501Steel Structures

501.1General Description

This work includes furnishing and building with structural steel and miscellaneous metals to the lines, grades, and dimensions shown on the plans or established by the Engineer. The work does not include bearing devices for prestressed concrete bridge members, utility installation hardware, or any metal covered under another Pay Item. 501.1.01 Definitions HTS Bolts: High Tensile-Strength bolts. 501.1.02 Related References

ANSI/AASHTO/AWS D 1.5 AISC Manual of Steel Construction ANSI B1.13 Class 2A ANSI 2.5, 3.2, 6.3, 12.5, 25, 46, 46.1 Part 1, 50 ASTM A 6/A 6M ASTM A153/A 153M ASTM A 325 (A 325M) ASTM A 490 (A490M) ASTM A 919 ASTM F 568M Class 4.6 501.1.03 Submittals

Furnish documentation required by the latest ANSI/AASHTO/AWS D 1.5 under radiographic, ultrasonic, and magnetic particle testing and reporting to the State’s inspector before the quality assurance inspection. 670 670 670 670 670 670

Prepare Shop Drawings for structural steel and other metal materials to be fabricated. Show the details necessary for shop fabrication and field erection.

sets of preliminary prints marked NOT FOR FIELD USE to the Department’s Bridge and Structural Design Engineer (the Bridge Engineer) for review before fabricating materials. As an option, shop drawings may be submitted on plan sheet sizes of 12 in. x 18 in. (305 mm x 457 mm) or 11 in. x 17 in. (279 mm x 432 mm) for review and approval. Information contained on these sheets must be legible. After shop drawings have been approved, submit an electronic file that is compatible with Bentley Microstation J (Version 7) Cadd operating system, or an electronic file in Adobe Acrobat Portable Document Format (.pdf) to the Engineer. For bridges carrying railroads only, after shop drawings have been approved, submit one full size set of reproducible drawings to the Department.

more complete sets of the final drawings to the Bridge Engineer. The Bridge Engineer will mark each drawing with a conditional approval stamp and return one stamped set to the fabricator. Furnish the Bridge Engineer with as many additional sets of final prints as required. The Bridge Engineer’s review and conditional approval of Shop Drawings is a service for the Contractor. The Department assumes no responsibility for the accuracy of the drawings, and the Contractor will not be relieved of any responsibility for conforming to the specifications and plans.

designated, furnish the Bridge Engineer a full set of permanent reproducibles of the final Shop Drawings.

American Welding Society. Explain special conditions in notes or details. Show the sequence and techniques for areas where shrinkage stress and distortion control is necessary.

the Bridge Engineer gives written consent. List and symbolize revisions on each drawing. Obtain written consent from the Bridge Engineer before substituting materials with dimensions and weights other than those shown on the plans. Make changes associated with an approved substitution at no expense to the Department.

than those shown on the plans, submit a proposal and Shop Drawings to the Bridge Engineer to get written approval before proceeding.

throughout fabrication. On the Shop Drawings, show the grade of steel to be used and identify each piece. Give pieces made of different types or grades of steel different assembly or erection marks. Maintain the identity of the mill test report number when assembly-marking individual pieces and when giving cutting instructions to the shop.

Ensure that the fabricator submits a proposed fabrication schedule to the State Materials and Research Engineer that includes the following: • Correct project number, including county • Bridge number • Starting date • Estimated completion date 671 671 671 671 671 671

Before fabrication begins, submit the fabricator’s written Quality Control program to the Office of Materials and Research for approval. This program and its personnel will be subject to verification when the Department’s Materials and Research Engineer deems necessary. Even with a State inspection, continue to perform Quality Control (QC) on all nonfracture-critical and fracture- critical members and components.

Furnish the number of copies of mill orders and shipping statements covering fabricated materials and related miscellaneous materials the Engineer directs. Show the weights of individual members on the statements.

Furnish the Engineer two certified, legible copies of mill test reports that show the results of physical tests and complete ladle analyses for each heat and grade of steel ordered. Refer to the ASTM designation of tests used. Furnish mill test reports at no expense to the Department.

Before structural steel fabrication begins, submit welding procedures to the Engineer for review and approval.

Furnish a manufacturer’s certification showing that the material requirements used for manufacturing the tested electrodes and furnished electrodes were the same for each lot of electrodes on the Project.

If required, prepare and submit falsework plans for the Engineer’s review. Continue to assume the responsibility to produce safe falsework. When erection is completed, remove falsework to the Engineer’s satisfaction.

Furnish the Engineer a diagram showing the camber at each splice point for each girder. Base the diagram on measurements taken during shop assembly. In the case of partial shop assembly, base the camber diagram on theoretical calculated values.

501.2Materials

Ensure that materials meet the requirements of the following specifications: Material Section Structural Steel 851.2.01 Cold-Finish Carbon Shafting 854.2.06 Steel Castings 854.2.07 Paints 870 Steel Bolts, Nuts, and Washers 852.2.01 Anchor Bolts 852.2.02 High Tensile-Strength Bolts, Nuts, and Washers 852.2.03 Shear Connectors 512 Elastomeric Pads 885.2.01 Plain Cotton Duck 881.2.01 Rubber-Impregnated Cotton Duck 881.2.02 672 672 672 672 672 672

Material Section Self-Lubricating Bronze Bearing and Expansion Plates Galvanizing and Bushings 857.2.03 ASTM A 153/A 153M

galvanized assemblies, use nuts with a clean, dry lubricant that contrasts with the color of the zinc coating.

otherwise shown on the plans. 501.2.01 Delivery, Storage, and Handling

Store fasteners to protect them from dirt and moisture. Take from storage only enough fasteners to install and tighten during a work shift. Return unused fasteners to protective storage at the end of the shift.

Load, transport, and unload girders without excessive stress or damage. The Engineer will observe the delivery of beams or girders and will immediately notify the Contractor of damaged or unsatisfactory material before the material is unloaded or as soon as the damage is discovered. If members are improperly handled, the Inspector may withhold or remove the final stamp of approval. Use Figure 1, Figure 2, and the following loading specifications and shipping details for truck, rail, or barge transportation.

shield to prevent gouging flanges and if providing adequate bracing to prevent bending the top flanges.

