Loading...
HomeMy WebLinkAboutB13-0552 B14-0032 Fabricator Certificate of ComplianceTOWN OF VAIL� Department of Community Development 75 South Frontage Road Vail, CO 81657 Tel: 970.479.2128 www.vailgov.com Development Review Coordinator TRANSMITTAL FORM Use this form when submitting additional information for planning applications or building permits. This form is also used for requesting a revision to building permits. A two hour minimum building review fee of $110 will be charged upon reissuance of the permit. Application /Permit #(s) information applies to: Attention: O Revisions © Response to Correction Letter B14 -0032 Martin Haeberle jZattached copy of correction letter Q Deferred Submittal 613 -0552 JR Mondragon ( Other Project Street Address: 463/473 Beaver Dam Rd (Number) (Street) Building /Complex Name: Applicant Information (architect, contractor, owner /owner's rep) Contact Name: RA Nelson Address: 51 Eagle Rd City Avon Contact Name: Grant Smith Contact Phone: 970- 391 -9736 (Suite #) State: CO Zip: 81620 Contact E -Mail: gsmith @ranelson.com I hereby acknowledge that I have read this application, filled out in full the information required, completed an accurate plot plan, and state that all the information as required is correct. I agree to comply with the information and plot plan, to comply with all Town ordinances and state laws, and to build this structure according to the town's zoning and subdivision codes, design review ap- proved, International Building and Residential Codes and other ordinances of the Town applicable thereto. Owner /Owner's Representative Signature (Required) For Office Use Only: Fee Paid: Received From: Cash CC: Visa / MC Last 4 CC # Authorization # Check # exp. date: Description of Transmittal/ List of Changes, Items Attached: Fabricator Certificate of Compliance - Per IBC 2012 1704.2.5 (use additional sheet if necessary) Building Permits: Revised ADDITIONAL Valuations (Labor & Materials) (DO NOT include original valuation) Building: Plumbing: Electrical: Mechanical. Total: Date Received: x $0 JUN 2-+ 201�5 TOWN OF VAIL nx.i., R.A.N E LSO N BUILDING MOUNTAIN RESORT COMMUNITIES Submittal Transmittal Coversheet — RA Nelson Job Name: 4W /4" tseaver uam tta Project Number: 74 -14 -00 Transmittal Date: 6/26/14 Transmitted to: KH Webb Q Martin and Martin Other Town of Vail Date Requested Back: 7/9/14 Submittal Signoff Requirements — Q KH Webb Q Trademark (Brian McAndrews) 0 Zekelman Q AM Town of Vail Submittal Title: Fabricator Certificate of Compliance Number of Pages in Submittal: 73 Pictures Included: Yes or No Submittal Division: 005 Submittal Type /s: 0 Product Data Q Shop Drawings Q Product Test Report 0✓ Certifications Q Warranty Information Q O/M Information Q Material Mockup Submittal Number /s: List Below 1. 005 -030- Fabricator Certificate of Compliance S. 2. 6. 3. i. 4. 8. Q Material Sample Q As Built Drawings Q Commissioning Report Q Substitution Request Q MSDS /SDS Q Other Submittal Information Notes Contractor is requesting approval as a TOV approved fabricator. Approval reduces the frequency and/or need for special inspections for shop welds as outlined on structural notes /special inspection requirements Submittal Substitution Info — 1. Is this product equal or greater in quality? 2. Is there a cost impact to the substitution? ZIMKOR LLC QUALITY MANUAL 7011 W. Titan Road Littleton, CO 80125 Phone: 303- 791 -1333 Fax: 303 -791 -1340 12014 Qua& Manual Distribution SUBMITTAL REVIEW Contractor's review is for general conformance with the Contract Documents. Subcontractor or Supplier are responsible for verifying all field dimensions, fabrication and construction means, methods, sequences and coordination with affected trades. This review does not alter, supersede or replace the requirements of the Subcontract Agreement or Purchase Agreement. This review does not relieve the Architect and / or Engineers of their contractual responsibilities. ]REVIEWED ❑ MAKE CORRECTIONS NOTED ❑ REVISE AND RESUBMIT ❑ REJECTED R.A. NELSON LLC Reviewed b : Grant Smith Date: 6/25/14 Submittal # Position Location Controlled Copy# Human Resources /Office Manager Office Original President/Operations Manager Office CC 1 Vice President /Const Svcs/Quality Manager Florida Office CC2 Detailing Manager Office CC3 Shop Superintendent Shop Office CC4 Quality Assurance Inspector Shop QC Office CC5 Materials Manager Office CC6 Manager of Estimating/Sales Office CC7 Shipping Manager Shop Ship ing Office CC8 AISC Certification /QMC Auditor Office CC9 Asst. Shop Superintendent Shop CC 10 ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 1 of 16 This quality manual has been approved by; Casey A. Brown, President and Management Representative, who carries the overall responsibility for this facility. Changes or revisions to the quality manual will be reviewed and authorized by the President. Zimkor LLC Quality Manual Revision Histo Revision Date Approved By Brief Description of Change 4/29/2005 Denver Johnson Entire rewrite to AISC 2002 Certification Program 11/26/2007 Denver Johnson Added Production Manager Clarified PM /PC Responsibilities Clarified Detailing and Document Control Miscellaneous Clarifications 12/5/2008 Denver Johnson Controlled Copy to Asst. Shop Superintendent Changed "dealers" to "detailers" in Training section Changed Responsible Manager's names to Procs. 8.1 & 9.0 12/8/2009 Denver Johnson Deleted Chairman and Contracts Manager copies causing all Controlled #s to change Changed Production Manager to Operations Manager in Procs. 9.0 & 10.0 Changed wording. in 4 paragraphs of Proc.6.0 1/6/2011 Casey Brown Changed President /Mgmt Rep's name Added title of Revision History on table Chan ed 2 sentences in Proc. 8.0 1/30/2012 Casey Brown Changed Procs. 6.0 and 8.1 1/11/2013 Casey Brown Deleted Chairman from distribution & changed some Controlled Copy numbers 1/20/ 2014 Case Brown Chan ed Procs. 9.0, 12.4 and 16.0 0 ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 2 of 16 Table of Contents 1. Purpose ....................................................................... ............................... 4 2. Scope .......................................................................... ............................... 4 3. References ................ ............................... .................... ............... 4 4. Definitions .... ............................... ....................... . ............................... 4 5. Management Responsibility .. ........................................ ............................... 4 6. Contract and Project Specification Review .................... ............................... 7 7. Detailing ................... ............................... . ............ ............. 7 8. Document and Data Control .......................................... .......................:....... 9 9. Control of Quality Records ............................................ ............................... 10 10. Purchasing ................................................................... ............................... 11 11. Material Identification ..................................................... ............................... 12 12, Fabrication Process Control ............................................ ............................... 12 13. Inspection and Testing ..... .............................................. .I............................. 1.3 14. Calibration of Inspection, Measuring and Test Equipment . ............................... 14 15. Control of Nonconformances ......................................... ............................... 14 16. Corrective Action .......................................................... ............................... 15 17. Handling, Storage and Delivery of Product and Materials ................................. 15 18. Training ............ ............................... .., ..................... 15 19. Internal Audit ................................................................. ............................... 16 Appendix A - Quality Management System PROCEDURES ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 3 of 16 I i i i 1. Purpose The purpose of this manual is to outline the criteria within Zimkor LLC to meet AISC certification. 2. Scope It allows customers and others a means to understand Zimkor LLC's Quality Management System 3. References Zimkor LLC has the applicable reference documents, standards, codes, or other applicable documents readily accessible to the individuals who need them. Zimkor LLC also assures that these references are both current and meet the requirements of customer contracts. References utilized are in 7.2.1 of this manual. 4. Definitions Zimkor LLC has made every effort to emulate the definitions as outlined by AISC's Building Certification Standard. Any definitions which are unique to the Company will be listed below as determined necessary. 5. Management Responsibility Zimkor LLC's Executive Management Team (EMT) is responsible for developing a commitment to quality, directing the corporation to achieve that quality, providing personnel and resources as applicable, and overseeing the Quality Management System in an effort to comply with its quality directives. Commitment (Policy) Zimkor LLC has established and implemented a company policy with respect to quality. Quality Vision Statement - Zimkor LLC is committed to a process of continuous improvement that will consistently provide products and services that meet our customer's expectations and requirements. Zimkor LLC employees have the right and the responsibility to participate in this process through their daily attitudes and performance. This policy statement is disseminated to all personnel to ensure that every employee is aware of the company's commitment to quality, and their role is helping to achieve it. Direction and Leadership Zimkor recognizes that effective leadership begins at the top with the EMT. Our commitment to the highest quality standards is made evident to the people who report directly to us. These people in turn carry on that leadership to the people reporting to them and so on to all employees. This commitment to quality applies equally to all personnel regardless of the position they hold within the company. T ie-qu fj- mansgemen-t= sysfemis r- 4iiewed annually" -by aei3afIrrerit- d e c �i - -_ —_ -_ - -- -. management to ensure its continuing adequacy and effectiveness. Changes or additions to the system are made to achieve improvements in attaining customer satisfaction. Records of management reviews are maintained in the Quality Management System files maintained by ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 4 of 16 the Office Manager and include such information as: audit results, customer feedback, and information from previous management review (outputs) which include product conformity reports and improvement of product quality and resources needed. Management Representative The President of Zimkor LLC is responsible for ensuring that procedures are established, implemented and maintained for the quality management system. These procedures are in accordance with the AISC Certification Standard for Steel Building Structures. The Quality Manager submits a written, annual report to the Executive Management Team (EMT) on the performance of the quality management system and any need for change or improvement. The report is reviewed by the EMT who determines whether or not it is in the company's best interest to act on the recommendations for improvement. Resources Executive management provides the resources necessary to achieve conformity to contract specifications. Such resources include personnel, work space equipped with appropriate utilities, and equipment. Product evaluations and internal audits are conducted to ensure that resources remain adequate for the production of quality product. Personnel Minimum qualifications exist for all personnel, including the Quality Assurance personnel. The minimum qualifications for each position within the company are defined in specific job descriptions which are found in the Human Resources Department. The personnel responsible for the performance of work affecting quality, and their interrelationship with other employees within the corporation are defined and documented using organization charts that are also found within the Human Resources Department. Personnel can be assigned to more than one function, provided they are qualified to perform each job. Annual performance reviews are conducted by department supervisors to ensure that the qualifications of the personnel performing specific duties are concurrent with changing job requirements. On -the -job training is employed to ensure that all employees have a thorough understanding of and ability to perform their specific job requirements. Buildings, Workspace and Associated Utilities Zimkor LLC has adequate workspace within their buildings to provide the amount of space necessary to produce quality product. There is ample space provided for administration, as well as shop functions such as fitting, bolting, welding, painting etc. Areas suitable for the storage and shipping of materials are also provided. Process Equipment (both hardware and software) Zimkor LLC provides adequate equipment for the production of quality product and the -- - - -- maintenance -of - corresponding- reeerds: Suc- h- eopmer +t-inc- lude"4op- mQciainery, ,as -veil as- — - - computers with appropriate software to maintain adequate records of equipment, products; - processes, production schedules and personnel. ZiMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 5 of 16 Equipment is tested periodically and repaired or updated whenever the need arises. Equipment is maintained to ensure conformance to the highest quality standards. Internal Communication Executive management has established internal communications procedures to ensure that any and all information regarding the quality management system's standards and processes reach all individuals within the corporation whose job functions directly impact product quality. Such communication may take the form of written policies and procedures, postings in relevant areas of the shop floor, emails, and /or verbal instruction or commentary during department meetings. Documentation Requirements General Requirements Zimkor LLC's Quality Management System consists of documentation conducive to the production of a quality product. Such documentation provides a written policy statement with stated goals and objectives, written procedures and corresponding quality records, and a written quality manual. Quality Manual Zimkor LLC's written Quality Manual contains documentation outlining the requirements of the Quality Management System. Such documentation includes, but is not limited to, a quality policy with stated goals and objectives, written procedures and corresponding quality records, and any other documents needed to ensure the effective operation of the quality management system. The Quality Manual also describes the communication processes that exist to effectively disseminate information between departments in order to ensure that all personnel possess the most current product requirement information. Such effective transfer of information is necessary to reduce the occurrence of nonconformities due to outdated information being used within a department. Organization Within Zimkor LLC's Quality Manual are detailed policies and procedures necessary to maintain an effective Quality Management System. Such documents demonstrate strict compliance to AISC's Certification Standard for Steel Building Structures. Quality Management System reference documents contain an organizational chart, as well as job descriptions and qualifications of key personnel, a facility plan, and an equipment list. The Quality Manual is reviewed annually to ensure that all information contained within it is current. Any outdated information is removed and discarded immediately. Approval Zimkor LLC's Quality Manual is approved by the President. Changes to any of the documents -- contained-in --the manual -are approved -first tay the- QudAft and& 666Me EMT, an�theri _ submitted to the President for approval and signature.. ZIMKOR LLC Quality Manual Rev. 1/20/14 uncontrolled Copy Page 6 of 16 6. Contract and Project Specification Review and Communication Zimkor LLC has documented and implemented a procedure for contract and project specification review. (Ref. Contract and Project Specification Procedure #6.0). All contracts and project specifications are reviewed when they are received in order to determine the resources necessary to fulfill the contract requirements. Once a contract has been awarded, or notice to proceed issued providing funding authorization for a particular project, the estimating department provides a job write -up. The job write -up is distributed to all departments for planning and implementation. A schedule is then developed for the implementation and completion of the ordered project. 7. Detailing Detailing Procedures Preparation of Shop Drawings and Erection Drawings Zimkor LLC has documented and implemented a Detailing Procedure which explains how shop and erection drawings are developed and produced. (Ref. Preparation of Shop and Erection Drawings Procedure #7.0). These drawings incorporate project specifications, codes and customer requirements, and ensure that they are in compliance with the relevant /AISC Standards. The procedure also documents how information is tracked and communication with the customer is maintained via RFI's (Requests for Information). Detailing Standards Zimkor LLC utilizes detailing standards which describe Zimkor's preferred methods for the selection of material and the means to identify how holes, fasteners, cuts and copes, etc. are shown on the shop drawings. Provisions for Checking Shop and Erection Drawings Zimkor LLC has a written procedure for the checking of shop and erection drawings. (Ref. Checking of Shop and Erection Drawings Procedure #7.1). Customer Approval of Shop Drawings Shop drawings released for fabrication are first approved by the customer. Approval returns are scanned in and stored electronically on the Zimkor LLC server for reference /archival purposes. The Project Coordinator maintains drawing logs for all shop, erection and vendor drawings. ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 7 of 16 Detailing Function Resources References Zimkor LLC maintains the following codes and standards for reference as to the pertinent codes and specifications required for the work to be performed: • AISC Selected ASTM Standards for Structural Steel Fabrication • Manual of Steel Construction, LRFD and ASD, which include the following specifications and codes: • Specification for Structural Steel Buildings • LRFD Specification for the Design of Steel Hollow Structural Sections • LRFD Specifications for Single -Angle Members • Specification for Structural Joints Using ASTM A325 or A490 Bolts • AISC Code of Standard Practice for Steel Buildings and Bridges • ANSI /AWS D1.1 Structural Welding Code -Steel • ANSI /AWS A2.4 Symbols ANSI /AWS A3.0 Terms and Definitions • Steel Structures Painting Manual, Volume I, Good Painting Practice • Steel Structures Painting Manual, Volume II, Systems and Specifications • AISC Detailing for Steel Construction • International Building Code (IBC) • Clark County Building Administrative Code • Southern Nevada Building Code Personnel Zimkor LLC employs a Project Administrator, Project Coordinators, and Project Managers who jointly ensure that all detailing functions are carried out according to the specifications of the AISC Certification Standard for Steel Building Structures and customer contract requirements. Detailing Management The Detailing Manager oversees the production of shop and erection drawings. His responsibilities include selecting and procuring subcontract detailing services, coordinating department production schedules, ensuring receipt of contract requirements at project initiation, coordinating and incorporating construction requirements, developing drafting standards and detailing procedures, and the training of Project Coordinators. Project Coordination Functions Project Coordinators are responsible for managing the subcontract detailing firms during drawing preparation, the RFI process, coordination of our work with others, the shop drawing process including review, approval submittal and return, scrub and issuance for construction, and the maintenance of RFI and shop drawing logs. They report to the Detailing Manager, who in turn reports to the Construction Services Manager. Connection Consultation ____ _...._, PrQjeG# p��ifi�pQtlne�fiQr ]�Citerc�r�tablished prior t4 detailing in the form of_Job Standards_ __ which are submitted to -fhe customer for "approval by the Engineer of Retard: If-engiryeering -, v -- - calculations are required by contract, Zimkor will subcontract an experienced P.E. licensed in the state required by the contract. ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 8 of 16 Subcontract Services Zimkor LLC utilizes subcontract services for detailing, connection consultation and checking of shop or erection drawings, as required. The Detailing Manager ensures that all subcontract services utilized are qualified, have received and acknowledged contract requirements and have the knowledge and expertise to assure compliance to all contract specifications and Zimkor requirements. Customer Supplied Shop Drawings Zimkor LLC has a written procedure for the receipt, revision and control of customer supplied shop drawings. (Ref. Customer Supplied Shop Drawings Procedure #7.2). Shop drawings received from the customer are entered in the Drawing Log. There they are identified by drawing number, revision, customer name and drawing title. 8. Document and Data Control Zimkor LLC has developed a written procedure for the control of documents and data pertinent to the Quality Management System. (Ref. Document Control - Quality Manual Procedure #8.0). Such documents and data include the Quality Manual, contract documents, shop and erection drawings, documented procedures required by the Standard, and all documents and data affecting quality. Review and Approval The Quality Manager reviews and approves all documents affecting quality. Revisions to the Quality Manual and other quality management system documents are reviewed by the Quality Manager, approved by the EMT and signed off on by the President prior to implementation. All quality documents, including the Quality Manual, are reviewed annually and updated at that time. Customer Requirements The Project Manager implements a procedure (Ref. Document Control - Customer Requirements and Project Documents Procedure #8.1) to receive and document customer requirements and contract changes as they occur throughout the production process. This procedure includes maintaining a Document Control Log that shows the receipt, approval, and distribution of original and revised design drawings and contract documents to the appropriate departments and personnel within the corporation, as well as subcontractors and /or suppliers. Revision Control The Quality Manager ensures that all documents within the Quality Manual have a cover page which contains the document's date of origin, a current revision date, and an approval signature. The Quality Manager maintains a master list of all changes and revisions, both - -_ -- electronically - gt7d1n -p heard -copy farrngi -f ensttre -thgt the fn- pst-curren4 revisions- afe_up -te- date _ -_ and in effect. Such a list is distributed to all quality personnel, as well as shop supervisors, to ensure that only the most current revisions to documented policies and procedures are being ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 9 of 16 utilized within the corporation. Documents are readily accessible and maintained within work areas of the shop to avoid the use of obsolete procedures in the production process. Access The Quality Manager ensures that the most current policies, procedures, and quality management system documents are disseminated to the appropriate personnel within each department. Department managers guarantee that all documents relevant to specific areas of operation are accessible to all personnel within that area who are responsible for performing work affecting product quality. Obsolescence and Transmittal The Quality Manager maintains a master list showing the most current revisions to the Quality Manual and other quality management system documents. The Project Manager maintains a Document Control Log of the most current revisions to contract requirements, job specifications, and design drawings. The Project Coordinator maintains a log of all shop and erection drawings documenting latest revision and current status. All controlled documents under their care and control that are obsolete are marked, segregated and, in the case of shop drawings, are destroyed to prevent their inadvertent use within the production process. All projects have prints issued to the shop floor, the number of which varies according to the complexity of the project requirements. The number of sets issued to the shop for each project is documented on transmittals issued by the Project Coordinator. Once a drawing is considered obsolete, all copies of that drawing are collected from the appropriate areas and compared to the number written in the log to ensure that all obsolete copies have been collected. When transferring quality sensitive documents between Zimkor and outside parties (i.e. the customer, contractors, coordination with other trades, subcontractors, etc.) a transmittal accompanies the documents. A copy of the transmittal will be placed in the Project's Correspondence file. 9. Control of Quality Records Zimkor LLC has established a written procedure for the identification, collection, storage, maintenance, retention and disposition of quality records. (Ref. Control of Quality Records Procedure #9.0) All quality records are stored on -site in each respective department in a way that prevents damage, deterioration or loss. They are labeled for easy identification and retrievability. Retention times are established and recorded for records retained for any purpose. The retention periods will be at least long enough to permit evaluation of the records during the course of project construction. A master list of all quality records is maintained by each department manager and includes the name of the document, the date of issuance, the retention period and the date of destruction (if applicable).. This list is reviewed._ and_ updated quarterly_for accuracy. 77 ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 10 of 16 Records that document quality typically include: • inspection records • NDT reports • drawing logs • MTR's (Mill Test Reports) • CofC's (Certificates of Compliance /Conformance) • design changes • RFI's (Requests for Information) • mill and consumable purchase orders • records or summaries of nonconformance reports • corrective action reports • internal and external quality management system audits 10. Purchasing Zimkor LLC has established and implemented a procedure to ensure that purchased material, products, services and subcontractors conform to project requirements. (Ref. Purchasing Procedure #10.0). Purchase orders, records of the qualification of suppliers and subcontractors, and records of the periodic evaluation of suppliers are maintained within the Materials Management Department. Purchasing Data Zimkor LLC clearly describes subcontracted work and the purchased products, materials and services ordered in Purchase Orders, Subcontracts, and other purchasing documents. Purchasing documents contain the following information: • Type of service, material, class, grade and other unique identification • Specifications, drawings, process requirements and inspection instructions that may apply • Delivery instructions and date • Certificate of Compliance /Conformance, Certified Mill Test Reports and /or NDT reports required • Compliance with ASTM A6, as appropriate • Special instructions or any other information pertinent to the product ordered. Selection of Subcontractors Suppliers and subcontractors are evaluated annually by conducting an audit or through documented past experience. Evaluation and selection is based on the quality of products or services, the ability to meet required specifications and timeliness. Additionally, consideration is given to the company's quality management system and any specific certification or inspection requirements. The subcontractor shall have the required level of AISC Certification on projects that require such certification, unless waived in writing by the customer. Verification of Purchased Product, Materials and Services All incoming product and material is checked by the purchasing manager to ensure that it _ _ ._. _ __ __ conf-o�ms tb the -p urchase order cir�uf3oo- iifiraEt, as well�as =t� � jecct Tac"rements, Test­reports, -_ -_ certificates of compliance and other evidence of quality control are kept on file in the Materials Management Department. ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 11 of 16 Customer Verification of Fabricated Product Customers are welcome at our facility at any time. Access and accommodation is afforded independent inspection performed by the customer. Control of Customer- Supplied Material Material supplied by the customer is received, verified, stored and maintained to avoid loss or damage. Material is inspected upon receipt. Any damage or non - conformance is reported to the customer. MTR's will be verified and maintained, except when controlled by the customer for material shipped from stock. 11. Material identification Zimkor LLC has established and implemented a written procedure for identification of material. (Ref. Material Identification Procedure # 11.0). This procedure complies with Identification of Material, Section 6.1 of the RISC Code of Standard Practice. Additionally, this procedure provides a method for all- material lot traceability and main- member piece -mark traceability through fabrication. Material purchase orders include the information outlined in ASTM A6 Section 4 "Ordering Information", as appropriate, and require Certified Mill Test Reports be provided. MTR's and certificates of conformance are retained for a minimum of two (2) years after project completion. Material in inventory is identified by shape, grade, heat number and purchase order procured under. Once entered into fabrication, it is identified by job number and main - member or detail piece -mark, but traceability back to a MTR is maintained through cutting documents. 12. Fabrication Process Control Zimkor LLC has established and implemented the procedures necessary to produce products with a quality level that meets applicable codes, specifications and project requirements. These cover the fabrication processes done at the shop facility, as well as those conducted at subcontracfi vendor sites. Welding See Welding Procedure # 12.0 which describes the qualifications of weld processes and the certification of welding operators. Bolting - _ _ _ _ _ _ -_.. _ - See Bolting Procedure* 12.1 which describes inspection and �es�ing of s�iop 11 -d col s. ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 12 of 16 Material. Preparation for Application of Coatings See Material Preparation for Application of Coating Procedure # 12.2 which describes the methods for cleaning of material preparatory to paint application. Coating Application See Coating Applications Procedure # 12.3 which describes materials, testing and methods of application of coatings. Maintenance See Equipment Maintenance Procedure # 12.4 which describes the preventative maintenance program used to maintain production equipment in proper working order. Cambering See Cambering Procedure # 12.5 for the methods used to produce specified camber in members. 13. Inspection and Testing Zimkor LLC has a written procedure of inspection and testing to ensure that product quality meets the project requirements. (Ref. Inspection and Testing Procedure-#13.0). Inspections are conducted at various intervals during the fabrication process. The level and frequency of inspections is increased when the level of defects increases. Inspections are done at receipt of material, in- process, and final inspection of all material and members prior to shipment. Records of inspections are maintained and provided to shop and corporate management. Quality Assurance Inspectors are trained in proper inspection techniques and acceptance criteria. The QAI is a full time position, and in addition to training and experience, requires AWS QC Welding Inspector Certification. A trained and qualified assistant QAI is available to substitute for or augment the QAI as ,needed. Inspection procedures include the following: Material Receipt - Materials received are compared to the purchase order requirements. Checks are performed to verify quantity, shape, grade and to spot any damage. Any apparent deviations from ASTM A6 are investigated. In- Process Inspection - Inspections are conducted in- process by both production and QC personnel to ensure fabrication is proceeding in accordance with project requirements and to inspect those items which may become inaccessible as fabrication continues. Members are Inspected -focshape; grade; heat - number, dimensions; fMing%i io1e- sizeVgttality1- Oo+ts- ernd =— - camber. Additionally, WPS's, preheat and welder qualifications are monitored. Production personnel check their own work to ensure correctness prior to sending the member to the next station. Deviations discovered during a QAI inspection are documented as non - conformances. ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 13 of 16 Final Inspection - QC personnel perform final inspection after welding and painting, but prior to sending parts to shipping. NDT of all CJP welds is either performed by the customer or sublet to qualified vendors. Records are maintained of all inspections, and deviations are documented as non - conformances. Customer's Independent Inspection - If the customer elects to perform inspection during fabrication, the QAI coordinates and facilitates these efforts with production. Customer's inspections augment or duplicate, but do not replace any standard in -house inspection procedures. 14. Calibration of Inspection, Measuring and Test Equipment Zimkor LLC has a written procedure defining the control, calibration and maintenance of test, inspection and measuring equipment used to verify the conformance of products to specified requirements. (Ref. Calibration Procedure #14.0). Calibration shall be with certified equipment having a known valid relationship to nationally recognized standards. If no national standard exists, the basis used for calibration shall be documented. Calibration of test, inspection and measuring equipment is performed at established intervals to ensure continued reliance on the equipment. The Quality Assurance inspector is responsible for maintaining all calibration records. Each record will include a description of the equipment, manufacturer, serial number, date of calibration, date when next calibration is due, the test equipment used, the standard calibrated to, and the calibration firm's and inspector's names. Inspection, measuring and test equipment is controlled by the Quality Assurance Inspector and is stored in the QC office to protect from damage. Calibrated equipment is identified with a label identifying serial number, calibration date, next calibration due date, and initials of the individual performing the calibration. Any equipment which is damaged in service, shows signs of erratic readings or is reasonably suspected of inaccuracies is removed from service by the QAI and sent for calibration, repair or replacement. 15. Control of Nonconformances Zimkor LLC has a written procedure to ensure product that does not comply with project requirements is prevented from reaching the customer and /or being used in the production /construction process. (Ref: Control of Nonconformance Procedure #15.0). Once identified, nonconforming product is segregated and tagged to prevent accidental return to production. An evaluation is done to determine if part should be repaired or replaced. Where warranted, the customer will be consulted for a determination of acceptability. Instances where the customer accepts product either nonconforming, or of questionable conformity, will have acceptance documented in writing. Nonconformances, bofih 1n.the_shop and in the field, are documented, monitored and analyzed td identify dreas of opportunity for improvement: ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 14 of 16 16. Corrective Action Zimkor LLC has a written procedure for the initiation of a corrective action. (Ref. Corrective Action Procedure #16.0). A corrective action is defined as an action taken to eliminate the causes of nonconformances. The determination as to whether or not to initiate a corrective action depends upon the degree to which a nonconformance jeopardizes the production of a quality product. A Corrective Action Report (CAR) is issued after periodic reviews of records or internal and external quality audit reports determine critical conformities to quality standards. Once a CAR is generated, management personnel determine and implement a course of action to correct the nonconformity. Periodic reviews are conducted to ensure the corrective action is being performed and is effective. CAR's are documented and maintained in a Corrective Action Report Log. 17. Handling, Storage and Delivery of Product and Materials Zimkor LLC has developed a means of handling, storing and delivering products and materials. Material is stored, handled and shipped in such a way as to avoid damage and deterioration. Material is also labeled for easy identification on shipping documents and potential traceability. If a shipping agreement exists between Zimkor LLC, the customer or the subcontractor, material is shipped in compliance with the agreement. This may include sequencing that complies with erection needs. Shipments by subcontractors are coordinated and monitored for compliance with shipping instructions. 