ESBD_443564_1754507700319_02. Specification 7380.pdf

Departmental Materials Specification DMS-7380

Materials and Tests Division 1 – 6 Effective Date: April 2022

Review Date: December 2023

DMS-7380

Steel Non-Bridge Member Fabrication Plant Qualification Effective Date: April 2022

1. DESCRIPTION

This Specification describes the qualification processes for fabrication plants producing steel non-bridge members listed in Article 3., “Steel Non-Bridge Members,” of this Specification for Department projects. The phrase “steel non-bridge members” in this Specification includes aluminum roadway illumination poles and luminaire arms. Each fabrication plant must meet the requirements of this Specification and the requirements of the Department’s Standard Specifications for Construction and Maintenance of Highways, Streets, and Bridges.

2. MATERIAL PRODUCER LIST

For the steel non-bridge members listed under Article 3., “Steel Non-Bridge Members,” the Materials and Tests Division (MTD) maintains the Material Producer List (MPL) of fabrication plants in accordance with the requirements of this Specification. Only steel non-bridge members, as listed in Article 3., “Steel Non-Bridge Members,” produced by fabrication plants listed on the applicable MPL can be used on Department projects.

3. STEEL NON-BRIDGE MEMBERS

Steel non-bridge members include the following:

Item 610, “Roadway Illumination Assemblies”

Item 613, “High Mast Illumination Poles”

Item 614, “High Mast Illumination Assemblies”

Item 650, “Overhead Sign Support”

Item 654, “Sign Walkways”

Item 686, “Traffic Signal Pole Assemblies (Steel)”

Special Specification 6064, “Intelligent Transportation System (ITS) Pole with Cabinet.”

4. QUALIFICATION PROCEDURE

4.1. Qualification Request. Submit a request for plant approval under DMS-7380 to DMS_Prequal@txdot.gov.

Requests must include the following in PDF format:

company and fabrication plant name;

physical and mailing addresses;

contact person (management representative appointed by executive management per the American Institute of Steel Construction (AISC)), title, phone number, and email address;

Fabricator Safety Point of Contact (SPOC). Designate a safety point of contact. Fabricator must adhere to applicable safety regulations and own safety program;

organizational work chart;

list of steel non-bridge members to be evaluated for qualification purposes;

mailto:DMS_Prequal@txdot.gov

Materials and Tests Division 2 – 6 Effective Date: April 2022 copy of AISC certification Certified Metal Component Manufacturers including a copy of the most recent complete audit report, exit meeting report, and written response to AISC of corrective actions for all specific discrepancies;

list of on-site Quality Control (QC) personnel and a detailed description of their QC-related experience;

copy of current AWS Certified Welding Inspectors (CWI) certifications for on-site QC welding inspection personnel;

copy of welding procedure specifications (WPS) and pertinent Procedure Qualification Records (PQR), if applicable, in accordance with the AWS D1.1, “Structural Welding Code – Steel.” Use WPS or PQR sample forms located in the current applicable AWS code or approved equal. Identify each joint or joint type;

copy of completed weld maps, provided by the Department, listing the welding procedure numbers proposed for use for each joint indicated;

copy of written plant-specific QC and production procedures for members fabricated by welding or bolting. Submit QC and production procedures for each steel non-bridge member that includes cutting, bending, fitting, and assembly, welding, drilling, punching, shearing, machining, bolting, cleaning, and coating operations. (See Section 5.2., “Responsibilities,” for minimum required QC responsibilities);

copy of procedures for permanent marking of members at required locations with the plant’s Department approved insignia. Use a low stress stencil when insignia is applied directly to the member;

copy of procedures for stamping of compliant members with the fabricator’s approved monogram stamp.

The fabricator’s designated approval stamp must be Department approved and listed on the MPL before use; and copy of proposed standardized repair procedures, if desired, for notches and gouges, heat straightening of shafts, seam weld repairs (other than incomplete joint penetration), and galvanized coating damage.

In addition to the items above, provide the following for products requiring nondestructive evaluation (NDE):

copy of the most recent Personnel Qualification and Certification Program in Nondestructive Testing (Written Practice), in accordance with the current Recommended Practice No. SNT-TC-1A, “Personnel Qualification and Certification in Nondestructive Testing,” or in accordance with the current ASNT Standard ANSI/ASNT CP-189, “Qualification and Certification of Nondestructive Testing Personnel,” published by the American Society for Nondestructive Testing, Inc. (ASNT);

list of all nondestructive testing (NDT) personnel and copy of the most recent NDT certifications in magnetic particle testing (MT) and ultrasonic testing (UT), in accordance with the applicable AWS code, for personnel performing and reviewing NDT. Administration of NDT Level I and II personnel certifications and approval of NDT test procedures must only be performed by current ASNT NDT Level III personnel certified in the specific methods;

UT procedures and technique in accordance with the AWS D1.1, “Structural Welding Code;”

proposed UT procedures for toe crack detection on high mast illumination pole ground sleeves; and proposed UT procedures for penetration depth verification of longitudinal seam welds, where specified, for various steel non-bridge members.

