503Reinforcing Steel

503.03 Schedule of Material When the Department does not furnish reinforcing steel

schedules, the Contractor shall submit order lists, bending diagrams and bar layout drawings to the Resident for approval. The reinforcing steel shall not be ordered until these lists and drawings are approved. Approval shall not relieve the Contractor of full responsibility for the satisfactory completion of this item. When the Department allows the use of precast concrete deck panels, or any other significant changes that affect the quantity of reinforcing steel, the Contractor shall be responsible for revising the reinforcing steel schedule; the revised schedule shall be submitted to the Resident for approval. 5-57

503.04 Protection of Material Reinforcement, either plain, galvanized, stainless, epoxy-

coated, zinc and epoxy dual-coated, or low-carbon chromium, shall be stored on skids or other supports a minimum of 12 inches above the ground surface and protected at all times from damage and surface contamination. The storage supports shall be constructed of wood or other material that will not damage the surface of the reinforcement or epoxy coating. Bundles of bars shall be stored on supports in a single layer. Each bundle shall be placed on the supports out of contact with adjacent bundles. Coated and uncoated steel reinforcing bars should be stored separately. Do not use carbon steel tools, chains, slings, etc. when fabricating or handling stainless steel reinforcing bars- use only nylon or polypropylene slings. Prior to shipping, ensure that all chains and steel bands will not come into direct contact with stainless steel reinforcing bars. Place wood or other soft materials (e.g., thick cardboard) under the tie-downs. Alternatively, use nylon or polypropylene straps to secure stainless steel reinforcing bars. When bundles of plain reinforcement steel and stainless steel reinforcing bars must be shipped one on top of the other, the stainless steel reinforcing bars should be loaded on top. Use wooden spacers to separate the two materials. If it is expected that epoxy-coated or zinc and epoxy dual-coated bars will be required to be stored outdoors for a period in excess of two months, then they shall be protected from ultraviolet radiation.

503.05 Fabrication Bending of reinforcing bars and tolerances for bending of

reinforcing bars shall be in conformance with the latest edition of the "Manual of Standard Practice of the Concrete Reinforcing Steel Institute" and the "Detailing Manual of the American Concrete Institute". Unless otherwise specifically authorized, bars shall be bent cold. 503.051 Epoxy Coating Reinforcing steel, specified on the design drawings to be epoxy coated or zinc and epoxy dual-coated, shall meet the requirements of AASHTO M284 (ASTM A775), Epoxy-Coated Steel Reinforcing Bars, or ASTM A1055, Zinc and Epoxy Dual-Coated Steel Reinforcing Bars as applicable and the following requirements:

503.06 Placing and Fastening All steel reinforcement shall be accurately placed in the

positions shown on the Plans and shall be firmly held there during the placing and setting of the concrete. Immediately before placing concrete, steel reinforcement shall be free from all foreign material, which could decrease the bond between the steel and concrete. Such foreign material shall include, but not be limited to, dirt, loose mill scale, excessive rust, paint, oil, bitumen and dried concrete mortar. Bars shall be fastened together at all intersections except where spacing is less than 1 foot in either direction, in which case, fastening at alternate intersections of each bar with other bars will be permitted, providing this will hold all the bars securely in position. This fastening may be done using tightly twisted wire or by welding, when permitted by the Fabrication Engineer. All welding shall be done in accordance with this specification. Welders must be qualified by passing qualification tests for the process and position to be used in accordance with AWS D1.4 Structural Welding Code – Reinforcing Steel. Welding shall only be done when performed in accordance with a welding procedure approved by the Fabrication Engineer. Weld area preheat shall comply with AWS D1.4. Weld areas shall be free of cracks, undercut or other deficiencies injurious to the reinforcing steel. Welds are not permitted within two bar diameters of a bend, if the bend radius is less than 16 bar diameters. Welds must comply with testing and sampling requirements in the Fabrication and Mechanical Properties sections of AASHTO M 54 (ASTM A184). Welds shall be able 5-60 to withstand a static load of 150 pounds applied perpendicular to the reinforcing grid. Tension specimens must meet the material requirements of the type bar used when tested with a welded joint approximately at the center of the specimen. Frequency of testing shall be for every 75,000 square feet, or fraction thereof, of reinforcing grid fastened by welding. No welding for fastening or supporting reinforcing steel in areas of high tensile stresses will be permitted. Welding on epoxy-coated or dual-coated reinforcing steel will not be permitted under any condition. In general, no welding will be permitted on the main reinforcing steel of superstructures. Proper distances from the forms shall be maintained by means of chairs, stays, blocks, ties, hangers or other approved means. Chairs used for this purpose shall be plastic, plastic coated, epoxy coated or plastic tipped. Where stainless steel reinforcement is specified, the plastic tipped chairs shall be made of stainless steel conforming to the requirements of ASTM A493, Type 316 or 316L. Blocks used for this purpose shall be precast portland cement mortar blocks of approved shape and dimensions. Blocks shall not be used in cases where the blocks will be visible in the finished product. Layers of bars may be separated by precast portland cement mortar blocks or other approved devices. The use of pebbles, pieces of broken stone or brick, metal pipe or wooden blocks shall not be permitted. The placing of reinforcement as concrete placement progresses, without definite and secure means of holding the steel in its correct position, shall not be permitted except in the case of welded steel wire fabric or reinforcing bar grids. Epoxy-coated, dual-coated, or galvanized reinforcing bars supported on formwork shall rest on coated wire bar supports, or on bar supports made of dielectric material or other acceptable materials. Wire bar supports shall be coated with dielectric material for a minimum distance of 2 inches from the point of contact with the reinforcing bars. Reinforcing bars used as support bars shall be epoxy-coated or zinc-coated as applicable. In walls, spreader bars shall be epoxy-coated or zinc-coated as applicable. Tie wire for epoxy-coated, zinc and epoxy dual-coated, galvanized, stainless, or low- carbon chromium reinforcing steel shall be soft annealed wire that has been nylon, epoxy or plastic coated. Tie wire for stainless steel reinforcement may also be uncoated stainless steel conforming to the requirements of ASTM A493, Type 316 or 316L. 16 gauge (or heavier) black-annealed ferrous metal wire may also be used for low-carbon chromium or plain reinforcement. When formwork for casting concrete is made of uncoated steel or stainless steel, the use of galvanized steel reinforcing bars shall require an electrical isolation of the formwork from the galvanized reinforcement. The Contractor is referred to Section X2 of ASTM A767, Guidelines for Use of Galvanized Reinforcing Bars with Non-Galvanized Steel Formwork, for more information. Field bending or cutting of epoxy-coated or dual-coated reinforcing bars will not be allowed, unless otherwise indicated on the Plans or permitted by the Resident. When field 5-61 bending or cutting is allowed, all damaged coating areas shall be repaired in accordance with the patching requirements, Section 503.052. All placing and fastening related guidelines in ASTM A775 or A1055, Section X1, Guidelines for Job-Site Practices, shall be considered mandatory where not already covered by this specification. Bars in bridge seats shall be placed so as to clear anchor bolts. When specified on the Plans, reinforcing steel shall be anchored into drilled holes. The anchoring material shall be one of the products listed on the Maine Department of Transportation's Qualified Products List, Epoxy and Resin Based Adhesive Bonding Systems. Installation shall be in accordance with the manufacturer's published recommendations. At each anchor location, existing reinforcing shall be located to avoid drilling through existing bars. Where interferences are found to exist, location adjustments will be determined by the Resident. Minimum embedment lengths of reinforcing bars shall comply with the manufacturer’s published recommendations for the anchoring material selected. These embedment lengths shall be verified by the Resident before installation of the reinforcing bars. The reinforcing steel lengths indicated on the Plans may be reduced, at the Contractor's option, to the determined minimum embedment lengths. Reinforcement shall be inspected and approved by the Resident before any concrete is placed.

