Stop the affected shipment, preserve its identity and condition, and notify the fabricator and carrier before unloading whenever possible. If the problem is found later, give notice promptly before erection. Then compare the steel with the purchase order, shipping records, material standard and project specifications; document the evidence; and route any suspected nonconformance to the authorized project engineer. Do not repair, substitute, clean, heat, straighten or erect questionable material until a written disposition is issued.
Rust alone is not a complete acceptance decision. The governing product standard and contract may permit some surface conditions while rejecting pitting, section loss, cracking, dimensional deviations or unidentified material. The exact tolerance, claim procedure and decision-maker come from the project documents, not from a universal “acceptable rust” rule.
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What to do in the first few minutes
- Pause unloading if safe. Keep damaged bundles, members, plates and packaging in the condition in which they arrived. Do not grind, blast, weld, heat, straighten, repaint or discard anything that could be evidence.
- Photograph the condition. Take overall photographs showing the truck or storage location and close-ups showing bends, dents, gouges, corrosion, pitting, cracks, coating damage, deformed holes, missing tags or other deviations. Include a scale where useful.
- Record identity. Write down the delivery date and time, carrier, bill-of-lading or shipment number, bundle and piece marks, heat or lot numbers, and the exact location where the condition was found.
- Notify the responsible parties. Contact the fabricator and carrier immediately, preferably before unloading. AISC 303-22, Section 6.6.5, states: “If material arrives at its destination in damaged condition, the receiving entity shall promptly notify the fabricator and carrier prior to unloading the material or promptly upon discovery prior to erection.”
- Quarantine the affected material. Mark it clearly and separate it from accepted stock so it cannot be installed accidentally. Maintain safe access, cribbing and weather protection while the disposition is pending.
The AISC notice sentence does not establish a carrier’s claim deadline or a required evidence package. Check the purchase order, shipping agreement and project contract for those requirements, and follow the project quality procedure for formal notifications.
Verify exactly what arrived
Match the shipment to the order
Use the purchase order, approved bill of materials, packing list, shipping documents and erection drawings together. Confirm section designation, plate thickness, length, quantity, grade, heat or lot information and any specified finish. A member that looks correct can still be the wrong grade or thickness; a correct grade without traceable identification can also be unacceptable under the contract.
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Separate identification from traceability
Identification means establishing that the specified grade and size are being used. Traceability links a particular piece or bundle to its mill test report or other required certification. Those are different controls. If the contract requires traceability, record the link for each affected piece rather than relying on a general certificate for the shipment.
Inspect visible condition and geometry
Look for impact marks, bent flanges or webs, twisted members, gouged edges, damaged connections, elongated or blocked holes, laminations, cracks, coating failure and water trapped inside bundles. Measure suspected deviations with calibrated tools and record the measurement, location, reference datum and instrument used. A visual impression such as “too short” or “badly bent” is not enough for an engineering disposition.
Classify the problem before deciding what it means
| Observed condition | Evidence to collect | Initial handling |
|---|---|---|
| Transit impact or deformation | Photographs, piece marks, measurements, packaging condition and carrier records | Hold the piece; notify fabricator and carrier before unloading when possible |
| Surface oxidation or mill scale | Location, extent, photographs and comparison with the specified surface condition | Do not reject automatically; evaluate under the applicable material standard and contract |
| Pitting, section loss, cracking or suspected lamination | Depth and area measurements, close-up images and any required examination | Quarantine and escalate to the responsible engineer or inspector |
| Wrong grade, size or missing certification | Tags, heat numbers, mill test reports, packing list and purchase-order requirements | Raise a documentation or material nonconformance; do not substitute informally |
| Dimensional deviation | Measured value, applicable tolerance, temperature or measurement conditions and drawing reference | Compare with the governing tolerance before choosing repair or rejection |
This classification prevents a common error: treating every visible imperfection as a material failure, or treating every brown surface as harmless rust. The same appearance can have different consequences depending on depth, location, structural demand and the requirement that applies.
