1050STEEL BRIDGE SUPERSTRUCTURE

1050.1DESCRIPTION—This work is the construction of a steel bridge superstructure and/or the furnishing

and installation of fabricated structural steel for repair, rehabilitation, or modification of steel structures.

1050.2MATERIAL—

• Cement Concrete Structures. Section 1001.2

• Preformed Neoprene Compression Joint Seal. Section 1008.2

• Pedestrian Railing. Section 1012.2

• Aluminum Bridge Hand Railing. Section 1023.2

• Steel Bridge Hand Railing. Section 1022.2

• Protective Barrier. Section 1015.2

• Protective Fence. Section 1016.2

• Penetrating Sealers for Reinforced Concrete Surfaces. Section 1019.2(a)

• Armored Preformed Neoprene Compression Dam. Section 1021.2

• Tooth Expansion Dam with Drain Trough. Section 1020.2

• Reinforcement Bars. Section 1002.2

• Neoprene Strip Seal Dam. Section 1026.2

• Shop Painting. Section 1060.2

• Field Painting. Section 1070.2

1050.3CONSTRUCTION—

and includes bearings, bearings and anchors set in the substructure, abutment backwalls, cheekwalls, bridge drainage down to but not including the drain box, and portions of wings and appurtenances above the horizontal construction joint nearest the bridge seat. Do not ship fabricated materials without approved

shop drawings marked “Accepted”. For fabricated structural steel repairs, verify dimensions in the field before fabrication. Repair damage due to construction operations to portions of the structure to remain, at no additional cost to the Department.

and as follows:

• Fabricated Structural Steel. Section 1105

• Cement Concrete Structures. Section 1001.3

• Reinforcement Bars. Section 1002.3

• Preformed Neoprene Compression Joint Seal for Bridges. Section 1008.3

• Tooth Expansion Dam with Drain Trough. Section 1020.3

• Neoprene Strip Seal Dam. Section 1026.3

• Armored Preformed Neoprene Compression Dam. Section 1021.3

• Pedestrian Railing. Section 1012.3

• Aluminum Bridge Hand Railing. Section 1023.3

• Steel Bridge Hand Railing. Section 1022.3

• Protective Barrier. Section 1015.3

• Protective Fence. Section 1016.3

• Penetrating Sealers for Reinforced Concrete Surfaces. Section 1019.3(a) or Section 1019.3(b)2 as indicated.

properly drained. Place girders and beams upright and shore them. Support long members, such as columns and chords, on skids placed near enough together to prevent injury from deflection. If the contract is for erection only, check material turned over against the shipping lists and promptly report in writing any shortage or injury discovered. The Contractor is responsible for the loss of any mater ial while in the Contractor's care, or for any damage caused to it after being received by the Contractor.

LRFD Bridge Construction Specification 11.2.2, 11.6.1, AASHTO Publications (Guide Design Specifications for Bridge Temporary Works and Construction Handbook for Bridge Temporary Works) and as specified in Section 105.03(c).

2.a General. Provide all tools, machinery, and equipment necessary to erect the falsework. Falsework is considered to be any temporary structure that supports structural elements of concrete, steel, masonry, or other materials during their construction or erection. Form travelers, as used in segmental cantilever construction, are considered to be a combination of falsework and forms. Have a Professional Engineer registered in the State sign and seal the working drawings for the falsework if the height of falsework exceeds 14 feet or if traffic, other than workers involved in constructing the bridge, will travel under the bridge. Furnish falsework of sufficient rigidity and strength to safely support all forces imposed, and to produce, in the finished structure, the lines and grades indicated.

2.b Design Loads. Ensure that the design load for falsework consists of the sum of dead and live vertical loads, and any horizontal loads. At a minimum, include in the dead loads the gravitational force of the falsework and all construction material to be supported. Assume the combined density of concrete, reinforcing and prestressing steel, and forms to be not less than 160 pounds per cubic foot of normal density concrete or 130 pounds per cubic foot of low-density concrete that is supported. For live loads, include the actual force of any equipment to be supported, applied as concentrated forces at the points of contact and a uniform force of not less than 20 pounds per square foot applied over the area supported, plus 75 pounds per linear foot applied at the outside edge of deck overhangs. For the design of the falsework bracing system, use the sum of the horizontal forces due to equipment, construction sequence, including unbalanced hydrostatic forces from fluid concrete, stream flow when applicable, and an allowance for wind. Use wind loads and distribution of wind loads to girders according to AASHTO Guide Specifications for Wind Loads on Bridges During Construction. However, do not allow the horizontal force to be resisted in any direction to be less than 2% of the total dead load. Do not exceed the load- carrying capacity of the structure, or portion of structure, according to AASHTO LRFD Specifications Article 3.4.2 by imposing forces on existing, new, or partially completed portions of structures due to construction operations. For the compressive strength of concrete, f'c, in computations of the load-carrying capacity, use the lesser of the actual compressive strength at the time of loading or the specified compressive strength of the concrete.

