835STEEL REINFORCEMENT

701

833.03Lagging Timber

Lagging timber shall be fresh, rough-cut hardwood. Lagging timber design and selection to be the responsibility of the contractor. PILING MATERIALS

834.01Concrete Piles

Precast prestressed concrete piles shall be manufactured in accordance with the requirements given in Section 513.

834.02Steel Pile Point Protectors

The pile points shall be fabricated from cast steel meeting or exceeding the requirements of AASHTO M 103M. The pile points shall be properly identified as to the heat from which they were fabricated, either by this number being cast into the point or by being legibly stenciled on each point. Certified mill test reports shall be submitted for the pile points in accordance with the requirements given for the submittal of certified mill test reports for Structural Steel.

834.03Steel Bearing Piles

The material in rolled steel piles and splices shall conform to the requirements of AASHTO M 270 {AASHTO M 270M}, unless otherwise specified by plan details. All piles shall be rolled steel sections of the section number, size, and weight per foot {mass per meter} indicated on the plans and shall be fabricated in conformity with the requirements of ASTM A 6 {ASTM A 6M}. The heat number and section size shall be legibly marked on each piece by stamp, paint, tag, sticker or other industry accepted method. Any piece that cannot be properly identified at time of use will be rejected.

834.04Steel Sheet Piles

Permanent steel sheet piling shall be of the type called for on the plans and shall conform to the requirements of AASHTO M 202 {AASHTO M 202M} and its supplementary requirement, S1. Temporary steel sheet piling shall conform to the requirements of AASHTO M 202 {AASHTO M 202M} and its supplementary requirement, S1 and may be either new piling or used piling, acceptable to the Engineer for the intended function. The temporary steel sheet piling shall be interlocking type piles having a 3/8 inch {9.4 mm} minimum web thickness.

834.05Storing and Handling Steel Piles

When placed in the leads, the pile shall conform to camber and sweep permitted by allowable mill tolerance. The method of storing and handling shall be such as to avoid undue bending stresses or other injury. Piles bent, cracked, or otherwise injured will be rejected. STEEL REINFORCEMENT

835.01General

All reinforcing steel shall be Grade 60 {Grade 420} steel, unless otherwise stipulated in these Specifications or specifically designated by plan details. All steel reinforcement bars (smooth and deformed) must come from an ALDOT approved steel mill. Approved steel mills are listed in the Department’s Materials, Sources and Devices with Special Acceptance Requirements Manual, List I-12, Deformed and Plain Steel Bar Producing Mills. All reinforcing bars over 1/4 of an inch {6 mm} in diameter shall have deformations as prescribed in AASHTO M 31.

835.02Reinforcing Bars

Steel reinforcement bars 1/4 of an inch {6 mm} or less in diameter shall meet the requirements of AASHTO M 32. Steel reinforcement bars over 1/4 of an inch {6 mm} in diameter shall meet the requirements of AASHTO M 31. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 702

835.03Reinforcing Mesh or Mats

WIRE FOR MESH REINFORCEMENT. - Plain wire for mesh reinforcement shall meet the requirements of AASHTO M 32. Deformed wire for mesh reinforcement shall meet the requirements of AASHTO M 225. WELDED WIRE REINFORCEMENT. - Welded plain wire reinforcement mesh shall meet the requirements of AASHTO M 55. Welded deformed wire reinforcement mesh shall meet the requirements of AASHTO M 221. FABRICATED BAR OR ROD MAT. - Fabricated bar or rod mat shall meet the requirements of AASHTO M 54.

835.04Spiral Reinforcement

Spiral reinforcement may be plain or deformed bars or may be cold drawn wire. Plain reinforcing bars shall conform (except for deformations) to AASHTO M 31, Grade 40 {Grade 300} or Grade 60 {Grade 420}. Deformed bars shall conform to Article 835.02. Cold drawn wire shall conform to AASHTO M 32.

835.05Dowel and Tie Bars for Concrete Pavement

Dowel bars shall be smooth round bars of the size shown by plan details. The bars shall be fabricated from steel conforming to AASHTO M 31 for Grade 60 {Grade 420}, or AASHTO M 227 for Grade 70 {Grade 480} or higher. The bars shall have a corrosion resistant coating conforming to the requirements of AASHTO M 254 for a Type A or Type B coating. One end of each dowel used in an expansion assembly shall be provided with an approved tight fitting non-collapsible expansion cap.

Standard tie bars shall be of the size shown by plan details, fabricated from deformed bars meeting the requirements of AASHTO M 31 for Grade 60 {Grade 420}. Multi-piece tie bars shall be of the size shown by plan details fabricated from deformed bars meeting the requirements of AASHTO M 31 for Grade 60 {Grade 420} steel. Connectors shall be of a type approved by the Engineer.

835.06Prestressing Steel

Unless otherwise shown by plan details, stressing cables shall meet the requirements of AASHTO M 203 (ASTM A 416) Grade 1860 (270 ksi {1860 MPa}).

Stressing bars, when allowed by plan details, shall meet the requirements of AASHTO M 275 (ASTM A 722) for Type 1 or Type II with Mill Test Reports including Supplemental Requirements S1, S2 and S3, unless other requirements are provided by the plans or proposal.

835.07Use, Care, and Handling

All reinforcement received on the project shall be placed in approved storage and shall be maintained clean, intact, and free from distortion. Reinforcement shall be free from loose or thick rust, which would impair bond of the steel with the concrete. Rust that produces only discoloration without reducing the cross section of the steel will not be considered objectionable. Only such reinforcement shall be distributed along the construction as needed for immediate use. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS

836.01General

Steels, when received from the mill shall be identified in accordance with ASTM A 6 {A 6M}. On steel piling the heat number and section size shall be legibly marked on each piece by stamp, paint, tag, sticker or other industry accepted method. Any piece that cannot be properly identified at time of use will be rejected until such time documentation or approved testing of the items in question can prove conformance to the requirements. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 703

Certified mill test reports or certified reports of tests made by other agencies which are recognized by the ALDOT, shall be furnished for each heat of steel verifying that the material meets the requirements of the type and grade specified. The Department reserves the right to make its own test of any material, and the material may be rejected if these tests prove the material does not meet the requirements. For identification purposes, the fabricator shall utilize low stress stencils to dye stamp the mill heat numbers of the flanges and webs in the webs of welded members and in the webs of rolled members. The heat numbers shall be legible, located adjacent to piece marks, and placed centered between the top and bottom flange in the first panel to the left end and near side of the member. All steel which is required to have a yield point greater than 36,000 psi {250 MPa} shall, at all times in the fabricator's plant, be color marked to identify its AASHTO, ASTM, or special specification.

unless otherwise noted hereinafter in this Section or shown on the plans. AASHTO material specifications shall govern in lieu of ASTM material specifications where an AASHTO equivalent specification exists for all references within any referenced specification. With the approval of the Engineer, materials (other than web and flange material and web splice and flange splice material) for members may be taken from stock, provided the fabricator provides all documentation which shows the material conforms to the required specifications, prior to use of such material. The term “main member”, as used hereinafter in this section or shown on the contract plans, is defined as any member requiring Charpy V-notch (CVN) testing. Structural steel members requiring Charpy V-notch testing shall include, but not be limited to, the following: o All rolled beams in the superstructure and steel pier caps. o All flanges and webs of steel plate girders and steel pier caps. o All cover plates for beams and girders. o All flange and web splice plates for beams, girders, and floorbeams or stringer beams. o All connection plates welded to rolled beams, steel plate girders, and steel pier caps. o All diaphragms or cross frames for curved beams and girders, including their gusset and connection plates. o All stringer beams (floorbeams) and any connection plates welded thereto. o All floorbeam trusses (cross frames) which support stringer beams (floorbeams), including their gusset and connection plates.