673 673 673 673 673 673

d. FIGURE 1 FIGURE 1 (METRIC) ** C = Over 40 ft 2 ft 5 req’d restraints Label top flange C = Over 15 ft Last support 0.6C 0.3C 0.3C 0.4C 0.4C 15 ft max. CT L * C = 0.2L min. C = 0.3L max. For short beams or girders supported on a flat bed the min. C may be disregarded. * If C = over 15 ft use additional restraint here. ** If C = over 40 ft use another restraint here. 0.4C may be increased to 15 ft to cut down or restraint length, or where angle is too flat. Beam of overhang ends shall be restrained against flapping horizontally and vertically. ** C = Over 12.2 m 600 mm 5 req’d restraints Label top flange C = Over 4.5 m Last support 0.6C 0.3C 0.3C 0.4C 0.4C 4.5 m max. CT * C = 0.2L min. C = 0.3L max. For short beams or girders supported on a flat bed the min. C may be disregarded. * If C = over 4.5 m use additional restraint here. ** If C = over 12.2 m use another restraint here. 0.4C may be increased to 4.5 m to cut-down or restraint length, or where angle is too flat. Beam of overhang ends shall be restrained against flapping horizontally and vertically. 674 674 674 674 674 674

Table of Dimensions—Feet 1 Min. C & T Remarks Min. C & T 75 15 60 22.5 16.5 80 16 64 24 17 85 17 68 25.5 18.1 90 18 72 Max C for 30 in WF 27 19.2 95 19 76 Max C for 33 in WF 28.5 20.3 100 20 80 Max C for 36 in WF 30 21.3 105 21 84 31.5 22.4 110 22 88 33 23.5 115 23 92 34.5 24.5 120 24 96 Preferred Max C for PLG 36 25.6 125 25 100 37.5 26.7 126 26 100 37.8 88.2 127 27 100 38.1 88.9 128 28 100 38.4 89.6 129 29 100 38.7 90.3 130 30 100 39 91 131 31 100 39.3 91.7 132 32 100 39.6 93.1 133 33 100 39.9 93.1 134 34 100 Max C for PLG 40.2 93.8 FIGURE 2 Blocking or bracing and beam spacers to hold beams and girders in place, webs vertical, and flanges horizontal. Solid, uniform bearing—no tilt of beams and girders. 675 675 675 675 675 675

Table of Dimensions—Feet 1 Min. C & T Remarks Min. C & T 23 4.5 18.2 6.9 16 24 4.9 19.5 7.3 17 26 5.2 20.7 7.8 18.1 27 5.5 21.9 Max C for 760 mm WF 8.2 19.2 29 5.8 23.2 Max C for 838 mm WF 8.7 20.3 30 6.1 24.3 Max C for 914 mm WF 9.1 21.3 32 6.4 25.6 9.6 22.4 34 6.7 26.8 10 23.5 35 7 28 10.5 24.5 37 7.3 29.3 Preferred Max C for PLG 11 25.6 38 7.6 30 11.4 26.7 38.4 7.9 30 11.5 26.9 38.7 8.2 30 11.6 27.1 39 8.5 30 11.7 27.3 39.3 8.8 30 11.8 27.5 39.6 9.1 30 11.9 27.7 39.9 9.4 30 12 28 40.2 9.7 30 12.1 28.2 40.5 10 30 12.2 28.4 40.8 10.4 30 Max C for PLG 12.3 28.6 FIGURE 2 (METRIC) Blocking or bracing and beam spacers to

hold beams and girders in place, webs

vertical, and flanges horizontal.

Solid, uniform bearing—no tilt of beams

and girders. 676676676676676676

Handle structural steel during storage in the same manner as during fabrication. See Subsection

501.2.01.B.2.a, General and Subsection 501.2.01.B.3, Handling.

Place beams and girders with their webs vertical. Shore, brace, or clamp beams and girders to resist

lateral forces during storage. Keep steel free from dirt, oil, grease, or other contaminants and protect it

from corrosion. Pitch trough sections to provide water drainage.

Do not stack beams and girders on each other.

Place long members on supports close together to prevent damage from deflection.

The Engineer will observe the storage and handling of beams or girders and ensure that they are

satisfactory before erection.

The material on which the beams and girder supports are placed shall be firm, well-drained, unyielding,

and not allow excessive or uneven settlement when the supports are loaded.

Store beams and girders on platforms, skids, or other supports on the ground above high-water elevation.

Shore supports with firm, well-drained unyielding material. Use material that settles evenly when the

supports are loaded.

Support beams and girders adjacent to the bearings and at intervals of no more than 25 ft. (7.5 m). Use

enough intermediate supports to prevent damage from deflection.

Handle steel members with clamps, plate hooks, or devices to avoid nicks, gouges, or depressions. Do not

use chains and chokers to handle steel members unless using a protective shield between the chain or choker

and the member.

Use spreader bars to lift beams and girders over 50 ft. (15 m) in length.

One-point pickups are allowed for beams and girders less than 50 ft. (15 m) long.

Use two-point pickups so the amount of overhang and distance between hooks does not exceed

the distances in the following table:

Beam Size 30 in. (760 mm)

WF

33 in. (840 mm)

WF

36 in. (920 mm)

WF

Plate Girders

2-point pick-up distance

between hooks linear feet

74 (22) 80 (24) 85 (26) 100(30)

2-point pick-up overhang linear

feet (meters) maximum

25 (7) 28 (8) 30 (9) 35 (10)

WF = Wide Flange

If using pick-ups that cause long overhangs, attach lines at beam ends to control movement.

Keep webs of beams and girders vertical while handling. Never drop, throw, or drag beams and girders.