2.c Clearances. Unless otherwise provided for roadways that are to remain open to traffic, supply minimum dimensions for clear openings through falsework at least 5 feet wider than the width of the approach traveled way, measured between barriers when used, and 14 feet hi gh, except over interstate routes and freeways use 14.4 feet for the minimum vertical clearance.

2.d Construction. Do not proceed with construction of falsework until the erection plan as specified in Section 1050.3(c)3 is accepted. Construct falsework and set it to grades that allow for its anticipated settlement and deflection, and for the vertical alignment and camber indicated or directed for the permanent structure. Use variable depth camber strips between falsework beams and soffit forms to accomplish this, if directed. Use suitable screw jacks, pairs of wedges or other devices at each post to adjust falsework to grade, to allow minor adjustments during the placement of concrete or structural steel should observed settlements deviate from those anticipated, and to allow f or the gradual release of the falsework. Provide tell -tales attached to the forms and extending to the ground, or other means, for accurate measurement of falsework settlement during the placing and curing of the concrete. Support falsework or formwork for deck slabs on girder bridges directly on the girders so that there will be no appreciable differential settlement during placing of the concrete. Brace and tie girders to resist any forces that would cause rotation or torsion in the girders caused by the placing of concrete for diaphragms or deck. Do not weld falsework support brackets or braces to structural steel members or reinforcing steel unless specifically allowed.

2.e Removal. Section 1001.3(q)

Engineer registered in the State. Provide details for all anticipated phases and conditions during erection. Include details of falsework, temporary bents, bracing, guys, dead-men, lifting devices, and attachments to bridge members. Include the sequence of erection, location of cranes and barges, crane capacities, crane operator’s license for the operator performing the crane work, location of lifting points on the bridge members, and weights of the members. If required, furnish calculations to demonstrate that allowable stresses are not exceeded, and that member capacities and final geometry will be correct. Include delivery plan with erection plan. The delivery plan is to include delivery routes, ingress and egress to the site , and any modifications required for safe transport to the site. List equipment needed to unload or move bridge members. Do not proceed with erection until the erection plan has been accepted. Maintain an accepted copy of the erection plan onsite during erection operations.

3.a Pre-Erection Meeting. Before erecting falsework or permanent bridge members, conduct a pre-erection meeting a minimum of 14 calendar days before erection with the Professional Engineer of

record for the erection plan, prime contractor, superintendent in charge of beam setting operation, crane operators or crane company representative, signal personnel, Structure Control Engineer, and onsite Representative to discuss the accepted erection plan. Conduct safety talk with crane operator as specified in Section 108.05(c)6.

3.b Conformance to Erection Plan. Ensure conformance to the erection plan. Any modification to or deviations from the accepted erection plan will require revised drawings, calculations, and verification of stresses and geometry.

3.c Erection Stresses. Account for any erection stresses that are induced in the structure as a result of the use of a method of erection or equipment which differs from that indicated or specified, and which will remain in the finished structure as locked-in stresses. Provide additional material, at no additional cost to the Department, to keep both temporary and final stresses within the allowable limits used in design. Provide temporary bracing or stiffening devices to accommodate handling stresses in individual members or segments of the structure during erection. Use wind loads and distribution of wind loads to girders according to AASHTO Guide Specifications for Wind Loads on Bridges During Construction.

3.d Maintaining Alignment and Camber. During erection, support segments of the structure in a manner that will produce the proper alignment and camber in the completed structure. Install cross frames and diagonal bracing, as necessary during the erection process, to provide stability and ensure correct geometry. Provide temporary bracing, if necessary, at any stage of erection.

4.a General. This work consists of furnishing and installing bridge bearings. Bearing types include, but are not limited to, elastomeric pad, rocker, roller, pot, spherical, disk, and sliding plate bearings. Included as components of bearings are masonry, sole and shim plates, bronze or copper -alloyed bearing and expansion plates, anchor bolts, PTFE sheets or surfacing, lubricants and adhesives. The furnishing and installation of bedding materials used under masonry plates is also included in this work. Construct bearings according to the indicated details. If complete details are not provided, furnish bearings that conform to the limited, indicated details and provide the design capacities for loads and movements shown or specified and the performance characteristics specified.

4.a.1 Working Drawings. If complete details for bearings and their anchorages are not indicated, prepare and submit working drawings for the bearings. Show all details of the bearings and of the materials proposed for use on such drawings, and have the drawings approved before fabrication of the bearings is begun.

