810Steel Structures

810.01 Description. This work consists of furnishing, fabricating, preparing, assembling,

erecting, and painting structural steel and all accessories and other metal parts required in steel spans. This work shall be constructed as indicated on the plans, in reasonably close conformity with the lines, grades, dimensions, and design shown, and in accordance with the applicable provisions and requirements in other sections of these specifications for the different items that constitute the complete structure. All structural steel work shall be performed in accordance with these specifications and the AASHTO Guide Specification for Highway Bridge Fabrication with HPS70W Steel . Fabricators shall be certified in accordance with the AISC Quality Certification Program in the Major Steel Bridges (CBR) category with Fracture Critical Endorsement (F) prior to the start of fabrication. These specifications apply to bolted and we lded construction when indicated in the contract.

810.02 Materials.

810.02.1 General. Unless otherwise specified, structural steel, miscellaneous metals, and

paints shall conform to the applicable requirements of this section and Sections 710, 716, 717, and 814. Unless otherwise specified, structural carbon steel, ASTM A709 Grade 50/50W, shall be furnished.

810.02.2 Drawings. The Contractor shall prepare shop drawings for all materials to be

fabricated. The size of the sheets on which the drawings are prepared shall conform to the standard bridge sheet of the Department. Two complete sets of prints shall be submitted to the Bridge Engineer for approval prior to ordering any materials for fabrication. For all fabrication to be done by welding, two copies of welding procedures in accordance with the provisions of ANSI/ASSHTO/AWS D1.5 Bridge Welding Code, hereinafter referred to as the Welding C ode, shall also be submitted to the Bridge Engineer for approval. After final approval of the shop drawings and welding procedures, if applicable, six complete sets of prints shall be submitted to the Bridge Engineer. As required by special conditions, the Bridge Engineer shall be furnished with as many additional sets of prints as may be necessary. Shop drawings for railroad bridges shall be prepared with ink on linen tracing cloth or other approved equal, which shall be delivered to the Bridge Engineer prior to final acceptance of the proj ect. No changes shall be made in a shop drawing after it has been approved, nor shall steel sections different from those shown on the plans be substituted except with the written consent or direction of the Engineer. Prior to the fabrication of any part of a structure, shop drawings and welding procedures for that part of the structure shall have been given final, unconditional approval by the Bridge Engineer. Work performed prior to approval of drawing and procedures may be rejected.

810.02.3 Shop Painting. Shop painting, unless otherwise designated or permitted, shall

consist of inorganic zinc primer, Section 710, applied as specified in Section 814. Machine-finished surfaces of pins, pin roller s and bores shall be coated as soon as practicable after acceptance with a heavy coat of Petrolatum meeting the requirements of ASTM D 217, NLGI Consistency Grade 2 or 3, or other approved coating prior to removal from the shop.

810.02.4 Storage of Materials. Structural material, either plain or fabricated, shall be

stored at the bridge shop above ground on platforms, skids, or other supports. It shall be kept free from dirt, grease, and other forei gn matter and shall be protected as far as practicable from corrosion.

810.02.5 Straightening Material. Rolled material, before being laid off or worked, must

be straight. If straightening is necessary, it shall be done by methods that will not injure the metal. Heat straightening of ASTM A514/A517 steel shall be done only under rigidly controlled procedures and each application subject to the approval of the Engineer. In no case shall the maximum temperature of the steel exceed 1125°F. Sharp kinks and bends will be cause for rejection of the material.

810.02.6 Curving Rolled Beams and Welded Girders. Steels that are manufactured to

a yield point greater than 50,000 psi shall not be heat curved.

810.02.6 1--Type of Heating. Beams and girders may be curved by either continuous or

V-type heating as approved by the Engineer. For the continuous method, a strip along the edge of the top and bottom flange shall be h eated simultaneously. The strip shall be of sufficient width and temperature to obtain the required curvature. For the V-type heating, the top and bottom flanges shall be heated in truncated triangular or wedge-shaped areas having their bases along the flange edge and spaced at regular intervals along each flange. The spacing and temperature shall be as requi red to obtain the requ ired curvature, and heating shall progress along the top and bottom flange at approximately the same rate. For the V-type heating, the apex of the truncated triangular area applied to the inside flange surface shall terminate just before the juncture of the web and the flange is reached. To avoid unnecessary web distortion, special care shall be taken when heating the inside flange surface so the heat is not applied directly to the web. When the radius of curvature is 1000 feet or more, the apex of the truncated tria ngular heating pattern applied to the outside flange surface shall extend to the juncture of the flange and web. When the radius of curvature is less than 1000 feet, the apex of the truncated triangular heating pattern applied to the outside flange surface sh all extend past the web for a distance equal to 1/8 of the flange or three (3) inches, whichever is less. The truncated triangular pattern shall have an included angle of approximately 15 to 30 degrees, but the base of the triangle shall not exceed 10 inches. Variations in the pattern s prescribed above may be made with the approval of the Engineer. For both types of heating, the flange edges to be heated are those that will be on the inside of the horizontal curve after c ooling. Heating both inside and outside flange surfaces is only mandatory when the flange thickness is 1¼ inches or greater, in which case the two surfaces shall be heated concurrently. The ma ximum temperatures shall be as prescribed below.

810.02.6 2--Temperature. The heat-curving operation shall be conducted in such a

manner that the temperature of the steel does not exceed 1150°F as measured by temperature indicating crayons or other suitable means. The girder shall not be artificially cooled until after naturally cooling to 600°F. The method of artificial cooling is subject to the approval of the Engineer.

810.02.6 3--Position for Heating. The girder may be heat- curved with the web in either

a vertical or a horizontal position. When curved in the vertical position, the girder shall be braced or supported in such a manner that the tendency of the girder to deflect laterally during the heat- curving process will not cause the girder to overturn. When curved in the horizontal position, the girder must be su pported near its ends and at intermediate points, if required, to obtain a uniform curvature. The bending stress in the flanges due to the dead weight of the girder must not exceed the usual allowable design stress. When the girder is positioned horizont ally for heating, intermediate safety catch blocks must be maintained at the mid-length of the girder within two inches of the flanges at all times during the heating process to guar d against a sudden sag due to plastic flange buckling.

810.02.6 4--Sequence of Operations. The girder shall be heat curved in the fabrication

shop before it is painted. The heat curving operation may be conducted either before or after all the required welding of transverse intermediate stiffeners is completed. However, unless provisions are made for girder shrinkage, connection plates and bearing stiffeners shall be located and attached after heat curving. If longitudinal stiffeners are required, they shall be heat curved or oxygen cut separately and then welded to the curved girder. When cover plates are to be attached to rolled beams, they may be attached before heat curving if the total thickness of one flange and cover plate is less than 2½ inches and the radius of curvature is greater than 1000 feet. For other rolled beams with cover plates, the beams must be heat-curved before the cover plates are attached. Cover plates must be either heat curved or oxygen cut separately and then welded to the curved beam.

810.02.6 5--Camber. Girders shall be cambered before heat curving. Camber for rolled

beams may be obtained by heat- cambering methods approved by the Engineer. For plate girders, the web shall be cut to the prescribed camber with suitable allowance for shrinkage due to cutting, welding, and heat curving. The heat-curving process may tend to change the vertical camber present before heating. This effect will be most pronounced when the top and bottom flanges are of unequal widths on a given transverse cross section. However, subject to the approval of the Engineer, m oderate deviations from specified camber may be corrected by a carefully supervised application of heat.

810.02.6 6--Measurement of Curvature and Camber. Horizontal curvature and vertical

camber shall not be measured for final acceptance before all welding and heating operations are completed, and the flanges have cooled to a uniform temperature. Horizontal curvature shall be checked with the girder in the vertical position by measuring off-sets from a string line or wire attached to both flanges or by using other suitable means. Camber shall be checked by adequate means.

