Master

ROADS and TRAFFIC AUTHORITY NSW
QA SPECI FI CATI ON G1
J OB SPECIFIC REQUIREMENTS
Copyright - Roads and Traffic Authority of New South Wales, 2005
VERSION FOR: Wardell Bridge Sheave
Repair
DATE: J anuary 2008

Wardell Bridge Sheave Repair 1

CONTENTS
1 GENERAL........................................................................................................................................1
1.1 Description of Works.....................................................................................................1
1.2 Structure of the Specification.........................................................................................3
2 SURVEILLANCE ..............................................................................................................................3
3 WORK PROGRAM ...........................................................................................................................4
4 PRICING..........................................................................................................................................4
5 ANNEXURE GL/1 SPECIFICATIONS..............................................................................................1
6 ANNEXURE GL/2 REFERENCE DOCUMENTS.................................................................................
7 ANNEXURE G1/C - SCHEDULES OF HOLD POINTS, WITNESS POINTS AND IDENTIFIED RECORDS...
C1 Schedule Of Hold Points and Witness points...................................................................
8 ANNEXURES G1/D TO G1/L (NOT USED) ......................................................................................
9 ANNEXURE G1/M REFERENCED DOCUMENTS..............................................................................


RTA QA SPECIFICATION G1
JOB SPECIFIC REQUIREMENTS
1 GENERAL

A major overhaul of the Wardell bridge situated approximately 10kms south of Ballina is currently
been undertaken. As part of this work four large counterweight sheaves were removed from the bridge
primarily to assist with the replacement of their bearings and to clean and repaint them. However,
following the sand blasting process, metal loss due to corrosion was observed across the running
surface of the sheaves in various locations and to various degrees. In general 3 of the sheaves have
significant corrosion across the running surface of the sheave, and in particular the outside grooves
appear to be corroded the most. A sketch of where the corrosion has occurred on the sheaves is
detailed in Attachment A. Details of the counterweight sheaves including dimensions given are given
in Attachment B.

Work generally involves the repair of the corroded surface by machining out the corroded profile, then
building up the profile using submerged arc welding and machining back to reform the original
profile. Additionally various NDT will be undertaken throughout the repair process in order to ensure
the quality and integrity of the repair.
It is anticipated that the process set out below will demonstrate that the quality of repair has been
carried out to the highest quality standard and if any defect have occurred as a result of the repair. It is
therefore essential that there is sufficient testing and documentation that demonstrates the repair has
not altered the mechanical and chemical properties of the sheave material. The Contractor can at
stage through the process request additional testing to ensure the above intention is met.
Metal samples of the sheaves have been sent to Anthony Thomas of Bureau Veritas for chemical
analysis. Anthony can be contacted at the address given below to obtain the results:

29 Rosegum Close, Warabrook NSW 2304
PO Box 96, Hunter Region Mail Centre NSW 2310
Tel: +61 (0) 2 4967 2788 Fax: +61 (0) 2 4960 1030
Direct: +61 (0) 2 4908 2502 Mobile: +61 0425253719
Email :tony.thomas@au.bureauveritas.com
Web :http://www.bureauveritas.com.au

The RTA will be responsible for the pickup and delivery of the sheaves only.

1.1 DESCRIPTION OF WORKS

The scope of the repairs involves but is not limited to the following:

a. RTA to deliver 4 off sheaves to the Contractors site facilities, metal analysis report
for each sheave is available, see information above.

b. Sheaves to undergo light sand blast to remove the paint prime coat.
G1 Job Specific Requirements
2 Wardell Bridge Sheave Repair

c. Prior to work commencing a quality plan is to be submitted for approval, this shall
include the following: proposed procedures for blasting, cleaning, testing, preheating
including maintaining the preheat, welding, stress relieving, machining, painting and
any other procedure related to this repair work. Additional it shall include the
Contractors Inspection and Test plan (ITP)

HOLD POINT
Process Held: Sheave testing
Submission Details: Project Quality Plan and Inspection and Test Plan
Release of Hold Point: Approval by Principal

d. Prior to any repairs being undertaken magnetic particle testing to be undertaken to
100% of the rope groves surface and additionally on the other areas of the sheave
surface, locations that fall outside the requirements of AS2574 are to be recorded.

e. Areas that fall outside of AS2574 will require a radiographic test and records retained.
Radiographic testing is to comply with AS3507, Ultrasonic Testing is to comply with
AS 2574.

f. Following the testing a full visual assessment of all 4 sheaves is to be undertaken, this
combined with the above-mentioned testing shall determine the full scope of repairs.
This will include the repairs to the running surface and any other defects, corrosion or
cracks observed in other locations on the sheave. The detailed scope of repairs
together with the results of the testing shall be then submitted to the RTA for
approval together with the documentation discussed earlier.

HOLD POINT
Process Held: Repair of Sheaves.
Submission Details: Details of final scope of work and results of testing.
Release of Hold Point: Approval by Principal

g. Sheaves grooves are to be machined to remove the corroded areas. In other areas
suitable preparation is to be undertaken.

h. Submerged arc welding to be undertaken in accordance with RTA welding
specifications listed below.

i. Approved stress relieving process to be applied.

j. Machine back profile to original.

Job Specific Requirements G1

k. Ultrasonic and X-ray any areas identified as defective from f, and other randomly
chosen locations so that a total of 4 separate areas are radiographed.

l. Carry out 100% ultrasonic and 100% magnetic particle testing to the remainder of the
sheave surface.

m. A final report is to be submitted to the RTA for approval detailing the findings of the
testing ie reporting on lack of fusion, shrinkage or cracking or any other defect
observed as a result of the repair process.

HOLD POINT
Process Held: Prime painting of the sheave.
Submission Details: Final report
Release of Hold Point: Approval by the Principal.

n. Following testing and signoff by the RTA sheaves to be primed painted to the
attached RTA specification B220.

1.2 STRUCTURE OF THE SPECIFICATION
This Specification includes Annexure G1/L that details additional requirements.
1.2.3 Referenced Documents
Unless otherwise specified or is specifically supplied by the Principal, the applicable issue of a
referenced document is the issue current at the date one week before the agreed price, or where no
issue is current at that date, the most recent issue.
Codes, standards, specifications and test methods are referred to in abbreviated form (eg AS 1234).
For convenience, the full titles are given in Annexure GL/1.
2 SURVEILLANCE

RTA surveillance officers shall be present to surveil the work processes in particular, the preheat,
welding and the stress relieving must be witnessed by the RTA Surveillance Officer. The Inspection
and Test Plan, submitted by the Contractor as part of its Project Quality Plan, must address this
requirement.

The hold points for welding procedure qualifications etc. are nominated in B204.

4 Wardell Bridge Sheave Repair

3 WORK PROGRAM
A program of work is to be submitted two weeks in advance in order for RTA to plan its surveillance
of the work.
4 PRICING
TBC


5 ANNEXURE GL/1 SPECIFICATIONS
RTA B200 Major Steel Structural Members
RTA B204 Welding of Bridges and Other Road Structures
RTA B220 Protective Treatment of Steel Work
AS2574 NDT Ultrasonic Testing
AS3507 NDT Radiographic Testing

Edition 2/Revision 1 ROADS and TRAFFIC AUTHORITY NSW
May 2000
QA SPECIFICATION B200
FABRICATION OF MAJ OR STEEL
STRUCTURAL MEMBERS
RNIC-QA-B200
VERSION For: Wardell Bridge
Sheaves
DATE: J anuary 2008
Fabrication of Major Steel Structural Members B200
Ed 2 /Rev 1 i

CONTENTS
CLAUSE PAGE
REVISIONS TO EDITION 2.............................................................................................................1
PROJ ECT SPECIFIC CHANGES.......................................................................................................1
1 GENERAL ...........................................................................................................................1
1.1 Scope...................................................................................................................1
1.2 Reference Documents.........................................................................................1
1.3 Provision for Surveillance..................................................................................2
1.4 Provision for Auditing........................................................................................2
2 ADDITIONAL QUALITY PLAN REQUIREMENTS....................................................................3
2.1 Quality Management...........................................................................................3
2.2 Procedures...........................................................................................................3
2.3 Fabrication Programme.......................................................................................3
2.4 Shop Drawings....................................................................................................4
3 MATERIALS........................................................................................................................5
3.1 General................................................................................................................5
3.2 Testing of Structural Steel for Sections, Plates and Bars...................................5
3.3 Restrictions on Use of Weld Repaired Steel and Steel with Repaired Surface
Defects................................................................................................................5
3.4 Identification of Materials..................................................................................5
3.5 Precutting of Steel by Merchants and Suppliers.................................................6
3.6 Storage of Materials............................................................................................6
3.7 Defective Materials.............................................................................................6
4 FABRICATION.....................................................................................................................7
4.1 Commencement of Fabrication...........................................................................7
4.2 Dimensional Tolerances.....................................................................................7
4.3 Straightening.....................................................................................................18
4.4 Plates and Flats.................................................................................................18
4.5 Cutting and Edge Treatment.............................................................................18
4.6 Repair of Material Surface Defects..................................................................20
4.7 Splices...............................................................................................................20
4.8 Cambering.........................................................................................................20
4.9 Bending.............................................................................................................20
4.10 Identification Marks..........................................................................................21
4.11 End Preparation of Girder Segments................................................................21
4.12 Correction of Distortion....................................................................................21
5 HOLES FOR BOLTING.......................................................................................................21
5.1 General..............................................................................................................21
5.2 Sub-Punched and Sub-Drilled Holes................................................................21
5.3 Reamed or Drilled Holes..................................................................................21
5.4 Holes for Field Connections.............................................................................22
5.5 Alignment.........................................................................................................22
B200 Fabrication of Major Steel Structural Members
ii Ed 2/Rev 1

6 WELDING..........................................................................................................................22
6.1 Welding Requirements......................................................................................22
7 SHOP ASSEMBLY ..............................................................................................................22
8 CERTIFICATION OF FABRICATION.....................................................................................23
9 MARKING, PACKING AND HANDLING...............................................................................23
10 PROTECTIVE TREATMENT.................................................................................................24
11 TRANSPORT TO SITE .........................................................................................................24
ANNEXURE B200/1 - SCHEDULES OF HOLD AND WITNESS POINTS AND IDENTIFIED RECORDS..25
ANNEXURE B200/2 - GUIDANCE ON TECHNICAL REQUIREMENTS..............................................26

LAST PAGE OF B200 IS..............................................................................................................26

(RTA COPYRIGHT)
Ed 2/ Rev 1 1

RTA QA SPECIFICATION B200
FABRICATION OF MAJOR STEEL STRUCTURAL MEMBERS
REVISIONS TO EDITION 2
This document is based on RTA Specification B200 Edition 2 Revision 0 October 1998.
All revisions to RTA B200 Ed 2/Rev 0 (other than minor editorial and project specific
changes) have been indicated by a vertical line in the margin as shown here.
PROJECT SPECIFIC CHANGES
Any project specific changes have been indicated in the following manner:
(a) The text which is additional to the base document and which is included in the
Specification is shown in bold italics eg Additional Text.
(b) Text which has been deleted from the base document and which is not included in the
Specification is shown struck out eg Deleted Text.
1 GENERAL
1.1 SCOPE
This Specification sets out the requirements for materials, fabrication, shop assembly,
marking, packing, handling and transport to the bridge site of steel girders, columns and other
structural members fabricated from plates and/or rolled sections. Welding shall be carried out
in accordance with RTA B204.
This Specification shall not apply to the fabrication of steel railings, lighting columns,
expansion joints, protection angles, bearings or piles.
1.2 REFERENCE DOCUMENTS
Unless otherwise specified the applicable issue of a reference document, except RTA
specifications, shall be the issue current at the date one week before the closing date for
tenders.
Standards, specifications and test methods are referred to in abbreviated form (eg AS 1100).
For convenience the full titles are given below:
Australian Standards
AS 1100 Technical drawings (parts as appropriate)
(RTA COPYRIGHT)
2 Ed 2/ Rev 1

AS 1101.3 Graphical symbols for general engineering - Welding and non-
destructive examination.
AS/NZS 1554.1 Welding of steel structures
AS 2812 Welding, brazing and cutting of metals - Glossary of terms
AS/NZS 3678 Structural steel- Hot-rolled plates, floor plates and slabs
AS/NZS 3679.1 Structural steel- Hot-rolled bars and sections
AS/NZS 3679.2 Structural steel- Welded I sections
AS 4100 Steel Structures
AS/NZS ISO 9002 Quality system - Model for quality assurance in production, installation
and servicing
RTA Specifications
RTA B204 Welding of Bridges and Other Road Structures
RTA B220 Protective Treatment of Steelwork
RTA B260 Erection of Structural Steelwork
RTA Q Quality System
Australian Institute of Steel Construction
Bolting of Steel Structures, Third edition - includes limit states provisions to AS 4100.
Welding Technology Institute of Australia Technical Notes
Technical Note 5 Flame Cutting of Steels
Technical Note 19 Cost Effective Quality Management for Welding TN 19-95
1.3 PROVISION FOR SURVEILLANCE
The Superintendent shall have full liberty during all working hours to enter the fabrication
shop for the purpose of surveillance.
The Contractor shall provide reasonable assistance, suitable accommodation for the
Superintendent at the fabrication site and full access to the works for this purpose.
Alternatively the Superintendent may approve office accommodation provided by the
Contractor in an existing building in the vicinity of the fabrication shop.
1.4 PROVISION FOR AUDITING
When required for the purpose of auditing, the Contractor shall lay out and arrange the
individual members or units so that identification marks on each may be readily distinguished
and so that each member or unit is accessible. The Contractor shall assist by turning the
members or parts to permit examination on all sides.
The Contractor shall bear the cost of all labour, tools, scaffolding and other equipment
required for this purpose.
The Contractor shall also make available at the site of the fabrication work suitable facilities
to accommodate an audit team of three persons for Scheduled Audits. The cost of providing
such facilities shall be borne by the Contractor.
(RTA COPYRIGHT)

Ed 2/ Rev 1 3

2 ADDITIONAL QUALITY PLAN REQUIREMENTS
2.1 QUALITY MANAGEMENT
The Contractor shall ensure that the quality system operating for the work complies with the
requirements of RTA Q and the steel fabricator implements a quality system complying with
AS/NZS ISO 9002.
2.2 PROCEDURES
Details of the procedures for assembly and fabrication shall be submitted with the PROJ ECT
QUALITY PLAN. These procedures shall be comprehensive and shall cover all aspects of
the work.
All procedures, work instructions etc. shall make reference to and include appropriate safe
working practices and requirements.
The procedures shall include, but not be limited to:-
(a) Assembly including dimensional control and details of manufacturing jigs
(b) Cambering
(c) Repairs and corrections allowed under this Specification
(d) Shop assembly
(e) End finishing for field joints
(f) Transport, handling and storage, including measures to prevent distortion and damage
to the steelwork and its protective coating.
When RTA B220 and/or RTA B260 are included in the Specification, the procedures required
under the Clause "Painting Procedures and Programming" in B220, and the Clauses "Erection
Equipment" and "Erection Method" in B260 shall be included with the above.
2.3 FABRICATION PROGRAMME
The Contractor shall submit a fabrication programme as part of its PROJ ECT QUALITY
PLAN (refer to RTA Q) showing the proposed sequence of operations and the proposed time
required for all members and/or parts, which shall be identified by name and mark.
(RTA COPYRIGHT)
4 Ed 2/ Rev 1

2.4 SHOP DRAWINGS
The Contractor shall prepare shop drawings for the fabrication of all members. The
Contractor shall arrange for these drawings to be verified by personnel other than those
directly involved in the drafting of the shop drawings [refer to RTA Q Clause 4.1.2(c)].
The details shown on the shop drawings shall be consistent with the Drawings and shall
comply with the following:-
(a) The marking plan shall show the location, as appropriate, of Abutment A and B,
Upstream and Downstream, span numbers, pier numbers and North orientation. Where
the shop drawings depict any part of the Contract Drawings that part shall be clearly
identified on the shop drawings.
(b) Shop drawings shall conform to AS 1100 as appropriate. Drawings showing only the
cutting dimensions of webs, flanges and the like shall not be considered as shop
drawings.
(c) Welding and cutting definitions shall conform to AS 2812.
(d) Welding symbols shall conform to AS 1101.3.
(e) Complete information regarding the location, type, category, size and extent of all
welds shall be clearly shown on the shop drawings. These drawings shall clearly
distinguish between shop and field welds.
(f) J oints or groups of joints in which it is especially important that the welding sequence
and technique of welding be carefully controlled to minimise shrinkage stresses and
distortion shall be noted on the drawings. J oints where no welding is permitted shall
also be clearly indicated. Weld lengths specified on the drawings shall be the required
effective lengths.
(g) Each member shall be clearly identified with the identification marks shown on the
Drawings. Each type of component shall be further identified to readily distinguish it
from all other types.
(h) For assemblies, all associated bolting, accessories and/or joining details shall be shown
on the shop drawings.
(i) Details shall be shown of all holes and attachments required for temporary work such as
formwork and lifting lugs. Methods of sealing all such holes shall be shown.
Four copies of the shop drawings, certified by the Contractor as complying with the above
requirements, shall be submitted to the Superintendent at least ten (10) working days before
fabrication commences.
The Contractor shall be responsible for the correctness of the shop drawings. Submission of
the shop drawings to the Superintendent shall not relieve the Contractor of its responsibilities
under the Contract.
The Contractor shall submit to the Superintendent two copies of the "Work as Executed" shop
drawings within four (4) weeks of the completion of fabrication and erection of the steel
members.
(RTA COPYRIGHT)

Ed 2/ Rev 1 5

3 MATERIALS
3.1 GENERAL
All materials supplied must comply with standards and specifications shown on the drawings
unless otherwise specified.
3.2 TESTING OF STRUCTURAL STEEL FOR SECTIONS, PLATES AND BARS
All supplied structural steel shall be manufactured by companies using quality systems
certified to AS/NZS ISO 9002 by a third party accredited by the J oint Accreditation System
of Australia and New Zealand. The Contractor shall ensure that all materials comply with the
relevant Australian Standards and specifications. A mill certificate with appropriate NATA
registration from the material supplier shall constitute documentary evidence of compliance.
3.3 RESTRICTIONS ON USE OF WELD REPAIRED STEEL AND STEEL WITH
REPAIRED SURFACE DEFECTS
Subject to the prior approval of the Superintendent, steel containing surface defects may be
repaired by welding in accordance with the RTA B204. The Contractor shall submit details of
any proposal to use weld repaired steel, including the proposed location in the structure, prior
to use of such steel. Any piece of steel containing a surface defect which has been repaired
by welding shall not be used in a part of the structure which is subject to significant tensile
stress, unless the steel has been normalised after welding.
HOLD POINT
Process Held: Use of weld repaired steel.
Submission Details: Details of weld repaired steel proposed to be used in the work
shall be submitted at least three (3) working days before such
steel is to be used.
Release of Hold Point: The Superintendent will examine the submitted documents prior
to authorising the release of the Hold Point

All grinding of surface imperfections and defects shall produce a surface roughness similar to,
and blend with, the finish on surrounding areas. Any significant surface defect areas
corrected by grinding shall not be located on the outside (visible) surface of outside members.
Such grinding shall be carried out by a grinding wheel of grain size No. 46 or finer.
3.4 IDENTIFICATION OF MATERIALS
The Contractor shall establish and maintain a comprehensive system of identification records
which shall be kept up to date. The records shall include which items are cut from each of
piece of material and where each item is used in each member. Two copies of these records
shall be forwarded to the Superintendent on request.
(RTA COPYRIGHT)
6 Ed 2/ Rev 1

3.5 PRECUTTING OF STEEL BY MERCHANTS AND SUPPLIERS
Any cutting or shaping of steel plates and sections after the steel has left the steel mill shall be
regarded as fabrication work and shall be carried out in accordance with the requirements of
this Specification.
3.6 STORAGE OF MATERIALS
All steel, whether fabricated or not, shall be stored in such a manner that it will not be bent or
damaged and will be adequately protected against corrosion. Generally, storage at least 200
mm above the ground on platforms, slabs, or other supports under cover will be satisfactory.
3.7 DEFECTIVE MATERIALS
Where defects arising from the manufacture of the steel become evident at any stage of
fabrication, the steel shall be deemed to be nonconforming.
(RTA COPYRIGHT)

Ed 2/ Rev 1 7

4 FABRICATION
4.1 COMMENCEMENT OF FABRICATION
The Contractor shall give at least five (5) working days advance notice in writing before
commencing fabrication work, and this shall be allowed for in its programme.
HOLD POINT
Process Held: Commencement of fabrication work.
Submission Details: Procedures as detailed in Clause 2.2, Items (a), (b), (c) and (d)
and shop drawings as detailed in Clause 2.4 shall be submitted
at least ten (10) working days prior to commencement of
fabrication work.
to authorising the release of the Hold Point.
4.2 DIMENSIONAL TOLERANCES
Member dimensions shall be measured for conformance when all fabrication and heating
operations are completed and the member has cooled to a uniform temperature, and prior to
protective treatment.
Measurements of length shall be checked with a standard steel measuring tape or band and
corrected to a standard temperature of 20C.
Dimensions of fabricated members, in addition to complying with the tolerances stated in the
relevant Standard, shall be within the tolerances stated hereunder unless tighter tolerances are
called for on the Drawings or otherwise specified in which case such tighter tolerances shall
govern. Tolerances expressed as values shall be taken as occurring in either direction.
Tolerances expressed as +values shall be taken as occurring only in the direction indicated.
Where a tolerance is not specified hereunder or otherwise specified it shall be 2 mm.
Where parts are to fit together on assembly or erection, tolerances shall be such that all parts
fit together within the tolerances as specified.
(RTA COPYRIGHT)
8 Ed 2/ Rev 1

4.2.1 Cross Sections
Tolerances on any cross-section of a rolled section or a plate shall comply with the
requirements of AS 3678 or AS 3679 as appropriate.
For built-up sections the deviations from the specified dimensions shall not exceed the
following:

Dimension Application Tolerance
(a) Depth of a section - d
(see Figure B200.1)

for d 900 mm:
for d > 900 mm:

at splices:
(Dimension d is measured along the
centreline of the web)
3 mm
the lesser of :
6 mm or d/300 mm
1.5 mm
(b) Width of flange - b
f

(see Figure B200.1)
for all values of flange widths:
(Direction of measurement is parallel
to the plane of the flange)
6 mm
(c) Out of square of an
individual flange
- a
1
or a
o

(see Figure B200.1)
for a
1
or a
o
:

(Direction of measurement is parallel
to the centreline of the web)
the greater of:
3 mm or b
f
/200 mm

b
f
a
1
d
a
o
Fig B200.1 Tolerances on cross section
(RTA COPYRIGHT)

Ed 2/ Rev 1 9

(d) Out of flatness of a
web -
w

(see Figure B200.2)
unstiffened web:
(
w
measured on a gauge length
of d
1
in the direction of d
1
)
stiffened web with intermediate
transverse stiffeners:
This tolerance shall not apply to
webs with longitudinal stiffeners
w
measured on a gauge length of
b in the direction of b where b
shall be taken as d
1
or spacing
between the enclosing stiffeners
whichever is the lesser
(Direction of measurement is at a
right angle to the web surface)
d
1
/150 mm

b

/100 mm
(e) Deviation from
verticality of a web at
a support -
v

(see Figure B200.2

v
:
This tolerance shall not apply
to box girders
right angle to the plumb line)
the greater of:
3 mm or d /300 mm
(f) Off centre of a web - e
(see Figure B200.3)
e:
6 mm

v
d
1 d
w
Fig B200.2 Tolerances on web

(RTA COPYRIGHT)
10 Ed 2/ Rev 1

(g) Deviation from shape
of box section
(see Figure B200.4)
at diaphragm: the greater of:
5 mm or
(a
2
+a
3
)/400 mm
At locations of welded or bolted cross girders or bracing, all parts shall fit together on
erection in accordance with the Specification.

