SECTION 607 STRUCTURAL STEEL BRIDGES
607.01 DESCRIPTION. Build steel bridges, and perform other structural steel and
miscellaneous metal construction. The dimensions specified in the Plans are for a normal temperature of 60 F with dead load on the structure.
a.Primary Bridge Members include:
a.Web and Flanges of plate, tub, and box girders
b.Rolled Beams and cover plates
c.Floor Beam webs and flanges
d.Arch Ribs and arch ties beams or girders
e.Truss Members
f.Diaphragm members for tub girders
g.Splice Plates for primary members
h.Any other member designated as “primary” or “main” on the plans
b.Secondary Bridge Members include:
a.Bracing (diaphragms, cross frames, and lateral bracing.
c.Miscellaneous Bridge Members
a.All other miscellaneous bridge items not considered primary or secondary bridge members
607.02 Materials and Equipment.
607.02.01 Paint. Conform to Section 821.
607.02.02 Structural Steels. Conform to Section 812.
607.02.03 Miscellaneous Metals. Conform to Section 813 for pins and rollers; bearing
and expansion plates (rockers and expansion dams); aluminum; high-strength steel bolts, nuts, and washers; and welding. Use flat and smooth circular washers and square or rectangular beveled washers. Ensure that bolt dimensions conform to the heavy hexagon structural bolt requirements of ASME/ANSI 18.2.6 and Section 813. Ensure that nut dimensions conform to the heavy hexagon nut requirements of ASME/ANSI B18.2.2 and Section 813. Identify heavy hexagonal structural bolts, manufactured according to ASTM F3125 Grade A325, on the top of the head by 3 radial lines, the legend “A 325”, and the manufacturer’s mark. Identify Grade 2H nuts on at least one face by the marking “2H” or “2HB”, and Grade DH by the marking “DH”. Ensure that all nuts bear the manufacturer’s identification mark. Heavy hexagonal structural bolts have shorter thread lengths than other standard bolts. Depending on the amount of bolt length added to adjust for incremental stock lengths, the full thread may extend into the grip as much as 3/8 inch for the following bolt sizes; 1/2 inch, 5/8 inch, 3/4 inch, 7/8 inch, 1 1/4 inch and 1 1/2 inch, and as much as 1/2 inch for the following bolt sizes; one inch, 1 1/8 inch, and 1 3/8 inch. The fabricator may include some of the thread run-out into the plane of the sh ear. When the thickness of an outside part adjacent to the nut is less than these values, the fabricator may use the next increment of bolt length together with a sufficient number of flat circular washers to ensure full seating of the nut.
607.02.04 Wrenches. Use manual or power torque wrenches. Use power wrenches
of adequate capacity and of sufficient air supply to perform the required tightening of bolts in approximately 10 seconds.
607.02.05 Direct Tension Indicators. Use direct tension indicators conforming to
ASTM F 959. Determine correct bolt tension by examining the gap between the washer and bolt head remaining after tightening. 607-1 Include with each shipment of direct tensi on indicators, reports of actual tests showing the bolt tension achieved when the indicators are loaded. Ensure that the bolt tension is 20 percent greater than the tension specified in the Bolt Tension table in Subsection
607.03.05 Furnish test reports for representative samples of each lot or heat and each size
tension indicator in the shipment, and provide packaging that easily identifies individual lots or heats. The Department may perform any additional sampling or testing the Engineer deems necessary. Mark the tension indicators with the correct grade (A 325 or A 490) to ensure ready verification on the job.
607.02.06 Tapes. Use only tapes that are correctly calibrated with NIST to ensure
correct fit of the work.
607.03 Construction.
607.03.01 Shop Drawings and Welding Procedures. Submit detailed shop drawings
and welding procedures with supporting procedure qualification records to the Division of Structural Design or their designated representative (“Reviewer”). The Department will furnish plans showing sufficient details for the Contractor to prepare detailed shop drawings. Include welding procedures and details, when required, as part of the shop drawings. The Department will not consider the shop drawing submittal process to be complete without the submittal of welding procedures. Submit a shop drawing submittal schedule (Schedule) for review and approval no later than fifteen calendar days prior to the first submittal. List all anticipated shop drawing packages for the project by component and superstructure unit, span or pier, and show the estimated submittal dates for each package. Upda te the Schedule and resubmit to the Engineer, for review but not approval, on the first day of each calendar month until all required shop drawing submittals have been approved. Submit shop drawings in substantial conformance with the latest Schedule submitted to the Engineer, and include all relevant drawings and construction procedures necessary for a thorough review. Allow sufficient lead time to permit a complete review. Submit shop drawings in electronic format. Make all drawing submittals in a 22 inch by 36 inch Portable Document Format (PDF) that will produce clear prints and sharp lines on both 11 inch by 17 inch prints and 22 inch by 36 inch prints (“PDF Prints”). The Department reserves the right to require hard copy prints on a case-by-case basis. Submission of two or three-dimensional computer modeling data will not by itself constitute a complete shop drawing submittal. The use of two- or three-dimensional computer modeling techniques to facilitate fabricat ion will not relieve the fabricator from providing detailed shop drawings of all bridge members and components for the Department's records. Submit to the Reviewer PDF Print Files of the detailed shop drawings and welding procedures. Electronically stamp all shop drawings and procedures with the Contractor’s stamp as an acknowledgment that the Contractor has reviewed the submittal for completeness and appropriateness. Each sheet will be electronically stamped by the Reviewer. The Reviewer will return one PDF file of reviewed shop drawings with all required corrections noted. When corrections and resubmittal are required, submit PDF Print Files of the corrected set of drawings . After the final review, when additional resubmittal is unnecessary, the Reviewer will forward the reviewed shop drawing PDF Print files with the Reviewer’s Stamp indicating approval (or conditional approval) and any final comments to the DOSD Shop Plan Coordinator for distribution. Only plans submitted directly to the Shop Plan Coordinator by the Reviewer will be distributed, and only plans electronically stamped “distributed by the Division of Structural Design” are to be used for fabrication. 607-2 After fabrication is complete and the Engineer has approved the structural steel for shipment, furnish to the Engineer one electr onic set of the as-built shop drawings, including the welding procedures, as PDF Prints. Review cycles will begin the first Business Day after a submittal is received (“logged”), or the next Business Day after the submittal date indicated on the most recently submitted Schedule, whichever occurs later. Submittals received after 2:00 PM Eastern Time will be logged as the next Business Day following receipt of the submission. ‘Business Days’ are weekdays, Monday thr ough Friday except official Department holidays. The Reviewer will determine if all relevant drawings and construction procedures have been submitted. If a submission is incomplete or otherwise requires additional information or data to properly complete the review, the review cycle for the submission will be reset and the cycle will begin as specified in the previous paragraph once all required information is received (logged.) Review cycle durations for shop drawing submittal packages deemed complete by the Reviewer are as follows: Allow at minimum 30 Business Days for review of shop drawing submissions of primary bridge members. Allow at minimum 15 Business Days for review of shop drawing submissions for the secondary bridge members. Allow at minimum 7 Business Days for review of other miscellaneous bridge members shop drawing packages. No claims for delay will be considered for shop drawing reviews when the Engineer has indicated that relevant drawings or construction procedures are insufficient for a thorough review. No claims for delay will be considered for shop drawing reviews when information relevant to the submittal review is still in the process of being developed. Additional time to review requested changes to any relevant drawings and construction procedures will not be considered cause for delay claims. Do not make changes to any drawing after the Engineer has reviewed it without the Engineer’s written approval or written direction. Only make substitutions of sections different from those shown on the drawings when the Engineer approves in writing. Although the drawings may have been review ed, take responsibility for the correctness of the drawings and for shop fits and field connections. Take responsibility for any material ordered or work done before the Engineer reviews the drawings and welding procedures. When the design drawings differ from the requirements of this section, the design drawings govern.
