00560.00 538 Section 00560 - Structural Steel Bridges
Description
00560.00Scope - This Work consists of furnishing, fabricating, and erecting steel Structures as
shown or specified. It also includes miscellaneous metal Work on Bridges and Structures, such as access hole covers, frames, ladders, hangers, anchor bolts, scuppers, conduits, ducts, bearing devices, and structural steel shapes.
00560.02Prefabrication Conference - Meet with the Steel Fabricator, the Engineer and the
Agency's steel Inspector for a conference at a time mutually agreed upon in advance of ordering steel Materials for fabrication. At this conference, present and discuss all phases of the steel fabrication schedule and Work . A prefabrication conference is not required for miscellaneous metal Work , unless required by Special Provision.
00560.03Working Drawings - Submit uns tamped Working Drawings according to 00150.35. Any
Work performed before review of these drawings shall be at the Contractor's risk. When M aterial is ordered in advance, obtain approval before placing the order. Provide steel identification on the Worki ng Drawings according to 00560.22(a).
and detail" requirements. The Engineer assumes no responsibility for errors in dimensions.
performed before review of these revisions shall be at the Contractor's risk.
00560.04Erection Plan - Submit a stamped erection plan according to 00150.35 at least 21
Calendar Days before the start of steel erection Work, consisting of the erection plan and procedure describing the Contractor’s methods. Do not perform Work until approval has been obtained. This review does not relieve the Contractor of the responsibility for the safety of the method or Equipment, or from carrying out the Work in full according to the Plans and Specifications.
Prepare erection plan following the procedures outlined in Section 2.2 of the AASHTO/NSBA Steel Bridge Collaboration S10.1 Steel Bridge Erection Guide Specification . Provide complete details of the erection process including, at a minimum, the following:
Plan of work area showing Structure location relative to supports and all obstructions. Temporary falsework support, bracing, guys, deadmen, and attachments to other Structure components or objects. Procedure and sequence of operation. Erection sequence for all pieces. Girder stresses during progressive stages of erection. Ensure temporary stresses in members being erected do not cause permanent damage and that stability is maintained throughout the erection operations. Member weights and center of gravity location of pieces to be lifted, lift points, and lifting devices, spreaders, glommers, etc. Crane(s) make and model, mass, geometry , lift capacity, outrigger size and reactions. Girder launcher or trolley details and capacity (if intended for use). Locations of cranes, barges, trucks delivering girders, and the location of cranes and outriggers relative to other Structures, including retaining walls and wingwalls. 00560.22 539 Include drawings, notes, catalog cuts, and calculations clearly showing the above listed details, assumptions, dimensions and erection plan. Include material properties, specifications, structural analysis, and any other data used. If lifting brackets are bolted to the girder top flanges, submit the following:
Supporting calculations for the lifting bracket with the erection plan. Include calculations of critical stresses in the girder including local stresses in the flanges at lifting bracket locations. Include computation of the lifting bracket and associated bolt hole locations and the expected orientation of the girder during picking operation. Load test and certify the lifting bracket for a load at least twice the working load and at all angles it will be used (angle of load or rigging). Certification documentation from a previous project may be submitted. Show the location of all bolt holes in girders added for the lifting bracket connections.
00560.05Pre -Erection Coor dination Meeting - Hold an erection coordination meeting with the
Engineer at least 7 Calendar Days before beginning any steel erection operations to discuss erection procedures, schedules, staging, personnel, Equipment to be used, and other elements of t he approved erection plan.
Materials
00560.10Materials - Furnish structural plates, shapes, bars, and miscellaneous metals meeting the
requirements of Section 02530 and Section 02560.
Shop Fabrication
00560.20Notice of Work - Give the Engineer at least 14 Calendar Days' notice of the beginning of
Work at the mill, when directed, or at the shop, so inspection may be provided. The term "mill" means any rolling mill or foundry where Material for the Work is to be manufactured. Do not fabricate Material , or perform Work at the mill or shop, before the En gineer has been notified.
00560.22Test Results Certificate and Steel Identification :
chemical analysis and physical tests for each heat or plate of steel, for all members according to 00165.35 and Section 02530. Identify each piece of steel to be fabricated. Identify on Working Drawings each piece to be made of steel other than AASHTO M 270 (ASTM A709), Grade 36 steel. Give pieces made of different grades of steel different assembling or erecting marks, even though they are of identical dimensions and detail. Provide a system of marking individual pieces made of stee l, other than AASHTO M 270 (ASTM A709), Grade 36, and issue cutting instructions to the shop (generally by cross -referencing the assembly marks on the Working Drawings with the corresponding item on the mill purchase order) that maintain identity of the he at number.
Material that can be identified by heat number and mill test report may be furnished from stock.
Mark any unmarked excess material placed in stock for later use with the heat number and with its AASHTO M 160 ( ASTM A6) specification identification color code.
00560.22 540 (b) Steel Identification during Fabrication - During fabrication, and until member assembly, each piece of steel, other than AASHTO M 270 ( ASTM A709), Grade 36 steel, shall show clearly and legibly its specification identification color c ode shown in AASHTO M 160 ( ASTM A6).
Individually marked pieces of steel used in furnished size, or reduced from furnished size, may be used only if end or edge trim does not disturb the heat number or color code. Any usable piece may be used without further color coding providing the heat number or color code remains legible. Mark individual pieces, other than AASHTO M 270 ( ASTM A709), Grade 36, with the AASHTO M 160 ( ASTM A6) specification identification color code before cutting to a smalle r size.
