1105FABRICATED STRUCTURAL STEEL AND ALUMINUM

1105.01GENERAL REQUIREMENTS—

required to prequalify according to the American Institute of Steel Construction’s (AISC) Quality Certification Program and obtain approval from the C hief Structural Materials Engineer. Plants and shops must be registered and certified under the AISC program with SBR: Certified Bridge Fabricator-Simple; IBR: Certified Bridge Fabricator-Intermediate; ABR: Certified Bridge Fabricator-Advanced; or CPT: Certified Component Manufacturer - Bridge, as applicable, and must submit a valid certificate to the Chief Structural Materials Engineer, at 81 Lab Lane, Harrisburg, PA, 17110. Annual submission of an endorsed copy of the certificate is required for continued prequalification. Fabricators applying for initial Bulletin 15 approval or approved fabricators wishing to upgrade certification must obtain approval to fabricate structures which have Publication 408 Section specific Bulletin 15 fabricator listings or to fabricate High Performance Steel (HPS) members and are required to furnish acceptable references for which the fabricator has successfully completed fabrication of similar members. If unable to furnish acceptable references, the fabricator must satisfactorily produce a sample member to obtain Department approval and listing in Bulletin 15. Only fabricators having ABR certification, including the Fracture Critical endorsement, may fabricate the following:

• Main members for arches, continuous span trusses, cable-stayed bridges, and suspension bridges.

Only fabricators having either IBR or ABR certification, including the Fracture Critical endorsement, may fabricate the following:

• Fracture critical members and attachments, except as specified in Section 1105.01(a).

Only fabricators having either IBR or ABR certification may fabricate the following:

• Main bridge members, except for certain rolled beams.

• Welded floor beams

• Cross frames and diaphragms for curved bridges

• Bracing, portals, and stiffening members for arches, trusses, cable-stayed and suspension bridges.

• Rolled beams with butt welds, or that are heat-curved, heat-cambered, or cold cambered.

Fabricators having either SBR, IBR, or ABR certification may fabricate the following:

• Rolled beams with bearing stiffeners and diaphragm connection or cover plates2

• Cross frames and diaphragms for straight bridges

• Shop-fabricated material for reinforcing existing bridges1

• Lateral bracing except for arches, trusses, cable-stayed, and suspension bridges1

Notes: 1. Fabricate in an IBR or ABR certified plant if welding is required.

Engineer to perform heat cambering or cold cambering on rolled beams.

Fabricators having SBR, IBR, ABR, or CPT certification may fabricate the following:

• Expansion dams

• Bridge drainage material

• Welded bearings

• Inspection walks

• Steel grid flooring

• Overhead sign structures

• Welded sound barrier supports

• Bridge railing

• Pedestrian railing

• Welded protective barrier

• Traffic, lighting, or camera poles

AISC certification is not required for the following:

• Castings, forgings, and machined parts not welded

• Non-metallic bearing

• Protective fence

• Material not requiring shop fabrication or shop welding, such as plates and sh apes for strengthening existing bridges and manufactured items accepted by certification.

Prequalification of ‘machine shops’ (who provide services and materials to approved fabricators) for listing in Bulletin 15 is required. Approved fabricators are not required to prequalify as machine shops. Approved machine shops may perform one or more of the following operations3:

• Cutting or shearing materials to finish size.

• Grinding

• Drilling or punching

• Cold bending

• Machining

• Flattening

Note: 3. Individual shop operations may be limited. Refer to Bulletin 15 for limitations. Machine shops cannot produce fracture critical members without project specific approval from the Chief Structural Materials Engineer except if the material is being produced for and shipped to a fabricator having AISC IBR or ABR certification, including Fracture Critical endorsement.

Shop drawings stamped “Accepted as Noted” allow fabrication only. The fabricator will make the noted changes to the drawings and resubmit for final acceptance before shipping. “ACCEPTED” Drawing are required for shipment to project. Bridge members and other structures are generally designed in lengths, depths, and widths that can be transported from the fabrication source to the project. Field splices, if required, must be indicated and detailed on the shop drawings. If required by th e District Executive, submit design computations prepared by a Professional Engineer registered in the State according to the Design Manual, Part 4, Structures. The District Executive will not review requests for elimination of field splices unless a notice is included from the BOO that a hauling permit can be obtained to ship beams exceeding the dimensions shown on the structure drawings.

The fabricator is responsible for notifying their assigned consultant inspection firm a minimum of 48 hours (excluding weekends and holidays ) before the beginning of work so that arrangements can be made for inspection. The Representative may waive shop inspection and make a complete inspection at a later stage in the construction sequence. Furnish certified mill reports, in duplicate, covering the structural steel used.

work. Furnish an Inspector’s Field Office, Type C, as specified in Section 714.5(a), except provide a four - drawer, -fire-resistant (-D-label) metal file cabinet in place of a -two-drawer, -fire-resistant (-D-label-) metal file cabinet and a wired broadband Internet service, for exclusive use by Department personnel. Choose a service that provides the fastest available highspeed broadband internet access, with a minimum connection of 5 Mbps per inspector, to the account by means of a Cable or Digital Subscriber Line (DSL). Provide a wireless broadband router, with a minimum -security setting of WPA2, to connect to the provided wired broadband. Based on the specific type of high- speed connection provided, furnish a compatible modem with built-in hardware firewall protection. If such high- speed wired broadband connection is not attainable at the Inspector Office desk area, alternate internet connectivity options must be submitted to the Chief Structural Materials Engineer for review and acceptance. Demonstrate connectivity with the Internet Service Provider once the service is initiated. To ensure reliability and continued access , audits of this connection may be done at any time by qualified PennDOT/OA IT Personnel. Allow inspectors employed by the Department unrestricted access to work in process and stored material during plant working hours.

conforming to the requirements of these Specifications. In case of dispute, the Contractor may appeal to the Representative, whose decision will be final.

may be rejected later if they do not conform to the specifications. Repair or replace rejected material or members.

to prepare the specimens and to make the tests.

directed. Show the weights of the individual members on the statement. Ensure that the fabricator submits a copy of the shipping invoice to the Department's Shop Inspector to be stamped for verification of inspection and acceptance of steel items before shipment. Forward the stamped copy of the shipping invoice with the shipment for the project file. The Shop Inspector will review and accept mill certifications and return them to the fabricator.

