AISC 2010 New Draft Standard

AISCQC030
AISC 20X-XX
AISC Certification Committee – Bridge Fabricator Task Group Draft: dated March 15, 2010
This is a working draft document under development and consideration by an AISC Committee and should not be relied upon or
used for any other purpose. Draft documents may change significantly in subsequent versions.
1
2
AISC Certification Program for

Steel Bridge Fabricators
Standard for Steel Bridges—20XX
3
4 Issued by the
5 AMERICAN INSTITUTE OF STEEL CONSTRUCTION
6 Prepared under the direction of the
7 AISC CERTIFICATION COMMITTEE
8
AMERICAN INSTITUTE OF STEEL CONSTRUCTION

AISCQC030
AISC Certification Committee – Bridge Fabricator Task Group Draft: dated March 15, 2010 Page 2 of 25
1 AISC© 20XX
2 by
3 American Institute of Steel Construction
4 All rights reserved. This book or any part thereof must not be reproduced in any form without
5 the written permission of the publisher. The AISC logo is a registered trademark of AISC.
6
7 The information presented in this standard has been prepared by the Certification Committee of the American
8 Institute of Steel Construction (AISC) in a consensus manner in accordance with recognized industry standards,
9 codes, and practices. The standard has been prepared within the scope and for the purposes stated in the body
10 of this document and for no other purpose.
11 The standard has been developed by a balanced committee of participants in the industry who have particular
12 experience and expertise in the topics addressed in the standard. Every effort has been made to solicit comments
13 and participation from a broad cross section of the construction industry. Participation by any federal or state
14 agency representative(s) in this process is not to be interpreted as government endorsement of this standard.
15 AISC accepts responsibility for only those interpretations of this standard that are issued in writing and in
16 accordance with governing AISC procedures and policies. Issuances of informal interpretations are not
17 necessarily the official interpretation of AISC or its Certification Committee. This standard is subject to revision at
18 any time by the AISC Certification Committee.
19 Neither AISC nor its program auditors approve, rate, or endorse any item, construction technique, proprietary
Draft Document
20 device, or activity referenced in this standard. Nor do they take any position with respect to the validity of any
21 patent rights asserted in connection with any items referenced in this standard, nor suggest infringement of any
22 patent, nor undertake to insure or indemnify anyone utilizing this standard against liability for infringement of any
23 applicable Letters Patent.
24 AISC disclaims for itself, its committee members and its program auditors any liability for any injury to persons or
25 to property or other damages of any nature whatsoever, whether special, indirect, consequential or
26 compensatory, directly or indirectly resulting from the publication, use of, or reliance upon this standard or
27 application of the activities or devices referenced herein.
28 Caution must be exercised when relying upon other specifications or codes developed by other bodies and
29 incorporated by reference herein. Such material may be modified or amended from time to time by such other
30 bodies subsequent to the printing of this standard. AISC bears no responsibility for such material other than to
31 refer to it as being applicable to this standard and to incorporate it by reference at the time of the initial publication
32 of this standard.
AISC Certification Program for Steel Bridge Fabricators—Standard for Steel Bridges—20XX
AISCQC030
1 Prepared Under the Direction of the
AISC CERTIFICATION COMMITTEE

Draft Document
ADVISORY
2 Prepared Under the Direction of the
BRIDGE FABRICATOR CERTIFICATION TASK GROUP
AISCQC030
1 Table of Contents
2 1. Purpose ...............................................................................................................................................................5
3 2. Program Scope and Fabricator Eligibility .......................................................................................................5
4 3. References..........................................................................................................................................................5
5 4. Definitions...........................................................................................................................................................5
6 5. Management Responsibility..............................................................................................................................8
7 5.1 Quality Policy and Quality Goals............................................................................................................................. 8
8 5.2 Direction and Leadership ........................................................................................................................................ 8
9 5.3 Management Representative for Quality................................................................................................................. 9
10 5.4 Resources............................................................................................................................................................... 9
11 5.5 Internal Communication ........................................................................................................................................ 11
12 5.6 Documentation Requirements .............................................................................................................................. 11
13 6. Contract and Project Specification Review and Communication ...............................................................12
14 7. Detailing ............................................................................................................................................................12
15 7.1 Detailing Procedures............................................................................................................................................. 12
16 7.2 Detailing Personnel............................................................................................................................................... 14
17 8. Document and Data Control............................................................................................................................15
18 8.1 Review and Approval ............................................................................................................................................ 15
19 8.2 Customer Requirements ....................................................................................................................................... 15
20 8.3 Revision Control ................................................................................................................................................... 15
21 8.4 Access .................................................................................................................................................................. 15
22 8.5 Obsolescence and Transmittal ............................................................................................................................. 15
23 9. Control of Quality Records .............................................................................................................................16
24 9.1 Retention of Quality Records ................................................................................................................................ 16
25 9.2 Availability of Quality Records .............................................................................................................................. 16
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26 10. Purchasing........................................................................................................................................................16
27 10.1 Purchasing Data ................................................................................................................................................... 17
28 10.2 Selection and Evaluation of Subcontractors and Suppliers................................................................................... 17
29 10.3 Verification of Purchased Product, Materials, and Services.................................................................................. 18
30 11. Material Identification and Traceability..........................................................................................................18
31 11.1 Material Identification ............................................................................................................................................ 18
32 11.2 Material Traceability.............................................................................................................................................. 18
33 12. Fabrication Process Control...........................................................................................................................19
34 12.1 Welding................................................................................................................................................................. 19
35 12.2 Bolt Installation ..................................................................................................................................................... 19
36 12.3 Material Preparation for Application of Coatings................................................................................................... 19
37 12.4 Coating Application ............................................................................................................................................... 19
38 12.5 Equipment Maintenance ....................................................................................................................................... 19
39 13. Inspection and Testing ....................................................................................................................................19
40 13.1 Assignment of QC Inspections and Monitoring ..................................................................................................... 20
41 13.2 Inspection Procedure ............................................................................................................................................ 20
42 14. Calibration of Inspection, Measuring, and Test Equipment ........................................................................21
43 15. Control of Nonconformances .........................................................................................................................22
44 15.1 Nonconformance with the Quality Management System ...................................................................................... 22
45 15.2 Nonconforming Product ........................................................................................................................................ 22
46 16. Corrective Action .............................................................................................................................................22
47 17. Handling, Storage and Delivery of Product and Materials...........................................................................23
48 18. Training .............................................................................................................................................................23
49 19. Internal Audit ....................................................................................................................................................23
50 SUPPLEMENTAL REQUIREMENTS (reference section 2. Program Scope and Fabricator Eligibility)..........24
51 S[F] REQUIREMENTS FOR FABRICATORS OF BRIDGES WITH FRACTURE-CRITICAL MEMBERS......24
52 S[I] REQUIREMENTS FOR FABRICATORS OF INTERMEDIATE BRIDGES...............................................24
53 S[A] REQUIREMENTS FOR FABRICATORS OF ADVANCED BRIDGES .....................................................25
AISCQC030
1 1. Purpose
2 The purpose of the AISC Certification Program for Steel Bridge Fabricators is to confirm to owners, the design
3 community, the construction industry, and the public that a certified steel bridge fabrication facility has the
4 personnel, organization, experience, documented procedures, knowledge, equipment, and commitment to
5 produce fabricated steel of the quality required for steel highway bridge construction.
6 2. Program Scope and Fabricator Eligibility

