Shop Inspection Handbook for Structural Steel Buildings 2010

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A reference guide for steel fabricators, inspectors and others involved in the structural steel building industry

 

The Shop Inspection Handbook for Structural Steel Buildings is a useful tool for everyone involved with the inspection of steel fabrication for buildings.

 

The Handbook provides the essential information for inspecting steel fabrication, including:

  • Tabulation of applicable standards, specifications and references
  • Structural steel materials
  • Fabrication and tolerances
  • Welding and welding materials
  • Bolting and bolting materials
  • Surface preparation and coatings

The Handbook provides quality information from the numerous standards and codes that govern steel fabrication, including:

  • AISC Specification for Structural Steel Buildings (AISC 360-10)
  • AISC Code of Standard Practice (AISC 303-10)
  • RCSC Specification for Structural Joints Using High Strength Bolts (RCSC 2009)
  • AWS D1.1 Structural Welding Code – Steel (AWS D1.1/D1.1M: 2010)
  • AWS A5.XX Filler Metal Specifications
  • ASTM Steel Standards
  • ASTM Fastener Standards
  • SSPC Surface Preparation and Coating Standards

Shop inspection personnel should not be expected to have all these references memorized, nor carry these references everywhere they go. The Shop Inspection Handbook for Structural Steel Buildings keeps this information handy and easily accessible.

 

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The Handbook is printed and published in a durable three-ring binder (included), enabling the inspector the opportunity to customize, update and add his/her own information to the provided material.

1 copy $ 75.00 each
2 – 5 copies $ 60.00 each
6+ copies $ 50.00 each

Table of Contents

Standards, Specifications and References

AISC: American Institute of Steel Construction

RCSC: Research Council on Structural Connections

AWS: American Welding Society

Specifications and Standards

Filler Metal Specifications

Qualification and Certification Standards

Inspection References

Welding and Cutting Practices References

ASNT: American Society of Nondestructive Testing

Standards

References

Training Materials

ASTM: American Society for Testing and Materials

Structural Steels

Steel Castings and Forgings

Structural Steel Testing

Fasteners

General Inspection

Penetrant Testing

Magnetic Particle Testing

Ultrasonic Testing

Radiographic Testing

SSPC: The Society for Protective Coatings

Surface Preparation Specifications and Standards

Qualification Procedures and Quality Systems

Other Qualification Procedures and Quality Systems

References

AGA: American Galvanizers Association

ASTM: American Society for Testing and Materials – for Galvanizing

Structural Steel Materials Inspection

Structural Steels Listed in AISC Specification Section A3.1a – yield and tensile strengths

Shapes, Plates and Bars

Pipe and Structural Tubing

Sheet

ASTM A6 Shape Groupings (historical)

Bar, Plate, Strip and Sheet Nomenclature

ASTM A6 Color Identification System (historical)

Mill Product Identification

Steel Compositions – A36, A572, A913, A992

Charpy V-Notch Impact Test for Structural Shapes: Alternate Core Location

ASTM Tolerances for Shapes

Permitted Mill Cross-Sectional Variations for W Shapes

Mill Straightness Tolerances for W Shapes

Permitted Mill Cut Length Variations for W and HP Shapes

Permitted Mill End Out-of-Square for W and HP Shapes

Permitted Variations in Mill Cut Length and End Out-of-Square for End-Milled Shapes

Permitted Mill Cross-Sectional Variations for S-Shapes and M-Shapes

Permitted Mill Cross-Sectional Variations for Channels

Permitted Mill Variations in Depth for Split Tee Sections

Permitted Mill Cross-Sectional Variations for Angles

Mill Straightness Tolerances for S, M, C, MC, L, T and Z Shapes

Permitted Variations in Mill Cut Length for S, M, C, MC, L, T, Z and Bulb Angle Shapes

ASTM Tolerances for Hollow Structural Sections

ASTM A53 (Round)

ASTM A500 (Round)

ASTM A501 (Round)

ASTM A618 (Round)

ASTM A847 (Round)

ASTM A500 (Rectangular)

ASTM A501 (Rectangular)

ASTM A618 (Rectangular)

ASTM A847 (Rectangular)

Mill Steel Surface Conditioning and Repair

Steel Fabrication Inspection

Member Length (other than columns)

Column Length (one or both ends milled)

Member Straightness Tolerances (other than compression members or columns)

