542High-Strength Bolts

542.1 Description

This Work consists of providi ng and installing high-strength bo lts.

542.2 Materials

When the Contract requires galvanized fasteners, the Contractor shall mechanically galvanize in accordance with ASTM B 695, Class 50. The Contractor shall mark bolts, nuts, and washers in accordanc e with the applicable AASHTO or ASTM Specifications. 542.2.1 Bolts The Contractor shall provide headed bolts in accordance with AS TM F 3125. The Contractor shall ensure that bolt dimensions are in accordance with ANSI B 18.2.1 and nut dimensions are in accordance wi th ANSI B 18.2.2. These dimensi ons are tabulated in Table 542.2.1:1, “Dimensions of High-Strength Bolts.” For dime nsion labels, the Contractor shall refer to Figure 542.2.1:1, “ASTM F 3125 Bolts.” The Contractor shall ensure that hardness for bolts with diamet ers from 1/2 inch to one

542.2.2 Nuts

The Contractor shall provide nuts in accordance with ASTM A 563 with dimensions in accordance with ANSI B 18.2.2 a nd Table 542.2.1:1, “Dimensions of High-Strength Bolts.” The Contractor shall ensure plain (ungalvanized) nuts are of gr ades 2, C, D, or C3 with a minimum Rockwell B hardness of 89 or Brinell hardness of 180, o r heat-treated grades 2H, DH, or DH3. The Contractor shall provide heat-treated, grade 2 galvanized n uts The Contractor shall provide mechanically galvanized nuts in accordance with ASTM B 695, Class 50. The Contractor shall overtap nuts before galvanizing. The Contract or shall overtap so the nut will assemble freely on the coated bolt in accordance with ASTM A 56 3. Bolts and nuts in each galvanized assembly shall be galvanized by the same method; bol ts and nuts galvanized by different methods shall not be mixed together and must be store d in distinctively separate containers and locations. The Contractor shall lubricate galvanized nuts with a dyed lubr icant of a color that contrasts with the galvanizing color and is distinctly differen t from dyed lubricants used for other types of galvanized nuts. All galvanized bolts and nuts shall come from the manufacturer in assemblies in watertight containers and shall n ot be mixed with other production lots of fastener assemblies. All high strength bolt fastener assemblies shall be stored in their original containers, in protected shelter, unti l placed into use. The fasteners shall be protected from contamination, with lubricant remaining intact. Bolt and nut assemblies shall remain in their original containers and only removed as n ecessary to be placed into use. Bolt and nut assemblies that are not used by the end of the wor k period shall be promptly returned to their original containers and protected storage. S hould the lubricant on bolt and nut assemblies be contaminated or removed, it must be replaced only with an approved lubricant and in the manner as specified by the fastener assemb ly manufacturer.

