural Fabrication Unit will provide the Engineer with the quantity and type of

nonconforming material for the project office’s records. Only one price adjustment should be

applied to a given quantity of material; however, if multiple nonconformance issues occur then

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the price reduction may be increased on a case by case basis. In general, if the quantity in

question is subject to more than one of the following price reductions then the greater price

reduction would apply.

Any structural precast concrete element judged to be structurally or otherwise unacceptable by

MDOT due to low strength, cracking, breakage, honeycombing, or other deficiency will be

rejected and replaced. Note that honeycombing with exposed prestressing strand automatically

falls into this category.

Any structural precast concrete element judged to be acceptable, but deficient by MDOT due to

any of the following issues will be subject to the pay deductions listed below. These guidelines for

standard deductions are intended to be applied to typical problem severity in the majority of

cases. In occasional cases where problem severity is lower or higher than typical, the pay

deduction may be decreased or increased, respectively. Standard deductions shown represent

a percentage of bid item price for the structural precast concrete element.

2.3.1 Nonconforming Compressive Strength Compressive strength below specified level at required test age for strand release,

stripping forms, shipping, etc. is subject to the greater of $500 or 20% deduction on the bid

item price if the elements are approved for use. This price reduction would apply for all

elements represented by the tested cylinders.

2.3.2 Nonconforming Fabrication Defects Price reduction for the following fabrication defects and nonconformance issues will be

recommended by the Structural Fabrication Unit and should be implemented by the

Engineer. The following table of deductions will be applied to infrequent occurrences of

the stated defects. In the event of repeated occurrences of the same defect, these

deductions will be doubled. Note that negative pay adjustments may be waived for

minor fabrication and nonconformance defects judged to be inconsequential. The

following price reduction percentages are deducted from the bid item price and are only

applicable to nonconforming structural precast elements determined by the Engineer to

be acceptable:

Misalignment of form and soffit joints (1/8 inch or greater on flat surface) – 10%

deduction;

Inadequately sealed joints with significant mortar washout – 10% deduction;

Cracking/spalling caused by fabrication and curing – 10% deduction;

Dimensional tolerance deviations outside contract documents – 10% deduction;

Honeycombing – 10% deduction;

* Curing temperature – 10% deduction;

Broken/cracked components – 10% deduction.

* Structural precast concrete elements cured at elevated temperatures are suspect in

terms of durability. The Structural Fabrication Unit will make a recommendation to the

Engineer to either reject the element or accept it with a price reduction.

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2.3.3 Nonconforming Miscellaneous Items The Engineer must determine the quantity of nonconforming material. Only one price

adjustment will be applied to a given quantity of material. If the quantity in question is

subject to more than one of the following conditions, apply the adjustment with the

greater price reduction.

2.3.4 Minor Nonconformance If the structural element does not conform to the requirements of the contract, but is

accepted, apply one of the following two price reductions (if not already covered in part

2.3.1 or 2.3.2):

1. 20% price reduction on the bid item price;

2. 50% price reduction on all material (invoice) costs utilized to fabricate the structural

precast concrete element.

2.3.5 Major Nonconformance The Engineer should not pay for elements determined by the Department to be in major

nonconformance with the contract requirements.

2.4 Nonconforming Structural Steel Due to the specialized nature and track record of structural steel fabrication, acceptable

nonconformance rarely lends itself to recommended price reductions. In general, deficient

structural welds can be easily replaced and the homogenous nature of steel typically means if

the material does not meet specification then it is rarely accepted even with a price reduction.

However, the Structural Fabrication Unit would review and provide a recommended price

reduction to the Engineer on a case by case basis depending on the nature of the deficiency,

recurrence, etc. Dimensional tolerance deviations outside the contract documents is an example

of a workmanship nonconformance subject to a 10% price deduction from the bid item price if

the structural steel element is determined by the Engineer to be acceptable.

2.5 Special Cases For other nonconforming issues not covered above, consult personnel in the appropriate area of

the Bureau of Field Services for guidance. Some examples of items in which it may be

unacceptable to leave the nonconforming item in place, even at reduced cost, include the

following:

Bar reinforcement;

Anchor bolts;

High strength bolts.

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Nonconformance Reporting Process


statewide consistency managing and responding to a structural fabrication nonconformance report

(NCR). MDOT’s Structural Fabrication Unit is responsible for implementing the Department’s quality

assurance program for structural elements that are required to be accepted based on “Fabrication

Inspection” per MDOT’s Materials Quality Assurance Procedures (MQAP) manual. MDOT utilizes vendor

inspectors to provide shop inspection for these structural elements. When nonconformance occurs, it is

important for MDOT to quickly respond to a NCR submittal to keep the project moving forward. This

document is broken down into the following sections:

1. Nonconformance

2. QC Nonconformance Report

3. QA Nonconformance Report

4. NCR Submittal Process

5. MDOT Standard Repair Procedures

6. Innovative Contracting

1. Nonconformance Nonconformance is defined to be an alteration in the work or a fabrication error that results in the

element not meeting project specifications. A NCR is not to be confused with a request for information

(RFI) that is defined to be a request by the Fabricator seeking additional information or proposing an

alternate material, fabrication method, or inspection method. A RFI is typically submitted before

fabrication work begins, whereas a NCR is submitted after a nonconformance is observed by quality

control (QC). Nonconformance renders the affected element unacceptable until such time as the issue

is referred to MDOT for disposition. Nonconformance that results in the Fabricator rejecting an element

does not require a NCR to be submitted for review; however, MDOT does request the Fabricator to send

our quality assurance inspector (QAI) written correspondence that clearly documents who rejected the

element, why it was rejected, when it was rejected, and proposed changes to the piece mark naming

convention for the fabrication inspection records.

Nonconformance is generally defined to be material or workmanship in nature and is further classified by

MDOT to be minor or major. Minor nonconformance can be repaired by the Fabricator using a

preapproved MDOT standard repair procedure that can be found in the MDOT Structural Precast Concrete Standard Repair Program and does not need to be approved by MDOT on a case by case

basis throughout the project. Major nonconformance can typically be repaired by the Fabricator using a

MDOT standard repair procedure that can be found in the MDOT Structural Precast Concrete Standard Repair Program and does need to be approved by MDOT on a case by case basis throughout the

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project. Below are common minor nonconformances that can be repaired using a preapproved MDOT

standard repair procedure:

• Cosmetic and in-process weld defects;

• Concrete air hole;

• Epoxy coated reinforcing steel damage;

• Coating damage;

• Hot-dip galvanizing damage.

Examples of major nonconformances include, but are not limited to the following:

• Buy America;

• Material specifications;

• Element dimensions;

• Unauthorized repairs;

• NCR corrective action without adequate notification;

• Coating system requirements;

• Unauthorized welds;

• Defective structural welds;

• Unqualified welder or welding operator;

• Welding without approved weld procedure specifications (WPS);

• Overheating steel and not maintaining preheat;

• Fresh concrete properties;

• Strength requirements;

• Concrete curing requirements;

• Honeycombing, voids, and concrete damage (except air holes).

The QAI should obtain clarification from the Structural Fabrication Unit if the QAI has questions regarding

the proper disposition method for nonconformances. All nonconformance issues observed by the QAI

must be brought to the attention of the Fabricator immediately upon discovery; however, the QAI must

not direct corrective action. The QAI must notify the Structural Fabrication Unit immediately if the

Fabricator fails to take corrective action or continues to fabricate nonconforming elements. Verbally

notifying the Fabricator of nonconformance is sometimes sufficient; however major nonconformance

issues should always be followed up in writing to the Fabricator via email with a carbon copy to the

Structural Fabrication Unit. The Structural Fabrication Unit will decide if the Fabricator’s operations

warrant notifying the MDOT Construction Engineer (Engineer) and MDOT Design Project Manager (Design

PM) to prevent schedule delays or potential claims. An internal conference call amongst the Structural

Fabrication Unit, Engineer, Design PM, and QAI may be needed to better understand the issue and to

discuss MDOT’s Structural Fabrication Nonconformance Policy to ensure statewide consistency with

acceptance of nonconforming materials and potential price reductions if nonconforming elements are

permitted to be incorporated into the project.

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The Structural Fabrication Unit is responsible for coordinating MDOTs NCR review process and should

provide a timely response or acknowledgement (explanation, decision, request for additional

information, or estimate of time needed to evaluate) within three business days after receiving the NCR

submittal. The Structural Fabrication Unit will distribute all NCRs that are design related to the Design PM

for their disposition and then the Design PM is responsible for engaging other MDOT areas (Roadside

Development, Geometrics, etc.), as applicable. All NCRs are required to be stamped “Approved” by the

Structural Fabrication Unit on the coversheet if they are found to be acceptable to MDOT.

