SMITH-EMERY LABORATORIES

104 West 40th Street Suite 400#

New York City, NY 10018

WEEKLY SURVEILLANCE REPORT

Project Name: Lighthouse Point Date: 20-Aug-2023
Fabricator: Big Span Structures
Fabricator Address: Zaragoza 997, Sin Nombre de Col 10, 66072 Cd Gral Escobedo, N. L., Monterrey, Mexico
Inspection(s) Performed: Facility Audit for Lighthouse Point Fabric Canopy fabrication.
Document(s) Reviewed: Fabrication drawings, material receiving records, welding procedure, and welder qualification
records & inspection records.

Inspection Request (IR): WEEKLY REPORT

Executive Summary: This is the summary report for the work observed at the fabricator mentioned above for the
week ending Sunday, August 20, 2023.

 Smith Emery Laboratories (SEL) Quality Assurance Inspector Shailesh Wadkar (QAI) was present at the Big
Span Structures facility at Nuevo Leon, Monterrey, Mexico from Monday to Sunday for Week ending
August/20/2023.

 The objective of this surveillance is to evaluate Big Span Structure’s general compliance with Clients
requirements which includes, but is not limited to, American Welding Society (AWS) D1.1 - 2015 Structural
Welding Code-Steel, and current relevant material specifications.

Updated manpower details are shown in the chart below.

Total man power Total welders BR3-1 staffing DP1-C/D/E/Diablo staffing BR1-A/D staffing
Manpower statistics FB1
35
30
25
20
15
10
5
0
2-May
4-May
6-May
9-May
11-May
13-May
16-May
18-May
20-May
23-May
25-May
27-May
30-May

10-Jun
13-Jun
15-Jun
17-Jun
20-Jun
22-Jun
24-Jun
27-Jun
29-Jun
1-Jun
3-Jun
6-Jun
8-Jun
26-Apr
28-Apr

11-Jul
13-Jul
15-Jul
18-Jul
20-Jul
22-Jul
25-Jul
27-Jul
31-Jul
1-Jul
4-Jul
6-Jul
8-Jul

2-Aug
4-Aug
6-Aug
8-Aug
10-Aug
12-Aug
14-Aug
16-Aug
18-Aug
20-Aug
 Overall view of the fabrication shop – Bay 1

Overall view of the fabrication shop – Bay 2

Key points this week related to production progress:

1) BR1-1st assembly: Flush grinding of the diablo connections at the bottom end of the HSS beam (closer to the
perimeter of the assembly) is completed.
2) BR1-1st assembly: Fit-up and welding of the diablo connection at the top end of the assembly is in progress.
Flush grinding of the completed diablo connections at the top end of the HSS beam is in progress.
3) BR1-1st assembly: Fit-up and welding of the HSS connection with the main pipe (at the top end of the assembly)
is in progress.
4) BR1-1st assembly: Fit-up and welding of the diablo connections on the perimeter HSS is in progress.
5) DP1-C: Fit-up of the columns with perimeter HSS on DP1-C is in progress (for leaf B, C & D).
6) DP1-C: Fit-up correction of the columns with perimeter HSS on DP1-C is in progress (for leaf E, F & G).
7) DP1-C: Leaf A is dismantled as the perimeter HSS pipe of this leaf was not of correct profile.
8) Fabrication of the branch connections of this assembly is in progress.
9) Welder qualification test coupon welding was conducted for 2 welders (GTAW - 6GR).

Production concerns:

1) BR1-1, DP1-C & DP1-D assemblies: WQT tests / certificates for 6GR position, yet to be submitted (applicable for
welders utilized for welding of T-K-Y joints).
2) Welding procedure - 6GR position - FCAW process and GTAW process - not yet submitted.
3) Fit-up correction for welds on BR1-2nd assembly is to be done - no root gap seen on few of the identified joints.

Production Activities:

Issues related with the Government Regulations were resolved and the fabrication activities were resumed on
Monday (14-Aug) onwards.

