460STRUCTURAL STEEL AND MISCELLANEOUS METALS

460-1Description

460-1.1General: Prepare, fabricate, assemble, erect, and perform all nondes tructive

testing for structural steel or miscellaneous metal structures, or portions thereof in accordance with the Contract Documents . Obtain Structural Steel and Miscellaneous Metals from a fabricator that is currently on the Department’s Production Facility Listing. Fabricators seeking inclusion on the list shall meet the req uirements of Section 105. As used in this specification, the following terms shall apply: Main or primary load -carrying member or component: This designation refers to the following;

(I or box, curved or straight)

curved beams or girders

traffic live load and/or other loads

or box girders (trapezoidal members) and their connection plates

cross frame and diaphragm connection and gusset plates, but not transverse and bearing stiffeners (unless acting as a cross frame or diaphragm )

secondary in the Contract Documents

Documents

Miscellaneous components - This designation refers to, but is not limited to, the following:

460-1.2Fabrication Categories : As a prerequisite for being on the Department’s

Production Facility Listing, fabricators must currently be accredited in accordance with one of the programs in Table 460-1, by fabrication category/categories of the products that they are producing. 634 FY 2023-24 Return to Table of Contents Fabricators are required to submit their proposed fabrication Quality Control (QC) Plan for review by the Department.

Table 460-1 Fabrication Categories Structure Type Accepted Accreditation Program Simple Steel Bridge: Pedestrian bridge (prefabricated steel truss pedestrian bridges meeting the Category 1 conditions of FDOT Design Manual 266.4), bridge grid decking AISC Simple Bridge Steel Bridge: Vehicular bridge, Pedestrian bridge (all others) AISC Advanced Bridge Fracture Critical Endorsement Structural Highway Metal Components , Group I: bridge machinery, bridge bearings, modular joints, load plates, laminated bearing pads, cantilever, truss/span, monotube, gantry, mast arms, steel light poles, aluminum light poles, aluminum j -arms, drainage (welded gratings, frames, inlets) AISC Components Manufacturer or AWS Welding Fabricator Structural Highway Metal Components, Group II: bridge forgings, bridge castings, steel railing, aluminum railing, castings (manhole, grating, inlet, frame), guardrail, coated steel fence, elastomeric bearing pads, stay in -place forms ISO 9001 Notes: An AISC fracture critical (FC) endorsement is required for all FC work. Other accreditations programs may be submitted to the FDOT State Materials Office for review and consideration in addition to the programs listed in the table above.

460-2Materials

Provide the materials specified in the Contract Documents in accordance with Sections 6, 105, ASTM A6, and AASHTO/AWS D1.5, Bridge Welding Code. Fabricate all unpainted steel elements using steels with weathering characteristics as defined in ASTM A709 for grades with a “W” suffix. Structural components designated as “fracture critical” shall conform to the provisions of the AASHTO/AWS D1.5, Bridge Welding Code, Clause 12-AASHTO/AWS Fracture Critical Control Plan for Non -Redundant Members, in a ddition to the requirements of the Contract Documents. Meet the additional following requirements: Steel and Miscellaneous Metal Items ................. Section 962 Material Testing and Certifications .................... Section 962 Galvanizing ................................ ......................... Section 962 Structural Coatings ................................ ..............Section 560 Structural Coating Materials ............................... Section 975

460-3Pre-Assembly Requirements

460-3.1Shop Drawings: When shop drawings are required, submit such drawings in

accordance with Section 5. For drawing presentation format, refer to the AASHTO/NSBA Steel Bridge Col laboration “Guidelines for Shop Detail Drawing Presentation”. 635 FY 2023-24 Return to Table of Contents

460-3.2Welding Procedures: Submit all shop and field welding procedures to the

Engineer. Such procedures shall contain a notation that they have been reviewed by a Certified Welding Inspector, and shall be signed, dated and stamped accordingly.

460-3.3Pre-Assembly Meeting: Prior to commencing work, a meeting shall be held

between the Contractor and the Engineer. Representatives of the Fabricator, Suppliers or subcontractors may attend the meeting if requested by the Engineer or Contractor. During this meeting, the Engineer may review various aspects of the job, including but not limited to, any of the following:

painting.

specific fabrication/erection operations.

specifically between the fabrication shop blocking diagrams and available site locations for temporary support during erection.

460-3.4Access to Fabrication Facilities: Provide the Engineer full access of facilities or

sites where the product is being stored, fa bricated, assembled , coated or erected. Provide and maintain office facilities at the fabrication facility for the Department’s inspectors that ensure a reasonable amount of privacy, are clean, properly illuminated, heated or air -conditioned as necessary and are relatively free of noise, dust an d odors. Locate the office reasonably close to the work and provide access any time fabrication, assembly or erection operations are in progress. Provide a desk, chair, and a four -drawer locking file cabinet for the use by each inspector and the Engineer. Provide a telephone within the office with an outside line suitable for modem communication. Provide ready access to adequate parking, fax and copy machines, and clean, contractor -maintained restrooms within a reasonable distance to the office. The Engin eer may observe any or all activities and perform nondestructive testing of materials, components and the fabricated product to the extent considered necessary to confirm the conformance with Contract Documents.

460-3.5Notification Prior to Commencement of Assembly : Notify the Engineer at

least one wee k prior to beginning assembly , when conducted in -state, and at least two weeks prior to beginning assembly , when conducted out -of-state.

460-4Shop Workmanship and Assembly

460-4.1Handling , Transporting and Storage of Materials:

636 FY 2023-24 Return to Table of Contents 460-4.1.1 General: Handle, transport and store plates, shapes, assemblies, fastener components and other parts in a manner that protects them from damage and facilitates subsequent inspections in a safe manner. Provide storage which will keep materials, assemblies, other c omponents and parts clean, and free from dirt, grease, other foreign matter , unacceptable corrosion or coating deterioration , and any other adverse environmental conditions. 460-4.1.2 Bulk Mate rials: Ensure that all bulk materials, such as shear studs , are stored together in individual LOTs and that the outside of each container has a list and description of the contents. Maintain a sep arate list of the weights of all tools and erection materials. 460-4.1.3 Fastener Assemblies (Bolts, Nuts and Washers): Transport and store fastener assemblies in sealed, watertight containers. Label the side of each container with the supplier’s name and LOT identification number, and marked to identify the cont ents and size of the fastener components. Ensure that all surfaces of the nuts are lubricated prior to their placement in watertight containers. Provide containers for components that are capable of protecting them from moisture and other harmful materials . Maintain containers in their sealed conditions until they are opened for use at their assembly locations. Do not remove more fastener assemblies from the protected area than can be installed and tightened during a work shift. Leave the containers unop ened until needed for assembly. At the end of the work shift, return unused fastener assemblies to the protected storage area for future use. Protect opened storage containers from contamination. 460-4.1.4 Coatings: Store coatings in accordance with Sections 962, and 975 and the manufacturer’s recommendations. Notify the Engineer if the manufacturer’s recommendations vary from that provided in the Contract Documents. 460-4.1.5 Anchor Rods and Nuts: Ship anchor rods and nuts as an assembly. Washers may be shipped separate from the assembly.

460-4.2Material Traceability:

460-4.2.1 General : All materials arriving at the shop shall be properly identified in accordance the requirements of ASTM A6. Document all m ain load-carrying member material, high -strength fastener assemblies, and weld materials incorporated into the work through the entire fabrication process. Document this material traceability in a report type format that correlates heat numbers to their re spective locations in the completed members. Submit diagrams and sketches as requested by the Engineer for clarity. At the fabrication facility, m aintain the records of the material testing and certification processes and component/part identification a s part of the fabricator’s permanent project records for a period of not less than two years as measured from the last shipment of materials from the fabricator’s facility . Submit all project-related records to the Engineer. Mark the weight on members w eighing more than three tons , in a visible location. 460-4.2.2 Match Marking of Members and Assemblies: Match mark all connecting members or parts that have been reamed or drilled while assembled . The fabricator shall submit a diagram showi ng all marks and c learly indicate the location of all the marks on the shop drawings. Use painted marks, attached metal tags, other durable methods which do not degrade the finish of the piece, including plasma etching or low-stress type steel die stamps to identify and match mark pieces. If steel die stamps are used, they must be blunt nosed or 637FY 2023-24Return to Table of Contents

interrupted dot dies, manufactured to produce impressions that are rounded at the bottom of the

impression. Re-mark coated type markings as necessary to maintain continuity in traceability.

Plasma etching using robotic equipment may be used to mark the surface of a steel plate when

done at 10 amps and at 150 inches per minute. Plasma etching outside of these parameters

requires Engineer approval.

Mark splice plates and girders so that upon erection, the mark on the splice

plate is located opposite a matching mark on the girder. Place the mark on web splice plates,

midway down the long side of the plate, on either the right or left side, to correspond with the

girder to which the splice plate will be temporarily attached for shipping to the erection site.

Make a matching stamp on the girder web opposite the mark on the splice plate.

