2471Structural Metals

2471.1DESCRIPTION

This Work consists of shop and field Work for manufacturing, fabricating, and coating structural metals. A Definitions For the purpose of the work specified in section 2471, “Structural Metals,” the Department defines: Fabricator Manufacturer or supplier of fabricated structural metals. In the event that the Contractor performs this Work, the term will mean the Contractor or the Contractor’s agent. Minor Structural Components Materials used in the following applications:

ballast plates, diaphragms for Bridges (except curved steel Bridges), pile and appurtenances, drainage systems, guardrail connections, railings, fencing, conduit systems, and protection angles

Major Structural Components Components other than minor structural components as defined in Minor Structural Components. Supplier Fabricator, galvanizer, and paint shop. Tension Areas

greater than 4 degrees, and/or members are designed as an interactive 2-D structure where members are sharing or distributing load to one another, and/or Contract requires full assembly in fabrication.

2471.2MATERIALS

Provide new Materials in accordance with the following sections. Unless otherwise required by the Contract, use structural steel in Bridges in accordance with 3309, “High-Strength Low-Alloy Structural Steel,” and use structural steel for other Structures in accordance with 3306, “Low-Carbon Structural Steel.” Provide Materials from mills, warehouses, or processors with supporting certified MTRs meeting the requirements of applicable ASTM specifications. If the MTR does not contain sufficient information, provide copies of the test results to the Bridge Engineer for review and approval before fabrication. C Structural Alloy Steel D Pin and Roller Steel L Bronze

R Pipe

2471.3CONSTRUCTION REQUIREMENTS

A General Provide the Bridge Engineer with a list of Fabricators, galvanizers, and painters, including addresses, and a list of products they will provide. Do not order Materials or direct the Fabricator to perform shop Work until the Bridge Engineer approves of the shop drawings. If installing fabricated components on an existing Structure, measure field dimensions in accordance with 2433, “Structure Renovation. B Certification Requirements B.1 Simple Steel Bridge Structures and Components Provide a certification from a Fabricator certified in accordance with AISC Quality Certification Program Category, Simple Steel Bridge Structures (Sbr) for the following types of Structures and Structure components:

300,000 pounds

B.2 Major Steel Bridges Provide a certification from a Fabricator certified in accordance with AISC Quality Certification Program Category, Major Steel Bridges (Cbr) for the following types of S tructures and Structure components:

300,000 pounds

B.3 Fracture Critical Items Provide a certification from a Fabricator certified in accordance with AISC Quality Certification Program Category, Major Steel Bridges (Cbr) with Fracture Critical Member endorsement (F). B.4 Coating Application Contractor/Fabricator performing coating application must demonstrate qualification by obtaining the AISC Sophisticated Paint Endorsement (SPE), SSPC QP Certification, or a quality certification system acceptable to the Bridge Engineer, and a Quality Manual (QM) that is acceptable to the Bridge Engineer. C Shop Drawings C.1 General Submit to the Bridge Engineer shop drawings from the Fabricator that include the following:

with 2471, “Structural Metals”

Ensure shop drawings include welding symbols meeting the requirements of ANSI/AWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examination. Verify that the Fabricator placed Welding Procedure Specification (WPS) numbers in the tail of the arrow(s). Submit shop drawings from the Fabricator for the complete fabrication of structural metals as required by the Contract. If the Department provides standard detail drawings as required by the Contract, submit finished detail drawings from the Fabricator with additions and revisions. If the Contract requires a Standard Plate, the Department will not require redetailed plates except to indicate fit at connections to other structural members for changes shown on the Plans or to complete detailed information to the shop or the Material Supplier. Provide these detail changes from the Fabricator.

C.2 Format Submit shop drawings from the Fabricator meeting the following characteristics and requirements: C.2.a Full Size Paper Format

sharply defined prints can be made for the Bridge Engineer's review and inspection purposes

information:

11 inch by 17 inch without affecting readability

with piece marks and quantities, including dimensions

numbers, including a brief description for reference C.2.b PDF Format

prepared in a neat and legible form in electronic PDF format that is clear, sharply defined electronic prints can be made for the Bridge Engineer’s review and inspection purposes

“Full Size Paper Format” C.2.c Standard Sheets Contractor may also provide standard sheets from the Fabricator with fastener lists. C.3 Submittal for Bridge Engineer's Review and Acceptance Submit two sets of prints of required shop drawings, meeting 2471.3C.2, “Format,” from the Fabricator to the Bridge Engineer for review and release for fabrication. Shop drawings must comply with the Contract documents. Provide written authorization from the design EOR (Engineer of Record) for any deviation from the Contract documents. Incorporate contractor comments into shop drawings prior to submittal to reviewer . The reviewer will return one set of prints of the shop drawings to the Fabricator with comments. Submit only checked drawings, in complete collated sets, from the Fabricator for review. The Contractor may submit details such as ice-breakers, anchorages, bearing plates, and castings, separately to facilitate the Work.

