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. 5-76
504.42 Bearings and Anchorages Finish bridge seats true to lin e 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 3 0 Kips and 70 Kips for 1 inch and 1½-inch anchor rods respectively. The Department reserves the right to perform in-place pullout t ests. 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 a ll holes. Use a minimum of eight drift pins in each flange and web connection. Install an d tension a minimum of 50% of the bolts in each contiguous group before the member is release d from the crane. Tension field splices within 72 hours of bolt installation. Protect sp lices from rain or other conditions that will, in the opinion of the Resident, degrade t he lubrication on the bolts.
504.44 Connections Using High Strength Bolts Provide all necessary torque and power
wrenches, calibration equipment, feeler gauges and labor requir ed 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. Provid e calibration documentation. Both the tension-measuring devi ce and the torque wrench shall r emain at the job site during steel erection. The torque wrench shall have a maximum capacit y that is approximately 100% greater than the anticipat ed job torque. Torque wrenches shall be equipped with a dial face gauge and a memory pointer that remains at the applie d torque reading. Torque wrenches shall be graduated in increments not to exceed two per cent 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 Prot ect fasteners from dirt
and moisture. Take only as many fasteners as anticipated to be installed during a work shift from protected storage. Retur n unused fasteners to protected s torage at the end of the workday. Clean and lubricate rusty and dirty fasteners prior t o installation with a lubricant recommended by the bolt supplier or manufacturer. Tension Cont rol (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 oute r face of the bolted parts has a slope of more than 1 to 20 with respect to a plane normal to th e bolt axis, a hardened beveled washer shall be used. Bolted parts shall fit solidly t ogether when assembled. All faying surfaces shall be free of mill scale, dirt, burrs, or ot her material that would prevent solid seating of the parts. 5-77 Install bolts with a hardened washer under the element turned i n tightening. Hardened washers are required over slotted and oversize holes.
504.46 Fastener Assemblies for Testing Provide fastener assemb lies (bolt, washer, nut
and DTI, if required) to the Resident two weeks prior to beginn ing 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. Re place unacceptable fastener assembly lots.
504.47 Verification Perform a Rotational Capacity Test (RCT) f or each Rotational
Capacity (R-C) lot at the job site immediately prior to install ation. 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 pro duction lot immediately prior to installation. Give the Department adequate notification in order to witness b oth 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 fasten er 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 diam eter from each R-C lot. Perform the RCT in the following manner:
1.Insert the fastener assembly in the tension-measuring device using enough hardened washers under the nut (a minimum of one) so that there is full nut engagement (threads flush with the end of the nut) and no mor e than 3 threads visible aft er the assembly is brought to a snug-tight condition with a hand wrench (approximately 10% of t he Minimum Installation Tension from Table 1).
2.Mark the faceplate of the tension measuring device with a li ne at 0º, 120º, 180º, and 240º. Mark the torque wrench socket so that the total amount o f nut rotation can be measured and recorded. Note: the lines are for measuring tota l rotation of the turned element and have nothing to do with minimum installation tensio n.
3.Bring the fastener assembly to at least the Minimum Installation Tension from Table 1 using the torque wrench.
4.At a point after the required Minimum Installation Tension has been achieved, measure and record the tension and the torque. Take the reading as close as possible to the Minimum Installation Tension from Table 1. Table 1 5-78 Minimum Installation Tension Requirements and Turn Test Tension -U.S. Customary Bolt Diameter (inches) 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 Installation Tension (kips) 19 28 39 51 56 71 85 Turn Test Tension (kips) 22 32 45 59 64 82 98
5.Further tighten the fastener assembly to the total rotation (from snug tight) specified in Table 2 below: Table 2 Total Fastener Rotation from Snug Tight Bolt length up to and including 4 di ameters 2/3 turn (240 degre es) Bolt length over 4 diameters up to and including 8 diameters 1 turn (360 degrees) Bolt length over 8 diameters and less than 12 diameters 1-1/6 ( 420 degrees) 12 diameters and greater test not applicable
6.Measure and record the tensi on after total rotation of the n ut. The measured tension must be equal to or greater than the Turn Test Tension value sh own in Table 1 for the diameter bolt being tested. If the measured tension is less th an the required Turn Test Tension, the fastener assembly has failed.
