MDOT QA ITP – Structural Steel Fabrication Level II Page 1 of 6

This QA ITP supplements the inspection procedures of the SFQM and other supporting QA documents by tabulating the
progression of QA inspections and tests required by MDOT as part of its acceptance of Level II structural steel fabricated
members.

Level II structural steel fabrication inspection is considered standard shop inspection for auxiliary load carrying members and
ancillary products, typically characterized by reduced inspection frequency and sample size as indicated in the MDOT Work
Assignment (WA). Reduced inspection is defined as a maximum of 48 hours (travel time not included) every two weeks. More
information can be found in MDOT’s Consultant Managed Fabrication Inspection Program document. Contact SFU for approval
prior to exceeding the inspection frequency limits (both onsite and remote) if more inspection time is proposed based on the
Fabricator’s operations. QAIs are required onsite only part-time and may perform some activities remotely when prearranged
with the SFU and the Fabricator. Visits to Fabricator subcontractors and component manufacturers require SFU approval or
direction via WA.

According to the established shop inspection level, the Consultant determines the schedule for part-time and remote activity.

QAI must not arrive to the fabrication shop earlier than the day prior to the start of fabrication to begin prefabrication activities
without SFU approval.
FOR REVIEW - 21 MARCH 2019

SFU may require or perform special onsite inspections or process audits to supplement full-time remote inspection.

All instances of required SFU approval noted in this document must be in writing from the MDOT PM.

1.1 QAI Activities (Inspection and Test Items)

QAI activities are listed in the table below along with their referenced requirements, activity codes, frequency, description, and
output/record. Each activity is assigned a code to designate whether the activity is performed by the Fabricator and observed by
the QAI or is performed by the QAI either solely or as an independent check of a QC inspection or test. The activity codes are
defined in Section 1.2 below.

The term “Suitable intervals” when used in this ITP means the activity is required to occur at least once per project (or once per
multiple projects going through the fabrication plant concurrently) with follow up duration and frequency determined by the QAI
based on conditions such as QC inspection effectiveness and production workmanship provided the QAI works within the limits
of their inspection hours. Duration is the time spent observing an activity. Duration is the time spent observing an activity.
Frequency is how often an observation is required and is expressed as elapsed time or quantity of work completed between
observations. At the QAI’s discretion, duration and frequency may differ between projects based on project complexity or
Fabricator experience and may change during a project based on Fabricator performance provided the QAI works within the
limits of their inspection hours. Duration is the time spent observing an activity.

Conformance of certain quality control and fabrication activities that occur without QAI presence must be substantiated by the
QAI with direct proof or competent evidence. QC inspections are substantiated by reviewing quality documentation supplied by
the QCI and follow-up review, onsite or remote, with the QCI. Fabrication steps are similarly substantiated during the next onsite
QA inspection or they are substantiated remotely while the QAI is offsite through electronic submittals, video or photographic
evidence, and video or phone interviews.

When used in the Description column the term “verify” is the action by the QAI to establish correspondence of observed facts or
details with recorded facts and details. It implies a responsibility by the QAI to confirm completion and conformance of an action
or condition with expected requirements. For a Level II ITP it implies either onsite or remote QAI activity.

1.2 QAI Activity Codes

M = Monitor: QAI routinely observes the Fabricator’s active quality control and fabrication activities at suitable intervals. The
Fabricator’s activities may be conducted without the QAI being present to monitor, even if the QAI is onsite.

P = Perform: QAI is responsible for actual completion of the step. These activities include verification inspections, tests, and
review of quality control records for adequacy and completeness.

W = Witness: QAI must be present and observe the required activity performed by the Fabricator.

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 MDOT QA ITP – Structural Steel Fabrication Level II Page 2 of 6

1.3 Hold Points

Some activities are identified as hold points. These are sensitive steps that require QAI notification by the Fabricator. Fabrication
must not proceed past these points until the QAI is either satisfied of the outcome through direct testing or observation of
testing, or the QAI grants a waiver or conditional release of the hold point based on situational evaluation. QAI satisfaction or
waiver does not constitute product acceptance, which is the responsibility of the Fabricator. Hold points are understood to be
waived for times when the QAI is not scheduled to be onsite.