Mark individual pieces of steel, other than AASHTO M 270 ( ASTM A709), Grade 36 steel, which are furnished in tagged lifts or bundles with the AASHTO M 160 ( ASTM A6) specification identification color code immediately on being removed from the bundle or lift. Pieces of steel, other than AASHTO M 270 ( ASTM A709), Grade 36 steel, which before assembling into members, will be subject to fabricating operations such as heating, blast cleaning, galvanizing or other coating that might obliterate paint color code marking, shall be marked for grade by steel die stamping or by a substantial tag firmly attached. Use only rounded characters when primary stress components are identified by steel die stamping. Impressions shall have a maximum allowable dept h of 0.010 inch and shall be placed a minimum distance of 2 inches from edges of tension- stressed plate members. Characters shall be 1/4 inch to 3/8 inch high and shall have a minimum face radius of 0.015 inch.
furnished for fabrication. The plates, shapes or bars from which check samples are required will be as designated on the Plans, and shall be ordered from the mill with the extra size required for samples. The Engineer may take additional samples from drop-offs or scrap material as deemed necessary. No more than two samples will be required from any one plate according to AASHTO M 270 ( ASTM A709) Grade 36, 50, HPS 50W and HPS 70 W with QT processing, or from any one shape or bar. Remove material for check samples in the presence of the Engineer. The Engineer will select the locations where samples are to be taken. Check samples may be ordered cut from either end of the designated steel plate, according to AASHTO M 270 (ASTM A709) Grade 36, 50, HPS 50W and HPS 70 W with QT processing, or shape or bar. To verify accuracy of test reports for HPS 50W and HPS 70W with thermo- mechanical control process, check samples of both ends of each plate is required.
Check samples in plates shall be rectangular, not less than 24 inches long in the required direction, depending on plate width, for the longitudinal axis of tensile specimens, and 5 inches wide. Bend specimens, where required, shall be not less than 24 i nches long in the direction of rolling of the plate. Check samples in bars or shapes shall be the full section and at least 24 inches long. In removing the sample, take care not to damage it by overheating. The Agency will be responsible for the necessar y machining of check test specimens and their testing. To expedite obtaining test results, the Contractor may, if approved, perform machining and testing of specimens, in the presence of the Engineer.
The normal basis of acceptance of Material will be th e mill report or other test report, and fabrication need not be held up pending results of check tests. If the check tests indicate Material with properties failing to meet the minimum requirements of the material specification, the Material may be rejected and the Contractor required to order new Material at no additional cost to the Agency.
For purposes of determining compliance with the Specifications, if the results on an original tensile specimen are within 2,000 psi of the required tensile strength, within 1,000 psi of the required yield point, or within 2 percent of the required elongation, a retest will be allowed on two random specimens from the heat or lot. If the results from both of these retest specimens meet 00560.25 541 Specifications, the heat or lot w ill be accepted. The specimens shall be oriented with the final direction of rolling in the same manner as the original specimen, and may come from any location within the plate. The extra material from plates, shapes or bars that is not used for check t esting shall become the property of the Contractor.
the fabrication operation the identification of steel has been maintained according to this Specification.
00560.23Shop Inspection and Testing :
the Engineer free access to the M aterial and Work for inspection.
members will not prevent their subsequent rejection, if later found damaged or defective, nor relieve the Contractor of the responsibility to correct or replace the Work at no additional cost to the Agency.
marking.
00560.24Transporting to, Handling and Storage at Shop - In transporting, handling, and storing
the steel Work at the shop, avoid bending, scraping, or overstressing the pieces. Reject pieces bent or otherwise damaged. In addition:
• Conduct the loading, transporting and unloading of pieces so the metal remains clean. • Keep Materials free from dirt, oil or other c ontaminants, and protect from corrosion. • If pieces are shop -painted, handle with slings or other means that will not damage coating system. • Handle and store girders and beams upright, and shore. • Support and handle members so Camber is maintained. • Support l ong members, such as columns and chords, on skids placed near enough together to prevent damage from deflection. • Store Materials on platforms, skids or other supports above ground and high water elevations and slightly pitch all trough sections that might retain water to provide drainage.
00560.25Plate Work :
members according to AWS D1.5, and as specified.
members, and splice plates for flanges and main tension members, so the primary direction of rolling is parallel to the direction of the main tensile or compressive stresses.
plate more than 5/8 inch in thickness and carrying calculated stress.
00560.26 542 (2) Flame Cutting - Flame cut structural steel according to AWS D1.5, and as specified.
AWS D1.5, and as specified.
• Rounded at the corners of the plate before bending, to a radius of 1/16 inch throughout the portion of the plate at which the bending is to occur. • Bent at right angles to the direction of rolling, except that cold-bent r ibs for orthotropic -deck Structures may be bent in the direction of rolling if allowed. • Bent so no cracking of the plate occurs. Minimum bend radii, measured to the concave face of the metal, are:
Plate Thickness
Up to Over 1/2" Over 1" Over 1 1/2" Over 2 1/2" 1/2" to 1" to 1 1/2" to 2 1/2" to 4" All grades of structural steel 2 t 2.5 t 3 t 3.5 t 4 t in this Specification
Where t = Plate thickness in inches Low alloy steel in thicknesses over 1/2 inch may require hot bending for small radii .