Steel Grade Thickness Test Requirements M 270 Grade 36 Up to 4" 15 ft. lb. @ 70°F. (Min. Ser. Temp. 0°F. and above) M 270 Grade 50 & Grade 50W Up to 4" Mech. Fastened Up to 2" Welded Over 2" to 4" Welded 15 ft. lb. @ 40°F. 15 ft. lb. @ 40°F. 20 ft. lb. @ 40°F. (Min. Ser. Temp. -1°F. to -30°F.) {250} {Up to 102 mm} {20 J @ 21 °C} {Min. Ser. Temp. - 18 °C and above} {345 & 345W} {Up to 102 mm Mech. Fastened} {Up to 51 mm Welded} {Over 51 mm to 102 mm Welded} {20 J @ 4 °C} {20 J @ 4 °C} {27 J @ 4 °C} {Min. Ser. Temp. - 18 °C to -34°C} If the yield point of the material exceeds 65 ksi {450 MPa}, the temperature of the CVN value for acceptability shall be reduced by 15 °F {8 °C} for each increment of 10 ksi {70 MPa} above 65 ksi {450 MPa}.

The material supplied shall meet the longitudinal Charpy V-notch test noted below. Sampling and testing shall be in accordance with AASHTO T 243 with the (H) frequency of heat testing used. All members requiring CVN testing shall have heat numbers legibly marked during fabrication. When designated on the plans, the Contractor (Fabricator) shall furnish one main load carrying member (girder flange) 18 inches {460 mm} overlength per individual ALDOT bridge project, in order to provide an 18 inch {460 mm} sample for Departmental job control testing. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 704

Unless otherwise shown on the plans, steel plates for main members shall be cut and fabricated so that the primary direction of rolling is parallel to the direction of the main tensile and/or compressive stresses.

and 836.42. Threads for all bolts and pins for structural steel construction shall conform to the American National Standard for Unified Screw Threads, ANSI B1.1, Class 2A for external threads and Class 2B for internal threads, except that pin ends having a diameter of 1.375 inches {35 mm} or more shall be threaded six threads to the inch {25 mm}. All bolt heads and nuts shall be hexagonal shaped with dimensions conforming to the requirements for Hexagon Structural Bolts and Heavy Semi-Finished Hexagon Nuts of ANSI Standard B18.2.1 and B18.2.2.

and shipped as a unit unless otherwise approved by the Engineer. The method of securing the bearing unit for shipment shall be as shown by the plan details or a method acceptable to the Engineer. The diameter of pins used in cast and built-up bearing shall be within 1/16 inch {1.6 mm} of the diameter specified by the plans with pin holes not in excess of the pin diameter by more than 1/16 inch {1.6 mm}.

requirements of Article 836.01, except that it shall contain not less than 0.20 percent of copper. Copper bearing steels for other structural uses shall be as specified.

on the plans.

to AASHTO M 270 of the Grade as shown on the contract plans (Grade 50 or Grade 50W). AASHTO M 270 Grade 50 {Grade 345} steel shall be limited to structural shapes in groups 1, 2 and 3 in ASTM A 6 {A 6M} and to plates and bars in thicknesses through 4 inches {102 mm}. Plates and bars over 3/4 inch {19 mm} through 4 inches {102 mm} in thickness shall be "killed-fine grain practice."

application shall conform to the requirements of ASTM A 296 of the grade specified on the plans.

AASHTO M 314 (maximum tensile strength is waived). Galvanization of the anchor bolt from 3 inches {75 mm} below the top of the concrete to the top of the anchor bolt shall be required. The remaining length of the anchor bolt will not be required to be galvanized.

When full size tests of structural members are required the methods and procedures shall be provided in the plans and specifications.

836.02Steel Forging

Carbon steel forgings shall, unless otherwise specified by plan details, conform to the requirements of AASHTO M 102 for Class C material. All forgings shall be annealed prior to being machined to form finished parts. A record of the annealing charges shall be furnished the Engineer by the manufacturer showing the forgings in each charge, the melt or melts from which they were secured, and the treatment they received.

836.03Blank

836.04Steel Castings

Steel castings shall conform to the requirements of AASHTO M 103, Grade 70-36, unless otherwise specified, and the following:

section or member nor less than 1/2 inch {13 mm}.

AASHTO M 103 {M 103M}. Certification of annealing process shall be furnished by the manufacturer. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 705

sponginess, cracks, blow holes and other defects in positions affecting their strength and value for the service intended. No finished casting shall have visible blow holes so located that a straight line laid in any direction will cut a total length of cavity greater than 1 inch {25 mm} in any 1 foot {300 mm}, nor shall any single blow hole exceed 1 inch {25 mm} in any dimension or have an area greater than 1/2 square inch {13 mm 2}. Blow holes shall not have a depth injuriously affecting the strength of the casting. Minor defects which do not impair the strength may, if approved, be welded by the electric process. The defects shall be removed to solid metal by chipping, drilling or other satisfactory methods and, after welding, the castings shall be annealed, if required. No cracks, flaws or other defects shall appear after such treatment. No sharp unfilleted angles or corners will be allowed. Castings that have been welded without the Engineer's permission shall be rejected.

uniform surface.

actual weight {mass} (actual weight {mass} less than 95% of computed weight {mass} shall be cause for rejection of casting) and/or by suspending the casting and hammering it all over, comparing soundness of the ring.

836.05Gray Iron Castings

Gray iron castings shall be boldly filleted at angles and the arrises shall be sharp and perfect. They shall be true to pattern in form and dimensions. Castings will be classified under one of the following grades:

Grade "A" Castings shall conform to the requirements of Class No. 30 A for Gray Iron Castings, AASHTO M 105.

Grade "B" Castings shall conform to the requirements of Class No. 20 A for Gray Iron Castings, AASHTO M 105. All castings shall be of the Grade "A" classification unless otherwise noted.

All castings shall be blast cleaned of scale and sand so as to present a smooth, clean and uniform surface.