The prefabrication meeting minute template initially establishes the minimum number of QAI hold points – see blue shaded
rows below. The QAI may recommend or request modification or addition of hold points for the approval of the SFU, at the start
of fabrication – see note below.

QAI may request additional inspections, tests, or hold points during the fabrication process due to established action
limits/suspension limits being exceeded or in reaction to a loss of confidence in a process. Additional inspections, tests, or hold
points will be conveyed in writing to the Fabricator and must result in minimal impact to project schedule. SFU approval is
required – see note below.

Ideally, the Fabricator must convey project schedules in writing to confirm when hold point inspections will occur and that the
FOR REVIEW - 21 MARCH 2019

QAI is available for the hold point inspection as requested by the Fabricator. The QAI must reply to any written requests for hold
point inspections. Other forms of communication are acceptable if documented (defining Fabricator notification to the QAI and
QAI response) and agreed to at the prefabrication meeting.

Note - Any increase in inspection criteria or inspection hold points must be based on objective evidence. Rationale for additional
inspection or hold point should be discussed with the MDOT Structural Steel Specialist prior to notifying the Fabricator of the
new inspection requirements.

1.4 Output/Records
Where the Fabrication Inspection Report (Form 5617) is listed in the Output/Record column, the QAI may substitute a
Consultant form meeting the requirements of the SFQM. Where other MDOT forms are listed, it is implied they are only
necessary when the associated activities are performed.

1.5 ITP Table

The ITP table starting next page is sufficient for most projects. However, adjustments are permitted to suit specific project
needs. Any adjustments must conform to project requirements and must be made in writing and submitted to the SFU for
approval. Once approved, it must be shared with the Fabricator prior to start of production, preferably before or during the
prefab meeting. Adjustments to hold points must conform to Section 1.3 above.

Custom ITPs developed by the Contractor or Consultant are also permitted but must address all inspection and test activities
listed in the ITP Table.

Altering the conditions detailed in the above introduction and outline is not permitted without SFU approval.

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Referenced
Inspection/Test Item QAI Frequency Description Output / Record
Requirement

Verify that shop drawings in use are approved.

SFQM 1.9.1 If Engineer permits Fabricator to proceed without
SFQM [Link] & approved drawings, notify Consultant PM and
await instruction to proceed. Fabrication
Approved Shop [Link] Initially and each
P If non-approved drawings are used for Inspection Report
Drawings or revision
fabrication, compare approved drawings to (Form 5617)
SFQM [Link] & unapproved drawings and note deviations during
[Link] fabrication – notify Consultant PM of any
discrepancy.
MDOT Inspect materials that will be used in the
Prefabrication fabrication process and ensure they are being
Meeting Minutes stored correctly, tagged for traceability purposes, Fabrication
and are in conformance with the contract. Inspection Report
MDOT SSC
(Form 5617)
105.01.B During initial material Conduct sampling and verify testing complete as
Material Inventory P required. Sample
SFQM [Link].3 & inventory
Identification
FOR REVIEW - 21 MARCH 2019

[Link].1 Verify mill test reports match base metals.

(Form 1923)
or Send email to QC and Consultant PM when there
Email
SFQM [Link].3 & are deficiencies.
[Link].1 Release hold point (onsite inspection only)
Inspect and monitor the Fabricator’s work area
and equipment, ensuring it is adequate and
maintained in a condition to yield products
SFQM [Link].3 &
conforming to project requirements.
Operations [Link].3 Fabrication
Note - Equipment includes cutting, welding,
(Facility and or M Suitable intervals Inspection Report
handling, forming, hole-making, surface
Equipment) SFQM [Link].3 & (Form 5617)
preparation, coating, and inspection and testing
[Link].3 as applicable.
Verify calibrations of inspection and testing
equipment.

SFQM [Link].2 Verify all welders are MDOT qualified including

tack welders, welders, and welding operators. Fabrication
Qualified Welders or P Each welder Inspection Report
Verify welder continuity has not been disrupted in (Form 5617)
SFQM [Link].2 the three-month period.

