Steel Bridge Fabrication

QC/QA Guidelines
G4.1-2019

American Association of State Highway

and Transportation Officials
National Steel Bridge Alliance
AASHTO/NSBA Steel Bridge Collaboration
 PREFACE
This document is a standard developed by the AASHTO/NSBA Steel Bridge Collaboration. The primary
goal of the Collaboration is to achieve steel bridge design and construction of the highest quality and value through
standardization of the design, fabrication, and erection processes. Each standard represents the consensus of a
diverse group of professionals.

It is intended that Owners adopt and implement Collaboration standards in their entirety to facilitate the
achievement of standardization. It is understood, however, that local statutes or preferences may prevent full
adoption of the document. In such cases, Owners should adopt these documents with the exceptions they feel are
necessary.

Cover graphics courtesy of Atema Inc.and High Steel Structures, LLC.

DISCLAIMER
The information presented in this publication has been prepared in accordance with recognized
engineering principles and is for general information only. While it is believed to be accurate, this information
should not be used or relied upon for any specific application without competent professional examination and
verification of its accuracy, suitability, and applicability by a licensed professional engineer, designer, or
architect.

The publication of the material contained herein is not intended as a representation or warranty of the
part of the American Association of State Highway and Transportation Officials (AASHTO) or the National Steel
Bridge Alliance (NSBA) or of any other person named herein, that this information is suitable for any general or
particular use or of freedom from infringement of any patent or patents. Anyone making use of this information
assumes all liability arising from such use.

Caution must be exercised when relying upon other specifications and codes developed by other bodies
and incorporated by reference herein since such material may be modified or amended from time to time
subsequent to the printing of this edition. The authors and publishers bear no responsibility for such material other
than to refer to it and incorporate it by reference at the time of the initial publication of this edition.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.

AASHTO Document No: NSBASBFQC-2 ISBN: 978-1-56051-740-5

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS
444 North Capitol Street, N.W. Suite 249
Washington, D.C. 20001

EXECUTIVE COMMITTEE
2019–2020

OFFICERS:

PRESIDENT: Patrick McKenna, Missouri*

VICE PRESIDENT: Victoria Sheehan, New Hampshire*

SECRETARY-TREASURER: Scott Bennett, Arkansas

EXECUTIVE DIRECTOR: Jim Tymon, Washington, D. C.

REGIONAL REPRESENTATIVES:

REGION I: Vacant
Diane Gutierrez-Scaccetti, New Jersey

REGION II: Melinda McGrath, Mississippi

Russell McMurry, Georgia

REGION III: Mark Lowe, Iowa

Craig Thompson, Wisconsin

REGION IV: Kyle Schneweis, Nebraska

James Bass, Texas

IMMEDIATE PAST PRESIDENT: Carlos Braceras, Utah

*Elected at the 2019 Annual Meeting in St. Louis, Missouri

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 This page intentionally left blank.

ii

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
AASHTO COMMITTEE ON BRIDGES AND STRUCTURES, 2019
CARMEN E.L. SWANWICK, Chair
SCOT BECKER, Vice Chair
JOSEPH L. HARTMANN, Federal Highway Administration, U.S. DOT Liaison
PATRICIA J. BUSH, AASHTO Liaison

ALABAMA, William “Tim” Colquett, Eric J. MASSACHUSETTS, Alexander K. Bardow,

Christie, Joe Rigney
Randall Mullins MICHIGAN, Matthew Chynoweth, Rebecca Curtis,
ALASKA, Richard A. Pratt, Leslie Daughtery, Richard E. Liptak
Elmer E. Marx MINNESOTA, Kevin L. Western, Arielle Ehrlich,
ARIZONA, David L. Eberhart, David Benton, Ed Lutgen
Pe-Shen Yang MISSISSIPPI, Justin Walker, Scott Westerfield
ARKANSAS, Charles “Rick” Ellis, Michael Hill, MISSOURI, Dennis Heckman, Greg E. Sanders
Joe Sartini MONTANA, Stephanie Brandenberger,
CALIFORNIA, Thomas A. Ostrom, Amanda Jackson, Dustin E. Rouse
Gedmund Setberg, Dolores Valls NEBRASKA, Mark J. Traynowicz, Mark Ahlman,
COLORADO, Michael Collins, Stephen Harelson, Fouad Jaber
Jessica Martinez NEVADA, Jessen Mortensen, Troy Martin
CONNECTICUT, Timothy D. Fields, Mary E. Baker NEW HAMPSHIRE, Robert Landry, David L. Scott
DELAWARE, Jason N. Hastings, Jason Arndt, NEW JERSEY, Eddy Germain,
Craig A. Stevens Xiaohua “Hannah” Cheng
DISTRICT OF COLUMBIA, Konjit C. “Connie” NEW MEXICO, Shane Kuhlman, Kathy Crowell,
Eskender, Donald L. Cooney, Richard Kenney Jeff C. Vigil
FLORIDA, Sam Fallaha, William Potter, NEW YORK, Richard Marchione, Brenda Crudele,
Jeff A. Pouliotte Ernest Holmberg
GEORGIA, Bill DuVall, Douglas D. Franks, NORTH CAROLINA, Brian Hanks, Scott Hidden,
Steve Gaston Girchuru Muchane
HAWAII, James Fu, Kevin Murata, John Williams NORTH DAKOTA, Jon D. Ketterling,
IDAHO, Matthew M. Farrar Jason R. Thorenson
ILLINOIS, Carl Puzey, Tim A. Armbrecht, OHIO, Timothy J. Keller, Alexander B.C. Dettloff,
Jayme Schiff Jeffrey E. Syar
INDIANA, Anne M. Rearick, Andrew Fitzgerald, OKLAHOMA, Steven J. Jacobi, Walter L. Peters,
Stephanie Wagner Tim Tegeler
IOWA, James S. Nelson, Ahmad Abu-Hawash, OREGON, Albert Nako, Tanarat Potisuk
Michael Nop PENNSYLVANIA, Thomas P. Macioce,
KANSAS, Karen Peterson Richard Runyen, Louis J. Ruzzi
KENTUCKY, Bart Asher, Andy Barber, PUERTO RICO, (Vacant)
Marvin Wolfe RHODE ISLAND, Georgette K. Chahine,
LOUISIANA, Zhengzheng “Jenny” Fu, Artur Keith Gaulin
D’Andrea, Chris Guidry SOUTH CAROLINA, Terry B. Koon, Hongfen Li,
MAINE, Wayne L. Frankhauser, Jeff S. Folsom, Jeff Sizemore
Michael H. Wight SOUTH DAKOTA, Steve Johnson, Dave Madden,
MARYLAND, Maurizio Agostino, Jesse Creel, Todd S. Thompson
Jeffrey Robert TENNESSEE, Ted A. Kniazewycz

iii

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
TEXAS, Graham Bettis, Bernie Carrasco,
Jamie F. Farris
UTAH, Carmen E.L. Swanwick,
Cheryl Hersh Simmons, Rebecca Nix
VERMONT, Kristin M. Higgins, Jim Lacroix
VIRGINIA, Kendal R. Walus, Prasad L. Nallapaneni,
Andrew M. Zickler
WASHINGTON STATE, Mark A. Gaines,
Tony M. Allen, Bijan Khaleghi
WEST VIRGINIA, Tracy W. Brown, Ahmed Mongi
WISCONSIN, Scot Becker, Bill C. Dreher,
William L. Oliva
WYOMING, Michael E. Menghini, Jeff R. Booher,
Paul Cortez

