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Bureau of Bridges and Structures Structural Fabrication Unit
STRUCTURAL FABRICATION UNIT
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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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STRUCTURAL FABRICATION UNIT
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STRUCTURAL FABRICATION INSPECTION WEB LINKS
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MICHIGAN DEPARTMENT OF TRANSPORTATION
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.
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Structural Fabrication
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:
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
contract requirements.
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
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
Materials Quality Assurance Procedures Manual 2012
4.05
4. MDOT Shop Drawing Review 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
4.05.03. 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:
Materials Quality Assurance Procedures Manual 2012
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
4. MDOT Shop Drawing Review 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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2
STRUCTURAL FABRICATION UNIT
V011717
REQUEST FOR INFORMATION PROCESS
PAGE 1 of 3
MICHIGAN DEPARTMENT OF TRANSPORTATION
Structural Fabrication
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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V011717
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MICHIGAN DEPARTMENT OF TRANSPORTATION
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:
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.
STRUCTURAL FABRICATION UNIT
V011717
REQUEST FOR INFORMATION PROCESS
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MICHIGAN DEPARTMENT OF TRANSPORTATION
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
3
STRUCTURAL FABRICATION UNIT
V101915
NONCONFORMANCE POLICY
PAGE 1 of 5
MICHIGAN DEPARTMENT OF TRANSPORTATION
Structural Fabrication
Nonconformance Policy
Description The purpose of this document is to provide the Michigan Department of Transportation (MDOT) with
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
STRUCTURAL FABRICATION UNIT
V101915
NONCONFORMANCE POLICY
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MICHIGAN DEPARTMENT OF TRANSPORTATION
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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MICHIGAN DEPARTMENT OF TRANSPORTATION
Structural Fabrication
Nonconformance Reporting 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 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
resolved before the element can be considered for acceptance.
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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:
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
ProjectWise.
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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.
Michigan Department of Transportation
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
JOB DESCRIPTION JOB NUMBER
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
Michigan Department of Transportation
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
4
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MICHIGAN DEPARTMENT OF TRANSPORTATION
Structural Fabrication
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
contract documents and
permanently incorporated
Welded Wire
Fabric
Mild fabric
reinforcement for
strengthening concrete
Yes Yes
Welded wire fabric is specified in
contract documents and
permanently incorporated
Sole Plates
Steel plate cast over
support and bears on
the elastomeric pad
Yes Yes
Sole plates are specified in the
contract documents and
permanently incorporated
Position Dowels
Dowels used to provide
translation restraint for
beams
Yes Yes
Dowels are specified in the
contract documents and
permanently incorporated
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
FHWA memo dated 12/21/12
rescinded
MSEW Lifting
Device
Device for moving
MSEW panels, posts, and
copings
Yes Yes FHWA memo dated 12/21/12
rescinded
Sound Wall
Lifting Device
Device for moving
sound wall panels and
posts
Yes Yes FHWA memo dated 12/21/12
rescinded
STRUCTURAL FABRICATION UNIT
V092717
BUY AMERICA
PAGE 4 of 5
MICHIGAN DEPARTMENT OF TRANSPORTATION
Table 1 (continued). 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
Tie Wire Secures bar
reinforcement Yes No
FHWA memo dated 12/21/12
rescinded
Bar Chair Supports bar
reinforcement Yes No
FHWA memo dated 12/21/12
rescinded
Screed
Supporting
Frame (pipe)
Supports screed
machine Yes No
FHWA memo dated 12/21/12
rescinded
SIP Deck Clip Support location for
attaching SIP decking Yes No
FHWA memo dated 12/21/12
rescinded
Half Hanger
Anchor Supports false work Yes No
FHWA memo dated 12/21/12
rescinded
False Work Insert Supports false work Yes No FHWA memo dated 12/21/12
rescinded
Safety Line
Embed Provides tie off Yes No
FHWA memo dated 12/21/12
rescinded
Spun Pole
Structural Steel
Mounts cameras, etc. to
pole Yes No
FHWA memo dated 12/21/12
rescinded
Spun Pole
Hardware
Mounts cameras, etc. to
pole Yes No
FHWA memo dated 12/21/12
rescinded
Concrete Insert Attach threaded bar
reinforcement or bolt Yes No
FHWA memo dated 12/21/12
rescinded
STRUCTURAL FABRICATION UNIT
V092717
BUY AMERICA
PAGE 5 of 5
MICHIGAN DEPARTMENT OF TRANSPORTATION
Table 2. Steel and iron components used in fabricating structural steel elements.
STRUCTURAL STEEL FABRICATION
Component Description Buy
America
Step
Cert
Why Buy America is/is not
Required
Structural Steel
Rolled
Shape/Plate
Structural steel used for
fabrication of bridge or
highway elements
Yes Yes
Structural steel is specified in
contract documents and
permanently incorporated
Hollow Structural
Sections (HSS)
Structural steel used for
fabrication of bridge or
highway elements
Yes Yes
Structural steel is specified in
contract documents and
permanently incorporated
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
Yes Yes FHWA memo dated 12/21/12
rescinded
Welding Rod Weld metal used in
SMAW process Yes Yes
FHWA memo dated 12/21/12
rescinded
Welding Wire
Weld metal used in
GMAW, SAW, or FCAW
processes
Yes Yes FHWA memo dated 12/21/12
rescinded
(This page intentionally left blank)
(This page intentionally left blank)
(This page intentionally left blank)
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.