Fig B200.3 Tolerance on
off centre of a web
e
Nominal web
centreline
a
2
a
3
Fig B200.4 Tolerance on
shape of a box girder
(RTA COPYRIGHT)

Ed 2/ Rev 1 11

(h) Out of flatness of a
flange -
f

(see Figure B200.5)

f
:
This tolerance shall not apply to
box girders or flanges comprising
plate panels
The gauge length is the lesser of
the section depth or spacing
between stiffeners as appropriate.
(Direction of measurement is the
plumb line)
the lesser of:
3 mm or b
f
/150 mm

f
f
Cross section
Fig B200.5 Tolerance on out of flatness of a flange
b
f
Elevation
Flange edge
f

(RTA COPYRIGHT)
12 Ed 2/ Rev 1

(i) Flatness and finish of
bearing seats
The bearing seat shall be that area
of plate which bears directly on a
bearing or bearing plate.
As nominated by the
manufacturer
The Contractor shall obtain the tolerances required for the flatness and finish of bearing
seats from the manufacturer of the bearings prior to commencement of fabrication.
(j) Twist deviation - D
t

(see Figure B200.6)
Away from bearing seat
locations, the angular rotation
of any cross-section expressed
in terms of total horizontal
deviation D
t
of any line within
the section relative to its
position shown in the
Drawings:
shall not exceed:
1 mm per 100 mm depth
of section (unless noted
otherwise on the Drawings
or in the Specification), or
15 mm,
whichever is the lesser.
At bearing seat locations, D
t
:

(Direction of measurement is at right
angles to the plumb line)
shall not exceed:
0.5 mm per 100 mm
depth of section or
7.5 mm,
whichever is the lesser.

Fig B200.6 Twist deviation of cross section
D
t
Section position as
shown in Drawings
Actual section
position
d

(RTA COPYRIGHT)

Ed 2/ Rev 1 13

4.2.2 Girders
For girder segments which are to be connected at the bridge site to form continuous girders,
the length of each girder segment and/or the location of bolt holes if any shall be such that all
parts will fit together on erection.
To satisfy these tolerances, due allowance shall be made during fabrication for any change in
dimensions which may result from the erection procedure; refer to Clause 4.11.

(a) Length overall length 10 m:
overall length > 10 m:
centreline to centreline of
bearings 10 m:
centreline to centreline of
bearings >10 m:
2 mm
4 mm

2 mm

4 mm
(b) Straightness
(see Figure B200.7)
Camber:

Sweep:
the lesser of:
+10 mm or +L/1000 mm
the greater of:
3 mm or L/1000 mm

where L is the length of the girder in the completed structure or
the length of each fabricated piece.
At the location of welded or bolted cross girders or bracing, all
parts shall fit together on erection.
Camber Sweep
(a) Camber
Plan view with web horizontal
(b) Sweep
Plan view with web vertical
Fig B200.7 Tolerances on camber and sweep of girders

(RTA COPYRIGHT)
14 Ed 2/ Rev 1

4.2.3 Compression members

(a) Length deviation of member from its detailed
length:
2 mm
(b) Straightness deviation from either principal axis:
(Direction of measurement is at right angles
to a straight line between the two ends)
the greater of:
3 mm or L/1000 mm
(c) Full contact
splice
maximum clearance between abutting
bearing surfaces:
shall not exceed:
0.5 mm over 67% of
contact area , or
1 mm

4.2.4 Tension members

(a) Length overall length 10 m:
overall length > 10 m:
2 mm
4 mm
(b) Straightness deviation from either principal axis:
(Direction of measurement is at right angles
to a straight line between the two ends)
the greater of L/500 mm

(RTA COPYRIGHT)

Ed 2/ Rev 1 15

4.2.5 Straightness of stiffeners
Straightness of longitudinal compression flange stiffeners in box girders and box compression
members and all web stiffeners in plate and box girders shall be as follows:

(a) in-plane deviation
-
sx

(see Figure B200.8)
sx
:
where:
G is the gauge length, equal to L,
and
L is the maximum clear length of
stiffener in mm
right angle to a straight line between
the two ends)
the greater of:
2 mm or G/750 mm,

(b) out-of-plane deviation
from specified shape
-
sy

(see Figure B200.9)
sx
:
where
G is the gauge length and is the
lesser of 2b or L;
b is the shortest side in mm of
plate panel in which the stiffener
is one of its boundaries; and
L is the maximum clear length of
stiffener in mm
right angle to a straight line between
the two ends)
the greater of:
2 mm, or

G
f
y
450 250
mm
(RTA COPYRIGHT)
16 Ed 2/ Rev 1

Stiffener
Web
sx
Top flange
sx
Web
Stiffener
In plane deviation of stiffener
in a plate girder
In plane deviation of stiffener
in a box girder
Fig 200.8 Tolerances on in plane straightness of stiffeners
Flange
L
L

Flange
Top flange
Web
Web
sy
sy
Elevation Section - top view
Out of plane deviation of
stiffener in a plate girder
Out of plane deviation of
stiffener in a box girder
Fig B200.9 Tolerance on out of plane straightness of stiffeners

(RTA COPYRIGHT)

Ed 2/ Rev 1 17

4.2.6 Flatness of plate panels

(a) out of flatness -
x

(see Figure B200.10)
for
b
t f
y
> 30
250
,
x
:
the greater of:
G
f
y
450 250
or 3 mm
(b)
for
b
t f
y
30
250
,
x
:
no requirement unless
otherwise specified

where:
G is the gauge length in mm and is the lesser of a or 2b;
a is the length of the longer side of the plate panel;
b is the length of the shorter side of the plate panel;
b
t f
y
30
250
is the specified yield strength of the steel in MPa; and
t is the plate thickness
(Direction of measurement is at a right angle to a straight line
between the two ends)

Section A-A
Fig B200.10 Tolerance on out
of flatness of plate panels
Plate
Stiffener
G
a
Flange
Web
a
b
Stiffeners
Measurement
direction
Stiffeners
Plate
A A
a
b
Measurement
direction
x

(RTA COPYRIGHT)
18 Ed 2/ Rev 1

4.2.7 Alignment at splice joints

(a) Butt welded joint root faces - z
(see Fig B200.11)
z : 1.5 mm
(b) Bolted joints members shall be aligned such
that all parts fit on erection

Butt weld root face
Fig B200.11 Tolerance on alignment
of butt welded joints
z

4.3 STRAIGHTENING
Before any marking out or other work is done, all plates shall be made flat and all bars and
sections made straight and free from twist so that, when assembled, adjacent surfaces shall be
in close contact throughout. The methods adopted for the above work shall be such as to not
damage the material.
4.4 PLATES AND FLATS
Where indicated on the drawings, plates and flats shall be aligned in such a manner that the
main stresses will be in the direction of rolling.
Stripped plates shall be finished square, straight and plane without burrs or imperfections.
Plates shall be marked before cutting so that the cut pieces are identifiable at all times.
4.5 CUTTING AND EDGE TREATMENT
4.5.1 General
Steelwork may be cut by flame cutting, sawing or shearing unless otherwise specified below.
Surfaces produced by such cutting shall be representative of good workmanship, finished
square (unless a bevelled edge is called for), true to the required dimensions and free from
(RTA COPYRIGHT)

Ed 2/ Rev 1 19

defects, such as excessive roughness, which would impair the service performance or
seriously interfere with subsequent fabrication and protective treatment.
Shearing shall not be used for main plates, reinforcing plates, main gussets, splice plates and
diaphragms except in a direction perpendicular to the direction of their main stresses.
Shearing of items over 16 mm thick shall not be carried out when the item is to be galvanised
and subject to tensile stresses unless the item is subsequently stress relieved. Distortions
caused by shearing shall be removed.
Re-entrant corners shall be smoothly rounded to a radius of 20 mm.
Unless shown otherwise on the Drawings, all corners on exposed edges shall be rounded to a
radius of approximately 1.5 mm, except where such edges are subsequently to be welded.
Rolled edges need not be rounded provided the corners have a similar radius.
Flame cutting shall be carried out wherever possible by machines which are mechanically
guided and moved at uniform speed. Hand cutting shall only be used for secondary cuts, hole
preparation, repairs and other work where machine cutting is not possible.
Any cut surface to be incorporated in a weld shall comply with AS 1554.1 and the depth of
isolated gouges shall not be greater than 2 mm.
Flame cutting of plates, sections and other components with surfaces which will be used in
the "as-cut" condition, shall be carried out with procedures giving minimum reduction in
properties at the cut surface and shall satisfy the requirements given below.
Any cut surfaces to be used in the "as cut" condition shall have:-
(a) a surface roughness (CLA) not greater than 12 m (ie WTIA Roughness Class 2 as
shown in WTIA Technical Note 5).
(b) a depth of isolated gouges not greater than 3 mm. All gouges less than 3 mm in depth
shall be repaired as specified in Clause 4.5.2 below.
(c) a surface quality which will not impair subsequent fabrication and protective coating
requirements. Note that the flame cut surface may require a light surface grind to
render it suitable for subsequent protective coating requirements.
4.5.2 Repairs
Cut surfaces may be ground to obtain the specified surface roughness. Grinding marks shall
be parallel to the direction of the cut.
For steel with a flame cut surface which is to be used in the "as-cut" condition, edges with
occasional striations or gouges which are less than 3 mm in depth may be accepted provided
that these defects are corrected by grinding. The resulting depression, which shall not exceed
3 mm, shall be tapered out smoothly for a distance of at least 75 mm on both sides of the
defect.
(RTA COPYRIGHT)
20 Ed 2/ Rev 1

4.6 REPAIR OF MATERIAL SURFACE DEFECTS
Any defects, score marks or bruises found during fabrication shall be ground out as detailed
in Clause 3.3.
4.7 SPLICES
Shop splices in the component parts of welded members shall be made before the parts are
assembled.
Where splice locations are not shown on the Drawings or where splices at locations other than
those shown on the Drawings are proposed, details of the design and position of the proposed
splices shall be submitted for the approval of the Superintendent.

HOLD POINT (For members with splice locations nominated by the
Contractor)
Process Held: Commencement of fabrication of relevant members.
Submission Details: Details of design and locations of proposed splices to be used in
the work shall be submitted at least ten (10) working days prior
to the proposed commencement of fabrication.
Release of Hold Point: The Superintendent will examine the submitted proposal and, if
approved, will authorise the release of the Hold Point
4.8 CAMBERING
Camber in a built-up section shall be obtained by cutting webs to the shapes shown in the
Drawings.
Cambering of rolled sections and adjustment to the camber in built-up sections shall be
carried out to the requirements of Clause 4.12.
If, in the measurement of camber, the member spans between supports, allowance shall be
made for the deflection due to self weight. This allowance shall be calculated by an Engineer
who is eligible for Corporate Membership of the Institution of Engineers, Australia.
4.9 BENDING
Bending and forming plates or sections during fabrication shall conform to the manufacturer's
recommendations and/or the relevant Australian Standard.
(RTA COPYRIGHT)

Ed 2/ Rev 1 21

4.10 IDENTIFICATION MARKS
Each component shall be metal stamped with an identification mark which remains
recognisable after protective treatment, but which is located in a hidden or inconspicuous
position after erection.
4.11 END PREPARATION OF GIRDER SEGMENTS
Where field joints are required, the ends of all girder segments shall be finished true, as
shown on the Drawings, to a tolerance of 1 mm over the depth and width of the girder.
Surveyed datum lines shall be used to ensure the correct horizontal and vertical alignment of
the girder segment end while positioned as required in the completed structure.
The preparation of the edges of the end plates for field welded splices shall be carried out
subsequent to the end finishing.
One girder segment length shall be left long for final cutting to length on site or during shop
assembly so as to attain the required overall length tolerances.
4.12 CORRECTION OF DISTORTION
Distortion resulting from welding and fabrication may be corrected by mechanical or thermal
means in accordance with the methods and conditions given in RTA B204 Clause 6.3.1.4.
5 HOLES FOR BOLTING
5.1 GENERAL
The diameters of the bolt holes shall be in accordance with the requirements of AS 4100,
except that, for M24 bolts and smaller, this shall be 2 mm greater than the diameters of the
bolts shown on the Drawings unless otherwise specified.
Holes may be either drilled full-size or reamed to full-size after sub-drilling or sub-punching.
5.2 SUB-PUNCHED AND SUB-DRILLED HOLES
Sub-punched and sub-drilled holes shall be smaller in diameter than the nominal diameter of
bolts by 3 mm.
For sub-punched holes the diameter of the die shall not exceed the diameter of the punch by
more than 1 mm. Holes shall be clean cut, without torn or ragged edges.
5.3 REAMED OR DRILLED HOLES
Reamed or drilled holes shall be cylindrical and perpendicular to the face of the member
unless otherwise shown on the Drawings. Reaming and drilling shall be done by mechanical
means.
(RTA COPYRIGHT)
22 Ed 2/ Rev 1

Connecting parts shall be assembled and held securely while being reamed or drilled and shall
be match-marked before separating the parts.
All burrs shall be removed. If necessary, assembled parts shall be taken apart for removal of
burrs caused by drilling and reaming.
5.4 HOLES FOR FIELD CONNECTIONS
Holes for field connections and field splices of main members shall be reamed or drilled with
the members assembled in the shop in their correct relative positions.
All adjoining main members in an assembly shall be assembled before reaming or drilling is
commenced. All joints and associated splice plates shall be matchmarked before the structure
is dismantled.
Holes for field connections of minor members may be reamed or drilled with the members
assembled. Alternatively these connections may be sub-punched or sub-drilled and reamed or
drilled from the solid to a hardened steel template not less than 25 mm thick, and all
corresponding holes in the members to which they connect shall be reamed or drilled to the
same template.
5.5 ALIGNMENT
All matching holes in any contiguous group shall register with each other so that a gauge or
drift 2 mm less in diameter than the holes shall pass freely through the assembled contact
faces at right angles to them.
The Contractor shall be responsible for the accuracy of all holes regardless of variations in
dimensions of rolled sections or tolerances allowed in fabrication.
6 WELDING
6.1 WELDING REQUIREMENTS
All welding (including that for shear stud connectors) shall be carried out in accordance with
RTA B204.
7 SHOP ASSEMBLY
Shop assembly will not be required for girders for simply supported girder spans less than
25 m in length unless otherwise specified.
For spans 25 m or greater in length with steel cross girders or cross frames, the first two lines
of girders (ie. abutment A to abutment B) fabricated shall be shop assembled to check the
fabrication procedures, the fit of the components and verify the suitability of the templates
used in fabrication.
(RTA COPYRIGHT)

Ed 2/ Rev 1 23

The Contractor shall supply certification of satisfactory shop assembly.
8 CERTIFICATION OF FABRICATION

HOLD POINT
Process Held: Commencement of Marking, Packing and Handling.
Submission Details: Certification and fabrication records verifying:
that each item fabricated conforms to the requirements of the
Drawings and this Specification; and
that all fabrication defects particularly those related to welding
have been treated in accordance with the requirements of this
Specification and RTA B204,
at least ten (10) working days prior to the marking, packing and
handling of the fabricated member
9 MARKING, PACKING AND HANDLING
Each part shall be marked with durable distinguishing marks. Paint of different colours shall
be used to distinguish similar parts.
Two copies of drawings showing these markings shall be supplied to the Superintendent when
the steelwork is despatched.
All open joints, ends and projecting parts shall be protected from damage in transit in such a
manner as to stiffen the member and prevent distortion.
Shipping marks shall be carefully stencilled on each piece in a conspicuous position.
Members shall have their mass clearly marked upon them.
Special care shall be taken in the packing and methods of support and lifting during handling
of all structural steelwork to prevent distortion or damage to the steelwork and its protective
coating.
HOLD POINT
Process Held: Transport to other yards or to site.
Submission Details: Certification of shop assembly and procedures required in
Clause 2.2, Items (e) and (f) shall be submitted at least ten (10)
working days prior to the transport of any of the fabricated
members to any other place
(RTA COPYRIGHT)
24 Ed 2/ Rev 1

10 PROTECTIVE TREATMENT
Protective treatment shall be carried out in accordance with RTA B220.
11 TRANSPORT TO SITE
The Contractor shall ensure that during transport of any part of the work, there will be no
distortion, loss of camber or damage to the steelwork and its protective coating.
(RTA COPYRIGHT)

Ed 2/ Rev 1 25

ANNEXURE B200/1 - SCHEDULES OF HOLD AND WITNESS POINTS
AND IDENTIFIED RECORDS

1. Schedule of Hold and Witness Points

CLAUSE HOLD/WITNESS
POINT
DESCRIPTION
3.3 HOLD Weld repaired steel
4.1 HOLD Commencement of fabrication
4.7 HOLD Proposal for splices
8 HOLD Marking, packing and handling
9 HOLD Transport to other yards or to site

2. Schedule of Identified Records
The records listed below are Identified Records for the purposes of RTA G2 Clause 19 and
RTA G7 Clause 6.

Clause Description of the Identified Record
2.4 Shop drawings certified as complying with requirements as listed

2.4 "Work as executed" shop drawings

3.3 Details of weld repaired steel to be used in the work

3.4 Identification records for each piece of material (on request by the
Superintendent)

4.1 Procedures and shop drawings as detailed

4.7 Details of design and location of proposed splices

8 Certification and fabrication records verifying that each item complies
with the Drawings and Specification and that all fabrication defects have
been treated

(RTA COPYRIGHT)
26 Ed 2/ Rev 1

ANNEXURE B200/2 - GUIDANCE ON TECHNICAL REQUIREMENTS
Guidance on some of the requirements of RTA B200 is available in the following cross-
referenced publication:

Requirement B200 Clause Guidance Publication
Quality system 2.1 SAA HB 66
Welding procedures 2.1 WTIA Technical Note 19
Bolting 5.1 AISC Bolting of Steel Structures

Referenced Guidance Publications


Technical Note 19 Cost Effective Quality Management for Welding

Australian Institute of Steel Construction

Bolting of Steel Structures, Third edition - includes limit states provisions to AS 4100.

Other Publications

SAA/SNZ HB66 Quality Assurance Explained.
.