MARYLAND TRANSPORTATION
AUTHORITY, James Harkness
MULTNOMAH COUNTY
TRANSPORTATION DIVISION,
Jon Henrichsen
NEW YORK STATE BRIDGE AUTHORITY,
William Moreau
TRANSPORTATION RESEARCH BOARD,
Waseem Dekelbab
U.S. ARMY CORPS OF ENGINEERS—
Phillip W. Sauser
U.S. COAST GUARD, Kamal Elnahal
U.S. DEPARTMENT OF AGRICULTURE—
FOREST SERVICE, John R. Kattell

iv

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
AASHTO/NSBA STEEL BRIDGE COLLABORATION
CONTRIBUTOR LIST

Bruce Abernathy, Maryland State Highway Administration

Frank Adragna, TRC Companies, Inc.
Camille Bernier, Canam–Bridges
Art Bustos, AISC
Terry Cummings, TRC Companies, Inc.
Denis Dubois, HRV Conformance Verification Associates, Inc.
Steve Duke, Florida Department of Transportation
Philip Dzikowski, Wood Environment and Infrastructure Solutions
Jon Edwards, DOT Quality Services
Sammy Elsayed, Skanska USA Civil
Martin Francis, ArcelorMittal
Karl Frank, NSBA–Consultant
Christopher Garrell, NSBA
John Gast, Consultant
Heather Gilmer, HRV Conformance Verification Associates, Inc.
Rich Giusti Jr., Haydon Bolts Inc.
Caleb Gunter, South Carolina Department of Transportation
Chad Hawkins, South Carolina Department of Transportation
Jamie Hilton, KTA–Tator, Inc.
Robert Horwhat, TRC Companies, Inc.
Adil Khan, Wood Environment and Infrastructure Solutions
Pat Loftus, Industrial Steel Construction, Inc.
Timothy McCullough, Florida Department of Transportation
Ronnie Medlock, High Steel Structures LLC
Teresa Michalk, Texas Department of Transportation
Burl Mitchell, Structural Steel Products Corp.
Raymond Monson, Pennoni Associates Inc.
Justin Ocel, FHWA
Anna Petroski, DOT Quality Services
Brian Raff, AISC
Ronald Runk, High Steel Structures LLC
Phil Sauser, U.S. Army Corps of Engineers
Robert Stachel, HRV Conformance Verification Associates, Inc.
Jonathan Stratton, Structural Steel Products Corp.
Brad Streeter, D.S. Brown
Maury Tayarani, Pennoni Associates Inc.
Dayi Wang, FHWA
Gary Wisch, DeLong's, Inc.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 This page intentionally left blank.

vi

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 TABLE OF CONTENTS
Section 1—Introduction ..................................................................................................................................1
Section 2—Definitions and Acronyms ...........................................................................................................3
Section 3—Plant Certifications .......................................................................................................................5
Section 4—Reference Documents and Personnel Qualifications ....................................................................7
4.1—Reference Documents .........................................................................................................................7
4.2—Personnel Qualifications .....................................................................................................................7
4.2.1—Fabricator.....................................................................................................................................7
4.2.2—Owner ..........................................................................................................................................7
Section 5—Management Responsibilities .......................................................................................................9
5.1—Team Effort ........................................................................................................................................9
5.2—Owner .................................................................................................................................................9
5.3—Fabricator ...........................................................................................................................................9
Section 6—Fabricator Contract Documentation Review and Communication ............................................. 11
6.1—General ............................................................................................................................................. 11
6.2—Contract Review ............................................................................................................................... 11
6.3—Contract Review Record................................................................................................................... 11
6.4—Project Communication .................................................................................................................... 12
Section 7—Shop Detailing ............................................................................................................................ 13
Section 8—Fabricator Document and Data Control ...................................................................................... 15
8.1—Review and Approval ....................................................................................................................... 15
8.2—Revision Control............................................................................................................................... 15
8.3—Access............................................................................................................................................... 16
8.4—Obsolescence .................................................................................................................................... 16
8.5—Transmittal ....................................................................................................................................... 16
Section 9—Fabricator Control of Quality Records ....................................................................................... 17
9.1—Retention of Quality Records ........................................................................................................... 18
9.2—Availability of Quality Records........................................................................................................ 18
Section 10—Fabricator Purchasing ............................................................................................................... 19
10.1—Fabrication, Coating, Detailing and the NDE Subcontractor ......................................................... 19
10.2—Selection and Evaluation of Subcontractors and Suppliers ............................................................ 19
10.3—Purchase Orders and Subcontracts ................................................................................................. 19
10.4—Acceptance of Purchased Product, Materials, and Services ........................................................... 19
Section 11—Material Identification by Fabricator ........................................................................................ 21
Section 12—Fabrication Process Control...................................................................................................... 23
Section 13—Inspection and Testing .............................................................................................................. 25
13.1—Inspection ....................................................................................................................................... 25
13.2—Nondestructive Evaluation ............................................................................................................. 25

vii

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
Section 14—Fabricator’s Calibration and Verification of Inspection Measuring and Testing Equipment ... 27
14.1—Inspection and Testing Equipment ................................................................................................. 27
Section 15—Control of Nonconformance ..................................................................................................... 29
Section 16—Corrective Action ..................................................................................................................... 31
Section 17—Handling, Storage, and Delivery of Product and Materials ...................................................... 33
Section 18—Fabricator Training ................................................................................................................... 35
18.1—General ........................................................................................................................................... 35
18.1.1—Specifications, Codes, and Standards ...................................................................................... 35
18.1.2—Material Handling .................................................................................................................... 35
18.1.3—Material Preparation ................................................................................................................ 35
18.1.4—Fitting, Fastening, and Shop Assembly ................................................................................... 35
18.1.5—Welding ................................................................................................................................... 36
18.1.6—Nondestructive Evaluation ...................................................................................................... 36
18.1.7—Surface Preparation and Shop Coating .................................................................................... 36
18.1.8—Reporting and Documentation ................................................................................................. 36
Section 19—Audits ....................................................................................................................................... 37
19.1—Fabricator ....................................................................................................................................... 37
19.2—Owner ............................................................................................................................................. 37