503.07 Splicing Reinforcing bars shall be spliced in accordance with the requirements

of this section, and in the locations shown on the Plans. No modifications of, or additions to, the splice arrangements shown on the Plans shall be made without the Resident's prior approval. Any additional splices authorized shall be staggered as much as possible. All splices shall be made in a manner that will ensure that not less than 75 percent of the clear concrete cover and not less than 75 percent of the minimum clear distance to other bars will be maintained, as compared to the cover and clear distance requirements for the unspliced bar. Lapped splices shall be made by placing the bars in contact and wiring them together. Splice laps shall be made in accordance with the following table, unless otherwise noted on the Plans: US CUSTOMARY UNITS Minimum Lap Splice Length (inches) 1 Bar Type/ Bar Size #3 #4 #5 #6 #7 #8 #9 #10 #11 Plain or Galvanized 16 16 20 24 30 39 49 62 77 Epoxy or Dual-Coated 19 19 24 29 36 47 74 93 115 5-62 Low-carbon Chromium 20 26 33 39 49 65 82 104 127 Stainless 16 20 25 30 37 49 61 78 96 1 Lap Splice lengths are based on the following parameters: Mini mum center-to- center spacing between bars of 6 inches; nominal yield strength of the reinforcing steel equal to 60 ksi (100 ksi for low-carbon chromium reinforc ement, 75 ksi for stainless steel reinforcement); minimum 28-day compressive strength of concrete equal to 4,000 psi; Class B tension lap splice. When any of th e preceding parameters are altered, appropriate minimum lap splice lengths will be as shown on the Plans. When lap splices are placed horizontally in an e lement where the concrete depth below the splice will be 12 inches, or more, the indicated lap splice lengths shall be multiplied by a factor of 1.4. Mechanical couplers may be used for splicing reinforcing bars, provided they are approved by the Resident and conform to the following requirements:

503.08 Lapping Sections of welded steel wire fabric shall be securely fastened to

adjoining sections and overlapped. All laps for wire sizes D4 thru D20 shall be 14 inches. Reinforcing bar grids shall be spliced as required for the individual bars, per the table in

503.09 Substitution Substitution of different size bars shall not be permitted except with

the written authorization of the Resident. 5-63

503.10 Method of Measurement Reinforcing steel bars, either plain, galvanized,

stainless, epoxy-coated, zinc and epoxy dual-coated, or low-carbon chromium, shall be measured by the computed number of pounds or by the lump sum, of steel reinforcement authorized, as indicated in the Contract. Welded steel wire fabric shall be measured by the computed number of pounds or by the lump sum of fabric authorized, as indicated in the Contract. Splices made using mechanical devices or by welding, as shown on the Plans or required by the specifications, will be measured as the number of splices of each kind satisfactorily made and accepted. Weights will be computed in accordance with the following: For steel bars, either plain, galvanized, stainless, epoxy-coated, zinc and epoxy dual- coated, or low-carbon chromium, weights will be computed in accordance with the following table: US CUSTOMARY UNITS Pounds per Foot Bar Size #3 #4 #5 #6 #7 #8 #9 #10 #11 Weight 0.376 0.668 1.043 1.502 2.044 2.67 3.4 4.303 5.313 For welded steel wire fabric, weights will be computed in accor dance with the following table: US CUSTOMARY UNITS Size in inches 6 by 6 3 by 6 4 by 4 6 by 6 Gauge W1.4 by W1.4 W1.4 by W1.4 W1.4 by W1.4 W2.9 by W2.9 Weight (lbs./100 ft2) 21 30 31 42 For other sizes of fabric, the commercially recognized weights will be used. No addition to, or deduction from, the theoretical weight per foot of the uncoated bars will be made because of additional requirements for blast cleaning and epoxy, zinc, or dual- coating of the bars. Lapped splices and splices made using mechanical devices or by welding, that are authorized at the Contractor's request, will not be measured for payment.

