The Shop Inspection Handbook for Structural Steel Buildings is a useful tool for everyone involved with the inspection of steel fabrication for buildings.

The Handbook provides the essential information for inspecting steel fabrication, including:

• Applicable standards, specifications and references

• Structural steel materials

• Fabrication and tolerances

• Welding and welding materials

• Bolting and bolting materials

• Surface preparation and coatings

The Handbook provides quality information from the numerous standards and codes that govern steel fabrication, including:

• AISC Specification for Structural Steel Buildings

• AISC Code of Standard Practice

• RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts

• AWS D1.1 Structural Welding Code - Steel

• AWS A5.XX Filler Metal Specifications

• ASTM Steel and Fastener Standards

• SSPC Surface Preparation and Coating Standards

Shop inspection personnel should not be expected to have all these references memorized, nor carry these references everywhere they go. The Shop Inspection Handbook for Structural Steel Buildings keeps this information handy and easily accessible.

The Handbook is printed and published in a durable three-ring binder (included), enabling the inspector the opportunity to customize, update and add his/her own information to the provided material.

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Table of Contents

Standards, Specifications and References

AISC: American Institute of Steel Construction
RCSC: Research Council on Structural Connections
AWS: American Welding Society
ASNT: American Society of Nondestructive Testing
ASTM: American Society for Testing and Materials
SSPC: The Society for Protective Coatings
AGA: American Galvanizers Association
ASTM: American Society for Testing and Materials

Structural Steel Inspection

Structural Steels Listed in AISC Specification Section A3.1a
ASTM A6 Shape Groupings
Bar, Plate, Strip and Sheet Nomenclature
ASTM A6 Color Identification System
Product Identification
Steel Compositions - A36, A572, A913, A992
Charpy V-Notch Impact Test for Structural Shapes: Alternate Core Location

Tolerances for Shapes
    Permitted Cross-Sectional Variations for W Shapes
    Mill Straightness Tolerances for W Shapes
    Permitted Variations in Cut Length of W and HP Shapes
    Permitted End Out-of-Square for W and HP Shapes
    Permitted Variations in Cut Length for S, M, C, MC, L, T, Z and Bulb Angle Shapes
    Permitted Variations in Cut Length and End Out-of-Square for Milled Shapes
    Permitted Cross-Sectional Variations for S-Shapes and M-Shapes
    Permitted Cross-Sectional Variations for Channels
    Permitted Variations in Depth for Split Tee Sections
    Permitted Cross-Sectional Variations for Angles

Tolerances for Hollow Structural Sections
    ASTM A53 (Round)
    ASTM A500 (Round)
    ASTM A501 (Round)
    ASTM A618 (Round)
    ASTM A847 (Round)
    ASTM A500 (Rectangular)
    ASTM A501 (Rectangular)
    ASTM A618 (Rectangular)
    ASTM A847 (Rectangular)

Surface Condition and Repair

Steel Fabrication Inspection

Column Length
Member Length (other than columns with finished ends)

Member Straightness Tolerances (other than compression members)
Member Straightness Tolerances (compression members)
Welded Beam and Girder Straightness (with no camber specified)
Welded Beam and Girder Sweep
Welded Column and Truss Straightness
Fabrication Practice

Induced Beam Camber
Induced Camber Tolerances for Beams 50 Feet and Under in Length
Induced Camber Tolerances for Beams Over 50 Feet in Length
Camber Tolerances for Trusses
Welded Beam and Girder Camber (Typical Girder)
Welded Beam and Girder Camber (without Designed Concrete Haunch)

Variation Between Web and Flange Centerlines for Welded Built-Up Members
Welded Beam and Girder Flange Warpage and Tilt
Welded Beam and Girder Depth Variation

Stiffener Location and Fit
Thermal Cutting Quality
Beam Copes and Reentrant Corners
Common Access Hole Details
Surface Reconditioning
Finished Surfaces
Architecturally Exposed Structural Steel

Bolting Inspection

Principal North American Producers and Suppliers of ASTM A325, F1852, and A490 Bolts
Bolt Head Markings
    A325 and A490
    A449 and A354
    A307
Nut Markings
    A563 and A194 
Manufacturer Certification and Packaging Requirements
    A325
    F1852
    A490
    A563
    A959
    F1554

Dimensions
    A325 and A490 Heavy Hex Bolts
    A307, A449 and A354 Hex Bolts
    F1852 Twist-Off-Type Tension-Control Bolts (Button Head Type)
    A563 and A194 Heavy Hex Nuts
    F436 Washers
    F959 Direct Tension Indicators

Suitable A563 Heavy Hex Nuts for A325, F1852 and A490 Bolts
Suitable A194 Heavy Hex Nuts for A325, F1852 and A490 Bolts
Suitable A563 Heavy Hex Nuts for A307 Bolts
Suitable A563 Heavy Hex Nuts for A449 Bolts
Suitable A563 Heavy Hex Nuts for A354 Bolts

Hole-Making
Nominal Bolt Hole Dimensions

Lubrication of Black Fasteners
Lubrication of Galvanized Fasteners
AASHTO Maximum Torque for Rotational-Capacity Testing

Joint Types
    Loading - Shear Only
    Loading - Combined Shear & Tension
    Loading - Applied Tension Only
    Previous Nomenclature

Bolt Tension Calibration Devices
Skidmore-Wilhelm Data

Snug-Tightened Joints

Inspection Procedures-Pretensioned and Slip-Critical Joints Common to all Pretensioning Methods
Systematic Tightening
Pre-Installation Verification Requirements - General
Pretensioned and Slip-Critical Joints - General Required Minimum Bolt Pretension