4.a.2 Packaging, Handling, and Storage. Before shipment from the point of manufacture, package bearings in such a manner to ensure that during shipment and storage the bearings will be protected against damage from handling, weather, or any normal hazard. Clearly identify each completed bearing's components; securely bolt, strap, or otherwise fasten its components to prevent any relative movement; and mark on its top its location and orientation in each structure in the project, in conform ity with the plans. Do not dismantle bearings at the site unless absolutely necessary for inspection or installation. Store all bearing devices and components at the work site in an area that provides protection from environmental and physical damage. Ensure that bearings are clean and free of all foreign substances when installed.

4.a.3 Manufacture or Fabrication. Unless otherwise specified or indicated, furnish the surface finish of bearing components that come into contact with each other or with concrete, but are not embedded in concrete, as specified in Section 1105.03(q).

4.a.4 Construction and Installation. Install bearings to the positions indicated. At the time of installation, set bearings to the dimensions prescribed by the manufacturer, the Representative, or as indicated. Adjust bearings as necessary to take into account the temperature and future movements of the bridge. Set bridge bearings level, in exact position, and to have full and even bearing on all bearing planes. For bearing surfaces located at improper elevations or set not level and true to plane, either grind

the surface, grout pack bearings, or modify the bearing such that intended bearing placement is as originally designed with the least amount of bearing modification. Use a filler or fabric material as specified in Section 1113.03(h) to bed on the concrete metallic bearing assemblies not embedded in the concrete. Set elastomeric bearing pads directly on properly prepared concrete surfaces without bedding material. For bearings seated directly on steel work, machine the supporting surface so as to provide a level and planar surface to place the bearing.

4.b Preparation of Bearing Areas. Prepare bearing areas as specified in Section 1001.3(k)9 and furnish bedding material as specified in Section 1113.03(h).

4.c Elastomeric Bearings. Elastomeric bearings include unreinforced pads (consisting of neoprene only) and reinforced pads with steel or fabric laminates. Furnish bearings with the dimensions, material properties, neoprene grade and type of laminates indicated.

4.c.1 Setting Bearing Pads. Set bearing pads as specified in Section 1080.3(c)2 and as indicated. Where elastomeric bearings are used at piers of continuous bridges, provide full contact between the beam, the bearing pad, and the beam seat, unless the plans indicate that a lift-off condition is expected when the beam is initially set on the pad.

4.c.2 Resetting Bearing Pads. If indicated, reset expansion bearings after all dead loads have been placed. Submit a plan showing and describing the jacking procedure for review and acceptance at least 2 weeks before proceeding with the jacking operations. Provide calculations showing actual and allowable bearing stresses in the bearing plates and bearing areas at the jacking locations. Have the plans and calculations sealed and signed by a Professional Engineer registered in the State. Before resetting, truck mixers and slip- forming equipment, necessary for placement of barriers and sidewalks, will be allowed on the structure. Do not allow other construction equipment or traffic on the structure until the bearings are reset. Coordinate t he resetting operation with the installation of on- bridge hardware, including conduits, utilities, expansion dams, and drainage, to prevent damage to these components when the beams are jacked and lowered. Furnish jacks with a working capacity at least equal to the jacking forces indicated. Jack beams at expansion bearings to achieve a 1/16-inch gap between the bottom of beam or sole plate and the top of the entire bearing pad. Place jacks at jacking points indicated. Unless indicated otherwise, jack all beams simultaneously. Limit the differential rise between all beams to 1/8 inch during jacking. After jacking, center the pad beneath the sole plate or beam bearing area as indicated. Lower the beams onto the bearings in the same manner as they were jacked. Reset bearings when the ambient temperature is above 20F and below 85F.

4.d Anchor Bolts.

4.d.1 Fabrication. Furnish threaded and headed anchor bolts to secure a satisfactory grip upon the material used to embed them in the holes.

4.d.2 Setting Anchor Bolts. Set by template to the indicated elevation and alignment. As an alternate, set in preformed holes 3 inches larger than the bolt diameter. Clean the holes, set and fix the bolts, and fill the holes with nonshrink grout, as specified in Section 1001.2(e). Use drilled holes, as a substitute for preformed holes, in abutments and solid piers only. Protect the holes against water entry during freezing periods. Limit the threaded projection above the nut to between 3/16 inch and 1 inch.

4.e Setting Bearings. As shown on the Standard Drawings and as follows: Align masonry plates and set them so they will be centered with the rockers, rollers, sole plates, and bearing plates, at 68F and under full dead load. Make adjustment for the difference in temperature, from 68F, at time of erection. Compensate for the cha nge in length of the bottom chord, or flange, due to the later addition of dead loads. Maximum deviation of the top of rockers from a vertical position, and maximum eccentricity of the

parts of sliding bearings, is 0.0001(L) + 0.25 inch, where L, in inches, is the horizontal distance between the expansion bearing and the fixed bearing.

