Prof. Ir. Jamasri, Ph.D., IPU., AER.

Department of Mechanical & Industrial Engineering

Engineering Faculty UGM

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 PREFABRICATION
Once the Contractor has been selected and the Fabricator for
the structural steel construction works has been identified, a
number of activities need to occur before the actual start of the
physical fabrication activities, such as:
• The fabricator develops shop drawings, translating the design
drawings and specifications into drawings and instructions to
enable the work to be implemented by the shop personnel.
• The shop drawings need to be reviewed by the Engineer of
Record (EOR) to confirm compliance with the design and
specifications.
• The fabricator also needs to ensure that it has all necessary
procedures in place to be able to actually perform the work.

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 PREFABRICATION
Prior to the start of the actual work, a number of activities
has to be performed, includes the following:
• Welding Procedure Specification (WPS)
• REPAIR PROCEDURES FOR COMMON SITUATIONS
• Procedure Qualification Record (PQR) and Welder
Qualification Test Record (WQTR)
• SHOP QA/QC PLAN
• THIRD PARTY QUALITY ASSURANCE
• PRE-FABRICATION MEETING
• Formal Request for Information (RFI)

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 Welding Procedure Specification (WPS)
• WPS is the 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.
• The purpose of the document is to guide welders to the accepted
procedures so that repeatable and trusted welding techniques are
used.
• A WPS is developed for each type of material to be used and for
each welding process (type) that will be performed.
• A sketch of the joint detail and a description of what is being welded
using the WPS should be included, such as crossframe welding,
flanges, splicing stiffeners to flange, etc.
• The fabricator’s WPS needs to demonstrate compliance with
applicable codes and industry standards called for in the
specifications.

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Example of WPS

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 REPAIR PROCEDURES FOR COMMON SITUATIONS
• The procedures to be used to
commonly encountered fabrication
and welding deficiencies should
be prepared in advance of the
start of the operations so as not to
create unnecessary delays
• Examples of frequently
encountered conditions include
base metal defect repairs, burn
gouge repairs, heat
straightening/curving, weld
undercut and underfill, crack
repair, internal weld defect repair
(discovered through non-
destructive testing techniques),
poor weld profiles, distortion
repairs, misdrilled holes and
others.
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 PQR/WPQR
• (PQR/WPQR) is a record for an individual welder documenting that
he/she adequately performed a test weld, and that weld was
laboratory tested to confirm that the procedure, as performed by that
individual, would produce a good weld with predictable mechanical
characteristics.
• This process validates that the fabricator has the ability to perform
the work as described in the WPS.
• Each individual welder that the fabricator plans to use to perform
work on the project should be certified with a qualification test
documented in a Welder Qualification Test Record (WQTR) that
shows they have the understanding, skill and demonstrated ability to
perform the work within the specified WPS and produce an
acceptable weld.
• The inability to have an adequate number of welders qualified to
perform the needed welding operations can result in serious
disruptions to the fabrication process.

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Example PQR adopted from AWS D1.5

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 SHOP QA/QC PLAN
• The fabricator shall have a formal, written Quality Control/Quality
Assurance program in place prior to the start of work on the project.
• The Quality Control aspect of this program is to identify the controls
to be implemented to confirm to the codes, drawings and
specification requirements to ensure that all of the shop operation
activities, including measures taken to ensure that the ways, means,
methods and techniques will achieve full compliance with the
contract requirements.
• This should include having the appropriate WPS and shop drawings
applicable to each production element in the immediate possession
of the general workers and welders during the performance of any
work activities.
• This should also address non-destructive testing methods that the
fabricator will use to confirm the adequacy of the completed welding
activities

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 SHOP QA/QC PLAN (Cont..)
• The Quality Assurance aspect of this program is to define the
measures undertaken by the fabricator to monitor the performance
of the work to confirm that the Quality Control measures are being
implemented as required.
• The Contractor, and its fabricator, is responsible for ensuring the
work is performed in full compliance with the contract requirements.
A common challenge for many agencies is confirming whether the
fabricator is adequately implementing the Quality Assurance aspect
of their QA/QC program.
• Production operational demands of cost and schedule often result in
conflicts with the adequate implementation of the functions of the
Quality Assurance personnel of the fabricator.
• A properly functioning and implemented QA/QC program provides
the greatest potential for achieving the end objective of an end
product in full compliance with the contract requirements.

