steel.pdf

05-07-01

STEEL PRODUCTS MANUFACTURING ANDFABRICATION QUALIFICATION AUDIT

NAME OF PRECAST PLANT:

DATE:

ADDRESS:

FACILITIES’ AUTHORIZED QUALITY CONTROL REPRESENTATIVE(S):

CONTRACTOR’S QUALITY CONTROL MANAGER:

ORIGINAL OR FOLLOW-UP VISIT:

NAME(S) OF AUDITOR(S):

In order to pass an audit, all the requests and audit forms must be complete and inconformance with the Contract Plans and Special Provisions.

Steel Manufactures and Fabricators, that do not produce fasteners, are not required toanswer Sections M through L. Steel Fastener Manufactures, that do not make other steelproducts, are not required to answer Sections A through L. With the exception noted herefor fasteners, the Contractor must answer "yes" to all audit questions and have writtendocumentation to support the affirmative responses.

The passing of an audit performed by the Engineer shall consist of the Engineer’s answerof “yes” to all questions, verification of the documentation to support the affirmativeresponses, and having all required submittals completed and in conformance with theContract Documents.

The procedure for requesting another audit in the event of an audit failure is as specified inthe Contract Special Provisions.

We the undersigned have read and understand the “Steel Products Manufacturing andFabrication Qualification Audit”, the Contract Plans, Special Provisions, and Engineer’sEstimate pertaining to this audit and are providing the following information.

________________________________________________________

General Contractor Date

________________________________________________________

General Contractor’s Quality Control Manager Date

________________________________________________________

Facility Authorized Representative Date

A. SPECIFICATIONS AND STANDARDS

YES NO NA DETAILED INFORMATION

1. Does the Fabricator/Manufacturerhave a copy of CALTRANSspecifications and are theFabricator's personnel familiar withthese specifications?

2. Does the Fabricator/Manufacturerhave a copy of AWS D1.5-95 and96, D1.1-96 and 98, and D1.4-92?

3. Does the Fabricator/Manufacturerhave copies of all materialspecifications referenced in thecontract (e.g. ASTM)?

4. Does the Fabricator/Manufacturerhave personnel that areknowledgable and experiencedwith the material codes andspecifications referenced in thecontract?

5. Is there a written procedure in placeto disseminate specificationrequirements and changes toappropriate personnel?

B. READING / INTERPRETING SHOP DRAWINGS


1. Does the Fabricator/Manufacturerhave personnel capable ofsupervising, evaluating andcoordinating shop drawingpreparation and review?

2. Do the shop drawings denotematerials to be utilized in the finalstructure?

3. Do shop drawings identify fracturecritical materials and welds, whenapplicable?

4. Do the materials and processesspecified or indicated on the shopdrawings agree with the contractdocuments material requirementsfor work ongoing in the shop?

C. DRAWING CONTROL


1. Does the Fabricator orManufacturer have a writtenprocedure for tracking designdrawings as follows.

a. ____ receipt?b. ____ on file?c. ____ revisions?

2. Does the tracking procedureutilized trace each phase fromdrawing preparation, showingreceipt, submittal for approval,approval, resubmittals and datesent to shop for fabrication?

3. Do the shop plans correspond tothe latest revision?

D. WORK ORDER – JOB CONTROL


1. Does the Fabricator/Manufacturerhave an established job controlnumber and identification systemfor all work completed andaccepted by in-house QC?

2. Are all received correspondencemarked with a distinguishableidentifying mark?

3. Are correspondence filesmaintained and seggregated foreach project?

4. Is received correspondence

a. ____ stamped received?b. ____ dated?c. ____ initialed?

E. MATERIAL PROCUREMENT AND SUBCONTRACTS


1. Are purchase orders or any othertype of materials procurementforms on file for verification anddocumentation of the orders?

2. Are all materials ordered orprocured to the required standardsand specifications specified in thecorresponding contractdocuments?

3. Do the Fabricator’s orManufacturer’s procurementdocuments require that hissuppliers must furnish materialtesting reports (MTR’s)?

4. Do the procurement documentsstate how the material should bemarked and identified?

5. Are procedures in place to asssurethat subcontracted fabrication isordered to contract requirements?

F. MATERIAL RECEIVING


1. Is there an established writtenprocedure for the reception ofmaterials and subassemblies?

2. Are reception inspections done toall incoming materials andsubassemblies arriving at thisfacility?

3. Does the materials andsubassemblies receivinginspector confirms anddocuments the following:a. ____ proper grade ofmaterial?b. ____ proper materialmarking and

identification?c. ____ proper materialdimentions?d. ____ compliance withdimentional tolerances?e. ____heat numbers onmaterial match heatnumbers on

corresponding mill certificates?