viii
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
 SECTION 1—INTRODUCTION
The purpose of this document is to provide guidance to Owner Agencies, Fabricators, and Contractors for
maintaining and ensuring quality inspection and verification standards for fabrication of steel bridges. This document,
intended to replace S4.1, provides information that is complementary to applicable welding codes and AISC standards
and will be useful for developing a Fabricator Quality Control (QC) System and corresponding Quality System
Manual. Duties and responsibilities of the Fabricators and Owner Agencies are addressed. The predecessor to this
document, AASHTO–NSBA Steel Bridge Collaboration S4.1, Steel Bridge Fabrication QC/QA Guide Specification,
described recommended detailed activities for Fabricators and Owners based largely on the AISC certification
program, AASHTO/AWS D1.5M/D1.5 Bridge Welding Code requirements and a consensus of professionals in the
industry. This document has been written with the assumption that applicable welding codes and AISC certification
requirements are met. Where AISC certification is not required, Owners and Fabricators should be familiar with
applicable AISC requirements and incorporate similar provisions as appropriate. Topics are organized to have similar
document structure to the AISC Certification Program for Steel Bridge Fabricators, in order to bring consistency
among varying stakeholders and avoid conflicting information. When Sections are referenced herein, they are sections
of this document, not the AISC standards. Numbered section references to AASHTO/AWS D1.5 are from the 2015
edition.

1
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
2 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 2—DEFINITIONS AND ACRONYMS
Terms used in this document are in accordance with the AASHTO–NSBA Steel Bridge Collaboration
standards. Terms that are specifically significant to this document are defined as follows:

AASHTO—American Association of State Highway and Transportation Officials

Acceptance—All factors used by the Agency (e.g., sampling, testing, and inspection) to evaluate
the degree of compliance with Contract requirements and to determine the corresponding value
for a given product.
Agency—Any organization, constituted under federal, state, or municipal laws that is
responsible for administering contracts for highway or transportation construction (see Owner).
AISC—American Institute of Steel Construction
ASTM—ASTM International
AWS—American Welding Society
BCI—Bridge Coating Inspector
CAR—Corrective Action Report
CIP—Coating Inspection Program
CMTR—Certified Mill Test Report
CWI—AWS Certified Welding Inspector
Contractor—The Contractor is responsible for proper completion of all tasks required by the
Contract. Subcontractors, including Fabricators, Erectors, and field coaters may be used by the
Contractor, but the Contractor retains responsibility for all material, operations, and the final
product. The Contractor should permit direct subcontractor interaction with the Owner to expedite
the project, but subcontractors must obtain the Contractor’s approval before implementing any
proposed modifications to Contract requirements accepted by the Owner.
Fabricator—In this document, refers to the facility performing such shop activities as cutting,
welding, drilling, punching, bolting, cleaning, and coating of structural steel. The term
“Fabricator” also includes project-related agents of the Fabricator, such as those who design
proprietary items or prepare shop detail drawings. In some cases the Fabricator may also be the
Contractor, but usually the Fabricator is a subcontractor.
FHWA—Federal Highway Administration
Inspection—The examination by the Owner, Contractor, or Fabricator, of processes and products
to verify conformance with Contract requirements.
Inspector—When used by itself, the term “Inspector” is to mean either the Owner’s Inspector or
the Fabricator’s QC Inspector.
NACE—NACE International
NCR—Nonconformance Report
NDE—Nondestructive Evaluation
NSBA—National Steel Bridge Alliance

3
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
4 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

Owner—In this document, “Owner” refers to the Owner Agency paying the Contractor to fulfill
the terms of the Contract. The Owner also encompasses those preparing the Contract documents,
including the structure’s adequate design, and individuals authorized to represent the Agency
during construction, commonly called the “Engineer” and the “Inspector”. The Engineer and
Inspector may be employees of the Agency or professional firms contracted by the Agency for the
work (see Agency, earlier).
Owner Inspection—Inspection and testing are activities carried out by the Owner to confirm that
fabricated materials meet the contract documents and the Fabricator is complying with their QSM.
Owner inspection could also include acceptance inspection by representatives of a public-private
partnership or Design Build entity.
Owner Inspector—The Owner’s representative in matters of Owner inspection.
QC—Quality Control—The system used by the Contractor/Fabricator to monitor, assess, and
adjust their production or placement processes to ensure that the final product will meet the
specified level of quality. QC includes sampling, testing, inspection, evaluation, and corrective
action (when required) to maintain continuous control of the fabrication or placement process.
QCI—Quality Control Inspector—A qualified individual who performs formal QC inspection and
testing as defined by the Fabricator’s Quality System Manual.
QSM—Quality System Manual—A written document that describes the overall QC operating
procedures for the Fabricator. A Fabricator’s QSM documents the internal policies for achieving
quality and the assignment of responsibility and accountability for QC within the Fabricator’s
organization. It may also describe the minimum QC requirements expected of parties
subcontracted to the Fabricator who supply constituent materials or who are involved in handling
or processing of the Fabricator’s products. Related terms include Quality Plan, Quality Control
Plan, Quality Assurance Manual, and Quality Management.
RFI—Request for Information
SSPC—Society for Protective Coatings
Spot Inspection—The examination of selected portions of the Fabricator’s processes or products
to verify conformance with Contract requirements.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 3—PLANT CERTIFICATIONS
For the purpose of this guide, plant certification means certification through AISC in the appropriate category
for the type of structure being fabricated. This guide also recognizes that the Owner may choose other certification
processes as they may deem necessary.
AISC categories for bridge Fabricator are Advanced, Intermediate, and Simple Bridge. There also may be a
need for Advanced and Intermediate Bridge certified Fabricators to have the Fracture-Critical endorsement. Refer to
Article 2.1 of AASHTO–NSBA S2.1, Steel Bridge Fabrication Guide Specification for descriptions of bridge
fabrication categories. A Fabricator that supplies bridge components or highway components should be certified to
the AISC Metals Component Certification Program.
When a Fabricator applies coatings, the Owner may require certification as defined in Article 3.1 of
AASHTO–NSBA S8.1, Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel
Bridges.
It is the responsibility of the Contractor to select a Fabricator that has the correct certifications and
endorsements for the work proposed in the Contract documents. It is the responsibility of the Owner to verify that the
Fabricator has the correct certifications and endorsements for the work proposed in the Contract documents.

