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Guide to Surveillance ofStructural Steelwork
Technical Bulletin No 46
Guide to Surveillance of Structural
Steelwork
Technical Bulletin No 46
November 2003
VicRoads and its employees or agents involved in thepreparation and publication of this Technical Bulletin do notaccept any contractual, tortious or other form of liability for itscontents or for consequences arising from its use. Persons usingthe information contained in the Bulletin should apply, andrely upon, their own skill and judgement.
This Guide provides a methodology for quality surveillance ofstructural steelwork during fabrication and site work for VicRoadscontracts and works. The main aims of the Guide are to ensure that:
• Surveillance is carried out in a uniform and consistent manner,following principles of quality management
• Observation records of workshop and on-site steelwork fabricationcontain sufficient detail
ABOUT VICROADS
VicRoads is the Victorian State Road Authority responsible for themanagement of the road network.
ii
Foreword
Table ofContents
Guide to Surveillance of Structural Steelwork ............. iForeword ............................................................... iiTable of Contents ................................................... iii1. Introduction ...................................................... 1
1.1 Purpose .................................................................................... 11.2 Scope ........................................................................................ 11.3 Structural Steelwork ............................................................... 1
2. Surveillance in a Quality Assurance Environment .. 22.1 The Quality Assurance Environment .................................... 22.2 The VicRoads Framework for
Quality Assurance Contracting .............................................. 22.3 Aim of Surveillance of Structural Steelwork ........................ 3
3. Roles and Responsibilities................................... 43.1 The Role of VicRoads in Structural Steelwork ..................... 43.2 The Role of the Contractor..................................................... 43.3 The Role of the Structural Steelwork
Surveillance Officer ................................................................ 4
4. Structural Steelwork Surveillance Procedures......... 54.1 General ..................................................................................... 54.2 Quality Plans ............................................................................ 54.3 Surveillance Checklists .......................................................... 64.4 Surveillance Processes ........................................................... 6
5. Pre-Construction Activities .................................. 75.1 Introduction ............................................................................. 75.2 Contract Quality Plan.............................................................. 75.3 Surveillance Documentation and Reporting System .......... 75.4 Contract Documentation (Quality Plan, Drawings, Specifi-
cation) ....................................................................................... 75.5 Manufacturing Processes ....................................................... 8
6. Field Surveillance Activities ................................ 96.1 Introduction ............................................................................. 96.2 Surveillance Schedule ............................................................ 96.3 Surveillance Record ................................................................ 96.4 Contract Review – Welding .................................................. 106.5 Sub-Contracting ..................................................................... 106.6 Welding, Inspection and Testing Personnel –
Qualifications and Competencies ........................................ 116.7 Materials and Welding Consumables ................................. 116.8 Welding Activities .................................................................. 126.9 Cutting and Edge Treatment Activities .............................. 126.10 Assembly Activities ............................................................... 136.11 Erection Activities ................................................................. 146.12 Inspection Activities .............................................................. 156.13 Non-Conformance ................................................................. 15 iii
7. Reporting of Surveillance ................................ 188. References .................................................... 209. Additional Reading ........................................ 21Appendix A - Accreditation Criteria Surveillance of
Structural Steelwork ....................................... 22Company Accreditation ................................................................. 22Business Rules ............................................................................... 22Personnel Qualification.................................................................. 22Personnel Experience .................................................................... 23Resources, Records and Reports ................................................. 23Ethics and Independence .............................................................. 23
Appendix B - Checklists for Surveillanceof Structural Steelwork.................................... 25
Appendix C - Sample SurveillanceRecord and Report Form................................. 28
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1
Introduction
1.1 PurposeThe purpose of this Guide is to:
• Set criteria for the qualification and accreditation of StructuralSteelwork Surveillance Officers
• Provide guidance to Structural Steelwork Surveillance Officers inworking with quality assurance contracts
• Promote consistency in the surveillance of quality assurancecontracts
• Provide a training basis for Structural Steelwork SurveillanceOfficers
The Guide is intended for use in quality assessment of VicRoadsconstruction and maintenance contracts, for structural steelwork.