(This page intentionally left blank)
5
STRUCTURAL FABRICATION UNIT
V052416
WELDER QUALIFICATION PROGRAM
PAGE 1 of 3
MICHIGAN DEPARTMENT OF TRANSPORTATION
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.
STRUCTURAL FABRICATION UNIT
V052416
WELDER QUALIFICATION PROGRAM
PAGE 2 of 3
MICHIGAN DEPARTMENT OF TRANSPORTATION
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:
• 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.
STRUCTURAL FABRICATION UNIT
V052416
WELDER QUALIFICATION PROGRAM
PAGE 3 of 3
MICHIGAN DEPARTMENT OF TRANSPORTATION
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
contract requirements.
(This page intentionally left blank)
(This page intentionally left blank)
(This page intentionally left blank)
Page 1 of 2
Michigan Department of Transportation
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
Page 2 of 2
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.
Page 1 of 2
Michigan Department of Transportation
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
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
Page 2 of 2
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
6
STRUCTURAL FABRICATION UNIT
V092517
METALS LABORATORY SAMPLING GUIDANCE
PAGE 1 of 6
MICHIGAN DEPARTMENT OF TRANSPORTATION
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.
STRUCTURAL FABRICATION UNIT
V092517
METALS LABORATORY SAMPLING GUIDANCE
PAGE 2 of 6
MICHIGAN DEPARTMENT OF TRANSPORTATION
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
STRUCTURAL FABRICATION UNIT
V092517
METALS LABORATORY SAMPLING GUIDANCE
PAGE 3 of 6
MICHIGAN DEPARTMENT OF TRANSPORTATION
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.
STRUCTURAL FABRICATION UNIT
V092517
METALS LABORATORY SAMPLING GUIDANCE
PAGE 4 of 6
MICHIGAN DEPARTMENT OF TRANSPORTATION
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:
You can find Samplemanager training videos on the MDOT YouTube page or they are available via email
by request.
STRUCTURAL FABRICATION UNIT
V092517
METALS LABORATORY SAMPLING GUIDANCE
PAGE 5 of 6
MICHIGAN DEPARTMENT OF TRANSPORTATION
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)
STRUCTURAL FABRICATION UNIT
V092517
METALS LABORATORY SAMPLING GUIDANCE
PAGE 6 of 6
MICHIGAN DEPARTMENT OF TRANSPORTATION
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)
File 302
Clear Form
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)
Clear Form
EXAMPLE
7
STRUCTURAL FABRICATION UNIT
V110515
E-CONSTRUCTION PROCESS
PAGE 1 of 2
MICHIGAN DEPARTMENT OF TRANSPORTATION
Structural Fabrication
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
Structural Fabrication
STRUCTURAL FABRICATION UNIT
V110515
E-CONSTRUCTION PROCESS
PAGE 2 of 2
MICHIGAN DEPARTMENT OF TRANSPORTATION
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
o Xxxxx TSC or Region Projects
JN XXXXXX
• Construction
o Field Services
Structural Fabrication
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
o Xxxxx TSC or Region Projects
JN XXXXXX
• Construction
o Field Services
Structural Fabrication
(This page intentionally left blank)
(This page intentionally left blank)
STRUCTURAL FABRICATION UNIT
V110817BOOKMARKING TEMPLATE
PAGE 1 of 1
MICHIGAN DEPARTMENT OF TRANSPORTATION
Structural Fabrication
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
(This page intentionally left blank)
8
Page 1 of 1
Michigan Department of Transportation
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
GENERAL INFORMATION INSPECTOR / AGENCY DATE
FABRICATOR / LOCATION CONTROL SECTION
JOB DESCRIPTION JOB NUMBER
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
Clear Form
Page 1 of 1
Michigan Department of Transportation
0538 (01/18) FABRICATION INSPECTION REPORT To be completed by the QA inspector and included in the final project documentation.
GENERAL INFORMATION INSPECTOR / AGENCY DATE
FABRICATOR / LOCATION CONTROL SECTION
JOB DESCRIPTION JOB NUMBER
FABRICATION DETAILS – DAILY NARRATIVE
Clear Form
Page 1 of 1
Michigan Department of Transportation
0538D (01/18) MILL CERTIFICATION RECORD To be completed by the QA inspector and included in the final project documentation.
GENERAL INFORMATION INSPECTOR / AGENCY DATE
FABRICATOR / LOCATION CONTROL SECTION
JOB DESCRIPTION JOB NUMBER
CERTIFICATION DETAILS GIRDER NUMBER
LINE NUMBER
TOP FLANGE
BOTTOM FLANGE WEB HEAT NUMBER TYPE OF STEEL MILL
CERTS
COMMENTS
Clear Form
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