Verify that WPSs and welding sequences are

SFQM [Link].3 agreed to and understood by QAI, QC, and Fabrication
Approved Welding Fabricator.
or P Each WPS Inspection Report
Procedures
SFQM [Link].3 Verify all WPSs are approved and posted at each (Form 5617)
welding station.

SFQM [Link].1& Examine the steel and verify quality of

Base Metal [Link].4 fabrication, especially edge preparation, before Fabrication
Preparation and or M Suitable intervals fit-up. Inspection Report
Assembly for Welding SFQM [Link].1 & Verify that QC is maintaining heat number (Form 5617)
[Link].4 traceability back to piece mark in the structure.

Check root face, bevel angle, cleanliness, match

SFQM [Link].5 marks, alignment of adjoined parts, uniformity Fabrication
Weld Joint Fit-up or M Suitable intervals and size of root openings. Check edges for Inspection Report
SFQM [Link].5 internal discontinuities at weld joints. Check all (Form 5617)
critical measurements affecting fit-up.

SFQM [Link].6 Check fixtures, clamping, and pre-cambering

Fabrication
Fixturing and arrangements for adequacy. Ensure tack welds
or M Suitable intervals Inspection Report
Fabrication Aids are small, smooth and of specified quality. Verify
SFQM [Link].6 (Form 5617)
runoff tabs or extension plates are in place.

Verify welder qualification, WPS qualification/pre-

SFQM [Link] qualification, base metal preparation, as-fit joint Fabrication
Pre-Welding Final details, and fixturing and fabrication aids are Inspection Report
or P Suitable intervals
Review acceptable for production welding. (Form
SFQM [Link] 5617/0538)
Release hold point. Relax hold point after.

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Referenced
Inspection/Test Item QAI Frequency Description Output / Record
Requirement

Verify that production welding is following the

approved and stamped WPSs.
SFQM [Link] Fabrication
Verify that welding is conducted properly with
WPS Review or M Suitable intervals Inspection Report
respect to weather conditions (wind and
SFQM [Link] (Form 5617)
precipitation).
Verify proper preheat is used prior to welding.

SFQM [Link] Fabrication

Verify that electrodes and fluxes are properly
Electrode Storage or M Suitable intervals Inspection Report
stored.
SFQM [Link] (Form 5617)

Verify that welder is using proper technique for

the specified weld procedure and joint.
SFQM [Link] Verify that arc strikes are not outside the weld Fabrication
FOR REVIEW - 21 MARCH 2019

Production Welding or M Suitable intervals joint. Inspection Report

SFQM [Link] Verify root pass penetration. (Form 5617)
Verify weld pass cleaning with proper equipment.

Monitor use of heating procedures, use of

SFQM [Link] equipment, and temperature monitoring for all Fabrication
Heat Application or M Suitable intervals applications other than preheat (cambering, Inspection Report
SFQM [Link] curving, distortion control, straightening, etc.). (Form 5617)
Ensure heat correction is performed prior to NDT.

Spot check weld size, length and proper location

per the approved shop drawings.
Verify welder identification on splices of primary
components (arm, upright, and base plates for
arm and upright).
SFQM [Link] Verify visual appearance of weld for profile and Fabrication
Prior to NDT or P Suitable intervals surface discontinuities per AWS D1.X after QC Inspection Report
SFQM [Link] inspection. (Form 5617)
Release hold point.
Hold point may be waived if the Fabricator has an
effective communication plan in place with the
QAI on notification of upcoming NDT operations
as established during the prefabrication meeting.
Observe use of NDT procedure and procedure
appears to be correct for the type of NDT being
SFQM [Link] Fabrication
performed (e.g. MT procedure for MT inspection).
NDT Process Review or P Each project Inspection Report
Verify all weld joints requiring NDT are addressed
SFQM [Link] (Form 5617)
by the Fabricator’s plan.
Review NDT technician certifications.
Observe NDT of non-critical joints at frequent
SFQM [Link] intervals to verify proper procedures are used –
duration of observation as determined by the Fabrication
NDT: Non-critical
or M Suitable intervals QAI. Inspection Report
Joints
SFQM [Link] (Form 5617)
Note – Joints not specified as critical below or
designated critical at the prefabrication meeting.
Witness at least one complete NDT examination
of a critical joint to verify proper procedures are
SFQM [Link] used, including equipment setup. Monitor as
needed on remaining critical joints. Fabrication
NDT: Critical Joints or W Suitable intervals Inspection Report
Note – Pole and arm to base plates, splices, and (Form 5617)
SFQM [Link] stiffeners/saddle plates are common types of
critical joints. Other joints may be specified as
critical at the prefabrication meeting.

