QC Manual Section 12 Ingles

vhicoa venezuelan QUALITY CONTROL MANUAL
Procedure for Fracture Control Plan

heavy industries c.a. (Ref. AASHTO/AWS D1.5, Section 12)
2da Av. Campo Alegre, Torre Credival, Piso 2,
Oficina 2B. Caracas, Venezuela
Prepared by: Elis Rojas March 2006 Rev. 0
Approved by: Mauricio Van Dam March 2006
12.1 General Provisions 12.2.2 Fracture Critical Member (FCM) (Cont’d)

The designation “FCM” shall mean fracture
This Fracture Control Plan shall apply to fracture critical member of member component.
critical non-redundant members. All steel bridge Members and components that are not subject
members and member components designated on the to tensile stress under any condition of live load
plans or else where in the contract documents as shall not be defined as fracture critical. (Ref.
fracture critical shall be subject to the additional Sect. 12.2.2 of D1.5)
provisions of the AASHTO/AWS D1.5 Section 12.
12.2.3 Attachments
It is the policy of the VHICOA to have available a Any attachment welded to a tension zone of an
competent staff that will ensure the correct translation FCM member shall be considered and FCM
of information contained within the customer's design when any dimension of the attachment exceeds
drawings and specifications, including design loads, 100mm (4 in.) in the direction parallel to the
into connection development for our shop detail calculated tensile stress under any condition of
drawings. The end result is to provide a finished live load shall not be defined as fracture critical.
product, which meets the customer's requirements (Ref. Sect. 12.2.2.1 of D1.5)
and is based on good engineering practice.
12.2.4 Welds
To ensure that this policy is carried out, the Vice All welds to FCMs shall be considered fracture
President of Operations has instituted a procedure critical and shall conform to the requirements of
whereby the Estimating, Sales, Project Management, this FCP. Welds to compression members or
Engineering, Drafting, Purchasing, Fabrication, Quality compression areas of bending members shall
Control and Quality Assurance Departments share in not be defined as fracture critical. (Ref. Sect.
the responsibility and compliance with the Code of 12.2.2.2 AASHTO/AWS D1.5)
Standard Practice of the AISC and AASHTO/AWS
D1.5 requirements. 12.3Contract Documents
12.2 Definitions 12.3.1 All fracture critical members shall be identified

on the plans, or otherwise described in the
12.2.1 Fracture Control plan (FCP) contract documents by the Engineer prior to
The designation “FCP” shall mean fracture bidding. Each FCM shall be individually
control plan and shall include all provisions of designated. All other provisions of the
this Procedure and AASHTO/AWS section AASHTO/AWS Sect. 12.3 shall apply.
12 Fracture Control Plan.
12.3.2 Shop Drawings
12.2.2 Fracture Critical Member (FCM) Shop drawings shall meet the requirements of
Fracture critical members or member 2.1 of AASHTO/D1.5.
components are tension members or tension
components of bending members (including 12.3.3 Engineer’s Review
those subject to reversal of stress), the The Engineer shall review all shop drawings to
failure of which would be expected to result ensure that all FCM is identified. WPSs for
in collapse of the bridge. construction and repair shall be reviewed for
acceptability.
12.3.4 Acceptance
Detailed shop drawings and WPSs shall be
submitted to the Engineer for review, whose
acceptance, or acceptance-as-noted, shall be
required prior to fabrication.
Page 1 of 14
12.4 Purchasing Base Metal Requirements 12.4.4 Purchasing Data

The Purchase Order shall include the
12.4.1 Purchase Orders following information: Material Grade of Steel,
The Purchasing Manager places orders for and specify killed fine-grain practice for steel
inventory based on shop needs and used in FCMs, and stipulate that no welded
schedules. Information required on purchase repairs shall be performed by the producing
orders is addressed in sect. 12.4 of mill, the minimum CVN toughness values
AASHTO/D1.5 Requirements for FCM and require at specific test temperatures, Method
this FCP. of Joining and AASHTO Temperature Zone in
which the structure will be constructed shall
12.4.2 The Purchasing Manager is responsible for be noted in the mill order. Supplementary
ensuring certificates of conformance are Requirements for individual steel plates may
received for purchased items. The MTR will be specified to have a toughness exceeding
be reviewed for conformance to the order and the minimum CVN as described in12.4.5 of
AASHTO requirements for type, size and AASHTO/D1.5 by listing special requirements
grade. Each item received will be identified on in the contract documents, includes optional
the packing list verifying receipt and through-thickness and low-sulfur
compliance. MTR’s/Certificates of requirements, drawings as needed,
Conformance will be attached to each processing requirements and inspections
PO/Packing List. The supplier’s will be notified required. Base metal identification when heat
when Certificates of Conformance are non- numbers and other identification markings are
conforming or missing. A shortage list will be applied by die stamping, low-stress dies shall
made for reports not received/incorrect or be used. Documents required are attached to
materials that may be non-conforming. A copy the P. O. The Purchase Order specifies that
of the shortage report identifying materials to the supplier is required to comply with the
be placed on hold will be sent to production. A requirements of AASHTO/AWS D1.5
copy of the shortage report will be sent to QC. FRACTURE CONTROL PLAN & ASTM A6.
Non-conformances will be resolved prior to
further processing of the material or 12.5Welding Processed
acceptance. The shop will not cut materials
requiring heat number trace-ability until MTR’s Approved Processes: SMAW, SAW and FCAW
are received and verification by QC. with metal-cored electrodes may be used to
construct or repair FCMs. The Engineer may
12.4.3 Approved Base Metals designate the use of specific processes or
Unless otherwise specified, base metals to be process controls for specific bridge welds. All
welded shall meet the requirements of the special provisions shall be specified in the
latest edition of AASHTO M270M (M270) contract documents.
(ASTM A 709M [A 709M]) for the grade of
steel shown on the plans or described in the
specifications. All Grade 345W (50) steels that
is to be welded shall be Type 1,2, or 3. Other
steels may be approved by the Engineer use
in the fabrication of FCMs.
Page 2 of 14
12.6Consumable Requirements 12.6.5 (Cont’d)

