704 - PILING
700-18 Avoid extensions, splices or build-ups on prestressed concrete piles whenever possible. When splicing is
necessary, make them as shown in the Contract Documents. If the pile driving procedure causes crushing or spallin g of the prestressed concrete piles, or deformation of the steel piles, remove and replace the damaged piles with new, longer piles. A second p ile may be driven adjacent to the damaged pile, when approved by the Engineer and can be accomplished without detriment to the structure. Do not force misaligned piles into proper position. Re move and replace piles driven out of their proper location with new, longer piles. If the driven pile is 35 feet or less in length, the maximum allowable variation from the vertical or battered lines shown in the Contract Documents is ¼ inch per foot of length. If the driven pile is greater than 35 feet in length, the maximum allowable variation from the vertical or battered lines shown in the Contract Documents is ⅛ inch per foot of length. The maximum allowable variation on the head of the driven pile from the position shown on the Contract Documents is 2 inches for piles used in bents, and 6 inches for foundation piles. Drive all piles in the orientation shown on the Plans. If the axial orientation of the pile rotates or twists by more than 10°, the Field Engineer will contact the Bureau of Structures and Geotechnical Services. Re-drive all piles pushed up by the driving of adjacent piles, or by any other cause.
d.Bearing Values and Required Penetration. Drive the piling to attain, as a minimum, the specified bearing value, penetration and pile tip elevation. Stop dr iving the piling (regardless of the penetration) if 1½ times the specified minimum driving resistance is attained. Stop driving the piling if, in the opinion of the Engineer, the specified minimum driving resistance, penetration and pile tip elevation can not be attained without damage to the piling. If the specified minimum driving resistance is not attained with the specified number and length of piling, the Engineer may allow additional piling be driven so that the maximum load on any pile does not exceed its safe carrying capacity. In the absence of loading tests, determine the sa fe bearing values of piles by the formulas in TABLE 704- 1. 704 - PILING
700-19 Table 704-1: Pile Formulas
Hammer Pile Type Formula Gravity Timber 1.0SH W2P Gravity Steel Steel Shell Steel Sheet )XW(W 35.0SHW3P Air/Steam (Single Acting) All Types 1.0SH W2P Air/Steam (Double Acting) All Types 1.0SE2P Delmag and McKierman-Terry* All Types W**X1.0SH W6.1P Link-Belt* All Types W**X1.0SE6.1P *diesel hammers ** For diesel hammers, the quantity X/W shall not be less than 1. P = safe bearing power in pounds W = weight in pounds, of striking part of hammer H = height of fall in feet E = energy of ram in foot-pounds per blow S = the average penetration in inches per blow for th e last 5 blows for gravity hammers and the last 20 blows for air/steam or diesel hammers X = weight in pounds of the pile plus the weight of any cap and/or anvil used on the pile during driving The above formulas are applicable only when: The hammer has a free fall; The penetration is reasonably quick and uniform; and There is no appreciable bounce after the blow. If water jets are used in connection with the driving, determine the bearing capac ity by the formulas above from the results of driving after the jets have be en withdrawn, or a load test may be applied. The energy rating used to determine if any type or brand of diesel hammer is of adequate size other than those shown in TABLE 704-1 , is 80% of the energy rating as listed by the manufacturer. Use an energy rating of 100% of the energy rating listed by the manufacturer for computing bearing values and to determine if an air/steam is of adequate size. If the number of blows per minute for an air/steam hammer deviates significantly from the number designated by the manufacturer, take corrective action as directed by the manufacturer.
e.Piling Restrike Procedure. If a pile does not attain the minimum driving resistance within a few feet of the plan elevation, the pile restrike procedure may be used. Contact the Regional Geology Office for guidance before using the restrike procedure. Restrike procedures differ depending on whether a Test Pile, Test Pile (Special) or neither is called for in the Contract Documents. When a PDA is used, the restrike procedure will be as directed by the Regional Geologist.
1.Use the following procedure when neither a Test Pi le nor a Test Pile (Special) is called for in the Contract Documents, and the PDA is not available. The following procedure shall be used. Drive all of the piling in a group to within 2 feet of plan elevation; A group of piling is defined as all piles contained within a single footing. All of the piling in the pile group shall s it undisturbed for a minimum of 24 hours; Prior to starting the restrike procedure, warm the hammer up at a location as far away from the pile group as practical, preferably in another substructure member or pile group; 704 - PILING
700-20 Using the warmed up hammer, immediately restrike 20% of the piles in a group, with a minimum of 2 in
a group restruck. Of these, restrike the piles in a single group with the furthest spacing away from each other. When possible, restrike those with the lowest resistance during driving. Restrike for 30 blows or until the pile penetrates an additional 4 inches, whichever comes first. Record the penetration for every 5 blows. In the event the pile movement is less than ½ inch during the restrike, the restrike may be terminated after 20 blows. Restrike additional (the 20% or 2 minimum specified above) pile in the group as directed by the Engineer. The driving resistance of the piling is computed based on the average penetration, if any, for the first 5 blows. The driving resistance of each piling is the driving resistance computed for the pile that was restruck. If the computed driving resistance is less than the design pile load, splice additiona l length onto each piling in the group and resume driving each piling until the required driving resistance is achieved.