Do not allow beams or girders to bend about the weak axis, even under their own weight. When shipping

beams or girders upside-down, use caution when turning them over for shipment and turning them

right-side up at their destination. Use enough blocking and pick-up points to prevent excess stress on

the girder. 677677677677677677

501.3Construction Requirements

501.3.01 Personnel

Employ structural steel fabricators certified under the AISC Certification Program, Category III—Major

Steel Bridges.

Qualify field welders according to ANSI/AASHTO/AWS D 1.5. Employ certified welders who possess a current

welding certification card issued by the Department’s Office of Materials and Research.

501.3.02 Equipment

Have a tension measuring device at all job sites where High Tensile-Strength bolts are installed and tightened. Use

the tension-measuring device to:

• Confirm the proper snug tight and final installation bolt tension

• Calibrate wrenches properly

• Ensure the bolting crew understands the importance of proper bolt tensioning

At least once a year, have an approved testing agency calibrate the tension-measuring device to confirm

its accuracy.

If using the calibrated wrench method to tighten HTS bolts, calibrate the wrench at least once each working day

for each diameter, length, and grade of bolt to be installed. Recalibrate the wrench when adding or deleting the air

hose, changing compressors, or performing similar tasks.

Use the wrench in job-site tightening under the exact conditions that it was calibrated. Recalibrate wrenches if a

significant difference is noted in the surface condition or level of lubrication of the bolt threads, nuts, or washers.

Use electric drying ovens approved by the Engineer to dry electrodes according to ANSI/AASHTO/ AWS D 1.5.

Use proper lifting equipment that can carefully handle steel members without bending, twisting, damaging, or

excessively stressing parts. Use cranes that have at least a two-part line for lifting.

The Department will terminate shop inspection if lifting equipment is operated or maintained in a

hazardous manner.

Proposed erection equipment is subject to the Engineer’s review. Even with this review, assume responsibility for

providing adequate and safe equipment and for carrying out the work according to the plans and specifications.

Begin erection only after the Engineer’s review.

501.3.03 Preparation

Before beginning the bolting operation, the Engineer will verify the Contractor’s installation method. Verification

will determine if the method used (calibrated wrench or turn-of-nut) will produce the correct bolt tension in the

HTS structural bolts of the completed connection.

If the method is successful, the total clamping force of bolts will be transferred to the connected members and will

resist slipping through friction. 678678678678678678

Do not use bolts tightened during installation method tests or use other previously used HTS structural bolts in the

work.

Test both methods of tightening (calibrated wrench or turn-of-nut) with the following procedures:

face and the underside of the bolt head.

under the turned element.

tension calibrator, or drive socket and tension calibrator.

When using an impact wrench:

1) Tighten each of the three assemblies beyond snug tight.

2) Adjust the wrench to cut out at a tension no less than 5 to 10 percent higher than the appropriate

tension shown in Table A: Required Fastener Tension.

Bolts tightened to this cut-out point should consistently develop the required minimum tension. This

cut-out point shall be the actual job-site setting.

When using a manual torque wrench:

1) Tighten each of the three assemblies beyond snug tight.

2) Note the torque required to induce a bolt tension 5 to 10 percent higher than the appropriate tension

shown in Table A: Required Fastener Tension.

3) Measure torque with the nut in rotation.

4) Average the three tests to find the minimum torque to use for job-site installation tightening.

5) If the torque wrench produces erratic results, do not use that wrench.

When using the turn-of-nut method, tighten the three assemblies beyond snug tight to the appropriate

rotation shown in Table B: Nut Rotation from Snug Tight. Ensure that at this rotation, the minimum bolt

tension is 5 to 10 percent higher than the appropriate tension shown in Table A: Required Fastener Tension. 679679679679679679

Table A: Required Fastener Tension

Nominal Bolt Diameter and Thread Pitch Minimum Tension (1) in kips (kN)

ASTM A325 (A 325M)Bolts ASTM A490 (A 490M) Bolts

1/2 12 15

5/8 (M 16 x 2) 19 (91) 24 (114)

3/4 (M20 x 2.5) 28 (142) 35 (179)

7/8 (M22 x 2.5) 39 (176) 49 (221)

1 (M24 x 3) 51(205) 64 (257)

1-1/8 (M27 x 3) 56 (267) 80 (334)

1-1/4 (M30 x 3.5) 71(326) 102(408)

1-3/8 85 121

1-1/2 (M36 x 4) 103 (475) 148 (495)

full-size A 325 (A 325M) and A 490 (A 490M) bolts with UNC (metric) threads loaded in axial tension) rounded to the

nearest kip (kN).

Table B: Nut Rotation(1) from Snug Tight

Bolt Length (measured

from underside of head

to end of bolt)

Both faces normal

to bolt axis

One face normal, one faced

sloped not more than 1:20

Both faces sloped not more

than 1:20

4 x bolt diameter or less 1/3 turn 1/2 turn 2/3 turn

Greater than 4 but no

more than 8 x bolt

diameter

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

Greater than 8 but no

more than 12 x bolt

diameter

2/3 turn 5/6 turn 1 turn

less, the tolerance of plus 30 degrees, minus 0 degrees applies. For bolts installed by 2/3 turn and more, a tolerance of

plus 45 degrees, minus 30 degrees applies.

501.3.04 Fabrication

Ensure that rolled material is straight to the mill tolerances provided in ASTM A 6/A 6M before it is laid off or

worked. Use straightening methods that do not injure the metal. Sharp kinks and bends will be cause for rejection

the material. 680680680680680680

The fabricator may use stock materials for minor Items whose quantity for the Project is less than the minimum

required for mill rolling if the following requirements are met:

material meets the required specification.

Instead of these requirements, the Engineer may take representative stock samples and test them at the

Contractor’s expense.

Provide a system of assembly-marking individual pieces and the issuance of cutting instructions to the shop that

will maintain identity of the mill test report number.

Before cutting or placing individual pieces of steel in stock for later use, mark the pieces with the following:

• Mill test report number

• Heat number

• Color code, if any

Transfer heat numbers and color codes only in the presence of the Inspector.