Fabricator may submit the shop drawings to the Contractor. Stamp these drawings with “For Contractor Use Only.” Do not forward these stamped drawings to Department. Submit a schedule showing the submission dates of shop drawings and anticipated dates for shop fabrication from the Fabricator, as directed by the Bridge Engineer. Arrange the schedule to avoid delay in completing the Work. If constructing a Structure composed of several units, consider submitting shop drawings of the separate units in proper order to expedite the review and release for fabrication of the details. If the Bridge Engineer requests changes to the submitted drawings or if the F abricator makes additional changes not required by the Bridge Engineer, provide revised drawings, with revision control, from the Fabricator with circles, underscores, or other marks to distinguish the changes from unchanged details or dimensions. The Bridge Engineer will release shop drawings for fabrication after corrections are completed. Provide six sets of corrected drawings and additional copies as required by the Contract or requested by the Bridge Engineer from the Fabricator at no additional cost to the Department. Mark the corrected drawings as Revision 0 and remove all comments and marks to make clean drawings for acceptance, stamping, and distribution for use. The shop drawings accepted by the Bridge Engineer will become part of the Contract. Do not make changes on accepted drawings unless otherwise approved by the Engineer in writing. Mark changes approved by the Bridge Engineer on the accepted shop drawings with revision version in number sequence next to all changes and resubmit them for approval, stamping as revised sheet and distributing to replace the superseded version of drawings. The Bridge Engineer‘s acceptance of shop drawings will not relieve the Contractor of full responsibility for submission of complete and accurate drawings and for the accurate assembly and fitting of structural members. C.4 Submittal for Completed Work After the Fabricator completes the shop Work, provide detailed shop drawings to the Bridge Engineer in two formats:

Ensure that the drawings submitted accurately reflect the actual configuration of structural members and components, including modifications made during fabrication and after delivery to the Project, under the fabricator’s direction. If making the electronic files by scanning, use a minimum scan resolution of 400 dpi. D General Fabrication Practices Provide structural Material fabricated and assembled meeting the requirements of AASHTO/NSBA Steel Bridge Collaboration Steel Bridge Fabrication Guide Specification and AWS welding codes, except as modified in this section. Provide Material structurally welded meeting the requirements of ANSI/AASHTO/AWS D1.5 Bridge Welding Code, for Major Structural Components and AWS D1.1, Structural Welding - Steel, for Minor Structural Components. Ensure the Certified Welding Inspector (CWI), or an equivalent, witnesses the welder and welding operator qualification tests unless otherwise specified in this section. Before the start of Work, the Supplier will be qualified on Approved Suppliers for Fabricated Structural Metals Products list as maintained by the Structural Metals Engineer on the Bridge Office website or become qualified. To become qualified, the Supplier is to submit a Quality Manual (QM) to the

Structural Metals Engineer for review and acceptance, at least 60 Calendar Days before beginning Work. The QM is to meet the requirements of the MnDOT Supplier Qualification Standard which will be the basis for acceptance by the Structural Metals Engineer. Upon acceptance of the QM, a supplier is qualified and will be listed on the Approved Suppliers for Fabricated Structural Metals Products list. In addition to routine inspections, the Structural Metals Engineer will audit suppliers with approved QMs on a biannual or annual basis or as otherwise directed by the Structural Metals Engineer to ensure the implementation of the QM. The Department will invoke its Corrective Action Process if the routine inspections or audits indicate non-conformance. Any corrective actions deemed appropriate by the Structural Metals Engineer, are effective immediately and apply to any Work remaining on current and future Projects. If the Structural Metals Engineer determines that Work does not comply with the QM or that fabrication does not follow approved fabrication procedures, the Structural Metals Engineer will deem the Materials as non-conforming in accordance with 1503, “Conformity with Contract Documents,” and 1512, “Unacceptable and Unauthorized Work.” If the Structural Metals Engineer finds non-conforming Work, direct the Supplier to immediately correct the procedure and submit a written non-conformance report, containing data required by the Structural Metals Engineer to ensure compliance with the QM, Specifications, and drawings. Perform additional testing as required by the Structural Metals Engineer at no additional cost to the Department. For repeat offences or negligence, the Department will require corrective action of hiring a third-party Quality Control Inspector at no additional cost to the Department. The Contractor may obtain a copy of the Department’s Corrective Action Process from the Structural Metals Engineer. D.1 Prefabrication Conference Before fabrication, the Bridge Engineer may schedule a prefabrication conference with the Contractor and the Fabricator to discuss pertinent Specifications, procedures, and requirements of the job. The Bridge Engineer will consult the Contractor and the Fabricator to decide the location, date, and agenda items for the conference. D.2 Notification Notify the Bridge Engineer at least 5 Business Days before the Fabricator begins Work so that the Bridge Engineer may perform inspections. Do not allow the Fabricator to begin Work before notifying the Bridge Engineer. D.3 Identification of Materials Before fabrication begins, the Fabricator will provide a copy of purchase orders, Mill Test Report (MTR), or other documentation required by the Bridge Engineer, indicating that the Materials meet the physical, chemical, and source (mill) requirements of this section for each heat of steel used in the Work. The Fabricator will provide copies of purchase orders when placing the orders. When the Materials are received, the Fabricator will indicate in writing or by ink stamp that the MTRs have been checked for compliance. Include the name of the individual who checked the MTR and the date of inspection with the purchase order . If the Bridge Engineer determines that the documentation is incomplete, direct the Fabricator to sample and test Materials as directed by the Bridge Engineer at no additional cost to the Department. Provide Scale weights of individual members or sections as required by the Bridge Engineer. Except for the following, the Fabricator of Minor Structural Components will provide Certificates of Compliance and shipping documents for each C ontract Item to the Bridge Engineer instead of submitting purchase orders and MTRs:

In conjunction with the Fabricator, keep appropriate documentation on file for at least seven years. During each stage of fabrication of Major Structural Components, ensure the Fabricator provides and maintains identification to establish the heat of the Material from which the component is fabricated. Provide the Bridge Engineer with a list showing heat numbers referenced to the Material incorporated into each component. The Bridge Engineer will reject Material that loses its identity unless the identity can be reestablished to the satisfaction of the Bridge Engineer. Provide wide flange beams, flanges, webs, splice plates, welded cover plates, and fracture critical members with identification numbers placed on each individual piece of Material that referenced to the corresponding heat number. Ensure the Fabricator uses non-oil-based markers or low stress die stamps for the identification coding of Material. D.4 Weld Identification System Before implementation, ensure the Fabricator uses the Department standard weld identification system as described in 2471.3D.4.a, “Standard Weld Identification System,” or an alternate system approved by the Bridge Engineer to identify welds subject to radiographic testing, ultrasonic testing, or both. Use a traceability system with a unique identification assigned to welds being examined. Do not repeat identification numbers. Use identification numbers traceable back to the original member examined and document the identification number on the shop drawings. D.4.a Standard Weld Identification System D.4.a(1) Piece Mark Provide Material marked with the Fabricator’s piece identification as shown on the approved shop drawings. D.4.a(2) Splice Plane Number For the purpose of the Work specified in section 2471.3D.4.a, “Standard Weld Identification System,” the Department defines a splice plane as a 3 feet wide vertical section of a piece that contains a full penetration welded splice in any component of the piece. The Department considers any other full penetration welded splice in any component of the piece within the 3 feet vertical splice plane in the same splice plane. Provide the number of the splice plane on the piece starting from the left end of the piece as shown on the radiographic diagram. D.4.a(3) Piece Components Code Verify that the Fabricator placed film identification numbers or location marks, only on film, meeting the requirements of AWS D 1.5, Bridge Welding Code. Begin marking from near side (NS) edge for flanges and the bottom edge for webs.

flanges

D.4.a(4) General Notes Ensure the Fabricator performs the following:

meeting the requirements of AWS D1.5, Bridge Welding Code except as modified by this section

components of the piece before welding by placing punch marks 1 foot back from the centerline of the weld and 1 inch from the edge of the plate

as directed by the Bridge Engineer

100 percent, include the untested areas in the Film Identification Number scheme D.5 Storage of Materials Store Material above ground on platforms, skids, or other supports . Protect Material from dirt, oil, and other foreign matter. Drain Material so that water is never in constant contact with the surface. Replace damaged Material with new Material or repair using a procedure approved by the Bridge Engineer. D.6 Nonconformances Provide an established quality system outlined in the QM for controlling nonconforming Material from the Fabricator, including procedures for identification, isolation, and disposition. Submit Nonconformance Report (NCR) forms from the Supplier to the Bridge Engineer documenting deviation from the QCP, approved shop drawings, the P lans, or Specifications. Include the following in the Nonconformance Report form:

Address non-conforming Material with an NCR no more than 5 Working Days after discovery.

The Bridge Engineer will advise the supplier of the resolution to non-conformance in writing. E Structural Components E.1 Welded Shear Stud Connectors In accordance with OSHA Subpart R 1926.754, attach shear stud connectors and other similar devices to the top flange of beams or other steel components after the installation of decking falsework or other walking surfaces. E.2 End Connection Angles The Bridge Engineer will only require finishing of end connection angles to correct a non-conforming assembly. Produce a finished angle at least 3/8 inch thick. Do not reduce the original thickness of the angle by greater than 1/8 inch. Grind flush portions of members extending beyond the face of the connection angles. Do not recess the web of a connecting member by greater than 3/8 inch from the face of the connection angles. E.3 Bolts Provide high strength structural steel bolts in accordance with 3391, “Fasteners,” except the Contractor may use common structural steel bolts for connections in expansion and deflection devices and in hand railings. Place structural bolts with a projection from 1/8 inch to 3/8 inch through the nut. Provide extra bolts in the amount of 5 bolts plus 5 percent of the actual number of field bolts necessary, at no additional cost to the Department. The Department will not include this number of additional bolts in the Plan Quantity and will include the cost of these additional bolts in the Contract Unit Prices for the bolts in the Contract Item. E.4 Pins and Rollers Provide pins and rollers with a 75 micro inch finish. Provide pin threads meeting the requirements of American Standard Coarse Thread Series Class 2 and free fit meeting the requirements of ANSI B1.1. Thread pin ends and nuts with diameters of at least 1 3/8 inches with 6 threads per 1 inch. Provide nuts meeting the following requirements and characteristics:

Steel,” 3309, “High-Strength Low-Alloy Structural Steel,” and 3310, “High- Strength Low-Alloy Columbium-Vanadium Steel”

Machine the grip face of the nut square to the axis of the pin. Ensure the recessed face of the nuts will bear uniformly against the end face of the pin when turning the nut tight . Place pins with a projection of at least 1/4 inch through the nut after assembly. If making a recessed cut between the threads and the shoulder of the pin, do not make cuts wider than 1/4 inch or deeper than the base of the thread. E.5 Shims For the purpose of the Work specified in section 2471.3E.5, “Shims,” the Department defines shims as metal plates not shown on the Plans that bring metal surfaces of members into contact or bring the Structure to the grade or alignment shown on the Plans.

Make shims 1/8 inch or thicker of structural steel. Make shims 1/8 inch or thinner from sheet steel or sheet brass. Provide shims at no additional cost to the Department. F Structural Fabrication Ensure the Fabricator performs the following: F.1 Cutting Cut steel and fabricate steel plates and splice plates for Major Structural Components so the primary direction of rolling is parallel to the direction of the main tensile or compressive stresses. Cut metals to the size shown on the Plans with allowance for necessary or required finishing operations. Cut metals within 1/16 inch from true lines. For the purpose of the Work specified in section 2471.3F, Structural Fabrication,” the Department defines true lines as theoretical lines exactly corresponding to and used to transfer dimensions as shown on the P lans to Materials for cutting, drilling, and fitting. Cut flange plates or other members to a true curve. Do not use a series of straight cuts to create the curve. F.1.a Re-Entrants Form interior and reentrant corners with a radius of at least 1 inch. Form filleted corners with radii no greater than 1 inch by drilling. F.1.b Shearing Do not shear nonferrous metals with a thickness greater than 1/2 inch. F.1.c Edge and Corner Condition All exposed edges and corners are to be free of slag, burrs, and gouges. F.2 Machining F.2.a General Perform heat treatment before final machining. For the purpose of the Work in and systematically applying heat at a temperature below the melting point of any ferrous castings, weldment, or other components. F.2.b Machining Tolerances For members requiring machine finishing, the standard tolerance is ±0.005 inch. For bearing assemblies, a tolerance of ±0.03 inches will be applied to the following:

F.2.c Machine Lubricant Use machining lubricant on structural Material requiring machine Work or drilling capable of being completely removed.

F.2.d Surface Finish For machine finish surfaces, unless otherwise specified, the required finish will be 125 micro inches. F.3 Bending Before bending, round the corners of the plates to a radius of 1/16 inch throughout the portion of the plate at which the bending is to occur as shown on the P lans. Bend metals before coating or heat treatment. Bend without causing fractures, kinks, reduced section below minimum, or other defects in the Material. F.4 Cambering and Curving The Bridge Engineer will verify measurements of vertical camber and horizontal curvature for final acceptance after the completion of welding and heating operations and after the flanges cool to uniform ambient temperature. The Bridge Engineer will check horizontal curvature with the girder in the vertical position. The Bridge Engineer may reject Materials showing over hardening, fractures, or other defects due to improper heating. F.5 Straightening Material Straighten Material without shearing, fracturing, stressing, or damaging the bolts, welds, or base metal. Use straightening methods approved by the Bridge Engineer. Replace Material damaged during straightening operations with new Material at no additional cost to the Department. If the Bridge Engineer determines it is not possible to straighten a member as part of an assembly, remove the bent Material from the assembly, straighten, and reassemble. F.6 Dimensional Tolerances Provide fascia beam webs with a flatness tolerance no greater than half the limit in ANSI/AASHTO/AWS D1.5 Bridge Welding Code. Flange and splice plates to be longitudinally flat to 1/16 inch in the contact area in order to achieve full connection contact with bolts tightened to the snug tight condition . Additionally, flange plates are to be perpendicular to the web within 1/16 inch in the connection area. Flatness of surfaces intended for contact bearing with other structural parts will be within 0.03 inches for each contact surface. For Materials that are warped or distorted, straighten to 1/8 inch in 10 feet, with Bridge Engineers approval. G Structural Welding Ensure the Fabricator performs the following: G.1 General Obtain written approval from the Bridge Engineer before performing welding, including weld repair, or deviating from the approved shop drawings or P roject Plan. Artificial cooling of any production welds will not be allowed. Submit Weld Procedure Specifications (WPS) with shop drawings. Do not begin fabrication until the Bridge Engineer has approved the WPS(s). The Bridge Engineer may require testing for particular weld details described in the WPS to assure the Bridge Engineer that proper welds can be made. Test welds as required by the Bridge Engineer.