Unacceptable NCRs are returned to the Contractor with an appropriate response and stamped “Not

Approved”. Corrective action that requires use of a weld procedure specification (WPS) will require the

Structural Fabrication Unit to stamp the WPS in addition to the NCR.

2. QC Nonconformance Report QC NCRs are generated by the Fabricator after their QCI observes a nonconformance during their

inspection. The Fabricator is required to submit the NCR to MDOT as discussed in Section 4 of this

document if they intend to have the element considered by MDOT to be incorporated into the project.

Although not required, it is highly recommended that the QCI discuss the NCR submittal with the QAI to

ensure it is in general conformance with MDOT requirements. The QAI should not review the actual NCR

at this point in time since they will be asked to verify that the NCR is accurate by the Structural Fabrication

Unit after the Contractor submits it to MDOT.

MDOT has developed a standard Nonconformance Report (Form 0559) that should be used by the

Fabricator. Use of the form is recommended to facilitate a faster review process. NCRs submitted for

review are required to include, at a minimum, the following information:

• Follow MDOT’s file naming convention as shown on the NCR form;

• MDOT project information (structure number, control section, job number, project location, and

element mark);

• NCR number in ascending order for each project (resubmittals use the same NCR number, but

would have a different revision number);

• Clearly state the nonconformance;

• State the reason for nonconformance;

• State measures to prevent nonconformance from occurring again;

• Include supporting documentation (marked up shop drawings, QC reports, WPS, PQR, numerous

high resolution photos showing all locations proposed to be repaired, etc.);

• State proposed corrective action (repair procedure, NDE, MDOT standard repair procedure, etc.);

• Indicate the urgency of a reply.

The Fabricator must notify the QAI, prior to performing repairs to the nonconforming element, so MDOT

has the opportunity to witness the repair. Elements containing repairs performed without adequate

notification for QA inspection may not be approved for use. All nonconformances must be properly

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3. QA Nonconformance Report It is not common for MDOT to write a NCR; however, a QA NCR could be issued due to the following

reasons:

1. Fabricator does not acknowledge a material or workmanship nonconformance.

2. QAI verification inspection results in major nonconformance missed by QCI during their inspection.

The Structural Fabrication Unit uses the standard Quality Assurance Nonconformance Report (Form 0560) for a QA NCR and submits the completed form to the Engineer and Design PM for their review and

subsequent discussion. It is important for QA to document when QC is ineffective so the appropriate

quality management system organization (AISC, NPCA, and PCI) specified by MDOT in the contract

documents can follow up with the complaint. The Fabricator is required to respond to the QA NCR by

either submitting their own NCR acknowledging they are in agreement with the QA NCR or in writing that

they are in disagreement. The Fabricator’s NCR is required to include all of the information stated in

Section 2 of this document. A conference call may be requested by the Structural Fabrication Unit

between the Engineer, QAI, Contractor, Fabricator, and QCI to discuss the NCR.

Once all elements have been re-inspected by the QCI, they must notify the QAI via email or by submittal

of the QC report that the QC inspection is complete for the elements under consideration. The QAI will

start the QA verification inspection again and if major nonconformances are found then the process will

repeat itself. It is important to note that the QAI must not perform their QA verification inspection until

after QCI notifies them via email or by submittal of the QC report that their QC inspection is complete for

the elements under consideration. This prevents QA from inspecting prior to QC.

4. NCR Submittal Process Listed below is MDOT’s structural fabrication NCR submittal process:

1. Fabricator names NCR file per MDOT’s file naming convention shown on Form 0559.

2. Fabricator must send NCR to the Structural Fabrication Unit and carbon copy the Engineer and

Contractor. All correspondence to the Structural Fabrication Unit must be sent using the following

email resource:

[email protected]

3. Structural Fabrication Unit distributes NCR to QAI and Design PM (if applicable) and begins

reviewing.

4. Design PM distributes NCR to other areas (e.g. Geometrics, Load Rating, Geotechnical, Roadside

Development), as applicable, and provides all comments to the Structural Fabrication Unit.

5. Structural Fabrication Unit provides response on NCR via email to Fabricator and carbon copies

the Engineer, Contractor, Design PM, and QAI.

6. QAI places final NCR and correspondence in the fabrication inspection file that will be stored in

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5. MDOT Standard Repair Procedures The Structural Fabrication Unit has developed standard repair procedures to expedite the review process

for common repairs to structural elements. These repair procedures have been reviewed by industry and

should be used by Fabricators when applicable to speed up the review process. Standard repair

procedures for structural steel have not been developed at the time of this document, but will be added

in subsequent revisions.

Listed below are the MDOT standard structural precast concrete repair procedures, which can be found

in MDOT’s Structural Precast Concrete Repair Guidance Document on MDOT’s Structural Fabrication

Unit’s website:

1. * Procedure #1: Air Hole

2. Procedure #2: Minor Surface Defect

3. Procedure #3: Major Surface Defect

4. * Procedure #4: Hot-Dip Galvanize

5. Procedure #5: Fiber Reinforced Polymer

6. * Procedure #6: Epoxy Bar

7. Procedure #7: Epoxy Injection

* Indicates MDOT standard repair procedure for minor nonconformance. These procedures can be

preapproved by the Structural Fabrication Unit before the project begins and do not need to be

approved on a case by case basis throughout the project. Fabricator is required to notify the QAI when

the repairs will be performed so they can have the opportunity to witness. Fabricator must have copies

of the standard repair plan with them at all times while performing the repair.

Listed below is the MDOT standard structural steel repair procedure:

1. Procedure #1: Shop Coating Repairs

6. Innovative Contracting The nonconformance reporting process described above applies to Design-Bid-Build projects. This

section will discuss subtle changes required to successfully submit NCRs for innovative contracting such as

Design-Build projects. Fabrication nonconformance should already be addressed in the Design-Build

Design Quality Manual (DQM); however, MDOT’s Structural Fabrication Nonconformance Policy provides

MDOT with statewide consistency in addressing material and fabrication nonconformance issues.

Design-Build is an innovative construction method that pairs the Engineer of Record (EOR) with the

Contractor. The main difference between a Design-Build and a Design-Bid-Build project is that the EOR

on the Design-Build team is required to completely review and approve the NCR submittal prior to

MDOT’s review. Once the Design-Build team is satisfied with the submittal, the MDOT Design-Build Project

Manager (Design Build PM) acts as the MDOT NCR coordinator and distributes the submittal to the

Structural Fabrication Unit for review. The Structural Fabrication Unit returns any comments to the Design

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Build PM. If satisfied, the Structural Fabrication Unit stamps “Approved” stamp on the NCR. The Design

Build PM must be included on all correspondence related to a NCR, therefore Section 4 (NCR Submittal

Process) must be revised to reflect this.


0559 (01/18) NONCONFORMANCE REPORT NCR #

To be completed by the fabricator and submitted to the Structural Fabrication Unit. Naming Convention: 0559 SN-CS-JN Fabricator NCR# REV#.pdf

GENERAL INFORMATION FABRICATOR / LOCATION CONTROL SECTION


NCR SUBJECT STRUCTURE #

DATE

NONCONFORMANCE DESCRIPTION

REASON FOR NONCONFORMANCE

RECURRENCE PREVENTION ACTION

CORRECTIVE ACTION

Nonconformances render the element unacceptable for use unless the Engineer approves the nonconformance. BBS Approval Block

• Combine this document with all relevant QC reports, photos, repair plans, WPS, etc. into one PDF document prior tosubmitting to the Structural Fabrication Unit for approval. cc the Contractor and Engineer.

Clear Form

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0560 (01/18) QUALITY ASSURANCE NONCONFORMANCE REPORT

QA NCR #

To be completed by the MDOT QA inspector and submitted to the Structural Fabrication Unit. Naming Convention: 0560 SN-CS-JN Fabricator QA NCR# REV#.pdf

GENERAL INFORMATION PREPARED BY - COMPANY CONTROL SECTION

FABRICATOR / LOCATION JOB NUMBER

JOB DESCRIPTION STRUCTURE #

NCR SUBJECT DATE

NONCONFORMANCE DESCRIPTION

• Combine this document with all relevant QC reports, photos, repair plans, WPS, etc. into one PDF document prior tosubmitting to the Structural Fabrication Unit.