7 This Certification Standard for Steel Bridges offers assistance to steel bridge professionals, owners, general
8 contractors, and other interested parties in assessing fabricators’ capability to satisfy project quality needs. Users
9 of this standard are encouraged to evaluate fabricator capability independently.
10 The standard describes requirements for certification of facilities that fabricate and supply steel highway bridges.
11 These facilities have quality management systems with defined functions and responsibilities.
12 The quality management system of fabrication facilities (not products) is certified. The certification should not be
13 understood as a product inspection of fabricated steel bridges. Certification includes all functions of providing
14 steel bridge fabrication from receipt of contract through final delivery. The scope of this certification does not
15 include design or erection, nor is it intended for bridge rehabilitation or pedestrian bridges.
16 The certification program is open to all fabricators of steel highway bridges, regardless of size and regardless of
17 AISC membership status.
18 Fabricators producing fracture-critical members, intermediate bridges, or advanced bridges shall also be required
19 to meet specific supplemental requirements to this standard.
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20 3. References
21 The fabricator shall have the reference documents and standards necessary to make personnel aware of work
22 requirements. References shall be consistent with the requirements of existing contracts and be readily available
23 to those who need them.
24 4. Definitions
25 The following terms are italicized where used in this standard to alert the user that the term is defined in this
26 section. As used in this standard, the words shall or will denote a mandatory requirement. The word should
27 denotes a guideline or recommendation. The word may denotes an opportunity to make a choice.
28 Advanced Bridge. A bridge that is neither a simple bridge nor an intermediate bridge. Examples include
29 trapezoidal box girders, closed box girders, trusses, arches, and bascule bridges.
30 AISC. American Institute of Steel Construction—the certifying body.
31 ASNT. The American Society for Nondestructive Testing.
32 ASTM. American Society for Testing and Materials.
33 AWS. American Welding Society.
34 C of C. Certificate of Compliance or Certificate of Conformance.
35 Checker. A person in a detailing organization who, because of experience and ability, has advanced successfully
36 to a position of responsibility with the ability to perform the final verification of shop drawings without direct
37 supervision.
38 Checking (of shop drawings, digital manufacturing models, and erection drawings). A detailed review of all
39 sketches and dimensions on shop drawings, digital manufacturing models, and erection drawings by a qualified
40 checker other than the original detailer.
AISCQC030
1 Contract Documents. The documents that define the responsibilities of the parties that are involved in bidding,
2 fabricating, and erecting steel bridges. These documents normally include the design drawings, the specifications,
3 and the contract.
4 Corrective Action. The action or actions undertaken to identify and eliminate the root cause of a product or
5 process nonconformance to prevent its recurrence. Corrective action is not the repair or rework of identified
6 nonconforming product or process to meet specified requirements.
7 Design Drawings. The graphic and pictorial portions of the contract documents showing the design, location, and
8 dimensions of the work. These documents generally include plans, elevations, sections, details, schedules,
9 diagrams, and notes.
10 Detailer. Person who performs the function of detailing.
11 Detailing. The function that produces shop drawings, digital manufacturing models, and erection drawings from
12 contract documents.
13 Documented Procedure (quality management system procedure). A procedure that is established, documented,
14 implemented, and maintained. The documentation provides information about how to perform the activity or
15 process consistently. Documentation can include written instructions, drawings, diagrams, charts, specifications,
16 and references or excerpts of appropriate technical standards and codes. Documentation shall contain:
17  The purpose of the procedure
18  Process definition that includes steps required for completion
19  Assignment of responsibility for completion
20  Assignment of responsibility for review of the procedure
21  Identification of records that are generated
Draft Document
22 Documented Training. Training in which there is a record of the course outline, a record of who attended, the date
23 it was given, and the instructor who provides the training.
24 Erection Drawings. Field-installation or member-placement drawings that are prepared by the fabricator to show
25 the location and attachment of the individual shipping pieces.
26 Executive Management. The chief executive officer, president, or other individuals with executive function and the
27 authority to assign resources. Executive management has ultimate authority in final decision-making for all
28 aspects of the quality management system.
29 Fabrication. The process of preparation and assembly of individual parts into a shipping piece. Fabrication
30 includes all production operations performed in the manufacturing and shipping of the product (e.g., assembly,
31 welding, drilling, sawing, milling, and thermal and mechanical cutting).
32 Fabricator. The entity that is responsible for fabricating the steel bridge. NOTE: The fabricator referenced in this
33 document is the entity being certified.
34 Intermediate Bridge. (1) A rolled-beam bridge with field or shop splices, either straight or with radius over 500 ft.,
35 (2) a built-up I-shaped plate girder bridge with constant web depth (except for dapped ends), with or without
36 splices, either straight or with radius over 500 ft., (3) a built-up I-shaped plate girder with variable web depth
37 (e.g., haunched), either straight or with radius over 1000 ft.
38 Manufacturing Model. Digital sub-model of the Logical Product Model as defined in Appendix A of the AISC Code
39 of Standard Practice for Steel Buildings and Bridges. The manufacturing model includes data represented in
40 detailing for fabrication.
41 MTR. Material test report, manufacturer’s test report, or mill test report, meeting the requirements of Section 14 of
42 ASTM A 6.
43 Nonconformances. Attributes of materials, consumables, fabricated product (in-process or final), and processes
44 that do not meet contract, regulatory, or fabricator-defined requirements.
45 NDT (NDE). Nondestructive Testing (Nondestructive Examination).
AISCQC030
1 Objective Evidence. Data supporting the existence or verification of something. In this context, it is evidence that
2 the quality management system is functioning properly. Objective evidence can be obtained through:
3  Observation of the performance of a task or physical products
4  Measurements
5  Tests
6  Review of a record, documented procedure, or other document
7  The result of an interview with one or more employees about their duties or performance of a task
8 Owner. The entity or its authorized representative who has authority to define or accept changes to contract
9 requirements and who is or represents the ultimate owner of the finished/completed product.
10 PQR. Procedure qualification record as defined by AWS A3.0.
11 Quality Assurance (QA). That part of quality management focused on providing confidence that quality
12 requirements will be fulfilled. For the purposes of this program, quality assurance is the planned system of
13 documented procedures and organizational requirements developed and implemented for the purpose of assuring
14 compliance with the requirements of the contract documents, providing confidence that quality goals are
15 achieved, and measuring effectiveness of the quality management system. Quality assurance encompasses such
16 areas as compliance with project specification technical requirements, compliance with referenced standards, and
17 achievement of customer service objectives. Specific functions included in quality assurance are:
18  Determination of quality criteria to meet, as a minimum, the requirements of the contract documents
19  Establishment of a plan to monitor quality, including assignment of quality control (inspection), in order to
20 meet, as a minimum, the requirements of the contract documents
21  Determination of acceptance criteria
22  Determination of QC personnel qualifications
 Oversight (periodic monitoring) of QC activities
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23
24  Summarizing and reporting quality conformance measures to all levels of management
25  Oversight of corrective action process.
26 Some documents used in the steel bridge industry define QA as the quality verification activities carried out by the
27 owner, but in this standard, QA refers to the fabricator’s activities as described above.
28 Quality Control (QC). QC, for the purpose of this standard, is the inspection of work, i.e.. conformity evaluation
29 and judgment accompanied as appropriate by measuring, testing, or gauging. QC includes but is not limited to
30 confirming that documented procedures are met; personnel performing the work are properly qualified; equipment
31 is appropriate and in acceptable working order; and the proper materials are used as well as in compliance with
32 inspection criteria.
33 Quality Manual. A document stating the quality policy and describing the quality management system of the
34 fabricator’s organization.
35 Quality Management System. A system to establish policy, objectives, plans, and resources to direct and control
36 an organization with regard to quality.
37 Quality Record. A specific type of quality document that provides objective evidence of activities performed or
38 results achieved.
39 RCSC. Research Council on Structural Connections.
40 Repair. Action taken on a nonconforming product to make it acceptable for the intended use.
41 Rework. Action taken on a nonconforming product to make it conform to the requirements.
42 RFI. Request for Information. A written request to the owner for information or clarification generated after award
43 of the contract.
44 Shipping Piece. Individual member for field erection carrying a specific identification mark.
45 Shop Drawings. Drawings of the individual shipping pieces that are to be produced in the fabrication shop.
AISCQC030
1 Simple Bridge. A bridge consisting of unspliced rolled sections.