503.11 Basis of Payment The accepted quantity of reinforcing steel, either plain,

stainless or low carbon chromium, will be paid for at the Contract unit price per pound or by the lump sum, for each item involved, complete, and accepted. The accepted quantity of epoxy-coated, galvanized or zinc and epoxy dual-coated reinforcing steel will be paid for at the Contract unit price per pound or by the lump sum, for each item involved, complete and accepted, and all additional expenses that may be incurred 5-64 by the Contractor or their suppliers as a result of the requirements in these specifications will be considered incidental to, and included in, the Contract unit price per pound or lump sum price. When reinforcing steel schedules are required, they shall be considered incidental to the related Contract items. Payment for work associated with revisions to the reinforcing steel schedule, required when the Department allows the use of precast concrete deck panels, or any other significant changes that affect the quantity of reinforcing steel, shall be considered incidental to related Contract items. The accepted quantity of welded steel wire fabric will be paid for at the Contract unit price per pound or by the lump sum, in place, complete and accepted. The accepted quantity of mechanical and/or welded splices will be paid for at the Contract unit price each, complete and accepted, for each type specified. Payment will not be made for any materials used to hold reinforcement in place or for extra weight due to substitutions and splices made for the Contractor's convenience. When reinforcing steel is specified to be anchored into drilled holes, no additional payment will be made for drilling and anchoring reinforcing steel or cutting of reinforcing steel to embedment lengths. Payment for additional material samples, as required for testing by the Department, shall be considered incidental to related Contract items. Payment will be made under: Pay Item Pay Unit

503.12 Reinforcing Steel, Fabricated and Delivered Pound

503.121 Reinforcing Steel, Fabricated and Delivered Lump Sum

503.13 Reinforcing Steel, Placing P ound

503.131 Reinforcing Steel, Placing L u m p S u m

503.14 Epoxy-Coated Reinforcing Steel, Pound

Fabricated and Delivered, 503.141 Epoxy-Coated Reinforcing Steel, L u m p S u m Fabricated and Delivered

503.15 Epoxy-Coated Reinforcing Steel, Placing Pound

503.151 Epoxy-Coated Reinforcing Steel, Placing Lump Sum

503.16 Welded Steel Wire Fabric, Complete in place Pound

503.161 Welded Steel Wire Fabric, Complete in place Lump Sum

503.17 Mechanical/Welded Splice E a c h

503.19 Low-Carbon Chromium Reinforcement, P ound

F a b r i c a t e d and Delivered 503.191 Low-Carbon Chromium Reinforcement, L u m p S u m 5-65 F a b r i c a t e d and Delivered

503.20 Low-Carbon Chromium Reinforcement, Placing Pound

503.201 Low-Carbon Chromium Reinforcement, Placing Lump Sum

503.22 Zinc-Coated (Galvanized) Reinforcing Steel, Pou nd

F a b r i c a t e d and Delivered 503.221 Zinc-Coated (Galvanized) Reinforcing Steel, Lum p Sum F a b r i c a t e d and Delivered

503.23 Zinc-Coated (Galvanized) Reinforcing Steel, Placing Pou nd

503.231 Zinc-Coated (Galvanized) Reinforcing Steel, Placing Lum p Sum

503.26 Stainless Steel Reinforcement, P ound

Fabricated and Delivered 503.261 Stainless Steel Reinforcement, L u m p S u m Fabricated and Delivered

503.27 Stainless Steel Reinforcement, Placing P ound

503.271 Stainless Steel Reinforcement, Placing L u m p S u m

503.28 Zinc and Epoxy Dual-Coated Reinforcing Steel, Pound

F a b r i c a t e d and Delivered 503.281 Zinc and Epoxy Dual-Coated Reinforcing Steel, Lump Su m F a b r i c a t e d and Delivered

503.29 Zinc and Epoxy Dual-Coated Reinforcing Steel, Pound

P l a c i n g 503.291 Zinc and Epoxy Dual-Coated Reinforcing Steel, Lump Su m P l a c i n g SECTION 504 STRUCTURAL STEEL GENERAL REQUIREMENTS

504.01 Description This work shall consist of detailing, fabricating and erecting

structural steel bridges, ancillary bridge products and other steel structures. Materials, workmanship, inspection and documentation not specifically addressed by this Specification shall done be in accordance with the applicable sections of the AASHTO/AWS D1.5 Bridge Welding Code including Commentary (the D1.5 Code), the AASHTO Guide Specification For Highway Bridge Fabrication with HPS 70W (HPS 485W) STEEL (the Fab Guide) and other Standards and Specifications referenced herein. ALL REQUIREMENTS IN THIS SPECIFICATION ARE THE RESPONSIBILITY OF THE CONTRACTOR UNLESS NOTED OTHERWISE.

504.02 Materials Materials shall meet the requirements of the following sections of

504.03 Drawings Prepare shop detail, erection and other necessary drawings in

accordance with Section 105.7–Working Drawings. Show nondestructive examination symbols on the Shop Drawings. Include a fastener assembly table showing the number, size, length location and number of all bolts. Procedure Qualification Records and Weld Procedure Specifications are part of the shop drawing submittal. Weld Procedure Specifications that have been previously reviewed by the Department and are in conformance with the D1.5 Code need not be re-submitted. The drawings will be reviewed in accordance with the applicable requirements of Section 105.7 of the Standard Specifications, the AASHTO/NSBA Shop Detail Drawing Review/Approval Guidelines, G1.1 and this Specification. Review times will be in accordance with Section 105.7.2 of the Standard Specifications.