810.02.7 Finish. Portions of work exposed to view shall be finished neatly. Shearing,

flame cutting, and chipping shall be done carefully and accurately.

810.02.8 Bolt Holes. All holes for bolts shall be eith er punched or dr illed. Material

forming parts of a member composed of not more than five thicknesses of metal may be punched 1/16 inch larger than the nominal diameter of the bolts whenever the thickness of the material is not greater than 3/4 inch for structural steel, 5/8 inch for high strength steel, or 1/2 inch for quenched and tempered all oy steel, unless subpunching and reaming is required under Subsection 810.02.11.1. When there are more than five thicknesses or when any of the main material is thicker than 3/4 inch for structural steel, 5/8 inch for high strength steel, or 1/2 inch for quenched and tempered alloy steel, all holes shall either be subdrilled or drilled full size. When required under Subsection 810.02.11, all holes shall be either subpunched or subdrilled 3/16 inch smaller and after assembling, reamed 1/ 16 inch larger or drilled full size to 1/16 inch larger than the nominal diameter of bolts . Holes shall be subdrilled if thickness limitation governs.

810.02.9 Punched Holes. The diameter of the die shall not exceed the diameter of the

punch by more than 1/16 inch. If any holes must be enlarged to admit the bolts, such holes shall be reamed. Holes must be clean cut without torn or ragged edges. Poor matching of holes will be cause for rejection.

810.02.10 Reamed or Drilled Holes. Reamed or drilled holes shall be cylindrical,

perpendicular to the member, and shall comply w ith the requirements of Subsection

810.02.8 as to size. Where pr acticable, reamers shall be dir ected by mechanical means.

Burrs on the outside surfaces shall be removed. Poor matching of holes will be cause for rejection. Reaming and drilling shall be done with twist drills. If required by the Engineer, assembled parts shall be taken apart for removal of burrs caused by drilling. Connecting parts requiring reamed or drilled holes shall be assembled and securely held while being reamed or drilled and shall be match marked before disassembling.

810.02.11 Preparation of Field Connections.

810.02.11 1--Subpunching and Reaming of Field Connections. Unless otherwise

specified, holes in all field connections and field splices of main members of trusses, arches, continuous beam spans, bents, each face of towers, plate girders, and rigid frames shall be subpunched or subdrilled if subdrilling is required by Subsection 810.02.8, and subsequently reamed while assembled or to a steel template, as required by Subsection

810.02 16.

All holes for floorbeam and stringer field end connections shall be subpunched and reamed to a steel template or reamed while assembled. Reaming or drilling full size of field connection holes through a steel template shall be done after the template has been located with utmost care as to position and angle and firmly bolted in place. Templates used for reaming matching members, or the opposite faces of a single member, shall be exact duplicates. Templates used for connections on like parts or members shall be accurately located so that the parts or members are duplicates and require no match-marking. For any connection, in lieu of subpunching and reaming or subdrilling and reaming, the fabricator shall have the option of drilling holes full size with all thicknesses of material assembled in proper position. If additional subpunching and reaming is required, it shall be as specified on the plans.

810.02.11 2--Numerically-Controlled Drilled Field Connections. Alternately, for any

connection or splice designated in Subsection 810.02.11.1 in lieu of sub-sized holes and reaming while assembled, or drilling holes full-size while assembled, the Contractor shall have the option to drill bolt holes full-size in unassembled pieces and/or connections including templates for use with matching sub-sized and reamed holes by means of suitable numerically-controlled (N/C) drilling equipment subject to the specific provisions contained in this article. If N/C drilling equipment is used, the Engineer, unless otherwise stated in the special provisions or on the plans, may require the Contractor, by means of check assemblies, to demonstrate that this drilling procedure consistently produces holes and connections meeting the requirements of Subsections 810.02.13 and 810.02.16. The Contractor shall submit to the Engineer for approval a detailed outline of the procedures proposed to be followed in accomplishing the work from initial drilling through check assembly, if required, to include the specific members of the structure that may be N/C drilled, the sizes of the holes, the location of common index and other reference points, composition of check assemblies, and all other pertinent information. Holes drilled by N/C drilling equipment shall be drilled to appropriate size either through individual pieces or any combination of pieces held tightly together.

810.02.12 Accuracy of Punched and Drilled Holes. All holes punched full size,

subpunched, or subdrilled shall be so accurately punched that after assembling, before any reaming is done, a cylindrical pin ⅛-inch smaller in diameter than the nominal size of the punched hole may be entered perpendicular to the face of the member, without drifting, in at least 75 percent of the contiguous holes in the same plane. If this requirement is not fulfilled, the badly punched pieces will be rejected. If any hole will not pass a pin 3/16 inch smaller in diameter than the nominal size of the punched hole, this will be cause for rejection.

810.02.13 Accuracy of Reamed and Drilled Holes. When holes are reamed or drilled,

85 percent of the holes in any contiguous group shall, after reaming or drilling, show no offset greater than 1/32 inch between adjacent thicknesses of metal. All steel templates shall have hardened steel bushings in holes accurately dimensioned from the center lines of the connection as inscribed on the template. The center lines shall be used in accurately locating the template from the milled or scribed ends of the members.

810.02.14 Fitting for Bolting. Surfaces of metal in contact shall be cleaned before

assembling. The parts of a member shall be assembled, well pinned, and firmly drawn together with bolts before reaming is commenced. Assembled pieces shall be taken apart, if necessary, for the removal of burrs and shavings produced by the reaming operation. The member shall be free from twists, bends, and other deformation. Preparatory to the shop riveting of full-sized punched material, the rivet holes, if necessary, shall be spear-reamed for the admission of the rivets. The reamed holes shall not be more than 1/16 inch larger than the nominal diameter of the rivets. End connection angles, stiffener angles, and similar parts shall be carefully adjusted to correct position and bolted, clamped, or otherwise firmly held in place until riveted. Parts not completely riveted in the shop shall be secured by bolts, insofar as practicable, to prevent damage in shipment and handling.

810.02.15 Unpainted Weathering Structural Steel. Unless otherwise specified,

material designated as A709 Grade 50W and A709 HPS70W structural steel that is not to be painted shall be blast cleaned to remove mill scale or other substances. Blast cleaning shall conform to SSPC-SP6, Commercial Blast Cleaning. Care shall be taken that dents, scratches, gouges or identification marks will not appear on exposed surfaces. All steel is to remain in the unpainted condition and shall be handled so that it is kept free of all grease, oil, concrete, chalk marks, dirt, or any other foreign material that might affect the natural and uniform weathering of the steel. Any foreign material that adheres to the steel during the fabrication or construction process that will inhibit the formation of the oxide film shall be removed as soon as practicable according to the SSPC Surface Preparation Specification by one of the following four methods.

810.02.16 Shop Assembling.

810.02.16 1--General. The field connections of main members of trusses, arches,

continuous beam spans, bents, each face of towers, plate girders, and rigid frames shall be assembled in the shop with milled ends of compression members in full bearing, and then shall have their subsize holes reamed to specified size while the connections are assembled. Assembly shall be Full Truss or Girder Assembly unless Progressive Truss or Girder Assembly, Full Chord Assembly, Progressive Chord Assembly, or Special Complete Structure Assembly is specified in the special provisions or on the plans. Modifications to these assemblies may be allowed when approved in writing by the Bridge Engineer. When required on the plans, check assemblies and N/C drilled field connections shall be in accordance with the provisions of Subsection 810.02.16.7. Each assembly, including camber, alignment, accuracy of holes, and fit of milled joints, shall be approved by the Engineer before reaming is commenced or before an N/C drilled check assembly is dismantled. A camber diagram shall be furnished the Engineer by the Fabricator showing the camber at each panel point in the cases of trusses or arch ribs, and at the location of field splices and fractions of span length in case of continuous beam and girders or rigid frames. Fraction points of span lengths shall be 1/4 points minimum, 1/10 points maximum. When the shop assembly is full truss or girder assembly or special complete structure assembly, the camber diagram shall show the camber measured in assembly. When any of the other methods of shop assembly is used, the camber diagram shall show calculated camber.

