1605 - REINFORCING STEEL SPLICES
1600-12 Section 1605
REINFORCING STEEL SPLICES 1605.1 DESCRIPTION This specification covers devices and systems for splicing steel bars for concrete reinforcement. Thermomechanical splices are produced by a process that introduces molten filler metal into an annular space around the bars created by a high strength st eel sleeve of larger diameter than the bars. Make the mechanical splices with any mechani cal device or system which will meet the physical requirements cited below. 1605.2 REQUIREMENTS When tested in tension, develop all splices to at least 125% of the minimum yield strength specified for the bars being spliced. After loading in tension to 30 ksi then relaxing to 3 ks i, the total slip of the bar within the splice sleeve shall not exceed 0.01 inch for #14 bars and smaller, and 0.03 inch for #18 size bars. Displacements will be measured between gage points clear of the splice sleeve. For those splicing systems to be prequalified in the “fatigue resistant” group, provide splices capable of withstanding a load range of 12 ksi (3 ksi to 15 ksi, tension) for a minimum of 1,000,000 cycles. Prepare and mount splices on bars in a fabricator's shop for ship ment to the project that meet SECTION 1601 including prequalified plant status. 1605.3 TEST METHODS Splicing devices or systems will be tension tested according to the procedures of AASHTO M 31, “Deformed and Plain Carbon Steel Bars for Concrete Reinforcement” and slip tested according to subsection 1605.2 . 1605.4 PREQUALIFICATION Prepare 3 fully assembled test specimens each for bar sizes number 4, 6 and 8, and forward them to the Engineer of Tests along with the following information: Name, address and telephone number of the manufactur er. Include the name of the preferred contact person. Brand name of the splice. Type and description of the splice. Information regarding recommended usage and splicing instructions. Material Safety Data Sheets (if applicable). For those splicing systems to be prequalified in the “fatigue resistant” group, submit test results from an independent testing laboratory demonstrating that the splice meets the fatigue requirements described above. Test splices for #4, #8, and # 11 size, Grade 60 reinforcing steel. These sizes represent the small, medium, and large sizes common in construction. Exceptions to the bar sizes specified above ma y be authorized by th e Engineer of Tests. The samples provided will be tested to destruction and test reports prepared. During testing, the Engineer of Tests will determine if operator prequalification is require d for field and/or fabricator shop splicing, and enter that information on the test reports. The test reports and the information supplied will be reviewed by the Bureau Chief of Construction and Materials. The manufacturer will be a dvised as to whether or not the product is prequalified. The Bureau of Construction and Materials will mainta in a list of prequalified splicing systems. Products will remain prequalified as long as the manufacturing pr ocesses remain unchanged, a nd field experience indicates that the product functions appropriately. Changes in manufacturing processes require new prequalification testing. Failure of the product to function appropriately in the fi eld will be cause for removal from prequalified status. Products removed from prequalified status will be consid ered for requalification if the manufacturer can provide 1605 - REINFORCING STEEL SPLICES
1600-13 evidence that the cause of failure has been positively identified, and necessary changes and quality control measures
have been implemented to eliminate that cause. Complete prequalification testing will be required for products that have been removed from prequalified status. 1605.5 BASIS OF ACCEPTANCE Prequalification as specified in subsection 1605.4 . Receipt and approval of a Type C certification as specified in DIVISION 2600 . Satisfactory results of testing by lot during construction, as outlined in DIVISION 700 . Samples submitted should be fully assembled in the field by personnel that will be performing the assembly operation. 1606 - STRAND FOR PRESTRESSED CONCRETE
1600-14 Section 1606
STRAND FOR PRESTRESSED CONCRETE 1606.1 DESCRIPTION This specification covers 7-wire, non-coated steel strand for use in pre-tensioned, pre-stressed concrete construction. 1606.2 REQUIREMENTS Provide wire strand for use in bonded and pre-tensioned concrete that complies with ASTM A 416. Provide low relaxation, Grade 270 strand unless otherwise specified. Store strand provided under this specification under conditions which maintains the strand in a dry condition and not in direct contact with the soil. When properly stored, the strand may remain in storage for a period not to exceed 6 months from the date of delivery to the pre-stress concrete production plant. Strand in storage in excess of 6 months must be re-tested by the manufacturer or an independent laboratory and a new certification issued before using it. 1606.3 TEST METHODS Test material as specified in ASTM A 416. 1606.4 PREQUALIFICATION None Required. 1606.5 BASIS OF ACCEPTANCE Acceptance of strand provided unde r this specification will be based on satisfactory results of tests conducted at the MRC on samples repr esenting each lot of material. 1607 - STRUCTURAL STEEL
1600-15 Section 1607
STRUCTURAL STEEL 1607.1 DESCRIPTION This specification governs the structural steel shapes, plates, bars, and bearing pins utilized for construction purposes. 1607.2 REQUIREMENTS
a.General. Dimensions, standard ASTM/AISC shapes, a nd specific fabrication requirements are as specified in the Contract Documents. Property requirements for the base steel are governed by the classification, designation, or grade of steel specified in the Contract Documents and in accordance with subsection 1607.2b . If a steel component is utilized in a fracture critical applicatio n, this must be designated in the Contract Documents according to the provisions of AASHTO M 270 inclusive of Su pplementary Requirement S84.