Place the mark on top or bottom flange splice plates, on the right or left

end of the plate, corresponding to the girder to which the plate will be attached for shipment to

the erection site. Place a corresponding mark on the girder flange opposite the mark in the splice

plate.

As an alternate location for tub girder bottom flange splice plates, place

the mark midway down the long side of the plate, on either the right or left side, to correspond

with the girder to which the splice plate will be temporarily attached for shipping to the erection

site. Make a matching mark on the girder flange opposite the mark on the splice plate.

Mark girders and beams on the left end, according to the orientation

shown in the shop drawings, near the top flange. Mark diaphragms in the middle upper portion of

the web. Mark cross-frames in the middle of the top or bottom horizontal member.

When heat numbers and other identification marking are applied by die

stamping to fracture critical members, low stress dies shall be used.

Low-stress die stamp markings applied to fracture critical members shall

be placed in locations or zones shown or described in the approved shop drawings. Low-stress or

compression areas are preferred.

Ensure that during fabrication, the heat number is maintained on each

primary load-carrying component by paint until the component is permanently joined into a

piece marked member or assembly.

460-4.3Workmanship:

460-4.3.1 Cutting, Shearing and Machining: Cutting (including burning and

sawing), shearing, and machining shall be accomplished in accordance with the

AASHTO/AWS 1.5, Bridge Welding Code and the following requirements:

Plane, mill, grind or thermally cut the sheared edges of main load-carrying

member plate components greater than 5/8 inch thick to a depth of 1/4 inch.

Cut and fabricate steel plates so that the primary direction of rolling is

parallel to the direction of the member or component main stress. For flanges and webs, the

direction of rolling is parallel to the flanges unless noted otherwise in the Contract Documents.

Web splice plates may be rolled parallel to their length.

460-4.3.2 Bending:

460-4.3.2.1 Cold Bending: Fracture critical and non fracture critical

plates and bars shall be cold bent, unless otherwise permitted according to the provisions of

The minimum bend radii measured to the concave face of the plate,

shall be taken as 5.0(t) for all grades and thicknesses of steel conforming to structural steel for

bridges, AASHTO M 270M/M 270 (ASTM A709/A709M), where ‘t’ is the thickness of the plate 638FY 2023-24Return to Table of Contents

in inches. For cross-frame or diaphragm connection plates up to 0.75 inches, the minimum

bending radii may be taken as 1.5(t). For all other grades of steel the minimum bend radii

recommendations from the plate fabricator shall be followed, but the radii shall not be less than

the minimums specified herein.

Wherever possible, bend lines shall be oriented perpendicular to

the direction of final rolling of the plate. If the bend lines are parallel to the direction of final

rolling, the minimum bend radii shall be increased to 7.5(t).

460-4.3.2.2 Hot Bending: Fracture critical and non-fracture critical plates

and bars may be bent hot subject to the approval of the Engineer. Heat-shrink methods as

described in 460-4.3.4 are also permitted. If hot bending is to be employed, the heating and

bending procedure shall be submitted for review and approval by the Engineer. The plates and

bars shall be bent hot at a temperature above the blue brittle temperature of steel (700° F), not to

exceed the temperature limits in Table 460-2. The minimum radii of the hot bend must satisfy

the requirements of 460-4.3.2.1.

460-4.3.3 Straightening: Member components, such as plates, angles or shapes,

are to be straightened before the parts are assembled. Perform straightening such that no cracking

or other damage occurs in the part. If heat is to be used for straightening, follow the provisions of

460-4.3.4.

460-4.3.4 Heat Application:

460-4.3.4.1 General: At various points during the fabrication of structural

steel, applications of heat may be necessary for hot-bending, cambering, curving or

straightening. Use the temperature limits and guidelines given in this Section, unless alternate

procedures have been approved by the Engineer. Routine straightening of material other than

quenched and tempered material shall be done in accordance with the temperature limits and

guidelines as specified herein, but do not require a submitted procedure.

Heat curving may be used in conjunction with a cut-curve

procedure, in which a portion of the curvature is obtained by cutting the plates to all or part of

the required radius, except as limited by 460-4.3.4.4.

460-4.3.4.2 Heating Process and Equipment:

460-4.3.4.2.1 Maximum Temperatures: The maximum allowable

temperature to which the material can be heated is given in Table 460-2, Maximum Temperature

Limits for Heat Applications.

Table 460-2

Maximum Temperature Limits for Heat Applications

ASTM A709 Grade Maximum Temperature, °F

36, 50, 50S, 50W & HPS 50W 1,200

HPS 70W & HPS 100W 1,100

460-4.3.4.2.2 Timing of Heat Applications: Conduct heating

operations prior to the application of coatings.

460-4.3.4.2.3 Allowable Preload Stresses: Preload compressive

stresses will be permitted up to 0.5 times the minimum specified yield strength (Fy) of the

material. This stress limit is applicable to all steels covered by this specification as listed in

Table 460-2. If jacks are used, energize and lock off prior to the application of heat. 639FY 2023-24Return to Table of Contents

460-4.3.4.2.4 Heating Tips: Apply heat using orifice tips only.

Select tip sizes proportional to the thickness of the heated material.

460-4.3.4.2.5 Torches: Manipulate the heating torches to guard

against general and surface overheating. In addition, place heat reflective sheet material against

the web before applying heat to the inside flange surface. When heating the inside flange surface,

point the torches to prevent applying heat directly to the web.

460-4.3.4.2.6 Heating Patterns: Fundamental heating patterns

(such as vee, line, edge, spot, and strip) may be used separately or in combination. Mark vee and

strip heat patterns on the material surfaces prior to heating. When heating, bring the steel within

the planned pattern to the specified heating temperature as rapidly as possible without

overheating the steel. Apply heat in accordance with the approved procedure.

460-4.3.4.2.7 Thin Wide Plates: Prevent buckling of thin wide

plates by not applying excessive heat.

460-4.3.4.2.8 Verification of Temperatures: Use temperature-

sensitive crayons, pyrometers, or infrared non-contact thermometers for verifying temperatures

during heating operations. When heating patterns are used, make regular verifications of the

temperatures throughout the pattern. Remove the heating flame from the material before taking

measurements.

460-4.3.4.2.9 Cooling: Prior to the use of any artificial cooling,

allow steel to cool below 600°F. Use only dry compressed air. Do not quench with water or a

water and air mixture.

460-4.3.4.2.10 Reheating: Reheat only after the material has

cooled below 250°F.

460-4.3.4.2.11 Over Heating: The Engineer may reject the

product, if any portion of the material is exposed to heating higher than the allowable

temperature.

460-4.3.4.3 Heat-Curving of Bridge Members (Weak Axis Shaping):

460-4.3.4.3.1 General: Rolled beams and girders may be heat-

curved at the job site, provided that the heating is performed in accordance with the Engineer’s

approval.

460-4.3.4.3.2 Sequence of Operations: Heat curve members prior

to the attachment of longitudinal stiffeners.

460-4.3.4.3.3 Web Position: When the radius is less than

1,000 feet, heat curve members with the web in the horizontal position or preloaded to induce

stress prior to heating. Otherwise, members may be heat-curved with the web in either the

vertical or horizontal position.

460-4.3.4.3.4 Subsequent Heats: If multiple locations are to be

heated, do not reheat the same location until after at least three heats at other locations.

460-4.3.4.3.5 Locating Heating Patterns: Space the heating

patterns along the full length of each flange to produce a circular (not parabolic) curvature.

Adjust the heating patterns to produce the necessary curvature. Compensate for differences in

flange thickness and width as necessary. Use enough heating patterns in each piece to eliminate

chording effects.

460-4.3.4.4 Minimum Radius for Heat-Curving: Heat-curving of beams

and girders is allowed when the horizontal radius of curvature measured to the centerline of the

member web is greater than both values calculated by Equations 4.1 and 4.2 below, and greater 640FY 2023-24Return to Table of Contents

than 150 feet at any and all cross sections throughout the length of the member. Do not heat

curve steels with a minimum specified yield strength greater than 50 ksi, other than

ASTM A709, Grade HPS 70W. tF

bD

R

y

ψ

=

in. (Equation 4.1) ψ y F

b

R 7500

=

in. (Equation 4.2)

where:

Fy = specified minimum yield point of member web, ksi;

ψ = ratio of the total cross section area to the cross-sectional area of both flanges;

b = width of the widest flange, inch;

D = clear distance between flanges, inch;

t = web thickness, inch;

R = radius, inch.

In addition to the above requirements, do not heat curve if the radius is

less than 1,000 feet when the flange thickness exceeds 3 inches or the flange width exceeds 30 inches.

460-4.3.4.5 Heat-Cambering (Strong Axis Shaping):

460-4.3.4.5.1 General: Procedures for cambering of built-up plate

girders shall be submitted as a part of the Producer Quality Control (QC) Plan. In the procedures,

address any proposed preloading and heat application and control. Minor heat adjustments in

camber at the finishing stage of the girder do not require approval if the patterns and

temperatures are followed in accordance with the approved procedures.