Any casting weighing less than 95% of the weight {mass} computed from its dimensions shall be rejected.

836.06Malleable Iron Castings

Malleable iron castings shall conform to the requirements of ASTM A 47, Grade No. 35018. Castings shall be boldly filleted at angles and the arrises shall be sharp and perfect. The dimensions of fillets shall not be less than provided in Article 836.04. The surfaces shall have a workmanlike finish. Malleable castings shall be true to pattern in form and dimension, free from pouring faults, sponginess, cracks, blow holes and other defects in positions affecting their strength and value for the service intended. Cleaning shall be as provided in Subarticle 836.05(b). Soundness shall be checked as provided in Subarticle 836.04(e).

836.07Ductile Iron Castings

Ductile iron castings shall conform to the requirements of ASTM A 536, Grade 60-40-18. Castings shall be boldly filleted at angles and the arrises shall be sharp and perfect. The dimensions of fillets shall not be less than provided in Article 836.04. The surfaces shall have a workmanlike finish. Malleable castings shall be true to pattern in form and dimension, free from pouring faults, sponginess, cracks, blow holes and other defects in positions affecting their strength and value for the service intended. Cleaning shall be as provided in Subarticle 836.04(d). Soundness shall be checked as provided in Subarticle 836.04(e). STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 706

836.08Self-Lubricating Bronze Or PTFE Bearing Plates

These bearing plates shall be an article of standard production by an established manufacturer of such equipment. They shall be provided with trepanned or drilled recesses (not grooves) which shall be filled with a lubricating compound capable of withstanding the atmospheric elements and consisting of graphite and metallic substances with a lubricating binder. Such compound shall be pressed into the recesses by hydraulic presses so as to form dense non-plastic lubricating inserts. The lubricating area shall comprise not less than 25 percent of the total area. The manufacturer shall furnish additional lubrication and just prior to assembling, the entire sliding surfaces of members in contact with plates shall be thoroughly lubricated with the approved lubricant. The bearing plates shall be made of bronze conforming to the requirements for Bronze Castings for Bridges and Turntables, AASHTO M 107, Alloy D, Copper Alloy 905, except that a maximum of 2-1/2 percent lead will be permitted. This will modify minimum on copper to 84.5 percent, minimum on tin to 8.5 percent and maximum on zinc to 3.75 percent. The coefficient of friction shall not exceed one-tenth.

The structural steel portion of the bearing plate shall meet the requirements of AASHTO M 270 GRADE 36 {M 270M GRADE 250} unless shown otherwise on the plans. The material, fabrication and installation requirements for Polytetrafluoroethylene (PTFE) polymer shall be those given in SECTION 837. The coefficient of friction shall not exceed one-tenth.

836.09Grounding Materials For Steel Bridges

Standard stranded copper grounding conductor shall be bare annealed Class B stranded electric conductor. Extra flexible grounding conductor shall be Class G bare annealed stranded electric conductor. Grounding rods shall be 5/8 inch x 8 feet {16 mm x 2.5 m}, minimum size, copperclad steel grounding rods as manufactured by A.B. Chance, McGraw-Edison, Joslyn Manufacturing and Supply Company, or approved equal. Exothermic welding shall be by the Cadwell process or an approved equivalent method. All materials shall conform to the National Electrical Manufacturers' Association (NEMA) or the Underwriter's Laboratories, Inc. standards.

836.10Lead Plates, Etc

Lead used for plates, pipes, etc., shall conform to the requirements of ASTM B 29 for common desilverized lead.

836.11Hardware For Timber Bridges

Machine bolts, nuts, washers, drift bolts, lag bolts and screws, dowels, nails, spikes, shear rings and plates and other miscellaneous hardware shall be common stock hardware items, either plain or galvanized. Galvanization when specified shall be in accordance with AASHTO M 232.

836.12and 836.13 Blank

836.14Shop and Working Drawings

The plans furnished the Contractor by the Department are not intended for use as shop or working drawings. Shop drawings and working drawings will be required as specified in Article 105.02. All applicable ALDOT specifications shall be referenced on the first shop drawing sheet by specification number and title. Shop drawings shall include camber and sweep diagrams covering steel portions of all structures. Fabricators shall furnish verification certificates of the actual measurements of the camber placed in each beam, girder or truss.

836.15Mill Orders and Shipping Statements

The Contractor shall furnish the Engineer with as many copies of mill orders and shipping statements as may be directed. The weights {masses} of the individual members shall be shown.

836.16Notice and Facilities For Inspection

After the Bridge Engineer has received the fabricator notification required by 508.03(b) and as the fabrication begins, copies of the mill test reports and fabricators material information, for materials STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 707

which require CVN testing, shall be supplied to the Bridge Engineer or his representative prior to completion and acceptance of fabrication. No materials or members will be accepted by the Bridge Engineer's representative on structural steel until the Department's form BBF-1 (available from the Bridge Engineer) and the supporting mill test reports for the materials have been furnished and approved by the Department. A complete package of this information shall be given to the ALDOT representative at the fabricator's plant, to be followed by a submittal to the ALDOT Materials & Tests' Certification office where official certification and approval is processed. The BBF-1 form shall be signed by a company official and shall be notarized. The acceptance of members as fabricated may be noted by the affixing of the ALDOT Stamp on the member by the Bridge Engineer's representative. The Contractor/Fabricator shall provide ALDOT with adequate, suitable office facilities and equipment when required for the inspection of materials and workmanship in the fabrication plant. This office shall be conveniently located near the fabricating plant or work site, shall be private and not shared with the fabricator or any other agency, and shall be equipped so that it may be locked. It shall be climate controlled, water tight, and include necessary office furnishings such as a desk/table, chairs, and file cabinet. (Telephone is optional). Inspectors shall be allowed free access to the necessary parts of the work. Refer to Articles 105.09,

105.10, and 105.11 concerning the duties of the Inspector(s) and inspection of work

Unless otherwise provided, the Contractor shall furnish, without extra compensation, test specimens as provided herein. Fabrication shops shall have a master tape calibrated by the National Institute of Standards and Technology. All tapes used in fabrication measurements shall be calibrated with the master tape before being used on the project. Any master tape found damaged or with a certification over two years old shall be replaced or recalibrated. The quality control program for any fabrication work performed will be subject to the review of the Bridge Engineer. A written current copy of the fabricator's Quality Control Manual and current copies of all nondestructive testing and Quality Control Inspection personnel certifications associated with fabrication work shall be on file with the Bridge Engineer prior to the beginning of work. Any bridge fabrication facility that is required to have an AISC Certification of Intermediate Bridge or Advanced Bridge shall have a Certified Welding Inspector (CWI) employed by, or retained by, and preferably working with the fabricator's quality control office. A CWI shall be present on all shifts and shall be available at any location that fabrication and welding are to take place. Quality Control guidelines and all welding code requirements shall conform to the AASHTO/AWS D1.5M/d1.5:2015, Bridge Welding Code, Seventh Edition. If the Bridge Engineer finds the fabricator's Quality Control Department is not providing sufficient inspection on the work in progress, he may suspend all or any portion of the work in progress (reference is made to Article 105.01 and Subarticle 108.07(a)). Work may resume only after necessary adjustments to the Quality Control Program are instituted which will assure conformance to the contract requirements. All nondestructive testing personnel shall meet the requirements set forth in the "ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel (ANSI/ASNT CP-105-2011)".