2 Specifications†. The portion of the contract documents that consists of the written requirements for materials,
3 standards, and workmanship.
4 SSPC. SSPC: The Society for Protective Coatings, which was formerly known as the Steel Structures Painting
5 Council.
6 Standard. The Certification Standard for Steel Bridges
7 Subcontractor. A firm that performs a portion of the fabricator’s contract work such as fabrication, detailing,
8 coating application, inspection, or consulting services.
9 Supplier. A firm that supplies materials (including but not limited to mill materials, process supplies, welding
10 consumables, coatings, and process machinery) and completed purchased product needed to fulfill the
11 fabricator’s contract requirements.
12 Training. See Documented Training.
13 WPS. Welding procedure specification as defined by AWS A3.0.
14 5. Management Responsibility
15 Management at all levels shall define and adopt a commitment to quality. Management shall direct and lead the
16 fabricator to assure continuous progress toward achieving the objectives of the commitment. The fabricator’s
17 quality assurance management is responsible for developing and maintaining a quality management system to
18 meet the specific requirements of this standard, industry and government regulations, and contract requirements.
19 5.1 Quality Policy and Quality Goals
Draft Document
20 Executive management shall adopt, document, and maintain a quality policy. The policy shall define:
21  A commitment to quality, including a commitment to meet contract requirements
22  Quality management system objectives that provide a framework for establishing and reviewing quality
23 goals of the fabricator’s organization.
24 Management at all levels shall ensure that the quality policy is understood, implemented, and maintained at
25 appropriate levels of the fabricator’s organization.
26 Executive management shall direct the development of systems necessary and establish measurable quality
27 goals to achieve the objectives of the fabricator’s quality policy. Executive management along with quality
28 assurance management shall document and demonstrate that:
29  There is a minimum of one specific measurable quality goal related to steel bridge fabrication
30  Specific measurements related to goals are being recorded
31  Current goal achievement levels are known relative to a previous measurement or baseline
32  As quality goals are achieved, new goals are set that demonstrate commitment to continual improvement.
33 New goals can be a new level of achievement for a previous goal, or a new goal that has not been
34 previously examined.
35 5.2 Direction and Leadership
36 Executive management and quality assurance management shall review the fabricator’s quality management
37 system at planned intervals, but not less than annually.
38 Records from management reviews shall be maintained. Management review requirements shall be defined
39 by the fabricator and include a specific method to obtain, appropriately analyze, and then report the following:
40  Results of internal, external, and AISC audits
41  Opportunities for improvement of product quality
42  Corrective action activity and resolution based on internal and external findings
43  Need for changes to the quality management system
AISCQC030
1  Customer feedback, for example; surveys, letters of recognition, personal interviews, requests for rework
2 and complaints
3  The level of qualification and training of personnel
4  Channels for communication to address and resolve all quality issues including customer complaints
5  Process performance, which is the effectiveness of the means, methods, and practices that produce the
6 product. Process performance may be monitored with measures and data that include: process
7 nonconformance records (e.g., errors in following documented welding, bolting or detailing procedures),
8 shipping delays, improper disposition of nonconformances, AISC audit corrective action requests not
9 closed in time, failure to conduct management review or other meetings per documented procedure.
10  Product nonconformance (for example, errors in welding, bolting and coating, or dimensionality)
11  Results from previous management reviews.
12 Results from the management review shall include the record and implementation plan for any decisions and
13 actions related to:
14  Improvement of the effectiveness of the quality management system and its processes
15  Improvement of product quality
16  Resource needs (see Section 5.4)
17 5.3 Management Representative for Quality
18 Executive management shall appoint a member of management who may or may not be the chief executive—
19 and who, regardless of other responsibilities, shall have the ability, responsibility, and authority to:
20  Ensure that documented procedures needed for the quality management system are established,
21 implemented and maintained in accordance with this standard.
22  Report to executive management on the performance of the quality management system and any need
Draft Document
23 for improvement.
24  Promote awareness of contract requirements throughout the fabricator’s organization.
25  Review the quality management system at defined intervals sufficient to ensure the stability of the quality
26 management system and its relevance and effectiveness in satisfying this standard.
27  Communicate with external parties on matters relating to the quality management system.
28 For many fabricators, the Management Representative for Quality will be the QA Manager.
29 5.4 Resources
30 The fabricator shall have the resources needed to comply with contract documents..
31 5.4.1 Personnel
32 The qualification requirements, responsibility, authority, and the interrelation of functional positions that
33 manage, perform, and verify work affecting quality shall be documented as required in Section 5.6.
34 Personnel performing defined functions shall have the required qualifications and the ability to
35 successfully perform the function. Objective evidence of qualification may be demonstrated through
36 biographies, resumes, training records, and individual licenses or certifications.
37 Qualification requirements:
38  For production and QA management functions: at least 5 years steel fabrication experience or
39 training.
40  For QC and purchasing management functions and for detailing checkers: at least 3 years steel
41 fabrication experience or training.
42 Personnel can be assigned to more than one task, provided they are qualified and able to fully perform
43 the duties of each position. Individual(s) responsible for quality assurance or for quality control
44 management (including the Management Representative for Quality) may not serve as or report to
45 production management.
46 Production supervisors shall be familiar with the requirements of applicable specifications.
AISCQC030
1 Qualified management shall be assigned to manage the functions detailed in Sections 5 through 19 of
2 this standard and shall include as a minimum the Management Representative for Quality and positions
3 that manage:
4  Detailing
5  Purchasing
6  Fabrication operations
7  Quality assurance
8  Quality control
9 Management at all levels shall be aware of the requirements for the management review detailed in
10 Section 5.2 and the results of the most recent review.
11 The fabricator shall have the following personnel on staff or available under contract, certified in
12 accordance with ASNT-TC-1A:
13  at least one Certified Level III NDT administrator for each NDT method performed in the shop
14  at least one Certified Level II technician for each NDT method performed in the shop
15 The fabricator shall have documented procedures for certifying and updating NDE personnel.
16 The fabricator shall have enough AWS Certified Welding Inspectors to monitor all shifts on which welding
17 is performed.
18 The fabricator shall have a competent welding technician on staff. The welding technician shall have
19 extensive knowledge and experience with or education in welding processes, procedures, and equipment
20 and with the development, preparation, and execution of welding procedure qualification testing.
21 5.4.2 Buildings, Workspace, and Associated Utilities
Draft Document
22 A fabrication facility shall consist of areas and buildings that provide space for the routine functions
23 considered to be part of steel fabrication.
24 The areas and buildings (including housekeeping, air supply, and electrical supply) shall be conducive to
25 achieving consistent quality work.
26 5.4.3 Fabrication Process Equipment
27 The fabricator shall have under their control the equipment and software necessary to perform fabrication
28 consistent with the contract documents.
29 Equipment shall include, as a minimum:
30  Mechanically guided burning equipment
31  Hole-making equipment (e.g., drills and punches)
32  Cutting and finishing equipment (e.g., shears, saw, milling machine, planer, grinder)
33  Metalizing equipment, if applicable
34  Stud welding equipment, if applicable
35  Surface preparation and coating equipment, if applicable
36  Cranes
37 5.4.4 Inspection Equipment
38 The fabricator shall have the following inspection equipment, at a minimum:
39  tapeline
40  welding gages
41  temperature indicating devices
42  paint thickness gages, if applicable
43  torque wrenches
44  tension indicating device (e.g., Skidmore-Wilhelm)
45  radiographic interpretation equipment including viewing room and viewer, if radiographic testing is
46 performed in the shop
AISCQC030
1  ultrasound scope, if ultrasonic testing is performed by shop personnel