Edition 2 / Revision 1 ROADS and TRAFFIC AUTHORITY NSW
February 2007
QA SPECI FI CATI ON B204
WELDING OF BRIDGES AND
OTHER ROAD STRUCTURES
Copyright-Roads and Traffic Authority of New South Wales, 2006
RNIC-QA-B204
VERSION For: Wardell Bridge
DATE: J anuary 2008
.
(RTA COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
Ed 2 / Rev 1 1

CONTENTS
CLAUSE PAGE
FOREWORD..................................................................................... ERROR! BOOKMARK NOT DEFINED.
RTA Copyright and Use of this Document.................................. Error! Bookmark not defined.
Revisions to Edition 2.................................................................. Error! Bookmark not defined.
Project Specific Changes............................................................. Error! Bookmark not defined.
1 GENERAL........................................................................................................................................3
1.1 Scope..............................................................................................................................3
1.3 Applicability of Referenced Standards...........................................................................4
2 ADDITIONAL QUALITY PLAN REQUIREMENTS...............................................................................4
2.1 Quality Management and Supervision...........................................................................4
2.2 Nomination of Personnel ................................................................................................5
2.3 Technical Procedures......................................................................................................5
3 SAFETY REQUIREMENTS................................................................................................................6
3.1 Personnel ........................................................................................................................6
3.2 Equipment.......................................................................................................................6
4 WELDING PROCEDURES.................................................................................................................6
4.1 General ...........................................................................................................................6
4.2 Qualification of Welding Procedure...............................................................................6
5 PERSONNEL QUALIFICATIONS........................................................................................................8
5.1 General ...........................................................................................................................8
5.2 Welding Supervisor(s)....................................................................................................9
5.3 Inspector(s).....................................................................................................................9
5.4 Welders.........................................................................................................................10
6 WELDING OF STEELWORK............................................................................................................10
6.1 General .........................................................................................................................10
6.2 Consumables.................................................................................................................15
6.3 Workmanship...............................................................................................................15
6.4 Inspection of Welds......................................................................................................17
6.5 Non-conforming Welds................................................................................................17
7 STUD WELDING............................................................................................................................18
7.1 General .........................................................................................................................18
7.2 Certification of Studs....................................................................................................18
7.3 Qualification of Operators............................................................................................18
7.4 Commencement of Stud Welding.................................................................................19
7.5 Testing of Finished Stud Welds...................................................................................19
7.6 Alternative Welding Processes and Repair...................................................................19
8 WELDING OF REINFORCING STEEL FOR CONCRETE.....................................................................20
8.1 General .........................................................................................................................20
8.2 Additional Requirements..............................................................................................20
9 WELDING OF HIGH STRENGTH QUENCHED AND TEMPERED STEELS..........................................21
9.1 General .........................................................................................................................21
9.2 Additional Requirements..............................................................................................21
B204 Welding of Bridges and Other Road Structures
2 Ed 2 / Rev 1

ANNEXURE B204/A PROJ ECT SPECIFIC REQUIREMENTS.....................................................................23
A1 Requirements for Special Test Piece(s)........................................................................23
ANNEXURE B204/B PAYMENT.......................................................................................................23
ANNEXURE B204/C - SCHEDULES OF HOLD AND WITNESS POINTS AND IDENTIFIED RECORDS...........24
C1 Schedule of Hold and Witness Points...........................................................................24
C2 Schedule of Identified Records.....................................................................................24
ANNEXURE B204/D (NOT USED) .........................................................................................................24
ANNEXURE B204/E - LIST OF CROSS-REFERENCES TO APPENDIX D OF AS/NZS 1554.1......................25
ANNEXURE B204/F - GUIDANCE ON TECHNICAL REQUIREMENTS ........................................................25
ANNEXURE B204/G MODEL CHECKLIST TACK WELDING AND WELDING OF STEEL
REINFORCEMENT..........................................................................................................................27
ANNEXURE B204/H MODEL WELDING PROCEDURE QUALIFICATION RECORDS AND WELDING
PROCEDURE SPECIFICATIONS FOR TACK WELDING AND WELDING OF STEEL REINFORCEMENT28
ANNEXURES B204/I TO B204/L (NOT USED) .......................................................................................47
ANNEXURE B204/M - REFERENCED DOCUMENTS.................................................................................47
LAST PAGE OF RTA B204......................................................................................................................47
Welding of Bridges and Other Road Structures B204
Ed 2 / Rev 1 3

WELDING OF BRIDGES AND OTHER ROAD STRUCTURES
1 GENERAL
1.1 SCOPE
This Specification sets out the minimum requirements for the preparation, welding, inspection and
testing, and final acceptance of fabricated steel structures which are covered by technical
specifications requiring compliance with this Specification.
Unless otherwise specified on the Drawing(s) or within this Specification, all welding must be in
accordance with AS/NZS 1554.1 category SP.
Where this Specification refers only to AS/NZS 1554, this shall mean a reference to the appropriate
part of this Standard listed in Annexure B204/M.
Welds not carried out in conformity with this Specification is deemed to be non-conforming.
This Specification includes a series of annexures that detail additional requirements.
1.2.1 Details of Work
Project specific requirements are shown in Annexure B204/A.
1.2.2 Payment
The method of payment is detailed in Annexure B204/B.
1.2.3 Schedules of HOLD POINTS, WITNESS POINTS and Identified Records
The schedules in Annexure B204/C list the HOLD POINTS and WITNESS POINTS that must be
observed. Refer to RTA Q for the definitions of HOLD POINTS and WITNESS POINTS.
The records listed in Annexure B204/C are Identified Records for the purposes of RTA Q Clause E2.
reference document, other than RTA specifications, shall be the issue current at the date one week
before the closing date for tenders, or where no issue is current at that date, the most recent issue.
Standards, specifications and test methods are referred to in abbreviated form (e.g. AS 1171). For
convenience the full titles are given in Annexure B204/M. When referring to a part of a standard, the
title of the standard, if appropriate, is referenced separately and the part only by its subtitle.
4 Ed 2 / Rev 1

1.3 APPLICABILITY OF REFERENCED STANDARDS
Welds specified on the Drawings as category SFP must be in accordance with AS/NZS 1554.5
unless otherwise specified. In such cases, where this Specification refers to clauses or tables in
AS/NZS 1554.1, reference must be made to similar clauses and tables in AS/NZS 1554.5.
Where quenched and tempered steels are used as the base metal for welding, carry out the welding in
accordance with AS/NZS 1554.4 and Clause 9 of this Specification.
Where seal welds or category GP welds are specified on the Drawings, they must comply with
AS/NZS 1554.1.
Stud welding must be in accordance with Clause 7 of this Specification and AS/NZS 1554.2. Welding
of reinforcing steels must be in accordance with Clause 8 of this Specification and AS/NZS 1554.3.
For these two applications Clauses 7 and 8 of this Specification shall override the requirements of
Clauses 6.2 to 6.4 where they are in contradiction.
All matters raised by Appendix D AS/NZS 1554.1 that need to be specifically addressed are covered
by this Specification, and for ease of use are cross-referenced in Annexure B204/E.
Further guidance is provided by the cross-referenced publications detailed in Annexure B204/F.
Unless otherwise specified, weld symbols on the Drawings must conform to AS 1101.3.
Unless otherwise specified, welding for steel pile casings and tubes must also conform to AS 1579.
2 ADDITIONAL QUALITY PLAN REQUIREMENTS
HOLD POINT
Process Held: Commencement of welding.
Submission Details: Quality Plan. Information and evidence proving conformity with Clause 2.
Release of Hold Point: The Principal will examine the submitted documents prior to authorising the
release of the Hold Point or may request further information or evidence.
2.1 QUALITY MANAGEMENT AND SUPERVISION
Ensure that the quality management system operating for Work under this Specification complies with
AS/NZS ISO 9001 or, preferably, with AS/NZS ISO 3834.2 or AS/NZS ISO 3834.3.
For the purposes of the Principals surveillance and audit, provide a welding programme and
acceptable accommodation.
The Welding Supervisor must keep readily accessible for inspection a complete weld map and records
of materials certification and welder qualification.
Ed 2 / Rev 1 5

2.2 NOMINATION OF PERSONNEL
Nominate in your Quality Plan the names and qualifications of all personnel to be associated in the
planning, production and inspection of all welds in the work except the names of welders to be
qualified by testing (see Clause 5 of this Specification).
Identify the responsibilities of the following personnel:
(a) Welding Supervisor(s)
(b) Welding Inspector(s)
(c) Welders
(d) Non-destructive examination technicians and operators
For the purposes of this Specification the role of the welding coordinator under AS/NZS ISO 3834.2
and AS/NZS ISO 3834.3 shall be deemed to be performed by the Welding Supervisor.
The Welding Supervisor and the Welding Inspector must not be the same person and must not carry
out welding for the Works.
The Welding Supervisor must be an employee or agent of the fabricator or company carrying out the
welding.
The Welding Inspector must be an employee or agent of the Contractor.
2.3 TECHNICAL PROCEDURES
Submit the following technical procedures including, but not limited to:
(a) Disposition of non-conforming welds;
(b) Identification and removal of welders constantly producing non-conforming welds as defined by
Clause 5.4.2 of this Specification;
(c) Cutting of fusion faces when welding reinforcing steel, as appropriate;
(d) Peening of intermediate weld runs, as appropriate;
(e) Correction of welding distortion, as appropriate;
(f) Provisions for maintaining site joint gap within tolerances during site welding;
(g) Control of site welding and provisions for addressing and release of Hold Points including, but
not limited to, the following where applicable:
(i) in precasting yards, welding and tack welding of steel reinforcement;
(ii) for bridge girders, butt welding of field splices;
(iii) Grade 500 MPa steel reinforcement;
(iv) steel piles or pile segments;
(v) welding productivity and sequence of welding; and
(vi) protection of weldment and heat affected zone (HAZ) against embrittlement by
atmosphere and other site conditions.
6 Ed 2 / Rev 1

3 SAFETY REQUIREMENTS
3.1 PERSONNEL
Carry out welding in accordance with the safety requirements of AS/NZS 1554 (e.g. AS/NZS 1554.1
Clause 1.8.1).
Take precautions to protect all those associated with the welding and persons working in the vicinity
of the welding operation (including visitors). Include in such precautions the prevention of electric
shock, exposure to arc radiation, exposure to hot metal and exposure to concentrations of welding
fume exceeding the recommendations of NOHSC:1003.
Satisfy the requirements of AS 1674.2 for electrical safety for welding in confined spaces and/or in
similar conditions where there is a high risk of electric shock to personnel.
Where exposure to welding fume is likely to exceed NOHSC:1003 limits, provide all affected people
with suitable personal protective equipment (PPE).
Provide adequate protection for all personnel within ten (10) metres of any open arc welding process
and any plasma cutting operation. Such protection may include the use of welding screens to shield
persons in the vicinity of welding operations from the effects of optical and ultraviolet radiation.
3.2 EQUIPMENT
All welding equipment and plant used must comply with AS/NZS 1554 (e.g. AS/NZS 1554.1
Clause 1.8.2).
Portable equipment for electric arc welding must satisfy the requirements of AS/NZS 3195.
4 WELDING PROCEDURES
4.1 GENERAL
Carry out welding using approved qualified welding procedures as detailed in Clause 4.2 of this
Specification.
Procedures shall be qualified by any of the methods allowed in AS/NZS 1554 (e.g. Clause 4.2 of
AS/NZS 1554.1) unless otherwise specified in this Specification.
The benefits of increased penetration from fully automatic arc welding processes may be utilised in
accordance with the conditions of Clauses 3.2.2 and 3.3.2 of AS/NZS 1554.1.
4.2 QUALIFICATION OF WELDING PROCEDURE
All procedures (i.e. the preparation, welding consumables and welding parameters) must be qualified
and approved by the Welding Inspector.
Document the procedure in a Welding Procedure Qualification Record (PQR or WPQR) and a
Welding Procedure Specification (WPS).
Ed 2 / Rev 1 7

A procedure shall only be deemed qualified after the Welding Inspector examines and/or witnesses the
procedure documentation and/or testing and certifies such a procedure as qualified. Such certification
must contain the Welding Inspectors signature and registration number of the Welding Inspectors
accreditation. A copy of the certified qualified welding procedure must accompany each welding test
piece submitted for destructive or non-destructive testing.
The extent of testing and/ or documentation of a welding procedure is dependent on the details of such
a procedure as shown hereunder.
Category SP fillet welds must be qualified with a macro test.
4.2.1 Prequalified Welding Procedures
Welding procedures prequalified in accordance with AS/NZS 1554 shall be deemed qualified for this
work upon certification by the Welding Inspector of the submitted Welding Procedure
Specification(s).
4.2.2 Qualification of Welding Procedure by Testing
WITNESS POINT For welding procedures qualified by testing
Process to be Witnessed: Any welding and testing required for qualifying a welding procedure.
Submission Details: At least three (3) working days notification of the time and place
where the welding and testing of all test pieces and/or assemblies will
be carried out.
The welding of all test pieces must be done under the direct supervision of the Welding Supervisor
and in the presence of the Welding Inspector.
The Welding Inspector must examine the Welding Procedure Specification and ensure that all test
pieces have been welded accordingly. Upon receiving conforming test results, the Welding Inspector
must certify the procedure as qualified.
Where electroslag or electrogas welding methods are to be used, determine the tolerances for butt
welded joints on the basis of the results of the qualification tests carried out in accordance with
AS/NZS 1554.1.
Keep records of all qualification tests associated with all welding procedures, together with the
relevant Welding Procedure Specifications, and make them available to those authorised to examine
them.
Include in these results a photograph or sketch of the macro test unless the test piece is to be retained
by you. Where a macro test only is required, the test piece may be prepared and examined instead of
referring it to a NATA laboratory, provided that the test piece is prepared and examined by the
Welding Inspector in accordance with Clause 4.7.4 of AS/NZS 1554.1 and prior approval for this has
been given by the Principal.
The test pieces and/or assemblies shall represent the actual conditions of fabrication including
anticipated weather and other environmental conditions, degree of restraint, welding through holes,
welding with the aid of mirrors, welding at floor level etc. Where nominated by the Principal in
Annexure B204/A, use a special test piece replicating the necessary conditions to verify the suitability
of the welding procedure (e.g. see Clause 4.7.2 of AS/NZS 1554.1). The tolerances for the preparation
of such test pieces must comply with Tables E of AS/NZS 1554.1.
8 Ed 2 / Rev 1

Where GP category welding or seal weld is specified, welding procedures must be qualified as
required by AS/NZS 1554 for GP category welds. Where testing is not required by AS/NZS 1554 the
procedure must still be documented and approved as detailed in Clause 4.2 of this Specification.
Where the weld arc energy exceeds the limitations accepted for prequalified consumables in
accordance with Clause 4.6 of AS/NZS 1554.1, carry out impact tests on the heat affected zone (HAZ)
of the parent steel to verify that the impact properties of the HAZ continue to meet the minimum
requirement for that steel as in AS/NZS 1554 or other applicable material Standards as specified on
the Drawings.
Hardness tests on the HAZ are only required when the requirements for preheating temperature related
to arc energy input do not comply with Clause 5.3.4 of AS/NZS 1554.1.
Use of a steel type which is not specifically provided for by AS/NZS 1554.1 must be treated as using
non-qualified consumables for the purpose of qualifying by testing.
4.2.3 Qualification of Previously Used Welding Procedure
Welding procedures previously qualified and used on other work shall be deemed qualified for this
work upon certification of the relevant documentary evidence by the Welding Inspector provided that:
(a) the procedure is being used within the limits of its essential variables as defined by
AS/NZS 1554;
(b) all qualification documents as required by AS/NZS 1554 (or the application Standard to which
the procedure was qualified) are available to support the procedure qualification record;
(c) the welder demonstrates an ability to produce a weld procedure specification (WPS) sample,
verified by NATA accredited testing; and
(d) NDE records are available demonstrating successful use of that procedure.
5 PERSONNEL QUALIFICATIONS
5.1 GENERAL
Ensure personnel qualifications which are partly or wholly obtained outside Australia or New Zealand
are equivalent to the specified requirements for Australian qualification.
HOLD POINT
Process Held: Use of persons with qualifications obtained outside Australia or New
Zealand where a qualification is required.
Submission Details: Details of the qualification and WTIAs assessment and certification of
equivalency with Australian requirements at least ten (10) working days
prior to commencement of using such persons.
release of the Hold Point or may request further evidence of qualification.

Ed 2 / Rev 1 9

5.2 WELDING SUPERVISOR(S)
Ensure that all welding is supervised on the workshop floor by a qualified Welding Supervisor(s) with
a thorough working knowledge and understanding of the AS/NZS 1554 series of Standards. Such a
person must satisfy the requirements of Clauses 4.12.1(a), (b), (c) or (d) of AS/NZS 1554.1.
5.3 INSPECTOR(S)
5.3.1 Welding Inspector(s)
Ensure that all welding is inspected by a qualified Welding Inspector with suitable training and
experience in the fabrication and inspection of welded structures satisfying the requirements of:
(a) Clause 5.2 above; or
(b) Clause 7.2 of AS/NZS 1554.1; or
(c) Have equivalent overseas qualifications.
The Welding Inspector is responsible for ensuring that all welding conforms to the requirements of
this Specification.
The Welding Inspector may examine backgouge areas and issue a report giving the results of such an
examination (NATA accreditation is not required), using the Magnetic Particle Examination method
(MPE - refer to AS 1171) or Liquid Penetrant Examination method (LPE - refer to AS 2062).
HOLD POINT
Process Held: Use of MPE and/or LPE by Welding Inspector only.
Submission Details: Documents demonstrating training background, experience and competency
of the Welding Inspector at least two (2) working days prior to the start of
first examination.
release of the Hold Point.
5.3.2 NDE Technicians
Ensure that all various non-destructive examinations (NDE, e.g. ultrasonic examination, radiography
etc.) are carried out by technicians suitably qualified and accredited for carrying out the examination
method employed (see Clause 7.4 of AS/NZS 1554.1). Such a technician must be accredited by:
(a) Australian Institute of Non-destructive Testing (AINDT); or
(b) Certification Board of Inspection Personnel, New Zealand (CBIP-NZ); or
(c) Equivalent overseas institutions.
The currency of the above qualifications and accreditations must comply with the requirements of the
issuing institution. Lapsed qualifications and accreditations will not be acceptable.
All non-destructive examination reports must be prepared by qualified and accredited NDE
technicians, and must contain the NDE technicians signature and registration number of the NDE
technicians qualification and accreditation. In such instances NATA-endorsed examination reports
will not be required.
10 Ed 2 / Rev 1

5.4 WELDERS
5.4.1 Qualification of Welders
A Welder cannot be a Welding Supervisor or a Welding Inspector for the Works.
Use only qualified welders with proven ability to produce sound welds. Such welders are those who:
(a) satisfy the requirements of Clause 4.12.2 of AS/NZS 1554.1 and can produce documented
evidence (e.g. NDE records traceable to the welder) of having successfully and consistently
produced welds to SP quality during the previous six months; or
(b) meet the requirements of AS 3992 Clause 9.2 or AS 2980; or
(c) hold equivalent overseas qualifications; or
(d) whilst not satisfying the requirements of item (a), (b) or (c) above, can demonstrate compliance
with SP requirements by means of a macro test for the welding procedures similar to and
representative of those to be used in the work particularly in terms of welding positions.
In special cases including, but not limited to:
(i) welding through holes;
(ii) welding with the assistance of mirrors;
(iii) restricted access to the weldment;
(iv) welding at or near ground level; and
(v) where environmental circumstances are likely to interfere with the welding process,
each welder who is required to weld on such occasions must demonstrate an ability to produce sound
welds under those conditions by carrying out welding in a simulated working position, verified by
means of a macro test conducted as above.
5.4.2 Poor Welding
Remove from the work any welder who during fabrication, produces at most three non-conforming
welds and determine the reason(s) for failure. Where the cause of the failure has been rectified
through retraining, the welder must demonstrate competency to produce sound welds before
submitting for re-qualification as specified in Clause 5.4.1 of this Specification.
6 WELDING OF STEELWORK
6.1 GENERAL
Welding must be carried out in the presence of the Welding Supervisor, witnessed and inspected by
the Welding Inspector.
6.1.1 Commencement of Welding
Prior to the commencement of any welding on the work, submit copies of the following
documentation:
(a) the personnel qualifications (see Clauses 2.2, 5.1, 5.2 and 5.3 of this Specification);
(b) technical procedures (see Clause 2.3 of this Specification); and
Ed 2 / Rev 1 11

(c) welding procedures associated with that work together with qualification records.
HOLD POINT
Process Held: Commencement of welding.
Submission Details: All details in Clause 6.1.1 at least two (2) working days prior to
commencement of any welding.
Give the Principal a minimum of two (2) working days advance notice in writing before commencing
welding work.
6.1.2 Use of Welding Procedures Not Already Approved
Prior to the use of any welding procedure on the work that has not been included in Clause 6.1.1
above, submit to the Principal copies of such a procedure and supporting qualification. Where a
welding procedure qualification record is accepted, then the welder must demonstrate a capability to
produce the weld from a representative simulated welding position.
HOLD POINT
Process Held: Use of a welding procedure not already approved.
Submission Details: All details in Clause 6.1.2 at least ten (10) working days prior to
commencement of using such a welding procedure.
6.1.3 Marking of Welds
When welding on bridges, bridge components or piles, all welders must clearly identify their work
either through the use of weld maps or by marking their identification symbol adjacent to each weld.
Do not use chalk, crayons and other marking substances that may interfere with the application,
adherence or final appearance of any protective coating to be applied to the structure.
6.1.4 Use of Filler Plates
Do not use filler plates unless otherwise specified.
6.1.5 Welding and Inspection of Similar Components
Where the work includes similar components, inspect the first one welded (referred to as the
prototype) and submit the relevant documentation to the Principal prior to any welding of subsequent
similar components.
The prototype must be inspected by the Welding Inspector to check that welding processes are
satisfactory, dimensional tolerances are not exceeded and that welding of adjacent items will result in
a completed component which is within tolerance.
12 Ed 2 / Rev 1