4. Are receiving inspectionsdocumented for:a. ____ acceptance andrejection ofnonconformingmaterials and subassemblies?b. ____ corrective actionstaken to

deal with non-correctable andcorrectable

nonconformitiesobserved during thereception inspection?

5. Are acceptance tolerancesavailable for reference at thereceiving inspection station?


6. Does the Fabricator orManufacturer have a materialidentification system to assurecontrol of materials of differentgrade and size (as applicable)?

7. Does the Fabricator orManufacturer segregate controlledmaterials by project?

8. Does the Fabricator/Manufacturerhave mill test reports (MTR’s) forall material currently infabrication?

9. Are MTR’s traceable to stored orstocked material?

10. Are materials stored or stocked soas to prevent damage to the rawmaterials or final fabricatedpieces?

11. Are the stored or stockedmaterials clearly marked oridentified?

G. EQUIPMENT/FACILITIES, HANDLING AND STORAGE PROCEDURES


1. Does the Fabricator orManufacturer have adequateequipment to fabricate to the unitson the contract plans for thiscontract? Attach list of theavailable equipment.

2. Is the material handling equipmentadequate for the type of workbeing done?

3. Does the Fabricator orManufacturer have adequatewritten procedures that describe orillustrate the proper way to:

a. ____ handle materials in theyard?b. ____ handle materials in the

plant?c. ____ move inprocessmaterials and

subassemblies?d. ____ provide correct bracingand

blocking for materialsand

subassemblies?e. ____ prevent material and

subassemblydeterioration?f. ____ provide correct storagefor

fabricated products?g. ____ handle and shipping of

fabricated products?

H. WELDING AND WELDING CONSUMABLES


1. Does the Fabricator/Manufacturerhave welding procedurespecifications and procedurequalification records (ifapplicable) per contractdocuments?

2. Are theFabricator's/Manufacturer’swelders certified in conformancewith CALTRANS and AWSrequirements?

3. Do theFabricator’s/Manufacturer’sprocedures address therequirements of AWS D1.5,Sections 2 “Design of WeldedConnections” and 3.4 “Control ofDistortion and Shrinkage”?

4. Is the Fabricator/Manufactureraware of the fracture criticalrequirements of AWS D1.5,chapter 12, and of a fracturecontrol plan, if applicable?

5. Are approved welding proceduresreadily available or posted near allwelding machines?

6. Do welders know and understandwhich WPS is to be used with eachspecific weld?

7. Are welded structures and andspecific welds traceable to thewelder(s) and or welding crew thatcompleted the job?

8. Does the Fabricator/Manufacturerhave and properly maintainappropriate equipment for preheatand interpass heating?

9. Are maximum interpass andminimum WPS preheattemperatures properly monitored?


10.

Are flame cut edges inspected byquality control inspectors to verifycompliance with AWS D1.5, D1.1,D1.4?

11.

Do quality control inspectorsverify and document joint fit-upbefore welding?

12.

Do the quality control inspectorsverify and document the utilizationof WPSs?

13.

Are meters and other devices usedto record or display weldingvariables checked for accuracyevery three months?

14.

Is the equipment used for verifyingmeters and other devices certifiedannually?

15.

Are welding consumables storedin accordance with AWS D1.5,D1.1, or D1.4?

16.

Are welding consumables at thework station protected fromcontamination and damage?

17.

Does the Fabricator orManufacturer control the exposuretime of low-hydrogen SMAWelectrodes following removal fromhermetically sealed containers,drying ovens, or storage ovens?

18.

Are consumable manufacturercertification reports on file andavailable?

I. HIGH-STRENGTH BOLTING


1. Are copies of the current RCSCand all appropriate ASTMSpecification available?

2. Does a written procedure exist forsampling, testing, and approvinghigh-strength fasteners andfastener components prior to useby the Fabricator or Manufacturer?

3. Does the Fabricator orManufacturer have copies of allrequired test reports for fastenercomponents (i.e., bolts, nuts,washers, and DTIs according torequirements in appropriate ASTMspecifications)?