2  magnetic particle testing (MT) equipment, if MT is performed by shop personnel
3  Reference standards for use in periodically calibrating equipment such as paint gauges, tapeline,
4 NDT equipment, torque wrenches (see Section 14).
5 5.5 Internal Communication
6 Executive management shall ensure that appropriate communication processes are established within the
7 fabricator’s organization and that communication takes place regarding the effectiveness of the quality
8 management system.
9 Drawing, material and production due dates shall be scheduled by suitable areas or sequences, and
10 schedules shall be disseminated to appropriate personnel.
11 Drawing, material and production schedules shall be maintained and current throughout the year.
12 Quality issues shall be discussed at regular documented meetings (at least quarterly).
13 5.6 Documentation Requirements
14 5.6.1 General Requirements
15 Quality management system documentation shall include:
16  A quality manual
17  Statements of a quality policy and quality objectives (as described in Section 5.1)
18  Documented procedures and their associated quality records required by this standard
19  Documents needed by the fabricator to ensure the effective planning, operation, and control of its
20 processes
Draft Document
21 5.6.2 Quality Manual

22 The fabricator shall establish and maintain a quality manual satisfying all of the requirements of this
23 standard, as well as applicable reference documents, industry and government regulations, codes, and
24 contract requirements. Requirements may be satisfied in a single document called the quality manual or
25 may be satisfied in separate documents referenced by the quality manual.
26 5.6.2.1 Organization
27 The quality manual shall include a page showing the current revision date and the name and location
28 of the fabricator.
29 The quality manual shall include or reference documents that include:
30  Policies and organizational description
31  Organizational chart describing responsibility, authority, and the interrelationship of functional
32 positions that manage, perform, and verify work affecting quality
33  Job descriptions and required qualifications for executive management and functional positions
34 that manage, perform, and verify work affecting quality
35  Evidence of qualification for individuals in positions requiring it
36  A facility plan
37  An equipment list
38  Established documented procedures
39  Description of the interaction and communication between the individual processes within the
40 system used by the fabricator to produce products of the required quality
41 Documented procedures may be issued separately or be an integral part of the quality manual. The
42 fabricator determines the level of detail in the quality manual and documented procedures. At a
43 minimum, these documents shall be detailed sufficiently to describe the quality management system
44 used by the fabricator to assure the required quality.
AISCQC030
1 Management of relevant functions shall define what additional documented procedures, drawings, or
2 other documents are required beyond the minimum requirements set by this standard to meet the
3 needs of the fabricator’s organization and its customers.
4 5.6.2.2 Approval
5 Executive management shall approve the quality manual. At a minimum, the quality manual shall be
6 signed and dated by the highest ranking individual responsible for the facility.
7 6. Contract and Project Specification Review and Communication

8 The fabricator shall develop a documented procedure for contract and project specification review requiring
9 completion of these reviews for each steel bridge project performed. The review shall begin no later than the
10 fabricator’s acceptance of responsibility for performing the work. Ideally, the review should begin during the
11 project estimation or bid process.
12 The review shall identify, determine, plan, and record the specific project requirements as well as define
13 distribution of the recorded specific project requirements (such as coating requirements, weld restrictions, etc.) to
14 the responsible individuals in the fabricator’s organization, and identify new documented quality procedures that
15 must be created for the work. This review shall consider any issue that affects the fabricator’s capability to
16 perform the work. The review shall include fabrication and erection requirements (such as erection aids and
17 sequencing of NDT) and priorities.
18 The documented procedure shall provide for review of the original contract documents, revised contract
19 documents and changes received through clarification (e.g. requests for information or other sources) to assure
20 that the affected staff (e.g., engineering, procurement, assembly, QC) fully understand the applicable contract
21 requirements.
Draft Document
22 Evidence of contract review can take the form of technical summaries, signoffs, change orders, schedules and
23 allocation of adequate resources. Such evidence shall indicate consideration of pertinent sections of this standard
24 managed by the functions listed in Section 5.4.1 and other critical project requirements that, if missed, may have
25 a major impact on project quality and satisfying the contract.
26 7. Detailing
27 7.1 Detailing Procedures
28 7.1.1 Preparation of Shop Drawings and Erection Drawings
29 The shop and erection drawings produced shall incorporate all contract requirements, specifications,
30 codes, and relevant standards to adequately procure materials, fabricate the steel bridge, and provide
31 instructions to the erector for location of shipping pieces in the completed structure. To ensure this, a
32 documented procedure for preparation of shop and erection drawings shall be developed, which
33 describes:
34  How project requirements are reviewed and incorporated.
35  How the fabricator coordinates, proposes changes, and tracks information with the general
36 contractor or owner (e.g., change orders and RFIs), and how the associated resolutions are tracked
37 and controlled.
38 7.1.2 Detailing Standards
39 The fabricator shall prepare and use detailing standards describing technical preferences and
40 requirements customarily used in the shop. These standards shall show special information required on
41 advance bills such as allowances for cuts, camber, or supplementary requirements. The detailing
42 standards shall include how bills of material are prepared which, at a minimum, include:
43  Sizes and quantities
44  Appropriate ASTM specification references
AISCQC030
1  Special ordering information

2  Any allowances or tolerances
3 The detailing standards shall describe the fabricator’s preferred methods of drawing layout, including but
4 not limited to:
5  Views
6  Title block information
7  The method of designating shipping sequences
8  The piece marking system
9  Commonly used shop abbreviations
10  Showing bolt placement lists (including bolt type and installation requirements)
11  Information required on weld symbols including any special NDT requirements
12 The detailing standards shall describe the fabricator’s preferred method for:
13  Selection of connection geometry
14  Detailing holes, fasteners, washers, cuts, and copes
15  Assignment of appropriate welding symbols (shop and field welds)
16  Selecting bolt installation method
17  Showing surface preparation (including specification of surface finish)
18  Designating coating requirements (including coating materials and dry film thickness)
19  Showing any necessary special instructions to fabricate and erect the steel bridge.
20 7.1.3 Shop and Erection Drawings
21 The fabricator shall develop a documented procedure to provide for checking of all shop and erection
22 drawings and to describe the method used to release shop drawings for fabrication.
Draft Document
23 7.1.3.1 Checking of Shop and Erection Drawings

24 The documented procedure for checking of shop and erection drawings shall describe the method
25 used by the fabricator or its subcontractor to perform and record the final check of shop and erection
26 drawings to ensure compliance with contract documents before release for fabrication and erection.
27 Evidence of the effective implementation of such methods may include signatures, stamps, logs, files,
28 or lists. Records shall provide means for identification of the individual checker who performed the
29 final check of each shop or erection drawing.
30 For computer-generated shop drawings and manufacturing models, the documented procedure shall
31 identify the data, variables, graphics, calculating formulas, and other output that are checked to verify
32 the accuracy of the software.
33 When detailing is performed by a subcontractor, the documented procedure shall define the extent of
34 review by detailing management and checking of received detailing products before release for
35 fabrication and erection.
36 The documented procedure for checking shop drawings, manufacturing models, and erection
37 drawings shall include comparing those documents and models to project requirements that include,
38 but are not limited to:
39  Geometry
40  Use of the correct connections
41  Proper notes
42  Proper material usage
43  Assignment of complete welding symbols
44  Proper coatings and preparation
45  Proper representation on erection drawings including the notation of any necessary instructions
46 and depiction of details necessary to conduct the work in the field
AISCQC030
1 7.1.3.2 Approval of Shop Drawings and Release for Fabrication