Store materials on platforms, skids, or other supports. Place and support materials to avoid overstress, deformation, or damage. Exercise special care for curved members. Keep materials free from dirt, grease, and other foreign materials. Ensure proper drainage and protect materials from corrosion.

initiate fabrication without an approved QC plan.

Engineer for review and approval. Develop the plan according to the criteria established in AASHTO-NSBA Steel Bridge Collaboration document S4. 1- 2002 “Steel Bridge Fabrication QC/QA Guide Specification” (refer to Publication 135 for an outline of the QC plan criteria). Facilities performing welding that require non-destructive testing must submit their written practice according to the current version of ASNT - SNT- TC-1A. Pre-qualified shops must submit an updated QC Plan to the Chief Structural Materials Engineer if there are any changes in materials, processes, or personnel.

experience to be responsible for QC during the fabrication process, storage, and shipment. Do not proceed with fabrication until qualified QC personnel are present and approved by the Department. Provide an AWS Certified Welding Inspector (CWI) on site as the Fabricator's d esignated QC Representative to oversee all processes of fabrication that involve welding, application of heat, or straightening of material.

1105.02MATERIAL—

(Structural Steel Shapes).

2.a Cold -Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes. ASTM A500, Grade A, B, or C. or ASTM A1085 Grade A.

2.b Hot-Formed Welded and Seamless Carbon Steel Structural Tubing. ASTM A501

3.a High-Strength Low -Alloy, Quenched and Tempered High Performance Steel (HPS) Structural Steel Plate. AASHTO M 270 (ASTM A709), Grade HPS 70W and Grade HPS 100W including requirements for Non-Fracture Critical Material Toughness Testing or Fracture Critical Material Toughness Testing, for Zone 3, as applicable. Identify Fracture Critical Material (FCM) on the shop drawings. Grade substitution for any HPS material indicated on the plans is not allowed. Provide mill test reports that indicate either Quenched and Tempered (Q&T) or Thermo-Mechanical Control Process (TMCP) and indicate on the accepted shop drawings. Mill orders must stipulate that no welded repairs are to be performed by the producing mill. Limit plate length to 50 feet maximum mill delivery length for Q&T plate.

3.b High-Strength Low -Alloy TMCP Structural Steel Plate. AASHTO M 270 ( ASTM A709), Grade HPS 70W, up to 2 inches thick and meeting the requirements as specified in Section 1105.02(a)3.a.

3.c High-Strength Low-Alloy Structural Steel. AASHTO M 270 (ASTM A709), Grades 50, 50W, or HPS 50W, ASTM A572, Grade 50, of a quality suitable for welding.

3.d High -Strength Low -Alloy Columbium -Vanadium Steel of Structural Quality. AASHTO M 270 (ASTM A709), Grade 50, ASTM A572, Grade 50.

3.e High-Strength Low-Alloy Structural Steel with 50,000 pounds per square inch Minimum Yield Point to 4 inches Thick. AASHTO M 270 ( ASTM A709), Grade 50W, ASTM A588 (Grades A, B, and C only4).

Note: 4. Plate thicknesses greater than 4 inches are required to conform to the physical properties listed in the specification for plate thicknesses 4 inches and under.

3.f High-Yield Strength, Quenched and Tempered Alloy Steel Plate.

3.f.1 High-Yield Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding. AASHTO M 270 (ASTM A709), Grade HPS 100W.

3.f.2 High-Strength Alloy Steel Plates, Quenched and Tempered, for Pressure Vessels. ASTM A517. Conforming to the supplementary notch toughness requirements of ASTM A20.

3.f.3 Quenched and Tempered Alloy Steel Structural Shapes and Seamless Mechanical Tubing. Products conforming to all of the mechanical and chemical requirements of ASTM A709, Grade HPS 100W steel, except with a maximum tensile strength of 140,000 pounds per square inch for structural shapes and 145,000 pounds per square inch for seamless mechanical tubing, are to be considered as ASTM A709.

3.g. Stainless Steel. As indicated on the plans. Use only prequalified base metals listed in AWS D1.6M/D1.6 – 2007.

– 2014

steel conforming to the supplementary notch toughness requirements for the longitudinal Charpy V-notch tests specified for Zone 2 of the applicable AASHTO Materials Specifications. Unless otherwise indicated, the supplemental requirements are mandatory for the following Primary Member Components subject to tensile stress:

• Girders, beams, stringers, floor beams, bent caps, bulkheads, and straddle beams.

• Truss chords, diagonals, verticals, and portal and sway bracing members

• Arch ribs and built-up or welded tie girders

• Rigid frames

• Gusset plates and splice plates in trusses, arch ribs, tie girders, and rigid frames.

• Splice plates and cover plates in girders, beams, stringers, floor beams, bent caps, and

• straddle beams

• Bracing members supporting arch ribs

• Permanent bottom-flange lateral bracing members and mechanically fastened or welded bottom- flange lateral connection plates in straight and horizontally-curved bridges

• Diaphragm and cross -frame members and mechanically fastened or welded crossframe gusset plates in horizontally-curved bridges or straight girder bridges if the skew is less than 70 degrees.

• Mechanically fastened or welded longitudinal web and flange stiffeners.

• Mechanically fastened or welded batten plates and stay plates, lacing, and continuous nonperforated or perforated plates in built-up members.

• Eyebars and hanger plates

• Miscellaneous structural components or attachments not mentioned above joining two primary members.

The requirements are not mandatory for Secondary Member Components:

• Top flange lateral bracing members or struts and top flange lateral connection plates in horizontally- curved bridges or straight girder bridges if the skew is 70 degrees or greater .