b.Structural Steel.
1.Provide steel that complies with AASHTO M 270 or ASTM A 709. Miscellaneous structural items may utilize ASTM A 36 or A 500; etc., but material change s to the Contract Documents require the approval of the State Bridge Office or the Bureau of Construction and Ma terials, Operations Engineer . When AASHTO M 270 is specified, and unless shown otherwise in the Contract Documents, the requirements for toughness testing, Zone 2 or Zone 3 level as specified in the Contract Documents, are mandatory whether the steel component is subject to tensile stress or utilized in a fracture critical application or not. When ASTM A 709 followed by the letter “T” or “F” and a temperature zone number is specified, the supplementary requirements for toughness described above for AASHTO M 270 are required.
2.Steel component edges that ar e produced by methods, such as mechanical shearing, that induce significant residual stress fields are to be stress relieved by machining not less than ¼ inch of material from the edge if the component is over 5/8 inch in thickness and subject to a calculated stress field. Fabrication procedures that produce low radius edge intersections are to have thes e stress concentration effects reduced by a fillet at the intersection of not less than 1 inch radius in accordan ce with the requirements and procedures of AASHTO/AWS D1.5. Discontinuities such as seams, rolling laps, tears, gas porosity etc. observed in steel components and weldments are subject to the detecti on methods, acceptability criteria, repair methods and procedures, and other requirements of AASHTO/AWS D1.5. Unless specified otherwise, steel components and fabrications are subject to AASHTO/AWS D1.5 for the quality of the final product. In addition, all structural steel components are subject to the quality requirements of ASTM A 6 throughout the fabrication process.
3.Produce bearing pins from steel that complies with ASTM A 108, SAE 1018, or subsection 1607.2b.(1) unless specified otherwise in the Contract Documents.
c.Structural Steel (Merchant Quality). This is a hot-rolled carbon steel in shapes or bars for use in non- critical parts of a structure or facility. It must be su itable for moderate cold bending, moderate hot forming, punching and welding, and capable of serving it’s intended purpose. 1607.3 TEST METHODS Conduct all tests required by the applicable AASHTO, ASTM, AISC, AWS, or other component or material specifications of subsection 1607.2b . 1607.4 PREQUALIFICATION Not applicable. 1607.5 BASIS OF ACCEPTANCE
a.Structural Steel . Submit for approval a Type A certification (certified mill test report), as specified in
Division 2600 — , that governs the analysis of all ba r steel heats delivered to the project.
1607 - STRUCTURAL STEEL 1600-16
b.Structural Steel (Merchant Quality) . Acceptance will be based on vi sual inspection for condition and compliance with dimensional requirements.
c.The final disposition of steel components provided th rough this specification will be completed at the final destination as the result of inspection by field personnel for the quality of workmanship, the delivery condition, compliance with dimensional requirements and receipt. Cert ain fabricated structural components may also require inspection during the production process at the fabrication facility. 1608 - STRUCTURAL STEEL TUBING
1600-17 Section 1608
STRUCTURAL STEEL TUBING 1608.1 DESCRIPTION This specification governs cold and hot formed welded and seamless steel structural tubing. This includes round, square, rectangular, or special shape structural tubing, tapered or nontapered, for welded, riveted, or bolted construction of bridges, buildings, and general applications. 1608.2 REQUIREMENTS
a.General .