542.2.3 Washers

The Contractor shall provide wa shers in accordance with ASTM F 436, type 1 carbon steel and / or type 3 weathering steel. The Contractor shall use flat circular hardened washers in acco rdance with Table 542.2.3:1, “Circular Was her Dimensions,” and Table 542.2. 3:3, “Washer Tolerances.” Should the surface beneath where the head or nut will bear have a slope greater than 1:20 with respect to the plane normal to the bolt axis, the Con tractor shall use square or rectangular beveled washers that taper in thickness in accordan ce with Table 542.2.3:2, “Square or Rectangular Beveled Washers for American Standard Be ams and Channels,” and Table 542.2.3:3, “Washer Toleranc es.” Where necessary to provi de a proper fit, the Contractor shall clip washers on one (1) side no closer than ⅞ of the bolt diameter from the center of the washer and only such that the hole in the outer p ly of the joint is completely covered to prevent entry of moisture into the connection. When a short-slotted hole occurs in an outer ply of a joint wit h ASTM F 3125 bolts, an ASTM F 436 washer or a 5/16-inch thick common plate washer shal l be used as required to completely cover the hole. When a long-slotted hole occurs in an outer ply of a joint with ASTM F 3125 bolts, an ASTM F 436 washer and a 3/8-inch thick plate, as wide or wider than the washer and long Section 542: High-Strength Bolts Page 504 enough to completely cover the hole shall be used. Table 542.2.3:1 Circular Washer Dimensions Bolt size D Nominal outside diameter Nominal diameter of hole Thickness Minimum Maximum 1/2 1 1/16 17/32 0.097 0.177 5/8 1 5/16 21/32 0.122 0.177 3/4 1 15/32 13/16 0.122 0.177 7/8 1 3/4 15/16 0.136 0.177 1 2 11/16 0.136 0.177 1 1/8 2 1/4 1 1/4 0.136 0.177 1 1/4 2 1/2 1 3/8 0.136 0.177 1 3/8 2 3/4 1 1/2 0.136 0.177 1 1/2 3 1 5/8 0.136 0.177 1 3/4 3 3/8 1 7/8 0.178 a 0 . 2 8a 2 3 3/4 2 1/8 0.178a 0 . 2 8a Over 2 to 4 incl. 2D-1/2 D+1/8 0.24b 0 . 3 4b Note: All dimensions in inches. a 3/16 inch nominal b 1/4 inch nominal Table 542.2.3:2 Square or Rectangular Beveled Washers for American Standard Bea ms and Channels Bolt size (in) Minimum side dimension (in) Mean thickness (in) Slope or taper in thickness 1/2 1 3/4 5/16 1:6 5/8 1 3/4 5/16 1:6 3/4 1 3/4 5/16 1:6 7/8 1 3/4 5/16 1:6 1 1 3/4 5/16 1:6 1 1/8 2 1/4 5/16 1:6 1 1/4 2 1/4 5/16 1:6 1 3/8 2 1/4 5/16 1:6 1 1/2 2 1/4 5/16 1:6 Note: Hole tolerances are the same as for circular washers. Table 542.2.3:3 Washer Tolerances Dimension ≤1 1/2 inch nominal size, inclusive >1 1/2 inch nominal size Nominal diameter of hole -0, +1/32 - 0, +1/16 Nominal outside dimensions -1/32, +1/4 -1/32, +1/4 Flatness; maximum deviation from Washer Tolerances Dimension ≤1 1/2 inch nominal size, inclusive >1 1/2 inch nominal size straightedge placed on “cut” side shall not exceed 0.01 inch 0.015 inch Burr shall not project above immediately adjacent washer face more than 0.01 inch 0.015 inch

542.2.4 Direct Tension Indicators

The Contractor shall use direc t tension indicators in accordanc e with ASTM F 959. The Contractor shall provide test reports for each production l ot of a shipment in accordance with ASTM F 959, paragraph 15.2. Table 542.2.4:1 Dimensions of Direct Tension Indicators, Type F 3125 Bolt size (in) Outside diameter (in) No. of protrusions (equally spaced) Thickness (in) Inside diameter (in) Min. Max. Without protrusions, minimum With protrusions, maximum Min. Max. 1/2 1.167 1.187 4 0.104 0.180 0.523 0.527 5/8 1.355 1.375 4 0.126 0.220 0.654 0.658 3/4 1.605 1.625 5 0.126 0.230 0.786 0.790 7/8 1.855 1.875 5 0.142 0.240 0.917 0.921 1 1.980 2.000 6 0.158 0.270 1.048 1.052 1 1/8 2.230 2.250 6 0.158 0.270 1.179 1.183 1 1/4 2.480 2.500 7 0.158 0.270 1.311 1.315 1 3/8 2.730 2.750 7 0.158 0.270 1.442 1.446 1 1/2 2.980 3.000 8 0.158 0.270 1.573 1.577

542.2.5 Testing and Test Reports

542.2.5 1 Testing of Bolts

The Contractor shall conduct proof load tests in accordance wit h ASTM F 606, Method 1. The Contractor shall conduct wedge tests on full size bolts in accordance with ASTM F 606, paragraph 3.5. The Contractor shall perform tests on galvanized bolts after galvanizing. The Contractor shall ensure that the minimum testing frequency is in accordance with ASTM F 3125. The Contractor shall measure zinc coating thickne ss on galvanized bolts on the wrench flats or bolt head tops.