4. For each fastener component, hasthe Fabricator or Manufacturerbeen prequalified by Caltrans?

5. Does the Fabricator orManufacturer have manufacturer’sinstallation instructions for TCbolts and DTIs, if applicable?

6. Are written procedures availableto conduct high-strength bolting:

a. Installation verificationtests?

b. Rotational capacity test?

c. Job inspection torquedetermination?

d. long and short boltstesting?


7. Are procedures in place to performinstallation verification tests ofeach lot of fasteners at a frequencyas required in the RCSCSpecification?

8. Does the equipment on hand forhigh-strength bolting, include:

a. a bolt tensionmeasuring device withappropriate bushings?

b. a set of tapered feelergages for inspecting DTIs?

c. a torque wrench withdial or digital readout?

d. a pneumatic or electricwrench with a positivemechanism that activateswhen proper tension isreached?

9. Has the contractor’s boltingequipment (torque wrench,calibrated wrench, bolt load meter,torque multiplier) been calibratedby an accredited testing lab?

10.

Is the accredited testing lab’s.calibration equipment traceable toNIST standards?

11.

Has each piece of equipment beencalibrated within the past year?

12.

Are calibration curves and plots onhand and is the accuracy of theequipment within acceptabletolerances?

13.

If the turn-of-nut installationprocedure is being used, is thematch-marking procedure properlyunderstood and utilized?


14.

Is the sealing compound used toseal sheared ends of TC bolts:

a. of the type recommended byRSCS?

b. Applied to the correctthickness?

c. Applied as soon as TC boltshave been sheared?

15.

Has the paint used in fayingsurfaces been tested and qualifiedfor the maximum thickness and theminimum cure time specified inthe contract specifications forbolting plates?

16.

Are procedures available to ensurethat hot-dip-galvanized fayingsurfaces are:

a. flat and free from runs orglobs?

b. roughened by hand wirebrushing?

17.

Will bolt tension of all completedbolted joints be inspected anddocumented immediately aftereach joint has been completedusing the arbitration method of theRCSC Specification?


18.

Are all fastener componentsproperly stored and handled toensure that:

a. components are coveredand protected frommoisture?

b. unused components arereturned to their originalcontainers at the end ofeach shift?

c. different lots are storedseparately tomaintainintegrety betweenlots?

19.

Does the Fabricator orManufacturer use drill templateswith hardened bushings whendrilling bolt holes?

J. COATING PROCESS


1. Are the facilities and equipmentsuitable for performing cleaningand painting in conformance withthe specfications for this contract?

2. Does a written procedure exist thataddresses:

a. measuring and recordingtemperature?

b. measuring and recordinghumidity?

c. measuring and recordingwet film thickness?

d. measuring and recordingdry film measurements?

3. Are the facilities and equipmentsuitable for performinggalvanizing in conformance withappropriate ASTM specifications?

4. Are thickness measurements ofgalvanized surfaces performed anddocumented?

5. Does a written repair procedureexist for repair of galvanizingholidays?

K. QUALITY CONTROL AND QUALITY CONTROL INSPECTORS


1. Does the Fabricator orManufacturer have a writtenQuality Control Manual thatdescribes the company policy,support and commitment toquality?

2. Does the Fabricator orManufacturer have a written jobdescription and an organizationalchart that reflects its commitmentto quality?

3 Does the Quality control Manualinclude sections that deal with:

a. Contract review?

b. Documents and drawingscontrol?

c. Materials purchasing?

d. Product identification andtraceability?

e. Process control?

f. Inspection and testing?

g. Control of inspection,measuring and test equipment?

h. Control of nonconformingproducts?

i. Corrective and preventiveactions?

j. Handling and storage?

k. Packaging and delivery?

l. Internal audits?

m. Manual review and update?

4. Does the Fabricator have aregistered Certified WeldingInspector (CWI) on his full timestaff or on contract?


5. Were Quality Control personnelavailable in the plant during thisinspection audit as required in theContract documents?

6. Does the Fabricator have certifiedNDT personnel on his full timestaff?

7. Does the Fabricator have sub-contracts for all or part of hisNDT?

8. Are the subcontractor’squalifications verified by theFabricator?

9. Does the Fabricator orManufacturer have certificationsfor all inspection personnel (staffand subcontractor) on file andreadily available?