836.17Handling, Storage and Transporting Of Materials

The loading, unloading, handling and storing of materials shall be so conducted that the metal will not be injured or damaged. Structural material delivered at the bridge shop receiving yard shall be stored above the surface of the ground upon platforms, skids, or other supports and shall be protected from corrosion. It shall be kept free from accumulations of dirt, grease or foreign matter. During and after fabrication, proper lifting equipment with the capacity to handle members carefully at all times so that no member or part thereof will be bent, excessively stressed, deformed or otherwise damaged shall be used. Handling of members shall require the use of suitable clamps, plate hooks or other suitable devices. Chains or chokers will not be allowed without the use of a protective shield between the chain and the member. Members longer than 50 feet {15 m} shall utilize a two or more point pickup method. Members shall be transported in such a manner that they will not be excessively stressed, deformed or otherwise damaged. Unless otherwise authorized for exceptionally deep girders, girders and beams shall be stored and transported in a "workway position" as used in the structure with appropriate shoring and blocking methods suitable to the Engineer. Chain tie downs shall be provided with protection shields. Multiple stacking of beams and girders may only be done in a manner acceptable to the Engineer. Any suspected damage from handling, storage or hauling shall be cause for the Engineer to order verification of design camber and/or repair of the beam or girder. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 708

All structural materials shall be examined by shop personnel and/or quality control, at the earliest possible time for evidence of any defects. If pitting or other defects are plainly visible during early stages of fabrication prior to any required surface preparation (sand or shot blasting), evaluation shall be required. Information regarding actual material thickness, amount of area affected and end use of material being evaluated will be submitted to the Engineer for acceptability. Any required conditioning will be allowed only when in compliance with ASTM A 6 {A 6M}. The above shall also apply to pitting of fabricated material stored prior to shipment and to material delivered to the bridge site. Attention is called to Subarticle 106.05(b). Preparation and shipment of fabricated pieces shall conform to the following: Loose Members.

damage in shipping or handling.

protected. Packages.

crates, kegs, or barrels. A list and description of the contained material shall be plainly marked on the outside of each shipped container.

suit the requirements of the masonry construction. Loading diagrams shall be provided to the Bridge Engineer for his review when Structural Steel items are to be shipped by barge or railcar.

836.18Straightening Material

Rolled material, before it is marked, laid out, or otherwise worked in the shop must be straight or cambered as shown on the plans. Material with sharp kinks or bends may be rejected. If straightening is necessary it shall be done by methods that will not injure the metal and must be approved by the Engineer. Heat straightening will be permitted provided the metal is not heated above 1100°F {590 °C}. (controlled by the use of heat crayons furnished by the Fabricator or other approved means). After heating, the metal shall not be artificially cooled until after naturally cooling to 600 °F {315 °C} or less. The method of artificial cooling is subject to the approval of the Engineer. Water or water spray misting shall not be used as a means of artificial cooling. After straightening, the surface of the metal shall be carefully inspected for evidence of fracture.

836.19Workmanship and Finish

Workmanship and finish shall be first class in every respect. Materials at the shop shall be kept clean and protected from the weather insofar as practical. Shearing, burning, chipping and grinding shall be neatly and accurately done in a workmanlike manner. Damage incurred to members or the surfaces of members for any reason shall be cause for the Engineer to order the damage repaired or to reject the member in accordance with the following:

the plate thickness below the permissible minimum thickness allowed by ASTM A 6 {A 6 M} or the thickness of structural shapes in excess of 1/32 inch {0.8 mm} for material less than 3/8 inch {9.5 mm} in thickness, 1/16 inch {3.2 mm} for materials 3/8 inch to 2 inches {9.5 mm to 50 mm} inclusive in thickness or 1/8 {3.2 mm} in for material over 2 inches {50 mm} thick are considered repairable. Damage in excess of the limits noted will be evaluated by the Engineer as to whether to reject or allow repair of member.

Engineer’s representative to determine if the damage is repairable and if repairable, the repairs necessary for acceptance. Continued use of lifting devices that cause damage, especially that which reduces the specified thickness by more than 1/16 inch {1.6 mm}, will be cause for the rejection of all such members so damaged.

surfaces; however, when evaluation of base metal defects becomes necessary, such evaluation shall be done in the presence of the Bridge Engineer’s representative. The type of evaluation shall be determined by the fabricators quality control personnel subject to the STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 709

approval of the Bridge Engineer's Representative. After evaluation of such defects and where welding is necessary on rolled surfaces, stringer beads shall be placed parallel to the direction of stress. All welding shall be performed by competent welders using low hydrogen welding electrodes and/or welding consumables listed in an ALDOT approved welding procedure (WPS). The Engineer shall be the sole judge as to the acceptability of the repair work; any unacceptable work shall be cause for rejection of a member.

materials from damage caused by fitting tools or devices. If evidence of base metal damage appears due to misuse of such devices, the material may be deemed unacceptable.

done to the bend lines shown on the plans by a mechanically operated press without avoidable or unnecessary decrease in section.

to the following:

to the direction of rolling.

preferably shall be greater, than shown in the following table. Plate Thickness "t" Bend Radii For All Grades of Steel t  1/2 in {t  12 mm} 2t 1/2 in.  t  1 in. {12 mm  t  25 mm} 2.5t 1 in.  t  1.5 in. {25 mm  t  38 mm} 3t 1.5 in.  t  2.5 in. {38 mm  t  60 mm} 3.5t 2.5 in.  t  4 in. {60 mm  t  100 mm} 4t If a shorter radius is essential, the plates shall be bent hot. Hot-bent plates shall conform to requirement Item 1 above.

mm} throughout that portion of the plate at which the bending is to occur.

exceed 1100 °F {590 °C}. as evidenced by heat crayons or other approved means. Material that has been heated shall be slowly cooled after the bending has been completed.