542.2.5 2 Testing of Nuts

The Contractor shall proof load test in accordance with ASTM F 606, paragraph 4.2. The Contractor shall ensure that the minimum testing frequency is in accordance with ASTM A 563. The Contractor shall test galvanized nuts after ov ertapping, galvanizing, and lubricating.

542.2.5 3 Testing of Washers

The Contractor shall test galvani zed washers for hardness after galvanizing. The Contractor shall remove the coating before conducting the hardn ess tests.

542.2.5 4 Testing of Assemblies

The Contractor shall provide the manufacturer’s or distributor’ s rotational capacity test results on bolt, nut, and washer assemblies. The Contractor sh all use washers in the test, even if washers are not used in the assembly on the Project. The Contractor shall test each combination of bolt production l ot, nut lot, and washer lot as an assembly. Unless required by the installation procedures , the Contractor shall not include washers in the lot identification. The Contractor shall assign a rotational capacity lot number to each lot combination tested. The minimum testing frequency is two (2) assemblies per rotatio nal capacity lot.

542.2.5 4.1 Procedure for Rotational Capacity Tests for Long Bo lts

The Contractor shall test bolts long enough to test in a tensio n calibrator in accordance with the following procedures: 1. Mark the calibrator face plate with lines at vertical and at 1/3 (120°) and 2/3 (240°) of a turn, clockwise from vertical; 2. Use a calibrated torque wrench; 3. Use spacers with a hole size no larger than 1/16 inch larger than the bolt to be tested; 4. Mount the bolt calibrator on a steel frame or section such a s a flange or a cross frame. 4.1. Put the nut on the bolt. Measure from the end of the thre aded shank to the underside of the bolt head when there are 3 to 4 full threads o f the bolt between the bearing face of the nut and the bolt head; 4.2. Put the bolt in the tension calibrator and install the req uired number of shim plates and washers needed to produce the measurement from Step 4.1 (always install one (1) washer under the nut); 4.3. Snug tighten the bolt with a hand wrench to the tension li sted in Table 542.2.5.4.1:1, “Snug Tight Tension;” do not exceed two (2 ) kips more than that value; Table 542.2.5.4.1:1 Snug Tight Tension Bolt diameter (in) Installation tension, minimum (kip) 1/2 1 5/8 2 Snug Tight Tension Bolt diameter (in) Installation tension, minimum (kip) 3/4 3 ⅞ 4 1 5 1 1/8 6 1 1/4 7 1 3/8 9 1 ½ 10 4.4. Match mark the nut to the vertical line on the bolt calibr ator faceplate; 4.5. Using the calibrated manual torque wrench, slowly tighten the b olt to at least the tension listed in Table 542.2.5.4.1:2, “Installation Tensio n.” Measure and record the torque and the tension generated simultaneously with that torque. Measure torque with the nut in motion; Table 542.2.5.4.1:2 Installation Tension Bolt diameter (in) Snug tension, minimum (kip) 1/2 12 5/8 19 3/4 28 7/8 39 1 51 1 1/8 56 1 1/4 71 1 3/8 85 1 1/2 103 4.6. Calculate the torque in accordance with the following equa tion: 4dTV ( 1 ) Where, V is the calculated torque value T is the measured tension in pounds d is the bolt diameter in feet Record the calculated value. The measured torque values must e qual or be less than the calculated torque. Assemblies with measured torque va lues exceeding this calculated value fail the test. 4.7. For assemblies passing Step 4.6, further tighten the bolt to the rotation listed in Table 542.2.5.4.1:3, “Required Rotation.” Measure the rotat ion from the vertical line to the initial match marking in Step 4.4. Record the bolt tension. Required Rotation Bolt length (L) measured in step 1 Required rotation (turns) L  4d 2/3 4d < L  8d 1 L > 8d 1 1/3 Note: d = bolt diameter. Assemblies that fail before completing the required rotation by stripping or fracture fail the test. Bolt tension measured at the required rotation must equal or ex ceed the values in Table 542.2.5.4.1:4, “Minimum Tension Requirements.” Assemb lies that do not meet this tension fail. Table 542.2.5.4.1:4 Minimum Tension Requirements Bolt diameter (in) Tension, minimum (kip) 1/2 14 5/8 22 3/4 32 7/8 45 1 59 1 1/8 64 1 1/4 82 1 3/8 98 1 ½ 118 4.8. Loosen and remove nut and examine the threads on the nut a nd bolt. Assemblies showing evidence of thread shear failure, stripping, or torsion failure fail.