Turn-of-the-Nut Pretensioning Method
    Inspection Procedure
    Pre-Installation Verification when bolts are long enough to fit into a Skidmore-Wilhelm
    Pre-Installation Verification when bolts are too short to fit into a Skidmore-Wilhelm
    Installation Procedure

Twist-Off-Type Tension Control Bolt Pretension Method
    Inspection Procedure
    Pre-Installation Verification when bolts are long enough to fit into a Skidmore-Wilhelm
    Pre-Installation Verification when bolts are too short to fit into a Skidmore-Wilhelm
    Installation Procedure

Direct Tension Indicator Pretensioning Method
    Inspection Procedure
    Pre-Installation Verification when bolts are long enough to fit into a Skidmore-Wilhelm
    Pre-Installation Verification when bolts are too short to fit into a Skidmore-Wilhelm
    Installation Procedure

Calibrated Wrench Pretensioning Method
    Inspection Procedure
    Pre-Installation Verification when bolts are long enough to fit into a Skidmore-Wilhelm
    Pre-Installation Verification when bolts are too short to fit into a Skidmore-Wilhelm
    Installation Procedure

Arbitration of Disputes
    Torque Method - Long Bolts
    Torque Method - Short Bolts

Determining the DTI Calibration for Calibrated Wrench and Twist-Off Bolt Installation
Methods, and Arbitration of Disputes, when using Short Bolts

Stickout
Requirements for Washers
Reuse of Bolts Previously Pretensioned
Bursts

Welding Inspection

Welding Inspection - General Provisions
    Inspection Prior to Welding
    Inspection During Welding
    Inspection After Welding

SMAW - Shielded Metal Arc Welding
    A5.1 Classification System for Carbon Steel Electrodes for SMAW
    A5.5 Classification Systems for Low-Alloy Steel Electrodes for SMAW
    SMAW Electrode Properties - A5.1
    SMAW Electrode Properties - A5.5
    Permissible Atmospheric Exposure of Low-Hydrogen SMAW Electrodes

FCAW - Flux Cored Arc Welding
    A5.20 Classification System for Carbon Steel Electrodes for FCAW
    A5.29 Classification System for Low Alloy Steel Electrodes for FCAW
    FCAW Electrode Properties - A5.20
    FCAW Electrode Properties - A5.29

GMAW - Gas Metal Arc Welding
    AWS A5.18 Classification System for Carbon Steel Electrodes for GMAW
    AWS A5.28 Classification System for Low Alloy Steel Electrodes for GMAW
    GMAW Electrode Properties - A5.18
    GMAW Electrode Properties - A5.28

Matching Filler Metals
    Notes to Filler Metal Tables - FM-I through IV
    Table FM-I
    Table FM-II
    Table FM-III
    Table FM-IV

Welding Positions
    Fillet Weld Positions on Plate
    Groove Weld Positions on Plate
    Fillet Weld Positions on Tubular Product
    Groove Weld Positions on Tubular Product

WPS - Welding Procedure Specifications
    Typical Elements in a Welding Procedure Specification (WPS)
    Common Tolerances for WPS Adjustment
    SMAW Typical Amperage Ranges
    FCAW Welding Procedure Adjustments

Preheat and Interpass Temperatures
    Notes for Tables PHIT - A through D
    Table PHIT - A
    Table PHIT - B
    Table PHIT - C
    Table PHIT - D

Weld Quality
    Assembly Fit-Up Tolerances for Fillet Welds
    Measurement of Fillet Welds
    Assembly Fit-Up Tolerances and Measurement of Groove Welded Joints
    Fillet Weld Size
    Fillet Weld Convexity
    Fillet Weld Concavity
    Groove Weld Reinforcement
    Groove Weld Underfill
    Location
    Overlap
    Undercut
    Crater
    Spatter
    Surface Slag
    Slag Inclusions
    Piping Porosity
    Subsurface Porosity
    Incomplete Fusion
    Incomplete Joint Penetration
    Cracks

Prequalified Groove Weld Joints
    Identification of Prequalified Groove Weld Joints
    Notes - Prequalified Groove Weld Joint Details
    B-P1a
    B-P1b
    B-P1c
    BC-P2
    BTC-P4
    B-L1a
    B-L1b
    B-U2
    B-U2a
    B-U4a
    TC-U4a

Welder Qualification Using Plate Tests
Electrode Diameters
Welding Symbols
Filter Shades for Welding and Cutting
Safety

Surface Preparation and Coatings Inspection

Shop Cleaning and Painting
ASTM Standards Regarding Surface Preparation and Coatings
Surface Preparation Specifications
Comparison of SSPC and ISO Visual Standards

Instructions for Use of Common Inspection Tools
    Taylor Pocket Sling Psychrometer Model 1330
    Weksler Pocket Sling Psychrometer Model WE-10-140
    Keane-Tator Surface Profile Comparator
    Elcometer Surface Profile Gage Model 123
    Testex Press-O-Film(R) Surface Profile Gage
    "Business Card" Wet Film Thickness Gage
    Gardner Wet Film Thickness Gage Model C (Similar to Erichsen Gage Model 234)
    Erichsen/Rossman Dry Film Thickness Gage Model DF-233
    Erichsen/Rossman Wet and Dry Film Thickness Gage Model WF-296
    Defelsko PosiTest Dry Film Thickness Gage
    Elcometer Dial Dry Film Thickness Gage Model 126