Camber in rolled beams shall be accomplished by the heat up-set method utilizing the lowest possible temperature not to exceed 1100 °F {590 °C}, as evidenced by infrared thermometers or heat crayons. The application of heat shall be carefully supervised using a method acceptable to the Engineer. Camber for built-up girders shall be accomplished by cutting the web to the prescribed camber with suitable allowance for shrinkage due to cutting and welding. However, moderate variation from the prescribed camber tolerance may be corrected by a carefully supervised application of heat not to exceed 1100 °F {590 °C} as evidenced by infrared thermometers or heat crayons. Horizontal curving of rolled beams shall be accomplished by the heat up-set method which will require a written procedure approved by the Engineer. Said procedure shall utilize the lowest temperature possible but not in excess of 1100 °F {590 °C} as evidenced by infrared thermometers or heat crayons. Horizontal curving of built-up girders shall be accomplished by cutting flange plates to the radii shown by the plan details from wider plates, unless the heat up-set method is allowed by the plans or proposal. When the heat up-set method is allowed, such will require a written procedure approved by the Engineer. Said procedure shall utilize minimum temperatures not to exceed 1100°F {590 °C} as evidenced by infrared thermometers or heat crayons. After heating of metals as noted, the metal shall not be artificially cooled until after naturally cooling to 600°F {315 °C}. or less. The method of artificial cooling must be acceptable to the Engineer. Water or water spray misting shall not be used as a means of artificial cooling. Any material that is heated above the temperature limit noted will be rejected until tests and investigations reveal the material is suitable for use. The Fabricator shall be solely responsible for providing any test data or STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 710

other information deemed necessary by the Engineer to evaluate the acceptability of the material at no cost to the Department. The fabricator's Quality Control Inspector shall furnish verification certificates of the actual measurements of the camber, overall length and horizontal sweep placed in each beam or girder. Actual measurements shall be verified and recorded by the Fabricator's Quality Control Inspector.

If requirements for camber and sweep are not given in the contract, welded beams and girders shall be straight within a plus and minus tolerance for straightness. The straightness tolerance shall be +/- 1/8 inches per foot times the number of feet from the nearest end of the beam or girder divided by 10 {+/- 3 mm times the number of millimeters from the nearest end of the beam or girder divided by 3000}.

The camber of welded beams, girders, and armor plates shall be within a plus and minus tolerance measured in inches. The tolerance shall be + 1/8 inches and - 0 inches per foot times the number of feet from the nearest end of the beam, girder, or armor plate divided by 10 {+ 3 mm and - 0 mm times the number of millimeters from the nearest end of the beam, girder, or armor plate divided by 3000}.

The sweep of horizontally welded beams and girders shall be within a plus and minus tolerance measured in inches. The tolerance shall be +/- 1/8 inches per foot times the number of feet from the nearest end of the beam or girder divided by 10 {+/- 3 mm times the number of millimeters from the nearest end of the beam or girder divided by 3000}. The horizontal alignment of the sweep of the top and bottom flanges at any point along welded beam or girder shall be within 3/8 inch {10 mm).

The profile of the surface of a structural steel finger joint, measured along the centerline of the finger plate sections of the finger joint (transverse to the centerline of the roadway) shall be within a plus and minus tolerance. The tolerance shall be + 1/16 inch and - 0 inches per foot times the number of feet from the nearest end of the joint divided by 10 {+ 2 mm and - 0 mm times the number of millimeters from the nearest end of the joint divided by 3000}. When all fabrication is completed the flat surfaces of each finger plate section shall be straight edged for flatness and any area found exceeding 1/8 inch in 10 feet {3 mm in 3 m} shall be marked and corrected by approved methods. A 10 foot {3 m} straight-edge shall be used and lapped at least 5 feet {1.5 m} over the prior 10 foot {3 m} check.

836.20Thermal Cutting

Steel may be thermal cut, provided a smooth surface is secured by the use of a mechanical guide. Thermal cutting by hand shall be done only when approved, and the surface shall be made smooth by planing, chipping or grinding. Re-entrant cuts shall be filleted to a radius of not less than 3/4 inch {19 mm}. Defects in cut edges shall not be repaired by welding except with approval of the Engineer for occasional notches or gouges less than 7/16 inch {11 mm} deep for material up to 4 inches {100 mm} thick and less than 5/8 inch {16 mm} for material over 4 inches {100 mm} thick. Such weld repairs shall be made by suitably preparing the defect, welding with low hydrogen electrodes not exceeding 5/32 inch {4 mm} in diameter, observing the applicable requirements of Departmental welding requirements and grinding the completed weld smooth and flush with the adjacent surface to produce a workmanlike finish. Other methods of cutting steel may be acceptable provided the method will produce cut surfaces within the required tolerances for thermal cut surfaces.

836.21Substitutions

Substitutions of sections having different dimensions than those shown on the plans shall be made only when approved in writing. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 711

836.22Fastener Holes

In any one connection, all holes may be oversized or slotted by no more than 1/32 inch {0.8 mm}. In any one connection, a maximum of 10 % of the holes may be oversized or slotted by no more than 1/16 inch {1.6 mm} larger than the nominal diameter of the fastener.

Holes for connections in structural steel "main members" ("main members" as defined in Article

) shall be made in accordance with one or more of the following procedures:

assembled; - Drilling full size holes in the assembled members by using a steel template with hardened steel bushings with the holes accurately dimensioned from the centerlines of the connection; - Drilled using Computer Numerically Controlled (CNC) machinery. Web and flange splice plates shall be match marked to the splice locations regardless of the method used for drilling the holes.

Holes in members other than "main members" ("main members" as defined in Article 836.01) may be punched with a full size die if the thickness of the member is not greater than:

- Not greater than 3/4 inch {20 mm} for carbon steel and; - Not greater than 5/8 inch {16 mm} for high strength steel and; - Not greater than 1/2 inch {13 mm} for quenched and tempered alloy steel. The diameter of the die shall not exceed the diameter of the punch by more than 1/16 inch {1.6 mm}. Punched holes shall be clean cut and without torn or ragged edges.

Web and flange splice plates shall be match marked to the splice locations regardless of the method used for creating the fastener holes. Members drilled while assembled shall be securely held in the correct position while being drilled. Burrs on the metal surfaces shall be removed. Plug welding of any mis-located or mis-sized holes is not allowed.

provided, it may be required that any or all holes be (1) subpunched (or subdrilled) and either reamed or drilled to full size or (2) drilled full size from the solid. All subpunched holes shall be 3/16 inch {4.8 mm} smaller than the nominal diameter of the fastener.

done) a cylindrical pin 1/8 inch {3 mm} smaller in diameter than the nominal size of the punched hole may be entered perpendicular to the face of the member, without drifting, in at least 75 percent of the contiguous holes in the same surface or in like proportion for any group of holes. If this requirement is not fulfilled, the badly punched pieces will be rejected. If any hole will not pass a pin 3/16 inch {4.8 mm} smaller in diameter than the nominal size of the punched hole, this will be cause for rejection.

