INSPECTION REPORT

Description Acceptable Remarks

(Yes / No)
Qualification And Experience
Does Quality Control Inspectors fabrication
inspection experience meet the minimum
requirement?
Does Quality Control Inspectors coating
inspection experience meet the minimum
requirement?
Is the recommended inspection equipment’s
available for use?
Quality Control Plan (QCP)
Does the QC Engineer brief about the Quality
Control Plan (QCP)?
Does the copy of QCP available to the consultant
for review during inspection?
Does the QCP adequately describe the means
and methods for ensuring satisfactory materials
and workmanship for the work proposed?
Inspection And Testing Equipment’s
Do the fabricator records indicate the routine
checking and calibrating of the testing
equipment?
Does the fabricator maintain calibration records
readily accessible for the consultant during
inspection?
Control Of Raw Materials
Does the fabricator inspect all the incoming
materials?
Does the fabricator verify that no repairs have
been made at the producing mill except as
allowed in ASTM A 6 (Facture critical members
must not have any welded repairs unless
authorized in writing by client or consultant)?
Does the fabricator verify material surface
quality prior to fabrication?
Has the fabricator produced any quality control
records in related to the raw materials selection?
Welding Procedure And Consumables
Does the QC describe the procedures for welding
control (welding procedures specifications,
procedure qualification etc.)?
Does the QC describe the procedures for control

AL FAJER ENGINEERING CONSULTANTS INSPECTION REPORT

 of welding consumables?
Has the fabricator maintain record readily
available for consultant review?
Nondestructive Examination (NDE)
Does the fabricator follow as established practice
that confirms to AASHTO/AWS D1.1 and /or
D1.5 and the contractor documents as
applicable?
If NDE services are contracted out, does the
fabricator ensure that NDE agencies staff satisfy
applicable ASNT requirements?
Does the fabricator provide a copy of written
NDE practices upon requests?
Does the fabricator maintain NDE test records?
Does the fabricator provide test report and
summaries of all required NDE to consultant
review?
Welder / Welding Operator Qualifications
Has the fabricator, at minimum, documented and
maintained the following?
a) The extent to which QC department
will be involved in qualification
b) The responsible party for selection
and testing qualification plates,
authentication or test report and the
disposition or specimens
c) Appropriate forms and records
d) Fabricator method for documenting
continued experience
e) Fabricators master list of qualified
welder, welding operators and tack
welders
Has the fabricator made all welder qualification
record available for consultant review?
Drawings
Revised shop drawings for 2.2 m block work and
above sheeting to submitted for approval
Records
Does the fabricator maintain current and
complete records of inspection, measurements
and test?
Does the fabricator document, report and keep
record of the reportable non-conformance?
For items that require full or partial shop
assemblies, does the fabricator maintain a record
of required measurements, indication of
compliance or deviation noted (in drawings and
documents)?
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 Material Traceability (MTRs)
Does the fabricator review MTRs for contract
documents compliance prior to start fabrication
procedure?
Does the fabricator control, identify and
reproduce MTRs for the steel materials used
from the fabricators store or from warehouse
purchase?
Does the fabricator identify and trace materials
for primary members throughout fabrication?
Does the fabricator provide MTRs to consultant
review on request?
Does the fabricator correlate mill identified
materials with shop drawing piece marks and
supply a copy of the information to consultant
for review?
Preparation Materials
Is the fabricator addressing the following:
a) Identification and marking of
materials from mill to finished
product
b) Quality of cut and sheared edges
c) Plate quality with notation of surface
and internal defects and repairs
d) NDE requirements and acceptance
criteria for repairs
e) Dimensional accuracy of component
parts whether fabricated or pre
manufactured
Fitting
Is the fabricator addressing the following:
a) Dimensional accuracy and fit of all
components
b) Specified tolerance of members prior
to welding
Welding
Is the fabricator addressing the following:
a) Cleanliness (condition of unaccepted
mill scale , rust or contaminants)
b) Joint preparation
c) Properly cleaned tack welds of
suitable quality and size
d) Use of approved welding procedures
e) Weld quality and soundness
requirements as per AWS D1.1
f) Welders qualified for process and

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 position to be welded
g) Inter-pass cleaning and temperature
h) Weld back-gouging and cleaning
i) Fillet weld size, placement and
profile
j) Grove weld reinforcement
k) Grinding or finishing of welds
l) Avoiding, pre compensating and
correcting welding induced distortion
m) Visual weld quality
n) Post heat as required
o) Storage, handling and reuse of SAW
flux and SMAW electrodes
Cambering, Curving And Straightening
Is the fabricator addressing the following:
a) Adequate blocking elevations and
intervals
b) Size and location of heating patterns
c) Maximum temperature and proper
temperature monitoring
d) Controlled cooling
e) Final dimension
Shop Assembly Of Main Members
Is the fabricator addressing the following:
a) Dimensional accuracy of each piece
(deviation from specified length,
camber, sweep)
b) Individual member distortion, local
and overall (twist, sweep, out of
flatness of flange or web)
c) Clearance of bearing fit or adjacent
members in assembly
d) Assembly blocking
dimensions/curve/camber
offsets/elevations
e) Splice plate and secured fill plate
dimensions and fit (gaps , non-
parallel)
f) Bolt hole accuracy including
adequate edge distance
g) Bolt hole conditions including shape
and squareness to faying surface
h) Match marking of splice plates and
correction location of all piece marks

