740 – POLYMER CONCRETE OVERLAY REPAIR 700-146 (16) Finish the exposed edges at the ends of the bridge and at expansion joints to minimize bridge deck roughness.
17.Apply a bond breaker to all expansion joints.
18.Vacuum or broom excess aggregat e from the bridge deck after the pol ymer is sufficiently cured. If damage or tearing occurs, stop brooming or vacuuming and allow additional curing time. See subsection 740.3g. for polymer overlay material curing guidelines.
f.Face of Curbs, Barriers , and Corral Rail Posts. Use a paintbrush or roller to apply the polymer resin on the face of curbs, barrier s, and corral rail posts. On bridges with a corral rail, apply the polymer resin to the front face and adjacent sides of all posts. On bridges with curbs apply the polymer resin to the top of the curb face. On bridges without curbs apply the polymer resin to the edge of the deck. On bridges with continuous concrete barrier rails, apply the polymer resin to the first break in the geometry of the barrier or a minimum of 6 inches , uniform. Protect areas above the break line (or minimum of 6 inches) from resin. Apply so the top threshold of the resin follows a uniform line along the rail. This work is subsidiary to the bid item Single-Layer Polymer Concrete Overlay. Apply primer (if required) and polymer to the curb or barrier as each of the overlay applications are performed.
g.Curing. Polymer concrete material curing guidelines.
1.Epoxy. Follow TABLE 740-2 . TABLE 740-2: EPOXY OVERLAY CURE TIMES Average Temperature of Overlay Components, °F
55-59 60-64 65-69 70-74 75-79 80-85 85+
Minimum Cure Time (hours) 6.5 6.5 5 4 3 3 3 Cure the epoxy polymer concrete overlay for a minimum of 8 hours if the air temperature falls below 55 F during the curing period.
2.Methyl Methacrylate. Follow TABLE 740-3 . TABLE 740-3:METHYL M ETHACRYLATE CURE TIMES Course Ambient Temperature °F
30-40 40-50 50-60 60-70 70-80 80-90
Primer 30 25 22 20 15 10 Polymer Overlay 50 40 35 30 25 20 Sealer 35 30 25 22 20 15 Methyl Methacrylate cure times can be adjusted (longer or shorter) by changing the amount of hardener in the mix.
3.Polyester. Proportion polyester such that the cure times are be tween 30 and 120 minutes. Accelerators and inhibitors may be required to achieve proper set time s. Proportion all materials as recommended by the material manufacturer/supplier.
4.Plan and perform the work in such a way as to provide for the minimu m curing times specified.
h.Testing. Polymer Concrete Overlay Bond Evaluation for Portland cement concrete patches, polymer concrete patches and existing polymer concrete ove rlay surfaces as outlined in KT-70, Part V.
1.Place a polymer concrete test pa tch of not less than 0.5 square yards per lane or planned completed day’s work whichever is smaller. Submit a sequence plan to the Engineer. Test patches shall be full depth, placed by the normal construction sequence. Test patches should be representative of the work being performed.
2.Perform a minimum of 4 pull-off tests on each patch as outlined in KT-70, Part V. 740 – POLYMER CONCRETE OVERLAY REPAIR 700-147 (3) Final acceptance will be based on the following re sults of the test outlined in KT-70, Part V: Type 1 – Failure in the concrete at a depth greater than or equal to ¼ inch over more than 50% of the test area for 3 out of 4 tests in the test patch. Type 2 – Failure in the concrete at a depth less than ¼ inch over more than 50% of the test area for 3 out of 4 tests in the test patch. Minimum Tensile Rupture Strength of 250 psi from an average of 3 out of 4 tests on a test patch regardless of depth of failure.
4.If failure in the concrete is at a depth less than ¼ inch and the Minimum Tensile Rupture Strength is less than 250 psi, or the failure in the concrete is less than 50% of the test area, ad ditional surface preparation is necessary.
5.If failure is at the polymer to polymer bond and below 250 psi, more surface preparation of the existing polymer overlay or polymer concrete patches is necessary.
6.If failure is in the new or existing polymer overl ay (Type 4), remove the overlay and evaluate the material before proceeding with placement.
7.A failure in the concrete below 250 psi and greater than ¼ inch deep indicates weak concrete, not poor overlay bond. No additional su rface preparation is required.
8.Do not perform tensile adhesion tests when ambient or deck temper atures are above 85°F.
i.Correction of Unbonded or Damaged Areas On New Work. Repair new overlay areas discovered to be unbounded by tapping or chaining and areas where the overlay was damaged by the Contractor’s operation.
1.Saw cut the unbonded or damaged areas to the top of the concrete bridge d eck surface or the existing polymer concrete overlay surface, rem ove the unbounded or damaged overlay w ith small air tools (15-pound class maximum) or shot blasting.