2 The documented procedure for release of shop and erection drawings shall describe the method
3 used to document owner approval of shop drawings released for fabrication, whether produced in-
4 house or through a subcontractor. Such methods may include signatures, stamps, logs, files, or lists.
5 7.1.3.3 Owner-Supplied Shop Drawings
6 When the fabricator receives shop drawings from the owner, a documented procedure shall define
7 the method of receipt, revision, and control of those drawings.
8 7.2 Detailing Personnel
9 The fabricator’s staff shall manage detailing. Detailing functions may be performed by employees or
10 subcontractors.
11 7.2.1 Detailing Management
12 Responsibilities for detailing management shall include:
13  Overseeing the production of shop and erection drawings
14  Communicating with designers
15  Scheduling
16  Developing and maintaining company detailing standards and documented detailing procedures
17  Transmittals related to obtaining approval from the owner’s designated representative for design or
18 construction
19  Coordinating and incorporating construction requirements
20  Training of employed detailers and checkers.
Draft Document
21 Qualification requirements for detailing management personnel shall include experience in detailing and
22 checking shop and erection drawings approved by an owner for a variety of structures representative of
23 projects the fabricator provides. The fabricator shall determine and describe methods to demonstrate
24 competence.
25 Detailing management shall be familiar with the requirements of pertinent codes and specifications.
26 7.2.2 Detailing Functions
27 Personnel who perform detailing or checking of shop and erection drawings shall have experience in
28 drawing projects similar to the projects the company provides and shall have knowledge of applicable
29 material specifications and of mill rolling practices as they affect the detailing of structural steel.
30 Detailers in training shall work under the supervision of a trained detailer or checker.
31 A qualified checker shall check all shop drawings before release for fabrication. Qualification
32 requirements for checkers shall be defined and documented as required in Section 5.4.1 and include
33 training and experience in connection selection. Demonstrated competency of employed and
34 subcontracted individuals performing final checks shall be documented by detailing management.
35 7.2.3 Subcontract Services
36 In lieu of employed staff personnel, subcontractors may be used for the following functions: detailing,
37 connection consultation, checking of shop and erection drawings, and training of detailers and checkers.
38 However, the fabricator retains the responsibility for compliance with the requirements of this standard.
39 The fabricator shall define and document the qualification and selection process for choosing
40 subcontractors as required in Section 10.2.
AISCQC030
1 8. Document and Data Control

2 The fabricator shall develop a documented procedure to control documents and data affecting quality including:
3  The quality manual
4  Contract documents (dissemination and revision control)
5  Shop and erection drawings
6  Detailing standards
7  All documented procedures
8 8.1 Review and Approval
9 The fabricator shall designate which function and authority levels have responsibility for review and approval
10 of internal standards and documented procedures. Revisions to the quality manual and other quality
11 management system documents shall be reviewed for adequacy and approved by the same function and
12 authority level that authorized the original document. The documented procedure for document and data
13 control shall describe the frequency and requirements for review and updating, and establish a method to
14 identify changes.
15 8.2 Customer Requirements
16 The documented procedure shall define methods for receipt and documentation of owner and general
17 contractor requirements and fabricator-originated changes as they occur throughout the fabrication and
18 detailing process. Requirements may be received in original contract documents; in subsequent
19 telecommunications, letters, transmittals related to product requirements; and in change orders or contract
20 addenda.
21 The documented procedure shall require records (e.g., logs, files, or master lists) that show receipt of change
Draft Document
22 data, incorporation, issue, and distribution of approved and revised shop drawings and erection drawings to
23 all necessary departments and personnel at the fabricator’s facility and necessary external organizations,
24 subcontractors, or suppliers.
25 8.3 Revision Control
26 The revision to the previous document shall be clearly identifiable on each amended document and reflected
27 in data controlled by the documented procedure and there shall be a method for monitoring and identifying
28 the latest revision. The fabricator shall establish a method to ensure identification of changes to the quality
29 manual or referenced documented procedures from previous revisions. Documents shall remain legible and
30 easily identifiable.
31 8.4 Access
32 Relevant and current documented procedures and policies pertinent to an area of operation or management
33 shall be available and readily accessible to all personnel responsible for performing work affecting the product
34 quality.
35 8.5 Obsolescence and Transmittal
36 The documented procedure shall describe methods to prevent inadvertent use of controlled documents that
37 are obsolete in the fabrication or erection process.
38 A method shall be established and maintained showing the latest revisions and location of:
39  The quality manual and other quality management system documents
40  Contract documents including design drawings and owner change orders
41  Shop and erection drawings
42 A transmittal system shall be established to record the distribution of drawings, documents, and specifications
43 to all recipients. This system shall have provisions for establishing project-specific distribution lists in
44 accordance with the requirements of the contract documents.
45 The records shall indicate the status of approval and release to fabrication or erection.
AISCQC030
1 9. Control of Quality Records

2 The fabricator shall develop a documented procedure for quality records that provides for:
3  Identification
4  Collection
5  Storage
6  Maintenance
7  Retention (time duration)
8  Disposition.
9 All quality records shall be legible and shall be stored in such a way that they are retrievable from facilities that
10 provide a suitable environment to prevent damage, deterioration or loss. Quality records typically include, but are
11 not limited to:
12  Inspection records
13  NDT reports
14  Drawing logs
15  MTRs
16  C of Cs
17  Radiographs, if retained by fabricator rather than owner
18  Contract review
19  Contract clarifications
20  Design change records, including contract construction changes and addendums
21  RFIs with owner responses
22  Mill and consumable purchase orders

Draft Document
23 Records or summaries of nonconformance reports

24  Corrective action reports
25  Training records
26  Subcontractor and supplier qualifications and evaluations
27  Internal and external quality management system audit records
28 9.1 Retention of Quality Records
29 Retention times shall be established and recorded for records retained for any purpose. The retention periods
30 shall be at least long enough to permit evaluation of the records during the course of project construction
31 unless a longer period is required by contract or government regulation, and not less than the duration of any
32 warranty provided by the fabricator.
33 9.2 Availability of Quality Records
34 Specific quality records required by contract or regulation shall be made available for the owner’s review and
35 evaluation by the fabricator for the required time period.
36 10. Purchasing
37 The fabricator shall develop a documented procedure to ensure that subcontractors and suppliers provide
38 materials, products, and services conforming to project requirements. Responsibility for quality of the
39 subcontracted products and services remains with the fabricator. Purchasing documents, subcontractor and
40 supplier qualification records, and records of the periodic evaluation of subcontractors and suppliers shall be
41 maintained.
42 Purchasing personnel shall be familiar with ordering information required to control variables affecting the quality
43 of purchased material. The fabricator shall ensure that proper instructions, current copies of relevant codes and
44 specifications, and all relevant contract requirements are furnished to purchasing personnel.
AISCQC030
1 10.1 Purchasing Data

2 The fabricator shall clearly describe subcontracted work and the purchased products, materials, and services
3 ordered in written purchasing documents. This shall include but not be limited to:
4  The type of service, material, class, grade, and other unique identification
5  The applicable specifications, drawings, process requirements, and inspection instructions and any
6 witness points required by the owner or the quality management system
7  Delivery instructions and date
8  Required C of Cs, MTRs, and NDT reports.
9 Purchasing documents for materials furnished to ASTM specifications shall include the information required in
10 the “Order Information” section of the ASTM standard.
11 10.2 Selection and Evaluation of Subcontractors and Suppliers
12 The fabricator shall evaluate and select subcontractors and suppliers on the basis of their ability to meet
13 subcontract requirements, the fabricator’s quality management system, the requirements of this standard,
14 project requirements, and any specific inspection requirements.
15 A documented procedure shall be developed that describes how the fabricator conducts initial and ongoing
16 evaluation of all subcontractors and suppliers. Management shall determine:
17  Evaluation criteria
18  Reevaluation interval
19  Personnel involved in the evaluation process
20 The fabricator shall evaluate subcontractors and suppliers via an audit or documented acceptable past
21 experience. As a minimum, quality of the finished products and timely, proper delivery of services or products
Draft Document
22 shall be part of the documented evaluation procedure.