1.Unless specified otherwise in the Contract Documents, welds in tubing and structures fabricated from tubing are to comply with AWS D1.1. Circumferential weld s and longitudinal welds within the area of a slip joint are to exhibit complete joint penetration. Other long itudinal welds are permitted partial joint penetration as a percentage of the governing plate thickness. This value is not permitted to be less than 60% for a plate thickness of 0.4 inch or less and not less than 80% for a plate thickness greater than 0.4 inch. Discontinuities such as hot and cold cracks, craters, undercut, gas porosity, inclusions, etc. observed in welds are subject to the detection methods, acceptability criteria, repair methods and procedures, and AW S D1.1. Nonstandard or special shape tubing is to comply with the design specified in the Contract Documents.
2.If not governed by the component specification, when corrosion protection coatings are specified for tubing and tubing structures, these components are to be zinc coated by hot dip galvanizing after fabrication in compliance with ASTM A 123, Thicknes s Grade 85. Aluminum coating appli cation after fabrication is acceptable when permitted and regulated by the specification that governs the component. Grade 85 should still be a valid designation.
b.Materials Specifications. Cold formed welded and seamless stru ctural steel tubing .............................. ASTM A 500 Hot formed welded and seamless struct ural steel tubing ............................... ASTM A 501 1608.3 TEST METHODS Conduct all tests required by the applicable ASTM, AWS, or other component or material specifications of subsection 1608.2 . Coating thickness may be measured by any one of the methods specified in ASTM B 633 and by eddy current methods, ASTM B 244, provided that appropriate calibration procedures and standards have been applied. The magnetic induction and eddy current methods are nondestructive in nature and are preferred. Destructive techniques, i.e., coating remova l, may be utilized as referee methods. 1608.4 PREQUALIFICATION Not applicable. 1608.5 BASIS OF ACCEPTANCE Submit for approval to the proj ect Engineer and Materials Regional Laboratory a Type A certification (certified mill test report), as specified in DIVISION 2600 , that governs the analysis of all heats delivered to the project. Inspection, and testing when applicable, by field personnel of steel structural tubing and structures fabricated from this tubing for compliance with co rrosion protection coating thickness, weld quality, and dimensional requirements. The final disposition of tubing and structures fabricated from tubing will be completed at the final destination as the result of inspection for the quality of workmanship, the delivery condition. Certain fabricated tubing and tubing structures may also require inspection during the production process at the fabrication facility. 1609 - STEEL PILING AND PILE POINTS
1600-18 Section 1609
STEEL PILING AND PILE POINTS 1609.1 DESCRIPTION This specification governs structural steel piles, steel sh ells to be utilized as forms for in situ cast concrete piles, steel sheet piling, and fabricated or cast steel pile points. 1609.2 REQUIREMENTS
a.General. Dimensions, standard ASTM/AISC shapes, pipe and tubing sizes, weights, wall thickness, and specific fabrication requirements are as specified in the C ontract Documents. Comply with nationally accepted size standards whenever possible. Property requirements for the base steel are governed by the classification, designation, or grade of steel specified in the Contract Documents and with subsection 1609.2b.
b.Materials Specifications.
1.Unless specified otherwise, provide steel pile s that comply with the ASTM/AISC standard shape dimensions and ASTM A 6. The majority of the AISC shap es are also governed by the ASTM specification, in that instance, the ASTM requirements prevail. Unless specifi ed otherwise, provide steel that complies with ASTM A 709 Grade 50 or ASTM A 572 Grade 50 . As a minimum, each pile section must have the heat number durably affixed to it.
2.Steel shells with respect to their longitudinal dimension may be of a uniform or tapered section, fluted, helix corrugated, or a non-deformed surface round pipe. Pipe may be seamless, electric resistance welded longitudinally, or welded in a helix pattern by gas metal arc welding (GMAW) or other acceptable meth od. Furnace welding is not permitted. Provide pipe or pipe piles for shells that complies with ASTM A 252 Grade 3. Unle ss specified otherwise, provide steel for fluted and corrugated shells that complies with ASTM A 568 cold rolled carbon steel sheet SAE 1010, maximum carbon level. The dimensional and weight tolerances of ASTM A 252 ap ply to all steel shells with the diameter of fluted and helix corrugated shells defined by the flute or helix crown diameter. Specify wall thickness in thousandths of an inch. The degree of taper for tapered shells is as defined in the Contract Documents with the outside diameter at any location as previously defined. Any completed shell, with point, is to be of sufficient ri gidity so as to as to retain the original shape profile, resist the soil pressure, and not permit the influx of water afte r it and the adjacent shells have been driven into place. As a minimum, each pile section must have the heat number durably affixed to it.