2.Shot blast the existing concrete bridge deck surface or existing polym er concrete overlay surface of the unbonded area to remove contaminan ts, and replace the overlay according to standard placement procedures at no additional compensation.
j.Weather Limitations.
1.Epoxy. Do not place the polymer concrete overlay if the air temper ature is expected to drop below 55F within 8 hours of placement.
2.Methyl Methacrylate. Do not place any component of the polymer concrete overlay if the air or substrate temperature is at or expected to drop below 40 F during installation without inclusion of cold temperature additive at the dosage specified by methacrylate manufacturer/supplier’s mixing guide.
3.Polyester. Do not place any component of the polymer concrete overlay if the air or substrate temperature is at or expected to drop below 40 F during installation.
4.General. Do not place the polymer concrete overlay when the deck temperature will exceed 90 F. Do not place the polymer concrete overla y if gel time is less than 10 minutes. Polymer concrete overlay can be placed outside the specified temperature ranges with the approval of the Engineer and the material manufacturer/supplier. Discu ss changes to temperature limitations at the preconstruction conference. Submit changes, including a written statem ent from the material manufacturer/supplier recommending the changes, to the Engineer for approval. 740.4 MEASUREMENT AND PAYMENT The Engineer will measure polymer concrete overlay re pair areas by the square yard prior to placing the patch material. The measured pay quantity will be those ar eas sounded by the Engineer and marked as unsound or delaminated polymer concrete overlay. The Engineer will measure single-layer polymer concre te overlay by the square yard. The Engineer will measure the bridge roadway width and the bridge length from end of wear ing surface to end of wearing surface. Payment for "Polymer Concrete Overlay Repair" and "Single-Layer Polymer Concrete Overlay" at the contract unit price is full comp ensation for the specified work. 741 – CASED PILING 700-148 SECTION 741 CASED PILING 741.1 DESCRIPTION Construct and install a casing to enclose and isolate piling within a retaining wall mass. Brace, dewater, backfill and place steel cap plate on casing. BID ITEM UNITS Cased Pile Linear Foot 741.2 MATERIALS
a.Casing. Provide a casing with a diameter 12 inches larger than the diameter of the pile, and of sufficient thickness to carry the working stresses and loads imposed on the casing during construction. At a minimum, use 14-gage corrugated metal pipe (CMP) for the permanent casing. When specified, provide a permanent casing that is less than or equal to 1 inch out-of-round. The deviation of a chord from end to end shall be a maximum of 2 inches. The Engineer will accept the casing based on complian ce with the specified requirements, and visual inspection of condition.
b.Aggregate. Provide meeting the following requirements: Sieve Size Percent Retained by Weight 3/8" 0 - 20% No.8 40 - 80% No.100 98 - 100% Provide clean, naturally rounded (not crushed) aggregat e. Provide aggregate free of deleterious substances such as shale, with a maximum limestone content of 10%. Obtain the Regional Geologist’s approval of the aggregate, before installing it in the casing backfill system. Such approval could take up to 7 days. Aggregates covered by this subsection are accep ted based on the procedures described in subsection 1101.5 .
c.Cap Plate. Provide structural steel cap plate conforming to ASTM–A36 materials and galvanized according to ASTM 123. Fabricat e a round cap plate that is ¾-inch thick and 6 inches la rger in diameter than the casing which it covers. The cap plate will fit the profile of the pile being used so that there is a maximum of a ½- inch gap between the cap plate and the pile. Cut out the shap e of the pile into the cap plate, prior to galvanizing. Submit shop drawings according to SECTION 105 . 741.3 CONSTRUCTION REQUIREMENTS Prior to driving the pile, construct the cased pile by first pre-drilling a minimum of 5 feet into in-situ material at the location shown on the plans. Center the pre-drilled hole at the pile locations. Construct the pre-drilled hole 3 inches larger than the nominal diameter of the casing defined above. Locate and construct the casing according to the tolerances in subsection 704.3c . After driving the pile, install the casing over the p ile and embed into the predrilled hole. Plumb and center the casing with the pile. Install the cap plate to rest on top of the cas ing and center on the pile and the casing. Brace the casing to prevent movement during backfilling and retaining wall construction. Backfill casing with the aggregate to within 15 feet of the top of the pile; the remainder will be left open. 741.4 MEASUREMENT AND PAYMENT The Engineer will measure the cased pile by the linear foot. Payment for "Cased Pile" at the contract unit price is full compensation for th e specified work. Piling construction, measurement and payment will be handled under SECTION 704 . 742 – HEAT STRAIGHTENING 700-149 SECTION 742 HEAT STRAIGHTENING (IN-PLACE) OF DAMAGED STRUCTURAL STEEL 742.1 DESCRIPTION Use heat straightening to repair damaged sections of the existing structural steel beams and girders shown in the Contract Documents, or designated by the Engineer. B I D I T E M U N I T S Heat Straightening Repair Linear Foot 742.2 MATERIALS Provide materials that comply w ith the applicable requirements. Organic Zinc Primer ............................................................................................... SECTION 1802 Waterborne Acry lic Top Coat ................................................................................ SECTION 1806 Calcium Sulfonate Al kyd Paint System ................................................................. SECTION 1808 742.3 CONSTRUCTION REQUIREMENTS
a.General. Heat Straightening is a repair procedure in which a limited amount of heat is applied in specific patterns to plastically deformed regions of dama ged steel in repetitive cycles of heating and cooling to produce a gradual straightening of the member. A limited amount of force may be used to restrain the member from excessive out of plane movement during heating. Force is not the primary method of straightening. Procedures using forces that result in stresses over the yield stress of the material at the applied temperature, such as Hot Mechanical Stra ightening and Hot Working, are prohibited. The repair must be directly supervised by a person with successful experience in heat straightening repairs of comparable bridge structures. Provide the Engin eer with written documentation of past experience before beginning the repair work.