18. Training Zimkor LLC has developed a means to ensure that personnel responsible for the quality of products and services receive initial and periodic training in their specific job functions. Periodic training may occur whenever there is a change in their specific duties or a procedural change in a particular job is implemented. Such personnel include operators (welders, machinists, etc.), inspection personnel, receiving personnel, detailers, purchasing agents, shop supervisors, and management personnel. This training ensures that the individual possesses the understanding necessary to perform the functions of their job in an efficient and productive manner. Training results for these personnel are documented and reviewed on a periodic basis to ensure compliance to job qualification specifications. Personnel receive training whenever changes to the requirements of their assigned job function occur. Such training is documented and maintained in their individual personnel files located in ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 15 of 16 19. Internal Audit Zimkor LLC's executive management conducts an internal audit of each element of the quality management system at least once a year to verify their compliance and effectiveness. The audit is performed by the Quality Manager. The results of the audit are reviewed with the management personnel responsible for the efficient operation of that particular function. A written result of the audit is maintained in the Quality Management System files located in the Office Manager's office. A Corrective Action Report may be initiated on any nonconformity noted during an audit depending upon the severity of the nonconformity. When a Corrective Action Report is generated, a follow up audit is conducted to ensure that corrective actions have been implemented in a timely manner to ensure the continuous improvement of the quality management system. ZIMKOR LLC Quality Manual Rev. 1/20/14 Uncontrolled Copy Page 16 of 16 Zimkor Quality Management System PROCEDURES Effective PR# Title Date Revision Revision 1/30/2012 6.0 Contract and Project Specification Review 11126/2007 7.0 Preparation of Shop and Erection Drawings 11/26/2007 7.1 Checking of Shop and Erection Drawings 4/29/2005 7.2 Customer Supplied Shop Drawings 1/6/2011 8.0 Document Control - Quality Manual 1/30/2012 8.1 Document Control — Customer Requirements and 9/14/2005 10 Project Documents 1/20/2014 9.0 Control of Quality Records 12/812009 10.0 Purchasing 4129/2005 11.0 Material Identification 11/26/2007 12.0 Welding 11126/2007 12.1 Bolting 4/29/2005 12.2 Material Preparation for Application of Coating 9/1/2006 12.3 Coating Applications 1120/2014 12.4 Equipment Maintenance 4/29/2005 12.5 Cambering 11126/2007 13.0 Inspection and Testing 11/26/2007 14.0 Calibration 4/29/2005 15.0 Control of Nonconformances 1/2012014 16.0 Corrective Action Distributed 1/20/14 4 Revision Revision Approved By Brief Description of Change Date Number -- 4/29/2005 9 Denver Johnson Entire rewrite to AISC 2002 Certification Program 9/14/2005 10 Denver Johnson Revised entire bolting procedure; Revised calibrated tools, frequency and added accuracy 10/2712005 11 Denver Johnson Revised calibrated tools, frequency and accuracy 9/1/2006 12 Denver Johnson Revised approved vendor list evaluation timeline, wet to dry film test, and calibrated tools list 11/26/2007 13 Denver Johnson Revised 6.0, 7.0, 7.1, 8.1, 9.0, 10.0, 12.0, 12.1, 12.4, - 1-3.x, --and I4:0 -to-- clarify PM /PC, add -- Production- __ - - -___- Manayer, plus miscellaneous clarifications Distributed 1/20/14 Revision Date Revision Number Approved By Brief Description of Change 12/5/2008 14 Denver Johnson Revised 8.1, 9.0 12/8/2009 15 Denver Johnson Revised 6.0, 9.0, 10.0 1/6/2011 16 Casey Brown Changed Approved By person's name Revised 8.0 1/3012012 17 Casey Brown I Revised 6.0 and 8.1 1/20/2014 18 Casey Brown Revised 9.0, 12.4 and 16.0 . i Distributed 1/20/14 i Zimkor LLC Quality Management System PROCEDURE Responsible Mana er Casey Brown Revision Effective Date Contract and Project Specification Review 17 1/30/2012 1. Purpose Page 1 of 3 To identify, record, coordinate and distribute the various project requirements to the production entities responsible for meeting them. 2. Procedure Once a contract has been awarded, or notice to proceed providing funding authorization for a particular project, the Estimating Department will provide a Job Write -up that will include the following: Job Name and Job # Customer Contract Amount Estimate of Shop Hours and Material Dollars by Phase or work package Kind of Contract (fixed price, time and material, other) Schedule agreed to at bid time - -.' Penalty Clauses noted in bid documents Listing of all Drawings Bid From Listing of all Drawings Excluded Listing of Exclusions Specifications included in the Bid Documents Addenda received by number Any other pertinent bid documents (ASI's, Bulletins, etc.) All Alternates or Value Engineering Proposals, accepted or not Surface Preparation and Shop Painting requirements by type of work Subcontractors utilized in preparing the bid Any Project Requirements, Tolerances, Procedures or Special Inspection indicated in the bid documents that are beyond the requirements of AISC or AWS Any other special conditions that should be noted Special inspections required by spec to be performed by the customer Special inspections required by spec to be performed by Zimkor The job Write -Up is distributed to all departments. Once a Subcontract is received, a Contract Review occurs within one week between Executive Management, the Project Manager, and the Project Estimator. Each party is responsible for reviewing contract terms relating to their area of responsibility, including review with key subcontractors and suppliers for the project (see attached Contract Review Checklists). If during the initial review it is determined that the Subcontract Agreement differs from the Zimkor company standards or proposal quotation for the project, these concerns will be addressed and negotiated with the Customer. Once a mutually acceptable agreement is obtained, the Subcontract is executed by Executive Management and returned to the Customer for their execution. A copy _will be maintained-in- the -- project jab_ file .until_the..fully_exe -cuted_-c.Qpy is received. _ Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Casey Brown Revision Effective Date Contract and Project Specification Review 17 1/30/2012 PR #6.0 Page 2 of 3 Project Management shall create and maintain a Document Control Log for each job which identifies all Contract Documents to be incorporated into the project and includes their issue dates. Project Management will post a log file in the projects directory along with all document files for access by all departments requiring them. As new or revised Contract Documents are received, Project Management will update the Document Control Log to include them. Throughout the project, revisions to Contract Documents will be reviewed by the Project Manager as required to ensure compliance with the Contract Documents. Questions for the Owner, Designers, or Contractor will be documented through Requests For Information (RFI) and logged in the RFI Log by Project Management. Potential cost and/or schedule impacts to the project will be determined by the Project Manager and a Charge Order Request will be prepared as warranted due to Contract Drawing revisions. A Work Authorization is prepared to direct contract changes to all departments affected. The Project Manager will review the Contract Documents to develop an overall project strategy with particular emphasis on identifying special material, fabrication, or erection requirements. This may be facilitated by a Project Kickoff Meeting when appropriate with representatives from each department, and the Customer if their input is necessary, to discuss issues and potential conflicts. The Project Manager may record notes from the meeting noting the items discussed, any action items resulting from the discussion, who is responsible to take action and the date the action is to be completed by. The Project Manager's Kickoff Meeting notes will serve as the record and will be used to track any actions requiring follow -up. Small jobs can be exempted from the Project Kickoff Meeting at the discretion of Project Manager. The Detailing Manager will access the Contract Documents and Specifications and Document Control Log and is responsible to insure that all Drafting personnel and Detailing Subcontractors are working from complete and current Contract Documents. The Detailing Manager will review with the Project Manager any special fabrication or erection requirements to insure that the shop and erection drawings adequately address these special issues as well as addressing the overall project strategy. The Project Manager will assist the Materials Manager in the selection of major Vendors, and will provide Materials Manager with all applicable documents. The Project Manager or the Materials Manager will issue these documents to the Vendor along with a Purchase Order requiring adherence to all applicable Contract Drawings and Specifications. It will be the responsibility of the Project Manager, Materials Manager and /or Quality Assurance to see that these requirements are met. The Operations Manager administers subcontracted fabrication services and the Project Manager administers subcontracted erection services, as well as major buyouts, such as joist, deck and grating. Each ensures that their Subcontracts or Purchase Orders adhere to all applicable Contract Documents. 3. Records Job Write -Up RFi Document Control Log Change Order Request Work Authorization Project Kickoff Meeting Notes Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE ,esponsible Manager Casey Brown 2evision Effective Contract and Project Specification Review Date 17 1/30/2012 PR #6.0 Page 3 of 3 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date Descri tion 9 4/29/2005 Entire rewrite to AISC 2002 Certification Program 13 11/26/2007 Added clarification regarding contracts, RFI's, Project Kickoff Meeting Notes, Production Manager and added to the Records section 15 12/8/2009 Changed name of Responsible Manager Changed our of the paragraphs' wording_ i 17 1/30/2012 Changed contract review procedure Change Project Manager's duties, in some cases, to Project Management's duties Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Brent Ross Revision Effective Date Preparation of S_ hop and Erection Drawings 13 11/26/2007 W PR #7.0 Page 1 of 3 1. Purpose To generate accurate and complete information for the shop to fabricate steel products meeting the specified requirements of the customer and complete erection information for the erector /customer's use in the field. 2. Procedure Detailing is initiated by the issuance of a Project Write -Up by Sales. The Write -Up identifies the project scope, bid documents, specifications, addendas, along with any special instructions, including any project requirements amended by contract. The Project Manager establishes a Document Control Log, listing current issuance by drawing number. To expand on the Write -Up, input is solicited and detailing instructions, Job Standards, as well as preferences and requirements related to material, fabrication, erection, safety, quality and finance, are prepared by the Project Manager, Construction Services Manager and others further defining scope and exclusions. The Detailing Manager ensures this information is compiled and provided to the detailers. All subsequent contract documents and information, including revised or added design drawings, specifications, ASI's, etc are reviewed by the PM for impact, and issued to detailing for incorporation into shop drawings. The Document Control Log is updated by the Project Manager to identify current documents and their issue date. Changes to project scope or requirements are documented by issuance of a Work Authorization by the PM describing the change and authorizing the work to commence. Zimkor - initiated RFI's are logged and submitted by the Project Coordinator. Upon return, these are logged and reviewed by the Project Coordinator, provided to the PM for impact review and issued to detailing for incorporation into shop drawings. Contractor initiated RFI's are processed and distributed upon receipt in the same manner. When required, outside consulting firms are retained to perform design services. Selection is based on the firm's expertise and licensing required by specification. Shop drawings are sublet to qualified detailing firms. Selection is based on the firm's qualifications, expertise, availability, schedule requirements and budget. All current contract documents, scope lists, detailing instructions, special instructions, Detailing Standards and, where applicable, Job Standards are provided for the detailer's use, Purchase Orders specifically require adherence to AISC, AWS and project specifications, as well as Zimkor Standards. Submittal packages are sequenced and scheduled to support overall project requirements Approval packages submitted by sublet detailing firms are reviewed by the Project Coordinator (PC) and the PM for conformance to project requirements, instructions and standards prior to approval submittal. Until approved and ready for release to construction, all drawings carry a "For Approval" stamp. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Brent Ross Revision I Effective Date Preparation of Shop and Erection Drawings 13 , 11/26/2007 PR #7A Page 2 of 3 A log of all shop and supplier's drawings is maintained by the PC identifying drawing number and revision, and listing dates submitted for approval, returned from approval, issued to fabrication, and issued for field use. Returned approval drawings are reviewed initially by the PC for comments, required changes identified, and are forwarded to the PM for scope review and the Detailer for incorporation. Based on the approval disposition, these are then re- issued for final approval, or issued to fab /field. Formal review and approval of shop drawings is encouraged at all times, however, written directive from the customer waiving drawing approval will be followed. If the customer issues a verbal directive waiving approval, but declines providing a written directive, the Project Manager will forward written confirmation to the customer to document the directive, followed by release of the drawings to fabrication. Upon initial release for fabrication or field use, drawings are identified as Revision 0, dated in the "shop" column of the title block and stamped "For Construction ". Subsequent revisions are overwritten, clouded, identified by a numeric revision number, a revision description is added and drawings are stamped "Revised ". All design drawings issued for detailing, and all shop and erection drawings issued for approval, fabrication, coordination or field use are accompanied by a transmittal listing the recipient, the drawings and the purpose for which they are being forwarded. If field modifications to members or their connections are required, in lieu of erection plans, Field Work drawings are provided to the erector to describe the work to be done. When required, advance bills are issued for material procurement listing quantity, size, grade and length of material. Material requirements on shop drawings are identified as A992 for all WF, A36 for all other rolled sections, A500 Gr B for all HSS, and A53 Gr B for all pipe. Any material specification other than these is specifically listed in the Bill of Materlal. Applicable project specifications are issued to the shop, QC and the field by the PM. As needed to ensure compliance with project requirements, supplementary instructions are issued to the shop and field to augment shop and erection drawings. Selected miscellaneous items are issued to fabrication via Material Cutting Lists accompanied by sketches as required. The Detailing Manager maintains a Detailing Standards Manual which, when followed, will ensure shop drawings consistently meet in -house presentation and fabrication preferences and AISC and AWS requirements. f The Project Manager confirms receipt of any undocumented change to the project requirements, either verbal or otherwise, in writing to the customer. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Brent Ross Revision Effective Date Preparation of Shop and Erection Drawings 13 11126/2007 PR #7.0 Page 3 of 3 All project documentation, including original drawings, approval drawings, specs, transmittals and addendas are filed and/or stored, available for reference as needed. Record of Field Problem forms are used to identify and research drawing, fabrication or installation errors. Detailing errors are forwarded to the detailer for review. Subcontract detailing firms are evaluated by the Detailing Manager and approved subdetailer list is updated at least annually. 3. Records Project Write -Up Detailing Instructions Detailing Standards Manual Job Standards Advance Bill Sublet Detailer Qualification Form Drawing Log RFI Log Material Cutting List Shop Supplementary Instructions Record of Field Problem 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date Description 9 4/29/2005 Entire rewrite to AISC 2002 Certification Program 13 11/26/2007 Miscellaneous changes in the Procedure section regarding Project Coordinator duties. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Brent Ross _ Revision Effective Date Checking of Shop and Erection Drawings 13 11/26/2007 PR #7.1 Page 1 of 1 1. Purpose To ensure accurate and complete information for the shop to fabricate steel products meeting the specified requirements of the customer and complete erection information for the erector /customer's use in the field. 2. Procedure All shop and erection drawings are required to be fully checked by a qualified checker. Manual checking of CAD drawings is conducted. Manual checking is our means of verifying the accuracy of computer detailing software. Generally, this is assigned to the sublet detailing firm as part of their scope of work. As needed, independent checking services are retained. Shop and erection drawings are checked prior to submittal for approval unless other arrangements have been agreed to. Approval packages submitted by sublet detailing firms are reviewed by the Project Coordinator for conformance to project requirements, instructions and standards, and are then forwarded to the Project Manager for scope and schedule review, then submitted. Sublet drawings and in -house drawings will receive the checker's initials and date in the drawing title block, after checking has been completed. The detailing firm or in -house checker will keep the check prints available for reference until the project is completely erected. All changes /revisions resulting from ASI's, RFI's or approval comments will require the same level of checking as the original scope of work. 3. Records Check Prints 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date Description 9 4/29/2005 Entire rewrite to AISC 2002 Certification Program 13 11/26/2007 Verification of computer detailing accuracy, statement regarding checking of drawings, and change of person reviewing approval__ acka es from subs. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Brent Ross Revision Effective Date Customer Supplied Shop Drawings 9 J 4/29/2005 PR #7.2 Page 1 of 1 1. Purpose To manage the receipt, control and disbursement of customer supplied shop drawings. 