505STEEL STRUCTURES

Art. 504.07 Steel Structures 334

504.07Method of Measurement. This work will be measured for payment as

follows.

shall conform to Article 202.07(a).

prestressed concrete deck beams will be measured by the square foot (square meter) of horizontal surface area of the individual slabs or beams, as shown on the plans. In determining the total number of square feet (square meters) to be paid for, the overall horizontal surface area of all the slabs or beams specified will be used.

Precast, prestressed concrete I-beams, Bulb T-beams, or IL-beams will be measured by the foot (meter). In determining the total length of beams to be paid for, the specified overall length of the individual beams will be used.

Precast concrete pile caps will be measured for payment in place as each precast concrete cap.

504.08Basis of Payment. This work will be paid for at the contract unit price

per square foot (square meter) for PRECAST CONCRETE BRIDGE SLAB and PRECAST, PRESTRESSED CONCRETE DECK BEAMS, of the depth specified, or per foot (meter) for FURNISHING AND ERECTING PRECAST PRESTRESSED CONCRETE BEAMS, of the type and depth specified.

Precast concrete pile caps will be paid for at the contract unit price per each for PRECAST CONCRETE CAPS.

505.01Description. This work shall consist of furnishing, erecting, and

painting steel structures or portions thereof.

505.02Materials. Materials shall be according to the following

Item Article/Section

Materials for structures that will carry railroad traffic shall satisfy AREMA Specifications.

Steel Structures Art. 505.04 335

505.03Drawings. Before steel fabrication begins, the Contractor shall submit

electronic files of shop drawings to the Engineer for review and approval. These drawings shall be proportioned and prepared so they will print as 11 x 17 in. (275 x 425 mm) sheets without manipulation. Each sheet shall provide adequate space for review and approval stamps at the lower right corner, and both lettering and details shall ensure legibility for review and reproduction after microfilming. Each drawing shall be completely titled according to the contract plans, including structure number, state contract number, route, section, and county, and shall pertain to only one structure. If the submitted shop drawings have significant discrepancies, revised sets must be submitted until details comply with the contract requirements. After all review comments have been addressed, corrected, and approved, the shop drawings shall be distributed and become a part of the contract. Changes to previously approved shop drawings shall be subject to the approval of the Engineer, and the Engineer shall be supplied with a record of all such changes.

After the Engineer’s preliminary approval and prior to distribution, shop drawings for structures that will carry railroad traffic shall also be submitted for the approval of the Railroad Engineer.

During the preparation of shop drawings, the Contractor shall check all pertinent dimensions of the steel work shown in the plans and shall report any discrepancies discovered to the Engineer for revision and correction before fabrication is begun. Allowance will be made to the Contractor for additional material fabricated to correct reported contract plan errors.

505.04Fabrication. Structural steel shall be fabricated and stored according

to the following requirements, except for structures carrying railroad traffic. The AREMA Specifications shall govern fabrication of structures carrying railroad traffic, except the requirements of this section shall govern when they are more demanding. Fabrication shall be performed by structural steel fabricators meeting the certification requirements of Article 106.08.

applicable Specification and Code requirements.

stored above the ground upon platforms, skids, or other supports. It shall be kept free from dirt, grease, or other foreign matter, and shall be protected as far as practicable from corrosion.

which will not injure the metal. Sharp kinks and bends may be cause for rejection of the material. Heat straightening of AASHTO M 270 Grade 100W material shall be done only when approved by the Engineer and then only under rigidly controlled procedures.

The Contractor shall fabricate curved welded girders by cutting the flanges to the required curvature prior to welding the web unless the provisions of Article 11.4.12.2.2 of the AASHTO LRFD Bridge Construction Specifications regarding cross-sectional limitations and radius limitations on heat curving are met. If the limitations are met, curved welded girders or rolled beams may be fabricated as a straight unit, and through the application of heat

Art. 505.04 Steel Structures 336 induce the required curvature. Heat-curving will not be permitted on beams or girders fabricated of AASHTO M 270 Grade HPS 485W (HPS 70W) or 690W (100W) steels. Cold bending of beams or girders to the required curvature will be permitted provided the proposed detailed procedures receive the Engineer’s approval and the finished member approximates a smooth curve without kinks or twist. When beams or girders are to be heat curved, the Contractor shall satisfy the following requirements.

or V-type heating. For both types of heating, the flange areas to be heated are those that will be on the inside of the horizontal curve after cooling. Heating both inside and outside flange surfaces is mandatory when the flange thickness is 1 1/4 in. (30 mm) or greater, and the two surfaces shall be heated concurrently. The heating shall progress along the top and bottom flange at approximately the same rate. Heating shall be performed using multi-orifice (rosebud) heating torches manipulated to avoid overheating. Torches shall use air-propane or air- natural gas unless other methods are approved by the Engineer for the specific girder configuration.

For the continuous method, strips centered approximately 2 in. (50 mm) inside the edge of the top and bottom flanges shall be heated simultaneously. The strips shall be of sufficient width and temperature to obtain the required curvature.

For the V-type heating, the top and bottom flanges shall be heated in truncated triangular areas spaced at regular intervals along each flange. The heat patterns applied to the inside flange surface shall terminate just before reaching the juncture of the web and the flange. For curvature radii greater than 1000 ft (300 m), heating patterns on the outside flange surfaces shall have their apex coincide with the plane of the web centerline, and for smaller radii, the outside patterns shall extend past the web centerline a distance of 1/8 of the flange width or 3 in. (75 mm), whichever is less.

Beginning at the truncated end of each heating pattern, heating shall progress toward the base of the pattern, spreading with an included angle of 15 to 30 degrees. The base of the pattern shall not exceed 10 in. (250 mm) regardless of flange width and thickness. The heating torch progresses toward the base of the heating pattern after the truncated end of the truncated pattern reaches the specified temperature. Once heating begins to progress towards the base at the pattern, the heating torch(es) shall not be returned to the apex of the heating triangle. Heat pattern spacing and size shall be as required to obtain the required curvature.

The maximum temperature shall be prescribed below. If chording or twisting occurs in the member that is unsatisfactory to the Engineer, the Contractor shall correct the situation using Engineer-approved methods to obtain acceptable results.

Steel Structures Art. 505.04 337

internal temperature of the steel does not exceed 1150 °F (620 °C). “Internal steel temperature” shall be represented by the surface temperature approximately five seconds after passage of the torch. Heating shall be confined to the planned patterns or areas, and shall bring the steel within the pattern to the desired temperature as rapidly as possible without overheating. The temperature range shall be documented, based on frequent monitoring with appropriate temperature indicating crayons or other calibrated equipment during the heating and cooling of the member. Any procedure which causes the internal steel temperature to exceed 1150 °F (620 °C) will be considered destructive heating and be cause for rejection of the member. Steel rejected for overheating may be investigated for reacceptance or repair by tests acceptable to the Engineer. The costs of such tests shall be borne by the Contractor.

After completing a planned set of heat patterns along the member’s length, additional heat shall not be applied until the entire member has cooled below 160 °F (70 °C) and the net displacement has been verified. Accelerated cooling with water or water mist will not be permitted. Cooling with dry compressed air will be permitted after the steel has cooled to 600 °F (315 °C).

vertical or horizontal. When curved in the web-vertical position, the member shall be braced or supported so that the lateral deflection will not cause instability. When curved in the web horizontal position, the member shall be supported near its ends and have limiting blocks at intermediate points as to obtain the desired curvature. Restraints or preloads may be used to facilitate heat-induced steel movements, but additional external loads shall not be applied to heated steel. Preloads, including the member’s self-weight, shall not cause stresses exceeding 50 percent of the material’s nominal yield at ambient temperature.

are painted. The heat curving may be conducted either before or after transverse intermediate stiffeners are installed. Unless provisions are made for girder shrinkage, connection and bearing plates shall be located and attached after heat-curving. If longitudinal stiffeners or cover plates are required, they shall be curved separately and then welded to the previously curved girder.

Girders shall be fabricated to specified cambers by cutting web plates to the required geometries before attaching flanges. Heating may be used for small camber corrections if the method and points of application are approved by the Engineer. The prescribed camber shall be obtained before heat-curving and the Contractor shall make allowance for any anticipated losses during fabrication. Rolled shapes shall not be shop cambered, unless otherwise specified. If the contract requires cambering rolled shapes or if straightening as received material is necessary, proposed procedures must be submitted for the Engineer’s approval.

