806BRIDGE RAILINGS

806.01 Description. This item shall consist of railings for

approaches, bridges, headwalls, wingwalls, retainin g walls, etc., of the material or combination of materials specified, constructed according to the plans and specifications.

806.02 Materials. (a) Aluminum Products. Aluminum railing,

including tubing, pipe, extrusions, posts, and fast enings, shall be aluminum alloy meeting the requirements shown on th e plans. Aluminum alloy surfaces contacting concrete shall b e coated with an aluminum impregnated caulking compound or other suitable material approved in writing by the Engineer. The outside surfaces of flanges and edges of flange s of cast aluminum posts shall be given a #220 grit finish, a fter which all exposed surfaces of the cast posts shall be given a coat of clear lacquer suitable for use on aluminum materials. Th e inside surfaces of posts shall have no special finish. Welding, where shown on the plans, shall be accompl ished by an arc welding process in which no welding flux is use d. AWS D 1.2, Welding of Aluminum Alloys, shall be the governing specification for aluminum products.

806.03 Line and Grade. The line and grade of the railing shall

be true to that shown on the plans. Vertical membe rs, including posts, shall be plumb unless otherwise noted on the plans.

806.04 Expansion Joints. Expansion joints shall be so

constructed as to permit freedom of movement. Afte r work has been completed, loose or thin shells of mortar like ly to spall under movement shall be carefully removed from expansion joints by means of a sharp chisel.

806.05 Construction Requirements. (a) General. When spans

are supported by falsework, railings shall not be p laced until the falsework for the span has been removed and the spa n is in its final position.

806.06 Method of Measurement. (a) Metal Bridge Railing will

be measured by the linear foot (meter). The measur ement will be made along the roadway face of the railing, from en d to end of each continuous length of railing.

806.07 Basis of Payment. (a) Metal bridge railing completed

and accepted and measured as provided above will be paid for at the contract unit price bid per linear foot (meter) for Metal Bridge Railing of the type specified, which price shall be full compensation for furnishing all materials, including posts, fitt ings, and fastenings for railing; for fabrication and erection; for prep aration of shop drawings; and for all labor, equipment, tools, and incidentals necessary to complete the work.

807.01 Description. This item shall consist of furnishing,

fabricating, assembling, erecting, and painting str uctural metals for bridge structures and other steel products accordin g to these specifications and the plans. GENERAL

807.02 Sufficiency of Fabricator. All structural steel fabricators

shall be certified for AISC Category SBR (Simple St eel Bridge Structures), CBR (Major Steel Bridges), or CPT (Bri dge Component Standard), as appropriate, except as provided herei n. In addition, the fabricator shall have the appropriate Paint End orsement (P1, P2, or P3) which qualifies them for the application of sophisticated coating systems. When the Contractor elects to purchase items of str uctural steel manufactured outside the United States, such materi als shall be furnished only from those foreign manufacturers who have previously established, to the satisfaction of the Engineer, the sufficiency of their in-plant quality control to gi ve satisfactory assurance of their ability to furnish material unif ormly and consistently in conformance with the Specifications and according to Subsection 106.01. Proof of sufficiency must be provided to the Engine er by the Contractor and the Engineer's approval obtained bef ore foreign manufactured structural steel items are incorporate d into the work. Proof may be established by: 1) the Contractor prov iding the Engineer with a detailed written certification by a n established and approved independent testing and inspection laborat ory or agency showing evidence that the foreign manufacturer has previously established in-plant quality control to give assura nce of their ability to furnish material uniformly and consistently in c onformance with the specifications, or 2) a thorough in-plant inspe ction of the foreign manufacturer's facilities by the Engineer or his ap pointed representative as deemed necessary by the Engineer. The cost of determining sufficiency, established ei ther by detailed written evidence or a thorough in-plant in spection by the Engineer or his appointed representative, shall be borne by the Contractor. Payment of all expenses incurred by th e Engineer or his 765 appointed representative in making such in-plant in spection as deemed necessary by the Engineer shall be made by t he Contractor to the Department upon receipt of detailed billing prepared by the Department and presented to the Contractor. Prior to shipment or fabrication of any foreign pro duced structural steel, the Contractor shall obtain all t he Certified Mill Test Reports, clearly identifiable to the lot of materia l to be shipped by heat numbers and color-coding, and submit these to the Engineer for complete review and analysis, and shall have receiv ed approval of them. Structural steel materials that are manufactured ou tside the United States shall be delivered to the fabrication site where it shall be retained a sufficient period of time to permit i nspection, sampling, and testing as deemed necessary by the En gineer prior to fabrication. The Contractor shall make all pieces of all materials available to the Engineer for inspection, sampling, and testing.

807.03 Governing Specifications. In case of conflict between

the Standard Specifications and any referenced spec ifications in this Section, the Standard Specifications shall govern.

807.04 Shop Drawings Required of the Contractor.

807.05 Structural Steel. Unless otherwise specified, structural

steel shall conform to the requirements of Structur al Steel for Bridges, AASHTO M 270, except that the Charpy V-Not ch Impact test requirements shall apply only to materials des ignated on the contract drawings as main load carrying member comp onents. When Charpy V-Notch tests are required, the test re sults shall conform to the requirements specified for Zone I mi nimum service temperature. Grade 36 (250) shall be furnished unless otherwise specified. Steel shall be furnished according to the following specifications:

807.06 High Strength Bolts, Nuts, and Washers for S tructural

Steel Connections. (a) Specifications. High strength bolts shall be heavy hex and shall conform to the requirements of ASTM A325, except as modified herein. Type 1 bolts shall be p rovided when used with painted structural steel or when galvaniz ed bolts are specified. Type 3 bolts shall be provided when use d with unpainted weathering structural steel. The maximum hardness of high strength bolts shall be 33 Hardness Rockwell C . Nuts shall be heavy hex and shall conform to the re quirements of ASTM A563 or AASHTO M 292. Nuts for plain, uncoate d Type 1 bolts shall be Grade 2H, Grade DH or DH3 (Grade 10S , or 10S3). Nuts for Type 3 bolts shall be Grade DH3 (Grade 10S 3). Nuts for galvanized bolts shall be Grade 2H or Grade DH (Gra de 10S). When galvanized nuts are furnished, the zinc coatin g, overtapping, lubrication, and proof loading shall be in accordan ce with ASTM A563. Washers shall conform to the requirements of ASTM F 436. Where necessary, washers may be clipped on one side to a point not closer than 7/8 of the bolt diameter from the cente r of the washer. Beveled washers shall be used in the flanges of Ame rican Standard beams and channels. Weathering steel washers shall be used with Type 3 bolts. When galvanized bolt assemblies are specified, the bolts, nuts, and washers shall be galvanized according to AASHT O M232, Class C, or ASTM B595, Class 50. All components in a fastener assembly shall be galvanized by the same process. Galvanized nuts shall be provided with a lubricant that is clean and dry to the touch. The lubricant shall contain a visible dye so that a visual check can be made for the lubricant a t the time of field installation. Plain, uncoated bolts, nuts, and was hers must be "oily" to the touch when installed. 768 (b) Required Tests. High strength fasteners, plain and galvanized, shall be subjected to a rotational capa city test according to ASTM A325, Section 6.3, and shall meet the foll owing requirements:

807.08 Welded Stud Shear Connectors. Shear connector studs

shall conform to the requirements of Steel Bars, Ca rbon, Cold Finished Standard Quality, AASHTO M 169, cold-drawn bars, Grades 1015, 1018, and 1020, either semi-killed or killed. If flux retaining caps are used, the steel for the caps sha ll be of a low carbon grade suitable for welding and shall comply with Steel, Carbon, Cold-rolled Strip, ASTM A 109M (A 109). Tensile properties, as determined by tests of bar s tock after drawing or of finished studs, shall conform to the following minimum requirements: Tensile Strength 60,000 psi (415 MPa) Yield Strength 50,000 psi (345 MPa) (0.2% offset) Elongation 20% in 2" (50 mm) Reduction of area 50% Tensile properties shall be determined according to the applicable sections of AASHTO T 244. Tensile tests of finishe d studs shall be made on studs welded to test plates using a test fi xture conforming to ANSI/AASHTO/AWS D1.5 Bridge Welding Code require ments. If fracture occurs outside the middle half of the g age length, the test shall be repeated. Finished studs shall be of uniform quality and cond ition, free from laps, fins, seams, cracks, twists, bends, or o ther injurious defects. Finish shall be as produced by cold drawi ng, cold rolling, or machining. Studs shall be marked to identify th e manufacturer. The manufacturer shall certify that the studs as de livered are in accordance with the material requirements of this S ection. Certified 771 copies of in-plant quality control test reports sha ll be furnished to the Engineer. Samples of studs of each type and size used may be selected, as necessary, for checking the requirements of this Se ction.

