Quality Assurance Support for Hydraulic Steel Structures for Montgomery New River

The U.S. Army Corps of Engineers, Pittsburgh District, currently has a contract for the construction of a new lock chamber which includes the fabrication of a Hydraulic Steel Structures (HSS). Hydraulic Steel Structures are any steel structures used to control or regulate water; they are typically part of a larger navigation or flood control project. During the fabrication of these structures, it is required that they be inspected on a regular basis to ensure compliance with contract requirements set forth by the Plans and Specifications.

Many HSS are comprised of Fracture Critical Members (FCM) which requires specific criteria for fabrication (material toughness, weld processes, procedures and methods, etc.) and inspection in accordance with a Fracture Control Plan (FCP). Part of the acceptance of each fabrication is a thorough Quality Assurance (QA) review of the shop drawings, welding process, weld procedures, weld methods, materials, coating systems, metals used in fabrication, welds, weld results, qualifications of fabricators, welders, coaters, and any other parameters that affect quality of materials and introduce discontinuities of each fabricated item. QA Inspection of these HSS requires specific knowledge in, but not limited to, Army Corps of Engineers HSS Guide Specification, AISC, AWS Bridge Welding Code Dl.5, including FCM designation, AASHTO/NSBA Steel Bridge Collaboration S4.1, ASTM coating standards, and SSPC coating standards. Additionally, the QA inspectors should be well versed in welding and coating procedures and methodologies. The Pittsburgh District Construction Division in conjunction with the Responsible Structural Design Section Engineer and/or Structural Engineers of Record (SEOR) are responsible for the QA Inspections of the HSS to make sure that all the applicable code requirements and quality control procedures are being followed and documented.

Period of Performance

The basic scope of work is twelve-months, with three (3) additional twelve-month option periods to extend the period of performance.

QUALIFICATION REQUIREMENTS

The individual shall be an AWS Certified Welding Inspector in conformance with AWS QC1 with a Dl.5 endorsement and shall have a minimum of ten years' experience relating to steel fabrication with a scope similar to the subject HSS contracts. The individual shall have experience in interpreting the results of each of the NDTs. Non-destructive testing (NDT) personnel shall be qualified to ANSI/ASNT CP-189 NDT Level II or Level III. Offerors shall provide Past Performance References for similar types of service. Submit copies of certificates showing evidence of qualifications or certifications for welding inspectors and NDT personnel.

Provide a certified coating inspector who is listed as either SSPC-PCI Level 2, NACE CIP Level 2, or AMPP Level 2 for all surface preparation and painting activities for hydraulic steel structures. Submit a copy of the applicable Inspector's SSPC, NACE, or AMPP Certificates. Submit all renewals if they occur during the contract performance period.

Renewals must be achieved prior expirations occurring.

Services Required

The Contractor shall provide Quality Assurance Services to the Pittsburgh District (CELRP) for the HSS being fabricated. The Quality Assurance Inspector (QAI) performs verification tests, inspections, and observations to ensure the fabricated items conform to the contract requirements. The QAI should develop consistent communication with the Contracting Officer's Representative (COR) and Project Engineer from the Government throughout the life of the services provided. The QAI shall provide the following tasks as described below:

a. Review the Government QA Plan

b. HSS Shop Fabrication Drawing Review

c. Pre-fabrication Review

d. Shop Weld Control

e. Shop Fabrication Control

f. Shop Coatings Control

g. Nondestructive Evaluation

h. Quality Assurance Inspector (QAI) Reports

• 1. QAI reports will be issued for each inspection performed at the fabrication shop per each site visit. The format of this report shall be submitted to the Government prior to the first site visit for approval (sample available upon request) and include the following at a minimum:
• 1. Date, locations, attendees, shop material control, shop fabrication control, shop welding control, inspections/tests performed, deficiencies, corrected deficiencies, and photographs
• 2. QC activities: narrative of shop activities, QC documents reviewed, nonconformance reports recently issued, etc.
• 3. Inspections performed, including the area of the structure involved and the results of the inspection. Surface preparation operations performed, including the area of the structure involved, the mode of preparation, the kinds of solvent, abrasive, or power tools employed, and whether contract requirements were met.
• 4. Documentation of QAI random NDT performed for each shop visit and evaluation. Inclusive of test location, location map, weld number, etc.
• 5. All reports shall include digital photographs documenting inspection findings. Photographs are required for both acceptable and unacceptable conditions, providing a complete visual record. Photographs shall be captured in full native high resolution. Photographs shall be saved in a universally accessible, non-proprietary format (e.g., JPG, PNG, TIFF). Each photograph shall be clearly labeled with a descriptive file name that includes, at a minimum: Date of photograph, Inspector's initials, Item/Component inspected, and Specific finding (e.g., "Crack - Weld Joint," "Acceptable - Surface Finish") Example:
• 20251028_JDS_MiterGate_CrackWeldJoint.jpg

Site Visits to HSS Manufacturing Facility The following site visits are required:

• As necessary to perform verification testing detailed above during permanent welding and coating of the structures. Advanced coordination with the Contracting Officers Representative prior to site visits should occur to coordinate any attendance by Government personnel. A written report will follow each inspection.
• Fabrication schedules will be provided when available by USACE. Coordination to report for Site Visits is anticipated to be one (1) month advanced notice from the COR. However, shorter notices can occur pending fabrication progress and construction at Montgomery Locks and Dam.
• Site visits to known HSS manufacturing locations will take place at the following addresses, and additional visits to other manufacturing sites may be required:

Precision Build Solutions 5205 Adamo Drive, Tampa, FL 33619

Precision Build Solutions 12781 US Highway 41 South, Gibsonton, FL 33534

Thompson Metal Fab, Inc. 3000 SE Hidden Way, Vancouver, WA 98661

Electro Hydraulic Machinery Co. 2501 John P. Lyons Lane, Pembroke Park, FL 33009

G&G Steel, Inc. 15825 Hwy 243 Industrial Park, Russellville, AL 35653

Engineered Products, Inc. 200 Jones Street, Verona, PA 15147

Advantage Steel & Construction LLC. 2300 S Noah Dr, Saxonburg, PA 16056

ALFAB, Inc. 220 Boll Weevil Circle East Enterprise, Alabama 36330