no damage to the coating that may adversely
12.6.1 All welding consumables shall be heat or lot affect weld quality. Electrodes from containers
tested by the manufacturer to determine that have lost their hermetic seal and
conformance with the requirements of AWS electrodes with broken coatings within the
A5.01. Tests shall be conducted on welds usable length shall not be used.
produced during classification testing to
determine the amount of diffusible hydrogen 12.6.5.1 After removal from the sealed containers,
per 100 grams of weld metal. Diffusible electrodes shall be stored in an electrically
hydrogen tests shall be performed under heated, thermostatically controlled oven at
mercury or by the gas chromatograph a minimum temperature of 120oC [250oF]
method as specified in AWS A4.3, Standard until dispensed for use in the work.
Methods for Determination of the Diffusible
Hydrogen. When welding consumables are 12.6.5.2 SMAW electrodes shall have a maximum
accepted as described, production welds atmospheric exposure as specified in table
shall not be required to be tested for 4.7 except as provided for in section
diffusible hydrogen. 12.6.5.8 of the AASHTO/D1.5. Electrodes
with the ASW filler metal specifications
12.6.2 SMAW. optional supplemental moisture resistance
All SMAW electrodes shall conform to the designator “R” may be exposed to the
AWS filler metal specification optional atmosphere for up to nine hours when
supplemental designator H4. welding steels with a minimum specified
yield strength of 345MPa [50 ksi] or less.
12.6.2.1 SMAW electrodes conforming to the AWS Moisture-resistant electrodes shall be
filler metal specifications for diffusible received in containers that bear the
hydrogen designator H4 or classified additional designator R, or H4R.
with the optional R designator and
E7018M may also be used for tack 12.6.5.3 Electrodes removed from heated storage
welding steel that is not preheated. shall be dispensed directly to welders for
immediate use. They shall be kept in
12.6.3 Weld metal strength and ductility shall containers that protect them from
conform to the requirements of table 4.1 and contamination by moisture, oil, grease,
4.2 of AWS D1.5 unless other wise provided and other sources of hydrogen, until used.
in the contract documents. The containers (scabbards) may be open
at the top. Welders shall not be given
12.6.4 Weld Metal Toughness Requirements shall more electrodes than can be used within
comply with the section 12.6.4 and table the exposure limits allowed by this FCP.
12.1 of AASHTO/D1.5.
12.6.6 SAW
12.6.5 All SMAW electrodes shall be manufactured,
packaged in hermetically sealed containers, 12.6.6.1 All SAW electrodes and fluxes used to
stored, transported and delivered so that weld base metal shall conform to the
when removed from the container, the diffusible hydrogen requirements of the
electrodes are undamaged and meet the AWS filler metal specifications optional
diffusible hydrogen limits specified in 12.6.2 supplemental designator H4.
of AASHTO/D1.5. Electrode containers shall
remain sealed until the electrodes are to be
used in the work or are place in heated
storage. Electrodes shall be examined
before use to ensure there is
Page 3 of 14
12.6.6.2 electrodes shall be received in packaging that 12.6.6.6 Open Top Flux Systems
protects the electrode and coatings, if present, from When open top, hopper-type flux
damage. When removed from protective packaging systems have not been refilled, or
and installed on machines, care shall be taken to welding has been suspended for six
protect the electrodes and coatings, if present, from hours, the top 10 mm [3/8 in.] of flux
deterioration or damage. No one shall modify or in the hopper shall be removed and
lubricate an electrode after manufacture for any appropriate make-up flux added
reason. Flux shall be received in moisture-resistant before welding is resumed.
packaging, transported and stored in a manner that
will preserve the original manufactured condition. 12.6.6.7 Time Limits for Flux Replacement
Flux from containers and packages that have been The time limits of 12.6.6.5 and
broken or opened prior to use shall not be used to 12.6.6.6 may be extended based
weld FCMs. upon the results of tests acceptable
to the Engineer.
12.6.6.3 Flux Handling and Drying (Baking) All of the
contents of each container of SAW flux shall be 12.6.6.8 Pneumatic Flux Delivery Systems
place in an approved storage and drying oven Compressed air used in pneumatic
directly upon opening the flux to the atmosphere. flux delivery systems shall be
All flux shall be baked at 2900C [5500F] minimum for effectively filtered and dried to
at least two hours, or as recommended by the remove moisture, oil, rust and other
manufacturer, and then stored continuously at contaminants. Dryers, unless
1200C [2500F] minimum until dispensed for use. automatically drained, shall be
manually drained daily to ensure
12.6.6.4 Drying and Storage Temperatures Flux drying and proper operation. Air lines shall be
storage ovens shall be electrically heated and checked by venting the line to the
thermostatically controlled to provide temperatures atmosphere away from the work
of 1200C-2900C [2500F-5500F]. whenever the pressure container is
refilled to verify the air is clean and
12.6.6.5 Discharge and Refill of Flux Hoppers dry.
Welding machine flux hoppers and pressure
containers shall be emptied of flux, entrapped fines 12.6.6.9 Flux Recovery
and other particles, each time welding is suspended Flux that has not been melted
for 10 hours or more. during the welding operation may
be reused after recovery by
vacuuming, use of catch pans,
sweeping from weldment surfaces
or other means. Recovered flux
shall be passed through an
appropriate screen and over a
suitable magnet to remove
unwanted particles and materials
before being returned to the flux
supply system. Flux may be
recovered directly back into welding
machine flux containers, provided it
is recovered within a maximum of
five minutes of being deposited on
the steel. Flux recovered within a
maximum of one hour may be
returned to a flux drying oven. Flux
exposed to the atmosphere for
more than one hour after welding,
and all flux that cannot be
recovered from clean, dry, metal
surfaces, shall be discarded.
Page 4 of 14
12.6.6.10 Recovered Flux 12.6.7.4 Electrode Storage