1.2 ScopeThis document puts in place a recommended system for theappointment and duties of a Structural Steelwork Surveillance Officer,and provides a set of checklist guides, to ensure quality standards,specifications and contract obligations are met.
This Guide does not cover every possible contingency and theinformation herein can be expanded both in scope and depth as theneed arises. There will always be the need for the StructuralSteelwork Surveillance Officer to apply judgement, and, when in doubt,seek further specialist advice.
1.3 Structural SteelworkStructural steelwork activities at the fabrication shop and during onsiteworks include supply of materials, material handling, cutting,assembly, welding, holing, bolting and transport.
Welding is generally an integral part of structural steelwork. It isregarded by AS/NZS ISO 9001:20001 as a process which requiresvalidation to ensure planned results are achieved. In Australia, AS/NZS 1554 Part 12 is the normal welding standard for structuralsteelwork. AS/NZS 1554 Part 1 requires a weld to be made fromknown materials by a qualified welder, using an approved procedureand consumables of specified grade and quality. An appropriate level ofinspection and supervision of the welding must be performed. AS/NZS ISO 38343 describes the quality system elements which shouldprovide the required level of quality for welded structural steelwork.
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2
Surveillancein a
QualityAssurance
Environment
2.1 The Quality Assurance EnvironmentQuality assurance is applied to the structural steel works as a part of amanagement system to ensure that:
• Contractor/sub-contractor relationships are working• Processes are being managed• People have sufficient empowerment and responsibility to do their
jobs• Products meet the specified criteria, i.e., standards and
specifications are achieved.
2.2 The VicRoads Framework for QualityAssurance Contracting
This Guide has been produced by VicRoads to complement theAustroads publications Quality Assurance in Contracts4 and Guide toField Surveillance of Quality Assurance Contracts5. The secondpublication is referred to within this Guide as the Austroads Guide.
The contents of this Guide specifically address Contractor surveillanceactivities associated with the implementation of that portion of theQuality Plan covering processes associated with fabrication anderection of structural steelwork. The Quality Plan covering structuralsteelwork processes is generally owned by the Structural SteelworkSub-contractor and is reviewed by the Contractor.
Figure 2.1Figure 2.1Figure 2.1Figure 2.1Figure 2.1 Welding, including automated procedures suchWelding, including automated procedures suchWelding, including automated procedures suchWelding, including automated procedures suchWelding, including automated procedures suchas submerged arc welding, requires assuranceas submerged arc welding, requires assuranceas submerged arc welding, requires assuranceas submerged arc welding, requires assuranceas submerged arc welding, requires assurancethat itthat itthat itthat itthat it has been carried out according to qualityhas been carried out according to qualityhas been carried out according to qualityhas been carried out according to qualityhas been carried out according to quality
specifications.specifications.specifications.specifications.specifications.
2
2.3 Aim of Surveillance of Structural SteelworkThe surveillance of structural steelwork determines, in a systematicmanner, that the Contractor’s and Structural Steel Sub-contractor’sQuality Plans are implemented, that the Contract Specificationrequirements for the manufacture and erection of structural steelworkare complied with, and that the specified quality is achieved.Surveillance is carried out both on the fabrication and erection of newstructural steelwork, and on maintenance or repair of existingstructural steelwork.
Each process used in the fabrication of structural steelwork should beobserved for verification that the detail of the process has been carriedout in accordance with written instructions and that the specifiedrequirements have been achieved.
The personnel who carry out surveillance require detailed knowledgeof steel fabrication and erection procedures and must be trained toobserve and seek appropriate evidence of compliance with procedures.In particular these personnel must be conversant with the followingVicRoads Standard Specifications for Roadworks and Bridgeworks:
• Section 630 – Fabrication of Steelwork• Section 670 – Steel Bridge Barriers• Section 671 – Concrete and Combined Concrete and Steel Bridge
Barriers
The Structural Steelwork Surveillance Officer is retained by, and actson behalf of, the Contractor and generally carries out surveillance ofsub-contracted, structural steelwork. In the event that the structuralsteelwork is not sub-contracted then the Structural SteelworkSurveillance Officer will be retained by the Structural Steelwork Sub-contractor, who in this instance is also the Contractor.