00560.26Welding :
inspection of welds for Bridge Structures shall all conform to AWS D1.5.
inspection of welds for non- Bridge Structures shall all conform to AWS D1.1. Non -Bridge Structures include bridge railing posts, railing splices, deck expansion joints, earthquake restraints and similar Structures. Submit all welding procedure specifications to the Engineer for approval. Test earthquake restraint welds radiographically or ultrasonically. Testing will be witnessed by the Engineer. Additional inspection for earthquake restraint weldss hall include:
• Ultrasonic inspection of 100 percent of the complete penetration welds using a straight beam transducer. A weld will be acceptable if it has no indications of cracks and no indications of lack of fusion between adjacent layers of weld metal and between weld metal and base metal. • Magnetic particle inspection of 10 percent of the fillet welds.
00560.27Bolt Holes :
than 1/16 inch. Ream any holes that are required to be enlarged to admit the bolts. Make clean cut holes without torn or ragged edges. Poor matching of holes will be cause for rejection.
00560.27 543 (b) Drilled or Reamed Holes - Assemble and securely hold connecting parts requiring drilled or reamed holes. Match-mark connecting parts before disassembling.
Where practicable, direct reamers by mechanical means.
Perform drilling and reaming with twist drills. Make drilled or reamed holes cylindrical, perpendicular to the member, and complying with the size requirements of the Specifications. Remove burrs on the outside surf aces. If required, take apart assembled parts for removal of burrs caused by drilling.
Poor matching of holes will be cause for rejection.
subdrilled so accurately that after assembling (before any reaming is done) a cylindrical pin 1/8 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 connecting holes in the same plane. Non-conforming pieces will be rejected. If any hole will not pass a pin 3/16 inch smaller than the nominal size of the hole, the non-conforming pieces will be rejected.
the holes in any connecting group shall, after drilling or reaming, show no offset greater than 1/32 inch between adjacent thicknesses of metal.
Provide steel templates with hardened steel bushings in holes and accur ately dimensioned from centerlines of the connections inscribed on the template. Use the centerlines in accurately locating the template from the milled or scribed ends of the members. When steel templates 1 inch or greater in thickness are used six or f ewer times in drilling members, hardened steel bushings are not required.
pin, and firmly draw together the parts of a member before drilling, reaming, or bol ting is commenced. Take apart assembled pieces, if necessary, for the removal of burrs and shavings produced by the operation. Construct the member free from twists, bends, and other deformation. Perform drift pinning during assembling only to bring the parts into position and not sufficient to enlarge the holes or distort the metal.
high- strength bolts and unfinished bolts. Wh en there are not more than five thicknesses of material in a member, and the material is not thicker than 3/4 inch for structural steel or 5/8 inch for high- strength steel, the metal may be punched 1/16 inch larger than the nominal diameter of the bolts unless subpunching and reaming are required by the Specifications .
When there are more than five material thicknesses in a member, or when any material is thicker than 3/4 inch for structural steel or 5/8 inch for high- strength steel, either sub drill holes or drill full size.
When required by 00560.27(g), subpunch or sub drill all holes 3/16 inch smaller and, after assembling, ream 1/16 inch larger or drill full size to 1/16 inch larger than the nominal diameter of the bolts. Sub drill if thickness limitation governs.
Holes not more than 1/32 inch larger than the nominal diameter resulting from a drill or reamer of the nominal diameter are considered acceptable. The slightly conical hole from punching operations is considered acceptable.
00560.27 544 (g) Holes for Ribbed Bolts, Turned Bolts, and Others - Make holes with a driving fit as specified for ribbed bolts, turned bolts, or other approved bearing-type bolts by one of these methods:
• Subpunch or sub drill 3/16 inch smaller than the nominal diam eter of the bolt and ream, while assembled, • Drill to a steel template, or • Drill from the solid after assembling.
(or sub drill if subdrilling is required according to 00560.27(f) or 00560.27(g)) and subsequently ream holes in all field connections and field splices of main members of trusses, arches, continuous beam spans, bents, towers (each face), plate girders, and rigid frames while assembled on a steel template, as required by 00560.43. Holes for field splices of rolled beam stringers continuous over floor beams or crossframes may be drilled full size unassembled to a steel template.
Subpunch and ream all holes for floor beam and s tringer field end connections to a steel template or ream while assembled. Drill or ream full size field connection holes through a steel template after the template has been carefully located as to position and angle and firmly bolted in place. Make tem plates used for reaming matching members, or the opposite faces of a single member, exact duplicates. Locate templates used for connections on like parts or members so accurately that the parts or members are duplicates and require no match-marking.
For any field connection, instead of subpunching and reaming or subdrilling and reaming, the Contractor may drill holes full size with all thicknesses of material assembled in proper position.
Use templates as described above, or do not interchange splice plates.
connection or splice designated in 00560.27(f), instead of subpunching and reaming field connections according to 00560.27(h), the Contractor may punch or drill bolt holes full -size in unassembled pieces and connections, including templates, for use with matching subsized and reamed holes by means of suitable numerically controlled punching or drilling Equipment subject to this Section. Punch or drill full -size ho les according to 00560.27(c).
Submit for review a detailed outline of the procedures proposed for accomplishing the Work from initial punching or drilling through check assembly, if required. Include the specific members of the Structure that may be numerically controlled punched or drilled, the sizes of the holes, the location of common index and other reference points, composition of check assemblies, and all other pertinent information. Do not begin until written approval is received.
Punch or drill holes by numerically controlled Equipment to appropriate size through individual pieces, or drill through any combination of pieces held tightly together. Use each splice plate only once as a template and do not interchange after assembly drilling is complete.