Member Straightness Tolerances – Compression Members

Member Straightness Tolerances – Compression Members and Columns

Member Straightness Tolerances – Columns

Welded Column and Truss Member Straightness

Welded Beam and Girder Straightness (with no camber specified)

Welded Beam and Girder Sweep

Rolled Beam Fabrication Practice

Natural Beam Camber

Induced Camber Tolerances for Beams 50 Feet and Under in Length

Induced Camber Tolerances for Beams Over 50 Feet in Length

Camber Tolerances for Trusses

Welded Beam and Girder Camber (Typical Girder)

Welded Beam and Girder Camber (without Designed Concrete Haunch)

Variation Between Web and Flange Centerlines for Welded Built-Up Members

Welded Beam and Girder Flange Warpage and Tilt

Welded Beam and Girder Depth Variation

Stiffener Location and Fit

Thermal Cutting Quality

Beam Copes

Reentrant Corners

Weld Access Holes

Surface Reconditioning

Finished Surfaces

Architecturally Exposed Structural Steel (AESS)

Welding Inspection

AISC 360-10 Chapter N – Welding Inspection Tasks

Inspection Tasks Prior to Welding

Inspection Tasks During Welding

Inspection Tasks After Welding

Welding Inspection – General Provisions

Inspection Prior to Welding

Inspection During Welding

Inspection After Welding

SMAW – Shielded Metal Arc Welding

A5.1 Classification System for Carbon Steel Electrodes for SMAW

A5.5 Classification Systems for Low-Alloy Steel Electrodes for SMAW

SMAW Electrode Properties – A5.1

SMAW Electrode Properties – A5.5

Permissible Atmospheric Exposure of Low-Hydrogen SMAW Electrodes

FCAW – Flux Cored Arc Welding

A5.20 Classification System for Carbon Steel Electrodes for FCAW

A5.29 Classification System for Low-Alloy Steel Electrodes for FCAW

FCAW Electrode Properties – A5.20

FCAW Electrode Properties – A5.29

GMAW – Gas Metal Arc Welding

AWS A5.18 Classification System for Carbon Steel Electrodes for GMAW

AWS A5.28 Classification System for Low-Alloy Steel Electrodes for GMAW

GMAW Electrode Properties – A5.18

GMAW Electrode Properties – A5.28

Matching Filler Metals

Notes to Filler Metal Tables – FM-I through FM-IV

Table FM-I

Table FM-II

Table FM-III

Table FM-IV

Welding Positions

Fillet Weld Positions on Plate

Groove Weld Positions on Plate

Fillet Weld Positions on Tubular Product

Groove Weld Positions on Tubular Product

Welder Qualification Using Plate Tests

WPS – Welding Procedure Specifications

Typical Elements in a Welding Procedure Specification (WPS)

Prequalified WPS Variables and Production Ranges for SMAW

Prequalified WPS Variables and Production Ranges for FCAW

Prequalified WPS Variables and Production Ranges for GMAW

Prequalified WPS Variables and Production Ranges for SAW

Permitted Changes for WPS Adjustment from PQR Essential Variables for SMAW

Permitted Changes for WPS Adjustment from PQR Essential Variables for FCAW

Permitted Changes for WPS Adjustment from PQR Essential Variables for GMAW

Permitted Changes for WPS Adjustment from PQR Essential Variables for SAW

Permitted Changes for WPS Adjustment from PQR Essential Variables with CVN Reqts

SMAW Typical Amperage Ranges

FCAW Welding Procedure Adjustments

WPS Heat Input Guidelines for FCAW

Preheat and Interpass Temperatures

Notes for Tables TEMP-A through TEMP-D

Table TEMP-A

Table TEMP-B

Table TEMP-C

Table TEMP-D

Weld Quality

Assembly Fit-Up Tolerances for Fillet Welds

Measurement of Fillet Welds

Assembly Fit-Up Tolerances and Measurement of Groove Welded Joints

Fillet Weld Size

Fillet Weld Convexity

Fillet Weld Concavity

Groove Weld Reinforcement

Groove Weld Underfill

Location

Overlap

Undercut

Crater

Spatter

Surface Slag

Slag Inclusions

Piping Porosity

Subsurface Porosity

Porosity

Incomplete Fusion

Incomplete Joint Penetration

Cracks

Prequalified Groove Weld Joints

Identification of Prequalified Groove Weld Joints

Notes – Prequalified Groove Weld Joint Details

B-P1a

B-P1b

B-P1c

BC-P2

BTC-P4

B-L1a

B-L1b

B-U2

B-U2a

B-U3b, B-U3-GF

B-U4a

TC-U4a

TC-U4b

Electrode Diameters

Welding Symbols

Filter Shades for Welding and Cutting

Safety References

Safety Warnings

Bolting Inspection

AISC 360-10 Chapter N – Bolting Inspection Tasks

Inspection Tasks Prior to Bolting

Inspection Tasks During Bolting

Inspection Tasks After Bolting

Principal North American Producers and Suppliers of ASTM A325, F1852, A490 and F2280 Bolts