• Diaphragm and cross -frame members and mechanically fastened or welded cross -frame gusset plates in straight bridges if the skew is 70 degrees or greater.

• Bearings, filler plates, sole plates, and masonry plates.

• Mechanically fastened or welded transverse intermediate web stiffeners, transverse flange stiffeners, bearing stiffeners, and transverse connection plates.

• Miscellaneous nonstructural components or attachments (e.g., expansion dams, drainage material, brackets, other miscellaneous attachments).

If directed, provide samples for Charpy V-Notch testing from steel used in fabricating plates and shapes. Submit the samples to the Chief Structural Materials Engineer, BoB, Structural Materials Division, 81 Lab Lane, Harrisburg, PA 17110. Obtain the samples from plates delivered to the fabricator.

indicated or specified:

• ASTM A307, Grades A or B

1.a Nuts. Use ASTM A563 nuts of the Grade and Style conforming to the Grade and Diameter of ASTM A307 bolts, of all surface finishes, as follows, unless otherwise specified:

Bolts (inch) Nuts Grade A, 1/4 to 1 1/2 Grade A, Hex Grade A, over 1 1/2 to 4 Grade A, Heavy Hex Grade B, 1/4 to 4 Grade A, Heavy Hex

Nuts of other grades and styles having specified proof load stresses (ASTM A563, Table 3) greater than the grade and style of nuts shown above are also suitable. Overtap and lubricate galvanized nuts in conformance with ASTM A563.

1.b Washers. ASTM F436, Type 1 or ANSI B18.22M

either straight or bent) and cap screws, hot dip or mechanically galvanize as specified in Section 1105.02(s).

2.a Nuts. ASTM A563, of suitable style according to the contract documents. Hot dip or mechanically galvanize to match anchor bolt coating process as specified in Section 1105.02(s). Galvanized nuts must be Grade DH . Overtap and lubricate galvanized nuts according to ASTM A563. Overtap only to the minimum extent necessary to allow assembly on the bolt threads.

2.b Washers. ASTM F436, Type 1, hot dip or mechanically galvanize as specified in Section 1105.02(s).

or bent) and cap screws (fully threaded shank) , hot dip or mechanically galvanize as specified in Section

3.a Nuts. ASTM A563, of suitable style according to ASTM F1554, Section 6.7, unless otherwise specified in the contract documents. Hot dip or mechanically galvanize to match anchor bolt coating process as specified in Section 1105.02(s). Galvanized nuts must be Grade DH. Overtap and lubricate galvanized nuts according to ASTM A563. Overtap only to the minimum extent necessary to allow assembly on the bolt threads.

3.b Washers. ASTM F436, Type 1, hot dip or mechanically galvanize as specified in Section 1105.02(s).

nuts, hardened washers and, if specified, direct tension indicator devices (DTIs) for structural joints, from manufacturers listed in Bulletin 15, and unless otherwise indicated or specified, conforming to the following requirements: For painted, galvanized or metalized steel structures, including coated portions of weathering steel structures, use Type 1 bolts, nuts, and washers mechanically galvanized (except ASTM F3125 Grade A490 assemblies) according to ASTM B695 as specified in Section 1105.02(s). ASTM F3125 Grade A490 bolts, if approved for use, must not be galvanized under any circumstances. Galvanized bolts, nuts, and washers of an assembly must each be galvanized by the same process. For uncoated, bare AASHTO M 270 (ASTM A709), Grades 50W, HPS 50W, HPS 70W, or HPS 100W weathering steel structures, use plain (uncoated) Type 3 bolts, nuts, and washers conforming to atmospheric corrosion resistance requirements of AASHTO M 270 (ASTM A709), Grade 50W. Perform testing of bolts, nuts, and washers, including initial rotational capacity testing of assemblies , as specified in Section 1105.02(d)7 below.

in conformance with the “Product Marking” section of the applicable AASHTO or ASTM standards.

Bolts and for Heavy Hex Nuts given in ANSI/ASME Standards B18.2.6 and B18.2.2, respectively. Conform to the requirements of ASTM F436 for washer dimensions.

bolts are prohibited unless specifically approved for use by the Chief Bridge Engineer.) Provide a lot number on the supplier's certification corresponding to that appearing on the shipping package and certification Form CS-4171. Note on the supplier's certification when and where all testing was done, including the rotational capacity tests specified. If galvanized Grade A325 bolts are used, include the zinc thickness on the supplier’s certification. Furnish bolts with diameters of 1/2 inch to 1- 1/2 inch inclusive. ASTM F3125 Grade A325 bolts must have a maximum hardness of 33 HRC. Provide plain (uncoated) bolts “oily” to the touch when installed.

specified. Use only the Grade and finish of nuts corresponding to the bolt Type and finish as listed below:

F3125 Bolts Nuts Grade A325 Type 1, uncoated ASTM A563 Grades C, C3, D, DH, DH3; or A194 Grade 2H; uncoated Grade A325 Type 1, galvanized ASTM A563 Grade DH; or A194 Grade 2H; galvanized Grade A325 Type 3, uncoated ASTM A563 Grades C3, DH3; uncoated Grade A490 Type 1, uncoated ASTM A563 Grades DH, DH3; or A194 Grade 2H; uncoated Grade A490 Type 3, uncoated ASTM A563 Grade DH3; uncoated

Mechanically galvanize all nuts according to ASTM B695 as specified in Section 1105.02(s). Lubricate all galvanized nuts. Use a lubricant containing a dye of any color that contrasts with the color of the galvanizing so that a visual check can be made for the lubricant at the time of field installation. At a minimum, apply lubricant to the threaded portions and to both bearing faces of each nut. Plain nuts must have a minimum hardness of 89 HRB. Maximum hardness cannot exceed the limits in ASTM A563. Furnish galvanized nuts that are tapped oversize only to the minimum extent necessary to allow assembly on the bolt thread in the coated condition. Tap oversize before galvanizing. When ASTM A194 Grade 2H nuts are supplied, the zinc coating, overtapping, lubrication, and rotational capacity testing must be according to these specifications and ASTM A563. Furnish plain (uncoated) nuts “oily” to the touch when installed.

mechanically galvanize according to ASTM B695 as specified in Section 1105.02(s). Use Type 1 washers with Type 1 bolts and Type 3 washers with Type 3 bolts.