Notwithstanding Clause 6.4 of this Specification, the extent of weld inspection on the prototype of
components for I, box and trough girder bridges must comprise 100% testing of all butt welds using
either ultrasonic or radiographic testing methods, with 100% MPE testing of all crucifix fillet welds
and 33% of all other fillet welds. Carry out all such tests on the prototype welds at least forty eight
(48) hours after the weld to be tested and its adjacent welds have cooled to ambient temperature.
Carry out weld inspections after all heat treatment is completed.
HOLD POINT
Process Held: Commencement of welding of subsequent similar components.
Submission Details: Documents demonstrating compliance of the prototype with Clause 6.1.5 of
this Specification at least one (1) day prior to commencement of welding of
subsequent similar components.
6.1.6 Test Pieces
Prepare and test welded test pieces representative of each type of weld within the limits of the essential
variables of the welding procedure for the completed weld where:
(a) the length of weld represented exceeds 200 m for automatic welding or 100 m for manual or semi-
automatic welding; and
(b) the welding is not done in a reasonably continuous operation using the same welding procedure; or
(c) the welds are field welds.
Make the test piece from material of the same standard, grade and heat treatment conditions as the
material used in the structure. Each plate making up the test piece must be at least 150 mm x 150 mm.
Example test pieces are shown in Figures B204.1A and B204.1B.
Verify weld quality by carrying out a macro and bend test on the welds in the test piece and examine
using radiographics or ultrasonics for butt welds and MPE for fillet welds.
Ed 2 / Rev 1 13

Figure B204.1A Example test pieces for shop welds
14 Ed 2 / Rev 1

Figure B204.1B Example test pieces for field welds
Ed 2 / Rev 1 15

6.2 CONSUMABLES
All welding consumables must conform to the requirements of AS/NZS 1554.1 Clause 4.6. The
hydrogen content of deposited weld metal must not exceed 10 ml H
2
/ 100 g weld metal. Only
hydrogen controlled (low hydrogen) consumables and/or processes must be used in order to meet this
requirement (i.e. H
10
classification or better except for gas metal arc welding consumables which may
be H
15
).
Store and dry (if required) all consumables in accordance with the manufacturers instructions prior to
and during use.
The minimum nominal tensile strength of weld metal used shall be 480 MPa (e.g. E48XX, W502,
W503 etc. or stronger) for all steels other than reinforcing steel for concrete. For reinforcing steel
refer to Clause 8.2 of this Specification.
Obtain a certificate or letter of conformity from the manufacturer that the batch of consumables
supplied and used in the work conform to the relevant Australian Standard and classification as
described in Table 4.6.1(A) of AS/NZS 1554.1.
If prequalified consumables are to be used outside of their manufacturers specifications for which
they are prequalified, these consumables shall be deemed non-prequalified and additional qualification
tests must be undertaken to establish suitability for the application (e.g. Table 4.7.1 of
AS/NZS 1554.1).
Notwithstanding the requirements of AS/NZS 1554.1, for the qualification of consumables for welding
processes incorporating shielding gas, the specific combination of gas and wire must be qualified as
certified by Lloyds or other ship classification societies.
6.3 WORKMANSHIP
6.3.1 Control of Distortion and Residual Stress
6.3.1.1 General
Ensure that welding is done in a manner and sequence so as to minimise and control
shrinkage and distortion in accordance with Clause 5.7 of AS/NZS 1554.1 and the following
requirements:
(a) deposit all welds in a sequence that will balance the heat applied to the member(s)
whilst welding progresses;
(b) commence welding from points that are fixed in position with respect to each other
and progress towards points where there is greater relative freedom of movement; and
(c) weld first joints which are expected to have the largest amount of shrinkage with as
little restraint as possible.
6.3.1.2 Welding and Cutting Under Stress
Do not weld and/or cut under stress.
6.3.1.3 Peening
Peening to correct distortion is permitted in accordance with the limits specified in
Clause 5.7.3 of AS/NZS 1554.1. Prior to the peening operation, submit the procedure to the
Principal (see Clauses 2.3 and 6.1.1).
16 Ed 2 / Rev 1

Hammering is not permitted.
6.3.1.4 Correction of Distortion
Distortion may be corrected by mechanical or thermal means provided that the process used
does not damage the components or impair its intended use. In addition, the following
requirements apply where flame or heating methods are to be used:
(a) The temperature of the steel must not exceed 600C. Measure and record this
temperature.
(b) Do not artificially cool until the temperature of the steel has dropped below 300C.
(c) Do not cool heated parts with solid water jets. Water fog nozzles may be used.
6.3.2 Welding Technique
6.3.2.1 General
Comply with the following requirements:
(a) Complete and inspect all butt welds in any part of a member as specified in Clause 6.4
of this Specification before that part is welded to any other part.
(b) Use run-on and run-off tabs with minimum length of 50 mm and of the same thickness
and preparation as the joint for all butt welds.
(c) Terminate welds such that the tail of any weld crater (especially in Submerged Arc
Welding) is at least 20 mm beyond the edge of the parts being joined. Whenever
possible this must be done by use of weld tabs duplicating the joint being welded.
(d) The method of removal of run-on and run-off tabs must not damage the parent
material. Make the ends of the welds smooth and flush with the edges of the abutting
parts.
(e) Do not use antispatter fluids and compounds.
(f) Arc strikes are not permitted.
(g) Terminate all welds so as to completely fill the weld crater. Resume interrupted weld
runs within the crater of the previous run so as to fill the weld to its correct height and
melt out any imperfections within the crater.
(h) Remove all slag and injurious foreign materials prior to the commencement of
welding and between weld runs including any slag within the weld crater of an
interrupted run.
6.3.2.2 Appearance and Finish of Welds
For all welds:
(a) Dress butt welds smooth and flush with abutting surfaces where required for correct
assembly and/ or where specified on the Drawings, and inspect and NDE test.
(b) Remove all weld spatter from the surface of the weld and the parent material.
(c) Remove slag from all completed welds and clean both the weld and the parent metal
from fabrication contamination.
(d) Reinstate and inspect surfaces of temporary welds in accordance with Clause 5.9 of
AS/NZS 1554.1.
Ed 2 / Rev 1 17

(e) Ensure all finished weld faces are compatible with the protective coating system
specified.
6.4 INSPECTION OF WELDS
Inspect welds in accordance with the methods nominated in AS/NZS 1554.1. In addition, apply the
following:
(a) For welds where category SFP is specified, the minimum extent of testing shall be as provided
for SP category below and/ or as given in Table 7.4 of AS/NZS 1554.5 whichever is the
greater.
(b) For SP category welds, the minimum extent and type of inspection shall be as given in Table
B204.2. Where not specified in this table, on the Drawings or in other documents associated
with the work, the maximum recommendations of Table 7.4 of AS/NZS 1554.1 must apply.
(c) For GP category welds carry out 100% visual scanning and 100% visual examination. Other
inspection methods are only required if specified on the Drawings or in other documents
associated with the work.
(d) For radiographic and ultrasonic examination, determine h by sectioning or vertical ultrasonic
sizing in accordance with AS 2177.1 and AS 2207 respectively.
(e) For NDE only use those techniques that are covered by Section 6 of AS/NZS 1554.1 except that
the ultrasonic examination method must comply with AS 2207. Remove weld tabs prior to
NDE inspection.
(f) Use one metre or the actual weld length (whichever is the lesser) as the value L of a
continuous weld length for the assessment of weld imperfections as detailed in Section 6 of
AS/NZS 1554.1.
(g) Unless otherwise specified carry out weld inspections to be covered by test certificates at least
48 hours after the joint and all adjacent welds have been completed and have cooled to ambient
temperature, and where post weld heat treatment is specified or applied, such testing must occur
only after completion of the heat treatment.
(h) Where unacceptable imperfections are detected during audit testing or surveillance carried out
by the Principal, repair such imperfections and 100% retest, including 100% testing of a further
300 mm each side of the repair zone, all at your expense.
(i) Examine multi-pass welds in plates with thicknesses greater than 20 mm for transverse cracking
by ultrasonic methods as specified in Table B204.2.
HOLD POINT
Process Held: Completion of weld inspection.
Submission Details: Evidence that all testing in Clauses 6.4 and 6.5 has been carried out as
specified.
6.5 NON-CONFORMING WELDS
When a weld is inspected by NDE and the level of imperfection detected exceeds the permissible
values shown in Table 6.2.1 and Table 6.2.2 of AS/NZS 1554.1, such a weld shall be a
non-conforming weld. Inspect the remainder of the weld as follows:
18 Ed 2 / Rev 1

(a) For manual and semi-automatic processes (e.g. FCAW, GMAW, MMAW etc.), 100% inspect
the weld metal adjacent to the non-conforming weld section for an additional 300 mm minimum
in each direction. Examine the remaining part of the weld in accordance with Table B204.2 and
Clause 6.4 of this Specification. Where another non-conforming weld is detected, repeat the
same cycle of inspection until no more non-conforming welds are found.
(b) For automatic processes (e.g. SAW), if any defect is found 100% test the remainder of the weld
in accordance with the methods given in Table B204.2 and Clause 6.4.
The Principal must be notified of any non-conformity together with the extent of the non-conformity.
The disposition proposed in the Non-Conformity Report submitted to the Principal must conform to
the following:
(a) Where you can demonstrate to the satisfaction of the Principal through the use of fracture
mechanics (see Clause 6.7 of AS/NZS 1554.1) or through other suitable assessment methods
that the defect will not impair the performance of the structure, the defect need not be repaired;
or
(b) Repair the defect using a welding procedure qualified in accordance with Clause 4.2 of this
Specification or requalified as required by AS/NZS 1554,e.g. AS/NZS 1554.1 Clause 4.11 (note
that the qualified procedure used to produce the weld may be used to repair the defect).
Note that even though an imperfection may be acceptable under this Section, the presence of surface
breaking imperfections may interfere with your obligation to produce a weld with a surface finish
suitable for application of the protective coating (see Clause 6.3.2.2) and thus some rectification work
may be necessary.
100% NDE inspect all welds for conformity, including 300 mm on each side of the repair zone.
7 STUD WELDING
7.1 GENERAL
Supply, weld and inspect stud shear connectors in accordance with AS/NZS 1554.2 and this
Specification.
7.2 CERTIFICATION OF STUDS
Obtain certification from the stud supplier that the materials of the studs and their bases comply with
the appropriate specification as required by Clause 2.2.3 and Paragraph C10, Appendix C of
AS/NZS 1554.2.
7.3 QUALIFICATION OF OPERATORS
Provide certification that each operator has passed a qualification test in accordance with Clause 4.3 of
AS/NZS 1554.2.
Ed 2 / Rev 1 19

7.4 COMMENCEMENT OF STUD WELDING
HOLD POINT
Process Held: Commencement of stud welding.
Submission Details: All details in Clauses 7.2 and 7.3 at least two (2) working days prior to
commencement of any welding.
Give the Principal a minimum of two (2) working days advance notice in writing before commencing
stud welding work.
7.5 TESTING OF FINISHED STUD WELDS
Test each stud in the work by striking it with a light hammer (ring test) in the presence of the
Principal. Test by taking a steel hammer of approximately 1 kg in weight and using a free swing to
strike the stud, then striking it again in the opposite direction. Then bend test, in accordance with
AS/NZS 1554.2, any studs that do not give a consistent ringing sound.
Also perform bend tests on a random selection of 5% of studs on each member in addition to those
tested in accordance with Section 6 of AS/NZS 1554.2. In the bend test, bend the stud at an angle of
30 to its original axis. Bend only in the longitudinal direction of the member and towards its centre.
After bending, examine the stud for cracks. Remove and replace any stud which exhibits cracks using
the arc stud welding process.
WITNESS POINT
Process to be Witnessed: Testing of finished stud welds
Submission Details: At least three (3) working days notification prior to testing of welded
studs using ring and bend tests as detailed in Clause 7.5 of this
Specification
Mark any selected studs which fail. Bend test additional studs in the near vicinity of the failed stud.
Do not bend back studs unless required for clearance.
7.6 ALTERNATIVE WELDING PROCESSES AND REPAIR
Studs may be welded or repaired using qualified flux cored arc, gas metal-arc or manual metal-arc
welding subject to the following:
(a) The weld repairs must be at least category SP;
(b) The parent material must be free from loose or thick scale, slag, rust, moisture or other
material that prevents conforming welds or produces unsafe fumes;
(c) The stud base must be clean and prepared so that the outside circumference fits tightly against
the parent material.
(d) Minimum fillet weld sizes must conform to Table B204.1.
20 Ed 2 / Rev 1

Table B204.1 Minimum Fillet Weld Size for Studs
Stud diameter
millimetres
Minimum size fillet
millimetres
6.4 to 11.1 5
12.7 6
15.9 to 19.0 8
22.2 to 25.4 10
8 WELDING OF REINFORCING STEEL FOR CONCRETE
8.1 GENERAL
Welding (including tack welds) of reinforcing steel must comply with AS/NZS 1554.3. In addition,
for steel grades not qualified or covered by AS/NZS 1554.3, apply the bar manufacturers
recommendations.
Welding of reinforcing steels onto steel plates must comply with Clause 3.2.3 of AS/NZS 1554.3 for
anchorage splices, the requirements of this Specification and AS/NZS 1554.1, AS/NZS 1554.4 or
AS/NZS 1554.5, as appropriate.
Apply all requirements of the previous Clauses of this Specification including the Hold Points (e.g.
welding procedures, qualifications of personnel, welding of steel structures etc.) to the welding of
reinforcing steels, where relevant. Where reference is made in those Clauses to AS/NZS 1554 or
AS/NZS 1554.1, apply the corresponding Clauses in AS/NZS 1554.3.
A model checklist for welding and tack welding of steel reinforcement is included in
Annexure B204/G.
Some model welding procedure qualification records and welding procedure specifications for
non-structural/locational tack welding and welding of steel reinforcement are included in Annexure
B204/H. The relevant model WPQRs and WPSs may be used for structural tack welding provided
matching strength consumables of classifications E5518, E6218, W55X, W62X, W55XX.X or
W62XX.X are used.
8.2 ADDITIONAL REQUIREMENTS
Apply the following requirements for the welding of reinforcing steel bars. They override the previous
Clauses of this Specification or AS/NZS 1554 when they are in contradiction:
(a) Consumables for locational tack welds (refer to Figure B1 of AS 1554.3) may be non-hydrogen
controlled, as permitted by AS/NZS 1554.3. Conform also to Clause 3.3.4 of AS 1554.3.
(b) Locational tack welding need not be supervised by a Welding Supervisor, provided:
(i) Welders are qualified in the presence of a Welding Supervisor and in accordance with the
requirements of AS/NZS 1554.3;
(ii) Audits of locational tack welding performed by qualified welders are carried out by a
Welding Supervisor at least every 6 months; and
Ed 2 / Rev 1 21

(iii) The Principal carries out regular inspections of the locational tack welding to verify
conformity with AS/NZS 1554.3;
(c) Non-qualified personnel must not perform any locational tack welding or other welding.
(d) Use butt welded splices only if acceptable to the Principal;
(e) Any welding procedure, regardless of the method used for its qualification, must be tested in
accordance with Clause 7 of AS/NZS 1554.3 before it is used for the first time on RTA works.
Subsequent use of such a procedure is acceptable without these additional tests provided that
records of these tests and their results are available and meet the requirements of Clause 7.3 of
AS/NZS 1554.3.
(f) Provide a Weld Procedure Specification (WPS) for automated machine welds, and demonstrate
that the strength of such welds is not less than that achieved by welding in accordance with a
relevant model WPS in Annexure B204/H.
(g) Carry out preparation or cutting of the fusion face, where appropriate, by a method complying
with the submitted technical procedure (see Clause 2.3 of this Specification).
(h) The extent of inspection must be 100% visual scanning and 100% visual examination with
permissible levels of imperfection equivalent to those of Table 9.2 of AS/NZS 1554.3.
9 WELDING OF HIGH STRENGTH QUENCHED AND TEMPERED
STEELS
9.1 GENERAL
Welding of steelwork using quenched and tempered steels must be in accordance with
AS/NZS 1554.4, category SP unless otherwise specified on the Drawings. Welds in structural
members subject to high levels of fatigue and specified on the Drawings as category FP must be in
accordance with the requirements for FP welds in AS/NZS 1554.4 unless otherwise specified.
Relevant requirements of previous Clauses of this Specification including the Hold Points (e.g.
welding procedures, qualifications of personnel, welding of steelwork etc.) shall apply to the welding
of quenched and tempered steels. Where reference is made to AS/NZS 1554 or AS/NZS 1554.1,
reference must be made to appropriate clauses in AS/NZS 1554.4.
9.2 ADDITIONAL REQUIREMENTS
For the welding of quenched and tempered steels the following overrides the previous Clauses of this
Specification or AS/NZS 1554 when they are in contradiction:
(a) Where thermal methods are used to correct distortion, the temperature of the steelwork must not
exceed the tempering temperature of the steel less 20C.
(b) For welds specified on the Drawings as Category FP, the minimum extent of testing must be
as provided for SP Category in Table B204.2 or as given in Table 7.4 of AS/NZS 1554.4
Category FP, whichever is the greater.
(c) For SP category welds, the minimum extent and type of inspection must be as given in Table
B204.2. Where not specified in this table, on the Drawings or in other documents associated
with the work, apply the maximum recommendations of Table 7.4 of AS/NZS 1554.4.

22 Ed 2 / Rev 1

Table B204.2 - Extent and Type of Inspection for SP Category Welds
Inspection
method
Weld location Minimum extent of inspection for
each weld
Visual scanning
1

All joints 100%
Visual
examination
2

All joints 100%
MPE/LPE
3
Bridge Components
Stiffener welds at crucifix locations (single run
fillet welds)
100% (MPE only)
Stiffener fillets at site joints 100% (MPE only)
Edges of flange butt joints 100% (MPE only)
Single pass fillet welds
o All stiffeners, diaphragms or diaphragm
stiffeners to tension flange; Diaphragm
stiffener to diaphragm
o All stiffeners, diaphragms or diaphragm
stiffeners to compression flange or web
plates; End plates to tension flange,
compression flange and web plate

100% (MPE only)

20%(MPE only)

Back gouging 20% (MPE only)
All other welds 2% (MPE only)
All Other Structural Members The maximum of AS/NZS 1554
recommendations
Repairs
Repaired defects in base metal 100%
Remaining weld after removal of defected weld 100% (MPE only)
Repaired or replaced weld 100%
Ultrasonic or Bridge Components
radiographic Flange butt joints 50%
Web butt joints 300 mm minimum each end of joint
Web to flange butt joint 100% within 500 mm each side of
diaphragms
10% for other locations in addition to
all ends of welds

Web to flange multipass fillet welds
4

10% - in addition to all ends of welds,
lifting lug locations and at diaphragm
locations
All stiffeners, diaphragms or diaphragm
stiffeners to tension flange (butt and multipass
fillet welds)
4

100%
4

All stiffeners, diaphragms or diaphragm
stiffeners to compression flange or web plates;
Diaphragm stiffener to diaphragm; End plates to
tension flange, compression flange and web plate
(butt and multipass fillet welds)
4

10%
4

All other welds 10%
All site joint welds 100%
All Other Structural Members The maximum of AS/NZS 1554
recommendations

1
Detection of gross defects and omission of welds
2
Examination of the quality of the specified extent of weld
3
Magnetic Particle Examination / Liquid Penetrant Examination
4
Inspect using both MPE and ultrasonic methods.
Ed 2 / Rev 1 23

ANNEXURE B204/A PROJECT SPECIFIC REQUIREMENTS
A1 REQUIREMENTS FOR SPECIAL TEST PIECE(S)
(J ob Specific- Ref. Clause 4.2.2)
The Works covered by this Specification require the preparation and testing of special test piece(s) as
detailed in Clause 4.2.2 of this Specification and:
(a) as detailed in the following table:

Test Piece
Identification
Conditions To Be Replicated Comments

and
(b) as specified in the Quality Plan.

ANNEXURE B204/B PAYMENT
(Refer to Clause 1.2.2)
Except where specific pay items are provided, all costs associated with qualification of welding
procedures and welders, inspection and testing of welding shall be deemed to be included in the rates
and prices generally for the work under the Contract.
All repairs to welds shall be at your cost including the cost of any subsequent NDE.
24 Ed 2 / Rev 1

ANNEXURE B204/C - SCHEDULES OF HOLD AND WITNESS POINTS
C1 SCHEDULE OF HOLD AND WITNESS POINTS

Clause Point Description
2 HOLD Commencement of welding
4.2.2 WITNESS Welding procedures qualified by testing
5.1 HOLD Equivalency of overseas qualifications to be verified by WTIA.
5.3.1 HOLD Use of MPE and/or LPE by Welding Inspector
6.1.1 HOLD Commencement of welding
6.1.2 HOLD New welding procedures
6.1.5 HOLD Completion of prototype
6.4 HOLD Completion of weld inspection
7.4 HOLD Commencement of stud welding
7.5 WITNESS Testing of finished stud welds
C2 SCHEDULE OF IDENTIFIED RECORDS
The records listed below are Identified Records for the purposes of RTA Q Clause E2Clause E2.