Art. 505.04 Steel Structures 338

Horizontal curvature and vertical camber will not be measured for final acceptance until all heating and welding operations are completed and the flanges have cooled to a uniform temperature. Horizontal curvature will be checked with the beam or girder in upright position. For beams or girders curved after reaming or drilling field splices, at least 20 percent of the girder or beam lines shall be check assembled after curving to verify final geometry. If problems are discovered, additional lines shall be checked until the Engineer is satisfied that the problems have been corrected.

cases hereafter, drilling may be substituted for punching of full-size holes; subdrilling may be substituted for subpunching; and holes may be drilled in assembly (“from the solid”) instead of being subpunched or subdrilled and reamed. Drilling in assembly shall be done with the material in the same configuration required for reaming. Holes punched or drilled full-size shall be 1/16 in. (2 mm) larger than the nominal diameter of the fasteners. Subpunched holes for fastener diameters greater than 5/8 in. (16 mm) shall be 3/16 in. (5 mm) smaller than the nominal diameter of the fasteners and for smaller fasteners, the holes shall be subpunched to the fastener’s nominal diameter. Subpunched or subdrilled holes shall be reamed to 1/16 in. (2 mm) larger than the nominal diameter of the fasteners.

Holes in carbon steel thicker than 3/4 in. (19 mm) or alloy steel thicker than 5/8 in. (16 mm) shall be drilled or subdrilled and reamed. Punching or subpunching shall not be permitted.

Where reaming is not required, holes in carbon steel up to 3/4 in. (19 mm) thick or in alloy steel up to 5/8 in. (16 mm) thick may be punched to their final specified size.

Holes for field connections of beams, girders, main truss or arch connections, skewed portals, and rigid frames carrying design loads shall be subpunched and reamed with the members assembled in the shop and supported against deadload deflection.

The accuracy of the assembly, including camber, alignment of subpunched holes, and finished-to-bear joints shall be approved by the Engineer before reaming is commenced.

Holes may be punched or drilled to their final specified size for field connections of secondary items including: lateral bracing for girders, truss cords, and arch ribs; hanger supports for laterals and utilities; portal and sway bracing; and cross frames or diaphragms that do not require reamed holes. All holes for end field connections of floor beams shall be subpunched or subdrilled and then reamed to a template, and all corresponding holes in the members to which they connect shall be reamed to the same template, or these connections may be reamed with the members assembled. Stringer connections to floor beams may have holes punched or drilled to their final specified size. Reaming templates shall have

Steel Structures Art. 505.04 339 hardened steel bushings and reference lines inscribed to locate the template on the members.

Computer-numerically-controlled (CNC) equipment may be used to produce full-sized holes in components otherwise requiring reamed, sub-sized holes, subject to the Engineer’s approval and the demonstrated accuracy of the CNC system. Accuracy must be verified by periodic check assemblies of components, and the Contractor’s quality control plan for the system must be acceptable to the Engineer. Errors detected by check assemblies will require additional assemblies to define the extent of problems and subsequent CNC work may be restricted or prohibited until system corrections are accepted by the Engineer.

of the punch by more than 1/16 in. (2 mm). Holes shall be cleanly cut, without torn or ragged edges.

be so accurate that after steel is assembled and before reaming, a cylindrical pin 1/8 in. (3 mm) smaller in diameter than the punched hole may be inserted perpendicular to the face of the member, without drifting, through at least 75 percent of the holes in the connection or the pieces will be rejected. Holes punched or drilled to their final specified size without assembly shall be so accurate that fasteners may be installed without reaming or additional drilling.

to the faying (contact) surface of the connection. Drilling shall be done with twist drills and reaming with fluted or adjustable reamers. Where practical, reaming shall be directed by mechanical means, and done after all the components are assembled and firmly secured. Unless otherwise approved by the Engineer, assembled parts shall be taken apart for removal of cutting oil, shavings, and burrs caused by drilling and reaming.

reamed, drilled from the solid, or made by CNC equipment, 85 percent of the holes in any group shall show no offset greater than 1/32 in. (1 mm) between adjacent thickness of metal.

regardless of tolerance in dimensions of rolled sections or fabricated members. If the required accuracy cannot be obtained otherwise, holes shall be drilled with the members assembled.

bolted using high-strength steel bolts.

bolts shall be reamed or drilled 1/32 in. (1 mm) larger in diameter than

Art. 505.04 Steel Structures 340 the bolt. The threads of each turned bolt shall be entirely outside the grip of the metal. A washer 1/4 in. (6 mm) thick shall be used under each nut.

assembled. Contact surfaces, including those adjacent to bolt heads, nuts, or washers, shall be free of all mill scale, dirt, burrs, and other defects that would prevent solid seating of all parts. Methods of installation and tightening shall be according to the “Specification for Structural Joints Using High-Strength Bolts”, for slip-critical connections as issued by the Research Council on Structural Connections Joints of the Engineering Foundation, except as follows.

To ensure solid seating of all parts of a slip-critical connection, no visible gap shall remain between the faying surfaces when all bolts are tightened to the snug tight condition, producing a bolt tension of approximately 10,000 lb (45 kN). All high-strength bolts shall have a hardened washer under the element (nut or bolt head) turned in tightening, regardless of the method used in tightening.

Inspection will be according to the requirements of the latest issue of the “Specification for Structural Joints Using High-Strength Bolts” for slip-critical connections. The Contractor shall provide a calibration device capable of indicating bolt tension. The calibration device shall be capable of testing the shortest bolt length encountered on the structure down to the following minimum lengths.

Bolt Diameter Minimum Length 5/8 and 3/4 in. (M16 and M20) 2 in. (50 mm) 7/8 in. (M22) 2.25 in. (60 mm) 1 in. (M26) 2.5 in. (65 mm)

The following fastening systems and installation methods will be allowed as options for all high-strength bolted connections: load indicating washer system, twist-off type fastener system, lock-pin and collar type fastener system, and turn-of-the-nut method. The Calibrated Wrench method will not be permitted.

The Contractor shall furnish a calibrated dial inspection torque wrench for use by the Engineer.

In addition to the field Rotation Capacity tests required in Article 505.04(f)(3)g.1., prior to its actual installation, a representative sample of not less than three fasteners of each diameter, length, and grade will be tested at the job site in the calibration device for approval. This field test will be performed according to the Procedure for Installation and Tightening for the particular fastening system as set forth in the Department’s Construction Manual. Each powered tool to be used in the actual field installation will be used for at least one of the samples tested. Each worker who is to perform actual field installation will be required to perform and pass at least one of the sample tests,

Steel Structures Art. 505.04 341 using the same equipment and methods that will be used for the actual field installation. Any worker who undertightens or overtightens the fastener during the test will not be allowed to perform actual field installation unless they perform a successful retest. If any fastener fails to meet the required minimum tension, the lot it was taken from will be rejected.

After all erection pins are removed, the fasteners in all holes of the connection shall be initially brought to a snug tight condition, approximately 10,000 lb (45 kN), progressing systematically from the most rigid part of the connection to the free edges in a manner minimizing relaxation of previously tightened fasteners. When testing for acceptance, the torque corresponding to the snug tight condition may be verified on the calibration device prior to failure.

After all fasteners in the connection are snug tight, they shall be fully tightened progressing systematically from the center most rigid part of the connection to its free edges.

For the twist-off or lock-pin and collar type fastener systems, the fractured end of the fastener, where the splined or pintailed end broke away, shall be cleaned with a wire brush or power tool prior to painting. After cleaning, the exposed end shall be given one coat of an approved high-build aluminum epoxy mastic and then painted with the paint specified for field painting the structure. The minimum dry film thickness of the aluminum epoxy mastic coating shall be 5.0 mils (125 microns).

The fastening systems shall meet the following requirements.

be according to ASTM F 959 (F 959M), except the average gap for giving the required minimum bolt tension shall be 0.005 in. (125 micron) for galvanized bolts.

checking the direct tension indicator when placed under the bolt head. The bolts shall be assembled with the direct tension indicator as they are to be installed in the field, including lubrication. Both the turn required by the impact wrench and the tension in lb (kN) shall be determined at snug tight, 0.015 and 0.005 in. (380 and 125 micron) gaps. This calibration test shall demonstrate that each bolt develops a tension not less than five percent greater than the tension required when the direct tension indicator average gap is 0.005 in. (125 micron). Average gap shall be measured according to Table 4 of ASTM F 959-06. If the bolt does not develop the minimum required tension at 0.005 in. (125 micron) gap with the direct tension indicator, the lot represented by the direct tension indicator will be rejected.

Art. 505.04 Steel Structures 342

assembled under the bolt head with the protrusions bearing against the underside of the bolt head and shall not be placed under the element turned for tightening. A galvanized hardened washer shall be provided under the nut. For plain finished bolts the direct tension indicator may be placed under either the bolt head or the nut. A hardened washer shall be used between the direct tension indicator and the turned element with the protrusions bearing against the hardened washer.

The Engineer will check the gap with gap gauges. The Contractor shall supply a sufficient number of 0.001, 0.005 and 0.015 in. (25, 125 and 380 micron) gauges for inspection purposes.