ASTM F959, except as amended as follows: Each lot of DTIs delivered to a PennDOT project must be sampled and tested by P ennDOT before use. Select at random, according to PTM No. 1, a minimum of 16 samples from each lot and forward these, along with Form TR-447, to the LTS for testing. Provide DTIs with each having a hardness not greater than 109 HRB (35 HRC) and within ± 2 HRB of the lot’s target HRB (as indicated on the CS-4171 certification provided by the manufacturer). Furnish Type 325 or Type 490 DTIs for use with ASTM F3125 Grade A325 Type 1 or ASTM F3125 Grade A490 Type 1 bolts, respectively. Furnish Type 325-3 or Type 490-3 DTIs with ASTM F3125 Grade A325 Type 3 or ASTM F3125 Grade A490 Type 3 bolts, respectively. Where galvanized DTIs are specified, mechanically galvanize according to ASTM B695 as specified in Section 1105.02(s). Ship each lot in protective containers marked with the type, lot number, quantity, and total lot size. Include a copy of the certification with each shipment. Handle and store DTI devices according to the manufacturer's recommendations.

and as follows:

7.a Bolts. Perform proof load tests according to ASTM F606, Section 3.2.1, Method 1. Perform wedge tests according to ASTM F606, Section 3.5. Perform the tests on full size bolts unless otherwise approved by P ennDOT, and at the minimum frequency according to ASTM F3125 Section 9.5 for Grade A325 or Grade A490, and Section 11.4 for ASTM F1852 and ASTM F2280, as applicable. If ASTM F3125 Grade A325 bolts are to be galvanized, perform testing after galvanizing. Determine the thickness of zinc coating on galvanized bolts by taking measurements on the wrench flats or on the top of the bolt head.

7.b Nuts. Perform proof load tests according to ASTM F606, Section 4.2, at the minimum frequency specified in ASTM A563, Section 9.3, or AASHTO M 292 (ASTM A194), Section 4.4, as applicable. If nuts are to be galvanized, perform testing after galvanizing, overtapping, and lubricating. Determine the thickness of zinc coating on galvanized nuts by taking measurements on the wrench flats.

7.c Washers. If galvanized washers are supplied, perform hardness testing after galvanizing. Remove the galvanized coating before taking hardness measurements. If galvanized washers are supplied, measure the thickness of zinc coating.

7.d Assembl y Testing and Installation . Manufacturers and suppliers of bolt, nut, and washer assemblies are required to perform initial rotational-capacity tests on all plain (uncoated) and galvanized bolt, nut, and washer assemblies before delivery to the fabricator or contractor. Test galvanized assemblies after galvanizing. Washers are required as part of the test, even if not required as part of the installation procedure. Perform rotational capacity testing according to ASTM F3125, except as modified by the AASHTO Bridge Construction Specifications (2017, Edition 4) Section 11.5. 5.4.2, PTM No. 427, and as follows, unless otherwise approved by PennDOT:

• When DTIs are planned for use in the assembly, omit the DTIs from the rotational capacity test.

• Test each bolt production lot, nut lot, and washer lot in combination as an assembly. If washers are not required as part of the installation procedure, do not include in the lot identification.

• Assign a rotational-capacity lot number to each combination of lots tested.

• Test a minimum of two assemblies per rotational-capacity lot.

• Test the bolt, nut, and washer assembly in a Skidmore-Wilhelm Calibrator or an acceptable equivalent device. Test bolts too short to test in a calibrator according to PTM No. 427.

7.d.1 Installation. Install, test, and inspect high strength bolt assemblies as specified in Section 1050.3(c)7, according to PTM No. 427, and PTM No. 429, unless otherwise specified.

test reports as required in the applicable PennDOT, AASHTO, and/or ASTM standards and as specified below. Report the location where tests were performed and date of testing. Ensure that the manufacturer or distributor performing tests certifies that the results recorded are accurate.

8.a Mill Test Report (MTR). Furnish a MTR for all mill steel used in manufacturing bolts, nuts, and washers. Indicate where the material was melted and manufactured.

8.b Manufacturer Certified Test Report (MCTR). Provide a MCTR for each item furnished. Ensure that the manufacturer performing the rotational-capacity test include the following on the MCTR:

• The Lot Number of each of the items tested.

• The Rotational-Capacity Lot Number.

• The results of required tests.

• The location where tests were performed and date of testing.

• Certification that the MCTR's for the items conform to this specification and the applicable AASHTO or ASTM standards.

• The location where the bolt, nut, and washer assembly components were manufactured and coated.

8.c Distributor Certified Test Report (DCTR). Ensure that the distributor performing tests furnish a certified test report including the following:

• The MCTR for the various bolt, nut, and washer assembly components.

• The results of all required tests, including the rotational-capacity test if performed by the distributor instead of the manufacturer.

• The location where tests were performed and date of testing.

• The Rotational-Capacity Lot Number.

• Certification that the MCTR's conform to this specification and the applicable AASHTO or ASTM standards.

bars, Grade 1015, 1018, or 1020, either semi -or fully-killed. If flux retaining caps are used, furnish caps of low carbon grade steel suitable for welding and conforming to ASTM A109.

to the applicable sections of ASTM A370. Perform tensile tests of finished studs on studs welded to test plates using a test fixture similar to that shown in Figure 7.2 of AASHTO/AWS D1.5M/D1.5 - 2015. If fracture occurs outside of the middle half of the gage length, repeat the test. The required tensile properties are:

Tensile Strength 60,000 psi (min.) Yield Strength* 50,000 psi (min.) Elongation 20% in 2 inches (min.) Reduction of area 50% (min.) * As determined by a 0.2% offset method.

cracks, twists, bends, or other injurious defects. Produce finish by cold drawing, cold rolling, or machining.

material requirements of this section. Furnish certified copies of in-plant QC test reports to the Representative upon request.

the contract. The Representative will select the samples.

