Posted by Phil Zammit, AWS CWI Nace Level 3
California Transportation Department - or CALTRANS - as commonly referred, invokes apprehension and dread among any business that has to deal with them. The experience of Brooklyn Iron Works in performing the Antioch Bridge Seismic Retrofit started very much the same way.
Caltrans functions more or less like the entire State of California's attitude towards auto emissions. I think they have the strictest standards in the nation. For this Antioch Bridge job they, like BIW, found themselves juggling the application of the D1.1 (Structural Steel) and the D1.5 (Bridge) welding codes. Before you even start, they require the submission of a WQCP (Welding Quality Control Plan) and a PQCP (Paint Quality Control Plan). This exercise goes back and forth several times before it is finally approved. Then comes the welding procedures - perhaps the stinky-est part of the process. While they quote the requirements of the "code", they inject several of their own "special requirements" or statements such as "Clause 4.2.2 should read……..". One in particular is the way they interpret PQR essential variables. The Code committee interprets PQR essential variables as applicable to the WPS, not the PQR itself. In other words, run the PQR as you see fit to achieve your goal. Then, once the PQR has been proven successful, when you develop the WPS out of it, that's when you have to abide by the essential variables. Not for Caltrans! If the PQR essential variables say you cannot change the amperage (or travel speed) by more than +/- 10%, you have to abide by that during the performance of the PQR!! When challenged about the impracticality of this type of rule, they conceded to splitting the weld into a root, a fill and a cover zone, thus allowing some leeway. While the whole process can be cumbersome, I have to admit that they are very cooperative and open to sound ideas and arguments. All they are after is a premium product. So is the fabricator because doing the job right the first time is obviously the most cost effective way to do business.
Overall I would have to say dealing with Caltrans is an experience I will never forget.
Phil Zammit
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| Antioch Bridge, CA 2011 |
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| Antioch Bridge, CA 2011 |