Clear Form

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Buy America Guidance Document

Description The purpose of this document is to provide the Michigan Department of Transportation’s (MDOT)

Structural Fabrication Unit with guidance to supplement MDOT’s 12SP-105A Special Provision for Source of

Steel and Iron (Buy America). The Structural Fabrication Unit is responsible for implementing the

Department’s quality assurance program for material required to be accepted based on “Fabrication

Inspection” per MDOT’s Materials Quality Assurance Procedures (MQAP) manual. It is important to note

that this document is not contractual and all project related decisions should be based on the project

specifications. This guidance document will be used to ensure statewide consistency in performing

quality assurance (QA) verification inspection at fabrication facilities for Buy America compliance. It

provides a brief background on FHWA’s Buy America policy, what step certification is, where more Buy

America information can be found, how foreign steel or iron could be incorporated into the project, and

tables that provide common steel and iron components used in the fabrication process of structural

precast concrete and structural steel elements. This document is broken down into the following sections:

1. Background

2. Step Certification

3. Foreign Steel or Iron

4. Buy America Tables

1. Background

The FHWA’s Buy America policy is based upon the statutory provisions in the Surface Transportation

Assistance Act of 1982, as implemented with a November 25, 1983 final rule. FHWA has since issued

clarifications and interpretations on the Buy America policy and standing waiver of 1983 with memo’s

issued on December 22, 1997, June 13, 2011 and December 21, 2012; however, the December 21, 2012

memo was rescinded on December 22, 2015. In general, FHWA’s Buy America policy requires a domestic

manufacturing process for all steel (including stainless steel; however, brass, bronze and copper are not

subject to Buy America) or iron manufactured products (including the application of protective coatings,

but not the coating itself) that are permanently incorporated into a Federal-aid highway construction

project.

Title 23 Section 313 and FHWA's regulations in 23 CFR 635.410 provide that the Administrator may issue a

waiver. Procedures for any waivers are in the FHWA guidance for Buy America on the FHWA website.

Waivers are very rare and typically take about 9 months to be issued, which would require them to be

submitted during the design stage. Additionally, the FHWA's regulations permit a minimal use of foreign

steel and iron in the amount of $2,500 or one-tenth of one percent (0.1%), whichever is greater, to be

used in a Federal-aid project. Note that application of Buy America is triggered by the obligation of

Federal funds. If any amount of Federal funding is used in the project then Buy America requirements

apply. Map 21 requires all parts of a project to comply with Buy America if any previous parts of the

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larger project used Federal funds. This includes environmental EIS, planning, design, small subparts, etc.

FHWA may issue a standing national or regional waiver if it is warranted, although it is extremely rare (only

4 ever issued). The waiver would be granted by the Secretary of Transportation if the product is not

manufactured in the United States and the public rulemaking process demonstrates that non-domestic

availability of the product would adversely impact the Federal-aid program in multiple states, specific

region, and/or nationwide.

2. Step Certification

Step certification is the process under which each handler (supplier, fabricator, manufacturer, processor,

etc.) of the steel and iron products certifies that their step in the manufacturing process was domestically

performed. Contractors must provide manufacturers’ step certifications to the Engineer showing the steel

and iron products are of domestic origin prior to permanent incorporation into the Federal-aid highway

project. MDOT requires step certification for all steel and iron related pay items, materials, products, and

components as specified on the Department website. The Department will maintain a list of these pay

items, materials, products, and/or components on the following website:

http://www.michigan.gov/documents/mdot/MDOT_BuyAmericaRequirements_387704_7.pdf

Raw materials are not required to meet Buy America; however, every step from melting through coating

application and anything else is subject to meet Buy America. If a steel or iron component has any step

performed by a non-domestic source then the total cost for the entire component would need to be less

than the allowable foreign limit in order to be incorporated into the project.

3. Foreign Steel or Iron

It is the Contractor’s responsibility to seek approval from the Engineer to use foreign steel or iron prior to

incorporation into the project. Additionally, it is the Contractor’s responsibility to keep track of the

amount of foreign steel or iron used on the project.

For additional information on Buy America requirements, please refer to any project specific Special

Provision for Source of Steel and Iron (Buy America), MDOT Construction Manual, MDOT MQAP Manua

(section 4.12), and the FHWA website.

4. Buy America Tables

Below are several tables displaying common steel and iron components used in the fabrication of

structural precast concrete and structural steel elements. This information has been prepared exclusively

for MDOT’s Structural Fabrication Unit to assist with the Buy America requirements. These tables are not

complete and in no way relieve the contractor of their contractual obligations to meet Buy America

requirements for MDOT projects.

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Table 1. Steel and iron components used in fabricating structural precast concrete elements.

STRUCTURAL PRECAST CONCRETE FABRICATION

Component Description Buy

America

Step

Cert

Why Buy America is/is not

Required

Prestressing

Strand

High strength strand for

prestressing concrete Yes Yes

Prestressing strand is specified in

contract documents and

permanently incorporated

Bar

Reinforcement

Mild bar reinforcement

for strengthening

concrete

Yes Yes

Bar reinforcement is specified in



Welded Wire

Fabric

Mild fabric

reinforcement for

strengthening concrete

Yes Yes

Welded wire fabric is specified in



Sole Plates

Steel plate cast over

support and bears on

the elastomeric pad

Yes Yes

Sole plates are specified in the



Position Dowels

Dowels used to provide

translation restraint for

beams

Yes Yes

Dowels are specified in the



MSE Connection

Lug

Connects wall panel to

reinforcement Yes Yes

Connection lug is specified in SP

and permanently incorporated

Laminated

Elastomeric Pad

Steel shims used to

reinforce elastomeric

pads

Yes Yes FHWA memo dated 12/21/12

rescinded

PCI Beam Lifting

Strand

Device for moving

beams Yes Yes

FHWA memo dated 12/21/12

rescinded

Culvert Lifting

Device

Device for moving

culverts Yes Yes


rescinded

MSEW Lifting

Device

Device for moving

MSEW panels, posts, and

copings


rescinded

Sound Wall

Lifting Device

Device for moving

sound wall panels and

posts


rescinded

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V092717

BUY AMERICA

PAGE 4 of 5


Table 1 (continued). Steel and iron components used in fabricating structural precast concrete elements.

STRUCTURAL PRECAST CONCRETE FABRICATION


America

Step

Cert


Required

Tie Wire Secures bar

reinforcement Yes No


rescinded

Bar Chair Supports bar

reinforcement Yes No


rescinded

Screed

Supporting

Frame (pipe)

Supports screed

machine Yes No


rescinded

SIP Deck Clip Support location for

attaching SIP decking Yes No


rescinded

Half Hanger

Anchor Supports false work Yes No


rescinded

False Work Insert Supports false work Yes No FHWA memo dated 12/21/12

rescinded

Safety Line

Embed Provides tie off Yes No


rescinded

Spun Pole

Structural Steel

Mounts cameras, etc. to

pole Yes No


rescinded

Spun Pole

Hardware

Mounts cameras, etc. to

pole Yes No


rescinded

Concrete Insert Attach threaded bar

reinforcement or bolt Yes No


rescinded

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V092717

BUY AMERICA

PAGE 5 of 5


Table 2. Steel and iron components used in fabricating structural steel elements.

STRUCTURAL STEEL FABRICATION


America

Step

Cert


Required

Structural Steel

Rolled

Shape/Plate

Structural steel used for

fabrication of bridge or

highway elements

Yes Yes

Structural steel is specified in



Hollow Structural

Sections (HSS)

Structural steel used for

fabrication of bridge or

highway elements

Yes Yes

Structural steel is specified in



High Strength

Bolts

Bolts for structural steel

connections Yes Yes

Bolts are specified in the contract

documents and permanently

incorporated

Anchor Bolts Bolts for anchoring

structural elements Yes Yes

Bolts are specified in the contract

documents and permanently

incorporated

Laminated

Elastomeric Pad

Steel shims used to

reinforce elastomeric

pads


rescinded

Welding Rod Weld metal used in

SMAW process Yes Yes


rescinded

Welding Wire

Weld metal used in

GMAW, SAW, or FCAW

processes


rescinded

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Date

Company Name Company Address City, State, Zip Subject: Buy America Certification for Project (Structure No-XXXXX-XXXXXX)

I, (company representative), certify that the following pay items shipped/provided to the subject project are in full compliance with the Federal Highway Administration (FHWA) Buy America requirements as specified in Title 23 of the Federal Code of Regulations (CFR) Section 635.410.