3.Provide steel sheet piling that complies with AA SHTO M 202. As a minimum, each section must have the heat number durably affixed to it.
4.Pile points may be fabricated or cast from steel as specified in the Contract Do cuments. For steel piles, provide only cast steel points that comply with ASTM A 148, Grade 80-50. For steel sh ells, fabricate points out of steel that complies with ASTM A 36 or provide cast steel points that comply with ASTM A 27, Grade 65-35. Other steels and fabrication procedures may be used if granted prior approval by the KDOT. Submit shop drawings that provide detailed dimensions, steel designation, point attachment methods, and any other pertinent information to the KDOT for approval. As a minimum, each point must have the heat or lot number durably affixed to it. 1609.3 TEST METHODS Conduct all tests required by the applicable AASHTO, ASTM, AISC, or other component or material specifications of subsection 1609.2b . 1609.4 PREQUALIFICATION Not applicable. 1609.5 BASIS OF ACCEPTANCE Submit for approval a Type A certification ( certified mill test report), as specified in DIVISION 2600 , that 1609 - STEEL PILING AND PILE POINTS
1600-19 governs the analysis of all heats delivered to the project. Component s are to be identified according to subsection
1609.2b . The final disposition of structural steel pile sections and points provided through this specification will be completed at the final destination as the result of inspection by field personnel for the quality of workmanship, the delivery condition, the condition after being driven, co mpliance with dimensional requirements, receipt and approval of the associated required documentation, and proper identification of the components. 1610 - STEEL FOR BRIDGE DRAIN SYSTEMS
1600-20 Section 1610
STEEL FOR BRIDGE DRAIN SYSTEMS 1610.1 DESCRIPTION This specification governs steel drainage systems applied to bridges. 1610.2 REQUIREMENTS
a.General. The drainage system design, dimensions, method of corrosion protection, and specific fabrication requirements are to be as specified in the Contract Documents. Each method of corrosion protection dictates the use of certain steels. Only 1 method of corrosion protection is allowed for a structure. Property requirements for the steels and components are governed by the classifications, designations, or grades of steel, and the component specifications de signated in the Contract Do cuments and in accordance with subsection 1610.2b .
b.Material Specifications .
1.When it is specified that corrosion protection be provided by zinc coatings applied by hot dip galvanizing, identified as HDG, use structural steel and pi pe that complies with ASTM A 36 and A 53 respectively. The testing requirements of DIVISION 1600 for A 53 pipe are not required. Co at the pipe with zinc in accordance with A 53. Furnace welded pipe is not acceptable and the hydrostatic and flattening tests are not required. Coat components produced from structural steel and or pipe with zinc by hot dip galvanizing, preferably after fabrication, in compliance with ASTM A 123. When coating by this method after fabrication is not practical, protect all areas where the coating is removed by welding or other procedures by application of a zinc or zinc alloy coating as specified in DIVISION 1800 . Thoroughly clean the damaged areas before application of the coating.
2.When it is specified that corrosion protection be provided by copper bearing weathering steels, identified as CBW, use structural steel and pipe that complies with ASTM A 242 or A 588 and ASTM A 618, Grade II, respectively. The minimum accep table copper content is 0.20%.