b.Equipment. Use an oxygen-fuel combination for heating. For fuel, use propane, acetylene or a similar fuel. Apply heat using either single or multiple orifice tips only. The maximum tip size is limited to 1 inch. Verify temperatures during heat straightening with temperature sensitive crayons, a pyrometer, or an infrared non-contact thermometer. Provide the heat indicati ng device, and make it availabl e to the Engineer at all times. Use either hydraulic or mechanical jacks, co me-alongs or other force application devices.
c.Application of Heat . Apply heat to the member w ith vee (triangular shaped) heats or line heats to the flange and with vee, line or strip heats to the web. The base of individual vee heats shall not exceed 10 inches. A series of heats applied consecutively to different el ements of the member at the same cross section is referred to as a heating pattern. Select heating patterns a nd sequences to match the type of damage and cross section shape. Do not heat the steel over 1100 F during heat straightening unless sp ecified otherwise in the Contract Documents. Heat the steel in a single pass following the heating pattern and allow cooling to 250 F prior to reheating. Water-cooling is not permitted. Shift vee heats along the zone of yielded material on successive heating patterns. Simultaneous vee heats are permitted provided that the clear spacing between vees is greater than the width of the plate element. Heating patterns other than those suggested in the Contract Documents may be used if approved by the Engineer. If no suggested heating patterns are provided in the Contract Documents, submit proposed heating patterns to the Engineer for approval.
d.Application of Jacking Forces. Only use jacking forces to restra in the members or elements against undesired movement associated with ex pansion during the cycles of applying heats. Place jacks to resist forces during the heating process. As the straightening occurs during cooling, the forces should be relieved. 742 – HEAT STRAIGHTENING 700-150 The maximum allowable jacking force for members may be calculated by a licensed Professional Engineer, in accordance with the met hods outlined in US DOT report no. FHWA-IF -99-004, “Heat-Straightening Repairs of Damaged Steel Bridges”, with calculations submitted for approval by the Bridge Office before work begins; or, the limit may be estimated in the field by limiting the jack ing force to the force require d to produce the following deflections on the unheated steel members. For 36 ksi Steel: max = 1/y max * (L/140)2 For 50 ksi Steel: max = 1/y max * (L/120)2 where: = The maximum deflection (in inches) between supports for a jacking force producing a maximum bending stress equal to ½ of the yield stress. For lateral displacements this would be the lateral deflection. ymax = The distance (in inches) from the centroid of th e steel section to the extreme fiber about the axis of bending. For lateral displacement of an “I” shaped beam this would be ½ of the flange width. L = The distance (in inches) between supports, fo r lateral displacements this is the distance between the cross frames/diaphragms in place during heat straightening. Do not increase the jacking force during heating or until the steel is cool to the touch between heats. Assume that the existing steel has a yield strength of 36,000 psi, unless specified otherwise in the Contract Documents. No deflection is allowed for other bridge members being used as supports for the jacking device. For repairs of local flange bending, the jacking force is limited to that which produces no deflection of the unheated flange.
e.Tolerances. Completed tolerances for straightness of the bottom flange are within ¼ inch of horizontal at the flange edge and ½ inch of horizo ntal sweep in 20 feet at the point of impact. The completed tolerances for the web are 1/100 th of the web depth or ¼ inch, whichever is greater, out of vertical alignment; and no more than ¼ inch of localized deviation as measured with a straightedge vertically and horizontally against the web. Meet these tolerances before attaching any cross frames. Do not for ce the member into position and then attach the cross frame to hold the member in position.
f.Crack and Gouge Repair. Grind smooth all nicks, gouges and scrapes. Arrest all web cracks by drilling a 1 inch hole at each end of each crack. Locate the end of each crack by dye penetrant, magnetic particle or other approved non-destructive testing method.