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 THIRD PARTY QUALITY ASSURANCE
• Third Party Quality Assurance services provide an independent
characteristic that is not able to be achieved by the fabricator’s in-
house Quality Assurance personnel.
• The use of such Third Party QA services enables the QA function to
be able to occur with a significantly greater level of independence.
• The Third Party QA personnel serve as the eyes and ears of the
client and are not under the control of the fabricator.
• The purpose is to provide independent unbiased assurance that the
approved QA/QC plan, code, specifications and approved drawings
are adhered to by the fabricator.
• Third Party QA can begin even before material arrives at the
fabricator’s shop, with the review and validation of the existence of
necessary WPSs and PQRs to enable the fabricator to proceed with
its fabrication operations as soon as the material arrives at the
fabricator’s shop.

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 THIRD PARTY QUALITY ASSURANCE

• The Third Party QA services would continue thru the fabrication

operations and any coatings processes and conclude with the
loading and binding of completed fabrications on shipping vehicles.
• Decisions on whether to have part time or full time Independent QA
coverage may be influenced by the complexity of the fabrication, the
Owner/Agency’s experience with the Contractor/ Fabricator, or client
preference.

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 PRE-FABRICATION MEETING
• A Prefabrication Meeting should be held with all involved parties
prior to the start of the fabrication activities. Involved parties should
include the Client, its Engineer, Construction Manager and Third
Party QA, the Contractor and the Fabricator, including its QA/QC
personnel.
• Lines of communication should be clearly established for any issues
that arise and decision making roles of the parties should be clearly
defined.
• Any known issues with contract or specification requirements should
be presented.
• Critical inspection Hold Points should be identified.
• The failure to conduct such a Pre-fabrication meeting at the outset of
the work frequently results in confusion, miscommunications and
delays to the project activities when issues develop.

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 Formal Request for Information (RFI)

• RFIs process should be established to facilitate the

tracking and monitoring of issues that arise, and
ensuring their timely resolution by any required
reviewers.
• All potentially affected parties should be included in the
distribution of the RFIs and the resolution of the issue
raised needs to be disseminated to all the team
members.

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 FABRICATION
The fabrication process typically involves the following series of
operations:
• RECEIVING MATERIALS/MTRS
• CUTTING OF SHEET
• TACK WELDING/FIT-UP
• PREEHATING OPERATIONS AND INTERPASS TEMPERATURES
• WELDING PROCESSES
• BOLT HOLES
• NON-DESTRUCTIVE TESTING
• BOLTED CONNECTIONS
• NON-CONFORMANCE REPORTS (NCRs)
• COATINGS /PAINTINGS
• PRE-ASSEMBLY/SHOP ASSEMBLY/SHOP LAYDOWN
• ERECTION PLAN / SCHEDULE
• SHIPPING
• ERECTION/FIELD INSTALLATION

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 RECEIVING MATERIALS/MTRS

• All material to be used as part of the fabrication process

should be accompanied by Material/Mill Test Reports
(MTR).
• This documentation must be reviewed for conformance
with the specifications.
• A particular point of concern for federally funded projects
is whether or not the documentation indicates that the
material is from a foreign source.

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Mill Test Certificate

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 CUTTING OF SHEET STEEL

• Several methods may be used to perform

material cutting, including flame cutting,
sawing, shearing, plasma cutting, water jet
and laser.
• Heat number traceability on all but product
must be maintained.

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Marking Prior to Cutting

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 TACK WELDING/FIT-UP
• Once component pieces of metal have been cut and
prepared, the parts are preliminarily assembled in their
intended configuration.
• The parts are then tack welded into position sufficiently
to enable the welding operation to commence.
• The tack welds shall be made in the joint and
incorporated into the final welds.
• No tack welding is to occur outside of the planned
locations for the permanent welds.
• This operation may include additional bracing of the
components to counteract the tendency of the plate to
flex or bend during the welding operations.

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 PREEHATING OPERATIONS AND
INTERPASS TEMPERATURES
• The welding operation requires an appropriate level of
preheating of the adjoining plates to prepare the actual
welding process.
• Continuous monitoring of the preheated plate, both prior
to the start of the welding operation and during the inter-
pass welding activities, is essential to ensuring that the
material does not fall below the necessary temperature
range while the welding process is occurring.