10. Does the Fabricator orManufacturer have a copy of thewritten practice for NDT on file?

11. Does the written practice meet orexceed the recommendations ofSNT-TC-1A?

12. Does the Fabricator orManufacturer maintaindocumentation for all qualitycontrol testing?

8. Are the subcontractor’squalifications verified by theFabricator?


13. Do quality control inspectors havesufficient equipment to adequatelyperform their tasks

a. ____tape line?

b. ____calipers?

c. ____tag systems?

d. ____fillet weld gages?

e. ____chipping hammer?

f. ____magnifying glass?

g. ____amp tongs?

h. ____paint gages?

i. ____ flashlight?

j. ____preheat & interpass temperature measuring

and testing devices?

k. ____mirror?

14. Does the Fabricator orManufacturer have writtenprocedures for:

a. ____ minor repairs?

b.____ major repairs?

c ____ documentation for

reinspection ofrepairs?

15. Are quality control personnelconversant with the quality controlrequirements?

16. Does the Fabricator orManufacturer maintain a qualitycontrol program that isindependent from production?


17. Do the quality control inspectorshave the responsibility ofinforming line foreman andsuperintendent when observingany non-conforming workprocesses and performances?

18. Is the CWI given sufficientauthority to stop work in order toprevent unacceptable work fromproceeding?

L. COMPLETED MEMBER STORAGE AND FINAL INSPECTION


1. Does the Fabricator orManufacturer understand that thereis a 48-hr. notification for finalCaltrans inspection?

2. Is the Fabricator or Manufactureraware that he must providecomplete paper work, including acertificate of compliance andweights, for final inspection?

3. Does the Fabricator orManufacturer have the materiallocated and identified for finalinspection?

4. Are completed members properlystored to prevent damage?

5. Are all primary load-carryingcomponents traceable to MTR’s?

6. Does the Fabricator orManufacturer understand thatmaterial release tags should becompleted and attached only bythe Engineer or his authorizedrepresentative?

M. QUALIFICATION REQUIREMENTS FOR FASTENER MANUFACTURERS


1. Does the Manufacturer marks thefasteners, as required by ASTMspecification, with a uniqueidentification marking symbol thatis registered with the U.S. Patentand Trademark Office?

2. Is the fastener Manufacturercurrently certified to QualitySystem (QS) 9000?

3. Was the accreditation granted byan approved (Caltransacknowledged) third partyaccreditation agency?

4. Was the Manufacturer certifiedusing a (QS) 9000 Standard noolder than the 3rd Edition?

5. Does the manufacturer haveadequate facilities and machineryto manufacture the fastenercomponents? Attach a list of theavailable equipment.

6. Does the manufacturer haveadequate gages and quality controltools to evaluate the compliance offastener components withspecifications? Attach a list of theavailable equipment.

7. Have samples of all fastenercomponents (or similarcomponents) to be furnished forthe contract been tested andapproved by Caltrans prior to theManufacturer producing fastenercomponents for the contract?

8. Do appropriate personnel from thefastener manufacturer have a copyof the ASTM F1470 specification?

9. Did the Manufacturer personneldemonstrated knowledge andunderstanding of the ASTM F1470specification?


10. Did the Manufacturer verify thatall the Secondary Processors havedetailed QC Plans and that theyare certified to the QS 9000standard?

11. Have all the Secondary Processors(including zinc coating processorsand heat treaters) been audited bythe fastener manufacturer to verycompliance with Quality Controlrequirements??

12. Did the Manufacturer verify thatthe Secondary Processors havecopies of all appropriate consensusstandards for the product they aretreating?

13. Are all fastener components andsystems retested and recertified bythe prime Manufacturer orDistributor after all secondaryprocessing is completed?

14. Have all fastener components beentested by a testing laboratoryacknowledge by Caltrans orrecognized and approved byNIST?

15. Did the Manufacturer verify thatthe testing laboratory meetsrequirements of ISO/1EC Guides25 and/or 58?

16. Did the Manufacturer verify thatappropiate personnel from theirtesting laboratory have a copy ofthe ASTM F1470 specification?

17. Does the testing laboratory havetesting procedures and copies ofstandard documents related totesting of fastener products?

18. Does the technician doing thetesting have copies of the testingprocedures?


19. Have samples of all test reports (aslisted in appropriate ASTMspecifications) been reviewed andapproved by Caltrans?

20. Does the Manufacturer providesacceptable installation instructionsfor alternate fastener systems (i.e.,TC bolts and DTI’s) or fastenercomponents?

21. Do lubricants used bymanufacturer on zinc-coatedproducts comply with Caltrans andASTM requirements for:

a. ___Cleanliness and Drynessto touch?

b. ___Color and dye?

c. ___Solubility in water?