23 10.2.1 Fabrication Subcontractors
24 Subcontractors performing welding, bolting, or assembly shall have the applicable AISC Certification on
25 projects requiring AISC Certification.
26 10.2.2 Detailing Subcontractors
27 The fabricator’s documented procedure defines the methods used for initial and ongoing evaluation of
28 detailing subcontractors and may include direct or third party review of one or more of the following:
29  Drawing products and other work to assess ability to perform the specific type of work the fabricator
30 is subcontracting.
31  Implementation and effectiveness of documented procedures to track RFIs.
32  Employment experience records for individual detailers and checkers.
33  For ongoing evaluation, detailing error frequency and severity from fabricator records.
34 The fabricator’s documented procedure shall define detailing subcontractor evaluation criteria that include
35 how the following information is identified on or incorporated into drawings:
36  Material requirements and special conditions
37  Coating requirements
38  Contract document special conditions
39  Inspection requirements
40  Welding symbols
41  Conformance to the fabricator’s detailing standard
42  Drawing check complete
43  Identification of checkers
AISCQC030
1 When the fabricator awards detailing subcontracts in advance of evaluation, the fabricator’s documented
2 procedure shall include methods to assess the “pre-evaluation” level of risk to meeting:
3  Subcontract requirements
4  The fabricator’s quality management system
5  The requirements of this standard
6  Project requirements
7  Specific inspection requirements
8 For “award in advance of evaluation”, the fabricator’s documented procedure shall require a full initial
9 evaluation of detailing subcontractors during the performance of the subcontracted work. Ongoing
10 evaluation as required in the documented procedure shall be conducted if the detailing subcontractor is to
11 be considered as a source for future work.
12 10.3 Verification of Purchased Product, Materials, and Services
13 The fabricator’s documented procedure for purchasing shall define the extent of control necessary to ensure
14 conformance to the project requirements. This may depend upon the type of product, the potential impact of
15 subcontracted product on the quality of the final product or the records available for the demonstrated
16 capability and performance of similar products in previous projects. Test reports, C of Cs, or other evidence of
17 quality control shall be kept on file as defined in the fabricator’s documented procedure required by Section 9.
18 11. Material Identification and Traceability

19 The fabricator shall develop a documented procedure for identification of material and material traceability.
20 11.1 Material Identification
Draft Document
21 The documented procedure shall describe how the fabricator marks or maintains the identification of base
22 materials from the point of receipt to the point of the first fabricating operation (or beyond, if required; see
23 11.2) to assure incorporation of the correct materials into the product.
24  Structural steel material shall be identified as stated in contract documents.
25  Welding consumables shall be identified in accordance with the appropriate ANSI/AWS specification.
26  Coating materials (excluding metallic coating) shall be identified on the container by, at a minimum, color
27 (pigment description and federal standard number, or manufacturer’s number), lot/batch number, ID/stock
28 number, and quantity of coating in container, date of manufacture and manufacturer’s name and address.
29  Metallic coatings shall be identified by, at a minimum, composition and the appropriate ASTM
30 specification, including hot dip or mechanical galvanizing and metallizing.
31  Fasteners shall be stored in containers clearly identified by type, grade, size, and lot number(s).
32 Records that provide a basis for material identification (e.g., MTRs and C of Cs for base materials, fasteners,
33 welding consumables, and coatings) shall be filed and retained as defined in the fabricator’s documented
34 procedure required by Section 9.
35 11.2 Material Traceability
36 The fabricator shall develop a documented procedure to maintain traceability of materials from the point of
37 receipt and throughout the course of fabrication. The fabricator may use a marking method that identifies
38 material type and grade or use a method that provides traceability through piece, assembly, or group
39 numbering. Material traceability to corresponding heat numbers is necessary only when specifically required
40 by contract or by supplemental requirements of this standard.
AISCQC030
1 12. Fabrication Process Control

2 The fabricator shall develop documented procedures for process control necessary to produce a consistent
3 acceptable level of furnished product quality in accordance with the applicable codes and specifications.
4 Fabrication processes include but are not limited to thermal and mechanical cutting, fitting and assembly, welding,
5 drilling, punching, bolting, shearing, milling, sweep and camber, bending and straightening, heating operations,
6 and coating.
7 The process definition shall show inspection points and a sampling plan as defined in Section 13. The
8 documented fabrication procedures shall include steps in which production workers verify that their work is
9 visually in accordance with requirements before handing it off to later stages of production or to QC personnel.
10 Effective implementation of the following documented procedures is required as a minimum:
11 12.1 Welding
12 The fabricator’s documented procedure for welding shall include:
13  WPSs
14  Preheat requirements
15  PQRs (when required)
16  Storage (including ovens) and identification requirements for welding consumables
17  Welder, welding operator, and tack welder qualifications and qualification test records, in accordance with
18 AASHTO/AWS D1.5
19  Welder, welding operator, and tack welder performance records - to provide objective evidence that the
20 “period of effectiveness” has not been exceeded and satisfactory performance is consistently achieved.
21  Traceability of welds to the welders who produce them
Draft Document
22 Approved WPSs shall be in close proximity to and used by the welders.

23 12.2 Bolt Installation
24 The fabricator’s documented bolting procedure shall include storage, rotational capacity testing if required by
25 contract documents, pre-installation verification, installation, and inspection of fastener assemblies for
26 snug-tightened, pretensioned, and slip-critical joint types. The documented procedure shall meet the
27 requirements of the RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts.
28 12.3 Material Preparation for Application of Coatings
29 The fabricator’s documented procedure shall support achievement of cleanliness and surface profile required
30 by coating manufacturer recommendations and product data sheets and by project specifications.
31 12.4 Coating Application
32 The fabricator’s documented procedure shall support application and curing of coatings in accordance with
33 manufacturer recommendations and product data sheets and with project specifications.
34 If complex coating systems (as defined in the AISC/SSPC Certification Standard for Shop Application of
35 Complex Protective Coating Systems) are applied on projects requiring AISC certification to this standard, the
36 fabricator (or coating subcontractor) shall also be certified to the AISC/SSPC Certification Standard for Shop
37 Application of Complex Protective Coating Systems.
38 12.5 Equipment Maintenance
39 The fabricator shall develop a documented procedure defining an equipment maintenance program to
40 produce the required quality. The documented procedure shall define evaluation and preventive maintenance
41 for, at minimum, equipment critical to product quality and delivery requirements.
42 13. Inspection and Testing

