INCIDENTAL CONSTRUCTION
502-1 Description.
Furnish and install welded shear connectors on steel beams and girders at locations shown in the Contract Documents. Field weld shear connectors located on the top flange only after the deck forms are in place. Installation of shear connectors in the fabrication plant is not permitted.
502-2 General Requirements.
502-2.1 Design: Provide shear connector studs of a design suitable for end -welding to
steel beams and girders, with automatically timed stud welding equipment. Provide the type, size or diameter, and length of stud as specified by the Contract Documents, and as approved by the Engineer. Meet the allowable tolerances on dimensions as specified in 502 -7.
502-2.2 Arc-Shield: Furnish an arc -shield (ferrule), of heat -resistant ceramic or other
suitable material, with each stud. Use material that is not detrimental to the welds, does not cause excessive slag, and has sufficient strength not to crumble or break due to thermal or structure shock before the weld is completed.
502-2.3 Flux: Furnish flux for welding with each stud, either attached to the end of the
stud or combined with the arc -shield for automatic application in the welding operation.
502-2.4 Coatings: Do not pa int or galvanize studs.
502-2.5 Qualification: Use only qualified studs, passing the tests prescribed in 502 -6.
Use the same arc -shield in production as used in the qualification tests.
502-2.6 Data to be Submitted: Before placing orders for studs, submi t to the Engineer
for approval, the following information on the studs to be purchased:
1.The name of the manufacturer.
2.A detailed description of the stud and arc -shield to be furnished.
3.A certification from the manufacturer that the stud is q ualified as specified in
502-2 5.
4.The qualification test report as certified by the testing laboratory.
502-2.7 Freedom from Defects: After welding, ensure that the studs are free from any
defect or substance that would interfere with their function as shear connectors.
502-3 Materials.
502-3.1 Metal: For shear connector studs, meet the requirements of ASTM A108, cold -
drawn bar, Grades 1015, 1017, or 1020, either semi -killed or fully -killed. If using flux -retaining caps, use caps of a low -carbon grad e steel suitable for welding and meeting the requirements of ASTM A109.
502-3.2 Mechanical Properties: For tensile properties as determined by tests of bar
stock after drawing, or of finished studs, meet the following requirements: Tensile strength ................................ .. 60,000 psi (minimum) Yield strength* ................................ ... 50,000 psi (minimum) Elongation ................................ . 20% in 2 inches (minimum) FY 2023-24 Return to Table of Contents Reduction of area ................................ ........ 50% (minimum) *As determined by 0.2% offset method. Determine tensile properties in accordance with ASTM A370. Perform tensile tests of finished studs on studs welded to test plates. If fracture occurs outside of the middle half of the gage length, repeat the test.
502-3.3 Quality and Finish: Provide finished studs of uniform quality and condition,
free from injurious laps, fins, seams, c racks, twists, bends, and other injurious defects. Produce a finish by cold drawing, cold rolling, or machining.
502-3.4 Certification: Ensure that the manufacturer certifies that the studs, as delivered,
are in accordance with the materials requirements of this Subarticle. Submit certified in -plant quality control test reports to the Engineer upon request.
502-4 Construction Requirements.
502-4.1 Equipment: End weld stud shear connectors to steel beams or girders with
automatically timed stud welding equ ipment connected to a suitable power source.
502-4.2 Interlocking: If two or more stud welding guns are to be operated from the same
power source, interlock them so that only one gun at a time can operate and the operating gun finishes each weld before st arting another weld.
502-4.3 Condition of Studs: At the time of welding, ensure that the studs are free from
rust, rust pits, scale, oil, and other deleterious matter which would adversely affect the welding operation.
502-4.4 Weather Limitations: Do not weld when the base metal temperature is below
0ºF, or when the surface is wet or exposed to rain or snow.
502-4.5 Position of Welding Gun: While operating, hold the welding gun in position
without movement until the weld metal has solidified.
502-4.6 Preparation of Areas: Prepare the surface where studs are to be we lded by
wire-brushing, peening, prick -punching, grinding, or other approved methods to remove paint, scale, rust, oils, or other deleterious matter which would adversely affect the welding ope ration.
502-4.7 Spacing: Ensure that longitudinal and lateral spacing of studs with respect to
each other and to edges of beam or girder flanges does not vary more than 1/2 inch from the dimensions shown in the Plans. However, the Engineer will allow a va riation of 1 inch where required to avoid interference with other attachments on the beam or where welding a new stud to replace a defective stud. Provide a minimum distance of 1 inch from the edge of a stud to the edge of a beam, but where possible provid e at least 1 -1/2 inches.