5
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
6 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 4—REFERENCE DOCUMENTS AND PERSONNEL
QUALIFICATIONS

4.1—REFERENCE DOCUMENTS

Contractors, Fabricators, and Owners should have the reference documents and standards necessary to make
personnel aware of work requirements. These documents should be consistent with the requirements as defined in
the Contract documents and be readily available to those who need them.

4.2—PERSONNEL QUALIFICATIONS

4.2.1—Fabricator

Personnel should be well-qualified and experienced for the duties they are expected to perform and products
they will be fabricating. For example, welding personnel that are qualified and experienced with pipe work may not
be suitable to weld bridge work without some additional training and certification. This is applicable for all
personnel within a facility. Minimum experience is recommended for all personnel. All personnel must be properly
evaluated to ensure familiarity with code and common requirements.
Bridge fabrication generally requires the presence of a CWI when welding operations occur; however, a new
CWI employee that comes from a different industry may not be appropriate to perform all phases of inspection.
The following table is a recommendation for minimum amount of bridge fabrication inspection experience.
Inspectors who have less experience than recommended should work under the oversight of an Inspector having the
recommended experience.

Project Type Inspection Experience

Simple Bridge 1 year
Intermediate Bridge 2 years
Advanced Bridge 3 years
3 years, where at least 1 of the 3 years
Fracture-critical members
shall include fracture-critical inspection.

Coatings Inspectors should have at least one year of experience in surface preparation and coating inspection
and have documented training in materials preparation, coatings application, and inspection. Inspectors who have less
experience should work under the oversight of an Inspector having those qualifications.
The following is a recommendation for the minimum qualifications for lead coatings Inspectors:

 NACE CIP, Level 2 or 3, or

 SSPC BCI, Level II, or
 5 years of applicable complex coatings inspection experience in the types of coating systems regularly applied
by the Fabricator, or as specified by Contract documents, or
 as defined in the AISC Sophisticated Paint Endorsement when applicable.

Coatings Inspectors must be trained in accordance with applicable AASHTO–NSBA Steel Bridge
Collaboration documents.

4.2.2—Owner

The Owner should visit fabrication facilities to obtain firsthand knowledge of the facilities’ qualifications to
ensure that minimum standards are maintained. When welding inspection is required, it is recommended that the
Owner or their representatives be qualified in accordance with Clause 6 of AASHTO/AWS D1.5. When coating
inspection is required, the Owner or their representative should be qualified as a lead Inspector in accordance with
Article 4.2.1.

7
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
8 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 5—MANAGEMENT RESPONSIBILITIES
5.1—TEAM EFFORT

Fabricators and Owners should approach quality control and Owner Acceptance activities as a team effort to
facilitate acceptable and timely fabrication.
All parties should cooperate and maintain open lines of communication so that problems can be addressed
and resolved in a timely manner.
Owner Acceptance inspection does not relieve the Fabricator from the responsibility to perform required QC
testing and inspection.

5.2—OWNER

The Owner should institute specifications requiring Contractors and Fabricators to develop, implement, and
maintain Quality Control systems that will result in the fabrication and construction of acceptable products.
The Owner should review a copy of the Fabricator’s QSM and maintain on file for future reference. All
efforts should be taken to keep the QSM confidential.
Owner Inspection is the prerogative of the Owner. The Owner may monitor the Fabricator’s processes and
verify conformity of the work with the Contract requirements.
If the Owner opts to inspect, then the Inspector will observe fabrication and perform testing of materials and
fabricated products as necessary to confirm the effectiveness of the Fabricator’s Quality System Manual (QSM).
The Inspector has the right to observe all phases of the work, from initial receipt and preparation of raw
materials through welding, NDE, assembly, cleaning, coating, and shipping.
The frequency and nature of inspection will vary with the type of structure, the experience and abilities of
the Fabricator, and other factors that affect the quality of the work.
The Inspector will verify that production quality and fabrication processes satisfy Contract requirements,
including the QSM, and accept materials that satisfy the Contract requirements.
The Inspector will not waive items that are contractual obligations of the Fabricator and will not accept
material that does not conform to the Contract requirements. However, based on experience and knowledge of the
specific situation, the Owner may accept materials and products that are not in conformance with the Contract and
may allow material substitutions. Permitted deviations from the Contract are to be documented by the Fabricator, and
the Inspector notified that the Owner has accepted the deviation.
The Inspector will not direct the Fabricator’s work. However, the Inspector should advise the Fabricator,
through designated channels, to discontinue any operation that would result in noncompliance with the Contract
requirements.
The Inspector will direct all official communications through designated channels and will not convey
judgments about shop quality or employee competence to production personnel.
The Inspector will not divulge a Fabricator’s proprietary information to another Fabricator and will not
distribute any proprietary information received from the Fabricator except for the contractual needs of the Owner.

5.3—FABRICATOR

The Fabricator’s management should define and adopt a commitment to quality. Management should
develop, implement, and maintain a QSM that includes a quality policy that is understood, implemented, and
maintained at all levels of the Fabricator’s organization. Management at all levels should commit to supporting the
QSM and should provide the organization and resources necessary to implement and maintain the QSM.
A QSM should be developed to ensure the effective planning, operation, and control of the Fabricator’s
processes. The QSM should reflect a commitment to quality and describe the quality control activities that will be
employed on each project. The QSM should be implemented to ensure that the finished product meets or exceeds
Contract requirements.
The Fabricator should provide the Owner with a copy of the QSM.
The Fabricator should provide qualified QCIs who report to personnel responsible for quality control as
defined by the QSM. QCIs should not report to production management.

9
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
10 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

The Fabricator should notify the Owner prior to cutting materials ordered for the Owner’s project. Present
all documents for the Owner Inspector. They should be organized in a manner that will allow a thorough review of
the documentation.
The Fabricator should provide the Owner Inspector full access to shop facilities where the work is being
stored, fabricated, or assembled. The Fabricator should make available all materials necessary for inspection of
components and assemblies.
The Fabricator should keep the Owner Inspector informed about the production scheduling, QC inspection
activities, and pending nondestructive examinations.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
SECTION 6—FABRICATOR CONTRACT DOCUMENTATION REVIEW
AND COMMUNICATION
6.1—GENERAL

The Fabricator should have a clear understanding of the Owner’s project as it is defined through
specifications, design drawings, and general Contract documents, and convey the Owner’s project requirements to the
appropriate personnel in order to deliver the project as specified.