4.f Spherical Bearings. Fabricate, test, and install spherical bearings as indicated.

4.g Separate Contracts for Substructure and Superstructure. If the substructure and superstructure are built under separate contracts, proceed as follows:

4.g.1 Substructure Contractor. Accurately place the anchor bolts and grind the bearing areas to the correct plane and elevation. At the completion of the substructure, make an as -built survey to accurately show the as -built versus the plan location of all substructure centerlines, girder centerlines, anchor bolt group centerlines, anchor bolts, bearing elevations, and any other elements or items that may affect the layout or placement of the work to be furnished by the superstructure contractor. Show all of the pertinent as -built survey information, including dimensions, elevations, and angles on suitable drawings, as specified for shop drawings, together with the corresponding design drawing information for direct comparison. Submit the original drawings, or equal, to the Department as soon as practical after completion of the survey. Conduct the survey and have the survey drawings signed by a Surveyor or Professional Engineer registered in the State. Provide documented evidence to show that the bearings can be set properly within the tolerances specified in Section 1050.3(c)4.

4.g.2 Superstructure Contractor. Use the as -built survey information, furnished by the substructure contractor, for the accurate layout of the connecting parts of the work. Verify location, level, and elevation of all bearing seats and anchor bolts as soon as possible. Verify, before the fabrication of any metal work, in cases where the substructure is completed before award of the superstructure contract, or before erection of the metal work, in cases where fabrication has been started before completion of the substructure. Furnish and install bedding, bearings, and nuts and washers for anchor bolts.

4.h High-Load Multi-Rotational Bearings. If required, construct as follows: Provide complete erection and installation procedures for acceptance before installation. Evenly support bearings over their upper and lower surfaces under all erection and service conditions. Lift bearings by undersides only or by specially designed lifting lugs. Take care to avoid damage to and contamination of bearing surfaces during installation. Align the centerlines of the bearing assembly with those of the substructure and superstructure. On guided bearings take special care to properly align the guiding mechanism with the designated expansion direction of the structure. Leave bearing straps or retaining clamps in place as long as possible to ensure parts of bearing are not inadvertently displaced relative to each other. Take care to remove straps or clamps before any normal structural movement takes place, such as post-tensioning. Set offsets of upper and lower bearing parts as indicated. Under dead load, the distance between the upper and lower bearing plates will not be out of parallel by more than 1/8 inch measured from edge to edge. Make the mating surface of the superstructure level within a slope of 100:1. Have no local irregularities exceeding 1/16 inch. During welding of sole plates to girders, limit the temperature of the metal adjacent to neoprene and PTFE to a maximum of 300F. Use temperature indicating markers.

4.h.1 Bearing Seats. Provide bedding material for steel bearings as specified in Section 1113.03(h).

Use methods that will not produce fracture or other injury to the metal. Straighten distorted non-fracture critical members by mechanical means or, if allowed, by carefully planned procedures and supervised application of a limited amount of localized heat. Heat -straighten Grades HPS 70W and HPS 100W steel members only under rigidly controlled procedures, each application subject to approval. Do not allow the maximum temperature to exceed the following values:

Steel Grade Distance from Weld Max. Temp.

HPS 70W > 6 inches 1,050F HPS 70W < 6 inches 900F HPS 100W > 6 inches 1,100F HPS 100W < 6 inches 950F

In all other steels, do not allow the temperature of the heated area to exceed 1, 150F as controlled by temperature indicating crayons or other approved methods. Ensure that parts to be heat -straightened are substantially free of stress and from external forces, except stresses resulting from mechanical means used in conjunction with the application of heat. Evidence of fracture following straightening of a bend or buckle will be cause for rejection of the damaged piece.

match-marks. Carefully handle the material so that no parts will be bent, broken, or otherwise damaged. Do not hammer members if it will injure or distort them. Clean bearing surfaces and surfaces to be in permanent contact before the members ar e assembled. Fill one- half of the holes of splices and field connections with bolts and cylindrical erection pins (half bolts and half pins) before installing and tightening the balance of high-strength bolts. Fill three-fourths of the holes of splices and connections carrying traffic during erection before installing and tightening the balance of high-strength bolts. Fitting-up bolts may be the same high-strength bolts used in the installation. If other fitting-up bolts are used, supply fitting-up bolts of the same nominal diameter as the high-strength bolts, but supply cylindrical erection pins 1/32 inch larger.

and as follows: (Note: Do not use ASTM F3125 Grade 490 bolts unless approved for use by the Chief Bridge Engineer or the Chief Bridge Engineer’s designee, on a project by project basis.)