Pay Item

Please see below example pay items. Delete and enter the project specific pay items.

Culv, Precast Conc Box, 20 foot by 8 foot

Prest Conc Box Beam, Furn, 21 inch

Prest Conc Bulb-Tee Beam, Furn, 48 inch by 49 inch

Spun Conc Pole, Type A

Structural Steel, Mixed, Furn and Fab

Structural Steel, Plate, Furn, Fab, and Erect

Mast Arm Pole, Cat I

If any of the above compliance statements change while providing material to this project we will immediately notify the prime contractor and the engineer.

Signature Delete this text prior to converting to pdf and place your e-signature here.

Date

Company Name Company Address City, State, Zip Subject: Buy America Step Certification for Project (Structure No-XXXXX-XXXXXX)

I, (company representative), certify that the (melting and manufacturing, bending, welding, cutting, coating, galvanizing), process for manufacturing or fabricating, the following material shipped or provided to the subject project are in full compliance with the Federal Highway Administration (FHWA) Buy America requirements as specified in Title 23 of the Federal Code of Regulations (CFR) Section 635.410.

Material: (Delete this text and all materials not being step certified for Buy America compliance. Fill in the company name for the process of the materia, and modify the listed processes as needed).

- Prestressing Strand

Company Name, Prestressing Strand, Buy America Compliance for melting and manufacturing into wire (mill)

Company Name, Prestressing Strand, Buy America Compliance for manufacturing into strand and cutting (manufacturer)

Company Name, Prestressing Strand, Buy America Compliance for cutting, grinding, and coating strand end (fabricator)

- Bar Reinforcement

Company Name, Bar Reinforcement, Buy America Compliance for melting and manufacturing into bar reinforcement (mill)

Company Name, Bar Reinforcement, Buy America Compliance for cutting, bending, and coating (manufacturer)

Company Name, Bar Reinforcement, Buy America Compliance for cutting, bending, and coating repairs (fabricator, if applicable)

- Structural Steel Plate

Company Name, Steel for Structural Steel Plate, Buy America Compliance for melting and manufacturing into steel plate (mill)

Company Name, Steel for Structural Steel Plate, Buy America Compliance for cutting, bending, drilling, punching, shearing, and welding (service vendor, if applicable)

Company Name, Steel for Structural Steel Plate, Buy America Compliance for cutting, bending, drilling, punching, shearing, and welding (fabricator, if applicable)

Company Name, Steel for Structural Steel Plate, Buy America Compliance for machining (machine shop, if applicable)

Company Name, Steel for Structural Steel Plate, Buy America Compliance for galvanizing (galvanizer, if applicable)

Company Name, Steel for Structural Steel Plate, Buy America Compliance for coating (painter, if applicable)

If any of the above compliance statements change while providing material to this project we will immediately notify the prime contractor and the engineer.

Signature Delete this text prior to converting to pdf and place your e-signature here.

It should be noted that a complete list of the associated manufacturing and/or fabricating steps is to be provided with the step certification documentation along with which steps the respective letter(s) are addressing. This will allow MDOT to document the steps in the process to ensure documentation with federal regulations.


V052416

WELDER QUALIFICATION PROGRAM

PAGE 1 of 3


Welder Qualification Program

Description The Michigan Department of Transportation’s (MDOT) Welder Qualification Program is managed by the

Operations Field Services Division, Structural Fabrication Unit and was developed to qualify field and AISC

shop (hereafter called shop) welders performing work for the Department. MDOT uses independent third

party laboratories to perform the qualification testing in accordance with the American Welding Society

(AWS) D1.1, Structural Welding Code – Steel (hereafter called AWS D1.1), AASHTO/AWS D1.5, Bridge Welding Code (hereafter called AWS D1.5) or ANSI/AWS D1.2, Structural Welding Code - Aluminum

(hereafter called AWS D1.2) based on the type of work being performed. Contractors must be awarded

a MDOT project that requires the contractor’s welders to be MDOT Qualified before making a request to

have their welders tested. MDOT will test a reasonable number of welders required to complete the

project at no cost to the contractor for the initial test. All re-tests will be at the contractor’s expense.

After a second failed test the welder will not be tested again in the same process and position until after

a meeting with the Structural Fabrication Unit to discuss training. See the Welder Qualification Program

Guidelines section below for more information on period of effectiveness for qualified welders and other

responsibilities.

Below is a list of typical field and shop welding that can only be performed by a MDOT qualified welder

as specified in the contract documents:

• Bridge welding to AWS D1.5 as specified in section 707 of the MDOT Standard Specifications for

Construction;

• Highway structure (sign structures, traffic signal mast arms, high mast luminaires, DMS structures,

etc. as stated in the contract documents, etc.) welding to AWS D1.1 as specified in the contract

documents;

• Primary member pile welding to AWS D1.5 per the current FUSP 12SP705(A), Pile Splicing;

• Contractor add-ons in tension zones (detailed in contract plans) of bridge elements. Note

welding must follow AWS D1.5 in tension zones;

• Other miscellaneous structures required to be welded by a MDOT qualified welder per AWS D1.1

or AWS D1.5 as stated in the contract documents.

Note that a MDOT qualified welder is also permitted to perform all welding privileges granted to a MDOT

certified welder provided they adhere to the certified welder responsibilities set forth in the MDOT Welder

Certification Program. Please direct any questions you may have concerning the MDOT Welder

Qualification Program to the Structural Fabrication Unit at [email protected].

Welding on fracture critical elements requires a welder to meet the AWS D1.5 clause 12 fracture control

plan. MDOT’s qualified welder test report can be used in conjunction with the fabricator’s radiographic

test results. Fabricator must arrange to perform their radiographic testing prior to MDOT’s laboratory

performing mechanical testing.

http://www.michigan.gov/documents/mdot/MDOT_Certified_Weld_Testing_Agency_Program_082312_396129_7.pdf

http://www.michigan.gov/documents/mdot/MDOT_Certified_Weld_Testing_Agency_Program_082312_396129_7.pdf



V052416


PAGE 2 of 3


Testing Laboratory Responsibilities Welder qualification testing must be in accordance with the latest AWS D1.5 code followed by MDOT (as

modified by Special Provision 12SP707(A), Structural Steel and Aluminum Construction) and has an

effective period of two (2) years for field welding and three (3) years for shop welding. Laboratories are

strictly prohibited from using a third party to perform any portion (cutting, bending, testing, interpretation,

reporting, etc.) of the welder qualification testing, unless approved by the MDOT Structural Fabrication

Engineer. Welder qualification testing is required to adhere to the following:

• Perform MDOT welder qualification testing after being notified by MDOT’s Structural Fabrication

Unit or MDOT’s shop inspector;

• Retain a record of all applicable documentation related to the welder qualification testing

(mill certifications, reports, etc.) for a minimum of 3 years;

• Maintain a welder qualification log documenting relevant information for every welder that is

tested as part of this program. MDOT may ask to review these records during random audits,

therefore they must be kept available at all times.

• Perform all mechanical test requirements in accordance with AWS D1.1, AWS D1.2, or AWS

D1.5, as applicable; and

• Retain the weld test coupons for 6 months after the reported test date.

The testing laboratory must have a Certified Welding Inspector (CWI) on staff to perform or oversee the

required mechanical testing and sign the test report. All testing laboratories must report test results on

MDOT Form 0396 (Welder Qualification Test Report). The Structural Fabrication Unit requires the report to be electronically sent via email to the Structural Fabrication Unit’s email resource shown below and using

the following file naming convention:

• [email protected]

• 0396 Last First Position Process Expiration Date

• Example: 0396 Fox Bill 4G SMAW 050614

Welder Qualification Program Guidelines MDOT qualified welders are required to adhere to the following responsibilities or risk loss of qualification:

1. Must follow all contract documents including the MDOT Standard Specifications for Construction,

AWS D1.1 and AWS D1.5 [as modified by the current Special Provision 12SP707(A), Structural Steel and Aluminum Construction], special provisions, special details, and contract plans.

2. Qualification is required for field and shop welding as stated in the contract documents. See

above list for common welding that requires a qualified welder.

3. Welder qualification remains in effect for two (2) years for field welders and three (3) years for

shop welders, unless the welder does not engage in welding for at least 3 months, or a specific

reason exists to question the welder’s ability. Qualification begins from the coupon welding date

and not the laboratory test report date. The Engineer may require a confirming qualification test

during the progress of the work.

http://mdotcf.state.mi.us/public/dessssp/spss_source/12SP-707A-02(1).pdf





V052416


PAGE 3 of 3


4. MDOT qualified field welders are not permitted to perform MDOT qualified shop welding and vice

versa.