6.2—CONTRACT REVIEW

The Fabricator should address the following recommendations and assure Contract review and project
specifications are readily available to appropriate personnel.
Thoroughly review all applicable original Contract documents, revised Contract documents, and changes
received through clarification at the time a project is accepted. Perform the review process again when Contract
requirements are revised by clarifications from an RFI, a response to an RFI, or other official communication from
the Contractor. Require this review only for the areas affected by the changes.
Contract and project specification review is conducted for each project. The review should identify and
address critical project requirements that have impact on project quality and that satisfy the Contract requirements
and schedule.
Perform the initial review no later than the Fabricator’s acceptance of responsibility for performing the work.
Begin the review during the project estimation or bid process.
In the review, identify, determine, plan, and record the specific project requirements. Define distribution of
the record to the responsible individuals in the organization and identify new documented quality procedures that must
be created for the work. Consider any issue that affects the Fabricator’s capability to perform the work, including
manufacturing, fabrication, and coating requirements.
Conduct and organize the review and the methods to communicate the review results to the next steps in the
process. Ensure that the managers and staff with responsibility for execution fully understand the applicable Contract
requirements. The distribution process and methods should verify receipt, monitor progress, and establish
completion schedules.

6.3—CONTRACT REVIEW RECORD

Show in a Contract review record how these items were reviewed:

• Management of Project—Record decisions during communications with the Owner, Contractor, and
Fabricator during the project, and at completion. Record the Contract revisions that define the project and the
revisions of the codes and standards that affect the scope of work. Record the decisions on coordination and
follow up with the Owner Inspector. Show evidence of the review of the fabrication/manufacturing schedule.

• Requests for Information (RFIs)—Record items during the review and subsequent pre-fabrication
meetings that identify RFIs necessary to aid the production of shop and erection drawings.

• Purchasing—Record the review of the required materials, sourcing guidelines, FHWA Buy America, and
vendor approval, and identify difficult lead times. Identify the need for subcontracting and notify the Owner
where applicable. Consider including how material is protected, packaged, or handled for delivery to the
shop; certificates of conformance; material test reports; or other details.

• Detailing—Review and note the sequencing and delivery requirements. Note the planning necessary to
obtain required field measurements and the timing for assembly requirements. Show review of the assembly
requirements and required tolerances. Clearly identify the submittals required and the timing necessary to
satisfy the Owner’s requirements.

11
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
12 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

• Material Identification and Traceability—Record any deviations from shop standard identification, as well
as requirements for the involvement of an Owner’s representative (present for the material traceability and
review of Certified Mill Test Reports (CMTR), etc.). Record project-specific requirements related to material
identification and traceability.

• Fabrication/Manufacturing Process—Review capability and load on equipment and work stations.

Consider the relevance and impact of various manufacturing processes on the project.

• Inspection—Note any NDE requirements, including frequency or documentation, and unique inspection
requirements for coatings. Note any deviations from standard practices, procedures, and methods. Note any
independent testing or witnessing requirements.

Show the review and consideration of shift coverage for the Fabricator’s inspection personnel. Appraise the
personnel experience required and any requirements for documenting the technical experience and
certification of personnel.

• Training and Qualification—Identify qualifications needed beyond current levels to meet Contract
requirements.

6.4—PROJECT COMMUNICATION

The Fabricator should determine the means of communication as part of the Contract review and before work
begins. Record contact information and any specific communication requirements mandated by Contract documents.
Identify appropriate personnel for communication with the Owner, Contractor, and the Owner’s Inspector.
Pre-fabrication meetings are one form of communication that facilitates effective quality control and Owner
acceptance. Hold pre-fabrication meetings for projects when required by the Contract documents or when any
stakeholder calls for a pre-fabrication meeting. The Fabricator may also conduct internal pre-fabrication meetings
without the attendance of the Owner, or other stakeholders.
Pre-fabrication meetings should be conducted as described in AASHTO–NSBA Steel Bridge Collaboration
S2.1, Steel Bridge Fabrication Guide Specification.
If a project pre-fabrication meeting is held, include the pre-fabrication meeting record, including a description
of decisions, as part of the Contract Review Record. Conduct the meeting at a time agreeable to all parties.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 7—SHOP DETAILING
In addition to Section 7, Detailing, of the AISC Certification Program for Steel Bridge Fabricators, see the
following publications for additional guidance:

• G1.1, Shop Detail Drawing Review/Approval Guidelines

• G1.3, Shop Detail Drawing Presentation Guidelines

13
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
14 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 8—FABRICATOR DOCUMENT AND DATA CONTROL
Development of written procedures is crucial for document and data control, and to the overall performance
of the Fabricator’s QC system. Addressing such items as the QSM and other Contract documents provides direction
for the coordination of the Fabricator QC and Owner Inspector interaction. This written procedure should clearly
define what and how documents are controlled.

The written procedure should be the master document with headings which address:

• The QSM.
• Contract documents (dissemination and revision control).
• Shop and erection framing drawings.
• Detailing standards.
• All documented procedures related to the fabrication of a project.

8.1—REVIEW AND APPROVAL

Prior to issue and release, documents are reviewed for adequacy, correctness, and conformity to quality
policies. A document is considered to be formally issued when it is authorized and approved for release by the issuing
authority. Documents that require more than one approval signature should clearly indicate how many and which
signatures are required for approval and issue.
If electronic copies are used, only accepted and authorized electronic documents should be posted in the
controlled files on a network.
Some document forms that are used for data gathering (e.g., traveler, inspection forms) may not directly
identify the approving and releasing authority. These document forms should be controlled. A record of the approval
and release is maintained by a system administrator or another authorized person who posts the document on the
network or in a master file.
A master file of all types of documents should be maintained. The master file can be made up of lists in the
form of a log, catalog cards, computer database, etc. The file should identify each issued document by its title,
code/number, date of issue, the last revision level, and distribution (if not otherwise provided).
Data records that are specified in the QSM, such as completed travelers and NDE reports, are generated at
the shop floor level. The completed data form should be made readily available to the Owner Inspector for review.
Signatures/initials by authorized personnel indicate accuracy of the data.
Unnecessarily long, complicated, and bureaucratic procedures should be avoided. Documents must be readily
understandable by those who are expected to use them.
The scope of the Fabricator’s review of Contract documents and subsequent changes would typically include
information being complete and accurate, with identification of any revisions, the most current revision level, and
verification that the document has been accepted by the Owner’s issuing authority. A path of action should be defined
by the Fabricator if errors are detected or completeness is lacking which could cause confusion.
When shop drawings have been prepared, accepted, and released for fabrication, it is not suitable to introduce
Owner’s documents, especially drawings, on the production floor in their original form. Any consolidated and re-
interpreted documents are reviewed and accepted prior to release. These should be controlled as if they were original
Owner’s documents. Original Owner’s documents should be preserved and be readily available for reference.
Only accepted documents may be used in production or inspection operations. The acceptance is indicated
by a note stating that the document is accepted for production use and a signature of authorized personnel as defined
by the QSM.