504.04 Facility Requirements Fabricate steel in a facility holding a current AISC or

Department shop certification as follows: Type of Product Type of Certification Required 1,2,3,4

504.05 Notice of Beginning Work Give the Fabrication Engineer a minimum of two

weeks notice for in-state work and three weeks notice for out-of-state work prior to beginning production. Provide the Fabrication Engineer with a copy of the production 5-67 schedule. If the production schedule changes, notify the Fabrication Engineer no less than 3 working days prior to the initial start-up date. If work is suspended on a project, the Fabrication Engineer will require 72 hours notice prior to the resumption of work. Any work done without the Quality Assurance Inspector (QAI) present will be subject to rejection.

504.06 Inspection Quality Control (QC) is the responsibility of the Contractor. Inspect

all aspects of the work and supervise all nondestructive examination (NDE). Record measurements and test results in a clear and legible manner. Reject materials and workmanship that do not meet contract requirements. The Contractor may perform NDE in addition to the minimum required. Provide a copy of all measurements and testing to the QAI. Quality Assurance (QA) is the prerogative of the Department. The QAI will ensure that the QC Department is performing properly, verify documentation, periodically inspect workmanship and witness NDE. The QAI will schedule testing deemed necessary by the Fabrication Engineer in addition to the minimum testing requirements in a manner that minimizes interference with the production schedule.

504.07 Inspector's Authority The QAI has the authority to reject material or

workmanship that does not meet the contract requirements. The acceptance of material or workmanship by the QAI will not prevent subsequent rejection if the work or material is found unacceptable.

504.08 Rejections Correct or replace rejected material and/or workmanship. Generate a

non-conformance report (NCR). Provide a copy to the QAI and forward a copy to the Fabrication Engineer for review and comments. Structural Defects: Repair structural defects only with the approval of the Fabrication Engineer. Submit a nonconformance report (NCR) to the Fabrication Engineer with a proposed repair procedure. Do not perform structural repairs without an NCR that has been reviewed by the Fabrication Engineer. Give the QAI adequate notice prior to beginning structural repairs. In the event that an item fabricated under this Specification does not meet the contract requirements but is deemed suitable for use by the Department, said item may be accepted in accordance with Section 100 of the Standard Specifications (see 106.8), Non-Conforming Work.

504.09 Facilities for Fabrication Inspection Provide a private office at the fabrication

plant for QA personnel. The office shall be in close proximity to the work. The office shall be climate controlled to maintain the temperature between 68° F and 75° F and have the exit(s) closed by a door(s) equipped with a lock and two keys which shall be furnished to the QAI (s). The QAIs’ office shall meet the following minimum requirements: Description Quantity 5-68 Office area (minimum ft2) 100 Drafting Table Surface (ft2) 3 5 Drafting stools-each 1 O f f i c e D e s k 1 Ergonomic Swivel Chairs 1 per inspector Folding Chairs 2 High-speed internet connection (ports) or wireless 1 per ins pector Fluorescent Lighting of 100 ft-candles minimum for all work areas 2 110 Volt 60 Cycle Electric Wall Outlets 3 W a l l C l o s e t 1 Waste Basket with trash bags 1 W a t e r C o o l e r 1 B r o o m 1 D u s t p a n 1 Cleaning Materials-floor, surfaces, windows - duration of the project The Contractor is responsible for disposing of trash and supplying commercially bottled water for the water cooler. The QAI will have the option to reject any furniture or supplies provided to the Inspector’s Office based on general condition. Provide parking spaces for QA personnel in close proximity to the QAIs’ Office. Maintain the pathway between the parking area and the QAIs’ office so that it is free of obstacles, debris, snow and ice. The facilities and all furnishings shall remain the property of the Contractor upon completion of the work. Payment for the facilities, heating, lighting, telephone installation, internet connection, basic monthly telephone and internet charges and all furnishings shall be incidental to the Contract. Failure to comply with the above requirements will be considered denial of access to work for the purpose of inspection. The Department will reject all work done when access for inspection is denied.

504.10 Mill Test Reports Provide legible Certified Mill Test Reports (CMTRs) for all

steel and iron material. Provide the CMTRs prior to fabrication. If the Contractor begins fabrication, including cutting material, before the QAI has verified the CMTRs and mill markings, the material will be rejected. Furnish Certified Mill Test Reports for fasteners. The supplier shall perform a Rotational Capacity Test (RCT) for both plain and galvanized bolts in accordance with AASHTO M 164M/M 164 (ASTM A 325) for each combination of bolts, nuts and washers supplied. Each combination shall be assigned a unique Rotational Capacity (R-C) lot number. 5-69

504.11 Material Identification and Control Mark steel plates and shapes as specified in

AASHTO M 160 (ASTM A 6). Only use material from stock if it can be positively identified, properly documented and the direction of rolling can be determined. Store material and fabricated items off the ground. Protect the material and fabricated items from dirt, grease, other foreign materials and significant corrosion. Store fasteners in a protected environment. Provide four fastener assemblies for each lot, length and combination to the Fabrication Engineer for testing. A fastener assembly consists of a bolt, washer, nut and direct tension indicator (when required). Provide the fastener samples to the Fabrication Engineer immediately upon delivery to the fabrication shop or job site. Provide Certificates of Conformance for welding consumables that are not on the Department’s pre-approved electrode list.