810.02.16 2--Full Truss or Girder Assembly. Full truss or girder assembly shall consist

of assembling all members of each truss, arch rib, bent, tower face, continuous beam line, plate girder, or rigid frame at one time.

810.02.16 3--Progressive Truss or Girder Assembly. Progressive truss or girder

assembly shall consist of assembling initially for each truss, arch rib, bent, tower face, continuous beam line, plate girder, or rigid frame at least three contiguous shop sections or all members in at least three contiguous panels but not less than the number of panels associated with three contiguous chord lengths, i.e., length between field splices, and not less than 150 feet in the case of structures longer than 150 feet. At least one shop section or panel or as many panels as are associated with a chord length shall be added at the advancing end of the assembly before any member is removed from the rearward end, so that the assembled portion of the structure is never less than that specified above.

810.02.16 4--Full Chord Assembly. Full chord assembly shall consist of assembling, with

geometric angles at the joints, the full length of each chord of each truss or open spandrel arch, or each leg of each bent or tower, then reaming their field connection holes while the members are assembled and reaming the web member connection to steel templates set at geometric not cambered angular relation to the chord lines. Field connection holes in web members shall be reamed to steel templates. At least one end of each web member shall be milled or shall be scribed normal to the longitudinal axis of the member and the templates at both ends of the member shall be accurately located from one of the milled ends or scribed lines.

810.02.16 5--Progressive Chord Assembly. Progressive chord assembly shall consist of

assembling contiguous chord members in the manner specified for full chord assembly and in the number and length specified for progressive truss or girder assembly.

810.02.16 6--Special Complete Structure Assembly. Special complete structure

assembly shall consist of assembling the entire structure, including the floor system. This procedure is ordinarily needed only for complicated structures such as those having curved girders, or extreme skew in combination with severe grade or camber, and will be required only when so indicated on the plans.

810.02.16 7--Check Assemblies with Numerically Controlled Drilled Field

Connections. Unless otherwise indicated, a check assembly shall be fabricated for each major structural type and shall consist of at least three contiguous shop sections or, in a truss, all members in at least three contiguous panels but not less than the number of panels associated with three contiguous chord lengths, i.e., length between field splices. Check assemblies should be based on the proposed order of erection, joints in bearings, special complex points, and similar considerations. Such special points could be the portals of skewed trusses, etc. Use of either geometric angles, giving theoretically zero secondary stresses under dead- load conditions after erection, or cambered angles, giving theoretically zero secondary stresses under no-load conditions, should be designated on the plans or in the special provisions. The check assemblies shall preferably be the first such section of each major structural type to be fabricated. No match-marking and no shop assemblies other than the check assemblies will be required. If the check assembly fails in some specific manner to demonstrate that the required accuracy is being obtained, further check assemblies may be required by the Engineer, for which there shall be no additional cost to the State.

810.02.17 Drifting of Holes. The drifting done during assembling shall be only such as

to bring the parts into position and not sufficient to enlarge the holes or distort the metal. If any holes must be enlarged to admit the rivets, they shall be reamed.

810.02.18 Match-Marking. Connecting parts assembled in the shop for the purpose of

reaming holes in field connections shall be match-marked, and a diagram showing such marks shall be furnished to the Engineer.

810.02.19 Blank.

810.02.20 Bolts and Bolted Connections. Bolted connections fabricated using high

strength bolts shall conform to Subsection 810.02.21.

810.02.20 1--General. Bolts shall be unfinished, turned, or ribbed bolts conforming to the

requirements for Grade A Bolts of Specification for Low-Carbon Steel Externally and Internally Threaded Standard Fasteners, ASTM A 307. Bolted connections shall be used only as indicated by the plans or special provisions. Bolts shall have single self-locking nuts or double nuts unless otherwise shown on the plans or in the special provisions. Beveled washers shall be used where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis.

810.02.20 2--Unfinished Bolts. Unfinished bolts shall be furnished unless other types are

specified.

810.02.20 3--Turned Bolts. The surface of the body of turned bolts shall meet the ANSI

roughness rating value of 125. Heads and nuts shall be hexagonal with standard dimensions for bolts of the nominal size specified or the next larger nominal size. Diameter of threads shall be equal to the body of the bolt or the nominal diameter of the bolt specified. Holes for turned bolts shall be carefully reamed with bolts furnished to provide for a light driving fit. Threads shall be entirely outside of the holes. A washer shall be provided under the nut.

810.02.20 4--Ribbed Bolts. The body of ribbed bolts shall be of an approved form with

continuous longitudinal ribs. The diameter of the body measured on a circle through the points of the ribs shall be 5/64 inch greater than the nominal diameter specified for the bolts. Ribbed bolts shall be furnished with round heads conforming to ANSI B 18.5 unless otherwise specified. Nuts shall be hexagonal, either recessed or with a washer of suitable thickness. Ribbed bolts shall make a driving fit with the holes. The hardness of the ribs shall be such that the ribs do not mash down enough to permit the bolts to turn in the holes during tightening. If for any reason the bolt twists before drawing tight, the hole shall be carefully reamed and an oversized bolt used as a replacement.

810.02.21 Connections Using High Strength Bolts. This subsection covers the

assembly of structural joints using ASTM A 325 high strength bolts for structural steel joints or ASTM A 490 quenched and tempered alloy bolts for structural steel joints, or equivalent fasteners, tightened to a high tension. The bolts are used in holes conforming to the requirements of Subsections 810.02.8, 810.02.9 and 810.02.10.

810.02.21 1--Bolts, Nuts, Washers and Direct Tension Indicators (DTI). All bolts,

nuts, washers and DTI shall conform to the requirements of Section 717 for such items. Unless otherwise shown on the plans, all threaded bolts shall be of sufficient length to provide at least full-thread engagement, as defined in Subsection 810.04.4, immediately prior to final tensioning. All markings on bolts, nuts, washers and DTIs must include the symbol of the manufacturer and not the distributor or any other trading entity. This is spelled out in all ASTM specifications covering these product categories. A325 bolts shall be marked "A325" and A490 bolts marked "A490.” Type 1 A325 bolts shall be marked with three radial lines 120° apart. Type 3 A325 bolts shall have A325 underlined plus other distinguishing marks indicating that the bolt is atmospheric corrosion resistant and of a weathering type. Type 2 A325 bolts shall be marked with three radial lines 60° apart. DTIs shall also be marked "325" in the case of Type "325" or "490".