807.09 Steel Forgings and Steel Shafting. (a) Carbo n Steel

Forgings. Steel forgings shall conform to AASHTO M 102. Class C forgings shall be furnished unless otherwis e specified.

807.10 Steel Castings. (a) General. Steel castings for use in

highway bridge components shall conform to AASHTO M 103. Grade 70-36 (485-250) steel shall be used unless ot herwise specified.

807.11 Iron Castings. (a) General. Iron castings shall be gray

iron castings conforming to AASHTO M 105, Class No. 30 unless otherwise specified.

807.12 Ductile Iron Castings. (a) General. Ductile iron

castings shall conform to ASTM A 536, Grade 414-276 -18, unless otherwise specified. In addition to the specified test coupons, test specimens from parts integral with the castings, su ch as risers, shall be tested for castings weighing more than 1000 poun ds (454 kg) to 772 determine that the required quality is obtained thr oughout the casting.

807.13 Malleable Castings. (a) General. Malleable castings

shall conform to ASTM A 47 (A 47M). Grade No. 3501 8 shall be furnished unless otherwise specified.

807.14 Bronze or Copper-Alloy Bearing and Expansion

Plates. (a) Bronze Bearing Plates. Bronze bearing and expansion plates shall conform to ASTM B22. Alloy C91100 sh all be furnished unless otherwise specified.

807.15 Bearing Pads. (a) Preformed Fabric Pads. Preformed

fabric pads shall be composed of multiple layers of 8 ounce (270 g/sq m) cotton duck impregnated and bound with high quality natural rubber, or of equivalent and equally suitab le materials, compressed into resilient pads of uniform thickness . The number of plies shall be such as to produce the specified thi ckness after compression and vulcanizing. The finished pads sha ll withstand compression loads perpendicular to the plane of the laminations of not less than 10,000 psi (70 MPa) without detriment al reduction in thickness or extrusion. The Contractor shall obtai n from the manufacturer a certificate of compliance with these requirements. This certificate shall be maintained on file by the Contractor and furnished to the Engineer upon request.

807.16 Paint. Paint for metal shall be as specified in

Subsection 807.75.

807.17 Sheet Metal for Water Stops and General Use.

807.19 Galvanizing. When galvanizing is specified, ferrous

metal products shall be galvanized according to AA SHTO M 111.

807.20 Nylon Reinforced Neoprene Trough. Neoprene shall be

100% virgin polychloroprene meeting the requirement s of Subsection 808.02 for 50-durometer hardness except that the Instantaneous Thermal Stiffening requirements (ASTM D 1043 Test) are not required. In addition to the require ments of Subsection 808.02, the elastomer shall have no failure when te sted for brittleness according to ASTM D 2137, Method B (-40 º F [-40º C]). The woven nylon reinforcement fabric shall conform to the following minimum requirements:

807.21 Inspection of Fabrication. Upon award of the Contract,

the Contractor shall inform the Engineer of the loc ation where the fabrication of structural steel will be performed. This information must be received at the earliest possible date in o rder that provisions may be made to provide structural steel fabrication inspection. The Department will make arrangements for all struc tural steel fabrication inspection, sampling, and testing, as d eemed necessary by the Engineer. 775 The Contractor shall furnish facilities for the ins pection of material and workmanship in the mill and shop. Ins pectors shall be allowed free access to all necessary areas of the p lant. Inspectors shall have the authority to reject any m aterial or work that does not meet the requirements of these specif ications.

807.22 Notice of Beginning Work. The Contractor shall give

the Engineer ample notice of the beginning of work in the shop so that inspection may be provided. No work shall be performed in the shop before the Engineer has been notified.

807.23 Quality Control of Fabrication. (a) General. The

Contractor shall be responsible for the Quality Con trol of structural steel fabrication, as required by contract document s and/or referenced specifications. The Contractor and/or th e Fabricator shall submit a Quality Control Plan for the fabrication o f structural steel on each project directly to the Materials Engineer for approval. The Plan shall detail the inspection and testing propos ed to comply with this Specification, and it shall be submitted suffi ciently in advance to allow a complete review by the Engineer. Fabric ation of structural steel shall not be started until approva l of the Plan has been obtained. In lieu of this, the Contractor and /or the Fabricator may utilize a previously approved Quality Control P lan already on file with the Department. The Contractor shall be responsible for the costs i nvolved in development and execution of this Quality Control P lan, including non-destructive testing specified in the AASHTO/AWS D1.5 Bridge Welding Code, the Standard Specifications, the plan s, and in other referenced specifications. Further, the Contractor shall be responsible for the cost of the necessary correctio n of all deficiencies. Any extra non-destructive testing necessitated by w elds performed for the convenience of the Contractor or Fabricator shall be at no cost to the Department. When due to mater ial deficiency or fabrication errors, the cost of any extra non-destr uctive testing deemed necessary by the Engineer to assure specific ation compliance or maintain the integrity of the structu ral steel shall be at no cost to the Department. The Fabricator shall have, either in his employ or available under contract, a welding inspector who is a current AWS Certified 776 Welding Inspector or one who by other experience or qualification is acceptable to the Engineer.

807.24 Quality of Workmanship. Workmanship and finish

shall be equal to the best general practice in mode rn fabrication shops. Fabrication shall be accomplished in a cont rolled environment with adequate protection from the weath er.

807.25 Identification of Steels. Each piece of steel to be

fabricated for the project shall be properly identi fied. Shop drawings shall identify each piece of steel wi th an erection or assembly mark . Pieces made of different grades of steel shall no t be given the same assembling or erecting mark, even though they are of identical dimensions and detail. The Contractor's system of assembly-marking individ ual pieces and the issuance of cutting instructions to the sho p shall be such as 778 to maintain the identity of the mill test number fo r primary members. During fabrication, up to the point of assembling m embers, each piece of steel other than Grade 36 (250) steel shal l show clearly and legibly its identification color code as shown in t he following Color Coding chart: COLOR CODING Grade 100 (690) Red Grade 50 (345) Green & Yellow Grade 50W (345W) Blue & Yellow Other grades of steel, except Grade 36 (250), not c overed above nor included in the ASTM A6 specifications shall ha ve an individual color code which shall be established and on record for the Engineer. Individually marked pieces of steel that are reduce d from furnished size may be used without further color co ding provided that the heat number and color code remain legible. Pieces for secondary members that are cut to smaller sizes sha ll, before cutting, be legibly marked with the identification color cod e. Pieces that are furnished in tagged lifts or bundles shall be marke d with the identification color code immediately upon being re moved from the lift or bundle. Pieces of steel that, prior to assembling into memb ers, will be subjected to fabricating operations such as blast c leaning, galvanizing, heating, or painting which may obliter ate the identification color code or heat number shall be m arked by steel die stamping or by a substantial tag firmly attached. If steel die stamping is used, it shall be the low stress type a nd high stress areas of the pieces shall be avoided. The Contractor may furnish material from stock for secondary members if the material can be identified by heat n umber and mill test report. Excess material placed in stock for later use shall be marked with the mill heat number and its identification color c ode when separated from the full-size piece furnished by the supplier.