Bolted trusses, arches, continuous beam spans and plate girders shall be assembled in the shop either in an upright position or on their side. After the members have been adjusted to line and fit with proper camber and rigidly fastened (i.e., drift pinned) together, the holes for field connections shall be reamed or drilled. Filler plates for bolted beam and girder splices have been based on theoretical dimensions. The thickness of the plates shall be adjusted in the shop to take care of any difference greater than 1/16 inch {1.6 mm} between the theoretical and actual dimensions. Splices in members of the same theoretical size will require filler plates if the actual dimensions vary more than 1/16 inch {1.6 mm}. After assembling, sub-punched or sub-drilled holes shall be reamed to a diameter 1/16 inch {1.6 mm} larger than the nominal diameter of the fastener. Reaming shall be done after all the pieces to be connected are assembled and firmly fastened together. Reaming of fastener holes shall be done STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 712

with twist drills or with short taper reamers. Where practicable, reamers shall be directed by mechanical means. Burrs resulting from reaming or drilling shall be removed.

Reamed or drilled holes shall be cylindrical and perpendicular to the member and their accuracy shall be the same as provided for punched holes (Subarticle 836.22(b)) except that, after reaming or drilling, 85 percent of the contiguous holes in the same surface, or in like proportion for any group of holes, shall not show an offset greater than 1/32 inch {0.8 mm} between adjacent thickness of metal. There shall be no drifting in the shop or field to enlarge mismatched holes. If any holes must be enlarged to admit the fastener, they shall be reamed.

 1" Fastener: 1-3/4" {45 mm};  7/8" Fastener: 1-1/2" {38 mm};  3/4" Fastener: 1-1/4" {32 mm};  5/8" Fastener: 1-1/8" {29 mm}. The minimum distance from the center of any fastener to a rolled or planed edge, except in flanges of beams and channels, shall be:  1" Fastener: 1-1/2" {38 mm};  7/8" Fastener: 1-1/4" {32 mm};  3/4" Fastener: 1-1/8" {29 mm};  5/8" Fastener: 1" {25 mm}. In the flanges of beams and channels the minimum distance from the center of the fastener to a edge shall be:  1" Fastener: 1-1/4" {32 mm};  7/8" Fastener: 1-1/8" {29 mm};  3/4" Fastener: 1" {25 mm};  5/8" Fastener: 7/8" {22 mm}.

be less than three times the diameter of the fastener minus the nominal diameter of the hole. The distance to an edge shall not be less than the amount shown in Item 836.22(e)1. minus 1/2 the nominal diameter of the hole.

836.23Through 836.26 Blank

836.27Shop Assembling

All surfaces of metal that will be in contact when assembled shall be cleaned before assembly but shall not be painted unless otherwise specified by plan details. No temporary welds for fitting aids or for other purposes will be allowed unless shown on the approved drawings. All welding (including stiffeners) shall be completed on beams or girders before they are put into laydown and/or assembled.

plate girder spans and stringer beams, is done, a "laydown", consisting of at least three contiguous shop sections or all members in at least three contiguous panels but not less than the number of panels associated with three contiguous chord lengths (lengths between field splices) and not less than 150 feet {46 m} in the case of structures longer than 150 feet {46 m}, shall be required. All individual members (girders and beams) which require horizontal curvature shall be processed in the laydown with the required curvature. Shop assembly may proceed so long as one section of the minimum size "lay down" has been satisfactorily assembled in a preceding "lay down." All trusses shall be assembled in the shop. All expansion dams (finger joints) shall be assembled in the shop. Expansion dams shall be shipped assembled, including troughs, unless otherwise shown on the plans. For structures having curved girders, girders with integral steel caps, extreme skews in combination with severe grade or camber, or other complex characteristics, the plans may direct that STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 713

the entire structure, including the floor system, be assembled in the shop. The assembly, including camber, alignment, accuracy and fit of joints, shall be approved by the fabricator's Quality Control Inspector before reaming or drilling is commenced.

together with bolts before reaming or shop fastening is commenced. Assembled pieces shall be taken apart for the removal of burrs and shavings produced by reaming or drilling operation. The member shall be free from twists, bends and other deformations.

necessary, shall be spear-reamed for the admission of the fastener. The reamed or drilled holes shall not be more than 1/16 inch {1.6 mm} larger than the nominal diameter of the fastener.

brought to an even bearing. No milling shall be done until members are completely shop assembled, unless otherwise provided on the plans. Where joints are not faced (field splices in continuous steel girder lines), the opening shall not exceed 3/8 inch {9.5 mm}.

shown on the approved shop drawings, in the fabrication shop after cleaning (blasting) and coating

836.28Blank

836.29Match-Marking

Connecting parts assembled in the shop for the purpose of reaming or drilling holes in field connections shall be match-marked with low stress stencils using figures and letters at least 3/8 inch {10 mm} high, and a diagram showing such marks shall be shown on approved shop drawings. Reamed parts shall not be interchanged.

836.30Rivets

In removing rivets, care shall be taken not to injure the adjacent metal, and, if necessary, they shall be drilled out.

836.31Blank

836.32Bolts, and Bolted Connections

ASTM A 307 unless otherwise specified.

that both head and nut will bear squarely-against the metal.

are to be used in beveled surfaces, beveled washers shall be provided to give full bearing to the head or nut. All bolts shall have cut threads neatly and accurately finished.

otherwise shown on the plans.

Bolts transmitting shear shall be threaded to such a length that not more than one thread will be within the grip of the metal. The bolts shall be of such length that they will extend entirely through their nuts, but not more than 1/4 inch {6 mm} beyond them.

the threads entirely outside of the holes and under the washer, and a washer shall be used. The heads and nuts shall be hexagonal.

m}

used to prevent damaging the threads.

836.33High Strength Fasteners

The components of high strength bolt assemblies shall meet the requirements of the following: STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 714

 ASTM A 325 {A 325M} - Bolts  ASTM A 563 {A 563M} - Nuts  ASTM F 436 {F 436M} - Washers  ASTM F 959 - Direct Tension Indicators Unless otherwise noted by plan details, or approved by the Engineer, Type 1 bolts shall be used for standard construction and Type 3 bolts shall be used with weathering steel. Galvanization, where required shall be in accordance with the provisions of ASTM B 695 Class 50. When an Inorganic Zinc Paint Primer is specified on the contract plans, all bolts shall be galvanized. The producer, supplier and distributor shall submit the documentation required to certify that the bolt assembly components are in compliance with these specifications. These requirements shall be modified or supplemented as follows:

Acceptance of bolts, nuts, washers and direct tension indicator washers shall be based on the "Production Lot Method" of identification and quality assurance. A production lot is a group of bolts, nuts, washers or load indicator washers that are the same nominal size, are produced from the same heat of steel and are processed together through all operations to the shipping container. The manufacturer shall identify and maintain the integrity of each production lot from raw-material selection through all processing operations and treatments to final packing and shipment.

Bolts shall meet the hardness requirements given in ASTM A 325 {A 325M}.