7.a General. Obtain the “snug tight” condition as defined in Section 1050.3(c)7.d for any method of final tightening except direct-tension-indicator (DTI) tightening or tightening of alternate design fasteners. Assemble fasteners of appropriately assigned lot numbers together when installed. Protect such fasteners from dirt and moisture at the job site. Take only as many fasteners as are anticipated to be installed and tightened during a work shift from protected storage. Return fasteners not used to protected storage at the end of the shift. Do not clean lubricant from fasteners that is required to be present in as - delivered condition. Before installation, clean and relubricate fasteners for slip- critical connections which accumulate rust or dirt resulting from job site conditions. If relubrication is required, use a lubricant recommended by the fastener manufacturer. Provide a Skidmore-Wilhelm Calibrator, or other equivalent bolt tension measuring device, at each job site, during erection. Perform periodic testing (at least once each working day if calibrated wrench method is used) to ensure compliance with the installation test procedures specified herein for turn-of-the- nut tightening, calibrated wrench tightening, installation of alternate design bolts, and direct tension indicator tightening. Bolts that are too short for the Skidmore- Wilhelm Calibrator may be tested using DTI devices. In that case, calibrate the DTI devices in the Skidmore- Wilhelm Calibrator using longer bolts, according to PTM No. 429 as applicable. Install fasteners together with washers of size and quality specified, located as required below, in properly aligned holes, and tighten by any of the methods specified in Sections 1050.3(c)7.d through 1050.3(c)7.g to at least the minimum tension specified in Table A, when all the fasteners are tight. When it is impractical to turn the nut, tighten the fastener by turning the bolt while the nut is prevented from rotating. If impact wrenches are used, provide adequate wrench capacity and sufficient air supply to perform the required tightening of each bolt in approximately 10 seconds. Do not reuse ASTM F3125 Grade A 490 fasteners or galvanized ASTM F3125 Grade A 325 fasteners. Reuse other ASTM F3125 Grade A 325 fasteners only if approved by the Representative. Do not consider as reuse touching up or retightening previously tightened bolts that may have been loosened by the tightening of adjacent bolts provided the snugging up continues from the initial position and does not

require greater rotation, including the tolerance, than that required by Table B.

7.b Rotational -Capacity Tests. Perform the rotational capacity test on each bolt/nut/washer assembly lot, as specified in Section 1105.02(d)7d , immediately before the start of bolt installation in the fabrication shop or at the project site. Document test results according to PTM No. 427 . If testing and installation is performed in the fabrication shop, submit test results to the BDTD, SMS at the MTL. If testing and installation is performed at the project site, submit test results to the Repr esentative. All job- site rotational capacity tests are to be performed by the fabricator or Contractor, as applicable at the site of bolt installation, and witnessed by the Inspector. Hardened steel washers are required under the turned element (nut) or as directed by the Representative as part of the test, although they may not be required in the actual installation. Mark fastener containers for each assembly lot after testing to indicate their acceptance.

7.c Requirement for Washers. Where the outer face of the bolted parts has a slope greater than 20:1 with respect to a plane normal to the bolt axis, use a hardened beveled washer to compensate for the lack of parallelism. For American Standard Beams and Channels use hardened beveled washers that are square or rectangular, that conform to ASTM F436, and that taper in thickness. Where necessary, clip washers on one side to a point not closer than 7/8 of the bolt diameter from the center of the washer. Hardened washers or plate washers are required for all connections using ASTM F3125 Grade A 325 bolts and ASTM F3125 Grade A 490 bolts unless indicated. Use hardened washers under the element turned in tightening when the tightening is to be performed by turn-of-the-nut method and calibrated wrench method. Hardened steel washers are required under the turned element as part of rotational -capacity tests, even if they are not required in the actual installation. Where ASTM F3125 Grade A 325 bolts equal to or less than 1.0 inch in diameter are to be installed in oversize or short slotted holes in an outer ply, a hardened washer conforming to ASTM F436 will be used. Where ASTM F3125 Grade A 325 bolts equal to or less than 1.0 inch in diameter are to be installed in long slotted holes in an outer ply, provide a single plate washer or continuous bar of at least 5/16- inch thickness with standard holes. Furnish washers or bars of sufficient size to completely cover the slot after installation. Use a single hardened washer conforming to ASTM F436 with a minimum thickness of 5/16 inch, or use washers or bars of structural grade material but need not be hardened. Do not use multiple hardened washers or bars to achieve a thickness of 5/16 inch. As an alternate satisfying the requirements for washers, use alternate design fasteners conforming to the requirements specified in Section 1050.3(c)7.c.1, if approved, with a geometry that provides a bearing circle on the head or nut with a diameter equal to or greater than the diameter of hardened washers conforming to the requirements of ASTM F436 . Such fasteners may be used in standard size round holes without washers.