607.03.02 Fabricated Structural Steel
a.Prequalification. Structural steel and aluminum fabricators performing work for the Department are required to prequalify according to th e American Institute of Steel Construction’s (AISC) Qua lity Certification Program and obtain approval from the Director of Construction. Plants and shops must be registered and certified under the AISC program with SBR: Certified Bridge Fabricator-Simple; IBR: Certified Bridge Fabricator-Intermediate; ABR: Certified Bridge Fabricator- Advanced; or CPT: Bridge Component Manufacturer, as applicable, and must 607-3 submit a valid certificate to the Division of Construction. Only fabricators having ABR certification, including the Fracture Critical endorsement, may fabricate the following: ● Main members for arches, continuous span trusses, cable-stayed bridges, and suspension bridges. Only fabricators having either IBR or ABR certification, including the Fracture Critical endorsement, may fabricate the following: ● Fracture critical members and attachments, except as specified above. Only fabricators having either IBR or ABR certification may fabricate the following: ● Main bridge members, except for certain rolled beams ● Welded Plate Girders ● Welded floor beams ● Cross frames and diaphragms for curved bridges ● Bracing, portals, and stiffening memb ers for arches, trusses, cable-stayed and suspension bridges ● Rolled beams with butt welds, or that are heat-curved, heat-cambered, or cold cambered. Fabricators having either SBR, IBR, or ABR certification may fabricate the following: ● Rolled beams with bearing stiffeners and diaphragm connection or cover plates2 ● Cross frames and diaphragms for straight bridges ● Shop-fabricated material for reinforcing existing bridges1 ● Lateral bracing except for arches, trusses, cable-stayed, and suspension bridges1 Note 1: Fabricate in an IBR or ABR certified plant if welding is required. Note 2: SBR certified plants must qualify for initial approval from the Division of Construction to perform heat cambering or cold cambering on rolled beams. Fabricators having SBR, IBR, ABR, or CPT certification may fabricate the following: ● Expansion dams ● Bridge drainage material ● Welded bearings ● Inspection walks 607-4 ● Steel grid flooring ● Welded sound barrier supports ● Bridge railing ● Pedestrian railing ● Structure mounted guide rail ● Welded protective barrier ● Armored Edges AISC certification is not required for the following: ● Castings, forgings, and machined parts not welded ● Non-metallic bearing ● Protective fence ● Material not requiring shop fabrication or shop welding, such as plates and shapes for strengthening existing bridges and manufactured items accepted by certification Prequalification of ‘machine shops’ (who provide services and materials to approved fabricators) is not required. Machine shops may perform one or more of the following operations3: ● Cutting or shearing materials to finish size ● Grinding ● Drilling or punching ● Cold bending ● Machining ● Flattening Note 3: Individual shop operations may be limited. Machine shops cannot produce fracture critical members without project specific approval from the Division of Construction except if the material is being produced for and shipped to a fabricator having AISC IBR or ABR certification, including Fracture Critical endorsement.
A.Quality of Workmanship. Ensure that workmanship and finish are in accordance to the latest AISC Code of Standard Practice for Steel Buildings and Bridges at the time of letting.
B.Storage of Materials. Store structural material, either plain or fabricated, at the fabricating shop above ground upon platforms, skids, or other supports. Keep it free from dirt, grease, and other foreign matter and protect it from corrosion.
C.Straightening Materials. Before measuring or working rolled material, ensure that it is straight. When straightening is necessary, use methods that will not injure the metal. If sharp kinks and bends are evident, the Engineer will reject the material.
D.Finish. Blast clean all structural steel to SSPC SP5/NACE No. 1 white metal blast, prior to beginning any fabrication. Provide a neat finish to the work. Shear, flame cut, grind, and chip carefully and accurately. Remove all burrs resulting from reaming or drilling.
607.03.03 Bolt Holes. Either punch or drill all holes for connections.
607-5
A.Punched Work. Punch all holes full-size except:
1.When there are more than 5 thicknesses, or when any of the main material is thicker than 3/4 inch in structural carbon steel, 5/8 inch in high-strength low alloy steel, or 1/2 inch in quenched and tempered alloy steel, sub-punch all holes, and ream them after assembling according to the requirements of C) below.
2.When the metal is thicker than the size of the bolts, drill the holes according to the requirements of D) below.
3.Sub-punch and ream punched holes for stringer and floor beam field connections according to the requirements C) below, or sub-punch and ream to a metal template no less than one inch thick, without assembling.
4.Sub-punch and ream punched holes in field connections of main truss or arch members, skew portals, skew portal br acing plate, girder spans, continuous I-beam spans and rigid frames. Punch holes in connection plates or other parts of such members according to the re quirements of C) below. Main truss members are the top and bottom chords, end posts, and web members forming the truss.
B.Punched Holes. Punch full-size holes 1/16 inch larger than the nominal diameter of the bolt except as noted below. Do not allow the diameter of the die to exceed the diameter of the punch by more than 3/32 inch . Ensure that holes are cut cleanly without torn or ragged edges. Punch holes so that, after assembling the component parts of a member and before reaming, a cylindrical pin 1/8 inch smaller than the nominal diameter of the punched hole may be passed through at least 75 of any group of 100 contiguous holes, or in like proportion for any smaller group of holes. When 10 percent or more of any group of 100 or fewer holes will not pass a pin 3/16 inch smaller than the nominal diameter of the punched hole, the Engineer will reject the mispunched pieces. Ream any holes that must be enlarged to admit bolts. Holes in longitudinal main-carrying members, transverse floor beams, and any components designated as Fracture Critical (FCMs) shall not be punched full size.
C.Sub-Punched and Reamed Holes. Punch sub-punched and reamed holes for bolts 3/16 inch smaller than the nominal diameter of the bolts. Ensure that the punch and die have the same relative sizes as specified for full size punched holes. After assembling, ream sub-punched holes to a diameter of 1/16 inch larger than the nominal diameter of the bolt. After assembling and firmly bolting pieces forming a built member perform reaming. Do not interchange reamed parts. Ream holes with twist drills or with short taper reamers. Do not direct reamers by hand unless the Engineer approves. Use solvents, detergents, or other Engineer approved means before cleaning and painting, to thoroughly remove any oil or grease used as a reaming lubricant.
D.Drilled Holes. Ensure that drilled holes are 1/16 inch larger than the nominal diameter of the bolt. However, do not allow drilled holes for turned bolts to be more than 1/32 inch larger than the diameter of the finished bolt. Hold parts securely together while drilling assembled members. Do not use numerical tape or electronic computer controlled drills unless the fabricator can provide a history showing defect free work of this type. This means that previous work was free of misdrilled holes caused by human errors or machine errors. Drill holes according to the requirements of E) below. Submit to the Engineer for review with the shop drawings, the proposed procedure for drilling holes and assuring correct fit of members. When using numerical tape or electronic computer controlled drills, the Department will require shop assembly of at least 25 percent of the splices and at least 10 percent of floor beam and bracket main member connections as proof of accurate fit. In the event holes do not match as 607-6 prescribed for the assembled pieces, assemble and ream all splices to fit and use metal templates to ream all other floor beam connections.
E.Accuracy of Reamed and Drilled Holes. Ensure that reamed or drilled holes are cylindrical and perpendicular to the member. After reaming or drilling, do not allow 85 of any group of 100 contiguous holes, or in like proportion for any smaller group of holes, to show an offset greater than 1/32 inch between adjacent thicknesses of metal.
F.Edge Distance of Bolts. Maintain a minimum distance from the center of any bolt to an edge of a plate or steel member: For 1 1/4 inch diameters, 1 5/8 inch. For 1 1/8 inch diameters, 1 1/2 inch For one inch diameters, 1 1/4 inch. For 7/8 inch diameters, 1 1/8 inch. For 3/4 inch diameters, 1 inch. For 5/8 inch diameters, 7/8 inch. Ensure that the maximum distance from any edge is 8 times the thickness of the thinnest outside plate, but does not exceed 5 inches. If the design drawings or the Engineer approves in writing, the Department will allow the use of oversize, short-slotted, and long-slotted holes according to the applicable structural steel design sections of the AASHTO LRFD Bridge Design Specifications.
607.03.04 Shop Assembly and Material Traceability. Conform to the requirements
of A) through D) below when not using numer ical tape or electronic controlled drills; conform to E) below for all structural steel fabrication.
A.Assembling Trusses and Other Supports. Assemble trusses, arches, skew portals, skew portal bracing, girder spans, continuous I-beam spans, and rigid frames in the shop, and adjust the parts to line, camber, and fit for drilling or reaming of field connections.
B.Assembling Members. Thoroughly clean surfaces of metal in contact before assembly. Before reaming, assemble, well pin, and firmly draw together the parts of a member with bolts. When necessary, take apart assembled pieces to remove burrs and shavings produced by the reaming operation. Ensure that members are free from twists, bends, and other deformation. Progressively shop assemble each longitudinal girder unit in no less than 3 contiguous sections adjusted to line, elevation, camber, and fit for drilling or reaming. Add at least one section at the rear end of the assembly when removing any section from the advancing end to ensure that the assembled portion of the structure is never less than 3 contiguous sections. With connected parts assembled, either drill or ream other major bolted connections to the longitudinal girders in the shop or drill or ream to a metal template without assembly. Keep girder sections assembled until match marked and the Engineer has inspected and approved them. Do not apply the assembly requirement for drilling or punching to connections for cross frames, diaphragms, lateral bracing, expansion dams, and other minor members.