D, F, or G.

AASHTO M 169 (ASTM A108), UNS Designations G10160-G10300, inclusive, unless otherwise indicated or specified.

AASHTO M 103 ( ASTM A27). Provide steel of Grade 70-36, Class 1 or 2 as indicated, unless otherwise specified.

M 163 (ASTM A743), Grade CA 15, unless otherwise indicated or specified.

pouring faults, sponginess, cracks, blow-holes, and other defects in positions affecting the castings' strength and value for the service intended. Provide boldly filleted angles and sharp and perfect ar rises. The Contractor may correct defects not affecting the strength and value of the casting for the service intended if allowed in writing by the Chief Bridge Engineer. The Representative may reject castings containing:

• A blow-hole having a length greater than 1 inch, a cross-sectional area greater than 1/2 square inch, or a depth greater than 1/2 inch.

• A group of holes in a straight line with a total length greater than or equal to 1 foot, measured on the surface of the casting, and with an aggregate length greater than 1 inch.

4.a Major Castings. Major castings are those subject to high loading whose failure in service would cause major damage (e.g., bridge bearings or machinery parts in movable bridges). All castings over 1,000 pounds are major castings. Test major castings by radiographing with x-ray or gamma ray apparatus according to ASTM E1030 and E186, E280 or E446, as applicable, and according to Table A below.

4.b Minor Castings. Minor castings are those whose failure would not lead to failure of main bridge members (e.g., scuppers or gratings). Test minor castings by suspending them and hammering them all over.

4.c Rejection. The Representative may reject castings that contain cracks, flaws, or other defects that appear during or after testing.

Class 35B, unless otherwise indicated or specified. For castings subject to traffic loads furnish gray iron castings conforming to AASHTO M 105 (ASTM A48), Class 35B and AASHTO M 306, unless otherwise indicated or specified.

unless otherwise indicated or specified.

unless otherwise indicated or specified. In addition to the specified test coupons, test specimens from parts integral with the castings, such as risers, for castings having a weight more than 1,000 pounds. Ensure that the required quality is obtained in the castings in the finished condition.

TABLE A Severity Levels - Radiographically Inspected Castings* Specification ASTM Designation Discontinuity Type Designation Acceptable** Severity Level Remarks E446

up to 2 inches A B Ca Cb Cc Cd D E F G

- - - -

None Allowed None Allowed None Allowed None Allowed E186

2 inches to 4 1/2 inches A B Ca Cb Cc D E F

- - -

None Allowed None Allowed None Allowed

E280

4 1/2 inches to 12 inches A B Ca Cb Cc D E F

- - -

None Allowed None Allowed None Allowed * Radiograph all critical areas, but not less than 25% of each casting, or 25% of all castings, as indicated or as directed. ** If unacceptable defects are found in more than 10% of the radiographs, radiograph 100% of castings until the accumulated rejection level falls to 10% or less. The Contractor may then resume testing 25% of castings.

from pouring faults, sponginess, cracks, blow holes, and other defects in positions affecting the castings’ strength and value for the service intended. Provide boldly filleted angles and sharp and perfect ar rises.

except with a maximum of 2 1/2% lead, unless otherwise indicated or specified. If indicated, make surfaces permanently self-lubricated. Provide a coefficient of friction of less than 0.10 or as indicated.

after assembly.

or Grade 50W, Type 2 or AASHTO M 270 (ASTM A709) Grade 50W, and conforming to either ASTM A53, or to ASTM A714, Class 4, Grade V.

after assembly.

B152 Section 11.2 and ASTM B577. Make lapped joints by soldering or by riveting and soldering.

Make lapped joints by soldering.

If the applicable material specifications do not include galvanizing, galvanize according to ASTM A153; ASTM B633; ASTM A392, Class 2 coating; ASTM B695 and B696; AASHTO M 111(ASTM A123); or AASHTO M 232 (ASTM A153), as applicable. Test for the specified weight of galvanizing according to AASHTO T 65 (ASTM A90). Comply with ASTM A143 and ASTM A385. Before galvanizing, blast beams and girder to SSPC-SP6 (commercial blast). Solvent wipe to SSPC - SP1 before blast cleaning as necessary. Grind cut edges as needed to remove any skim, scale or deleterious material that is present.

ASTM A780.

• Non-welded secondary bridge members

• Railings

• Drainage Scuppers

• Downspouts

• Inlet grates

• Utility brackets

• Angle Supports

• Embedded plates

Quenching after galvanizing is not allowed for the following items without approval of the Engineer:

• Primary bridge members

• Welded secondary members

• Sign Structures

• Traffic and lighting poles

• Any member to be painted after galvanizing.

Items not listed may not be quenched without approval of the Engineer.

• Structural steel for bridges, AASHTO M 270 (ASTM A709), Grade 36, ASTM A36.

• Structural steel for bridges, AASHTO M 270 ( ASTM A709), Grades 50, 50W, and HPS 50W, ASTM A572, Grade 50, ASTM A588, Grades A, B, and C only.

1105.03FABRICATION—

and as follows:

1.a General. Flanges of curved, welded girders may be cut to the radii as indicated or curved by the application of heat as specified in Sections 1105.03(a)2 through 1105.03(a)8. Do not heat straighten or heat curve steels that are manufactured to a specified minimum yield point greater than 50,000 pounds per square inch without approval.