807.26 Welding. (a) General. Welding of steel structures shall

be accomplished by the electric arc process accordi ng to the 779 AASHTO/AWS D1.5 Bridge Welding Code, except as modi fied herein. Welding shall be done by certified welders or certi fied welding operators approved by the Engineer, except that sho p or field applied stud shear connectors welded using automati cally timed stud welding equipment shall be accomplished by operator s qualified according to Section 7 of the AASHTO/AWS D1.5 Brid ge Welding Code. The Engineer will consider a welder/welder operator qualified if

807.27 Straightening Rolled Material. Rolled material must be

straight before being laid off or worked. Bends an d distortions may be cause for rejection. If straightening is necess ary and approved by the Engineer, it shall be accomplished by using met hods that will not damage the metal. Heat straightening of materi als other than Grade 100 (690) may be accomplished by careful appl ication of localized heat. The temperature of the heated area shall not exceed 1150° F (620° C). Heat straightening of Grade 100 (690) steel shall b e accomplished only under rigidly controlled procedur es. Each application shall be subject to the approval of the Engineer and in no case shall the maximum temperature of the steel exc eed 1100° F (590° C). Materials shall not be artificially cooled, except by forced air, until after the metal has cooled to 600° F (320° C) . Below 600° F (320° C) the material may be cooled by forced air o r mist, but may not be submerged in liquid or sprayed with liquid.

807.28 Curving Rolled Beams and Welded Girders.

807.29 Vertical Cambering of Beams and Girders. Design

camber of welded girders shall be cut in the web pl ates before girder assembly. Allowance should be made for shrinkage d ue to cutting and welding. Small amounts of heat may be used to correct minor differences from specified design camber. Design camber shall be produced in rolled beams by mechanical methods and/or controlled application of heat. The size, number, shape, and placement of heating patterns shall be s uch that distortion is minimal and that buckling is kept within the min imum standard rolling tolerances for out-of-flatness of beam webs . Beams with severe web buckles from improper heat cambering wil l be rejected. The vertical cambering operation shall be conducted in such a manner that the temperature of the steel does not e xceed 1150° F (620° C) as measured by indicating crayons or other suitable means. Beams and girders shall not be artificially cooled except as permitted in Subsection 807.27. Vertical camber will be measured for final acceptan ce to the nearest 1/8 inch (millimeter). Tolerance shall be ±1/4 inch (±6 mm) from the specified camber.

807.30 Annealing and Stress Relieving. Structural members

that are specified to be annealed or normalized sha ll have finished machining, boring, and straightening performed subs equent to heat treatment. Normalizing and full annealing shall be as defined in ASTM A 919. The temperatures shall be maintained uniformly thro ughout the furnace during the heating and cooling so that the temperature at no two points on the member will differ by more than 1 00° F (56° C) at any one time. 785 Members of Grade 100 (690) steel shall not be annea led or normalized and shall be stress relieved only with t he approval of the Engineer. A record of each furnace charge shall identify the pieces in the charge and show the temperatures and schedule actua lly used. Proper instruments, including recording pyrometers, shall be provided for determining the temperatures of member s in the furnace at any time. The records of the treatment operation shall be available to and meet the approval of the Engineer. The holding temperature for stress relieving Grade 100 (690) st eel shall not exceed 1100° F (590° C). Members such as bridge shoes, pedestals, or other p arts that are built up by welding sections of plate together shal l be stress relieved, when specified, according to the procedu re in the current AASHTO/AWS D1.5 Bridge Welding Code.

807.31 Facing of Bearing Surfaces. The surface finish of

bearing or base plates and other bearing surfaces t hat are to come in contact with each other or with concrete shall meet the ANSI surface roughness requirements as defined in ANSI B 46.1-88 , Surface Roughness, Waviness and Lay, Part I: Steel slabs........................................ . ANSI 2.0 mils (RMS) [50 µm] Heavy plates in contact in shoes to be welded ...................... ANSI 1.0 mils (RMS) [25 µm] Milled ends of compression members, milled or ground ends of stiffeners and fillers .................................... ANSI 0.5 mils (RMS) [12 µm] Bridge rollers and rockers ................ ANSI 0. 24 mils (RMS) [6 µm] Pins and pin holes ............................ ANS I 0.12 mils (RMS) [3 µm] Sliding bearings ............................... AN SI 0.12 mils (RMS) [3 µm]

807.32 Oxygen Cutting of Structural Steel. Steel and weld

metal may be oxygen cut provided a smooth and regul ar surface free from cracks and notches is secured, and further pro vided that an accurate profile is obtained by the use of a mechan ical guide. Oxygen cut surfaces of members shall have corners r ounded to 1/16" (1.5 mm) radius by grinding after cutting. H and cutting shall be according to the AASHTO/AWS D1.5 Bridge Welding Code and approved by the Engineer. 786 Mill scale and extraneous material shall be removed from the torch side of Grade 100 (690) steel plates along th e lines to be flame cut, when necessary, to preclude excessive notches.

807.33 Orientation of Plates. Unless otherwise shown on the

plans, steel plates for webs, flanges, cover plates , and flange splice plates shall be cut and fabricated so that the prim ary direction of rolling is parallel to the direction of the main te nsile and/or compressive stresses to which the plate will be sub jected in the finished structure.

807.34 Sheared Edges of Structural Plates. (a) Edge Planing.

Sheared edges of plates more than 5/8" (16 mm) in t hickness that are subject to stress shall be planed to a depth of 1/4 " (6 mm). Re- entrant corners shall be filled to a minimum radius of 3/4" (19 mm) before cutting.

807.35 Bent Plates. Unwelded, cold-bent, load-carrying, rolled-

steel plates shall be taken from stock plates so th at the bend line will be at right angles to the direction of rolling, unl ess otherwise noted in the plans. Bending shall be such that no cracking of the plate occurs. Minimum bend radii, measured to the concave face of the metal, shall be as shown in Table 807-2. TABLE 807-2 MINIMUM BEND RADII Plate Thickness (t) Up to ½" (12 m

807.36 Fit of Stiffeners. Stiffeners shall be fabricated according

to the details shown on the plans.

807.37 Abutting Joints. Abutting joints in compression

members and girder flanges and, where specified, in tension members shall be faced and brought to an even beari ng. Where joints are not faced, the opening shall not exceed 1/4" (6 mm).

807.38 Bolted Web Splices. The clearance between the ends of

the web plates at a bolted splice shall not exceed 3/8" (9 mm). Edge distance requirements listed in Subsection 807.42(a ) shall be measured from the actual edge of web plate.

807.39 End Connection Angles. Floorbeams, stringers, and

girders having end connection angles shall be built to the exact length shown on the plans, measured between the hee ls of the connection angles, with a permissible tolerance of 0 to minus 1/16" (-1.5 mm). Where continuity is required, end conne ctions shall be faced. The thickness of the connection angles afte r facing shall not be less than 3/8" (9 mm) nor less than that shown o n the shop drawings.

807.40 Lacing Bars. The ends of lacing bars shall be neatly

rounded unless another form is required.