3.When it is specified that corrosion protection be provided through the use of stainless steels, identified as SST, use basis stainless structural steel and pipe that complies with ASTM A 240, AISI/SAE designations 302, 304 or 305, or ASTM A 358, Class 2, Grade 304 and A 312 respectively. Hydrostatic testing is not required. Weld stainless steels according to the procedur es of the applicable specification in order to avoid cracking and weld area sensitization to corrosion. 1610.3 TEST METHODS Conduct all tests required by the applicable ASTM or other component or material specifications of subsection 1610.2b . Measure the coating thickness by any one of the methods specified in ASTM B 633 and by eddy current methods, ASTM B 244, provided that appropriate calibration procedures and standards have been applied. The magnetic induction and eddy current methods are nondestructive in nature and are preferred. Destructive techniques, i.e., coating remova l, may be utilized as referee methods. 1610.4 PREQUALIFICATION Not applicable. 1610.5 BASIS OF ACCEPTANCE Submit for approval to the Regional Materials Laborato ry a Type A certification (certified mill test report), as specified in DIVISION 2600 , for all drainage system components, excluding pipe, when the HDG or CBW corrosion protection method is specified and all components, including pipe, when the SST method is specified. Receipt and approval of a Type D certification as specified in DIVISION 2600 for pipe when the HDG or CBW corrosion protection method is specified. Inspection and testing by field personnel of all co mponents for compliance with dimensional requirements for all drainage system components and corrosion protection coating thickness when the HDG protection method is specified. Coating thickness is to be measur ed according to any of the procedures of subsection 1610.3 . The final disposition of all drainage system component s will be completed at the final destination as the result of inspection for the quality of workmanship and the delivery condition. 1611 – PIPE FOR SONIC TESTING
1600-21 Section 1611
PIPE FOR SONIC TESTING 1611.1 DESCRIPTION This specification governs the pipe used for sonic testing as part of the construction of drilled shafts as shown in the Contract Documents. 1611.2 REQUIREMENTS Provide 2-inch diameter steel pipe that complies with ASTM A 53 or ASTM A 500, Grade B, Standard Weight. Provide clean pipe (both intern al and external surfaces) w ith watertight joints. If any lacquer or other coating is present, sand blast the pipe prior to installation into the rebar cage. The internal joints shall be flush. Provide screw-on watertight shoes, couplers and caps for the pipes. As an alternative, provide clean, non-threaded pipe , and provide smooth shoes, couplers and caps. Fillet weld each seam. 1611.3 TEST METHODS Test according to the requirements of subsection 1611.2 . 1611.4 PREQUALIFICATION Not applicable. 1611.5 BASIS OF ACCEPTANCE Receipt and approval of a Type D certification as specified in DIVISION 2600 . The final disposition of all components will be complete d at the final destination as the result of inspection for the quality of workmanship and the delivery condition. 1612 - GRAY-IRON CASTINGS
1600-22 Section 1612
GRAY-IRON CASTINGS 1612.1 DESCRIPTION This specification governs gray-iron castings that are subject to strength requirements. 1612.2 REQUIREMENTS
a.Physical. The cast alloy is to comply with AASHTO M 105, Class 30B.
b.Dimensions. The finished cast products are to comply with the dimensional requirements in the Contract Documents.
c.Finish.
1.Provide all the cast products in the as-cast and as-machined condition.
2.Weld repairing of casting flaws will not be pe rmitted without the express written consent of the KDOT. 1612.3 TEST METHODS Tension testing of specimens representative of the cas t products is mandatory. Perform the testing in accordance to AASHTO M 105. Any additional tests will be according to the agreem ent procedures of AASHTO M 105 and the associated methods and requirements. 1612.4 PREQUALIFICATION Not applicable. 1612.5 BASIS OF ACCEPTANCE Submit for approval a Type A certification ( certified mill test report), as specified in DIVISION 2600 , that governs the analysis of all he ats delivered to the project. The KDOT reserves the right to call for and test sp ecimens from certified lots to verify the certification results. Specimens may be cast test bars from the manufacturer or sections cut from actual castings if test bars are not available, or there is reason to suspect their validity. 1613 - MALLEABLE CAST IRON PRODUCTS
1600-23 Section 1613
MALLEABLE CAST IR ON PRODUCTS 1613.1 DESCRIPTION This specification governs products for various applications cast from malleable iron. 1613.2 REQUIREMENTS
a.General. Provide castings that comply with the design, dimensions, requirement for corrosion protection, and specific fabrication requ irements specified in the Contract Do cuments. Unless corrosion protection is specified, the cast products are to be provided in the as-cast and as-machined condition.
b.Material Specifications.
1.Provide ferritic malleable iron castings that comply with ASTM A 47. Weld joining or repair of these castings is permitted only with prior approval of the KDOT and must be in compliance with ASTM A 47.