43 The fabricator shall develop a documented procedure for inspection and testing activities to verify that the product
44 quality meets the project requirements.
AISCQC030
1 The documented procedure for inspection and testing shall define receipt, in-process, and final inspection of all
2 materials and products furnished to a project.
3 Product determined during inspection and testing to be nonconforming shall be addressed by the fabricator’s
4 documented nonconformance procedure required in Section 15.
5 The documented procedure for inspection and testing shall show inspection points and a sampling plan based on
6 identification of the source and magnitude of probable defects. Probable defects may be identified from
7 non-conformance records (Section 15). For each type of inspection less than 100 percent, the documented
8 procedure shall describe the methods for establishing sampling plans and for adjusting the level and frequency of
9 inspection to assure expected contract quality. The fabricator’s methods shall adjust the level and frequency of
10 inspection at any time the required level of quality is not met. The level or frequency of an inspection sampling
11 plan shall not be zero where a nonconformance has been identified and corrective action has not been fully
12 implemented and verified as effective.
13 13.1 Assignment of QC Inspections and Monitoring
14 The documented inspection procedure shall define inspection and testing and the required records to meet
15 the project requirements and shall assign QC inspection and monitoring duties.
16 Qualification requirements for QC inspectors shall be defined and documented as required in Section 5.4.1.
17 QC inspectors shall be assigned on the basis of qualification, evidenced by experience, training, and
18 education. Qualification standards and certifications granted by recognized industry organizations related to
19 steel bridge fabrication can be used as a basis for qualification.
20 QC inspectors shall be periodically monitored by QA witnessing QC work or repeating their duties. The
21 documented procedure shall indicate how often quality control activities are sampled and checked.
Draft Document
22 Production personnel may be assigned to QC inspection duties under the following conditions:
23  They are trained and knowledgeable in the practice proper inspection methods and acceptance criteria
24 specified for the material or products they are inspecting and hold the required certification as applicable.
25  They are aware of their responsibilities and are given time to perform them.
26  They do not inspect their own work.
27  Their inspections are monitored by qualified quality control personnel.
28 13.2 Inspection Procedure
29 The fabricator’s documented procedure shall include provisions for the following:
30 13.2.1 Material Receipt Inspection
31 Materials received shall be checked for conformance with the purchase order requirements. The receiver
32 shall identify the material, grade, size, and quantity and look for visible shipping damage.
33 MTRs and C of Cs for base materials, fasteners, welding consumables, coatings, and any other product
34 which becomes part of the shipped component shall be checked for compliance with the purchase order
35 requirements.
36 If materials are supplied by the owner; the fabricator shall verify, store, and maintain materials in an
37 appropriate fashion. Verification shall include confirmation that the material is what is required and meets
38 the quality requirements.
39 13.2.2 In-Process Inspection
40 The fabricator shall employ in-process inspection plans and practices to provide a level of compliance
41 assurance for specified process requirements and inspection acceptance criteria that are not verifiable at
42 final inspection or that can hinder assembly. In-process inspection is appropriate for processes including
43 but not limited to welding, bolting, coating surface preparation, and coating application. In-process
44 inspection is also appropriate for work that will not be visible or accessible during final inspection.
AISCQC030
1 Materials shall be inspected for specification and grade, workmanship, and tolerances using appropriate
2 codes, standards, or a documented plan before fabrication begins. Compliance with the fabricator’s
3 documented process control procedures shall be monitored.
4 13.2.3 Final Inspection
5 The fabricator shall conduct final inspection. Designated, qualified QC inspectors shall perform the final
6 inspection of all steel bridge products prior to shipping.
7 Demonstrated competency of employees and subcontracted individuals performing final inspection shall
8 be documented and evidenced by experience, training, and education.
9 13.2.4 Inspection Records
10 The documented inspection procedure shall indicate what records and marks are used to document
11 inspections. In-process inspections shall be verifiable until the final inspection of the piece.
12 Final inspections shall be documented. The quality records produced shall be filed and retained as
13 defined in the fabricator’s documented procedure required by Section 9. Inspection records shall clearly
14 show the products and product aspects that were inspected and who performed the inspection.
15 14. Calibration of Inspection, Measuring, and Test Equipment

16 The fabricator shall develop a documented procedure to control, calibrate, and maintain inspection, measuring,
17 and test equipment used to demonstrate that products and processes comply with specified requirements. Tools
18 with devices for measuring properties or process variables are included when used to demonstrate the
19 compliance of products and processes to the specified requirements.
Draft Document
20 The documented procedure shall define equipment calibration frequency. However, the volt/amp meters used to
21 verify compliance with WPS parameters (on a welding machine or auxiliary meters) shall be calibrated whenever
22 the accuracy of the meter is in question and at a minimum every twelve months.
23 Inspection, measuring and test equipment shall be used in a manner consistent with the required measurement.
24 The precision capability of the equipment used shall support reliable determination of compliance with acceptance
25 criteria. Owners may require that technical data and reference standards pertaining to the measurement
26 equipment be made available for verification that the equipment is calibrated and performing properly.
27 For inspection, measuring, and test equipment used to demonstrate the compliance of products and processes to
28 the specified requirements, the documented procedure shall include:
29  An equipment list that provides a means for unique identification of each piece of equipment
30  Service use for each piece of equipment including the required precision for the types of inspections,
31 measurements or tests
32  Handling and storage of inspection, measuring, and test equipment to maintain accuracy and fitness for
33 use
34  Calibration frequency for each piece of equipment based upon service use, requirements of this standard,
35 manufacturer’s recommendations, project requirements, specification requirements
36  Identification of standards or certified equipment having a known valid relationship to internationally or
37 nationally recognized standards used to calibrate each listed piece of equipment. Where such standards
38 do not exist, the basis used for calibration shall be documented
39  The documented calibration procedure for each piece of equipment calibrated at the fabricator’s facility
40  The calibration accuracy acceptance criteria for each piece of equipment
41  The action to be taken when equipment does not meet the calibration accuracy acceptance criteria
42  Calibration quality record maintenance as defined in the fabricator’s documented procedure required by
43 Section 9
44  Method of preventing inadvertent use of uncalibrated equipment where calibration is required.
AISCQC030
1 15. Control of Nonconformances

2 The fabricator shall develop a documented procedure to identify and control nonconformances. Nonconformances
3 may be identified by the fabricator’s inspection program, by process monitoring, during internal and external
4 audits, or by owner representatives or other observers. Nonconformances are then addressed by the corrective
5 action documented procedure (Section 16) and reviewed during the management review (Section 5.2). QC
6 inspectors finding nonconforming work shall have authority to stop the work and responsibility to inform the
7 operating supervisor of the nonconformance.
8 15.1 Nonconformance with the Quality Management System
9 Nonconformances are not limited to nonconforming product. A nonconformance related to the performance of
10 the quality management system shall be documented to the detail level described by the documented
11 procedure.
12 15.2 Nonconforming Product
13 Nonconforming product not satisfying specified requirements shall be documented and prevented from
14 unintentionally reaching the job site. The documented procedure shall provide for identification,
15 documentation, evaluation, segregation (when practical), treatment of nonconforming product, and for
16 notification of the relevant functions concerned.
17 Nonconforming product shall be clearly marked as soon as practical after discovery. Records shall be kept of
18 the pieces affected, the nature of the nonconformance, the treatment selection, authorization, and
19 reinspection results, if applicable.
20 Owner approval is typically required by contract for treatment of nonconformances and will be documented in
21 writing.
Draft Document
22 The responsibility, authority, and required qualifications for the personnel selecting treatment of
23 nonconforming product shall be defined by the documented procedure. The treatment of nonconforming
24 product may be:
25  Redesign for approval
26  Rework
27  Owner-approved nonconforming product (repair or use as is)
28  Scrap.
29 If the treatment is rework or repair, the result shall be inspected per drawing, specification, project
30 requirements, and the fabricator’s documented inspection procedure.
31 16. Corrective Action

32 The fabricator shall develop a documented procedure for corrective action. Any corrective action taken shall be
33 appropriate for the magnitude of problems and commensurate with the risks to product quality.
34 The corrective action documented procedure shall include periodic review of records or summaries of
35 nonconformances and of internal and external quality audit reports for determination and initiation of corrective
36 actions. Corrective action may be applied when:
37  There is a nonconformance that is repetitive in nature. This can be identified by periodically reviewing
38 nonconformance reports or summaries for negative trends.
39  Process nonconformances are found during the internal and external quality audits indicating that the
40 quality management system may not be implemented and functioning as stated in the quality manual.
41  Nonconformance with the quality management system is found during the day-to-day execution of the
42 system.
43  Nonconformance is unacceptable due to cost or severity.
44  A complaint has been received from an owner, general contractor, or erector.
AISCQC030
1 The corrective action documented procedure shall address these steps:

2 1. Document a corrective action request (CAR) that includes the nonconformance to be addressed and the
3 requirement that has not been met. The corrective action documented procedure shall define the
4 functional positions authorized to issue a CAR and initiate the corrective action process.
5 2. Assign responsibility and establish a timeframe for the response to a CAR.
6 3. Investigate and document the scope of the nonconformance, root causes, measures taken to bring a
7 nonconforming product or process into conformance with specified requirements, and list the actions to
8 be taken to prevent recurrence.
9 4. Communicate the corrective action request and resolution to executive management and appropriate
10 members of the organization.
11 5. Follow up with periodic monitoring to assure the corrective action is implemented and is effective.
12 17. Handling, Storage and Delivery of Product and Materials