If numerically controlled punching or drilling Equipment is used, the Engineer may require the Contractor, by means of check assemblies, to demonstrate that this punching or drilling procedure consistently produces holes and connections conforming to 00560.27(g) and 00560.43.
00560.29 545 00560.28 Carbon Steel Bolt Connections - Unless otherwise shown or specified, make connections with unfinished carbon steel bolts nuts and washers conforming to Section 02560. Use holes confor ming to 00560.27.
• The body surface shall have a surface roughness of 125 microinches, or less, according to ANSI B46.1. • The unthreaded body shall equal total thickness of connected parts. • The outer thread diameter shall equal the nominal diameter of the bolt specified. • Heads and nuts shall be hexagonal with standard dimensions for bolts of the nominal size specified or the next larger nominal size. • Install bolts in carefully reamed holes wit h a tight driving fit.
• The body shall have 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 bolt diameter specified. • Round heads shall conform to ASME B 18.5 unless otherwise specified. • Ribbed bolts shall make a driving fit with the holes. • The hardness of the ribs shall be such that the ribs do not permit the bolts to turn in the holes during tightening. • If for any reason the bolt twists before drawing tight, ream the hole and use an oversized bolt as a replacement. • Nuts shall be hexagonal, with standard dimensions for bolts of nominal size specified or the next larger nominal size.
head) in tightening. Use beveled washers where bearing faces have a Slope of more than 1:20 with respect to a plane normal to the bolt axis.
finished side shall be against the washer or plate.
00560.29High -Strength Bolt Connections:
bolts conforming to ASTM F3125, Grade A325 or Grade F1852 or equivalent fastener using bolts, nuts, and washers conforming to Section 02560 and in holes conforming to 00560.27. Fit-up bolted connections as follows:
• Provide all steel Material within the grip of high- strength bolts (no compressible material such as gaskets or insulation). • Remove burrs that would prevent solid seating, so that parts fit solidly together after bolts are tightened. • Make Slope of surfaces in contact with the bolt head or nut less than 1:20 with respect to a plane normal to the bolt axis. 00560.29 546 • Install all bolts, unless otherwise shown, to expose the heads on the exterior surface of the Structure .
• Where the outer surface of the bolted parts has a Slope greater than 1:20 with respect to a plane normal to the bolt axis, use a hardened, beveled washer to compensate for the lack of parallelism. • Where ASTM F3125, Grade A325 or Grade F1852 bolts of any diameter are to be installed in standard, oversize, or short slotted hole in an outer ply, provide a hardened washer under the element of the fastener (nut or bolt head) turned in tightening. • Where ASTM F3125, Grade A325 or Grade F1852 bolts of any diameter are to be installed in a long slotted hole in an outer ply, use plate washers or continuous bars of at least 5/16 inch thickness with standard holes. Provide washers or bars with sufficient size to completely cover the slot after installation. Make the plate washer from structural grade steel. In addition to a plate washer, provide a hardened washer under element of the fastener (nut or bolt head) turned in tightening. • Oversize and slotted holes are defined by the Manual of Steel Construction Load and Resistance Factor Design (AISC). • Do not use direct tension indicators.
nut free of scale, oil, grease, dirt, foreign material, and unless otherwise shown or specified, free of paint, lacquer, rust inhibitor, galvanizing or other coating.
bolted joints for coated steel according to Section 00594. Prior to assembly, prepare the contact surfaces with approved methods not harmful to the primer.
Coat fasteners visible to the public, as determined by the Engineer, according to Section 00594 (except the primer coat) after installation.
high- strength fasteners either black or galvanized as the Contractor elects. Use fasteners that meet the following requirements:
surrounding areas stained by the black fasteners, after installation, using an appr oved method. Coat according to Section 00594.
the public, as determined by the Engineer, and coat according to Section 00594 after installation.
high- strength fasteners, including hardened flat washers, galvanized according to 02560.40 prior to installation. In areas visible to the public, as determined by the Engineer, clean and prepare fasteners as approved, and coat according to Section 00594.
within slip -critical bolted joints for non- coated weathering steel according to SSPC -SP 10 "Near White B last Cleaning". Make the appearance of the blast -cleaned surface to closely approximate Pictorial Standard Sa 2-1/2 of SSPC -Vis 1.
00560.29 547 Use only fasteners that are black.
Prior to final bolting, ensure all steel -to-steel contact surfaces have maintained the minimum requirements of SSPC -SP 6 Commercial Blast Cleaning. The minimum appearance of the surface shall approximate Pictorial Standard Sa 2 of SSPC -VIS 1, Pictorial Surface Preparation Standards for Painting Steel Surfaces. Surfaces that do not meet the requirements of SSPC - SP 6 shall be hand tooled or re -blasted until the appearance of the blast -cleaned surface closely resembles Pictorial Standard Sa 2-1/2 of SSPC -VIS 1 as determined by the Engineer.
connections by means of hand wire brushing. Power wire brushing is not allowed.
capacity lot numbers) to all fasteners before shipping them. Assemble all components during installation of the fasteners. Protect fasteners from dirt and moisture at the Project Site. Take from protected storage only as many fasteners as anticipated to be installed and tightened during a work shift. Return fasteners not used to protected storage at the end of the shift.
Do not remove lubricant present in as -delivered condition. If necessary, clean and lubricate fasteners and retest before installation. Use lubricant according to 02560.70. Do not re-lubricate Tension Control fasteners. Install the bolt, nut, and washer or assembly so that at least three and not more than five threads are located between the bearing face of the nut and the bolt head.