2.When corrosion protection is specified, zinc coat the castings by the hot dip galvanizing process in compliance with ASTM A 47, Supplementary Requirement S5. 1613.3 TEST METHODS. Conduct all tests required by the applicable ASTM specifications of subsection 1613.2b . Measure coating thickness by any one of the methods specified in AS TM B 633 and by eddy curr ent methods, ASTM B 244, provided that appropriate calibration procedures and standards have been applied. The magnetic induction and eddy current methods are nondestructive in nature and are preferred. Destructive techniques, i.e., coating removal, may be utilized as referee methods. 1613.4 PREQUALIFICATION Not applicable. 1613.5 BASIS OF ACCEPTANCE. Receipt and approval of a Type D certification as specified in DIVISION 2600 . Inspection and testing by field personnel of all co mponents for compliance with dimensional requirements and corrosion protection coating thickness when corrosion protection is specified. Coating thickness is to be measured according to any of the procedures of subsection 1613.3 . The final disposition of all components will be complete d at the final destination as the result of inspection for the quality of workmanship and the delivery condition. 1614 - CAST STEEL PRODUCTS
1600-24 Section 1614
CAST STEEL PRODUCTS 1614.1 DESCRIPTION This specification governs products fo r various applications cast from steel. 1614.2 REQUIREMENTS
a.General. Provide castings that comply with the design, dimensions, and specific fabrication requirements as specified in the Co ntract Documents. Provide the products in the as-cast and as-machined condition.
b.Material Specifications. The steel castings provided through this specification are to comply with ASTM A 27. Unless specified otherwis e, annealed Grade 65-35 is required with the Class as specified on the Contract Documents. Comply with ASTM A 27 fo r all weld joining or repair of these castings. 1614.3 TEST METHODS Conduct all tests required by the applicable ASTM specifications of subsection 1614.2b . 1614.4 PREQUALIFICATION Not applicable. 1614.5 BASIS OF ACCEPTANCE Receipt and approval of a Type D certification as specified in DIVISION 2600 . The KDOT reserves the right to request and test specimens from delivered casting lots to verify specification compliance. Specimens may be cast test bars from the manufacturer or sections removed from castings if test bars are not available, or th ere is reason to suspect their validity. The final disposition of all castings will be completed at the final destination as the result of inspection for the quality of workmanship and the delivery condition. 1615 - ANCHOR BOLTS FOR STRUCTURAL USES
1600-25 Section 1615
ANCHOR BOLTS FOR STRUCTURAL USES 1615.1 DESCRIPTION This specification governs the threaded and non-th readed fastener components utilized for anchoring structural components to a concrete foundation or base. 1615.2 REQUIREMENTS
a.General. Fastener components and coatings governed through this specification must comply with subsection 1615.2b unless specified otherwise in the Contract Documents. For threaded fastener components, comply with the thread series requirements of ANSI/ASME B1.1 Coarse Thread Series, with a tolerance class that accommodates the corrosion protec tive coating when applicable.
b.Material Specifications.
1.Provide externally threaded steel rods or anch or bolts that comply with AASHTO M 314 with the thread series as denoted in subsection 1615.2a . Provide cut or rolled threads for bridge bearing applications. Provide rolled threads for all other applications. The Grade and coating for corrosion protection is dictated by the intended application and specified in the Contract Documents. Provide nuts intended for use with these anchor bolts that comply with ASTM A 563 inclusiv e of the Appendices. They also must be compatible with the strength requirements for the Grade of anchor bolt specified accordi ng to the guidelines of ASTM A 563 for the Property Class and design style of the nut. All nuts must comply w ith their respective Property Class requirements of ASTM A 563. Plain, or flat, washers for use with these fastener components must comply with ASTM F 436. The washer type and series are determined by the intended application.
2.Provide swedge anchor bolts with deformations that comply with the following requirements. Depth - no more than 1/8 inches. Radius – not less than ½ inches. No more than one deformation occurring in any plane perpendicular to the shaft of the bolt. At least one deformation within each 1 inch length of bolt. Adjacent deformations shall be out of phase by a minimum of 90 degrees.