5. Welders must have a copy of their qualification report (MDOT Form 0396 - Welder Qualification Test Report) available at all times. Failure to produce the report while welding on a MDOT project

will result in welding privileges removed from the project until the qualification report is provided.

6. Qualification is good for specific welding processes and positions as permitted by AWS D1.1 and

D1.5. Welders must not weld on MDOT projects using welding processes or positions they are not

qualified to.

7. Form 0394 – AWS D1.1 Field Welding Plan or Form 0395 – AASHTO/AWS D1.5 Field Welding Plan

must be completed for all field welding and approved by the MDOT Structural Fabrication Unit

before welding can begin.

8. All WPSs are subject to qualification testing.

9. Do not perform welding when the ambient temperature is below 40° F unless heating and housing

is approved by the Engineer.

10. Preheat surfaces for welding in accordance with subsection 707.03.D.8.b of the Standard

Specifications for Construction for AWS D1.5 welding. Preheat surfaces for welding in accordance

with AWS D1.1 when welding to AWS D1.1.

11. Do not weld during periods of precipitation (rain, snow, or heavy fog) with low hydrogen welding

rods unless heating and housing is approved by the Engineer.

12. Welders must not use low hydrogen electrodes that have become wet. They must also not weld

using low hydrogen electrodes during periods of precipitation (rain, snow, heavy fog, etc.).

13. The welder is responsible for assuring the electrodes and flux are stored in accordance with the


http://www.michigan.gov/documents/mdot/Form_0394_D1_1_Field_Welding_Plan_060515_494946_7.docx

http://www.michigan.gov/documents/mdot/Form_0395_D1_5_Field_Welding_Plan_060515_494948_7.docx

of 2


1929 (01/18) WELDER QUALIFICATION FIELD DATA REPORT

To be completed by a MDOT representative and submitted to the testing lab along with the test coupon, material test reports and associated weld procedure.

GENERAL INFORMATION INSPECTOR / AGENCY DATE

TESTING OF CONTROL SECTION

INITIAL OR RETEST? JOB NUMBER

WELDER IDENTIFICATION WELDER NAME COMPANY

WELDER EMAIL ADDRESS

IDENTIFYING MARKS CITY STATE ZIP

SAMPLE INFORMATION WELDING INFORMATION WELDING LOCATION MACHINE NAME

WELDING PROCESS TYPE OF ARC FILLET SIZE

WELDING POSITION CURRENT / POLARITY

WELDING METHOD AMPERAGE

BASE METAL VOLTAGE

BASE METAL ASTM / GR PREHEAT TEMP (°F)

BASE METAL THICKNESS (in) ATMOSPHERIC TEMP (°F)

SOURCE OF BASE METAL TRAVEL SPEED (IPM)

FILLER METAL SPECIFICATION WIRE CONSUMING SPEED (IPM)

FILLER METAL CLASSIFICATION INTERPASS TEMP (°F)

ELECTRODE DIAMETER NUMBER OF PASSES

FLUX TYPE CLEANING METHOD

TEST SPECIFICATION

TESTING REQUIRED

COMMENTS

Clear Form

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1929 (01/18)

WELDER QUALIFICATION FIELD DATA REPORT

GENERAL INSTRUCTIONS

1. Welder qualification testing must be in accordance with the American Welding Society (AWS)D1.1, Structural Welding Code – Steel, AASHTO/AWS D1.5, Bridge Welding Code or AWS D1.2,Structural Welding Code – Aluminum based on the type of work being performed.

2. Position for fillet and groove testing must be according to the code except the axis must not beinclined and face must not be rotated.

3. All field measurements must be actual measurements observed during the welding of the testplate. If measurements are not observed, “N/R” (not recorded) must be entered into the formfield. Information must not be copied directly from the weld procedure specification for thepurpose of filling out this form.

4. This form must be combined with the CMTR’s and associated weld procedure and shipped withthe associated test plate to the testing laboratory.

5. Prior to sending the test plate to the testing laboratory, the witnessing inspector must performvisual testing (VT) inspection on the test plates ensuring the test plates meet specifications. Testplates that do not pass this VT must not be sent to the testing lab for additional testing.

6. Witnessing inspector may allow a welder to retest immediately, without MDOT approval, if theweld defect is the result of something outside of the welder’s control (i.e. welding machine powerfailure). All other retests must be approved by the MDOT Structural Fabrication Unit.

7. Delivering the test plates to the testing laboratory, and any associated shipping cost, is theresponsibility of the fabricator/contractor. Please contact the MDOT Structural Fabrication Unit([email protected]) for the testing laboratory address.

8. For more information see the MDOT Welder Qualification Program.

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0396 (01/18) WELDER QUALIFICATIONTEST REPORT

To be completed by the testing lab and submitted to the Structural Fab Unit.Naming Convention: 0396 Last First Position Expiration Date

EXPIRATION DATE

GENERAL INFORMATIONWELDER NAME DATE SAMPLED

WELDER EMAIL SAMPLED BY

COMPANY COMPANY

SOURCE OF BASE METAL WELDING LOCATION

BASE METAL WELDING PROCESS

BASE METAL ASTM / GR. WELDING POSITION

BASE METAL THICKNESS (in) WELDING METHOD

SHOP / FIELD DATA LABORATORY DATAMACHINE NAME TESTING LAB

FILLER METAL SPECIFICATION DATE RECEIVED

FILLER METAL CLASSIFICATION TESTING OF

ELECTRODE DIAMETER TEST SPECIFICATION

FLUX TYPE

PREHEAT TEMPERATURE (°F)BEND TEST RESULTS REMARKS

ATMOSPHERIC TEMP (°F)

CURRENT / POLARITY

AMPERAGE

VOLTAGE

TRAVEL SPEED (IPM)

Final Test Result:INTERPASS TEMPERATURE (°F)

WIRE CONSUMING SPEED (IPM)

REMARKS SIGNED

__________________________________________________________AWS-CWI

Send completed report to the MDOT Structural Fabrication Unit ([email protected]).

1/1/21

Joe Welder

Manual

2FSMAW

Shop

AWS D1.5

Joe Welder

[email protected]

Joe's Welding

1/1/18

Inspector

Inspector Company

Joe's Welding

Steel

A709 Gr 50

1"

Shop

SMAW

2F

Manual

Lincoln 775

A5.1

E7018

1/8"

N/A

75

75

DCEP

138

23

N/A

450

N/A

1/2/18

Welder

AWS D1.5

Fillet Break Pass

Macroetch Pass

PASS

JeffWeiler

Digitally signed by Jeff Weiler DN: cn=Jeff Weiler, o=Michigan Department of Transportation, ou=Structural Fabrication Unit, [email protected], c=US Location: Construction & Technology BuildingDate: 2017.11.13 15:19:21 -05'00'

Testing Lab X

EXAMPLE

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0396 (01/18)

WELDER QUALIFICATIONTEST REPORT

To be completed by the testing lab and submitted to the Structural Fab Unit.Naming Convention: 0396 Last First Position Expiration Date

EXPIRATION DATE

WELDER GUIDELINES

1. Must follow all contract documents including the MDOT Standard Specifications for Construction,AWS D1.1 and AWS D1.5 [as modified by the current Special Provision 12SP707(A), StructuralSteel and Aluminum Construction], special provisions, special details, and contract plans.

2. Qualification is required for field and shop welding as stated in the contract documents. Seeabove list for common welding that requires a qualified welder.

3. Welder qualification remains in effect for two (2) years for field welders and three (3) years forshop welders, unless the welder does not engage in welding for at least 3 months, or a specificreason exists to question the welder’s ability. Qualification begins from the coupon welding dateand not the laboratory test report date. The Engineer may require a confirming qualification testduring the progress of the work.

4. MDOT qualified field welders are not permitted to perform MDOT qualified shop welding and viceversa.

5. Welders must have a copy of their qualification report (MDOT Form 0396 - Welder QualificationTest Report) available at all times. Failure to produce the report while welding on a MDOT projectwill result in welding privileges removed from the project until the qualification report is provided.

6. Qualification is good for specific welding processes and positions as permitted by AWS D1.1 andD1.5. Welders must not weld on MDOT projects using welding processes or positions they are notqualified to.