504.12 Protective Coatings If paint is specified, apply the coating in accordance with

Section 506 of the Standard Specifications or Special Provision 506 as applicable. When galvanizing is specified, clean the steel in accordance with SSPC-SP 6 prior to galvanizing. Galvanize in accordance with AASHTO M 111 (ASTM A 123). Galvanize fasteners in accordance with ASTM F 2329-05 or AASHTO M 198 Class 50 (ASTM B 695 Class 50). Galvanized nuts shall be lubricated with a water-soluble lubricant containing a dye that contrasts with the color of the galvanizing.

504.13 Unpainted Steel Clean all surfaces to a minimum SSPC-SP 6, Commercial Blast

Cleaning. Steel may be abrasive-blast cleaned prior to fabrication. Clean steel that is abrasive cleaned prior to fabrication in accordance with SSPC-SP 6 shall be cleaned in accordance with SSPC-SP 1 Solvent Cleaning after fabrication is complete. Disassemble bolted field splices and solvent clean all faying surfaces in accordance with SSPC-SP 1 Solvent Cleaning after drilling or reaming is complete. Inspect the splices prior to re- assembly. HIGHWAY BRIDGE FABRICATION

504.14 Materials for Bridges The grade of steel is designated on the Plans. Do not

substitute material without the approval of the Fabrication Engineer.

504.15 Handling Material Handle material in a manner that prevents nicks, gouges or

other damage from chains, wire ropes or other handling devices during all phases of fabrication.

504.16 Plates for Fabricated Members Cut plates subject to calculated stress, including

splice plates, so that the direction of rolling is parallel to the primary stresses. The direction of primary stresses for web and field splice material is parallel to the flanges unless 5-70 otherwise shown. Transfer heat numbers to each primary member used in fabrication. Primary members include flanges, webs, splice plates, bearing stiffeners, connection plates and diaphragm material on curved bridges.

504.17 Correcting Materials Correct material by a method that does not damage the

material. If heating of the steel is required, submit a written procedure to the Fabrication Engineer for review. Do not use external force in conjunction with heating unless authorized in the procedure. Following corrective work, inspect the steel with nondestructive testing methods acceptable to the Fabrication Engineer. The presence of cracks or fractures will be cause for rejection of the material.

504.18 Base Metal Repairs Make base metal repairs in accordance with the D1.5 Code.

Submit an NCR to the Fabrication Engineer for review if the repair area exceeds the allowable limits for base metal repairs as specified in the D1.5 Code. Notify the QAI prior to beginning the repairs.

504.19 Thermal Cutting Thermal cut steel using automatic equipment or a mechanical

guide. Adjust the rate of travel of the cutting equipment to prevent hardening the steel. Do not cut material freehand.

504.20 Edge Hardness Edge Hardness testing is not required.

504.21 Edge Planing Plane sheared edges of plates greater than 5/8 inch thick to a depth

of 3/16 inch.

504.22 Bent Plates Cold-bend rolled steel plates in accordance with the

AASHTO/NSBA S 2.1 Steel Bridge Fabrication Guide Specifications, Table 4.2 and the following:

504.23 Die Stamping Die stamp primary members (including splice material,

diaphragms and cross frames on curved bridges) in no-stress locations. No-stress locations include the ends of girders within the cross-sectional area, web splice plates in the middle third of the plate height and outside the outermost row of bolt holes and flange splice plate ends between the outermost row of holes and the edge. Use blunt-nose, low-stress dies.

504.24 Camber and Curvature When camber or curvature is required for stringers or

girders, it will be specified on the Plans. Measure and record specified camber or curvature using the same ordinates shown on the reviewed shop drawings after all welding is complete. When no camber or curvature is specified, variations in straightness of rolled shapes, with and without cover plates, shall not exceed the tolerances of AASHTO M 160 (ASTM A 6).

504.25 Heat Cambering and Curving Minor correction of camber or sweep of welded

plate girders is considered part of ordinary shop fabrication practice and does not require an approved procedure, however, use the following guidelines:

504.26 Welding Qualify welders and Weld Procedure Specifications in accordance with

the most recent edition of the D1.5 Code. Provide a list of qualified welders including process and position to the QAI prior to beginning fabrication. Submit the Weld Procedure Specifications to the Fabrication Engineer for review prior to beginning work. Weld Procedure Specifications previously reviewed and still valid in accordance with the D1.5 Code are acceptable without re-submission.

504.27 Welding Requirements Calibrate welding equipment at the intervals indicated in

the D1.5 Code. Meters shall be accurate within 2% throughout the range of the WPS. Work done with equipment that is not properly calibrated will be rejected. Provide copies of the calibration records to the QAI. The QAI can require the Contractor to demonstrate the accuracy of the meters at any time. Display a copy of the applicable Weld Procedure Specification at each welding station. Weld within the parameters of the Weld Procedure Specification. Failure to display a Weld Procedure Specification at the welding station will make all welding performed at that station subject to rejection. Perform all preheat, welding and postheat in accordance with the D1.5 Code and this Specification. Provide the appropriate temperature indicating crayons at each workstation to verify preheat. Calibrated digital thermometers may be used with the approval of the Fabrication Engineer instead of temperature indicating crayons. 5-73 Weld flange plate and web plate butt joints, web to flange welds, stiffener and connection plate to web welds, and cover plate to flange welds using an automatic weld process. Make repairs with the same process used for the original welds, except that repairs less than 12 inches in length may be made with a different process using an approved Weld Procedure Specification. Do not blend repair welds by grinding unless the original weld requires grinding.