810.02.21 2--Bolted Parts. The slope of surfaces of bolted parts in contact with the bolt

head and nut shall not exceed 1:20 with respect to a plane normal to the bolt axis. Bolted parts shall fit solidly together when assembled and shall not be separated by gaskets or any other interposed compressible material. When assembled, all joint surfaces, including those adjacent to the bolt heads, nuts, or washers, shall be free of scale, except tight mill scale, and shall also be free of dirt, loose scale, burrs, other foreign material, and other defects that would prevent solid seating of the parts. Paint is permitted in bearing-type connections. Contact surfaces within friction-type joints shall be free of oil, paint, lacquer or other coatings, except as listed below:

810.03 Construction Requirements.

810.03.1 Installation.

810.03.1 1--Bolt Tension. Each fastener shall be tightened to provide, when all fasteners

in the joint are tight, at least the minimum bolt tension for the size and grade of fastener used, as shown in the following table: BOLT TENSION Bolt Size, Minimum Bolt Tension, pounds inches ASTM A 325 Bolts ASTM A 490 Bolts 1/2 12,050 14,900 5/8 19,200 23,700 3/4 28,400 35,100 7/8 39,250 48,500 1 51,500 63,600 1 1/8 56,450 80,100 1 1/4 71,700 101,800 1 3/8 85,450 121,300 1 1/2 104,000 147,500 The rotational-capacity test described in Subsection 717.02.3.4 shall be performed on each rotational-capacity lot prior to the start of bolt installation. Hardened steel washers are required as part of the test although they may not be required in the actual installation procedure. A Skidmore-Wilhelm Calibrator or an equivalent tension measuring device shall be required at each job site during erection. Periodic testing, at least one each working day when the calibrated wrench method is used, shall be performed to assure compliance with the installation requirements for calibrated wrench tightening, turn-of nut tightening or DTI tightening. The Contractor shall provide all wrenches necessary for obtaining the specified bolt tension, and shall also provide, at no additional costs to the State, the necessary inspection wrenches and provisions for calibration of such wrenches as specified in this subsection and in Subsection 810.03.2. Threaded bolts shall be checked for tension with properly calibrated wrenches, by the turn- of-nut method, or by the use of DTIs. When required because of bolt entering and wrench operating clearances, tightening may be accomplished by turning the bolt while the nut is prevented from rotating, provided the requirements of Subsections 810.03.1.2 and

810.03.1 5 are met.

Impact wrenches, if used, shall be of adequate capacity and sufficiently supplied with air to perform the required tightening of each bolt in approximately 10 seconds. ASTM A490 and galvanized ASTM A325 bolts shall not be reused. Other ASTM A325 bolts may be reused, but not more than once, if approved by the Engineer. Retightening previously tightened bolts that may have been loosened by the tightening of adjacent bolts shall not be considered as a reuse. Galvanized nuts shall be checked to verify that a visible lubricant is on the threads. Black bolts shall be "oily" to the touch when delivered and installed. Weathered or rusted bolts and nuts shall be cleaned and re-lubricated prior to installation. When required, bolt, nut and washer combinations as installed shall be from the same rotational-capacity lot, reference Subsection 717.02.

810.03.1 2--Washers. All fasteners shall have a hardened washer under the element (nut

or bolt head) turned in tightening except that ASTM A325 bolts installed by the turn of the nut method in holes that are not oversize or slotted may have the washer omitted. Hardened washers shall be used under both the head and nut regardless of the element turned in the case of ASTM A490 bolts if the material against which it bears has a specified yield strength less than 40 ksi. When ASTM A 490 bolts over one inch in diameter are used in conjunction with short slotted or oversized holes, the hardened washers shall be at least 5/16 inch thick. Where an outer face of the bolted parts has a slope of more than 1:20 with respect to a plane normal to the bolt axis, a smooth beveled washer shall be used to compensate for the lack of parallelism.

810.03.1 3--Calibrated Wrench Tightening. When calibrated wrenches are used to

provide the bolt tension specified in Subsection 810.03.1.1, their setting shall be such as to induce a bolt tension five percent to ten percent in excess of this value. These wrenches shall be calibrated at least once each working day by tightening, in a device capable of indicating actual bolt tension, not less than three typical bolts of each diameter to be installed. Power wrenches shall be adjusted to stall or cut-out at the selected tension. If manual torque wrenches are used, the torque indication corresponding to the calibrating tension shall be noted and used in the installation of all bolts of the tested lot. Nuts shall be in the tightening direction when torque is measured. When using calibrated wrenches to install several bolts in a single joint, the wrench shall be returned to "touch up" bolts previously tightened, which may have been loosened by the tightening of subsequent bolts, until all are tightened to the specified tension. The required torque for calibrated wrenches may be approximated by the following formula: T (inch-pounds) = 0.2 x Bolt Diameter (inches) x Bolt Tension (pounds)

810.03.1 4--Turn-of-Nut Tightening. When the turn-of-nut method is used to provide the

bolt tension specified in Subsection 810.03.1.1, there shall first be enough bolts brought to a "snug tight" condition to ensure that the parts of the joint are brought into full contact with each other. "Snug tight" is defined as the initial tightening of the nut such that a load in the bolt of not less than 10% of the specified proof load for each type and size bolt used is produced. Following this initial operation, bolts shall be placed in the remaining holes in the connection and brought to snug tightness. All bolts in the joint shall then be tightened additionally by the applicable nut rotation specified in the following table with tightening progressing systematically from the most rigid part of the joint to its free edges. During this operation there shall be no rotation of the part not turned by the wrench. NUT ROTATION (1) FROM SNUG-TIGHT CONDITION For coarse thread heavy hexagon structural bolts of all sizes and lengths and heavy hexagon semi-finished nuts Disposition of Outer Faces of Bolted Parts Bolt Length, as measured from underside of head to extreme end of point Both faces normal to bolt axis One face normal to bolt axis and other face sloped not more than 1:20. Bevel washer not used. Bolt faces sloped not more than 1:20 from normal to bolt axis. Bevel washers not used. Up to and including 4 diameters 1/3 turn* 1/2 turn* 2/3 turn** Over 4 diameters but not exceeding 8 diameters 1/2 turn* 2/3 turn** 5/6 turn** Over 8 diameters but not exceeding 12 diameters 2/3 turn** 5/6 turn** 1 turn** (1) Nut rotation is rotation relative to bolt regardless of the element, nut or bolt, being turned. * Rotation Tolerance: Plus or minus 30 degrees ** Rotation Tolerance: Plus or minus 45 degrees

810.03.1 5--Direct Tension Indicators Tightening. When DTI are required on the plans,

the Contractor shall furnish a copy of the manufacturer's written installation instructions to the Bridge Engineer for approval prior to beginning work. It shall be the Contractor's responsibility to have a manufacturer's representative on the job site during initial installation of bolted connections to instruct personnel on the correct method of installation and inspection of the DTI. The DTI shall be installed and the bolts tightened in strict accordance with the manufacturer's written instruction. The DTI are in addition to washers required by the plans and Standard Specifications. DTI protrusions for all installations shall bear against a hardened unturned surface, normally either the underside of the bolt head or a hardened washer, and never directly against the turned element. Prior to the final tightening of all high strength bolts, all the plies of steel shall be drawn together by partially compressing DTI protrusions to ensure "snug tight" conditions. The final tightening shall progress systematically from the most rigid part of the joint to its free edges until the DTI on all bolts are closed to 0.005 inch. DTI shall not be reused. If it becomes necessary to loosen a bolt previously tensioned, the DTI shall be discarded and replaced. Bolts shall be of sufficient length to accommodate an indicator and washers made necessary by its use. The Contractor shall furnish a Skidmore-Wilhelm device or approved equal capable of measuring actual bolt tension. At least three typical bolts and DTIs shall be tightened in a device capable of determining their performance characteristics prior to the start of bolt placement. The device shall be made available thereafter during bolt placement for similar checks not to exceed intervals of one week unless directed otherwise by the Bridge Engineer. High strength bolts, nuts, washers, and DTIs shall be shipped to the project site in sealed metal containers or an approved equal. They shall be stored out of the weather in a location approved by the Engineer. The containers shall remain unopened until the contents are needed for erection. Bolts that, before use, have been exposed and become dried out or rusty will be rejected and will not be used until they are cleaned and lubricated.

810.03.1 6--Lock-Pin and Collar Fasteners. The installation of lock-pin and collar

fasteners shall be by methods and procedures approved by the Engineer.