Do not utilize heat-cambering as the primary source of

vertical camber in horizontally curved main load-carrying members; cut the web plate to the

required position. Only use heat-cambering on horizontally curved main members to adjust cut

cambering with the approval of the Engineer.

460-4.3.4.5.2 Web Position: Support members to be heat-

cambered with the web vertical. Space supports to take maximum advantage of dead load in the

member prior to the application of heat.

460-4.3.4.5.3 Subsequent Heats: If multiple locations are to be

heated, do not reheat the same location until after at least three heats at other locations.

460-4.3.4.5.4 Rolled Beams: Rolled beams may be heat-cambered

to provide the required curvature at the producing mill. Attach all detail material, such as

connection plates, bearing stiffeners and gusset plates, after the beam has been heat-cambered.

460-4.3.4.6 Heat-Straightening Damaged Structural Steel:

460-4.3.4.6.1 General: Submit procedures for heat-straightening

for the Engineer’s review prior to beginning the work. Describe in detail the distortion to be

corrected and all details for preloading, heating, cooling, verifying final dimensions, and

nondestructive testing. 641FY 2023-24Return to Table of Contents

460-4.3.4.6.2 Cracking: As a minimum, visually examine all heat-

straightened areas. Notify the Engineer when suspected areas of cracking are found. Examine

these areas by one or more of the following methods, as directed by the Engineer:

460-4.3.4.6.3 Restraining Forces: Restraining forces (usually

jacks) shall be set to restrain the steel during heating, but allow free contraction during cooling.

In addition, apply the restraining forces in a direction tending to restore the member and limit the

magnitude so that the material is not overstressed during heating.

460-4.3.4.6.4 Heating: Heat the steel in a single pass following the

specified pattern and allow it to cool to below 250°F prior to reheating. Select heating patterns

and sequences appropriate for the type of damage and shape of the cross section. Simultaneous

vee heats may be used provided the clear spacing between vees is greater than the width of the

plate element.

460-4.3.4.6.5 Subsequent Repair: Heat cambered members

damaged after cambering may be repaired. However, do not repair previously heat-straightened

members in the same region of damage without the approval of the Engineer.

460-4.3.4.7 Heat Treatment:

460-4.3.4.7.1 General: When any special form of heat treatment is

required, it will be described in the Contract Documents. Perform heat treatments prior to any

boring, machining or straightening operations.

460-4.3.4.7.2 Stress Relief: Where required, perform thermal

stress relief in accordance with the procedure outlined in the AASHTO/AWS D1.5, Bridge

Welding Code. Provide welding materials consistent with the stress relieving process utilized.

460-4.3.4.7.3 Normalizing and Annealing: Where required by the

Contract Documents, perform normalizing and annealing as defined in ASTM A941. Maintain

temperatures uniformly throughout the furnace during heating and cooling so that the

temperatures at any points on the member do not differ by more than 130°F.

460-4.3.4.8 Contact and Bearing Surfaces: Provide surface finishes of

bearings, base plates, and other contact surfaces in accordance with the ANSI surface roughness

requirements as defined in ANSI B46.1, Surface Roughness, Waviness and Lay, Part I, given in

Table 460-3, ANSI Surface Roughness Requirements.

Table 460-3

ANSI Surface Roughness Requirements

Steel slabs ANSI 2000 micro-inch

Heavy plates in contact with shoes to be welded ANSI 1000 micro-inch

Milled ends to compression members, milled or

ground ends of stiffeners or rockers ANSI 500 micro-inch

Bridge rollers and rockers ANSI 250 micro-inch

Sliding bearings ANSI 125 micro-inch

Pins and pin holes ANSI 125 micro-inch 642FY 2023-24Return to Table of Contents

460-4.3.4.9 Cleaning and Coating (Including Galvanizing):

460-4.3.4.9.1 General: Clean and coat the work in accordance

with 460-2 and/or 460-7.2 and Sections 560, and 562.

460-4.3.4.9.2 Removal of Lubricants: Remove lubricants from

the exposed surfaces of installed fastener assemblies and other surfaces in accordance with the

approved Producer QC Plan or the paint manufacturer’s recommendations prior to painting.

Demonstrate the procedures to the Engineer prior to preparations for painting. Bring to the

Engineer’s attention any manufacturer’s processes or procedures that conflict with those

specified in the Contract Documents.

460-4.3.5 Bolt Holes:

460-4.3.5.1 General: Unless shown otherwise in the Contract Documents,

the bolt hole geometry is to be as shown in Table 460-4, Bolt Hole Geometry.

Table 460-4

Bolt Hole Geometry

Bolt Diameter

(d), inch

Standard

(Diameter, inch)

Oversize

(Diameter, inch)

Short-Slotted

(Width, inch by

Length, inch)

Long-Slotted

(Width, inch by

Length, inch)

1/2 9/16 5/8 9/16 x 11/16 9/16 x 1 1/4

5/8 11/16 13/16 11/16 x 7/8 11/16 x 1 9/16

3/4 13/16 15/16 13/16 x 1 13/16 x 1 7/8

7/8 15/16 1 1/16 15/16 x 1 1/8 15/16 x 2 3/16

1 1 1/16 1 1/4 1 1/16 x 1 5/16 1 1/16 x 2 1/2

> 1 1/8 d + 1/16 D + 5/16 (d + 1/16) x (d + 3/8) (d + 1/16) x

(2.5 x d)

Note: Except as shown elsewhere in the Contract Documents, bolt holes in the connections of primary members are to be

standard size.

460-4.3.5.2 Holes, Tolerances and Quality: Make bolt (and anchor rod)

holes using any method suitable to the Fabricator and as specified below; except holes for high

strength fasteners in main or primary load-carrying members which are not to be punched full

size, but may be thermally cut in accordance with 460-4.3.5.4 and ground smooth with the

approval of the Engineer.

The misalignment of holes in a bolt group relative to the same

holes in the component or components it is joined to in a connection, shall not exceed 1/32 inch

for 85% of the bolt holes in that group. Bolt holes are to be normal to the work and have no tears,

cracks, fins, dirt, loose rust, burrs or other anomalies, and the surface is to be flat within a slope

of 1/20. Bolt holes are to be round within plus or minus 1/32 inch and within plus or minus 1/32

inch of the specified size. For subsize holes, a pin 1/8 inch smaller than the subsize holes must be

able to pass through all assembled plies in at least 75% of the locations prior to reaming. Holes

inclined more than 3 degrees to a surface in any direction must have a hardened beveled washer

provided at that face. Unless specified elsewhere in the Contract Documents, it is not required to

coat the inside of the bolt holes.

460-4.3.5.3 Slotted Holes: Slots may be made by a single punch, or by

joining two adjacent drilled or punched holes when punching is permitted. When joining holes,

thermal cutting is to follow the common tangent to the two holes, and this cut is to be ground. Do 643FY 2023-24Return to Table of Contents

not make slotted holes more than 1/32 inch in width nor 1/16 inch greater in length than

specified. Grind smooth any flame cut portions of the slot to ANSI 1000 micro-inches.

460-4.3.5.4 Holes in Plates Not Subjected to Tensile Stress: Large

diameter holes in heavy plates not subjected to tensile stress (such as bearing plates) and slotted

holes in materials not subject to tensile stress may be thermally cut, followed by appropriate

grinding to smooth the periphery. Stop the practice if gouges or other defects occur, or if directed

by the Engineer. These holes are to meet the following criteria:

Do not thermally cut holes in ASTM A709, GradeHPS 100W steel.

Provide hole centerlines aligned within plus or minus 1/16 inch of theoretical. The inside (cut)

faces of the hole are to be perpendicular to the plane of the plate. Eighty-five percent of the

1/16 inch. Local notches, gouges or the maximum diameter shall not exceed that specified in the

Contract Documents plus or minus 3/32 inch.

460-4.3.5.5 Punching: Material forming parts of a member composed of

five thicknesses or less of metal may be punched full-size. When more than five thicknesses of

material are joined, material shall be subdrilled or subpunched and then reamed full-size, or

drilled full-size while in assembly. Subpunched or subdrilled holes, when required, must be at

least 3/16 inches smaller than the finished hole size.

Holes in cross frames, lateral bracing components, and the

corresponding holes in connection plates between girders and cross frames or lateral components

may be punched full size. Holes in longitudinal main load-carrying members, transverse

floorbeams, and any components designated as fracture critical (FCMs) shall not be punched

full-size.

460-4.3.5.6 Edge Distance: Provide minimum as-fabricated distance from

the center of a bolt hole to an edge as given in Table 460-5, Edge Distances, unless otherwise

shown in the Contract Documents.

Table 460-5

Edge Distances

Fastener Size, Inch Sheared Edge, Inch Rolled Edges of Plates or Shapes

or Gas Cut Edges Inch

5/8 1-1/8 7/8

3/4 1-1/4 1

7/8 1-1/2 1-1/8

1 1-3/4 1-1/4

460-4.3.5.7 Bolted Splice Gaps: Unless shown elsewhere in the Contract

Documents, the tolerance for bolted splice gaps (open distance face-of-web/flange to face-of-

web/flange) shall be from zero (no gap between faces) to a maximum of 1/8 inch greater than the

gap shown on the Plans. If no gap is shown in the Plans, assume that a nominal gap of 3/8 inch is

required. In addition, meet the edge distance requirements, provided above.