When flux is recovered, at least one When welding is to be suspended for more
third of the total flux used in welding than 8 hours, electrodes shall be removed
shall be properly dried new flux. It shall from the machines and stored in airtight
be added in a way that will ensure coverings or placed in a storage or drying
mixing with the recovered flux. over maintained at a temperature of
1200C-2900C [2500F-5500F] or as
12.6.7 FCAW Electrodes recommended by the manufacturer.
12.6.7.1 All FCAW electrodes shall conform to the 12.6.7.5 Time Limit for Electrode Exposure Electrodes
diffusible hydrogen requirements of the not consumed within 24 hours of
AWS filler metal specifications optional accumulated exposure outside sealed or
supplemental designator H4 or H8. heated storage shall be redried by baking
as described in 12.6.7.6. Electrodes shall
12.6.7.2 Electrode Packaging be identified to facilitate monitoring of total
FCAW shall be received in moisture- atmospheric exposure time. The time
resistant packages that are undamaged. limits may be extended based upon the
They shall be protected against results of tests acceptable to the engineer.
contamination and injury during
shipment and storage. Electrode 12.6.7.6 Drying Temperatures
packages shall remain effectively sealed When approved by manufacturer, FCAW
against moisture until the electrode is electrodes on metal supports may be
required for use. baked once at 2600C-2900C [5500F-5500F]
for a minimum four hours, or as specified
12.6.7.3 Shielding Gas by the manufacturer, to restore their
Any shielding gas or gas mixture condition. If the electrode or the electrode
qualified as described in sect. 5.12 or support is damaged by baking, the
5.13 of the AASHTO/AWS may be used. electrode shall not be used to weld FCMs.
The manufacturer shall provide
certification that the gas or gas mixture 12.7 Welding Procedure Specification (WPS)
conforms to the requirements of sect. WPS qualification shall be performed per 5.12
4.13. or 5.13, except as modified by 12.7 of
AASHTO/D1.5.
12.8 Certification and Qualification

The fabrication shop shall be certified under
the AISC Quality Certification Program.
12.8.1 Individual Qualification