2.Use the following procedure when a Test Pile is called for in the Contract Documents, and the PDA is not available. The following procedure must be used. Drive the Test Pile to within 2 feet of plan elevation; The Test Pile shall sit undisturbed for a minimum of 24 hours; Prior to starting the restrike procedure, warm the hammer up at a location as far away from the Test Pile as practical, preferably in another substructure member or pile group; The Test Pile is then immediately restruck with the warmed-up hammer for 30 blows or until the pile penetrates an additional 4 inches, whichever comes firs t. Record the penetration for every 5 blows. In the event the pile movement is less than ½ inch during the restrike, the restrike may be terminated after 20 blows. The driving resistance of the Test Pile is computed ba sed on the average penetration, if any, for the first 5 blows. If the computed driving resi stance is less than the design pile load, splice additional length and resume driving until the minimum driving resistance is achieved.
3.When a Test Pile (Special) is called for on the pl ans, or a PDA is available, follow the recommendations of the Regional Geologist for the Restrike Procedure.
f.Pile Cut-Off and Pile Painting.
1.After the piles are driven as specified, cut the piles off at the de signated elevation. If capping is required, make the connection as sh own in the Contract Documents. Pile cut-off material becomes the property of KDOT, if the Engineer determines the pile cut-off material is worth salvaging. Store the salvageable material at the site selected by the Engineer. Pile cut-off material determined to not be salvageable becomes the property of the Contractor.
2.Paint the exposed portion of steel piles, steel sh eet piles, or the shells or castings of cast-in-place concrete piles. Unless otherwise noted in the Contract Documents, apply the paint in the field. Use the same kind of paint and total number of coats as specified for the stru ctural steel on the structure. If a paint system is not specified for the structure, use a prim e coat of inorganic zinc as required for the shop coat and an acrylic or polyurethane finish coat, as specified in DIVISION 700 for the final coat. Apply the paint to the pile for a distance of 1 foot below the bottom of the channel, top of the embankment, natural ground or normal low water elevation.
g.Cast-In-Place Concrete Piles. After the steel shells are driven as specified, remove all loose material from inside the steel shell. Unless specified otherwise in th e Contract Documents, use Grad e 3.5 concrete to fill the steel shells. Do not place concrete in th e steel shell until the driving of all steel shells within a radius of 15 feet from the pile is completed, or until all the piles for any one bent are driven. If this can not be done, discontinue all driving within the above limits until the concrete in the last pile cast is a mi nimum of 7 days old. Remove accumulations of water from inside the steel shells before concrete is placed. Consolidate the conc rete in the upper 15 feet of the steel shell by internal vibration.