Tighten all connections progressing systematically from the most rigid part of the connection to the free edges.
The Eng ineer will do the following:
Before installing fasteners: • Check markings, surface conditions, fastener storage conditions, and faying surfaces of joints. • Observe calibration and testing procedures. During fastener installation, monitor to: • Confirm that t he installation procedure is followed and that, when fastener assemblies are supplied, the tensions specified in Table 00560-1 are achieved. • Assure that the installation method demonstrated in the Verification Testing procedure develops the specified tensi on. Provide a tension measuring device at the Project Site that has the capacity for the bolt being installed. Confirm the accuracy of the tension-measuring device through calibration by an approved testing agency at the start of Work and at least annually. Use the tension- measuring device to:
Calibrate wrenches. Assist the bolting crew in understanding and proper use of the method to be used. Confirm the ability of the complete fastener assembly to be used in the Work , including lubrication satisfies t he tension requirements of Table 00560- 1.
00560.29 548 Install and tighten all fasteners in aligned holes to at least the tension specified in Table 00560-1. Tightening may be done by turning the bolt while the nut is prevented from rotating when it is impractica ble to turn the nut, if approved. When impact wrenches are used, provide them with enough capacity and supplied air to tighten each bolt in 10 seconds or less.
Non-galvanized fasteners may be reused once if approved. Retightening previously tightened fasteners loosened by the tightening of adjacent fasteners will not be considered a reuse. Do not reuse galvanized fasteners.
Use bolt, nut, and washer combinations from the same rotational -capacity lot.
Verify correct lengths of all ASTM F3125, Grade A325 or Grade F1852 bolts. In the tightened connection, do not allow the unthreaded portion of the bolt to jam against the internal threads of the nut.
In the Specifications, "snug-tight" is defined as having all plies of the connection in firm contact.
Table 00560-1 Required Fastener Tension in Bolts
Nominal Bolt Minimum Tension Size (inch) (kips) 1/2 12 5/8 19 3/4 28 7/8 39 1 51 1 1/8 64 1 1/4 81 1 3/8 97 1 1/2 118
at the Project Site .
to 02560.60.
tension- measuring device. Test a representative sample of not less than three bolt and nut assemblies of each diameter, length, and grade to be used. Use a special round head insert in place of the typical hex head inser t.
Repeat Verification Testing when the condition of fasteners are altered, when changes in method, Equipment or personnel occur, or as directed. Conduct verification tests in two stages:
First, demonstrate the method for estimating the snug- tight condition to be used on the final product. Record the snug -tight tension. 00560.29 549 Next, apply a tension control shear wrench to demonstrate that each bolt develops a tension not less than 5 percent greater than required by Table 00560-1. Follow manufacturer's i nstallation procedure for installation of bolts. Record the final tension.
tension- measuring device. Provide a torque wrench with sufficient capacity to perform testing. Match the sampled fastener conditions to the conditions under inspection. Test at least three randomly sampled bolt, nut, and washer assemblies for each diameter, length, and grade used. Tension the sampled bolts to the specified tension in Table 00560 -1 by any c onvenient means. Apply the Inspection Torque wrench to the tensioned bolt to determine the torque required to turn the nut 5 degrees (approximately 1 inch at a 12 inch radius) in the tensioning direction. Calculate the Inspection Torque by averaging the three bolt, nut and washer assemblies of each diameter, length, and grade.
Repeat the Inspection Torque determination when the fasteners conditions are altered, when changes in method, Equipment , or personnel occur, or as directed.
First, using the method developed in the Verification Testing procedure, snug the connection with all bolts installed in all holes of the connection and tension to achieve snug-tight condition.
Next, apply the tension control shear wrench until the spline fractures.
connections using the Inspection Torque wrench and visually inspect splines for each bolt in the connection. Conduct inspection tests before loss of lubricant and before corrosion begins. Select at random 10 percent or at least two, whichever is greater, of the tensioned bolts and nuts on the Structure for each separate connection. Appl y the Inspection Torque to each nut in the tensioning direction. If the Inspection Torque does not turn the bolt or nut, the connection will be considered properly tensioned. If the Inspection Torque turns the bolt or nut, apply the Inspection Torque to all the bolts and nut in the connection. Re-tension and re - inspect all bolts and nuts that turned at this inspection. The Contractor may re- tension all the bolts in the connection and resubmit it for inspection, provided fasteners assemblies are not dama ged.
Project Site.
to 02560.60.
tension- measuring device. Test a representative sample of not less than three bolt and nut assemblies of each diameter, length, and grade used.
Repeat Verification Testing if the condition of fasteners are altered, when changes in method, Equipment or personnel occur, or as directed. Conduct verification tests in two stages:
00560.29 550 First, demonstrate the method for estimating the snug-tight condition using the same method to be used on the final product. Record the s nug-tight tension. Match mark the bolt, nut, and plate.
Next, apply a tensioning wrench to achieve the nut rotation requirement of Table 00560-3 and develop a tension of not less than 5 percent greater than required in Table 00560- 1. If necessary, incre ase rotation to meet these requirements. Record all tension and rotation readings.
tension- measuring device. Provide a torque wrench with sufficient capacity to perform testing. Match the sampled fastener conditions to the conditions under inspection. Test at least three randomly sampled bolt, nut, and washer assemblies for each diameter, length, and grade used. Tension the sampled bolts to the specified tension in Table 00560 -1 by any convenient means. Apply the Inspection Torque wrench to the tensioned bolt to determine the torque required to turn the nut 5 degrees (approximately 1 inch at a 12 inch radius) in the tensioning direction. Calculate the Inspection Torque by averaging three bolt, nut, and washer assemblies of each diameter, length, and grade.