All persons that construct, inspect, or test
FCMs shall be qualified per OSC Quality
Manual sect. 11.
Page 5 of 14
12.8.2 Welding Personnel Qualifications 12.10.1 with 6.26 of the AASHTO/AWS D1.5. No
All welders, including welding operators and laminar discontinuities shall be allowed in the
tack welders, shall be qualified by test within fusion face of groove welds in butt joints
6 months of beginning welding or shall be subject to calculated tensile stress normal to
regularly requalified on an annual basis. For the weld axis, or in the sides (edge) of
welders and welding operators, initial contiguous base metal within 300 mm [12
qualification shall be based upon acceptable in.] of such welds. Except as noted base
results of both mechanical (bend) test and metal at the fusion face of butt, T-, and
RT as described in Section 5, Part B. of corner joints may have discontinuities
AASHTO/AWS D1.5. allowed by 3.2 of AASHTO/AWS D1.5.
Repair welding, if any, shall be done in
12.9 Quality Plan for Receiving of FCM conformance with 12.17.3. Excavated, or
Receiving shall notify QC upon receipt of any repaired, surfaces shall be finished to
Fracture Critical material. QC shall visually produce conditions suitable for final welding.
inspect FCM for Conformity to AASHTO
M160/M160M (ASTM A6/A 6M) 12.11 Repair of Base Metal
requirements for straightness, obvious Base-metal discontinuities adjacent to
damages and defects. Verify heat number, fracture-critical butt joints as described in
grade, length and size with MTR. 12.10 shall be repaired or replaced as
allowed in section 12.11 of AASHTO/AWS
12.10 Thermal Cutting D1.5.
Edges and ends of plates shall be cut to size
by thermal cutting. Universal mill and 12.12 Straightening, Curving, and Cambering
sheared plates shall have a minimum of 5 Cold bending shall be prohibited for all
mm [3.16 in.] of material removed from rolled fracture critical steels. Bent and Distorted
or sheared edges and from ends by thermal material may be corrected prior to assembly
cutting prior to assembly and welding. This and welding by approved Heat-shrink
provision shall not apply to edges of bars method as described in 3.7.3 of the
and shapes as defined in AASHTO AASHTO/AWS D1.5.
M160/M160M (ASTM A 6/a 6M), or the ends
of stiffeners and connection plates where
there is no calculated tensile stress.
12.10.1 Thermal-Cut Edge Requirements Thermal-

cut edges (TCEs) shall meet the
requirements of 3.2 of AASHTO/AWS D1.5
unless otherwise specified in the contract
documents. Visually-detected discontinuities
shall be inspected further using MT as
described in ASTM E 709, and the standards
of acceptance shall be in conformance 1. Place the stringer with the web in the vertical position.
2. Place a support at each end of the stringer, place one
support at approx. 1/4 of the length of the stringer, place
one support at the mid point of the stringer, place one
support at approx. 3/4 of the length of the stringer, the
spacing of the supports are to assure a uniform curvature
in the member. The intermediate supports shall be kept
at a distance not more than two inches below the flange
of the stringer to prevent against sudden sags. The
height of the supports shall be based on how much
camber is needed in the stringer, but at no times shall be
more than two inches below the flange of the stringer.
3. The flange, which will be concave after cambering, shall
be placed upward.
Page 6 of 14
12.13 Tack Welds and Temporary Welds 12.16.1.1 Inspection Personnel Qualifications
All tack welds used in assembly shall be Inspectors shall be qualified as
located within the joint. Tack welds shall specified in 6.1.3. Lead QC and QA Inspectors
meet the requirements of Table 12.2 of shall have a minimum of three years experience
AASHTO/AWS D1.5. Temporary Welds shall in steel bridge fabrication
be removed as outlined in sect. 12.13.3 inspection. A lead inspector shall be defined as
AASHTO/AWS D1.5. the leader of the QA or QC inspection team at a
specific work location, one who assigns other
12.14 Preheat and Interpass Temperature Control inspectors as necessary and supervises their
Preheat and interpass temperature control work. The lead inspector shall be familiar with
shall be as specified in 4.2 AASHTO/AWS and shall have seen each FCM that
D1.5. The minimum preheat and interpass he or she has inspection responsibility for and
temperature for AASHTO M270M (M270) may accept as described in 12.16.5.2. All
Grade 250 (36), 345 (50), 345W (50W), and inspectors shall have the authority to accept or
485W (70W) (ASTM A 709M (A 709) Grade reject materials and workmanship subject to
250 [36], 345 [50], 345W [50W], and 485W review by the lead inspector.
[70W]) steels shall be as described in Tables 12.16.1.2
12.3 and 12.4. The minimum and maximum
preheat temperatures for all other approved 12.16.1.3 NDT Technicians
steel grades shall be per sect. 12.14 of Shall be qualified to ASNT Level II or III in
AASHTO/AWS D1.5. conformance with Recommended Practice
SNT-TC-1A.
12.15 Postweld Thermal Treatments
Shall be required when specified in the 12.16.2 Inspection Requirements
contract documents, WPS, repair procedure, Butt joints in tension and repaired groove
or when required by the Engineer to prevent welds in butt joints shall be QC inspected by
cracking or minimize lamellar tearing. Per both RT and UT. All tension and repaired
sect. 12.15 of AASHTO/AWS D1.5. groove welds in T- and corner joints shall be
QC inspected by UT. Fillet weld repairs shall
12.16 Weld Inspection be inspected by MT. The test length shall
All welds, including repair welds, shall be include 100 percent of the length of the
inspected as required by Section 6 and shall repair, and, when appropriate, at least 300
meet the additional requirements of this FCP mm [12 in.] beyond the ends of each repair
and AASHTO/AWS D1.5. weld.
12.16.1 QA/QC
The Engineer shall provide QA inspection
per the provisions of the contract documents.
The Contractor will provide QC inspection
and tests as described in Section 6 and 12 of
AASHTO/AWS D1.5.
Page 7 of 14
REPAIR PROCEDURE (NON-CRITICAL REPAIRS) Perform MT or PT to determine if the discontinuity was

