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.
(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;
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
B246 Manufacture and Supply of Minor Aluminium Items
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.
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
Manufacture and Supply of Minor Aluminium Items B246
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.
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
B246 Manufacture and Supply of Minor Aluminium Items
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.
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
Manufacture and Supply of Minor Aluminium Items B246
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.
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
B246 Manufacture and Supply of Minor Aluminium Items
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
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
Manufacture and Supply of Minor Aluminium Items B246
Ed 3 / Rev 1 7
ANNEXURES B246/E TO B246/L – (NOT USED)
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
B246 Manufacture and Supply of Minor Aluminium Items
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