C.Drifting of Holes. Only allow drifting during assembly to the extent that it brings the parts into position, but does not enlarge holes or distort the metal. Ream all holes that must be enlarged. Do not allow reaming to exceed the allowable tolerances.
D.Match Marking and Identification. Match mark connecting parts assembled in the shop for the purpose of reaming holes in field connections, according to the diagram shown on reviewed shop drawings. Match mark with 3/8 inch steel, low stress riser dies.
E.Material Traceability. Ensure that the fabricator can demonstrate by a written procedure and by actual practice a method of material application and traceability, 607-7 visible (attached to each shipping piece) at least through the “fit up” operation, of all elements of a shipping piece. Ensure that the traceability method is capable of verifying proper material application as it relates to material specification designation; heat number and manufacturer; and material test reports for special requirements where required. In addition, upon completion of fabrication, furnish the Department with a list of each component of each major load-carrying member and the heat number and manufacturer applicable to the material used for each, including sketches or diagrams when necessary. Provide this list as part of the final shop drawings.
607.03.05 Bolted Connections Using High-Strength Steel Bolts.
A.General. Use friction type joints for all connections made with high-strength steel bolts.
B.Bolt Length. To determine the required bolt length, add the grip, the adjustment for bolt size specified in the following table, 3/16 inch for each hardened flat washer, and 5/16 inch for each beveled washer. Grip is the total thickness of all connected materials, exclusive of washers. Then round up to the next 1/4 inch length. The adjustment in the above table allows for manufacturing tolerances and for the use of a heavy hexagon nut, and provides adequate “stick through” at the end of the bolt. Provide adequate bolt length to allow for the exposure of at least 2 complete threads beyond the face of the nut after tightening.
C.Hardened Washer. Where necessary, clip washers on one side and no closer than 0.875 of the bolt diameter from the center of the washer. Install bolts with a hardened washer under the nut or bolt head, whichever is the element turned in tightening. The Department will allow the use of a flat washer when the abutting surface adjacent to the bolt head or nut does not have a slope of more than 1:20 with respect to a plane normal to the bolt axis. Where outer faces of the bolted parts have a slope of more than 1:20 with respect to a plane normal to the bolt axis, use a smooth beveled washer to compensate for lack of parallelism. Ensure that bolted parts fit solidly together when assembled and are not separated by gaskets or any other interposed compressible material. Keep all joint surfaces free of dirt, burrs, and other def ects that would prevent solid seating of the parts. Maintain contact surfaces free of oil, excess primer, and any other foreign matter.
D.Bolt Tension. Tighten all bolts, with properly calibrated wrenches, to provide at least the required minimum bolt tension values shown in the following table on BOLT SIZE ADJUSTMENT Nominal Bolt Size Adjustment for Bolt Size (inch) (inch) 1/2 11/16 5/8 7/8 3/4 1 7/8 1 1/8 1 1 1/4 1 1/8 1 1/2 1 1/4 1 5/8 1 3/8 1 3/4 1 1/2 1 7/8 607-8 completion of the joint.
E.Direct Tension Indicators. The Department requires tightening of all high- strength bolts in diameters of 1/2 inch through 1 1/2 inch inclusive, using direct tension indicators. Before work begins, furnish the Engineer with the manufacturer’s written installation instructions. Install direct tension indicators, and tighten the bolts according to these instructions. Under normal conditions, install the tension indicator under the non-turned element of the fastening system. Obtain the Engineer’s permission before installing tension indicators under the turned element. If the Engineer determines that it is necessary to install the tension indicator under the turned element, install additional hardened washers according to the manufacturer’s instructions. Use bolt lengths sufficient to accommodate the tension indicators and any additional washers required. Do not reuse tension indicators. If it becomes necessary to loosen a previously tensioned bolt, discard and replace the tension indicator. The fastener assembly may also need to be replaced. Furnish a device capable of measuring actual bolt tension. Before work begins, tighten at least 3 typical bolts and direct tension indicators in the device to the correct bolt tension. Keep the tension device available thereafter for additional checks when the Engineer deems necessary. The Engineer will inspect bolt installation by inserting a feeler gage into the opening between adjacent flattened protrusions. The Engineer will examine at least 10 percent, but no less than 2, of th e bolts in each connection. The Engineer will consider the installation acceptable if the gage will not enter the opening. The Engineer will not consider a zero gap as cause for rejection. If the gap is not uniform around the bolt, the Engineer will base acceptance on the average gap. That is, the Engineer will check the gap at several points around the bolt and if the gage will not enter the gap on at least half the tries, the installation will be acceptable. If the structure is to be painted, seal the gap behind the indicator completely with a compatible coating. Furnish tension indicators in addition to washers.
F.Calibrated Wrenches. Set the calibrated wrenches used to provide the bolt tension specified in 607.03.05 Section D so as to induce a bolt tension at least 5 percent in excess of this value. Calibrate the wrenches twice daily by tightening, in a device capable of indicating actual bolt tension, no less than 3 typical bolt assemblies from the lot to be installed. Adjust power wrenches to st all or cut-out at the selected tension. BOLT TENSION Nominal Bolt Size (inch) Minimum Bolt Tension ASTM F 3125 Bolts A325 (KIPS) ASTM F3125 A 490 Bolts (KIPS) ½ 12 15 5/8 19 24 ¾ 28 35 7/8 39 49 1 51 64 1 1/8 64 80 1 ¼ 81 102 1 3/8 97 121 1 ½ 118 148 607-9 When using manual torque wrenches, note the torque indication corresponding to the calibrating tension and use it in the installation of all bolts of the tested lot. When measuring torque, keep nuts in tightening motion. For short-grip bolts, the Department will allow calibration of wrenches by using direct-tension indicating washers with solid plates in a manner acceptable to the Engineer. When using calibrated wrenches to install several bolts in a single joint, use the wrench to “touch up” bolts previously tightened, which may have been loosened by tightening of the subsequent bolts, until all are tightened to the prescribed amount. When required, because of bolt entering and wrench operation clearances, tighten by turning the bolt while preventing the nut from rotating. Furnish all tension machines and torque wrenches. The Engineer will approve the procedure for calibration of wrenches. Operate a manual torque wrench as the Engineer spot inspects installed bolts by observing the indicated torque. Use a torque wrench that has been calibrated as previously described in this subsection. When the Engineer is inspecting bolts, apply the inspecting wrench and its required torque to 10 percent of the bolts, but not less than 2 bolts, selected at random in a connection. The Engineer will accept the connection as properly tightened if the nut or bolt head does not turn when applying the required torque. When applying the required torque and a nut or bolt turns, the Engineer will test all bolts in the connection. Tighten all bolts whose nut or bolt head is turned by the required torque. The Engineer will re-inspect all connections whose nut or bolt head is turned by the required torque. Alternatively, the Department will allow retightening of all of the bolts in the connection and then resubmit the connection for the Engineer to inspect.
G.Storage. Store bolts and nuts in a dry location until use to protect them from contamination by foreign substances and the formation of rust. Only open shipping containers when needed for the work or for inspection purposes. Properly cover and store partially used containers to avoid contamination or exposure to moisture. Only install bolts and nuts that are clean and free of excessive rust. Do not consider a thin, tightly adhering rust as cause to require cleaning; however, apply an organic lubricant to the threads and bearing surface of all nuts to be used when either bolts or nuts show evidence of rust on the threads.
H.Turn-of-Nut. In lieu of using calibrated wrenches, the Department will allow the use of the turn-of-nut method to install bolts. During installation, regardless of the tightening method used, install bolts in all holes of the connection and bring them to a “snug tight” condition. Snug tight is the tightness that exists when the plies of the joint are in firm contact. Attain this condition either by a few impacts of an impact wrench or by the full effort of an ordinary spud wrench. When snug tightening, progress systematically from the most rigid part of the connection to the free edges, and then retighten the bolts of the connection in a similar systematic manner as necessary until all bolts are simultaneously snug tight and the connection is fully connected. 607-10 When using turn-of-nut tightening: Check a representative sample of not less than three bolt and nut assemblies of each diameter, length, and grade at the start of work in a device capable of indicating bolt tension. Use the test to demonstrate that the method for estimating the snug tight condition and controlling the turns from snug tight to be used by the bolting crew to develop a tension not less than 5 percent greater than the required tension specified in table above. After bringing to a “snug tight” condition, further tighten all bolts in the connection by the applicable amount of rotation specified in the following table. During the tightening operation, do not allow any rotation of the part not turned by the wrench. When tightening, progress systematically from the most rigid part of the joint to its free edges. (1)Nut rotation is relative to bolt, regardless whether turning the element (nut or bolt). For installing bolts by half turn and less, the tolerance is 30; for installing bolts by two-thirds turn and more, the tolerance is 45. (2)Applicable only to connections in which all material within the turn grip of thebolt is steel. (3)There is no research available to establish the turn-of-nut procedure for bolt lengths exceeding 12 diameters. Therefore, determine the required rotation by actual test in a suitable tension measuring device that simulates conditions ofsolidly fitted steel.