Torque wrenches shall only be used as needed for verification purposes. Overtightening may produce total zero gaps. Total zero gap occurs when a 0.001 in. (25 micron) feeler gauge cannot enter any gap in the direct indicating washer. No more than ten percent of the bolts with total zero gap in any one connection will be allowed. If the number of total zero gap bolts exceeds ten percent of the bolts in the connection, a sufficient number of these bolts shall be removed and replaced to bring the percent within the ten percent allowed. No more than ten percent of the galvanized bolts will be allowed per connection with gaps between 0.005 and 0.015 in. (125 and 380 micron) or over 0.015 in. (380 micron) for plain finish bolts. If there are more than ten percent of these bolts per connection, additional tightening will be required to reduce the number of excessive gaps to less than ten percent of the total number of bolts. The Engineer will check 100 percent of the gaps of the first two connections with feeler gauges for each bolting crew. Testing at 100 percent will continue if the bolt tightening does not meet the above requirements. Once the above bolting requirements are met, a minimum of 20 percent but not less than ten bolts of each connection, and only one bolt of each cross frame or diaphragm connection will be tested with feeler gauges. The remainder of the bolts will be visually inspected. If ten percent of this sampling is total zero gap or ten percent greater than 0.005 in. (125 micron) gap, the entire connection will be tested.

and tightening of connections shall be achieved by the use of a twist-off type fastener system meeting the requirements of section 2(d) of the “Specification for Structural Joints Using High-Strength Bolts”. The twist-off bolts shall consist of a threaded bolt with a splined end extension that shears off at a given torque.

assembly and tightening of connections shall be achieved by the

Steel Structures Art. 505.04 343 use of a lock-pin and collar type fastener system meeting the requirements of section 2(d) of the “Specification for Structural Joints Using High-Strength Bolts”. The lock-pin shall be round headed with a pintail that yields at a given load, and the collars shall be of the flanged type and equipped with tablocks to prevent slipping during installation.

A galvanized hardened washer according to ASTM F 436 (F 436M) may be used under the bolt head for joint thickness adjustment, provided the installed fastener conforms to the maximum permissible dimensions “A” and “B” from inspection charts provided by the supplier. Loose or relaxed fasteners shall be removed and replaced with new fasteners. Each fastener will be visually inspected according to the inspection charts provided by the supplier.

The “A” dimension from inspection charts provided by the supplier may be increased to 1/8 in. (3 mm) and still meet all published values, provided there is no requirement to meet ASTM specifications pertaining to locking grooves (threads) in the shear plane.

A properly installed high-tensile fastener shall possess the dimensional characteristics from inspection charts provided by the supplier. Should the dimensions “A” or “B” exceed the indicated values, the fastener is being used out-of-grip. A “C” dimension of less than the values specified is an indication of incomplete swage. A “D” dimension exceeding the tabulated values is an indication of an incorrect or worn anvil on the installation tool. Fasteners falling outside of these ranges shall be removed and replaced.

according to Section 8(d)(1) of the “Specification for Structural Joints Using High-Strength Bolts”, except as follows.

“snug tight” condition, the outer face of the nut shall be match- marked with the protruding portion of the bolt to visually determine the relative rotation occurring between the bolt and the nut during the process of final tightening. The wrench operator shall make marks with a permanent ink type marker or other approved means.

For connections with individual plates 1 in. (25 mm) and thicker, a minimum of two cycles of systematic snug tightening will be required to minimize relaxation of previously tightened fasteners prior to final tightening.

be accepted by the Engineer on the basis of a visual inspection of the match-marks on the bolts.

Art. 505.04 Steel Structures 344

Capacity tests are required for the Turn-of-the-Nut Method, Load Indicating washer, and Twist-Off type fastener Systems.

M36) inclusive shall be as follows.

Bolt Size (Inclusive) Hardness Number Brinell Rockwell C

1/2 to 1 in. Min. Max. Min. Max. 248 311 24 33 Vickers Rockwell

M16 to M36 Min. Max. Min. Max. 255 336 C23 C34

performed after galvanizing. The coating shall be removed prior to taking hardness measurements.

Rotational-capacity tests shall be required and will be performed on all black or galvanized (after galvanizing) bolt, nut, and washer assemblies by the manufacturer or distributor, and the following requirements shall be met prior to shipping.

ASTM F 3125 Grade A 325 (F 3125M Grade A 325M).

shall be tested as an assembly.

combination of lots tested.

rotational-capacity lot.

Skidmore-Wilhelm Calibrator or an acceptable equivalent device.

Bolts too short to test in a tension calibrating device shall be tested in a steel joint. The tension requirement specified in Article 505.04(f)(3)b.7. need not apply. The maximum torque requirement specified in Article 505.04(f)(3)b.8. shall be computed using a value of P equal to the turn test tension shown in the table in Article 505.04(f)(3)b.7.

percent of the installation tension), shall be as follows.

Steel Structures Art. 505.04 345 Bolt Length Minimum Rotation ≤ 4 bolt diameters 240 (2/3 turn) >4 and ≤ 8 bolt diameters 360 (1 turn) > 8 bolt diameters 480 (1 1/3 turn)

greater than 1.15 times the required installation tension. The installation tension and the tension for the turn test for ASTM F 3125 Grade A 325 (F 3125M Grade A 325M) bolts shall be as follows.

Diameter (in.) 1/2 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 Installation Tension (kips) 12 19 28 39 51 56 71 85 103 Turn Test Tension (kips) 14 22 32 45 59 65 82 98 119

Diameter (mm) 16 20 22 24 27 30 36 Installation Tension

Turn Test Tension

169 209 244 316 388 564

exceeded, one reading of tension and torque shall be taken and recorded. The torque value shall conform to the following.

Torque shall be less than or equal to 0.25 PD.

Where: Torque = measured torque ft lb (kN m) P = measured bolt tension lb (kN) D = bolt diameter ft (m)

thickness and the appropriate AASHTO tests shall be documented.

documented.

agency. The manufacturer or distributor that performs the tests shall certify the results recorded as accurate.

Art. 505.04 Steel Structures 346 (a.) MTR shall be furnished for all mill steel used in the manufacture of bolts, nuts, or washers.

(b.) MTR shall indicate where the material was melted and manufactured.

(a.) The manufacturer of the bolts, nuts, and washers shall furnish MCTR for the item furnished.

(b.) Each MCTR shall show the relevant information according to the reporting of the testing required.

(c.) The manufacturer performing the rotational-capacity test shall include on the MCTR the following information.

(1.) The lot number of each of the items tested.

(2.) The rotational-capacity lot number according to Article 505.04(f)(3)b.3.

(3.) The results of the tests required in Article 505.04(f)(3)b.

(4.) The information required in Article 505.04(f)(3)c.

(5.) A statement that MCTR for the items are according to this specification and the appropriate AASHTO specifications.

(6.) The location where the bolt assembly components were manufactured.

include the following.

(a.) Include MCTR above for the various bolt assembly components.

(b.) Include rotational-capacity tests by either the manufacturer or the distributor.

(c.) Show the results of the tests required in Article 505.04(f)(3)b.

(d.) Show the pertinent information required in Article 505.04(f)(3)c.

(e.) Show the rotational-capacity lot number as required in Article 505.04(f)(3)b.3.

Steel Structures Art. 505.04 347 (f.) Shall certify that the MCTR are in conformance to this specification and the appropriate AASHTO specifications.

be shipped in the same container. When there is only one production lot number for each size of nut and washer, the nuts and washers may be shipped in separate containers. Each container shall be permanently marked with the rotational-capacity lot number such that identification will be possible at any stage prior to installation. The rotational- capacity lot number shall be placed on both the container itself and the lid.

the Engineer.

prior to the installation of high-strength bolts.

above shall be performed on each rotational-capacity lot at each job site prior to the start of bolt installation. If any bolt fails to meet the required minimum tension, the lot from which it was taken will be rejected.

(a.) Galvanized nuts shall be checked to verify that a visible lubricant is on the threads.

(b.) Black bolts shall be “oily” to the touch when delivered and installed.

(c.) Slightly weathered or lightly rusted bolts or nuts that fail to meet the above requirements shall be cleaned and relubricated prior to testing. Recleaned or relubricated bolt, nut, and washer assemblies shall be retested according to the rotational-capacity test, prior to final installation.

the same rotational-capacity lot.

rolling direction parallel to the member’s longitudinal centerline. Web splice plates, connecting plates, gusset plates, and stiffeners may have their primary rolling direction in either direction. Parts of a member shall be assembled, well pinned and/or firmly drawn together with bolts before reaming or tightening of fasteners is commenced. The member shall be free from twists, bends, and other deformations that would prevent the solid

Art. 505.04 Steel Structures 348 seating required under Article 505.04(f)(2). A 1/8 in. (3 mm) or greater difference in plate thickness or member depths across a bolted splice shall be rectified with shims included during reaming, match marked, and shipped with member.

Parts not completely fastened in the shop shall be secured insofar as practicable to prevent damage in shipment and handling. Members assembled in the shop for reaming of field connections shall remain assembled until shop inspection by the Department has been made.