807.41 Eyebars. Pin holes may be flame cut at least 2" (50 mm)

smaller in diameter than the finished pin diameter. Eyebars that are to be placed side by side in the structure shall be securely fastened together in the order that they will be placed on t he pin and bored at both ends while fastened. Eyebars shall be packed and match marked for shipment and erection. All identifying marks shall be 788 stamped with steel stencils on the edge of one head of each member so as to be visible when the bars are nested in pla ce in the structure. The eyebars shall be straight and free from twists and the pin holes shall be accurately located on the centerline of th e bar. The inclination of any bar to the plane of the truss sh all not exceed 1/16" per foot (5 mm/m). The edges of eyebars that lie between the transvers e centerlines of their pin holes shall be cut simultaneously with two mechanical torches operated abreast and guided by a substantia l template in such a manner as to prevent distortion of the plate s.

807.42 Bolt Holes. (a) General. Holes for bolts shall be either

punched or drilled. All holes shall be cylindrical , perpendicular to the member, and have a maximum out of round toleran ce of 1/16" (1.5 mm). Where shown on the plans, holes for bolt s in secondary member connections may be oversize or slotted. The minimum distance between centers of bolt holes shall be three times the diameter of the bolt but not be less than the following for: 1" bolts: 3½" M24 bolts: 84 mm 7/8" bolts: 3" M22 bolts: 77 mm 3/4" bolts: 2½" M20 bolts: 70 mm 5/8” bolts: 2¼" M16 bolts: 56 mm The minimum distance from the center of any bolt ho le to a sheared or flame cut edge shall be for: 1" bolts: 1¾" M24 bolts: 42 mm 7/8" bolts: 1½" M22 bolts: 38 mm 3/4" bolts: 1¼" M20 bolts: 35 mm 5/8” bolts: 1 1/8" M16 bolts: 28 mm The minimum distance from the center of any bolt ho le to a rolled or planed edge, except in flanges of beams a nd channels, shall be for: 1" bolts: 1½" M24 bolts: 36 mm 7/8" bolts: 1¼" M22 bolts: 33 mm 3/4" bolts: 1 1/8" M20 bolts: 30 mm 5/8” bolts: 1" M16 bolts: 24 mm 789 In the flanges of beams and channels, the minimum d istance from the center of any bolt hole to a rolled or planed e dge shall be for: 1" bolts: 1¼" M24 bolts: 30 mm 7/8" bolts: 1 1/8" M22 bolts: 27 mm 3/4" bolts: 1" M20 bolts: 25 mm 5/8” bolts: 7/8" M16 bolts: 20 mm The maximum distance of the center of the first bol t hole from any edge shall be 8 times the thickness of the thin nest outside plate but shall not exceed 5" (125 mm).

807.43 Punched Holes. The diameter of the die for hole

punching shall not exceed the diameter of the punch by more than 1/16" (1.5 mm). Holes that must be enlarged to adm it the bolts shall be reamed. Holes must be clean cut without torn or ragged edges.

807.44 Reamed or Drilled Holes. Where practicable, reamers

shall be directed by mechanical means. Burrs on th e outside surfaces shall be removed. Reaming and drilling shall be accomplished with twi st drills. If required by the Engineer, assembled parts shall be dismantled for removal of burrs. Connecting parts requiring reame d or drilled 790 holes shall be assembled and securely held while be ing reamed or drilled and shall be match marked before disassembl ing.

807.45 Subpunching, Subdrilling, and Reaming of Hol es for

Field Connections. Holes for all field connections of main members shall be subpunched or subdrilled and subse quently reamed while assembled, or reamed using a steel tem plate, as required by Subsection 807.54. Automatically contr olled drilling may be used for splice plates and for one side of m ain member connections. The splice plate shall be used as a t emplate to drill the opposite side of the main member connection while a ssembled. Holes for floor beam and stringer end connections s hall be subpunched or subdrilled and reamed using a steel t emplate, or reamed while assembled. Reaming or drilling full s ize of field connection holes through a steel template shall be accomplished after the template has been accurately located and firmly bolted in place. Templates used for reaming matching members or the opposite faces of a single member shall be exact du plicates. Templates used for connections on like parts or mem bers shall be accurately located so that the parts or members are duplicates and require no match-marking. Automatically controlled drilling may be used in lieu of using a steel template. Steel templates shall have hardened steel bushings in the holes that are accurately dimensioned from the centerline s of the connection as inscribed on the template. The cente rlines shall be used in accurately locating the template from the m illed or scribed ends of the members.

807.46 Accuracy of Subpunched and Subdrilled Holes. Holes

punched, subpunched, or subdrilled shall be accurat ely punched or drilled so that after assembling and before reaming , a cylindrical pin 1/8" (3 mm) smaller in diameter than the nominal si ze of the hole may be entered perpendicular to the face of the mem ber, without drifting, in at least 75% of the contiguous holes i n the same plane. If this requirement is not fulfilled, the member wi ll be rejected. If a pin 3/16" (5 mm) smaller in diameter than the nomin al size of any hole will not pass through the hole, this will be c ause for rejection.

807.47 Accuracy of Reamed and Drilled Holes. When holes

are reamed, drilled, or punched to full size, 85% o f the holes in any contiguous group shall show no offset greater than 1/32" (0.8 mm) between adjacent thicknesses of metal. 791 807.48 Bolting for Reaming. Surfaces of metal in contact shall be cleaned before assembling. The parts of a membe r shall be assembled and firmly drawn together with bolts befo re reaming begins. After reaming, members shall be cleaned of burrs and shavings and shall be free from twists, bends, and other deformation.

807.49 Pins and Rollers. Pins and rollers shall be accurately

turned to the specified dimensions and shall be str aight, smooth, and free from flaws. Pins and rollers more than 9" (22 5 mm) in diameter shall be forged and annealed. Pins and rollers 9" (225 mm) or less in diameter may be either forged and annealed or co ld-finished carbon-steel shafting. In pins larger than 9" (225 mm) in diameter, a hole of the diameter specified on the plans shall be bored full length along the pin axis after the forged pin has been allowed to p roperly cool to a temperature below the critical range. Drilling sha ll be accomplished before the annealing process.

807.50 Boring Pin Holes. Pin holes shall be bored true to the

specified diameter, smooth, straight, at right angl es with the axis of the member, and parallel with each other unless oth erwise specified. The final surface shall be produced by a finishing cut. The distance outside to outside of end holes in ten sion members and inside to inside of end holes in compression me mbers shall not vary from that specified more than 1/32" (0.8 mm). Boring of holes in built-up members shall be performed after fabric ation is completed.

807.51 Pin Clearances. The diameter of the pin hole shall not

exceed that of the pin by more than 1/50" (0.5 mm) for pins 5" (125 mm) or less in diameter or by 1/32" (0.8 mm) f or larger pins.

807.52 Threads for Unfinished Bolts and Pins. Threads for

bolts and pins for structural steel construction sh all conform to the current Unified Standard Series UNC-ANSI B 1.1, Cla ss 2A for external threads and Class 2B for internal threads, except that pin ends having a diameter of 1 3/8" (35 mm) or more sh all be threaded 6 threads to 1" (6 threads to 25.4 mm).

807.53 Pilot and Driving Nuts. Two pilot nuts and two driving

nuts for each size of pin shall be furnished, unles s otherwise specified. 792 807.54 Shop Assembling. (a) General. The field connections of main members shall be assembled in the shop with mi lled ends of compression members in full bearing. After assembl y, the sub-size holes shall be reamed to specified size.

807.55 Drifting of Holes. The drifting accomplished during

assembly shall be sufficient to bring the parts int o position, but shall not enlarge the holes or distort the metal.

807.56 Match-Marking. Connecting parts that are assembled in

the shop for the purpose of reaming field connectio n holes shall be match-marked. A diagram showing such marks shall b e furnished to the Engineer upon request.

807.57 Finished Members. Finished members shall be true to

line and free from twists, bends, and open joints. When finished members are moved to storage they sha ll be picked up at two or more points. They shall be car efully handled to prevent damage, and placed on skids above the groun d. Long members shall be supported sufficiently to prevent damage from deflection.