I.Rotational-Capacity Test. Perform the rotational-capacity test described in Section 813 on each rotational-capacity lot prior to the start of bolt installation. Use hardened steel washers for the test even if they are not required in the actual installation procedures. Verify that a visible lubricant is on the threads of galvanized nuts. Ensure that black bolts are oily to the touch when delivered and installed. Before installing, clean and relubricate weathered or rusted bolts or nuts not conforming to the requirements of the rotational-capacity test. Retreat recleaned or relubricated nut and washer assemblies to conform to rotational-capacity test requirements before installing. Use bolt, nut and washer (when required) combinations from the same lot used for the rotational-capacity test.
607.03.06 Reuse of ASTM F3125 Grade A 325 Bolts. The Department will allow
the use of non-galvanized ASTM F3125 Grade A 325 high-strength bolts one additional NUT ROTATION FROM SNUG TIGHT CONDITIONS(1),(2),(3) Bolt Length Disposition of Outer Faces of Bolted Parts (Under side of head to end of bolt.) Both faces normal to bolt axis One face normal to bolt axis and other sloped not more than 1:20 (beveled washer not used) Both faces sloped not more than 1:20 from normal to the bolt axis (beveled washer not used) Up to and including 4 diameters 1/3 turn 1/2 turn 2/3 turn Over 4 diameters but not exceeding 8 diameters 1/2 turn 2/3 turn 5/6 turn Over 8 diameters but not exceeding 12 diameters 2/3 turn 5/6 turn 1 turn 607-11 time after initially tightening them to specification tension, provided a close visual inspection indicates no distress in the bolt. This allows non-galvanized ASTM F3125 Grade A 325 bolts to remain installed when tightened to specification tension twice, one time at original installation and one time at reuse. Do not consider touching up or retightening previously tightened bolts, which may have been loosened by the tightening of adjacent bolts, as reuse, providing the snugging up continues from the initial position. When removing and loosening a bolt after it has been tightened to specification tension twice, discard the bolt and substitute a new bolt. Reuse of galvanized ASTM F3125 Grade A 325 bolts is not allowed. Reuse of any type of ASTM F3125 Grade A 490 bolt is not allowed.
607.03.07 Welds. Perform all welding, when authorized, according to requirements
specified in ANSI/AASHTO/AWS D1.5 Bridge Welding Code current edition with interims. Do not field weld, except as specified in the Plans, without the Engineer’s written permission. Ensure that in all cases, welders, welding operators, and tackers have been qualified by testing according to KM 64-110 and/or AWS within the previous 24 months of the time of actual weld performance. Repair or replace welds shown by visual inspection or by nondestructive testing to be defective in accordance with the Bridge Welding Code. All repairs, replacements, and re-inspection costs shall be at the Contractor's sole expense.
607.03.08 Planing and Finishing.
A.Edge Planing. Plane to a depth of 1/4 inch all sheared edges of plates that are more than 5/8 inch thick and carry calculated stress. The Department will allow fillet re-entranting cuts before cutting.
B.Thermal Cutting. Use a mechanical guide to obtain a true profile. Hand-cut only when approved. Cutting (including burning and sawing), shearing, and machining shall be done in accordance with the requirements of the AASHTO/AWS D1.5 Bridge Welding Code and the following: Plane, mill, grind, or thermally cut the sheared edge s of main load-carrying member plate components greater than 5/8” thick to a depth of ¼ inch. Cut and fabricate the steel plates so that the primary direction of rolling is parallel to the direction of the member or component main stress. For flanges and webs, the direction of rolling is parallel to the flanges unless otherwise noted in the Contract Documents. Web splices may be rolled parallel to their length.
C.Heat Curving. The fabricator may either fabricate welded girders by flame cutting the flanges to the required curvature from rectangular plates before fitting and welding to the web, or fabricate welded girders or rolled beams by fabricating straight units and then, through the application of heat to the flange edges, induce the required curvature. Do not perform heat curving in beams or girders having a radius shorter than the minimum radius of curvature as determined by the procedures outlined in the current edition of the AASHTO LRFD Bridge Construction Specifications. When the Contract requires heat curving rolled beams or welded girders, ensure that the work conforms to the following requirements. Curve beams and girders by either continuous or V-type heating. For the continuous method, simultaneously heat a strip along the edge of the top and bottom flanges. Ensure that the strip is of sufficient width and temperature to obtain the required curvature. For the V-type heating, heat the top and bottom flanges in truncated triangular areas having their bases along the flange edge and spaced at regular intervals along each flange. Determine the spacing and temperature of the areas necessary to obtai n the specified curvature. Apply heat along the top and bottom flanges at approximately the same rate. For V-type heating, terminate the apex of each truncated triangular area applied to the inside of a flange surface just before reaching the juncture of the 607-12 web and the flange. To avoid unnecessary web distortion, carefully heat the inside flange surfaces (the surfaces that intersect the web) to avoid applying heat directly to the web. When the radius of curvature is 1,000 feet or more, extend the apex of each truncated triangular heating area applied to the outside of a flange surface to the juncture of the flange and web. When the radius of curvature is less than 1,000 feet, extend the apex of each truncated triangular heating area applied to the outside of a flange surface past the web for a distance equal to 1/8 of the flange width or 3 inches, whichever is less. Ensure that each truncated triangular area has an included angle of approximately 15 to 30 degrees; however, do not allow the length of the base of each triangle to exceed 10 inches. Obtain the Engineer’s approval before making any variation in the patterns as prescribed in this subsection. For both types of heating, heat the flange areas that will be on the inside of the horizontal curve. Concurrently heat both surfaces of flanges when the flange thickness is 1 1/4 inch or greater. Space the heating patterns uniformly along the full length of each flange to produce a uniform arc of a circular curve in the member. When heating causes a chording effect that the Engineer judges not aesthetically pleasing, ensure that th e fabricator reheats the member using additional heating patterns as required to obtain the desired results. Conduct the heat-curving operation so that temperature of the steel does not exceed 1,200 F for ASTM A709 Grades 36, 50, 50S, 50W, and HPS 50W. Do not exceed 1,100 F for ASTM A709 Grades HPS 70W and HPS 100W. Confine heating to the patterns or areas specified in this section, and apply heat to bring the steel within the patterns or areas to the required temperature as rapidly as possible without overheating the steel. Consider any heating procedure which causes a portion of the steel to be heated to a te mperature greater than the temperatures listed above as destructive heating and as a possible cause for rejection of the steel. The fabricator may propose to the Engineer various means to reaccept, repair, or replace the steel rejected for overheating. The Engineer will review the fabricator’s proposal. Do not artificially cool the steel until it has cooled naturally to 600 F. Never quench the steel with water or water and air. When appropriate, cool the steel with dry compressed air only after it has cooled to 600 F. The fabricator shall maintain temperature controls using temperature indicating crayons or other suitable means during heating and cooling of the steel. The Department will allow heat curving of beams and girders with the web in either a vertical or horizontal position. When heat curving beams and girders in the vertical position, brace or support them in such a manner that the tendency to deflect laterally during the heat-curving process will not cause them to overturn. When heat curving beams and girders in the horizontal position, support them near the ends and at intermediate points, as required, to obtain a uniform curvature. Do not allow the bending stress in the flanges due to the dead weight of a beam or girder to exceed 20,000 psi. When a beam or girder is positioned horizontally for heating, maintain intermediate safety catch blocks at the midlength within 2 inches of the flanges at all times during the heating process to guard against a sudden sag due to plastic flange buckling. Heat curve beams and girders in the fabrication shop before painting. The Department will allow performing of the heat-curving operation either before or after completing all required welding of transverse intermediate stiffeners. However, unless provisions are made for girder shrinkage, locate and attach all connection plates and bearing stiffeners after heat curving. When the Engineer requires longitudinal stiffeners heat curve or flame cut them to the required radius and then weld them to the curved girder. When attaching cover plates to rolled beams, attach them before heat curving when the total thickness of one flange and cover plates is less than 2 1/2 inches and the radius of curvature is greater than 1,000 feet. For other rolled beams with cover plates, heat curve the beams before attaching the cover plates; either heat curve or oxygen cut cover plates separately and then weld them to the curved beams. 607-13 Camber girders before heat curving. Obtain camber for rolled beams by heat-cambering or cold-cambering methods approved by the Engineer. For welded plate or built-up girders, cut the web to the prescribed camber with suitable allowance for shrinkage due to cutting, welding, and heat curving. The curving process may tend to change the existing vertical camber. This change will be most pronounced when the top and bottom flanges are of unequal widths on a given transverse cross section. However, subj ect to approval of the Engineer, correct moderate deviations from the specified camber by a carefully supervised application of heat. The Engineer will not measure horizontal curvature and vertical camber for final acceptance until after the fabricator has completed all welding and heating operations and the flanges have cooled to a uniform temperature. The Engineer will check the horizontal curvature in each edge of each flange with the beam or girder in the vertical position by measuring offsets from a stringline or wire or by using other suitable means. The Engineer will check camber by similar means.