Fitting-up and shipping bolts, templates, jigs, shipping or shop assembly braces, and other items provided by the shop for fabrication or shipping but not incorporated in the final structure are considered incidental to the fabrication of the steel and will not be paid for as structural steel.

into position, but shall neither enlarge the full-size holes nor induce permanent distortion in any portions of the final structure.

be individually match marked while assembled and a diagram showing such marks shall be included in the shop detail drawings. Individually match marked items shall not be interchanged.

members shall be done using low or mini-stress dies. Letters and numbers shall be 3/8 or 1/2 in. (10 or 13 mm) tall. When used, the dies shall be lightly struck to produce an impression that can be clearly seen in the absence of paint and mill scale.

provided that a smooth, accurate profile, free from cracks and notches, is obtained by the use of a mechanical guide. Hand cutting of material remaining in the final structure shall be done only where approved by the Engineer, and shall be followed by grinding.

Reentrant cuts shall have a radius of not less than 3/4 in. (19 mm) and be finished to an ANSI surface roughness not exceeding 500 µ in. (13 µm).

Surface roughness exceeding the applicable limits of Article 505.04(l)(2) or the BWC and gouges not more than 3/16 in. (5 mm) deep on thermal cut edges (TCEs) shall be removed by machining or grinding and be faired to the surface with a slope of 1 to 10 or less. Material surface defects and gouges due to thermal cutting or handling damage that are more than 3/16 in. (5 mm) deep may be repaired according to the BWC using a procedure approved by the Engineer for the material type and thickness involved. The completed weld shall be ground to match the adjacent surface and nondestructively inspected by magnetic particle or ultrasonic testing, as approved by the Engineer.

Steel Structures Art. 505.04 349

thick and carrying calculated stress shall be planed to a depth of 1/4 in. (6 mm). Sheared edges of material up to 5/8 in. (16 mm) thick which carry calculated stress shall be planed to a depth of not less than 1/8 in. (3 mm) unless enclosed by welds. Sheared edges of material not carrying calculated stress and exposed after fabrication shall be ground or planed to remove evidence of tearing and sharp corners.

pedestals, bolsters, column cap and base plates, and masonry (base) plates shall be planed or otherwise finished as necessary to be within 1/16 in. (2 mm) of planar. Cast pedestals shall be planed on surfaces that are to be in contact with steel and shall be finished to a maximum of ANSI roughness not exceeding 2000 µ in. (50 µm) on surfaces in contact with masonry, leveling plates, or pads.

The surface finish of bearing and base plates and other bearing surfaces that come in contact shall meet the following requirements as defined in ANSI B 46.1, Surface Roughness, Waviness and Lay, Part 1.

Steel slabs ANSI 2000 µ in. 50 µm Heavy plates in contact in shoes to be welded

ANSI 1000 µ in. 25 µm Milled or faced ends of compression members, milled or ground ends of stiffeners

ANSI 500 µ in. 13 µm Bridge rollers and rockers ANSI 250 µ in. 6 µm Pin holes ANSI 125 µ in. 3 µm Sliding self-lubricating bearings ANSI 125 µ in. 3 µm

Bronze or copper-alloy bearing plates shall be self-lubricated by special graphited and metallic inserts. The manufacturer’s proposed materials and methods for producing the bearing plate shall meet with the approval of the Engineer.

and brought into uniform bearing, with no gaps exceeding 1/32 in. (1 mm), before welding or producing full-size holes during shop assembly. Abutting joints in tension members and at beam or girder splices need not be faced but the clearance within field bolted connections shall be from 1/16 to 1/4 in. (2 to 6 mm).

stringers shall be coplanar and positioned for the length of the member with such accuracy that milling to the exact member length will not reduce their thickness by more than 1/8 in. (3 mm).

shall be free of abrupt irregularities and dull to the touch. Fins, burrs,

Art. 505.04 Steel Structures 350 cutting slag, significant deformities, gouges, sharpness (corner more acute than 1/32 in. (1 mm)) radius, and other hazards to handling or impediments to proper coating application and performance shall be corrected by grinding and/or other Engineer-approved methods. When painting is required, it shall be done according to Section 506.

and stiffener angles intended as supports for concentrated loads shall be milled or ground to secure an even bearing against the flange angles or beam flanges with no gaps exceeding 1/32 in. (1 mm).

For welded construction, bearing stiffeners shall be milled or ground to bear at the bearing ends and a tight fit provided at the other ends.

uplift shall be fabricated from rolled plate. The primary plate rolling direction shall be along the length (vertical axis) of the link. The material shall have a minimum Charpy V-Notch toughness of 35 ft lb at 20 °F (48 J at –7 °C) and a minimum elongation of 22 percent in 2 in. (50 mm). Nominal yield strength of the link material shall not exceed 70 ksi (480,000 kPa). The links shall be straight and parallel. Holes in links and webs for pins or bushings shall have a maximum roughness equivalent to 125 µ in. (3 µm) finish.

dimensions shown on the drawings. The final surface shall be produced by a finishing cut, except expansion rollers made from cold finished steel bars having a smooth, true surface, need not be turned. Pins for pin and link assemblies or bearings with uplift shall have a ground finish equivalent to a 32 µ in. (0.8 µm) maximum roughness and shall be 100 percent inspected by magnetic particle or dye penetrant testing after grinding. Any cracks or other flaws detected shall be reported to the Engineer and will be cause for rejection. After testing, unpainted carbon steel pins shall be coated for corrosion protection according to Article 506.09(k). Rollers shall be shop primed after testing.

the member and parallel to each other, unless otherwise required. The actual distance from center to center of pins at link connections shall not vary from that specified by more than 1/8 in. (3 mm). The boring shall be done after the member is fabricated. If metallic pin bushings are required, they shall be shrunk fit and their internal diameters shall be ground to 32 µ in. (0.8 µm) maximum roughness.

shall be according to ANSI Standard B4, Class RC8, loose running fit. For pins bearing on metallic shrink fit bushings, the fit shall be ANSI Standard B4, Class RC7. For pins bearing on Teflon Impregnated fiber reinforced bushings, the bushing manufacturer’s recommended tolerances for fit shall be followed for the hole and pin diameters. Tolerances for all pin diameters and pin holes shall satisfy the following.

Steel Structures Art. 505.04 351 Nominal Diameter Range of Clearance Tolerance from Nominal Sizes Hole Pin in. in. x 10-3 in. x 10-3 in. x 10-3” 1.97 - 3.15 6.0 - 13.5 +4.5 -6.0 -9.0 3.15 - 4.73 7.0 - 15.5 +5.0 -7.0 -10.5 4.73 - 7.09 8.0 - 18.0 +6.0 -8.0 -12.0 7.09 - 9.85 10.0 - 21.5 +7.0 -10.0 -14.5 9.85 - 12.41 12.0 - 25.0 +8.0 -12.0 -17.0

12.4115.75 14.0 - 29.0 +9.0

-14.0 -20.0

Nominal Diameter Range of Clearance Tolerance from Nominal Sizes Hole Pin

50 - 80 152 - 343 +114 -152 -229 80 - 120 178 - 394 +127 -178 -267 120 - 180 203 - 457 +152 -203 -305 180 - 250 254 - 546 +178 -254 -368 250 - 315 305 - 635 +203 -305 -432 315 - 400 356 - 737 +229 -356 -508

AASHTO/AWS D1.5/D1.5M Bridge Welding Code, except steel tubular structures shall be covered by the AWS D1.1/D1.1M Structural Welding Code - Steel. Steel shall only be shop welded to remedy minor defects or according to details shown on shop drawings approved by the Engineer. Proposed details and procedures for field welding of structural steel shall be approved by the Engineer before welding begins.

Shop and field welding shall be performed using Welding Procedure Specifications approved by the Engineer with shielded metal arc welding (SMAW), submerged arc welding (SAW), gas metal arc welding (GMAW), or flux cored arc welding (FCAW) consumables permitted by the BWC. Other processes or consumables shall be specifically authorized by the Engineer on a project by project basis. Welders shall be qualified according to the BWC or Structural Welding Code.

sections of BWC shall apply.

the base metals shown in each row of the following list shall be

Art. 505.04 Steel Structures 352 considered equivalent for the purposes of fabrication and weld procedure qualifications.

English Row ASTM Specification Previous Current AASHTO Specification Previous Current 1 A 36 A 709 Gr. 36 Note 1 M 270 Gr. 36 2 A 572 A 709 Gr. 50 Gr. 50 M 270 Gr. 50 3 A588 A 709 Gr. 50W Note 1 M270 Gr. 50W 4 Note 1 A 709 Gr. HPS 70W Note 1 M 270 Gr. HPS 70W 5 A 514 A 709 Gr. HPS 100W Note 1 M 270 Gr. HPS 100W Note 1. Previous specification deleted.