All structural steelwork surveillance shall be carried out by StructuralSteelwork Surveillance Officers who are authorized signatoriesemployed by organizations holding inspection accreditation with theNational Association of Testing Authorities, Australia (NATA).Accreditation shall be to AS/NZS ISO/IEC 17020 – General Criteria forthe Operation of Various Types of Bodies Performing Inspection6, forsurveillance of structural steelwork, in accordance with theaccreditation criteria in this Guide.
The criteria for accreditation of Structural Steelwork SurveillanceOfficers and companies offering these surveillance services areprovided in Appendix A.
Under VicRoads’ specifications, the Superintendent reserves the rightto undertake independent audit and surveillance activities,notwithstanding the fact that a Structural Steelwork SurveillanceOfficer may be deployed on the works.
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Roles andResponsibilities
3.1 The Role of VicRoads in StructuralSteelwork
A VicRoads officer is normally appointed as the Superintendent ofVicRoads awarded contracts. The Superintendent will arrangesurveillance and audits to verify the effectiveness of the Contractor’sQuality System and compliance with the management plans andprocedures.
3.2 The Role of the ContractorContractors have the responsibility for the conduct of regularsurveillance and audit of all on-site and off-site sub-contractors.Contractors are responsible for establishing, undertaking andcontinuing control and process checks to ensure the specified criteriafor structural steelwork are met.
Where structural steelwork is carried out as a sub-contract, theContractor shall conduct surveillance of the sub-contracted worksutilizing the services of a Structural Steelwork Surveillance Officer. Itis the responsibility of the Contractor to procure the services of aStructural Steelwork Surveillance Officer to undertake surveillance ofsub-contracted steel fabrication works. A specific aspect of theContractor’s Quality Plan should cover the surveillance of sub-contracted structural steelwork. The Structural Steelwork Sub-contractor shall prepare a separate Quality Plan covering processesassociated with the structural steelwork. It is essential that theStructural Steelwork Sub-contractor’s Quality Plan is reviewed by theContractor.
The Contractor must monitor the performance of the Sub-contractor bysurveillance of structural steelwork to obtain assurance that the Sub-contractor complies with the quality system and meets the specifiedquality criteria.
3.3 The Role of the Structural SteelworkSurveillance Officer
The Structural Steelwork Surveillance Officer generally acts on behalfof the Contractor and carries out surveillance of sub-contracted,structural steelwork.
The Structural Steelwork Surveillance Officer verifies theimplementation of the Structural Steelwork Sub-contractor’s QualityPlan, the conduct of the fabrication process and verification of specifiedrequirements for structural steelwork during the contract deliveryprocess. The general role of surveillance officers in Contract Deliveryis described in the Austroads Guide.
Where specifications nominate ‘Hold Points’ during the course of acontract, these can only be released by a Structural SteelworkSurveillance Officer.
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3
5
4.1 GeneralIn a construction process for structural steelwork, the activitiesundertaken by the Contractor and the Structural SteelworkSurveillance Officer involve the following:
• Preparation of Contractor’s Quality Plan (Contractor activity)• Review of the Structural Steelwork Sub-contractor’s Quality Plan
(Contractor activity)• Pre-construction activities (Contractor & Surveillance Officer
activity)• Field surveillance activities (Surveillance Officer activity)
4.2 Quality PlansUnder AS/NZS ISO 9001:2000 “The organization shall establish,document, implement and maintain a quality management system andcontinually improve its effectiveness in accordance with the requirementsof this International Standard.The organization shall:
(a) identify the processes needed for the quality management systemand their application throughout the organization,
(b) determine the sequence and interaction of these processes,(c) determine criteria and methods needed to ensure that both the
operation and control of these processes are effective,(d) ensure the availability of resources and information necessary to
support the operation and monitoring of these processes,(e) monitor measure and analyse these processes, and(f) implement actions necessary to achieve planned results and
continual improvement of these processes.Where an organization chooses to outsource any process that affectsproduct conformity with requirements, the organization shall ensurecontrol over such processes. Control of such outsourced processesshall be identified within the quality management system.