D.Facing of Bearing Surfaces. Ensure that the surface finish of bearing and base plates and other bearing surfaces that are to come in contact with each other or with concrete conforms to the surface roughness requirements as defined in ANSI B46.1, Part I: Steel Slabs ANSI 2000 Heavy plates in contact in shoes to be welded ANSI 1000 Milled ends of compression member s, stiffeners, and fillers ANSI 500 Bridge rollers and rockers ANSI 250 Pins and pin holes ANSI 125 Sliding bearings ANSI 125 With the exception of abutting joints and base plates, coat machine-finished surfaces with waterproof grease or other approved coating, as soon as practical after the Engineer has accepted the structural steel and before removing it from the shop. Apply one coat of an approved rust inhibiting primer compatible with the finished coat instead of zinc rich primer to machine finished surfaces that are to be painted.
E.Abutting Joints. Face abutting ends of compression members and girder flanges accurately to secure an even bearing when assembled in the structure. Rough finish ends of tension members at splices to secure close and neat but not contact fitting joints. Where joints are not faced, do not allow the opening to exceed 1/4 inch.
F.End Connection Angles. Build floor beams, stringers, and girders having end connection angles to the exact length specified in the Plans measured between the heels of the connection angles, with a permissible tolerance of 0 to - 1/16 inch. Where the Contract requires continuity, face end connections. Do not allow the thickness of the connection angles to be less than 3/8 inch, or less than that shown on the detailed drawings.
G.Finished Members. Ensure that finished members are true to line and free from twists, bends, and open joints.
H.Web Plates. Cut web plates to provide for camber of the girder. At bolted web splices, do not allow clearance between ends of web plates to exceed 3/8 inch.
I.Fit of Stiffeners. Mill or grind bearing stiffeners of girders and stiffeners intended as supports for concentrated loads to secure an even bearing against the flanges. Ensure that intermediate stiffeners fit sufficiently tight to exclude water after being painted. Ensure that clearance between the ends of horizontal stiffeners and the sides of vertical stiffeners is one inch. Place bearing stiffeners plumb. Place intermediate stiffeners perpendicular to flanges.
J.Bent Plates. Ensure that unwelded, cold-bent, load-carrying, rolled-steel plates conform to the following: 607-14
1.Take them from stock plates so the bend line will be at right angles to the direction of rolling.
2.The radius of bends, measured to the concave face for steel conforming to AASHTO M270/ ASTM A709, shall not be less and preferably shall be greater than 5.0T for all grades a nd thicknesses. For cross-frame or diaphragm connection plates up to 0.75 in. thick, the minimum radius is 1.5T. For all other grades of steel, the minimum bend radii recommendations from the plate manufacturer shall be followed, but the minimum radii shall not be less than the minimums required herein. “T” is the thickness of the plate. Plates may be bent hot, subject to approval of the Engineer. Steel must be bent at temperatures greater than 700 F but not greater than 1,200 F; except for ASTM A 709 Grades HPS 70W and HPS 100W in which case bend at a temperature not to exceed 1,100 F. Ensure that hot-bent plates conform to the requirements of 1) and 2) above.
607.03.09 Pins and Rollers.
A.General. Accurately turn pins and rollers to the dimensions shown on the drawings. Furnish pins and rollers that are straight, smooth, and free from flaws. Produce the final surface by a finishing cut, and provide a smooth finished surface with an ANSI 125 standard finish. Forge and anneal pins and rollers more than 9 inches in diameter. In pins larger than 9 inches in diameter, bore a hole 2 inches or more in diameter full length along the axis after the forging has cooled to a temperature below the critical range. Bore under suitable conditions to prevent injury by too rapid cooling and before being annealed. Furnish 2 pilot nuts and 2 driving nuts for each size of pin.
B.Boring Pin Holes. Bore pin holes true to the specified diameter, smooth and straight, at right angles with the axis of the member and parallel with each other. Produce the final surface by a finishing cut, and leave the finished surface smooth and polished. Do not allow the outside-to-outside distance of holes in tension members and inside-to-inside distance of holes in compression members to vary from that specified by more than 1/32 inch. Bore holes in built-up members after completing connections.
C.Pin Clearances. Do not allow the diameter of the pin hole to exceed that of the pin by more than 1/64 inch for pins 5 inches or less in diameter, or 1/32 inch for larger pins.
607.03.10 Threads for Bolts and Pins. Furnish threads for bolts and pins that
conform to the ASME/ANSI B1.1, Class 2A for external threads and Class 2B for internal threads, except that pin ends having a diameter of 1 3/8 inches or more shall be threaded 6 threads to the one inch, and except as required for high-strength steel bolts.
607.03.11 Annealing and Stress Relieving. For structural members indicated in the
Contract to be annealed or normalized, finish machining, boring, and straightening after heat treatment. Normalize and anneal (full annealing) as specified in ASTM A941. Maintain temperatures uniformly throughout the furnace during heating and cooling so that temperatures at points on the members will not differ by more than 100 F at any one time. Maintain a record of each furnace charge that identifies pieces in the charge and lists temperatures and schedule actually used. Provide proper instruments, including recording pyrometers, for determining temperatures of members in the furnace at any time. Make records of the treatment operation available to the Engineer. Stress relieve members, such as bridge shoe s, pedestals, or other parts built up by welding sections of plates together according to the requirements of AWS D1.5 when required by the Contract. 607-15
607.03.12 Forgings. Furnish forgings that are free from internal and external cracks
and other harmful defects. The Engineer will determine the method of inspection.
607.03.13 Mill and Shop Inspection and Shipping.
A.Notice of Beginning Work. Designate to the Engineer within 30 days subsequent to the award of the Contract the locations of fabricating shops and estimated quantities of steel to be fabricated at each. The Department will not allow structural steel to be fabricated in more than 2 fabricating locations (a location will be considered all shops within one city) unless approved in writing by the Engineer. The Engineer will not allow any work to be done in the shop before granting authorization to proceed. Furnish the Department copies of mill tests and analyses reports of such structural shapes bearing the manufacturer’s name and heat number. When such identification does not exist, the Engineer may require samples for test purposes be cut from the materials. When mill tests and analyses, or subsequent tests of samples, indicate material does not comply with this section, the Engineer will reject such materials. When the Engineer rejects materials, furnish suitable material.
B.Facilities for Inspection. Furnish all facilities for inspection of material and workmanship in the mill and shop, and allow the Inspector free access to necessary parts of the premises. Notify the Engineer when material is ready for shop inspection. Furnish power and utilities for operating inspection equipment, provide shop space for inspection work, handle material as necessary, and enforce required safety precautions for radioactive exposure.
C.Mill Orders, Change Orders, Shipping Statements, Mill Test Reports, and Shop Bills. Furnish a pdf compatible copy of mill orders, change orders, mill shipping statements, mill test reports, fabricator’s shop bills (when not attached to drawings), and shipping statements to the Engineer for all structural steel materials. Ensure that mill test reports show that all materials conform to this section and are signed by a responsible representative of the company. Include the weights of individual members on shipping statements.
D.Facilities for Testing. Furnish test specimens, and all labor, testing machines, and tools necessary to prepare specimens and make full size tests.
E.Rejections. The Inspector’s initial acceptance of any material or finished members will not prevent the Engineer from subsequently rejecting material or finished members when he determines that they do not conform to the Contract.
F.Weighing of Members. When the Contract specifies that the Department will pay for any part of the material by weight, weigh the finished work in the presence of the Inspector. Supply accurate scales and perform all work involved in handling and weighing various parts.
G.Marking and Shipping. Paint or mark each member with an erection mark for identification and furnish an erection diagram with erection marks shown thereon. Mark the weights of members weighing more than 3 tons on the member. Load structural members on trucks or car s so that they may be transported and unloaded at their destination without being excessively stressed, deformed, or otherwise damaged. Ship girders and store them with the web vertical, unless the Engineer allows in writing. The Cabi net’s Shop Inspector will not stamp for acceptance until the members are loaded on cars or trucks just prior to shipping. Pack bolts of one length and diameter and loose nuts and washers of each size separately. Mark a list and description of contents on the outside of each container.