13 Material shall be stored, loaded, and shipped to avoid loss or damage and minimize deterioration. Material shall
14 be marked with identification and shall be listed on a manifest or shipping documents. The fabricator shall provide
15 for suitable loading, blocking, and bracing for shipment.
16 If a shipping agreement between the fabricator and the owner, general contractor, or subcontractors exists,
17 material shall be shipped in compliance with the agreement, including sequencing that complies with erection
18 needs. Shipments by subcontractors shall be coordinated and monitored for compliance with shipping
19 instructions.
20 Owner-supplied material or material paid for as “material on hand” before fabrication shall be protected to prevent
21 use in other than its intended purpose. Any such product that is lost, damaged, or is otherwise unsuitable for use
22 shall be recorded and reported to the owner.
Draft Document
23 18. Training
24 Personnel responsible for functions that affect quality, including, but not limited to, project managers, detailers,
25 inspectors, welding personnel, fitters, and painters, shall receive initial and periodic documented training. Training
26 records are quality records controlled as required in Section 9.
27 Personnel providing training shall have appropriate training or experience in the subject they are teaching.
28 Training course outlines include the subject and the key points. Evaluation of student comprehension of course
29 material is desirable.
30 19. Internal Audit

31 The fabricator shall perform an internal audit of the quality management system at least once a year to evaluate
32 compliance and the effectiveness of implementation. Different parts of the quality management system may be
33 audited at different times and different frequencies. Audits shall be scheduled based on the importance of the
34 area being audited.
35 The Management Representative for Quality or a qualified individual, independent of the function being audited,
36 shall perform the audit and provide a written quality record of each audit result.
AISCQC030
1 SUPPLEMENTAL REQUIREMENTS
2 (reference section 2. Program Scope and Fabricator Eligibility)
3 S[F] REQUIREMENTS FOR FABRICATORS OF BRIDGES WITH FRACTURE-CRITICAL

4 MEMBERS
5 F2. Program Scope and Fabricator Eligibility
6 To be certified under this standard, the fabricator shall have:
7  supplied non-fracture-critical intermediate or advanced bridges, established a documented training
8 program for the purpose of communicating fracture-critical work functions to the work forces, and
9 demonstrated capability to fabricate fracture-critical members.
10 F5.6.2.1 Organization:
11 The quality manual shall include or reference a written Fracture Control Plan meeting the requirements of AWS
12 D1.5.
13 F7.1.3. Detailing Standards

14 The detailing standards for preparation of bills of material shall include whether the material is to be used for
15 fracture-critical applications.
16 The detailing standards for the fabricator’s preferred methods of drawing layout shall include the means for noting
17 fracture-critical welds.
18 F10.1 Purchasing Data

Draft Document
19 The fabricator’s written purchasing documents shall indicate material to be used for fracture-critical applications.
20 F11.2 Material Traceability
21 The fabricator’s documented procedure for identification of material and material traceability shall include
22 provisions for maintaining heat and MTR identity of fracture-critical material throughout the fabrication process.
23 F12.1 Welding
24 The fabricator’s documented procedure for welding shall include:
25  PQRs
26  fracture-critical provisions for welding procedure qualification, preheat, and storage of consumables.
27 F13.2 Inspection Procedure

28 The fabricator’s documented procedure shall include provisions for inspection of fracture-critical welds.
29 F15.3 Repairs to Fracture-Critical Welds

30 The fabricator’s documented procedure shall include provisions for repair of critical and non-critical fracture-
31 critical welds in accordance with AWS D1.5
32 S[I] REQUIREMENTS FOR FABRICATORS OF INTERMEDIATE BRIDGES

33 I2. Program Scope and Fabricator Eligibility
35  supplied plate girder spans with field splices for highway or railroad bridges within the last five years, or
36  supplied simple bridges, established a documented training program for the purpose of communicating
37 intermediate bridge work functions to the work forces, and demonstrated capability to fabricate
38 intermediate bridges.
AISCQC030
1 I5.4.3 Fabrication Process Equipment

2 Equipment shall include automatic, machine, or semiautomatic equipment for making continuous welds
3 I7.1.2 Detailing Standards

4 The detailing standards shall describe the fabricator’s preferred method for creating shop assembly (blocking)
5 drawings.
6 I7.2.2 Detailing Functions

7 Detailing personnel shall have an understanding of bridge geometry, including but not limited to vertical and
8 horizontal alignment, cross-slope, and roadway transitions.
9 I12. Laydown/Assembly
10 The fabricator’s documented procedure for shop assembly of field connections shall include, at a minimum, the
11 following items:
12  provisions for control of assembled dimensions for both vertical and horizontal geometry
13  provisions for control of accuracy of drilling and reaming of field connections
14  documented procedures, including reference drawings, for match-marking shop-assembled pieces
15  provisions for assuring the accuracy of numerically controlled equipment, if contract documents permit the
16 use of such equipment in lieu of physical assembly
17
18 S[A] REQUIREMENTS FOR FABRICATORS OF ADVANCED BRIDGES

Draft Document
19 A2. Program Scope and Fabricator Eligibility

21  supplied advanced bridges for highway or railroad applications within the last five years, or
22  supplied intermediate bridges for highway or railroad use, established a documented training program for
23 the purpose of communicating advanced bridge work functions to the work forces, and demonstrated
24 capability to fabricate advanced bridges.
25 Fabricators of advanced bridges shall meet the supplemental requirements for fabricators of intermediate bridges.
26 Users of this standard are encouraged to evaluate fabricator capability on a project-specific basis.
27 A6 Contract and Project Specification Review and Communication

28 The fabricator's documented procedure shall include a process for communicating with individuals in the
29 fabricator's organization, the general contractor, and the owner regarding special fabrication-related requirements
30 for advanced bridges including:
31  shop assemblies
32  dimensional control and verification
33  welding
34  NDT
35  high-performance materials
36  other atypical or special job requirements
37 The fabricator’s documented procedure shall include provisions for communication with the general contractor
38 and the erector about fabrication issues that may affect erection.
39 A12.1 Welding
40 The fabricator’s documented procedure for welding shall include a distortion control program.

AISC 2010 New Draft Standard

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AISCQC030

AISC Certification Program for

AMERICAN INSTITUTE OF STEEL CONSTRUCTION

3 American Institute of Steel Construction

1 Prepared Under the Direction of the

AISC CERTIFICATION COMMITTEE

2 Prepared Under the Direction of the

BRIDGE FABRICATOR CERTIFICATION TASK GROUP

6 2. Program Scope and Fabricator Eligibility

1 Simple Bridge. A bridge consisting of unspliced rolled sections.

1  ultrasound scope, if ultrasonic testing is performed by shop personnel

21 5.6.2 Quality Manual

7 6. Contract and Project Specification Review and Communication

1  Special ordering information

23 7.1.3.1 Checking of Shop and Erection Drawings

1 7.1.3.2 Approval of Shop Drawings and Release for Fabrication

1 8. Document and Data Control

1 9. Control of Quality Records

23 Records or summaries of nonconformance reports

1 10.1 Purchasing Data

22 shall be part of the documented evaluation procedure.

18 11. Material Identification and Traceability

1 12. Fabrication Process Control

22 Approved WPSs shall be in close proximity to and used by the welders.

42 13. Inspection and Testing

15 14. Calibration of Inspection, Measuring, and Test Equipment

1 15. Control of Nonconformances

31 16. Corrective Action

1 The corrective action documented procedure shall address these steps:

12 17. Handling, Storage and Delivery of Product and Materials

30 19. Internal Audit

3 S[F] REQUIREMENTS FOR FABRICATORS OF BRIDGES WITH FRACTURE-CRITICAL

13 F7.1.3. Detailing Standards

18 F10.1 Purchasing Data

20 F11.2 Material Traceability

27 F13.2 Inspection Procedure

29 F15.3 Repairs to Fracture-Critical Welds

32 S[I] REQUIREMENTS FOR FABRICATORS OF INTERMEDIATE BRIDGES

1 I5.4.3 Fabrication Process Equipment

3 I7.1.2 Detailing Standards

6 I7.2.2 Detailing Functions

18 S[A] REQUIREMENTS FOR FABRICATORS OF ADVANCED BRIDGES

19 A2. Program Scope and Fabricator Eligibility

27 A6 Contract and Project Specification Review and Communication

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