B246 Manufacture and Supply of Minor Aluminium Items · (d) structural aluminium drawn tube must...

Edition 3 / Revision 1 TRANSPORT FOR NSW

June 2020

TRANSPORT FOR NSW (TfNSW)

QA SPECIFICATION B246

MANUFACTURE AND SUPPLY OF MINOR ALUMINIUM ITEMS

NOTICE

This document is a Transport for NSW QA Specification. It has been developed for use with

roadworks and bridgeworks contracts let by Transport for NSW or by local councils in NSW. It is not

suitable for any other purpose and must not be used for any other purpose or in any other context.

Copyright in this document belongs to Transport for NSW.

REVISION REGISTER

Ed/Rev

Number

Clause

Number Description of Revision

Authorised

By Date

Ed 1/Rev 0 First Issued GM, CMS 10.09.91

Ed 2/Rev 0 Reformatted and clause numbers changed. GM, PSP (per W Ho)

19.09.96

Ed 2/Rev 1 1.2 References updated. GM, RNIC (W Ho)

23.07.97

1.4, 3.1 Quality Plan requirements transferred to new

clause.

4 Hold Point defined

Annexure

B246/1

New Annexure with Schedule of Hold Points

Ed 2/Rev 2 Annexure

B246/1

New schedule listing Identified Records GM, RNIC 03.05.00

Ed 3/Rev 0 Notice RMS PO Box and Fax numbers updated. GM, IC 15.05.09

Foreward Foreword, incorporating copyright clause,

added

Global Text revised to direct imperative style.

“shall” replaced by “must”.

Clauses rearranged and renumbered.

Reformatting and minor editing to clarify

intent.

1.2.5 Definitions of “you” and “your” added

1.3 Retitled to “PROJECT QUALITY PLAN”.

Requirement for Project Quality Plan to

comply with Annexure B246/D added.

Ed 3/Rev 1 Global References to “Roads and Maritime

Services” or “RMS” changed to “Transport

for NSW” or “TfNSW” respectively.

DCS 22.06.20

Edition 3 / Revision 1 TRANSPORT FOR NSW

June 2020

QA SPECIFICATION B246

MANUFACTURE AND SUPPLY OF

MINOR ALUMINIUM ITEMS

Copyright – Transport for NSW

IC-QA-B246

VERSION FOR:

DATE:

Manufacture and Supply of Minor Aluminium Items B246

Ed 3 / Rev 1 i

CONTENTS

CLAUSE PAGE

FOREWORD ............................................................................................................................................... II TfNSW Copyright and Use of this Document ............................................................................... ii Revisions to Previous Version ....................................................................................................... ii Project Specific Changes ............................................................................................................... ii

1 GENERAL ........................................................................................................................................ 1 1.1 Scope .............................................................................................................................. 1 1.2 Structure of the Specification ......................................................................................... 1 1.3 Planning Documents ....................................................................................................... 1

2 MATERIALS .................................................................................................................................... 2 2.1 General ........................................................................................................................... 2 2.2 Testing And Identification of Materials ......................................................................... 2 2.3 Repair of Defects ............................................................................................................ 2 2.4 Damaged Aluminium ..................................................................................................... 2 2.5 Storage Of Materials ....................................................................................................... 3

3 ASSEMBLY AND FABRICATION CONTROL ...................................................................................... 3 3.1 Programme ..................................................................................................................... 3 3.2 Prototype Components ................................................................................................... 3 3.3 Identification Marks ....................................................................................................... 3

4 FABRICATION ................................................................................................................................. 3 4.1 Cutting and Edge Treatment ........................................................................................... 3 4.2 Repair of Surface Defects ............................................................................................... 4 4.3 Holes for bolting ............................................................................................................. 4 4.4 Welding .......................................................................................................................... 4 4.5 Certification of Fabrication ............................................................................................ 4

5 TRANSPORT, HANDLING AND STORAGE ........................................................................................ 5

ANNEXURE B246/A – PROJECT SPECIFIC REQUIREMENTS ...................................................................... 6

ANNEXURE B246/B – (NOT USED) ........................................................................................................... 6

ANNEXURE B246/C – SCHEDULES OF HOLD POINTS AND IDENTIFIED RECORDS .................................... 6 C1 Schedule of Hold Points ................................................................................................. 6 C2 Schedule of Identified Records....................................................................................... 6

ANNEXURE B246/D – PLANNING DOCUMENTS ....................................................................................... 6

ANNEXURES B246/E TO B246/L – (NOT USED) ....................................................................................... 7

ANNEXURE B246/M – REFERENCED DOCUMENTS .................................................................................. 8

LAST PAGE OF THIS DOCUMENT IS ............................................................................................................ 8

B246 Manufacture and Supply of Minor Aluminium Items

ii Ed 3 / Rev 1

FOREWORD

TFNSW COPYRIGHT AND USE OF THIS DOCUMENT

Copyright in this document belongs to Transport for NSW.