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 i) Removal of drilling burrs
Does the fabricator provide any documents of as
build shop assembly report
Abrasive Sandblasting And Cleaning
Is the fabricator addressing the following:
a) Proper solvent cleaning to remove
surface contamination prior to
mechanical cleaning
b) Blast media gradation and cleanliness
c) Verification and documentation of
required surface cleanliness and
profiles ( SA 2.5)
d) Checking the compressed air system
for contaminants specially if used to
remove shot/grit.
e) Proper functioning of blasting
equipment’s
f) Treatment of material defects (scabs,
fins, slivers) exposed during blasting
including re blasting if necessary after
repairs.
g) Proper corner and edge treatment as
required for coating system
Coating
Is the fabricator addressing the following:
a) Coating sampling by fabricator
including witnessing and delivery to
client, consultant approval
b) Maintenance of airline oil and air
moisture traps
c) Equipment’s for mixing, application,
repair, film measurement and safety
d) Mixing and agitation
e) Monitoring shell life of consumables
f) Application methods: spray nozzles,
patterns, sequencing for typical
configuration and for areas
inaccessible for spraying.
g) Minimum percentage mixing (solid
liquid ratio).
h) Coating repair for damage, dry spray,
runs, sacks and under/over thickness
i) Ambient temperature, steel
temperature, relative humidity and

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 dew point
j) Control of mileage, wet bar dry as
applicable as per society for
protective coatings- SSPC PA2
k) Intervals between coating
applications
l) Curing assessment
m) Availability of reports ( materials
used, ambient conditions, curing
details, dry/wet film thickness
reading, defects and corrective
actions made) for consultant review.
Does the fabricator produce any compliance
report for material preparation, fitting, welding,
cambering, curving & straightening, shop
assembly of main members, sandblasting,
cleaning and coating followed at site?

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 ANNEXURE- A

MATERIAL SELECTION

1. Generally the materials delivered to the yard will be cross verified with mill test reports
(MTR) for technical specification, material grade & quality, shipping damages and mill
test certificate.
2. The mill test certificate results will be reviewed against the standard test results; say
chemical & mechanical properties.
3. The materials allocated for the project will be stacked separately with desired project
code number.
4. Upon receive of the material requisition the store will deploy the preselected and
preapproved material to the production team for material preparation.

MATERIAL SIZING AND FABRICATION

1. Upon receiving of the materials, the production team starts the cutting and sizing based
on the unique mark number given, which will be maintained till the end for traceability of
the material.
2. During fabrication, the drawing number or erection mark number as per the spec shall be
punched on the min member as a permanent identification. The master list of permanent
mark number maintained by the quality department shall contain the material grade and
heat number. This enables to trace back the original delivery, material grade and heat
number of the material being used for the project.
3. The cutting and sizing of the material shall be done by machine cutting, gas cutting, laser
jet cutting depending on the size and shape of the final product.
4. The designs are being carried out in Tekla model software. The NC files generated with
the help of software is being transferred to the CNC machine and all cutting of plates and
profiles are carried out by a CNC programmer and controlled by a CNC operator.
5. The gas cut surface which does not meet the requirements will be finished by grinding.
The cut edges shall be free from defects, straight and uniform throughout.
6. Piercing of holes for high strength bolts shall be done by drilling machine or punching
machine. Punching is generally done if the plate thickness is not more than 13 mm. Slag
or burr occurred in the drilling/punching shall be rectified by grinding.
7. Prior fabrication the fit up shall be inspected with relevant shop drawings and WPS.
8. Upon completion of fit up production the material shall be undergone 100% dimensional
inspection, surface edges shall free from imperfection, foreign materials that may affect
the weld quality and dimensional tolerances as per AWS D1.1, approved WPS and
project specifications.

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 WELD QUALITY

1. Welding shall be carries as per AWS D1.1 and approved WPS.

2. Welders and welding operators shall be qualified to AWS D1.1 and certifications; which
needs to be revalidated every 6 months.
3. The welding surface shall be clean and free from moisture, slag, oil, grease, scale, rust
etc.
4. Welding process shall be selected based on the joint confirmation as per the approved
WPS and to limit heat input shall be confirmed to table 3.2 of ASW D1.1 in order to
avoid distortion and residual stresses.
5. The welding shall be carried in controlled conditions and weld profiles & transistion shall
be smooth enough to ensure the satisfactory melting.
6. Upon completion of welding procedure visual inspection of 100% weld beads shall be
done in accordance with ASW D1.1 Table 6.1. The various defects associated with
welding are: Cracks, Incomplete Fusion, Incomplete Penetration, Slag Inclusions,
Tungsten Inclusions, Overlap, Porosity (Blowholes), Arc Strikes, Undercut, Overfill,
internal Concavity etc.
7. Upon passing of visual inspection the materials shall be undergone for Non-Destructive
Testing (NDT) such as magnetic particle testing and ultrasonic testing as per approved
Inspection Test Plan (ITP).
8. The NDT shall be carried out by a 3rd party company meeting AWS D1.1 acceptance
standards.