Clause Description of the Identified Record
6.1.1 Details of personnel qualifications, technical procedures and welding processes
6.1.5 Documents demonstrating compliance of prototype
6.3.1.3 Peening procedure
6.5 Non-conformities and proposed disposition for welds
7.2 & 7.3 Certification of studs and operators
ANNEXURE B204/D (NOT USED)
Ed 2 / Rev 1 25

ANNEXURE B204/E - LIST OF CROSS-REFERENCES TO APPENDIX D
OF AS/NZS 1554.1
(Refer to Clause 1.3.)

Appendix D of AS/NZS 1554.1 RTA B204
Item Clause Clause
a 3.1.2 1.1, 1.3, 6.2 & 8.2
b 3.2.2 & 3.3.2 4.1
c 3.5 1.3
d 4.1 & 4.2 4.1, 4.2 & 6.1.2
e 4.2 4.1, 4.2 & 6.1.2
f 4.6.1 6.2
g 4.7.1 4.2.2
h Table 4.7.1 4.2.2
i Table 4.7.1 & Clause 4.7.9 4.2.2
j 4.7.2 4.2.2
k 4.10 4.2.2
l 4.12.1 5.1 & 5.2
m 4.12.2 5.1 &5.4.1
n 5.2.2 4.2.2 & 6.3
o 5.2.2 4.2.2 & 6.3
p 5.7.2 6.3.1.2
q 5.7.3 6.3.1.3
r 5.7.4 6.3.1.4
s 5.11 & 5.12 6.1.3, 6.3.2.2 & 6.5
t 6.3, 6.4, 6.5, 6.6 & 7.4 6.4
u 6.3.1, 6.4.1, 6.5 & 6.6 6.4
v 6.3.3, 6.4.3 & 6.7 6.5
w 6.8 6.4
x 7.4 5.3.2
y 7.4 6.4

ANNEXURE B204/F - GUIDANCE ON TECHNICAL REQUIREMENTS
26 Ed 2 / Rev 1

(Refer to Clause 1.3.)
Guidance on some of the requirements of RTA B204 is available in the following cross-referenced
publication:

Requirement B204 Clause Guidance Publication
Safety personnel 3.1 WTIA Technical Note 22
Safety equipment 3.2 WTIA Technical Note 7
Welding procedures 4 Appendix A, WTIA Technical Note 19
Weld marking 6.1.3 Chapter 8, WTIA Technical Note 19
Storing of consumables 6.2 WTIA Technical Note 3
WTIA Technical Note 2; and
Control of distortion 6.3.1
Procedure Handbook of Arc Welding published
by The Lincoln Electric Company

Inspection of welded
reinforcing steel bars
8.2 Section F, WTIA Technical Note 11

Referenced Guidance Publications
Technical Note 2 Welding Aluminium with the Inert Gas Processes
Technical Note 3 Care & Conditioning of Arc Welding Consumables
Technical Note 7 Health & Safety in Welding
Technical Note 11 Commentary on The Structural Steel Welding Code AS 1554
Technical Note 15 Welding & Fabrication of Quenched & Tempered Steels
Technical Note 19 Cost Effective Quality Management for Welding
Technical Note 22 Welding Electrical Safety

Other Publications
The Lincoln Electric Company The Procedure Handbook of Arc Welding
EN 719 Welding Coordinator Qualifications
ISO 14731 The Coordinator Tasks and responsibilities

Ed 2 / Rev 1 27

ANNEXURE B204/G MODEL CHECKLIST TACK WELDING AND WELDING OF STEEL REINFORCEMENT
(Refer Clause 8)
Item B204 Requirement B204
Clause
AS/NZS
1554.3 Clause
Hold/Witness
Point
Conforms Does Not
Conform
Inspectors Comments
1
Quality Plan 2 Hold
2
Qualified Welding Procedure 4 4 Witness
3
Previously Used Qualified Welding Procedure 4 4
4
Qualified Personnel 5.1 Hold

a. Welding Supervisor 5.2 4.10.1

b. Welding Inspector 5.3 10.2

c. MPE and LPE Inspection 5 9.3; 9.4 Hold

d. Overseas Personnel 5 Hold
5
Qualified Welders 5.4 4.10.2
6
Commencement of Welding 6 Hold
7
Weld Procedures Not Approved 6 4.5.2; 7 Hold
8
Welding and Inspection of Similar Components 6 Hold
9
Consumables 6 4.5

a. Stick Electrodes 6

b. Gas/Wire 6
10
Inspection of Welds 6 10.3.1; 10.3.2 Hold
11
Non-Conforming Welds 6
12
Additional Requirements 8.1; 8.2 Appendix C

28 Ed 2 / Rev 1

ANNEXURE B204/H MODEL WELDING PROCEDURE
QUALIFICATION RECORDS AND WELDING PROCEDURE
SPECIFICATIONS FOR TACK WELDING AND WELDING OF
STEEL REINFORCEMENT
(Refer Clause 8.1)

Ed 2 / Rev 1 29

WELDING PROCEDURE QUALIFICATION RECORD
Material/Grade AS-NZS 4761-500N Bar Weldability Group Number 4
Fabricator N/A PQR No RTA PQR 0001
Standard AS-NZS 1554.3 Date Apr-05
Process MMAW WPS No RTA WPS 0001
Edge Prep Cut and Grind Page No 1
Welding Direction Drag/pull Revision and Date 0
Range Qualified 9mm to 18mm Position Flat
Preheat Temp N/A PWHT N/A
Method and Check N/A Hold Time N/A
Inter-run Temp 200'C Max Other AS-NZS 1554.3 App-B
Prequal Joint No Appendix C Root Face 'Fr' N/A
Joint Tolerances To Table Appendix C Included Angle '0' N/A
Root gap 'G' 0mm Backing N/A
Material Thickness Dia 12mm Combined Thickness N/A
Joint Sequence Run Sequence
Welding Consumables
Specifications Root E4113 Remainder Same Flux
Classification Root AS1553 Remainder Same
Shielding Gas N/A Flowrate N/A N/A
Purge Gas N/A Flowrate N/A
Weld Run Details Welding Parameters
Pass No Side Position 0mm Trade
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 Flat 3.2mm CIG Weld 118 21 DCEP 240 0.6195
Technique Stringer/Weave Stringer
Single or Multi run Single Stick-Out N/A
Initial Cleaning Wire Brush Back Gouge N/A
Inter Run Clean Wire Brush Gouge Check N/A
Test Results
Test Type Visual Macro Tensile Bend Charpy V Hardness Other Date Checked
Test by Yes Yes Yes Yes
Report no
Result
Notes/ Revisions 1.This tackweld shall not have any structural performance. 2. This tackweld shall not be
used for lifting. 3.This tackweld shall only be used for location purposes only.
Welders Name
Witnessed by Sign Date
Approved by Sign Date
12mm diameter bar tackwelds
12mm Rebar
12mm Rebar
6 spot tackwelds welded between the
ribs on the bar at two times the dia of
the bar


30 Ed 2 / Rev 1

WELDING PROCEDURE SPECIFICATION
Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
Welders Name
12mm diameter bar tackwelds
12mm Rebar
12mm
R b
the bar


Ed 2 / Rev 1 31

Materal/Grade AS-NZS 4761-500N Bar Weldability Group Number 4
Prequal Joint No Appedix C Root Face 'Fr' N/A
Joint Tolerances To Table Appedix C Included Angle '0' N/A
Materal Thickness Dia 24mm Combined Thickness N/A
Welding Consumables
Pass No Side Position Omm Trade
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
Test Results
Report no
Result
Welders Name
Wittnessed by Sign Date
24mm diameter bar
24mm Rebar
24mm Rebar
the bar


32 Ed 2 / Rev 1

Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
Welders Name
24mm diameter bar
24mm Rebar
24mm Rebar
the bar


Ed 2 / Rev 1 33

Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
Test Results
Report no
Result
Welders Name
28mm diameter bar
28mm Rebar
28mm Rebar
the bar


34 Ed 2 / Rev 1

Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
Welders Name
28mm diameter bar
28mm Rebar
28mm Rebar
the bar


Ed 2 / Rev 1 35

Range Qualified 9mm to 18mm Position Horizontal 2F
Prequal Joint No Appendix B Root Face 'Fr' N/A
Joint Tolerances To Table Appendix B Included Angle '0' N/A
Material Thickness Dia 12mm to 12mm Combined Thickness N/A
Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
Test Results
Test by Yes Yes
Report no
Result
Welders Name
12mm diameter bars cross tack weld
12mm
Rebar
12mm
Rebar
12mm
Rebar
12mm
Rebar
1
1
4mm


36 Ed 2 / Rev 1

Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
Welders Name
12mm diameter bars cross tack weld
12mm
Rebar
12mm
Rebar
12mm
Rebar
12mm
Rebar
1
1
4mm


Ed 2 / Rev 1 37

Range Qualified 9mm to 18mm & 18 to 36 Position Horizontal 2F
Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
Test Results
Test by Yes Yes
Report no
Result
Welders Name
12mm and 24mm diameter bars cross tack weld
24mm
Rebar
12mm
Rebar
12mm
Rebar
24mm
Rebar
1
1
4mm


38 Ed 2 / Rev 1

Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
Notes/ Revisions 1.This tack weld shall not have any structural performance. 2. This tack weld shall not be
used for lifting. 3.This tack weld shall only be used for location purposes only.
Welders Name
12mm and 24mm diameter bars cross tack weld
24mm
Rebar
12mm
Rebar
12mm
Rebar
24mm
Rebar
1
1
4mm


Ed 2 / Rev 1 39

Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
Test Results
Test by Yes Yes
Report no
Result
Welders Name
12mm and 28mm diameter bars cross tackweld
28mm
Rebar
12mm
Rebar
12mm
Rebar
28mm
Rebar
1
1
4mm


40 Ed 2 / Rev 1

Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
Welders Name
12mm and 28mm diameter bars cross tackweld
28mm
Rebar
12mm
Rebar
12mm
Rebar
28mm
Rebar
1
1
4mm


Ed 2 / Rev 1 41

Inter-run Temp 200'C Max Other AS-NZS 1554.3 Cl.3.2.2
Prequal Joint No L-d Root Face 'Fr' N/A
Joint Tolerances To Table F-4 Included Angle '0' N/A
* Refer to Standard for values for bars other than 12 mm diameter
Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
2 1 3.2mm CIG Weld 125 20 DCEP 150 1
Test Results
Test by Yes Yes
Report no
Result
Notes/ Revisions
Welders Name
12mm diameter bars load bearing lap splice
12mm
Rebar
12mm
Rebar
12mm
Rebar
12mm
Rebar
1
5mm*
120 mm*
m
2
1
2
0 mm Gap


42 Ed 2 / Rev 1

Joint Tolerances To Table F-4 Included Angle '0' N/A
Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
2 1 3.2mm CIG Weld 125 20 DCEP 150 1
Notes/ Revisions
Welders Name
12mm
Rebar
12mm
Rebar
12mm
Rebar
12mm
Rebar
1
5mm*
120 mm*
m
2
1
2
0 mm Gap


Ed 2 / Rev 1 43

Joint Tolerances To Table F4 Included Angle '0' N/A
Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
2 1 3.2mm CIG Weld 125 20 DCEP 150 1
Test Results
Test by Yes Yes
Report no
Result
Notes/ Revisions
Welders Name
24mm
Rebar
24mm
Rebar
24mm
Rebar
24mm
Rebar
1
10mm*
240mm*
2
1
2
0 mm Gap


44 Ed 2 / Rev 1

Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
2 1 3.2mm CIG Weld 125 20 DCEP 150 1
Notes/ Revisions
Welders Name
24mm
Rebar
24mm
Rebar
24mm
Rebar
24mm
Rebar
1
10mm*
240mm*
2
1
2
0 mm Gap


Ed 2 / Rev 1 45

Range Qualified 21mm to 42mm Dia Position Horizontal 2F
Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
2 1 3.2mm CIG Weld 125 20 DCEP 150 1
Test Results
Test by Yes Yes
Report no
Result
Notes/ Revisions
Welders Name
28mm
Rebar
28mm
Rebar
28mm
Rebar
28mm
Rebar
1
12mm*
280mm*
2
1
2
0 mm Gap


46 Ed 2 / Rev 1

Range Qualified 21mm to 42mm Dia Position Horizontal 2F
Welding Consumables
Name
Amps Volts Current
Polarity
T/ Speed
mm/min
Heat input
KJ
1 1 3.2mm CIG Weld 125 20 DCEP 150 1
2 1 3.2mm CIG Weld 125 20 DCEP 150 1
Notes/ Revisions
Welders Name
28mm
Rebar
28mm
Rebar
28mm
Rebar
28mm
Rebar
1
12mm*
280mm*
2
1
2
0 mm Gap


Ed 2 / Rev 1 47

ANNEXURES B204/I TO B204/L (NOT USED)
ANNEXURE B204/M - REFERENCED DOCUMENTS
AS 1101 Graphical symbols for general engineering
AS 1101.3 Welding and non-destructive examination
AS 1171 Non-destructive testing Magnetic particle testing of ferromagnetic products,
components and structures
AS/NZS 1554 Structural steel welding
AS/NZS 1554.1 Welding of steel structures
AS/NZS 1554.2 Stud welding (steel studs to steel)
AS/NZS 1554.3 Welding of reinforcing steel
AS/NZS 1554.4 Welding of high strength quenched and tempered steels
AS/NZS 1554.5 Welding of steel structures subject to high levels of fatigue loading
AS 1579 Arc-welded steel pipes and fittings for water and waste-water
AS 1674.2 Safety in welding and allied processes - Electrical
AS 2062 Non-destructive testing Penetrant testing of products and components
AS 2177.1 Non-destructive testing Radiography of welded butt joints in metal Methods
of test
AS 2207 Non-destructive testing Ultrasonic testing of fusion welded joints in carbon
and low alloy steel
AS 2980 Qualification of welders for fusion welding of steels
AS/NZS 3195 Approval and test specification Portable machines for electric arc welding and
allied processes
AS 3992 Pressure equipment - Welding and brazing qualification
AS/NZS ISO 9001 Quality management systems Requirements
AS/NZS ISO 3834 Quality requirements for welding Fusion welding of metallic materials
AS/NZS ISO 3834.2 Comprehensive quality requirements
AS/NZS ISO 3834.3 Standard quality requirements
RTA Specifications
RTA Q Quality Management System
Other Publications
NOHSC:1003 Adopted National Exposure Standards for Atmospheric Contaminants in the
Occupational Environment, National Occupational Health and Safety
Commission (NOHSC). Presently replaced by the Office of the Australian
Safety and Compensation Council (OASCC)

B220 - Wardell Sheave Repairs ROADS and TRAFFIC AUTHORITY NSW
J anuary 2008
QA SPECI FI CATI ON B220
PROTECTIVE TREATMENT OF
BRIDGE STEELWORK
RNIC-QA-B220
VERSION FOR: Wardell Sheave Repairs
DATE: J anuary 2008

Protective Treatment of Bridge Steelwork B220
B220 Wardell Sheave Repairs. i

CONTENTS
FOREWORD...............................................................................................................................................II
RTA Copyright and Use of this Document....................................................................................ii
Revisions to Edition 1....................................................................................................................ii
Project Specific Changes...............................................................................................................ii
1 GENERAL........................................................................................................................................1
1.1 Scope..............................................................................................................................1
1.3 Definitions......................................................................................................................2
2 RESOURCES....................................................................................................................................2
2.1 Plant and Equipment.......................................................................................................2
2.2 Materials.........................................................................................................................2
3 EXECUTION....................................................................................................................................4
3.1 General ...........................................................................................................................4
3.2 Emissions Control ..........................................................................................................4
3.3 Hot-dip Galvanizing.......................................................................................................4
3.4 Paint Coating Systems....................................................................................................5
3.5 Connections....................................................................................................................6
3.6 Surface Preparation........................................................................................................8
3.7 Paint Application............................................................................................................9
3.8 Care of the Work..........................................................................................................12
4 CONFORMITY ...............................................................................................................................13
4.1 Dry Film Thickness......................................................................................................13
4.2 Adhesion.......................................................................................................................13
4.3 Appearance...................................................................................................................13
4.4 Nonconformity.............................................................................................................14
4.5 Records.........................................................................................................................14
ANNEXURE B220/A DETAILS OF WORK..............................................................................................16
ANNEXURE B220/B - PAYMENT.............................................................................................................18
B.1 General .........................................................................................................................18
B.2 Pay Items......................................................................................................................18
ANNEXURE B220/C SCHEDULE OF HOLD AND WITNESS POINTS AND IDENTIFIED RECORDS............19
C.1 Schedule of Hold and Witness Points...........................................................................19
C.2 Schedule of Identified Records.....................................................................................19
ANNEXURE B220/D PLANNING DOCUMENTS......................................................................................20
D.1 Information to be Included in the Project Quality Plan................................................20
ANNEXURE B220/E PAINT COATING SYSTEMS...................................................................................21
E.1 Explanation of Table....................................................................................................21
E.2 Coating Systems...........................................................................................................22
ANNEXURES B220/F TO B220/L - (NOT USED) ......................................................................................38
ANNEXURE B220/M REFERENCED DOCUMENTS................................................................................39

B220 Protective Treatment of Bridge Steelwork
ii B220 Wardell Sheave Repairs

LAST PAGE OF RTA B220 IS...................................................................................................................39

FOREWORD
RTA COPYRIGHT AND USE OF THIS DOCUMENT
When this document forms part of a contract
This document should be read with all the documents forming the Contract.
When this document does not form part of a contract
This copy is not a controlled document. Observe the Notice that appears on the first page of the copy
controlled by RTA. A full copy of the latest version of the document is available on the RTA Internet
website: www.rta.nsw.gov.au/doingbusinesswithus/specifications
REVISIONS TO EDITION 1
This document is based on RTA Specification B220 Edition 1 Revision 0 April 2004.
All revisions to RTA B220 Ed 1/Rev 0 (other than minor editorial and project specific changes) have
been indicated by a vertical line in the margin as shown here.
PROJECT SPECIFIC CHANGES
Any project specific changes have been indicated in the following manner:-
(a) Text which is additional to the base document and which is included in the Specification is
shown in bold italics e.g. Additional Text.
(b) Text which has been deleted from the base document and which is not included in the
Specification is shown struck out e.g. Deleted Text.


B220 Wardell Sheave Repairs 1

PROTECTIVE TREATMENT OF BRIDGE STEELWORK
1 GENERAL
1.1 SCOPE
This Specification sets out the requirements for the protective treatment of BRIDGE STEELWORK. It
includes provisions for the painting of new steelwork and the maintenance painting of existing
steelwork.
This Specification includes a series of annexures that detail additional requirements.
1.2.1 Details of work
Details of work to be carried out under this Specification are described in Annexure B220/A.
1.2.2 Payment
Payment for the activities associated with completing the work detailed under this Specification must
be made using the Pay Item(s) referred to in Annexure B220/B.
1.2.3 Schedules of HOLD POINTS, WITNESS POINTS and Identified Records
The schedules in Annexure B220/C list the HOLD POINTS and WITNESS POINTS that must be
observed. Refer to RTA Q for the definitions of HOLD POINTS and WITNESS POINTS.
The records listed in Annexure B220/C are Identified Records for the purposes of RTA Q Clause E2.
1.2.4 Planning Documents
The PROJ ECT QUALITY PLAN must include each of the documents and requirements listed in
Annexure B220/D and must be implemented.
If the Contract does not require you to implement a PROJ ECT QUALITY PLAN, the documents
listed in Annexure B220/D must be submitted to the Principal for consideration at least 5 working
days prior to work commencing and must be implemented.
referenced document is the issue current one week before closing date for tenders, or where no issue is
current at that date, the most recent issue.
Codes, standards, specifications and test methods are referred to in an abbreviated form (e.g.
AS 2312). For convenience, the full titles are given in Annexure B220/M.
2 B220 Wardell Sheave Repairs

1.3 DEFINITIONS
The following definition applies to this Specification:
BRIDGE STEELWORK refers to all ferrous components including steel, wrought-iron and cast-iron
bridge components.
DFT refers to Dry Film Thickness.
Apply the definitions of painting terms contained in AS 2310.
2 RESOURCES
2.1 PLANT AND EQUIPMENT
2.1.1 General
Meet the obligations for plant and equipment in RTA G22.
2.1.2 Blasting and Painting Equipment
Ensure that clean dry air is supplied for abrasive blast cleaning, blowing down and spraying. Fit and
regularly maintain oil and water traps to all air-lines.
Employ new in-line air supply filters at the beginning of the Contract. Replace filters at the
manufacturers recommended date for replacement or earlier if found to be ineffective.
Ensure that water used for washing down and high-pressure water blasting is clean, free from
chlorides and free from any other deleterious contaminants. Maintain any supply water treatment
system.
Ensure any used water is treated to remove contaminants before recycling or discharge. Maintain used
water treatment system so that the water discharged from the system meets all environmental and steel
contamination requirements.
Use electric arc plasma equipment for hot metal spray work.
Include the procedure for monitoring and replacement of in-line air supply filters for blasting helmets
in the PROJ ECT QUALITY PLAN.
Include the procedures for monitoring of the water quality and maintenance of any water treatment
system in the PROJ ECT QUALITY PLAN.
2.2 MATERIALS
2.2.1 Cleaning Solutions
Use cleaning solutions for removal of non-water soluble contamination (e.g. grease, lifting chain
lubricant or road grime) according to recommendations of AS 1627.1.
B220 Wardell Sheave Repairs. 3

2.2.2 Water for blast cleaning
Use only water that is free from contaminants deleterious to the surface of the steel for high pressure
water blasting and jet washing.
2.2.3 Abrasives
Use only steel grit and other metal abrasives for the abrasive blast cleaning of new steelwork and use
permanent blast chambers fitted with mechanical recycling systems and dust extractors that ensure that
the abrasives are not exposed to water and are dry at all times.
Use only garnet abrasives for all on-site work, regardless of whether the work is carried out in a
weatherproof containment or not.
Do not use copper and other mineral slag abrasives that contain various forms of heavy metals.
Remove all inspirable dust and toxic contaminants from abrasives used as a blasting medium prior to
their re-use in the blasting process.
Analyse abrasives before first use for the presence of water-soluble salts and total lead content. The
water-soluble salts content must be less than 50 parts per million (ppm). The total lead content must
be less than 100 ppm.
Prior to the commencement of abrasive blast cleaning, submit a certificate from the abrasive supplier
that the abrasive conforms to these requirements.
2.2.4 Paint
Use paints and thinners conforming to RTA B221.
A single manufacturer must supply all paints.
All paints brought to site must be in their original unopened containers, bearing the manufacturers
label, batch number, coating colour and expiry date where applicable.
Store paint under conditions that do not lead to deterioration of the paint and store according to the
paint manufacturers recommendations.
Prior to the commencement of painting, provide written advice from the paint supplier on how to
interpret the paint suppliers batch coding and labelling to permit determination of the batch number
and the expiry date of the paint.
The Principal may take half-litre samples of the paints supplied for the work to test compliance with
RTA B221. Submit a copy of the manufacturers record of test when requested by the Principal.
Immediately removed nonconforming paint from site and replace.
2.2.5 Thinners
For each of the paint products to be applied, use only the specific thinners recommended by the paint
manufacturer for the thinning of paint.