Color code steel pieces according to ASTM A 6/A 6M specification identification. Establish and record an

individual color code for steels not included in the A 6/A 6M specification.

If steel is subject to fabrication that might erase a painted color code mark before assembly, stamp it with a steel

die or attach a tag.

• Erection mark or match mark according to the erection diagram on the shop drawings.

• Weight, if a member weighs more than 3 tons (3 Mg).

• Smooth surface free of notches and cracks

• Accurate profile using a mechanical guide

Ensure that oxygen cutting conforms with AWS D 1.5. Oxygen-cut by hand only where approved.

After cutting, round the corners of oxygen-cut surfaces to a 1/16 in. (2 mm) radius by grinding.

including attaching cover plates and shear connectors. Do not use cambering methods that will induce

stresses that may impair the service life of the member.

and have been inspected.

Shop Drawings) caused by web distortion from either of the following:

Oxygen cutting

Weld metal shrinkage

681681681681681681

Ensure that the surface finish of bearings, base plates, and other bearing surfaces in contact with each other

or with concrete meets the ANSI surface roughness requirements, defined in ANSI B 46.1 Part 1, as follows:

Surface Finish Requirement

Steel slabs ANSI 2,000 (50 μm)

Heavy plates in contact in shoes to be welded ANSI 1,000 (25 μm)

Milled ends of compression members and milled or ground ends

of stiffeners and fillers

ANSI 500 (12.5 μm)

Bridge rollers and rockers ANSI 250 (6.3 μm)

Pins and pin holes ANSI 125 (3.2 μm)

Sliding bearings ANSI 125 (125 μm)

Finish surfaces that contact metal or masonry as specified below.

Straighten warped or deformed plates before machining; then do one of the following to the surfaces of

plates contacting masonry:

1) Machine the surfaces to an ANSI 2,000 (50 μm) surface roughness rating value.

2) Straighten the surfaces so that the maximum clearance under a straightedge placed across the

bearing surface in any direction is 1/16 in. (2 mm)

Bearing Surfaces.

Perform final machining after the assembly is completely fabricated. If the completed assembly must be

heat-treated, perform final machining after the heat treatment.

Do not machine-finish the surface in contact with the elastomeric pad.

finish cut is in the direction of the expected movement, unless using non directional finishing equipment.

abutting joints and bring them to even bearings. When facing joints is not required, ensure an opening of

1/4 in. (6 mm) or less.

After heat treatment, machine-finish, bore, and straighten the structural members required by the plans to be

annealed or normalized. Perform full annealing and normalizing according to ASTM A 919 and the following:

any two points on a member does not exceed 100 °F (40 °C).

schedule used.

The method of recording the treatment operation procedures is subject to the Inspector’s approval.

the furnace. 682682682682682682

according to AWS specifications.

Fabricate the ends of beams and girders to be vertical in the final erected position, unless otherwise

shown on the plans.

Build end connection angles to the exact length shown on the plans, measured between the heels of the

connection angles. The allowed tolerance is plus 0 to minus 1/16 in. (plus 0 to minus 2 mm).

Where continuity is required, face end connections. Ensure that the connection angle thickness after

facing is no less than 3/8 in. (10 mm) or the amount shown on the plans.

At the shop, shape the plates, angles, or other structural shapes to conform to the section of the

concrete deck. Ensure that painting and other fabrication requirements conform to the specifications for

these Items.

Ensure that unwelded, cold-bent, load-carrying, rolled steel plates meet the following requirements:

1) The bend lines are at right angles to the rolling direction.

2) The plate will not crack during bending.

Minimum bend radii, measured to the concave face of the metal, for all grades of steel used in this

specification, are shown in the following table:

Thickness “T” in Inches (Millimeters) Minimum Bend Radii

Up to ½ (12) 2 T

Over 1/2 to 1 (12 to 25) 2-1/2 T

Over 1 to 1-1/2 (25 to 38) 3 T

Over 1-1/2 to 2-1/2 (38 to 60) 3-1/2 T

Over 2-1/2 to 4 (60 to 100) 4 T

Low-alloy steel in thicknesses over 1/2 in. (12 mm) may require hot bending for small radii. If a shorter

radius is essential, bend plates hot at 1,200 °F (650 °C) or less. Ensure that hot-bent plates have bend

lines at right angles to the rolling direction.

3) Round the corners of plates to a radius of 1/16 in. (2 mm) before bending.

Ensure that bearing stiffeners and stiffeners used as supports for concentrated loads have full bearing on

the flanges they transmit load to or the flanges they receive load from. Mill or grind the bearing surfaces

of stiffeners.

On weldable steel in flange compression areas, the Contractor may weld stiffeners as shown on

the plans.

Ensure that stiffeners not located at points of concentrated loads fit tightly enough to keep water out after

painting, unless otherwise shown.

Turn pins accurately to the dimensions shown on the Shop Drawings. Ensure that pins are straight,

smooth, and flawless. The pins may be forged and annealed or of cold-finished, carbon steel shafting. 683683683683683683

Furnish two pilot nuts and two driving nuts for each size of pin, unless otherwise specified.

Bore pin holes in members so they are:

True to the specified diameter

Smooth

Straight

At right angles to the axis of the members

Parallel with each other, unless otherwise required

Produce the final surface with a finishing cut. Bore holes in built-up members after completing bolting or

welding.

Ensure that pin hole diameters meet the following requirements:

Pin Diameter Pin Hole Diameter

5 in. (125 mm) or less Must not exceed pin diameter by more than 1/50 in. (0.50 mm)

Larger than 5 in. (125 mm) Must not exceed pin diameter by more than 1/32 in. (0.75 mm)

For structural steel construction, use threads for bolts and pins that conform to the Unified Screw Threads

ANSI B1.13 (Metric Screw Threads, ANSI B 1.13M), Class 2A for external threads, and Class 2B for

internal threads except pin ends with a diameter of 1 3/8 in (35 mm).