The organization shall plan and carry out production and serviceprovision under controlled conditions”.
To demonstrate compliance with AS/NZS ISO 9001:2000 both theContractor and Structural Steelwork Sub-contractor normally prepare aQuality Plan for each job, which becomes the basis for surveillanceand technical audit. The Quality Plan covering processes associatedwith structural steelwork fabrication is generally prepared and ownedby the Structural Steelwork Sub-contractor and is reviewed by theContractor.
For structural steelwork, the Quality Plan covering processes for eachjob shall:
• Be site or contract specific• Describe the processes and reference the standards for structural
steelwork that the Contractor will follow to achieve the agreedstandard of work
• Specifically describe the areas of responsibility and accountability
4
StructuralSteelworkSurveillanceProcedures
6
of the Contractor’s personnel• Provide details of materials such as steel, bolts, welding
consumables, etc and names of suppliers• Provide details of manufacturing processes and procedures• Provide details of any sub-contractors to be used and their
responsibility in the process• List the quality records to be kept which provide evidence of
compliance• Provide inspection and testing plans and checklists for materials
and processes• Provide for identification of non-conformances and methods to deal
with them• Contain or refer to other relevant documents such as the
Contractor’s Quality Manual and Operating Procedures Manual• Provide certificates of material performance and outline process
for traceability and identification.
When used during the fabrication process, the above documentscollect information which demonstrate that the Quality Plan has beenfollowed.
4.3 Surveillance ChecklistsWhen surveillance of structural steelwork is conducted, surveillancechecklists should be used to ensure all relevant items are covered.Appendix B contains checklists based on the system elements of AS/NZS ISO 3834, Part 3 Standard Quality Requirements. The checklistsin Appendix B are considered a minimum standard and shall besupplemented to include items specific to the particular contract.
4.4 Surveillance ProcessesThe Structural Steelwork Surveillance Officer conducts surveillance ofthe Structural Steelwork Sub-contractor’s processes by observing eachprocess, at a frequency determined by the surveillance schedule.Verification shall be made that the details of the process have beencarried out in accordance with the written instructions and that thespecified requirements have been achieved. The use of checklists isrecommended. Reporting of the results of surveillance should bemade to the contract party that is one level above that which is beingsurveilled.
Pre-construction activities, field surveillance activities and reportingare described in Sections 5, 6 and 7 of this Guide, respectively.
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5.1 IntroductionThis section describes activities that the Structural SteelworkSurveillance Officer should carry out prior to commencement offabrication of structural steelwork. These activities are coveredgenerally in Section 6 of the Austroads Guide.
5.2 Contract Quality PlanThe Quality Plan will detail requirements for the activities to be carriedout by the Structural Steelwork Surveillance Officer. Theserequirements will cover, for example, the conduct of communicationsbetween parties, a process for reporting and resolution of non-conformances, maintenance of diary records, etc.
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5.3 Surveillance Documentation andReporting System
The Structural Steelwork Surveillance Officer shall use a securesystem for reporting and storing information collected during thecourse of the surveillance. Each surveillance shall have a uniqueidentification code.
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5.4 Contract Documentation (Quality Plan,Drawings, Specification)
The Structural Steelwork Surveillance Officer must have a thoroughunderstanding of all relevant documentation applicable to structuralsteelwork. This documentation includes:• Contractor’s Quality Plan relating to structural steelwork• Quality Plan from the Structural Steelwork Sub-contractor• Drawings and specification for the structural steelwork• Relevant standards and guidelines
5
Pre-ConstructionActivities
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5.5 Manufacturing ProcessesThe Structural Steelwork Surveillance Officer must be familiar with theprocesses related to steelwork fabrication and subsequent transportand onsite works, particularly for processes where the results orquality cannot be verified by subsequent inspection and testing of theproduct and where, for example, processing deficiencies may becomeapparent only after the product is in use. The sequence and interationof these processes shall also be determined. For structural steelwork,such processes include welding, cutting and the application of heat tosteel.