Do use to thin paint solvents that are specified only for the cleaning of equipment. Prior to application
of paint, flush or otherwise remove from painting equipment solvents that are used for cleaning
equipment.
2.2.6 Fillers
Use only a two-part solventless epoxy putty that is suitable for use as a filler for crevices and gaps
between steel.
2.2.7 Hot Metal Spray
Use only a wire comprising 85% zinc and 15% aluminium. Wire must conform to AS. The Principal
may sample up to 100 grams of wire from each coil to test the wire for conformance.
3 EXECUTION
3.1 GENERAL
Carry out all work in accordance with the recommendations and advice of AS 2312 and AS 1627
unless otherwise specified herein.
3.2 EMISSIONS CONTROL
Employ containment and other measures for all surface preparation and paint application work to
prevent emissions from surface preparation operations, paint overspray or other discharges of
materials of any form into any river or waterway, into the air or onto any soils, onto passing vehicles,
pedestrians and other members of the public and their property. Employ water treatment and recycling
to minimise the water use where jet washing is used for preparing steelwork for painting.
Containments for abrasive blast cleaning work may be either permanent blast chambers or temporary
enclosures.
Ensure all containments comply with all environmental and occupational health and safety legislation.
Carry out painting works involving the surface preparation of paint coatings containing lead and/or
asbestos in accordance with RTA B223.
Employ screens, drop-sheets or similar measures to prevent coating surfaces not included in the
Contract.
Apply paint coating systems for new steelwork under enclosed conditions that protect blast cleaned
and freshly painted surfaces from damage from environmental exposure or air-borne dust or other
contamination.
3.3 HOT-DIP GALVANIZING
3.3.1 General
Carry out hot-dip galvanizing in accordance with AS/NZS 4680.
Ensure hollow members to be hot-dip galvanized are free from crevices, open and not sealed.

Ensure internal surfaces of hot-dip galvanized hollow members are galvanized.
Ensure galvanized coatings are free of the following:
(a) brittle, uneven and/or loosely adhering coatings on flame cut edges;
(b) pin-holes in galvanized coatings along welds; and
(c) white rust, ferrous rust and other surface contamination or stains that diminish the appearance or
function of the galvanized coating.
3.3.2 Repairs
Repair damaged galvanized coatings as follows:
(a) Degrease surfaces according to AS 1627.1 using a suitable proprietary cleaner containing
solvent and emulsifiable degreasers.
(b) Abrade damaged area by hand or power tool or by abrasive blast cleaning, as appropriate for
size and situation of area to be treated. Exposed steel must be bright, free of rust and other
surface impurities immediately prior to painting.
(c) Apply one coat of two pack, zinc rich epoxy primer paint to exposed steel and adjacent sound
galvanised coating to provide a dry film thickness of 75 microns.
3.4 PAINT COATING SYSTEMS
3.4.1 General
Paint coating systems for painted bridge steelwork are specified in Annexure B220/E.
3.4.2 Hollow Members
Fully seal hollow non-galvanised members with interiors that are inaccessible after fabrication by
continuous welding prior to painting. Use sealing welds between intermittent welds.
Internal surfaces of fully sealed hollow members require no protective treatment but must be dry and
free of any loose or other materials that may have long-term deleterious affects on the internal surfaces
and welds.
Paint internal surfaces of box girders with provision for entry of personnel in the finished structure
using the paint coating system specified in Annexure B220/E.
3.4.3 Surfaces in Contact with Concrete
3.4.3.1 Atmospheric Exposure
For surfaces of steelwork in contact with concrete in the completed structure exposed to
atmospheric conditions:
(a) Up to 50 mm of the adjacent exposed surface of steelwork apply the same surface
preparation and shop applied coatings as that employed on adjacent exposed surfaces
surface of steelwork.
(b) Beyond 50 mm from an exposed surface of steelwork apply the same surface
preparation and primer but coatings applied after the primer may be reduced in build to
give a total minimum dry film thickness, including primer, of 150 microns. For a single
coat system, the minimum dry film thickness of the single coating must be 150 microns.

3.4.3.2 Immersed Conditions
For surfaces of steelwork in contact with concrete in the completed structure and adjacent to
surfaces subject to immersion in water:
(a) Up to 200 mm from an exposed surface of steelwork provide the surface preparation and
the full protective treatment employed on the exposed surfaces.
(b) Beyond 200 mm from an exposed surface of steelwork provide the surface preparation,
full primer and a minimum total DFT of build and top coats of one half that applied to the
exposed surfaces.
3.4.3.3 Shear Studs
Abrasive blast clean shear studs to AS 1627.4 Sa 2 and then protect with coatings as per
the base steel area but with total dry film thickness of 50 to 150 microns.
3.4.4 Paint Coating Repairs
Repair all areas of damaged paintwork and areas at support locations for temporary scaffolding in
accordance with the specified paint coating system subject to following modifications:
(a) Areas less than 100 cm
2
may be prepared by power tool or abrasive paper.
(b) Exposed steel surfaces at repair areas must be bright, free of rust and other surface impurities
immediately prior to painting.
(c) Zinc phosphate epoxy primer may be used in lieu of zinc rich epoxy primer for priming areas
less than 100 cm
2
.
To achieve uniform appearance and colour and to blend in with previously applied paint, apply a light,
feathered spray application of the final topcoat paint to areas adjoining repairs.
3.5 CONNECTIONS
3.5.1 Fixings
The protective treatment of bolts, nuts, screws and washers must be in accordance with RTA B240.
3.5.2 Friction-Type Bolted Connections
3.5.2.1 General
Faying surfaces of friction-type bolted connections designed to AS 4100 must have a
minimum coefficient of friction of 0.35 measured according to AS 4100 Appendix J .
3.5.2.2 Galvanized members
Lightly abrade faying surfaces of friction grip bolted connections on galvanized members to
achieve the specified minimum coefficient of friction by means of one or more of the
following:
(a) by a light "brush off" abrasive blast clean to a dull grey finish;
(b) by buffing the surface with a carborundum impregnated, nylon buffing disc using a
slow revving grinder to a dull grey finish; and/or
(c) by lightly abrading with 120-grit paper to a dull grey finish.

3.5.2.3 Painted Members
Unless hot metal spray is specified, faying surfaces on painted members must be coated with
a zinc rich primer, irrespective of the coating system used elsewhere on the members.
The coating system for faying surfaces of painted members must be as follows:
(a) degrease surfaces according to AS 1627.1 using a suitable proprietary cleaner
containing solvent and emulsifiable degreasers;
(b) abrasive blast clean to AS 1627.4 Sa 2 with surface profile 45 to 65 microns; and
(c) apply one coat of a zinc rich primer having dry film thickness of 75 microns.
The zinc rich primer on faying surfaces must be either:
(i) an inorganic zinc primer conforming to AS 3750.15 Type 4 and APAS 2908, or
(ii) a zinc rich epoxy primer conforming to AS/NZS 3750.9 and APAS 2916.
If requested by the Principal, provide evidence that zinc paint coatings applied to faying
surfaces have the minimum coefficient of friction specified above.
3.5.2.4 Hot Metal Spray Faying Surfaces
Where specified, use hot metal spray on the faying surfaces. The coating system for hot
metal spray must be as follows:
(a) degrease surfaces according to AS 1627.1 using a suitable proprietary cleaner containing
solvent and emulsifiable degreasers; and
(b)
i. abrasive blast clean to AS 1627.4 Sa 3 with surface profile 45 to 65 microns;
and
ii. apply one coat of a hot metal spray having a thickness of 75 microns.
3.5.3 Masking at Connections
Mask connection areas of steel members that are to be blast cleaned and painted before site welding or
bolting as follows:
(a) mask areas adjacent to field welds to leave an uncoated margin of 75 mm to the first coat and an
additional 50 mm margin for each subsequent coat; and
(b) mask faying surfaces of friction-type bolted connections coated with zinc primer paint or hot
metal spray to leave a margin of 50 mm around the perimeter of the contact surface to the
second coat and an additional 50 mm margin for each subsequent coat.
Following completion of connection, prepare the surface, lightly feather masked coating edges and
apply paint coatings specified for the connected members.
3.5.4 Painting of Bolted Connections
Paint hot-dip galvanized and zinc plated nuts, bolts and washers, splice plates and other fixing
components of bolted connections of painted members as follows:
(a) degrease galvanized and zinc coated surfaces according to AS 1627.1 using a suitable
proprietary cleaner containing solvent and emulsifiable degreasers;
(b) lightly abrade hot-dip galvanized splice plates as per the surface preparation of galvanised
members;

(c) repair damaged areas of zinc coating as specified above for paint coating repairs; and
(d) apply paint coatings specified for the connected members.
3.6 SURFACE PREPARATION
3.6.1 General
Prepare surfaces of all iron and steelwork according to the requirements and recommendations of
AS 1627 unless otherwise specified in this Specification. Assess the surface profile of the steel to
ensure that the proposed blast preparation process will provide the required surface profile.
3.6.2 Preliminary cleaning
Remove heavy localised deposits of contaminants by scraping or other mechanical means that do not
spread contaminants over less contaminated areas.
3.6.3 Oil and Grease Removal
Clean areas contaminated with oil, grease and bitumen spray using an alkaline or solvent cleaning
process according to AS 1627.1 prior to blast cleaning or any other surface preparation process or
painting.
3.6.4 Sharp Edges
Sharp edges and corners, including sharp edges resulting from loss of section caused by rust, must be
rounded by hand or power tools to a minimum radius of 1.5 mm prior to painting.

WITNESS POINT

Process to be Witnessed: Commencement abrasive Blast Cleaning
Submission Details: 2 days prior notice of intention to commence abrasive blast cleaning
3.6.5 Abrasive Blast Cleaning
3.6.5.1 Procedures
Record the air temperature, surface temperature, relative humidity, dew point and time
immediately prior to commencement of abrasive blast cleaning. Record the air temperature,
surface temperature, relative humidity, dew point and time every two hours during blast
cleaning and immediately on completion of blast cleaning.
Abrasive blast clean surfaces using a dry abrasive blast cleaning process according to AS
1627.4 to achieve the specified class of surface preparation and profile.
You must abrasive blast clean all interior surfaces of members comprising two or more flat
plates, back-to-back angles, channels or other sections.
You need not remove sound coatings or sealants that remain under rivet heads, in corners, in
gaps between elements of built-up sections or in crevices after abrasive blast cleaning.
You must ensure no significant quantities of spent abrasive and removed paint particles
remain in on-site containments overnight. Collect and remove spent abrasive and removed
paint particles from contained areas at least once per day.

3.6.5.2 Surface Contaminants
Abrasive blast cleaned and painted surfaces must be free of salts, loose particles, paint over
spray or dust from abrasive blast cleaning and other surface contaminants prior to the
application of paint.
Remove any salts by jet washing and re-blast.
Remove surface contaminants by blowing down with compressed air and brushing with a
soft bristle brush. Air used to blow down surfaces must be free of oil and moisture.
Remove all residual dust on surfaces by vacuum.
3.6.6 Inspection
Prior to painting, inspect 100% of the area to be painted to ensure conformance with the surface
preparation requirements.

WITNESS POINT

Process to be Witnessed: Commencement of primer and commencement of other coats
Submission Details: Evidence by the Contractor of surface preparation having been
properly completed and documented on the Contractors ITP record
3.6.7 Records
Record details of the surface preparation procedures used on the work using AS 3894.10, AS 3894.14
or their equivalent.
As a minimum, include records of the following:
(a) name/s of cleaning solution manufacturer/s;
(b) product names of cleaning solutions;
(c) designation of each member or area where cleaning solution is used;
(d) the method/s of surface preparation employed;
(e) the class of surface preparation and profile of blast cleaned surfaces;
(f) the type and grade of abrasive;
(g) soluble salt and lead content of non-metallic abrasives; and
(h) records of the air temperature, surface temperature, relative humidity, dew point and times of
commencement and completion.
3.7 PAINT APPLICATION
3.7.1 Method
Except as otherwise specified below in this clause or Annexure B220/E, apply all paints and coatings
by spray using airless or air-assisted airless equipment.
Conventional spray equipment may be used for the application of zinc epoxy primers.
Employ brush and roller application as specified for stripe coats.

Ensure that the DFT is between the minimum specified DFT and three times the minimum specified
DFT at all locations.
Ensure that each coat is applied before the maximum recoat time specified by the Manufacturer but
after the previous coat has reached a sufficient degree of cure to accept the coat. Adjust curing times
according to the ambient conditions and the manufacturers recommendations.
3.7.2 Mixing Paints
Mix paints according to the Product Data Sheet or as advised by the Coating Manufacturer. Observe
mixing requirements including thinner type and quantity, and any induction times.
Hand mixing of coatings or packs of coatings that do not exceed 5 litres in total must be permitted.
Mechanical mixing must be employed for all kit sizes exceeding 5 litres in volume. For multi-package
coatings, both components must be thoroughly and separately mixed before blending together.
Mix coatings or packs of coatings that do not exceed 5 litres in total by hand or mechanical means.
Mechanically mix all kit sizes exceeding 5 litres in volume. For multi-package coatings, thoroughly
and separately mix both components before blending together.
Mix the total contents of the respective containers of the two components in a multi-package coating.
The contents of either of the two components must not be split unless an accurate means of
proportioning the components is provided.
When absolute colour consistency is required, pre-mix or box the Pack A components of coating products
that have been tinted to the required colour prior to the addition of the curing agent or converter and before
coating application.
For coatings containing heavy bodied materials, e.g., zinc metal filled coatings, the paint must be
strained using an appropriate mesh size to collect any agglomerations and continuously mechanically
agitated during application to prevent settling.
3.7.3 Application of Primer
Apply primers to prepared surfaces before any deterioration, discolouration or contamination of the
prepared surface occurs and, unless you use dehumidification control, on the same day as surface
preparation.
In all cases, ensure the class of surface preparation and surface profile is as specified at the time that
the primer coating is applied. If any deterioration in the standard of the prepared surface occurs by the
time that the primer is scheduled to be applied, the surface preparation must be repeated at no cost to
the Principal until you achieve the correct standard.
3.7.4 Application Conditions
Apply all paint coatings under paint application conditions recommended by the paint manufacturer.
Submit details of paint application conditions recommended by the manufacturer for all paints prior to
the commencement of paint application. Details must include, but not be limited to, the following:
(a) the maximum and minimum ambient temperature;
(b) the maximum and minimum temperature of surfaces to be painted;
(c) the maximum and minimum (if applicable) relative humidity;
(d) the minimum additional temperature of the surface to be painted above the dew point; and

(e) the minimum and/or maximum time delays between the applications of successive coats.
You may use dehumidification units and heaters that vary the relative humidity and temperature within
the working area to satisfy the paint manufacturers recommended application conditions. When you
use such equipment to vary paint application conditions, you must use the equipment during the whole
time that work is being performed, including the recommended curing period after the last application
of paint.

WITNESS POINT

Process to be witnessed: Commencement of Painting
Submission Details: Submission of test results that demonstrate that conditions for the
application of paint are appropriate
3.7.5 Stripe Coats
For each paint coating in a coating system, include a stripe coat of the paint prior to the general
application of the paint by spray. Apply wet-on wet applications of the stripe coat and the full
application of paint according to the paint manufacturers recommendations.
Where specified, a separate additional stripe coat, having a colour distinctly different to the underlying
and subsequent coatings, must also be applied. This stripe coat must be fully cured prior to the
application of the next coating.
Apply stripe coats to shadowed and other difficult to spray areas such as nuts, bolts, washers, rivets,
unsealed and filled lap joints and crevices formed by plates and sections in contact. Also apply stripe
coats to areas prone to corrosion such as exposed edges, holes, welds, corners and pitted areas.
Apply stripe coats to all interior surfaces of hollow latticed members, lower and upper chords of
trusses and the base of lift span towers.
Apply stripe coats by spray, roller or brush as necessary to ensure complete coverage of all shadowed
and other difficult to spray areas and to ensure all crevices and surface imperfections in the steelwork
are full of paint.
Apply stripe coats to all rivets with difficult to spray surfaces, all bolts, nuts and washers, all welds
and crevices by brush.
3.7.6 Crevices and Gaps
Fill any crevices and gaps that are not filled following application of the primer and other coatings
excluding the topcoat paint using a two-pack, solventless epoxy putty that is compatible with
subsequently applied coatings and is recommended by the paint manufacturer for this purpose.
Fill gaps between back to back angles or other sections with an epoxy putty only at upward facing
locations that have the potential to hold water and/or dirt such as at points of intersection of battens in
latticed members.
Apply a stripe coat of the epoxy build coat paint and other paints in the coating system to filled
crevices and gaps prior to the application of the topcoat.

3.7.7 Wet Film Thickness
Take wet film thickness measurements during application of all paints according to AS 3894.3,
Appendix C to ensure that the specified film builds are achieved. Include wet film thickness
measurements in the Inspection and Test Plan (ITP).
3.7.8 Records
Record details of the paint application procedures employed and data, using AS 3894.10 and/or
AS 3894.14 or equivalent for this purpose. These records must be made available to the Principal at
any time upon request.
The records must include, but not be limited to, the following:
(a) details of spray equipment;
(b) dates and times of blast cleaning and application of first coat of primer paint;
(c) dates and times of application of subsequent paint coatings;
(d) batch numbers of each product and designation of each member or area that each batch of paint
is used; and
(e) paint application conditions, namely:
(i) ambient temperature;
(ii) temperature of surface;
(iii) relative humidity; and
(iv) dew point.
3.8 CARE OF THE WORK
3.8.1 Lifting and Handling of Steelwork
Employ effective measures preventing damage to the protective treatment during all phases of lifting,
handling, storage, loading and transit of painted and galvanized steelwork.
Use lifting lugs for lifting steelwork where provided. Where lifting lugs are not provided, use chains
or steel strand encased in a full-length nylon braid sheath for lifting steelwork. Use chains or steel
strand with full-length nylon braid sheathing to secure steelwork for transport to site. Bare chains or
steel strand bearing directly on coated steel surfaces must not be used.
Store painted girders with soffits of girders a minimum distance of 600 millimetres above the ground.
For all steelwork, allow a minimum curing period of 72 hours from the completion of painting before
loading of steelwork for transport to site.
3.8.2 Construction Damage
Exercise due care at all times during all phases of construction to avoid damage to the protective
treatment of steelwork.
Prevent steel filings, weld spatter and spatter from oxy and acetylene burning or similar from
depositing on painted or galvanized surfaces. Immediately remove such material that does deposit on
painted surfaces to prevent rust staining of the painted surface.