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Start with the governing requirement
ASTM A6/A6M contains provisions for structural shapes and plates, including mill tolerances and permissible surface conditions. AISC explains that material complying with those provisions can contain certain surface imperfections when received. The project specification may impose additional surface, cleaning, coating or appearance requirements, so the purchase order and contract control the acceptance decision for that project.
Describe the condition precisely
Record whether the steel has light, uniform oxidation; loose scale; localized deep pitting; edge corrosion; gouging; cracking; or apparent section loss. Note whether the condition is on a primary tension area, a connection surface, a faying surface, a weld preparation or a location that will be concealed. “Rusted” is not a measurable finding until the location and severity are described.
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Understand what cleaning can reveal
AISC notes that ASTM A6/A6M material is commonly subject to visual acceptance or rejection at the mill and at fabricator receipt, although more extensive inspection may be used. Blast cleaning can expose imperfections that were hidden by mill scale or superficial rust. Requirements for remedial work should therefore be established in the contract rather than improvised after cleaning.
Know what the guidance does not establish
There is no single universal rust-depth threshold in the general guidance that makes every structural member acceptable or rejectable. Superficial oxidation is not automatically a nonconformance, while pitting, cracking, measurable section loss or a defect affecting a connection may require engineering action. If the condition cannot be classified confidently, keep the piece on hold and obtain the project’s required inspection or engineering review.
Checking whether steel is out of tolerance
Use the right reference for each measurement
Compare a measured length, thickness, straightness, camber, twist, flange width, web depth or hole location with the tolerance in the applicable ASTM product standard, approved drawing, project specification or fabrication requirement. Do not apply a tolerance from a different shape, product or edition. Confirm which edition the contract adopted and whether a local building code adds requirements.
Measure in a repeatable way
- Identify the datum and the points used for the measurement.
- Use calibrated tapes, rules, levels, laser tools or gauges appropriate to the tolerance.
- Record temperature or support conditions when they could affect length, sweep or camber.
- Measure more than one location if the suspected deviation varies along the member.
- Preserve the original measurement record and photographs with the piece mark.
A member that is outside a fabrication tolerance may still be capable of being made suitable, but that decision belongs in the project’s nonconformance process. A member within tolerance is not automatically acceptable if its grade, traceability or condition fails another requirement.
Raise a formal nonconformance when requirements may not be met
If grade, dimensions, condition, workmanship or records appear inconsistent with the contract, identify the affected material and issue the project’s nonconformance report or equivalent notification. State the requirement, the observed condition, the evidence, the affected quantity and the immediate containment action. Attach photographs, measurements, certificates and shipping records rather than relying on a verbal description.
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AISC 360-16 states that nonconforming material or workmanship is to be brought into conformance or made suitable for its intended use as determined by the Engineer of Record, and refers to reporting nonconformance and to repair, replacement or acceptance dispositions. The project’s adopted edition and contract may assign steps differently, so verify the actual workflow before acting.
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| Disposition | When it may be appropriate | Controls required |
|---|---|---|
| Replace | Damage, wrong material, severe corrosion or deviation cannot be justified for the intended use | Replacement identification, revised delivery records and removal or controlled storage of rejected material |
| Repair or rework | The condition can be corrected without reducing required strength, durability, fit or serviceability | Engineer-approved method, qualified personnel, inspection and updated records |
| Accept as is | Evidence shows the material meets the governing requirement or is suitable for the intended use | Documented approval by the authorized decision-maker and linkage to the affected pieces |
| Further examination | Visual evidence is inconclusive or the consequence of a defect is significant | Specified inspection method, acceptance criteria and a recorded result |
“Use as is” is not a receiving clerk’s decision. It is a documented engineering or contractual disposition made by the person authorized under the project documents.
Who can authorize acceptance, repair or substitution?
Start with the contract’s responsibility matrix, quality plan and delegated authorities. The fabricator may be able to propose a repair, but proposal is not approval. The carrier can document transit damage, but cannot decide structural suitability. The receiving contractor can quarantine and report the material, but should not unilaterally accept a lower grade or altered geometry. Under the AISC 360-16 language cited above, suitability decisions for nonconforming material are determined by the Engineer of Record; confirm the adopted edition and project-specific role before relying on that allocation.
