Information
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Document No.
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Audit Title
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Client / Site
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Conducted on
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Prepared by
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Location
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Personnel
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Other company information
5 Management Responsibility
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Handwritten notes
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5.1 (a) Has executive management established and documented a Quality policy?
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5.1 (b) Have measurable Quality goals been established and measured to a baseline?
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5.2 Have Management reviews taken place and include all required bullet points?
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5.3 Has a Management Representative been appointed and does their duties include all of the bullet points?
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SPE 5.3.3 Is there adequate process equipment?
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5.4 Have adequate resources been provided which include personnel, buildings, workspace, equipment and utilities?
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5.4.1 Is there evidence that QA, MR and Production management have 5 years experience in steel fabrication?
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5.4.1 Is there evidence that QC, purchasing management and detailing checkers have 3 yrs experience in steel fabrication?
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SPE 5.3.1 does top individual for coating have 1 year experience and is the objective evidence?
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5.4.1 Sufficient welding inspectors on staff? AWS CWI?
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5.4.1 Sufficient ASNT qualified personnel on staff or under contract? Administrator and technician?
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5.4.1 Is there a competent welding technician on staff?
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5.4.1 QA QC MR may not report to production, is there an org chart to show this separation?
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5.4.1 Is there evidence that the management functions have qualifications (bullets)<br>
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5.4.2 Bldgs, workspace, Utilities. SPE 5.3.2 Can the firm demonstrate methods to control ambient conditions to prevent surface contamination? (P1,2,3)
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5.4.3 Process equipment and software SPE 5.3.3 (bullets)
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5.4.4 Is there adequate inspection equipment?<br>SPE 5.3.4
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5.5 Have appropriate lines of communication regarding the effectiveness of the QMS been established?
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5.6 Have the documentation requirements for an effective QMS been established, maintained and approved?
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5.6 Other Documentation requirements - Org chart, Facility plan, Equipment list, Process interactions ...SPE 5.4
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F 5.6.2.1 Fracture Control Plan - detailing, Procurement, Welding, Fabrication, Inspection, Repairs....
6. Contract and Project Specification Review and Communication.
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Handwritten notes
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6. Is there an approved documented procedure for contract and spec review?
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6. Does review provide for the identification planning and recording of project Requirments?
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6. Are there records for audit samples of these reviews?
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6. Is there an effective communication process? Changes, RFI process, Distribution....
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A6 Is there an effective and controlled communication and recording process for decisions and approvals for Advanced bridge requirements?
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These include special fabrication-related requirements for advanced bridges such as: Shop assemblies, dimensional control and verification, welding, NDT, high performance materials, erection considerations...
7. Detailing
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Handwritten notes
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7.1.1 Is there an approved documented procedure for preparation of shop & erection dwgs?
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7.1.1 Is there a effective RFI process in place?
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7.1.2 Are detailing standards which include all bullet points of the standard being effectively utilized?
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I 7.1.2 Are the methods for presenting Assembly drawings included in the detailing standard?
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F 7.1.2 Are the methods for Identifying Fracture Critical Welds on Erection Framing Drawings included in the detailing standard?
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7.1.3.1 Is there an approved documented procedure for Checking of shop & erection dwgs?
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7.1.3 Is there a provision describing the method used to release drawings for fabrication?
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7.1.3.1 Does it call for the identification of the individual checker?
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7.1.3.1 Does it identification of method to verify output of computer generated dwgs and or models?
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7.1.3.1 Does it include (if applicable) extent of review of sub-contracted detailed dwgs?
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7.1.3.1 Does the procedure for checking include all of the bulleted items per the standard?
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7.1.3.2 Is the Customer approval process documented?
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7.1.3.3 Is the Control of external supplied dwgs process documented?
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7.2.1 Are required references (per contract) maintained? Element 3
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7.2.1 Has the responsibilities for detailing management been assigned to a qualified representative within the organization?
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7.2.1 Are Detailing management responsibilities defined per the standard (bullets)?
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7.2.2 Are experience qualifications of personnel utilized for Detailing and Checking verifiable? 5.4.1
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I 7.2.2 Is there evidence that detailing personnel have understanding of bridge geometry such as vertical and horizontal alignment, cross slope and roadway transitions?
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7.2.3 Subcontract detailers..Has the qualification and selection process been defined as per 10.2?
8. Document and Data Control (Review, Approval, Revision, Access, Obsolescence and Transmittal0
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Hand written notes
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8. Is there an approved documented procedure for document and data control?
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8.1 Are QMS documents reviewed for adequacy and approved by the appropriate level of authority?
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8.1 Has the frequency of this review been established? SPE
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8.2 Are customer requirement revisions controled and distributed to necessary departments?
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8.2 Has a method of recording the receipt, change, issue and distribution been established and in use?
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8.3 Is there a revision control process for QMS documents?
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8.4 Do personnel have access to relevant and current procedures and policies?
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8.5 Is there an effective method established to prevent inadvertent use of obsolescent controlled documents? SPE 8.4
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8.5 Is there a transmittal system established for controlled documents?