g.Inspection. After straightening is complete inspect the flanges for crack by dye penetrant, magnetic particle or other approved non-destruc tive testing method. The Engineer will w itness this testing. Remove minor (< ½ inch) cracks found by this inspection by grinding. Larg er cracks found will be revi ewed by the Engineer and repaired as directed by the Engineer. Any crack repair, unless shown in the Contract Documents, by methods other than grinding or drilling is considered Extra Work, SECTION 104 .
h.Painting. Restore the paint on the damaged portions of the beams, girders, cross frames and diaphragms, including paint damaged by the repair process. If the existing surface is a lead based paint system, clean the surfaces of loose mate rial and oil, then coat the cleaned surfaces with a calcium su lfonate alkyd paint system according to the manufacturer’s recommendations. If the existing surface is not a lead based paint system , sandblast the surfaces clean , then coat the cleaned surfaces with an organic zinc primer and waterborne acrylic top coat acco rding to "Repainting Existing Steel Bridges- Painting in Kind", SECTION 702 . As far as it is practicable, match the finish coat to the existing paint color. The Engineer is the final arbitrator of color match. 742 – HEAT STRAIGHTENING 700-151 742.4 MEASUREMENT AND PAYMENT The Engineer will measure the linear feet of primar y member that requires heat straightening repair. Inspection, non-destructive testing, crack and gouge repair, secondary member heat straightening and painting are subsidiary. Payment for "Heat Straightening Repair" at the contr act unit price is full compensation for the specified work. 743 – ROLLED BEAM DETOUR BRIDGE 700-152 SECTION 743 ROLLED BEAM DETOUR BRIDGE 743.1 DESCRIPTION Erect and Remove or Furnish the Rolled Beam Detour Bridge as shown in the Contract Documents. B I D I T E M S U N I T S Erect and Remove Rolled Beam Detour Bridge Lump Sum Furnish Rolled Beam Detour Bridge Lump Sum 743.2 MATERIALS Use material complying with the details shown in the Contract Documents. The Engineer will accept the material on the basis of compliance with dimensional requirements, condition, and visual inspection at the point of usage. 743.3 CONSTRUCTION REQUIREMENTS Construct the rolled beam detour bridge as shown on the Contract Documents. 743.4 MEASUREMENT AND PAYMENT The Engineer will measure the erect and remove rolled beam detour br idge and furnish rolled beam detour bridge by the Lump Sum. Payment for "Erect and Remove Rolled Beam Detour Br idge" and "Furnish Rolled Beam Detour Bridge" at the contract unit price is full compensation for the specified work. The Engineer will pay for Erect and Remove Rolled Beam Detour Bridge according to TABLE 743-1 . TABLE 743-1: PAYMENT FOR ERECT AND REMOVE ROLLED BEAM DETOUR BRIDGE Pay % of Contract Unit Price Milestone 75 Erection of the structure has been completed. 100 When the structure has been dismantled and all the pa rts to be returned have been properly inventoried and stockpiled at the storage site listed in the Contract Documents. 744 – STRUCTURAL STEEL FABRICATION - GENERAL 700-153 SECTION 744 STRUCTURAL STEEL FABRICATION - GENERAL 744.1 DESCRIPTION Shop fabricate the structural steel according to the Contract Documents. This specification applies to all welded steel structures or items covered by American Welding Society (AWS) D1.1-2010, “Structural Welding Code – Steel”, all welded aluminum alloy structures covered by the AWS D1.2-2014, “Structural Welding Code – Aluminum”, and all stainless steel items covered by the AWS D1.6-2007, “Structural Welding Code – Stainless Steel”. See SECTION 705 for the fabrication of structural steel for bridges on highway and public roads carrying vehicular traffic and the fiel d welding of structural steel to highway bridges. 744.2 MATERIALS
a.General. Provide materials that comply with the applicable requirements. Castings ................................................................................................................. DIVISION 1600 Structural Steel ...................................................................................................... DIVISION 1600 Structural Stee l Tubing .......................................................................................... DIVISION 1600 Steel For Bridge Drain Systems ............................................................................ DIVISION 1600 Welded Stud Shear Connectors ............................................................................. DIVISION 1600 Steel Fast eners ....................................................................................................... DIVISION 1600 Steel Pi pe ............................................................................................................... DIVISION 1600 Aluminum Alloys .................................................................................................. DIVISION 1600
b.Preliminary Shop Requirements.
1.Point of Fabrication. Within 10 business days after signing the contract, notify the appropriate KDOT office and the Bureau Chief of Construction and Materials in writing of the firm (name and location) that will fabricate the structure. Produce and fabricate all structural steel within the Continental United States (see SECTION 106.1 ).