1.b. High Performance Steel. Section 1105.02(a)3.a. Use procedures approved by the Chief Structural Materials Engineer when applying short term application of heat to High Performance Steel for heat curving, heat straightening or camber and sweep adjustments. Limit heat to 1 ,100F maximum unless otherwise approved.

approved.

2.a Continuous Heating. For the continuous method, heat a strip or intermittent strips along the edge of the top and bottom flange approximately simultaneously depending on flange widths and thicknesses. Use a strip of sufficient width and temperature to obtain the required curvature.

2.b V-type Heating. For the V-type heating, heat the top and bottom flanges in truncated triangular or wedge-shaped areas having their base along the flange edge and spaced at regular intervals along each flange. Use the spacing and temperature necessary to obtain the required curvature and to allow heating to progress along the top and bottom at approximately the same rate. Terminate the apex of the tr uncated triangular area applied to the inside flange surface just before the junction of the web and the flange is reached. When heating the inside flange surface (the surfaces that intersect the web), do not apply heat directly to the web. If the radius of curvature is 1,000 feet or more, extend the apex of the truncated triangular heating pattern applied to the outside flange surface to the juncture of the flange and web. If the radius of curvature is less than 1,000 feet, extend the apex of the truncated triangular heating pattern applied to the outside flange surface past the web for a distance equal to one -eighth of the flange or 3 inches, whichever is less. For the truncated triangular pattern, provide an included angle of approximately 15 to 30 degrees, but do not exceed 10 inches for the base of the triangle. Do not make variations in the patterns prescribed above unless allowed. For both types of heating, heat the flange edges that will be on the inside of the horizontal curve after cooling. Heat both the inside and outside flange surfaces only if the flange thickness is 1 1/4 inches or greater. Heat the two surfaces concurrently.

welded I-section plate girders will be allowed if all of the following criteria specified in Section 1105.03(a)3.a through Section 1105.03(a)3.d below are satisfied.

3.a Cross-Sectional Criteria.

• R > 1,000 feet, if (tf > 3.0 in.) or (b > 30.0 in.), otherwise R > 150 feet

• Ψ ≤ 2.0

• Ψf ≥ 0.20

• tnf ≤ tf

in which:

Ψ = 𝑏𝑏𝑛𝑛𝑛𝑛𝑡𝑡𝑛𝑛𝑛𝑛 + 𝑏𝑏 𝑡𝑡𝑛𝑛 + 𝐷𝐷𝑤𝑤𝑡𝑡𝑤𝑤 𝑏𝑏𝑛𝑛𝑛𝑛𝑡𝑡𝑛𝑛𝑛𝑛+𝑏𝑏 𝑡𝑡𝑛𝑛

Ψf = 𝑏𝑏𝑛𝑛𝑛𝑛𝑡𝑡𝑛𝑛𝑛𝑛 𝑏𝑏𝑡𝑡𝑛𝑛 ≤ 1.0

where:

R = horizontal radius of curvature measured to the centerline of the girder web b = width of wider flange (inch) b nf = width of narrower flange (inch) Dw = clear distance between flanges (inch) tf = thickness of wider flange (inch) tnf = thickness of narrower flange (inch) tw = web thickness (inch)

3.b Minimum Radius for Doubly -Symmetric Beams and Girders. The horizontal radius of curvature measured to the centerline of web, in inches, for heat curved doubly-symmetric beams and girders cannot be less than a value calculated from the following:

• If 𝐷𝐷𝑤𝑤 𝑡𝑡𝑤𝑤 >

�𝐹𝐹𝑦𝑦𝑤𝑤 , then

R = 0.0365 𝑏𝑏 𝛹𝛹 � 𝐷𝐷𝑤𝑤 𝑡𝑡𝑤𝑤 �

• Otherwise

R = 12,800𝑏𝑏 𝐹𝐹𝑦𝑦𝑤𝑤𝛹𝛹

where:

F yw = specified minimum yield strength of a web (kilopound per square inch)

3.c Minimum Radius for Singly-Symmetric Beams and Girders. The horizontal radius of curvature measured to the centerline of web, in inches, for heat curved singly -symmetric beams and girders cannot be less than that calculated for doubly -symmetric members in S ection 1105.03(a) 3.b. Additionally, for

singly-symmetric girders with Ψ greater than or equal to 1.46, and with Ψf less than Ψfo , the radius cannot be less than the value calculated from the following:

R = �1.43𝛹𝛹 �1 − 𝛹𝛹𝑛𝑛 𝛹𝛹𝑛𝑛𝑓𝑓 �

+ 1� � 12,800𝑏𝑏 𝐹𝐹𝑦𝑦𝑤𝑤𝛹𝛹 �

in which:

𝛹𝛹𝑓𝑓𝑓𝑓 = 0.68Ψ – 0.79

3.d Minimum Radius for Hybrid Girders. Heat curving of hybrid girders which meet the following criteria will be allowed:

• 𝜂𝜂𝑤𝑤 ≤ 𝜂𝜂𝑓𝑓, and

• 𝜂𝜂𝑤𝑤 = 𝜂𝜂𝑓𝑓 if 𝜂𝜂𝑓𝑓 < 1

• 𝑏𝑏𝑦𝑦𝑓𝑓 > 𝑏𝑏𝑦𝑦𝑓𝑓𝑤𝑤 if 𝜂𝜂𝑓𝑓 < 1

in which:

𝜂𝜂𝑓𝑓 = 𝐹𝐹𝑦𝑦𝑓𝑓𝑤𝑤 𝐹𝐹𝑦𝑦𝑓𝑓

𝜂𝜂𝑤𝑤 = 𝐹𝐹𝑦𝑦𝑤𝑤 𝐹𝐹𝑦𝑦𝑓𝑓

where:

F yfw = yield stress of flange with lower yield stress (kilopound per square inch) Fyf = yield stress of flange with higher yield stress (kilopond per square inch) Fyw = yield stress of web (kilopound per square inch) byfw = width of flange with lower yield stress (inch) byf = width of flange with higher yield stress (inch)