3.If not governed by the component specification, when corrosion protection coatings are specified for fastener components, zinc coat these components in compliance with ASTM F 2329 for hot dip galvanizing or by the mechanical deposition of a zinc coating in compliance with ASTM B 695, Class 50. Aluminum coating is acceptable when permitted and regulated by the specification that gove rns the component. 1615.3 TEST METHODS Conduct all tests required by the applicable AASHTO, ASTM, ASME, ANSI, or other component or material specifications of subsection 1615.2b . Measure the coating thickness by any one of the methods specified in ASTM B 633 and by eddy current methods, ASTM B 244, provided that appropriate calibration procedures and standards have been applied. The magnetic induction and eddy current methods are nondestructive in nature and are preferred. Destructive techniques, i.e., coatin g removal, may be utilized as referee methods. 1615.4 PREQUALIFICATION Not applicable. 1615.5 BASIS OF ACCEPTANCE Submit for approval a Type A certification (certified mill te st report), as specified in DIVISION 2600 , for all fastener components. In the event subsection 1615.5a cannot be complied with, submit samp les representative of the lot(s) and heat(s) of the components and materials provided to the Engineer of Tests for testing. These samples must comply with subsection 1615.2 . Inspection by field personnel of all fastener components for compliance with corrosion protection and dimensional requirements. The final disposition of fastener components will be completed at the final destination as the result of inspection for the quality of workmanship, the delivery condition. 1616 - STEEL FASTENERS
1600-26 Section 1616
STEEL FASTENERS 1616.1 DESCRIPTION This specification governs threaded and non-threaded fastener components and the requirements for their corrosion protection. 1616.2 REQUIREMENTS
a.General. Provide fastener components and coatings that comply with subsection 1616.2b unless specified otherwise on the Contract Documents. For threaded fastener components, comply with the thread series of ANSI/ASME B1.1 Coarse Thread Series, with a tolerance class that accommodates the corrosion protective coating when applicable.
b.Material Specifications.
1.Provide externally threaded steel fasteners intend ed for general applications that comply with ASTM A 307 inclusive of the Appendices. The property grade specified is to be dictated by the intended application, nominal size, and availability, however Grade A is recommended fo r most purposes. Provide nuts intended for use with these fasteners that comply w ith ASTM A 563 inclusive of the Appendices. Provide nuts that are also compatible with the Grade of externally threaded fastener according to th e guidelines of ASTM A 563 for the property grade and design style of the nut. Test all nuts for compliance w ith their respective property grade requirements of ASTM A 563 regardless of application. Provide plain, or flat, wa shers for use with these fasten er components that comply with ANSI/ASME B18.22M, Type A or Type B, and ASTM F 844. Determine the washer type and series by the intended application. When atmospheric corrosion resistant steel is required, all fastener assembly components are to be produced from weathering steel.
2.Provide externally thr eaded steel fasteners for app lications where high strength is a prerequisite that meet ASTM A 325 for Type 1, or Type 3 when the formation of a protective oxide coating is required for protection from atmospheric corrosion. Provide nuts intended for us e with these fasteners are to be of a property grade specified by ASTM A 325 that comply with ASTM A 563 inclusive of the Appe ndices. Provide nu ts that are also compatible with the Grade of externally threaded fasten er according to the guidelines of ASTM A 563 for the property grade and design style of the nut. Test all nuts for compliance with their respective property grade requirements of ASTM A 563 regardless of application. Pr ovide plain, or flat, washers for use with these fastener components as specified by ASTM A 325 and comply with ASTM F 436. Externally threaded steel fasteners that comply with ASTM A 490, magnetic particle inspection (MPI) requirement waived, and nuts that comply with ASTM A 194 may be utilized in lieu of A 325 and A 563 co mponents. When atmospheri c corrosion resistant steel is required, all fastener assembly components are to be produced from weathering steel.
3.Provide all high strength steel bolts, nuts, and wa shers that comply with the rotational capacity test requirements of the 3rd edition (with Interim Specifications) of the AASHTO LRFD Bridge Construction Specifications, Section 11.5.6.4.2. The rotational capacity test procedures, as developed by the FHWA, are presented in KT-MR11, Rotational Capacity Testing of High Strength Fasteners. (4) When specified, provide lock washers that comp ly with ASME B18.22.1. Determine the washer type and series by the intended application.