Provide information or Procedure Qualification Records (PQRs) demonstrating that the proposed WPSs meet the requirements of the ANSI/AASHTO/AWS D1.5 Bridge Welding Code

Provide a minimum weld size per BWC when a weld symbol is void of a weld size. For the purpose of the Work in 2471.3G, “Structural Welding,” a weld repair is defined as any area of the welded product not in compliance with the WPS, approved Quality Manual , or current edition of BWC. Notify the Bridge Engineer to witness welding and testing. If the Bridge Engineer cannot witness qualification or certification welding or testing, arrange the witness of an approved third-party, at no additional cost to the Department. Conduct testing of qualification welds in a laboratory accredited by the American Association for Laboratory Accreditation (A2LA) or an approved equal at no additional cost to the Department. G.1.a Welded Flange Splices Place welded flange splices at least 12 inches from web splices. For welded girders with radii no greater than 1,900 feet, the Department will allow additional splices only on individual flanges that are uniform in thickness and greater than 39 feet in length. The Department will allow these splices in addition to the splices shown on the Plans. Provide flanges with no more than two additional splices. Locate additional splices in accordance with the following:

plates

groove welds as shown on the Plans

G.1.b Web-to-Flange Welds For the purpose of the Work in 2471.3G.1, “General,” the Department defines a repair as any area of the welded product not meeting the requirements of BWC . Limit each individual web-to-flange weld repairs to 2 percent of the weld length and grinding web-to-flange weld repairs to 5 percent of the weld length. If the Contractor exceeds the repair limits, the Bridge Engineer will revoke the WPS used to perform the initial production welding. G.2 Preparation of Base Metal For coated metals, remove coatings on either side of the weld area to a distance of at least 2 inches. G.3 Conditions for Welding Preheat without producing visible moisture in the weld joint before welding. G.4 Backing Produce “Complete Joint Penetration” (CJP) groove welds using steel backing that is continuous for the full length of the weld. Make joints in the steel backing CJP joints, also.

H Fracture Critical Members Ensure the Fabricator performs the following:

Plan (FCP) for fracture critical Bridge members and as modified by this section

provide written exemption from these requirements for welds in designated members not subject to tension forces

H.1 Fracture Critical Welder Qualifications Provide fracture critical members welded by welders meeting the certification requirements in accordance with BWC. Annual requalification is to be based on acceptable radiographic test results of either a production groove weld or test plate . If employing a welder requalified by test, use a WPS written in accordance with the requirements of BWC and show the applicable test plate. I Hole Forming Operations I.1 Bolt Holes Hole forming operations other than drilling will require a written procedure in the suppliers Quality Manual and a verification test for each hole forming process. Produce holes after any required bending, cambering, curving, or heat-treating of member. Sub-punching or sub-drilling of holes is permitted only where specifically allowed by thisS pecification. Except for field connections and field splices, the Contractor may punch Material forming parts of a member composed of no greater than five thicknesses of metal 1/16 inch larger than the Nominal diameter of the bolts for any of the following:

1/2 inch In addition to drilling and punching, the Fabricator may produce holes for Minor Structural Components by plasma, water jet, or laser cutting methods. Produce holes and slots that meet the following criteria:

I.1.a Line Assembly Ensure the Fabricator performs the following:

flange and web splices full size in the assembled position

diaphragm stiffeners, lateral bracing, and lateral bracing connection plates +3/16 inch greater than the bolt diameter to facilitate alignment

requirements of ASTM F436, Standard Specification for Hardened Steel Washers Inch and Metric Dimensions, under the bolt head and nut I.1.b Full Assembly If the Contract requires full assembly, ensure the Fabricator drills bolt holes for field connections, in members and components of each structural unit, from the solid to the specified size while assembled with the following exceptions: Two sub-sized holes may be used to attach each diaphragm to stiffeners and field splice plates to webs and flanges to facilitate assembly. The Fabricator has the option to drill one ply of a field connection with full size holes providing it is used as a template only once. I.1.c Punched Bolt Holes Ensure the diameter of the die does not exceed the diameter of the punch by greater than 1/16 inch. If the Fabricator enlarges holes to admit the bolts, provide a written repair procedure from the Fabricator to the Bridge Engineer for approval. I.1.d Field Connection Bolt Holes Ensure the fabricator drills holes full size to a steel template while assembled for the following:

trusses, arches, continuous beam spans, bents, towers (each face), plate girders, and rigid frames The Contractor may drill holes for the following full size and unassembled to a steel template if approved by the Bridge Engineer in writing:

cross frames

If using a steel template for drilling field connection holes to full size, ensure the Fabricator locates the template to the correct position and angle, bolts the template in place before drilling, and uses duplicate templates to drill matching members and the opposite faces of a single member. I.2 Boring Pin Holes Ensure the Fabricator produces the final surface of pin holes by a finishing cut, and provides pin holes in diameters in accordance with the following:

Ensure the distance outside-to-outside of end holes in tension members and inside-to-inside of end holes in compression members does not vary from that specified by greater than 1/32 inch. Ensure the Fabricator bores pin holes in built-up members after the completion of assembly.

