SECTION 813 MISCELLANEOUS METALS
813.01 PINS AND ROLLERS. Use steel specified in the AASHTO LRFD Bridge
Design Specifications conforming to ASTM A108, ASTM A668 or ASTM A709, Grades 36, 50, or 50W.
813.02 STEEL CASTING. Conform to AASHTO M 103, Grade 70-36 (ASTM A 27).
813.03 EXPANDING STEEL MANHOLE RISERS. Use an approved type that expands
to fit tightly and rigidly within the existing frame.
813.04 GRAY IRON CASTINGS. Conform to ASTM A48, Class 30-B.
813.05 MALLEABLE CASTINGS. Conform to ASTM A 47. Use the grade specified.
813.06 RIGHT-OF-WAY MONUMENTS. See section 726.
813.07 LEAD PLATES. Manufacture plates from lead conforming to ASTM B 29.
813.08 Aluminum.
813.08.01 Cast Aluminum Sand Castings. Conform to ASTM B 26, Alloy 356.0-T6.
813.08.02 Aluminum Alloy Permanent Mold Castings. Conform to ASTM B 108.
813.08.03 Aluminum Alloy Sheet and Plate. Conform to ASTM B 209.
813.08.04 Aluminum Alloy Extruded Bars, Rods, Shapes and Tubes. Conform to
ASTM B 221, Alloy 6061-T 6511 or Alloy 6063-T 6.
813.08.05 Aluminum Alloy Rolled or Extruded Shapes. Conform to ASTM B 308,
Alloy 6061-T6.
813.08.06 Aluminum Alloy Seamless Pipe. Conform to ASTM B 241, Alloy 6061-T
6 and 6063-T 6.
813.08.07 Aluminum and Aluminum Alloy Bars, Rods, and Wire Bolts. Conform
to ASTM F 468, Alloy 2024-T 4. Give finished bolts a minimum anodic coating of 0.0002 inch.
813.08.08 Aluminum Nuts. Conform to ASTM F 467, Alloy 6061-T6 or 6062-T 9.
Give finished nuts a minimum anodic coating of 0.0002 inch.
813.08.09 Welding Rods. Conform to AWS A5.10.
813.09 Steel Bolts, Nuts, and Washers.
813.09.01 Carbon Steel Bolts and Nuts. Conform to ASTM A 307. Nuts conform
to AASHTO M 291.
813.09.02 High-Strength Steel Bolts, Nuts, and Washers. Mark all bolts, nuts, and
washers according to the appropriate ASTM Specifications. Assure all bolts, nuts, washers and miscellaneous metals are kept dry, free from debris, and lubricated. If using galvanized bolts, nuts, or washers, measure th e thickness of the zinc coating. Take m easurements on the wrench flats or top of bolt head. Submit mill test reports for all steel used in the manufacture of the bolts, nuts, or 813-1 washers to the Department for approval. Include with the mill test reports the place where the material was melted and manufactured. The Department will take field samples for testing to verify compliance with this section. Ship bolts, nuts, and washers (where required) from each rotational-capacity lot in the same container. If there is only one production lot number for each size of nut and washer, the Department will allow shipping of the nuts and washers in separate containers. Permanently mark each container with the rotational-capacity lot number to allow identification at any stage before installation. Supply the appropriate mill test report, manufacturer’s certified test report, or distri butor’s certified test report to the Engineer before beginning installation. For bolts, nuts, and washers, conform to the following dimensions: (1)ANSI Standards B 18.2.1 and B 18.2.2 shall govern tolerance to these dimensions. BOLT AND NUT DIMENSIONS (1) Bolt Dimensions Nut Dimensions in in Heav y Hexa gon Heav y Nominal Structural Bolts Hexagon Nuts Bolt Width Hei ght Threa d Width Hei ght Size Across Length Across in Flats Flats D F H T W H 1/2 7/8 5/16 1 7/8 31/64 5/8 1 1/16 25/64 1 1/4 1 1/16 39/64 3/4 1 1/4 15/32 1 3/8 1 1/4 47/64 7/8 1 7/16 35/64 1 1/2 1 7/16 55/64 1 1 5/8 39/64 1 3/4 1 5/8 63/64 1 1/8 1 13/16 11/16 2 1 13/16 1 7/64 1 1/4 2 25/32 2 2 1 7/32 1 3/8 2 3/16 27/32 2 1/4 2 3/16 1 11/32 1 1/2 2 3/8 15/16 2 1/4 2 3/8 1 15/32 813-2 (1)ANSI Standard B 18.22.1 Type A washer tole rances apply to the nominal dimensions for outside diameter and hole diameter. (2)May be exceeded by 1/4 inch. (3)3/16 inch nominal.