8.2—REVISION CONTROL

It is common that someone other than the originator of a document would request the issue of a new document
or revision of an existing one. A draft of the proposed document or revision should be submitted to the responsible
manager to review, approve, and re-issue. Final revisions should always rest with the same function and authority
level that authorized the original document, unless specifically designated otherwise. Revisions can be made by
handwritten corrections but must be signed and dated. Issuing of revised documents should follow the same rules that

15
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
16 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

apply to initial issues. Revisions of documents are distributed to the same personnel and locations as the original
issues. Access should be limited to files with superseded revisions of controlled documents.
It is important to clearly define, in the revision procedure, when a document is considered to be formally
issued. Typically, this is when it is authorized with the required approval signatures.
All active quality procedures and documents must show the latest revision. Ideally, a master index should
reflect all active procedures and documents along with their revision level. Contract documents, including design
drawings and Owner change orders, must show the latest revision level. Any shop and erection framing drawings must
show the latest revision level of each document.
It may be customary to print paper copies of electronic documents for reference or use. It is difficult to control
printed copies. How the Fabricator chooses to deal with uncontrolled printed copies should be addressed in the QSM.

8.3—ACCESS

Electronic controlled documents can be posted on the network and made available for viewing and printing
from computers and terminals. Uncontrolled copies of documents should not be used by personnel or outside parties
who manage or verify work.

8.4—OBSOLESCENCE

Masters and copies of obsolete documents are sometimes retained for preservation of knowledge or legal
reasons.
Archives of historical documents such as old drawings, specifications, reports, standards, samples, and so
forth can be considered inactive, and neither maintained nor controlled unless as specified in Article 9.1.

8.5—TRANSMITTAL

A transmittal system to indicate the status and distribution of controlled documents should be defined in the
QSM.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 9—FABRICATOR CONTROL OF QUALITY RECORDS
The Fabricator should develop a documented procedure that identifies all controllable records, their location
(plus backup location if electronic), who maintains the records, retention period, and method of disposal. The matrix
table shown below is one way to record this information. The table provides an example of some typical quality
records, which is not necessarily all-inclusive.

Retrieval
Collection and
Retention
(list of Storage backup of Disposal
Identification Maintenance (time
items in (location) electronic (method)
duration)
category) data
(location)
Contract review
Contract clarifications
Design change records,
including Contract
construction changes and
addenda
RFIs with Owner
responses
Drawing logs
Mill and consumable
purchase orders
Manufacturers’ Test
Reports
Certificates of Compliance
Inspection records
NDE reports
Radiographs, if retained by
the Fabricator rather than
the Owner
Records or summaries of
nonconformance reports
Corrective action reports
Training records
Subcontractor and supplier
qualifications and
evaluations
Internal and external audit
records

Records are identifiable to the product, person, or event to which they pertain. Records are dated and identify
the person who established the record.
For projects that are small or simple, Fabricators sometimes prefer to keep records on shop drawings rather
than creating additional forms for documentation. This practice is acceptable as long as all pertinent information can
reasonably be maintained and conveyed.

17
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
18 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

9.1—RETENTION OF QUALITY RECORDS

Retention times of the various quality records, specified in the QSM, should be documented in a procedure
for control of quality records. The retention periods should be at least long enough to permit evaluation of the records
during the course of project construction unless a longer period is required by Contract or government regulation, and
not less than the duration of any warranty provided by the Fabricator.

9.2—AVAILABILITY OF QUALITY RECORDS

Specific quality records required by Contract or regulation should be made available for review and
evaluation by either Fabricator QC staff or Owner Acceptance staff during the length of time specified in the Quality
Plan or Contract documents.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 10—FABRICATOR PURCHASING
Purchasing and subcontracting are essential tasks for all Fabricators. It is essential that the Purchasing
function be formalized to support the quality initiatives of the Fabricator and provide a platform to ensure the
Subcontractors and material suppliers engaged are held, at a minimum, to a similar level of accountability.

10.1—FABRICATION, COATING, DETAILING, AND THE NDE SUBCONTRACTOR

A robust and detailed purchasing program can mitigate the risks of subcontracting and promote effective
partnering. If the Fabricator chooses to subcontract fundamental tasks that are considered intrinsic to their own
operation, it is imperative that the same level of certification is to be expected of their vendor partner. Ongoing
assessment and evaluation are key elements to effective active management of the relationship with the Subcontractor.
It is recommended that the Fabricator forge a relationship with its Subcontractors to ensure that the relevant
portions of the Fabricator’s QSM are fully embraced by the Subcontractor.

10.2—SELECTION AND EVALUATION OF SUBCONTRACTORS AND SUPPLIERS

It is in the best interests of all parties to take proper steps to ensure subcontractors and suppliers acknowledge
and take no exceptions to the quality initiatives conveyed by the Fabricator. The QSM of the Fabricator as it relates
to subcontractor requirements should be accepted in its entirety or with mutually-accepted modifications. If
modifications are made, they must be documented. Suppliers that provide products that affect the quality of the
Fabricator’s product should have their own quality policies that will meet the objectives of the Fabricator’s QSM.
Evaluation and selection, as well as ongoing review, are the responsibility of the Fabricator to ensure compliance to
the QSM. Continued compliance remains an active objective of both the vendor and the Fabricator. Evaluations could
take the form of, but not be limited to, independent audits, self-audits, and reviews of the subcontractors’ and suppliers’
quality records.

10.3—PURCHASE ORDERS AND SUBCONTRACTS

Purchase orders and subcontracts are tools for conveying the requirements of the contractual relationship
between the Fabricator and the material suppliers and service providers. They are not limited to a singular format, but
can reflect variable formats as required to properly define the terms and conditions of the purchase and supply
agreement. This document should be detailed and reflect all pertinent information as defined by industry standards to
convey the project requirements the Fabricator is bound to, as well as the scope of supply agreed to by the Fabricator
and the vendor.

10.4—ACCEPTANCE OF PURCHASED PRODUCT, MATERIALS, AND SERVICES

The Fabricator’s QSM must include provisions for acceptance of the material or finished product beyond that
of receipt. These provisions should be defined as it relates to the products or services provided and should be conveyed
as part of the purchasing process. All documents deemed essential by the Fabricator should be maintained for future
reference as defined in the Fabricator’s documented procedure covered in Section 9 for control of quality records.