7.Upon completion of steps 1 through 6:
a.The torque measured in step 4 shall not exceed the value obtain ed by the following equation: Measured Torque ≤ 0.25 PD Where: P = Measured Bolt Tension -pounds (Step 4) D = Nominal Bolt Diameter -feet (bolt diameter in Inches divided by 12)
b.If the torque measured in step 4 is greater than the torque cal culated in step 7, the fastener has failed the test. Re- lubricate all fasteners in th e lot and re-test.
c.Disassemble each fastener assembly and run the nut down the ful l length of the threads excluding the grip length (the length between the bolt head and washer face of the nut). If evidence is found of torsional failure, shear failure or stripping of the threads, the assembly failed the test. Slight necking in the g rip length is not a failure.
d.If either bolt assembly fails the test, the R-C lot has fa iled. Re-lubricate all bolts from that lot and perform the test again. If either bolt fails the second test, the R-C lot shall be rejected. 5-79
8.Test bolts that are too short to fit in the tension-measurin g device in a solid joint such as a bearing stiffener or connection plate. The hole in t he joint may not be more than 1/16 inch greater in diameter tha n the bolt being tested. Rand omly select two fastener assemblies from each R-C lot. Mark the nut relative to the ste el joint in such a manner that rotation can be measured. Snug tighten the bolt with a spud wr ench using approximately the same effort used to snug-tighten longer bolts in a tension meas uring device. Restrain the bolt with a wrench to prevent rotation. Rotate the nut from sn ug tight to 1/3 turn with a torque wrench. Record the torque required to reach that rotati on while the turned element is in motion. If the measured torque exceeds the maximum torque l isted in Table 3 the fasteners have failed the test. If the fasteners fail the firs t test, re-lubricate all fasteners from that R-C lot, randomly select t wo samples and re-test. If ther e is no stripping or fracture the fasteners pass. If the either fastener fails the second test, the R-C lot is rejected. Table 3 Maximum Allowable Torque Bolt Diameter (inches) 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 Torque (ft-lbs) 500 820 1230 1500 2140 2810 3690
9.Discard bolts used for the Rotational Capacity Test.
504.49 DTI Verification Test Perfo rm the DTI Verification Test for each production lot
of DTIs in combination with eac h R-C lot of fasteners. If any of the three test assemblies fails, three additional samples from the same production lot sh all be tested as the first. If any of the three samples fails the second test, the lot shall b e rejected. Perform the test in TWO STEPS:
1.Step 1 is a test to determine that the DTI’s are acceptabl e when the fastener is brought to the minimum allowable tension. a) Randomly select three fastener assemblies from each R-C lot.
b.Install each bolt in the tension-measuring device with the b olt head bearing against the faceplate (the front of the tension-measuring device). Pla ce the DTI under the bolt head with the protrusions bearing aga inst the washer face of the bol t. This is done so that the DTI is accessible for inspection with a feeler gauge. Install the nut and hardened washer using a filler sleeve between the bolt bushing (the back of the tension -measuring device) and the hardened washer under the nut. Two or more hardened washers ma y be used under the nut instead of a filler sleeve if the washers do not interfere with the proper operation of the tension-measuring device. When the bolt is brought to snug-tig ht condition, there should be 3 to 5 threads visible.
c.Using two wrenches, one to restrain the unturned element of the bolt assembly, tighten the nut to the Bolt Tension listed in Table 4. If an i mpact wrench is used, tighten the bolt to approximately 50% of the required tension and use a tor que wrench to bring the fastener to the required tension.
Source: Maine Standard Specifications for Road and Bridge Construction, 2020 Edition. Pages 367–371 of 817.