There is one particular change that causes concern, at least, for myself. Over the past few years there has been an extremely growing emphasis on “dual certified” CWI’s. This emphasis brings up a few questions that we need to briefly consider.
*The first question is ‘What does “dual-certified” even mean?’ This is very important to our discussion because the answer can lead to a very wide application. In my particular world it normally means the client wants someone with both CWI and UT Level II. No, they don’t mean someone with their CWI and MT cert, they want the CWI/UT. The even more concerning part here is that they don’t want JUST a CWI with UT either. They want CWI, UT AND MT qualifications. And normally they would really like some bolting background and even an ICC cert to prove code familiarity.
In other circles they will often want someone with CWI and NACE qualifications or on occasion CWI and fireproofing. But often, even if they want one of these, they still want NDE certs. In other words, we really are not talking about “dual-certifications” at all. We are talking about ‘triple’ or ‘quadruple’ certs with all the NDE you can possibly add to your CWI and having NACE, PT, and/or bolting can be a definite positive factor.
*The second question here is ‘Why the extreme push for CWI/NDE combo inspectors?’ As in most questions of this nature, we must ‘follow the money’. Sure, for small inspections agencies and on small jobs, especially with periodic inspections being the only Special Inspections required, it is prudent for the agency to hire and dispatch multi-qualified inspectors. When expanding this to larger contracts with continuous inspections we find clients trying to cut corners and expenses on Third Party Inspections by just hiring one inspector per shift or even per day from the Inspections Agency gaining the contract.
Another aspect, from the Inspections Agency perspective, is dependent upon how they ‘bid’ the job in order to guarantee the awarding of the contract. More than one company has been known to cut personnel to a minimum to make money on the contract. And using people with more than one qualification makes sense to them. Even with contracts that specify continuous inspections (according to IBC and AISC that means someone is to be on site whenever work is being performed) they send people on jobs in other shops and/or field erection while they are also dispatched to the continuous inspections job. They cut their costs to the bone but then make sure to be required to come back for re-inspections because of non-compliance issues or other factors that can be charged to the fabricator/erector instead of their customer to make up for the low ball bid.
*After looking at the two previous questions, the third question that comes up is ‘What are the consequences of this emphasis on “dual certified” welding inspectors?’ That can get to be a quite lengthy discussion but lets see if we can’t clarify some concerns over on this topic.
Looking at this we will focus on structural steel fabrication and erection. A large percentage of Fabrication Contractors are small enough that even when they have a viable inspections program, as compared to an inspections payroll with no truly trained/qualified personnel, they can’t afford to hire, train, and then pay a rate that would allow them to keep NDE personnel. Even those who can, the Client/Engineer generally prefers their TPI representatives to be the final say on NDE anyway. Thus, many contracts via the Contract Documents specify that only TPI need perform NDE. This keeps down the arguments and frustration of NDE being performed properly or not. Or, does it? Fabricators with their own NDE personnel can at the least cut down drastically on the number of rejections when the TPI checks the members for soundness.
But, the disagreements get going when improperly trained UT techs pass CJP after CJP and then a tech comes in who knows what they are doing and all of a sudden there are rejects everywhere. Techs not properly calibrating and using blocks not certified and/or specified by the applicable code, techs not correctly applying accept/reject criteria, techs not following code procedures, yet both are contracted to the same Inspections Agency. It is obvious where the fault lies, why were these people not tested by the contracting agency? Follow the money. Testing and training takes time. UT sample plates cost money.
A vast number of clients are trying to cut expenses on projects by denying per diem, overtime rates, and several other factors. This is often done through the Engineer or TPI agency with the main inspections contract. Contract inspectors are told, ‘work OT at straight time or we will find someone who will because there is no money in the job for OT.’ But, if inspectors would stand strong and say ‘no’ to these conditions we could force change for the better. Clients have told them, ‘If they don’t want to work for straight time, bring in a second inspector for the next 2-4 hours’. None of us wants to drive 50-100 miles and then work a part shift. How would we schedule the rest of our day?
I am seeing more jobs come through with VT being cancelled and only requiring NDE on a periodic basis. Jobs that, due to the D1.8 Demand Critical Welds, other seismic conditions, CJP and Mult-pass Fillet Welds and the location of the final project, should definitely be Continuous VT AND NDE. Add to that NDE personnel that are not properly qualified and you have disasters waiting to happen, even without an earthquake.
*This all comes back around to the Dual Certified Inspector for the fourth question. The CWI should be documenting that the UT/MT tech is performing their job correctly. But, when the two are one and the same, who is making sure the job is done as specified? Obviously not the Inspections Agency contracting the techs. They don’t even make sure that the already tested (yesterday) CWI knows how to perform the required inspections. And up pops D1.8 and they don’t even know what it is let alone have a copy nor have ever worked to it with a mentor. Neither the CWI nor the UT tech knows how to apply it correctly.
D1.8 has its’ own distinctive requirements. VT, MT, and UT special procedures for training, qualification, and practice. So many jobs being worked on today are in areas requiring D1.8 procedures for Demand Critical welds and other special applications. And yet there is a grossly untrained, inexperienced, unknowledgeable, batch of inspectors being used to complete jobs with no qualifications or experience in D1.8. For example, how often do you document pounds of lift for your Mag Yoke? Do you even carry the correct weight with you?
How many of the CWI/NDE techs that you have worked around or hired have a Level III on retainer? How many have been asked to provide proof of Professional Services/E&O insurance? How many have been proven to qualify per D1.8? Do you even know where the added requirements are in D1.8?