2.Shop Drawings. The Contractor or fabricator must submit shop drawings of structural steel, structural aluminum alloys, and castings according to SECTION 105 . Do not perform any fabrication until the approved shop drawings are in the hands of the Inspector and fabricator, and the Engineer has authorized fabrication. Any purchase of materials before fabrication authorization is at the Contractor’s risk. Changes on approved shop drawings or contract plans are su bject to the approval of the Engineer. Notify the Engineer with a record of such changes. Submit revise d sheets of the same size as th e shop drawings originally submitted. Show approved welding procedure numbers in the tail of weld symbols on submitted shop drawings. Submit 2 copies of each procedure requiring approval to the Bureau of Construction and Materials. All weld procedures referenced in a set of shop drawings must be approved before the shop drawings can be approved. Provide a diagram on the shop detail plans giving sufficient dimensions for accurate fabrication and inspection of the structure. The Contractor is responsible for the correctness of the shop fit-up and field connections, even though the shop drawings have been approved by the Engineer. See SECTION 105 .
3.Notice of Beginning of Work. In order to provide inspection, notify the Engineer before beginning work in the shop. Give a minimum of 24 hours’ notice before beginning work in shops in the State of Kansas, and give a minimum of 7 calendar days’ notice before beginning work in shops in the contiguous United States.
4.Material Acceptance. Submit to the Bureau Ch ief of Construction and Mate rials, 1 copy of each mill test report for each heat number to be us ed before the layout, and use such steel in the fabrication of the structure. If no shop inspection is provided by KDOT, submit mill test reports (Type A certifications) in accordance with SECTION 2601 . Submit a fabricator’s guarantee indica ting that the attached certified mill test reports pertain to all heat numbers used in the structure, and all material complies wi th the Contract Documents. Include the following in the guarantee: 744 – STRUCTURAL STEEL FABRICATION - GENERAL 700-154 fabricator’s name; KDOT project number; structure or station number; fabricator’s purchase order number; list heat numbers; size and shape of pieces; number of pieces to be used for each size of each heat; and steel or aluminum alloy producer’s name and the ASTM or AASHTO designation for the material that is required in the Contract Documents. The guarantee must include the notarized signature of an official of the company who is authorized to legally bind the statement on the company’s behalf. All structural steel shall comply with the ASTM A 6 quality requirements until released for shipment. Dependent on the material being used, repair welding shall comply with the requirements of AWS D1.1, "Structural Welding Code - Steel" or AWS D1.2, “Structural Welding Code – Aluminum”, with the corresponding exceptions and additions noted later in this section, or AWS D1.6, “Structural Welding Code – Stainless Steel”. The term "mill" means any rolling mill or foundry where material for th e work is manufactured. When any ASTM or AASHTO steel is specified in the Contract Documents, the mill mu st certify that the material complies with the specified chemical an d physical requirements. The fabricator must obtain written pe rmission from KDOT to substitute a grade of steel or aluminum alloy that is not indicated in the Contract Documents fo r one that is shown in the Contract Documents.
5.Facilities for Inspection and Testing. During all hou rs of operation allow the Engineer free access to all parts of the work and the shop where fabrication is performed. Provide an enclosed office area for the exclusive use of the Engineer at the location of fabrication. The area must satisfy the requirements of a Field Office (Special) in SECTION 803 , except as modified below: Minimum floor area = 120 square feet; Single workbench or table - 30 inch by 8 feet (minimum dimensions); Desk - 30 inch by 5 feet, with drawers; Swivel desk chair with arm rests; Waste paper basket; and Storage/Filing cabinet with lock and key When directed by the Engineer, prom ptly repair or replace any damaged or non-functioning items. Provide parking near the office with direct accessibility to th e office and shop.
6.Test Specimens - Provide "all-weld-metal" tensi on specimens and specimens for other weld tests as directed by the Engineer. Preparation and possible shipment of specimens are subsidiary to the fabrication of the structure. (6.1) – Steel Bar, Plate, Shapes. When directed by the Engineer, prepare 4 inch by 24 inch test specimens of the base metal. Orient the specimen so the direction of rolling is according to the latest edition of ASTM A 6. (6.2) – Steel Tubes and Pipes, Aluminum Alloy Products – When directed by the Engineer, prepare base metal or product specimens of the dimensions specified by the Engineer.
c.Handling. Conduct the loading, transporting, unloading and storing of structural st eel to keep the metal clean, above ground and free from in jury. Use protective devices or so fteners to safegu ard plate edges. Store structural steel, either plain or fabricated, ab ove the ground on platforms, skids or other supports, and keep free from corrosion, dirt, grease and other foreign matter. Store girders and beams upright with sufficient support to prevent warping or change in design camber.
d.Shop Fabrication.
1.Identification. All pieces of all grades of steel and aluminum alloy us ed in fabrication of main members must bear the heat number assigned by the rolling mill. Preserve the heat number un til the Engineer advises the fabricator that the unit is acceptable for cleaning and painting. Id entify the grade of steel as specified in ASTM A 6.