SAND BLASTING AND SURFACE PREPARATION

1. Surface preparation shall be done using Abrasive blast cleaning. Before carring out the
same the surface shall be free from moisture, oil greases and heavy deposits of rust. Oil &
greases shall be removed then by cleaning with water and subsequently dried prior to
blast cleaning. Excessive deposits of shall be removed with impact cleaning tools.
2. Steel grit/shot shall be used as abrasive and it shall be ensured that the abrasives shall be
free from impurities, not be rusty, worn or dull when compared to fresh materials.
3. The compressed air to be used for abrasive blast cleaning shall be dry & free from oil.
Adequate separators & traps shall be installed in the coolest part of the system and they
shall be emptied to prevent the carry-over of oil & water. Accumulations of oil and water
shall be removed from air receiver by regular purging. Blasting nozzles shall be replaced
when wear reaches 50%. Air compressors shall not deliver air at temperatures in excess
of 110°C.
4. Abrasive blast cleaning shall not be carried out when the surface temperature of the
substrate is less than 3°C above the ambient Dew Point Temperature and when the
relative humidity is greater than 85%.
5. Abrasive blast cleaning shall remove all mill scale, rust and other corrosion products,
paint and any other foreign matter to achieve a surface cleanliness of SA 2.5, in
accordance with ISO 8501-1 with a surface roughness in the range 50μ to 85μ peak to

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 valley height. Welds and Weld preparation areas that have to remain unpainted in order
that Hydro testing/NDT/further welding may be carried out, shall be abrasive blast
cleaned and masked prior to the application of the coating system.
6. The surface preparation shall be compared with the Surface Profile Comparator and
checked whether the required surface finish (SA 2.5) has been obtained as per the
requirements of ISO 8501-1. Surface roughness i.e. Peak to Valley distance is measured
using Press’O’Film (Testex Tape).

PAINTING AND FINISHING

1. The surfaces that are wetted by rain or moisture prior to painting shall be reblasted before
the primer coat is applied. Abrasive blast cleaning shall overlap by at least 25mm on any
adjacent painted surface.
2. After the surface has been blast cleaned the debris and steel particles are cleaned away by
any of the following methods viz. vacuum cleaning, blowing away with oil free
compressed air or cleaning with brush.
3. All paints shall be applied, mixed and thinned in accordance with the paint
Manufacturer’s Instructions.
4. Paint shall be thoroughly stirred to give uniform consistency before use. Paint that is
supplied with more than one component shall be thoroughly mixed in the proportions
laid down by the paint manufacturer.
5. Paint which has set hard enough for it to be thinned before it can be brought to
consistency shall not be used for painting, as excessive thinners will affect its quality.
6. Paint shall not be applied under the following conditions:
a. When the temperature of the substrate is less than 3°C above the Dew Point of the
surrounding air.
b. When the ambient temperature is below 10°C or outside the range recommended
by the paint manufacturer.
c. When the deposition of water occurs on the substrate in the form of rain, frost,
condensation etc.
d. When more than 4 hrs has elapsed after the completion of surface preparation or
when a rust bloom has formed on a prepared surface.
e. When painting is being carried out in the open if there is a likelihood of the
weather conditions becoming unfavorable within two hours after completion of
the coating.
f. When dust or blown sand can affect coating.
g. When the relative humidity is greater than 85%.
7. The first coat of paint shall be applied as quickly as possible after surface preparation
has taken place, and before any re-rusting/contamination occurs.
8. Before the application of each coat of paint, the previous coat of paint shall be
allowed to fully cure in line with the time and temperature conditions given by the
paint manufacturer.

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 9. The paint shall be applied in an even, continuous film. Particular attention shall be
paid to the edges, weld and corners and areas of difficult geometry in order that the
specified Dry Film Thickness is achieved in these areas.
10. Adequate ventilation shall be provided during the application and curing of the paint,
especially if this is carried out in enclosed conditions.
11. All inaccessible areas after assembly shall be fully painted prior to assembly.
12. All paints shall be mixed and applied as instructed by the manufacturer. In order to
ensure that the specified Dry Film Thickness is achieved, regular checks of the Wet
Film Thickness shall be made during application using a suitable instrument such as a
Whirling Hygrometer.
13. Dry Film Thickness as specified shall be strictly adhered to and they shall be checked
using a calibrated DFT Gauge. The instrument shall be used, strictly as per the
manufacturer’s instructions.
14. The painted surface shall be free from runs, sags and pinholes. Any defect or damage
shall be repaired before the application of further coats of paint, and if necessary the
defective area shall be made paint free.

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