*We then come to our fifth question, ‘I got my CWI, now what?’ This question is asked so often it has gotten old. But, it is a legitimate question. More experienced CWI’s need to take time to mentor even if that only means pointing newbies down the road to broaden their experience and knowledge. Guidance is needed for correctly starting a business, getting familiar with other codes (AISC, IBC, NACE, ASNT, API-beyond 1104, and others), finding jobs they are actually QUALIFIED to work on, learning how to handle report writing and other customer relations issues, and knowing where to get the correct E&O insurance. The inspections world does not stop at D1.1 or API 1104. Looking at only AWS we find D1.2, D1.3, D1.3, D1.5, D1.6, D14’s, D9.2, D15, and the aforementioned D1.8. Lack of knowledge in the extended range of applicable codes involved in a project can get the inspector as well as the contractor into trouble real quick.
With all of this information we come to our sixth question: “How do I keep current on all of these codes and certs?” Follow the money. Yes, it takes time and money. And this is a critical question when looking at the issue of the “dual certified” inspector. When clients require so many certs, how do inspectors keep it all current to keep working? It can be a real challenge. Acquiring PDH’s/CEU’s, going to testing sites when required beyond just sending in your money, eye exams, paperwork, photos, etc. Quite a few CWI’s fail their nine year re-cert for the following reason, too much to do so they take what appears to be the fastest, easiest, cheapest way, the Part B exam. They get pigeon holed for nine years and then fail the Part B, especially in its’ newest form, because there is a lot there that they haven’t been exposed to for nine years.
*Seventh question, “How do I manage my time on the shop floor or in the field?” This is really a good one. So many shops, even smaller ones, can keep the TPI NDE tech so busy with UT and MT, especially on SidePlate jobs and others with special NDE needs, that between the testing and report writing it is quite impossible to do a proper job as the CWI making sure everything else is being done as required. Just look at AISC 360 Chapter N and see the job requirements for the CWI. But the same person is to be performing NDE at the same time? Most jobs truly need two men on a day shift at the least and often two on swing shift as well. You may get by with one person with triple (not dual) certs on swing shift but even on smaller crews it is often not a recommended practice.
If the TPI were ONLY performing the observation requirements of AISC 360 chapter N you may have a little bit more time but it never works that way. Especially on the jobs requiring D1.8. The Engineer through the General Notes, Contract Documents, SidePlate Notes, and others will lay more responsibilities on the TPI than the list in Chapter N. Add to that the list given by certain city Building Authorities Having Jurisdiction and you will be so busy doing CWI work you don’t have time for NDE, or, visa versa. And some require such extensive reports that you almost don’t have time on the floor to do the inspections you are supposed to be reporting on.
I have seen a couple of jobs so overstaffed with CWI’s and NDE techs that it was totally off the wall stupid. And the reports were just as ridiculous. And if you got switched to a different shop performing work on the same job, nothing was the same. And I do mean NOTHING. But the opposite is more often the case we encounter. We struggle through with worse than a skeleton crew and don’t do justice to any of our responsibilities. If all you are doing is performing NDE, filling in the NDE reports, and signing off on completed items, when do you take care of all the items during fit up, welding, and clean up?
Management, organization, training, observation/testing, all must take place to assure responsibility in honest, accurate, ethical, dependable inspections in both visual and NDE beyond VT. And the Inspections Agency with the contract to provide shop and erection inspections is often falling down on the job. They contract anyone and everyone close to the shop or field job in process and don’t even know if the person has any knowledge or experience with that particular type of work. AISC 341 has several different types of systems for handling seismic conditions. And many inspectors I encounter have never worked with even one of them or know where to find the information about them to begin to understand their responsibility in observation and inspection. The inspector is never checked on, tested, interviewed, or mentored to assure a QUALITY job.
The bottom line conclusion of this is that we need to verify that inspectors are properly qualified not just certified for the work at hand. Both CWI’s and NDE techs. Then, we need to make sure they have all the correct equipment to perform their job, CWI and NDE. Then, we need to make sure enough personnel is assigned to the job to get it completed correctly, CWI and NDE. Lastly, we need to make sure we are not giving in to ridiculous work contracts and receiving less compensation than we should be. All of the classes, experience, knowledge, certifications, tools, insurance, and cost of living cost money to get and to keep.
Both Quality Control and Quality Assurance are critical to long lasting, safe, and sound construction in all sectors. Properly administered QC and QA will enhance productivity, product quality, and profits. QC/QA is not a drain on profits, it will add to profits by reducing repairs, replacements, cancelled jobs, and other expenses often incurred when poor QC is being practiced. Not to mention law suits over poor work or even injuries or loss of life from poor workmanship.
Edit- added two paragraphs: This is not to say that the CWI should not get additional certs and especially in NDE. The best way to know a welder is doing his job correctly is to have been one. The same with NDE. If the CWI takes classes to at least become a Level I then they know what to watch for and make sure all is well. Being a level II in a couple of disciplines means you have the ability to keep things flowing in your organization if the other NDE personnel are busy. Having some familiarity with NACE means you are better able to understand how the surface prep is to be taken care of. This is generally specified in shop and design drawings which means I often comment to the lead person in the area when I spot something out of place especially if the shop is doing any painting before shipping which is very often the case.
As such, take classes to become conversant in other disciplines. AWS has several which can enhance your CWI with Endorsements, as do other organizations. (I don’t want to start listing as I will forget someone and it is not my intention to advertise for special groups). We also have a new Inspections Conference coming up January 21-23, 2020 in Houston, TX which will have classes to show you how to proceed to add to your knowledge and skills. AWS, ASNT, NACE, and AISC are partnered together in this new venue. You can find it on the AWS website at aws.org .