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6
FieldSurveillanceActivities
6.1 IntroductionThis section describes the activities a Structural SteelworkSurveillance Officer may carry out during the fabrication and erectionof structural steelwork. Some of these activities are covered generallyin Section 7 of the Austroads Guide.
6.2 Surveillance ScheduleThe Structural Steelwork Surveillance Officer shall develop asurveillance schedule for the approval of the Contractor. Thisschedule should be based on the risk of specific aspects of the processand requirements of the specification.
Surveillance frequency should be higher in the early stages offabrication. An initial surveillance is required at the commencement ofthe contract to assess compliance with supervision, qualification ofpersonnel and procedures, material supply and inspectionrequirements. As fabrication procedures are observed to be in placeand delivering the required product quality, the frequency ofsurveillance could be reduced. However, both the frequency andduration of surveillance should be increased where non-conformancesarise which are detrimental to product quality or the potential servicelife, or both of these aspects.
The Structural Steelwork Surveillance Officer attends the StructuralSteelwork Sub-contractor’s works or worksite in accordance with thesurveillance schedule.
Surveillance near contract completion is required to assess compliancewith inspection and testing, and resolution of non-conformances.
Surveillance is required to observe critical production activities,including weld joint preparations, welding, witnessing of weld testplates, checks of camber, non-destructive inspection, plate edgetreatments, tensioning of bolts, erection of steelwork, site welding anduse of re-work procedures.
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6.3 Surveillance RecordSurveillance carried out by the Structural Steelwork SurveillanceOfficer shall be recorded on check lists and Surveillance Record andReport Forms.
Other activities and important site events during the contract are to berecorded to provide an accurate account of events and resources, asobserved during surveillance. Photographic and video methods maybe used to record progress of the works and significant events orproducts. 9
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6.4 Contract Review – WeldingAt the initial surveillance, the Structural Steelwork Surveillance Officershould assess that the Structural Steelwork Sub-contractor hascompleted a contract review process. This review identifies specificrequirements for the contract regarding:
• Application standards to be used• Welding procedures required for the contract and if specific
procedures require qualification and approval prior to use inproduction
• Method for obtaining welding procedure approval• Welder qualification and welding supervisor qualification• Inspection and testing procedures• Selection, identification and traceability of materials• Specification requirements, including contract specific clauses
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6.5 Sub-ContractingIn structural steelwork, some activities are supplied by sub-contractorsto the Structural Steelwork Sub-contractor. The Structural SteelworkSurveillance Officer should assess that the Structural Steelwork Sub-contractor has evaluated and selected sub-contractors/suppliers ontheir ability to meet specified requirements, including quality.
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10
6.6 Welding, Inspection and TestingPersonnel – Qualifications andCompetencies
All personnel involved in welding, inspection and testing requirequalification in their field. The Structural Steelwork SurveillanceOfficer shall assess that qualification of the following personnel meetthe specification requirements:
• Welders• Welding supervisors• Welding inspectors• Non-destructive inspection personnel• Mechanical testing companies
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Figure Figure Figure Figure Figure 66666.1.1.1.1.1 A surveillance officer must ascertain specifiedA surveillance officer must ascertain specifiedA surveillance officer must ascertain specifiedA surveillance officer must ascertain specifiedA surveillance officer must ascertain specifiedtesting is carried out, such as this ultrasonictesting is carried out, such as this ultrasonictesting is carried out, such as this ultrasonictesting is carried out, such as this ultrasonictesting is carried out, such as this ultrasonicinspection of a butt weldinspection of a butt weldinspection of a butt weldinspection of a butt weldinspection of a butt weld
6.7 Materials and Welding ConsumablesThe Structural Steelwork Sub-contractor has responsibility to ensurethat steelwork is supplied in accordance with the specification.