H.Handling Material. Conduct loading, transporting, unloading, and storing of structural material to maintain it clean and free from injury. 607-16
607.03.14 Field Inspection. When the substructure is constructed under a separate
contract, establish lines and elevations for setting steel from the completed substructure. Obtain the Engineer’s approval of the existing lines and elevations prior to submitting shop details for review. The Engineer’s approval of the established lines and elevations does not relieve the substructure contractor from the responsibility for constructing the substructure to the lines and elevations shown. Provide inspection facilities to inspect erectio n of structural steel. When the Contract does not require shop inspection of the structural steel, the Engineer will inspect the material and workmanship upon site delivery.
607.03.15 Field Storing and Handling Materials. Place material to be stored on
blocking above ground. Maintain it clean and properly drained. Place uniform depth girders and beams upright. Support long members, such as columns and chords, on skids placed to prevent injury from deflection. Use extreme care in handling the steel at all times to prevent damage of any parts. Insulate the steel from binding chains with approved softeners. Pad the hooks and slings used to hoist steel. Place the steel so that rubbing will not occur during shipment. Store the steel at the job site on pallets, or other means approved by the Engineer, so that it does not rest on the ground and so that its components do not fall or rest on each other.
607.03.16 Falsework, Erection Methods, and Equipment. Ensure falsework is
properly designed by a Registered Professional Engineer licensed to practice in Kentucky. Construct and maintain falsework for the loads that will be placed thereon. When required, prepare and submit for review plans for falsework or for changes in an existing structure necessary for maintaining traffic. Although the Engineer has reviewed these plans, take responsibility for the falsework design. Before starting work present for the Engineer’s review, the proposed method of erection, and the proposed amount and character of equipment to use for erection. Although the Engineer has reviewed this method, take responsibility for safety and erection. The Contractor shall have a Registered Professional Engineer, licensed to practice in Kentucky, inspect the completed falsework assembly supporting a bridge superstructure prior to placing loads. The Professional Engineer shall provide a certification, based upon visual inspection of the completed falsework assembly, that the falsework assembly conforms to the approved working drawings. However, such certification shall not require an exhausti ve inspection or testing or make the Professional Engineer liable for any deficiencies in workmanship or materials employed by the Contractor or for such conditions that cannot be ascertained from a visual inspection. When placing falsework installations adjacent to an open public road, design and protect the falsework system from errant highway vehicles or from vibration forces caused by passing vehicles.
607.03.17 Bearings and Anchorages.
Set all bearing assemblies level and to the elevations specified in the Plans. Make adjustments in the horizontal positions of bearing assemblies for temperature as the Engi neer directs. Obtain full bearing on the concrete under bearing assemblies regardless of tolerances. Set masonry plates and the bearing plat es of bearing assemblies on ground concrete surfaces, or elastomeric bearing pads , or on lead plates in conformance with the details specified in the Plans. Immediately before setting bearing assemblies or masonry plates, thoroughly clean the surfaces of concrete and metal to be in contact. Provide an approved Type IV epoxy resin system conforming to Section 826 for installing anchor bolts. Drill and install anchor bolts to the embedment depth shown in the plans. Install epoxy adhesive anch orages in accordance with manufacturer’s recommendations including hole size, drillin g equipment and method, hole cleaning 607-17 equipment and method, mixing and dispensing epoxy, and anchor insertion. Provide an embedment depth capable of developing the yield strength of the anchor bolt in shear and tension if applicable based on the manufacturer’s literature for the epoxy material and anchor bolt material used, ad justed for edge distance and anchor spacing if applicable if no required resistance or embedment depth is shown in the plans. Do not alter the manufacturer’s mixing nozzle or dispenser. Anchor bolts must be clean and free from grease, oil, or other foreign material. Furnish epoxy resin system manufacturer’s written recommendations for installation, cleaning, and use for approval. Demonstrate the hole cleaning and installation method to the Engineer for approval and continue the approved process for all anchor bolt locations. Ensure that the final adjustment and setting of expansion rockers, rollers, and anchor bolts takes into consideration dead load elongation in the span and temperature at the time of setting. Normal temperature is considered to be 60°F. Set rockers so as to be vertical at 60°F, after applying all dead load. Adjust nuts on anchor bolts at the expansion ends of spans to allow free movement of the span. Tighten nuts on anchor bolts at fixed ends of spans in accordance with the Specifications. When expansion devices such as rockers and expansion dams have been rigidly fixed to hold them in correct alignment, release them immediately upon completing concrete placement in the portion of the structure they are installed.
607.03.18 Straightening Bent Material. Straighten bent plates and angles or other
shapes by methods that will not produce fracture or other injury. Do not heat the metal unless the Engineer allows, in which case do not heat to a higher temperature than 1,200 F for all all steels except for A709 HPS 70W and HPS 100W, which must not be heated greater than 1100 F as determined by a temperature stick or crayon. After heating and straightening, cool the metal as slowly as possible. Following straightening, carefully inspect the surface of the metal for evidence of fracture. The Department will reject metal with sharp kinks and bends. Do not straighten material by direct hammering.
607.03.19 Field Assembling.
Assemble parts accurately as shown, and follow all match marks. Handle material so no part will be bent, broken, or otherwise damaged. Do not injure or distort the members by hammering them. Clean bearing surfaces and surfaces to be in permanent contact before assembling the members. Unless erected by the cantilever method, erect truss spans on blocking that is placed to provide proper camber. Leave blocking in place until tension chord splices a nd all other truss connections are pinned and bolted, and then release it sufficiently from the falsework to bring compression chord joints into full bearing.
607.03.20 Pin Connections. Use pilot and driving nuts in driving pins. Drive pins so
that members will take full bearing. Screw pin nuts tight and burr the threads at the face of the nut with a pointed tool.
607.03.21 Misfits. The Engineer will allow the correction of minor misfits using small
amounts of reaming, cutting, and chipping. However, immediately report to the Engineer any error in shop fabrication or deformation resulting from handling and transportation that prevents proper assembly and fitting of parts by moderate use of drift pins or by a moderate amount of reaming and slight chipping or cutting. Ream no more than 10% of the holes in the plate connection (flange or web), and ensure no single hole is more than 1/8 in. larger than the nominal bolt diameter. Submit the proposed correction methods for members with defects that exceed these limits or prevent the proper assembly of parts. Straighten structural members in accordance with AASHTO/NSBA S2.2. Make all corrections in the presence of the Engineer at no expense to the Department. Do not remove and reweld gusset plates without approval. Obtain the Engineer’s approval of the proposed method for correction. Make the correction in the Engineer’s presence. 607-18 For beams or girders that do not conform to the plan camber and grade in the erected position, either adjust the depth of the concrete slab haunch over the steel supporting members or rework the girder camber to meet the plan grade and slab thickness. Do not allow shear connectors to penetrate the slab less than 2 inches.
607.03.22 Removal of Falsework. Upon completion of erection and before final
acceptance, remove all falsework, excavated or useless materials, rubbish, and temporary buildings. Replace or renew any fences damaged and restore in an acceptable manner all property, both public and private, which may have been damaged during prosecution of work. Leave the bridge site and adjacent highway in a neat and presentable condition satisfactory to the Engineer. Remove all excavated material or falsework placed in the stream channel during construction before final acceptance.
607.03.23 Cleaning and Painting.
A.General. Conform to Section 821. Furnish a coating system from the Departments List of Approved Materials for Bridge Coa tings, Class I, three coat system with zinc rich primer. Furnish a coating system in which all coats are produced by the same manufacturer. Follow the manufacturer’s recommendations for all mixing and application conditions and methods. Apply the prime coat in the shop. Field apply the remaining coatings of the selected coating system, including stripe coating of primer, intermediate and finish coat. When using thinners, mix according to the manufacturer’s written recommendation in the presence of the Engineer. Furnish copies of the manufacturer’s t echnical data sheets, material safety data sheets, and application procedures to the Engineer for review and approval before beginning painting. Submit written procedures for compliance with this subsection for cleaning and painting in both the shop and the field to the Engineer for approval before beginning work. Include at least the following:
1.Surface Preparation Methods and Equipment. Detail all equipment and operational procedures intended to be utilized in any process which prepares a surface to receive a coating.
2.Painting Methods and Equipment. Detail all equipment and operational procedures intended to be utilized in the application of coatings.
