635 604- 5 Basis of Payment: Structural steel for use in steel structures will be paid at the contract unit price per pound or at the contract lump sum price, complete in place. When the lump sum basis of payment is specified and an alteration in the work is ordered which increases or decreases the quantity of structural steel required, a theoretical unit price, determined by dividing the lump sum bid price by the total estimated quantity of structural steel shown on the project plans, will be the basis for payment for the increase or decrease in quantity. The theoretical unit price will be subject to adjustment, all in accordance with the provisions of Subsection 104.02 of the specifications. No measurement or direct payment will be made for any additional weight resulting from substitution of structural steel sections as specified in Subsection 604- 3.03 of the specifications. Partial payment may be made in accordance with the provisions of Subsection 109.07 of the specifications. 605- 1 Description: The work under this section shall consist of fabricati ng, furnishing, and placing steel reinforcement of the quality, coating, type, size, shape, and quantity designated, all in accordance with the details shown on the project plans and the requirements of these specifications. 605- 2 Materials: Steel reinforcing bars, wire, and welded wire fabric shall conform to the requirements of Section 1003 of the specifications. 605- 3 Construction Requirements : 605- 3.01 General: When the project plans show a bar list and bending diagram, the contractor shall carefully check the schedule against the details in advance of ordering materials. When bar bending diagrams are not shown on the project plans, shop drawings and lists showing the bending of reinforcement bars shall be submitted by the contractor to the Engineer for approval, but such approval shall not relieve the contractor of responsibility for the correctness of such drawings and lists. TABLE OF CONTENTS INDEX 636 Any discrepancy or error found by the contractor in checking a bar list or bending diagram shown on the project plans or in preparing shop drawings or lists shall be reported immediately to the Engineer, and the discrepancy or error shall be corrected in advance of fabrication and delivery of materials. Steel reinforcement shall be protected at all times from damage. When placed in the work, all reinforcement shall be free of dirt, oil, paint and grease. Rust, surface irregularities or mill scale shall not be cause for rejection, provided the weight, dimensions, cr oss-sectional area and tensile properties of a manually wire brushed test specimen are not less than the requirements of these specifications. When bending is required, it shall be done without the use of heat, and bars having cracks or splits at the bends will be rejected. Grade 40 bars which are No. 8 and larger and all sizes of Grade 60 bars shall not be rebent at the same location. Grade 40 bars which are size No. 7 and smaller may be rebent once at the same location. Reinforcement shall be accurately fabricated and placed as shown on the plans and shall be firmly held in place by wire ties at all intersections and splices with 16 gauge or heavier tie wires and with precast mortar blocks or ferrous metal chairs, space rs, metal hangers, supporting wires , or other approved supports at the spacing necessary to maintain the specified clearance of the reinforcing steel. The use of pebbles, broken stone, concrete masonry blocks, brick, metal pipe, or wood blocks will not be permitted for the purpose of spacing or support. Where reinforcement spacing is less than 12 inches in each direction alternate intersections may be tied. Tack welding of reinforcement will not be permitted unless approved in writing by the Engineer. If tack welding of reinforcement is approved the reinforcement shall be deformed and shall conform to the requirements of ASTM A706. Before placing the pier column and superstructure reinforcement, the contractor shall insure that the vertical reinforcing steel will not interfere with the horizontal cap reinforcing steel and tendon ducts. Reinforcing steel shall not be cut to facilitate installation. The following tolerances will be allowed when placing, tying, and supporting reinforcing steel:
measured vertically, of the position indicated on the plans;
clearance from the forms shall be within 1/4 inch of the clearance shown on t he plans; and
in spacing; however, the specified number of bars shall be placed. TABLE OF CONTENTS INDEX 637 No concrete shall be placed until reinforcement in the member has been inspected and approved by the Engineer. Reinforcement which does not conform to the above tolerances shall be adjusted or repaired prior to concrete placement. When required by the project plans, all reinforcement and all other steel elements to be encased in the concrete of a bridge deck or bri dge barriers shall be epoxy coated. Reinforcement that is to be partially within these concrete elements, but extends into other structural elements, will not require coating on that part which is to be outside the bridge deck or bridge barrier concrete. 