460-4.3.5.8 Maximum Edge Distance: Unless otherwise specified in the

Contract Documents, the maximum fabricated distance from any edge to the center of the hole

shall be 8 times the thickness of the thinnest outside plate, not to exceed 5 inches with no

additional tolerance allowed. 644FY 2023-24Return to Table of Contents

460-4.3.5.9 Spacing of Bolt Holes: Space bolt holes within plus or minus

3/16 inch of that shown in the Contract Documents.

460-4.3.5.10 Holding of Plies: When drilling or reaming is accomplished

through multiple plies of material, do not hold the materials together by welds not specified in

the Contract Drawings.

460-4.4Member Geometry:

460-4.4.1 General:

460-4.4.1.1 Tolerances: Provide dimensional tolerances as follows:

miscellaneous steel in accordance with ASTM A6;

Bridge Welding Code and as described below;

AASHTO/AWS D1.5, apply AASHTO/AWS D1.5, Bridge Welding Code, except as noted

below or as directed by the Engineer.

460-4.4.1.2 Camber and Sweep: Tolerances for camber and sweep of

continuous and simply supported girders of any shape shall be as described in the

AASHTO/AWS D1.5, Bridge Welding Code. The camber and sweep tolerances for steel pier

caps shall be the same as those specified for girders. Measure sweep for horizontally curved

members from the theoretical centerline for comparison to the aforementioned requirements.

460-4.4.1.3 Alternate Sections: Rolled sections or fabricated sections of

equal or slightly greater dimensions than the section specified may be proposed for the

Engineer’s approval. Changes that reduce fatigue resistance or significantly affect splice design

or deflection will require complete design calculations.

460-4.4.1.4 Web Flatness: Maximum deviation from flatness for webs of

curved and/or cambered sections shall be the same as for straight built-up girders. Measure

curved girder web flatness using a straightedge oriented perpendicular to the flanges (“vertical”,

flange to flange).

460-4.4.1.5 Girder Length: If measuring girder length with a device that

is free of thermal effects, appropriately adjust the measurements to the reference temperature

shown in the Contract Documents. Measure the length of horizontally curved girders along the

arc.

460-4.4.2 Specialty Structures:

460-4.4.2.1 Box Members as Bent Caps:

460-4.4.2.1.1 Tolerances: Unless otherwise shown in the Contract

Documents, submit tolerances for bearing planes and box twist to the Engineer for review and

approval. Prior to submitting these tolerance values for approval, coordinate between the Erector

and the Fabricator.

460-4.4.2.1.2 Bearings: Unless otherwise specified in the Contract

Documents, each bearing is to be true to a tolerance of 1/32 inch across its entire width in either

direction.

460-4.4.2.1.3 Beam Trueness: Unless otherwise specified in the

Contract Documents, the plane of beam supports on the box girder (the bearing area specifically

attached to the box girder) is to be true to the box girder bearing within 1/16 inch in the short

direction and true to the vertical axis of the nesting girders (those girders attached to or resting

on the box girder) within 1/16 inch. 645FY 2023-24Return to Table of Contents

460-4.4.2.2 Trapezoidal Bridge Members: As a minimum, trapezoidal

bridge members (tub or box girders) shall meet AASHTO/AWS D1.5, Bridge Welding Code

dimensional tolerances. Camber may be verified with the girder in its upright position, supported

to avoid dead load deflections.

460-4.4.2.3 Pinholes: Unless shown elsewhere in the Contract

Documents, bore pinholes:

more than 0.015 inch for pins 5 inches or less in diameter, or 1/32 inch for larger pins.

460-4.4.2.4 Truss Chord Joints: Abutting joints in truss chords not

specified to be mill-to-bear shall have openings of 1/4 inch, plus or minus 1/8 inch.

Abutting joints in truss chords specified to be mill-to-bear shall be

faced and brought into bearing. When assembled, provide 85% or more of the abutting surfaces

in full contact. Allowable visible gaps shall not exceed 1/64 inch.

460-4.4.2.5 Horizontally Curved Beams and Skewed Steel Girders:

Account for torsion induced deflections for horizontally curved beams and skewed steel girders.

Unless otherwise defined in the Contract Documents, a horizontally curved beam or girder is a

longitudinal or transverse bridge component with a radius less than 10,000 feet anywhere along

its continuous length.

460-4.5Shop Assembly:

460-4.5.1 General: Ensure the fit of all connections and the geometry of all

components. Unless specified elsewhere in the Contract Documents, check the fit of all

longitudinal girder/beam lines in accordance with 460-4.5.1.1. Perform this prior to transporting

the pieces in question to the site for erection.

460-4.5.1.1 Progressive Girder or Truss Assembly: Assemble the

structure for a minimum of three spans, panels, field sections, segments or longitudinal chords of

the structure. Successive assemblies shall consist of at least one longitudinal segment of the

previous assembly, repositioned as necessary for accurate alignment, plus two or more

longitudinal segments added at the advancing end. For entire structures less than 150 feet in

length or less than three segments, assemble the entire longitudinal line. Meet the requirements

of 460-4.5.1.4 when utilizing computer-numerically-controlled drilling equipment.

When a transverse structural steel member or members is required

for the continuation of the uninterrupted girder or beam line, truss, arch rib, bent tower face or

rigid frame, and is designated elsewhere in the Contract Documents to be shop assembled, the

Fabricator may include this member or component in a separate subassembly and not the three

segment longitudinal assembly (discussed above). If combined in a different subassembly,

include the longitudinal member(s) or component(s), as designated elsewhere in the Contract

Documents to be shop assembled, that frame directly into the transverse structural member. Do

not include the transverse member(s) in the longitudinal assembly unless directed so elsewhere

in the Contract Documents or by the Engineer. Account for end rotations and deflections as

necessary, and submit the procedure to the Engineer for review.

460-4.5.1.2 Progressive Chord Assembly: When specified elsewhere in

the Contract Documents, assemble the truss chords for a minimum of three panels or longitudinal 646FY 2023-24Return to Table of Contents

segments of the structure. Successive assemblies shall consist of at least one longitudinal

segment of the previous assembly, repositioned as necessary for accurate alignment, plus two or

more longitudinal segments added at the advancing end. For entire structures less than 150 feet

in length or less than three segments, assemble the entire longitudinal line. Meet the

requirements of 460-4.5.1.4 when using computer-numerically-controlled drilling equipment.

Account for transverse members indicted elsewhere in the Contract

Documents to be included in the shop assembly as in 460-4.5.1.1.

When assembled in accordance with this subsection, the holes of

the connections will be so located that they will be drilled to the final geometric angles. This will

require that the truss members, when erected under the no load (or practically no load or stress)

condition, must be bent and forced to fit the end conditions. This condition will introduce an

initial reverse secondary stress that will theoretically wane when the structure assumes the

loading for which it is cambered. Submit the procedure to the Engineer for review.

460-4.5.1.3 Special Complete Structure Assembly: When specified

elsewhere in the Contract Documents, this type of shop assembly will include assembling the

entire structure including the diaphragms, cross frames, integral steel substructure and floor

components. Miscellaneous components are not included unless directed elsewhere in the

Contract Documents. Establish procedures for each structure or structure type including

consideration of incremental erection, temporary field support locations, stage construction and

final tightening of field connections. Submit the procedures for review by the Engineer.

460-4.5.1.4 Computer-Numerically-Controlled (CNC) Drilling

Associated with Progressive Girder, Truss or Chord Assembly: If the Fabricator chooses to

drill the holes in all plies of all connections of the continuous main girder or beam line, truss,

arch rib, bent, tower face or rigid frame and any intersecting (transverse) members utilizing

computer-controlled-numerical drilling procedures, piece-wise assembly of the entire continuous

girder or beam line, truss, arch rib, bent, tower face or rigid frame is not required if the following

requirements are met:

Prior to transporting to the site, perform a check fit of the first

three spans, panels, field sections, segments or longitudinal chords; or entire first bent, tower

face or rigid frame of the structure to ensure the accuracy of the CNC procedures and equipment.

As selected by and at the discretion of the Engineer and prior to

transporting to the site, perform another check fit of a different assembly of three spans, panels,

field sections, segments or longitudinal chords; or another entire bent, tower face or rigid frame

of the structure to ensure that the accuracy of the CNC procedures and equipment is maintained.

If either of the above fails to meet the Contract requirements, assemble the entire girder or beam

line, truss, arch rib, bent, tower face or rigid frame as originally prescribed in 460-4.5.1.1 or 460-

4.5.1.2 as prescribed elsewhere in the Contract Documents. Account for transverse members

indicated elsewhere in the Contract Documents to be included in the shop assembly as in 460-

4.5.1.1.

460-4.6Evaluation of Work: The Engineer will evaluate and accept materials and work

conforming to the Contract Documents. These evaluations may take place prior to or following

delivery of the materials to the site of the structure. Materials or work that fails to meet Contract

requirements will be rejected.