19
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
20 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 11—MATERIAL IDENTIFICATION BY FABRICATOR
The Fabricator’s material identification procedure should describe how materials must be marked for
identification from the point of receipt of material, through fabrication, and final shipment of the product to assure
incorporation of the correct material into the final product.
Receipt inspection by the Fabricator should verify the material received is in conformance with the purchase
order and project specifications. During the fabrication process, the Fabricator should identify and track material for
all members requiring traceability. This includes the correlation of mill-identified materials with shop drawing piece
marks. The Fabricator should maintain a documented procedure or a marking method that will identify material type
and grade which provides traceability. Suggested ways to provide traceability include piece, assembly, or group
numbering. The Fabricator should mark individual pieces during assembly and issue cutting instructions using a
system that will maintain the identity of the original piece. Transfer of the material heat numbers by use of permanent
paint markings or by low-stress stencils should be per the Fabricator’s approved identification system. The process of
transferring the heat numbers should be performed as soon as the material enters the shop and carry all markings on
each piece throughout final fabrication. All numbers should be transferred before cutting primary structural steel
bridge members into smaller sections. A loss of traceability of material for primary bridge members may render the
section unacceptable for use.
A final report should detail the identification of fabricated material along with the approved CMTR. Logs
recording required material identification for the component parts of finished pieces should be included in the final
documentation package to the Owner.

21
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
22 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 12—FABRICATION PROCESS CONTROL
The Fabricator should develop documented procedures for process control necessary to consistently produce
an acceptable product. The procedure should show inspection points. If inspection is at less than 100 percent
frequency, and the frequency is not defined in the Contract documents, the procedure should include a sampling plan.
The means and methods, where possible, should follow industry standards, Manufacturer’s
recommendations, product data sheets, and Contract documents. When conflicting situations develop, agreement must
be achieved between the Fabricator and Owner regarding the defining constraints.
Innovative and progressive technologies are essential for mutual benefit and growth of the industry. These
should always be considered by the Fabricator and Owner.

23
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
24 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 13—INSPECTION AND TESTING

13.1—INSPECTION

The Fabricator should define quality control actions to address requirements for inspection as listed in
this section.
Quality control may require formal, documented inspection activities by the QCI. Alternatively, informal
monitoring activities conducted by production personnel may suffice if all of the following conditions are met:

• Production personnel are trained in acceptance criteria

• Production personnel are trained to be responsible for evaluating the work and noting noncompliance items.
All non-compliances should be documented and turned over to QCI for further action.
• QCI monitors production personnel performing inspection.
• QCI performs spot inspection of the work

If applicable, include the inspection or monitoring frequency established by the Fabricator. The extent of
monitoring may be less than 100 percent, provided the following criteria are considered:

• Contract documents, code, and specification requirements

• The defined sampling plan
• The demonstrated consistency or variability of the process
• Recent history of documented nonconformances.

The Fabricator should describe QCI recordkeeping. For inspection, records must be detailed and must be
initialed by QCIs indicating conformance with Contract requirements and agreed-upon corrective actions required for
NCRs.

13.2—NONDESTRUCTIVE EVALUATION

The Fabricator should establish and follow a practice that satisfies Contract requirements and conforms to
the AASHTO/AWS D1.5M/D1.5 Bridge Welding Code or other applicable welding code and applicable ASNT SNT-
TC-1A requirements and should include the following:

• Identification of a certified ASNT Level III in the applicable methods (may be an employee or a consultant)
• Written practices approved by the Level III
• NDE Level II certification of practicing Inspectors in the applicable methods
• NDE Level I certification of apprentice Inspectors, with proper Level II oversight
• Applicable code requirements for procedures.
• Where contracted services are used for NDE, ensure that the NDE agency’s staff also satisfies the applicable
ASNT requirements and that copies of current NDE certifications are on file.
• Provide a copy of the written NDE practices to the Owner upon request.
• Make NDE training and certification records available for the Owner’s review.

The Owner’s Inspector should be notified of all NDE to facilitate witnessing. Copies of all QC test results
and records should be readily available for the Owner’s Inspector upon request.

25
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
26 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 14—FABRICATOR’S CALIBRATION AND VERIFICATION
OF INSPECTION MEASURING AND TESTING EQUIPMENT

14.1—INSPECTION AND TESTING EQUIPMENT

• Check and calibrate testing equipment in accordance with applicable standards, codes, and Contract
requirements.
• Verify the accuracy of the equipment at the frequency designated in the QSM.
• Maintain calibration records and make them readily accessible.
• Where appropriate, identify the personnel and entities responsible for the calibration and record keeping of
various types of equipment.

27
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
28 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 15—CONTROL OF NONCONFORMANCE
The Fabricator’s QSM should include procedures to cover nonconformances. These procedures should be
implemented when any aspect of the Fabricator’s processes, or the results of the processes, do not conform to the
QSM or the Contract requirements. The nonconformance procedures should ensure the following:

• The responsibilities and authorities for the management of nonconformances are identified. This applies to
both product and process nonconformances.
• Nonconforming processes are identified and evaluated, and corrective action is taken as necessary.
• Nonconforming products are identified and, if necessary, separated from conforming product if future tasks
are impacted by the nonconforming condition.
• Nonconformance documentation can be initiated by the Fabricator, the Owner or any stakeholder bound by
the Contract requirements. It is the responsibility of the party documenting the nonconformance to identify
the portion of the Contract requirements that the process or product does not satisfy.
• When the Fabricator proposes accepting a nonconformance “as-is” or with remediation not fully meeting
Contract requirements, the Fabricator, Owner, and the Contractor (if it impacts them), should conduct an
evaluation of the proposed action by the Fabricator to determine its acceptability. Upon acceptance, revised
drawings should be provided to all affected parties. If the proposal is not accepted, the nonconformance
should be corrected to meet Contract requirements, which could include replacement of the product.
• Final acceptance of any remediation effort is typically by the Owner.
• Completed documentation includes product identification, the nature of the nonconforming work, disposition
of nonconformance, and the review and approval status of nonconforming work.
• Where the evaluation indicates that nonconformances could recur or there is doubt about the compliance of
the Fabricator’s operations with its own QSM, the corrective action procedures in Section 16 are followed.

29
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
30 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 16—CORRECTIVE ACTION
The Fabricator should have procedures for corrective action in response to nonconformances. The procedures
should include a method of tracking corrective actions.
Corrective actions should match the significance of the nonconformance. Corrective actions should be
selected that will most likely eliminate or prevent the nonconformance from reoccurring. Corrective actions should
have a timeline for completion.
A corrective action plan should start with an investigation into the root cause of the nonconformance.
Appropriate personnel should be designated to author the corrective action plan and implement a corrective action for
nonconformance. The Fabricator should submit the completed corrective action documentation to the Owner for
review and acceptance, if required. Corrective actions resulting from internal audits need not be submitted to
the Owner.
The Fabricator should implement, monitor for effectiveness, and document the results of the
corrective action.