2. Procedure The Project Manager will date stamp all incoming customer supplied shop drawings, then enter the drawings into the Drawing Log, identifying each by drawing number, revision number, customer name and drawing title. If the customer's drawing number is not compatible with our computerized material control system, an in -house drawing number based on phase number is assigned. If the initial drawing received from the customer does not carry a revision number, it will be assigned revision number 0 (zero) for tracking purposes. Each drawing will receive a cross reference stamp that will identify it to Zimkor Job No., Phase No., Dwg. No. and Revision No. as follows: Zimkor LLC Job No. 7011 W. Titan Road Phase No. Littleton, CO 80125 Dwg. No. 303 -791 -1333 Revision No. Once entered in the Drawing Log, customer supplied drawings are tracked and logged the same as in- house drawings. Individual drawings are tracked by date submitted for approval, date return from approval, date issued to fabrication and date issued to file and construction. If revised drawings are issued by the customer, they are date stamped, logged in, received a cross reference stamp and their issuance to approval, shop and /or file /construction is tracked and logged. 3. Records Drawing Log i 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. - -- - - -- — No. Effective Date Description 9 4/29/2005 Entire rewrite to AISC 2002 Certification Program Distributed 1/20/14 i Zimkor LLC Quality Management System PROCEDURE Responsible Manager John Quinn Revision Effective Date Document Control — Quality Manual 16 1!6/2011 PR #8.0 1. Purpose Page 1 of 2 To control the Quality Manual and the procedures and related documents referenced by the Quality Manual to ensure the timely review, revision, approval and distribution of updates. Additionally, to ensure controlled copy recipients have the most current revisions. See Procedure #8,1 for Document Control — Customer Requirements and Project Documents. 2. Procedure Department managers are responsible to establish, monitor and upgrade documented procedures related to the work of their department. The quality manager is responsible for conducting annual quality audits, maintaining the Quality Manual and distributing the manual, including reference documents. The EMT is responsible for annual review of the overall quality program. The president is responsible for corporate approval of the Manual, including any annual revisions. Controlled copies will contain a Controlled Copy Distribution page identifying the QM copy number, to whom it has been issued, the issue date, and the current revision. Uncontrolled copies of the manual will contain an Uncontrolled Copy distribution page identifying the issue date and the current revision. An internal audit of the quality program is conducted by the quality manager at least once a year. Each element of the AISC Quality Certification Standard is assessed and noted on the Internal Audit Checklist. Deficiencies or opportunities for improvement are reviewed with the appropriate department head and corrective action either undertaken or recommended for consideration during the annual management review. As required to maintain certifications, third -party audits are performed. These may include, but are not limited to: Quality Management Company (AISC), City and County of Los Angeles, and Clark County Department of Development Services Building Division (CCDDS -BD). It is understood that CCDDS -BD may conduct announced or unannounced audits of the fabrication facility at no cost to the jurisdiction. Revisions to the manual will be distributed to controlled copy holders by the quality manager. Revisions are to be inserted in the manual, and the superseded sheets destroyed. A Transmittal /Receipt Acknowledgement will accompany manuals and revisions issued to Zimkor personnel to confirm receipt and updating. Supervisors and department heads are to ensure that all Zimkor personnel whose work is governed by the manual are familiar with the current procedures related to their work and have access to a copy of the manual. Current revisions to the manual will be highlighted with a revision bar in the left margin as illustrated here. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager John Quinn Revision Effective Date Document Control — Quality Manual 16 1/6/2011 PR #8.0 Page 2 of 2 To aid in revision identification and tracking, the manual contains a descriptive Revision History Page which accompanies each revision issuance. The quality manager maintains both a master copy of the current manual and a master log of controlled copy holders. These are saved in electronic and hardcopy form. Current revisions to procedures will be highlighted with a revision bar in the left margin as illustrated here. Revisions will be listed and described in a Revision History contained in each procedure. 3. Records Internal Audit Checklist Quality Manual Transmittal /Receipt Acknowledgement 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date Description 9 4129/2005 Entire rewrite to AISC 2002 Certification Program 16 1/6!2011 Deleted scheduled date of annual revisions Added revision bar illustration regarding procedure changes Distributed 1/20/14 t 1 t Zimkor LLC Quality Management System PROCEDURE Responsible Manager Casey Brown 9 412912005 Document Control — Customer Requirements and Revision Effective Date Project Documents 17 1/30/2012 PR #81 Page 1 of 1 1. Purpose To ensure that customer requirements received during preparation of shop drawings and fabrication are identified, coordinated, distributed and incorporated into the work as required to meet the updated project requirements. 2. Procedure Customer - issued contract documents which affect project requirements (ASI's, RFI's, revised design drawings, etc) are processed by the Project Manager as defined in Procedure PR 6.0 – Contract and Specification Review, page 2. Changes to project requirements may be received through additions, deletions or revisions resulting from approver notations made on shop drawings submittals. The Project Coordinator submits /transmits checked Shop Drawings prepared from the Contract Documents for Customer approval. Upon return, the Project Coordinator provides the primary and initial review of the Shop Drawings. Any changes noted on the approved Shop Drawings are evaluated by the Project Coordinator with respect to conformance to the Contract Documents. Any variations from the Contract Documents are noted by the Project Coordinator and discussed with the Project Manager to obtain an authorization to proceed with these changes. The Project Manager will discuss all approval changes with the Customer to obtain authorization to proceed with the changes prior to proceeding with the work. The Project Manager will submit Change Order Requests to the Customer as appropriate for any additional work. The approved and noted Shop Drawings are then forwarded to the Project Coordinator with an authorization to proceed with any approval revisions. 3. Records RF I's Transmittals Change Order Requests Work Authorizations Approval Drawings 4 Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date Description 9 412912005 Entire rewrite to AISC 2002 Certification Program 13 11/26/2007 Miscellaneous changes to the Procedure. -14 -- 12/5/2008 ! ResponsibleMana .Qer's name chan ed - -- -- 17 1/30/2012 1 Changed typo of "ad" to "and" — Distributed 1/20/14 s j Zimkor LLC Quality Management System PROCEDURE Responsible Manager Cruz Cunningham Revision Effective Date Control of Quality Records 16 1/20/2014 PR #9.4 Page 1 of 2 1. Purpose To retain and control quality records to ensure protection from damage or deterioration, and to facilitate locating and retrieval as needed. 2. Procedure Electronic copies of records residing in job files on the server are backed up at least weekly and archived. Original paper records are controlled by the assigned responsible personnel, and stored as listed below. All project related quality records are stored for a minimum of two years from project closeout. All quality program related records are stored for a minimum of 5 years. 3. Records Description Controlled By Location Contract and specification reviews Project Manager Job File Document Control Log Project Mana er Computer Network Serve Requests For Information Project Coordinator Job File Shop Drawing Los Project Coordinator Computer Network Server Drawing Transmittals Project Coordinator Job File Detailing Purchase Order Detailing Manager Job File Material and Consumables Purchase Orders Materials Manager Materials Manager's Office Mill Test Reports, Certificates of Conformance Materials Manager Materials Manager's Office NDT Reports QA Ins ector QCM Files Main Office Calibration Records QA Inspector QCM Files Main Office Inspection Reports QA Inspector President's Office Fabrication Variance Reports QA Inspector President's Office Field Reports Project Manager Job File Qualifications /Evaluations of Suppliers Materials manager Materials Manager's Office Qualifications /Evaluations of Detailers Detailing Mana ger Detailing Manager's Office Qualifications /Evaluations of Subcontractors Operations Manager QCM Files Main Office WPS's, PQR's QA Inspector QCM Files Main Office Welder Qualification Records QA Inspector QCM Files Main Office Welder Continuity Lo2 QA Ins ector QCM Files Main Office Maintenance Records Shop Superintendent Shop Maintenance Office Internal/External Quali Audits Quality Manager QCM Files Main OMce EMT Quality Reviews Quality Mana er QCM Files Main O 'ce Corrective Action Reports Quality Manager QCM Files Main Of ce Training Los Quality Manager QCM Files Main Office Distributed 1/20/14 I i i ! i } Zimkor LLC Quality Management System PROCEDURE Responsible Manager C_ ruz Cunningham _ Revision Effective Date Control of Quality Records 16 1 1/2020/14 PR #9.0 Page 2 of 2 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date Description _ 9 4/29/2005 Entire rewrite to AISC 2002 Certification Program 13 11!26/2007 Added new records to list and changed controllers and locations of various records 14 12/5/2008 _ Responsible Manager identified by name 15 12/8/2009 Changed Contracts Manager to Operations Manager 16 1/20/2014 Added Training Logs to list Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager4 Gary Slaughter Revision I Effective Date Purchasing 15 12/8/2009 PR #10.0 Page 1 of 4 1. Purpose To ensure purchased material, products, services and subcontractors conform to project requirements. To ensure that purchase orders and subcontracts clearly and completely define the product or service ordered. To ensure suppliers and subcontractors meet Zimkor's requirements. To evaluate and maintain records of acceptable suppliers and subcontractors. 2. Procedure Responsibilities Responsibilities for issuing Purchase Orders, verification of material or services received, and evaluation and selection of suppliers and subs are standardized as follows: Raw and mill material — Materials Manager Steel Processing — Materials Manager and Operations Manager Detailing Services — Detailing Manager and Project Coordinators Engineering Services — Detailing Manager Production Consumables — Shop Superintendent Equipment Repair — Shop Superintendent Paint and Supplies — Shipping Manager Delivery Services — Shipping Manager Buyout Products — Project Manager Subfabrication — Operations Manager or Shop Superintendent Special Coatings — Shipping Manager inspection Services — Quality Assurance inspector Purchasing Data Material and subcontract services will be ordered to meet the requirements called out on advance bills, shop drawings or customer's contract documents and specifications. Purchase Orders and subcontracts issued completely describe the requirements and contain the following information: • Type of material or service, including class, grade and other unique identification • Project number, phase number and cost type • Specifications, drawings and process or inspection requirements that apply • Delivery instructions and date • Certificate of Compliance /Conformance, Certified Mill Test Reports and/or any NDT reports required • Required compliance with ASTM A6, as applicable • Special instructions or any other required information pertinent to the product ordered. Quotation requests will make the bidder aware of pertinent scope and quality requirements through inclusion of sufficient bid documents to adequately define the work. All structural materials including rolled sections, plate, tube, pipe, bolts and headed anchor studs are ordered by the "MatWi6l6- W6nagemenf- Department to meet ASTM or other natior%1I stand-ardtreferenced by project specification. Purchase orders identify quantity, shape and lengths. Mill test reports and /or certificates of compliance are required. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager. Gary Slaughter Revision I Effective Date Purchasing _ 15 12/8/2049 _ PR #10.0 Page 2 of 4 Gases, welding wire, paint and other consumables are ordered to job specifications or, If not specified, to nationally recognized standards issued by ASTM, AWS, or SSPC. Purchase orders identify manufacturer and product. Certificates of conformance are required. Selection of Suppliers and Subcontractors All suppliers and subcontractors will be chosen from approved vendor lists. Responsibilities for vendor lists is as follows: Raw and mill material — Materials Manager Steel Processing — Materials Manager Detailing Services — Detailing Manager Engineering Services — Detailing Manager Production Consumables — Shop Superintendent Equipment Repair — Shop Superintendent Paint and Supplies — Shipping Manager Delivery Services — Shipping Manager Buyout Products — Operations Manager Subfabrication — Operations Manager — , Special Coatings — Shipping Manager Inspection Services — Quality Assurance Inspector Responsible party listed will maintain the approved vendor list by continual evaluation of companies performing the work. Evaluation will be on quality of services, timeliness and ability to meet specification. Firms meeting the responsible manager's criteria are added on a trial basis. Approved vendor lists will be updated and validated yearly by the responsible manager. When a level of certification is specified by contract or government agency (AISC certification, City, State or County license requirements) fabrication shall be sublet only to a vendor holding the required certification or license unless waived in writing by the customer. Quality assurance measures required by Zimkor for subcontracted fabrication shall be appropriate to the complexity, difficulty and importance to structural integrity of the product. On subcontract fabrication jobs requiring Zimkor QA inspection, a copy of the purchase order and appropriate shop drawings shall be furnished to the Quality Assurance Inspector. Any special instructions to QA will be issued via memo (scheduling, stop work points, history, etc.) by the Project Manager. Verification of Purchased Product Materials and Services It is the responsibility of the issuer of the purchase order or subcontract to assure vendor performance after order is placed. For suppliers, adequate performance would include proper paper work and material marking when material is received, and meeting required material specifications. All test reports will be checked against specifications to -- assure the material shipped - -meets the requirements of the order. All packing lists..for steel and quenched and. tempered bolts should note the heat numbers of the material and have attached test reports. Steel inventory is added into the material tracking software system with the heat number and purchase order noted. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Gary Slaughter Revision Effective Date Purchasing 15 12/8/2009 _ _ _ PR #10.0 Page 3of4 When wire or paint are received, a certificate of compliance is provided by the vendor. All paint used at Zimkor has a Materials Safety Data Sheet on file in the Administrative Department. As material is received, it is checked by the receiving clerk or yard leader against what is called out on the purchase order verifying the correct quantity, size, length and specification. A visual inspection for damage or any suspected nonconformances to ASTM A6 is done. Discrepancies are noted on the purchase order copy and turned in with the packing list to the Materials Management Department. If there are discrepancies noted, the material will be set aside to assure it is not used, and will result in the following; • Yard is asked to verify once more material, length, and heat number to make sure Zimkor has not made a mistake. • Material is returned. If material is returned, a red slip is filled out by Materials that lists the material to be returned, the purchase order number, and the reason for the return. A copy of this delivery report is faxed to the vendor to notify them of material to be picked up. • A copy of the return delivery report is kept on file in the Materials Manager's Department. When the material is picked up, the delivery report from the yard is matched up with the copy on file in materials. Invoices that list the material to be returned are put on hold until the material is picked up and a credit has been received. Material is entered in the material tracking software system with the purchase order number and the heat number. The purchase order is dated to show that the correct test reports were received. Customer Verification The customer will be afforded the right to verify final product meets project requirements. Customer Supplied Material Material supplied by the customer will be received, identified and controlled as purchased material, with the exception the customer may retain control of the related MTRs as required to meet their quality program requirements. Any material damage, loss or nonconformance is reported to the customer. 3. Records Project Write -Ups Estimates Advance Bill if required Purchase Orders Certified Mill Test Reports Certificates of Conformance Cutting Lists Master Ship Lists Vendor Evaluations Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Gary Slaughter Revision Effective Date Purchasing 15 12/8/2009 PR #10.0 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. Page 4 of 4 No. Effective Date Description 9 4/2912005 Entire rewrite to AISC 2002 Certification Program _ 12 9/1/2006 Identified interval for evaluation/updating evaluation/updating approved vendor lists 13 11/26/2007 Added Production Manager and Project Coordinators to responsible party lists 15 12/8/2009 Changed Production Manager to Operations Manager Distributed 1120/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Gary Slaughter Revision Effective Date Material Identification T 9 4/29/2005 PR #11.0 1. Purpose Page 1 of 1 To ensure that structural materials used in the fabrication process can be identified during fabrication by size and grade back to a certif ied mill test report(s). 