807.58 Certification of Identification. The Contractor shall

furnish an affidavit certifying that throughout the fabrication operation the identification of steel has been main tained according to this specification.

807.59 Storage of Materials. Structural material, either plain or

fabricated, shall be stored above the ground upon p latforms, skids, or other supports. It shall be kept free from dirt , grease, and other foreign matter, and shall be protected as far as pr acticable from corrosion. Handling of materials shall not cause d amage or undue stress.

807.60 Weighing of Members. In case it is specified that any

part of the material is to be paid for by actual we ight, finished work shall be weighed in the presence of the Inspector. The Contractor shall supply satisfactory scales and shall perform all work involved in handling and weighing the various parts. 794 807.61 Marking and Shipping. Each member shall be printed or marked with an erection mark for identification. An erection diagram shall be furnished showing the appropriate erection marks. If steel die stamping is used for marking, it shall be the low stress type and high stress areas of members shall be avoi ded. The Contractor shall furnish sufficient copies of m aterial orders, shipping statements, and erection diagrams as the E ngineer may direct. The weights of the individual members shall be shown on the statements. Members weighing more than 3 tons (3 m etric tons) shall have the weights marked thereon. Structural members shall be loaded on trucks or car s in such a manner that they may be transported and unloaded at their destination without being excessively stressed, def ormed, or otherwise damaged. Bolts of each size, loose nuts or washers of each s ize, and fasteners tested as an assembly for rotational capa city tests shall be packed separately. A list and description of the c ontained material shall be plainly marked on the outside of each ship ping container. ERECTION

807.62 Erection of Steel Structures. When the substructure and

superstructure are constructed under separate contr acts, the Department will provide the substructure constructe d to established lines and elevations and properly finished. When B ridge Construction Control is not included in the Contrac t, the Department will establish the lines and elevations required fo r erection of the superstructure steel. The Contractor shall erect the structure steel, rem ove any designated temporary construction, and perform all work required to complete the structure or structures as provided in the Contract, including the removal of the old structure or struc tures when specified.

807.63 Methods and Equipment. Before starting the work of

erection, the Contractor shall advise the Engineer, for informational and record purposes, of the method of erection he p roposes to follow and the type of equipment he proposes for use. The Contractor shall be responsible for the safety of his methods and eq uipment and for performing the work according to the plans and spec ifications. 795 807.64 Falsework. Details of falsework construction for steel erection, complete with dimensions, design calculat ions, and kind and condition of materials, shall be submitted to t he Engineer prior to construction for informational and record purpos es. These details shall be prepared and/or approved by a Registered P rofessional Engineer. Construction shall be according to the d etails submitted to the Engineer for informational purposes. The Co ntractor shall be responsible for the results obtained by the use of the falsework design. All falsework shall be designed and constructed to provide the necessary rigidity and to support the loads without appreciable settlement or deformation. Falsework shall be set to give the finished structure the camber specified. Falsework that cannot be founded on a satisfactory footing shall be supported on piling which shall be spaced, drive n, and removed as specified in the Contractor's falsework details. Upon completion of the steel erection the Contracto r shall remove all falsework prior to placing the deck.

807.65 Handling and Storing Materials. Material to be stored

shall be supported on skids above the ground. It s hall be kept clean and properly drained. Girders and beams shall be p laced upright and properly shored. Long members, such as columns and chords, shall be properly supported to prevent damage from deflection.

807.66 Bearings and Anchorage. Bearing plates shall not be

placed upon bridge seat bearing areas that are impr operly finished, deformed, or irregular. Bearing plates shall be se t level and in the specified position and shall have uniform bearing o n the masonry. Bearing plates shall be accurately set on preformed fabric or elastomeric pads meeting the requirements of Subsec tion 807.15. Anchor bolts shall be set in holes drilled in the b ridge seat or cast in place. Bolts placed in drilled holes shall be a ccurately set and fixed with an approved epoxy or non-shrink grout fr om the QPL that completely fills the holes. The location of anchor bolts in relation to slotted holes in expansion shoes shall be determine d by the air temperature and the amount of expansion at the time of erection. Nuts on anchor bolts at the expansion ends of spans shall be adjusted to permit free movement of the span. 796 807.67 Field Welding. All field welding shall be accomplished according to the applicable provisions of 807.26.

807.68 Straightening Bent Members and Correcting Ca mber.

807.69 Assembling Steel. Steel members shall be accurately

assembled as shown on the plans and match-marks sha ll be followed. Members shall be carefully handled so th at no parts will be bent, broken, or otherwise damaged. Hammering w hich will damage or distort the members will not be allowed. Bearing surfaces and surfaces to be in permanent contact sh all be cleaned before the members are assembled. 797 Unless erected by the cantilever method, truss span s shall be erected on blocking so as to give the trusses prope r camber. The blocking shall be left in place until the tension c hord splices are fully bolted and all other truss connections pinned and bolted. Permanent bolts in splices of butt joints of compre ssion members and permanent bolts in railings shall not be tighte ned until the span has been made self-supporting. Field connections using high strength bolts shall c omply with the following assembly requirements: • At least 4 erection pins, installed in extreme hole locations, shall be used. The actual number of erection pins required shall be sufficient to ensure proper alignment of t he remaining holes. • A total of at least one half of the holes shall be filled with a combination of fitting-up bolts and the above requi red erection pins. At least 50% of this combination shall be fi tting-up bolts. Fitting-up bolts shall be symmetrically pla ced. For splices, the above requirements shall be applie d to each element of the splice (i.e. top flange, web, bottom flange) on each side of the joint. Fitting-up bolts may be either the same high streng th bolts used for final assembly or they may be other bolts of th e same nominal diameter as the high strength bolts. If non-high s trength fitting-up bolts are used, they will be removed and replaced p rior to the final assembly. Fitting-up bolts that are hammered into position shall not be used in the final assembly if thread damage has occurred. Erection pins shall be cylindrical and shall have a diameter 1/32" (0.8 mm) larger than the high strength bolts used i n final assembly. The erection pins, as well as any fit-up bolts that are not part of the final assembly, shall be furnished by the Contracto r at no cost to the Department.

807.70 Unfinished Bolt Connections. Unfinished bolts shall

conform to the requirements of ASTM A 307, Grade A. Bolts shall have single self-locking nuts or double nuts unless otherwise specified. Beveled washers shall be used where bea ring faces have a slope of more than 1:20 with respect to a plane nor mal to the bolt axis. 798 807.71 High Strength Bolt Connections. (a) General. High strength bolts meeting the requirements of ASTM A32 5 shall be furnished unless otherwise specified. Bolts shall be placed with heads on the outside fac e of exterior girders and the bottom of girder flanges. High strength fasteners, other than those used in b olted field splices for main load-carrying members, may be re-u sed one time after initial tightening to specification tension, provided that a close visual inspection indicates that there is no distre ss in the bolt, no damage to the threads, and that the nut runs freely on the bolt. When it becomes necessary to remove or loosen a bol t assembly after it has been tightened to specification tensio n twice, the assembly must be discarded and a new one substitute d. High strength fasteners used in bolted field splice s for main load- carrying members may be tightened to specification tension only once. Retightening previously tightened bolts that may ha ve been loosened by the tightening of adjacent bolts will n ot be considered as re-use provided the retightening continues from the initial position and does not require greater rotation, inc luding the tolerance, than that required by Table 807-1. All fitting-up bolts shall be brought to a snug tig ht condition before installing and tightening the balance of hig h strength bolts. Snug tight is defined as the tightness that exists when the plies of the joint are in firm contact. Following the initial snug tightening of the fittin g-up bolts, the remaining holes shall be filled with high strength bolts and tightened to a snug tight condition. Erection pins and any f itting-up bolts not suitable for final assembly shall then be replaced with high strength bolts and installed to a snug tight condition. All bolts in the connection shall then be tightened to the specified tension. Snug tightening and tightening shall progress syste matically from the most rigid part of the joint to its free edges.