Repeat the Inspection Torque determination when the fastener conditions are altered, when changes in method, Equipment , or personnel occur, or as directed.
First, using the method developed in the Verification Testing procedure, snug the connection with all bolts installed in all holes of the connection and tension to achieve snug-tight co ndition by snugging in multiple cycles. Match mark each fastener bolt, nut and plate.
Next, apply the tensioning wrench to achieve the nut rotation determined during the Verification Testing. Do not allow the bolt to turn during the tightening process.
connections using the Inspection Torque wrench and the match marked nut rotation for each bolt in the connection. Conduct inspection tests before loss of lubricant a nd before corrosion begins.
Select at random 10 percent or at least two, whichever is greater, of the tensioned bolts and nuts on the Structure for each separate connection. Apply the Inspection Torque to each nut the tensioning direction. If the Inspection Torque does not turn the bolt or nut, the connection will be considered properly tensioned. If the Inspection Torque turns the bolt or nut, apply the Inspection Torque to all bolts in the connection. Re-tension and re-inspect all bolts and nuts that turned at this inspection. The Contractor may re-tension all the bolts in the connection and resubmit it for inspection, provided fastener assemblies are not damaged. 00560.40 551
Table 00560 -3 Nut Rotation from Snug -Tight Condition 1 Disposition of Outer Faces of Bolted Parts Bolt Length (underside of head to end of bolt) Both faces normal to bolt axis One face normal to bolt axis and other sloped not more than 1:20 (beveled washer not used) Both Faces sloped not more than 1:20 from normal to bolt axis (beveled washer 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 2/3 turn (1 1/6 turn) 5/6 turn (1 1/2 turn) 1 turn (1 5/6 turn) 1 Nut rotation is relative to bolt, regardless of the element (nut or bolt) being turned. For bolts installed by one-half turn and less, the tolerance shall be plus or minus 30°; for bolts installed by two -thirds turn and more, the tolerance shall be plus or minus 45°. 2 No research has been performed by the Research Council on Structural Connections to establish the turn -of-nut procedure for bolt lengths exceeding 12 diameters. Therefore, the required rotation shall be determined by actual test in a suitable tension measuring device according to 00560.29 (d)(2). 3 Values in parentheses are twice the rotation as defined in 02560.60(a)(1) and 02560.60(a)(2) for zinc coated ASTM F3125, Grade A325 or Grade F1852 bolts only.
Labor
00560.30Fabricators - Structural steel Bridge fabricators shall have an American Institute of Steel
Construction (AISC) Certified Bridge Fabricator - Intermediate (IBR) certification. For fracture critical Structures, the fabricator shall also have an AISC Fracture Critical Endorsement (F C). All fabricators of earthquake restraints shall have either a current AISC IBR certification or a Certified Bridge Fabricator - Simple (SBR) certification.
Construction
00560.40Members Work :
angles to exact length shown, as measured between the heels of the connection angles, with a permissible tolerance of + 0 to – 1/16 inch. Where continuity is required, face end connecti ons. Provide connection angles with a thickness of not less than 3/8 inch, nor less than shown after facing.
00560.40 552 (c) Stiffeners - Fabricate end stiffeners of girders and stiffeners intended as supports for concentrated loads to have full bearing (either mil led, ground, or on weldable steel in compression areas of flanges, welded as specified) on the flanges to which they transmit load or from which they receive load. Fabricate stiffeners not intended to support concentrated loads, according to AWS D1.5, unl ess specified otherwise.
joints in trusses, columns and girder flanges, to give a square joint and uniform bearing. At joints not required to be faced, the openin g shall not exceed 1/4 inch.
structural members which are specified to be annealed or normalized subsequent to heat treatment. Normalize and anneal (full annealing) according to ASTM A941. Maintain the temperatures uniformly throughout the furnace during the heating and cooling so the temperature at no two points on the member will differ by more than 100 °F at any one time.
Make a record identifying the pieces in each furnace charge and show the temperatures and schedule actually used. Provide proper instruments, including recording pyrometers, for determining at any time the temperatures of members in the furnace. Provide the records of the treatment operati on to the Engineer.
Stress relieve members, such as bridge shoes, pedestals or other parts that are built up by welding sections of plate together according to AWS D1.5, when specified.
surfaces that are to come in contact with each other or with concrete shall conform to ANSI surface roughness requirements of ANSI B46.1, Surface Roughness, Waviness and Lay, Part I, and the following table:
Member Maximum Surface Roughness
Steel slabs .................................................................................. 2,000 microinch Heavy plates in contact with shoes to be welded ....................... 1,000 microinch Milled ends of compression members, milled or ground ends of stiffeners and fillers .......................................... 500 microinch Bridge rollers and rockers ............................................................. 250 microinch Pins and pin holes ......................................................................... 125 microinch Sliding bearings ............................................................................. 125 microinch
and free from flaws. Pins and rollers more than 9 inches in diameter shall be forged and annealed carbon-steel shafting. Pins and rollers 9 inches or less in diameter may be cold-finished or forged and annealed carbon- steel shafting. In pins larger than 9 inches in diameter, bore a hole not less than 2 inches in diameter full length along the axis after the forging has cooled to a temperature below the critical range, under conditions that prevent injury by too rapid cooling, and before annealing.