4.2. Evaluation. MTD will review the qualification request documentation for all fabrication plants. If the qualification request includes the required information, MTD will perform an initial Department-directed plant audit to ensure compliance with this Specification. The Department will evaluate all fabrication plants for adequate equipment, processes, organization, experience, knowledge, and competent personnel to produce acceptable work. Personnel performing NDT must be qualified in accordance with Section 441.3.1.5.3., “Nondestructive Testing (NDT),” unless specified otherwise herein. At the discretion of the Engineer, ultrasound technicians are required to pass a hands-on UT examination administered by the Materials and Tests Division.

4.2.1. Qualification. If the required submittals and Department audits verify compliance with this Specification, the Department will list the fabrication plant on the appropriate MPL. MTD reserves the right to perform additional audits (announced or unannounced) at its discretion for a plant to remain on the MPL as an approved fabrication plant of steel non-bridge members.

Materials and Tests Division 3 – 6 Effective Date: April 2022

Fabrication plants listed on the MPL must promptly resubmit the following when changes occur to maintain approval status:

copy of current AISC certification for Certified Metal Component Manufacturers including a copy of the most recent complete audit report, exit meeting report, and written response to AISC of corrective actions for all specific discrepancies;

current AWS CWI certifications for approved on-site QC welding inspection personnel;

QC personnel list and a detailed description of their QC related experience as required by Section 4.1., “Qualification Request”;

organizational work chart;

QC and Production procedures when requesting changes to the approved version;

WPSs, PQRs, and weld maps;

copy of the Personnel Qualification and Certification Program in Nondestructive Testing (Written Practice), in accordance with the current ASNT Recommended Practice No. SNT-TC-1A or in accordance with the current ASNT Standard ANSI/ASNT CP-189; and

NDT personnel list and copy of the applicable NDT certifications, in accordance with AWS D1.1, for approved personnel performing and reviewing all required NDT. Administration of NDT Level I and Level II personnel certifications and approval of NDT test procedures must only be performed by current ASNT NDT Level III personnel certified in the specific methods.

Include date of revision and highlighted changes on appropriate submittals. Failure to maintain and provide the above may result in removal from the MPL for applicable products.

Fabrication plants must also adequately implement corrective actions to all deficiencies found during additional Department-directed audits and any follow-up plant audits.

4.2.2. Failure. Plants that fail to qualify under this Specification cannot furnish steel non-bridge members for Department projects and must show evidence of correction of all deficiencies before consideration for qualification.

4.3. Random Inspection and Testing. The Department reserves the right to inspect, sample, test, conduct random audits of plants, and review documentation at any time to ensure compliance with this Specification and other applicable specifications. Provide facilities and safe access to allow for inspection of materials, the process of fabrication, and the finished steel members. Notify the Department before commencing fabrication by completing Department Form 2585 (aka FN-1), “TxDOT Fabrication Notification.” Coordinate the scheduling of any inspections that the Department requests to perform.

4.4. Disqualification. Any fabricator who fails to comply with the requirements of this Specification is subject to disqualification, which includes removal from the MPL. A disqualified fabricator is prohibited from furnishing product to Department projects and may not bid any work let during the disqualification period. The disqualification period will be a minimum of 30 days or as determined by MTD.

Causes for disqualification include, but are not limited to:

repeatedly failing to submit Department Form 2585 (aka FN-1), “TxDOT Fabrication Notification,” or repeatedly submitting the form with inaccurate information;

repeatedly failing to submit Department Form 2586 (aka NB-2), “Steel Non-Bridge Member Worksheet DMS-7380,” and the corresponding documentation in accordance with Section 5.2.3., “Certification of Product”;

repetitive poor quality and workmanship;

falsification of or incomplete documentation;

lack of certified or qualified QC personnel or failing to notify the Department when QC (CWI) personnel changes occur; or certifying or furnishing products that do not meet specifications.

Materials and Tests Division 4 – 6 Effective Date: April 2022

If a fabricator has been disqualified, all previously produced products will be subject to review and possible removal from assigned projects. If the Department disqualifies a fabricator, the Department may permit the subcontracting of pending or outstanding product quantities for active projects to another Department-approved fabrication plant for the specific product.

4.5. Re-Qualification. Once the disqualification period established by MTD has elapsed, the fabricator may begin the re-qualification process. The fabricator must pass an additional AISC and Department-directed audit and provide the Department with evidence of corrected deficiencies.

The fabricator must bear all Department expenses associated with re-qualification.

4.6. Inactive Fabricator. If a fabricator does not furnish any steel non-bridge members as defined in Article 3., “Steel Non-Bridge Members,” to Department projects for a period of 2 yr., MTD may remove the fabricator from the MPL due to inactivity.

MTD will consider future qualification after the fabricator indicates it will furnish steel non-bridge members to Department projects and is in accordance with this Specification.

5. QC PERSONNEL

Submit and receive Department approval for all changes to QC personnel before performing work.