605- 3.02 Splicing and Lapping: All reinforcement shall be furnished in the full lengths indicated on the project plans. S plicing of bars, except as shown on the plans, will not be permitted without the Engineer's approval. Splices shall be staggered as far as possible. The type and method of splices or connections shall be approved by the Engineer. The contractor may use either lap splices, full welded splices, or mechanical connections for reinforcement bars up to and including bar size No. 11. Where the bar size exceeds No. 11, full welded splices or mechanical connections shall be used. Welded splices shall not be used on epoxy- coated bars, and no welding shall be performed close enough to epoxy- coated bars to cause any heating of the coating. All exterior surfaces of positive connectors for epoxy -coated bars shall have the same coating as the bar. In lapped splices, t he bars shall be placed in contact with one another and wired together in such a manner as to maintain a clearance of not less than the minimum clear distance to other bars and the minimum distance to the surface of the concrete, as specified in the AASHTO Standard Specifications for Highway Bridges. Lap lengths shall be as shown on the plans. A full welded splice is one in which the bars are butted and welded to develop, in tension, at least 125 percent of the specified yield strength of the bar. Test requirements shall be as specified in AWS D 1.4. Welding shall be performed in accordance with the requirements of Subsection 604- 3.06 of the specifications. A mechanical connection is one in which the bars are connected to develop an ultimate strength, in t ension or compression as required, of at least 125 percent of the specified yield strength of the bar. Except as otherwise specified, mechanical splices shall be made in accordance with the manufacturer's recommendations as approved by the Engineer. As a condition of approval, the contractor shall make three test splices in the presence of the Engineer of each size it intends TABLE OF CONTENTS INDEX 638 to splice. Two of the test splices shall be tension tested to 125 percent of the specified yield strength of the bar and one splice shall be tested to destruction by an approved laboratory and certified reports of the tests shall be submitted to the Engineer for approval. Field splices shall be subject to visual inspection and physical testing. A minimum of 2 percent of the field splices chosen at random by the Engineer shall be removed and tested to 125 percent of specified yield strength by the Engineer. Samples shall be at least 42 inches long with the splice at mid length. Sheets of welded wire fabric or bar mat reinforcement shall overlap each other sufficiently to maintain a uniform strength and shall be securely fastened at the ends and edges. The edge lap shall not be less than one mesh width. 605- 3.03 Epoxy - Coated Reinforcement:
The requirements of this subsection for epoxy -coated reinforcement are in addition to the previous requirements which apply to un -coated reinforcement.
All handling systems for coated bars shall have padded contact areas for the bars wherever possible. All bundling bands shall be padded and all bundles shall be lifted with a strong back, multiple supports or a platform bridge so as to prevent bar to bar abrasion from sags in the bar bundle. The bars or bundles shall not be dropped or dragged. All hardware that will remain permanently in concrete using epoxy coated reinforcement shall be made of or coated with a dielectric material. Such hardware includes reinforcement chairs, tie wires, screed rail supports, or any other item that would be a potential source of corrosion. The specific hardware that the contractor proposes to use shall be approved by the Engineer. The contractor shall be r equired to field repair damaged areas of the coating, and to replace items exhibiting severely damaged coatings. The material used for field repair shall be that supplied by the coating applicator. Field repair shall be required wherever the area of coati ng damage exceeds 2 percent of the surface area of the bar in a one- foot length and the damaged spot is larger than 1/4 by 1/4- inch. Field repair will not be allowed on bars which have severely damaged coatings. A severely damaged coating is defined as a coating which has a total damaged area greater than 5 percent of the surface area of the reinforcing bar. The Engineer shall be the sole determiner of the TABLE OF CONTENTS INDEX 639 severity of damaged area for purposes of repair or replacement. A reinforcing bar having a coating determined by the Engineer to be severely damaged shall not be incorporated in the work and it shall be removed from the work site. All such bars shall be replaced in kind by the contractor at no additional cost to the Department. 605- 3.04 Dowel Placement : Dowel placement shall consist of drilling or coring dowel holes, furnishing , and placing setting materials and placing metal dowels in accordance with the details shown on the plans and the requir ements of the specifications. The diameter of dowel holes shall be 1/4 inch larger than the diameter of the dowels to be placed and the depth of the holes shall be as shown on the plans. Setting materials shall be an approved epoxy adhesive unless otherwise specified on the plans. The minimum tensile pull out strength of the dowel anchorage shall be as specified on the plans. If required by the Engineer, the contractor shall submit details of the anchorage system to the Engineer prior to dowel placement. 