Provide threads for all bolts and pins for structural steel construction according to AS ME B1.1, Unified Inch Screw Threads, Class 2A for external threads and Class 2B for internal threads, except for pin ends having a diameter of 1 3/8 inch, or more, use a thread pitch of 6 threads per inch.
to the axis of the member and parallel with each other unless otherwise specified. Produce the final surface by a finishing cut. 00560.43 553 The diameter of the pin hole shall not exceed that of the pin by more tha n 0.02 inch for pins 5 inches or less in diameter, or by 0.03 inch for larger pins. 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 more than 1/32 inch. Bore holes in built-up members after the fabrication is completed.
according to AWS D1.5.
00560.41Repair of Defects - Do not begin the repair of defec ts in the fabricated material until the
proposed corrective procedure has been approved.
00560.42Cambering - Provide a smooth, unbroken curve or Camber over the full length of the
member when shown. Camber roll beams in the fabricating shop by use of heat or hydraulic jacks. The temperature of the heated area shall not exceed 1,200 °F as controlled by pyrometric stick (temperature crayon) or thermometers. Do not quench to a ccelerate cooling.
Trim web plates of cambered plate girders before assembly.
Camber truss spans according to 00560.46.
00560.43Shop Assembling :
continuous beam spans, bents, towers (each face), plate girders and rigid frames with milled ends of compression members in full bearing, and then ream their subsize holes to specified size while the connections are assembled. Use full truss or girder assembly, unless progressive truss or girder assembly, full chord assembly, progressive chord assembly, or complete Structure assembly is specified. Make check assemblies with numerically controlled punched or drilled field connections and template drilled field connections of rolled beam stringers continuous over floor beams or cross frames according to 00560.43(g). Obtain approval for each assembly, including Camber, alignment, accuracy of holes and fit of milled joints before reaming is commenced or before a numerically controlled drilled check assembly is dismantled. Furnish a C amber diagram, prepared by the fabricator, showing the C amber at each panel point in the cases of trusses or arch ribs, and at the location of field splices and fractions of span length (quarter points minimum, tenth points maximum) in the cases of continuous beam and girders or rigid frames. When the shop assembly is Full Truss or Girder Assembly or Complete Structure Assembly, show the C amber measured in assembly. When any of the other methods of shop assembly is used, show calculated Camber.
face, conti nuous beam line, plate girder or rigid frame at one time.
or rigid frame, all members in at least three connecting panels, but not less than the number of panels in three connecting chord lengths. 00560.44 554 Assemble, initially for each arch rib, continuous beam line or plate girder, at least three connecting shop sections. Make successive assemblies with at least one panel or section of the previous assembly (repositioned if necessary and adequately pinned to assure accurate alignment) plus two or more panels or sections added at the advancing end. In the case of Structures longer than 150 feet, make each assembly not less than 150 feet long regardless of the length of individual continuous panels or sections.
The sequence of assembly may start from any location in the Structure and proceed in one or both directions, so long as the preceding requirements are satisfied.
Obtain approval for assemblies consisting of less than three panels or shop sections.
chord of each truss or open spandrel arch, or each leg of each bent or tower, then ream their field connection holes while the members are assembled, and ream the web member connections to steel templates set at geometric (not cambered) angular relation to the chord lines. Mill at least one end of each web member or scribe normal to the longitudinal axis of the member and accurately locate the templates at both ends of the member from one of the milled ends or scribed lines.
specified for Full Chord Assembly and in the number and length specified for Progressive Truss or Girder Assembly.
Connections - A check ass embly consists of at least three connecting shop sections, or in a truss, all members in at least three connecting panels, but not less than the number of panels in three connecting chord lengths; that is, the length between field splices. Check assemblies shall be based on the proposed order of erection, joints in bearings, special complex points such as the portals of skewed trusses, and similar considerations, as directed. Check assemblies shall be the first such sections of each major structural type to be fabricated.
Use 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) as shown or specified.
No match- marking and no shop assemblies other than the check assemblies are required.
If the check assembly fails to demonstrate that the required accuracy is being obtained, further check assemblies may be required at no additional cost to the Agency. Acceptance of the check assembly does not relieve the Contractor of the responsibility for assuring accurate fit -up during erection.
reaming holes in field connections, and furni sh a diagram showing such marks to the Engineer.
00560.44Coatings :
00560.46 555 (b) Othe r Coatings - Unless otherwise shown or specified, prepare and coat all steel surfaces according to Section 00594.
00560.45Marking and Transporting to Site - Handle members and transport to the Project Site
according to 00560.24 and the following:
Mark each member with an erection mark for identification and furnish an erection diagram showing the erection marks. Mark the weight of members weighing more than 6,000 pounds on the member. Load structural members on trucks or cars so they may be transported and unloaded without being excessively stressed, deformed or otherwise damaged. Ship fasteners (bolts, nuts, and washers) according to 02560.60(a)(3). Do not allow welding to be done on the steel members for the purpose of transporting anchorage. List and describe the contained Material plainly on the outside of each shipping container. Furnish as many copies of material orders, shipping statements and erection diagrams as directed and show the weights of the individual members on the statements. Brace the girders properly and adequately, so as to eliminate cyclic out -of-plane bending stresses in the web gap between the end of stiffener on the web and the girder flange due to cyclic swaying motion in transit. Take care to minimize dynamic loads transmi tted to girder support points during transit. Furnish the Engineer stamped detail Plans of loading, unloading, supporting and bracing of the steel plate girders on trucks or cars for shipment to the Project Site, according to 00150.35. The review will not relieve the Contractor of responsibility for safe transportation of steel members.