2.Straightening Material. All mill material must be straight before being laid out for work. If straightening is required, do not injure the metal. H eat straightening must comply with AWS D1.1, "Structural 744 – STRUCTURAL STEEL FABRICATION - GENERAL 700-155 Welding Code - Steel" or AWS D1.2, “Structural Welding Code – Aluminum”, as applicable for the material being used. Submit the proposed heat straightening procedure to the Engineer for approval. Sharp kinks and bends are cause for rejection of the material. Steel mill material mu st not exceed dimensional tolera nces outlined in the latest edition of ASTM A 6. (3) Welding and Gas Cutting. Dependent on the mate rial be used, perform welding and gas cutting of structural steel and aluminum alloy according to the requ irements of the AW S D1.1, "Structural Welding Code - Steel" or AWS D1.2, “Structural Welding Code – Aluminum ”, with the corresponding exceptions and additions noted later in this section, or AWS D1.6, “Structural Welding Code – Stainless Steel”.
4.Finish. Neatly finish all work. Carefully and accurately shear and clip. Fabricate finished members true to line and detailed dimension, and free from twists, bends, open joints or other defects. (5) Welded Stud Shear Connectors. Apply welded st ud shear connectors to the de signated structural steel members during shop fabrication. If the circumstances warrant, and if the Engineer appr oves the Contractor’s procedures, welded stud shear connectors may be field applied. Approval is based on demonstrating to the Engineer’s satisfaction, that the Contractor can: remove any shop applied coating removed from the top flange without damaging the structural member; weld the stud shear connectors to the structural member; and blast clean and prime coat the top flange and stud shear connectors.
6.Shop Assembly for Final Inspection. Unless otherwise provided both in writing and shown on the approved shop drawings, assemble, securely support, adjust and maintain to proper line, grade, camber and suitable clearances all members. After the assembly is completely set up, the fabricat or’s quality control personnel must check blocking, sweep and bearing-to-bearing measurements prior to any checking by the Engineer.
7.Shop Painting. Prepare the structural steel su rfaces and shop paint the prepared surfaces according to SECTION 714 .
8.Shop Bolted Connections. Perform all bolting according to SECTION 712.
9.Overhead Sign Structures, Cantilever Sign Struct ures, Bridge Mounted Sign Attachments, High Mast Light Poles, Lighting and Traffic Signal Poles: (9.1) except as noted in (9.2), nondestructively te st 100% of all complete joint penetration (CJP) groove welds. (9.1.1) use Radiography Testing (RT) or Ultr asonic Testing (UT) wh en the thickness of the thinnest connecting material is 1/4 inches or more. (9.1.2) except as noted in (9.1.3), use Magnetic Particle Testing (MT) when the thickness of the thinnest connecting material is less than 1/4 inches. (9.1.3) use RT for all CJP welds in High Mast Light Poles when the thickness of the thinnest connecting material is less than 1/4 inches. (9.2) For mast arms having an OD of less than 6 inches (measured anywhere along it length), MT 100% of the mast arm to pole connection CJP welds on a random 1 out of 4 structures, or fraction thereof. (9.3) Inspect partial penetration groove welds and fillet welds on a random 1 out of 4 structures, or fraction thereof. For each structure selected, inspect: (9.3.1) a minimum of 4 inches out of every 48 inches of all partial penetration groove welds, including the 4 inches nearest a connection. Use MT. (9.3.2) 100% of all tube-to-transverse plate (i.e. flanges, base plates, connection plate, etc.) welds. Use MT. (9.3.3) 100% of the perimeter hand hole welds. Use MT. (9.3.4) 100% of all welds connecting a device or accessory to the tube wall. Use MT. (9.3.5) 100% of the mast ar m-to-pole connection welds when the OD of the mast arm is less than 6 inches (measured anywhere along it length). Use Visible Liquid Penetrant Testing (PT). (9.3.6) 100% of all tube-to-transverse plat e welds of aluminum alloy structures or structural elements. Use PT while being witnessed by the Engineer. (9.4) after galvanizing, UT only the tube-to-tran sverse plate CJP groove welds noted on the shop drawings as needing this additional inspection. 744 – STRUCTURAL STEEL FABRICATION - GENERAL 700-156 (10) Overhead Sign Structures. After heading the 7/8 inch diameter rivet used in the Truss to End Support Coupling, the minimum flange thickness can be no less than 3/8 inches, measured at any point along the head’s circumference.
11.Steel Bridge Bearings. At the option of the En gineer, steel bearing device inspection will require that either 1 device in 10, or fraction thereo f, be tested 100%, or a10% of each device will be tested using PT or MT. When tested at the 1 in 10 rate, the Engineer will select which device to test. When tested at the 10% rate, the Engineer will select the weld locations to test, which can vary from device to device. The welding of dissimilar metals is not prequalified.