9. Control of Quality Records - (Identification, Collection, Storage, Retrieval, Maintenance, Retention, Disposition)
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Hand written notes
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9. Is there an approved documented procedure for the control of Quality records?
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Procedure to include: Identification, Collection, Storage, Maintenance, Retrieval, Retention, (backup of electronic data) Disposition and loss prevention.
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9.1 Are retention times recorded and maintained? SPE 9.2
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9.2 Are Quality records made available for evaluation and review to the owner and fabricator for required time period?
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SPE 9.3 Minimum required records:<br>
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Contract review RFI Training COC Qualification and evaluation of sub contractors and suppliers Deviations Surface prep and coating application NC & CA Final inspection Management review
10. Purchasing
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Hand written notes
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10. Is there an approved documented procedure for purchasing? SPE 10.1
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10.1 Is purchasing data clearly described on PO documents? SPE 10.2
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Type of service, material Applicable specifications (witness points) Delivery instructions Required COC, MTR, Other required records ASTM order information SPE - product data sheets and required testing data
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F AWS D1.5 12.6.7.3 COC for welding gas (4.13) <br>12.6.1 for wire (a501)
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F 10.1 Is Material used for FC applications identified on purchasing documents? <br>AWS D1.5 12.4 base metal ...fine grain practice, CVN testing req, prohibit mill repairs ...toughness on mill order I.e. 709 req 25@40 for FC <br>AWS D1.5 12.6 consumables ...certified test results..heat and lot as defined in AWS 5.01....exempt ASME, ABS or loyds...12.6.2.1 diffusible hydrogen determined by AWS A4.3...12.6.2.2 H designator...
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10.2 is there an selection and evaluation process for suppliers and sub-contractors and is there a procedure and records maintained? SPE 10.3 suppliers 10.4 Sub-contractors
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10.3 Do fabrication subcontractors have the required AISC certification?
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10.4 Are detailing subcontractors evaluated and is this process defined and records maintained?
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10.5 Is verification of purchased items under control and are records maintained as required by procedure?
11. Material Identification
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Hand written notes
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11.1 Is there an approved documented procedure for material identification from the point of receipt to the 1st fabrication process and is it being followed?
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Identification of SS material - MTR Coating materials - SPE container - color, number ID, lot/batch, quantity, date of manufacture, manufacture ID Metallic coating - composition and ASTM Fasteners - type, grade, size, lot, MTR
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11.1 Are records maintained...COC, MTR etc?
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F 11.2 does procedure and practice provide for heat traceability and MTR ID for FC material throughout fabrication process?
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11.2 Is material traceable to corresponding heat # if req by contract?
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SPE 11.2 Are coating materials stored properly? Expired material marked?
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SPE 11.3 COC for Coating materials - product name, manufacture name, batch number, date of manufacture, product data sheet, statement that product complies to spec, <br>
12. Fabrication process control
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Hand written notes
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12. Are there approved procedures in place for fabrication processes including "special processes" done at the facility?
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Processes include: thermal and mechanical cutting, fitting and assembly, welding, drilling, punching, bolting, shearing, milling, sweep, camber, bending, straightening, heating and coating
Welding
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12.1 is there an approved and Effective welding procedure in place that includes records of:<br>WPS <br>Preheat<br>PQR <br>WQTR<br>Welder POE
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I 5.4.3 Are Welding processes and equipment automatic, mechanized or semi-automatic? (No SMAW exclusive for intermediate)
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12.1 WPS - Welding procedure specification per applicable code(s)
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F 12.1 WPS FC
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12.1 Pre-heat / post heat requirements
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F 12.1 Pre heat / post heat for FC (AWS D1.5
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F 12.1 FC consumable storage (AWS D1.5 12.6)
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12.1 PQR-where required
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F 12.1 FC PQR for code approved processes (ESW EGW and GMAW prohibited AWS 12.5.1) GMAW metal cored see 12.5.1 (AWS D 1.5 12.7.4 POE of PQR) fillet weld soundness test (AWS D1.5 12.7.3)<br>
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F12.1 PQR POE (AWS D 1.5 12.7.4)
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12.1 WQTR-welder qualification test records (AWS D1.5) and POE
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F12.1 WPQR POE welder performance qualification records, evidence that POE has not expired (AWS D 1.5 12.8.2)
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12.1 Traceability of welds to the welders who produce them.
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12.1 WPS close proximity and used by the welders.
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A 12.1 Is there an effective Distortion control program?
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12.1 Is there a flux recovery and drying procedure? AWS D1.5 12.6.6 SAW
Bolting
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12.2 Bolt installation
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12.2 Is there an approved/demonstrable procedure and practice for bolt installation which includes the fabricators Pre installation verification testing preferred method for pretensioned and slip critical joints?
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12.2 Is there an approved/demonstrable procedure and process for RCT per AASHTO?
Coating
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12.3 Is there an approved procedure and process in place and being followed for material preparations or to application of coatings?
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SPE 12.1 Is there a controlled process for surface preparation?
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12.4 Is there an approved procedure and process in place and being followed for coating application?