Expeditiously remove concrete and slurry deposits on painted steelwork resulting from deck
construction using a method that does not damage the protective coating.
3.8.3 Damage to Property
Clean up spillages and overspray.
Refer Clause 29 of the General Conditions of Contract C2-GC21 - Care of People, Property and the
Environment.
4 CONFORMITY
4.1 DRY FILM THICKNESS
Determine the dry film thickness (DFT) of coatings on all surfaces at the completion of each coating
according to AS 3894.3 Method B.
Use an electronic electromagnetic DFT gauge with statistical capacity such as Elcometer Models 345,
456, or 355, PosiTector 6000 or similar dry film thickness gauge with a permanent hard copy record
produced for each definable area.
Measured DFT for each coating must achieve the minimum DFT specified in Annexure B220/E.
Use school grade chalk, adhesive inspection labels or masking tape to mark defects. Do not use
crayon, paint or spirit based ink pens.

WITNESS POINT

Process to be witnessed: Commencement of over-coating of a painted surface
Submission Details: Notification of the location, date and time proposed to commence
each overcoating. Submission of DFT records.
4.2 ADHESION
Carry out adhesion testing where there are indications to suggest that coatings are unsound such as the
presence of bubbling, blistering, wrinkling, and flaking or other visible defects.
The tensile adhesion of cured coatings to metal and paint coating substrates must exceed 2.0 MPa,
measured according to AS 1580.408.5.
4.3 APPEARANCE
On completion, all painted surfaces must be uniform in appearance and colour. Repair areas must
have the same appearance and colour as adjacent surfaces. Irregularly coated patches must not be
apparent.
Fishtails and other indications of poor paint application technique or equipment must not be evident.
Surfaces must have a smooth, even finish free from runs, missed areas, voids, pinholes, sags, fat edges,
blisters, stickiness, inclusions, overspray, overbuild and other paint film defects.

Areas of rust staining, staining from hardwood, formwork or other staining on painted surfaces must
not be apparent.
4.4 NONCONFORMITY
4.4.1 General
All applied coatings must comply with all specified requirements related to DFT, adhesion and other
defects that would limit the long-term performance of the coating.
Repair or replace any coatings that do not comply with the specified requirements.
Remove all areas of rust staining; staining from hardwood, formwork or other staining on painted
surfaces must be removed by solvent or detergent washing
You must investigate all substantial coating defects and report the results of such investigations to the
Principal in writing, along with proposed corrective actions to prevent further instances of such failure.
Repairs to coatings must be satisfactorily completed prior to the application of any subsequent coating.
4.4.2 Paint coatings
Where bubbling and other visible defects occur in 10% or more of the surface, or when the tensile
adhesion of cured coatings to metal and paint coating substrates is less than 2.0 MPa, measured
according to AS 1580.408.5, abrasive blast clean all affected surfaces of contiguous members to bare
metal and repaint.
Where the paint coating is less than the specified minimum DFT or greater than three times the
minimum DFT, abrasive blast clean all affected surfaces of contiguous members to bare metal and
repaints.
.If the completed paintwork on the outer face and soffit of exterior girders and other surfaces in
general public view is not uniform in appearance and colour as a result of coating repairs, apply a
further application of the topcoat paint having a minimum DFT of 40 microns, for the full length of
the girder or member, to those surfaces deemed necessary by the Principal. This additional application
of topcoat paint must be at no extra cost to the Principal.

WITNESS POINT

Process to be witnessed: Commencement of rectification to substantial coating defects
Submission Details: Notification of the location, date and time proposed to commence each
rectification. Submission of a written report on the causes of coating
defects and proposed corrective actions to the Quality Plan to prevent
future coating defects.
4.5 RECORDS
The records must include, but not be limited to:
(a) the surface preparation;
(b) the dry film thickness of coatings at the completion of each coat of paint, as applicable for each
definable area; and

(c) appearance of the finished surface

HOLD POINT

Process Held: Removal of access and/or containment in each separable area or section,
e.g. one bay or span.
Submission Details: Contractors daily inspection records for the bay or span including DFT
records.
Release of Hold Point: The Principal will consider the details submitted and spot check prior to
authorising the release of the Hold Point.


ANNEXURE B220/A DETAILS OF WORK

Contract:
Contract No
Bridge No
Location:
Local Government:
Details of work:
Zinc coatings are unsuitable for immersion and must not be used where prolonged immersion is
likely.
Standard Colour Scheme and Coating Systems:
The standard colour scheme is RTA Bridge Grey for all exterior surfaces and white for all interior
surfaces.
Coating Systems:
(a) External Surfaces, atmospheric exposure, new steel substrate SC1 or SC2
(b) External Surfaces, atmospheric exposure, existing steel substrate SC2
(c) External Surfaces, atmospheric exposure, galvanized steel substrate SC3
(d) Internal Surfaces, atmospheric exposure new steel substrate SC4 or SC5
(e) Internal Surfaces, atmospheric exposure existing steel substrate SC5
(f) Internal Surfaces, atmospheric exposure, galvanized steel substrate SC6
(g) All Surfaces subject to immersion SC7
(h) All Faying Surfaces where curing time is not available, atmospheric exposure, new or existing
steel substrate SC8
(i) External Accessible Surfaces coated with SC8, new Hot Metal Spray, SC9
(j) External Accessible Surfaces coated with existing Hot Metal Spray SC10
(k) Internal Accessible Surfaces coated with SC8, new Hot Metal Spray SC11
(l) Internal Accessible Surfaces coated with existing Hot Metal Spray SC12
(m) External Surfaces, atmospheric exposure, existing steel substrate where full cleaning not
achievable (subject to approval by the Principal) SC13
(n) Internal Surfaces, atmospheric exposure, existing steel substrate where full cleaning not

Non-standard Colour Scheme and Coating Systems:
Steel subject to immersion must be Black, RTA Bridge Grey, Natural Grey or N35 (Light Grey)
to AS3700
Exterior surfaces as specified.
Interior surfaces choose from the systems for interior surfaces above. Colour white. .
(a) External Surfaces, atmospheric exposure, new steel substrate SC15 or SC16
(b) External Surfaces, atmospheric exposure, existing steel substrate SC16
(c) External Surfaces, atmospheric exposure, galvanized steel substrate SC17
(d) All Surfaces subject to immersion, steel substrate SC18
(e) All Faying Surfaces where curing time is not available, atmospheric exposure, new or existing
steel substrate SC8
(f) External Accessible Surfaces coated with SC8, new Hot Metal Spray, SC19
(g) External Accessible Surfaces coated with existing Hot Metal Spray SC20
(h) External Surfaces, atmospheric exposure, existing steel substrate where full cleaning not

Coating Systems are detailed in Annexure B220/E.


ANNEXURE B220/B - PAYMENT
B.1 GENERAL
In the Schedule of Prices accompanying the Lump Sum Tender, the cost of maintenance painting work
must be divided using the Pay Items in B220/B.2.
B.2 PAY ITEMS
B220P1 - Surface Preparation and Priming of Existing Steelwork
These items must include all costs of all cleaning and surface preparation activities associated with the
removal of existing coatings and corrosion products to bare steel. These items must also include all
costs of all activities associated with the application of the primer or other first coat of paint applied to
the blast-cleaned surface.
The quantity must be the total surface area of steelwork to be prepared and primed. The unit is per
square metre.
B220P2 - Application of Stripe, Build and Topcoats to Existing Steelwork
These items must include all costs of all activities associated with the application of stripe coats, build-
coats and topcoats. These items must also include all costs associated with surface preparation
activities required prior to application of these coatings and all costs associated with final touch-up
and repairs.
The quantity must be the total surface area of steelwork to be painted. The unit is per square metre.
B220P3 Painting of New Steelwork
These items must include all costs of all activities associated with the painting of new steelwork
including the surface preparation of the steelwork, the application of the specified paint coatings and
emissions control.
The quantity must be the total surface area of steelwork to be prepared and painted including areas
requiring repair and touch-up such as at bolted and site-welded connections.
The unit must be per square metre for all steelwork except for pedestrian and traffic barrier railings.
The unit for pedestrian and traffic barrier railings is per linear metre.


ANNEXURE B220/C SCHEDULE OF HOLD AND WITNESS POINTS
C.1 SCHEDULE OF HOLD AND WITNESS POINTS

Clause No. Type
Process Held or
Witnessed
Submission Details
3.6.5 Witness
Point
Abrasive Blast Cleaning 2 days notice of intention to commence
abrasive blast cleaning
3.6.6 Witness
Points
Commencement of
primer and
commencement of other
coats
Evidence by the Contractor of surface
preparation having been properly completed
and documented on the Contractors ITP
record
3.7.4 Witness
Point
Commencement of
Painting
Submission of the Contractors test results that
demonstrate that conditions for the application
of paint are appropriate
4.1 Witness
Point
Commencement of over-
coating of a painted
surface.
Submission of evidence by the Contractor of
DFT records
4.4 Witness
Point
Commencement of
rectification to
substantial coating
defects
Submission by the Contractor of a written
report on the causes of coating defects and
proposed corrective actions to the Quality Plan
to prevent future coating defects.
4.5 Hold
Point
Removal of access
and/or containment in
each separable area or
section, e.g. one bay or
span.
Contractors daily inspection records for the
bay or span including DFT records.
The Principals site Surveillance Officer will
consider the details submitted and spot check
prior to authorising the release of the Hold
Point.

C.2 SCHEDULE OF IDENTIFIED RECORDS

Clause No. Description of the Identified Record
3.6.7. Surface preparation procedures and conditions
3.7.8. paint application procedures and data
4.5 Dry film thicknesses of paint coating


ANNEXURE B220/D PLANNING DOCUMENTS
D.1 INFORMATION TO BE INCLUDED IN THE PROJECT QUALITY PLAN

Item Details
Material product
information
For all paints, thinners, preservatives, cleaning solutions the following
information:
Type of product, manufacturer and product name;
Technical data setting out manufacturers recommendations for use.
Material safety sheets (MSDS) showing all hazard and first aid
information for products.
For all paints, written advice from the paint supplier on how to interpret the
paint suppliers batch coding and labelling to permit determination of the
batch number and expiry date of the paint.

Plant and equipment Type, description, capacity and number of each of the following:
Abrasive blast cleaning plant;
Paint application equipment;
Ventilation equipment;
Waste collection equipment;
Abrasive recycling equipment;
Dehumidifying equipment;
Hot metal spray equipment.

Procedures
Procedure for monitoring and replacement of in-line air supply filters for
blasting helmets, refer Clauses 2.1.2.
Procedure for monitoring and maintaining water treatment equipment
Procedure for adjusting curing times to suit ambient conditions.
Procedure for adjusting cuing time due to changes in thickness.

Conformity data
Procedure for the routine submission of conformity data and supporting
documentation that certifies conformity of all work and materials to the
requirements of the Specification.


ANNEXURE B220/E PAINT COATING SYSTEMS
This Annexure sets out details of the coating system for new and previously coated steelwork.
E.1 EXPLANATION OF TABLE
References:
B220 (3.6.2) refers to QA Specification B220 Clause 3.6.2.
B221 (8) refers to QA Specification B221 Clause 8.
The inclusion of some references only in the tables makes no representation regarding the applicability
of other clauses in the Specification that are not in the tables.
Dry film thickness
DFT 75 m refers to dry film thickness of coating in micrometers (microns).
Meaning
NA means Not Applicable

E.2 COATING SYSTEMS
Coating System SC1: Polyurethane Coating System applied to steel substrate
Details: as set out in Table B220/E.1
Table B220/E.1

Item Description All surfaces
excluding
Column 4
Internal
surfaces
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
Remove mud, dirt and other loose contamination.
Wash using low pressure water jetting or spot clean
using buckets, brushes and water.
B220 (3.6.2)
Oil &Grease
Removal
Remove oil and grease in accordance with
AS 1627.1.
B220 (3.6.3)
Removal of
mill-scale
and rust
Abrasive blast clean in accordance with AS 1627.4 to
achieve a Sa 2 cleanliness as described in AS 2312
and as depicted pictorially as Sa 2 in AS 1627.9.
The surface profile of bare metal must be 40 to 70
m measured in accordance with AS 3894.5.
B220 (3.6.5)
Zinc Primer One full coat of inorganic zinc sislicate primer.
Applied to all surfaces.
Colour green
75 m 75 m B220 (3.7)
B220 (3.7.3)
B221 (5)
Stripe Coat One stripe coat of a high build, two-pack epoxy paint.
Applied to all crevices, edges, bolts, rivets, and other
nominated surfaces.
Colour R63 Red Oxide to AS 2700
100 m 100 m
(applied
to all
surfaces)
B220 (3.7.5)
B221 (8)
Build coat One coat of a high build, high solids, MIO pigmented,
two-pack epoxy coat. Applied to all surfaces.
Colour Natural Steel Grey
200 m 125 m B221 (9)
Topcoat

One coat of a high build, acrylic modified, two-
component polyurethane. Applied to all surfaces.
Colour RTA Bridge Grey
75 m 75 m B221 (10)
Total Dry
Film
Thickness
Without stripe coat Minimum DFT
With stripe coat Minimum DFT
350 m
450 m
NA
375 m
B220 (4.1)

Coating System SC2: Polyurethane Coating System applied to steel substrate
Table B220/E.2

excluding
Column 4
Internal
surfaces
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
B220 (3.6.2)
Oil &Grease
Removal
AS 1627.1.
B220 (3.6.3)
Removal of
old paint,
mill-scale
and rust
B220 (3.6.5)
B220 (3.6.6)
Zinc Primer One full coat of a polyamide-cured, two-pack zinc-rich
epoxy primer. Applied to all surfaces.
Colour green
75 m 75 m B220 (3.7)
B220 (3.7.3)
B221 (5)
nominated surfaces.
100 m 100 m
(applied
to all
surfaces)
B220 (3.7.5)
B221 (8)
200 m 125 m B221 (9)
Topcoat

75 m 75 m B221 (10)
Total Dry
Film
Thickness
350 m
450 m
NA
375 m
B220 (4.1)

Coating System SC3: Polyurethane Coating System applied to galvanized substrate

Table B220/E.3

Item Description Minimum
DFT
Reference
Preliminary
Cleaning
Remove mud, dirt and other loose contamination. Wash using low
pressure water jetting or spot clean using buckets, brushes and
water.
- B220 (4.6.2)
Oil &Grease
Removal
Remove oil and grease in accordance with AS 1627.1. - B220 (4.6.3)
Preparation
of
Galvanized
surface
Lightly abrade galvanized surface by a light "brush off" abrasive
blast clean to achieve a dull grey finish.
The surface profile of prepared galvanized must be 15 to 25 m
measured in accordance with AS 3894.5.
- B220 (4.6.5)
Primer One full coat of a polyamide-cured, two-pack zinc phosphate epoxy
primer. Applied to all surfaces.
50 m B220 (4.7)
B221 (6)
Build coat One coat of a high build, high solids, MIO pigmented, two-pack
epoxy coat. Applied to all surfaces.
150 m B221 (9)
Topcoat

One coat of a high build, acrylic modified, two-component
polyurethane. Applied to all surfaces.
75 m B221 (10)
Total Dry
Film
Thickness
Applied paint coating 275 m B220 (5.1)


Coating System SC4: Epoxy Coating System applied to steel substrate.
Table B220/E.4

excluding
Column 4
Internal
surfaces
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
B220 (3.6.2)
Oil &Grease
Removal
AS 1627.1.
B220 (3.6.3)
Removal of
mill-scale
and rust
B220 (3.6.5)
B220 (3.6.6)
Zinc Primer One coat of inorganic zinc silicate primer. Applied to
all surfaces.
Colour green
75 m 75 m B220 (3.7)
B220 (3.7.3)
B221 (5)
nominated surfaces.
100 m 100 m
(applied
to all
surfaces)
B220 (3.7.5)
B221 (8)
125m 125 m B221 (9)
Topcoat

One coat of a high build, high solids, two-pack epoxy
topcoat. Applied to all surfaces.
Colour: White.
125 m 125 m B221 (10)
Total Dry
Film
Thickness
325 m
425 m
NA
425 m
B220 (4.1)

Coating System SC5: Epoxy Coating System applied to steel substrate

Table B220/E.5

excluding
Column 4
Internal
surfaces
of
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
B220 (3.6.2)
Oil &Grease
Removal
AS 1627.1.
B220 (3.6.3)
Removal of
old paint,
mill-scale
and rust
B220 (3.6.5)
Colour green
75 m 75 m B220 (3.7)
B220 (3.7.3)
B221 (5)
nominated surfaces.
100 m 100 m
(applied
to all
surfaces)
B220 (3.7.5)
B221 (8)
125 m 125 m B221 (9)
Topcoat

topcoat. Applied to all surfaces.
Colour: White.
125 m 125 m B221 (10)
Total Dry
Film
Thickness
325 m
425 m
NA
425 m
B220 (4.1)


Coating System SC6: Epoxy Coating System applied to galvanized substrate
Table B220/E.6

DFT
Reference
Preliminary
Cleaning
water.
- B220 (4.6.2)
Oil &Grease
Removal
Preparation
of
Galvanized
surface
- B220 (4.6.5)
50 m B220 (4.7)
B221 (6)
150 m B221 (9)
Topcoat

One coat of a high build, high solids, two-pack epoxy topcoat.
Applied to all surfaces
Colour: White
75 m B221 (10)
Total Dry
Film
Thickness


C
C
C
o
o
o
a
a
a
t
t
t
i
i
i
n
n
n
g
g
g

S
S
S
y
y
y
s
s
s
t
t
t
e
e
e
m
m
m

S
S
S
C
C
C
7
7
7
:
:
:

E
E
E
p
p
p
o
o
o
x
x
x
y
y
y

C
C
C
o
o
o
a
a
a
t
t
t
i
i
i
n
n
n
g
g
g

S
S
S
y
y
y
s
s
s
t
t
t
e
e
e
m
m
m

a
a
a
p
p
p
p
p
p
l
l
l
i
i
i
e
e
e
d
d
d

t
t
t
o
o
o

s
s
s
t
t
t
e
e
e
e
e
e
l
l
l

s
s
s
u
u
u
b
b
b
s
s
s
t
t
t
r
r
r
a
a
a
t
t
t
e
e
e

s
s
s
u
u
u
b
b
b
j
j
j
e
e
e
c
c
c
t
t
t

t
t
t
o
o
o

i
i
i
m
m
m
m
m
m
e
e
e
r
r
r
s
s
s
i
i
i
o
o
o
n
n
n

D
D
D
e
e
e
t
t
t
a
a
a
i
i
i
l
l
l
s
s
s
:
:
:

a
a
a
s
s
s

s
s
s
e
e
e
t
t
t

o
o
o
u
u
u
t
t
t

i
i
i
n
n
n

T
T
T
a
a
a
b
b
b
l
l
l
e
e
e

M
M
M
/
/
/
2
2
2
.
.
.
7
7
7

Table M/2.7

DFT
Reference
Preliminary
Cleaning
water.
- M (4.6.2)
Oil &Grease
Removal
Remove oil and grease in accordance with AS 1627.1. - M (4.6.3)
Removal of
Coatings and
Corrosion
Abrasive blast clean in accordance with AS 1627.4 to achieve a Sa
2 cleanliness as described in AS 2312 and as depicted pictorially
as Sa 2 in AS 1627.9.
The surface profile of bare metal must be 65 to 100m measured
in accordance with AS 3894.5.
- M (4.6.6)
Topcoat One coat of a two-pack medium-build or ultra-build epoxy paint
applied to all pier surfaces.
Colour: RTA Bridge Grey.
The paint shall be a solvent borne epoxy system approved under
APAS Specification Nos 2973F and 2973S for fresh and salt-water
immersion respectively.
The paint shall be applied by airless spray in a series of multiple
cross spray patterns to attain the specified DFT in a single coat.
500m P (10)
Total Dry
Film
Thickness
Applied paint coating 500m M (5.1)


Coating System SC8: Hot Metal Spray.
Table B220/E.8

excluding
Column 4
Internal
surfaces
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
B220 (3.6.2)
Oil &Grease
Removal
AS 1627.1.
B220 (3.6.3)
Removal of
mill-scale
and rust
B220 (3.6.5)
Hot Metal
Spray
One coat of Zinc-Aluminium (85% Zinc, 15%
Aluminium by weight) Hot metal Spray applied to all
surfaces.
125 m 125 m B220 ()
B220 ()

Seal coat One seal coat of a low viscosity epoxy sealer applied
to all exposed surfaces. (Seal coat is not applied to
faying surfaces where curing time is limited)
Colour: Green
30 m 30 m
(applied
to all
surfaces)
B220 ()
B221 ()
Total Dry
Film
Thickness
Minimum DFT

125 m

125 m

B220 ()

Coating System SC9: Polyurethane Coating System applied to steel substrate over Hot Metal Spray
Table B220/E.9

excluding
Column 4
Internal
surfaces
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
B220 (3.6.2)
Oil &Grease
Removal
AS 1627.1.
B220 (3.6.3)
Removal of
mill-scale
and rust
Abrasive blast clean in accordance with AS 1627.4 or
high pressure water blast to achieve a Sa 3
cleanliness as described in AS 2312 and as depicted
pictorially as Sa 3 in AS 1627.9.
B220 (
3.6.5)
Hot Metal
Spray
surfaces.
125 m 125 m B220 ()
B220 ()

Tie coat One tie coat of a low viscosity epoxy sealer applied to
all exposed surfaces. (Seal coat is not applied to
Colour: Green
30 m 30 m
(applied
to all
surfaces)
B220 ()
B221 ()
200 m 200 m B221 ()
Topcoat