5.1. Qualifications. Provide an adequate number of qualified QC personnel and qualified AWS CWI certified QC personnel for each specific operation detailed in the plant’s QC and production procedures. Each plant must have an adequate number of CWI certified QC personnel during production. QC personnel must be on site working on the shop floor of the production areas and independent of production personnel, as determined by the Engineer. QC personnel must have the authority and management’s support to make general inspection related decisions. QC personnel must be proficient in utilizing the applicable plans, specifications, and test methods, and in verifying compliance with the QC and production procedures.

QC personnel performing the duties specified in Section 5.2., “Responsibilities,” are subject to Department approval. CWI QC personnel must be an employee of the fabricator.

5.2. Responsibilities. QC is solely the responsibility of the fabricator. The Department will not perform QC or act as a third-party witness for the fabricator. Perform the following activities, at a minimum, to ensure the quality and acceptability of fabricated products.

5.2.1. Inspection. QC personnel will follow approved procedures and verify correct processes for each member.

QC personnel must ensure, at a minimum:

specified materials utilized during fabrication and accurate material traceability;

use of proper WPSs and properly certified welding personnel;* proper weld joint preparation and fit-up, and evaluation of welding in accordance with the applicable AWS Code;* finished welds comply with Contract requirements;* proper procedures for all cutting, shearing, machining, bending, straightening, surface preparation, and bolting;

proper procedures for heat straightening of single weld seam shaft sections, when required;

proper procedures for verifying member geometry and fit up including required assembly procedures for high mast ring and support assemblies and overhead sign support structures (monotube and truss type structures);

proper NDT performed and evaluated in accordance with AWS D1.1 for high mast illumination poles, long mast arm assembly (LMA) traffic signal poles, ITS poles, monotube type overhead sign support structures, and cantilevered-truss type overhead sign support columns;

Materials and Tests Division 5 – 6 Effective Date: April 2022 proper procedures for all repairs, including NDE, if applicable, in accordance with QC and production procedures;* proper inspection and testing of coatings;

legible marking of product with the plant’s insignia at required locations;

legible marking of the design wind speed on ITS poles and traffic signal pole assemblies;

proper procedures for handling, storage, and loading of members; and final product acceptance including stamping of members with the fabricator’s approved monogram stamp.*

Note 1 ―* Denotes inspections that must be performed only by CWI-certified QC personnel.

5.2.2. Documentation. Maintain the following documentation, at a minimum, available upon Department request, until the Department’s final acceptance of the project and for a minimum of 7 yr.:

Department Form 1818 (a.k.a. D-9-USA-1), “Material Statement,” with supporting mill test reports (MTRs), certifications, and shipping invoices;

fabrication drawings and approved shop drawings, when required;

geometry and fit up worksheets, including assembly worksheets for overhead sign support structures;

NDT reports for high mast illumination poles, long mast arm assembly (LMA) traffic signal poles, ITS poles, monotube type overhead sign support structures, and cantilevered-truss type overhead sign support columns;

galvanizing inspection reports to include thickness readings and final appearance assessments;

paint coating inspection reports for application and final appearance coat compliance, include dry-film thickness test results for duplex systems (if applicable);

signed certification statements indicating the coating (galvanizing and paint) was applied in conformance with Department specifications and the Contract Plans; and properly completed Department Form 2586 (aka NB-2), “Steel Non-Bridge Member Worksheet DMS- 7380.”

5.2.3. Certification of Product. The fabricator’s CWI QC personnel must certify product conformance with all plans and specifications and submit required documentation within 14 days of the final coating application.

This product certification includes the following, at a minimum:

verification that product conforms with the approved shop drawings, if applicable, and all Contract requirements;

signed Department Form 2586 (aka NB-2), “Steel Non-Bridge Member Worksheet DMS-7380,” certifying that material, inspections, documentation, repairs (if applicable), and final product acceptance were properly performed;

verification of proper electronic submission of Department Form 1818 (aka D-9-USA-1), “Material Statement,” with supporting mill test reports (MTRs) and certifications, and Department Form 2586 (aka NB-2), “Steel Non-Bridge Member Worksheet DMS-7380”;

permanent marking of members at required locations with the plant’s Department approved insignia;

and stamping of compliant members with the fabricator’s approved monogram stamp. The fabricator’s designated approval stamp must be Department approved and listed on the MPL before use.

6. NONCONFORMANCE REPORT

When the requirements of this Specification or applicable specifications are not met, submit a nonconformance report (NCR) to the Department for approval. NCRs are also required when modifications to fabricated members are needed to accommodate unanticipated field conditions. Submit NCRs in accordance with Item 441, “Steel Structures.”

http://www.txdot.gov/txdoteforms/GetForm?formName=/1818.xdp&appID=/CST&status=/reportError.jsp&configFile=WFServletConfig.xml

Materials and Tests Division 6 – 6 Effective Date: April 2022

Receive Department approval before beginning repairs. Perform all repair work in strict compliance with the approved NCR and repair procedure.

7. ARCHIVED VERSIONS

Archived versions are available.