810.03.2 Inspection. The Engineer will observe the installation and tightening of bolts

to determine that the selected tightening procedure is properly used and will determine that all bolts are tightened. When the calibrated wrench method of tightening is used, the Engineer will have full opportunity to witness the calibration tests prescribed in Subsection

810.03.1 3.

The following inspection shall be used unless a more extensive or different inspection procedure is specified.

810.03.2 1--Inspecting Wrench. Either the Engineer, or the Contractor in the presence of

the Engineer, shall use an inspecting wrench that may be either a torque wrench or a power wrench that can be accurately adjusted in accordance with the requirements of Subsection

810.03.1 3.

810.03.2 2--Calibration Device. Three bolts of the same grade, size and conditions as

those under inspection shall be placed individually in a calibration device capable of indicating bolt tension. The length of the bolt may be any length representative of bolts used in the structure. There shall be a washer under the part turned in tightening each bolt.

810.03.2 3--Torque Wrench. When the inspecting wrench is a torque wrench, each bolt

specified in Subsection 810.03.2.2 shall be tightened in the calibration device by any convenient means to the minimum tension specified for its size in Subsection 810.03.1.1. The inspecting wrench then shall be applied to the tightened bolt and the torque necessary to turn the nut or head five degrees, approximately one inch at 12-inch radius, in the tightening direction shall be determined. The average torque measured in the tests of three bolts shall be taken as the job inspecting torque to be used in the manner specified in Subsection 810.03.2.5.

810.03.2 4--Power Wrench. When the inspecting wrench is a power wrench it shall be

adjusted so that it will tighten each bolt specified in Subsection 810.03.2.2 to a tension at least five but not more than ten percent greater than the minimum tension specified for its size in Subsection 810.03.1.1. This setting of wrench shall be taken as the job inspecting torque to be used in the manner specified in the following subsection.

810.03.2 5--Bolts. Bolts represented by the sample prescribed in Subsection 810.03.2.2

that have been tightened in the structure shall be inspected by applying, in the tightening direction, the inspecting wrench and its job inspecting torque to ten percent of the bolts, but not less than two bolts, selected at random in each connection. If no nut or bolt head is turned by this application of the job inspecting torque, the connection shall be accepted as properly tightened. If any nut or bolt head is turned by the application of the job inspecting torque, this torque shall be applied to all bolts in the connection, and all bolts whose nut or head is turned by the job inspecting torque shall be tightened and re-inspected, or alternatively, the fabricator or erector, at no additional cost to the State, may re-tighten all of the bolts in the connection in the manner required and subject to the limitations imposed for the initial tightening and then resubmit the connection for the specified inspection.

810.03.2 6--Direct Tension Indicators. When DTIs are used, the Department's inspector

will check for correct tensioning by inserting a correct-thickness pointed feeler gage into the opening between adjacent flattened protrusions in accordance with the manufacturer's instructions and Subsection 810.03.1.5. At least ten percent, but no less than two, of the bolts in each connection will be examined. A nil gap on ASTM A325 bolts is not cause for rejection. A nil gap for ASTM A490 bolts is not allowed.

810.03.2 7--Lock-pin and Collar Fasteners. The procedures for inspecting and testing

the lock-pin and collar fasteners and their installation to ensure that the required pre-load tension is provided shall be as approved by the Engineer.

810.03.3 Blank.

810.03.4 Plate Cut Edges.

810.03.4 1--Edge Planing. Sheared edges of plates more than 5/8 inch in thickness and

carrying calculated stress shall be planed to a depth of 1/4 inch. Re-entrant cuts shall be filleted to a minimum radius of 3/4 inch before cutting.

810.03.4 2--Visual Inspection and Repair of Plate Cut Edges. Visual inspection and

repair of plate cut edges shall be in accordance with the Welding Code.

810.03.5 Welds. Welding of steel structures, when authorized on the plans or on approved

working drawings, and pre-qualification of welding operators shall conform to the Welding Code. Welding shall be tested by non-destructive methods as prescribed in the Welding Code and as indicated on the plans. Edge blocks shall be used when radiographing butt welds greater than 1/2 inch thickness. The edge blocks shall have a length sufficient to extend beyond each side of the weld centerline for a minimum distance equal to the weld thickness, but no less than two inches, and shall have a thickness equal to or greater than the thickness of the weld. The minimum width of the edge blocks shall be equal to half the weld thickness, but not less than 1 inch. The edge blocks shall be centered on the weld with a snug fit against the plate being radiographed, allowing no more than 1/16 inch gap. Edge blocks shall be made of radiographically clean steel and the surface shall have a finish of ANSI 125 μinch, or smoother. Non-destructive testing shall be performed at the expense of the Contractor. Welded girders utilizing A709 HPS70W steels shall be fabricated in accordance with the AASHTO Guide Specification for Highway Bridge Fabrication with HPS70W Steel and ANSI/AASHTO/AWS D1.5 Bridge Welding Code. Only weld processes and consumables recommended by the Guide Specification for Highway Bridge Fabrication with HPS70W Steel will be permitted when welding high performance steel. Consumable handling requirements shall be in accordance with AWS D1.5, Sections 12.6.5, 12.6.6 and 12.6.7 and the AASHTO Guide Specification for Highway Bridge Fabrication with HPS70W Steel. Unless otherwise noted on the plans, filler metals shall be provided for all fillet welds in conformance with AWS D1.5, Table 4.1 (H8 maximum) for A709 Grade 50W base metal. Filler metals for single pass fillet welds need not meet the requirements for exposed bare applications. Filler metals for all full penetration groove welds connecting A709 HPS70W plate to A709 Grade 50W plate shall conform to the requirements for Grade 50W base metal as listed in AWS D1.5, Table 4.1 (H8 maximum). Filler metals for all full penetration groove welds connecting A709 HPS70W plates shall conform to the requirements for Grade HPS70W base metal as listed in AWS D1.5, Table 4.1 (H8 maximum). The Contractor may request approval of alternate consumables for matching strength welds. The request for approval must include documentation of successful welding in accordance with AWS D1.5, and include diffusible hydrogen tests as described in AWS D1.5, Article 12.6.2 indicating the deposited weld metal has a diffusible hydrogen level equivalent to H8 or less.

810.03.6 Oxygen Cutting. All oxygen cutting shall conform to the Welding Code.

810.03.7 Facing of Bearing Surfaces. The surface finish of bearing and base plates and

other bearing surfaces that are to come in contact with each other or with concrete shall meet the ANSI surface roughness requirements as defined in ANSI B 46.1, Surface Roughness, Waviness, and Lay, Part 1: Steel Slabs ................................................................................................ ANSI 2,000 Heavy plates in contact in shoes to be welded ......................................... ANSI 1,000 Milled ends of compression members, milled or ground ends of stiffeners and fillers ......................................................... ANSI 500 Bridge rollers and rockers ........................................................................... ANSI 250 Pins and pin holes ........................................................................................ ANSI 125 Sliding bearings ........................................................................................... ANSI 125

810.03.8 Abutting Joints. Abutting joints in compression members and girder flanges,

and in tension members where so specified on the drawings, shall be faced and brought to an even bearing. Where joints are not faced, the opening shall not exceed 1/4 inch.

810.03.9 End Connection Angles. Floorbeams, stringers and girders having end

connection angles shall be built to the exact length shown on the plans measured between the heels of the connection angles, with a permissible tolerance of zero inch to minus 1/16 inch. Where continuity is to be required, end connections shall be faced. The thickness of the connection angles shall not be less than 3/8 inch or that shown on the detail drawings.

810.03.10 Lacing Bars. The ends of lacing bars shall be neatly rounded unless another

form is required.

810.03.11 Fabrication of Members. Unless otherwise shown on the plans, steel plates

for main members and splice plates for flanges and main tension members, not secondary members, shall be cut and fabricated so that the primary direction of rolling is parallel to the direction of the main tensile and/or compressive stresses. Fabricated members shall be true to line and free from twists, bends and open joints.