(Metric) Row ASTM Specification Previous Current AASHTO Specification Previous Current 1 A 36M A 709M Gr. 250 Note 1 M 270M Gr. 250 2 A 572M A 709M Gr. 345 Gr. 345 Note 1 M 270M Gr. 345W 3 A 588M A 709M Gr. 345W Note 1 M 270M Gr. 345W 4 Note 1 A 709M Gr. HPS 485W Note 1 M 270M Gr. HPS 485W 5 A 514M A 709M Gr. HPS 690W Note 1 M 270M Gr. HPS 690W Note 1. Previous specification deleted.

Charpy-V-notch (CVN) Testing: All CVN testing shall meet the Impact Test Requirements for Zone 2.

Qualification or Verification testing. The Department will consider each fabrication organization as a separate Contractor for this requirement of the BWC. For fabricators operating in multiple locations, either with a group of buildings or at geographically separates facilities, weld procedures for the same type of equipment, used under similar operating conditions may be based on a common set of Procedure Qualification Reports (PQRs). If routine nondestructive testing reveals significant disparities in production quality that may be attributed to equipment variation then separate qualification tests shall be done at each location or machine involved. Non-FCM PQRs based on qualification tests, pretests, and/or verification tests shall remain valid as long as no significant changes occur in electrode/flux components or properties, subject to evidence of the shop’s successful use of the

Steel Structures Art. 505.04 353 process on equal or greater strength material at least every six months. If more than six months elapse without documented successful use of the process, the Engineer may require requalification of the PQR used to prepare the Weld Procedure Specification (WPS) proposed. Evidence of satisfactory use shall include Fracture Critical procedure tests, nondestructive examination of production welds, or welder/weld operator qualification tests. The Engineer will accept evidence of prior testing provided the PQR is complete and shows compliance with these specifications, and both the witnesses and the facility performing testing are satisfactory.

shall include: cross frames and diaphragms for non-curved structures and not designed to convey liveload stresses, expansion seal joints, pedestals and bolsters, retainer angles, walkway grating, and other items specifically identified by the Engineer.

welding shall bear the manufacturer’s marking showing the material to be of the proper class. The equipment and consumables to be used shall be submitted to the Engineer for approval, together with evidence of the manufacturer’s PQR and the Contractor’s verification test(s) or the Contractor’s PQR, except as exempted.

For flux cored electrodes, only E7XT-6 or E7XT-8 may be used in areas susceptible to drafts or wind exceeding 5 mph (8 km/hr). Other flux cored, metal cored, or solid electrodes utilizing gas shielding and satisfying the BWC may be used in enclosed, protected environments with air movement of less than 5 mph (8 km/hr). Welds made with E7XT-6 or E7XT-8 shall not be covered by or incorporated into welds made with other electrodes.

Electrodes and flux used for welding tubular steel structures and which satisfy prequalification requirements in the AWS D1.1/D1.1M Structural Welding Code - Steel shall not require qualification testing.

When PQR, Pretests, and/or Verification Tests are not required, variables affecting heat input shall be within ranges specified by consumable manufacturers, and supported by manufacturers’ compliance reports, not more than 12 months old, which shall be in a file maintained by the Contractor and furnished to the Engineer or Inspector upon request. Any parameters (including gas flow, current limits, E.S.O., and polarity) not within the manufacturer’s guidelines shall require qualification testing for the WPS. The Quality Assurance

Control (QC) Inspector shall ensure the Procedure Qualification Test weld parameter variables are being accurately monitored and recorded for each pass, and that specimen identity is constantly maintained. Similarly, the QA Inspector and QC Inspector shall ensure the critical weld parameters (preheat, travel speed, wire feed speed, current, etc.),

Art. 505.04 Steel Structures 354 consumable condition, and weld quality are adequately monitored throughout production.

When repetitive welding deficiencies persist even after adjustments are made, the QA Inspector shall have authority to prohibit use of the WPS, consumables involved, welding equipment and/or welding personnel, as applicable, for Department projects, until abnormalities are corrected to the QA Inspector’s satisfaction. Such deficiencies may include: lack of fusion or penetration, overlap, large or frequent slag inclusions, poor deslagging and interpass cleaning, ropiness, convexity or concavity of bead, gross porosity, and non-uniform weld size. If more serious deficiencies are noted, such as weld or underbead cracking, extensive lack of fusion, wet flux, contaminated weld zone, or not conforming to an approved WPS, the QA Inspector may require either removal of questionable welds or additional NDT. If deficiencies are attributable to the WPS or a specific electrode-flux combination, the Engineer will have authority to require the Contractor to either repeat Qualification Testing or to use another approved WPS.

submitted to the Engineer with fully documented and accepted PQRs (if applicable) for approval. The WPS submitted may be either generic for common situations on multiple projects or be tailored to suit the particular fabrication project.

The WPS shall include the following items: general instructions for fit- up, techniques and welding sequences; types of steel; joint description and preparations; welding position; polarity; amperage, voltage, and linear welding speed; electrode size and type; flux designation and consumable manufacturer’s trade name(s); approximate number of passes, maximum width and thickness of weld layers, and any procedure change between passes in the same weld; preheat-interpass temperatures, maximum and minimum; post heat temperature and duration; a diagram of the joint; and other data necessary to fully describe the welding procedure. A copy of the WPS shall be available at the welding operation.

be qualified by test according to the applicable welding code. Testing shall be administered and certified by a Certified Welding Inspector

accept evidence of previous qualification for welders under the applicable welding specifications.

but required by limiting lengths of material, may be used if they are detailed for the full strength of the member and are placed at locations approved by the Engineer. Complete joint penetration welds shall not have more than three repair welds made at a common location. Complete removal of the weld and adjacent base metal shall be required after the third repair.

Steel Structures Art. 505.04 355 Flange-to-web welds and shop welded splices in flanges or webs shall use the automatic submerged arc welding process. All fillet welding of stiffeners and connection plates to webs shall utilize automatic submerged arc welding, unless otherwise approved by the Engineer for specific situations.

If the applicable code permits welding on areas with tight mill scale present, WPSs utilizing consumables with sufficient deoxidizing capacity shall be employed to avoid porosity or lack of fusion. Tack welds shall start a minimum of 3 in. (75 mm) from the end and shall be a minimum of 1 1/2 in. (40 mm).

Ends of fillet welds shall have full throat and no unfilled craters. Fillet welds on stiffeners, connecting plates, gussets, and other assemblies (except for flange-to-web welds) shall terminate approximately 1/4 in. (6 mm) from the end of plate intersects to avoid undercut and other defects.

Special precautions shall be taken when welding during cold weather to avoid extreme thermal gradients and to avoid adversely effecting the manual functions of the welder or welding operator. In certain cases, the BWC minimum preheat and interpass temperatures may be insufficient for steels with nominal yield strengths exceeding 50 ksi (345,000 kPa) and thickness above 3/4 in. (19 mm). Preheat for these steels shall be calculated if the nominal welding electrode strength exceeds 80 ksi (550,000 kPa) and the plate sulfur content exceeds 0.01 percent, or if either plate’s carbon equivalent exceed 0.4 percent.

Tolerances for welded components shall be according to the applicable welding code, except the maximum deviation from specified camber for a span (abutment to-pier or pier-to-pier) or girder segment (abutment-to- splice or splice-to splice) shall be +3/4 in. (+19 mm) to 0 in. (0 mm).

Shop butt welds in flanges and webs shall be completed, tested, and accepted before the flanges are assembled on the web. Where possible, extension blocks (run on/run-off tabs) matching the joint’s cross section are to be used for all complete penetration welds and flange-to-web welds, unless additional material is provided to ensure full size welds the full length of the member.

according to the BWC, except as modified.

Prior to the start of fabrication of their first project for the Department, within the previous 24 months, the Contractor’s QC and production supervisors and the Engineer shall have a conference to ensure agreement regarding the details of the project, standard shop procedures, advance notifications to the Inspector, specific items for QC/QA acceptance, material documentation, cleaning and painting requirements, the sequence of fabrication to be followed, the status of qualifications for welders and welding operators, and approval of electrodes, wire, flux, other welding materials, and equipment.

Art. 505.04 Steel Structures 356

The welding and testing of all Procedure Qualification Test specimens shall be witnessed by personnel from two separate agencies, independent of the fabricator and acceptable to the Engineer. These may include the Inspector, Inspectors from other state DOTs, and/or qualified individuals from independent testing agencies which meet the approval of the Engineer.

Butt welds shall be radiographically (RT) or ultrasonically (UT) inspected according to the BWC, except: top and bottom 1/3 of each vertical web joint shall receive RT, and the remainder of that joint shall receive RT if unacceptable discontinuities are found in those areas; 50 percent of longitudinal web joints shall receive RT; and, except for webs, joints shall be considered “subject to tension or reversal of stress” if either plate joined requires Charpy V-notch (CVN) testing. In addition, butt welds in which the thickness of the thinner plate equals or exceeds 3 in. (75 mm) shall also receive UT. All joints to be inspected shall be free of paint, scale oil, and grease.