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SPE 12.2.1 Application records (see bullets)
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SPE 12.2 Is there an effective/demonstrable process for mixing and coating application? Including controlling conditions, debris, masking?
Equipment Maintenance
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12.5 Is there an approved procedure and process in place and being followed for equipment maintenance, including preventive maintenance?
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SPE 12.2.2 Is there an approved procedure for PM and prep and coating equipment?
13. Inspection and testing
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Hand written notes
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<br>13. Are there approved procedures and processes in place and being followed, including sampling plans, for inspection?
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13 Are levels and frequency adjusted accordingly of effectiveness? (Sampling plan cannot be 0)
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SPE 13 Is DFT inspection in accordance with SSPC-PA 2?
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13.1 Have qualified personnel been assigned inspection duties? ( Do not inspect their own work ) experience 1 year required 13.2.3 is their competency verifiable?<br>SPE 13.1
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13.2.1 Is receiving inspection carried out? are there indications of this process? MTR /COC verification of material received.
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13.2.2 Are there appropriate in-process inspections carried out? are there indications of this process?
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13.2.3 Is appropriate final inspections carried out? are they documented? competency of inspectors verifiable?
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13.2.4 Are there records and marks to document inspections? Are they verifiable until final inspection? Are records produced maintained per element 9?
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SPE 13.2 are final inspections recorded which include, surface prep, DFT, Visual, DFT accuracy per SSPC-PA 2
14 Calibration of inspection and test equipment
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Hand written notes
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14. Are there approved procedures in place for calibration of (MI&T) inspection and test equipment?
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14. Does the process and records indicate all of the bullet points required by the standard for each of the pieces of equipment?
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Service use Handling and storage Frequency ID of relationship to NIST Calibration procedure for each piece of M&TE Acceptance criteria Action taken when out of calibration Calibration record maintenance Protection fro inadvertent use of uncalibrated equipment
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14. Are there records of master gages where indicated traceable to NIST?
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SPE 14. Is there evidence of the Verification of accuracy of the DFT gage per SSPC PA 2 using shims/blocks traceable to NIST? Wet film gage as req by contract..
15. Control of Non-Conformances
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Hand written notes
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15. Is there an approved procedure in place for the control of non-conformances?
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15 Does it include inspectors authority to stop work and responsibility to inform production supervision?
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15. Are non-conformances being recorded? Do they include: what was inspected, who performed, date of inspection and inspection results?
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15.1 Do the procedures contain a provision for non-conforming processes?
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15.2 Are there methods to record non-conforming product and keep them from reaching the customer? Are they identified, evaluated, segregated and if repair Reinspected and recorded?
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15.2 Is there a material dispositioning process including engineering approval where required?
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SPE 15 Is there a provision for owners approval for use of where required? Expired materials are non-conforming. May be "used as is" or as "owner approved" ref SSPC PA 1.
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F 15.2 Is there a FC repair provision in the procedures? Critical and non-critical. If owner approval is required is a record kept?
16. Corrective Action
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Hand written notes
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16. Is there an approved procedure in place for Corrective Action?
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16. Is the CA process applied at the times indicated by the bullet points of the standard?<br>Customer complaint<br>Repetitive NC<br>In or Ex audit<br>QMS NC<br>Sever or costly NC
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16 Does the CA procedure include all of the bullet points of the standard?<br>Record <br>Assign responsibility<br>Remedial action<br>Investigate root cause<br>Actions to be taken to prevent reoccurrence<br>Communicate<br>Verify and monitor for effectiveness
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16. Are records of CA maintained at least until an annual MR takes place?
17. Handling, Storage, and Delivery of Product and Materials
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Hand written notes
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17. Are materials and product stored and shipped with care required by contract? SPE
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17 Is "material on hand" or owner supplied material protected?
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F Are consumables stored properly?
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F is material handled so as not to damage and cause unneeded base metal repair?
18. Training
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Hand written notes
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18. Do the records indicate the subject matter topics, course outline, qualified person providing the training, who attended and date of training? SPE
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18. Is there a record of comprehension of subject matter (desirable)?
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SPE 18.2 Does training include items listed in ASTM D 3276?
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Intermediate Bridge: Has fabricator established a training program for intermediate bridges for the workforce?
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Advanced Bridge: Has fabricator established a training program for advanced bridges for the workforce?
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Fracture Critical Bridge Members: Has fabricator established a training program for advanced bridges for the workforce?
19. Internal Audit
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Hand written notes
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19. Has an internal audit been conducted by a qualified individual? SPE
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19. Does the record indicate findings and are these incorporated into the CA process?
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19. Is the record of the IA maintained at least until the annual MR?
Qualifications for Supplements
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Intermediate bridge:<br>Has fabricator supplied plate girder spans with field splices for highway or railroad bridges within the last 5 yrs? See also training
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Advanced Bridge: <br>Has fabricator supplied advanced bridges or intermediate bridges within the last 5 years? See also training
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Fracture Critical:<br>Has the fabricator supplied FC members in accordance with AWS D 1.5 within the last 5 yrs? See also training.