502-4.8 Testing: After allowing them to cool, bend the first two studs welded on each
beam or girder, 45 degrees by striking the stud with a hammer. If failure occurs in the weld of either stud, correct the procedure, and weld and test two successive studs successfully before welding any more studs to the beam or girder. Inform the Engineer of any changes in the welding procedure at any time during construction. When the temperature of the base metal is below 32ºF, bend one stud in each 100 studs welded 45 degrees in addition to the first two bent as specified above.
502-4.9 Repair of Welds: The Contractor may repair studs, on which a full 360 degrees
weld is not obtained, in accordance with the procedures of ANSI/AASHTO/AWS D1.5, Bridge Welding Code. FY 2023-24 Return to Table of Contents
502-4.10 Reduction in Height: If the reduction in the height of studs as they are welded
becomes less than 1/16 inch, immediately stop welding and correct the cause. Do not resume welding until the cause has been corrected.
502-4.11 Replacing Studs: Before welding the replacement stud, remove the defective
stud, grind the area smooth and flush or, in the case of a pullout of metal, fill the pocket with weld metal, using the shielded metal -arc process with low -hydrogen welding elect rodes, and then grind flush. In compression areas of flanges, the Contractor may weld a new stud adjacent to the defective area in lieu of repair and replacement of the existing weld.
502-5 Inspection Requirements.
502-5.1 Bend Test: If visual inspection reveals any stud which does not show a full
360 degrees weld, any stud which has been repaired by welding, or any stud in which the reduction in height due to welding is less than normal, strike such stud with a hammer and bend 15 degrees off the vertical. For studs showing less than a 360 degrees weld, bend the stud in the direction opposite to the lack of weld. Replace studs that crack in either the weld or the shank. The Engineer may select additional studs to be subjected to the bend test specified abov e. The Contractor may leave the tested studs that show no sign of failure in the bent position.
502-5.2 Unsatisfactory Work: If, during the progress of the shear connectors work,
inspection and testing indicate that the shear connectors being obtained are not satisfactory, make such changes in welding procedure, welding equipment, and type of shear connector as necessary to secure satisfactory results, at no expense to the Department.
502-5.3 Requalification: If the Engineer requests, require the manufact urer of the studs
to submit sample studs for requalification in accordance with the procedures of 502 -6, at no expense to the Department.
502-6 Qualification Procedure.
502-6.1 Purpose: The purpose of this procedure is to prescribe weldability tests which
will qualify a shear connector stud for welding under shop or field conditions. The Contractor may have a university, independent laboratory, other testing authority, or agency perform the tests. Ensure that the agency performing the tests submits to the manufacturer of the stud a certified report giving procedures and results for all tests, including the information listed under
502-6 9.
502-6.2 Duration of Qualification: Once a type and size of stud with arc -shield has been
qualified, the Engineer will consider the stud qualified until the manufacturer makes any change in the base of the stud, the flux, or the arc -shield, which affects the welding characteristics.
502-6.3 Preparation of Specimens: Prepare test specimens by welding representative
studs to the center of square specimen plates, 1/2 to 3/4 inch thick, of structural steel, ASTM A36. The manufacturer may weld studs to a large plate and cut the specimen plates to a size suitable for test equipment used.
502-6.4 Welding Procedure: Weld studs wi th manufacturer recommended power
source, welding gun, and control equipment. Measure welding voltage, current, and time by suitable instrumentation, and record these measurements for each specimen. Ensure that lift and plunge are at the manufacturer -recommended optimum setting.
502-6.5 Number of Test Specimens :
1.Weld 30 test specimens consecutively, with time held constant at optimum but with current 10% below optimum. FY 2023-24 Return to Table of Contents
2.Weld 30 test specimens consecutively, with time held constant at optimum but with current 10% above optimum.
502-6.6 Qualification Tests :
502-6.6 1 Tensile Tests: Subject 10 of the specimens welded in accordance with
502-6 5(1), 10 in accordance with 502 -6.5(2) to a tensile test. The Engineer will consider a stud
qualified if all test specimens have a tensile strength above the minimum speci fied in 502 -3.2.