For hybrid sections with 𝜂𝜂𝑓𝑓 = 1 and 𝜂𝜂𝑤𝑤 < 1, the horizontal radius of curvature measured to the centerline of the girder, in inches, can not be less than the minimum radius determined from Section

(a)3.b and Section 1105.03(a)3.c, with Fyf substituted for Fyw in Section 1105.03(a)3.c

For hybrid sections with 𝜂𝜂𝑓𝑓 < 1, the horizontal radius of curvature measured to the centerline of the girder, in inches, cannot be less than the minimum radius determined from Section 1105.03(a)3.b. Additionally, for girders with 𝛹𝛹𝑓𝑓𝑓𝑓 greater than or equal to 0.2�𝜂𝜂𝑓𝑓 and with 𝛹𝛹𝑓𝑓 less than 𝛹𝛹𝑛𝑛𝑓𝑓 �𝜂𝜂𝑛𝑛 , the radius cannot be less than that determined as:

R = �1.43 �1 − 𝛹𝛹𝑛𝑛�𝜂𝜂𝑛𝑛 𝛹𝛹𝑛𝑛𝑓𝑓 �

∗ 𝛹𝛹 + 1� � 12,800𝑏𝑏 𝐹𝐹𝑦𝑦𝑤𝑤𝛹𝛹 �

not exceed 1,150F as measured by temperature indicating crayons or other suitable means. Do not artificially cool the girder until after it naturally cools to 600F. Obtain approval for the method of artificial cooling.

If curved in the vertical position, brace or support the girder in such a manner that the tendency of the girder to deflect laterally during the heat-curving process will not cause the girder to overturn. If curved in the horizontal position, support the girder near its ends and at intermediate points, as necessary, to obtain a uniform curvature. Do not allow the bending stress in the flanges due to the dead weight of the girder to exceed the usual allowable design stress. Maintain intermediate safety catch blocks at the mid-length of the girder within 2 inches of the flanges at all times during the heating process to guard against a sudden sag due to plastic flange buckling.

the heat curving operation either before or after all the required welding of transverse intermediate stiffeners is completed. However, unless provisions are made for girder shrinkage, locate and attach connection plates and bearing stiffeners after heat curving. If longitudinal stiffeners are required, heat-curve or oxygen- cut them separately and then weld them to the curved girder. When cover plates are to be attached to rolled beams, attach them before heat curving if the total thickness of one flange and cover plate is less than 2 1/2 inches and the radius of curvature is greater than 1,000 feet. For other rolled beams with cover plates, heat-curve the beams before the cover plates are attached; either heat -curve or oxygen- cut cover plates separately, then weld them to the curved beam.

heat-cambering or cold cambering methods. For plate girders, cut the web to the prescribed camber with suitable allowance for shrinkage due to cutting, welding, and heat -curving. However, if permitted, correct moderate deviations from specified camber by a carefully supervised application of heat. Correct deviations from the specified camber according to Publication 135.

all welding and heating operations are completed and the flanges have cooled to a uniform temperature. Check horizontal curvature with the girder in the vertical position.

and round edges by grinding or other acceptable means. When AASHTO M 270 (ASTM A709), Grade 50W, Grade HPS 70W, Grade HPS 100W, or ASTM A588, Grades A, B, and C weathering steels are specified for beams or girders, blast clean only the fascia side of exterior beams or girders according to SSPC-SP6, Commercial Blast Cleaning. At a minimum, blast clean from the top outside (fascia) edge of the top flange to the inside edge of the bottom flange including the bottom of the bottom flange. Blast clean the faying surfaces of splices and connections of all structural elements according to SSPC-SP-10-85. Re-blast unpainted elements that remain unassembled for a period of 12 months following the initial cleaning.

a standard hole diameter for bolts smaller than 1.0 inch in diameter as the nominal diameter of the bolt plus 1/16 in. For bolts 1.0 inch in diameter and larger, provide the hole diameter as the nominal diameter of the bolt plus 1/8 in. Unless subpunching and reaming is specified , holes may be punched full-size, 1/16 inch larger than the nominal diameter of the bolt, in material forming parts of a member composed of not more than five thicknesses of metal 1/16 inch larger than the nominal diameter of the bolts whenever the thickness of the material is not greater than 3/4 inch for structural steel, 5/8 inch for high- strength steel or 1/2 inch for quenched and tempered alloy steel. If there are more than five thicknesses or if any of the main material is thicker than 3/4 inch for structural steel, 5/8 inch for high- strength steel, or 1/2 inch for quenched and tempered alloy steel, either subdrill and ream or drill all holes full size. When subpunching and reaming is specified, either subpunch (or subdrill if thickness limitation governs) all holes 3/16 inch smaller than the nominal diameter of the bolts and, after assembling, ream to 1/16 inch larger than the nominal diameter of the bolts. Holes in fillers, cross frames, lateral bracing components and corresponding holes in connection plates between girders and cross frames or lateral components not designated as primary members may be punched full size. Do not punch full size holes in longitudinal main load carrying members, transverse floor

beams and any components designated as fracture critical (FCM); this restriction does not apply to fillers used in connections of FCMs. Where punching full size is allowed, holes may also be formed by plasma cutting or water-jetting as approved by the Chief Structural Materials Engineer. If reaming is not specified, drill all holes full size. When indicated, provide enlarged or slotted holes with high- strength bolts. Obtain advance approval from the Chief Structural Materials Engineer to produce round or slotted holes using plasma, laser, water jet, or oxygen- acetylene methods. Provide samples when requested, to verify dimensional accuracy and edge quality in advance of fabrication for the size of places to be used in production.

punch by more than 1/16 inch. Ream any holes that must be enlarged to admit the bolts. Cut holes clean without torn or ragged edges. The slightly conical hole that naturally results from punching operations is acceptable.