1) Bolts

Do not use ribbed bolts. Use unfinished bolts or turned bolts that conform to ASTM F 568M Class

4.6Use bolts with single self-locking nuts or double nuts unless otherwise shown

Use turned bolts with an ANSI surface roughness rating of 125 (3.2 μm).

2) Washers

Use beveled washers when bearing faces have a slope of more than 1 to 20 with respect to a plane

normal to the bolt axis.

3) Heads and Nuts

Use hexagonal heads and nuts with standard dimensions for bolts of nominal size specified or of the

next larger size. Provide a washer under the nut.

Use threads with a diameter equal to the body or nominal diameter of the bolt specified. For turned

bolts, threads shall be entirely outside of the holes.

Use anchor bolts of the size and shape specified on the plans.

Coat the following with rust-inhibiting grease or with other approved corrosion-preventive compounds:

• Opposing surfaces of sliding bearings

• Mating convex and concave surfaces of curved plates and rocker bearing assemblies

• Sliding surfaces opposite self-lubricating bronze surfaces

• Pins and pinholes

Coat other machined surfaces with one coat of the shop primer specified on the plans. Include convex faces

of rockers and sole plates at fixed bearings of spans that have line bearings on steel plates. 684684684684684684

Perform shop painting according to Section 535, especially Subsection 535.3.05.C, Paint New Steel

Structures, step 5.

Produce bolt holes as follows:

The Contractor may use full-size punched holes if these conditions exist:

• A member is composed of 5 or less separate thicknesses of metal, and

• The metal thickness of any one part is 3/4 in. (19 mm) or less for structural steel, or 5/ 8 in. (16 mm) or

less for high-strength steel.

Poor hole matching will be cause for rejection. Punch holes as follows:

more than 1/16 in. (2 mm).

Sub drill holes 3/16 in. (5 mm) smaller than the nominal diameter of the bolts.

After assembly, ream the holes if any one of the conditions exists:

• A member is composed of more than 5 separate thicknesses of metal.

• The metal thickness of any one main part is greater than 3/4 in. (20 mm) for structural steel or 5/8 in.

(16 mm) for high-strength steel.

• When required according to Subsection 501.3.05.E.1, Normal Assembly, step b.

Instead of sub punching and sub drilling, the Contractor may drill holes from the solid after assembly.

However, whether drilling from the solid or sub drilling and sub punching, ensure the following:

Accurately full-size punch, sub punch, or sub drill holes so that after assembly but before reaming, holes meet

the following requirements:

• A cylindrical pin 1/8 in. (3 mm) smaller than the nominal diameter of the punched hole can enter

perpendicular to the face of the member in at least 75 percent of the adjacent holes in the same plane

without drifting.

• A pin 3/16 in. (5 mm) smaller than the nominal diameter of the hole can pass through the hole.

If either of these requirements is not met, the faulty pieces will be rejected. 685685685685685685

Ensure that reamed and full-sized drilled holes are cylindrical, perpendicular to the member, and 1/16 in.

(2 mm) larger than the nominal diameter of the bolts. Ream and drill holes as follows:

or reaming.

1) Assemble the connecting parts.

2) Hold them securely while reaming or drilling.

3) Match-mark them before disassembling.

After drilling and reaming holes, ensure that at least 85 percent of the holes in any group have no offset

greater than 1/32 in. (0.75 mm) between adjacent thicknesses of metal. Make sure the remaining holes are not

elongated or show an offset greater than 1/16 in. (2 mm) between the adjacent thicknesses of metal.

Before reaming, drilling, or bolting, ensure that the pieces forming built-up members are:

• Straight

• Close-fitting

• Clean

• True to the required dimensions

• Free from twists, bends, open joints, burrs, and other defects resulting from faulty fabrication or

workmanship

• Well-pinned

• Firmly drawn together

Before shop bolting material with full-size punched holes:

Holes may be spear-reamed if necessary to clear and clean them for entering bolts.

place until bolted.

This section covers the shop and field connections of structural joints using High Tensile-Strength bolts tightened

to a specified tension. Use HTS structural bolts that meet the requirements of Subsection 852.2.03, High Tensile-

Strength Bolts. Furnish the bolts, nuts, and washers according to Subsection 852.2.03.

To seat parts solidly, keep joint surfaces (including those adjacent to the bolt heads, nut, or washers) free of scale

(except tight mill scale), dirt, burrs, metal spatters, and other defects. Ensure that joint contact surfaces are free of

oil, grease, paint, lacquer, galvanizing, rust, and other matter. Refer to the requirements of Subsection 535.3.05.C,

Paint New Steel Structures step 5.

Install fasteners with a hardened washer under the nut or bolt head, whichever is the element turned in tightening.

• When the slope of the bolted-part surfaces contacting the bolt head and nut do not exceed 1:20 (with respect

to a plane normal to the bolt axis), use a flat washer. 686686686686686686

• When the slope of an outer face of the bolted parts exceeds 1:20, use a smooth, beveled washer.

• If necessary, clip washers on one side to a point no closer than 85 percent of the bolt diameter from the

center of the washer.

When a joint assembly is complete, ensure that each bolt has a tension 5 to 10 percent above the required

minimum value shown in Table A: Required Fastener Tension.

Tighten HTS bolts with either the Calibrated Wrench Method or the Turn-of-Nut Method. For both methods,

conduct the final rotation of the nut or bolt (whichever is the turned element) from a snug-tight condition according

to Table B: Nut Rotation from Snug Tight.

Snug tight is the tightness achieved when the plies of the joint are in firm contact. Obtain this with a few impacts

of an impact wrench or with full effort using an ordinary spud wrench. Ensure that the snug tightening procedure

produces 10 to 30 percent of the required fastener tension shown in Table A: Required Fastener Tension.

Install bolts in the connection holes with a hardened washer under the turned element and bring the bolts up

to snug tight (described above) as follows:

1) Start the tightening pattern at the center of the pattern near the end of each member being spliced.

2) Work toward the edges of the splice plate.

tightening pattern until all bolts are simultaneously snug tight and the connection is fully compacted.

or manual torque). Systematically tighten from the most rigid part of the joint to its free edges.

tightening adjacent bolts are tightened to the prescribed amount.