removed as planned.
12.17 Repair Welding
Repair welding is defined as any welding, AASHTO-M270M (A709M Grade 36 & 50) steel with
including removal of weld or base metal in thickness up to 1-1/2 inches will be preheated to 150F
preparation for welding, necessary to correct min. (Grade 50W) steel with thickness up to 1-1/2
unacceptable discontinuities in materials or inches will be preheated to 200F min. (Grade 36 & 50)
workmanship. steel with thickness 1-1/2 to 2-1/2 inches will be
preheated to 200F min. (Grade 50W) steel with
12.17.2 NON-CRITICAL REPAIR WELDS thickness 1-1/2 to 2-1/2 inches will be preheated to
(PREAPPROVED) 300F min. (Grade 36 & 50) steel with thickness over 2
½ inches will be preheated to 300F min. (Grad 50W)
Non-critical repair welds are generally steel with thickness over 2 ½ inches will be preheated to
welds to deposit additional weld beads or 350F min. Maintain preheat and interpass temperature
layers to compensate for insufficient weld without interruption until repair is complete.
size and to fill limited excavations to
remove unacceptable edge or surface Electrodes purchased for the FCM in this standard shall
discontinuities, rollover or undercut, be H4R with a maximum diameter of 5/32”.
including:
Maximum pass thickness shall be 1/8” in the flat position
12.17.2 (1) GOUGES IN CUT EDGES THAT ARE or 3/16” in the vertical position. Any vertical welds will be
3/8” DEEP, OR LESS. made uphill. Any run-off tabs if used shall be shown in
detail sketches.
It is allowed to remove occasional notches or gouges
no more than 3/16 inch deep by machining or Immediately upon completion of welding and with no
grinding. Cut surfaces shall be left free of slag and reduction in temperature below preheat level, postheat
correction of discontinuities shall be faired to the
repair area to a temperature between 450F min. and
oxygen-cut surfaces with a slope not exceeding one
600F max. for 1 hour min. for each inch of weld
in ten. Other gouges in question will probably be over
thickness or for 2 hours, whichever is less.
3/16 inch deep.
Following postheat and after the plate has cooled
Gouges from cutting will be approximately
sufficiently, the repair weld surface shall be ground flush
perpendicular to the plate surface.
with the plate.
Grind area to remove slag remaining from cutting
Final inspection will be performed after removal of
operation. Grind and clean as necessary for visual
postheat, but not before the following waiting time:
and NDT. Ground surfaces shall form a smooth bright
surface. The excavation shall be shaped equal to the
Thickness Time
groove profile produced by gouging as specified
Material 2” or less 24 hours min.
under prequalified joints; SMAW B-U7 and/or SAW B-
Material over 2” 48 hours min.
U7-S.
After required waiting period, inspect by MT and/or PT.
The above preparation is for single-in-line defects.
Multiple parallel defects can be made with a wider
groove having the same geometry on the sides of the
removed area.
End of ground cavity shall taper smoothly up to plate

or end at the perpendicular plate surface where
required.
Page 8 of 14
12.17.2(2)LAMINAR DISCONTINUITIES Maximum pass thickness shall be 1/8” in the flat position
or 3/16” in the vertical position. Any vertical welds will be
Laminar discontinuities less than one inch deep, or made uphill. Any run-off tabs if used shall be shown in
with a depth less than one-half the thickness of the detail sketches.
cut edge, whichever is less, provided the discontinuity
is not within 12 inches of a butt joint loaded in tension. Immediately upon completion of welding and with no
Repair shall be made by excavating from the cut reduction in temperature below preheat level, postheat
edge. repair area to a temperature between 446F min. and
When arc gouging is used to prepare the groove, thickness or for 2 hours, whichever is less.
preheat prior to gouging. When grinding is used to
prepare the groove preheat prior to welding. Following postheat and after the plate has cooled
The excavation shall be shaped by grinding or air arc with the plate.
gouging equal to the groove profile produced by
gouging as specified under prequalified joints SMAW Final inspection will be performed after removal of
B-U7 and SAW B-U7-S. postheat, but not before the following waiting time:
The above preparation is for single-in-line defects. Thickness Time