Traceability of materials (such as steel plates, sections and bolts) andconsumables (such as welding electrodes, flux and gas) is often lostafter the materials are incorporated into the structure or the welds.Traceability is the responsibility of the Structural Steelwork Sub-contractor, who must demonstrate that materials and consumables ofthe specified grade and quality have been acquired for, assigned to andused in the works. 11
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6.8 Welding ActivitiesThe Structural Steelwork Surveillance Officer verifies that appropriatetechnical procedures are in place prior to the commencement of work;that these procedures are followed and that the appropriate level ofinspection has been carried.
out.
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6.9 Cutting and Edge Treatment ActivitiesCutting of steel can influence the quality of the finished structure,particularly at edges that are not fully fused in welding.
12
13
Figure 6.2Figure 6.2Figure 6.2Figure 6.2Figure 6.2 As part of surveillance, procedures such asAs part of surveillance, procedures such asAs part of surveillance, procedures such asAs part of surveillance, procedures such asAs part of surveillance, procedures such asbalanced flame cutting of flange plates to avoidbalanced flame cutting of flange plates to avoidbalanced flame cutting of flange plates to avoidbalanced flame cutting of flange plates to avoidbalanced flame cutting of flange plates to avoiddistortion, should be observed.distortion, should be observed.distortion, should be observed.distortion, should be observed.distortion, should be observed.
6.10 Assembly ActivitiesA variety of activities may be used in the assembly of structuralsteelwork. These depend on the detail design of each structure andany sub-assemblies.
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Figure 6.3Figure 6.3Figure 6.3Figure 6.3Figure 6.3 The Surveillance Officer must verify that theThe Surveillance Officer must verify that theThe Surveillance Officer must verify that theThe Surveillance Officer must verify that theThe Surveillance Officer must verify that thecamber is within specifications and tolerances.camber is within specifications and tolerances.camber is within specifications and tolerances.camber is within specifications and tolerances.camber is within specifications and tolerances.
6.11 Erection ActivitiesErection of structural steelwork on-site may be carried out by a sub-contractor with specialised equipment or methods. Erection is oftencarried out under conditions involving time restrictions, adverseweather, poor visibility during night work and traffic management.
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6.12 Inspection ActivitiesThe Structural Steelwork Sub-contractor is required to perform thenecessary level of inspections to provide assurance that steelwork ofthe specified quality will be supplied. The Structural SteelworkSurveillance Officer verifies that these inspections have occurredduring the works and that they have been performed by competentpersonnel. Inspection records should be available for welding, cutting,edge treatment, assembly and erection activities.
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6.13 Non-ConformanceThe Structural Steelwork Sub-contractor shall raise non-conformancereports when work is not in accordance with the specification ordrawings.
If the Structural Steelwork Surveillance Officer discovers a non-conformance, this shall be raised as a non-conformance with theContractor. The Contractor will then deal with the issue in accordancewith the contract.
15
Figure 6.4Figure 6.4Figure 6.4Figure 6.4Figure 6.4
Figure 6.5Figure 6.5Figure 6.5Figure 6.5Figure 6.5
A Surveillance Officer finding products outsideA Surveillance Officer finding products outsideA Surveillance Officer finding products outsideA Surveillance Officer finding products outsideA Surveillance Officer finding products outsidetolerances, such as damage to the web (Figuretolerances, such as damage to the web (Figuretolerances, such as damage to the web (Figuretolerances, such as damage to the web (Figuretolerances, such as damage to the web (Figure6.4), should raise non-conformances and where6.4), should raise non-conformances and where6.4), should raise non-conformances and where6.4), should raise non-conformances and where6.4), should raise non-conformances and whereappropriate, verify correctiveappropriate, verify correctiveappropriate, verify correctiveappropriate, verify correctiveappropriate, verify corrective techniques,techniques,techniques,techniques,techniques,such as the flame straightening (Figure 6.5).such as the flame straightening (Figure 6.5).such as the flame straightening (Figure 6.5).such as the flame straightening (Figure 6.5).such as the flame straightening (Figure 6.5).16
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Surveillance reports shall include any requirements for the NationalAssociation for Testing Authorities Australia (NATA) endorsement ofthe report, as well as specific information resulting from thesurveillance. Surveillance reports shall be made within two workingdays of conducting the surveillance.