If using a manual torque wrench, measure the target torque with the turned element in motion.

calibration does not rotate the nut or bolt head from snug tight more or less than that permitted in

Table B: Nut Rotation from Snug Tight.

When bolts are too short to fit in the tension calibrating device, use the Turn-of-Nut Method in the actual

work.

Install bolt connection holes with a hardened washer under the turned element and bring the bolts up to snug

tight (described above) as follows:

specified in Table B: Nut Rotation from Snug Tight.

1) Start the tightening pattern at the center of the pattern near the end of each member being spliced.

2) Work toward the edges of the splice plate.

Ensure that welded construction conforms to the requirements below. Electroslag or electragas welding

is prohibited. 687687687687687687

using methods permitted by 3.7 of ANSI/AASHTO/AWS D 1.5 specifications. If the weld is unacceptable, the

Engineer will reject the entire piece.

After welding repairs are made, the Engineer will have the repaired areas retested to determine if the repairs

meet specification requirements.

shown on the plans or permitted by the specifications.

Ensure that welded construction conforms to the American Welding Society (AWS) Bridge Welding Code

ANSI/AASHTO/AWS D 1.5 (including revisions) except as modified by these specifications and AASHTO.

Exceptions to the ANSI/AASHTO/AWS specifications are noted below.

laydown position (placed to grade from bearing to bearing).

ends at the center point of the web section.

consideration allowed mill tolerances on web-center-line-to-flange measurements. Pair shapes to provide

the best possible alignment.

be encased in concrete.

Subsection 535.3.05.E, Paint Steel H-Piling, Metal Shell Piling, and Steel Swaybracing and Subsection

535.3.05.F, Apply Special Protective Coatings to Steel Piling, Steel Swaybracing, and Concrete Piling,

remove the slag and do not clean any further.

clean or scrub welds with water and a stiff brush. Ensure that weld areas are clean and free of spatter,

rust, loose scale, oil, and dirt.

Special Provisions. When using water to clean, ensure that the surface is dry before painting. Clean and

prime welds as soon as practical after the weld is accepted and before the weld area rusts.

After welding studs to beams, visually inspect the studs and give a random number of them a light blow with a

hammer. Strike the following with a hammer and bend them 15 degrees from the correct installation axis:

• Studs that do not show a full 360-degree weld fillet.

• Studs that do not ring when given a light blow with a hammer.

• Studs that have been repaired by welding.

In case of a defective or repaired weld, bend the stud 15 degrees in the direction that places the defective

portion of the weld in the greatest tension.

Replace studs that crack (either in the weld, base metal, or the shank) during inspection or subsequent

straightening. See paragraph 4.30.4.

On studs that must be replaced, the Contractor may manually weld the stud with the following fillet welds: 688688688688688688

Stud Size Fillet Weld

3/4 in. (19 mm) Full 360 degrees–1/4 in. (6 mm)

7/8 in. (22 mm) Full 360 degrees–5/16 in. (8 mm)

1 in. (25 mm) Full 360 degrees–5/16 in. (8 mm)

501.3.05 Construction

The Engineer may permit straightening of plates, angles, other shapes, and built-up members if the straightening

is minor and can be accomplished in the field. Use only methods that do not injure the metal.

from the mechanical means used to apply the heat.

1) Heat the area to no more than 1150 °F (620 °C) as measured by temperature-indicating crayons,

liquids, or bimetal thermometers.

2) Cool the metal slowly after heating.

After the metal cools naturally to 600 °F (315 °C), the Contractor may use air-mist spray cooling.

of fracture and for general acceptability.

Proposed erection methods are subject to the Engineer’s review. Even with this review, assume responsibility for

providing adequate and safe methods and for carrying out the work according to the plans and specifications.

Begin erection only after the Engineer’s review.

Before assembly, clean surfaces that will permanently contact each other.

Assemble parts accurately, following the match marks, according to the plans and the erection diagram

shown in the Shop Drawings.

Do not hammer if it will injure or distort the members.

Ensure that fitting-up and drifting done during field assembly and connection meet the requirements of

Subsection 501.3.04.E.6, Fitting Up.

Before making field connections (bolting or welding) on continuous beams or girders, adjust splice joints to

the correct elevations and slopes and properly align the beams.

The Contractor may make beam and girder splices on the ground if using the proper blocking to give

adjoining sections the correct relative slopes.

Unless otherwise shown on the plans, provide formed holes for anchor bolts. Set the bolts using an approved

non-shrinking mortar. Place anchor bolts as follows:

consistency of thick paint.

689689689689689689

1) Mortar rises to the top of the hole.

2) The anchor bolt nut and washer rest firmly against the metal flange, plate, shoe, or pedestal.

3) The bolt has the correct projection above the top of the concrete bearing area.

to expand and contract without restraint.

to flanges as follows:

1) At both fixed and expansion ends, tighten nuts and bolts to bear on the washer and then back off one

full turn.

2) Draw nuts on other anchor bolts down to a tight fit.

3) Do not burr anchor bolt threads.

flanges according to the ambient temperature at bolt placement. This allows the beam and its attached

bearing components to expand or contract in the future.

Erect steel joints so that the surface in the finish grade plane (laterally and longitudinally) is true and free of

warping.

Keep joints from moving out of their correct position during concrete placement.

Cut loose temporary connections as soon as possible to avoid restraining expansion and contraction.

Note that openings shown on the plans are based on an erection temperature of 60 °F (15 °C). Make

corrections in the opening size for the actual erection temperature, and maintain the required opening.

Furnish pilot and driving nuts at no additional cost to the Department. Drive pins so that members take full

bearing. Provide pin nuts and run them up tight. Burr the threads at the face of the nut.

Correct misfits by reaming, cutting, and chipping during erection.

Immediately report to the Engineer errors that occur in shop fabrication or deformations from handling and

transportation that prevent assembling and fitting up parts properly. The Engineer must approve the

correction method.