h.Sheet Pile. Use a fabricated or cast driving head with corrugations to match the top of the sheeting while driving the sheet piling. 704 - PILING
700-21 704.5 Measurement and Payment
The Engineer will measure the length of steel pile, steel sheet pile, cast-in-place concrete pile and prestressed concrete pile remaining in the structure, by the linear foot. The Engineer will measure the length of prestressed concrete from the tip of the pile to the point that concrete is removed to provide the connection with the cap or footing. This measurement does not include the length of reinforcing steel extending beyond the pile and into the cap or footing. The Engineer will measure the actual length of ordered a nd accepted test pile and test pile (special) by the linear foot. The Engineer will measure each cast steel pile point used. If after driving the ordered and accepted length of pile, plan bearing is not achieve d and additional pile is required, the Engineer will measure for pa yment each pile splice needed to lengthe n the pile to achieve bearing. The Engineer will not measure for payment pile splices shown in the Contract Documents or pile splices approved for the Contractor’s convenience. The Engineer will measure pre-drilled pile holes by th e linear foot. The Engineer will measure pre-drilled pile holes from the elevation at the bottom of the hole to the bottom of the footing or abutment elevation shown in the Contract Documents. If the Contractor drills the pile holes to an elevation below that shown in the Contract Documents for bottom of hole, the additional drilling below the elevation shown in the Contract Documents is not measured for payment. Pre-drilled p ile holes not specified, but drilled for the Contractor’s convenience are not measured for payment. The Engineer will measure pile cut-off by the linear fo ot for Pile (*) (**). Pile cut-off is the difference between the length of pile ordered and accepted and the actual length of pile remaining in the structure. If the Contractor (for convenience or method of operation) uses a length of pile that exceeds the length of pile ordered and accepted, the excess length is not measured as pile cut-off. The Engineer will not measure pile cut-off of Test P ile (*) (**) and Test Pile (Special) (*) (**) for payment. If the pile for these items is cutoff and used /spliced on the project, the pile will not be measured for separate payment. Splices will be paid for according to this subsection. The Pile Restrike procedure shall not be paid for separately, but shall be subsidiary to the bid item "Piling", "Test Pile" and "Test Pile (Special)". Payment for the various types of "Piles" and "Test P iles", "Cast Steel Pile Poin ts" and "Pre-Drilled Pile Holes" at the contract unit prices is full compensation for the specified work. Payment for pile splices at 4 times the contract unit price of the type of pile spliced is full compensation for the specified work. Payment for pile cut-off per linear foot as shown in TABLE 704-2 is full compensation for the specified work. TABLE 704-2: PILE CUT-OFF PAYMENT Pile Type % of Contract Unit Price Paid Cast-in-place (Shell) 60 Pre-stressed concrete 75 Steel 75 Steel Sheet 75 The costs of all load tests ordered by the Engineer will be paid for as Extra Work as shown in SECTION 104. 705 - STRUCTURAL STEEL FABRICATION - BRIDGES
700-22 Section 705
STRUCTURAL STEEL FABRICATION - BRIDGES 705.1 DESCRIPTION Shop fabricate the structural steel according to the Contract Documents. This specification applies to bridges on highways and public roads carrying vehicular traffic. See SECTION 744 for all other steel or aluminum shop fabrication. 705.2 MATERIALS
a.General. Provide materials that comply with the applicable requirements. Castings ................................................................................................................. DIVISION 1600 Structural Steel ...................................................................................................... DIVISION 1600 Welded Stud Shear Connectors ............................................................................. DIVISION 1600 Steel Fast eners ....................................................................................................... DIVISION 1600
b.Preliminary Shop Requirements.
1.Point of Fabrication. Within 10 business days after signing the contract, no tify the State Bridge Office and the Bureau Chief of Construction and Materials in writin g of the firm (name and location) that will fabricate the structure. Produce and fabricat e all structural steel within th e Continental United States (see SECTION 106 ). Use fabricators of bridge beams and girders that are certified by the American Institute of Steel Construction in the appropriate category for the type of work being performed.
2.Shop Drawings. The Contractor or fabricator must submit shop drawings of both structural steel 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 for each span giving sufficient dimensions for accurate fabrication and inspection of the structure. Thes e dimensions must include, but are not limited to: Bearing-to-bearing lengths; and Vertical and horizontal curvature offsets at bearin g points and splices. Use the bottom of the web or the top of the bottom flange at the center line of the web as the reference point. 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 used before the layout, and use such steel in the fabrication of the structure. 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: fabricator’s name; KDOT project number; bridge or station number; fabricator’s purchase order number; 705 - STRUCTURAL STEEL FABRICATION - BRIDGES
700-23 list heat numbers;
size and shape of pieces; number of pieces to be used for each size of each heat; and steel manufacturer’s name and the ASTM or AASHTO designation for the steel 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. Repair welding shall comply with the requirements of AASHTO/AWS D1.5-2010, "Bridge Welding Code" with the exceptions and additions noted later in this section. 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 and physical requirements. Wh en the letter "T" or "F" and a temperature zone number follow the grade designation of an AASHTO or ASTM steel , the mill test report must include Charpy V-notch test results. When weathering steel is allowed or specified in the Contract Docu ments: ASTM A709 Grade 50W may be substituted for ASTM A709 Grade 36 or Grade 50, an d AASHTO M270 Gr ade 50WT2 may be substituted for AASHTO M270 Grade 50T2. When substituting weathering st eel for the structural steel shown in the Contract Documents, use the same size plate or rolled member. Do not use weathering steel in rocker bearing devices (or any component with finished surf aces), expansion devices or expansion device armoring. Except as noted in the previous paragraph, the fa bricator must obtain written permission from KDOT to substitute a grade of steel that is not indicated in the Contract Documents for 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. When directed by the Engineer, prepare 4-inch by 24-inch test specimens of the base metal. Orient the specimen so the di rection of rolling is according to the la test edition of ASTM A 6. Provide "all-weld-metal" tension specimens and specimens for other we ld tests as directed by the Engineer. Preparation and possible shipment of specimens are subsidia ry to the fabrication of the structure.