605- 4 Method of Measurement: 605- 4.01 General: No measurement for payment will be made for steel reinforcement, whether coated or uncoated as required, which is included in a precast concrete item which is listed in the bidding schedule as a unit to be paid for at a lump sum price. Steel reinforcement that is required on the plans to be epoxy- coated for use in bridge concrete and that is partially within the deck, yet projects into other structural elements, shall be included in the measurement and payment for Reinforcing Steel (Epoxy Coated). The contractor is required to coat only that part of the reinforcement that is contained in the deck or concrete bridge barriers. Except for that contained in a precast concrete item to be measured as a unit, steel reinforcement will be measured as a lump sum item or by the pound, as listed in the bidding schedule. Epoxy- coated reinforcement will be measured separate from un- coated reinforcement. Dowel placement will be measured by the unit eac h. TABLE OF CONTENTS INDEX 640 605- 4.02 Lump Sum Basis: The project plans will show an estimated net weight of reinforcing steel required for the work. This quantity shall be considered as approximate only. It shall be the responsibility of the bidder to determine the exact quantit ies of all reinforcing steel required, by computations based upon the details and notes shown on the project plans. It is understood that the quantities of all reinforcing steel required for the work shall be furnished by the contractor, including samples for testing. Measurement of the quantity furnished will be made either when an alteration in the work is ordered or when evidence shows or there is good reason to believe that the actual quantity of reinforcing steel varies from the total quantity shown on the project plans by 3 percent or more. When an alteration in the work is ordered or when the quantity varies as herein specified, the actual quantity of reinforcing steel will be computed by the Engineer and the amount of the increase or decrease will be measured by the pound. 605- 4.03 Weight Basis: Reinforcing Steel will be measured in pounds based on the total computed weight for the size and lengths of bars, wire, or welded wire fabric as shown on the plans or a uthorized. The weight of bars will be calculated from weight shown in Table 605- 1. The weight of welded wire fabric will be computed from the theoretical weight of plain wire of the corresponding gauge. If the weight per square foot is shown on the plans, that weight will be used. In measurement of the weight of epoxy- coated steel reinforcement, no addition to or deduction from the weights shown in Table 605- 1 will be made because of additional requirements for blast cleaning and epoxy coating. When laps are made for splices other than those shown on the plans for the convenience of the contractor, the extra steel will not be included in the measurement for payment. The measurement of samples for testing will be the weight in pounds of the samples selected by the Engineer or the weight in pounds of the full length of reinforcing steel bars supplied for sampling purposes when sampling is done at the construction site. TABLE OF CONTENTS INDEX 641 TABLE 605 -1 Deformed Bar Designation No. Weight, pounds per linear foot Nominal Diameter, inches 3 0.376 0.375 4 0.668 0.500 5 1.043 0.625 6 1.502 0.750 7 2.044 0.875 8 2.670 1.000 9 3.400 1.128 10 4.303 1.270 11 5.313 1.410 14 7.650 1.693 18 13.600 2.257 Note:
diameter of a plain round bar having the same weight per foot as the deformed bar. Bar numbers are based on the number of eighths of an inch included in the nominal diameter of the bars.
605- 5 Basis of Payment: The accepted quantities of Reinforcing Steel, of the type shown in the bidding schedule, measured as provided above, will be paid for at the contract lump sum price or the contract unit price per pound, complete in place. The lump sum price or unit price per pound shall also incl ude the cost of chairs, supports, fasteners, connections, tie wire, and any splices not specifically shown on the plans. If the Engineer permits the substitution of larger bars than those specified or splices not shown on the plans payment will be made on ly for the amount of steel which would have been required if the specified size and length had been used. The accepted quantity of dowels placed, measured as provided above, will be paid for at the contract unit price, which price shall be full compensation for the work complete in place. Steel reinforcement furnished for dowels will be measured and paid for under the Reinforcing Steel item. No measurement or direct payment will be made for furnishing and placing dowels which are required to replace existi ng reinforcing steel that is damaged as a result of the contractor's operations. TABLE OF CONTENTS INDEX 642 SECTION 606 OVERHEAD SIGN STRUCTURES : 606- 1 Description: The work under this section shall consist of furnishing and installing overhead sign structures in accordance with the details shown on the plans and in accordance with the requirements of these specifications. The type of sign structure to be installed at each location shall be as shown on the project plans. 606- 2 Materials: 606- 2.01 General: Certificates of Analysis conforming to the requirements of Subsection
106.05of the specific ations shall be submitted for all structural steel