The Structural Steelwork Surveillance Officer shall make available tothe Contractor and to VicRoads, at the request of the Superintendent,all relevant documentation collected during the course of thesurveillance.
Appendix C of this document contains an example of a basicSurveillance Record and Report Form.
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Reporting ofSurveillance
7
17
Surveillance reports may include comment onSurveillance reports may include comment onSurveillance reports may include comment onSurveillance reports may include comment onSurveillance reports may include comment onobservation of lifting and storage methods, such asobservation of lifting and storage methods, such asobservation of lifting and storage methods, such asobservation of lifting and storage methods, such asobservation of lifting and storage methods, such as
those used in the photographs above (Figures 7.1 & 7.2)those used in the photographs above (Figures 7.1 & 7.2)those used in the photographs above (Figures 7.1 & 7.2)those used in the photographs above (Figures 7.1 & 7.2)those used in the photographs above (Figures 7.1 & 7.2)
Figure 7.1Figure 7.1Figure 7.1Figure 7.1Figure 7.1
Figure 7.2Figure 7.2Figure 7.2Figure 7.2Figure 7.2
18
1 Standards Australia, AS/NZS ISO 9001:2000 — QualityMangement Systems — Requirements
2 Standards Australia, AS/NZS 1554, Part 1 — Welding of SteelStructures
3 Standards Australia, AS/NZS ISO 3834, Quality Systems forWelding — Standard quality requirements
4 Austroads, Quality Assurance in Contracts, Sydney 1994,AP–115/94
5 Austroads, Guide to Field Surveillance of Quality AssuranceContracts, Sydney 1995, AP-38/95
6 Standards Australia, AS/NZS ISO/IEC 17020, General Criteria forthe Operation of Various Types of Bodies Performing Inspection
7 Standards Australia, AS 1796, Certification of Welders and WeldingSupervisors
8 Standards Australia, AS 2214, Certification of Welding Supervisors–Structural Steel Welding
8
References
19
9
AdditionalReading
National Association of Australian State Road Authorities, BridgeWelding Practice, Sydney, 1980
Standards Australia, AS/NZS ISO/IEC 17020 — General Criteria forthe Operation of Various Types of Bodies Performing Inspection
Welding Technology Institute of Australia, Technical Note 11,Commentary on the Structural Steel Welding Standard AS/NZS 1554 — TN11 — 98
Welding Technology Institute of Australia, Technical Note 19, CostEffective Quality Management for Welding — TN19 — 95
20
Company AccreditationAll companies conducting surveillance of structural steelwork shallhold inspection accreditation with the National Association of TestingAuthorities, Australia (NATA). Accreditation shall be to AS/NZS ISO/IEC 17020 – General Criteria for the Operation of Various Types ofBodies Performing Inspection6, for surveillance of structural steelwork,in accordance with this Guide.
Business RulesCompanies conducting surveillance of structural steelwork shallevidence the following business information:
• Australian Business Number• WorkCover Employer Registration Number• Details of Public Liability and Professional Indemnity Insurance as
specified in the primary VicRoads contract.