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 TfNSW. A full copy of the latest version of the document is available on the TfNSW

Internet website: http://www.rms.nsw.gov.au/business-industry/partners-

suppliers/specifications/index.html

REVISIONS TO PREVIOUS VERSION

This document has been revised from Specification TfNSW B246 Edition 3 Revision 0.

All revisions to the previous version (other than minor editorial and project specific changes) are

indicated by a vertical line in the margin as shown here, except when it is a new edition and the text

has been extensively rewritten.

PROJECT SPECIFIC CHANGES

Any project specific changes are 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.

http://www.rms.nsw.gov.au/business-industry/partners-suppliers/specifications/index.html

http://www.rms.nsw.gov.au/business-industry/partners-suppliers/specifications/index.html

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

Ed 3 / Rev 1 1

TfNSW QA SPECIFICATION B246

MANUFACTURE AND SUPPLY OF MINOR ALUMINIUM ITEMS

1 GENERAL

1.1 SCOPE

This Specification sets out the requirements for the fabrication, supply and delivery of aluminium

expansion joints and other minor aluminium items, but excluding aluminium railings.

1.2 STRUCTURE OF THE SPECIFICATION

This Specification includes a series of annexures that detail additional requirements.

1.2.1 Details of Work

Project specific details of work are shown in Annexure B246/A.

1.2.2 (Not Used)

1.2.3 Schedules of HOLD POINTS and Identified Records

The schedules in Annexure B246/C list the HOLD POINTS that must be observed. Refer to

Specification TfNSW Q for the definition of HOLD POINTS.

The records listed in Annexure B246/C are Identified Records for the purposes of TfNSW Q

Annexure Q/E.

1.2.4 Referenced Documents

Unless specified otherwise, the applicable issue of a referenced document, other than a TfNSW

Specification, must 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 2350). For

convenience, the full titles are given in Annexure B246/M.

1.2.5 Definitions

The terms “you” and “your” mean “the Contractor” and “the Contractor’s” respectively.

1.3 PLANNING DOCUMENTS

The PROJECT QUALITY PLAN must include each of the documents and requirements listed in

Annexure B246/D and must be implemented.

Supply, as part of your PROJECT QUALITY PLAN, procedures for assembly, fabrication and

transport which must include, but not be limited to, the following:

(a) Assembly procedures, including dimensional control and details of manufacturing jigs;



2 Ed 3 / Rev 1

(b) System for identification of components;

(c) Procedures for trial assembly;

(d) Procedures for attachment of anchorages;

(e) Procedures for transport, handling and storage, including measures to prevent distortion and

damage to the aluminium work and its protective coating; and

(f) Procedure for curving and jointing (if applicable).

2 MATERIALS

2.1 GENERAL

Unless noted otherwise on the Drawings or in the Specification, materials used in the works must

comply with the following standards:

(a) structural aluminium sheet and plates must comply with AS/NZS 1734;

(b) structural aluminium drawn wire, rod, bar and strip must comply with AS/NZS 1865;

(c) structural aluminium extruded rod, bar, solid and hollow shapes must comply with

AS/NZS 1866;

(d) structural aluminium drawn tube must comply with AS/NZS 1867 unless noted otherwise on the

Drawings or in the Specification.

Tolerances for extruded sections must be as stated in "Aluminium Standards and Data - Wrought

Products", published by The Aluminium Development Council of Australia (Ltd), unless shown

otherwise on the Drawings.

2.2 TESTING AND IDENTIFICATION OF MATERIALS

Provide evidence that the materials or parts used conform to the tests required by the standards and to

other tests specified in this Specification.

Obtain, and retain, test certificates showing the results of mechanical tests and chemical analysis

(where applicable) of the material or parts used in the Works from a laboratory with the appropriate

NATA registration.

Identify all materials or parts used in the Works with the tests. Establish and maintain a

comprehensive system of identification records. Forward copies of all these records to the Principal

on request.

2.3 REPAIR OF DEFECTS

All grinding of surface defects must produce a surface roughness similar to the finish on surrounding

areas.

Weld repairs to materials are not permitted.

2.4 DAMAGED ALUMINIUM

Do not use in the Works aluminium which is bent, damaged or corroded.



Ed 3 / Rev 1 3

2.5 STORAGE OF MATERIALS

Store all aluminium, whether fabricated or not, in such a manner that corrosion is minimised.

Generally, storage at least 200 mm above the ground on platforms, slabs, or other supports under

cover will be satisfactory.

3 ASSEMBLY AND FABRICATION CONTROL

3.1 PROGRAMME

Submit to the Principal a programme showing the proposed sequence of operations at least five

working days before fabrication commences.

3.2 PROTOTYPE COMPONENTS

Give five working days' notice in writing to the Principal before commencing work, and allow for this

in your programme.

3.3 IDENTIFICATION MARKS

Metal stamp each component with an identification mark which is located in a hidden or

inconspicuous position after erection. Designate each type of component with a mark which is readily

distinguishable from the marks for all other types.