807.72 Pin Connections. Pilot and driving nuts shall be used in

driving pins for connections. Pins shall be so dri ven that the members will take full bearing on them. Pin nuts s hall be screwed up tight and the threads burred at the face of the nut with a pointed tool.

807.73 Misfits. The correction of minor misfits involving

harmless amounts of reaming, cutting, and chipping will be considered a legitimate part of the erection. Howe ver, any error in the shop fabrication or deformation resulting from handling and transportation that prevents the proper assembling and fitting up of parts by the moderate use of drift pins or by a mod erate amount of reaming and slight chipping or cutting, shall be re ported immediately to the Engineer and his approval of the method of correction obtained. The correction shall be made in his presence. The Contractor shall be responsible for all misfits , errors, and injuries and shall make the necessary corrections a nd replacements. 803 807.74 Profiling of Steel Beams and Girders. Upon completion of erection and bolting of beams and gir ders, the Contractor shall profile each beam or girder line. The profiling shall be accomplished prior to beginning any deck forming operations. These profiles will be used to establish a finished deck elevation to provide the correct deck thickness. This may requi re the construction of variable haunches over the beams or girders to obtain the correct deck elevation and thickness. A ll required haunches are considered variable and the extra mate rials and work required in construction of these haunches shall be at no cost to the Department. PAINTING

807.75 Painting -- General. The painting of metal structures

shall include, unless otherwise provided in the Con tract, the preparation of the metal surface and the applicatio n, protection, and drying of the paint coatings. All references to th is subsection at other locations in these specifications shall be de emed to include Subsections 807.75 through 807.88, as applicable. The prime and finish coats shall be the type and co lor specified in the Contract. The Contractor shall exercise every reasonable prec aution throughout the life of the project to prevent pollu tion of rivers, streams, or impoundments. Painting and cleaning op erations conducted over or in the vicinity of water shall be controlled to prevent materials or waste, considered a contaminan t by the Arkansas Department of Environmental Quality (ADEQ) , from falling into the water. All material or waste that falls into the water, or onto areas where there is a likelihood that it w ill be picked up by rising water levels, shall be retrieved and properl y disposed of in approved locations. When paint is to be applied to a structure that spa ns a waterway, the Contractor shall notify the ADEQ, in writing, a t least 2 weeks prior to the date work is to begin. A copy of this notification shall be furnished to the Engineer. The Contractor shall protect pedestrian, vehicular, or other traffic upon, underneath, or in the vicinity of the bridge, and all portions of the bridge superstructure and substructure against damage or disfigurement by drift, spatters, splashes, or smir ches of paint or paint materials. 804 All scaffolding, ladders, and other equipment, mate rials, or tools that restrict vertical or horizontal clearances sha ll be clear of all lanes and shoulders open to traffic when not in use or protected by appropriate traffic control devices.

807.76 Paint System. (a) General. The paint system shall

consist of an Inorganic Zinc-Rich Prime Coat applie d in the fabrication shop and a Finish System that shall be field applied. All coatings used shall be supplied by the same manufac turer to ensure compatibility. Lead and chromium pigments will not be permitted. All coatings shall meet the current EPA and ADEQ re strictions for Volatile Organic Compounds (VOC). The Engineer will verify the thickness of each pain t coat using a dry film thickness gauge. Dry film thickness will be determined by methods described by the Steel Structures Painting Council (SSPC). Any paint coat found to be deficient in thickness s hall be corrected according to the manufacturer's recommendations. T he correction shall be at no cost to the Department.

807.77 Neither the epoxy tie coat nor the urethan e coat shall be

applied until the preceding coat or any touch-up ha s cured for the minimum time as recommended by the manufacturer. T he minimum dry film thickness of the epoxy tie coat sh all be 2.0 mils (50 µm) unless otherwise recommended by the manufacturer . The minimum dry film thickness of the urethane coat sha ll be 3.0 mils (75 µm).

807.77 Materials. (a) Inorganic Zinc-Rich Primer. The prime

coat shall be an inorganic zinc-rich paint complyin g with the requirements of AASHTO M 300 for Type I or Type II. The paint shall qualify for a Class A classificatio n (slip coefficient of 0.33 or greater) when tested accordi ng to "Testing Methods to Determine the Slip Coefficient for Coati ngs used in Bolted Joints", in Appendix A of Specification for Structural Joints Using ASTM A 325 or A 490 Bolts as published by AISC.

807.78 Number of Coats. Steel shall receive one shop prime

coat, one epoxy tie coat, and one field finish coat . Previously applied coats which have been damaged or skinned sh all be corrected according to the manufacturer's recommend ations prior to the application of any succeeding coat. The variou s coats shall be sufficiently different in color as to permit detect ion of incomplete application.

807.79 Mixing of Paint. Paint shall be mixed before applying in

order to keep the pigments in uniform suspension. Mechanical mixers shall be used to mix the paint. Prior to applying, the paint shall be mixed a sufficient len gth of time to 807 thoroughly mix the pigment and the vehicle together , and it shall be kept thoroughly mixed during its application.

807.80 Thinning Paint. Paint shall be ready for use when

thoroughly mixed. However, where thinning by additi on of vehicle is recommended by the manufacturer, paint may be th inned according to those recommendations. The recommenda tions for thinning shall be plainly marked on the paint conta iner and the minimum dry film thickness shall be achieved. The addition of thinner shall not exceed the allowable VOC establis hed by ADEQ.

807.81 Weather Conditions for Painting. Paint shall be applied

according to the temperature, humidity range, and o ther limitations recommended by the manufacturer. Paint shall not b e applied when, in the opinion of the Engineer, conditions are unsa tisfactory for the work. Paint shall not be applied upon a damp or fr osted surface.

807.82 Application of Paint. (a) General. Painting shall be

accomplished in a neat and professional manner. Al l paint shall be applied using suitable conventional spray or airles s spray equipment. A uniform coating free from runs and sags shall be produced. Brushing may be used for touch-up or in areas inacc essible for spraying. All surfaces to be painted shall be clean and free from dust, oil, grease, or other objectionable matter.

807.83 Removal of Unsatisfactory Paint. If any painting

application produces a coat that is unsatisfactory to the Engineer, the paint shall be removed and the metal thoroughly cle aned and repainted. 808 807.84 Cleaning Surfaces. (a) General. Surfaces of metal to be painted shall be thoroughly cleaned by removing rus t, loose mill scale, dirt, oil, grease, and other foreign substan ces.

807.85 Shop Painting. Unless otherwise specified, structural

steel shall be given one shop coat of approved pain t before it is shipped from the plant. Surfaces that will not be exposed to the atmosphere in the final structure, and which will be inaccessible after ass embly, erection, or placement of concrete shall be given a prime coat b ut will not require a finish coat. Field contact surfaces of b olted connections, including all components of bolted splices, shall r eceive a prime coat of paint in the shop. A shop prime coat of paint shall be applied to the top of the top flanges of all beams and girders. Structural steel that is to be field welded shall n ot be painted before the field welding is complete. Unless otherwise specified, surfaces of iron and st eel castings, either milled or finished, shall be painted. With the exception of abutting joints and base plat es, machine- finished surfaces shall be coated, as soon as pract icable after being accepted, with a graphite dry film lubricant or oth er approved coating prior to removal from the shop. Erection and weight marks shall be painted upon sur face areas that have previously been painted with the shop coa t. Material shall not be loaded for shipment until it has thoroughly dried, and in no case less than 24 hours after the paint has been ap plied.