75 m 75 m B221 ()
Total Dry
Film
Thickness
Minimum DFT

400 m

400 m

B220 ()

Coating System SC10: Epoxy Coating System applied to steel substrate over Hot Metal Spray
Table B220/E.10

excluding
Column 4
Internal
surfaces
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
B220 (3.6.2)
Oil &Grease
Removal
AS 1627.1.
B220 (3.6.3)
Removal of
mill-scale
and rust
B220 (
3.6.5)
Hot Metal
Spray
surfaces.
125 m 125 m B220 ()
B220 ()

Colour: Green
30 m 30 m
(applied
to all
surfaces)
B220 ()
B221 ()
200 m 200 m B221 ()
Topcoat

topcoat. Applied to all surfaces
Colour: White
75 m 75 m B221 ()
Total Dry
Film
Thickness
Minimum DFT

400 m

400 m

B220 ()

Coating System SC11: Polyurethane Coating System applied to steel substrate. (Use subject to
approval by the Principal)
Table B220/E.11

excluding
Column 4
Internal
surfaces
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
B220 (3.6.2)
Oil &Grease
Removal
AS 1627.1.
B220 (3.6.3)
Removal of
mill-scale
and rust
Abrasive blast clean in accordance with AS 1627.4.
Power and hand tool areas where full cleaning is not
possible
B220 (3.6.5)
B220 (3.6.6)
Zinc Primer One full coat of a polyamide-cured, surface tolerant
epoxy. Applied to all surfaces.
Colour green
75 m 75 m B220 (3.7)
B220 (3.7.3)
B221 (5)
nominated surfaces.
100 m 100 m
(applied
to all
surfaces)
B220 (3.7.5)
B221 (8)
200 m 125 m B221 (9)
Topcoat

Colour RTA Bridge Grey.
75 m 75 m B221 (10)
Total Dry
Film
Thickness
350 m
450 m
350
375 m
B220 (4.1)


Coating System SC12: Polysiloxane Coating System applied to steel substrate
Table B220/E.12

excluding
Column 4
Internal
surfaces
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
B220 (3.6.2)
Oil &Grease
Removal
AS 1627.1.
B220 (3.6.3)
Removal of
mill-scale
and rust
B220 (3.6.5)
Zinc Primer One full coat of inorganic zinc sislicate primer.
Applied to all surfaces.
Colour green
75 m 75 m B220 (3.7)
B220 (3.7.3)
B221 (5)
nominated surfaces.
100 m 100 m
(applied
to all
surfaces)
B220 (3.7.5)
B221 (8)
200 m 125 m B221 (9)
Topcoat

One coat of a high build, (polysiloxane). Applied to all
surfaces.
Colour and gloss in accordance with the architectural
scheme.
75 m 75 m B221 (10)
Total Dry
Film
Thickness
350 m
450 m
NA
375 m
B220 (4.1)


Coating System SC13: Polysiloxane Coating System applied to steel substrate
Table B220/E.13

excluding
Column 4
Internal
surfaces
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
B220 (3.6.2)
Oil &Grease
Removal
AS 1627.1.
B220 (3.6.3)
Removal of
old paint,
mill-scale
and rust
B220 (3.6.5)
B220 (3.6.6)
Colour green
75 m 75 m B220 (3.7)
B220 (3.7.3)
B221 (5)
nominated surfaces.
100 m 100 m
(applied
to all
surfaces)
B220 (3.7.5)
B221 (8)
200 m 125 m B221 (9)
Topcoat

surfaces.
scheme.
75 m 75 m B221 (10)
Total Dry
Film
Thickness
350 m
450 m
NA
375 m
B220 (4.1)
Coating System SC14: Polysiloxane Coating System applied to galvanized substrate

Table B220/E.14

DFT
Reference
Preliminary
Cleaning
water.
- B220 (4.6.2)
Oil &Grease
Removal
Preparation
of
Galvanized
surface
- B220 (4.6.5)
50 m B220 (4.7)
B221 (6)
150 m B221 (9)
Topcoat

One coat of a high build, (polysiloxane). Applied to all surfaces.
Colour and gloss in accordance with the architectural scheme.
75 m B221 (10)
Total Dry
Film
Thickness


C
C
C
o
o
o
a
a
a
t
t
t
i
i
i
n
n
n
g
g
g

S
S
S
y
y
y
s
s
s
t
t
t
e
e
e
m
m
m

S
S
S
C
C
C
1
1
1
5
5
5
:
:
:

E
E
E
p
p
p
o
o
o
x
x
x
y
y
y

C
C
C
o
o
o
a
a
a
t
t
t
i
i
i
n
n
n
g
g
g

S
S
S
y
y
y
s
s
s
t
t
t
e
e
e
m
m
m

a
a
a
p
p
p
p
p
p
l
l
l
i
i
i
e
e
e
d
d
d

t
t
t
o
o
o

s
s
s
t
t
t
e
e
e
e
e
e
l
l
l

s
s
s
u
u
u
b
b
b
s
s
s
t
t
t
r
r
r
a
a
a
t
t
t
e
e
e

s
s
s
u
u
u
b
b
b
j
j
j
e
e
e
c
c
c
t
t
t

t
t
t
o
o
o

i
i
i
m
m
m
m
m
m
e
e
e
r
r
r
s
s
s
i
i
i
o
o
o
n
n
n

D
D
D
e
e
e
t
t
t
a
a
a
i
i
i
l
l
l
s
s
s
:
:
:

a
a
a
s
s
s

s
s
s
e
e
e
t
t
t

o
o
o
u
u
u
t
t
t

i
i
i
n
n
n

T
T
T
a
a
a
b
b
b
l
l
l
e
e
e

M
M
M
/
/
/
2
2
2
.
.
.
1
1
1
5
5
5

Table M/2.15

DFT
Reference
Preliminary
Cleaning
water.
- M (4.6.2)
Oil &Grease
Removal
Remove oil and grease in accordance with AS 1627.1. - M (4.6.3)
Removal of
Coatings and
Corrosion
Abrasive blast clean in accordance with AS 1627.4 to achieve a Sa
2 cleanliness as described in AS 2312 and as depicted pictorially
as Sa 2 in AS 1627.9.
The surface profile of bare metal must be 65 to 100m measured
in accordance with AS 3894.5.
- M (4.6.6)
Topcoat One coat of a two-pack medium-build or ultra-build epoxy paint
applied to all pier surfaces.
Colour: In accordance with the aritectural colour scheme.
The paint shall be a solvent borne epoxy system approved under
APAS Specification Nos 2973F and 2973S for fresh and salt-water
immersion respectively.
The paint shall be applied by airless spray in a series of multiple
cross spray patterns to attain the specified DFT in a single coat.
500m P (10)
Total Dry
Film
Thickness
Applied paint coating 500m M (5.1)

Coating System SC16: Polysiloxane Coating System applied to steel substrate over Hot Metal Spray
Table B220/E.16

excluding
Column 4
Internal
surfaces
latticed
members
Reference
Min DFT Min DFT
1 2 3 4 5
Preliminary
Cleaning
B220 (3.6.2)
Oil &Grease
Removal
AS 1627.1.
B220 (3.6.3)
Removal of
mill-scale
and rust
B220 (
3.6.5)
Hot Metal
Spray
surfaces.
125 m 125 m B220 ()
B220 ()

Colour: Green
30 m 30 m
(applied
to all
surfaces)
B220 ()
B221 ()
200 m 200 m B221 ()
Topcoat

surfaces.
scheme.
75 m 75 m B221 ()
Total Dry
Film
Thickness
Minimum DFT

400 m

400 m

B220 ()

ANNEXURES B220/F TO B220/L - (NOT USED)


ANNEXURE B220/M REFERENCED DOCUMENTS

Abbreviation Australian Standards
AS 1580.408.5 Methods of Test for Paint and Related Materials; Adhesion Tensile Adhesion
test.
AS 1627 Metal Finishing - Preparation and Pre-treatment of Surfaces
AS 1627.1 Cleaning Using Liquid Solvents and Alkaline Solutions
AS 1627.2 Power Tool Cleaning
AS 1627.4 Abrasive Blast Cleaning
AS 1627.9 Pictorial Surface Preparation Standards for Painting Steel Surfaces
AS 1214 Hot-dip galvanized coatings on threaded fasteners (ISO metric coarse thread
series)
AS 2310 Glossary of Paint and Painting Terms.
AS 2312 Guide to the protection of Iron and Steel against Exterior Atmospheric Exposure.
AS 3894.3 Site Testing of Protective Coatings Determination of Dry Film Thickness.
AS 3894.5 Determination of Surface Profile
AS 3894.6 Determination of Residual Contaminants
AS 3894.10 Site Testing of Protective Coatings Daily Inspection Report.
AS 3894.14 Site Testing of Protective Coatings Daily Painting Report.
AS 4361.1 Guide to Lead Paint Management. Part 1: Industrial Applications.
AS/NZS 4680 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles.
Reference No: APAS Specification
APAS 2916 Organic zinc rich coating for steel
APAS 2973 High-build epoxy
Reference No: RTA Specification
RTA Q6 Quality Management System (Type 6)
RTA B240 Supply of Bolts, Nuts, Screws and Washers
RTA B221 Lead Paint and Asbestos Paint Management
RTA B223 Paints and Thinners for Bridges

QA SPECIFICATION B221
PAINTS AND THINNERS
FOR BRIDGES

VERSION FOR:
Wardell Bridge Sheaves

DATE: J anuary 2008

B221 2008 for Wardell Bridge

CONTENTS
SCOPE:.........................................................................................................................................1
REFERENCE DOCUMENTS.............................................................................................................1
QUALITY SYSTEM........................................................................................................................1
APAS APPROVAL ........................................................................................................................1
ZINC-RICH EPOXY PRIMER ..........................................................................................................2
Specifications: ...................................................................................................................2
Colour 2
Application Properties:......................................................................................................2
ZINC PHOSPHATE EPOXY PRIMER................................................................................................2
Specifications: ...................................................................................................................2
SURFACE TOLERANT EPOXY PAINT .............................................................................................3
Specifications....................................................................................................................3
Compatibility with other coatings.....................................................................................3
Volume/Solids...................................................................................................................3
Application........................................................................................................................3
HIGH-BUILD EPOXY PAINT..........................................................................................................3
Specifications....................................................................................................................3
Volume/Solids...................................................................................................................3
Application........................................................................................................................3
MIO EPOXY PAINT ......................................................................................................................3
Specifications....................................................................................................................3
Colour 4
Main Pigment....................................................................................................................4
Volume/Solids...................................................................................................................4
Application........................................................................................................................4
MIO POLYURETHANE PAINT........................................................................................................4
Specifications: ...................................................................................................................4
Colour and Gloss...............................................................................................................4
Pigments............................................................................................................................4
Curing agent......................................................................................................................5
POLYURETHANE PAINT SOLID COLOUR ....................................................................................5
Specifications: ...................................................................................................................5
Colour and Gloss...............................................................................................................5
Pigments............................................................................................................................5
Curing agent......................................................................................................................5

POLYSILOXANE PAINT SOLID COLOUR......................................................................................6
Specifications: ...................................................................................................................6
Colour and Gloss...............................................................................................................6
Pigments............................................................................................................................6
Curing agent......................................................................................................................6
DELIVERY ....................................................................................................................................6
Identification of Containers...............................................................................................6

LAST PAGE OF QA SPECIFICATION PART P IS...............................................................................7

B221 2008 for Wardell Bridge 1

QA SPECIFICATION P

Paints and Thinners for Bridges
1 Scope:
This Specification sets out details and requirements for the supply of paints and thinners for
the painting of bridges.
2 Reference Documents
Unless otherwise specified use the issue current at the date one week before the closing date
for tenders.
Standards, specifications and test methods are referred to in abbreviated form (eg AS 1234).
For convenience, the full titles are given below:
AS 1580 Paints and related materials - Methods of test
AS 2700 Colour Standards for general purposes
AS 2855 Paints and related materials Micaceous iron oxide pigment
AS 3750.1 Paints for Steel Structures - Epoxy mastic (two-pack) For rusted steel
AS/NZS 3750.6 Paints for Steel Structures Full gloss polyurethane (two-pack)
AS/NZS 3750.9 Paints for Steel Structures Organic zinc-rich primer
AS/NZS 3750.13 Paints for Steel Structures Epoxy primer (two-pack)
AS/NZS 3750.14 Paints for Steel Structures High-build epoxy (two-pack)
AS/NZS ISO 9002 Quality Systems - Model for quality assurance in production,
installation and servicing
ISO Standards
ISO 8501-1 Preparation of steel substrates before application of paints and related
products - Visual assessment of surface cleanliness Rust grades and
preparation grades of uncoated steel substrates and of steel substrates
after overall removal of previous coatings.
APAS Specification
Specification 2916 Organic zinc rich coating for protection of steel
Specification 2973 Solvent borne epoxy enamel or epoxy system to 400um

3 Quality System
Establish and maintain a Quality System in accordance with ISO 9002 as a means of ensuring
that the product conforms to the Specification requirements.
4 APAS Approval
Supply paints approved under Australian Paint Approval Scheme (APAS) or
are manufactured by an APAS recognised manufacturing unit and are accepted by the
Principals Authorised Person as suitable for the specified purpose.


Where you want a paint to be accepted by the Principals Authorised Person, submit the
following information not less than 20 working days prior to ordering supply of the paint:
(a) The name of the manufacturer and proof that the manufacturer is recognised by APAS
(b) Whether the paints are approved to specifications of the APAS 2900 Series other than that
specified.
(c) Whether the paints are approved to the appropriate APAS Specification for colours other
than that specified
(d) The status of any current applications for APAS approval for the paints.
(e) RTA experience with the paints.
(f) Case histories supplied by the manufacturer.
(g) Evidence from the manufacturer that the paints are superior, with respect to application
characteristics or long term performance, to other of the manufacturers paints that are
approved under the specified or other relevant APAS Specifications.
The Pricncipals Authorised Person has absolute discretion to accept or reject a paint not
approved under APAS.
You must not use paint that is neither approved nor accepted.
5 Zinc-Rich Epoxy Primer
5.1 Specifications:
A two-pack, polyamide cured, zinc-rich epoxy primer paint meeting the general requirements
of AS/NZS 3750.9 Type 2 and approved to APAS Specification 2916You must pre-diperse
the zinc component.
5.2 Colour
Green when dry and with sufficient colour difference as a wet film, that it will provide an
easy visual difference to blasted steel in low-light situations.
5.3 Application Properties:
Suitable for application by spray to a DFT of 75 microns without loss of cohesion or cure
properties.
Suitable for application by conventional, airless and air-assisted airless spray equipment and
also for application by brush/roller for small areas and touch-up.
6 Zinc Phosphate Epoxy Primer
6.1 Specifications:
A two-pack, polyamide cured, zinc phosphate pigmented epoxy primer paint meeting the
general requirements of AS/NZS 3750.13 and approved to APAS Specification 2971.
Suitable for application by spray to a DFT of 75 microns without loss of cohesion or cure
properties.
Suitable for application by conventional, airless and air-assisted airless spray equipment and
also application by brush/roller for small areas and touch-up.

7 Surface Tolerant Epoxy Paint
7.1 Specifications
A two-pack surface tolerant epoxy paint meeting the general requirements of AS/NZS 3750.1
with respect to constitution, cure rate and pot life, and approved to APAS 2973.
It must use a polyamide or similar curing agent;
7.2 Compatibility with other coatings
Tolerant of being applied over sound zinc-rich epoxy coatings and be physically and
chemically compatible with later coatings in the system.
7.3 Volume/Solids
Volume/solids greater than 70%.
7.4 Application
Suitable for application by airless and air-assisted airless spray equipment and by brush and
roller to a DFT of 125 microns.
8 High-Build Epoxy Paint
8.1 Specifications
A two-pack, high-build epoxy paint meeting the general requirements of AS/NZS 3750.14
with respect to constitution, cure rate and pot life,and approved to APAS 2973.
It shall use a polyamide or similar curing agent;
It shall be
Tolerant of being applied over sound zinc-rich epoxy coatings and be physically and
chemically compatible with later coatings in the system.
8.3 Volume/Solids
8.4 Application
Suitable for application by airless and air-assisted airless spray equipment and by brush and
roller to a DFT of 125 microns.
9 MIO Epoxy Paint
9.1 Specifications
A two-pack MIO pigmented, high build, epoxy paint meeting the general requirements of
AS 3750.14 with respect to constitution, cure rate and pot life, and approved to APAS 2973.
Suitable for application to sound zinc-rich epoxy coatings and stripe coats of high-solids
epoxy stripe coating and be physically and chemically compatible with later coatings in the
system.

9.3 Colour
Supply in a factory batched colour as an approximate match to the APAS colour Natural
Steel Grey.
9.4 Main Pigment
Natural MIO that: -
(a) meets the requirements of AS 2855 with a lamellar content of at least 60%;
(b) retains its lamellar appearance into the dry film (excessive high speed dispersion and
fragmentation of the MIO shall be avoided);
(c) comprises at least 80% by mass of the total pigment, taken to be the pigments that could
impart colour to the product, that is, excluding extender pigments.
9.5 Volume/Solids
9.6 Application
Suitable for application by spray to a DFT of 200 microns as a single coat by airless and air-
assisted airless spray equipment.
Suitable for application by brush/roller for small areas and touch-up.
10 MIO Polyurethane Paint
10.1 Specifications:
A two-pack MIO pigmented, high build, recoatable, acrylic modified polyurethane topcoat
paint that meets the general requirements of AS/NZS 3750.6 with respect to constitution, cure
rate and pot life, except where as modified herein with respect to gloss level, film build, gloss
change and colour.
Tolerant of being applied over sound zinc-rich epoxy coatings; high solids epoxy coatings,
surface tolerant epoxy coatings and MIO epoxy coatings.
10.3 Colour and Gloss
Supply in a factory batched colour to match RTA Bridge Grey, using the RTA 2002 MIO
polyurethane colour/finish standard.
Finished gloss level, when applied by airless or air-assisted airless spray, of between 10 and
20 gloss units when measured with a 60 head in accordance with AS 1580, Method 602.2.
Have a high exterior durability with respect to weathering and UV resistance when cured,
with minimum colour shift in full light, part light and full shadow situations.
10.4 Pigments
The main pigment of MIO polyurethane paint - natural MIO that: -
(a) meets the requirements of AS 2855 with a lamellar content of at least 60%;
(b) retains its lamellar appearance into the dry film (excessive high speed dispersion and
fragmentation of the MIO during manufacture of the paint shall be avoided); and

(c) comprises at least 90% by mass of the total pigment, taken to be the pigments that could
impart colour to the product, that is, excluding extender pigments.
MIO loading - between 40 and 50 grams per square metre when applied at a dry film
thickness of 75 microns.
Add non-leafing aluminium as a secondary pigment, (colourant) to achieve the RTA Bridge
Grey colour.
MIO polyurethane paint must not contain titanium dioxide as a pigment or lightening agent.
Use tinters for minor colour adjustments only.
10.5 Curing agent
An aliphatic polyisocyanate curing agent.
The curing agent must comprise at least 17% of the total binder solids by weight.
Volume solids and rheology so that the mixed coating can be satisfactorily applied by spray to
a DFT of 75 microns as a single coat.
Suitable for application by airless and air-assisted airless spray equipment and also
application by brush/roller for small areas and touch-up.
11 Polyurethane Paint Solid Colour
A two-pack Pigmented, high build, recoatable, acrylic modified polyurethane topcoat paint
that meets the general requirements of AS/NZS 3750.6 with respect to constitution, cure rate
and pot life, except where as modified herein with respect to gloss level, film build, gloss
change and colour.
Supply in a factory batched to match the specified colour.
11.4 Pigments
Lead based pigments are not permissible.
11.5 Curing agent
An aliphatic polyisocyanate curing agent.

12 Polysiloxane Paint Solid Colour
A two-pack Pigmented, high build, recoatable, polysiloxane topcoat paint that meets the
general requirements of AS/NZS 3750.6 with respect to constitution, cure rate and pot life,
except where as modified herein with respect to gloss level, film build, gloss change and
colour.
Supply in a factory batched to match the specified colour.
12.4 Pigments
Lead based pigments are not permissible.
12.5 Curing agent
A siloxane curing agent containing at least 60% siloxane by weight.
13 Delivery
13.1 Identification of Containers
Mark each container clearly and durably with the following information:
(a) Manufacturer's name.
(b) Product Name or Trade Name
(c) Product Reference Number or Identification Number
(d) Batch Number or date of manufacture.

Wardell Bridge Sheave Repair

6 ANNEXURE GL/2 REFERENCE DOCUMENTS
Sheave Drawings
Site Measurements of Sheave Grooves
Site measurements of corrosion and details.
Photographs


7 ANNEXURE G1/C - SCHEDULES OF HOLD POINTS, WITNESS
POINTS AND IDENTIFIED RECORDS
C1 SCHEDULE OF HOLD POINTS AND WITNESS POINTS

Clause Hold/Witness
Point
Description
1.1.c G1.1 Project Quality Plan
1.1.f G1.2 Final agreed scope of work
1.1.m G1.3 Final Report


8 ANNEXURES G1/D TO G1/L (NOT USED)

9 ANNEXURE G1/M REFERENCED DOCUMENTS
RTA Specifications
RTA Q Quality Management System

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