A.Bolts. Conform to ASTM F3125 Grade A325 or ASTM F3125 Grade A490 as applicable. Perform proof load testing according to ASTM F 606 Method 1 at the minimum frequency specified in ASTM F3125 Grade A325. Perform wedge testing on full size bolts according to ASTM F 606 paragraph 3.5 at the minimum frequency specified in ASTM A 325. If bolts are to be galvanized, perform tests after galvanizing. Plain bolts must be oily to touch when delivered and installed.
B.Nuts. Conform to ASTM A 194 as applicab le or AASHTO M 291. If nuts are to be galvanized (hot dip or mechanically galvanized), use heat treated Grade 2H, DH, or DH3. For plain (ungalvanized) nuts, use Grades 2, C, D, or C3 with a minimum Rockwell hardness of 89 HRB (or Brinell Hardness 180 HB), or heat treated Grades 2H, DH, DH3. For nuts that are to be galvanized, overtap the nuts the minimum amount required for proper assembly allowing the nut to assemble freely on the bolt in the coated condition. Overtap the nuts according to the mechanical requirements of ASTM A563 and the rotational-capacity test requirements of this section. Lubricate galvanized nuts with a lubricant containing a dye that contrasts with the color of the galvanizing. Perform proof load testing according to ASTM F 606, paragraph 4.2 at the WASHER DIMENSIONS IN MILLIMETERS (1) S quare of Rectan gular Bevele d Circular Washers Washers for American Standard Beams and Channels Nominal Nominal Minimum Slope o r Bolt Outside Diameter Thickness Side Mean Taper in Size Diamete r(2) of Hole Min. Max. Dime nsion Thickness Thickness 1/2 1 1/16 17/32 0.097 0.177 1 3/4 5/16 1:6 5/8 1 5/16 21/32 0.122 0.177 1 3/4 5/16 1:6 3/4 1 15/32 13/16 0.122 0.177 1 3/4 5/16 1:6 7/8 1 3/4 15/16 0.136 0.177 1 3/4 5/16 1:6 1 2 1 1/16 0.136 0.177 1 3/4 5/16 1:6 1 1/8 2 1/4 1 1/4 0.136 0.177 2 1/4 5/16 1:6 1 1/4 2 1/2 1 3/8 0.136 0.177 2 1/4 5/16 1:6 1 3/8 2 3/4 1 1/2 0.136 0.177 2 1/4 5/16 1:6 1 1/2 3 1 5/8 0.136 0.177 2 1/4 5/16 1:6 1 3/4 3 3/8 1 7/8 0.178(3) 0.28 (3) 2 3 3/4 2 1/8 0.178 0.28 HARDNESS NUMBER Bolt Size Brinell Rockwell C (in) Min. Max. Min. Max. 1/2 - 1 253 319 25 34 813-3 minimum frequency specified in ASTM A 563 or ASTM A 194. If nuts are to be galvanized, perform tests after galvanizing, overtapping, and lubricating.
C.Washers. Conform to ASTM F436. If supplying galvanized washers, perform hardness testing after galvanizing. Remove coating before taking hardness measurements.
D.Direct Tension Indicators. Conform to ASTM F959.
E.Rotational-Capacity Test. Perform rotational-capacity tests on all black or galvanized (after galvanizing) bolt, nut, and washer assemblies by the manufacturer or distributor before shipping. Perform additional rotational- capacity tests on each lot at job sit. Use washers as part of the test even though they may not be required as part of the installation procedure. Perform the following:
1.Perform rotational-capacity testing according to ASTM F 3125.
2.Test each combination of bolt production lot, nut lot, and washer lot, shipped as a rotational-capacity lot, as an assembly. Where washers are not required by the installation procedures, the Department will not require lot identification for them.
3.Assign a rotational-capacity lot number to each combination of lots tested.
4.Test at least 2 assemblies per rotational-capacity lot.
5.Assemble the bolt, nut and washer assembly in a Skidmore-Wilhelm Calibrator or an acceptable equivalent device. For bolts too short to be assembled in the Skidmore-Wilhelm Calibrator, test them according to 14) below.
