903.23 Laboratory Testing Guidelines for Sec 903

This article establishes procedures for Laboratory testing and reporting samples of material used for installation of highway signing including nuts, bolts, washers, polyurethane foam and specimens for welder qualifications.

903.22.1 Procedure

903.22.1.1 Bolts, Nuts and Washers

Chemical tests, consisting of mass of coating, shall be determined according to AASHTO M232. Chemical analysis of the base metal shall be determined, when requested, according to EPG 1020.8.1.1 Chemical Tests. Original test data and calculations shall be recorded in Laboratory workbooks. Test results shall then be recorded through SiteManager.

Physical tests shall be conducted according to EPG 712.3.2.2 Physical Tests - Bolts and Nuts. Original test results and calculations shall be recorded through SiteManager.

903.22.1.2 Polyurethane Foam

Tests on samples of polyurethane foam shall be conducted in accordance with the following methods:

(a) Compressive Strength - ASTM D1621

(b) Density - ASTM D1622

Original test results and calculations shall be recorded through SiteManager.

903.22.1.3 Structural Steel Welding

Samples of structural steel welding shall be tested in accordance with EPG 712.3.2.3 Structural Steel Welding.

903.22.1.4 Aluminum Welding

Tests shall be performed in accordance with Section IX of the ASME Boiler and Pressure Vessel Code.

903.22.1.4.1 Welding Procedure Qualification

Original test results and calculations shall be recorded through SiteManager. Groove weld tests required for procedure qualification for welding aluminum plate and pipe are as follows:

(a) Tests required for thickness of 1/16 in. to and including 3/8 in. are:

Two root bend,

Two face bend and

Two reduced section tensile tests.

(b) Tests required for thickness over 3/8 in. but less than 3/4 in. are:

Two root bend,

Two face bend and

Two reduced section tensile tests.

Four side bend and

Two reduced section tensile tests.

(c) Tests required for thickness of 3/4 in. or over are:

Four side bend and,

Two reduced section tensile tests.

Fillet welds are not required for procedure qualification of aluminum welding.

903.22.1.4.2 Welder (Performance) Qualification

Original test results and calculations shall be recorded in SiteManager. Tests required for performance qualification for welding aluminum plate and pipe are as follows:

(a) Groove weld tests required for performance qualification of various thicknesses of aluminum are shown under (1), (2) and (3) below. The tests listed are for aluminum plate. If welded aluminum pipe is being tested, the number of tests shown shall be doubled.

(1) Tests required for thickness of 1/16 in. to and including 3/8 in. are:

One root bend and

One face bend test.

(2) Tests required for thickness over 3/8 in. but not less than 3/4 in. are:

One root bend and

One face bend test.

or

Two side bend tests.

(3) Test required for thickness of 3/4 in. and over are:

Two side bend tests.

(b) Fillet weld specimens for performance qualification consist of two macroetch and one fracture specimen cut from 3/16 in. to 3/8 in. welded aluminum plate. The test specimens shall be evaluated as follows:

(1) The two macroetch test specimens are inspected for:

Fusion,

Fillet size and

Profile.

(2) The fracture test specimen, when bent flat upon itself, shall not fracture or if it does fracture the fractured surfaces shall be inspected for:

Surface cracks,

Root fusion and

Gas pockets.

903.22.2 Sample Record

Test results for bolts, nuts, washers, and polyurethane foam shall be documented on the appropriate templates in SiteManager. The sample record is to indicate acceptance, qualified acceptance or rejection. Appropriate remarks, as described in EPG 106.20 Reporting, are to be included in the remarks to clarify conditions of acceptance or rejection.

Procedure qualification test results for welds shall be reported through SiteManager. Welder qualification test results are also reported through SiteManager.

Current welder qualification status is maintained in SiteManager by Bridge Engineering.