Multiple defects can be made with a wider groove Material 2” or less 24 hours min.
having the same geometry on the sides of the Material over 2” 48 hours min.
removed area.
Ends of cavity shall taper smoothly up to plate surface
at a slope not greater than 1 to 1.
MT or PT excavated area to insure removal of

discontinuity.
AASHTO-M270M (A709M Grade 36 & 50) steel with

thickness up to 1-1/2 inches will be preheated to
150F min. (Grade 50W) steel with thickness up to 1-
1/2 inches will be preheated to 200F min. (Grade 36
& 50) steel with thickness 1-1/2 to 2-1/2 inches will be
thickness 1-1/2 to 2-1/2 inches will be preheated to
300F min. (Grade 36 & 50) steel with thickness over
2 ½ inches will be preheated to 300F min. (Grad
50W) steel with thickness over 2 ½ inches will be
preheated to 350F min. Maintain preheat and
interpass temperature without interruption until repair
is complete.
Electrodes purchased for the FCM in this standard

shall be H4R with a maximum diameter of 5/32”.
Page 9 of 14
12.17.2 (3) REPAIR OF BASE METAL SURFACES The above preparation is for single-in-line defects.
AS PROVIDED IN AASHTO Multiple defects can be made with a wider groove
M160/M160M (ASTM A6/A6M). having the same geometry on the sides of the removed
area.
Plates may be conditioned for removal of
imperfections or depressions on surfaces by grinding, End of ground cavity shall taper smoothly up to plate or
provided the area ground is well faired without abrupt end at the perpendicular plate surface where required.
changes in contour and the grinding does not reduce
the thickness of the plate more than 7% under the MT or PT excavated area to insure removal of
nominal thickness for plates ordered to weight per discontinuity.
square foot, but in no case more than 1/8”, or below
the permissible thickness for plates ordered to AASHTO-M270M (A709M Grade 36 & 50) steel with
thickness in inches. Therefore, this procedure should thickness up to 1-1/2 inches will be preheated to 150F
be needed for repair of deeper defects. When min. (Grade 50W) steel with thickness up to 1-1/2
determining whether or not welding is required, the inches will be preheated to 200F min. (Grade 36 & 50)
defect area shall have been previously ground and steel with thickness 1-1/2 to 2-1/2 inches will be
faired during defect exploration. Imperfections where preheated to 200F min. (Grade 50W) steel with
a material separation existed (such as surface scab, thickness 1-1/2 to 2-1/2 inches will be preheated to
lap tears, cracked arc strikes) shall be MT inspected 300F min. (Grade 36 & 50) steel with thickness over 2
to assure removal of imperfections. Imperfections ½ inches will be preheated to 300F min. (Grad 50W)
without separations (such as popped out scabs, steel with thickness over 2 ½ inches will be preheated to
clamp marks) need only be ground to remove 350F min. Maintain preheat and interpass temperature
imperfections. The maximum depth imperfections without interruption until repair is complete.
repaired by this procedure shall be 30% of nominal
thickness. The deeper imperfections on the top and Electrodes purchased for the FCM in this standard shall
bottom surfaces of plates may be removed by be H4R with a maximum diameter of 5/32”.
chipping, grinding, or air arc gouging. The chipped,
ground or gouged area shall not exceed 2% of the Maximum pass thickness shall be 1/8” in the flat position
area of the surface being conditioned. The method of or 3/16” in the vertical position. Any vertical welds will be
repair and inspection used for plate can be used for made uphill. Any run-off tabs if used shall be shown in
structural size shapes and bar size shapes, but must detail sketches.
not exceed the depth limits for depositing weld metal
and total surface limit requirements listed under Immediately upon completion of welding and with no
ASTM A6/A6M. reduction in temperature below preheat level, postheat
Repair by welding will be permitted only when
approved by the inspector. Completion of repair shall
be as follows:
When arc gouging is used to prepare the groove,
preheat prior to gouging. When grinding is used to
with the plate.
prepare the groove preheat prior to welding.
The excavation shall be shaped by grinding or air arc
gouging equal to the groove profile produced by
gouging as specified under prequalified joints SMAW
Thickness Time
B-U7 and SAW B-U7-S.
Page 10 of 14
12.17.2(4) FIRST TIME EXCAVATION. If while the discontinuity is being removed, the
excavated cavity exceeds the limits given above, stop
First time excavation and repair from one side of the repair operation. The repair now is considered
groove welds and fillet welds that contain critical. (See AASHTO/AWS D1.5, 12.17.3).
unacceptable porosity, slag and fusion discontinuities,
provided the excavations do not exceed the following If the discontinuity is removed by removing no more
limits: metal than allowed within the scope of this procedure,
then prepare the excavated cavity for welding by
Length of weld “L” Length of Excavation grinding or gouging and grinding to the approximate
Up to 1’-6” L or 10”, shape as shown in sketch for Repair Procedure 9-66 for
whichever is less groove welds, and sketch for Repair Procedure 9-66 for
Over 1’-6” to 3’-0” 1’-0” fillet welds. Ground surfaces shall form a smooth bright
Over 3’-0” to 6’-0” 1’-6” surface.
Over 6’-0” to 12’-0” 2’
Over 12’-1” to 24’-0” 3’ The ends of the excavation in groove welds shall taper
Over 24’-0” 3’ or 10% L, up to the plate surface at a slope not greater than 1 to 1
whichever is greater and to the surface of fillet welds at the same slope.
The depth of groove weld excavation shall not exceed MT or PT ground area to insure removal of
65% of the weld size shown on the drawings. discontinuity.
Determine depth of repairable discontinuity in groove AASHTO-M270M (A709M Grade 36 & 50) steel with
welds from each plate surface using UT. Repairs will thickness up to 1-1/2 inches will be preheated to 150F
normally be done from the near surface, however, min. (Grade 50W) steel with thickness up to 1-1/2
material handling considerations may show a inches will be preheated to 200F min. (Grade 36 & 50)
preference for repairing from the far surface. This steel with thickness 1-1/2 to 2-1/2 inches will be
may not be done if the excavation can be expected to preheated to 200F min. (Grade 50W) steel with
exceed the 65% value given above. thickness 1-1/2 to 2-1/2 inches will be preheated to
300F min. (Grade 36 & 50) steel with thickness over 2
The length of repairable discontinuity in fillet welds ½ inches will be preheated to 300F min. (Grad 50W)
will be determined by MT and VT. steel with thickness over 2 ½ inches will be preheated to
350F min. Maintain preheat and interpass temperature
For groove welds, layout discontinuity location on without interruption until repair is complete.
plate surface as it appears to be located based on