Assume responsibility for misfits, errors in fabrication, and damage. Make corrections or replace parts at no

additional cost to the Department.

Unless otherwise required, level and finish bearing areas with a Type IV—Floated Surface Finish according to

Subsection 500.3.05.AB.5, Type IV—Floated Surface Finish.

conforms with Subsection 870.2.01.A.1, No. 1A, Red Primer as follows:

1) Coat the bearing area surface with red primer.

2) Place three layers of at least 8 oz (227 g) duck and coat each layer’s top surface with red primer. 690690690690690690

3) Position shoes or plates on the top layer of duck while red primer is still plastic.

4) Instead of red primer—saturated duck, the Contractor may substitute thin pads of an approved type

and thickness.

Prepare bearing areas as follows:

full bearing.

Machine-Finished Steel Surfaces and that will be exposed after erection as follows:

1) Remove the shop coating.

2) Replace the coating with the same paint system used on structural steel components.

Prepare machined surfaces that have been shop-coated according to Subsection 501.3.04.D.9, Coating

Machine-Finished Steel Surfaces and that will be in contact with self-lubricating bronze plates or bushings

as follows:

material.

Place elastomeric pads on concrete bearing areas that have the Type IV—Floated Surface Finish specified in

Subsection 500.3.05. AB.5, Type IV—Floated Surface Finish, unless otherwise required.

Ensure that plates that will contact elastomeric pads meet the no paint requirements of Subsection

535.3.05.C.5.e, Plates That Touch Elastomeric Pads.

Field paint according to Section 535 using the paint system required by the plans or Special Provisions. See also

Subsections 501.3.05.C.2, Steel on Steel, and 501.3.05.C.4, Steel on Elastomeric Pads.

Allow only enough drifting during assembly or field connections to bring the parts into position. Ensure that drifting

does not enlarge or distort holes.

Follow these requirements when shop assembling components.

Do normal shop assembly as follows:

tower face, bent, rigid frame, or plate girder in the shop.

501.3.04.E.1, Full-Size Punched Holes, and Subsection 501.3.04.E.2, Subpunched and Subdrilled Holes,

while assembled in the shop.

members are assembled:

Subpunch and ream the holes

Ream to a steel template 691691691691691691

When the Contract requires, make the complete shop assembly of an entire structure or a portion of it,

including the floor system.

When authorized by the Engineer or Inspector, modify the shop assembly requirements above to permit

partial shop assembly as follows:

three abutting sections.

faced ends in full bearing.

Ream and drill through templates as follows:

of the connection (inscribed on the template) and from the finished end of the template.

require no match-marking.

angle and bolting the templates firmly in place.

following:

1) Face or scribe at least one end of each web member normal to the long axis of the member.

2) Accurately set the templates at both ends from the faced or scribed end.

According to the erection diagram, match-mark connecting parts assembled in the shop to ream holes in field

connections.

501.3.06 Quality Acceptance

The Department will sample and test each heat number that structural steel is furnished from to fabricate

main members.

To facilitate this testing, ship one piece from each heat of main member structural steel to the fabrication site.

Provide pieces long enough to take a properly oriented, representative, 4 x 12 in (100 x 300 mm) sample. This

may require that the extra length pieces be 4 or 12 in. (100 or 300 mm) longer, depending on testing

orientation requirements.

Upon receiving HTS fastener assemblies (bolts, nuts, and washers), notify the Inspection Services Branch of

the Office of Materials and Research. The branch will verify that the Contractor has the documentation

required by Subsection 852.2.03, High Tensile-Strength Bolts and sample the assemblies as necessary.

The Inspector will check the following before or during the bolting operation. Provide the Inspector easy

access to the areas of the member to be inspected. 692692692692692692

The Inspector will:

torque wrenches have been calibrated at least daily for each diameter, length, and grade as shown in

this specification.

proper bolt tension is necessary.

If installation tension verification is necessary subsequent to installation and tightening of bolts, notify the

Inspection Services of the Office of Materials and Research.

Fasteners, for storage requirements.

demonstrate this knowledge by tightening a fastener in a bolt-tension calibrator.

the job-site tightening.

material are drawn together and that the procedure for snug tightening is followed.

tightening (from the snug tight position) produces the rotation specified in

Table B: Nut Rotation from Snug Tight.

In addition to the requirements specified in Subsection 501.3.04.C, Identifying Steel, the fabricator shall

demonstrate by written procedures and by actual practice a material application and traceability method for

the main stress-carrying elements of a shipping piece. The method must be visible at least through the

fit-up operation.

The traceability method shall verify proper material application as it relates to the following:

• Material specification designation

• Heat number

• Material test reports for special requirements

Give two weeks’ notice to the Department’s State Materials and Research Engineer (the Materials Engineer)

before beginning mill or shop work so that inspection arrangements can be made. Inspection at the mill or

shop is intended to facilitate work and avoid errors and does not relieve the Contractor of the responsibility for

imperfect material or work quality.

Do not roll or fabricate material until:

• You inform the Materials Engineer where the orders have been placed.

• The inspection is arranged or waived.

Furnish the facilities necessary for the inspection of materials and work quality in the mill and shop.

Allow Inspectors free access to the necessary mill and shop locations, and cooperate with the Inspector

during inspection.

Shop inspection is required for steel and other metal materials being fabricated.

Inspectors will do the following:

and specifications.

NOTE: Do not cut steel or apply prime paint until the Inspector completes this step. 693693693693693693

NOTE: Even if the Inspector accepts materials or members, they can be rejected later if found defective. Promptly

replace or repair rejected material or members at no additional cost to the Department.

Provide quality work and finish on shop work. Ensure that shearing, flame cutting, and chipping are neat and

accurate. Neatly finish all parts of the work.

