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SECTION 10 - STRUCTURAL STEEL AND HIGH STRENGTH BOLTING

OBJECTIVE

The customary practice of fabrication of steel in the shop prior to erection conveniently allows division of observation of structural steel into two basic categories, shop and field. While the purpose is to assure that proper quality control is exercised at each location, the environment differs. Often the shop is fabricating other projects concurrently and may operate two or three shifts per day. The shop work is closely related to mass production, while the field work relates closer to handcrafting.

These duties should be performed by qualified special inspectors under the direct supervision of the materials engineering laboratory. To better achieve the objective of quality assurance, it is wise to use only one agency to fulfill the duties of both shop and field observation.

OBSERVATION DUTIES

A. Documents

    1. Review the approved plans, specifications, and approved shop drawings.
    2. Review applicable sections of referenced codes, particularly the American Welding Society Structural Welding Code (AWS D1.1) and the Manual and Specifications of the American Institute of Steel Construction (AISC).
    3. Review welding procedure qualifications when other than standard AWS prequalified joints and procedures are involved.

B. Mill Test Reports

    1. Review mill test reports and check heat numbers with material as received. Verify that proper identification of steel is maintained during fabrication.

C. Sampling and Testing

    1. When required by project specifications (particularly schools and hospitals), mark sample location with steel stamp on each piece tested.
    2. Record sample number and location and check that delivered to laboratory and tested.
    3. When steel members are delivered to finish length and no "crop ends" are available for sample cutting, coordinate cutting and patching requirements with architect/engineer and fabricator.

D. Welding Observation

    1. Check each welder’s certification and verify that the welder does work only as covered by his certification.
    2. Keep a written record of each welder by name, his identifying steel mark, and the percentage of rejectable welds.
    3. Upon detection of a rejectable weld (either visually or by nondestructive test), the inspector-in-charge will notify the welder and/or his foreman for verification of defect. The inspector-in-charge will observe removal of defects and repairs to check whether acceptable procedures were used.
    4. Check structural members for thickness adjacent to welds.
    5. Inspect joints for proper preparation, including bevel, root faces, root opening, etc.
    6. Check the type and size of electrodes to be used for the various joints and positions. Check the storage facilities to see if they are adequate to keep the electrodes dry.
    7. Observe the technique of each welder periodically with the use of a welding inspection shield.
    8. Verify the use of proper preheat and interpass temperatures.
    9. Observe multi-pass welds continuously. Continuous observation is defined as follows: The inspector is present in the welding area at all times. The extent of inspection of individual welds will depend on the number of operators welding.
    10. Observe single pass fillet welds periodically (in accordance with code requirements), after determining that the operator is capable of producing the welds required.
    11. If straightening or restraining of weldments is necessary, verify that approved methods will be used.
    12. Tag or stamp accepted weldments with the inspector’s identification stamp.

E. Workmanship

    1. Check straightening and bending procedures.
    2. Check cut edges, including those flame cut, sheared, or milled.
    3. Check bolt holes in major connection for size.

F. Additional Field Duties

    1. Discuss welding sequence for general construction plans and for specific joint sequence with steel contractor and engineer to verify proper sequence to minimize restraint.
    2. Curing adverse weather conditions, check that adequate steps are taken to prevent moisture penetration at welding location.

G. High Strength Bolting

    1. Sample high strength bolts, washers, and nuts for testing from the lots in the shop or on the jobsite, if required.
    2. Review type of joint specified (i.e. slip critical, nonslip critical).
    3. Check bolts, nuts and washers for compliance to project specifications.
    4. Review the procedure for installation of bolts. The amount and type of inspection during installation will depend on the method used.
    5. Check joint surfaces to verify that they are free of burrs, dirt, etc.
    6. Verify installation procedures meet minimum bolt tensions required by code.
    7. Check calibration of wrenches for tightening capacity in a wrench calibrator.

H. Painting

    1. Verify cleaning operations to all surfaces to condition specified.
    2. Verify conformance of paint to specification.
    3. Verify application method, brush, roller, or spray.
    4. Check for thickness of each coating, final thickness, and holidays.
    5. Check touch-up for final finish.

I. Reports

Submit written progress reports describing their tests and observations made and showing the action taken to correct nonconforming work. Itemize any changes authorized by architect/engineer. Report all uncorrected deviations from plans or specifications.
 
 
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