The Engineer may, at his sole discretion, permit further inspections and testing of

materials or work that fail to meet Contract requirements for acceptance. The cost of such

inspections and tests shall be borne by the Contractor. 647FY 2023-24Return to Table of Contents

Bring to the attention of the Engineer, all nonconforming work and or materials

that cannot be brought into conformance with the Contract Documents using pre-established

procedures as outlined in the Department approved Producer QC Plan. Submit the following

information to the Engineer:

A cover letter prepared on the Contractor’s letterhead and addressed to the

Engineer briefly describing the nonconforming work and the proposed credit to the Contract

proportionate to the nonconformance. For each fabricating facility and for each project within

that fabrication facility, submittals must be numbered consecutively beginning with the number

1, at the start of each project. Erectors will start with one for each individual project.

A completed Department Nonconforming Structural Steel and Miscellaneous

Metal Component Data Sheet prepared by the Contractor and countersigned by the Engineer’s

designated representative to indicate agreement between the Contractor and the Department

regarding the nonconformance, not any solution, resolution or credit. If the Contractor and the

Engineer’s designated representative are not in agreement regarding the nonconformance, the

Engineer’s designated representative will either reject the submittal indicating the reason(s) for

the rejection or modify the submittal and forward to the Engineer. In the event of modification,

the Contractor will initial the submittal before being forwarded to the Engineer, thereby

indicating the Contractor’s concurrence with the modification.

A list of supporting information such as sketches, documentation, calculations,

pictures, etc., must be included in the appropriate space on the Nonconforming Component Data

Sheet. Supporting information regarding Contract Document noncompliance in the form of

separate documents is only necessary when space on the Department Nonconforming Structural

Steel and Miscellaneous Metal Component Data Sheet is inadequate for the required data. All of

the supporting information required for the form must be prepared by, or under the supervision

of, the Specialty Engineer who will sign and seal the supporting information.

If requested by the Engineer, submit a structural and durability evaluation of the

proposed repair and/or remediation. This evaluation must be conducted under the supervision of

a Specialty Engineer and the submittal is to bear the Specialty Engineer’s signature and seal.

460-4.7Member or Component Certification: Coordinate with the Engineer to

schedule final inspection of the completed work within two weeks prior to shipment or erection

to verify that all Contract Document requirements have been met. After verification that all

Contract Document requirements have been met and all necessary repairs have been

satisfactorily completed, the Quality Control Manager shall certify, by initials and/or signature,

such materials, components or members. The record shall include certification for:

1.Items being shipped or stored prior to final assembly. Affix a certification in the

form of a stamp or tag in accordance with 460-4.2 and as indicated in the Producer Q C Plan, and

with a copy of the certification placed in the Contractor’s permanent project records,

permanent project records.

Submit a summary certification at the least once a month or with each payment

request that includes the following or similar wording. “The undersigned, being a responsible

official of (insert Contractor identification) certifies that the materials, components or members

listed herein have been produced under strict quality control and meet the requirements of the

Contract Documents” Include a positive identification in the certification such that the applicable

materials, components and/or members can be uniquely identified utilizing just the summary

certification document. The Quality Control Manager shall sign this summary certification. 648FY 2023-24Return to Table of Contents

460-5Bolted Connections

460-5.1General: High strength bolts are described as follows:

Use bolts as follows:

structural steel connections for painted steel.

installed bolted structural steel connections that will be shop painted.

connections for weathering steel that is to remain unpainted.

designated as miscellaneous components where the fastener type is specified elsewhere in the

Contract Documents.

Tighten Grade A325 bolts in accordance with the procedures specified below for

turn-of-nut or direct-tension-indicator (DTI) tightening.

Lubricate and maintain consistency in lubrication of fastener assembly during

Rotational Capacity (RC) testing and installation. Assemblies that exhibit a loss of lubrication, as

determined by the Engineer, may be re-lubricated and retested prior to installation.

Use Grade A490 bolts only with the approval of the Engineer. Submit procedures

in accordance with ASTM F3125 Grade A490 for the handling, lubrication, installation,

tightening and testing of such bolts. Do not install Grade A490 bolts without prior approval of

the procedures by the Engineer.

When the Engineer approves ASTM A307 bolts for use in miscellaneous

components, tighten them such that the plies of the joint are in firm contact. Use three to five

impacts of an impact wrench or the full effort of a person using an ordinary spud wrench to

obtain a snug connection.

Fasten aluminum, other materials or assemblies of dissimilar materials in

accordance with the Contract Documents.

Install ordinary rough or machine bolts and nuts in accordance with the Contract

Documents.

460-5.2Testing:

460-5.2.1 Rotational Capacity (RC) Tests: At the location of and prior to

installation of permanent high-strength fasteners in main or primary load-carrying member

connections, perform RC tests in accordance with FM 5-581 (for long bolts) or FM 5-582 (for

short bolts) to ensure that the fasteners are capable of developing the specified strength and that

the fasteners are properly lubricated. As a minimum, test two assemblies per LOT designation.

The bolt, nut and washer shall come from the same LOT and be packed in the same container (or

group of containers assigned the same LOT), except in special cases where nuts and washers

have only one production LOT number for each size.

Short bolts may also be tested using FM 5-583 with DTIs calibrated with

long bolts installed in a Tension Measuring Device.

Washers are required for RC tests even though they may not be required

for jobsite installation. Where washers are not required for jobsite installation, LOT

identification is not required. The washer coating shall be the same as that for the bolt and nut.

If any of the required tests fails, the entire LOT will be rejected. 649FY 2023-24Return to Table of Contents

460-5.2.2 Verification of Direct Tension Indicator (DTI) Device Performance:

On a daily basis (when DTI devices are being installed) and at the location of installation,

perform DTI Verification tests in accordance with FM 5-583. Perform this test on a minimum of

two high-strength fastener assemblies from each fastener assembly LOT and position of the DTI

prior to production installation. If either assembly fails, test additional fastener assembly

LOT/DTI combinations as requested by the Engineer to verify that the Requirements of the

Contract Documents have been satisfied. These two tests are in addition to the RC tests required

in 460-5.2.1. If, after additional testing, the DTI fails to meet the requirements of FM 5-583, the

LOT will be rejected by the Engineer.

460-5.3Reuse and Retightening: Do not reuse Grade A490 bolts or galvanized

Grade A325 bolts. Black Grade A325 bolts with free spinning nuts may be reused one time with

the Engineer’s approval. Previously tightened bolts that may have been loosened by the

tightening of adjacent bolts can be further tightened from the original position. Ensure proper

lubrication prior to retightening. Discard and replace fractured or damaged bolts.

460-5.4Assembly of Bolted Connections:

460-5.4.1 General: Verify that the faying surfaces are in accordance with the

Contract Documents, are free of dirt or other foreign materials, and that the geometry of the bolt

holes and the connection meets the requirements of 460-4.3.5.

Install fastener assembly components of the same LOT and of the size and

quality specified in the Contract Documents. Provide final bolts, cylindrical erection pins or

other fit-up bolts as indicated in the Erection Plan.

When it is impractical to turn the nut, tighten the fastener by turning the

bolt while preventing the nut from rotating. During this tightening operation, do not allow the

rotation of the part of the fastener assembly not turned by the wrench.

460-5.4.2 Preparation of Faying Surfaces: Provide coated and non-coated

faying surfaces in accordance with the Contract Documents. Faying surfaces specified as blast-

cleaned must satisfy SSPC SP-10 ‘Near-White Blast Cleaning.’

When painting of the slip-critical faying surface of bolted connections is

required, use only the prime coat. Prepare and coat the faying surfaces prior to installation of the

fasteners. Provide certification of the slip critical classification required in the Contract

Documents.

Submit certification to the Engineer that galvanized faying surfaces meet

or exceed a Class C slip critical classification, unless a different classification is required

elsewhere in the Contract Documents. Mechanically roughen galvanized faying surfaces in

accordance with the galvanizer’s recommendations.

460-5.4.3 Reaming: Do not over size bolt holes by reaming (or any other

method) without the approval of the Engineer.

460-5.4.4 Drifting: Do not over size, stretch or otherwise damage bolt holes by

improper and excessive drifting.

460-5.4.5 Splice Plate Filler Material: Unless otherwise specified in the

Contract Documents, provide filler material edges within 1/8 inch of the adjacent splice material

edge. Where required for proper alignment at a bolted flange splice, additional filler material

may be added provided that the total thickness of filler plates is less than 1/4 inch.

460-5.4.6 Installation of Fastener Assemblies: Unless shown otherwise in the

Erection Plan, install the bolts of the connection by progressing systematically from the most

rigid part of the connection to the free edges. Install bolts in all holes of the connection and bring 650FY 2023-24Return to Table of Contents

them to a “snug tight” condition. Following the sequence indicated in the Erection Plan, further

tighten all the bolts in the connection.