2. Procedure All structural materials will be ordered with the requirement that certified mill test reports be furnished with the shipment or faxed to the Materials Management Department concurrently with delivery. The yard leader will verify the heat numbers on the material match those noted on the delivery ticket. If the material heat numbers do not match, the material will be set aside for vendor certification or return as described in Purchasing Procedure #10.0, Verification of Purchased Product Materials and Services. The pieces will be re- marked by the yard leader with the heat number if the mill heat number is not in an easily readable spot. Also marked on the material by the yard leader is the material size and purchase order number. If pieces are in bundles, the top piece will be marked and this will be transferred to bottom pieces as material is removed. All markings are legibly made with paint stick. Materials Management verifies that the packing slip, purchase order, heat number and test report all match up. If all match, the Materials Management Department will file the Mill Test Reports in the project file in the Materials Manager Assistant's office and the material will be entered into inventory records. If a mismatch is discovered, the material is set aside for vendor certification or return. When material is cut, the heat number(s) used for detail or main - member parts is noted on the cutting list by the machine operator. The machine operator will also write the heat number directly on any main member material using a paint stick. This heat number will stay on the member through the fabrication process. To maintain identification, all drops and remnants returned to stock are re- marked with the material identification, including the material size, heat number and purchase order number. The rems being returned to inventory are noted on the cutting list by the machine operator. The cutting lists noting the heat numbers used, along with the heat numbers and lengths of rems returned to stock, are turned into the Materials Management Department and the inventory adjusted accordingly. 3. Records Purchase orders Receivers MTR's Cutting lists Shop drawings Inventory records 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. -- — No. Effective Date I Description- - -------- - -,_ -- 9 1 4/29/2005 1 Entire rewrite to AISC 2002 Certification Program Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Mike Wray _ Revision Effective Date Welding 13 11/26/2007 PR #12,0 1. Purpose To ensure all welding is in accordance with project requirements and AWS D1.1. 2. Procedure All welding will be in accordance with AWS D1.1. Page 1 of 2 Prequalified welds will have a WPS developed for each process, joint and position Non prequalified welds will have a PQR and WPS developed for each process, joint and position. All welders will be certified in accordance with AWS D1.1 and will perform no welding that they do not carry certification for. Welding coupons are sent to an independent agency for testing. Potential welders or trainees are trained by certified welding supervisors. If a welder's qualification period of effectiveness has lapsed (6 months), a requalification test is required. Any welder failing the qualification test can retest after further training or practice, provided there is evidence that this individual has done so. All welds are performed according to the contract specifications. Copies of all welding records, PQR's, WPS's and welder cents are kept on file in the OC office. All welds are visually inspected by the Quality Assurance Inspector and records are kept daily and submitted to the Shop Superintendent for review. Welders can only perform welding operations on work that they are certified for. A continual performance problem by a welder shall be reviewed to determine the cause and measures taken to correct the problem. Welders shall identify their welds with an assigned identification initial near piece mark of beam or column. Welders are responsible to inspect their own work to determine if it is not in conformance prior to passing it on to the next workstation. Welding wire is stored in a designated area. Welders taking rolls fill in -a log indicating the date,. manufacturer, wire size, heat number and job number the wire will be used on. The log is picked up by the QC Inspector when the sheet is filled and kept on file in the QC office. Distributed 1/20114 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Mike Wray Revision Effective Date Welding 13 11/26/2007 PR #12.0 Page 2 of 2 3. Records Welding Procedure Specifications (WPS) Welding Qualification Record (PQR) Welder Certifications Welder Continuity Log Welding Wire Log 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date Description 9 4/29/2005 Entire rewrite to AISC 2002 Certification Program 13 11/26/2007 Changed Control person to Assurance Inspector and name of Maintenance of Certification form Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Mike Wray Revision I Effective Date Bolting 13 IF 11/2612007 PR #12.1 Page 1 of 5 1. Purpose To ensure all shop bolting is in accordance with project requirements and meets the RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts. 2. Procedure A. General The Shop Superintendent, or designated supervisor, will be responsible for high strength bolt verification and installation. Where required by project specification, inspection will be performed by owner's inspector, otherwise Zimkor's Quality Assurance Inspector will be responsible for inspection while the work is in progress. High strength fasteners shall be stored in closed containers to protect from dirt and corrosion. Fasteners are to be removed from protected storage only as needed. Prior to installation, the bolts, nuts and washers are to be verified to be of the specified grade and type through use of manufacturer's markings. The shop drawings will define if bolting is to be snug -tight or pretensioned. Where shop bolts are to be pretensioned, F1852 Twist -Off -Type Tension - Control bolts are used. F1852 bolts may be used in snug -tight joints. in this case pre - installation verification is not required, and inspection procedure remains as defined for snug - tightened joints, regardless of as- installed bolt tension. F1852 bolt assemblies are not to be lubricated or reused. A Skid more- Wilhelrn tension calibrator is required to perform the pre - installation verification. The tension calibrator should be calibrated at least annually. B. Snug Tightened Joints Pre - installation Verification 1. Pre - installation verification is not required for snug - tightened bolts. Installation 1. All bolts holes shall be aligned to allow bolts to be inserted without undue damage to the — — — threads: Burrs that extend more than 1/16" above the surface shall be removed. Bolts are to be placed in all holes, including required washers, and nuts threaded on. Distributed 1/20/14 R j 3 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Mike Wray Revision I Effective Date _ Bolting 13 11/26/2007 PR #12,1 Page 2 of 5 Snug the joint so that the "snug tight" condition is met. Systematically tighten bolts by using a spud wrench or impact wrench, starting with the most rigid part of the joint and proceeding toward the free edges. Snugging may be accomplished using a spud wrench, impact wrench, or any other suitable wrench. The snug tight condition is defined as the tightness that is attained with a few hits of an impact wrench or the full effort of an ironworker using an ordinary spud wrench to bring the connected plies into firm contact. The definition of firm contact is the condition that exists on a faying surface when the plies are solidly seated against each other, but not necessarily in continuous contact. Inspection 1. Prior to the start of work, inspect fastener assemblies to verify they are of the specified grade and type, are properly marked, and have proper documentation as required by project specifications. Inspect the storage methods to ensure fasteners are kept separate by lot and are identifiable until they are assembled, Galvanized assemblies must be kept together as a unit as shipped by the supplier. Verify bolts are properly lubricated. F1852 bolts, even when used In snug- tightened joints, are not to be relubricated, except by the manufacturer. Galvanized fasteners must be lubricated with the manufacturer's lubricant. 2. Inspect bolt holes to verify they adequately align and will allow bolts to be entered without damaging threads, and that excessive burrs do not exist. 3. After installation, inspect the joints to visually verify that the snug tight condition, as defined above, has been achieved. Verify the end of the bolt is at least flush with, and not below, the face of the nut. C. Pretensioned Joints Using F1852 Twist -Off Tension Control Bolts Pre - Installation Verification 1. Pretensioned (fully tightened) joints require that fastener assemblies (bolt, nut and washer) be tested prior to installation to verify that the bolting crew and the installation methods they employ will develop the required minimum bolt pretension. Three assemblies of each combination of diameter, grade, length and production lot used must be tested. 2. Take three F1852 "twist -off' bolts, nuts and washers of each diameter, grade, length and production lot as provided by manufacturer. Each set is called a "fastener assembly'. 3. Place bolt in Skidmore. Use a flat - roughened bushing on the back of the Skidmore. 4. Add flat plate shims and washers to have approximately two to three threads of stickout beyond the face of the nut when nut is fingertight. Place washer from the fastener assembly on last so that it is adjacent to the nut. Final Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Mike Wray Revision I Effective Date Bolting 13 11126/2007 PR #12.1 Page 3 of 5 stickout may vary between five threads and no stickout of threads. If bolt is too short to have no threads sticking out, use "Pre- Installation Verification — Short Bolts" procedure below. 5. Snug bolt using same technique (spud wrench, impact wrench), and same relative force, as will be used in production. 6. Further tighten bolt until spline shears off. 7. Verify achieved tension, as read on Skidmore dial gage, meets value listed in Table A. For diameters other than those listed, use 5% higher than the values in the RCSC Table 8.1. 8. Record results. 9. Remove assembly and repeat steps 2 -7 so that a total of three consecutive fastener assemblies are successfully tested. Pre - Installation Verification — Short Bolts 1. For bolts that are shorter than the minimum that can be read by the Skidmore, direct tension indicators (DTI's) must be used. 2. Take three F1852 "twist -off" bolts, nuts and washers of each length, diameter, grade and production lot as provided by manufacturer. These comprise a "fastener assembly ". 3. Take three F959 direct tension indicators (DTI's) of proper diameter and grade for the bolts being used. DTI's must be from a production lot that has had a "calibrated gap" determined using methods in "Determining the DTI Calibration" below. 4. Place bolt in steel plate with DTI beneath bolt head. Add flat plate shims and washers as necessary to have approximately two or three threads of stickout beyond face of nut when nut is fingertight. Place washer from fastener assembly on last so that it is adjacent to the nut. Final stickout may vary between five threads and no stickout of threads. Distributed 1/20114 i. i t a TABLE A Required Tension (kips) for Pre - Installation Verification and dti Calibration Bolt Diameter (inches) A325 Bolts F1852 Bolts A490 Bolts 3/4 29 37 718 41 51 1 54 67 8. Record results. 9. Remove assembly and repeat steps 2 -7 so that a total of three consecutive fastener assemblies are successfully tested. Pre - Installation Verification — Short Bolts 1. For bolts that are shorter than the minimum that can be read by the Skidmore, direct tension indicators (DTI's) must be used. 2. Take three F1852 "twist -off" bolts, nuts and washers of each length, diameter, grade and production lot as provided by manufacturer. These comprise a "fastener assembly ". 3. Take three F959 direct tension indicators (DTI's) of proper diameter and grade for the bolts being used. DTI's must be from a production lot that has had a "calibrated gap" determined using methods in "Determining the DTI Calibration" below. 4. Place bolt in steel plate with DTI beneath bolt head. Add flat plate shims and washers as necessary to have approximately two or three threads of stickout beyond face of nut when nut is fingertight. Place washer from fastener assembly on last so that it is adjacent to the nut. Final stickout may vary between five threads and no stickout of threads. Distributed 1/20114 i. i t a i Zimkor LLC Quality Management System PROCEDURE Responsible Manager Mike Wray Revision Effective Date Bolting 13 11/26/2007 PR #12.1 Page 4 of 5 5. Holding bolt head, gently snug bolt by tightening the nut by using technique (spud wrench, impact wrench) to be used on the structure. 6. Holding bolt head, tighten bolt by turning nut with installation wrench until bolt spline twists off. 7. Verify average gap in the DTI is less than the "calibrated gap" as established in separate procedure "Determining the DTI Calibration ". 8. Remove assembly and repeat steps 3 -6 so that a total of three consecutive assemblies have been tested and meet requirements that he DTI be compressed below "calibrated gap ". Determining the DTl Calibration For Twist -Off Bolts — Short Bolts 1. Select longer bolt of proper diameter and grade of a length adequate to fit in to Skidmore. 2. Use flat bushing in the back of Skidmore. 3. Install bolt in Skidmore with DTI under bolt head at the front of Skidmore. 4. Holding bolt head from turning, tighten the nut at rear of Skidmore until required tension as listed in Table A above is met. For diameters other than those listed, use 1.05% of the values in the RCSC Table 8.1, 5. Using feelers gages, measure and record the gap at each DTI gap location to the nearest .001 and determine the average gap for each DTI. 6. Repeat steps 1 -5 for three DTI's of the same manufacturer's production lot, as stamped on the DTI face. 7. Determine the average of the average gaps for the three DTI's, known as the "calibrated gap." Record this value along with the grade, diameter and production lot of DTI, Installation 1. All bolts holes shall be aligned to allow bolts to be inserted without undue damage to the threads. Burrs that extend more than 1/16" above the surface shall be removed, except if joint is slip - critical all burrs will be removed. Bolts are to be placed in all holes, including required washers, and nuts threaded on. 2. Snug joint to bring surfaces into firm contact. To obtain this, use impact wrench (few hits), or the full effort using a spud wrench. Do not allow spline to shear off. if this occurs, remove assembly and replace it with a new assembly (bolt, nut and washer). 3. Inspect joint to verify that joint is snug tight. 4. Systematically tighten each bolt until bolt spline shears off, working from most rigid part of the joint. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Mike Wray Revision Effective Date Bolting 13 11/26/2007 PR #12.1 Page 5 of 5 Inspection 1. Prior to the start of work, inspect fastener assemblies to verify they are of the specified grade and type, are properly marked, and have proper documentation as required by project specifications. Inspect the storage methods to ensure fasteners are kept separate by lot and are identifiable until they are assembled. Galvanized assemblies must be kept together as a unit as shipped by the supplier. Verify bolts are properly lubricated. F1852 bolts are not to be 1 relubricated, except by the manufacturer. Galvanized fasteners must be lubricated with the 1 manufacturer's lubricant. 2. Bolt holes are inspected to verify they adequately align and will allow bolts to be entered without damaging threads, and that burrs exceeding 1/1 6"do not exist. If joint is designated slip - critical, faying surfaces are inspected to verify all burrs have been removed and surface condition meets requirements noted on shop drawing. 3. Observe the pre - installation verification testing for the fastener assemblies to be installed. 4. After placement of bolts in holes and joints snugged, verify snug -tight condition, as defined above, has been achieved, splines are fully intact, and bolt length is proper for the grip. End of bolt must be at least flush with face of nut. Maximum stickout is four to six threads, but varies by diameter of bolt and production tolerances have been properly snugged by visual appearance. 5. Verify, through routine observation, that the splines are properly severed during installation by the bolting crew. 3. Records Shop Drawings TC Bolting Inspection Report 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date Description 9 4/29/2005 Entire rewrite to AISC 2002 Certification Program 10 9/14/2005 Revised entire bolting procedure 13 11/26/2007 j Changed Inspection Reports to TC Bolting Inspection Report _J Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Dave Genova Revision I Effective Date Material Preparation for Application of Coating 9 4/29/2005 - - PR #12.2 1. Purpose gage 1 of 1 To ensure surface preparation performed prior to other finishing meets contract requirements. 2. Procedure The shop drawings and master ship list issued to the shop for construction identify the surface preparation required by reference to SSPC SP numbers. Painters are trained in the requirements of the SSPC specifications, the methods of cleaning and the degree of cleanliness required. If the contract surface preparation requirements differ from SSPC specifications, the shop drawing will list the contract requirements. If no surface preparation is called for on shop drawings, then the members are cleaned of heavy oil and grease, and any dirt or other foreign material is swept or blown off. The painter is responsible to determine the surface prep by referring to the shop drawings or master ship lists. The following cleaning, as specified, is then done by the painter, or a painter's helper: SSPC -SP1 Solvent Cleaning SSPC -SP2 Hand Tool Cleaning SSPC -SP3 Power Tool Cleaning If blasting is required to any of the following specifications, it is subcontracted to an approved qualified painting firm: SSPC -SP5 White Metal Blast Cleaning SSPC -SP6 Commercial Blast Cleaning SSPC -SP7 Brush -Off Blast Cleaning SSPC -SP10 Near -White Blast Cleaning Purchase orders for blast cleaning are issued by the Shipping Manager, who is responsible for managing and approving the subcontracted work. The inspection standard for surface cleanliness is SSPC -Vis -1 Color Photographic Standards for Surface Preparation. If the customer wishes to perform independent surface preparation inspection, the Shipping Manager coordinates and facilitates this to occur prior to paint application. 3. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date I Description - - 19 -J- -4/2912005 - -I=nure rewrite to AISC 2002 Certification Program- Distributed 1/20114 i Zimkor LLC Quality Management System PROCEDURE Responsible Manager Dave Genova Revision Effective Date Coating Applications 12 9/1/2046 - -- PR #12.3 4 Page 1 of 2 1. Purpose To ensure the application of coatings is performed in accordance with contract requirements and paint manufacturer's recommendations. 