836STRUCTURAL STEEL, FASTENERS AND MISCELLANEOUS METALS

836.01 General.

835.07 Use, 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. R ust 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

836.01 General.

836.01 General.

• All floorbeam trusses (cross frames) w hich support stringer beams (floorbeams), including their gusset and connection plates. 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. 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}. 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. Unless otherwise shown on the plans, steel plates for main members shall be cut a nd fabricated so that the primary direction of rolling is parallel to the direction of the main tensile and/or compressive stresses.

836.05 Gray Iron Castings.

mm} bel ow 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.

836.02 Steel 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 recei ved.

836.03 Blank.

836.04 Steel Castings.

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

836.05 Gray Iron Castings.

836.06 Malleable Iron Castings.

836.06 Malleable 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 thei r 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).

836.07 Ductile 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. M alleable 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 Subartic le 836.04(d). Soundness shall be checked as provided in Subarticle 836.04(e).

836.08 Self -Lubricating Bronze Or PTFE Bearing Plates.

836.09 Grounding Materials For Steel Bridges.

Standard stranded co pper 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, cop perclad 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.

836.10 Lead Plates, Etc.

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

836.16 Notice and Facilities For Inspection.

836.11 Hardwar e 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.

836.12 and 836.13 Blank.

836.14 Shop 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 stru ctures. Fabricators shall furnish verification certificates of the actual measurements of the camber placed in each beam, girder or truss.

836.15 Mill Orders and Shipping Statements.

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

836.16 Notice 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 which require CVN testing, shall be supplied to the Bridge Engineer or his representative prior to completion and acceptance of fabrication. No mate rials 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 pro cessed. 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 S tamp 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 i s 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 Engin eer. 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)).

836.17 Handling, Storage and Transporting Of Materials.

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 m eet the requirements set forth in the "ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel (ANSI/ASNT CP -105-2011)".

836.17 Handling, Storage and Transporting Of Materials.

The loading, unloading, handling and storing of m aterials 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 fr om 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 cha in 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. 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 su rface 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). Preparat ion and shipment of fabricated pieces shall conform to the following: Loose Members.

836.18 Straightening Material.

Rolled material, before it is marked, laid out, or otherwise worked in the shop must be straight or cambered as shown on the p lans. 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 a bove 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.

836.19 Workmanship and Finish.

836.19 Workmanship and Finish.

836.19 Workmanship and Finish.

836.22 Fastener Holes.

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.

836.20 Thermal 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. S uch 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 smo oth 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.

836.21 Substitutions.

Substitut ions of sections having different dimensions than those shown on the plans shall be made only when approved in writing.

836.22 Fastener Holes.

836.22 Fastener Holes.

836.32 Bolts, and Bolted Connections.

836.23 Through 836.26 Blank.

836.27 Shop Assemblin g.

836.28 Blank.

836.29 Match -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.

836.30 Rivets.

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

836.31 Blank.

836.32 Bolts, and Bolted Connections.

836.33 High Strength Fasteners.

836.33 High Strength Fasteners.

The components of high strength bolt assemblies shall meet the requirements of the following: 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 a nd 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:

836.33 High Strength Fasteners.

836.34 Sheared Edges.

Torque < 0.25 PD Where: Torque = measured torque (foot -pounds); P = measured bolt tension (pounds) and D = bolt diameter (feet).

836.34 Sheared 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.

836.35 Facing 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.

836.42 Pins and Rollers.

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 o ther 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 µm} Steel slabs ANSI 2000 {50 µm} Heavy plates in contact in shoes to be welded ANSI 1000 {25 µm} Milled ends of compression members, milled or ground ends of stiffeners and fillers ANSI 500 {12.5 µm} Bridge rollers and rockers ANSI 250 {6.3 µm} Pins and pin holes ANSI 125 {3.2 µm} Sliding bearings ANSI 125 {3.2 µm} Surfaces of bronze bearing plates intended for sliding contact shall be carefully milled and polish finished.

836.36 Blank.

836.37 Blank.

836.38 Finished Members.

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

836.39 Blank.

836.40 Blank.

836.41 Stress 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 requirement s 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.

836.42 Pins and Rollers.

836.43 through 836.45 Blank.

The diameter of pins and rollers shall not exceed 1/16 inch {1.6 mm} plus or minu s from the diameter specified by the plans or ordered by the Engineer.

836.43 through 836.45 Blank.

836.46 Welds.

Article 3 — 1. A new sentence shall be added to paragraph 3.1.3 as follows:

"Shop welding, except for minor secondary members and mi nor 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 sh eared 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 ar ea." 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 si de, 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 produc ing 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."