807.86 Field Painting. When erection work is complete, any

adhering rust, scale, dirt, oil, grease, or other f oreign materials shall be removed as specified in Subsection 807.84. 810 All areas of prime coat and/or shop applied epoxy t ie coat that have been damaged or are otherwise defective shall be corrected according to the manufacturer's recommendations pri or to application of the finish system. Areas requiring a finish coat on which the prime and/or epoxy tie coat was not appli ed shall be cleaned and the required coats applied prior to app lication of the finish coat. All surfaces shall be free of any sol uble residue or excessive amounts of loose zinc before the finish o r epoxy tie coat is applied. All paint, including prime, epoxy tie coat, and ure thane finish coat, shall be properly cured according to the manu facturer’s recommendations; and limitations on recoat time com plied with. Subsequent coatings shall be applied as soon as pra ctical after recoat requirements are met. When application of subseque nt coatings is not done within the specified time, the previously applied coating may require additional surface preparation, subject to the manufacturer’s recommendations. Epoxy tie coats and finish coats shall not be appli ed to the contact surfaces of bolted connections. Surfaces that will be inaccessible after erection and will be exposed to the atmospher e shall be painted with the applicable field coats prior to erection. When the paint applied for correcting the shop coat has thoroughly dried and the field cleaning has been satisfactorily completed, t he required field coats shall be applied. Small cracks and cavities that were not sealed in a watertight manner by the field prime co at shall be filled with an additional application of field prime coat paint before the finish system is applied. The following provision shall apply to the applicat ion of the field prime and the finish system: To secure a maximum c oating on edges of plates, shapes, bolts, and other parts sub jected to special wear, the edges shall first be coated with a longit udinal motion and the bolts with a rotary motion followed immediately by the general painting of the whole surface, including the edges and bolts. If traffic produces an objectionable amount of dust , the Contractor shall, at no cost to the Department, set tle the dust for the necessary distance on each side of the structure an d take any other precautions necessary to prevent dust and dirt from coming in contact with surfaces to be painted or with freshly painted surfaces. 811 The application of the finish coat shall be deferre d until adjoining concrete work has been placed and finished.

807.87 Preparing Galvanized Surfaces for Painting. When

required, the painting of galvanized surfaces shall be deferred as long as possible to allow weathering of the surface s. Before painting, galvanized surfaces shall be prepa red as follows: All soil, concrete spatter, and other surface dirt shall be removed with a stiff brush, scraper, or other suitable mean s. All surfaces shall be cleaned with alkaline deterge nts such as trisodium phosphate. Surfaces cleaned with deterge nts shall be thoroughly rinsed with hot water to remove alkaline residue. Solvents may be required to remove certain contamin ants, including oil or grease. When solvents are used, special car e shall be taken to assure proper ventilation and safe working conditio ns. Manufacturers' recommendations for the use of solve nts shall be followed. The use of gasoline, benzene, low-flash naphtha, or other highly volatile fluids, and the washing of galvanized surf aces with vinegar or other acids prior to painting will not be allowe d. As an alternative to detergent and solvent cleaning , sweep blasting of the galvanized surface will be permitte d. The field prime and finish system shall be applied according to Subsection 807.86.

807.88 Repairing Damaged Galvanized Coatings. Galvanizing

that has been chipped off or damaged in handling, t ransporting, or welding shall be repaired by field galvanizing. Field galvanizing shall be accomplished by the appl ication of a paste composed of approved zinc powder and flux wit h a minimum amount of water. The areas to be coated shall be t horoughly cleaned, including removal of any slag on welds, be fore the paste is applied. The surface to be coated shall first be h eated with a torch to a temperature sufficient that the metallics in the paste are melted when applied to the heated surface. Extreme care s hall be taken to assure that surrounding surfaces are not damaged by the torch. The flux in the paste will cause a black residue on the surface of the coated parts. This black residue shall be removed by rinsing with water or wiping with a clean, damp cloth. 812 Other methods of repairs may be used as allowed by ASTM A 780, Repair of Hot-Dip Galvanized Coatings. Products used for repair shall be as listed on the Departmen t's QPL or as approved by the Engineer. Repair to damaged galvanized coatings shall be acco mplished at no cost to the Department.

807.89 Method of Measurement. (a) Measurement for structural

steel will be based on plan quantities of the weigh t of structural steel in the fabricated structure. When this weight is a ltered by the Engineer, the weight of structural steel for paymen t will be adjusted to account for the change. Where the Fabricator's or Contractor's calculations indicate an error in plan quantities t hat varies more than 1% from the planned project quantity, calculations may be submitted for checking by the Department and, if ve rified, the corrected weight will be used. The weight of shop and field paint, boxes, crates, and other containers used for packin g, and for sills, struts, and rods used for supporting members during transportation, will be excluded. If the scale weight of any member is less than 97.5 % of the computed weight, the member will be rejected. The weights are computed on the following basis:

807.90 Basis of Payment. (a) Structural Steel. Work

completed and accepted and measured as provided abo ve, will be paid for at the contract unit price bid per pound ( kilogram) for Structural Steel in Beam Spans, Structural Steel in Truss Spans, Structural Steel in Plate Girder Spans, or other cl assifications of metal for steel structures shown on the plans and i n the proposal, as the case may be, which price shall be full compensa tion for furnishing materials; for fabrication, shop work in cluding shop painting, transportation, falsework, erection, and repairing galvanizing; for performing quality control and acc eptance sampling and testing; and for all labor, equipment, tools, a nd incidentals necessary to complete the work. Unless otherwise provided, metal drains, bearing an d expansion plates and shapes, and rockers and shoes will be pa id for at the unit price bid for the structural steel for the spans on which this material is used.

808.01 Description. This item shall consist of elastomeric

bearings and shall include unreinforced pads (consi sting of Elastomer only) and reinforced bearings with steel lamina, furnished and constructed according to these specifications a nd the details shown on the plans.

808.02 Materials . Elastomeric bearings shall be supplied by a

manufacturer listed on the QPL. The elastomer comp ound shall be of 100% virgin polychloroprene (neoprene) and shall meet the minimum requirements shown in Table 808-1. The tes ting methods given in Table 808-1 shall be used when determining material properties. When test specimens are cut from the f inished product, a 10% variation in the physical properties indicated will be allowed. Elastomers for steel reinforced bearings shall be 5 0-durometer hardness. Elastomers in unreinforced pads may be 50, 60, or 70- durometer hardness. Steel lamina shall be rolled mild steel conforming to AASHTO M 270 Grade 36 [250] (except that Charpy V-Notch Im pact tests are not required), ASTM A 1011, SS or HSLAS, or equival ent, shall have a minimum yield strength of 30,000 psi (205 MP a), and shall be ordered to the nominal thickness specified on th e plans. External load plates shall conform to the requireme nts of AASHTO M 270, Grades 36 (250), 50 (345), or 50W (34 5W) as noted on the plans, except that Charpy V-Notch Impa ct tests are not required. The vulcanized bond in reinforced bearings shall de velop a minimum peel strength of 40 pounds per inch (6.9 kN /m). Peel strength tests shall be performed according to ASTM D429 Method B.