12.Rejection. Repair or replace reject ed items as directed by the Engineer.
13.Release for Shipment. Do not release fabricated elements for ship ment from the fabrication or paint shop without approval of the Engineer.
e.Supplemental Requirements to the Structural Welding Code - Steel. The section and paragraph references cited in the paragraphs below are to AWS D1.1-2010. Add 2 new subsections as follows: SUBSECTION 1.10 EQUIPMENT CHECK Each DC generator shall have a service check by an NEWA member, a commercial electrical equipment company or by the fabricating plant's electrical maintenanc e engineer once each year. A service certificate shall be issued with each equipment check and shall be available for inspection by the Engineer. SUBSECTION 1.11 TEMPORARY WELDING AND TACKING The attachment of temporary fabrication, erection and construction items to main members by welding or tacking is prohibited except by written permission from the Bureau Chief of Construction and Materials. Permissible locations for such welds and tacks sh all be only at locations shown on approved shop drawings or at locations designated in writing by the Engineer. SUBSECTION 2.4.5 PLUG AND SLOT WELDS Add the following paragraph 2.4.5.5: Plug and slot welding is prohibited without the written approval of the Engineer. As a requirement for approval, all plug and slot welding shall be QC tested by nonde structive testing at no cost to the state. The type of testing shall be determined by the Engineer. SECTION 3 PREQUALIFICATION OF WPSs Add the following notes to Table 3.1: Only low hydrogen electrodes shall be used. SUBSECTION 3.2 WELDING PROCESSES Delete the first sentence of paragrap h 3.2.2 and replace with the following: ESW or EGW shall not be used. GTAW and GMAW-S welding may be used, provided the WPSs are qualified in conformance with the requirements of Clause 4. SUBSECTION 4.2 GENERAL REQUIREMENTS - QUALIFICATION Add the follow to paragraph 4.2.1.1: All PQR tests must be witnessed by the Engineer, another state’s representative approved by the Engineer, or an independent third party approved by the Engi neer. If representatives from other states or third parties witnessed a test, provide records of the test signed by the witness. All mechanical and nondestructive tests performed by independent laboratories on qualificati on specimens will be at no charge to the State. Provide signed documentation of the independent lab’s test results to the Engineer. When requested by th e Engineer, allow KDOT access to the test samples and the independent lab’s radiographs for inspection. Add the following to paragraph 4.2.2.2: All tests must be witnessed by the Engineer, another state’s representative approved by the Engineer, or an independent third party approved by the Engineer. If re presentatives from other states or third parties witnessed a test, records of the test must be signed by the witness. Add a new paragraph 4.2.4: 4.2.4 Additional Testing. The Engineer may order tests of welders, welding operators, tack welders, or WPSs whenever there is evidence that unacceptable welds are being or ha ve been produced. This additional testing 744 – STRUCTURAL STEEL FABRICATION - GENERAL 700-157 is at the fabricator’s expense. The Engineer may disquali fy personnel working for the fabricator who fail the additional testing, who commit serious violations of the specifications, or who repeatedly exhibit poor workmanship on KDOT projects. Revise paragraph 4.3.3 as follows: Replace “those authorized to exam ine them.” with ”the Engineer.” SUBSECTION 5.26 REPAIRS Add the following to paragraph 5.26.2: Do not use mechanical straightening methods w ithout the approval of th e Engineer, even when used in conjunction with the application of heat. SUBSECTION 6.1 INSPECTION – GENERAL REQUIREMENTS Add the following to paragraph 6.1.2.1: This type of inspection shall not be performed by an inspector or their assistants who are, or were previously, engaged in the welding, the general assembly, or the application of coatings. SUBSECTION 6.14 NONDESTRUCTIVE TESTING (NDT) PROCEDURES Delete paragraphs 6.14.4 and replace with the following: 6.14.4 When magnetic particle testing (MT) is used, the procedure and techniques shall be in accordance with the dry powder magnetic pa rticle examination of welds using th e yoke method. The yoke method shall be performed according to ASTM E 709, and the standard of acceptance shall conform with Clause 6, Part C, of this code.
1.The yoke method shall be performed using half-wave rectified direct current or alternating current.
2.Electromagnetic yokes shall have lifting forces complying with TABLE 744-1 . TABLE 744-1: ELECTROMAGNETIC YOKE SPACING Current Type Yoke Pole Leg Spacing (YPS) 2"YPS<4" 4" YPS6" AC 10 lbs. Not Applicable DC 30 lbs. 50 lbs. 6.14.4.1 Prior to MT, the surface shall be exam ined, and any adjacent area within a minimum of 1 inch of the surface to be tested, shall be dry and free of contaminants such as o il, grease, loose rust, loose sand, loose scale, lint, paint, welding flux, and weld spatter. Cleaning may be accomplished by detergents, orga nic solvents, descaling solutions, paint removers, vapor degreasing, sand or grit blasti ng, and ultrasonic cleaning methods. 6.14.4.2 The poles shall be oriented in two directions approximately 90 degrees apart at each inspection point, to detect both longitudinal and transverse discontinuities. The pole position shall overlap as testing progresses to insure 100 percent inspection of the areas to be te sted. Discontinuities are best detected when their axis is normal to the magnetic lines of force. Therefore, the yoke technique is most sensitive to discontinuities whose major access is normal to a line drawn between the two poles. 6.14.4.3 A report of magnetic particle examinati on shall be prepared and provided to the owner.