Markings

A325, A490 and A449 Bolts

A307 and A354 Bolts

A563 and A194 Nuts

Manufacturer Certification and Packaging Requirements

A325

F1852

A490

F2280

A563

F436

F959

F1554

Dimensions

Dimensions of A325 and A490 Heavy Hex Bolts

Dimensions of A307, A449 and A354 Hex Bolts

Dimensions of F1852 and F2280 Twist-Off-Type Tension-Control Bolts

Dimensions of A563 and A194 Heavy Hex Nuts

Dimensions of F436 Washers

Dimensions of F959 Direct-Tension-Indicators

Nuts

A563 Nuts for A325 and A490 Bolts

A563 Nuts for A307 Bolts

A563 Nuts for A449 Bolts

A563 Nuts for A354 Bolts

Hole-Making

Nominal Bolt Hole Dimensions

Lubrication

Lubrication of Black Fasteners

Lubrication of Galvanized Fasteners

AASHTO Maximum Torque for Rotational-Capacity Testing

Bolt Head Bursts

Requirements for Washers

Joint Types

Loading – Shear Only

Loading – Combined Shear & Tension

Loading – Applied Tension Only

Load Transfer through Shear-Bearing

Load Transfer through Friction

Load Transfer through Direct Tension

Bolt Tension Calibration Devices (BTCD)

Skidmore-Wilhelm Data

Snug-Tightened Joints

Systematic Tightening

Pre-Installation Verification Requirements

Pretensioned and Slip-Critical Joints – Required Minimum Bolt Pretension

Turn-of-the-Nut Pretensioning Method

Pre-Installation Verification for bolts using a BTCD

Pre-Installation Verification for bolts too short to fit into a BTCD

Installation Procedure – when turning the nut

Installation Procedure – when turning the bolt head

Inspection Procedure

Twist-Off-Type Tension Control Bolt Pretensioning Method

Pre-Installation Verification for bolts using a BTCD

Pre-Installation Verification for bolts too short to fit into a BTCD

Installation Procedure

Inspection Procedure

Direct Tension Indicator Pretensioning Method

Pre-Installation Verification for bolts using a BTCD

DTI placed under bolt head

DTI placed under nut

Pre-Installation Verification for bolts too short to fit into a BTCD

DTI placed under bolt head

DTI placed under nut

Installation Procedure – DTI placed under bolt head

Installation Procedure – DTI placed under nut

Inspection Procedure

Arbitration of Disputes

Torque Method – when bolts are long enough to fit into a Skidmore-Wilhelm

Torque Method – when bolts are too short to fit into a Skidmore-Wilhelm

DTI Calibration for Pre-Installation Verification Testing when using Short Bolts with the Calibrated Wrench Method, Twist-Off Bolt Method, or DTI Method; and for Arbitration of Disputes when using Short Bolts

Overtightening Bolts

Thread Stripping

Stickout

Reuse of Bolts Previously Pretensioned

Surface Preparation and Coatings Inspection

Shop Cleaning and Painting

ASTM Standards Regarding Surface Preparation and Coatings

Surface Preparation Specifications

Comparison of SSPC and ISO Visual Standards

Instructions for Use of Common Inspection Tools

Taylor Pocket Sling Psychrometer Model 1330

Weksler Pocket Sling Psychrometer Model WE-10-140

Keane-Tator Surface Profile Comparator

Elcometer Surface Profile Gage Model 123

Testex Press-O-Film(R) Surface Profile Gage

“Business Card” Wet Film Thickness Gage

Gardner Wet Film Thickness Gage Model C (Similar to Erichsen Gage Model 234)

Erichsen/Rossman Dry Film Thickness Gage Model DF-233

Erichsen/Rossman Wet and Dry Film Thickness Gage Model WF-296

Defelsko PosiTest Dry Film Thickness Gage

Elcometer Dial Dry Film Thickness Gage Model 126