810.03.12 Web Plates. In girders having no cover plates and not to be encased in

concrete, the top edge of the web plate shall not extend above the backs of the flange angles and shall not be more than 1/8 inch below at any point. Any portion of the plate projecting beyond the angles shall be chipped flush with the backs of the angles. Web plates of girders having cover plates may be 1/2 inch less in width than the distance back to back of flange angles. Splices in webs of girders without cover plates shall be sealed on the top with red lead paste prior to painting. At web splices, the clearance between the end of the web plates shall not exceed 3/8 inch. The clearance at the top and bottom ends of the web splice plates shall not exceed 1/4 inch.

810.03.13 Bent Plates. Unwelded, cold-bent, load-carrying, rolled-steel plates shall

conform to the following:

810.03.14 Fit of Stiffeners. End stiffeners of girders and stiffeners intended as supports

for concentrated loads shall have full bearing, either milled, ground or on weldable steel in compression areas of flanges, welded as shown on the plans or specified, on the flanges to which they transmit load or from which they receive load. Stiffeners not intended to support concentrated loads shall, unless shown or specified otherwise, fit sufficiently tight to exclude water after being painted. Fillers under stiffeners shall fit within 1/4 inch at each end.

810.03.15 Eyebars. Pin holes may be flame cut at least two inches smaller in diameter

than the finished pin diameter. All eyebars that are to be placed side by side in the structure shall be securely fastened together in the order that they will be placed on the pin and bored at both ends while so clamped. Eyebars shall be packed and match marked for shipment and erection. All identifying marks shall be stamped with steel stencils on the edge of one head of each member after fabrication is completed so as to be visible when the bars are nested in place on the structure. The eyebars shall be straight and free from twists and the pin holes shall be accurately located on the centerline of the bar. The inclination of any bar to the plane of the truss shall not exceed 1/16 inch to a foot. The edges of eyebars that lie between the transverse centerline of their pin holes shall be cut simultaneously with two mechanically operated torches abreast of each other, guided by a substantial template, in such a manner as to prevent distortion of the plates.

810.03.16 Annealing and Stress Relieving. Structural members that are indicated to be

annealed or normalized shall have finished machining, boring, and straightening done subsequent to heat treatment. Normalizing and annealing, full annealing, shall be as specified in ASTM E 44. The temperatures shall be maintained uniformly throughout the furnace during the heating and cooling so that the temperature at no two points on the member will differ by more than 100°F at any one time. Members of ASTM A514/A517 steels shall not be annealed or normalized and shall be stress relieved only with the approval of the Engineer. A record of each furnace charge shall identify the pieces in the charge and show the temperatures and schedule actually used. Proper instruments, including recording pyrometers, shall be provided for determining at any time the temperatures of members in the furnace. The records of the treatment operation shall be available to and meet the approval of the Engineer. The holding temperature for stress relieving ASTM A514/A517 steel shall not exceed 1125°F. Members, such as bridge shoes, pedestals, or other parts that are built up by welding sections of plate together shall be stress relieved in accordance with the Welding Code.

810.03.17 Pins and Rollers. Pins and rollers shall be accurately turned to the dimensions

shown on the drawings and shall be straight, smooth, and free from flaws. Pins and rollers more than nine inches in diameter shall be forged and annealed. Pins and rollers nine inches or less in diameter may be either forged and annealed or cold-finished carbon-steel shafting. In pins larger than nine inches in diameter, a hole not less than two inches in diameter shall be bored full length along the axis after the forging has been allowed to cool to a temperature below the critical range under suitable conditions to prevent injury by too rapid cooling and before being annealed.

810.03.18 Boring Pin Holes. Pin holes shall be bored true to the specified diameter,

smooth, and straight, at right angles with the axis of the member, and parallel with each other unless otherwise required. The final surface shall be produced by a finishing cut. The distance outside to outside of end holes in tension members and inside to inside of end holes in compression members shall not vary from that specified by more than 1/32 inch. Boring of holes in built-up members shall be done after the riveting is complete.

810.03.19 Pin Clearances. The diameter of the pin hole shall not exceed that of the pin

by more than 1/50 inch for pins five inches or less in diameter or 1/32 inch for larger pins.

810.03.20 Threads for Bolts and Pins. Threads for all bolts and pins for structural steel

construction shall conform to the Unified Standard Series UNC-ANSI B1.1, Class 2A for external threads and Class 2B for internal threads, except that pin ends having a diameter of 1 3/8 inches or more shall be threaded six threads to the inch.

810.03.21 Pilot and Driving Nuts. Two pilot nuts and two driving nuts for each size of

pin shall be furnished, unless otherwise specified.

810.03.22 Notice of Beginning Work. The Contractor shall give the Engineer ample

notice of the beginning of work at the mill or in the shop so that inspection may be provided. The term "mill" means any rolling mill or foundry where material for the work is to be manufactured. No material shall be manufactured or work done in the shop before the Engineer has been so notified. Prior to any fabrication, the fabricator shall have on hand Shop Drawings, Weld Procedures and a procedure for storage and handling of welding electrodes, wire and flux that have been approved by the Bridge Engineer. No fabrication shall begin until a prefabrication conference has been held and the facilities have been inspected and approved by the Bridge Engineer. When ordering structural steel, the fabricator shall specify the current ASTM designation for the material based on the date of advertisement for bids.

810.03.23 Facilities for Inspection. The Contractor shall furnish facilities for the

inspection of material and workmanship in the mill and shop, and the inspectors shall be allowed free access to the necessary parts of the works. Inspection at the mill and shop is intended as a means of facilitating the work and avoiding errors, and it is expressly understood that it will not relieve the Contractor from any responsibility in regard to imperfect material or workmanship and the necessity for replacing same.

810.03.24 Inspector's Authority. Inspectors shall have the authority to reject any

material or work that does not meet the requirements of the specifications. In case of dispute, the Contractor may appeal to the Engineer, whose decision shall be final. The acceptance of any material or finished members by the inspector shall not be a bar to their subsequent rejection, if found defective. Rejected material and workmanship shall be replaced promptly or made good by the Contractor. Material and workmanship not previously inspected will be inspected after its delivery to the site of the work.

810.03.25 Working Drawings and Identification of Steel During Fabrication.

810.03.25 1--Working Drawings. Shop drawings and other required drawings shall be

submitted to the Engineer in accordance with and subject to the provisions of Subsection

810.02 2.

Shop drawings for steel structures shall give full detailed dimensions and sizes of component parts of the structure and details of all miscellaneous parts such as pins, nuts, bolts, rivets, drains, etc. The Contractor expressly acknowledges by execution of the Contract that the Engineer's approval of the working drawings cover the requirements for "strength and detail" and that the Engineer assumes no responsibility for errors in dimensions.

810.03.25 2--Identification of Steels During Fabrication.

810.03.25 2.1--Identification by Contractor. The Engineer shall be furnished with four

complete copies of certified mill test reports showing chemical analysis and physical tests for each heat of steel for all members, unless excepted by the Engineer. Each piece of steel to be fabricated shall be properly identified for the Engineer. Shop drawings shall specifically identify each piece that is to be made of steel other than ASTM A709 Grade 50/50W. Pieces made of different grades of steel shall not be given the same assembling or erecting mark, even though they are of identical dimensions and detail. The Contractor's system of assembly-marking individual pieces, required to be made of steel other than ASTM A709 Grade 50/50W, and the issuance of cutting instructions to the shop, generally by cross-referencing of the assembly-marks shown on the shop drawings with the corresponding item covered on the mill purchase order, shall be such as to maintain identity of the mill test report number. Material the Contractor can identify by heat number and mill test report may be furnished from stock. All excess material placed in stock for later use shall be marked with the mill test report number and shall be marked with its ASTM A6 specification identification color code (see table below) when separated from the full-size pieces furnished by the supplier.