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Referenced
Inspection/Test Item QAI Frequency Description Output / Record
Requirement

Verify the locations of rejected weld, or rejected

portions of the weld, are identified in the NDT
SFQM [Link] reports and on the welded joint. Fabrication
NDT Review or P Each NDT report Obtain copies and review QC interpretations of Inspection Report
SFQM [Link] the NDT reports and bring disagreements with (Form 5617)
QC or NDT Technician to the attention of the
Consultant PM.
Observe QC inspection of final assemblies after
SFQM [Link] fabrication is complete. Fabrication
Assembly Inspection
or P Suitable intervals Verify results of reinspection after corrections are Inspection Report
(if required)
SFQM [Link] complete. (Form 5617)
Release hold point.
Visually confirm use of approved repair
procedures and materials (perform remotely if
MDOT not onsite). Fabrication
FOR REVIEW - 21 MARCH 2019

Approved Repairs Prefabrication P Suitable intervals Verify temperature monitoring for heating Inspection Report
Meeting Minutes operations to adjust camber and girder (Form 5617)
straightness/curvature (perform remotely if not
onsite).

SFQM [Link].4 Monitor the Fabricator’s operations to ensure

Fabrication
that grinding repairs, weld repairs, and other
Pre-blast inspection or M Suitable intervals Inspection Report
fabrication operations are complete before
SFQM [Link].4 (Form 5617)
surface preparation begins.

Observe surface preparation of steel members.

SFQM [Link].5 Spot check surface preparation by evaluating Fabrication
Surface Preparation or M Suitable intervals steel cleanliness and surface profile. Inspection Report
SFQM [Link].5 Verify QC inspections meet project requirements (Form 5617)
for frequency.
Monitor the Fabricator’s methods of recording
SFQM [Link].1 environmental conditions during surface
preparation and coating operations. Fabrication
Environmental
or M Suitable intervals Inspection Report
Conditions Review daily environmental reports to ensure
SFQM [Link].1 (Form 5617)
that coating operations meet the contract
requirements.
Observe the Fabricator preparing the coating
material for application.
SFQM [Link].2 Note the proper mixing, thinning, induction time, Fabrication
Coating Material
or M Suitable intervals screening and handling of the material. Inspection Report
Preparation
SFQM [Link].2 Verify that QC is documenting all batch numbers, (Form 5617)
color numbers, and one-year expiration date for
acceptance.

SFQM [Link].6 Observe application technique for the coating

Fabrication
system being applied follows the manufacturers
Coating Application or M Suitable intervals Inspection Report
recommended practices and project
SFQM [Link].6 (Form 5617)
requirements.

Conduct dry film and/or wet film thickness

inspections of completed coats applied to the
members. Spot checks are sufficient to verify QC
conformance to SSPC PA2.
Confirm proper cure time before next coat is
SFQM [Link].7 applied. Fabrication
Coating Inspection or P Suitable intervals Confirm approved coating repair procedures are Inspection Report
SFQM [Link].7 followed. (Form 5617)
Verify that QC test reports and required coating
application documents are in conformance with
the specifications.
Verify that all coated materials are properly
handled and stored for shipping.

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Referenced
Inspection/Test Item QAI Frequency Description Output / Record
Requirement

MDOT Inspect structural members after loading for

Prefabrication storage and handling defects. Fabrication
Meeting Minutes Inspection Report
Loading & Shipping – Each member, prior to Verify no unauthorized or undocumented repairs.
P (Form 5617)
QAI Acceptance SFQM 2.3.8 shipping Verify receipt of required QC documentation.
Fabricator’s Bill of
or Stamp the accepted members and the copies of Lading
SFQM 2.4.7 the Bill of Lading after loading inspection.
FOR REVIEW - 21 MARCH 2019

REVISION DATE: 04 OCTOBER 2021