2. Procedure Shop drawings and the master ship lists indicate the paint required. The Shipping Manager issues purchase orders for paint listing the job number(s) the paint is being purchased for. Upon receipt, the PO number is written on the cans as cross - reference means. Paint is retained in secure storage per manufacturer's recommendation to avoid damage or degradation. Spoiled, damaged or illegible containers are discarded. The Quality Assurance Inspector takes daily temperature and humidity readings to determine if conditions meet manufacturer's requirements prior to commencing painting. A daily five sample dry film thickness test is done by the QAI to ensure paint thickness meets specification. The painter refers to the master ship list to determine the correct paint to use and the required thickness. No paint areas are marked in white paint stick by the fitter in the shop. if there are questions regarding the no paint areas, a full set of shop drawings are available in the shipping office for reference. No paint blockouts are done using pieces of steel sheet or plate. One -part thinner or water based alkyd primers requiring an SP2 or 3 surface prep are applied at our shop facility. All other paints, along with any blast cleaning required, are sublet to qualified, approved painting firms. Purchase orders for subcontracted painting are issued by the Shipping Manager, who is responsible for managing and approving the subcontracted work. Paint is applied per manufacturer's recommendations using an air spray system. As required, thinning is done in accordance with manufacturer's application literature. Painting is done on horses over a concrete floor to avoid getting foreign material in the primer coat. If runs or sags occur, they are brushed out. If this is not possible, they are wiped with a rag and then resprayed. Drying time on thinner based primers is one to two hours to handle, and twenty four to forty eight hours to recoat. On water based primer,'' /2 hour to handle and 1'/z hours to recoat. { Material is allowed to dry before stacking or loading. Painted material is handled to avoid damage to the painted surfaces. Dunnage is used between levels as trailers are loaded, and where possible, levels are single layered. i Onsite training from equipment and paint manufacturer representatives is done to train painters on the proper use of equipment and the recommended application of product, Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Dave Genova Revision_ Effective Date Coating Applications 12 9/1/2006 PR #12.3 Paget of 2 3. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date Description 9 4/29/2005 Entire rewrite to AISC 2002 Certification Program 12 9/1/2006 Changed wet film thickness test to dry film thickness test Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Mike Wray Revision I Effective Date Equipment Maintenance 14 1/20/2014 _ PR #12.4 1. Purpose Page 1 of 1 To establish a program of preventative maintenance for equipment essential to the production of product required to meet project requirements. 2. Procedure 1. Overhead cranes, tower cranes and jib cranes will be inspected annually by an outside crane service. Major repairs will be done by an outside crane service; minor repairs will be done by our Maintenance personnel. Reports for any crane repairs will be submitted to the Shop Superintendent to be filed in the crane maintenance book. 2. Daily maintenance duties will be performed by machine operator on brakes, shears, and saws. (Check fluid levels and check for loose hoses, fittings, etc. Operators are responsible to report any operating or maintenance concerns to Shop Superintendent or Maintenance Department. 3. All other equipment including welders will be maintained as follows: a. Each machine will be inspected annually and any necessary repairs or adjustments will be made and recorded at that time. Log will be dated and signed off by Maintenance personnel. 4. Welding machines will have a welding machine calibration log in addition to the annual equipment maintenance log and will be checked to verify voltage and amperage readings every twelve months. 5. Maintenance logs and welding machine calibration logs will be replaced at the end of each year. Previous records will be stored in the QC office. A record of welding machine calibration logs will be kept in the QC office. 6. All chains and slings will be inspected annually by an outside company. They will be repaired or replaced as necessary. Any damage to chains or slings during production will be replaced and sent in for repair or replacement. 7. All manuals for service and repair for equipment will be kept in either maintenance or the Shop Superintendent's office. 3. Records 1, OSHA Inspection Records for ail cranes — copy kept in main office in the binders by the conference room 2. Crane Repairs done by outside crane service kept by purchase order — copy kept in purchasing 3. Records for Maintenance or Repair on shears, press brake, air compressor, and saws kept with machine. — copy in shop maintenance office 4. Calibration Records for welders kept in QC office 5. Chain and Sling Records kept in main office in the binders by the conference room 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date Description 9 4/2962005 Entire rewrite to AISC 2002 Certification Program 13 - 11/29/2007 - Deleted statement regarding plastic file pockets & changed quarterly to annual or twelve month inspections where noted. Also changed where revious and current calibration records are kept _ 14 1/2012014 Changed crane inspections from semi - annual) to annually. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Mike Wray Revision I Effective Date Cambering 9 4129/2005 PR #12.5 Page 1 of 2 1. Purpose To camber A36, A572 -50 and A992 wide flange beams in their strong axis to meet contract requirements. 2 Procedure Marking Beams called to be cambered on the shop drawings are highlighted by the layout person by spray painting each end white and adding a white identification mark on the outside of the bottom flange at beam center. The amount of camber is noted and circled on the lower portion of the web at beam center. Tolerance Unless noted otherwise on the shop drawing, camber tolerance is plus V / minus 0" as measured in the shop in an unstressed condition. Cold Cambering The machine operator loads the beam on to the camber machine on its side with the bottom of the beam towards the ram. The backstops are adjusted so they are two to four feet in from each end of the beam. A stringline is fitted to the beam to aid in measurements. The ram is advanced to deflect the beam somewhat more than specified camber, then held for a few seconds to let the beam take a set. If correct camber remains upon retraction of the ram, the operator marks "CC' (camber complete) next to the circled camber amount in the beam web. If too little camber exists, the ram is immediately reactivated to add more camber. If too much camber exists, the beam is removed from the machine and mild heat (200 °F to 550 °F) is uniformly applied to both the top and bottom flange over approximately the middle third of the beam. Upon cooling, camber is checked again and the beam either accepted, recambered in the machine, or reheated to remove more camber. Upon final acceptance the beam is marked "CC" near the camber callout. Heat Cambering The fitter places the beam upside down (with bottom flange up) on horses located near its ends, see Figure 1. Using a rosebud, areas of the web and bottom flange are heated to a light red color (1100 °F). The temperature is not to exceed 1200 °F, which is monitored with temperature sensitive crayons. As the heating proceeds, the beam initially bends opposite to that intended, but upon cooling straightens and then bends in the desired direction. The quantity of the heated areas is dependent on beam size and length, as well as the amount of camber required, and is determined through experience. Heated areas do not need to be equally spaced; but they should be symmetrical about the centerline of the span. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Mike Wray Revision Effective Date Cambering 9 4/29/2005 PR #12.5 Page 2 of 2 The heated areas are wedge shaped as shown in Figure 2. This is accomplished by heating spot A to a light red color, then proceeding slowly in a serpentine path in the direction of the arrow. The torch is directed forward along the path and progression is slow enough to bring each area to a light red color. The wedge shape should be an isosceles triangle with an angle A of between 200 to 400, the larger producing more movement. Once completed at 8 -C, it is not necessary to reheat point A. The flange is then heated by starting at point D and working toward the center, bringing the steel to alight red color. Optionally, the flange heating can begin using another torch as the web heating nears completion. Thick material (generally over 1 '/2 ") can be heated on both surfaces simultaneously. EYENTTUAL LOW.&& F1d46E (bojTTOM P1.6i.) �fearEn wfvbes Figure 1 D EvF.Nilltlt. [ONCdYL. PLtW(aE {8oT7bM fLb• � G B eN Figure 2 If correct camber remains upon cooling, the fitter /welder marks "CC" (camber complete) next to the circled camber amount in the beam web. if too little camber exists, additional wedges are heated until required camber is produced. If too much camber exists, the original process is repeated but on the opposite side of the beam and to a lesser extent (fewer wedges). Upon final acceptance, the beam is marked "CC" near the camber caliout. 3. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. Effective Date I Description ( 9 4/29/2005 1 Entire rewrite to A1SC 2002 Certification Program Distributed 1/20/14 r i t- Zimkor LLC Quality Management System PROCEDURE Responsible Manager Willie Clark Revision JEffectiveDate Inspection and Testing 13 1 11/28/2007 PR #13.0 Pagel of 2 1. Purpose To inspect and test products to ensure their conformance with contract requirements. 2, Procedure If customer's inspection requirements are more stringent than the company's, the customer's requirements will govern. This will be noted in the Job Write -up, and further defined for the shop via memo issued by the Project Manager. Personnel who perform inspections have the necessary documented experience, training and education in inspection methods and acceptance criteria. Quality Assurance Inspector will receive a copy of all approved fabrication drawings, project specifications and supplementary procedures as they are released for construction. A review of the drawings will be done to identify any special fabrication /welding /inspection requirements. As needed, the QAI and the Shop Superintendent will develop a fabrication /inspection plan, including inspection hold points. Each machine operator, fitter, welder and shopman is responsible for the in- process checking of their own work, including cutting quality, part and layout dimensions, weld quality, cambering, surface prep, painting, and any other applicable operation. No member is sent to the next work station knowing the work is deficient or that repairs are required. If a beam or column is placed on hold for revisions or for parts that are missing, a yellow or green tag will be attached to the member signifying it is on hold. In- process inspections are conducted by the Quality Assurance Inspector of those items that are not verifiable during final inspections, including weld joint fitup, welder machine settings and welds that become inaccessible as fabrication proceeds. Upon approving all dimensions and welding symbols, a white check mark is placed near the piecemark at the left end of column or beam. Upon approving all welding, a white OK is placed near the white check mark and can now be sent to shipping. Additionally, in- process inspections will be conducted at the request of production, or in accordance with an established fabrication /inspection plan. In- process inspections are documented by noting the fitter ID and heat number on the QC print. Deviations discovered during a QAI conducted in- process inspection are documented as a non - conformance. See Control of Non - Conformances Procedure 15.0. Final inspections will be made by the QAI of completely fabricated members prior to being moved to storage. Nonconforming members are tagged and sent back for corrections. Inspections are documented by listing welder ID, noting quantity of parts inspected, and stamping the date in red ink over fitter and welder ID's on the QC print. Additionally, all final inspections are logged onto the daily Inspection Report. This is forwarded daily to the Shop Superintendent for review, then to the President. Standard inspection levels are: Welding — 100% Dimensional — 25% Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Willie Clark Inspection and Testing _ Revision Effective Date 13 11!26!2007 _ —_ PR #13.4 _ A Solt Installations - 10% Cambering -10% Page 2 of 2 Paint - Daily temp /humidity reading per Coating Application Procedure 12.5, daily five sample MDFT verification, and periodic visual inspection of painting operation. If reject rates exceed the norm, QAI confers with Shop Superintendent. Superintendent addresses the problem with production personnel, while QAI increases inspection levels as determined necessary to ensure all potentially nonconforming members are caught. Once production adjustments are proven successful through a continued return of reject rates to the norm, inspection levels are returned to standard. If the customer chooses to conduct any independent fabrication inspection, the QAI is the contact to coordinate and facilitate these inspections. Customer conducted inspections do not replace any standard inhouse inspections. When NDT is sublet, the vendor is approved and managed by the QAI. All vendor personnel and the " -; testing performed is to meet the requirements of AWS D1.1 or the project specifications, whichever is more stringent. The QAl shall monitor the work and review and accept the results. When the governing agency having jurisdiction over the project has special requirements for subcontracted inspection firms, or requires use of pre- approved firms, the Project Manager provides this information to the QAI for use in selection of NDT subcontractor. 3. Records Inspection Report Fabrication Variance Report Field Variance Report Temperature Control /Paint Control Log Q.C. Prints 4. Revision History Changed paragraphs are marked with a revision bar in the left margin, No. Effective Date Description 9 4/29/2005 Entire rewrite to AISC 2002 Certification Pro ram 13 11/26/2007 Denotes system QA uses to putting a member on hold Denotes system QA uses to inspect material before & after _ welding Added Q.C. Prints to Records list Distributed 1/20114 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Willie Clark Revision Effective Date Calibration 13 11/26/2007 PR #14.4 Page 1 of 2 1. Purpose To control, calibrate and maintain the inspection, measuring and test equipment used to verify conformance of products to contract requirements. 2. Procedure All measuring and test equipment used to verify acceptance criteria of products and production equipment shall be controlled per this procedure. The Quality Assurance Inspector (QAI) is responsible for having the calibrations performed, labeling of calibrated tools, and maintenance of the tools and the Certificates of Calibration and calibration logs. Calibration of the DeFelsko PosiTest will be conducted by the QAI in accordance with DeFelsko Management Procedure 2502 -A, using DeFelsko Model CAL -S3 Thickness Calibration Standards. Calibration of all other inspection tools will be performed by a certifying laboratory to nationally recognized standards. A Certificate of Calibration will be maintained on each tool requiring calibration, listing tool description, manufacturer, serial number, date of calibration, date of next required calibration, the test equipment used, the standard calibrated to, facility and individual performing the calibration. If no national standard exists, the acceptance criteria will be documented on the Certificate of Calibration. These certificates will be maintained by the QAI. Calibrated tools are identified by a label identifying the unit as calibrated, the serial number, the date of calibration and the next calibration due date. During use, care is to be taken to ensure the proper handling and use of the equipment. All calibrated equipment is to be securely stored to prevent damage. Any unit reasonably suspected of damage or inaccuracy is to be taken out of service and recalibrated or replaced. Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager Willie Clark Revision I Effective Date Calibration 13 11/26/2007 PR #14.0 Page 2 of 2 Minimum frequency and accuracy of calibration ts;es: +fpllows. Tool Frequency (min) Accuracy DeFelsko PosiTest FM coating thickness gauge Daily +/-5% UB DL99B clamp -on meter Annually +/-2% #Q -13 Lufkin 100 ft tape As Needed A _ +/1116" in 100 ft 12' Craftsman tape Annually or As Needed +(_ 1132" in 12 ft ___ 25' Craftsman tape Annually or As Needed +/_ 1/32" in 25 ft 30' Craftsman tape Annually or As Needed +/_ 1/32" in 30 ft 35' Stanley tape Annually or As Needed +(_ 1132" in 35 ft 100' Stanley tape Annually or As Needed +/- 1/16" in 100 ft T�w 2' Square Annually or As Needed +/- 1/32" in 2 ft 1' -6" Square Annually or as Needed 1/32" in 1' -6" _ 1' Square Annually or As Needed +(_ 1/32" in 1 ft G.A.L. fillet weld gauges Annually -1/64" 3. Records Certificates of Calibration Calibration Log 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. No. i Effective Date LL Description 9 4129/2005 ___ Entire rewrite to AISC 2002 Certification Program 10 9/14/2005 Revised calibrated tools, frequency and added accuracy_,, 11 10/27/2005 Revised calibrated tools list 12 9/1/2006 Deleted Fluke tools from calibrated tools list 13 11/26/2007 1 Chan ed frequencies of calibrations Distributed 1/20/14 iresi, . 9 curacrt j `% e in ' 00 f= in 12 €t 1" iri 25 f f% in 30 f in100ft 32" in 2 ft Zimkor LLC Quality Management System PROCEDURE Responsible Manager Willie Clark Revision Effective Date Control of Nonconformances 9 _ 4129/2005 PR #15.0 1. Purpose Page 1 of 1 To prevent product that does not conform to specified requirements from reaching the customer. 2. Procedure Any employee discovering or becoming aware of a nonconformance is responsible to report it to the Shop Superintendent, Quality Assurance Inspector or the Project Manager. The Quality Assurance Inspector will affix an orange tag to any nonconforming item discovered during final inspection indicating nonacceptance and will initiate a Fabrication Variance Report. The Shop Superintendent is informed and a determination is made to either repair or replace the part(s). If there is a question as to the appropriate corrective action, the Project Manager is enlisted to secure direction from the customer. Following repair or replacement, the part is final inspected again and if found in compliance, the tag is removed. The Fabrication Variance Report is completed and issued to Shop Superintendent and President. If a nonconformance is discovered in the field, the Project Manager or the Field Rep will initiate a Field Problem Report and will direct the corrective efforts. As appropriate, the part(s) may be repaired, replaced, or accepted for use as is by the customer. Written documentation will be secured if nonconforming product is accepted by the customer. Upon completion of the correction, the Field Problem Report is completed and issued to the appropriate manager and the President. Nonconformances are reviewed weekly by the Quality Assurance Inspector and the President, and are monitored by the PM's and Dept Managers for trends or recurring problems warranting improvement efforts. 