For Grade A325 bolts, obtain the required bolt tension as shown in

Table 460-6, Minimum Required Fastener Tension in accordance with the turn-of-nut method

specified in 460-5.4.8, or when DTIs are used, the DTI tightening method specified in 460-5.4.9.

For connections (such as large main load-carrying members or truss joints)

in which previously tightened high strength bolts become loose and require retightening upon the

tensioning of others, install into a minimum of ten percent of the holes fully tensioned bolts prior

to final tensioning of the permanent bolts. Distribute these first bolts randomly throughout the

connection. If directed by the Engineer, remove the initial bolts and install permanent bolts at

each location, otherwise retighten in accordance with 460-5.3.

Table 460-6

Minimum Required Fastener Tension

Bolt Size,

inch

Tension Grade A325 bolts,

kips

5/8 19

3/4 28

7/8 39

1 51

1-1/8 64

1-1/4 81

1-3/8 97

1-1/2 118

460-5.4.7 Bolt Tension: Provide a Skidmore-Wilhelm Calibrator, or other

equivalent bolt tension measuring device, wherever final connections are being made. Confirm

the accuracy of the tension measuring device by having it calibrated by an approved testing

agency once a year.

460-5.4.8 Turn-of-Nut Tightening: For each work shift, perform tests utilizing a

representative sample of five fastener assemblies, from each LOT to be installed that shift.

Perform the tests using the tension measuring device, following the same procedure to be used

for actual installation of the fastener assemblies, to a snug-tight tension and corresponding

torque, which, when the additional turns required in Table 460-7, Nut Rotation from the Snug-

Tight Condition are added, will result in at least 1.05 times the minimum required fastener

installation tension as shown in Table 460-6. Place a washer under the part turned in the

tightening of the bolt. Consider the job inspection snug-tight torque as the average of three test

values determined after rejecting the high and low-test values.

For fastener assemblies too short to fit in the tension measuring device,

modify the determination of the job inspection snug-tight torque in accordance with FM 5-582.

460-5.4.8.1 Snug-Tight Condition: In the turn-of-nut method, first bring

all the fastener assemblies of the connection to a “snug-tight” condition to ensure that all parts of

the connection are in firm contact with each other. For the purposes of this specification, “firm

contact” shall mean the condition that exists on a faying surface when the plies are solidly seated

against each other, but not necessarily in continuous contact. Regard snug-tight as the tightness 651FY 2023-24Return to Table of Contents

required to produce the bolt tension, which following the final applied rotation, produces at least

1.05 times the minimum required bolt tension in accordance with Table 460-6, Minimum

Required Fastener Tension. In the presence of the Engineer, and on a daily basis, determine the

job inspection snug-tight torque as specified herein.

460-5.4.8.2 Final Tightening: After verification of the snug-tight

condition in accordance with 460-5.4.11 by the Engineer, tighten all fastener assemblies in the

joint by applying the applicable amount of nut rotation specified in Table 460-7, Nut Rotation

from the Snug-Tight Condition. Once snug-tight, bring all fasteners to the required tension

within the same work shift.

Table 460-7

Nut Rotation from the Snug-Tight Condition

Bolt Length Measured from

Underside of Head to End of

Bolt

Both Faces

Normal to

Bolt Axis

One Face Normal to Bolt

Axis and Other Face Sloped

Not More than 20:1.

Bevel Washer not Used.

Both Faces Sloped Not

More than 20:1 from

Normal to Bolt Axis.

Bevel Washers not

Used.

Up to and Including Four (4)

Diameters 1/3 turn 1/2 turn 2/3 turn

Over Four (4) Diameters but

not Exceeding Eight (8)

Diameters

1/2 turn 2/3 turn 5/6 turn

Over Eight (8) Diameters but

Not Exceeding Twelve (12)

Diameters

2/3 turn 5/6 turn 1 turn

Notes:

degrees.

simulating the actual conditions. Submit procedures to the Engineer for review.

460-5.4.9 Direct-Tension-Indicator (DTI) Tightening: After complying with

the requirements of 460-5.2.2, install and tighten DTI devices following the procedures

described in the DTI Verification Test. Do not permit the DTI to turn during installation and

tightening. Provide washers in accordance with 460-5.4.10.

460-5.4.9.1 Snug-Tight Condition: Install the bolts as specified through

Step 3 (Snug-Tight Condition) of the DTI Verification test. If the 0.005 inch feeler gage is

refused in more gaps than shown in the table in Step 3.5 of the test, or the DTI device becomes

loose and can be spun by hand, remove the bolt and DTI device, discarding the DTI device.

Provide a new DTI device and reinstall the assembly and bring to the snug-tight condition.

460-5.4.9.2 Final Tightening: After verification by the Engineer that the

snug-tight condition for all bolts has been met, tighten all fastener assemblies in the joint such

that the number of spaces in which the 0.005 inch thickness gauge is refused is equal to or

greater than the number shown in Table 460-8, DTI Device Tightening Criteria. Once snug-tight,

bring all fasteners to the required tension within the same work shift. 652FY 2023-24Return to Table of Contents

Table 460-8

DTI Device Tightening Criteria

Number of Spaces in DTI 4 5 6 7 8 9

Minimum Spaces in which Gage is Refused 2 3 3 4 4 5

Do not tighten the assembly beyond the smallest gap permitted in

Step 3.5 of FM 5-583. Remove and replace bolts, discarding the DTI, which have a DTI with a

smaller gap or no gap.

460-5.4.10 Washers:

460-5.4.10.1 General: Provide ASTM F436 hardened steel washers as

follows:

bolts, use a hardened washer under each element.

under the turned element.

tests.

than 20:1 with respect to a plane normal to the bolt axis, use a hardened, beveled washer to

compensate for the lack of parallelism.

an outer ply, provide a single washer satisfying ASTM F436, or continuous bar satisfying

ASTM A709: for Grade A325 bolts, provide a thickness of at least 5/16 inch; and for

Grade A490 bolts, provide a thickness of 3/8 inch. Provide these washers or bars to completely

cover the slot after installation. Provide a finish consistent with the bolt specified.

washers on one side to a point not closer than 7/8 of the bolt diameter from the center of the

washer, if necessary.

460-5.4.10.2 Use of Washers with Direct-Tension-Indicators (DTIs)

Devices: When DTIs are used; use ASTM F436 hardened washers as follows:

head, a hardened washer is to be located under the nut.

hardened washer is to be located between the nut and the DTI.

nut, a hardened washer is to be located under the bolt head.

bolt head, a hardened washer is to be located between the bolt head and the DTI.

460-5.4.11 Inspection:

460-5.4.11.1 Turn-of-Nut Tightening:

assemblies of the connection, within 24 hours of snugging the first bolt in the connection and in

the presence of the Engineer, verify for a minimum of three (3) bolts [two (2) for two bolt

connections] or 10% of the fastener assemblies, that the job inspection snug-tight torque has

been attained. These fasteners are to have a snug-tight torque equal to or exceeding that specified 653FY 2023-24Return to Table of Contents

in 460-5.4.8. Perform this check using the same torque wrench used in 460-5.4.8. For bolts tested

in accordance with FM 5-583 or when multiple torque wrenches are required, provide a

calibrated torque wrench or wrenches.

torque, test all remaining untested fastener assemblies using the torque wrench in the connection

in question. Following testing of all assemblies, bring to snug-tight all assemblies and retest as

stated above. Re-snug and retest as necessary using the calibrated torque wrench until the

minimum testing stated above is performed favorably.

by the Contractor, and in the presence of the Engineer, match mark the fastener assemblies on

the end of the bolt thread and on the nut, and then tighten the nut the amount of rotation specified

in Table 460-7, Nut Rotation from the Snug-Tight Condition. The Engineer will accept the

connection as fully tightened when all of the following conditions are met:

yielding has occurred in the fastener assembly,

460-5.4.11.2 Direct-Tension-Indicator (DTI) Tightening: Prior to

bringing the connection to a snug-tight condition, verify in the presence of the Engineer that the

‘dimples’ of the DTI are not deformed or damaged. Bring the connection to a snug-tight

condition and tighten in accordance with the requirements of 460-5.4.9. The Engineer will accept

the connection as fully tightened when all of the following conditions are met:

occurred in the fastener assembly,

460-6Welding

460-6.1General: Perform all shop and field welding in accordance with the applicable

AWS Welding Code. This requirement includes the use of qualified welders, qualified weld

procedures, and qualified inspection personnel.

460-6.2Welding on Non-Dynamically Loaded Elements: Perform welding on

miscellaneous components and other statically (non-dynamically, non-cyclically, etc.) loaded

structural elements in accordance with the AWS D1.1, Structural Welding Code, or the

AASHTO/AWS D1.5, Bridge Welding Code.

460-6.3Electroslag Welding: Perform NGI-ESW welding in accordance with the

AASHTO/AWS D1.5, Bridge Welding Code.

460-6.4Welding of Hollow Structural Steel Sections (Pipes and Tubes): Except as

noted in the Contract Documents, perform all shop and field welding of Hollow Structural

Shapes in accordance with the AWS D1.1, Structural Welding Code as amended herein.