All radiographs and digital images shall be taken and interpreted by qualified technicians acceptable to the Engineer. The original film or digital image and a complete report describing the procedure and the technicians interpretation, properly identified as to piece, location of the weld, contract and structure number, shall be submitted to the QA Inspector for approval prior to acceptance of the weld. If the original film or digital image is found to be unacceptable by review by the QA Inspector, another radiograph or digital image of the joint shall be taken. In the event the Contractor questions the QA Inspector’s interpretation of the radiographic films or digital images, a joint review of the film or image will be made. The Engineer’s final interpretation will govern.

When areas to be radiographed are too large for one film or digital image, overlapping exposures shall be made to cover the area. The limits for one film shall be 15 in. (375 mm) for web shots and 16 in. (400 mm) for flange shots 1 1/4 in. (30 mm) and thicker the limits shall be 15 in. (375 mm).

If radiographic inspections disclose rejectable defects, they shall be repaired and additional radiographs or digital images shall be taken for each repaired weld and submitted to the QA Inspector for approval.

The Contractor shall furnish the Engineer a shop drawing with the weld identification and showing assembly of the steel into final members or pieces. Lettering on radiographs or digital images of repairs shall show an “R” and the number of the repair shot. This additional identification shall be placed next to the film number and be included on the weld identification shop drawing.

Location marks shall be stamped in the steel by the Contractor prior to radiographing, using a prick punch with a dull tip. These will be located by lead arrows, but only the “floating” mark must be visible on the film. The location marks shall consist of center punch marks 1 1/2 in.

Steel Structures Art. 505.04 357 (40 mm) from the centerline of the weld for plates up to 3 in. (75 mm) thick or 2 in. (50 mm) from the centerline on thicker plates, and 2 1/4 in. (60 mm) in from each edge of the plate. In addition, there shall be one randomly placed, “floating” punch mark within each exposure at the same distance from the centerline. The punch marks shall be placed in the thinner plate. In a series of overlapping exposures, the location marks shall be placed at approximately every 15 in. (375 mm).

Complete penetration tee and corner joints of primary members shall be ultrasonically inspected. Complete penetration tee and corner joints in compression or shear shall have at least 1 ft (300 mm) of every 4 ft (1.2 m) and 1 ft (300 mm) of each joint less than 4 ft (1.2 m) ultrasonically inspected. This shall include flange-to-web welds in bending members and welds joining material that does not require Charpy V-notch (CVN) testing. If unacceptable defects are found in any test length, the full length of the weld or 3 ft (900 mm) either side of the test length, whichever is less, shall be ultrasonically inspected. If unacceptable defects are found in more than 20 percent of the 1 ft (300 mm) increment lengths tested, the full length of the joint shall be ultrasonically inspected. Complete penetration tee and corner joints subject to tension or stress reversal shall be ultrasonically inspected the full length of the joint. This shall include welds joining plates requiring CVN testing other than web-to-flange joints in bending members. Welds within 1 ft (300 mm) of repairs shall be retested after the repairs are made.

Partial magnetic particle inspection will be required of each fillet weld on nonfracture critical girders, floor beams, stringers and truss members, fabricated items subjected to tensile stress or reversal of stress, including fingerplate stools, and for root and final passes of partial penetration groove welds in primary members, unless specifically exempted by the Engineer. At least 1 ft (300 mm) of every 10 ft (3 m) of weld length or 1 ft (300 mm) of each weld less than 10 ft (3 m) in length, plus welds within 1 ft (300 mm) of all starts and stops shall be tested, except bearing assembly to flange and diaphragm seat angle to web welds shall only be tested when visual inspection indicates possible flaws. The test shall be located at random in the members so as to be typical of the welding. Random locations are subject to selection by the Engineer. If unacceptable defects are found in any test length of a fillet weld, the full length of the weld, or 5 ft (1.5 m) on either side of the test length, whichever is lesser, shall be magnetic particle tested.

For Fracture Critical Members (FCM), fillet welds on flanges and webs that may be in tension areas shall receive 100 percent magnetic particle inspection.

The magnetic inspection procedure and techniques shall be according to ASTM E 709. The QA Inspector will examine the magnetic test reports and give approval before the members will be accepted. Welds within 1 ft (300 mm) of repairs shall be retested after the repairs are made.

Art. 505.04 Steel Structures 358 Welded or cast steel bearing assemblies weighing more than 350 lb (160 kg) each shall be nondestructively examined by visual, magnetic particle and/or ultrasonic methods, as directed by the Engineer to ensure no critical flaws exist.

Surface porosity in all welds shall not exceed 3/16 in. in 1 in. (5 mm in 25 mm) of weld nor 3/8 in. in 1 ft (10 mm in 300 mm) of weld. Cluster porosity size shall be determined by describing a circle around the cluster of holes. If the circle diameter is 3/16 in. (5 mm) or greater, the porosity must be ground out and rewelded. For linear porosity, a line connecting three or more adjacent pores shall be drawn. Adjacent pores are defined as pores separated by less than 1/4 in. (5 mm). If the line drawn exceeds 3/8 in. in 1 ft (10 mm in 300 mm), the porosity shall be ground out and rewelded. The maximum diameter for a single pore shall not exceed 3/32 in. (2 mm). The maximum frequency shall not exceed 1 porosity episode in 4 in. (100 mm) nor 5 (6) episodes for every 4 ft (1.2 m) of weld. The above criteria shall also apply to all subsurface welds which are critical or heavily stressed welds that are subjected to various nondestructive tests.

The Contractor shall give the Engineer sufficient advance notice of the date on which the material will receive radiographic, ultrasonic, or magnetic particle inspection so that the Engineer may be present.

approved by the Engineer.

such as ASTM A 1011 or A 606 (A 606M) satisfying the physical and weathering or coating requirements of the material joined. Fills shall not be tack welded.

construction shall be according to the Unified Standard Series UNC-ANSI B 1.1, Class 2A for external threads and Class 2B for internal threads, except pin ends having a diameter of 1 3/8 in. (35 mm) or more shall have a thread pitch of 6 threads per inch (4.2 mm per thread).

505.05Inspection. All material and workmanship will be subject to QA

inspection by the Engineer. The cost of inspection, both at mill and shop, will be borne by the Department, except whenever any inspection is conducted outside the Continental United States, the Contractor shall bear the actual costs of travel and subsistence for the Department’s QA inspection.

week notice prior to the beginning of work for shops within Illinois, and at least two weeks notice for work outside state boundaries. The Contractor shall arrange members or units to be inspected so that identification marks are visible and each member or unit is accessible for measurements the QA Inspector may deem necessary. Upon the QA Inspector’s request, the

Steel Structures Art. 505.07 359 Contractor shall reposition the steel to permit full examination. Prior to shop inspection of an item, the Contractor shall furnish the QA Inspector with a list of its main stress carrying material, correlating the piece mark and heat numbers. The heat number, established by the rolling mill, shall be preserved on material through fabrication until the element is joined into a member with a permanent piece mark.

or sequentially assembled at the fabricating plant, subject to the Engineer’s approval of the fabricator’s proposed system. Continuous beams or girders and connections requiring reamed field connection holes shall be assembled, unless otherwise noted or approved by the Engineer before reaming is commenced. For girder or beam lines with more than three elements, at least three pieces shall be included in each assembly. Unless approved by the Engineer, assemblies made for reaming or drilling holes shall not be disassembled until after shop QA inspection has been made. Shop assembly of curved girders shall meet the additional requirements of Article 505.04(c)(4).

shop QA inspection and complete the inspection of fabricated material when it is delivered at the job site. The Contractor shall remain responsible for the fabricated items until job site acceptance is given.

505.06Cleaning and Painting. When specified, structural steel shall be

cleaned and painted according to Section 506. All high-strength bolts and other connectors, including nuts and washers, shall be mechanically galvanized according to Article 1006.08(a).

505.07Marking and Shipping. Each member shall receive an erection mark

for identification, and an erection diagram showing member locations shall be included in the shop drawings. If paint is used to locate (circle) metal stamped marks or to enhance their legibility (copy) on unpainted structures, the marks shall be placed in areas not highly visible after construction. Paint marks on outside faces of unpainted fascia members or on the underside of their bottom flanges shall be removed prior to shipping.

Pins, small parts, and small packages of bolts, washers, and nuts may be combined for shipment in boxes, crates, kegs, or barrels, but they shall be protected from damage and the gross weight of any container shall not exceed 300 lb (135 kg). A list and description of the contents shall be attached to the outside of each container. The loading, transportation, unloading, and storing of structural material shall be conducted so that the items will be kept clean and not be excessively stressed, deformed or otherwise damaged. For handling long steel members or large assemblies, lifting points, temporary supports and sequences, based on the Contractor’s calculations, shall ensure member stresses do not exceed 80 percent of the material’s minimum yield strength. These calculations shall be submitted to the Engineer for review. In storing and shipping members, blocking, bracing, and shoring shall be sized and placed as necessary to prevent excessive deflection or motion. Fabricated beams and girders shall be handled, stored, and shipped in an upright and final erection position unless otherwise approved by the Engineer.

