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Engineer, Caltrans
Welding
Applies to all Structural Steel
Contractor is responsible for QC
--Designate QC Inspector - CWI
CT is responsible for QA
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
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
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
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
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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
Field Welding
--Same requirements as shop welding
--Contractor to provide suitable enclosures to
permit field welding in inclement weather
per AWS and project requirements
,
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