Obtain written concurrence from every role the contract requires, which may include the Engineer of Record, owner, architect, inspection agency, fabricator and coating or welding authority. Keep the approval with the nonconformance record and identify exactly which piece marks and quantities it covers.
Why informal repairs create additional risk
- Heating or straightening can change material properties, introduce residual stress or violate a specified procedure.
- Grinding or gouging can reduce thickness, alter a connection surface or hide the original evidence.
- Welding over damage can create a defect or require qualifications and inspection not yet arranged.
- Substituting another grade or size can change strength, ductility, weight, connection design and fire or coating performance.
- Erecting before disposition can make inspection difficult and turn a receiving issue into a costly field rework problem.
Even apparently minor work should follow an approved method and inspection plan. If emergency stabilization is necessary for safety, perform only the minimum action needed to prevent injury or further damage, document it, and notify the responsible engineer immediately.
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Records that make a claim or engineering review defensible
Maintain one traceable file for each affected shipment or piece. Include:
- Purchase order, approved drawings, specifications and applicable material-standard references.
- Bill of lading, delivery ticket, packing list, carrier details and time of discovery.
- Piece, bundle, heat and lot marks, plus mill test reports or certificates.
- Photographs before unloading, after unloading if necessary, and after any authorized examination.
- Measured dimensions, inspection equipment identification and the person who took each measurement.
- Notification emails or letters to the fabricator, carrier and project representatives.
- Nonconformance report, proposed disposition, approvals, repair records and final inspection results.
- Updated status showing whether the material was accepted, repaired, replaced, returned or scrapped.
Do not overwrite original photographs or notes. If additional cleaning or examination changes the appearance, retain the “before” record and identify the date and method of the later work.
Managing the material while a decision is pending
Store quarantined steel on suitable supports so it does not acquire additional bending or standing-water damage. Protect identification tags from weather and keep pieces separated from accepted material. Control access in the laydown area and mark the status visibly in the material-tracking system. Coordinate the hold with the erection schedule, but do not remove it merely to avoid a crane or labor delay.
Ask the fabricator for a written response that addresses the observed condition, affected marks, proposed method and inspection requirements. If the response conflicts with the contract or project engineer’s direction, stop and escalate through the designated quality and engineering chain rather than choosing the fastest verbal answer.
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Practical examples
A bundle arrives with bent members and torn packaging
Photograph the truck, packaging and each marked member; record the shipment and piece marks; notify the fabricator and carrier before unloading if possible; and isolate the bundle. The engineer can then determine whether measured deformation affects fit or strength and whether replacement or an approved straightening procedure is appropriate.
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Plates show a uniform orange film but no measurable pitting
Record the surface condition and compare it with the specified product and finish requirements. Do not reject solely because the plates are discolored. If the contract requires a particular surface preparation, follow that requirement and inspect after cleaning for newly exposed imperfections.
A member has deep localized pits near a connection
Quarantine it, map and measure the pits, preserve photographs and traceability, and raise a nonconformance. Because the location may affect net section, bearing or connection performance, acceptance or repair requires the authorized engineering review rather than a cosmetic judgment.
The tag indicates a different grade from the mill certificate
Stop use and segregate the material. Reconcile the heat number, tags, certificates and shipping records with the fabricator. Do not relabel or substitute the piece until the project’s authorized party determines whether identity can be established or replacement is required.
Edition and contract checks before final disposition
AISC 303-22 is the published edition associated with the delivery-notification provision quoted above. A proposed later edition is not automatically an effective project standard. AISC 207-25 became effective February 1, 2026, but it is a certification-program standard and does not by itself determine whether a particular project may accept damaged or nonconforming steel. The surfaced AISC 360 disposition language is from the 2016 edition; verify the edition adopted by the project and by the local building code. Also verify the applicable ASTM product-standard edition, purchase-order terms, project specifications, shipping agreement and designated quality roles.
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