5.Provide Direct Tension Indicators (DTI) for high strength applications, or when specified in the contract documents, that comply with the requirements of ASTM F 959. Use “plain” Type 325 and Type 490 DTI’s with ASTM A 325 Type 1 and A 490 Type 1 structural bolts, respectively. Use “weathering steel” Type 325-3 and Type
490-3 DTI’s with ASTM A 325 Type 3 and A 490 Type 3 structural bolts, respectively. Incorporate circumferential indentations or edge notches on the exposed face of the DTI which are aligned
with feeler gage entry points. Indentations or notches sha ll be clearly visible after installation of the DTI, but not so large as to interfere with the function of the DTI. (6) Provide steel structural rivets that comply with ASTM A 502 for Grade 1 or Grade 2, or Grade 3 when the formation of a protective oxide coating is required for protection from atmospheric corrosion. Dimensions and design type are to be as specified for the intended application.
7.Miscellaneous fastener components not specifically addressed in this subsection are to comply with the applicable AASHTO, ASTM, ASME, ANSI, or other governing component or material specifications with the consensus of the component manufacturer and the KDOT. 1616 - STEEL FASTENERS
1600-27 (8) When corrosion protection coatings are specified for fastener components, provide components that are
zinc coated and in compliance with ASTM F 2329 for hot dip galvanizing or by the mechanical deposition of a zinc coating in compliance with ASTM B 695, Class 50. Fastener components of nominal size of less than 13 mm diameter may be zinc coated by an el ectrodeposition process. The coating is to be uniform, comply with ASTM B 633, and have a thickness in the range of 5 to 8 micrometers for use under mild to moderate service conditions, SC 1 to SC 2. Note that an electrodeposited zinc coating thic kness in excess of 8 micrometers may result in thread fit interference. Electrodeposited cadmium coating is also permitted when in compliance with ASTM B 766 and the same thickness range constraints as for electrodeposited zinc coating. Aluminum coating is acceptable when permitted and regulated by the specifi cation that governs the component.
9.In lieu of a separate nut, washer, and DTI, prov ide a combined nut and DTI assembly for use with high strength structural bolts. The nut component shall comply with subsection 1616.2b.(2) and the DTI component shall comply with subsection 1616.2b.(5) . Manufacture each lot of assemblies using a single DTI lot and a single nut lot. Identify assembly lots using the lot of the component DTIs. Unless the contract documents indicate otherwise, an F 436 washer need not be used when a bolt and combined nut/DTI assembly are used an d all of the following are satisfied: The fastener is used with a standard size hole. The bolt is not the turned fastener component. The combined nut/DTI manufacturer’s insta llation instructions and product literature demonstrate satisfactory performance w ithout the use of a hardened washer. The pre-installation verification testing demonstrates satisfactory performance without the use of a hardened washer.
10.Provide all high strength structural bolts an d combined nut/DTI assemblies that comply with the rotational capacity test requirements of subsection 1616.2b.(3) , modified to account for the flattening of protrusions on the DTI component of the assembly. 1616.3 TEST METHODS Conduct all tests required by the applicable AASHTO, ASTM, ASME, ANSI, or other component or material specifications of subsection 1616.2b . Coating thickness may be measured by any one of the methods specified in ASTM B 633 and by eddy current methods, ASTM E 376 (B 244 ma y also be useful as a technique guideline), provided that appropriate calibration procedures and standards have been applied. The magnetic induction and eddy current methods are nondestructive in nature and are preferred. Destructive techniques, i.e., coating removal, may be utilized as referee methods. Conduct rotational capacity testing on all coated and non-coated high strength threaded fastener component assemblies referenced in subsection 1616.2b(3) . 1616.4 PREQUALIFICATION Not applicable. 1616.5 BASIS OF ACCEPTANCE Submit for approval a Type A certification, as specified in DIVISION 2600 , for all fastener components provided through this specification. In addition, provide certifications for DTI’s showing the results of ASTM F 606 testing. A combined nut/DTI assembly require s a certification for each of its components. Compliance of samples of all fastener components utili zed for overhead lighting and signing, sign supports, bridge beam connections and splices, and any other applica tion considered relevant by the Engineer’s representative with subsection 1616.2b . Provide representative samples of the lot(s) and heat(s) of the components and materials, including combined nut/DTI assemblies (but not separate DTIs). Submit the samples to the Engineer of Tests for testing. Samples for testing are not required for fastener components used to attach sign panels to ground mounted sign supports nor for components used in break-away connections on ground mounted sign supports. The KDOT representative will inspect all fastener co mponents for compliance with corrosion protection, marking, and dimensional requirements. The final disposition of fastener components will be completed at the final destination as the result of inspection for the quality of workmanship, the delivery condition.
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 757–772 of 978.