Nuts to be galvanized shall be heat treated grade DH. Plain (ungalvanized) nuts shall be grades C, D or C3 with a minimum Rockwell hardness of 89 HRB (or Brinell hardness 180 HB), or heat treated grades DH or DH3. (The hardness requirements for grades C, D and C3 exceed the current AASHTO/ASTM requirements). Nuts that are to be galvanized shall be tapped oversize the minimum amount required for proper assembly. The amount of overtap in the nut shall be such that the nut will turn freely on the bolt in the coated condition. Galvanized nuts shall meet the mechanical requirements of ASTM A 563 {A 563M} and the rotational-capacity test herein (the overtapping requirements of ASTM A 563 {A 563M} paragraph 7.4 shall be considered maximum values instead of minimum, as currently shown).

All bolts, nuts and washers shall be marked in accordance with the appropriate AASHTO/ASTM Specifications.

Proof load tests (ASTM F 606 Method 1) are required. Minimum frequency of tests shall be as specified in ASTM A 325 {A 325M} paragraph 9.5. Wedge tests on full size bolts (ASTM F 606 paragraph 3.5) are required. If bolts are to be galvanized, tests shall be performed after galvanizing. Minimum frequency of tests shall be as specified in ASTM A 325 {A 325M} paragraph 9.5. If galvanized bolts are supplied, the thickness of the zinc coating shall be measured. Measurements shall be taken on the wrench flats or top of bolt head.

Proof load tests (ASTM F 606 paragraph 4.2) are required. Minimum frequency of tests shall be as specified in ASTM A 563 {A 563M} paragraph 9.3. If nuts are to be galvanized, tests shall be performed after galvanizing, overtapping and lubricating. If galvanized nuts are supplied, the thickness of the zinc coating shall be measured. Measurements shall be taken on the wrench flats.

If galvanized washers are supplied, hardness testing shall be performed after galvanizing. (Coating shall be removed prior to taking hardness measurements). The thickness of the zinc coating shall be measured. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 715

Rotational-capacity tests are required and shall be performed on all plain and galvanized (after galvanizing) bolt, nut and washer assemblies by the manufacturer or distributor prior to shipping. Washers are required as part of the test. The following shall apply:

accordance with the requirements of ASTM A 325 {A 325M}.

an assembly. Where washers are not required by the installation procedures, they need not be included in the lot identification. A production lot change of either the bolt, nut, or washer shall require the testing of additional assemblies

tested.

lot.

Calibrator or an acceptable equivalent device (note - this requirement supersedes the current ASTM A 325 {A 325M} requirement that the test be performed in a steel joint). For short bolts which are too short to be assembled in the Skidmore-Wilhelm Calibrator, See Subitem 836.33(c)4.i.

load), shall be:  240° (2/3 turn) for bolt lengths < 4 diameters  360° (1 turn) for bolt lengths > 4 diameters and < 8 diameters  480° (1 1/3 turn) for bolt lengths > 8 diameters

times the required installation tension. The installation tension and the tension for the turn test are shown below: Diameter (In.) 1/2 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 Req. Installation Tension (kips) 12 19 28 39 51 56 71 85 103 Turn Test Tension (kips) 14 22 32 45 59 64 82 98 118

Diameter {mm} 16 20 22 24 27 30 36 Req. Installation Tension {kN} 94.2 147 182 212 275 337 490 Turn Test Tension {kN} 108.3 169.1 209.3 243.8 316.3 387.6 563.5

of tension and torque shall be taken and recorded. The torque value shall conform to the following: Torque < 0.25 PD Where: Torque = measured torque (foot-pounds); P = measured bolt tension

steel joint. The tension requirement of Subitem 836.33(c)4.g. need not apply. The maximum torque requirement of Subitem 836.33(c)4.h. shall be computed using a value of P equal to the turn test tension shown in the table in Subitem

(c)4.g

The results of all tests (including zinc coating thickness) required herein and in the appropriate AASHTO specifications shall be recorded. The location where tests are performed and the date of tests shall be recorded.

An MTR shall be furnished for all mill steel used in the manufacture of the bolts, nuts, and washers. The place where the material was melted and manufactured shall be shown on the MTR. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 716

The manufacturer of the bolts, nuts and washers shall furnish test reports (MCTR) for the item furnished. Each MCTR shall show the relevant information required in accordance with Item 836.33(c)5. The manufacturer performing the rotational-capacity test shall include on the MCTR:

appropriate AASHTO specifications.

The DCTR shall include MCTR above for the various bolt assembly components. The rotational-capacity test may be performed by a distributor (in lieu of a manufacturer) and reported on the DCTR. The results of the tests required in Item 836.33(c)4. shall be shown on the DCTR. The pertinent information required in Item 836.33(c)5. shall be shown on the DCTR. The rotational-capacity lot number as required in Subitem 836.33(c)4.c. shall be shown on the DCTR. The DCTR shall contain a statement that the MCTR are in conformance to this specification and the appropriate AASHTO specifications.

Bolts, nuts and washers from each rotational-capacity lot shall be shipped in the same container. If there is only one production lot number for each size of nut and washer, the nuts and washers may be shipped in separate containers. Each container shall be permanently marked with the rotational- capacity lot number such that identification will be possible at any stage prior to installation.

836.34Sheared Edges

Sheared edges of plates more than 5/8 inch {16 mm} in thickness shall be planed to a depth of 1/4 inch {6 mm}. Plates 5/8 inch {16 mm} and less in thickness shall be ground to remove sharp corners and burrs. Re-entrants corners shall be filleted to a minimum radius of 3/4 inch {19 mm} before cutting.

836.35Facing Of Bearing Surfaces

The top and bottom surfaces of steel slabs and base plates and cap plates of columns and pedestals shall be planed, or else the plates or slabs hot-straightened. Parts of members in contact with them shall be faced and shall have full contact when assembled. For fit-up of sole plates or bearing seats of beams or girders see Article 836.46. Sole plate and masonry plate corrections may be made by planing or hot-straightening. In planing the surface of expansion bearings, the cut of the tool shall be in the direction of expansion. Cast pedestals shall be planed on surfaces to be in contact with steel, and the surface to be in contact with masonry rough finished. The surface finish of bearing and base plates and other bearing surfaces that are to come in contact with each other or with concrete shall meet the ANSI surface roughness requirements as defined in ANSI B46.1, Surface Roughness, Waviness and Lay, Part I unless otherwise specified, Steel slab in contact with Masonry ANSI 2000 {50 m} Steel slabs ANSI 2000 {50 m} Heavy plates in contact in shoes to be welded ANSI 1000 {25 m} Milled ends of compression members, milled or ground ends of stiffeners and fillers ANSI 500 {12.5 m} Bridge rollers and rockers ANSI 250 {6.3 m} Pins and pin holes ANSI 125 {3.2 m} Sliding bearings ANSI 125 {3.2 m} Surfaces of bronze bearing plates intended for sliding contact shall be carefully milled and polish finished. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 717

836.36Blank

836.37Blank

836.38Finished Members

These shall be true to line and free from twists, bends, and other defects.