6.Tighten the fastener assembly to the tensions listed below (-0/+2kips)
7.Match-mark the bolt, nut, and faceplate of the calibrator.
8.Tighten the fastener assembly to at least the minimum installation tension in the table below and record both the tension and the torque. The torque shall be read with the nut in motion. The torque shall not exceed 0.25PD where P=tension in pounds and D=diameter(in.)/12=bolt diameter in feet. Maximum torque values at minimum tension are provided in the table below. For tensions exceeding minimum tension, use the formula (0.25PD) to calculate maximum torque. PRETENSION REQUIREMENTS Diameter 120 ksi min. 150 ksi min. (inches) Tension (kips) Tension (kips) 1/2 1 1 5/8 2 2 3/4 3 4 7/8 4 5 1 5 6 1 1/8 6 8 1 1/4 8 10 1 3/8 10 12 1 1/2 12 15 813-4 MAXIMUM TORQUE AT MINIMUM DESIGN TENSION Diameter 120 ksi min. 120 ksi 150 ksi min. 150 ksi min. (inches) Min. Tension (kips) Max. Torque @ Min. Tension (ft-lbs) Min. Tension (kips) Max. Torque @ Min. Tension (ft-lbs) 1/2 12 125 15 156 5/8 19 247 24 312 3/4 28 437 35 546 7/8 39 710 49 893 1 51 1062 64 1333 1 1/8 64 1502 80 1875 1 1/4 81 2120 102 2656 1 3/8 97 2779 121 3466 1 1/2 118 3688 148 4625
9.Further tighten the nut to the rotation listed below. The rotation is measured from the initial marking in step 7. Assemblies that strip or fracture prior to this rotation fail the test. Bolt Length Up to 4D >4D to 8D >8D to 12D 120 ksi min. 240 degrees 360 degrees 420 degrees 150 ksi min. 240 degrees 300 degrees 360 degrees
10.Ensure the tension reached at the above rotation is > 1.15 x minimum installation tension. The minimum values are noted below. TENSION Diameter 120 ksi min. Req. Installation 120 ksi min. Turn Test Tension 150 ksi min. Req. Installation 150 ksi min. Turn Test Tension (inches) Tension (kips) (kips) Tension (kips) (kips) 1/2 12 14 15 17 5/8 19 22 24 28 3/4 28 32 35 40 7/8 39 45 49 56 1 51 59 64 74 1 1/8 64 74 80 92 1 1/4 81 94 102 117 1 3/8 97 112 121 139 1 1/2 118 136 148 170
11.Loosen and remove the nut. The nut shall turn on the threads to the position it was in during the test. The nut does not need to turn the full length of the 813-5 threads. Inability to turn the nut by hand indicates a thread failure. Broken bolts fail the test.
12.The assembly passes the RC test if all samples meet the requirements of steps 6-11.
13.The lot is non-conforming if the assembly fails to pass the following requirements:
a.Exceeding the maximum allowable torque in step 8.
b.Inability to reach rotation required in step 9.
c.Inability to remove the nut after installing to the rotation in step 9.
d.Failure to provide the tension required in step 10 after full rotation.
e.Shear failure of the threads as determined by visual examination of bolt and nut threads following removal.
f.Torsional or tension failure of bolt.
g.Note that elongation of the bolt, in the threads between the nut and the bolt head is to be expected and does not constitute a failure.
14.Test bolts too short for assembly in a Skidmore-Wilhelm Calibrator in a steel joint.
15.Pretension the assembly in the steel joint. The torque used shall not exceed the torque permitted in the table below. PRETENSION TORQUE VALUES Diameter 120 ksi min. 150 ksi min. (inches) Torque (ft-lbs) Torque (ft-lbs) 1/2 30 36 5/8 58 74 3/4 100 126 7/8 164 204 1 246 308 1 1/8 346 432 1 1/4 490 610 1 3/8 642 796 1 1/2 850 1062
16.Match mark the nut, bolt, and plate.