NDE. Mark plate showing intended limits of Electrodes purchased for the FCM in this standard shall
exploration. Mark fillet weld where discontinuities be H4R with a maximum diameter of 5/32”. The process
appear from MT or VT. used may be either SMAW or SAW depending upon
defect size and shop preference.
When arc gouging is used to prepare the groove,
preheat prior to gouging. When grinding is used to Maximum pass thickness shall be 1/8” for SMAW or ¼”
prepare the groove preheat prior to welding. for SAW. Any run-off tabs if used shall be shown in
detail sketches.
Using carbon arc air gouging or grinding excavate
metal to marked limits of intended exploration. Gouge Immediately upon completion of welding and with no
to anticipated depth of defect working in reduction in temperature below preheat level, postheat
approximately 1/8” layers or less. If the discontinuity
becomes visible during this operation, then
exploration may continue in length until the
discontinuity is removed.
Page 11 of 14
Following postheat and after the plate has cooled Immediately upon completion of welding and with no
sufficiently, the repair weld surface shall be ground reduction in temperature below preheat level, postheat
flush with the plate. repair area to a temperature between 446F min. and
Final inspection will be performed after removal of thickness or for 2 hours, whichever is less.
Thickness Time sufficiently, the repair weld surface shall be ground flush
Material 2” or less 24 hours min. with the plate.
After required waiting period, inspect by MT (for fillet postheat, but not before the following waiting time:
welds). For tension butt welds inspect by UT and RT.
Thickness Time
12.17.2(5)HOT OR RESTRAINT CRACKS Material 2” or less 24 hours min.
A repair to cracks confined to root passes, discovered
and corrected before depositing subsequent weld After required waiting period, inspect by MT and/or PT.
passes.
12.17.2(6)REPAIRS TO ENDS OF MEMBERS WHERE
Preheat as required and maintain until all welding is THERE IS NO DEADLOAD OR
performed. LIVELOAD STRESS.
Arc air gouge or grind to sound metal. Ground When arc gouging is used to prepare the groove,
surfaces shall form a smooth bright surface. preheat prior to gouging. When grinding is used to
prepare the groove preheat prior to welding.
VT and MT or PT the gouged and ground area to
insure removal of the crack. Gouge or grind to the approximate shape shown in
sketch for Repair Procedure 9-66. Ground surfaces
AASHTO-M270M (A709M Grade 36 & 50) steel with shall form a smooth bright surface.
thickness up to 1-1/2 inches will be preheated to
150F min. (Grade 50W) steel with thickness up to 1- Ends of cavity shall taper smoothly up to plate surface
1/2 inches will be preheated to 200F min. (Grade 36 at a slope not greater than 1 to 1.
& 50) steel with thickness 1-1/2 to 2-1/2 inches will be
preheated to 200F min. (Grade 50W) steel with MT or PT excavated area to insure removal of
thickness 1-1/2 to 2-1/2 inches will be preheated to discontinuity.
300F min. (Grade 36 & 50) steel with thickness over
2 ½ inches will be preheated to 300F min. (Grad AASHTO-M270M (A709M Grade 36 & 50) steel with
50W) steel with thickness over 2 ½ inches will be thickness up to 1-1/2 inches will be preheated to 150F
preheated to 350F min. Maintain preheat and min. (Grade 50W) steel with thickness up to 1-1/2
interpass temperature without interruption until repair inches will be preheated to 200F min. (Grade 36 & 50)
is complete. steel with thickness 1-1/2 to 2-1/2 inches will be
Electrodes purchased for the FCM in this standard thickness 1-1/2 to 2-1/2 inches will be preheated to
shall be H4R with a maximum diameter of 5/32”. 300F min. (Grade 36 & 50) steel with thickness over 2
½ inches will be preheated to 300F min. (Grad 50W)
Maximum pass thickness shall be 1/8”. steel with thickness over 2 ½ inches will be preheated to
350F min. Maintain preheat and interpass temperature
without interruption until repair is complete.
Page 12 of 14
Electrodes purchased for the FCM in this standard be preheated to 350F min. Maintain preheat and
shall be H4R with a maximum diameter of 5/32”. interpass temperature without interruption until repair is
complete.
Maximum pass thickness shall be 1/8” in the flat
position or 3/16” in the vertical position. Any vertical Electrodes purchased for the FCM in this standard shall
welds will be made uphill. Any run-off tabs if used be H4R with a maximum diameter of 5/32”. The process
shall be shown in detail sketches. used may be either SMAW or SAW depending upon
defect size and shop preference.
Immediately upon completion of welding and with no
reduction in temperature below preheat level, Maximum pass thickness shall be 1/8” for SMAW or ¼”
postheat repair area to a temperature between 446F for SAW. Any run-off tabs if used shall be shown in
min. and 600F max. for 1 hour min. for each inch of detail sketches.
weld thickness or for 2 hours, whichever is less.
Immediately upon completion of welding and with no
Following postheat and after the plate has cooled reduction in temperature below preheat level, postheat
sufficiently, the repair weld surface shall be ground repair area to a temperature between 446F min. and
flush with the plate. 600F max. for 1 hour min. for each inch of weld
postheat, but not before the following waiting time: Following postheat and after the plate has cooled
Thickness Time with the plate.
Material over 2” 48 hours min. Final inspection will be performed after removal of
After required waiting period, inspect by MT and/or
PT. Thickness Time
12.17.2(7) DEPOSITION OF WELD METAL Material over 2” 48 hours min.
Deposition of weld metal up to 3/8” or ¼” the material After required waiting period, inspect by MT or PT.
thickness, whichever is less, to correct for length or Inspect by UT and RT if required.
joint geometry.
12.17.2(8)EXCEPT AS REQUIRED BY 12.15, PWHT IS
MT or PT area where weld metal is to be deposited to NOT REQUIRED, UNLESS THE
insure no rejectable discontinuities is present. EXCAVATION IS GREATER THAN 1”
DEEP.
AASHTO-M270M (A709M Grade 36 & 50) steel with
thickness up to 1-1/2 inches will be preheated to 12.17.2.1 Repair procedures as described in these
150F min. (Grade 50W) steel with thickness up to 1- sections (AASHTO/AWS D1.5,
1/2 inches will be preheated to 200F min. (Grade 36 SECTION 12.17.2 (1 THRU 8) are
& 50) steel with thickness 1-1/2 to 2-1/2 inches will be considered non-critical and should be
preheated to 200F min. (Grade 50W) steel with accepted as pre-approved. All other
thickness 1-1/2 to 2-1/2 inches will be preheated to repair procedures are considered critical
300F min. (Grade 36 & 50) steel with thickness over and shall be individually approved by
2 ½ inches will be preheated to 300F min. (Grad the Engineer before repair welding is
50W) steel with thickness over 2 ½ inches will begun. AASHTO/AWS D1.5, SECTION
12.17.3.
All repair welding shall be subject to QC and QA