22. What is type and model number ofthe lubricant?

N. MATERIAL RECEIVING


1. Is there an established writtenprocedure for the reception ofmaterials?

2. Are reception inspections done toall incoming materials arriving atthis facility?


3. Does the manufacturer’s inspectorconfirms and documents :

a. ____ proper grade ofmaterial?b. ____ proper materialmarking and

identification?c. ____ proper materialdimensions?d. ____ compliance withdimentsional tolerances?e. ____heat numbers onmaterial match heatnumbers on

corresponding mill certificates?

4. Are receiving inspectionsdocumented for:

a. ____ acceptance andrejection ofnonconformingmaterials and subassemblies?b. ____ corrective actionstaken to

deal with non-correctable andcorrectable

nonconformitiesobserved during thereception inspection?

5. Are acceptance tolerancesavailable for reference at thereceiving inspection station?

6. Does the Manufacturer have amaterial identification system toassure control of materials ofdifferent heats, lots, and grade (asapplicable)?

7. Does the Manufacturer keep eachlot of material segregated andidentify so as to maintain lotintegrity of all metrials throughoutthe manufacturing process?


8. Does the Fabricator/Manufacturerhave mill test reports (MTR’s) forall material currently infabrication?

9. Are MTR’s traceable to stored orstocked material?

10. Are materials stored or stocked soas to prevent damage to the rawmaterials or completed fastenercomponents?

11. Are the stored or stockedmaterials clearly segregated, andmarked or identified by lotnumber?

O. HANDLING AND STORAGE EQUIPMENT, FACILITIES, AND PROCEDURESOF MATERIALS AND MANUFACTURED PRODUCTS


1. Does the Manufacturer haveadequate equipment to fabricatethe to units on the contract plansfor this contract? Attach list of theavailable equipment.

2. Is the material handling equipmentadequate for the type of workbeing done?


3. Does the Manufacturer haveadequate written procedures thatdescribe or illustrate the properway to:

a. ____ handle materials in theyard?b. ____ handle materials in the

plant?c. ____ move inprocessmaterials and

subassemblies?d. ____ provide correct bracingand

blocking for materialsand

subassemblies?e. ____ prevent material and

subassemblydeterioration?f. ____ provide correct storagefor

fabricated products?g. ____ handle and shipping of

fabricated products?

P. COATING PROCESS


1. Are the facilities and equipmentsuitable for performinggalvanizing in accordance withASTM specifications?

2. Are thickness measurements ofgalvanized surfaces performed anddocumented?

3. Is the maximum coating thicknesscontrolled so as not to beexcessive?

4. Are suitable gages and instrumentsavailable to check various threaddimensions (thread pitch, majorand minor diameters, etc.) aftergalvanizing?


5. Has lot integrety and segregationbeen maintained throughout thecoating process? (i.e., each lotclearly marked and segregatedbefore, during and afterprocessing)

Q. HEAT TREATING PROCESS


1. Are the facilities and equipmentsuitable for performing heattreating in accordance withappropriate ASTM specifications?

2. Is the equipment adequate toproduce a quality product withconsistent hardness and a tighthardness range?

3. Is the equipment used forquenching and tempering adequateto control bath temperature, so asto produce fastener componentswith consistent hardness andmetalurgical properties?

R. QUALITY CONTROL AND QUALITY CONTROL INSPECTORS


1. Does the Manufacturer have awritten Quality Control Manualthat describes the company policy,support and commitment toquality?

2. Does the Manufacturer have awritten job description and anorganizational chart that reflect itscommitment to quality?


3 Does the quality control manualinclude sections that deal with:

a. Materials purchasing?

b. Product identification andtraceability?

c. Process control?

d. Inspection and testing?

e. Control of inspection,measuring and test equipment?

f. Control of nonconformingproducts?

g. Corrective and preventiveactions?

h. Handling and storage?

i. Packaging and delivery?

4. Is all quality control testingdocumented?

5. Are quality control personnelconversant in and understand thequality control requirements?

6. Is quality control independentfrom production?

S. STORAGE AND FINAL INSPECTION OF COMPLETED FASTENERCOMPONENTS


1. Are manufactured productsproperly stored to preventdamage?

2. Are all components properlypackaged and marked per ASTMrequirements?

3. Are zinc-coated components offastener systems properlypackaged together as an assembly?

4. Has each assembly lot been testedas a rotational capacity lot andbeen given a Rocap lot number?

5. Is the Fabricator aware that hemust provide complete paperwork, including a certificate ofcompliance and weights, for finalinspection?