17.Prevent the bolt head from rotating and tension the bolt by rotating the nut the rotation specified in the table below. Take a torque reading at the required rotation with the nut in motion. Bolt Length Up to 4D >4D to 8D All Grades 120 degrees 180 degrees
18.The torque measurement taken in step 17 shall not exceed the torque listed in the following table: 813-6 MAXIMUM TORQUE VALUES Diameter 120 ksi min. 150 ksi min. (inches) Torque (ft-lbs) Torque (ft-lbs) 1/2 150 180 5/8 290 370 3/4 500 630 7/8 820 1020 1 1230 1540 1 1/8 1730 2160 1 1/4 2450 3050 1 3/8 3210 3980 1 1/2 4250 5310 Assemblies that exceed the above torque values fail the test. These torque values are based on the assumed tension of 1.15 x minimum installation tension.
19.Further tighten the nut the additional rotation listed below: Bolt Length Up to 4D >4D to 8D 120 ksi min. 120 degrees 180 degrees 150 ksi min. 90 degrees 120 degrees Assemblies that strip or fracture prior to this rotation fail the test.
20.Loosen and remove the nut. There shall be no signs of shear failure, stripping, or torsional failure. The nut shall turn on the threads to the position it was in during the test. The nut does not need to run the full length of the threads. Inability to turn the nut by hand is considered a thread failure. Broken bolts fail the test.
21.The assembly shall be considered nonconforming if the assembly fails to pass any of the following requirements:
a.Exceeding the maximum allowable torque in step 18.
b.Failure to achieve the required rotation in step 19.
c.Inability to remove the nut after installing to the rotation in step 19.
d.Shear failure of the threads as determined by visual examination of the bolt and nut threads following removal.
e.Torsional or torsional/tens ional failure of the bolt.
f.Note that elongation of the bolt, in the threads between the nut and the bolt head is to be expected and does not constitute a failure. The Department will not require an inspection agency present during testing; however, the manufacturer or distributor performing the tests shall certify that the results recorded are accura te. The Engineer reserves the right to witness testing on request. Ensure that the lot number appearing on the shipping package for bolts, washers, and nuts corresponds to the lot number identified on the distributor’s and manufacturer’s certification. Provide the Engineer with the certified test report from the manufacturer or distributor performing the rotational-capacity test. Include the following information: 813-7
a.The lot number of each of the items tested.
b.The rotational-capacity lot number.
c.A statement that the items conform to this section and the Contract.
d.The results of the tests.
e.The location and date of the tests.
f.The location where the bolt assembly components were manufactured.
813.09.03 Corrosion-Resisting Steel Bolts and Set Screws. Fabricate bolts and
screws from bars conforming to ASTM A 276. Use Types 302 or 304 for steel machine bolts to attach aluminum posts to concrete and for steel set screws for aluminum railings.
813.09.04 Stainless Steel Hardwa re, Bolts, Nuts, and Washers. Conform to ASTM
A 320.
813.09.05 Cadmium Coatings for Steel Anchor Bolts, Nuts, and Washers.
Conform to ASTM B 766, Class 12, Type II.
813.09.06 Anchor Bolts for Bearings and Anchorages . Conform to ASTM A449
Type 1 or ASTM F1554 Grade 105.
813.10 WELDING MATERIAL, PROCEDURES, AND INSPECTION. For bridges
comply with the ANSI/AASHTO/AWS D1.5 Bridge Welding Code with modifications and additions as specified in the Plans. For other steel structures comply with the AWS Structural Welding Code D1.1 with modifications and additions as specified in the Plans. For aluminum structures comply with the AWS Structural Welding Code-Aluminum D1.2.
813.11 STUD SHEAR CONNECTORS. Conform to AASHTO M 169 (ASTM A 108,
Grade 1015).
813.12 MATTRESSES AND GABIONS. Conform to ASTM A 975, Style 1 or ASTM
A 974, Style 1 or 2. Use wire with a minimum elongation of 10 percent of the length of the wire when tested according to ASTM A 370 without reducing the diameter or tensile strength of the wire. Supply lacing wire in sufficient quantity to ensure that all required tying, connecting, and lacing can be performed. For Department direct purchases, supply an amount of lacing wire equal to or greater than 8 percent of the weight of the units. Fabricate the mattress units to the dimensions required by the Contract. The Department will accept mattresses with dimensions within 3 percent of the ordered width.
813.12.01 Mattress Units. As an alternate to lacing wire, the Engineer will allow
mattress unit fasteners, from the Department’s List of Approved Materials, that conform to mattress unit manufacturer’s recommended assembly and connection instructions. Subdivide the mattress units into compartments a maximum of 3 feet in length extending over the full width of the mattress unit by inserting diaphragms made of the same mesh as the rest of the mattress unit. Secure the diaphragms in position on the bottom with a continuous spiral wire at the factory so no additional tying at this joint is necessary.