3. Records Fabrication Variance Report Field Problem Report 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. INo. I Effective Date I Description 1-9-1— 4/29/2005 1 Entire rewrite to AISC 2002 Certification Program Distributed 1/20/14 Zimkor LLC Quality Management System PROCEDURE Responsible Manager John Quinn Revision Effective Date Corrective Action 10 k 1/20/2014 PR #16.0 Page 1 of 1 1. Purpose To identify and correct the causes of recurring quality problems. 2. Procedure The management representative, quality manager, department or responsible managers all can initiate Corrective Action Reports (CAR) for quality problems, based upon frequency or severity of the discrepancy A master CAR # is assigned upon initiation. Additionally, the management representative will quarterly review recaps of Inspection Reports, Variance Reports, Field Problem Reports, backcharges and customer complaints. if a trend is identified as to frequency or type of problem which has not already been addressed, a CAR will be issued to the appropriate manager at that time. The initiator of the CAR and the quality manager fill out Section #1, Requirements Currently Not Being Met and Description of Problem. The manager of the area involved and the quality manager then review the problem and Section #2, Root Causes and Actions to Prevent Recurrence is filled out and issued to managers involved for review and initial implementation. During the follow -up period, the results of the initial implementation are reviewed and any necessary revisions to the corrective actions are made. When the quality manager determines the corrective effort has been successfully tested, finalized and incorporated, Section #3, Closeout is filled out and the closed out CAR is issued to all involved managers. CARS are stored along with other Quality Records in the QCM files, main office. Upon issuance of a master CAR #, the CAR remains in open status until signoff, when it changes to closed status. Open CAR's are included in the quarterly recap review. 3. Records Corrective Action Report Corrective Action Request Log 4. Revision History Changed paragraphs are marked with a revision bar in the left margin. N_ o. Effective Date 9 4/29/2005 _Description Entire rewrite to AISC 2002 Certification Program 10 1/20/2014 + Overall clarification revision Distributed 1/20/14 N N COD L. N V � a 0 Q 'N • N O N IM 'N v v v�O v v bA b C� �i 'v N r�l O N o z r. U 0� s LL LLJ N m 0 P'4 O N w O b y 0 U N U UJ�LU�rla?`pr" TDR Du'�L1F IC,' TIDN —i=—FT PECO?D LLC P.WS D1.1 Structural 1Neiding Code -Steel �— RADIDGP.APFHG TEST RESULTS Film Identification Results Film Identification Results Remarks iqurnher Number IJ /P. IJA Test;: NIA. Interpreted by: )QIA Date; NIA Drgani -_ation: We, the undersigned, c dance with the this record Section 4eof ANSI JAWS D1.1St ur uF- k and tested in accordance Authored -By, - — �� Ivtr,_J -Vt�, ark, , ZIMKOR LLC J , !� / _ Company: Date: �v Remarks prepared, elded, 'ode- St weel. J{Jia y ger cum- Littleton, CO 08125 Welder ID: A 7Se-0: RK Welder Name F :on Keiler FGP.W Revision: Oriqinal Date: S /03/08 �c p; \Wielder iv e: `1k+G�TF: \NPJ : -J- Record Actual Values Gwalir`ication Range Variables Used in Qualification F GAVd Processliype FLAW Single Single Electrode (single or multiple) D C E P DCEP Horizontal, Flat CurrenUPola rity 3G Groove: Vertical, Fillet: Vertical, Horizontal, Flat Position Up Up Backgoupe or Backinq Weld Progression BackgougelBacicing (YES or Id0) l acl:gouge Maierial /Spec. ASTItti 1.36 w P.STM P.36 Group �, or 1, to Group ? or 1 Base Metal (Plate) 0.125'— Unlimited Thickness: 1.404" Unlimite d Groove Fillet Thickness: (Fipeltube) 0.125 " - Unlimited 0.1?;'- Unlimited Groove Fillet Diameter. (Pipe) Over 24" Diameter Groove Over w' Diameter Fillet Filler Metal P, 5.20 E71T -1 (Hobarij Spec. No. E71T -1 (Hobart\ i G .Class F- ° COT- Gas /Flu:: Type 10p°o CO2 1r16" 1 \18" lecirods Diameter VISUAL IhSPECTI0N'. AcoeP AWS-CWI 98041461 3103 /DB Welding and 1 esting Witnessed by: Jesse A. Grantham' Bend Test ResultsTVr)e Result Guided I`pe Result Side 2 Accept Side 1 P.ccept — - - °- Fillet Test Results -• N/A �l ~� ILIA Fillet Size: I.i /A- /;ppearance: N/P Macroetch: Fracture Test Root Penetration:; 200E10D Jesse Grantham, AW5- CWI984A146•I Test #: 3/03/08 -� - Inspected by: Ur�eldinq Joining !>ngmt Grou ,West Date: Organeation: �— RADIDGP.APFHG TEST RESULTS Film Identification Results Film Identification Results Remarks iqurnher Number IJ /P. IJA Test;: NIA. Interpreted by: )QIA Date; NIA Drgani -_ation: We, the undersigned, c dance with the this record Section 4eof ANSI JAWS D1.1St ur uF- k and tested in accordance Authored -By, - — �� Ivtr,_J -Vt�, ark, , ZIMKOR LLC J , !� / _ Company: Date: �v Remarks prepared, elded, 'ode- St weel. J{Jia y ger cum- Littleton, CO 08125 aPr Oo 07 02 :1?P WJMG 30328047=7 P• 1 W—ELDER QUALIFICATION TEST P. =?DST (VI /,'— T R) AWE; D '1.1 Structural Welding Code - Steel N1gTP, No.: ZS -D6 RG 4 Welder Name: Ronnie Goss W Welder 10: t3 vVPS No.: '5 -06 W Welder Type: F Project Number: 2007165 Record Actual Values � Q Quaiificafion Range Used in Qualification Variables F FLAW F FCAVV Process/Type S Sinoie 5 5inule Electrode (single or multiple) D DCEP D DCtP CurrentlPolarity G Groove: Flat S Horizontal Position 2 2G F Fillet: Flat S Horizontal Weld Progression N No I IJo and Yes Backing or back weld 2 2' to Group 2 G Grou i or 2 materials MateriallSpec. p p,STto Ao G Group 1 or 2 materials Base Metal Thjckness: (Plate} 1 1 O0" 0 0.125" to Unlimited Groove 0 0.125 "to Unlimited Fillet Thickness: (Pipe /tube) 0 0.125 ^10 Unlimited Groove 0 0.125 "to Unlimited Fillet # # „ Diameter: (Pipe) O Over 24" diameter Groove O Over 24" diameter Fillet S Select Arc 720 1 Select Arc 720 Filler Metal S A 520 A A 5.20 ' Spec. No. G E7 '17 i 6 G IT-1 Gass E 6 F-No. 0 0 O 100% CD2 Type 1 111c ".' C 1 , , Diameter — —/ VISUAL INSPECTIDN - Accept Guided Send Test Results R P.esult I Vpe Result TVPe S Side 2 N Nccepi Side 1 S Side A N N/A Side 3 N A. Grantham. AWS -CWI #98041061 Tesl Number: 4 2007169 Inspected by. Jesse A 414107 organization: RADIOGRAPHIC 7EST RESULTS Film ldentjfication R Results Remarks Film Identincatiah F Remarks Number Number- N NIA NIA N Test Number: NIA Interpreted by: D Date: N N/A Organization: N welds were prepared, wed, We, the undersigned, cedih, thal t OR LLC Authorized Sy: Company: ZIMY. J. J i� GI C. w °9=r 4/4/07 -7&1j Titen Rood. - 1 ftir ti Li -con, CO 80125 LLO V1r= LD�PJOPER�' iO;✓.00A 1= 1C.,t,TlOh i�Si — AWS D1.1 StructLI al lrjelding Code - Stse1 ♦ iittlet:on, CO 08125 7011 Titan Road Welder ID: C Welder Ivan°: Hunrj r arra °_ca "M 3/1)8 �S -07 HC Orioinal Date: WCTR No.: 7rGAW Revision, �;_ 07 Welder TV WPS e: Record Aczual Values Qualification P,ange Variables Used in QUaIfTlCatf °n ` FGP,W ProcessType FGAW Single 5inple Electrode (single or multiple) DC- F' DC =P Current/Polarity Groove: Flori- ontal, Ffat 2G Fillet: Horizontal, Fiat Position I ill f' Weld Progression Bacl:poune or Backing Ba -,kgouge /Backing (YES or 1,40) t IviateriallSpec. ASTM M A36 Group 2 or 1, to Group 2 or 1 Ease I+�eta1 (Plate) U.12S° - Unlimited Thickness: 1.000 - tlnfimfted Groove Fillet Thickness: (Pipe /tube) 0 nlimited .110 - U Groove 0.125 - Unlimited Fillet Diameter. (Pipe) Over ?4" Diameter Groove Over ?4` Diameter Fillet Filler Metal .5?0 A, o 20 E71 i -1 (Hobart) Spec. No. (Hoba rt 6 Class F -N °' ( ° 1 00 °i� CC'z 100°1000".-CO2 Gas /Flux Type 1110" 1 1 _le-trode Dianetar VISUAL INS, =CTION: Accept JeS =° A. Grantham, AWS -VJ1 9l;0 =1001 Wei din g and Tesi:ing Witnessed b)': Guided Bend Test ResultsT`,Re Result e Result Side Acceot Side 1 Accept ` Fillet Test i asuITS I�1A. NA Fillet Size: N1A Appearance: Test Root Penetration; lv1A Macroetch: Fracture 9008117 Jesse Grantham. AWS-CWI 90041061 Test #: 3/13/Ofi a r h spected by uVesi Date: Weldfnq Joining hhpmt Group, Cxgani:.aifon: I RApf06RAPHlC TEST RESULTS Film Identification Results Remarks Film Identification Results Remarks Ivumbe.r Number IJIP. NA N/A Test 4: NIA NIA Interpreted by: MP 0relantalion: Date: and that the test weld prepared, welded, vlirrE P� d� undersigned, certi#j that file statements in this record are correct Section 4 of ANSUAWS D1.1 , Steel. Struciural?1j.lrlrra9 We,1he and tested in accordance wfth the reguirements of Ivlt_ raa er t� +illi� r:larl,�� 13 ZIIvl3COP, LLC Authorized By: [ Company: _— _ Date: _ ♦ iittlet:on, CO 08125 7011 Titan Road WELDEWDPERAI OR QUALIFICATION TEST Ri— =COF:t . t1� 7WOR, LLO AWS D1.1 Structural Welding Code - Steel WDTRIJo.; ZS- 07 Ki+A WelderlJame: Keller Miller. Welder ID: H Original Date: 3119/08 WPS: ZS-07� Welder Tv e: FCAW Revision: Record Actual Values Qualification Range Variables Used in Qualification. FCAW FCAW Process/Type Single Single Electrode (single or multiple) DCEP Current/Polarity DCEP Groove: Horizontal, Flat Position 2G Fillet: Horizontal, Flat N/A NIA Weld Progression Backpoupe Backgouge or Backing Eackgouge /Backing (YES or NO) Material /Sped. ASTM A36 to ASTM A36 Grou 2 or 1, to Grou 2 or 1 Base Metal Thickness: (Plate) 0.125" — Unlimited Groove o. Fillet Thickness: (Pipe/tube) 0,125 °- Unlimited Groove 0,125 ^ - Unlimited Fillet Diameter: (Pipe) Over 24" Diameter Groove Over 24" Diameter Fillet Filler Metal P, 5.20 A 520 Spec. No. E71T -1 (Hobart) E7 7-1 (Hobart) _ Class 6 F -No. 6 100 *1a CO2 100% CO2 Gas /Flux Type 1/16" 1/16'. Electrode Diameter VISUAL INSPECTION: Accept Welding & Testing Witnessed by: Jesse A. Grantham, AWS -CW1 9BO41D61 Guided Bend Test Results Result Type ,'Result Tye Acce t Side 2 Accept Side 1 Fillet Test Results Np, Size: Fillet Size: N/A -- Appearance: Fracture Test Rcat Penetration: N/A Mllet N/A ` Jesse Grantham, AWS -CWI 98041061 Test #: u v 2008130 , iF Inspected by: Organeation: Welding & Joining Mgmt Group, West_ Rate: 3119/08 . , _ RADIOGRAPHIC TEST RESULTS Film identification Film Identification Results Remarks Remarks Results Number Number NIA IJA . NIA Test #: N/A Interpreted by: NIA Date: IV /A Organization: We,.the undersigned, certify that the statements in this record are correct and that the test welds were prepareg. . )Qf� andtested in accordance with the requirements of Section 4 of ANSI /AWS D1.1 Structural Welding Ca to y ZIMKOR LLC Authorized Sy: -- - Company tark QC Manager -- - - - - - -- Date 3/19/08 *y, + Littleton, CO 08125 Eb COPY �IMK�R LLB WELDER/OPERATOR QUALIFICATION TEST RECORD (WQ T R) AWS D1.1 Structural Welding Code - Steel WQTR No.: ZS -07 RM Welder Name: Ron Mondragon Welder ID: K WPS : Z5 07 Welder Type: FCAW Revision: Original Date: 8/3111 Record Actual Values Qualification Range Variables Used in Qualification Process/Type Electrode (single 'or multiple) Current/Polarity Position Weld Progression Backgouge /Backing (YES or NO) Material /Spec. Base Metal Thickness: (Plate) Groove Fillet Thickness: (Pipe /tube) Groove Fillet Diameter: (Pipe) Groove Fillet Filler Metal Spec. No. Class F -No. Gas /Flux Type Electrode Diameter _ r-t11w Sin to Single DCEP DC EP 2G Groove: Horizontal, Flat Fillet: Horizontal, Flat NIA N/A Backgouoe Backgou e„ Backweld, or Back Result Side 1 ASTM A36 to ASTM A36 Group 2 or 1, to Group 2 or 1 Fillet Test Results 1.00" 0.125" — Unlimited NA Fillet Size: NIA Macroetch: 0.125" — Unlimited Fracture Test Root Penetratson: 0.125 " - Unlimited Jesse A. Grantham, AWS -CWI 98041061 Test #: 0.125- Unlimited Organization: Welding & Joining Mgmt Group, West Date: 813111 Over 24" Diameter Over 24" Diameter A 5.20 A 5.20 E71T -1 (Hobart) E71T -1 (Hobart 6 6 100% CO2 100%002 . 1116" 1/16" RADIOGRAPHIC TEST RESULTS Film Identification Results Remarks Film identification Results Remarks Number Number NA NIA AIfA Interpreted by: N/A ' G" "' Organization: NIA Date: NIA We, the undersigned, certify that the statements in this record are correct and that the test welds were prepared e and tester! in accordance with the requirements of Section 4 of ANSIJAWS 1 St uctur eidin de- eel, company: ZIMKOR LLC Autll By_ Date: 8/3111 i D Manager -- QC— I-EXP,si /1/2014 7 i VISUAL INSPECTION: Accept Welding Witnessed by: Willie Clark Guided Bend Test Results - T e Result T e Result Side 1 accept Side 2 acce t Fillet Test Results Appearance: NA Fillet Size: NIA Macroetch: NIA NIA rw Fracture Test Root Penetratson: Inspected by: Jesse A. Grantham, AWS -CWI 98041061 Test #: 2011304 Organization: Welding & Joining Mgmt Group, West Date: 813111 RADIOGRAPHIC TEST RESULTS Film Identification Results Remarks Film identification Results Remarks Number Number NA NIA AIfA Interpreted by: N/A ' G" "' Organization: NIA Date: NIA We, the undersigned, certify that the statements in this record are correct and that the test welds were prepared e and tester! in accordance with the requirements of Section 4 of ANSIJAWS 1 St uctur eidin de- eel, company: ZIMKOR LLC Autll By_ Date: 8/3111 i D Manager -- QC— I-EXP,si /1/2014 7 i � WELDEPJONEP,ATOR QUALIFICATION TEST PECORD (WOTP,) ,I�� R AWS DIA Structural Welding Code - Steel WQTR No.: ZS -11 ME Welder Name: Martin Estrada Welder ID: N WPS: ZS -11 WelderT e: FCAW Revision: Original Date: 5/30/D7 Record Actual. Values ( Qualification Range Variables Used in Qualification Process/Type Electrode (single or multiple) Current/Polarity Position Weld Progression BackgougelBacking (YES or NO) Material /Spec. Base Metal Thickness: (Plate) Groove Groove Fillet Thickness: (Pipe /tube) Groove Fillet Diameter. (Pipe) Groove FCAW FLAW Single. Sinqle DCEP DCEP 2G Groove: 2G , 1G: Fillet: Horiz and flat N/A N/A Yes Backing or Backgouge ASTM A36 to ASTM A36 Group 2, 1 to Group 2, 1 1.000" 0.125 " — Unlimited 0.125" — Unlimited 0.125 " - Unlimited 0.1.25 " - Unlimited Over 24" Diameter I over 24" Diameter Fillet Filler Metal Spec. No. Class F -No. Gas /Flu: Type Electrode Diameter Face 1 A520 E71T_ -1 Select Arc 720) 6 100% CO2 1/161, VISUAL INSPECTION Accept: Guided Bend Test Results Result I Type Accept Root 1 Fillet Test Results Appearance: NA Fillet Size: Fracture Test Root Penetration: Iq/A Macroetch: inspected by: Jesse Grantham, AWS -CWl 98041061 Test #: Organization: Weldinq & Joininq Mgmt Group, West Date: E71T -1 (Select Arc 6 10D°/o CO, 1 /16" ResUK Accept r� N/A INYA 2007261 5/30/07 RADIOGRAPHIC TEST RESULTS Film Identification Remarks Film Identification Results Remarks Results Number umber NA NIA Interpreted by: N/A ' es` *. " - Organization: N/A Date: IJ /A — Vve, the undersigned, certify that the statements in this record are correct and th � were prepared, welded; and tested in accordance with the requirements of Section 4 of ANSI/AWS$cuc I ' Iding Code- Steel. Company: ZIMKOR LLC Authorized By: Y� ±s QC 9 +. 0 Date: 7011 Taan Road + Littleton, CO 08125 MOKOR) L L C WELDER /OPERATOR QUALIFICATION TEST RECORD (WOTR) AWS D1.1 Structural Welding Code - Steel WQTR No.: ZS -07 BO _ Welder Name: Bruce Oxley Weider ID: Q WPS : ZS -07 Welder Type: FCAW Revision: Original Date: 3/27/10 Record Actual Values Variables Used in Qualification Qualific ation Range Process/Type FCAW FCAW Electrode (single or multiple) Single Single Current/Polarity DCEP DCEP Position 2G Groove: Horizontal, Flat Weld Progression Backgouge /Backing (YES or NO) Material /Spec. Base Metal Thickness: (Plate) Groove Fillet Thickness: (Pipe /tube) Groove Fillet Diameter: (Pipe) Groove Fillet Filler Metal Spec. No. Class F -No. Gas /Flux Type Electrode Diameter VISUAL INSPECTION: Accept Fillet. Honzontal, Flat N/A NIA Backgouge Back ou e or Backin Result Tye Result ASTM A36 to ASTM A36 Group 2 or 1, to Group 2 or 1 Accept 1.00" 0.125" — Unlimited 0.125" — Unlimited Appearance: NA Fillet Size: 0.125 " - Unlimited Fracture Test Root Penetration: NIA Macroetch: 0.125 " - Unlimited Inspected by: Jesse Grantham, AWS -CWI 98041061 Test #: 2010107 �0W K Over 24" Diameter Welding & Joining lAgmt Group, West Date: Over 24" Diameter A 5.20 A 5.20 E71T -1 (Hobart) E71T -1 (Hobart) 6 6 100% CO2 100% CO2 1/16" 1/16" RADIOGRAPHIC TEST RESULTS Film Identification Results Remarks Film Identification Results Remarks Number Number NA N/A Interpreted by: N/A Test #: N/A Organization: N/A - Date: N/A We, the undersigned, certify that the statements in this record are correct and that the test welds were<psepared, welded, and tested in accordance with the requirements of Section 4 of ANSUAWS D1.1 Structural Wetdin%-G.ode Steel. Company: ZIMKOR LLC Authorized By: Mr. J. W- ran' ers''�h Date: COY -- --- --- '7n4 i rt-- a—q- -- - -. - -- i h VISUAL INSPECTION: Accept Guided Bend Test Results Tye Result Tye Result Side 1 Accept Side 2 Accept Fillet Test Results Appearance: NA Fillet Size: N/A Y�'Y Fracture Test Root Penetration: NIA Macroetch: N/A Inspected by: Jesse Grantham, AWS -CWI 98041061 Test #: 2010107 �0W K Organization: Welding & Joining lAgmt Group, West Date: 3/27/10 RADIOGRAPHIC TEST RESULTS Film Identification Results Remarks Film Identification Results Remarks Number Number NA N/A Interpreted by: N/A Test #: N/A Organization: N/A - Date: N/A We, the undersigned, certify that the statements in this record are correct and that the test welds were<psepared, welded, and tested in accordance with the requirements of Section 4 of ANSUAWS D1.1 Structural Wetdin%-G.ode Steel. Company: ZIMKOR LLC Authorized By: Mr. J. W- ran' ers''�h Date: COY -- --- --- '7n4 i rt-- a—q- -- - -. - -- i h Feb 17 DS 01:33P rfmi -10;1 I 1 L L1J1'1G W —ELD —ER QUALIFICA T ION i EST R -FDP.T (VVQTr ) AVVS D 11 Structural Welding Code - St' -3l Vv +GTR No.: ?I -06 2 RG Welder Narne WP-C No.: ZI -06 -2 Welder Type: Variables Process/Type Electrode (single or multiple) Current/Polarity Position Weld Progression Backing or bade weld: lvateriailSpec. Base Metal Thickness: (Plate) Groove Fillet Thickness: (Pipe /tube) Groove Fillet Diameter. (Pipe) Groove Fillet Filler Metal Spec. No. Class F-No. GasJFlu:: Type Diameter Side Robert Genova Welder ID: R FLAW Rev.: Onninal Revision Date: 1116106 Record Actual Values Used in Qualification FCAW Single DCcP 1 G F-rojecl hJumber: 2005070 Quali1ic8tidn Range FLAW Single DCcP Groove: Flat Fillet: Flat & HorL?ontal I Yes Variables Process/Type Electrode (single or multiple) Current/Polarity Position Weld Progression Backing or bade weld: lvateriailSpec. Base Metal Thickness: (Plate) Groove Fillet Thickness: (Pipe /tube) Groove Fillet Diameter. (Pipe) Groove Fillet Filler Metal Spec. No. Class F-No. GasJFlu:: Type Diameter Side Robert Genova Welder ID: R FLAW Rev.: Onninal Revision Date: 1116106 Record Actual Values Used in Qualification FCAW Single DCcP 1 G F-rojecl hJumber: 2005070 Quali1ic8tidn Range FLAW Single DCcP Groove: Flat Fillet: Flat & HorL?ontal Yes packing only -croup 2io Grou ( Group 1 or? maieriais' ASTM A36 Groun 1 or 2 maierials 1.000" 0.125" to Unlimited 0.125" to Unlimited D.125' to Untimiied 0.125 ". to Unlimited I . j liver 24" diameter Over 24" diameter A, 5.20 A 52D E7 IT-1 =7 ii -1 10D r CO2 100 °,'o CC •• f Y 1116" 1 1116 -and lessi� V1sUA1. INSPECTION —Accept Guided Bend—lest—Result's Result TVpe Acceot side 2 Result Acceot JIVE J Welding Witnessed by: VVIMB Clark Inspecied by: Jesse A. Grantham, AVr1S_C1Af1 - !'Ho41001 Test Number: 200607D _ Organisation: Weldinn & Joining Momt Grouo, West Date:' 2116/06 RADIOGRAPHIC TDST P,ESULTS Film IdentincaGon Results Remarks Film Identification Results Remarks Number Number N/A N/A Interproted by: N/A Test Number. NIA Qrganiration: I41A Date: Id1A the statements in this record are correct and that the test welds were prepared, We, the undersigned, cerfir) that and tested in accordance with the requirements of Section 4 AWS Dd.1, Structural Welding Code - Str/' './fir company. Zimk or-lndustries. Inc. Authorized By. Wiliie Clark ! Li + L.Ittleton; CC 80125 71111 Vw Rd. r Filler Meld, A S?G � Spec. No. i (Hobart) `71T -1 (Hobsrt) Gass E7iT -i 6 ° 100 r0, F -No. 100 °�o GOs � GaslFlu )' Type 111 c" i i r'16" �lectrod� Diameter �jISUAL INSPCC I IOtJ: Accept Welding and Testing Witnessed by' Jesse A. a�tsults A j -C1Nt 9t3D410o1 5 /03lOEpesuli Result Tvpe Type I Side f Accept Side 1 Accept - Fillet Test Results NA Fillet Size: Appearance: Iq /A MaCrUetCll: FractureTesi Root Penetration: Inspected hy: Jesse Grantt+am, AVVS -CM 980410Gt Test : lh +gilding ,loininq Ivigmt Group, West Date Organtation: �— F ADIDGF;APHIC TEST RESULTS Film Identification Film Ideritfication Results Remarks {.Lumber Number IJ /H IJH Test-4: Interpreted by: N/A N/A Date: prgan�ation: he Undersigned, certify that statement -, in this record are correct and that the and undersigned, to UJe, t r in accordance with the requirements of Section 4 of ANSItAWS 1111 -- _IMKDR -LLC Authorized By_t�{�',li Company: Date: t NiA Is! /A 200Ey100 3103108 Results iWA NIA i- t j: Remarks Tre prepared, welded, Code- Steel. R Littleton, CO 08125 i-:.I R::CO D(VV -TP) VU.