In addition to the requirements set forth in the Standard Specifications, all steel fabrication shops and plants, shall be on an approved list prior to letting for work covered by Iowa Department of Transportation Standard Specifications for Highway & Bridge Construction.
Approval of fabrication shops and plants shall be on the following basis:
1. Only plants requesting qualification for Intermediate or Advanced Bridge per Standard Specification 2408.02 will require an on-site plant inspection.
2. Approved Quality Control Plan/procedures
3. Qualified quality control personnel
4. Applicable certifications
5. Shop approval (welding equipment, certified welders)
6. AISC quality certification program qualifications for fabrication
7. SSPC quality certification program qualifications of paint application
8. Facilities, capabilities, equipment and resources.
9. Quality management system for policies and objectives with defined positions and responsibilities.
Written Quality Policy:
A Statement of commitment to achieve quality goals signed by the highest level of management at the facility. The goals should include quality planning, training, personnel qualifications and quality control. Goals of each of these major function effecting quality such as management, engineering, operation, production, and QC (Quality Control) shall be considered.
· An organization chart showing the positions that effect quality control shall be listed. The chart shall show position titles and names (if chart is updated). The chart shall also show formal reporting relationship and informal relationship (with a dotted line) pertaining to quality system.
· Quality control personnel cannot perform double duties and cannot perform in production or management as well as in QC.
Approved fabricators are listed in the Materials Approved Products Listing Enterprise (MAPLE).
Approved fabricators with corresponding bridge components and miscellaneous items are listed at https://maple.iowadot.gov/files/557AB.pdf
All steel fabrication can be divided into two groups:
2. Other steel items are as follows:
a. Bridge Components as noted in the AASHTO / AWS D1.5, Chapter 1, General Provisions 1.3.6 welding of ancillary products and Miscellaneous Items. This includes swedge anchor bolts*, self lubricating bronze plate, sole plates, pintle plates, masonry plates, curved sole plates, finger joint devices, floor drains, drain pipe, welded wire fabric fence panels, metal railing (steel, aluminum, and stainless steel), bearing assemblies-castings, disc bearings, steel laminated elastomeric bearing pads**, and tread plates.
b. Traffic Signal Components
c. Sign Support Components
d. Lighting Structure Components – high mast lighting tower shall require procedure qualification reports (PQR) for verification of the weld procedure specifications.
e. Pre-engineered Steel Truss Trail Bridges
For all the items in group 2, welding procedures and requirements shall conform to the ANSI/AWS D1.1 Structural Welding Code, except that filler metal and welder qualification requirements shall be in accordance with AASHO / AWS D1.5.
* For swedge anchor bolts, consult IM 453.08
** For steel laminated elastomeric bearing pads, consult IM 495.03
Certified welding inspectors supplied by a testing agency to perform as in-house inspector or act as quality control manager must first provide documentation of experience and knowledge with issues concerning (WPS’s) assembly of bridge components (full assemblies/sub-assemblies/lay down assemblies/horizontal and vertical and knowledge of required tolerances to perform inspection. Also knowledge, experience and understanding of the surface preparation requirements and painting. Secondly the substitution of the certified welding inspectors must be pre-approved by the Structural Materials Engineer. Documentation verifying this accumulated experience must be submitted for review and approval by the office of Construction and Materials.
MAIN STRESS-CARRYING MEMBERS
The main members of steel structures are fined to include rolled section of flange and web plates in main beams and girders, floor beams, stringers, abutment diaphragms, cross frames carrying direct live loads, lateral bracing in horizontally curved bridges, cover plates, bearing stiffeners, pot bearing devices, splice plates, gusset plates, and stiffeners connecting live load carrying members to main beam or girder webs. The contract documents may also designate other members as main members.
For members that require Charpy V-Notch tests, see Article 4152.02B
All of the above require certified Mill Test Certifications and heat number identification.
All of the above main members have restrictive specifications governing shearing and hole punching.
Refer to Standard Specification 2408.02,L.
BRIDGE COMPONENTS & MISCELLANEOUS ITEMS
Bridge components and miscellaneous items shall be fabricated by an approved fabricating shop. See IM 557 Appendix B.
All fabricators in Group 1 and Group 2 shall provide a summary report of the fasteners to be furnished for each project. The summary reports shall include the fasteners certified mill test reports and shall identify the following:
No. of Pieces
Lot / Heat #
ACCEPTANCE OF MATERIALS
1. All products of iron, steel, or a coating of steel shall meet the requirements of IM 107, Buy America.
2. Materials Identification – The method of material identification and documentation such as heat number, grade, and type for any piece or any member shall be maintained throughout and to the end of the fabrication process. Material traceability by heat number shall be required.
3. Mill Test Reports – all mill test reports from the mills shall be certified (stamped, signed, and dated).
4. All sharp / cut edges shall be rounded with a grinder for safety handling and for purpose of galvanizing and painting.
5. Defect and other discrepancies shall be corrected, repaired, or otherwise replaced with an approved procedure or method.
6. Galvanizing test reports shall be certified by an approved galvanizer and shall include zinc thickness, production lots, dates, and ASTM specification requirements.
7. Galvanized fasteners:
High strength fasteners (ASTM A 325), anchor bolts and non-high strength fasteners, shall be galvanized by the following methods: ASTM F 2329 with bath zinc temperature (documented) not exceeding the 850şF or ASTM B 695 Gr. 55, Type 1.
REMOVAL FROM THE APPROVED LIST
Significant and/or repeated non-compliances (that are similar in nature) with the DOT contract documents will warrant a corrective action request (CAR) being submitted to the fabricator. The fabricator will have 20 working days to submit a corrective action plan for approval. Production may continue during this 20 day period with DOT inspection (when required). If the corrective action plan is not approved, the fabricator will be in conditional status for 30 working days. The fabricator shall hire a consultant to inspect the fabrication. A DOT Materials Fabrication Inspector 2 will oversee the fabricator and consultant. Products fabricated during this time will be approved for use based on acceptable consultant reports in conjunction with DOT review. Continued non-compliance will be considered grounds to remove the fabricator from the approved list. The current project will be completed with consultant inspection and DOT review. Conditional status will be withdrawn with a satisfactory report from the consultant at any time during the 30 day period.
Willful misrepresentation by the fabricator, intentional shipment of non-approved products or repeated placement on conditional status (three times in three years) will be considered grounds for removal from the approved list.
Any fabricator removed from the approved list may be considered for reinstatement by reapplying after the items of concern have been addressed.