7. Form 0394 – AWS D1.1 Field Welding Plan or Form 0395 – AASHTO/AWS D1.5 Field WeldingPlan must be completed for all field welding and approved by the MDOT Structural FabricationUnit before welding can begin.

8. All WPSs are subject to qualification testing.

9. Do not perform welding when the ambient temperature is below 40° F unless heating and housingis approved by the Engineer.

10. Preheat surfaces for welding in accordance with subsection 707.03.D.8.b of the StandardSpecifications for Construction for AWS D1.5 welding. Preheat surfaces for welding in accordancewith AWS D1.1 when welding to AWS D1.1.

11. Do not weld during periods of precipitation (rain, snow, or heavy fog) with low hydrogen weldingrods unless heating and housing is approved by the Engineer.

12. Welders must not use low hydrogen electrodes that have become wet. They must also not weldusing low hydrogen electrodes during periods of precipitation (rain, snow, heavy fog, etc.).

13. The welder is responsible for assuring the electrodes and flux are stored in accordance with thecontract requirements.

1/1/21

Joe Welder

Manual

2FSMAW

Shop

AWS D1.5

EXAMPLE

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V092517

METALS LABORATORY SAMPLING GUIDANCE

PAGE 1 of 6


Metals Laboratory Sampling

Guidance Document

Description The following procedures provide step by step instruction on sampling all materials required to be tested

by the Michigan Department of Transportation Metals Laboratory.

Sampling Instructions

1. Samples must be selected randomly without bias, must be representative of the material

sampled, and can only represent the population of material available at the time of sampling

(e.g. makeup material must be resampled since the original sample cannot statistically

represent material not available at the time of sampling). Specific sample size and frequency

can be found in the Materials Acceptance Requirements table located in the MDOT Materials

Source Guide.

2. All samples must be securely tagged with a numbered zip tie. Zip ties are provided by MDOT

and are uniquely numbered for sample identification purposes. High strength bolt samples

must be placed in plastic bags and closed with zip ties. All other samples must have zip ties

placed directly on the sample.

3. Population of material sampled must be tagged or marked in accordance with subsection

108 of the MDOT Materials Quality Assurance Procedures (MQAP) Manual.

4. Sample Identification (Form 1923) must be electronically prepared and filled out in detail for

each sample, placing the zip tie number in the remarks section. All available information for

proper identification of the sample must be provided, including the heat number, lot number,

tag number, batch number, serial number, and any other unique identification marks.

5. All material documentation for the sample must be electronically combined with Form 1923 as

the first page into one Adobe portable document format (PDF) file and submitted to the

testing lab via email to [email protected]. The email must have the zip tie

number in the subject line. The Contractor is responsible for providing all material certification

and test data reports to the MDOT inspector in PDF.

6. If the MDOT Standard Specifications for Construction do not apply to the sample, applicable

plan sheets, special provisions, or shop drawings must be included in the PDF submittal.

A. Material Sample File Naming Conventions:

• Acceptance or QA Sample: Control Section_Job Number_Material_Size_Date

Example: 63172 123143 Anchor Bolt 2in 07-09-2015

• Tested Stock Sample: TS_Material_Size_Date

Example: TS Extruded 12in 07-09-2015

• Certification Verification Sample: CV_CV Number_Material_Size_Date

Example: CV 2015-31 Rebar #5 07-09-2015

• A glossary of standard material names is included on page 2 of this document.

http://www.michigan.gov/documents/MDOT-Material_Source_Guide_Mat_Req_Table_84757_7.pdf




V092517


PAGE 2 of 6


7. Form 1923 must be securely attached to the sample using a method which would ensure the

form remains with the sample and is readable when it arrives at the testing lab.

8. The method of transportation of the samples to the testing lab is at the discretion of the

Contractor. The Contractor is responsible for all associated shipping costs and must determine

shipment method in a manner deemed most appropriate. Non-MDOT employees dropping

off samples must check in with security at the loading dock gate or south entrance of the C&T

building prior to dropping samples off to the Metals Laboratory (room 122).

9. All samples must be consigned to:

MDOT Metals Lab

C/o MDOT – Operations Field Services

C&T Building – Mail Code E-020

8885 Ricks Road

P.O. Box 30049

Lansing, MI 48909

10. Test results can typically be expected within 2 weeks after the sample arrives in the testing lab.

Inquiries regarding test results may be directed to [email protected].

11. Test reports can be found in the project specific ProjectWise folder at the location shown

below. Reports should not be placed in the fabrication inspection file or any other

construction folder to avoid duplication:

Region

o TSC

Project Specific JN

• Construction

o Field Services

Metals



V092517


PAGE 3 of 6


Glossary of Materials Tested by the MDOT Metals Laboratory

Spec Reference Material Name *File Name

712.03.L Mechanical Splicing Splice

713.02.A Temporary Support Hanger Rod Hanger Rod

905.03 Rebar Rebar

905.06 Welded Wire Fabric Welded Wire

905.07 Prestressing Strand Prestressing Strand

906.07 High Strength Bolts HS Bolt

907.05 High Tensile Wire Tensile Wire

908.09.A Bridge Rail Post Rail Post

908.09.A Bridge Rail Plate Rail Plate

908.09.B Bridge Tube Railing Bridge Tube

908.09.C Railing Anchor Studs Anchor Stud

908.11.A Guardrail Beam Guardrail

908.12 Guardrail Post Guardrail Post

908.14 Anchor Base Plate Base Plate

908.14.B Sign Support and Light Standard Anchor Bolts Anchor Bolt

908.14.C Traffic Signal Strain Poles Strain Poles

908.14.D Anchor Bolts for Other Purposes Anchor Other

909.05.A.1 Corrugated Steel Pipe Corrugated

914.07 Dowel Bars Dowel

918.11.A Guy Wire Guy Wire

919.02.A Extruded Aluminum Sign Planks Extruded Aluminum

919.02.A.3 Aluminum Sheet Aluminum Sheet

919.07.A Cantilever Pipe Wall Tubing

* This is to be used as the naming convention to save the file.


V092517


PAGE 4 of 6


Samplemanager login instructions (you must have a login name and password):

1. Open up Sample ID and certification paperwork.

2. In Samplemanager, click on “MDOT/Sample Submission” and then pick sample type.

3. Click on “Contract” button to pull up list of job numbers to pick one.

4. Click on “Metals” radio button.

5. Click on pulldown labeled “Material” to pick type of material.

6. Click on “Spec Level” in order to pick size of sample.

7. If remarks are needed, enter them in the “Remarks” box.

8. If needed, under “Send Results To” you can pick a person and reason for sending results.

9. Click “OK” to go to the next page for sample details.

10. Click on “Date Sampled” to pick the dates sampled. You can type it in or pick from the calendar.

11. Pick the “Supplier” from the dropdown list.

12. Pick a location from the “Sampled From” list.

13. Put in a number for “Quantity Represented”, this usually comes from the Materials Source List.

14. If needed, pick “Quantity Units” from the list.

15. Pick the “Sampled By” person from the dropdown list.

16. Pick the “Submitted By” person from the dropdown list.

17. Fill in the zip tie tag number or deer tag number.

18. If applicable, pick the “Manufacturer” of the bolt, nut and washer.

19. Also fill out the lot and heat numbers of the bolt nut and washer. If one component is not present,

pick “Not Supplied” as the manufacturer name from the dropdown list. Use the certifications to

find lot and heat numbers.

20. If applicable, also attempt to identify the products markings and enter these. Common

manufacturer’s markings are listed following this page.

Note: You can view logged samples by expanding the “Metals Lab” icon at the left of Samplemanager.

From there you will see different folders showing the state of testing for the samples. Also, if a company or

employee needs to be added to Samplemanager or you have login questions, please email:

[email protected].

You can find Samplemanager training videos on the MDOT YouTube page or they are available via email

by request.


https://www.youtube.com/user/MichiganDOT


V092517


PAGE 5 of 6


Metals Product Markings

Product, spec book

section and ASTM

Required markings Commonly seen

markings (and

manufacturer) Temporary Support

Hanger Rod

712.02A, ASTM A193

15.1 See Specification A962/A962M. The grade symbol shall be as shown in Table 4. From Table 4: B7

Rebar

905.03, A706, A615

16.2 Each manufacturer shall identify the symbols of his marking system. For Grade 60 [420] bars, the marking shall be either the number 60 [4] or a single continuous longitudinal line through at least five spaces offset from the center of the bar. For Grade 80 [550] bars, the marking shall be either the number 80 [6] or three continuous longitudinal lines through at least five spaces.