J Shop Assembly Ensure the Fabricator performs the following: Complete fabrication, weld inspection, nondestructive testing, and any repairs, before placing any component in the assembly. Adjust each assembly unit to the true field position with respect to alignment, camber, grade and skew, as shown on the Plans, prior to drilling field connection. The Fabricator may angularly rotate the assembly from true field position, with respect to grade, providing the F abricator supplies shop drawings showing elevations at points of bearing and the relative position of webs of main members, with respect to true field position. Provide calculations to support the information shown in the drawings . Rotation is not allowed on hold over members. For multiple span continuous Structures, both straight and curved, progressive assembly is allowed providing a length no shorter than the length supported by three adjacent points of bearing is used as a minimum length of each structural sub-assembly. For these progressive assemblies, hold over pieces between adjoining assemblies shall be held to the following tolerances in relation to their documented position prior to removal: Table 2471.3-1 Assembly Tolerances Vertical (inch) Horizontal (inch) Tilt (inch) At point of support +1/16, -0 +/-1/32 +/-1/32 At member ends +/-1/32 +/-1/32 +/-1/32

Clean metal surfaces in contact with each other before assembling. Assemble, pin, and draw together the parts of a member before drilling or bolting. Assemble Structures that contain secondary members utilizing full size holes in accordance with 2471.3J.2, “Full Assembly.” In the assembly Plan, identify maximum deviations of differential camber and sweep between girder lines. Provide a written record of each shop assembly set-up. Submit written record to Contractor and Bridge Engineer. The inspection of the assembly and the written report shall be completed by a competent individual with experience in structural assemblies. If a total station or similar device is used to check the assemblies the operator shall be certified to a National Standard or the E quipment manufacture. If a progressive assembly is used the written report shall contain the required information for each assembly and a final written report for the full length and width of the S tructure. Include the following assembly dimensions, theoretical (as shown on a blocking diagram) and actual measurements with the written record:

points, field splice locations, Plan ordinates closest to mid span and any other connection points

Temporary bolts shall be drawn sufficiently tight to bring the required parts into bearing and to preclude loosening of the nut. The permanent bolt assembly shall be in accordance with 2402, “Steel Bridge Construction.”

Take apart assembled pieces, if necessary, to remove burrs, shavings, or other irregularities produced by the operation. Adjust the members if they have any twists, bends, and other deformations. J.1 Line Assembly Assemble Major Structural Components, pedestrian truss Bridges, overhead sign trusses, and modular and finger expansion joint devices at the fabrication shop, unless otherwise required by the Contract. Line assemble primary members (such as but not limited to beams, girders, arches, trusses, etc.) full length with components completely assembled. J.2 Full Assembly Performs full assembly as required by the Contract in accordance with the following:

the Contract and assemble to the full width of the structural unit

requirements are specified in the Contract. This shall include at a minimum, five points of support for each individual main member: ends, 1/4 points, and midpoint

and transverse floor systems. The Department will not require components such as expansion and deflection devices and bearings to be assembled J.3 Match Marking Match mark connecting parts assembled in the shop to assure proper fit in the field using low stress die stamps before disassembly. Use a match marking system that uses a series of letters and numbers to indicate the exact location in the Structure without continual reference to detail drawings. Do not use shop piece marks as a match marking scheme. Mark pieces or parts planned for assembly at a point with the same mark to avoid rotation of pieces. Use Material used for match marking capable of removal without damage to the appearance of painted or unpainted surface visible in the completed Structure. K Uncoated Weathering Steel Surfaces Ensure the Fabricator performs the following:

3309, “High-Strength Low-Alloy Structural Steel,” or other types of weathered steel Material in accordance with SSPC-SP 1, Surface Preparation Specifications – Solvent Cleaning

connections, in the shop or field in accordance with SSPC-SP6/NACE No. 3, Commercial Blast Cleaning L Coating For the purpose of Work in specified in this section, the Department defines coating as any protective barrier including paint, galvanizing, or metalizing. Ensure the Fabricator performs the following:

Engineer and meeting the requirements of the AASHTO/NSBA Steel Bridge Fabrication QC/QA Guide Specification and the AASHTO/NSBA Guide Specification for Coating Systems with Inorganic Zinc-rich Primer

approves the Work The Bridge Engineer may reject Material coated before approval in accordance with 1512, “Unacceptable and Unauthorized Work.” Remove rejected Material as directed by the Bridge Engineer. L.1 Galvanizing Galvanize in accordance with 3392, “Galvanized Hardware,” 3394, “Galvanized Structural Shapes,” 2471, “Structural Metals,” and as shown in the Special Provisions. Purchase order(s) shall identify which specific items are to be duplex coated and which Materials to be galvanized are reactive (e.g. 3309, “High-Strength Low-Alloy Structural Steel,” etc.). Completely seal weld contacting or welded overlapping surfaces. Degrease Material for rolled or folded joints before forming. Clean Material of paint, lacquer, and crayon markings before galvanizing. Do not galvanize closed or blind sections of pipe. Prior to pickling and galvanizing, abrasive blast clean surfaces to be galvanized to SSPC-SP 6/NACE No. 3, “Commercial Blast Cleaning.” The following products are exempt from this requirement:

L.2 Metallizing Before metalizing steel surfaces, blast and clean meeting the requirements of AWS C2.18, Guide for Protection of Steel with Thermal Sprayed Coatings of Aluminum and Zinc and their Alloys and Composites. Use zinc metalizing wire or powder of a purity equal to Federal Specification MIL-W-6712 (99.9 percent zinc). Metalize to an average coating total thickness of 0.010 inches. Coat to a thickness of at least 0.0075 inches. Preheat the substrate to 250°F to eliminate surface condensation and reduce shrinkage and differentials between the coating and the substrate. Do not metalize unless approved by the Bridge Engineer in writing. L.3 Painting Prepare the surface and paint in accordance with 2479, “Inorganic Zinc-Rich Paint System,” unless otherwise required by the Contract.

Bevel corners of painted Bridge member edges to at least 1/16 inch. If thermal cutting Material to final size, grind or mill edges to remove thermal cutting marks sufficient to achieve and measure the required painting surface profile. M Fabricator Inspection Ensure the Fabricator provides QC personnel as required by the approved Quality Manual (QM) and the following: M.1 Nondestructive Testing M.1.a General Ensure the Fabricator performs nondestructive testing (NDT) in accordance with the appropriate ASTM specifications and applicable welding code specifications and the following:

Testing (ASNT) NDT Level II operator and qualified in accordance with ASNT-TC-1A

to the Bridge Engineer before performing any NDT inspections

procedures for each NDT method used

interim test reports submitted as performed M.1.b NDT Bridge Components Perform NDT at locations and frequencies in accordance with the Contract and/or the applicable welding code with the following modifications:

web splices

when used and left in place

compression or shear areas

point(s) of maximum tension 50 percent of the remaining area will be tested If the Contract or welding code does not otherwise specify NDT, 100 percent Ultrasonic Testing (UT) of any CJP is required. Ensure the Fabricator performs the following:

Engineer approves NDT of groove welds

procedure as described in 2471.3D.6, “Nonconformances,” at no additional cost to the Department

The Department may require NDT of areas not designated in the Contract for such inspection. If the inspection shows the area to be defective, the Fabricator shall perform the NDT at no additional cost to the Department. If the inspection is

satisfactory, the Department will pay for the inspection as Extra Work in accordance with 1402, “Contract Revisions.” In addition, when NDT of an area designated in the Contract for inspection shows defects, the Bridge Engineer may direct the Fabricator to perform NDT of adjacent areas to determine the extent of the defective area, at no additional cost to the Department. M.1.c Visual Testing Ensure the Fabricator performs visual inspections during the entire welding process and again after the weld is complete, cool, and clean of slag and residue . Final visual inspections for acceptance will be documented and made available to the Bridge Engineer for review. M.1.d Dye Penetrant Testing Ensure the Fabricator checks edges of complete penetration groove welds on Major Structural Components for 3 inches on each side of the centerline of the weld or 1 inch beyond either side of the weld area, whichever is greater, using Dye Penetrant Testing. The Fabricator may substitute Magnetic Particle Testing with approval from the Bridge Engineer. M.1.e Magnetic Particle Testing Ensure the Fabricator performs Magnetic Particle Testing on the following:

Structural Components and pedestrian Bridges

signs and high mast Light Poles Ensure the Fabricator locates the tests at random areas of the weld. Do not use the prod method unless approved by the Bridge Engineer. M.1.f Radiographic Testing (RT) Provide Computed Radiography (CR) or Digital Radiography (DR). The Department will retain ownership of radiographic images provided by the Contractor . Name image files with Bridge number and weld identification shot number. Electronic Radiography method(s) consist of CR utilizing Storage Phosphor Imaging Plate (SPIP) or DR utilizing a Digital Detector Array (DDA). Ensure CR complies with ASTM E2033, Standard Practice for Radiographic Examination Using Computed Radiology (Photostimulable Luminescence Method) , and ASTM E2445, Standard Practice for Performance Evaluation and Long-Term Stability of Computed Radiography Systems. Ensure DR complies with ASTM E2698, Standard Practice for Radiological Examination Using Digital Detector Arrays , and ASTM E2737, Standard Practice for Digital Detector Array Performance Evaluation and Long- Term Stability. Ensure SPIP and DDA widths are sufficient to depict all portions of the weld joint, including the HAZs, and provide sufficient additional space for the required hole - type or wire-type IQIs and radiograph identification without infringing upon the area of interest.