7.c.1 Alternate Fasteners. If alternate fasteners are allowed, proceed as specified in Section 1050.3(c)7.f and as follows: If allowed, use other fasteners or fastener assemblies that conform to the materials, manufacturing, and chemical composition requirements of ASTM F3125 Grade A 325 and that conform to the mechanical property requirements of the same specifications in full -size tests, and that have body diameter and bearing areas under the head and nut, or their equivalent, not less than those provided by a bolt and nut of the same nominal dimensions specified in Section 1105.02(d). Such alternate fasteners may differ in other dimensions from those of the specified bolts and nuts.

7.d Turn-of-the-Nut Tightening. Immediately before the start of bolting operations, perform pre- installation verification testing according to PTM No. 429, and as follows: Once per project per bolting crew, c heck a representative sample of not less than three of each diameter, length and grade to be used in the work at the start of work in a device capable of indicating bolt tension. Using the test, demonstrate that the method for achieving the snug tight condition (see below) and for controlling the turns from snug tight to be used by the bolting crew develops a tension not less than 5% greater than the tension required by Table A. Perform periodic retesting if directed by the Representative.

Following successful pre-installation testing, perform bolt installation as follows: Install bolts in all holes of the connection and bring them to a snug tight condition. Snug tight is defined as the tightness that exists when the plies of the joint are in firm contact. Use a few impacts of an impact wrench or the full effort of a worker using an ordinary spud wrench to attain the snug tight condition (use the same method that was used for pre-installation verification). Snug tighten the bolts of the connection by progressing systematically from the most rigid part of the connection to the free edges, and then retighten the bolts in a similar systematic manner as necessary until all bolts are simultaneously snug tight and the connection is fully compacted. Following this initial operation further tighten all bolts in the connection by the applicable amount of rotation specified in Table

tighten the bolts progressing from the most rigid part of the joint to its free edges.

7.e Calibrated-Wrench Tightening. Before the start of bolting operations, perform pre-installation torque calibration as stipulated in PTM No. 429 and as follows : Use calibrated wrench tightening only if installation procedures are calibrated on a daily basis and if a hardened washer is used under the element turned in tightening. Standard torques determined from tables or from formulas, which are assumed to relate torque to tension, are not acceptable. When calibrated wrenches are used for installation, set them to deliver a torque which has been calibrated to produce a tension not less than 5% in excess of the minimum tension specified in Table A. Calibrate the installation procedures at least once each working day for each fastener assembly rotational- capacity lot combination that is being installed in the work that day. Perform calibration in a device capable of indicating actual bolt tension by tightening three typical fastener assemblies from each rotational-capacity lot, bolts of each diameter, length, and grade, from the bolts being installed and with a hardened washer, from the washers being used in the work, under the element turned in tightening. Recalibrate wrenches if significant difference is noted in the surface condition of the bolts, threads, nuts, and washers. Verify during actual installation in the assembled steel work that the wrench adjustment selected by the calibration does not produce a nut or bolt head rotation from snug tight greater than that specified in Table B. If manual torque wrenches are used, turn nuts in the tightening direction while torque is measured. When calibrated wrenches are used to install and tension bolts in a connection, install bolts and nuts, with washers in all holes of the connection and bring them to a snug tight condition. Following this initial tightening operation, tighten the connection using the calibrated wrench. Tighten the bolts by progressing systematically from the most rigid part of the joint to its free edges. Use the wrench to again tighten previously tightened bolts that may have been relaxed as a result of the subsequent tightening of adjacent bolts, until all bolts are tightened to the prescribed amount.

7.f Installation of Alternate Design Bolts. When fasteners are to be installed that incorporate a design feature intended to indirectly indicate the bolt tension or to automatically provide the tension specified in Table A and have been qualified as specified in Section 1050.3(c)7.c.1, check a representative sample of not less than three bolts of each diameter, length, and grade, at the job site in a device capable of indicating bolt tension. Include flat, hardened washers in the test assembly , if required in the actual connection, arranged as those in the actual connections to be tensioned. Use the calibration test to demonstrate that each bolt develops a tension not less than 5% greater than the tension specified in Table

all connections. Perform periodic retesting when directed by the Representative. When alternate design fasteners that are intended to control or indicate bolt tension of the fasteners are used, install bolts in all holes of the connection and initially tighten them sufficiently to bring all plies of the joint into firm contact but without yielding or fracturing the control or indicator element of the fasteners. Then further tighten all fasteners, progressing systematically from the most rigid part of the connection to the free edges in a manner that will minimize relaxation of previously tightened fasteners. In some cases, to properly tension the bolts, perform more than a single cycle of systematic partial tightening before final twist-off of the control or indicator element of individual fasteners. Replace any individual fastener assembly if twist off occurs before the final tensioning cycle.