See rebar markings list

below (Appendix A).

*If rebar is coated, then

coating company is the

manufacturer (ABC

Coating Co.)

High Strength Bolts

906.07, ASTM F3125 grade

A325

From Table 1: A325 5.1 At a minimum, all bolts shall be marked as required in Table 1. Marking shall be on the bolt head and may be raised or depressed at the manufacturer’s option. The marking shall be visible after coating. 5.2 Grade and Type marking, and the manufacturer’s mark shall be in separate and distinct locations on the head. Other markings, if used, such as private label distributor’s mark shall also be separate and distinct.

nA325 (Nucor)

SLA325 (St. Louis Screw &

Bolt)

SLA325USA (St. Louis Screw

& Bolt)

GA325 (Gaffney Bolt Co.)

Nuts

906.07, 908.14, ASTM A563

gr. DH or ASTM A194 gr. 2H

14.5 Nuts made to the requirements of Grade DH shall be marked with the grade symbol, DH (or 2H) (Note 4) on one face. 14.7 In addition, nuts shall be marked with a symbol to identify the manufacturer or private label distributor, as appropriate.

DHU (Unytite)

Dhn (Nucor)

2HU (Unytite)

DHn (Nucor)

TDC2H (Dyson)

2HDHD/N (Dyson)

DMCDH (Dyson)

FSADH/2H (Foundation Systems)

Washers

906.07, 908.14

ASTM F436

15.1 Washers shall be marked with a symbol, or other distinguishing marks, to identify the manufacturer or private label distributor, as appropriate.

TSIF436 (Technical

Stamping)

PF436 (Prestige Stamping)

Ws (Wrought Washer)


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PAGE 6 of 6


Product, spec book

section and ASTM

Required markings Commonly seen

markings (and

manufacturer)

Anchor Bolts

908.14

ASTM F1554, grade 55 and

105

19.1 Unless otherwise specified (see Note 4), the end of each anchor bolt intended to project from the concrete shall be color coded to identify the grade as follows: Grade 36 Blue, grade 55 Yellow, grade 105 Red. S2. (not required by spec but informational) S2.1 The end of the anchor bolt intended to project from the concrete shall be steel die stamped with the manufacturer’s identification.

AVA 55 (AA Anchor Bolt)

ASI 55 (Alton Steel)

27 (“XX”) (Gerdau

Ameristeel)

S41 (“XXX”) (Cardinal

Fabricating)

FSA105 (Foundation

Systems)

Bridge Tube Railing

908.09B, ASTM A500 grade

B

908.09B The manufacturer of the structural shape must identify the product as follows: 1. Place identification before galvanizing; 2. Include heat number or other code traceable to the heat number; 3. Include manufacturer’s unique identification code; 4. Place identification on only one section face; 5. Repeat identification a no more than 4-foot intervals; 6. Do not extend identification into the curved surface at corners of section; and 7. Do not place identification on side facing traffic or side opposite traffic.

BMT U65 (Bull Moose

Tubing)

Railing Anchor Studs

908.09C, ASTM A449

16.1 Manufacturers Identification—All hex cap screws and bolts and one end of studs 3⁄8

in. and larger, and whenever feasible studs smaller than 3⁄8 in., shall be marked by the manufacturer with a unique identifier to identify the manufacturer or private label distributor, as appropriate. 16.2.1 Type 1 hex cap screws and bolts and one end of Type 1 studs 3⁄8 in. and larger, and whenever feasible studs smaller than 3⁄8 in., shall be marked “A449.”

BFA449 (Birmingham

Fastener)

SLA449 (St. Louis Screw &

Bolt)

JHBA449 (J.H. Botts)

Guardrail Beam

908.11A, AASHTO M180

11.1 Each beam element shall be identified by the following: Name or brand of manufacturer, identification symbols or code for heat, number and coating lot, AASHTO specification number, and class and type.

Michigan Department Of Transportation

1923 (05/13) SAMPLE

IDENTIFICATION Send sample to MDOT Construction Field Services

8885 Ricks Rd., Lansing, Michigan 48909 SEE INSTRUCTIONS BELOW

CONTROL SECTION

JOB NUMBER/PO NUMBER DATE SAMPLED

LAB NUMBER DATE RECEIVED

LAB: Aggregate AWI Concrete HMA Metals Soils/ Geotextiles

NAME OF MATERIAL

SOURCE / SUPPLIER / PIT NAME ADDRESS / PIT NUMBER

MANUFACTURER / PRODUCER ADDRESS

SAMPLED FROM

QUANTITY OF MATERIAL REPRESENTED BY SAMPLE

CONSIGNED TO ADDRESS

SAMPLED BY PHONE/EMAIL TITLE

SUBMITTED BY PHONE/EMAIL TITLE

INTENDED USE

SPECIFICATION SENDER’S SAMPLE I.D.

TYPE OF SAMPLE Acceptance Tested Stock Certification Verification # ______ New Source Information Q.A.

REMARKS

SEND RESULTS TO:

INSTRUCTIONS NOTE: This ID is the sole basis for identification and distribution of the report.

PLEASE BE ACCURATE CONTROL SECTION JOB NO. – As given or PURCHASE ORDER NO. – If applicable NAME OF MATERIAL – As shown in Standard Specifications – include dimensions for bolts, schedule # for conduit, cement type, etc. SOURCE – Contractor, supplier, producer, pit name, or location for naturally occurring materials ADDRESS – Address of source (city & state or county) SAMPLED FROM – Identifiable lot or batch number, and/or specific location, project site, source, etc. QUANTITY REPRESENTED – Number of pieces, feet, square feet, pounds, gallons, etc. CONSIGNED TO – If sampled at source other than project, state to whom and where the material is to be shipped SAMPLED BY – Name and Title if different from submitter INTENDED USE – State material’s use in general terms (e.g., SS-1h, CRS-2M, CSS-1h, etc. for bolts; geosynthetics for select backfill, embankment, 3ft. granular blanket, etc.) SPECIFICATION – Anchor Bolt, ASTM F1554, grade 55, 2012 Std. Spec. 908.14B Aluminum, ASTM B221, 2012 Std. Spec. 919.02A SENDERS SAMPLE ID – Lot, heat, roll, etc. number; sample dimensions; and any other details specific to the same (not sender’s name) REMARKS – State special tests to be run, if sample is rush or resample, and if results are to be phoned or emailed, state to whom (phone number or email)

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Michigan Department Of Transportation

1923 (05/13) SAMPLE

IDENTIFICATION Send sample to MDOT Construction Field Services

8885 Ricks Rd., Lansing, Michigan 48909 SEE INSTRUCTIONS BELOW

CONTROL SECTION

JOB NUMBER/PO NUMBER DATE SAMPLED

LAB NUMBER DATE RECEIVED

LAB: Aggregate AWI Concrete HMA Metals Soils/ Geotextiles

NAME OF MATERIAL

SOURCE / SUPPLIER / PIT NAME ADDRESS / PIT NUMBER

MANUFACTURER / PRODUCER ADDRESS

SAMPLED FROM

QUANTITY OF MATERIAL REPRESENTED BY SAMPLE

CONSIGNED TO ADDRESS

SAMPLED BY PHONE/EMAIL TITLE

SUBMITTED BY PHONE/EMAIL TITLE

INTENDED USE

SPECIFICATION SENDER’S SAMPLE I.D.

TYPE OF SAMPLE Acceptance Tested Stock Certification Verification # ______ New Source Information Q.A.

REMARKS

SEND RESULTS TO:

INSTRUCTIONS NOTE: This ID is the sole basis for identification and distribution of the report.