504.28 Welded Fabrication Each side of complete joint penetration welds, once begun,

shall be welded to completion without interruption or a delay between passes except as necessary to maintain interpass temperature requirements. After backgouging, the groove and 3 inches on either side of the groove and through the thickness of the steel shall be preheated in accordance with the D1.5 Code immediately before the resumption of welding. Single-pass fillet welds may be qualified by a Fillet Weld Soundness Test performed in accordance with the D1.5 Code as modified herein. Perform the “T” test by welding the smallest fillet weld to be used in production on one side and the largest fillet weld used in production on the other side of the “T”. Macroetch the test specimens in accordance with the requirements of Clause 5, Method of Testing Specimens, of the D1.5 Code. Acceptance and re-testing, if required, shall be in accordance with Clause 5 Test Results Required and Retests, of the D1.5 Code. The minimum heat input for single-pass fillet welds during testing and production shall be 35 kilojoules/in.

504.29 Welding ASTM A 709 HPS 70W Steel In addition to 504.28, use the most

recent edition of the D1.5 Code and the Fab Guide as amended herein when welding ASTM A 709 Gr. HPS 70W. Use only consumables that produce weld metal with diffusible hydrogen of H8or less. Handle and store consumables in accordance with the requirements of Clause 12 of the D1.5 Code. Preheat in accordance with Clause 4 of the D1.5 Code through the thickness of the steel and three inches in all directions from the weldment. Failure to properly preheat the steel will result in rejection of the weld metal. Remove and re-weld rejected weldments. HPS 70W may be joined to Grade 50W steel using a Weld Procedure Specification qualified for Grade 50W steel if the diffusible hydrogen content of the deposited weld metal is H 8 or less. Use minimum preheat temperature for Gr. HPS 70W in accordance with the D1.5 Code.

504.30 Nondestructive Testing Perform nondestructive testing in accordance with the

D1.5 Code and these Specifications. The QAI will witness nondestructive testing. Give the QAI adequate notice to facilitate the QAI’s presence. Failure to notify the QAI will result in re-testing with the QAI present. Document nondestructive testing on the appropriate forms from Annex III of the D1.5 Code, or an equivalent form. 5-74

504.31 Shop Assembly Assemble stringers and girders in accordance with the shop

assembly drawings. Measure and record the bearing-to-bearing dimensions, the bearing-to- field-splice dimensions and the offset from the reference line dimensions as shown on the shop assembly drawings. Give the QAI the opportunity to verify the measurements prior to disassembly.

504.32 Tolerances Dimensional tolerances for welded plate girders are described in the

D1.5 Code. Dimensional tolerances for rolled shapes are described in AASHTO M 160 (ASTM A6). The tolerance for the length of any primary bridge member is ±1/4 inch. The bearing-to-bearing tolerance is ±1/8 inch. The bearing elevation tolerance is ±1/8 inch. The offset tolerance for bolted field splices is ±3/4 inch.

504.33 Match marking Match mark drill assembled or ream assembled field splice

material prior to disassembly. Preserve the match marking through field erection.

504.34 Holes for High Strength Bolts Oversize holes are not allowed unless noted on

the Plans. Drill bolt holes full-size. Splice plates may be used as one-time templates to drill webs and flanges. The plates shall remain with the splice. Replace damaged plates used as a template. The Contractor may temporarily tack weld web splice plates to the web in the middle 1/3 of the web only. Completely remove tack welds by grinding and MT the tack areas. Do not tack weld flange splice plates to flanges. Holes for cross frames, diaphragms and associated connection plates may be punched when the thickness of the plate is ≤ 3/8 inch. The diameter of the die shall not exceed the diameter of the punch by more than 1/16 inch. Holes shall be clean cut, without torn or ragged edges. Make holes cylindrical and perpendicular to the member. Remove burrs from parts after drilling or reaming. Remove all visible drilling oil, lubricants and coolants, including water soluble lubricants and coolants from faying surfaces in accordance with SSPC-SP 1-Solvent Cleaning. The Contractor may thermal cut holes in bearing base plates using an automatic process. Do not exceed a surface roughness of ANSI 1000 micro-inches.

504.35 Accuracy of Holes Following the completion of the drilling of holes in a

contiguous group, with all plies of a connection in their proper position for assembly, all bolt holes shall accept a pin 1/32 inch smaller in diameter than the nominal bolt hole diameter. Provide a pin of the applicable diameter for inspection purposes. No finished bolt hole shall be located more than 1/8 inch from its theoretical location. The repair of mislocated holes shall be subject to the approval of the Fabrication Engineer.

504.36 Shop Bolts Install shop bolts in accordance with this Specification except that

adequately lubricated fastener assemblies that have been Rotational Capacity (Ro Cap) 5-75 tested by the supplier do not need to be Ro Cap tested prior to installation. As an alternative, Tension Control (TC) bolts meeting the requirements of ASTM F1852 may be used with the approval of the Fabrication Engineer. Submit a tensioning procedure for TC bolts to the Resident for review.

504.37 Bearings Finish bearings, base plates and other contact surfaces to the

requirements of Section 523.

504.38 Marking and Delivery Mark each piece as shown on the Shop Drawings. Place

erection marks, match marks and piece marks where they will not be exposed on the finished structure. Notify the Fabrication Engineer after the girders and stringers have been loaded on trailers and prior to shipment. Furnish the Resident copies of shipping documents and erection diagrams. Package bolts of each length and diameter, along with the required number of nuts and washers in waterproof containers. Attach a list of the fastener assemblies, including the identifying shipping lot number and Rotational-Capacity lot number in a waterproof envelope to the outside of the container.