4 FABRICATION

HOLD POINT

Process Held: Fabrication of the second and subsequent item for each component

fabricated under the Contract.

Submission Details: Details of a thorough dimensional check of the first item with certification

that the dimensions conform to the requirements of the Drawings and this

Specification.

Release of Hold Point: The Principal will consider the submitted documents and may examine the

component, prior to authorising the release of the Hold Point.

4.1 CUTTING AND EDGE TREATMENT

Aluminium work may be cut by plasma-arc cutting, sawing, routing, planing, grinding or shearing

unless specified otherwise. Finish the surfaces produced by such cutting square (unless a bevelled

edge is called for), true to the required dimensions and free from defects, such as excessive roughness,

which would impair the service performance or seriously interfere with subsequent fabrication and

protective treatment.

Flame cutting must not be used.



4 Ed 3 / Rev 1

Do not use grinding on surfaces prepared for welding.

Unless shown otherwise on the Drawings, round all corners on exposed edges to remove sharp edges.

Rolled and extruded edges need not be rounded provided the corners are not sharp.

Any cut surface to be incorporated in a weld must comply with AS/NZS 1665.

4.2 REPAIR OF SURFACE DEFECTS

Grind or plane out any defects, score marks or bruises found during fabrication so as to produce a

surface roughness similar to the finish on surrounding areas.

4.3 HOLES FOR BOLTING

4.3.1 General

The diameters of the bolt holes must be 2 mm greater than the diameters of the bolts shown on the

Drawings unless specified otherwise.

Holes may be either drilled full-size or reamed to full-size after sub-drilling or sub-punching.

4.3.2 Sub-Punched and Sub-Drilled Holes

Sub-punched and sub-drilled holes must be smaller in diameter than the nominal diameter of bolts by

3 mm.

For sub-punched holes the diameter of the die must not exceed the diameter of the punch by more than

1 mm. Holes must be clean cut, without torn or ragged edges.

4.3.3 Reamed or Drilled Holes

Reamed or drilled holes must be cylindrical and perpendicular to the face of the member unless shown

otherwise on the Drawings. Carry out reaming and drilling by mechanical means.

Connecting parts may be assembled and held securely while being reamed or drilled, in which case the

parts must be match-marked before separating.

Alternatively, holes for 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 must be reamed or drilled to the same template.

Remove burrs on the outside surfaces.

4.4 WELDING

All welding must conform to AS/NZS 1665, unless specified otherwise.

Weld quality must be Category B with no undercut, unless shown otherwise on the Drawings.

4.5 CERTIFICATION OF FABRICATION

Provide the Principal with certification that each item fabricated conforms to the requirements of the

Drawings and the Specification.



Ed 3 / Rev 1 5

5 TRANSPORT, HANDLING AND STORAGE

Carry out loading, transport, unloading, stacking and handling operations in such a way that the

surfaces are protected from damage and distortion.

Store components in such a manner that the surfaces are protected from corrosion.



6 Ed 3 / Rev 1

ANNEXURE B246/A – PROJECT SPECIFIC REQUIREMENTS

Insert any project specific requirements here. If there are none, delete this comment and replace the

title with “(NOT USED)”

ANNEXURE B246/B – (NOT USED)

ANNEXURE B246/C – SCHEDULES OF HOLD POINTS AND

IDENTIFIED RECORDS

Refer to Clause 1.2.3.

C1 SCHEDULE OF HOLD POINTS

Clause Type Description

4 Hold Fabrication of the second item of each Component

C2 SCHEDULE OF IDENTIFIED RECORDS

The records listed below are Identified Records for the purposes of TfNSW Q Annexure Q/E.

Clause Description of Identified Record

2.2 Records of all materials or parts used in the Works, including test certificates (on

request by the Principal)

4.5 Certification of conformity of fabricated items

ANNEXURE B246/D – PLANNING DOCUMENTS

Refer to Clause 1.3.

The following documents are a summary of documents that must be included in the PROJECT

QUALITY PLAN. The requirements of this Specification and others included in the Contract must be

reviewed to determine additional documentation requirements.

Clause Description

1.3 Procedures for assembly, fabrication and transport

5 Procedures for transport, handling and storage



Ed 3 / Rev 1 7

ANNEXURES B246/E TO B246/L – (NOT USED)



8 Ed 3 / Rev 1

ANNEXURE B246/M – REFERENCED DOCUMENTS

Refer to Clause 1.2.4.

TfNSW Specifications

TfNSW Q Quality Management System

Australian Standards

AS/NZS 1665 Welding of aluminium structures

AS/NZS 1734 Aluminium and aluminium alloys - Flat sheet, coiled sheet and plate

AS/NZS 1865 Aluminium and aluminium alloys - Drawn wire, rod, bar and strip

AS/NZS 1866 Aluminium and aluminium alloy - Extruded rod, bar solid and hollow shapes

AS/NZS 1867 Aluminium and aluminium alloy - Drawn tubes

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