705 - STRUCTURAL STEEL FABRICATION - BRIDGES
700-27 (16) Shop Painting. Prepare the structural steel surfaces and shop pa int the prepared surfaces according to
SECTION 714 .
17.Shop Bolted Connections. Perform all bolting according to SECTION 712 . The maximum deviation from detailed flatness for a connected plate (flange, web, splice, fille r, etc.) shall no t exceed D/(144*T0.5) inches or 3/16 inch, whichever is greater. D equals the least clear dimension (in inches) of the panel from edge to edge, flange to flange, web to web, stiffener to stiffener, or any comb ination thereof and T equals the thickness (in inches) of the connected plate. After snug tightening all fasteners, no gaps between the conn ected layers can be present except at the edges of splice plates away from bolt holes.
18.Enclosed structures not accessibl e after fabrication. All interior welds and connections as well as overall fit and finish must be inspected and accepted prior to full enclosure. Failure to provide the Engineer this opportunity will be cause for rejec tion of the fabricated element.
19.Rejection. Repair or replace reject ed items as directed by the Engineer.
20.Release for Shipment. Do not release fabricated elements for shipment fro m the fabrication shop or paint shop without approval of the Engineer.
e.Supplemental Requirements to the Welding Code. The section and paragraph references cited in the paragraphs below are to AASHTO/AWS D1.5-2010. SUBSECTION 1.3 WELDING PROCESSES Delete paragraph 1.3.2 and add the following: 1.3.2 Electrogas welding shall not be used. Replace the third sentence of paragraph 1.3.3 with the following: Only the “narrow-gap improved” ESW process (ESW-NG) shall be permitted. Add 2 new subsections as follows: SUBSECTION 1.12 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 1.13 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. A ll such tacks or temporary welds shall be made according to Paragraphs 3.3.6 and 3.3.7 and welders and/or tackers shall be qualified according to AWS requirements. SUBSECTION 2.9 DETAILS OF PLUG AND SLOT WELDS Add the following to paragraph 2.9.1.1: Plug welding is prohibited without the written approval of the Engineer. As a requirement for approval, all plug 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 3.4 CONTROL OF DISTORTION AND SHRINKAGE Add the following to paragraph 3.4.8: 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 3.5 DIMENSIONAL TOLERANCES Add the following to paragraph 3.5.1.2: Permissible variations in straightness of rolled beams, regardless of cross- section, shall not exceed 0.01inch/foot of beam length or 1 inch. Delete paragraph 3.5.1.3 and add the following: 3.5.1.3 Permissible variations in specified cambe r and blocking of welded girders and rolled beams, regardless of cross-section shall not exceed: -0, +¼ inch for spans (typ., bearing to bearing) 0 thru 100 feet -0, +½ inch for spans greater than 100 feet Permissible variations in blocking of rolled beams at field splices, regardless of cross-section, shall not exceed: 705 - STRUCTURAL STEEL FABRICATION - BRIDGES
700-28 ¼, +¼ inch for spans 0 through 100 feet
- ⅜, +⅜ inch for spans greater than 100 feet Permissible variations in blocking of welded gird ers and rolled beams, regardless of cross-section, shall not exceed: 0 for all supports Sign convention: (-) below, (+) a bove the detailed values or sh ape in the no-load condition. Delete paragraph 3.5.1.9 and replace with the following: The bearing ends of bearing stiffeners shall be flush and square with the web and shall have no less than 75% of the end area in contact with the flanges. “Contact” is achieved when a 0.005 inch feeler gauge cannot be inserted between stiffener and flange. The gap between stiffener and flange for the rema ining “non-contact” area shall be no greater than 1/32 inch. For steel slabs, base plates, bearing devices, cap plates of colu mns and pedestals bearings against or welded to beams and girders, no less than 75% of the common area shall be in contact with the flanges. Do not exceed a 1/32 inch gap for the 25% “non-contact” area. Add 3 new paragraphs as follows: 3.5.1.16 The permissible variation in length of beams or girders between the center line of bearing devices shall not exceed plus or minus ¼ inch for any one span or plus or minus ⅜ inch for any two or more spans. The actual centerline of any bearing device shall lie within the thickness of the bearing stiffener. 3.5.1.17 During shop assembly of horizontally curved welded beams or girders, the allowable variation in specified sweep at internal supports shall be ¼ inch. 3.5.1.18 During shop assembly of horizontally curved welded beams or girders, the allowable variation in specified sweep at any point be tween supports shall be the greater of: ⅛ inch per 10 feet of length, calculated using the distance to the nearest support, or ¼ inch. SECTION 4. TECHNIQUE. Add the following notes to Table 4.1: Only low hydrogen electrodes shall be used. E 7028 Electrodes may be used for shop fillet welds except for the attachment of gusset plates and bearing stiffeners to girders, bearing stiffeners to beams, web to flange welds and for welding floor beam truss assemblies. Welding shall be in the horizontal and flat positions only. SUBSECTION 5.2 WPS QUALIFICATION RESPONSIBILITY Replace the first sentence of paragraph 5.2.3 with the following: All welder, welding operator, and tack welder and PQR 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 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 qualification 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 the Engineer, allow KDOT access to the test samples and the independe nt lab’s radiographs for inspection. Delete paragraph 5.2.4 and replace with the following: 5.2.4 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 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 5.2.5 as follows: Replace “those authorized to exam ine them.” with ”the Engineer.” SUBSECTION 5.21 GENERAL REQUIREMENTS FOR WELDER QUALIFICATION Add the following to paragraph 5.21.6.1: 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. Revise paragraph 5.21.7 as follows: Replace “those authorized to exam ine them.” with ”the Engineer.” Add the following to paragraph 5.21.7:
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 358–359 of 978.