813.12.02 Gabion Baskets. As an alternate to lacing wire, the Engineer will allow
gabion unit fasteners, from the Department’s List of Approved Materials, that conform to mattress unit manufacturer’s recommended assembly and connection instructions. Supply diaphragms of the same material composition as the gabion to form individual cells of equal length and width when the gabion length exceeds its width. 813-8
813.12.03 Acceptance. Assure all bolts, nuts and washers are kept dry, free from
debris, and lubricated. Miscellaneous steel, bolts, and steel shipments not maintained in new condition will be rejected. The Department will test each shipment for wire size and zinc coating, and will perform any other Engineer ordered tests. The Department will accept shipments based on laboratory testing and the Engineer’s visual inspection. 813-9 SECTION 814 GUARDRAIL SYSTEMS
814.01 DESCRIPTION. This section covers material requirements for corrugated sheet
steel beams and accessories for guardrail, termin al sections, guardrail posts, offset blocks, end treatments, and timber guard posts.
814.02 BEAMS AND ACCESSORIES. Conform to AASHTO M 180. Hardware for
Type I, II, or III beams may be either hot-dip galvanized, electrogalvanized, or mechanically galvanized. Galvanize hardware according to AASHTO M 232. Galvanize beams according to AASHTO M 180. The Engineer will reject beams with zinc oxide (white rust) in amounts deemed objectionable. Furnish Ty pe II beams of either Class A, 0.105 inch thick or Class B, 0.135 inch thick as specified in the Contract.
814.03 TERMINAL SECTIONS. Conform to AASHTO M 180 and the details shown
on the Standard Drawings. Furnish Type 2 sect ions of either Class A, 0.105 inch thick or Class B, 0.135 inch thick as specified in the Contract.
814.04 GUARDRAIL POSTS. Provide either steel or timber, and use the same type
throughout the Project.
814.04.01 Steel Guardrail Posts. Fabricate from steel conforming to ASTM A 36 for
the wide flange shapes. Punch or drill holes for connector bolts before galvanizing. Galvanize all posts according to AASHTO M 111.
814.04.02 Timber Guardrail Posts. .Furnish either square sawn or round timber
guardrail posts. Conform to the nominal dime nsions shown on the Standard Drawings. The Engineer will allow a minus 2-inch tolerance from the specified nominal length. Saw the butts of all posts square, and finish th e tips as specified in the Contract. Bore bolt holes to a driving fit for the bolts. Frame, bore, and trim, as much as is practical, before giving the posts a preservative treatment. When it is necessary to bore or cut the posts after treatment, or when any treat ed surface has been badly scarred, treat the cut or scarred surface according to AWPA M4. Treat the posts with preservative according to AWPA U1, Section B, Paragraph 4.1 as applicable for guardrail posts. Use only one type throughout the project unless otherwise approved by the Engineer. Use any of the species of wood for round or square posts covered under AWPA U1. When furnishing oak posts, treat with creosote or creosote solution according to AWPA U1, Section B, Paragraph 4.1 for “Above Gr ound, Soil or Fresh Water Exposure.” See Subsection 818.01 for inspection, testing and acceptance procedures for Timber Guardrail Posts.
A.Square Sawed Posts. Ensure the posts, in the direction parallel to the axis of the bolt holes, do not exceed the dimensions specified in the Contract by more than 1/4 inch. Use posts that have straight grain, and that have a slope of the grain not deviating more than one inch in 12 inches from being parallel to any face when measured over the middle one-half of the length. The Engineer will not accept posts having a crook exceeding 1/2 inch in 10 feet. Limit wane to one end of the post only, and do not allow it to extend more than 10 feet from that end. Do not reduce the flat width of any face by more than 25 percent at the point of most wane. Do not use wood with ant tunnels, woodpecker holes, plugged holes, or any large unsightly gaps. The Department will allow wood with grub and worm holes less than 1/2 inch in average diameter, pr ovided that the sum of the diameters of all holes in any 12 inches of post length does not exceed 1/4 the nominal width of the face. Do not use posts showing signs of powder post beetle infestation. The 814-1
Source: Kentucky Standard Specifications for Road and Bridge Construction, 2019 Edition. Pages 589–597 of 718.