inspection.
Page 13 of 14
12.17.3 Critical Weld Repairs. Except as provided in

12.17.2, all welded repairs shall be considered critical.
They include, but are not limited to the following:
(1) Repair of gouges in cut edges greater than 10 mm
[3/8 in.] deep.
(2) Repair of laminar discontinuities, except as provided
in 12.17.2(2). Repair may be made from the cut
edge, or from a surface, as approved by the Engineer.
(3) Repair of surface or internal discontinuities in
rolled, forged, and cast products not covered by
12.17.2(3).
(4) Repair of cracks in base metal and welds including
lamellar tears except as provided in 12.17.2(5).
(5) Corrections requiring weld removal and rewelding
except as provided in 12.17.2(4).
(6) All welding to correct errors in fabrication such as
improper cutting, punching, drilling, machining, assembly,
etc.
Page 14 of 14

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vhicoa venezuelan QUALITY CONTROL MANUAL

Procedure for Fracture Control Plan

12.1 General Provisions 12.2.2 Fracture Critical Member (FCM) (Cont’d)

12.2 Definitions 12.3.1 All fracture critical members shall be identified

12.4 Purchasing Base Metal Requirements 12.4.4 Purchasing Data

12.6Consumable Requirements 12.6.5 (Cont’d)

12.6.6.10 Recovered Flux 12.6.7.4 Electrode Storage

12.8 Certification and Qualification

12.8.1 Individual Qualification

12.10.1 Thermal-Cut Edge Requirements Thermal-

REPAIR PROCEDURE (NON-CRITICAL REPAIRS) Perform MT or PT to determine if the discontinuity was

End of ground cavity shall taper smoothly up to plate

The above preparation is for single-in-line defects. Thickness Time

MT or PT excavated area to insure removal of

AASHTO-M270M (A709M Grade 36 & 50) steel with

Electrodes purchased for the FCM in this standard

After required waiting period, inspect by MT and/or PT.

All repair welding shall be subject to QC and QA

12.17.3 Critical Weld Repairs. Except as provided in

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