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504.31 Shop Assembly Assemble stringers and girders in accorda nce with the shop
assembly drawings. Measure and record the bearing-to-bearing d imensions, the bearing-to- field-splice dimensions and the offset from the reference line dimensions as shown on the shop assembly drawings. Give th e QAI the opportunity to verify the measurements prior to disassembly.
504.32 Tolerances Dimensional tolerances for welded plate gird ers are described in the
D1.5 Code. Dimensional tolerances for rolled shapes are descri bed 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 elevati on 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 assemb led field splice
material prior to disassembly. Preserve the match marking thro ugh field erection.
504.34 Holes for High Strength Bolts Oversize holes are not al lowed unless noted on
the Plans. Drill bolt holes full-size. Splice plates may be u sed as one-time templates to drill webs and flanges. The plates shall remain with the splice. Re place damaged plates used as a template. The Contractor may temporarily tack weld web splic e plates to the web in the middle 1/3 of the web only. Com pletely remove tack welds by gr inding and MT the tack areas. Do not tack weld flange splice plates to flanges. Holes for cross frames, diaphragms and associated connection pl ates may be punched when the thickness of the plat e 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 c lean 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, lubrican ts and coolants, including water soluble lubricants and coolants from faying surfaces in accorda nce with SSPC-SP 1-Solvent Cleaning. The Contractor may thermal cut holes in bearing base plates usi ng an automatic process. Do not exceed a surface roughness of ANSI 1000 micro-inches.
504.35 Accuracy of Holes Following the completion of the drill ing of holes in a
contiguous group, with all plies of a connection in their prope r position for assembly, all bolt holes shall accept a pin 1/32 inch smaller in diameter tha n the nominal bolt hole diameter. Provide a pin of the applicable diameter for inspect ion 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 S pecification except that
adequately lubricated fastener assemblies that have been Rotati onal 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 requirement s 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 Sh op 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 requi red 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 num ber 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. Suppor t material in a manner that will prevent damage due to excessive deflection and torsion. D o not use chains and wire rope slings in direct contact with fabricated members when bein g 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 f or review prior to
beginning steel erection. Schedule a pre-steel erection meetin g at the jobsite prior to the delivery of the steel to discuss the erection plan, personnel q ualifications, 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 Depar tment will furnish detailed Plans for the Bridge or Bridges to the Contractor.
504.41 Methods and Equipment Submit plans for any false work a nd/or modifications
to an existing structure necessitated by construction loading t o the Fabrication Engineer. The false work and/or modifications shall be designed, construc ted 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 s hall not relieve the Contractor of the responsibilit y for the safety of the method, equipment or from carrying out the work in accordance with the plans and Specifications. Do no t build or erect false work until the Fabrication Engineer has reviewed and returned the pl an.