PLEASE BE ACCURATE CONTROL SECTION JOB NO. – As given or PURCHASE ORDER NO. – If applicable NAME OF MATERIAL – As shown in Standard Specifications – include dimensions for bolts, schedule # for conduit, cement type, etc. SOURCE – Contractor, supplier, producer, pit name, or location for naturally occurring materials ADDRESS – Address of source (city & state or county) SAMPLED FROM – Identifiable lot or batch number, and/or specific location, project site, source, etc. QUANTITY REPRESENTED – Number of pieces, feet, square feet, pounds, gallons, etc. CONSIGNED TO – If sampled at source other than project, state to whom and where the material is to be shipped SAMPLED BY – Name and Title if different from submitter INTENDED USE – State material’s use in general terms (e.g., SS-1h, CRS-2M, CSS-1h, etc. for bolts; geosynthetics for select backfill, embankment, 3ft. granular blanket, etc.) SPECIFICATION – Anchor Bolt, ASTM F1554, grade 55, 2012 Std. Spec. 908.14B Aluminum, ASTM B221, 2012 Std. Spec. 919.02A SENDERS SAMPLE ID – Lot, heat, roll, etc. number; sample dimensions; and any other details specific to the same (not sender’s name) REMARKS – State special tests to be run, if sample is rush or resample, and if results are to be phoned or emailed, state to whom (phone number or email)

File 302

84913

111569 4/22/13

5/1/13

Anchor Bolts, grade 105

AA Anchor Bolt 7390 Salem Rd., Northville, MI 48167

Alton Steel Inc. #5 Cut St., Alton, IL 62002

Source

24

J. Ranck Electric 1993 Gover Parkway, Mt. Pleasant, MI 48858

Joshua Arritt 517-322-1330 / [email protected] Engineering Technician 11

Joshua Arritt 517-322-1330 / [email protected] Engineering Technician 11

Strain Pole Foundations

ASTM F1554, grade 105, MDOT 2012 Std. Spec 908.14B Tag # 153B

Remarks would go here for any type of special instructions regarding this sample

[email protected] (all results are now being sent by email)

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V110515

E-CONSTRUCTION PROCESS

PAGE 1 of 2



E-Construction Process

Description The purpose of this document is to provide the Michigan Department of Transportation’s Structural

Fabrication Unit with a process for implementing e-construction for structural fabrication inspection

record retention. E-construction requires all fabrication inspection records to be provided by the

contractor to MDOT in Adobe portable document format (PDF) files and for MDOT to store the records in

ProjectWise.

1. Receiving Fabricator Documents The fabricator must provide MDOT with electronic files in Adobe PDF. Documents are provided to

MDOT’s quality assurance inspector (QAI) in a timely manner (within 24 hours after the date

covered by the report for structural concrete) for their review prior to stamping structural elements

approved for use.

2. Creating Quality Assurance Documents The QAI must convert all QA documents into PDF files. If fillable forms are used then the files must

be “flattened” to embed all form fields, comments, and any other type of annotation into the

page content prior to combining the PDF files to prevent the fields in similar forms from merging.

The stamped Bill of Lading must be scanned by the QAI for inclusion in the final documentation

package. The paper copy can be discarded after scanning.

3. Assembling and Bookmarking Fabrication Inspection Files The QAI combines, arranges, and bookmarks all project QA and QC documents in one PDF

fabrication inspection file using Adobe Acrobat. See MDOT document titled Structural Fabrication Bookmarking Template for instructions on bookmarking.

4. Sending Fabrication Inspection File to MDOT QAI sends the fabrication inspection file to the MDOT Structural Fabrication Unit using a file transfer

protocol (FTP) program. The MDOT Structural Fabrication Unit randomly audits fabrication

inspection files and follows up with QAI to address any deficiencies.

5. Placing Fabrication Inspection Files into ProjectWise The MDOT Structural Fabrication Unit places the fabrication inspection file into ProjectWise at the

following location (in red) and assigns project attributes to the file:

Xxxxx Region

o Xxxxx TSC or Region Projects

JN XXXXXX

• Construction

o Field Services


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V110515

E-CONSTRUCTION PROCESS

PAGE 2 of 2


6. MDOT Fabrication Inspection Memorandum The MDOT Structural Fabrication Unit works with the MDOT Structure Technical Section

Administrative Assistant to prepare the memorandum (memo) for the MDOT Structural Fabrication

Engineer’s digital signature. The assistant places a copy of the signed memo into ProjectWise at

the following location (in red below) and assigns project attributes to the files for the project

office’s records:

Xxxxx Region


JN XXXXXX

• Construction

o Field Services


A copy of the signed memo is also placed into the Structural Fabrication Unit’s ProjectWise

storage folder for historical record.

7. Notification of Fabrication Inspection Completion The MDOT Structure Technical Section Administrative Assistant emails the ProjectWise link to the

structural fabrication folder (in red below) to the individuals listed on the fabrication inspection

memo:

Xxxxx Region


JN XXXXXX

• Construction

o Field Services


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V110817BOOKMARKING TEMPLATE

PAGE 1 of 1



Bookmarking Template

Description Use this table of contents template for bookmarking final e-construction project documentation files. This

document is both the instructions for assembling a fabrication inspection file and the template for

bookmarking the file. It contains the bookmarks for structural concrete (prestressed and non-prestressed)

and structural steel so the bookmarks not needed must be removed.

Inspection File Assembly Instructions

1. Assemble the inspection file by inserting QC and QA files in PDF format into this document.

2. Using this document as the first page in the inspection file, arrange the files using the

bookmarks shown in this document.

3. Click on the Bookmarks Tab to display the default bookmarks. Scroll through your document

and locate the page (or first page of a section with multiple pages) that corresponds to the

bookmark. Highlight the corresponding bookmark in the list, single right click, and select Set

Destination. Repeat for each applicable bookmark until every section of the inspection file is

bookmarked.

4. Delete any bookmarks that are not needed for your particular project.

5. Delete this document after the file is complete as it is no longer needed in the file.

6. Once document is complete, electronically sign the Inspector’s Project Folder Checklist.

File Naming Convention: “SN-CS-JN Element Inspected Date”

• SN: Structure Number

• CS: MDOT Control Section

• JN: MDOT Job Number

• Element Inspected: Bearing-type, high mast tower, modular expansion joint, sign structure-

type, structural steel-type, culvert-type, prestressed beam-type, precast bridge element-

type, sound wall, spun concrete pole, etc.

• Date: Date file is completed

Examples of this naming convention are shown below:

• B03-82117-112703 Structural Steel-Pin & Hanger 093013

• W01-73022-156776 Sound Wall 111716

• S17-09031-121776 Bearing-Disc 021514

• C07-11015-126765 Culvert-Three Sided 070416

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1942 (01/18) PROJECT FOLDER CHECKLIST To be completed by the QAI, combined with all other fabrication documentation,

and submitted to the MDOT Structural Fabrication Unit. Naming Convention: SN-CS-JN Element Inspected MMDDYY


FABRICATOR / LOCATION CONTROL SECTION


CERTIFICATIONS Inspector’s Project Folder Checklist – Structural Steel (MDOT Form 1942) Affidavit – Certificate of Conformance from Fabricator Fabricator QC Certifications (CWI, NDE, NACE, AISC, etc.) MDOT Welder Qualification Test Reports (MDOT Form 0396 for all welders who worked on the project)

MATERIALS Structural Steel (Plate, Rolled, and Hollow Structural Shapes), Stainless Steel, Aluminum

a. Material Mill Test Reportsb. Fabricator Material Traceability Documents (Material Cut List/Tracking Sheet, etc.)

High Strength Bolts a. ROCAP Test Reports (for shop installed bolts)

Other Hardware (Stainless or other hardware not specifically sampled and tested by MDOT) a. Material Mill Test Reports

Bearings a. Disc Bearings & Pot Bearings

i. Urethane Test Reports & Material CertificationsCoating Certifications from Coating Manufacturer Shear Developer / Stud & Position Dowel General Certifications Other Materials General Certifications (Bushings, Elastomer, etc.)

REPORTS / DOCUMENTATION MDOT Stamped “Approved for Use” Shipping Documents MDOT Report of Shop Inspection of Structural Steel (MDOT Form 0538) Fabricator MDOT Approved WPS’s & PQR’s Fabricator Camber/Sweep, Laydown, & Heat Cambering Reports Fabricator NDE QC Reports QA NDE Reports Fabricator Material Mill Certification Record (MDOT Form 0538D if necessary) Fabricator Coating Reports Fabricator Welding Consumables Certifications Fabricator Equipment Calibration Records Correspondence (RFI’s, NCR’s, Critical Emails, etc.)

COMMENTS

________________________________________________________ INSPECTOR’S SIGNATURE

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0538 (01/18) FABRICATION INSPECTION REPORT To be completed by the QA inspector and included in the final project documentation.




FABRICATION DETAILS – DAILY NARRATIVE

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0538D (01/18) MILL CERTIFICATION RECORD To be completed by the QA inspector and included in the final project documentation.




CERTIFICATION DETAILS GIRDER NUMBER

LINE NUMBER

TOP FLANGE

BOTTOM FLANGE WEB HEAT NUMBER TYPE OF STEEL MILL

CERTS

COMMENTS

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Bureau of Bridges and Structures Structural Fabrication … · Welder Qualification Test Report ......

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