7.g Direct Tension Indicator Tightening. Furnish DTIs conforming to the requirements as specified in Section 1105.02(d)6, and in sufficient numbers to allow for all required testing. When fastener assemblies using DTIs are proposed for use, perform preinstallation verification testing and subsequent fastener installation according to PTM No. 429 as applicable. Three verification tests are required for each

combination of fastener assembly rotational -capacity lot, DTI lot, and DTI position relative to the turned element to be used on the project. Unless otherwise approved, install the DTI under the head of the bolt, and turn the nut to tension the bolt.

TABLE A Required Fastener Tension Minimum Bolt Tension in Pounds* Bolt Size inches ASTM F3125 Grade A 325 ASTM F3125 Grade A 490 1/2 5/8 3/4 7/8

1-1/8 1-1/4 1-3/8 1-1/2 12,000 19,000 28,000 39,000 51,000 56,000 71,000 85,000 103,000 15,000 24,000 35,000 49,000 64,000 80,000 102,000 121,000 148,000 * Equal to 70% of specified minimum tensile strength of bolts (according to ASTM Specifications for tests of full-size ASTM F3125 Grade A 325 bolts and ASTM F3125 Grade A 490 bolts with UNC profile threads loaded in axial tension) rounded to the nearest kip.

TABLE B Nut Rotation from the Snug-Tight Condition(1),(2) Geometry of Outer Faces of Bolted Parts Bolt length measured from underside of head to end of bolt Both faces normal to bolt axis One face normal to bolt axis and other face sloped not more than 20:1. Bevel washer not used. Both faces sloped not more than 20:1 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(3) 2/3 turn 5/6 turn 1 turn

installed by 1/2 turn and less, the tolerance should be ±30 degrees; for bolts installed by 2/3 turn and more, the tolerance should be plus or minus 45 degrees.

Joints to establish the turn-of-nut procedure if bolt lengths exceed 12 diameters. Therefore, the required rotation must be determined by actual tests, in a suitable tension device, simulating the actual conditions.

7.h Lock -Pin and Collar Fasteners. If approved for use, test and install lock-pin and collar fasteners using approved methods and procedures, and as specified in Section 1050.3(c)7.f. Meet the requirements as specified in Section 1105.02(d)2 for the shank and head of high-strength steel lock-pin and collar fasteners. Provide each fastener with a solid- shank body of sufficient diameter to provide tensile and shear strength equivalent to or greater than that of the bolt indicated and a cold-forged head on one end, of type and dimensions approved; a shank length suitable for the material thickness fastened; locking grooves; breakneck groove; and pull grooves (all annular grooves ) on the opposite end. Provide each fastener with a steel locking collar of proper size for the shank diameter used which, by means of suitable installation tools, is cold-swaged into the locking grooves forming a head for the grooved end of the fastener after the pull groove section has been removed. Provide a steel locking collar with a standard product of an established manufacturer of lock-pin and collar fasteners, as approved.

7.i Inspection. In the presence of the Inspector, inspect the tightened bolts using a 1,000 foot- pound manual dial calibrated torque wrench, according to PTM No. 429 and as follows, unless alternate fasteners or direct tension indicator devices are used, allowing verification by other methods: At the Representative's option, this inspection can be performed either by the Inspector or the Contractor. Inspection tests must be conducted daily. Testing performed by the fabricator or Contractor wi ll be witnessed by the Representative. Individually place three fastener assemblies of the same lot size, grade, size, configuration, and condition as those under inspection in a device calibrated to measure bolt tension. Perform this calibration operation at least once each inspection day. Provide a washer under the part turned in tightening each bolt, if washers are used on the structure. If washers are not used on the structure, furnish the material used in the tension measuring device which abuts the part turned of the same specification as that used on the structure. In the calibrated device, tighten each bolt to the specified tension by any convenient means. Apply the calibrated torque wrench to the tightened bolt to determine the torque required to turn the nut or head five degrees (approximately 1 inch at a 12- inch radius) in the tightening direction. Take the average of the torque required for all three assemblies as the job-inspection torque. For final acceptance of connections installed using high-strength bolts, inspect 10% (two minimum) of the bolts in the connection using a calibrated torque wrench. Select bolts to be inspected according to PTM No. 1. Then apply the job- inspection torque to each with the calibrated torque wrench turned in the tightening direction. If this torque turns no bolt head or nut, the bolts in the connection will be considered to be properly tightened. But if the torque turns one or more bolt heads or nuts, apply the job-inspection torque to all bolts in the connection. Tighten and reinspect any bolt whose head or nut turns at this stage, or retighten all the bolts in the connection and resubmit it for inspection.

full bearing on them. Screw pin nuts up tight and burr the threads at the face of the nut with a pointed tool.

will be considered a legitimate part of the erection. However, errors in the shop fabrication or deformation resulting from handling and transporting will be cause for rejection. The Contractor is responsible for all misfits, errors, and damage. Make the necessary corrections and replacements to correct misfits, errors, and damage.

structural steel on existing structures, use the same primer on faying surfaces as the primer being applied in the field to the existing steel. Do not mate surfaces of different primers.

on faying surfaces as the primer being applied in the field to the existing steel. Do not mate surfaces of different primers.