3.Containment and access rigging. Detail all equipment and operational procedures to be utilized in the erection, maintenance, and dismantling of rigging, platforms, scaffoldings, and containments. All rigging and containment plans must be signed and stamped by a licensed Kentucky Professional Engineer. Include provisions for safety precautions, traffic control, and access. Address responsibility for damage to public, property and the environment due to any cleaning or painting operation.
4.Storage and Handling. Detail all equipment and operational procedures to be utilized in handling, storing, and transporting painted members.
5.Coating Manufacturer’s Special Instructions. Detail all recommendations and special instructions provided from the coatings manufacturer to be utilized for surface preparation or coatings application. Submit the coating manufacturers written approval for application of the coating system to surfaces prepared in accordance to the detailed operational procedures.
6.Quality Control Plan. Detail all equipment and operational procedures to be utilized to ensure the quality of the completed coating system. Quality Control is performed as Quality Cont rol/Quality Assurance (QC/QA), where the contractor or their representative assume the role of Quality Control (QC) and the KYTC or their representatives as sume the role of Quality Assurance (QA) with additional inspections for final and/or partial final acceptance. Include at least the following: 607-19
a.Name and qualifications of painting supervisors and inspection personnel.
b.Assurance of authority and responsibility for painting supervisors to halt operations and make corrections upon discovery of non-conforming work.
c.Methods of informing painting personnel of the written approved painting procedures and their responsibility to comply.
d.Equipment and operational procedures for inspection, acceptance or rejection, and documentation of surface preparation and coatings application operations.
e.Procedures and documentation for calibration and field verification of calibration of equipment utilized for inspection of surface preparation and coatings application.
f.Process for control of project related documentation. The Department requires acceptance testing of coatings on a per-lot basis per- shipment. The Division of Materials will perform acceptance testing. At his option, the Engineer may elect to conduct more frequent sampling and testing. The Engineer will obtain test samples of coatings to be applied at the shop and the field. Allow 10 working days for testing and approval of the sampled coating. Apply coating only after it has been approved by the Department. It is the Contractor’s responsibility to maintain an adequate inventory of approved coating. The Department assumes no responsibility for lost work due to rejection of coating or approved coating subsequently found to be defective during the application process. Store the coating according to Section 821. The Department will reject the coating when test results indicate that the material does not conform to the requirements of this section. Remove all rejected coating materials from the job before beginning any painting. Mix coatings with a high shear mixer according to the manufacturer’s instructions to obtain a smooth, lump-free consistency. Do not use paddle mixers or paint shakers. Mix in the original containers unless the Engineer approves otherwise. Ensure that all of the solids that may have settled to the bottom of the container are thoroughly dispersed. When specified by the manufacturer’s product data sheet or application instructions, continuously agitate the mixed coating throughout the application process. Apply coatings smoothly and uniformly allowing no excess coating to collect at any point. Paint the contacting surfaces of joints or connections with primer only. When deemed unsatisfactory by the Engineer, remove, clean, and prepare again all paint work at any stage of its completion. When necessary or requested by the Engineer, and at no additional cost to the Cabinet, furnish a technical representative from the coating manufacturer to observe the initial application of all coatings used, to advise as to proper application techniques, and to determine that proper results are being obtained. Ensure that the technical representative is also available to visit the project at all times during the work if the Engineer requests or deems a visit is necessary. Obtain and record ambient conditions (a ir temperature, steel temperature, relative humidity, and dew point) to verify compliance to this subsection. Apply coatings using methods recommended by the manufacture of the coating system to attain the manufacturers recommended dry film thickness as stated on the applicable technical data sheet. All coating thickness measurements are dry film thickness. Determine dry film thicknesses with a Type II nondestructive dry film thickness gage. At a minimum, verify calibration of the Type II gage in accordance with SSPC PA 2, 607-20 by placing a plastic shim representing the expected dry film thickness of the coating over a representatively blasted surface, before and after obtaining dry film thickness measurements for any surfaces painted in a shift. Obtain dry film thickness measurements in accordance with SSPC PA 2 per shift for each coating application. Use of a Tooke gage or other destructive film thickness gage to assess the coating thickness on all coats may be used at the Engineer’s discretion. The Engineer will reject the total coating system when any coating is determined to be less than the specified minimum thickness even when the total dry film thickness exceeds the total of the minimum for all coats. Provide OSHA compliant safe and adequate access for proper inspection of the cleaning and painting at both the fabrication plant and the construction site during all phases of work and for a period of at least 15 working days after completing each painting section. Furnish, erect, and move scaffolding or appropriate equipment approved by the Engineer, to allow the Inspector to closely inspect all surfaces. Use rubber rollers or other protective devices on scaffold fasteners. Do not use metal rollers or other types of fasteners that may mar or damage the freshly painted surfaces. Comply with all Federal, State, and local regulations relative to environmental contamination, safety, and protection of persons and property.
B.Preparation for Shop Coating. After fabrication and immediately before painting, remove all areas of oil, grease, or other deleterious material by solvent cleaning in accordance with SSPC SP 1. Perform blotter tests in accordance with ASTM D 4285 Standard Test Method for Indicating Oil or Water in Compressed Air; daily, per compressor, in the presence of the Engineer. Use compressed air only when there is no evidence of moisture or oil. Abrasive blast clean all exposed surfaces of the metal to a minimum of SSPC SP 10/NACE 2; Near White Metal Blast Cleaning. Use abrasive media that produces an angular profile and conforms to SSPC AB 1, AB 2, or AB 3 as applicab le. Ensure that the depth of the anchor profile of the abrasive blast-cleaned surfaces meets the coatings manufacturers recommended anchor profile range as stated on the applicable technical data sheet. If no range is recommended or the recommendation allows less than 1.5 mils of anchor profile, produce an anchor profile wi thin the range of 1.5 mils to 3.5 mils. Measure anchor profile on metal surfaces in accordance with ASTM D 4417 Method C. Take at a minimum, 3 randomly distributed anchor profile measurements for each 5,000-square foot ar ea of prepared surface. Remove all fins, tears, slivers, and burred or sharp edges that are presen t on steel members, and that appear during the blasting operation, by grinding and re-blasting the area to achieve the required anchor profile. Apply coating only after the Engineer inspects and approves the surfaces.
C.Application of Shop Coating. Apply one full coat of primer to all metal surfaces including insides of bolt holes, faying surfaces, cut outs, weep hole etc., prior to shipping steel from the plant. Include surfaces that are to be field bolted in contact. No allowances will be made for bare metal unless otherwise specified or by written permission of the Engineer. Apply primer only to clean, dry metal surfaces that meet the surface preparation standard. Ensure that the application and curing of the primer coat to surfaces that are to be field bolted in contact is in accordance with the manufacturer’s recommendations as stated on the certificate of analysis certifying Class B slip coefficient of the primer. Apply coating only when ambient conditions are in accordance with the coating manufacturers recommended ambient condition ranges for application. Maintain the manufacturer’s recommended ambient conditions for curing through full cure of the applied prime coat. In the location where application and curing of coatings is to be performed, record and verify ambient conditions through the use of a 24-hour data logger system. Ensure that the dry film thickness of the prime coat is within the manufacturers recommended dry film thickness application range on all surfaces, 607-21 except those that are to be field bolted in contact. Ensure that the dry film thickness on surfaces to be field bolted in contact does not exceed the maximum dry film thickness as stated on the certif icate of analysis certifying Class B slip coefficient of the primer. If the prime coat is deficient in thickness, follow the coating manufacturer’s recommendation to achieve acceptable full prime coat thickness. Protect freshly coated primed surfaces from subsequent blast cleaning operations. When damage occurs, thoroughly wire brush or if visible rust occurs, re-blast to the specified surface preparation condition. Vacuum and re-prime these surfaces. Do not apply successive coats of the system over the prime coat until it is fully cured. Apply the remaining coatings of the coating system in the shop before assembly or erection in areas that will be inaccessible when assembled in the field. Apply the shop primer to interior surfaces of box sections that are to be sealed by welding. Paint structural steel that is to be welded only after completing welding. When welding the steel in the shop and subsequently erected by bolting, apply one coat of primer after finishing the shop welding and blast cleaning. Paint surfaces of iron and steel castings only when directed according to Subsection 607.03.08 D). Transfer or preserve field identifica tion erection marks and weight marks. Load the steel for shipment only after the shop coating has fully cured and the Engineer has inspected it.