542.2.5 4.2 Procedure for Rotational Capacity Test for Short Bo lts

The Contractor shall test bolts that are too short for a tensio n calibrator in accordance with these procedures: Equipment requirements: 1. A calibrated torque wrench and a spud wrench; 2. Spacers with a hole size no larger than 1/16 inch greater th an the tested bolt; 3. A steel section with a normal size hole to install bolt. An y available splice hole with plate thicknesses that will provide the number of threads under the nut required in Step 3.1 of the following procedures is acceptable. The procedure is as follows: 3.1 Mark the steel section with lines at vertical and at 1/3 (1 20°) and 2/3 (240°) of a turn, clockwise from vertical; 3.2 Put the nut on the bolt. Measure the bolt length and the d istance from the end of the threaded shank to the underside of the bolt head when th ere are three

542.2.5 5 Reporting

The Contractor shall provide notarized manufacturer and distrib utor CTR and MTR for mill steel used to manufacture bolts, nuts and washers. The Co ntractor shall indicate the steel melting and manufacture location in the MTR. The Contractor shall show test results, including zinc coating thicknesses, in the CTR. The Contractor shall show test performance locations and test d ates in the CTR.

542.2.5 5.1 Manufacturer CTR

The Contractor shall provide CTRs from the bolt, nut, and washe r manufacturers that include the following: 1. Lot numbers of each item tested; 2. Rotational capacity test res ults, rotational capacity lot nu mbers, and individual lot numbers of the items tested, if performed by the manufacturer; 3. Results of all other required tests; and 4. Locations where the bolt assembly components were manufactur ed.

542.2.5 5.2 Distributor CTR

The Contractor shall provide CTR from the bolt, nut and washer distributors that include: 1. Documentation required in Sec tion 542.2.5.5.1, “Manufacturer CTR;” 2. Rotational capacity test res ults, rotational capacity lot nu mber, and individual lot numbers of the items tested, if performed by the distributor; a nd 3. A statement that the manufacturer’s CTR represents the same items.

542.2.5 6 Sampling and Testing by the Department

Before installation, the Project Manager will select two (2) bo lt, nut and hardened washer assemblies from each rotational capacity lot and at least three (3) direct-tension indicators with accompanying bolts, nuts and hardened washers, for each diamete r and grade of fastener for testing by the State Materials Bureau.

