Mock Exercise Instructions for

Fabricators of Simple Bridges

1. Scope

For applicability, refer to the ​Supplemental​ ​Requirements for Fabricators of Steel Bridges​.

This exercise will demonstrate fabrication knowledge, skills, and capability to produce fabricated
steel to the quality required for Simple Bridges.

2. Document Requirements

In addition to the required documents listed in the Program Requirements, the fabricator shall have
the following documents available for review during the site audit:

a. Valid FCAW or SAW Welding Procedure Specifications (WPS) with supporting Procedure
Qualification Record (PQR) in compliance with ​AASHTO/​AWS D1.5.
b. Current Welder Performance Qualification Records for all processes and positions to be used
in the exercise in compliance with ​AASHTO/​AWS D1.5.
c. Material Test Reports (MTRs) for materials used. (May be an example of an MTR.)
d. Purchase orders for materials used. (May be an example of a P.O.)

3. Welding

All welding, including tack welding, shall be in compliance with the latest edition of AASHTO/AWS
D1.5. SMAW or FCAW may be used for tack welding, however, FCAW or SAW shall be used for
fabrication. GMAW-S shall not be used without Engineer approval.

4. Bolting

The Turn-of-Nut method shall be used for all bolting in this exercise. All bolted connections shall be
considered slip critical.

5. Dimensional Tolerances

Dimensional tolerances shall be in compliance with AASHTO/AWS D1.5.

Effective Date September 1, 2019 1 of 4

6. Inspection and NDT

The fabricator shall perform in-process inspection prior to the site audit. Final inspection shall be
performed at the time of the audit. Visual inspection reports and any required NDT reports shall be
presented at the time of the audit. Qualifications of the QC inspector shall be verifiable in
compliance with AASHTO/AWS D1.5, Clause 6.

7. Fabrication

a. Fabricate the following structural members as shown on the attached drawings:

● Girder G1 (Rolled beam)

● Girder G2 (Rolled beam)
● 1- Diaphragm D2 (MC, W-Shape, or C Channel section)

b. Refer to the attached drawings. Fabrication to include the following considerations:

● Single-span bridge, Girders G1 and G2

● Girder depth: Minimum 18”, Maximum 36” rolled beams
● Girder length: 4’-0” minimum (to allow for fit-up of one diaphragm)
● Camber: Natural camber up.
● Girder spacing: 5 feet
● Intermediate diaphragm: Type 1
● Bridge skew: 10°
● Skewed connection stiffeners located at mid-point of beams
● Profile Grade Line (PGL): Centerline of G3
● Bridge slope: -5° from PGL to fascia girder

Do not assemble the fabricated members​. The Auditor shall observe the assembly of the fabricated
members. Refer to Table 1 for Fabrication, Inspection and Audit Activities.

8​. General Requirements

a. During the site audit, the personnel responsible for and performing the work shall demonstrate
understanding necessary for effective implementation of the requirements of the latest editions
of the applicable codes and standards.
b. The Auditor shall not perform any inspections, direct any work, or provide instruction. The
auditor may request alternate sequences in agreement with the auditee to meet unforeseen
on-site conditions.
c. The Auditor is present to observe the process and the application of the requirements by the
auditee.
d. All fabrication of the mock exercise shall be performed by the fabricator.

Effective Date September 1, 2019 2 of 4

TABLE 1 - Sequencing of Fabrication, Inspection, and Audit activities

Fabrication
# Inspection Instructions Audit Activities
Activity

In-process inspection and NDT The on-site auditor shall

shall be performed in observe the completed
compliance with the fabrication. Witness of NDT is
fabricator’s documented not required.
Fabricate Girders
1 procedures and the current
G1 and G2 and Fabricator’s QC and NDT
AASHTO/AWS D1.5, Bridge
Diaphragm D2 inspection records shall be
Welding Code.
made available for the on-site
auditor to review.

PIV demonstration shall be The on-site auditor shall

performed in compliance with observe the pre-installation
Pre-installation RCSC and the fabricator’s verification demonstration.
verification (PIV) documented procedure. Records shall be made
2
available for the on-site auditor
to review.

Rocap Testing shall be The on-site auditor shall

performed in compliance with observe Rocap Testing.
Rotational ASTM F3125 and the Records shall be made
3 Capacity (Rocap) fabricator’s documented available for the on-site auditor
Testing procedure. to review.

The on-site auditor shall

observe the assembly of girders
and diaphragm.
In-process inspection shall be
Assemble Girders NOTE: The bolted connections
4 performed in compliance with
and Diaphragm as (diaphragm to connection
the fabricator’s documented
shown on the stiffeners) shall be considered
procedures.
attached drawings slip critical.

Effective Date September 1, 2019 3 of 4

 Pretensioned bolt installation The on-site auditor shall
using the turn of the nut observe bolt installation.
method in compliance with
RCSC shall be done at the Fabricator’s QC and inspection
Bolt installation records shall be made available
5 time of the audit.
for the on-site auditor to review.

All required inspections shall The Fabricator’s QC and

be performed in compliance inspection records, including
6 Final Inspection with the fabricator’s QMS and NDT reports, shall be made
the current AASHTO/AWS available for the on-site auditor
D1.5 Bridge Welding Code. to review.

Effective Date September 1, 2019 4 of 4

 10° SKEW

AZIM
CL TO CL OF BEARINGS

UTH
G1 10° SKEW

INTERMEDIATE
D1

D2

D2

D2

D2
GIRD

STIFF. (TYP.)
(IF REQ' D.) G2
ER SP
GIRDER SPACING

CONNECTION PL.
A

CL OF BEARINGS CL OF BEARINGS
CING

D1
D1

D3
D3

D3
7" X 1/2" (MIN.)
END ABUTMENT (TYP.) END ABUTMENT
STATION G3 STATION
ALO

AZIMUTH
NG L

STATION
BEARING

D1
D3
C OF BE

D3
D3
D1

LINE STIFFENER (TYP.)

G4

AZIM
ARING

BEARING
D2

D3

D1
D2
D1

UTH
STIFFENER (TYP.)
S

G5

DIAPHRAGM SPACING (25' 0" MAX.)

SIZE & SPACING OF

INTERMEDIATE STIFFENERS
IF REQUIERED BY DESIGN (TYP.)
FRAMING PLAN
(SINGLE SPAN)
FOR SKEWS 20° AND UNDER, THE
DIAPHRAGMS AND THE STIFFENERS
THEY ARE CONNECTED TO SHALL BE
PLACED PARALLEL TO THE SKEW.
 CONNECTION P L
SEE LEVEL 7"x 21"(MIN.)
NOTE * (TYP.)

MC, W-SHAPE, OR C CHANNEL SECTION

INTERMEDIATE DIAPHRAGM-TYPE 1 *

NOTES:
5/16
1. DIAPHRAGM TO BE AT LEAST ONE-HALF OF THE
BEAM DEPTH.

2. BOLTED CONNECTIONS SHALL BE MADE USING

7 5/16
8" DIAM. ASTM F3125, GRADE A325 5/16
HIGH-STRENGTH BOLTS.

3.
* DIMENSIONS SHALL BE EQUAL.
5/16

INTERIOR GIRDER
CONNECTION PL