504.39 Handling and Storing Materials Store beams and girders in an upright position

on platforms, skids or other supports above the ground. Support material in a manner that will prevent damage due to excessive deflection and torsion. Do not use chains and wire rope slings in direct contact with fabricated members when being lifted or transported. Store bolts under sheltered conditions at all times. BRIDGE STEEL ERECTION

504.40 Plans Provide the Resident with a steel erection plan for review prior to

beginning steel erection. Schedule a pre-steel erection meeting at the jobsite prior to the delivery of the steel to discuss the erection plan, personnel qualifications, adequacy of tools and equipment and any other areas of concern to the Resident. If fabrication and erection of the Superstructure are done under separate contracts, the Department will furnish detailed Plans for the Bridge or Bridges to the Contractor.

504.41 Methods and Equipment Submit plans for any false work and/or modifications

to an existing structure necessitated by construction loading to the Fabrication Engineer. The false work and/or modifications shall be designed, constructed and maintained for the loads placed upon it. False work calculations and design shall be stamped by a licensed Professional Engineer. The review by the Fabrication Engineer shall not relieve the Contractor of the responsibility for the safety of the method, equipment or from carrying out the work in accordance with the plans and Specifications. Do not build or erect false work until the Fabrication Engineer has reviewed and returned the plan. 5-76

504.42 Bearings and Anchorages Finish bridge seats true to line and grade. Do not

place bearings upon bridge seats that are improperly finished. Cast anchor rods in place or set them in drilled holes. If the anchor rods are set in drilled holes, use an anchoring material from the Department Qualified Products List. Anchor rods shall be capable of developing unconfined pullout strength of 30 Kips and 70 Kips for 1 inch and 1½-inch anchor rods respectively. The Department reserves the right to perform in-place pullout tests. Replace bolts failing to meet the pullout strength requirements. Set bearings so that they are plumb or centered at 45 º F.

504.43 Assembling Steel Clean all faying surfaces before ass embly. Use drift pins

in both the web and flange connections to assure alignment of all holes. Use a minimum of eight drift pins in each flange and web connection. Install and tension a minimum of 50% of the bolts in each contiguous group before the member is released from the crane. Tension field splices within 72 hours of bolt installation. Protect splices from rain or other conditions that will, in the opinion of the Resident, degrade the lubrication on the bolts.

504.44 Connections Using High Strength Bolts Provide all necessary torque and power

wrenches, calibration equipment, feeler gauges and labor required for the testing, calibration, installation and inspection of high strength bolts. Provide a tension-measuring device (Skidmore-Wilhelm or approved equal) and torque wrench, both of which have been calibrated within 12 months, and are in good condition. Provide calibration documentation. Both the tension-measuring device and the torque wrench shall remain at the job site during steel erection. The torque wrench shall have a maximum capacity that is approximately 100% greater than the anticipated job torque. Torque wrenches shall be equipped with a dial face gauge and a memory pointer that remains at the applied torque reading. Torque wrenches shall be graduated in increments not to exceed two percent of the maximum capacity of the wrench and shall be readable to one percent of the maximum capacity.

504.45 Bolts, Nuts, Washers and Direct Tension Indicators Protect fasteners from dirt

and moisture. Take only as many fasteners as anticipated to be installed during a work shift from protected storage. Return unused fasteners to protected storage at the end of the workday. Clean and lubricate rusty and dirty fasteners prior to installation with a lubricant recommended by the bolt supplier or manufacturer. Tension Control (TC) fasteners shall only be re-lubricated by the manufacturer. Surfaces in contact with the bolt head and nut shall not have a slope more than 1 to 20 with respect to a plane normal to the bolt axis. Where an outer face of the bolted parts has a slope of more than 1 to 20 with respect to a plane normal to the bolt axis, a hardened beveled washer shall be used. Bolted parts shall fit solidly together when assembled. All faying surfaces shall be free of mill scale, dirt, burrs, or other material that would prevent solid seating of the parts. 5-77 Install bolts with a hardened washer under the element turned in tightening. Hardened washers are required over slotted and oversize holes.

504.46 Fastener Assemblies for Testing Provide fastener assemblies (bolt, washer, nut

and DTI, if required) to the Resident two weeks prior to beginning steel erection for testing. Randomly select and package four assemblies of each lot, length and diameter for independent verification testing. Identify each size fastener assembly separately with the lot numbers of the bolt/washer/nut/DTI combinations clearly marked. The cost of the assemblies is incidental to the appropriate contract items. Replace unacceptable fastener assembly lots.

504.47 Verification Perform a Rotational Capacity Test (RCT) for each Rotational

Capacity (R-C) lot at the job site immediately prior to installation. Do not use fasteners assemblies that have been used to perform the RCT in the final assembly of the steel. If DTI’s are used, perform a DTI Verification Test for each production lot immediately prior to installation. Give the Department adequate notification in order to witness both the RCT and DTI verification tests.

504.48 Rotational Capacity Test The RCT is intended to verify the effectiveness of the

lubricant and the compatibility of the components of the fastener assembly. The test shall be conducted using a tension-measuring device (Skidmore-Wilhelm or equivalent) and a torque wrench. Select two fastener assemblies of each length and diameter from each R-C lot. Perform the RCT in the following manner:

504.49 DTI Verification Test Perform the DTI Verification Test for each production lot

of DTIs in combination with each R-C lot of fasteners. If any of the three test assemblies fails, three additional samples from the same production lot shall be tested as the first. If any of the three samples fails the second test, the lot shall be rejected. Perform the test in TWO STEPS:

504.50 Installation and Tensioning High Strength Bolts Select one of the methods listed

below for installing and tensioning high strength bolts. Do not use standard torque determined by the use of tables or formulas that attempt to relate torque to tension.