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 WELDING PROCESSES
• The welding operation may involve various types of weld
configurations, including groove welds, fillet, single bevel or
double bevel conditions, CJP (complete joint penetration),
PJP (partial joint penetration).
• The orientation of welding operation may include Flat,
Horizontal, Vertical and Overhead positions. The welder
should be appropriately qualified for the type of weld and
configuration that is to be performed.
• Manual (stick)/Semi Automatic - (wire feed is
motorized)/Automatic (wire feed and travel speed are
motorized) welding processes.
• Welding Technique: GMAW, SMAW, SAW, FCAW, etc
• Welding Positions: 1F, 2F, 3F, 4F (Fillet Weld) & 1G, 2G, 3G,
4G (Grove Weld)

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Position of Test Plate

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Weld Joint Tests

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 BOLT HOLES
• Holes for bolting are normally performed with mechanical
or plasma drilling methods.
• All holes are to be drilled or punched depending on
thickness.
• There is to be no plasma or flame cutting of holes.
• A far too common problem is the failure to adequately
lay out the necessary hole pattern.
• Errors have included orienting the hole pattern from the
wrong side of the plate, out of round holes, infringement
on end distance, incorrect hole diameter, misalignment
between rows of holes, and deficient data entry for
computerized drilling machines.

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Drilling Holes

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 NON-DESTRUCTIVE TESTING (NDT)
• NDT methods are utilized to confirm the adequacy and internal
integrity of the welds.
• Standards that are available for guidance on when to have NDT
performed include:
AWS D1.1 Codes – Extent of Testing
AWS D1.5 Clause 6
Client standards
• Types of NDT include:
Visual Testing (VT)
Shear wave Ultrasonic Testing (UT)
Straight Beam UT
Phased Array UT
Magnetic Particle testing (MT)
Liquid Penetrant Testing (PT)
Radiographic Testing (RT)

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Inspection

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NON-CONFORMANCE REPORTS (NCRs)

• NCRs are used to address non-conformances (items not

meeting code or specification requirements) and to
recommend and secure approval for remedial measures
to address the non-conformance.
• The NCRs need to be timely initiated by the fabricator
and addressed by Client

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 BOLTED CONNECTIONS
• Bolted connections are frequently required as part of the fabricated
product. Particular concern exists in ensuring that the correct grades and
types of bolts are utilized and provided with the completed assembly.
• Some components can be partially assembled in the fabrication facility
for delivery to the job site. In such instances, the bolted assemblies need
to be tested for proper installation. Types of testing methods include:
 Rotational Capacity (ROCAP) A pretesting activity to verify
cleanliness and lubrication of bolts and nots. This should be done at
the point of installation as well as at the bolt manufacturing.
 Pre-Installation Verification (verifies that installers are using methods
that will result in proper bolt tension)
 Turn of the nut (tightened snug plus rotating the nut or bolt a specific
turn angle based on the bolt grade, length and diameter while
restraining the unturned element from rotating).
 Calibrated wrench (to specified torque)
 Direct tension Indicator (DTI)
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Slip on Bolted Connection

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 COATINGS / PAINTINGS
• Once the fabrication activities are complete, the
fabricated components frequently will require the
application of a coating system prior to storage and/or
shipment.
• Galvanizing (Hot dipping mainly for fabrications, dipping
or mechanical for bolts) - A zinc film is deposited on steel
to provide long term (generally 10 to 30 years) corrosion
protection and abrasion resistance
• Painting / Coating Systems

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Painting Tests

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PRE-ASSEMBLY/SHOP ASSEMBLY/SHOP
LAYDOWN
• A common specification requirement is for the fabricator to perform
a Shop Assembly of the completed structure prior to shipment.
• This task is used to prove the fabricated bridge parts will fit and bolt
together as required by the contract and shop drawings.
• Other methods can be used such as 3D modeling and/or computer
controlled drilling. The main concern is to have assurances that all
the completed components will correctly fit together during field
erection.
• Some of the key aspects of the fabrication that are able to be
verified with Shop Assembly include: Parts fit as intended; verify
superelevations and cambers. Usually this is verified and
documented by Total Station surveying after shop assembly.

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Assembly Process

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 ERECTION PLAN / SCHEDULE

• The Fabricator should provide detailed erection plans for

how the structure should be assembled in the field to
ensure that all the parts will come together as required.
• The erection plan should include, at a minimum,
minimum lifting capacity requirements, positions and
reaches for all picks/lift activities.
• Failure to do so can result in slight to major
misalignments in the field.

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Erection Process

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 SHIPPING
• A number of issues can exist in the shipping process.
• The loading operations must be concerned about
orientation of girders on trucks, lifting points and
methods, positioning of supports and methods and
locations of tie-downs on the transport vehicle.
• Photos should be taken at the completion of the loading
operation to document the pre-shipment condition.

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 ERECTION/FIELD INSTALLATION
• One of the end products of the fabrication process
should include an erection plan for the completed
assembly.
• This plan should include the sequence of assembly that
will result in the components properly mating for a
completed end product.
• The plan should include any specific concerns, such as
bearing points for temporary assembled components,
erection sequence, pick points, monitoring requirements,
and any other potential erection considerations.

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Lifting Process

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Lifting Process

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THANK YOU

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