BR1-1 (1st assembly):

The below noted table shows the summary of the production progress for BR1-1st assembly.

Side A Side B

Fit-up & welding of 6.625” dia HSS with the 8.625” dia Fit-up and welding is in Fit-up and welding is in
top main pipe. progress. progress.
 Welding of 6.625” dia HSS with the perimeter HSS
✔ ✔
(bottom connection).
Welding of the diablos with the HSS at the bottom
✔ ✔
end.
Fit-up and welding is in Fit-up and welding is in
Welding of the diablos with the HSS at the Top end.
progress. progress.

Fit-up and welding of diablos on the perimeter HSS at Fit-up complete. Welding
✔
bottom in progress.
Fit-up and welding of diablos on the perimeter HSS at
Fit-up is in progress Fit-up is in progress
top
Fabrication of the columns

Fit-up of the columns with the assembly

Flush grinding of the diablo welds @ the bottom end
✔ ✔
(HSS to perimeter HSS)
Flush grinding of the diablo welds @ the top end

2” x 3/8” flat bar fabrication & welding

Base metal repair welding on perimeter HSS sections of BR1-1 (1st assembly):
Base metal repair welding on the perimeter HSS section of this assembly was continued to be done. Spot welding,
utilizing flux cored arc welding process, followed by flush grinding was performed. This base metal damage concern
and the repair welding process was referred to EOR for his comments and was accepted.

BR1-1: Base metal repair welding + grinding on the perimeter HSS section of BR1-1 ongoing. Base metal repair
welding was referred to EOR for his comments and was accepted.

Base metal repair welding after removal of temporary attachments @ the diablo-HSS connections BR1-1 (1st
assembly):
Base metal repair welding + necessary grinding after removal of the temporary attachments at the diablo to HSS
joints is to be completed (at all the diablo connection locations). QAI performed the visual inspection and all the
locations that needed repair are marked and informed to BigSpan QC.
 BR1-1: Base metal repair welding after removal of temporary attachment is to be completed for all the diablo
loactions of this assembly.

BR1-1st Assembly:
QAI observed welding of vertical HSS with the perimeter HSS is complete. Welding of the diablos with the HSS at the
bottom end of the HSS beam & closer to the perimeter of the assembly is complete. Flush grinding of the diablo -HSS
connection welds is completed.

Fit-up and welding of the 6.625” dia HSS with the 8.625” dia top main pipe is in progress. QAI observed that the base
metal preparation is done before fit-up of these connections. QAI performed the fit-up inspection and was observed
satisfactory for welding. To ensure soundness of the weld at the HSS intersection with main pipe, welding of dia
6.625” HSS with dia 8.625” HSS is completed for one side of the assembly, inspected and accepted, before starting
the fit-up and welding of 6.625” HSS of the another side of this assembly.

BR1-1st assembly: Fit-up of the 6.625” dia HSS with the 8.625” dia top main pipe is in progress. Base metal
preparation and bevel preparation was verified during fit-up.

Fit-up of the diablos on 6.625” HSS @ the top end of the assembly and on the perimeter HSS section is in progress.
QAI verified the bevel preparation along with the root gap and was found acceptable. The orientation of the bolt
holes was verified and was observed in compliance with the drawing requirements. Welding is in progress for the
joints for which the fit-up is accepted. Welding was observed to be performed utilizing gas tungsten arc welding
(GTAW) process. Welding consumables were verified and was observed as INFRA ER70S-3.
BR1-1st assembly: Root gap and bevel angle was verified before fit-up of the connections and were found
acceptable.

BR1-1st assembly: Fit-up of the diablos on the

BR1-1st assembly: 2” x 3/8” thk plates were received
perimeter HSS is in progress. Orientation of the bolt
without R 1/4” radius on the edges. Deburring of the
holes and the stiffeners was verified and was observed
edges and removal of sharp corners is in progress.
as per drawing.