Ensure radiographic images are free from mechanical, chemical, or other blemishes to the extent that they cannot mask or be confused with the image of any discontinuity in the area of interest in the radiograph. Such blemishes include, but are not limited to the following:

Ensure the contrast and brightness range that demonstrates the required sensitivity be considered valid contrast and brightness values for interpretation. When multiple IQIs are utilized to cover different thickness ranges the contrast and brightness range that demonstrates the required IQI image of each IQI is determined . Intervening thicknesses may be interpreted using the overlapping portions of the determined contrast and brightness ranges. When there is no overlap, additional IQI(s) are to be used. When performing CR or DR, ensure a measuring Scale is utilized to serve as a length reference. The Scale is to be attached to the SPIP holder or DDA prior to exposure. As an alternative, when using SPIPs a transparent Scale with opaque gradations may be placed on the SPIP prior to processing. In any case, the reference comparator cannot interfere with interpretation of the image. Provide a Work station monitor for evaluating images equipped with a display resolution with a pixel count which is at least equal to the pixel count of the direct imaging plate. Archive images using a reproducible electronic medium. Provide data file format and storage that comply with ASTM E2339, Standard Practice for Digital Imaging and Communication in Nondestructive Evaluation (DICONDE), format. Documented and prove the image archival method (at system installation). Include the image file nomenclature to enable the retrieval of images at a later date. Archived image files must maintain the bit depth and spatial resolution of the original image. Image data compression is not allowed. Preserve (store) the initial image presented by the CR or DR system without altering the original spatial resolution and pixel intensity . Preserve

(excluding window/level and digital image zoom) to achieve the required image quality level. Store annotations made to the image in a manner which will not mask or hide diagnostic areas of the image. M.1.g Overhead Signs The Department considers sign posts and trusses for free standing cantilevered and non-cantilevered overhead signs as cyclically loaded Structures. Bridge mounted signs are considered statically loaded Structures. Provide overhead sign Structures welded in accordance with the requirements of AWS D1.1, Structural Welding – Steel, as outlined in the AASHTO Structural Supports for Highway Signs, Luminaires, and Traffic Signals. Perform RT, UT, and MT, as outlined in the current overhead sign standards sheets. The Bridge Engineer will base acceptance for overhead signs in accordance with AWS D1.1.

N Department Inspection N.1 General The Bridge Engineer will inspect Major and Minor Structural steel Components before use in the Work. The Bridge Engineer may perform inspections at the mill, foundry, fabrication shop, or in the field. The purpose of Department inspection(s) is to establish compliance with those test requirements and process controls outlined in the Contract as required by federal and State laws. The Department inspection does not supplement or replace the Supplier’s own Quality Control and does not relieve the Supplier of its responsibility for the correction of errors and faulty workmanship, or for the replacement of nonconforming Materials. The Department may reject Work not performed in accordance with the Supplier’s approved QM in accordance with 1512, “Unacceptable and Unauthorized Work.” The Department will not charge the Contractor for plant inspections by Department personnel. Provide the Department Inspectors with suitable hard hats, face and hand shields, safety glasses, respirators, and other safety Equipment necessary to ensure the Inspector's safety while performing structural metals inspections. Notify the Bridge Engineer at least 5 Business Days before the Fabricator begins Work to allow the Bridge Engineer to perform inspections. Do not allow the Fabricator to perform Work or manufacture Material until after notifying the Bridge Engineer. The Bridge Engineer may reject Work performed without notice in accordance with 1512, “Unacceptable and Unauthorized Work,” or may subject the Work performed to additional NDT, at no additional cost to the Department. The Department may reject Material or Work not meeting the requirements of the Contract. The Contractor, in conjunction with the Fabricator, may appeal to the Bridge Engineer. The Bridge Engineer will make final decisions on disputes. The Bridge Engineer may reject Material shipped to the Project Site without a Department inspection tag as unacceptable Work in accordance with 1512, “Unacceptable and Unauthorized Work.” N.2 Facilities for Inspection Ensure the Fabricator provides an office, access to a computer and a copy machine, and any needed tools and assistance to the Inspector for at least 30 Business Days before Work is scheduled to start to 30 Business Days after the shipment of Material. Ensure the Fabricator provides an Inspector’s office meeting the following requirements and characteristics:

necessary furniture

door

connection

The relevant Contract Unit Price for steel Bridge construction includes the cost of providing, maintaining, and repairing, or replacing inspection facilities as included in the cost of steel bridge construction. O Marking and Shipping Ensure the Fabricator performs the following:

approved by the Bridge Engineer

pounds. Ship pins with nuts in place

requirements of ASTM F3125, Standard Specification for High Strength Structural Bolts and Assemblies, Steel and Alloy Steel, Heat Treated, “Inch Dimensions 120 ksi and 150 ksi Minimum Tensile Strength, and Metric Dimensions 830 MPa and 1040 MPa Minimum Tensile Strength”

transporting, unloading, handling, and storage

Engineer. Block Material to prevent buckling, warping, or twisting during transportation

2471.4METHOD OF MEASUREMENT - BLANK

2471.5BASIS OF PAYMENT - BLANK