808.03 Fabrication . Bearings shall be furnished with the

dimensions shown on the plans unless otherwise appr oved by the Engineer. Shop drawings for reinforced bearings sh all be submitted to the Bridge Engineer and approval secured before fabrication is begun. Such drawings shall show the materials and fabrication procedures to be used, any changes from plan dimens ions, and the bearing orientation and manner of marking the orien tation when tapered external load plates are required. Unreinf orced pads may be fabricated without submission or approval of shop d rawings. 816 Changes from plan dimensions proposed by the Contra ctor and approved by the Engineer shall be at no additional cost to the Department. Reinforced bearings shall be cast as a unit in a m old and shall be bonded and vulcanized under heat and pressure. The mold finish shall conform to standard shop practice. Internal steel lamina and surfaces of external load plates (sole plates and m asonry plates) which are to be vulcanized shall be sandblasted and cleaned of all surface coatings, rust, mill scale, and dirt before bonding. Internal steel laminae shall be free of sharp edges and burr s and shall be sized to provide edge cover of ¼” (6 mm). External load plates (sole plates and masonry plates) shall be protected from rusting by the manufacturer and shall be vulcanized to the bea ring pad during the primary molding process. Reinforced bearings s hall be manufactured as a single unit. Unreinforced pads may be molded or extruded, and vu lcanized in large sheets and cut to size. Cutting shall not he at the materials, and shall produce a smooth finish to ANSI B46.1, 0.2 mi ls (0.006 mm). Unreinforced pads shall be molded or extruded to th e finished thickness. Plying pads of lesser thickness togethe r to make pads of finished thickness will not be allowed. Flash tolerance, finish, and appearance shall meet the requirements of the latest edition of the Rubber Ha ndbook as published by the Rubber Manufacturers Association, Inc., RMA F3 and T.063 for molded bearings and RMA F2 for extrud ed bearings.

808.04 Tolerances. Unreinforced pads, reinforced bearings, and

external load plates shall be built to the design d imensions and these specifications with the following tolerances:

808.05 Lot Testing . Testing for meeting the requirements of

Subsection 808.02 shall be performed by the manufac turer on each production lot of bearings. For each lot of reinforced bearings, a randomly sel ected sample comprising at least 10 percent of the lot shall be compression tested 818 by the manufacturer. Each bearing shall be individ ually loaded to 1.5 times its maximum design load shown on the plan s for a minimum period of 15 hours. If, during the test, t he load falls below 1.3 times the maximum design load, the test duratio n shall be increased by the period of time for which the load is below this limit. The bearing shall be examined visually at t he end of the test while it is still under load. If the bulging patte rn suggests lamina parallelism, a layer thickness that is outside the specified tolerances, or poor lamina bond, the bearing shall be rejected. If there are three or more surface cracks that are greater than 0.08" x 0.08" (2 mm wide and 2 mm deep), the bearing shall be rejected. If a sample fails any test required by this subsect ion, all bearings of that lot will be rejected, unless the manufactur er elects to test each bearing for the failing test(s) at no cost to the Department. A lot is defined as a group of no more than 100 bea rings which are manufactured from the same batch of elastomer, cured under the same conditions and are all the same size.

808.06 Visual Inspection and Proof Loading of Finis hed

Bearings . Every bearing shall be inspected for compliance with dimensional tolerances and for overall quality of m anufacture. In reinforced bearings, the edges of the internal stee l lamina shall be protected everywhere from corrosion. The manufacturer shall proof load each reinforced b earing individually with a compressive load equal to 1.5 t imes its maximum design load shown on the plans. The load s hall be held constant for five minutes, removed, and reapplied f or another five minutes. The bearing shall be examined visually wh ile under the second loading. If the bulging pattern suggests la mina parallelism, a layer thickness that is outside the specified toler ances, or poor lamina bond, the bearing shall be rejected. If the re are three or more separate surface cracks that are greater than 0.08" x 0.08" (2 mm wide and 2 mm deep), the bearing shall be rejected.

808.07 Certification and Marking. The manufacturer shall

certify that each bearing satisfies these specifica tions and shall supply a certified copy of all test results, includ ing the number of reinforced bearings that failed the proof load test . Certified mill certificates for internal steel lamina and external load plates shall also be supplied. 819 Each reinforced bearing shall be marked in indelibl e ink or flexible paint. The marking shall consist of the b ent/pier number, orientation, the order number, lot number, bearing identification number, and elastomer type and grade number. Unless otherwise specified, the marking shall be on a face that is v isible after erection of the bridge.

808.08 Installation . Reinforced bearings shall be placed on

level, uniform surfaces. Any misalignment in the s upport shall be corrected to form a level surface. Bottom external load plates (masonry plates), when used, shall be set on unrein forced pads. Preformed fabric pads meeting the requirements of S ubsection 807.15(a) may be used in lieu of unreinforced pads. Unless otherwise approved by the Engineer, the exte rnal load plate at expansion bearings may be welded to the be am/girder only when: • the approximate average air temperature during the 24 hour period immediately preceding welding is betwee n 40º F and 80º F (4º C and 27º C); and • the slots in the external load plate are positioned to center on the anchor bolts; and • no horizontal deformation of the elastomeric pad is evident. If welding at other temperatures is required, the E ngineer will provide adjustment data. In no case shall the elastomer or the bond be subje cted to temperatures higher than 400° F (204 ° C).

808.09 Method of Measurement. Reinforced elastomeric

bearings will be measured by the cubic inch (cubic centimeter) of elastomer material, including required lamina. No deductions will be made for bolt holes. External load plates will not be measured or paid for separately but will be considered included in the contract unit price bid for Elastomeric Bearings. Unreinforced pads will not be measured separately, but will be considered subsidiary to "Class S Concrete - Bridge ." TABLE 808-1 ELASTOMER MATERIAL PROPERTIES MATERIAL ASTM T E S T V A L U E S F O R : PROPERTY STD. TEST REQUIREMENTS 50 60 70 TEST Durometer Durometer Durometer Physical D 2240 Hardness(Shore A Durometer) 50 ± 5 60 ± 5 70 ± 5 Properties D 412 Tensile Strength, Minimum psi 2250 2250 225 0 (MPa) (1 5.5) (15.5) (15.5) Ultimate Elongation, Minimum % 400 350 300 Heat Resistance D 573 Change in Durometer Hard ness, 15 15 15 70 Hours Maximum Points at 212 °F (100 °C) Change in Tensile Strength, Max. % -15 -15 -15 Change in Ultimate Elongation, -40 -40 -40 Max. % Compression Set D 395 22 Hours @ 212°F (100 °C), Max. % 35 35 35 Method B Ozone D 1149 100 pphm ozone in air by volume, 20 % strain @100°F ± 2°F (37.7 °C ± 1 °C) No Cracks No Cracks No Cracks 100 Hours mounting procedure D518, Procedure A Instantaneous D 1043 Tested @ -25°F (-31.7 °C) Stiffness at Test Temperature shall not Thermal exceed 4 times the stiffness measured at Stiffening 73°F (23 °C) Shear Modulus D 4014 Using apparatus and procedure s 95-130 130-200 200-300 described in Annex A, Range, psi (MPa) (0.66-0.90) (0.90-1.38) (1.38-2.07) Note: All tests to be carried out at 73°F ± 4°F (23 °C ± 2 °C) unless otherwise noted. Shear modulus test is n ot required for unreinforced pads. 821 The quantities shown on the plans will be considere d as the final quantities and no further measurement will be made unless, in the opinion of the Engineer or upon evidence furnished by the Contractor, substantial variations exist between qu antities shown on the plans and actual quantities due to changes in a lignment, dimensions or apparent errors.

808.10 Basis of Payment. Work completed and accepted and

measured as provided above will be paid for at the contract unit price bid per cubic inch (cubic centimeter) for Ela stomeric Bearings, which price shall be full compensation for furnishi ng materials; for fabrication; for installation; and for all labor, e quipment, tools, and incidentals necessary to complete the work. Payment will be made under: Pay Item Pay Unit Elastomeric Bearings Cubic Inch (Cubic Centimeter)

BRIDGE RAILINGS in other states

• Indiana 706 · BRIDGE RAILINGS
• Michigan 711 · Bridge Railings
• Tennessee 620 · BRIDGE RAILINGS
• Vermont 525 · BRIDGE RAILINGS
• Washington 6-06 · Bridge Railings