2.a. Full or Zone Painting. For projects including full painting of the existing superstructure, or zone painting where the fabricated structural steel repairs are within the zones indicated, the coating system for the new steel can be shop applied as specified in Section 1060 or field applied as specified in Section 1070. Prepare and coat faying surfaces as specified in Sections 1070 and 1105.03(j)3.

2.b. Spot Painting. For projects that do not include full or zone painting or if the fabricated structural steel repairs indicated are outside the limits of the zone painting, the coating system for the new steel can be shop applied as specified in Section 1060 or field applied as specified in Section 1071. Prepare and coat faying surfaces as specified in Sections 1071 and 1105.03(j)3.

1050.4MEASUREMENT AND PAYMENT—

• Fabricated Structural Steel. Pound. The cost of welds in excess of those indicated and allowed by the District Bridge Engineer, due to the Contractor's request, is incidental to the other fabricated structural steel work. The cost of all nondestructive testing, including equipment, supplies, and technicians is also incidental to the other fabricated structural steel work.

• Cement Concrete Structures. Section 1001.4

• Preformed Neoprene Compression Joint Seal. Section 1008.4

• Pedestrian Railing. Section 1012.4

• Aluminum Bridge Hand Railing. Section 1023.4

• Steel Bridge Hand Railing. Section 1022.4

• Protective Barrier. Section 1015.4

• Protective Fence. Section 1016.4

• Penetrating Sealers for Reinforced Concrete Surfaces. Section 1019.4

• Armored Preformed Neoprene Compression Dam. Section 1021.4

• Tooth Expansion Dam with Drain Trough. Section 1020.4

• Reinforcement Bars. Section 1002.4

• Neoprene Strip Seal Dam. Section 1026.4

• High Load Multi-Rotational Bearings. Each. For the type indicated.

• Neoprene Bearing Pads. Each. For the type indicated.

• Reset Expansion Bearings, Steel Superstructure. Each

and inspect the repairs is incidental to this item. Modifications of existing steel for the repairs are incidental to the repairs. Field cutting and grinding, field welding, weld testing, field drilling bolt holes, existing rivet/bolt/weld removal, bolt hole reaming, high strength field bolting, bolts, nuts, washers, welds, and weld materials incorporated into the finished work are incidental to the fabricated structural steel repairs.

and inspect the repairs is incidental to this item. Modifications of existing steel for the repairs are incidental to the repairs. Field cutting and grinding, field welding, weld testing, field drilling bolt holes, existing rivet/bolt/weld removal, bolt hole reaming, and high strength field bolting are incidental to the fabricated structural steel repairs. The pay weight is based upon nominal weights for rolled and formed sections, nominal dimensioned plates, and other items, as listed in current AISC handbooks. Payment will be made only for actual new fabricated structural steel permanently installed in the rehabilitated structure excluding the weights listed in the following paragraphs: The weight of the bolts, nuts, washers, welds, and weld materials incorporated into the finished work are incidental to the weight of the installed fabricated Structural steel. The weight of the cuts, copes, bolt holes, or other material not incorporated into the finished work are incidental to the weight of the installed fabricated structural steel.

repairs, an item with a predetermined amount of money is included for unforeseen repairs. The item will have a unit of measure of Dollar, a unit price of $1.00, and a quantity equal to the predetermined amount. This item includes access to the unforeseen repair locations to perform and inspect the repairs . Because of the contingent or unpredictable nature of the work being performed, the provisions of Section

110.02(d) are not applicable to this item

Measured and paid for, under the Unforeseen Repairs item as follows:

items listed in the contract, at the contract unit price.

as follows:

• Negotiated Price. At price agreed upon with the Department before performing the work. If applicable, agreement is also required with FHWA.

• Force Account Basis. Section 110.03(d).

bridge superstructure. Shop or field painting of fabricated structural steel for repairs to existing steel superstructures is incidental to the fabricated structural steel repairs.

painting where the fabricated structural steel repairs are within the zones indicated, preparation and painting of existing steel faying surfaces for fabricated structural steel repairs is incidental to the painting items indicated.

projects that do not include full or zone painting or if the fabricated structural steel repairs indicated are outside the limits of the zone painting.

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