Fred-
The welding procedures are coming along.  Located a CWI to walk me through it.  My FCAW Qual. was lapsed [local juristiction WABO] so tested in FCAW unlimited Fri. results Mon 3/19 then do PQR on fillet using 4.20 detail B as suggested, inspector will do examination macros, write WPS and we should be good to go using new WPS and pre-qualified full pen with backing from D1.1.  When that's in place I will likely do another welder qual for GMAW, limited shop cert. 1G with backing per WABO and PQR for GMAW fillet.  Important distinction learned that neither local or AWS distinguishes between innershield and outershield.  FCAW is FCAW which made qualifying with outershield easier.  Your direction here was invaluable and acquiring AWS D1.1 as a source for information is also incredibly helpfull although assimilating it even in small chunks will be a long learning curve.

RE: Materials.  You may remember the A513 I had originally proposed.  That went away when the distributor brought their original price quote of A500 back to my attention.  The RFI requesting material change specification from A53 Grade B to A500 that you looked at has been submitted to contractor for owners approval and as of 3/16 has not been responded to.  I'm told it was probably kicked upstairs to Materials Dept. so we're still waiting.  Don't know what if any resistance can be anticipated but I've had enough anticipation this month to last me awhile.  If it comes to a dispute, I may reach out for further direction, but they have the certs. 100% melted and manufactured [I'm thinking that is the critical issue for them], chemistry and mechanicals that meet or exceed the A53 Grade B.  If rational minds don't prevail I'll have some more sleepless nights to anticipate.

Most of my "spare time" [between 4 AM and 7AM before the world begins] alloted to preparing shop drawings for the one job, getting the business re-formed as an LLC, money managment planning and adjusting schedules and priorities to fit other peoples.  Once the material issue is settled I'll sleep easier and be able to move that second project forward faster.  The next RFI will take up the 3/4" wall thickness falling below 1/8".  Have been councelled not to mention it by some, as it would likely go unnoticed but think your advice for the EOR approval is the best course of action. I'm hoping rational minds do prevail.  Just keep slugging away at it, head down one step at a time.  Didn't want to hound you unnecessaraly anymore untill I had good news to bring.  Maybe do that by weeks end.  Thanks for asking .

Cactus-
As you've probably gleaned from the other posts in this thread it is not an API documentation issue just a whole bunch of WSDOT handrail. As a welder doing naturl gas compressor stations I never had to deal with it, the inspectors checkers would just come by the hooch once or twice a day and write the heat # on your finished pieces and record it on their weld maps.  As an owner/operator this is the first run with WSDOT and their Standard Specifications and Construction Manual does not site criteria for material tracking directly.  It may by reference so I will go back to those sources and research it some more.  The API reference you gave may provide a model to simulate, hopefully a less time consuming and tedious one.  I will look to see if I can locate it through the info you left. Thanks.

Tim-
Thanks for that, I was thinking something along the same lines although I was hoping to simplify it by doing some kind of heat #/color coating match chart so individual pickets for example wouldn't have to have individual notations.  What you describe would be very time consuming.  The inspector doing the fabricator approval may have some suggestions or the authority to approve a color scheme tracking documentation providing the material invoice quantities match as built quantities and remnants.  We're only building handrail for the state, non of this is critical work but does need to be documented.  Using a paint code matched to Heat # would be a lot quicker/easier and logicaly should have as much documentation valididty as actual paint stick stenciling I would think.  It would be nice to know if the approach I would prefer has been used before in the same noncritical application I am describing.

Strother-
I think DOT is pretty much run on a state by state basis and will devise their own rules to suit themselves [within acceptable standards of course].  It sounds like your tracking methods would be the easiest means to handle it, and when I speak with the inspector who will be approving my material documentation procedure, I'm gonna run this by him and get his take on it before offering anything more comprehensive and time consuming.  Maybe your means and a daily production log with total material incorporated to compare to bill of lading for final tally will be enough.  Just need to meet the spec. on this, don't need to make extra work for myself.  Thanks all for the good ideas, feedback and voices of experience.  When this all gets set in place and given the green light over the next2-3 weeks, I'll still have a minimum of a month before doing any production maybe longer if Contractor doesn't meet their schedule.  Should be able to find time to write a report summarizing the many issues that have come up and how they were resolved both for the amusement of all and maybe for general guidline use to others contemplating this kind of work in the future.  Thanks again to everyone for helping out.