460-6.4.1 Highway Sign, Lighting and Traffic Signal Support Structures: For

structural steel supports for signs, lighting, and traffic signals, comply with the AWS D1.1

Structural Welding Code as amended by the following. 654FY 2023-24Return to Table of Contents

Unless otherwise shown in the Plans, perform ultrasonic testing (UT) or

radiographic testing (RT) on full penetration groove welds at the following frequency (use the

AWS D1.1 Tubular Connections Class R Criteria for UT and Cyclically Loaded Criteria for RT.

One hundred percent of each joint subject to tension or reversal of

stress.

Twenty-five percent of each joint subject to only compression or

shear. If discontinuities are found in the joint, the remainder of the joint shall be tested.

Perform Magnetic Particle Testing at the following frequencies:

A minimum of 25% of all fillet or partial penetration groove welds

in main members (Use the AWS D1.1 Tubular Connections Criteria). If discontinuities are

found, the remainder of the welds on the members shall be tested.

460-6.4.2 Tubular Bridge: Comply with the requirements of the AWS D1.1

Structural Welding Code as amended by the following:

Unless otherwise shown in the Plans, perform ultrasonic testing (UT) or

radiographic testing (RT) on full penetration groove welds at the following frequency (use the

AWS D1.1 Tubular Connections Class R Criteria for UT and Cyclically Loaded Criteria for RT).

One hundred percent of each joint subject to tension or reversal of

stress.

Twenty-five percent of each joint subject to only compression or

shear. If unacceptable discontinuities are found in the joint, the remainder of the joint shall be

tested.

Perform Magnetic Particle Testing at the following frequencies:

A minimum of 25% of all fillet or partial penetration groove welds in

main members (Use the AWS D1.1 Tubular Connections Criteria). If unacceptable

discontinuities are found, the remainder of the welds on the members shall be tested.

460-6.4.3 Overhead Sign Structures and Toll Gantries: Comply with the

requirements of the AWS D1.1 Structural Welding Code as amended by the following:

Unless otherwise shown in the Plans, perform 100 percent ultrasonic

testing (UT) or radiographic testing (RT) on all full penetration groove welds.

Prior to galvanizing, perform Magnetic Particle Testing (MT) at the

following frequencies:

One hundred percent of all fillet or partial penetration groove

welds in the upright columns. A minimum of 25% of all other fillet or partial penetration groove

welds in main members other than upright columns. If unacceptable discontinuities are found,

the remainder of the welds on the member shall be tested.

After members are galvanized, perform one hundred percent MT

of all fillet welds in the upright columns.

For acceptance, use AWS D1.1 Tubular Connection Criteria for MT, Tubular

Connection Class R Criteria for UT, and Cyclically Loaded Criteria for RT.

460-6.5Field Welding: Field weld only with the approval of the Engineer or as shown in

the Plans. All field welding operations must be conducted in accordance with AWS D1.5 and in

the presence of a Certified Welding Inspector.

460-6.6Tack Welds: Do not weld or tack any fill plates, brackets, clips, shipping

devices, or other materials not required by the Contract Documents or allowed by the

AASHTO/AWS D1.5 Bridge Welding Code. 655FY 2023-24Return to Table of Contents

460-7Erection

460-7.1Pre-erection Requirements:

460-7.1.1 Erection Quality Control (QC) Plan: Submit an Erection QC Plan for

review and approval of the Engineer.

460-7.1.2 Submittals: Meet the requirements of Sections 5 and 103 for any

required submittals. Provide submittals to the Engineer for review by the Department in

accordance with Section 5 and the Contract Documents.

460-7.1.3 Erection Plan: Submit, for the Engineer’s review, an Erection Plan

locating all primary members, lifting equipment and temporary supports or braces, and bolting

pattern tightening procedures not considered routine. Ensure that the plan includes the Specialty

Engineer’s signature and stamp. Include supporting calculations indicating that the design unit

stresses indicated in the Contract Documents have not been exceeded. Submit this plan or plans

to the Engineer three weeks before erecting the piece or pieces.

Include the following information in the Erection Plan:

foundations; surface roads and railroads; all streams, creeks and rivers; all overhead utilities; and

any underground utilities that could possibly impact, or be adversely affected by, erection

operations as determined by the Specialty Engineer.

and all primary load-carrying member bracing. Note any and all permanent or temporary support

and/or bracing locations, including crane-holding positions.

orientation for all primary load-carrying members.

mats and temporary excavation support.

configuration and boom extension utilized.

contained in the Erection Plan.

460-7.2Special Requirements for Uncoated Weathering Steel:

460-7.2.1 General: Do not use marking materials (grease sticks, crayons) that

leave behind a residual film that may affect the weathering process of the steel. Store the girders

as required for non-weathering steels.

460-7.2.2 Steel Preparations: Prior to erection, perform the following as

appropriate:

Blast clean the exposed fascia of the exterior girders (both I and box) to

meet SSPC-SP10 criteria; blast clean the remaining exposed surfaces of steel trapezoidal girders,

not required to be prepared otherwise, to meet SSPC-SP6 criteria; for steel I-girders, if a non-

uniform mill scale finish has developed, as determined by the Engineer, blast clean all remaining

exposed surfaces, not required to be prepared otherwise, to SSPC-SP6 criteria; coat the inside of

box members including, but not limited to, all bracing members, cross frames and diaphragms in

accordance with Section 560. Coat the exterior face of box girder end diaphragms and all interior 656FY 2023-24Return to Table of Contents

surfaces of box girders extending beyond the end diaphragm with an inorganic zinc coating

system in accordance with Section 560.

460-7.2.3 Concrete Substructure Preparations:

460-7.2.3.1 Substructure Areas Not Receiving Class 5 Finish: Prior to

erection of the girders, cover all exposed substructure concrete surfaces to protect them against

staining from the weathering steel components. Leave the covering in place until after placement

of the concrete deck. As directed by the Engineer, clean all visible stains on concrete in areas not

receiving a Class 5 Finish by sandblasting and follow-on cleaning using a stain remover or

commercial cleaner after completion of the structure in accordance with Section 400.

460-7.2.3.2 Substructure Areas Receiving a Class 5 Finish: If the

Class 5 Finish is to be applied prior to the placement of the concrete deck, cover all finish

concrete surfaces after application and curing of the Class 5 Finish to protect them from staining

from the weathering steel components. Leave the covering in place until after placement of the

concrete deck. Upon removal of the covering, reapply the Class 5 Finish to cover any stains

which may be present.

If the Class 5 Finish is to be applied after placement of the

concrete deck, no substructure covering will be required.

460-7.2.4 Structure and Site Clean Up: Upon the completion of construction,

remove all oil, dirt, grease or other foreign material, including excessive or uneven mill scale

from the steel. Remove lubricants from the exposed surfaces of installed fastener assemblies and

other surfaces in accordance with the manufacturer’s recommendations. Follow procedures

specified in Section 560 as appropriate. Final surface finish is to be an even mill scale as

approved by the Engineer.

460-7.3Coordination with Substructure: Prior to the erection of primary load-carrying

members, conduct a survey to document the vertical, longitudinal and transverse position of all

substructure units and anchor rod locations. Appropriately account for ambient temperature in

the survey.

Should a discrepancy be identified with the Contract Documents, submit the

necessary details to the Engineer for resolution.

460-7.4Placing Anchor Rods: Locate and place anchor rods within the tolerance shown

in the Contract Documents or within 1/4 inch of the theoretical location shown. If anchor rods

cannot be located to the specified tolerance, place only with the approval of the Engineer. Unless

shown otherwise in the Contract Documents, provide galvanized anchor rods, nuts and washers

as follows:

the substructure concrete strength, or as shown elsewhere in the Contract Documents.

recommendations.

coating.

460-7.5Preparation of Bearing Areas and Setting of Bearings: Prior to placing

superstructure bearing units (including but not limited to neoprene pads and masonry plates),

prepare the top of concrete pad (bearing area) in accordance with Section 400. If a discrepancy is

identified, report it to the Engineer for resolution. 657FY 2023-24Return to Table of Contents

For expansion bearings with slotted holes for anchor rods, which allow movement

of the superstructure with respect to the substructure, vary the location of the slotted plate in

relation to the anchor rods, in accordance with the prevailing temperature at the time of setting.

For fixed bearings at multiple adjacent piers, if necessary, horizontally jack the

substructure units to correctly set the centerline of bearing. Adequately account for temperature.

Unless specified elsewhere in the Contract Documents, locate the theoretical

centerline of bearings to within 1/16 inch transverse to longitudinal girder lines; and in the

direction parallel to the longitudinal girder line locate the theoretical centerline of bearing within

1/4 inch of the theoretical centerline of bearing.

After setting the bearings and installing anchor rod nuts, washers and any other

associated hardware specified in the Contract Documents, clean the protruding/exposed surfaces

of the assembly of all deleterious material. Finish-coat metal parts in accordance with 460-

4.3.4.9.