BR1-1st assembly: QAI verified the orientation and the angular alignment of the diablo stiffeners with reference
to the HSS connections.
 BR1-1st assembly: QAI verified the welding consumables, gas and flow rate while welding was in progress.
Welding process utilized was GTAW.

DP1-C Assembly:
The below noted table shows the summary of the production progress for DP1-C assembly.

DP1-C - fabrication summary Leaf A Leaf B Leaf C Leaf D Leaf E Leaf F Leaf G

Welding of horizontal HSS with

✔ ✔ ✔ ✔ ✔
perimeter HSS
Welding of diablos with
✔ ✔ ✔ ✔
horizontal HSS
Flush grinding of diablo to HSS
✔ ✔ ✔ ✔ ✔ ✔
welds
Fit-up of columns (in between
✔ ✔
leafs)
Welding of the column HSS
with diablos on columns
Welding of the column HSS
with leaf perimeter HSS
Fit-up of the perimeter end
sections
 Welding of perimeter HSS - butt
welds
Fabrication of Ø 6.625”
branches
Fabrication of Ø 8.625”
columns
Fit-up of the Ø 8.625” columns
with leaf perimeter HSS
Welding of 2” x 3/8” thk plate
on the perimeter pipe

QAI observed that the leaf A of this assembly is dismantled, as the perimeter HSS pipe was rejected (due to incorrect
profile after forming). This perimeter HSS is needed now to be redone followed by the assembly of the horizontal
HSS connections.

Flush grinding of the diablo to HSS connection weld of this assembly is in progress (for leaf G to leaf C). Fit-up / fit-up
correction of the columns with the leaf perimeter HSS, is in progress. Welding was performed utilizing GTAW
process. QAI verified the welding consumables and were observed as per WPS requirments.

DP1-C: Flush grinding of the diablo to HSS connection weld is in progress. Base metal repair after removal of
temporary attachment is to be completed.
 DP1-C: Fit-up or fit-up correction of the columns with the perimeter HSS is in progress.

DP1-C: Fabrication of the Ø 6.625” branch connections is in progress for this assembly.

Welder Qualifications:

 QAI observed BigSpan performing welding of WQT test coupon for GTAW welding process.
 Fitup of the test coupon was observed to be done as per figure 9.25 - test joint for T-K-Y connection without
backing - pipe joint and welded @ 6GR position.
 Test coupon thickness was observed as 0.28t * 0.562t, pipe dia of both the pieces was observed as 6.5” x 6”
length.
 Welders were identified as Rolando Vazquez Garcis (RVG) and Cesar Gildardo Gomez Cano (CGGC).
 Welding cousumables were verified and was observed as INFRA Electrodes, ER70S-3, 3.2mm dia, AWS A5.18,
ASME SFA 5.18, marked as INFRA ER70S-3.
 No pre heat was observed to be applied (ambient temperature was observed as 35°C) before starting the
welding of the coupon.
 Root gap of 3.2mm was maintained during fit-up.
 QAI performed visual inspection after completion of the root pas and final welding and was found acceptable
for further tests.
 WQT test coupons were prepared in compliance with the details as shown above.

GTAW welding process - WPS coupon (#1) welded @ GTAW welding process - WPS coupon (#2) welded @
6GR position - test coupon thickness 0.28 * 0.562 - 6GR position - test coupon thickness 0.28 * 0.562 -
welder Rolando Vazquez Garcis (RVG). welder Cesar Gildardo Gomez Cano (CGGC).
 Fit-up, root gap was verified before welding and was Consumables ER70S-3, 3.2mm dia, AWS A 5.18,
observed in compliance with the code requirements. marked as INFRA ER70S-3.

DP1-D / DP1-E / BR3-1 / BR1-2nd assembly:

No progress was observed on these assemblies as the man power is prioritized on DP1-C and BR1-1 assemblies.

Inspected By: Shailesh Wadkar Quality Assurance Inspector

AWS QC1 SCWI # 17060208

Reviewed By: Chris Dsouza QA Reviewer