= LD=-rJOP= ?I -',TOr QUAL IFir-ATION tN =lding Code Steel �IV �` r?� ! 1 .0 AVVS D!.1 Structural -7 Danny Jackson Welder ID: S ;;1031CyE; Ut /LTR Pia.: -c, -07 GJ lh+elder PJame: FC;A1h' Revision: Original Gate: wPS 'S -67 Welder Tope: Record ArTUaI Values Gua{iiicaiion F,'ang° Variables Used in Qualification I FGAVU ProcesSlType -� r CHVV Single Single. Electrode (single or multiple) G ��P DCEP Groove: Horizontal, Flat rAirrenl Polarity 2G Fillet: Hon ontai, Flat Position N/A Weld Progression Id1A, t;ad <gouge t3acl <gouge or t3ac1 <inq Eackgougel2acking (''(ES or id0) Material /Spec. f.STt, f.3Fa to ASTIA r•3G ? or i, it. Group 2 ar 1 Grout '. Base Metal (Plate) 0.1, —: Unlimited Thickness: 1.000" G.1'S "- Unlimited Groove Fillet Thickness: (Pipe /tube) -- 0.1_5 - Unlimited Groove I G.i'S- Unlimited Fillet Diameter: (Pipe) Jver 94" Dismater Groove Over 24" Diameter Fillet Filler Meld, A S?G � Spec. No. i (Hobart) `71T -1 (Hobsrt) Gass E7iT -i 6 ° 100 r0, F -No. 100 °�o GOs � GaslFlu )' Type 111 c" i i r'16" �lectrod� Diameter �jISUAL INSPCC I IOtJ: Accept Welding and Testing Witnessed by' Jesse A. a�tsults A j -C1Nt 9t3D410o1 5 /03lOEpesuli Result Tvpe Type I Side f Accept Side 1 Accept - Fillet Test Results NA Fillet Size: Appearance: Iq /A MaCrUetCll: FractureTesi Root Penetration: Inspected hy: Jesse Grantt+am, AVVS -CM 980410Gt Test : lh +gilding ,loininq Ivigmt Group, West Date Organtation: �— F ADIDGF;APHIC TEST RESULTS Film Identification Film Ideritfication Results Remarks {.Lumber Number IJ /H IJH Test-4: Interpreted by: N/A N/A Date: prgan�ation: he Undersigned, certify that statement -, in this record are correct and that the and undersigned, to UJe, t r in accordance with the requirements of Section 4 of ANSItAWS 1111 -- _IMKDR -LLC Authorized By_t�{�',li Company: Date: t NiA Is! /A 200Ey100 3103108 Results iWA NIA i- t j: Remarks Tre prepared, welded, Code- Steel. R Littleton, CO 08125 C a _ IFI.�A.i IJI1 --ST FR =COR=D ( Z,TFZ) / X _ _ _ 1 h ^, VlI_L DE i'0p. -1: .1 OJT:: i..�s -E. ,';1/4'S Di, i Structural VVeldlnO. Code - Stes1 WCTR Na: 'S -n+ MT Welder (Jame: Iviarl: Tanner Revision: lNelder ID: Y. Oiiainal Date: s!1 9/08 tA1PS FG�A\Ar Class Record Acival Values I Qualification P.ange Variables User! in CWUalification j 6 FCAtAI FLAW Process/Type Single Single Electrode (single Of muftiple) GC=P Current/Polarity DCEP Groove: Horizontal. Flat 2G Fillet: Horizontal, Flat Position Weld Progression v c JD N/A Eaclmouga r- ackqaupe or Bacl ;incl Backgoug -alZaclong ( I Lb or f ) l0ateriaYSpec. Base Metal Thickness: (Plate) Groove Fillet Thickness: (PipeAtube) Groove Fillet Diametsc (Pips) Groove Fillet -'ll� IJi�tal G to k S TM AM i Group 2 or 1, tci Grouo ? or 1 f.000" 0. Unumnetl Unlimited o.1?5 "- UniimiiPd U.12;"- Unlimited f Diameter Cjver24- DlametBf 1 F- .,r Spec. No. k. E71T -1 (Hoban) =71 T--1 (Hobal t) Class 6 F -No. 6 100 AG CD2 - Gas /Flux Type 1/1E" Eleclrcd- Dlam °ter VISUAL INISPECTION: k accept Udeiding Testing Witnessed by: Jess& A. Grantham, AVVS-CWI 980 -.1 D"1 Guided Bend Test Results Result Result I e Sid e ' _ ACCept Side 1 - r illei Test Results NIA 1Q. Fillet Size; Appearance: IJIA macroetch: Fracture Test Foot Penetration: . 2008130 Inspected icy: Jesse Grantham, AWS -01W 9SO -ttOf1 Test 3/19108 prganeaiion: Weldinp & Joining fvldrnt Group, West Date: FADIOGF.APhIIC TEST P.ESULTS Film Identification Results Remarks Film Identification Results Remarks Number Number - IJA Dale: Test : iJ /A Interpreted try: N/ IJIk, A N/A Urgani alion: in accordance with the requirements of Section 4 of ANSI /AWS D1.1Structur 1Areldinn E1S'L' tr t+t+e, the undersigned, certify that the statements hi this record are correct and that the test welds were prepared, �n,*:' f'• ; , and tested F,uthorized By: Company „ + 1titsriC ianzo 4; Date: 3149/0B •P utueton, CO 08125 ._._ --- _ 7U11_Titan Road. _._- ..___._...____--- _�•- .-.,.. - �__.�_ - _.— _-- ____. -.�._ —_ 1A1=� O ? =r =. T nli b! 1 =1C� T I.Dtt 7=-ET r M1C'�rRD 1\+\l���TR) t t -' i r i' rJ _rJ I, �, C' ` S`eal %R1 1"�1 L ..s -� -\r,.0 D i.' S�ra�Lural 1111�1cIinU �Je 75 -07 GUV _ Welder Name: INPc : __G7 \Helder Tyoe: Variables Process/Type Electrode (single or multiple) Current!?olarity Position Weld Progression Eactcgouge /Backing (YcS or 110) material ,'Spec. Base Metal Thickness: (Plate) Groove Filial Thickness: (Pipe/tube). Groove Fillet Diameter: (Pipe) Groove Fillet Filler Ma4al Spec. No. Mass F -No. Gas /Flu:: Type Eiaz;trode Diameter ;eoroe Uvortman FCAUV RBe ISIOn: �-) Record factual Values Used in Qualification F CA\Ar Sinnle DCPP 2G Nlk. Backaouge =.SThb ASTK4 ATE /-,5.20 E_71- , (�-i b 10flai. Ct 1!1 i.' Welder ID: � - Date: V1 WOE Cua)ification "mange FCAW Sinnle DCEP Groove: Horiaontal, Flat Fillet: Horiaontel, Flat IJlP. Bacitgouge or Backing ouv _' or 1 , to Grauu ' or 1 G.125" - Unlimited 0.125 " - Unlimited Unlimited 0,125-- Unlimited C)ver 24" Diam -3ter over A" Diameter A. u.20 E71 T -1 (Hobart) 6 100% CC'- 11iE" V1SU!aL ih:SP= CTIOt�: Accept Welding and Testing Witnessed by: Jesse A. Grantham, !tvvs` cwl 98DA- i Uc,1 Guibed Bend Test Results Result Result T yos T voe Side 2 accept Side 1 accept _ F.ADlOGF.APtiiCTEST RESULTS j Film Identific-ation Results Film identirication ReSUIts Remarks Number Number N/A NA 141A IJ /fi - Test w: - interpreted by: Date: 191A Organi-aiioi�: N/A 1pa i7a undersigned, certii\ that the siatemencw in This record are correct ancf that the test welds: were P and tested in accordance with the requirements of Section 4 of FtihJSl /�,iNS D1.iStructural We �n9% 'PAKO• R LLC Authorized By: r J. Ivillie Clark, G I -- _Cotnpa�• _ _ --.-�_ __Late: �., - - ,-- .�' -�-, Remarks wielded, peel. ,+, Litt(t3r n, CO' 08125 7011 Than Road __ F Fillei Test Results idle, IJA Fillet Size: Appearance: loacroetch: l Fracture Test R b1': J Jesse Grantham, AWS -CVVI 96041 OCI1 Test n: 003/08 Inspected b Welding & Joining Ivhlml Grnup, Wesi Gate: Remarks wielded, peel. ,+, Litt(t3r n, CO' 08125 7011 Than Road 7011 Titan Road Littleton, CO 06125 Paos 1 Oi 2 rrocadure S;p3 ;tTI :atiDn tltl� =j� �%1lelruing lNeldir,g Code AVVS D I I Structural r ° I x'118 /UE; ?t�GiE,11J IA' ?� 1Jo.: ?S -0i: ; et�ision Oriuinal Crate. 7 J. '�I r r� < <;- 'duiana''ar 4uthori_ed b : r , T e:- Manual aaiid" Vvelding , rocs....: PreQUa)iTied B -L'4rC F hriacl nine - Auto is ~- ,,ironing Pop lVo.: PDSITIO IJ JD)IdT DESIGN Groove Weld f Groove: r Fillet: V, H: F Posiiiorr, o, Graave: � Up, TVPz- Single Bevel 4izr lc31 Progression: Up up Ingle: �; Double tNeld Cacl,inq: Yes - IJa ); Backing Iviati: JLECTp,.CAL C}lkl`�,CT- P.IETICS Back Gouging: `,` °s >: i�lo - Aethod: ArclGrnd Transfer Mode (Glvf.4',IR!1: Shoe i- Circuiting �� pool Face: Root Opd9: O.D -0.1_. �=-- -- Globular Groove Angle: 4 t. Spray Pulsed G>rrrart AC DCEP x DCEI\I BASE METALS 1 F)ecrrod2 GT.aI : Size: Tun ton ( lvlalerial SPOL: Group 2 or 1, to Group 2 or 9s . ,Type or Grade: ' Tbj knesa Groove: 0.125"- Uird r-illat u-'_ 5' to U T= CHtq)G)U'c Dtan)eier (P1pe): rver?4" Diameter utringar or Ir ✓ca�� n ^aad:. Either or Both Bzse Matal Thickness U = Unl)mited _ AAuli! -pass or single Pass (Par side): Either or both Number of %acirodas: Sinale rIL LER ME`�AL 5 Electrode Spacing: Longitudinal I•IBI, �n ('• _ : A M,jS Speciftarlon: L at2ra! NIP. _ ��� 1 �. rj I t -1 f lDDart ,4y�., C,a:.sificaiion: ng)a lnta-r- a=s Cleaningg: hiiechanicaliv Clean Cr,a tact ! ube to Work Disr3nc6. Con Gas m --�" es Flow Rate 3C —40 ..fn uning: Size: inches 516 "_ 1" i 6..s Cup ----- FJacircd=rrlu;: Class. DOSTWELD i =.'.T i F,- '- .TIViENT Non= this VVPS PPEHEAT Tarnpa;ature: t M Preheat Teqo. Iviin: J2" F Max. a00° Time: F Cooling Raze: intzr -piss Temp. Min: :,2° F WELDING PPDGEDLJPE Filler Metals Current Travel Speed Typical Sketch Weld Process Class Die Type I Pofarifiv Amps Volts )FPM Joint Detail La >>er(s1 j FLAW E7 1T-1 1 /1I6" [)CEP 24:-292 — 26 -30 �_ G '! 0 FCAN E-V -1 1 DCEP 1 243 -297 243 -297 2E -3 {! - —_ - f 0 =6-30 Hs re � FCAW E7fi -1 CCEP 7011 Titan Road Littleton, CO 06125 � � � WELDEPJOPERATOR QUALIFICATION TEST RECORD (VVQTR) ��� ALAS DIA Structural Welding Code - Steel WQTR No.: ZS -11 ME Welder Name: Martin Estrada Welder ID: N WPS : ZS -11 Welder Type FCAW Revision: Original Date: 5/30107 Variables Record Actual Values I Qualification Range Used in Qualification Processaype FCAW FCAW Electrode (single or multiple) CurrenUPolanty Position Weld Progression BackgougelBacking (YES or NO) Material /Spec. Base Metal Thickness: (Plate) Groove Fillet Thickness: (Pipe /tube) Groove Fillet Diameter: (Pipe) Groove Fillet Filler Metal Spec, No, Class F -No. Gas /Flux Type Electrode Diameter Single Single DCEP DCEP 2G Groove: 2G , 1 G: Fillet: Horiz and flat N/A NIA Yes Backing or Backgouge Iding Code- Steel. Company: ZiMKOR LLC Authorized By: Date: ASTM A35 to ASTM A36 � Group 2, 1 to Group 2, 1 ResLnC -"'- 1.000" 0.125" — Unlimited Root 1 0.125" — Unlimited Accept- 7011 Titan Road + 0.125 " - Unlimited 0.125 " - Unlimited Fillet Test Results Over 24" Diameter Appearance: Over 24" Diameter A 5.20 E71T -1 (Select Arc 72 6 100% CO2 1/16" A 5.20 E71T -1 (Select Arc 6 i 100% CO2 1/16" RADIOGRAPHIC TEST RESULTS Film Identification Results Remarks Film Identification Results Remarks Number Number NA NIA Interpreted by: N/A Test ;t: VISUAL_ INSPECTION Organization: N/A Date: N/A We, the undersigned, certify that the statements in this record are correct and th Accept: were prepared, welded, and tested in accordance with the requirements of Section 4 of ANSI /AWShu Guided Bend Test Results Iding Code- Steel. Company: ZiMKOR LLC Authorized By: Date: Type Result Type ResLnC -"'- Face 1 Accept Root 1 Accept- 7011 Titan Road + Littleton, CO 08125 Fillet Test Results Y Appearance: NA Fillet Size: N/A , Fracture Test Root Penetration: NIA Macroetch: N/A Inspected by: Jesse Grantham, AWS -CWI 98041061 Test #: 2007261 Organization: Welding & Joininq Mqmt Grou , West Date: 5130/07 RADIOGRAPHIC TEST RESULTS Film Identification Results Remarks Film Identification Results Remarks Number Number NA NIA Interpreted by: N/A Test ;t: 114,1 Organization: N/A Date: N/A We, the undersigned, certify that the statements in this record are correct and th were prepared, welded, and tested in accordance with the requirements of Section 4 of ANSI /AWShu I Iding Code- Steel. Company: ZiMKOR LLC Authorized By: Date: L �� QC 7�f_g*jT , :, I Ik,r 7011 Titan Road + Littleton, CO 08125 7119!"t OR, L L C Welding Procedure Specification (Wr S) AWS D 1.1 Structural Welding Code — Steel Page 1 of I WELDING PROCEDURE WPS Na: ZS -11 Revision: Original Date: 5130107 P 200+7.26{ Current Authorized bj,� i ar Q t �'' ' anaggr Welding Process: FCAW Type:— Manual - �- rni -Au - tic '' 'X Supporting PQR No.: Prequalified B -U4b -F Machine - A�atomaiic Class I Dia. I JOINT DESIGN POSITION Type: Single Bevel Groove Weld Position of Groove: 2G Fillet: Flat Single: X Double Weld Vertical Progression: Up N/A N/A Backing: Yes -- No X Backing Matl: -- j E71T -1 i E71T -1 Back Gouging: Yes X No - Method: Arc/Grnd ELECTRICAL CHARACTERISTICS Root Opng: - 0.0-0,125' Root Face: -- Transfer Mode (GMAW): Short- Circuiting Groove Angle: 45` to 55' Globular As re Spray Pulsed BASE METALS Current: AC DCEP x DCEN Material Spec.: Group 1,2 to Group 1,2 Tungsten Electrode (G TAM: Size N/A Type or Grade: ASTM A36 to Grade A36 14 -20 Thickness Groove: 0.125 " - Ultd Fillet: 0.125" to U Diameter (Pipe): Over 24" Diameter TECHNIQUE Base Metal Thickness U = Unlimited Stringer or Weave Bead: Both Multi -pass or Single Pass (per side): Either or both FILLER METALS Number of Electrodes: Single AWS Specification: A5.20 Electrode Spacing: Longitudinal N/A AWS Classification: E71T -1 (Select Are 720) Lateral N/A f Angie N/A SHIELDING Inter -pass Cleaning Mechanically Clean Flux: — Gas Composition: Col Contact Tube to Work Distance: 318" - 3/" Gas Cup Size: inches '/2 -'/, Flow Rate: 30-40 cfh Peening: N/A Electrode -Flux Class. POSTWELD HEAT TREATMENT PREHEAT Temperature: None this 1 Preheat Temp. Min: 50° F Time: N/A 3tt -" ti 5 Inter -pass Temp. Min: 50° F Max. 500° F Cooling Rate: N/A :. -. i WELDING PROCEDURE Filler Metals Current Weld Layer(s) Process Class I Dia. I Type & I Polarity Amps Volts Travel Speed IPM Typical Sketch Joint Detail 1 2 FCAW FCAW j E71T -1 i E71T -1 I_ 1116" i 1/16" DCEP DCEP 243 -297 243 -297 26 -30 26 -30_ _ 14-20 14-20 As re FCAW E71T-1 1/16. DCEP ; 243 -297 26 -30 14 -20 f f" I� 7011 Titan Road ♦ Littleton, CO 08125 JL:J�JV Feb 1 ^r 0G OI:33P LIJMG WELD -ER QUALIFICATION TEST REPORT (1.,V T?) %imkor, LL C AWS D 1.1 Structural Welding Code - Steel Welder Name: Robert Genova Weider ID: R vVQTR No.: J -06 -2 RG FCAW Rev.: Onoinal Revision Date: 2116106 vvPS No.: 21 -06 -2 Welder Type + ,it-- Variables Processffype Electrode (single or multiple) Current/Polarity Position Weld Progression Backing ❑rbacl: weld: tvSalsrial/Spec. Base Metal Thickness: (Plate) Groove Fillet Thickness: (P)pe /tube) Groove Fillet Diameter. (Pipe) Groove Fillet Filler Metal Spec. No. Class F -No. GaslFlux Type niamaTar Inspected by: project Number: 2006070 Record Actual Values { Guali'lication Pange Used in Qualification i 2116!06 RADIOGRAPHIC TcST P,ESULTS FCAW FCAVtr Single Sinqie DCEP DCEP Number Groove: Flat 1G Fillet Fiat & Horizontal Yes Eackinn oniv Group 2 w Grou 2 Group 1 or 2 matenals" ASTM A36 Grouo 1 or 2 matenals i.bOD" 0.125" to Unlimited We, the undersigned, certi6o that the statements in this record are the of Section 4 AWS D1.1. 0.125" to Unlimited and tested 0.125" to Unlimited 0.12 -" to Unlimited htriliJe Clarh ' ( Over 24" diameter ( over 24" diameter A5.20 A520 E71T -1 6 v G 100 io CD2 100% CD, ili6" ( 1116' and less\ J)i4lr , Inspected by: Jesse A. Grantham, AVJS -CWI #980410061 Test Number: 200t5Uru Organization: Welding tt,loininq Momt Grouo, West Date: 2116!06 RADIOGRAPHIC TcST P,ESULTS FilmFilm Identification Results ( Remark Film Identin "cation Number Results Remarks Number I N1A N/A Test Number: N/A Interproted by: N/A Date: NIA Organization: NIA correct and that the test welds were prepared, w,�lOtidy We, the undersigned, certi6o that the statements in this record are the of Section 4 AWS D1.1. Structural Welding e S te%`jr• s and tested in accordance with requirements Company. 'imkor•Industries, Inc. Authorized By: htriliJe Clarh ' i rr 3 v. + Littleton, CO 80125 7011'fitan Rd. Zimkor LLC Irk P ge 1 oft �riis�, f Welding Procedure Specification �� ZS -06 'PS No. ZS -06 Revision 1 Date 1112712006 By Paul Gustafson Authorized By Willie Clark Date 11114/2006 Prequalified 0 Welding Processes) FCAW _ Type: Manual E) Machine ❑ Semi -Auto ® Auto ❑ Supporting PQR(s) JOINT Type T and Corner Joint a+ar•n Backing Yes ❑ No 19 Single Weld ❑ Double Weld Backing Material Any AWS I or 11 Root Opening See Joint Root Face Dimension See Joint Groove Angie See Joint Radius (J -U) NA Back Gouge Yes [9 No ❑ Method Air Arc 1 Grind j 1 T -3 I--" BASE METALS T POSITION Material Spec. Any AWS I or ll to Any AWS I or it Position of Groove All Fillet All Type or Grade Any AWS 1 or 11 to Any AWS I or It Vertical Progression: ® Up ❑ Down Thickness: Groove (in ) .125 Unlimited ELECTRICAL CHARACTERISTICS Fillet (in ).125 Unlimited Transfer Mode (GMAW): Diameter (Pipe, in ) over 24 Unlimited Short- Circuiting ❑ Globular 9 Spray ❑ FILLER METALS AWS Specification A5.20 AWS Classification E71T -1C SHIELDING Flux NA Select Arc 720 Current: AC ❑ DCEP 0 DCEN ❑ Pulsed ❑ Other NA Tungsten Electrode (GTAW): Size NA Type NA TECHNIQUE COZ Stringer or Weave Bead Both Gas Gas C i 2 100 % Multi -pass or Single Pass (per side) Single N --f Electrodes 1 Electrode -Flux (Class) Flow Rate 30-40 CFH u NA Gas Cup Size 0.500 " - 1.00 ", Electrode Spacing: Longitudinal NA Lateral NA PREHEAT Angle NA Preheat Ternp., Min. 70 F Contact Tube to Work, Distance NA Thickness Up to 314" Temperature 32 Peening NA Over 314' to 1 -112” 50 Interpass Cleaning Wire wheel, brush, grind Over 1 -112" to 2 -1/2" 150 Overt -1/2" 225 POSTWELD HEAT TREATMENT PWHT Required ❑ t i Tem Min 70 F Max. 550 F Temp. NA Time NA n erpass WELDING PROCEDURE _ LayerlPass. Process Fiilarmkal Class ` Drameter Cur'& Amps ar WFS Volts Travet Speed ; Other_No #es .. _ All I FCAW Select 720 1/16" DCEP 1 243 -297 A 1 -2 -6 -3300 --�� `14 -20 `(3/4 Stickoul a... a+ar•n ,ir"wN NyGp�+O L"wW IMwY 4•� � ♦�O•IrG f•W Myw�Y M+N/.a Yp l+.wlw�W a.0 „++ LrM.o f�a•"• 0•W++ ll 1] � -�^� Nr J.t+.f! N•� >Illt Iw.w� bPGn � 11.40Nw Hn4 + ru14 -M Ouu+i TLY•oCl u 1• W!4 < INl!7 NI Ican C.t ' .M'.N •w.r VI BASE METALS T POSITION Material Spec. Any AWS I or ll to Any AWS I or it Position of Groove All Fillet All Type or Grade Any AWS 1 or 11 to Any AWS I or It Vertical Progression: ® Up ❑ Down Thickness: Groove (in ) .125 Unlimited ELECTRICAL CHARACTERISTICS Fillet (in ).125 Unlimited Transfer Mode (GMAW): Diameter (Pipe, in ) over 24 Unlimited Short- Circuiting ❑ Globular 9 Spray ❑ FILLER METALS AWS Specification A5.20 AWS Classification E71T -1C SHIELDING Flux NA Select Arc 720 Current: AC ❑ DCEP 0 DCEN ❑ Pulsed ❑ Other NA Tungsten Electrode (GTAW): Size NA Type NA TECHNIQUE COZ Stringer or Weave Bead Both Gas Gas C i 2 100 % Multi -pass or Single Pass (per side) Single N --f Electrodes 1 Electrode -Flux (Class) Flow Rate 30-40 CFH u NA Gas Cup Size 0.500 " - 1.00 ", Electrode Spacing: Longitudinal NA Lateral NA PREHEAT Angle NA Preheat Ternp., Min. 70 F Contact Tube to Work, Distance NA Thickness Up to 314" Temperature 32 Peening NA Over 314' to 1 -112” 50 Interpass Cleaning Wire wheel, brush, grind Over 1 -112" to 2 -1/2" 150 Overt -1/2" 225 POSTWELD HEAT TREATMENT PWHT Required ❑ t i Tem Min 70 F Max. 550 F Temp. NA Time NA n erpass WELDING PROCEDURE _ LayerlPass. Process Fiilarmkal Class ` Drameter Cur'& Amps ar WFS Volts Travet Speed ; Other_No #es .. _ All I FCAW Select 720 1/16" DCEP 1 243 -297 A 1 -2 -6 -3300 --�� `14 -20 `(3/4 Stickoul