An Inspector will be assigned to the fabrication shop for as much time as the State Materials and Research

Engineer deems necessary. The State’s Inspector or authorized representative will inspect fabrication phases

that include, but are not limited to, the following:

• Certification and transfer of heat numbers and grade steel

• Dimensions and assembly

• Inspection and testing of shop welds

• Non-destructive testing

• Painting

• Random sampling

• Stamp of shop inspection

Assume the following quality control responsibilities for non-fracture critical and fracture critical members and

their components:

offering the welds to the State for quality assurance inspection.

Qualify shop weld procedures and welders according to ANSI/AASHTO/AWS D 1.5. The Engineer may accept

tests conducted by other states as evidence of qualification. In the absence of approved shop weld

procedures, welding operator and welder qualifications, qualify with the State Materials and Research

Engineer as follows:

ANSI/AASHTO/AWS D 1.5.

procedure qualification is not needed at the start of each new Project.

Furnish labor and equipment to do the following:

• Position welds for magnetic particle testing

• Help transport ultrasonic equipment

• Provide the Inspector easy access to testing areas

The Inspector’s access to work in the shop and field is top priority.

The Department of Transportation, in its routine quality assurance inspection, will ultrasonic or magnetic-

particle test approximately 25 percent of the welds. 694694694694694694

If testing indicates faulty work, the Inspector will immediately notify the Contractor of the necessary corrective

work. Ensure that welders are available to repair faulty work as soon as practical.

and groove welds may be delayed to:

Within 24 hours after welding has been completed for material 2 in. (50 mm) or less

Within 48 hours after welding has been completed for material over 2 in. (50 mm).

The fabricator may use, at its expense, nondestructive testing methods other than those specified to

examine weld passes or completed welds. Refer to ANSI/AASHTO/AWS D 1.5.

main members by the ultrasonic method.

In addition to the testing requirements of the plans, specification, and Special Provisions, the Engineer

may require ultrasonic testing if the quality of the work warrants it.

When field testing, provide a continuous walkway between the center-most line of stringers from one of the

approach fills to the farthest row of splices as follows:

connection on each row of stringers.

the web.

Ensure that the top of the working platform is no more than 3 in. (75 mm) above the top side of the

bottom flange.

of excessive knots or knots that could cause an unsafe condition.

part or member of the bridge.

a fixed part or member of the bridge.

unless the deck reinforcement steel has been put in place.

connections have been inspected and accepted.

For built-up members, the requirements of paragraph 3.5.1.7 of ANSI/AASHTO/AWS D 1.5, as modified, apply

except at ends to be field connected by welding. The combined warpage and tilt tolerances shall be one-half

that specified.

For rolled shapes, apply mill practice tolerances (ASTM A 6/A 6M) except at ends to be field connected by

welding. The combined warpage and tilt tolerances shall be one-half that specified.

Use the above tolerances unless there are deviations that are additive when measured at the toe. In this case,

ensure that the maximum offset between adjoining flanges does not exceed 1/4 in. (6 mm).

501.3.07 Contractor Warranty and Maintenance

General Provisions 101 through 150. 695695695695695695

501.4Measurement

Structural steel will be measured either per pound (kilogram) or per Lump Sum.

• Per pound (kilogram) basis. The quantity of structural steel to be measured for payment will be the net weight of

metal in the completed and accepted structure.

A unit weight of 490 lbs./ft.³ (7850 kg/m3) will be used to calculate the net weight of steel. The weights of rolled

shapes or plates will be computed based on their nominal weight per foot (meter) as listed in standard handbooks

such as the AISC Manual of Steel Construction.

• Lump sum basis. When the plans specify a Lump Sum basis, this work will be measured as an accepted Lump

Sum quantity, complete in place. Tabulated quantities are shown on the plans as a service, but they do not relieve

the Contractor of conforming to plan details. If the plan details and tabulated quantities differ, the plan details will

govern. The Contractor shall determine the actual quantities required before submitting a bid.

501.4.01 Limits

Assume the cost of qualification tests and test sample preparation required under these specifications. This cost

is considered incidental to The Work.

Ultrasonic or magnetic-particle testing by the Department of Transportation under its quality assurance inspection

rate of approximately 25 percent of welds will be performed at no cost to the Contractor.

The Contractor shall assume the cost of additional ultrasonic or magnetic-particle testing above the 25 percent

rate to determine the extent of weld defects and to check corrected work. The rate for this extra testing will be $75

per hour for the Inspector, equipment, travel, and subsistence.

If the Contractor is equipped with satisfactory ultrasonic or magnetic-particle inspection equipment, the

Contractor may test the Work corrected in the shop at no additional expense to the Department, but the Engineer

will interpret the ultrasonic and magnetic-particle inspection.

501.5Payment

This work will be paid for at the Contract Price per pound (kilogram) of structural steel or per Lump Sum, each

complete in place. The Contract Price for structural steel includes the costs of labor and equipment and the direct or

incidental costs of furnishing easy access for inspection and testing.

Payment will be made under:

Item No. 501 Structural steel, Bridge No._____ Per lump sum

Item No. 501 Structural steel Per lb (kg)

Item No. 501 Structural steel-swaybracing Per lb (kg 696696696696696696

501.5.01 Adjustments

The cost of steel joints and metal bearing assemblies used in structures with no structural steel Pay Item shall be

included in the Contract Price for superstructure concrete, unless otherwise shown on the plans.

When authorized changes are made, the Lump Sum payment will be adjusted on a negotiated basis.

On projects with multiple bridges, payments will be applied on an individual bridge basis.

Upon satisfactory completion of the erecting, bolting, and welding of structural steel for the bridge, 95 percent of

the Contract Price, either per Lump Sum Basis or per pound (kilogram) basis, will be included for payment on the

next statement.

Steel spans are considered satisfactorily erected when they are placed in their final positions on the substructure,

properly spaced, and anchored down. Bolting is considered satisfactorily complete when defective welds are

repaired and found satisfactory by additional inspection.

Upon satisfactory completion of field painting, the remaining 5 percent of the Contract Price will be included for

payment on the next statement.

Material allowance payments of structural steel will be determined and paid for in accordance with the

requirements of Section 109.. 697 697 697 697 697 697