Art. 505.08 Steel Structures 360 Steel lifting lugs on members will not be permitted if their installation and removal could possibly be detrimental to the structure. The following requirements shall also be met.

are accomplished under one contract and lifting lugs are used, the lugs shall be placed during fabrication. When no longer required, the lugs shall be removed.

The location, attachment, and removal method for the lugs shall be detailed on the shop drawings approved by the Engineer.

erection are accomplished under separate contracts and lifting lugs are desired by the erector but not shown on the contract plans, the erection Contractor shall be responsible for submittal of shop drawings to the Engineer for approval and for having the lugs furnished, installed and removed. When lifting lugs are detailed on the contract plans, the fabrication Contractor shall be responsible for furnishing and installing the lugs and the erection Contractor shall remove them when no longer required. The location, attachment, and removal method for the lugs shall be detailed on the shop drawings and approved by the Engineer.

505.08Erection. The Contractor shall erect the structural steel, remove the

temporary construction associated with the steel erection and do all work required to complete the structure as covered by the contract. The following requirements shall govern.

separate contracts, the Department will provide the substructure is within allowable tolerances for lines and elevations, and properly finished, and will establish the locations and elevations required for setting the steel.

and appliances, including pilot and driving nuts, cylindrical erection pins, and fitting-up bolts, necessary for the expeditious handling of the work. These items will be considered as equipment and shall remain the property of the Contractor.

handling of structural steel shall be according to Article 505.07 and shall be conducted so that the members will be kept clean and free from injury. When unloaded, the materials shall be placed on skids and braced to prevent excessive deflection, to keep the member off the ground and to provide adequate stability.

If the contract covering the erection of the steel does not include the fabrication, the erection Contractor shall check the material received and report promptly, in writing to the Engineer, any shortage or injury discovered. The erection Contractor shall be responsible for the loss of any material furnished by the Department or another Contractor after delivery and

Steel Structures Art. 505.08 361 acceptance at the job-site, or for any damage to such material during job- site storage or erection.

for the required loads and site conditions. The Contractor shall submit detailed plans for falsework, prepared and sealed by an Illinois Licensed Structural Engineer, for examination by the Engineer. If such plans are not satisfactory to the Engineer, the Contractor shall make such changes in them as may be required.

an erection plan to the Engineer for approval detailing the proposed methods of erection and the amount, location(s), and type(s) of equipment to be used.

placed upon areas that are improperly finished, damaged, or irregular.

Leveling plates, pads, and/or adjustment shims shall be placed beneath the bottom bearing plates or castings.

Anchor bolts shall be installed according to Article 521.06.

shapes and built-up members, when permitted by the Engineer, shall be done by methods that will not produce fracture or additional injury. Distorted members shall be straightened by mechanical means or, if approved by the Engineer, by the careful planned and supervised application of a limited amount of localized heat, under rigidly controlled procedures. Procedures using heat, with or without external restraints (jacks, come-alongs), shall be detailed to include heat patterns and locations, maximum temperatures, monitoring methods, restraint locations, and calculations of restraint forces.

Before beginning any work, these shall be submitted and received for the approval of the Engineer. For AASHTO M 270 (M 270M) Grades 70W, 100, or 100W (485W, 690 or 690W) steels, the temperature shall not exceed 1050 °F (565 °C), and for other steels, the temperature of the heated area shall not exceed 1150 °F (620 °C) as verified by temperature indicating crayons, infrared or bimetal thermometers. Parts to be heat straightened shall be substantially free of stress from external forces, except the preplanned restraints in the Engineer-approved proposal. Following the straightening of a bend or buckle, the surface of the metal shall be carefully inspected, and any evidence of fracture shall be immediately reported to the Engineer.

supported to provide the top of beam/web elevations shown on contract plans (without steel dead load deflection) until field splices are pinned and partially bolted.

Bearing surfaces and surfaces to be in permanent contact shall be cleaned of foreign material before the members are assembled. Detailed truss

Art. 505.08 Steel Structures 362 spans erection procedures shall be submitted for the Engineer’s approval. These shall include blocking and falsework plans, assembly sequence and bolting methods for chords, floor beams, stringers and bracing installation.

Bolted field splices in continuous beams or girders shall not be torqued until the entire continuous length is in place on the substructure. During erection, splices and field connections shall have 1/4 of the holes filled with finger- tight bolts and 1/4 with cylindrical erection pins. Bolt tightening shall not commence until all erection pins at a splice have been removed and all holes are filled with finger-tight bolts. Bolt tightening shall be according to Article 505.04(f). Temporary fitting-up bolts shall be the same diameter as the specified bolts, and cylindrical erection pins shall be 1/32 in. (1 mm) smaller than the hole.

Article 505.04(f). Drifting shall draw the parts into position but not enlarge the holes or distort the metal.

used, the bolts shall be brought to snug tight and loosening shall be prevented by either burring the threads at the face of the nut with a pointed tool or other mechanical means, including lockwashers and self-locking nuts.

pins. Pins shall be installed so that the members will take full bearing on them. Pin nuts shall be tightened sufficiently to limit lateral separation of material to 1/8 in. (3 mm) or that detailed by the contract plans, but not enough to clamp material and restrict rotation. Pins shall be double nutted with jam nuts or have other provisions to prevent loosening of single nuts under normal service conditions, subject to approval by the Engineer.

considered a part of the erection. Minor field corrections include grinding corners, burrs, or other small areas, removing less than 1/8 in. (3 mm) of material, or reaming of less than five percent of holes. Plates shall either be held tightly together during reaming or disassembled for cleaning. Any error in the shop fabrication or permanent deformation resulting from handling and transportation, which prevents the proper assembling and fitting up of parts by the use of cylindrical erection pins, or by minor field corrections, shall be reported immediately to the Engineer. Any proposed method of correction must be approved by the Engineer, and the correction shall be made in the Engineer’s presence. If the contract provides for complete fabrication and erection, the Contractor shall be responsible for all misfits, errors, and juries, and shall make the necessary corrections and replacements. If the contract provides for complete fabrication of the steel, the Contractor performing the fabrication shall be responsible for all errors in fabrication. The Engineer will determine: what corrections are considered to be of a minor nature and are included as part of the erection work; what damage or loss is the responsibility of the erection Contractor; and which problems are to be considered errors in fabrication, to be remedied at the expense of the Contractor responsible for the fabrication. Damage occurring during

Steel Structures Art. 505.08 363 transportation shall be corrected at the expense of the responsible Contractor.

single unit and of a design suitable for end-welding to steel with automatically timed stud welding equipment. Stud shear connectors that are to be welded to the top flanges of beams or girders shall be placed after the steel has been erected and suitable scaffolding or the deck forming has been provided so the hazard due to stud projections is at a minimum. Studs that are to be welded to expansion guards, bearing plates, or other locations not posing a hazard, may be placed in the shop.

If flux-retaining caps are used, the steel for the caps shall be of a low carbon grade suitable for welding and shall comply with ASTM A 109 (A 109M). Finished studs shall be of uniform quality and condition, free from injurious laps, fins, seams, cracks, twists, bends, or other injurious defects.

Finish shall be as produced by cold drawing, cold rolling, or machining. The manufacturer shall certify that the studs satisfy the requirements of this Section. Certified copies of in-plant quality control test reports shall be furnished to the Engineer upon request. An arc shield (ferrule) of heat- resistant ceramic or other suitable material shall be furnished with each stud. The material shall not be detrimental to the welds or cause excessive slag and shall have sufficient strength so as not to crumble or break due to thermal structural shock before the weld is completed. Flux for welding shall be furnished with each stud, either attached to the end of the stud or combined with the arc shield for automatic application in the welding operation.

automatically timed stud welding equipment connected to a suitable power source. If two or more stud welding guns are to be operated from the same power source, they shall be interlocked so that only one gun can operate at a time and so that the power source has fully recovered from making one weld before another weld is started.

Studs may be welded using two or more welding generators in parallel or by use of a battery operated source to supply the necessary amperage.

of any rust, rust pits, scale oil, or deleterious matter. The surface to receive the stud shall be free from mill scale and heavy rust. Paint, galvanizing and oil are contaminants and shall be removed.

Welding shall not be done when the base metal temperature is below 0 °F (-17 °C), or when the surface is wet. If it becomes necessary to weld the studs when the temperature of the base metal is below 0 °F (–17 °C), base metal shall be preheated and maintained above 32 °F (0 °C) during the welding operation.

Art. 505.08 Steel Structures 364 While in operation, the welding gun shall be held in position without movement until the weld has solidified.