7.Heat Curving Procedure. Girders and rolled beams may be heat curved by either the continuous or "V" heating methods. Before starting any fa brication and before submittal of shop dr awings for the structural steel, the Contractor or fabricator may request permission to heat-curve rolled beams in the shop or to heat-curve welded plate girders in lieu of flame cutting flanges to the desired horizontal curvature. Submit the request and proposed shop procedure to the Engineer for approval. The submittal must indicate the type of heating, heating temperature, position for heating, sequence of operations and the values to be used to compensate for possible loss of camber of heat-curved girders in service. The proposed procedure must comply with the latest editions of AASHTO/AWS D1.5, "Bridge Welding Code", AASHTO’s "Standard Specifications for Highway Bridges" and AASHTO’s "LRFD Bridge Construction Specifications".
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. 705 - STRUCTURAL STEEL FABRICATION - BRIDGES
700-24 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.Steel Identification. All pieces of all grades of steel used in fabr ication of main members, including webs, flanges, bearing stiffeners, bearing devices, splice plates and any cross member carrying stringers and their connection plates, must bear the heat number assigned by the rolling mill. Preserve the heat number until the Engineer advises the fabricator that th e unit is acceptable for cleaning and pain ting. Identify the grade 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. Heat straightening must comply with the latest versions of AASHTO/AWS D1.5, "Bridge Welding Code"; AASHTO’s "Standard Specifications for Highway Bridges"; AASHTO’s "LRFD Bridge Construction Specifications"; and the FHWA report, "Heat-Straightening Repairs of Damaged Steel Bridges". Submit the proposed heat straightening procedure to the Engineer for approval. Sharp kinks and bends are cause for rejection of the material. Mill material must not exceed dimensional tolerances outlined in the latest edition of ASTM A 6.
3.Welding and Gas Cutting. Perform welding an d gas cutting of structural steel according to the applicable requirements of the AA SHTO/AWS D1.5-2010, "Bridge Weld ing Code" with the exceptions and additions noted in this specification. Perform welding and gas cutting on steel bearings, bridge drainage sy stems, finger plate or modular expansion devices, and bridge rails according to SECTION 744 . At the option of the E ngineer, steel bearing device inspection will require that either 1 device in 10, or fraction thereof, be tested 100%, or a10% of each device will be tested using liquid penetrant or magnetic particle. When te sted 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.
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.Pins and Rollers. Accurately turn pins and rollers to the dimensions shown in the Contract Documents and keep them straight, smooth and free from flaw s. Produce the final surface by a finishing cut. Forge and anneal pins and rollers larger than 7 inches in diameter, unless shown otherwise in the Contract Documents. In addition, for pins larger than 9 inches in diameter, after the forging has been allowed to cool to a temperature below the critical range, under normal conditions, and before being annealed, bore a hole a minimum of 2 inches in diameter full length along the axis. (6) Boring Pin Holes. Bore pin holes true to the specified diameter, smooth and straight, at right angles with the axis of the member and paralle l with each other, unless otherwise specified. Produce the final surface by a finishing cut. Do not vary the distance outside-to-outside of holes in tension members and inside-to-inside of holes in compression members from the specified dimension more than 1/32 inch. Bore holes in built-up members after final assembly. (7) Pin Clearances. Do not exceed the diameter of the pi n hole by that of the pin more than 1/50 inch for pins 5 inches or less in diameter, or 1/32 inch for pins greater than 5 inches in diameter.
8.Threads. Closely match threads of bolts to the nut threads. Threads must be ANSI Unified Coarse Series (UNC), except make pin ends of diameters gr eater than 1 ½ inches, with 6 threads per inch.
9.Pilot and Driving Nuts. Provide 2 pilot nuts an d 2 driving nuts for each size of pin, unless otherwise specified. (10) Fit of Stiffeners. Mill, grind or machine cut be aring stiffeners intended as supports for concentrated loads to secure full bearing against the flange. Use interm ediate stiffeners with a tight fit and uniform distance between the flange plates and the ends of the stiffeners, unless shown otherwise in the Contract Documents. (11) Facing of Bearing Surfaces. Plane or heat straighten the top and bottom surfaces of steel slabs, base plates, bearing devices, cap plates of columns and pedestals to have full contact when assembled to the main members. Mill parts of members in co ntact with these items to true surfaces and correct bevels, after the main sections of these members and the end connection angles have been fully welded or bolted. Plane cast pedestals on surfaces in contact with steel.
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 349–355 of 978.