SMITH-EMERY LABORATORIES
791 E. Washington Blvd.
Los Angeles, CA 90021
DAILY INSPECTION REPORT
Project Name: Gaviota Secant Pile Wall - field welding Date: 2023-
07-26
Welding Contractor:Malcolm Drilling EA # 05-
1R1404
Jobsite Address: Buellton, CA SEL
Project # SEL-0724
Inspection(s) Performed: Welding inspection, Visual Inspection
Document(s) Reviewed: Field Drawing, Welding Procedures, AWS D1.1, Caltrans Standard
Specification
Inspection Request (IR)#: NA Jobsite Arrival Time:- 06:00 Hrs Jobsite Departure
Time:- 14:00 hrs
Summary of Observations:-
Smith Emery Quality Control Manager - Chris Dsouza (QCM) and Quality Control Inspector -
Shernell Concessio (QCI) arrived at Caltrans Field Welding Laydown Yard in Buellton, CA to
continue with inspection of the welding of Soldier Piles and double plates.
The following individuals present on the job site:-
Caltrans Structure Construction representative - Louis Coletta.
Malcolm Drilling welding superintendent - Chris Gilmore
o Additionally, Marion Casillas was introduced to help with a smaller tasks
around welding.
Material Verification:-
QCI reviewed new material (I-Beam) that arrived on the job site. The physical condition of the
material was satisfactory. Random dimensional checks were performed utilizing vernier
calipers and tape measure. Material grade and thickness met the requirements of approved
contract documents.
QCI conducted a count and a total of 76 I-beams have arrived at the job site.
QCI observed that Beam 03 after being welded with plates have been stacked seperately
over dunnage.
Welding:-
Welding Process:- FCAW
Welding Position: 2F
Electrode:- Lincoln Electric Innershield NR®-305
Electrode Diameter:- 3/32”
Type of Current:- Direct Current Electrode Positive (DCEP)
Welding Procedure Specification (WPS):- FCAW-LAP-NR305
Welding:-
Welding Procedure Specification (WPS):- FCAW-LAP-NR305
Beam 01 – QCI continued inspection during the fit-up and welding including verification of parameters
(Amps, Volts, Wirespeed, and Travel Speed) for conformance to WPS.
Welding was performed by Richard Day (RD). QCI confirmed that the plates were preheated at 150 F.
The QCI updated the welds for further correction, please see image and after correction VISUAL
Tested it okay, for FACE A.
Travel Speed, and Amperage and was recorded within the WPS range of 7.5 to 12.5 in./min at 11.75
in/min.
Welding for FACE A met the code requirements, followed by grinding to meet the standards of AWS
D1.1. Face A for Beam 01 was complete and Face B for Beam 01 has begun welding.
Welding was performed by Richard Day (RD). QCI confirmed that the plates were
preheated at 150 F
Wirespeed was noted as 160 in/min. and was noted to be within the WPS range of 160
– 300 in/min.
Voltage was noted as 24 volts.
Travel Speed was observed to be 11.75 in./min. and is within the WPS range of 7.5 to
12.5.
Upon completion of welding on Face A, QCI inspected the weld and noted the areas on steel
where weld repairs were required by grinding and/or welding. Areas with overlap and
excessive reinforcement were marked for grinding. Areas with poor/start-stop and insufficient
weld leg size were marked for weld repair directly on steel. Welds did not meet the visual
acceptance criteria requirements of AWS D1.1 2020 Figure 7.4 and Table 8.1
Beam 02 – QCI performed inspection during the fit-up and welding including verification of
parameters (Amps, Volts, Wirespeed, and Travel Speed) for conformance to WPS.
Welding was performed by Leonel Franco (LF). QCI inspected to check the plates were pre
heated at 150 F.
Wirespeed was noted as 240 in/min. and was noted to be within the WPS range of 160
– 300 in/min.
Voltage was noted as 23.2 volts. Welding was completed for first pass and second pass
to meet the code requirements, followed by grinding to meet the standards of AWS
D1.1
Upon completion of welding on Face A, QCI inspected the weld and noted the areas on steel
where weld repairs were required by grinding and/or welding. Areas with overlap and
excessive reinforcement were marked for grinding. Areas with poor/start-stop and insufficient
weld leg size were marked for weld repair directly on steel. Welds did not meet the visual
acceptance criteria requirements of AWS D1.1 2020 Figure 7.4 and Table 8.1
Beam 03 - QCI performed inspection during the fit-up and welding including verification of
parameters (Amps, Volts, Wirespeed, and Travel Speed) for conformance to WPS. Welding is
being performed by Leonel Franco (LF) on Face A side 1 & Richard day (RD) on Face A side
2. Welding is complete for Face A and Face B and meet code requirements as per AWS D1.1
and WPS.
Beam 04 - QCI performed inspection during the fit-up and welding including verification of
parameters (Amps, Volts, Wirespeed, and Travel Speed) for conformance to WPS. Welding is
paused for Beam 04 at the moment as the welders are working on Beam 02 and Beam 01
Overall Production Status
BEAM ID W24 x 250 Heat# Plate Heat# Welding ID QC VT Comments
FACE A – VT Welding pending
01 Sticker Missing S31003 RD
tested okay for FACE B
Face A – VT
Welding pending
02 579530 W3B740 LF tested okay
for Face B
okay
Face A & B – Moved to storage
03 579527 W3B740 LF/RD
VT tested okay over donnage
Paused –
04 Sticker Missing S31003 LF/RD welding Welding pending
pending
Photo 1 – Welding has begun on Face B Photo 2 – Weld defects corrected as per
standards
Photo 4 – QCI inspecting defects in welds
Photo 3 – QCI inspecting welds for Beam 02
for Beam 02
Remarks: General Conversation noted above
Inspected By: Shernell Concessio / Chris Dsouza QC Inspector
Reviewed By: Chris Dsouza QCM