Longitudinal and lateral spacings of studs with respect to each other and to edges of beam or girder flanges shall not vary more than 1/2 in. (13 mm) from the dimensions shown on the plans, except that a variation of 1 in. (25 mm) will be permitted where required to avoid obstruction with other attachments on the beam. The minimum distance from the edge of a stud shank to the edge of a beam or plate shall be 1 in. (25 mm).

beam or girder, after being allowed to cool, shall be bent 45 degrees by striking the stud with a hammer. If failure occurs in the weld of either stud, the procedure shall be corrected and 2 successive studs shall be successfully welded and tested before any more studs are welded to the beam or girder. This bend check shall also be made at the start of each day of the work, when the welding has been interrupted for an hour or more, when changing grounds, when changing weld settings or when changing cable loop due to arc blow (arc not going vertically from center stud to flange). In any case, no more than 500 studs shall be welded to a beam or girder without the welds being field bend tested according to the foregoing procedure. These bend tests shall be made by the operator and left in the bent position for inspection by the Engineer. All such studs that show no sign of failure as determined by the Engineer shall be left in the bent position. When 7/8 in. (22 mm) studs are welded, bend tests will be performed after every 250 studs. If due to low temperatures, preheating of the base metal has been utilized in preparation for automatic welding of studs to the beams or girders, the operator shall hammer bend to 45 degrees from the vertical two studs in each 100 welded in addition to the first two studs welded on each beam or girder. The studs shall be left in the bent position for examination by the Engineer.

Studs on which a full 360 degrees weld has not been obtained may, at the option of the Contractor, be repaired by adding a 5/16 in. (8 mm) fillet weld in place of the lack of weld, using the shielded metal-arc

weld shall extend at least 3/8 in. (10 mm) beyond each end of the discontinuity being repaired. The minimum preheat (flange and stud temperature) for SMAW repair welds is 70 °F (20 °C). The Engineer will bend test questionable studs as follows: Using a heavy hammer the Engineer will strike the stud to bend in the direction opposite to the weld deficiency until the shank is bent 15 degrees from the vertical (about 1 in. (25 mm) deflection). Then reversing direction, the stud will be driven back into the vertical position. If there is no visual distress evident in the weld, it will be considered satisfactory.

In addition to the bend tests accomplished by the operator to the satisfaction of the Engineer and the bend tests made by the Engineer, the Engineer will check approximately one percent of the studs at

Steel Structures Art. 505.09 365 random by striking the stud and bending to an angle of 45 degrees with the vertical. The studs shall be left in the bent position.

If a stud fails or it becomes necessary to remove a stud with a defective weld, the vacated area of the beam or girder flange shall be ground smooth and flush. In the case of pullout of the base metal, the pocket or defect shall be ground smooth to a slope of 1:3 (V:H), with final striations parallel to the longitudinal axis of the beam or girder flange. Defects deeper than 1/4 in. (6 mm) shall be reported to the Engineer for further direction on repair requirements. The new stud shall be placed outside of, but within 1 in. (25 mm) of, the repaired area.

If the Engineer notes a reduction of the height of the studs as they are welded, the work shall be stopped immediately and not resumed until the cause has been corrected. If the Engineer determines that the shear connectors are not satisfactory by inspection and testing during the progress of the work, the Contractor shall replace all defective studs and make necessary changes in the welding procedure or welding equipment to secure satisfactory results.

Article 505.04(q) and all field thermal (flame or plasma) cutting shall be according to Article 505.04(k). No field welding shall be done on main, load carrying members unless specified by the contract plans or with the written permission of the Engineer. The use of thermal cutting in other areas will be permitted only when specified by the contract plans or authorized by the Engineer, and shall be subject to the Engineer’s inspection. No thermal cutting equipment shall be permitted on the structure, except when in use according to the above requirements.

erecting adjacent structures, or for other tasks not directly related to construction of the structure shall not be operated upon or attached to any portion of the new structure without the written approval of the Engineer.

505.09Work Under Separate Contracts. When the fabrication, erection,

and painting of structural steel, construction of concrete decks, and other collateral work on a structure are accomplished under separate contracts, the following shall apply.

and painting of structural steel is accomplished under separate contracts, the fabrication Contractor shall be responsible for storing and protecting all fabricated structural steel up to 45 calendar days after completion dates, delivery dates or number of working days specified in the fabrication contract. All storage costs incurred by the fabrication Contractor during this 45 day period shall be borne by the fabrication Contractor.

the fabrication Contractor and the Engineer with a schedule for shipping the structural steel to the jobsite within 30 calendar days after the execution of the erection contract. This schedule shall specify the order items are to be

Art. 505.09 Steel Structures 366 received and their orientation for delivery, and must meet the approval of the Engineer. The erection Contractor will be responsible for receiving, unloading storing and protecting the structural steel in accordance with this schedule. If the erection Contractor elects to change this schedule, the erection Contractor shall be responsible for coordinating the change with the fabrication Contractor and for all costs and time delays associated with such changes.

Delivery of the structural steel to the jobsite shall be the responsibility of the fabrication Contractor. The mode of delivery shall be the option of the fabrication Contractor. Delivery shall be limited to the hours between 8:00 a.m. and 5:00 p.m. on weekdays only, excluding any observed holidays, unless otherwise approved by the Engineer. The erection Contractor shall be responsible for coordination of movement of the structural steel within the contract limits and shall be responsible for all demurrage charges. At the erection Contractor’s option and expense, steel may be requested at times other than the stated time.

completely installed until either final adjustments are made or the completion of subsequent contracts, shall be delivered and partially erected or stored as directed by the Engineer. These items shall be installed or adjusted, as required, by the Contractor performing the subsequent work.

505.10Field Painting. Steel structures shall be cleaned and field painted

according to Articles 506.07 and 506.10.

505.11Reserved

505.12Method of Measurement. All structural steel shown on the plans will

be included for payment unless it is specifically included with a separate pay item. All other structure items, unless they are included with separate pay items or specified as included into other items, will be included as structural steel, and the weight will be calculated based upon their actual density (mass).

The Contractor performing the erection shall furnish the erection bolts and pins, and also pilot and driving nuts when required. The Contractor performing the fabrication shall furnish all fasteners, washers, shipping bolt, and fitting-up diaphragms when required.

When minor items of structural steel are specified for payment by weight, the weight used will be the measured weight (mass) of the fabricated structural steel furnished. No measurement will be made or allowed for the weight (mass) of field weld material. The structural steel will be measured in pounds (kilograms) using the approved shipping weight (mass) or by measuring on approved platform scales. When the plan quantities of minor items of structural steel, such as expansion dams on concrete bridges or miscellaneous steel for the repair of existing structures, is approximately 10,000 lb (4500 kg) or less, the method of measurement for payment will be according to Article 202.07(a) unless a weigh ticket is provided.

Cleaning and Painting New Steel Structures Art. 506.03 367

505.13Basis of Payment. Structural steel furnished and erected in place will

be paid for at the lump sum price for FURNISHING AND ERECTING STRUCTURAL STEEL.

Fabricated structural steel furnished and delivered will be paid for at the lump sum price for FURNISHING STRUCTURAL STEEL.

Storage and care of the fabricated steel by the fabrication Contractor beyond the specified storage period, will be paid for at the contract unit price per calendar day for STORAGE OF STRUCTURAL STEEL if a pay item is provided for in the contract, or will be paid for according to Article 109.04 if a pay item is not provided in the contract.

Erected structural steel and other materials fabricated under this item will be paid for at the lump sum price for ERECTING STRUCTURAL STEEL.

If alterations or deductions to the work specified in the aforementioned lump sum items are ordered by the Engineer, the Contractor shall accept payment for any increase or decrease in the amount of structural steel and other materials according to Article 104.02(a). The unit price used for the adjusted work will be determined by dividing the lump sum price bid for the item by the Engineer’s calculated weight as shown on the contract plans. No adjustment in this plan weight will be allowed in calculation of the unit price for the adjusted work. If the weight (Mass) in pounds

the Engineer amounts to a change exceeding 0.5 percent of the Engineer’s calculated weight as shown on the contract plans or 3000 lb (1360 kg), whichever is larger, the unit price used for the increased or decreased amount of structural steel shall be agreed upon by the Contractor and Engineer.

When specified, minor items of structural steel furnished and erected complete in-place will be paid for at the contract unit price per pound (kilogram) for FURNISHING AND ERECTING STRUCTURAL STEEL.

Stud shear connectors that are to be field welded to the top flanges of beams or girders will be paid for at the contract unit price per each for STUD SHEAR CONNECTORS.

SECTION 506. CLEANING AND PAINTING NEW STEEL STRUCTURES

506.01Description. This work shall consist of the cleaning and preparation

of new steel surfaces, and the furnishing, application, and protection of the paint coatings. The paint system shall be as shown on the plans and as specified herein.

506.02Materials. Structural steel coatings shall be according to

Section 1008. All coating materials to be used on an individual structure shall be produced by the same manufacturer.

506.03Submittals . A minimum of 30 days prior to shop or field painting, the

Contractor shall submit the following for the Engineer’s review and acceptance: applicable plans, certifications, and information. Painting shall not commence until the submittals are accepted by the Engineer.