502-6.6 2 Bend Tests: Place 20 of the specimens welded in accordance with 502 -
6.5(1), 20 in accordance with 502 -6.5(2) in a bend testing device, and bend alternately 30 degrees in opposite directions until failure occurs. The Engineer will consider a stud qualified if, on all t est specimens, fracture occurs in the shank of the stud and not in the weld.
502-6.7 Retest: If weld failure occurs in any of the tensile or bend test groups, the
Contractor may retest that group. If weld failure repeats, consider the stud as having faile d to qualify.
502-6.8 Qualification: For a manufacturer ’s studs and arc -shields to be qualified, ensure
that each group of 30 studs, by test or retest, meets the requirements prescribed in 502 -6.6.
502-6.9 Report of Tests: Include the following in the la boratory report:
1.Drawings which show shapes and dimensions with tolerances of studs, arc - shields, and flux.
2.A complete description of materials used in the studs and arc -shields, including the quantity and analysis of the flux.
3.A certificati on that the studs and arc -shields described in the report are qualified in accordance with 502 -6.8.
502-7 Dimensions and Tolerances.
Meet the following dimensions and tolerances: Table 502-1 C L* H T 3/4 - 1/64 inch 4 +0.062 inches 4 -0.125 inches 1-1/4 ± 1/64 inch 3/8 inch minimum 7/8 - 1/64 inch 4 +0.062 inches 4 -0.125 inches 1-3/8 ± 1/64 inch 3/8 inch minimum *4 inches length is standard. The Contractor may obtain other lengths by special order. Where: C = Shaft diameter L = Total stud length measured from top of head to base of shaft H = Diameter of head T = Thickness of head
502-8 Method of Measurement.
For the purpose of payment, shear connectors will be classified as Structural Steel. The quantity to be paid for will be determined in accordance with Section 460. FY 2023-24 Return to Table of Contents
502-9 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section, including furnishing and installing shear connectors. Payment will be made in accordance with Section 460. FY 2023-24 Return to Table of Contents SECTION 504 STEEL GRID FLOORS
504-1 Description.
Furnish and erect open -type steel grid roadway and sidewalk floors, on the movable spans of bridges and at other locations shown in the Plans. Where specified in the Plans, completely fill the floor with concrete.
504-2 Materials and Construction Methods.
504-2.1 General: Meet the following requirements:
Portland Cement Concrete ................................ ..Section 346 Structural Steel and Miscellaneous Metals .........Section 460 Shop, Fie ld, and Maintenance Painting of Structural Steel ................................ .................... Section 560
504-2.2 Roadway Floor : Construct the roadway floor as an open steel grid with
rectangular openings. Place and weld the grid to the floor stringers as shown in the Plans. If the flooring requires secondary or supplemental stringers, the Department will consider these stringers and their fastenings a part of, and included in, the materials to be furnished and erected under this Section.
504-2.3 Sidewalk Floor: Erect sidewalk flooring consisting of a system of main bars and
secondary bars, arranged in a system of rectangular, ret iculum or U -shaped openings. Do not allow the clear distance in any opening to exceed 5/8 inch in one direction. Do not allow the longest dimension of any opening to exceed 3 inches. Place and weld the floor to the supporting members in accordance with the details shown in the Plans, or in accordance with the manufacturer ’s directions as approved by the Engineer.
504-2.4 Conformance with Manufacturer’s Specifications: Meet the manufacturer’s
specifications for the material and construction methods, as appr oved by the Engineer, for any type of steel floor used.
504-2.5 Use of Trade Names: Where the Plans refer to the type of floor by
manufacturer’s designation or trade name, the Contractor may use a similar floor providing equivalent section modulus per uni t width, and equivalent surface qualities, if approved by the Engineer.
504-3 Painting.
Apply to all exposed areas of steel grid floors the same number, type, and thicknesses of paint coatings as are specified for painting structural steel. Prepare the su rface the same as required for painting structural steel. Although not required, the Contractor may apply paint on areas to be covered by concrete.
504-4 Method of Measurement.
The quantities to be paid for will be the plan quantity, in square feet, insta lled, complete and accepted. Proper deductions for open joints in the floor will be made in calculating plan quantity.
504-5 Basis of Payment.
Prices and payments will be full compensation for all work specified in this Section, including furnishing and i nstalling the complete floor above the tops of the main floor members FY 2023-24 Return to Table of Contents
Source: Florida Standard Specifications for Road and Bridge Construction, 2024 Edition. Pages 712–716 of 1,299.