D.Preparation for Field Coatings. Clean by sections, bays, or other readily identifiable portions of the structure (Quality Control Areas (QA areas)). Apply coating only after the Engineer has inspected and accepted each section, bay, or portion. After erection, including all bolting and remedial work, prepare the shop applied prime coating for field applied coatings as follows. Remove all grease, oil, lubricants, or other deleterious ma terial from all surfaces to be painted including lubricant or residuals from the surfaces of all galvanized nuts, bolts and washers by solvent cleaning according to SSPC SP 1. When dry overspray from the shop applied primer exists, remove by sanding. High pressure water wash all structural steel at 4,500 to 5,000 psi with a zero degree spinner tip held normal to the surface and 12 to 18 inches from the surface using clean potable water. As needed, use a non-sudsing, biodegradable detergent to remove all surface contaminants not removed by high pressure water washing. Rinse all areas where a detergent or solvent was applied by high pressure water washing with clean potable water. Repair all damaged prime coating in accordance with the coating manufacture’s recommendations. Apply a field coat of approved zinc rich prime coating to all areas not possessing an acceptable shop applied prime coating or intact galvanized surfaces. Completely remove all dirt, dry spray and other foreign material before applying field coatings. Assume sole responsible for any damage resulting from field surface preparation operations. Stripe coating shall be in accordance with SSPC-PA Guide 11 and shall be applied to all coats of paint. Striping of primer applied to bare steel, iron or other metallic substrate, shall be app lied after the primer repaired/touch up field application (utilizing a contrasting color of approved zinc rich primer). Striping of subsequent coats of paint shall be performed prior to full coat application. All sharp and non-radiuse d edges, welds, outside corners, bolt heads, threads, nuts, rivet heads, edges and ends of plates, edges and ends of diaphragms, lattice straps, inside corner s of box members, seams, crevices, back to back members, pitted steel, other discontinuities and all other locations required by the Engineer, shall be stripped on all required coats of 607-22 the chosen paint system. Stripping shall extend a minimum of 1 inch from edges, corners, nuts, bolts, rivets, etc. Any alteration of striping coverage shall require written approval from the Engineer. All manufacture’s recommendations shall apply to stripe coating for recoat windows, dry to handle, dry to cure, and any other stated recommendations from the Manufacture’s Product Data Sheets (MPDS) for the paint system application. The stripe coats shall be applied by spray, brush, roller, daubers, and other means and method with approval of the Engineer. If the Contractor’s chosen method of applying stripe coat is not producing results acceptable to the Engineer, the Engineer will require th e stripe coat application method to be changed. The application of stripe coats, shall be considered incidental to painting of the bridge and incidental to each indi vidual coat application. Stripe coat application shall be considered a separate inspection point, within the inspection of each applied coat of a complete coating system. When application of any coating will exceed the recoat window of the previously applied coating, abrade the surface of the previously applied coating according to the coating manufacturer’s recommendations before applying additional coatings.
E.Application of Field Coatings. Apply field coatings between April 1st and November 15th. The Department may allow painting at other times when the Engineer approves in writing. Apply coatings only to clean and dry surfaces, when the ambient air temperature is 40 F or greater, the surface temperature of the steel members to be painted is at least 5 F above the dew point, and the relative humidity is less than 90 percent or in accordance with the coating manufacture’s recommended ambient condition ranges, whichever is more stringent. Record and verify that ambient conditions are in compliance at the location where painting is to be performed prior to beginning coating application and at a minimum of every 4 hours throughout the application and curing process for each applied coating. Additional monitoring and recording of ambient conditions may be required with noticeable change in weather conditions or at the Engineers discretion. Totally enclose each section, bay, or portion (Quality Control Areas) of the structure with containment meeting, at a minimum, the requirements of SSPC Guide 6 Class 2W during all coating applications including repair of coatings defects and deficiencies. Protect pedestrian, vehicular, and other traffic on or underneath the bridge and all portions of the bridge superstructure and substructure against damage or disfigurement by spatters, splashes, and smirches of coating or coating materials. Maintain the containment materials to prevent releases of coating materials. Monito r the containment a minimum of 15 minutes for each 4 hours of coating application operations in accordance with SSPC Guide 6 Method A and Visible Emissions Monitoring – General Surveillance Level 2 Emissions. Assume sole responsibility for all damages resulting from coating application operations. Submit a detailed written outline to the Engineer for approval before field painting. Include sketches, if necessary, of methods to prevent overspray drift. Include protection of vehicular traffic, boats, and marinas beneath the bridge, and buildings or other property in the vicinity of the bridge. Apply field coatings (full and stripe coats) only after satisfactorily completing field cleaning and ensuring that the coating applied for retouching the shop coat is thoroughly dry. Do not apply succeeding coats until the previous coats have dried throughout the full thickness of the coating film and the coating application has been accepted by the Engineer. Paint from the top of the structure toward the bottom, and proceed by sections, bays, or other readily identifiable portions of the structure, unless the Contract or Engineer directs otherwise. 607-23 Apply successive coats of the coating system to all exposed surfaces of the completed structure. Stencil the completion date of painting, including the year and month, on the structure as the Engineer directs.
F.Repair of Shop and Field Coatings. Repair according to the manufacturer’s recommendations and as otherwise specified in this section, or otherwise in accordance with the Engineers written approval When spot repair will not produce a uniform and durable coating, repaint the entire member as the Engineer directs. Repair surfaces before erection that will be inaccessible after erection.
607.03.24 Name Plates. When shown, furnish and install name plates including
fastening devices.
607.04 MEASUREMENT. The Department will measure the quantity by the lump sum.
The Department will not measure miscellaneous metals, shop inspections, inspection facilities and equipment, material samples for mill authorization, enforcement of required safety precaution for radioactive exposure, furnishing of technical representatives for paint, extra paint required when bolting, nameplates, or direct tension indicators for payment and will consider them incidental to this item of work.
607.05 PAYMENT. The Department will make payment for the completed and accepted
quantities under the following: Code Pay Item Pay Unit 08160 Structural Steel Lump Sum The Department will adjust the Contract unit price for Structural Steel by the following formula when the Engineer makes plan changes that result in an increase of the estimated plan weight of steel: Adjusted Contract = Original Contract x (Revised Estimated Plan Weight) Unit Price Unit Price (Original Estimated Plan Weight) Bear all shop inspection costs incurred at locations other than the 2 original designated locations. The Department will initially pay for the inspection cost. Reimburse the Department subsequently. The Department will consider payment as full compensation for all work required under this section. The Department will make partial payment for structural steel plate stored at the fabrication shop when requested. This appl ies to structural steel quantities of 1,000,000 pounds or more. 607-24 SECTION 608 - CONCRETE BRIDGES
608.01 DESCRIPTION. Construct concrete bridges and parts of other bridges that are
concrete.
608.02 Materials.
608.02.01 Concrete. Conform to Subsection 601.02 and 601.03.
608.02.02 Steel Reinforcement. Conform to Section 811.
608.02.03 Bearing and Expansion Plates. Conform to Section 813. When the
Contract requires self-lubricating plates, furnis h machine surfaces with trepanned recesses.
608.02.04 Rockers. Conform to Section 812.
608.02.05 Elastomeric Bearing Pads. Conform to Section 822.
608.02.06 Preformed Cork Expansion Joint Filler (Type II). Conform to Section
807. Use with bearing pads.
608.02.07 Forms. Conform to Subsection 601.02.
608.02.08 Structural Steel. Conform to Section 812.
608.02.09 Masonry Coating. Conform to Section 828.
608.02.10 Anchor Bolts. Conform to Section 813.
608.02.11 Precast and Prestressed Members. Conform to Subsection 605.
608.02.12 Concrete Curing Materials. Conform to Section 823.
608.03 Construction.
608.03.01 Foundation. Begin work after structure excavation, sheet piling, and all
bearing piles have been prepared according to Sections 603 and 604.
608.03.02 Falsework and Forms. Construct all falsework and forms according to
Subsections 601.03.11 and 601.03.12.
608.03.03 Classes of Concrete for Substructure. Use Class AA concrete in portions
of the substructure above the top of caps except pedestals. Use Class A concrete in portions of the substructure below the top of caps and in pedestals. When placing concrete under water, use Class A Modified concrete.
608.03.04 Placing Steel Reinforcement in Substructure. Place steel reinforcement
according to Subsection 602.03.
608.03.05 Placing Concrete in Substructure. Proportion, mix, and place concrete
according to Subsection 601.03. Construct construction joints according to Subsection
601.03.10 Place concrete for footings to the full depth in one continuous operation, and
allow them to set at least 12 hours before placing forms thereon for other parts of the substructure unit. Place concrete in columns in one continuous operation between construction joints. Allow concrete in columns to set at least 12 hours before placing forms for caps. Place concrete for bridge seats according to Subsection 601.03.09. Finish all exposed surfaces according to Subsection 601.03.18. Bevel all exposed 608-1
Source: Kentucky Standard Specifications for Road and Bridge Construction, 2019 Edition. Pages 349–372 of 718.