Mill test reports for structural steel used as specified under Subsection 606- 2.02 of the specifications shall include the results of the Charpy V - notch impact test values. 606- 2.02 Structural Shapes, Pl ates, and Bars: Shapes, plates, and bars for trusses, columns, and walkway assemblies of the sign structures shall be fabricated from structural steel conforming to the requirements of ASTM A 36. Structural steel used for the fabrication of columns or girder flanges, web plates, and truss chord angles shall be in accordance with longitudinal Charpy V -notch impact test values specified in Subsection 604- 2.01 of the specifications. 606- 2.03 Tapered Tubes: Tapered tube beams, arms, and poles for the bridge single beam sign structures and for the cantilever double arm sign structures shall be fabricated from structural steel conforming to the following requirements: ASTM A36, ASTM A283, ASTM A1011, ASTM A595 Grade A, ASTM A572 Grade 65 or equivalent, and have a minimum yield strength of 50, 55, or 65 kilopounds per square inch after fabrication. 606- 2.04 Pipe Poles for Cantilever Truss: Poles shall be welded or seamless steel pipe conformi ng to the requirements of ASTM A 53, Type E or S or A500, Grade B. 606- 2.05 Bolts, Nuts , and Washers: High -strength steel bolts, nuts, and washers shall conform to the requirements of ASTM F3125 GR A325. All other bolts and nuts shall TABLE OF CONTENTS INDEX 643 conform to the requi rements of ASTM A307 and shall be furnished with commercial quality washers. Anchor bolts for the sign foundations shall conform to the requirements of ASTM F1554 Grade 55. All bolts, nuts, and washers, except high- strength bolts and anchor bolts, shall be cadmium plated in accordance with the requirements of ASTM B766 or zinc plated in accordance with the requirements of ASTM B633. 606- 2.06 Concrete: Concrete for all sign structure foundations shall be ClassS (f’c = 3, 500 pounds per square inch) conforming to the requirements of Section 1006 of the specifications. 606- 2.07 Reinforcing Steel: Reinforcing steel bars shall confor m to the requirements of ASTM A615 Grade 60. Unless otherwise specified, steel bars meeting the requirements of ASTM A706 may be substituted for ASTM A615 steel bars. When ASTM A706 bars are used, tack welding of the reinforcement will not be permitted unless approved in writing by the Engineer. Reinforcing steel wire shall conform to the requirements of ASTM A82. 606- 2.08 Nonshrink Grout: Nonshrink grout shall conform to the requirements of ASTM C1107 and shall be approved by the Engineer. Grout shall be mixed, handled and placed in accordance with the manufacturer's recommendations. 606- 3 Construction Requirements: 606- 3.01 Shop Drawings: The contractor shall furnish shop drawings for approval by the Engineer prior to fabrication of the sign structure material. Shop drawings shall be furnished in accordance with the requirements of Subsection 105.03 of the specifications. The foundation shall be set at the elevation called for in the project plans and the embankment graded to match the top of the foundation as directed by the Engineer. 606- 3.02 Fabrication: Fabrication of component parts of the sign structures shall be in accordance with the approved shop drawings and shall conform to the requirements of Section 11, Steel Structures, of AASHTO LFRD Bridge Construction Specifications. TABLE OF CONTENTS INDEX 644 Fabrication of steel components shall not begin unti l arrangements have been made for shop inspection. Shop inspection of structural steel fabrication shall conform to Subsection 604- 3.04 of the specifications. 606- 3.03 Welding: Welding of structural tubing shall conform to the requirements of the American Welding Society, Structural Welding Code - Steel, D1.1, latest edition. 606- 3.04 Galvanizing: All steel surfaces of sign structures shall be galvanized after fabrication. Galvanizing shall conform to the requirements of ASTM A 123 and A 153. 606- 3.05 Foundations: Reinforced concrete foundations for the sign structures shall be constructed to conform to the details shown on the plans and in accordance with the requirements of Subsections 609- 1 through 609- 3 of the specifications. Con crete shall be placed, finished and cured in accordance with the requirements of Section 601 of the specifications. 606- 4 Method of Measurement: Overhead sign structures will be measured by the unit of each type or types of sign structures furnished and er ected. Foundations for the sign structures will be measured by the unit of each type or types of foundation constructed. 606- 5 Basis of Payment: The accepted quantities of various types of overhead sign structures and foundations, measured as provided above, will be paid for at the contract unit prices complete in place. The contract unit price paid per unit for each type and size of sign structure designated in the bidding schedule shall include full compensation for furnishing all labor, materials, tools, equipment , and incidentals, and for doing all the work involved in furnishing and erecting the sign structures complete in place, including painting, galvanizing if necessary, furnishing and placing nonshrink grout, furnishing tapered tube sign mounting brackets, and all necessary hardware except for anchor bolts which are considered as part of the foundations, all as shown on the plans and as specified in these specifications. TABLE OF CONTENTS INDEX