1.The report shall include the following minimum information:
a.Part identification
b.Examination procedure number (if applicable) (c) Date of examination
d.Technicians name, certification level, and signature
e.Name and signature of contractors or owners, Inspectors, or both who witnessed the examination
f.Examination results
g.Equipment make and model (h) Yoke spacing used
i.Particle manufacturer’s name and color
2.One copy of the report shall be provided to the contractor for the owner. 744 – STRUCTURAL STEEL FABRICATION - GENERAL 700-158 Add the following to paragraph 6.14.5: For detecting discontinuities in non-magnetic mate rials including stainless steel to stainless steel or stainless steel to carbon steel, visible liquid penetr ate testing (PT) will be used in lieu of MT. The standard methods, set forth in ASTM E 165 shall be used for PT inspection, a nd the standards of acceptance shall conform to Clause 6, Part C, of this code. SUBSECTION 6.17 RADIOGRAPHIC TESTING (RT) - PROCEDURE Delete paragraph 6.17.9 and replace with the following: 6.17.9 FILM SIZE - When the joint thickness is less than 3 inches, radiographs shall be 4 1/2 inches x 17 inches in size. When the length of th e joint is such that more than one radiograph is required, one of the films may be shortened to 4 1/2 inches x 10 at the contractor option. When joint thicknesses are 3 inches or greater, the minimum film size shall be 7 inches x 17 inches. Larger radiogra phs may be required in areas where there have been excessive repairs or where there are joints with unusual dimensions. Delete paragraph 6.17.12 and replace with the following: 6.17.12 One radiograph identification number shall be painted on the steel no closer than 3/4 inch from the weld edge at each radiograph location. Corresponding lead numbers shall be superimposed on the painted numbers to produce an image on the radiograph. A combination of letters and numbers may also be used. Two location dots shall be painted on the steel at each radiograph location no closer than 3/8 inch from the weld edge. The dots shall be placed at a random distance from the steel plate edges which are pe rpendicular to the length of the weld. The dots shall be placed in different loca tions for each radiograph location. One l ead arrow shall be placed so that its tip is superimposed on each of the two location dots. A location letter shall be painte d immediately under each arrow and a lead letter shall be superimposed on each painted letter. When radiographs are viewed, only those films representing the same joint should have location arrows an d location letters perfectly superimposed. Any additional information shall be produced on the radiograph no less the 3/4 inches from the edge of the weld either by pre-printing or by placing lead letters and numbers on the steel. See Fi gures 1 and 2. Information required to be shown on the radiograph shall include: the complete KDOT bridge number, initials of the radiographic inspection company, initials of the fabricator, the fabricator's shop order number, the radiographic identification number, the date, and the weld repair number if applicable. Add a new paragraph 6.17.14: 6.17.14 Unless otherwise noted on the shop drawings all butt welds will be evaluated as tension welds.
f.Supplemental Requirements to the St ructural Welding Code - Aluminum. The section and paragraph references cited in the paragraphs below are to AWS D1.2-2014. Add 2 new subsections as follows: SUBSECTION 1.9 EQUIPMENT CHECK Each DC generator shall have a service check by an NEWA member, a commercial electrical equipment company or by the fabricating plant's electrical maintenanc e engineer once each year. A service certificate shall be issued with each equipment check and shall be available for inspection by the Engineer. SUBSECTION 1.10 TEMPORARY WELDING AND TACKING The attachment of temporary fabrication, erection and construction items to main members by welding or tacking is prohibited except by written permission from the Bureau Chief of Construction and Materials. Permissible locations for such welds and tacks sh all be only at locations shown on approved shop drawings or at locations designated in writing by the Engineer. SUBSECTION 2.6 PLUG AND SLOT WELDS Add the following paragraph 2.6.9: Plug and slot welding is prohibited without the written approval of the Engineer. As a requirement for approval, all plug and slot welding shall be QC tested by nondestructive testing at no cost to the state. The type of testing shall be determined by the Engineer. SUBSECTION 3.1 GENERAL REQUIREMENTS – QUALIFICATION Revise item (5) as follows: Replace “those authorized to ex amine them.” with ”the Engineer.” Add 3 new paragraphs as follows:
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 477–489 of 978.