542.2.5 7 Shipping

The Contractor shall ship bolts, nuts, and washers from each ro tational capacity lot in the same container. If there is only one (1) production lot number for each size of nut, washer, and direct tension indicator, the Contractor may ship the nuts, washers, and direct tension indicators in separate containers. The Contractor shall permanently mark each container with the r otational capacity lot

542.3 Construction Requirements

The Contractor shall fabricate Materials it shall connect with high-strength bolts in accordance with Section 541, “Steel Structures.” The Contractor shall blast clean steel faying surfaces in accor dance with SSPC-SP 10. The Contractor shall ensure that the bolted part surfaces adjac ent to the bolt head and nut are parallel within the three (3) degrees for parallel surf ace rolled steel members. The Contractor shall use beveled washers on surfaces with more than a 1:20 slope for proper seating. The Contractor shall use bolted parts that fit solidl y together when assembled. The Contractor shall not use gaskets or other flexible material. The Contractor shall erect join ts and splices with cylindrical erection pins and bolts in accordance with Section 541, “Steel Structures.” Care shall be taken when using erection pins as to not enlarge, deform or unfair the holes. The Contra ctor shall use high-strength bolts instead of erection bolts if necessary. These can be left in p lace, provided they are not loosened and retightened.

542.3.1 Installation of Bolts

The Contractor shall ensure that bolt, nut, and washer combinat ions are from the same rotational capacity lot. The Contractor shall use bolts that will extend beyond the nut at least two (2) threads, but not more than 1/2 inch.

542.3.2 Lubrication

The Contractor shall ensure that black bolts are oily to the to uch when delivered and installed. The Contractor shall clean and relubricate weathered or rusted bolts and nuts before installation. The Contractor shall retest recleaned or relubri cated bolt, nut, and washer assemblies. Before installing galvanized nuts, the Contractor shall inspect the nuts to ensure the threads are properly lubricated. If lubricant is not visible o r if tensioning indicates that thread friction is too high, the Contractor shall apply an approved lu bricant to the remaining threads before installation.

542.3.3 Method of Installation

The Contractor shall install bolts in accordance with Figure 54 2.3.3:1, “Installation Details.” In general, the Contractor shall use Method I. The Contractor shall use Method 2 and Method 3, as approved by the Department, where bolt entry, wrench clearances, or inspection procedures mak e Method I impossible. The Contractor shall prevent the stationary element from turnin g. For oversized or slotted holes, the Contractor shall place addi tional hardened washers between the bolted Material and the fastener. Section 542: High-Strength Bolts Page 512 Wherever practical, the Contractor shall place the nut where it i s n o t v i s i b l e f r o m t h e Traveled Way. When one end of a bolted assembly is embedded in concrete, the Contractor shall place the assembly so the nut end is in the concrete. When tightening connections involvi ng several bolts, the Contra ctor shall draw together plies of the steel by snugging the bolts before starting the ti ghtening operations. First tighten near the center of the bolt group and work outwards alternating from side to side until the last bolts are tightened at the outside of the group. On connection s involving a large number of bolts or thick Materials, the Contractor shall tighten the bolt s to the point where the direct- tension indicators are partially compressed. In some cases, pro per tensioning of the bolts may require more than a single cycle of systematic partial tighteni ng before final tightening to deform the direct-tension indi cators to the specified gap. Tensioning with pneumatic or elec tric impact wrenches shall ach ieve the tension requirements within ten (10) seconds. The Contractor shall ensure that the final gap between the bol t head and the direct- tension indicator is less than or equal to 0.015 in for Method I and less than or equal to 0.005 in for Method 2 or Method 3. Installation Details The Contractor shall ensure that galvanized bolt assembly direc t tension indicator gap for all three (3) methods is less than or equal to 0.005 inch. The Contractor shall use Method 2 or Method 3 for galvanized bolt assem blies only after receiving De partment approval.

542.3.4 Inspection

The Department will visually inspect every bolt for gaps. The Department will also check at least ten percent (10%) of the bolts, but not less than two (2) bolts in each connection, using feeler gauges as described in the direct tension indicator manu facturer’s instructions and in ASTM F 959. If the inspections i ndicate improper installation, the Project Manager may reject the assemblies.

542.4 METHOD OF MEASUREMENT—Reserved

542.5 Basis of Payment

The Department will pay for high strength bolts as a part of St ructural Steel tonnage in accordance with Section 541, “Steel Structures.” Section 543: Metal Railing Page 514