31
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
32 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 17—HANDLING, STORAGE, AND DELIVERY OF PRODUCT
AND MATERIALS
All product and materials should be handled with proper equipment and rigging, as well as stored and loaded
for shipment using proper dunnage and restraints to ensure compliance with all applicable regulations.
The Fabricator should develop a documented procedure to promote safe and repeatable material handling,
and storage, and delivery techniques. Any items that are unique, or non-standard, should be addressed by customized
product- and/or project-specific handling, storage, and delivery guidelines.
Final shipment of fabricated structural steel will be approved by the Fabricator’s QC personnel designated
within their QSM, and may also include the Owner’s representative. A final report detailing final acceptance of
fabricated material along with signed bills of lading and approved shipping reports should be included in the final
documentation package to the Owner.

33
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
34 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 18—FABRICATOR TRAINING
18.1—GENERAL

AISC requires that personnel responsible for functions that affect quality, including detailers, machine
operators, fitters, welding personnel, coating applicators, and Inspectors shall receive initial and periodic documented
training. Inspectors should be trained in all facets of the fabrication they will be responsible for inspecting, but hands-
on training in the use of fabrication tools and equipment is not necessary.
Training, comprehension, and retention is a shared responsibility among all personnel in the organization,
and accountability for application is essential for the long-term success in terms of building quality into the product.
Personnel providing training should have appropriate training or experience in the subject they are teaching. Evaluate
student comprehension of course material and document successful completion.
Training records are quality records controlled as described in Section 9.
The following outlines general training requirements and topics that the Fabricator should consider in their
training program in addition to employees’ individual relevant prior experience. Topics should include training in the
following areas:

18.1.1—Specifications, Codes, and Standards

Personnel should be trained and familiar with the specifications, codes, and standards commonly applicable
to their role in the fabrication process. Some examples include:

 AASHTO/AWS D1.5M/D1.5 or other applicable welding code

 ASNT SNT-TC-1A or CP-189
 AISC certification programs
 AASHTO–NSBA Steel Bridge Collaboration documents
 Owner standard specifications
 Various SSPC, NACE, and ASTM standards as referenced in the Contract documents

18.1.2—Material Handling

Personnel should know the provisions of ASTM A6/A6M. Personnel should be familiar with the QSM
regarding traceability and procurement documentation of incoming material. Personnel should be given on-the-job
training with the appropriate tools and equipment for material handling.
All personnel should be trained in the proper methods to handle, support, and secure material to mitigate
damage and associated repair.
Proper tie-down and use of softeners should also be part of the training program.

18.1.3—Material Preparation

On-the-job training with the appropriate tools and equipment for material preparation (cutting, drilling,
punching, etc.) should provide the personnel an awareness of proper preparation techniques and appearance of
properly prepared materials. The personnel should also know the appropriate preparation tolerances involved.

18.1.4—Fitting, Fastening, and Shop Assembly

Personnel should be given on-the-job training with the tools used in fitting. This training should include
proper fitting techniques, appearance of properly fitted assemblies, and knowledge of the appropriate tolerances
involved.
The personnel must be capable of reading shop drawings and assembly diagrams, including match-marking
systems for components of bolted field splices. Personnel involved in bolting operations should be trained and
knowledgeable in proper bolting and tensioning methods. Training should include rotational capacity testing and
preinstallation verification testing.

35
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
36 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

18.1.5—Welding

The personnel should have knowledge of welding procedures, welding procedure specification
requirements, types of welding and welding limitations. They should also have knowledge of good welding
workmanship. Visual inspection is the primary weld inspection method, and welding personnel should receive on-
the-job training in this area from a qualified Inspector. The personnel should receive training in the use of weld
inspection tools, such as fillet weld and cam type gages. The personnel must learn what constitutes
satisfactory welds and what constitutes unsatisfactory welds. Personnel should also be trained in the usage of
meters and gauges used to verify the parameters of the welding operations.

18.1.6—Nondestructive Evaluation

Personnel performing required NDE including the following methods should be certified at the
appropriate level:

 visual testing
 liquid penetrant testing
 magnetic particle testing
 ultrasonic testing
 radiographic testing
 phased array ultrasonic testing

18.1.7—Surface Preparation and Shop Coating

Personnel should receive training for surface preparation related to coating requirements, machining, and
faying surfaces for slip-critical connections.
Personnel should receive training in the use of various surface comparators and measuring tools. Training
should also include cleanliness and profile requirements of the various coating systems.
Personnel should receive training and experience in the use of instruments that measure dew point, relative
humidity, surface and ambient temperatures, and their importance to the various coating systems and Manufacturers’
recommendations. Personnel should also be trained in the use of wet and dry film thickness measuring devices.

18.1.8—Reporting and Documentation

Personnel should receive training regarding the importance of accurate and detailed reports issued in a timely
manner.
Final documentation is important to a complete project. Training should include the importance of traceability
of material and material test reports from the mill.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.
 SECTION 19—AUDITS
19.1—FABRICATOR

The Fabricator should perform an internal audit of its QSM annually to evaluate the degree of production
compliance and effectiveness of implementation. Different areas of the QSM may be audited independently and at
different times and frequencies, as long as each area of the QSM receives an audit at least once every 12 months.
A management representative or other qualified individual should conduct the audit. Auditors typically do
not have direct responsibility or involvement for the areas they audit. Exceptions may be made under circumstances
requiring a specific skill or special knowledge of a process.
The auditor should prepare a written audit report detailing the audit, including observed findings and
nonconforming conditions. A written record of each audit should be provided by the auditor and should be kept on
file as defined in the Fabricator’s documented procedure covered in Section 9.
Where findings are identified that require corrective actions, they should be implemented in accordance with
Sections 15 and 16. Follow-up of the corrective actions is necessary in order to verify the effectiveness of the actions.
The follow-up timing should be defined as an element of the corrective action documentation.

19.2—OWNER

Owners may choose to perform audits of Fabricators’ QSMs in response to specific or systemic problems
identified during fabrication, as a general monitoring method, or as part of a process to approve Fabricators to perform
work. The Owner may require either a full audit on all areas of the QSM, or a partial audit on specific areas of concern
or emphasis.
The auditor should prepare a written audit report detailing the audit, including observed findings and
nonconforming conditions. After the Owner evaluates all findings and the status of corrective actions for findings and
nonconforming conditions, a summary should be forwarded to the Fabricator so that corrective actions may be planned
and implemented. The results of those actions should be documented and submitted to the Owner.

37
Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration
All rights reserved.
38 G4.1—STEEL BRIDGE FABRICATION QC/QA GUIDELINES

This page intentionally left blank.

Copyright © 2019 by the AASHTO/NSBA Steel Bridge Collaboration

All rights reserved.