QC/QA Process & A354 BD Rod Testing Program

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  • QC/QA Process &QC/QA Process &A354 BD Rod Testing Program

    Bahjat Dagher, PE

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    j gMaterial Engineering & Testing Services

  • O tliOutline Section I: Introduction Section II: Fabrication Process Section III: Quality Assurance Section IV: Testing Program for SAS Rods

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  • S ti I I t d tiSection I: Introduction

    2,306 anchor rods 17 groups of rods

    Top of Tower

    Top of W2 East Cable Band

    East Saddle Anchorage

    Top of E2

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    Bottom of Tower

    3

  • A354 Gr BD Anchor RodsAnchor RodsSAS

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  • A354 Gr BD Anchor Rods

    96 Rods224 Rods320 Rods

    Anchor RodsSAS

    274 Rods 25 Rods 108 Rods336 Rods

    192 Rods96 Rods

    274 Rods 25 Rods 108 Rods336 Rods

    4 Rods90 Rods 388 Rods 36 Rods

    24 Rods 43 Rods32 Rods 18 Rods

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  • A354 Gr BD Anchor Rods

    0.6 Fu0.7 Fu0.7 Fu

    Anchor RodsSAS

    0 32 Fu 0 68 Fu 0 5 Fu0 4 Fu

    0.7 Fu0.7 Fu

    0.32 Fu 0.68 Fu 0.5 Fu0.4 Fu

    0.1 Fu0.1 Fu 0.48 Fu 0.37 Fu

    0.16 Fu 0.1 Fu0.1 Fu 0.2 Fu

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  • S ti II F b i ti PSection II Fabrication Process

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  • F b i ti PFabrication ProcessSteel Mill

    Shipment of material from the mill to the fabricator

    Steel Mill

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  • F b i ti PFabrication ProcessSteel Mill Heat T t t

    Quenched & tempered Oven heated

    Steel Mill Treatment

    Induction coil

    Hardness, strength, grain size, other properties

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  • F b i ti PFabrication ProcessSteel Mill Heat T t t Threading

    All rod threads were cut with the exception of: E2 Bearing Top Rods (B1, B2, B3, B4) Rolled

    Steel Mill Treatment Threading

    g p ( , , , ) PWS Anchor Rods (80%) Rolled Tower Saddle Tie Rods Rolled B14 Cable Band Anchor Rods Rolled B14 Cable Band Anchor Rods Rolled

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  • F b i ti PFabrication ProcessQC

    T tiSteel MillHeat

    T t t Threading

    Mechanical Properties per ASTM A354 MT performed on rods specified by CCO 91

    TestingSteel Mill Treatment Threading

    MT performed on rods specified by CCO 91

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  • F b i ti PFabrication ProcessQC

    T tiSteel MillHeat

    T t t Threading Galvanizing

    Dry blast cleaned to a near white finish (SP-10) prior to galvanizing per ASTM A123

    TestingSteel Mill Treatment Threading Galvanizing

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  • S ti III Q lit ASection III Quality Assurance

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  • Q lit AQuality Assurance Audit

    Facility audits in 2007 and 2008 Audit performed by Caltrans

    Audit

    Audit performed by Caltrans Final results of audits: Pass

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  • Q lit AQuality AssuranceAudit Source I ti

    In-process inspection Thread dimensional verification

    Audit Inspection

    Thread dimensional verification Magnetic Particle Testing

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  • Q lit AQuality AssuranceAudit Source I ti

    Document V ifi ti

    Document verification Certificate of Compliances

    Audit Inspection Verification

    Certificate of Compliances Mill Test Reports QC test results

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  • Q lit AQuality AssuranceQA

    S liAuditSource

    I tiDocument V ifi ti

    Defined in state letter dated July 14, 2008 One full size sample per heat

    SamplingAudit Inspection Verification

    One full size sample per heat Two reduced size samples per heat

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  • Q lit AQuality AssuranceQA

    S liQA

    T tiAuditSource

    I tiDocument V ifi ti

    Tests performed: Full size tension

    Sampling TestingAudit Inspection Verification

    Full size tension Reduced section tension Hardness Coating thickness

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  • Q lit AQuality AssuranceQA

    S liQA

    T tiMETS

    R lAuditSource

    I tiDocument V ifi ti

    Orange Tag Material conforms to

    Blue Tag Material does not conform

    Sampling Testing ReleaseAudit Inspection Verification

    Material conforms to contract requirements

    Material does not conform to contract requirements but accepted as fit for purpose

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  • QC/QQC/QA Documentation

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  • Section IV Testing Program for SAS R dSAS Rods

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