810.03.25 2.2--Identification of Steels During Fabrication. During fabrication, up to the

point of assembling members, each piece of steel, other than ASTM A709 Grade 50/50W, shall show clearly and legibly its specification identification color code shown in the table below. Individually marked pieces of steel that are used in furnished size, or reduced from furnished size only by end or edge trim and do not disturb the heat number or color code or leave any usable piece, may be used without further color coding provided that the heat number or color code remains legible. Pieces of steel, other than ASTM A709 Grade 50/50W, that are to be cut to smaller size pieces shall, before cutting, be legibly marked with the ASTM A6 specification identification color code. Individual pieces of steel, other than ASTM A709 Grade 50/50W, that are furnished in tagged lifts or bundles shall be marked with the ASTM A6 specification identification color code immediately upon being removed from the bundle or lift. Pieces of steel, other than ASTM A36, that, prior to assembling into members, will be subject to fabricating operations such as blast cleaning, galvanizing, heating for forming, or painting that might obliterate paint color code marking shall be marked for grade by steel die stamping or by a substantial tag firmly attached. The following identification color code shall be used to identify material required to meet the individual specifications listed. IDENTIFICATION COLOR CODES ASTM A709 Grade 50/50W White ASTM A 514 Red ASTM A 517 Red and Blue ASTM A 572, Grade 50 Green and Yellow ASTM A 588 Blue and Yellow ASTM A 852 Blue and Orange Other steels, except ASTM A709 Grade 50/50W, not covered above, nor included in the ASTM A6 Specification, shall have an individual color code that shall be established and on record for the Engineer.

810.03.25 2.3--Certification of Identification. Upon request, the Contractor shall furnish

an affidavit certifying that throughout the fabrication operation, the identification of steel has been maintained in accordance with this specification.

810.03.26 Full Size Tests. When full size tests of fabricated structural members or

eyebars are required, the plans or specifications will state the number and the nature of the tests, the results to be attained, and the measurements of strength, deformation, or other performance that are to be made. The Contractor shall provide suitable facilities, material, supervision, and labor necessary for making and recording the tests. The members tested in accordance with the contract will be measured for payment in accordance with Subsection 810.04. The cost of testing including equipment, handling, supervision, labor, and incidentals for making the tests shall be included in the contract price for the fabrication or fabrication and erection of structural steel, whichever is the applicable item in the contract, unless otherwise specified.

810.03.27 Marking and Shipping. Each member shall be painted or marked with an

erection mark for identification, and an erection diagram shall be furnished with erection marks shown thereon. The Contractor shall furnish to the Engineer as many copies of material orders, shipping statements, and erection diagrams as the Engineer may direct. The weights of the individual members shall be shown on the statements. Members weighing more than three tons shall have the weights marked thereon. Structural members shall be loaded on trucks or cars in such a manner that they may be transported and unloaded at their destination without being excessively stressed, deformed or otherwise damaged. Bolts of one length and diameter and loose nuts or washers of each size shall be packed separately. Pins, small parts, and packages of bolts, washers, and nuts shall be shipped in boxes, crates, kegs, or barrels, but the gross weight of any package shall not exceed 300 pounds. A list and description of the contained material shall be plainly marked on the outside of each shipping container. When DTIs are required on plans, the bolts, nuts, washers and DTI shall be shipped and stored in accordance with Subsection 810.03.1.5.

810.03.28 Erection of Structure. If the substructure and superstructure are built under

separate contracts, the Department will provide the masonry, constructed to correct lines and elevations and properly finished. The Contractor shall erect the metal work, remove the temporary construction, and do all work required to complete the bridge or bridges as covered by the contract, including the removal of the old structure if stipulated, all in accordance with the plans and these specifications.

810.03.28 1--Plans. If the fabrication and erection of the superstructure are done under

separate contracts, the Department will furnish detail plans for the bridge or bridges to be erected, including shop details, camber diagrams, erection diagrams, list of field rivets and bolts, and copy of shipping statements showing a list of parts and their weights.

810.03.28 2--Plant. The Contractor shall provide the falsework and all tools, machinery,

and appliances, including drift pins and fitting-up bolts necessary for the timely prosecution of the work.

810.03.28 3--Delivery of Material. If the contract is for erection only, the Contractor shall

receive the materials entering into the finished structure, free of charge at the place designated and loaded or unloaded as specified.

810.03.28 4--Handling and Storing Materials. Material to be stored shall be placed on

skids above the ground. It shall be kept clean and properly drained. Girders and beams shall be placed upright and shored. Long members, such as columns and chords, shall be supported on skids placed near enough together to prevent injury from deflection. If the contract is for erection only, the Contractor shall check the material supplied against the shipping lists and report promptly in writing all shortages or injuries discovered. After receiving the material, the Contractor shall be responsible for the loss of any material and for all damage caused to it.

810.03.28 5--Falsework. The falsework shall be properly designed and substantially

constructed and maintained for the loads that will come upon it. The Contractor, if required, shall prepare and submit to the Engineer for approval plans for falsework or for changes in an existing structure necessary for maintaining traffic. Approval of the Contractor's plans shall not be considered as relieving the Contractor of any responsibility.

810.03.28 6--Methods and Equipment. Before starting erection, the Contractor shall

inform the Engineer fully as to the proposed method of erection and the amount and character of equipment proposed for use, all of which shall be subject to the approval of the Engineer. The approval of the Engineer shall not be considered as relieving the Contractor of the responsibility for the safety of the method or equipment used or from carrying out the work in full accordance with the plans and specifications. No work shall be done until the approval of the Engineer has been obtained.

810.03.28 7--Bearings and Anchorages. Masonry bearing plates shall not be placed upon

bridge seat bearing areas that are improperly finished, deformed, or irregular. Bearing plates shall be set level in exact position and shall have a full and even bearing upon the masonry. Unless otherwise directed by the Engineer, they shall be placed on a layer of sheet lead one-eighth inch in thickness. Elastomeric bearing pads, if used, shall be set directly on the masonry. The Contractor shall drill the holes and set the anchor bolts, except where the bolts are built into the masonry. The bolts shall be set accurately and fixed with hydraulic cement grout completely filling the holes. Location of anchors and setting of rockers or rollers shall take into account the variation from mean temperature at time of setting and anticipated lengthening of bottom chord or bottom flange due to dead load after setting, the intention being that, as near as practicable, at mean temperature and under dead load the rockers and rollers shall set vertical and anchor bolts at expansion bearings will center their slots. Care shall be taken that full and free movement of the superstructure at the movable bearings is not restricted by improper setting or adjustment of bearings or anchor bolt and nuts.

810.03.28 8--Straightening Bent Material. The straightening of plates, angles, other

shapes, and built-up members, when permitted by the Engineer, shall be done by methods that will not produce fracture or damage. Distorted members shall be straightened by mechanical means or, if approved by the Engineer, by the carefully planned and supervised application of limited localized heat, except that the straightening of ASTM A514/A517 or ASTM A709 HPS70W steel members shall be done only under rigidly controlled procedure, each application subject to the approval of the Engineer. In no case shall the maximum temperature of ASTM A514/A517 or ASTM A709 HPS70W steel exceed 1100°F, nor shall the temperature exceed 950°F at the weld metal or within six inches of the weld metal. Heat shall not be applied directly to the weld metal or within six inches of the weld metal. In all other steels, the temperature of the heated area shall not exceed 1150°F, a dull red, as controlled by temperature indicating crayons, liquids or bimetal thermometers. Parts to be heat straightened shall be substantially free of stress and from external forces, except stresses resulting from mechanical means used in conjunction with the application of heat. Following the straightening of a bend or buckle, the surface of the metal shall be carefully inspected for evidence of fracture.