504.51 Installation Install a hardened washer under the turned element and a hardened

washer on oversize holes. Install fasteners in all holes in a contiguous group, except for holes containing drift pins and bring them to a snug tight condition, progressing systematically from the most severely restrained location in a connection to the free edges. Do not remove the drift pins until a minimum of 50% of the fasteners have been tensioned. Do not force the bolts. If the bolts cannot be installed easily by hand, correct the hole alignment by installing more drift pins. Bolt Diameter (inches) ¾, 7/8 1, 1-1/8 1-1/4, 1-3/8 Number of Spaces in DTI 5 6 7 Maximum Number of gaps in which gage is refused * 2 2 3 5-81

504.52 Tensioning Install and tension bolts by: (1) the Calibrated Wrench method, (2)

the Turn of Nut method, (3) with Direct Tension Indicators or (4) Alternative Design Fasteners. Tension the fasteners systematically from the most rigid part of the joint to the free edges.

504.53 Inspection Inspect all completed joints within 72 hours following completion of

tensioning each joint or contiguous group of fasteners. Use the following inspection procedure:

504.54 Reuse of Bolts Reuse only black AASHTO M164M/M164 (ASTM

A325/A325M) bolts. Do not reuse galvanized fasteners.

504.55 Field Welding Welders shall have in their possession a valid certification for the

process and position to be used in production from the American Welding Society or other organization acceptable to the Resident. Submit a written Weld Procedure Specification for each joint to the Fabrication Engineer for review. Provide the Weld Procedure Specification to the welder and Resident prior to beginning welding. Do not perform field welding without an approved Weld Procedure Specification. Power sources shall have meters indicating amperage/voltage that have been calibrated within 1 year. Field welding and nondestructive examination of field welds shall be done in conformance with the requirements of the D 1.5 Code.

504.56 Misfits The correction of misfits involving minor reaming will be considered a

legitimate part of steel erection. Errors in shop fabrication or deformation from handling and transportation that prevents the proper assembling and fit-up of parts by the use of drift pins or by reaming (not to exceed 10% of the holes in a contiguous array) shall be reported immediately to the Resident. Provide a written proposal for correction to the Fabrication Engineer. Do not make any field corrections that involve cutting or welding without the permission of the Resident. ANCILLARY BRIDGE PRODUCTS and SUPPORT STRUCTURES

504.57 Ancillary Bridge Products Ancillary bridge products are defined in Subsection

713.01 of the Standard Specifications. Fabricate ancillary bridge products in accordance

with the D1.5 Code as applicable to ancillary bridge products and this Specification. Fabricate tubular products in accordance with the AWS D1.1 Structural Welding Code (the D1.1 Code).

504.58 Support Structures Weld support structures in accordance with the D1.1 Code.

Support structures shall include, but not be limited to, non-vehicular bridges, high mast poles, light and signal poles, dual purpose poles, strain poles and sign supports; cantilever, bridge and butterfly support structures. 5-85

504.59 Materials Materials for ancillary bridge products will be specified in the

Contract documents. When AASHTO M 270M/M 270 (ASTM A 709/A 709M) steel is specified for ancillary bridge products, equivalent ASTM grades of steel may be substituted. Provide Certified Mill Test Reports for all material.

504.60 Holes for Base Plates Holes in base plates may be drilled or thermal cut at the

Contractor’s option. The roughness shall not exceed condition of AWS C4.1-77, Sample 4. Do not deviate from specified dimension for thermal cut holes by more than 1/16 inch in any direction.

504.61 Bolted Connections Holes for bolted connections shall meet the requirements of

Subsections 504.34 and 504.35. High strength bolts shall be installed, tensioned and inspected in accordance with Subsections 504.50 through 504.54.

504.62 Anchor Rods Anchor rods shall be as shown on the Plans or in the Standard

Details. Anchor rods shall meet the material requirements of 720.07.

504.63 Support Structures Qualify Weld Procedure Specifications, welders and

welding operators in accordance with the D1.1 Code. Circumferential shop splices for poles shall be full penetration, butt welds. Welded longitudinal seams shall have 100 percent penetration for 6 inches on either side of a shop splice, and for the splice length plus 6 inches at the field splice end(s) of a shaft section. The remainder of the seam weld shall have a minimum effective weld throat of 60 percent of the wall thickness. Pole to base welds may be complete joint penetration welds or socket-type joints with two fillet welds. Prior to erection, the assembled shaft or structure shall not exhibit a sweep in excess of 0.2 percent of the nominal pole height or length, as measured with the pole or structure in a horizontal position. Shafts that are to remain unpainted shall have the lower edge of all field slip connections sealed around the entire circumference with a sealant that will remain flexible and not degrade from exposure to ultraviolet light.

504.64 Non Destructive Testing-Ancillary Bridge Products and Support Structures

Unless otherwise specified, nondestructive testing shall be as follows:

504.65 Method of Measurement Unless otherwise specified, structural steel will be

measured as one lump sum complete and accepted, consisting of all metal and related materials in the fabricated and erected structure as shown on the Plans, excluding railings and drains. Related materials shall include, but not be limited to, preformed pads placed under the bearings and, when required, self-lubricating bronze or copper-alloy bearing and expansion plates.

504.66 Basis of Payment Structural steel will be paid for at the contract lump sum price

for the respective contract items. Payment will be made under: Pay Item Pay Unit

504.70 Structural steel fabricated and delivered, L u m p S u m

504.701 Structural steel fabricated and delivered, roll Lum p Sum 504.702 Structural steel fabricated and delivered, welded Lu mp Sum

504.71 Structural steel erection L u m p S u m