Steve Margaris, Specifications

Engineer, Caltrans

SFOBB East Span Seismic Safety Project

 Steel Structures Special
Provisions
Welding
Steel Audits
Steel Structures (SAS)

SFOBB East Span Seismic Safety Project

 Welding

Applies to all Structural Steel

Contractor is responsible for QC
--Designate QC Inspector - CWI
CT is responsible for QA

SFOBB East Span Seismic Safety Project

 Welding Quality Control
Quality Control Manager (QCM)
--Responsible for quality of welding
--Represents Contractor and subcontractors
--May be an employee of the Contractor
--Must be CWI
--Submits, receives and approves all
reports and correspondence

SFOBB East Span Seismic Safety Project

 Welding Quality Control
Quality Control Plan (QCP)
Documentation of qualifications of all welding
personnel and weld processes
Welding NDT methods and frequencies
Method of identification and tracking of each
weld
Documentation of CT certification of UT
personnel

SFOBB East Span Seismic Safety Project

 Welding Quality Control

Documentation Submittals
Welding Report (within 7 days of welding)
Reports of all visual inspection and NDT
Reports
Documentation of evaluation of NDT and
reexamination of repaired welds
Daily welding production log

SFOBB East Span Seismic Safety Project

 Steel Audit
Applies to all structural steel
General steel meeting
Contractors self audit (Audit Form in
Information Handout)
CT audit (requires 50 working days)
Maximum 3 audits allowed
Documentation submittals--facility list, self
audit submittal
SFOBB East Span Seismic Safety Project
 Steel Structures (SAS)
Typical Structural Steel
Girders, plates, connections
Full scale mock-ups

SFOBB East Span Seismic Safety Project

 Steel Structures (SAS)
Non Typical Structural Steel
Hinge Pipe Beams
Castings
Portions of saddles
Modular Joint Seal Assemblies
Circular Segmented Bearings
Travelers

SFOBB East Span Seismic Safety Project

 Steel Structures (SAS)
Requires fabricators and suppliers AISC
certification Category Cbr, Major Steel
Bridges, with Endorsement F, Fracture
Critical Members
Requires erectors AISC certification
Category CASE, Certified Advanced Steel
Erector, with Endorsement F, Fracture
Critical Members

SFOBB East Span Seismic Safety Project

 Steel Structures (SAS)
Working Drawing Fabrication submittal
--Design geometry and fabrication
geometry lines
--Details of temporary and permanent
fabrication
--Distortion control plan per AWS
--Material and weld designations and shop
fabrication processes
SFOBB East Span Seismic Safety Project
 Working drawings fabrication (conted)
Orthotropic Box and Pipe Beam
--Method of rib or pipe beam fabrication
--Details of fabrication jigs
--Location of tack welds and the sequence of
all welding
--Methods of repair of elements that exceed
specified tolerances
--Fabrication schedule

SFOBB East Span Seismic Safety Project

 Erection Plan Working Drawings
--Details and limits of each section to be
erected
--Details of attachments to each section for
transportation and lifting
--Methods of transportation and lifting of each
section
--Methods of aligning adjacent sections
during erection

SFOBB East Span Seismic Safety Project

 Erection Plan Working Drawings (conted)
--Details of temporary work platforms and
other aids for field welding
--Locations and methods of tack welds and
final welds
--Supplemental calculations indicating the
stress on the permanent structure due to
attachments and erection and estimates of
final dimensions of the in-place condition

SFOBB East Span Seismic Safety Project

 Fabrication
--Full size mock-ups are required for tower
saddle, tower diaphragm, box panel with
closed ribs and pile to footing connection
--Examined visually and by UT or RT and MT
--Sectioned to produce two macroetch
samples for each weld and evaluated per
AWS

SFOBB East Span Seismic Safety Project

 Assembly
Tower sections
--Ends of each lift section shall be milled to
meet dimensional requirements. Each end
shall be in a horizontal plane when standing
on end.
--Sections shall be abutted in the shop to
ensure proper fit

SFOBB East Span Seismic Safety Project

 Assembly
Orthotropic box
--Shall be fabricated in subassemblies as
shown on the plans
--Subassemblies and preassembled sections
shall be within the dimensions and
tolerances shown on the plans, except for
camber
--Preassembly is required--three contiguous
sections checked for matching, alignment
and camber
SFOBB East Span Seismic Safety Project
 Shop Welding
Dimensional Tolerances
--Contractor to submit dimensional control
procedure and the use of dimensional
control templates for approval
--Dimensional tolerances shall conform to
AWS, and as modified by the plans and
special provisions.
--Box shall be checked against steel templates
--Box members shall be within 4 mm of
theoretical location
SFOBB East Span Seismic Safety Project
 Welding of Closed Ribs to Box shell plate
--Minimum 80% penetration of rib thickness
--Weld procedure trials using the SAW
automated welding method performed on a
rib prototype 10 m long, stop/restart 2 m
--Rib panel checked for straightness and
production tolerances
--Welds are 100% UT tested, rib is split in two
and macroetched in 21 locations minimum

SFOBB East Span Seismic Safety Project

 Welding of Closed Ribs to Box shell plate
Weld Evaluation Criteria
--Minimum 80% weld penetration
--No gross notches or burn-through at the rib
inside surface
--Tack welds shall be consumed
--Acceptable macrosections will be
considered qualified welds and will be used
as standards of acceptance of production
welds
SFOBB East Span Seismic Safety Project
 Welding of Closed Ribs to Box shell plate
Monitoring Production Welds
--Each welding machine tested every 4 hours
--Test specimens shall consist of run-off
extensions of production test panels
--Test specimen shall be macroetched
--If weld quality found unacceptable, welding
parameters must be adjusted and two
additional successful specimen trials must
be done
SFOBB East Span Seismic Safety Project
 Field Welding
--Same requirements as shop welding
--Contractor to provide suitable enclosures to
permit field welding in inclement weather
per AWS and project requirements

SFOBB East Span Seismic Safety Project

 Field Welding
Pile to pile footing connection
--Full scale wood mock-ups required of the
pile to pile footing connection
--Full scale steel mockups required of the pile
to footing sleeve connection to demonstrate
hole drilling, slot cutting, connection plate
fitting, welding and inspection
--Submittal of installation and welding
sequence procedure for each mock-up
SFOBB East Span Seismic Safety Project
 Field Welding
Pile to pile footing connection (conted)
--Procedure must describe equipment and
details of installing the seal, field cutting
slots in the piles and sleeves, installing the
connection plates and performing all
welding
--Engineer to witness fit-up and welding of
each mock-up

SFOBB East Span Seismic Safety Project

 Field Welding
Pile to pile footing connection (conted)
--Mock-up assembly to be MT and UT tested
--Macroetch specimens taken from pile to pile
sleeve connector plate. Each specimen shall
demonstrate the required weld size and
weld profile
--Results of the mock-up installation and
welding sequence procedure shall be
evaluated and final procedure developed

SFOBB East Span Seismic Safety Project