836.39Blank

836.40Blank

836.41Stress Relieving

Members such as bridge shoes or pedestals which are built-up by welding sections of plates together shall be stress relieved in accordance with the requirements given in ANSI/AASHTO/AWS D1.5/D1.5M- 2008 for stress relieving unless an alternate method has the written approval of the Bridge Engineer.

836.42Pins and Rollers

Pins and rollers shall be accurately turned to the dimensions shown on the drawings and shall be straight, smooth, and free from flaws. Pins and rollers more than 9 inches {228 mm}in diameter shall be forged and annealed, pins and rollers 9 inches {228 mm}or less in diameter may be either forged and annealed or cold finished carbon steel shafting. Pins and roller material shall conform to one of the following unless a specific Grade or Class is specified by plan details:  4" { 100 mm} in Diameter or less........AASHTO M 169*, Grade 1016 to 1030, Inclusive  0" to 20" { 0 mm to 508 mm} in diameter.........AASHTO M 102, Class C, Class D or Class G**  0" to 10" { 0 mm to 254 mm} in diameter.........AASHTO M 102, Class F * This material shall provide the following minimum values: o Yield - 36,000 psi {250 MPa} o Stress in extreme Fiber - 29,000 psi {200 MPa} o Shear - 14,000 psi {97 {MPa} o Bearing on Pins not subject to rotation 29,000 psi {200 MPa} o Bearing on Pins subject to rotation 14,000 psi {97 MPa} ** Rolled material with the same properties may be substituted for this class. In pins larger than 9 inches {228 mm} in diameter, a hole not less than 2 inches {50 mm} in diameter shall be bored full length along the axis after the forging has been allowed to cool to a temperature below the critical range under suitable conditions to prevent injury by too rapid cooling, and before being annealed. Two pilot nuts and two driving nuts shall be furnished for each size pin, unless otherwise provided by plans or directed. The diameter of pins and rollers shall not exceed 1/16 inch {1.6 mm} plus or minus from the diameter specified by the plans or ordered by the Engineer.

Pin holes shall be bored true to gage, smooth and straight, at right angles with the axis of the member and parallel with each other unless otherwise shown on the plans. Pins shall be parallel to each other unless otherwise shown on the plans. The final surface shall be obtained by a finishing cut. Boring of holes in built up members shall be done during the final lay down operation.

The diameter of the pin holes except as noted in Item 836.01(b)3 shall not exceed that of the pin by more than 1/50 inch {0.50 mm} for pins 5 inches {127 mm} or less in diameter or 1/32 inch {0.80 mm} for larger pins.

836.43through 836.45 Blank

836.46Welds

Shop welding shall be performed by Submerged Arc Welding (SAW) in accordance with the specification noted herein. In the event the above method cannot be used, approved manual welding or other approved and qualified automatic or semi-automatic methods may be authorized. STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS 718

Field Welding shall be performed by manual Shielded Metal Arc Welding (SMAW) using approved electrodes and procedures in accordance with the specifications noted herein. If a minimum of 3 inches (75 mm} of excess material beyond the theoretical end cuts does not exist, extension bars or run-off tabs shall be used at girder ends to ensure sound welds on web to flange welds. All welding shall be subject to the inspection and approval of the Engineer or his representative. During inspection of the work any workman, including welders and inspection technicians, who, in the opinion of the Engineer, produces inferior work, may under the provision of Article 108.06 be disqualified from performing Departmental work. All welding shall be in accordance with the AASHTO/AWS D1.5M/D1.5:2015, Bridge Welding Code, Seventh Edition as modified by the following:  Article 3.1. A new sentence shall be added to paragraph 3.1.3 as follows: "Shop welding, except for minor secondary members and minor repair welding, shall be done under a cover of a permanent structure and/or building capable of protecting the actual welding operation from inclement weather. Any standing water that would be dangerous to the welder or operator or to the integrity of the weld itself shall be cause for the welding to stop until such time as the situation is corrected."  Paragraph 3.2.9. The original A.W.S. subclause was deleted but shall be replaced with the following: "Paragraph 3.2.9. All corners of thermal cut or sheared edges, including edges of flanges of beams and girders along with splice material and other sharp edges deemed undesirable by the Engineer on structural members designated to be coated shall be slightly rounded. Said rounding shall be accomplished by light grinding to produce a satisfactory surface for painting (approximately 1/16 inch {1.6 mm} radius). The grinding shall be performed in such a manner as to produce a neat workmanship like product without nicks or notches in the metal."  A new paragraph to 3.5.1.9 shall be added as follows:  "Paragraph 3.5.1.9 Gaps shall not exceed 0.040 inches {1.0 mm) between the contact surfaces at the bottom flanges of beams or girders and steel bearing plates. There shall be no gap for at least 75% of this contact area."  New Paragraphs 4.9 and 4.10 shall be added as follows: "Paragraph 4.9 (SAW – single electrode), 4.10 (SAW – parallel and multiple electrodes). A properly operated heating torch shall run immediately ahead (about 12 inches {300 mm}, and on the same side, in advance of the point of welding) of the submerged arc welding head to remove moisture from the steel in the vicinity of the weld when making web to flange fillet welds of plate girders. Gases producing moisture in welding operations are discouraged unless it can be shown that the resultant temperature of the metal is sufficient to vaporize any moisture that might be present." Paragraphs 6.7.1, 6.7.1.1, and 6.7.1.2 in regard to Nondestructive Testing (NDT) of Complete Joint Penetration groove welds shall be deleted in their entirety and the following substituted in lieu thereof: "Paragraph 6.7.1 – Complete Joint Penetration (CJP) groove welds shall be tested by A.W.S. D1.5 Bridge Welding Code requirements in regard to and mandating the use of either radiographic testing (RT) or ultrasonic testing (UT) in accordance with the following: "6.7.1.1 - Shop Welds. 100% of all CJP butt weld splices in the following: all flanges (tension and compression) of beams and girders, all flanges of floorbeams, all members of floorbeam trusses which support stringer beams, all flanges of steel bent caps; and all chords, diagonals and verticals of trusses. 50% of all vertical CJP butt weld splices in webs of beams, girders, floorbeams, and steel bent caps. This requirement shall consist of 25% of the web depth beginning at the top of the web plate and 25% of the web depth beginning at the bottom of the web plate. If rejectable discontinuities are found in the vertical CJP butt welded splices, the remainder of the weld shall be tested. 15% of each longitudinal CJP butt weld splice in the webs of beams, girders, floorbeams, and steel bent caps, and in truss members. This requirement shall consist of 5% of weld length at each end of each plate and 5% of the weld length at the center of the plate (each plate is defined as that portion of web between vertical splices either welded or bolted).If rejectable discontinuities are found in a partially NDT examined longitudinal joint, additional NDT examinations using the original NDT process of that joint shall be made as required by the Engineer.