460-7.6Tightening of Anchor Bolt/Rod Nuts:

460-7.6.1 Fixed and Expansion Pot Bearing: Tighten anchor bolts or rod nuts to

a ‘snug tight’ condition such that the different mating surfaces (such as the top of concrete,

neoprene and steel) are in firm contact. The nut or bolt is to be tight enough to develop friction

between surfaces to prevent sliding, but not over-tightened that bulging or damage occurs in any

of the mating materials.

460-7.6.2 Fixed and Expansion Bearings with Elastomeric Bearing Pads:

Draw down the lower nut such that a total gap of 1/2 inch exists between the nut and bearing

plate. Tighten a second nut of the same specification to a snug tight condition against the lower

nut maintaining the required gap.

460-7.7Bolted Connections: For splice connections of primary members, as well as

connections of diaphragms or crossframes, fill at least 50% of the holes prior to crane release.

The 50% may be either erection bolts in a snug tight condition or full size erection pins, but at

least half (25% of all holes) shall be bolts, and sufficient pins shall be used near outside corners

of splice plates and at member ends near splice plate edges to ensure alignment. Filled holes

should be uniformly distributed between the web and flange connections for primary members

such that approximately 50% of the web connections are filled and approximately 50% of the

flange connections are filled. For diaphragms or cross-frames, the filled holes should be

uniformly distributed between all the bolt groups connecting the diaphragm or crossframe to the

primary member. The 50% requirement may be waived if a reduced percentage is calculated as

sufficient and shown on the approved Erection Plan. Primary member splice connections that are

made up on the ground (prior to erection) shall be 100 percent complete prior to any lifting

operation. Fully tighten all bolts prior to installation of deck forming for each unit.

460-7.8Final Position of Girder Webs: Unless shown elsewhere in the Contract

Documents, detail the girders and cross frames as directed by the Engineer. The final condition is

to be defined as with the deck and parapets cast, but without any future wearing surface. A web

will be considered plumb if it is within a tolerance horizontally between the top and bottom of

the web of 3/32 inch per foot of web depth compared against the theoretical position as required

in the Contract Documents. Measure the out-of-plumb perpendicular to the face of the web. Erect

trapezoidal girders to the geometry shown in the Contract Documents to the same 3/32 inch per

foot of web depth tolerance.

460-7.9Inspection and Final Acceptance:

658FY 2023-24Return to Table of Contents

460-7.9.1 General: Perform Quality Control inspections of all phases of the

work. The inspection frequency and depth shall be sufficient to ensure that all materials and

workmanship incorporated into the work meet the requirements of the Contract Documents and

that the processes are controlled to ensure that the final finished product(s) conform to the

physical characteristics and dimensions required by the Contract Documents. The Quality

Control Manager shall be responsible for all inspection operations. An adequate number of

Quality Control Inspectors shall be available to ensure review of all materials and fabrication

processes are preformed in accordance with the Producer QC Plan. Weekly meetings shall be

held with the Engineer to review inspection findings. The review of this information is to

identify any refinements and/or improvements in the process being utilized in the work. The

frequency of the meetings may be altered by the Engineer.

460-7.9.2 Inspection/Final Acceptance: Ensure the final alignment, profile and

fastening of the erected steel is in accordance with the Contract Documents.

460-8Method of Measurement

460-8.1General: The quantities to be paid for will be the items covered by this Section,

following acceptance by the Engineer. Partial payments may be made for fabricated components

yet to be assembled into larger components, members and assemblies as allowed for elsewhere in

the Contract Documents.

460-8.2Deductions and Allowances: No deductions from the computed weight of rolled

or fabricated structural steel or miscellaneous components will be made for sheared edges,

punchings, holes, milling, plaining or other items of waste associated with the finished

components or parts.

460-8.3Weights of Structural Steel and Miscellaneous Materials: The weights of

structural steel will be taken as nominal weights as reported in the AASHTO LRFD Bridge

Construction Specifications and ASTM Specifications, in that order of precedence, using the

dimensions shown in the Contract Documents.

460-8.4Structural Steel and Miscellaneous Metals: The quantity of structural steel and

miscellaneous metals becoming part of the completed structure and accepted by the Engineer

will be paid for at the plan quantity shown in the Contract Documents, or as modified by the

Engineer, measured in pounds, or by the Contract lump sum price for Structural Steel.

460-8.5High-Strength Fastener Assemblies: The weight of high-strength fastener

assemblies (including nuts and washers) installed by the Contractor and accepted by the

Engineer will be computed on the basis of an average length in accordance with Table 460-9:

Table 460-9

Weights of High-Strength Fastener Assemblies

Diameter of High-

Strength

Fasteners, inch

3/4 inch 7/8 inch 1 inch 1-1/8 inches 1-1/4 inches

Weight per 100,

pounds 52 100 135 182 238

The weight of high-strength fastener assemblies will be included in the

determination of the weight of the completed structure in determining the quantity paid when 659FY 2023-24Return to Table of Contents

payment is not by Lump Sum. The Engineer will determine values for sizes of high-strength

fastener assemblies not shown.

460-8.6Welding and Welds; Fasteners Not Designated as High-Strength; Anchor

Rods, Nuts, Bolts and Associated Washers; Transporting; Handling; and Erection:

Welding and welds; fastener assemblies not designated as high-strength; anchor rods, nuts, bolts

and associated washers; transporting; handling; and erection are considered incidental to the

work and will not be paid for separately.

460-8.7Shims and Fill Plates: The quantity of shims and fill plates will be included in

the determination of the weight of the completed structure in determining the quantity paid when

payment is not by Lump Sum.

460-8.8Coatings: The preparation, application, clean-up and the consumables used in

the coatings process are considered incidental to the work and will not be paid for separately.

460-8.9Weathering Steel Preparation, Handling and/or Clean-up: The preparation,

handling, and/or clean-up of weathering steel or the “rust" marks on other items (concrete units,

etc.) caused by the development of the patina are considered incidental to the work and will not

be paid for separately.

460-8.10Shear Connectors: Shear connectors are considered incidental to the work and

will not be paid for separately.

460-8.11Span Jacking (Fixed Bridge): Jacking of substructure units of adjacent fixed

piers required to set bearing in accordance with the Contract Documents is considered incidental

to the work and will not be paid for separately.

460-9Basis of Payment

460-9.1General: Prices and payments will be for full compensation for all work

specified in this Section completed and accepted, including but not limited to testing, bolting,

welding, cleaning and coating, temporary works and erection. No separate payment will be made

for falsework or other erection expense.

460-9.2Payment Items: Payment will be made under:

Item No. 460- 1- Structural Steel - Rehab - per pound.

Item No. 460- 2- Structural Steel - New/Widening - lump sum.

Item No. 460- 6- Ladders & Platforms - lump sum or per pound.

Item No. 460- 71- Metal Traffic Railing - per linear foot.

Item No. 460- 81- Rivet or High-Strength Bolt Replacement - each.

Item No. 460- 95- Structural Steel Repair - per pound.

Item No. 460- 98- Pipe Hanger - each.

Item No. 460-112- Anchor Bolt Replacement - each. 660FY 2023-24Return to Table of Contents MULTIROTATIONAL BEARINGS

461-1Description

Furnish and install multirotational bearings in accordance with the recommendations of the manufacturer and details shown in the Plans. Obtain all multirotational bearings from a fabricator that is currently on the Department’s Production Facility Listing. Provide bearings on each bridge from the same manufacturer. This Section covers the following types of multirotational bearings:

461-2Materials

Provide materials in accordance with the AASHTO LRFD Bridge Design Specifications and as follows.

461-2.1Structural Steel:

Furnish structural steel conforming to ASTM A709 Grade 50W.

461-2.2Stainless Steel:

Furnish stainless steel conformin g to ASTM A240, Type 316, 16 gage minimum thickness.

461-2.3Metalizing Wire:

Furnish metalizing wire in accordance with ASTM B833, having an 85% zinc/15% aluminum (Z30700) composition.

461-2.4Anchor Rods, Nuts and Washers:

Furnish galvanized anchor rods, nuts and washers in accordance with Section 962.

461-3Design

Design bearings in accordance with the AASHTO LRFD Bridge Design Specifications. Design bearing connections to allow for bearing replacement without having to remove the masonry plate o r sole plate. Detail all steel bearing components with sliding surfaces (e.g., stainless-steel plates or PTFE plates), masonry plates and elastomeric components to be replaceable. Welded attachments are not considered a replaceable connection. Design guided bearings for the lateral load shown in the Plans or 10% of the vertical load capacity of the bearing shown in the Plans, whichever is greater. For disc bearings, provide steel limiting rings around the top and bottom of the polyether urethane disc except if using the following: a minimum 62 Type (Shore) D durometer disc, a shear restraint device, and surface friction between the disc and steel plates.

461-4Shop Drawings

Submit shop drawings in accordance with Section 5. Include design calculations, s igned and sealed by a Specialty Engineer, confirming that all components are in conformance with the requirements of this Section. Include the following information on the shop drawings:

Article 18.1.1.

proper positioning settings for a minimum 100°F temperature range.

661 FY 2023-24 Return to Table of Contents