00560.46Erecting :
complete the Structures, including the removal of the old Structures according to Section 00501, if specified.
00540.42, and 00540.52. Review of the Contractor's Plans will not relieve the Contractor of any
responsibility.
Provide all facilities required for a thorough inspection of the Work . Material not previously inspected, as well as previously inspected Material, will be inspected after delivery to the construction Site.
to 00560.24 and 00560.45.
according to the following:
• Drill holes for anchor bolts and set them in portland cement grout, or preset them as specified. • Locate anchors and set rockers or rollers considering variation from mean temperature at the time of setting, and anticipated lengthening of bottom chord or bottom flange due to dead load after setting. As nearly as practica ble, at mean temperature and under dead load, the rockers and rollers shall stand vertically and anchor bolts at expansion bearings shall center their slots. 00560.46 556 • Provide full and free movement of the Superstructure at moveable bearings. Make sure it is not restricted by improper setting or adjustment of bearings or anchor bolts and nuts.
damaged.
Do not perform hammering which will injure or distort the members. Prepare bearing surfaces and surfaces to be in permanent contact before the members are assembled.
Assemble the parts accurately as shown, following any match -marks.
Unless erecting by the cantilever method, erect truss spans on blocking that gives the trusses proper Camber. Leave the blocking in place until the tension chord splices are completed and all other truss connections are pinned and bolted. Use fitting -up bolts of the same nominal diameter as the high- strength bolts, and cylindrical erection pins 1/32 inch larger. Fill 50 percent of the holes in splices and field connections with equal numbers of fitting- up bolts and cylindrical erection pin s before bolting with high- strength bolts. Fill 75 percent of the holes in splices and connections carrying added construction loads during erection with equal numbers of fitting up bolts and erection pins.
Tighten permanent bolts in butt -jointed splices of compression members and in railings after the span, if movable, has been swung.
Perform all field welding according to AWS D1.5 and all interim specifications. Before releasing the erection cranes for the bolted splices in the air, do the following:
Install 50 percent of the bolts in the top and bottom flanges and the web with all nuts finger - tight; Meet the erection bracing and support requirements shown and approved; Install top lateral bracing across the connection for tub girders, and fully tensi on the bolts connecting the bracing to the top flanges. If lifting brackets are bolted to the girder top flanges:
Drill bolt holes in the shop. Field drilling of bolt holes for lifting brackets is not allowed. Fill bolt holes in girder top flanges with high strength bolts after erection with fully torqued ASTM F3125 Grade A325 bolts. Place each bolt head on the bottom side of the top flange.
Securely tie, brace, or shore steel beams or girders immediately after erection as shown on the erection drawings. Maintain bracing or shoring until the diaphragms are in place and as shown in the erection drawings. Protect Railroad, Roadway, and marine traffic underneath previously erected girders or beams from falling objects.
take full bearing on them. Screw pin nuts up tight and burr the threads at the face of the nut with a pointed tool.
00560.90 557 (h) Misfits - The correction of minor misfits involving small amounts of reaming, cutting, and chipping will be considered a legitimate part of the erection. However, immediately report to the Engineer any error in the shop fabrication or deformation resulting from handling, storage and transportation which 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. Have the correction method approved. Make the correction in the Engineer's presence. The Contractor shall be responsible for all misfits, errors and injuries. Make the necessary corrections and replacements as approved by the Engineer.
Finishing and Cleaning Up
00560.70Finish (Non -Coated Weathering Steel Only) - Sandblast all exposed surfaces of
AASHTO M 270 (ASTM A709), Grade 50W non-coated weathering steel, according to SSPC -SP6, Commercial Blast Cleaning, SSPC's Steel Structures Painting Manual . The appearance of the blast -cleaned surface shall approximate Pictorial Standard Sa 2 of SSPC -VIS 1, Pictorial Surface Preparation Standards for Painting Steel Surfaces, except no mill scale particles will be allowed; only rust or mill scale stains down in the profile will be allowed. The use of acids to remove scale and stains in the field is not allowed.
Promptly clean exposed surfaces of steel contaminated with stains, oil or foreign material after the above sand blasting cleaning process, as directed, to preserve conditions for uniform weathering of steel.
Measurement
00560.80Measurement - No measurement of quantities will be made for Work performed under this
Section. Estimated quantities of structural steel will be listed in the Special Provisions.
00560.81Miscellaneous Metal - Minor metal parts such as access hole covers, frames, ladders,
hangers, anchor bolts, scuppers, conduits, ducts, bearing devices and other structural steel shapes, unless otherwise provided, will be classified as structural steel. The weight of miscellaneous metal will be included in the estimated quantity of structural steel specified.
Payment
00560.90Payment - The accepted quantities of Work performed under this Section will be paid for
at the Contract unit price, per unit of measurement, for the following items:
Pay Item Unit of Measurement
Payment will be payment in full for furnishing and placing all Materials, and for furnishing all Equipment , labor, and Incidentals necessary to complete the Work as specif ied.
00560.90 558 No separate or additional payment will be made for:
• bolts, studs or bearing devices made entirely of structural steel (such as rockers and hinges) fabricating, transporting and erecting the Structures furnishing, erecting, and removing falsework preparing and coating furnishing and installing plain elastomeric bearing pads