810.03.28 9--Cambering. Correction of errors in camber in welded beams and girders of

ASTM A514/A517 material shall be done only under rigidly controlled procedures, each application subject to approval of the Engineer.

810.03.28 10--Assembling Steel. The parts shall be accurately assembled as shown on the

plans and any match-marks shall be followed. The material shall be carefully handled so that no parts will be bent, broken, or otherwise damaged. Hammering that will injure or distort the members shall not be done. Bearing surfaces and surfaces to be in permanent contact shall be cleaned before the members are assembled. Unless erected by the cantilever method, truss spans shall be erected on blocking so as to give the trusses proper camber. The blocking shall be left in place until the tension chord splices are fully bolted and all other truss connections pinned and bolted. Permanent bolts in splices of butt joints of compression members and permanent bolts in railings shall not be driven or tightened until the span has been swung. Splices and field connections shall have one half of the holes filled with bolts and cylindrical erection pins, half bolts and half pins, before bolting with high strength bolts. Splices and connections carrying traffic during erection shall have three-fourths of the holes so filled.

810.03.28 11--Blank.

810.03.28 12--Pin Connections. Pilot and driving nuts shall be used in driving pins. They

shall be furnished by the Contractor without charge. Pins shall be so driven that the members will take full bearing on them. Pin nuts shall be screwed up tight and the threads burred at the face of the nut with a pointed tool.

810.03.28 13--Misfits. The correction of minor misfits involving harmless amounts of

reaming, cutting and chipping will be considered a legitimate part of the erection. However, any error in the shop fabrication or deformation resulting from handling and transportation that prevents the proper assembling and fitting up of parts by the moderate use of drift pins or by a moderate amount of reaming and slight chipping or cutting shall be reported immediately to the inspector. The method of correction shall require approval by the inspector in whose presence the correction will be made. If the contract provides for complete fabrication and erection, the Contractor shall be responsible for all misfits, errors, and injury and shall make the necessary corrections and replacements. If the contract is for erection only, the inspector, with the cooperation of the Contractor, will keep a correct record of labor and materials used, and the Contractor shall render within 30 days an itemized bill for the approval of the Engineer.

810.03.29 Removal of Old Structures and Falsework. Unless the contract indicates

that an old structure is to remain in place, the Contractor shall dismantle and dispose of such structure in accordance with the methods and requirements set out in Section 202. Upon completion of the erection and before final acceptance, the Contractor shall remove all falsework, excess excavation and useless materials. All excavated material or falsework placed in the stream channel during construction shall be removed by the Contractor before final acceptance.

810.04 Method of Measurement.

810.04.1 General. The steel superstructure will be measured as a lump sum quantity,

complete in place. Structural steel will be measured for payment by the pound based on the weight of metal in the fabricated structure as provided in the contract. Miscellaneous material items such as castings, bearing plates, lead sheets, anchor bolts, and all other metal for which no direct payment is specified and the contract proposal does not include a bid item for miscellaneous bridge appurtenances will be included in the measurement for structural steel except when the plans and specifications provide that payment will not be allowed for certain materials. When DTIs are not required by the contract and the Contractor elects to use such indicators, no measure for payment will be allowed.

810.04.2 Miscellaneous Bridge Appurtenances. When the bid schedule of the contract

contains a pay item for Miscellaneous Bridge Appurtenances, measurement will not be made of individual miscellaneous items, but all will be included in a single lump sum quantity, including all miscellaneous metals and other miscellaneous materials and work not specified to be measured for payment under or to be included in other items of work.

810.04.3 Payment of Weights.

Weights of metals to be paid for shall be based on computed weights. The weights of erection bolts, extra field rivets or high strength bolts, paint, and all boxes, crates, or other containers used for packing, together with sills, struts, and rods used for supporting members during transportation will be excluded. All metals not to remain in the completed structure will not be computed for payment. Where increases in size or weights of members have been made that were not ordered by the Engineer, but approved by him, measurement will be made on the sizes or weights indicated on the plans. Full size members tested as required under Subsection 810.03.26 and that meet the requirements of these specifications will be measured for payment at the same rate as for the structure.

810.04.4 Computation of Weights.

The weights of metals specified to be paid for by weight will be computed for payment from the following table: Weight in Pounds Metal Per Cubic Foot of Material Aluminum, cast or wrought ....................................................................................... 173.0 Bronze, cast ................................................................................................................ 536.0 Copper-alloy .............................................................................................................. 536.0 Copper sheet .............................................................................................................. 558.0 Iron, cast .................................................................................................................... 445.0 Iron, malleable ........................................................................................................... 470.0 Iron, wrought ............................................................................................................. 487.0 Lead, sheet ................................................................................................................. 707.0 Steel, rolled, cast, copper bearing, silicon, nickel and stainless ................................. 490.0 Zinc ............................................................................................................................ 450.0 The weight of rolled shapes and of plates shall be computed on the basis of their nominal weights and dimensions, as shown on the approved plans and shop drawings, deducting for copes, cuts and open holes. The weight of castings may be computed from the dimensions shown on the plans, with an addition of five percent for fillets and over-runs, or weighed on approved scales. No allowance will be made for the weight of paint. The weight of heads, nuts, single washers, DTIs when required, and threaded stick-through of all high tensile strength shop bolts will be included on the basis of the following weights: Diameter of Bolt, Inches Weight per 100 Bolts, Pounds 1/2 19.7 5/8 31.7 3/4 52.4 7/8 80.4 1 116.7 1 1/8 165.1 1 1/4 212.0 1 3/8 280.0 1 1/2 340.0 It shall be understood that the weight of the "threaded stick-through" of the bolts will be on the basis of the full-thread engagement. Full-thread engagement is defined as being accomplished when the end of the bolt is flush with the outer face of the nut. At the discretion of the Contractor, the next longer standard length of bolt than that necessary to accomplish full-threaded engagement may be furnished and used, at no additional cost to the State. The weight of weld metal will be computed on the basis of the theoretical volume from dimensions of the welds.

810.04.5 Deduction for Fabrication Inspection Cost Overruns. Under separate

agreement, the Department will contract with a private company to provide inspection services for structural steel fabrication on the project. By this agreement a maximum amount payable, including a fixed fee will be established beyond which no funds will be authorized for payment without a Supplemental Agreement. The Department will be responsible for structural steel fabrication inspection costs not to exceed the established maximum amount payable including the fixed fee and any additional amount authorized for payment by Supplemental Agreement. Structural steel fabrication inspection costs exceeding the above described amount will be deducted from monies due the Contractor under pay items 810-A, Structural Steel; 810-B, Steel Superstructure, and/or 810-C, Miscellaneous Bridge Appurtenances. Ninety percent (90%) of the amount bid for structural steel items listed above will be the maximum amount paid the Contractor until such time that final fabrication inspection costs have been determined and the Bridge Engineer notifies the Project Engineer to release full payment to the Contractor. Otherwise, the Bridge Engineer will advise the Project Engineer of the amount to withhold from the Contractor’s estimate to cover structural steel fabrication inspection costs that exceed the amount approved for payment by the Department.

810.05 Basis of Payment. Structural steel, subject to the deductions set out in Subsection

810.04 5, will be paid for at the contract unit price per pound. Steel superstructure and

miscellaneous bridge appurtenances when shown as a pay item will be paid for at the contract price, which price shall be full compensation for completing the work. Payment will be made under: 810-A: Structural Steel * - per pound 810-B: Steel Superstructure - lump sum 810-C: Miscellaneous Bridge Appurtenances - per pound or lump sum * Specify the type if other than A 50

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