Personnel QualificationIn addition to the general requirements specified by NATA, personnelshall meet the following requirements for qualifications and experiencebefore gaining inspection accreditation as an authorized signatory forstructural steelwork surveillance:
1. Attendance at a two day course on surveillance of constructionworks, conducted by a recognised training authority
2. Attendance at a two day course in auditing or quality managementprinciples, conducted by a recognised quality training organisation
3. At least one of the following qualifications or certifications:
• Welding/Fabrication Inspector (Welding Technology Instituteof Australia (WTIA)/Australian Institute for Certification ofInspection Personnel (AICIP))
• Senior Welding/Fabrication Inspector (WTIA/AICIP)• Welding Supervisor’s Certificate (AS 1796 Certificate No. 107)• Welding Supervisor’s Certificate – Structural Steel (AS 22148)• Welding Inspector Certificate recognised by WTIA
4. Practical experience in the fabrication of steelwork shall include:
• Fabrication of heavy plate structures or vessels• Use of plate thicknesses greater than 20 mm• Use of higher tensile steels• Butt and T-butt welding• Erection and site welding• High strength friction grip bolting
Documented evidence of qualifications and courses shall be providedat the initial assessment by NATA. Accredited companies shall retaincopies of this documentation for verification at subsequent re-assessments by NATA or at subsequent audits.
Appendix A
AccreditationCriteria
Surveillanceof StructuralSteelwork
21
Personnel ExperienceAll personnel conducting surveillance of structural steelwork shallmeet the following experience requirements:
• Sound and demonstrated knowledge of material standards,application codes, specifications, fabrication procedures and workstandards, including the application and use of AS/NZS 1554 Part1 in welding of structural steelwork
• Demonstrated competence to read and understand contract andshop drawings, material compliance certificates, weldingprocedure specifications, mechanical testing reports, non-destructive testing reports, inspection and test reports, and thelike, including the assessment of compliance of these documentswith specification criteria
• Demonstrated competence in the development, preparation andapproval of welding procedure specifications as defined in AS/NZS1554 Part 1
• Ability to prepare surveillance reports• Participation in at least three surveillance visits as a trainee
surveillance officer, under the mentorship of a person trained inquality auditing and experienced in structural steelworkfabrication, prior to gaining NATA signatory status
Referee persons, such as a principal of the surveillance company or ofthe Contractor’s company, shall independently verify experience bysigning experience statements at the appropriate entries.
Resources, Records and ReportsThe accredited surveillance company shall establish and maintain asurveillance record and reporting system. All personnel conductingsurveillance of structural steelwork shall use the surveillance reportingsystem established by the accredited surveillance company.Surveillance reports shall be issued to the Contractor within twoworking days of conduct of the surveillance. Security andconfidentiality of records and reports shall be maintained. Recordsand reports shall be held for three years after expiry of the contractdefects liability period.
Surveillance reports shall comply with the requirements of the NATAaccreditation.
Ethics and IndependenceAll surveillance companies and personnel conducting surveillance ofstructural steelwork shall:
• Exercise their professional and technical skills and judgement tothe best of their ability and discharge their professional andtechnical responsibilities with honesty, integrity and thoroughness
• Accurately and impartially record and report surveillance findingswithout the influence of any internal or external pressures orconsiderations
22
• Disclose to the Contractor any commercial or other relationshipsthey may have, or have had, with organizations to be assessed orrelated organizations or competitors
• Ensure that they do not disclose their surveillance findings, or anypart of their findings, to any third party other than VicRoads.
23
Appendix B
Checklistsfor
Surveillanceof Structural
Steelwork
24
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Appendix C
SampleSurveillanceRecord andReport Form
27
Contractor Surveillance No
Sub-Contractor/Supplier
Contract No.
Job/Product
Surveillance Officer Date of Surveillance
Job Engineer
Location of Surveillance
Procedures/Plans/ Tests Checked
Observations
Checklists Used
Number of Non-Conformances Observed
Details of Non-Conformances
Comments
Number of Non-Conformances Resolved
Date of Notification of Non-Conformance Resolutions
Disposition of Non-Conformances
Signature Date
28
VicRoads Publication No 00739
GeoPave
12 Lakeside Drive,Burwood East, 3151Phone: 9881-8907Facsimile: 9881-8900
VicRoads Bookshop
60 Denmark Street,Kew, 3101Phone: 9854-2782Facsimile: 9854-2468
www.vicroads.vic.gov.au