and conforming to the size requirements specified in Section 1105.03(c)1. Where practical, direct reamers by mechanical means. Remove burrs on the outside surfaces. Use twist drills, twist reamers, or rotobroach cutters for reaming and drilling. Assemble and securely hold connecting parts while they are being reamed or drilled. Match mark the connecting parts before disassembling.

equivalent of the nominal diameter. The slightly conical hole that results from punching operations is acceptable. Ensure that the width of slotted holes produced by flame cutting or a combination of drilling and flame cutting or punc hing and flame cutting are not more than 1/32 inch greater than the nominal width. Grind the flame cut surface smooth to obtain a maximum surface roughness of ANSI 1 mil.

holes or drilling full-sized holes while assembled, the Contractor may use computer numerically controlled

connections, and templates. The Contractor may use CNC equipment to either drill or punch holes through individual pieces or drill through any combination of pieces held tightly together. Provide full-size punched holes that meet the requirements of Section 1105.03(c)2. If CNC drilling or punching equipment is used, demonstrate the accuracy of the drilling or punching procedure by means of check assemblies as specified in Section 1105.03(g).

3/16 inch smaller than the nominal diameter of the bolt for turned bolts or other approved bearing-type bolts. After assembling, either ream, drill to a steel template, or drill from the solid. Provide a driving fit for the finished holes as indicated or according to the special provisions.

and field splices as follows:

• Field connections and field splices of main members of trusses, arches, continuous beam spans, bents, towers (each face), plate girders, and rigid frames. subpunch or subdrill and subsequently ream while assembled or drill full size through a steel template while assembled.

• Holes in cross frames, lateral bracing components and the corresponding hole in connection plates between girders and cross frames or lateral components not designated as primary member material may be punched full size. Do not punch holes in longitudinal main load carrying members, transverse floor beams and any components designated as fracture critical members (FCMs) .

• Field splices of rolled beam stringers continuous over floor beams or cross frames. the fabricator may drill full size unassembled to a steel template.

• Floor beams or cross frames. the fabricator may drill full size unassembled to a steel template.

• Floor beam and stringer field end connections . subpunch and ream while assembled or drill full size to a steel template while assembled.

For any connection, instead of subpunching and reaming, or subdrilling and reaming, the fabricator may drill holes full size with all thicknesses of material assembled in proper position.

When using a steel template, ream and drill full size all field connection holes through the template after the template has been placed in the proper position and angle and firmly bolted into place. Use templates that are exact duplicates for reaming matc hing members or the opposite faces of a single member. Accurately locate templates used for connections on like parts or members so that the parts or members are duplicates and require no match-marking.

and before any reaming is done, a cylindrical pin 1/8 inch smaller in diameter than the nominal size of the hole may be entered perpendicularly to the face of the member without drifting in at least 75% of the contiguous holes in the same plane. The Representative will reject pieces that do not conform to this requirement. Also, the Representative may reject any piece that contains at least one hole that will not pass a pin 3/16 inch smaller in diameter than the nominal size of the hole.

thicknesses of metal is no greater than 1/32 inch for at least 85% of the holes in any contiguous group. For all steel templates, provide hardened steel bushings in holes accurately dimensioned from the centerlines of the connection as inscribed on the template. Use the centerlines to accurately locate the template from the milled or scribed ends of the members.

together the parts of a member before drilling, reaming, or bolting. If necessary, dismantle assembled pieces to remove burrs and shavings produced by the operation. Furnish members free from twists, bends, and other deformation. When assembling, allow enough drifting to bring the parts into position, however, do not allow the drifting to enlarge the holes or distort the metal.

continuous beams, plate girders, bents, towers, and rigid frames before erection to verify the geometry of the completed structure or unit and to verify or prepare field splices. Submit an appropriate method of preassembly for approval. Provide a method and details of assembly consistent with the erection procedure indicated on the approved erection plans and camber diagrams. At a minimum, provide a preassembly procedure consisting of assembling three contiguous panels accurately adjusted for line and camber. Provide a procedure for progressive assemblies consisting of at least one section or panel of the previous assembly (repositioned if necessary and adequately pinned to ensure accurate alignment) plus two or more sections or panels added at the advancing end. For structures longer than 150 feet, furnish a procedure for assemblies not less than 150 feet long regardless of the length of individual continuous panels or sections. The Contractor may start the sequence of assembly from any location in the structure and proceed in one or both directions provided that the preceding requirements are satisfied. Use the Progressive Truss and Girder Assembly unless otherwise specified in the proposal.

Where applicable, assemble major components of compression members with finished-to-bear ends in full bearing, and then ream the sub-sized holes to the specified size.

furnish a check assembly for each major structural type of each project unless otherwise indicated or

specified in the special provisions. Provide check assemblies consisting of at least three contiguous shop sections or, for a truss, all members in at least three contiguous panels but not less than the number of panels associated with three contiguous chord lengths (i.e., length between field splices). Base check assemblies on the proposed order of erection, joints in bearings, special complex points, and similar considerations. Special complex points include the portals of skewed trusses. Use the first sections of each major structural type to be fabricated as the check assemblies. Obtain approval for each CNC drilled check assembly before reaming or dismantling the assembly. If a check assembly fails to demonstrate that the required accuracy is being obtained for camber, alignment, accuracy of holes, and fit of milled joints, the Representative may require add itional check assemblies. Additional check assemblies will be at no additional cost to the Department.

and verify the fit of members, including the proper space between abutting flanges.

field. Furnish a diagram showing match-marks to the Representative.

ASTM A307, Grade A Bolts. Provide bolts with single self -locking nuts or double nuts unless otherwise indicated or specified in the special provisions. Use beveled washers where bearing faces have a slope of more than 20:1 with respect to a plane normal to the bolt axis. For bolted connections fabricated with high-strength bolts, assemble connections as specified in Section

the body of the bolts. Furnish hexagonal heads and nuts with standard dimensions for bolts of the nominal size specified or the next larger nominal size. Provide thread diameters equal to the body of the bolt or the nominal diameter of the bolt specified. Carefully ream holes for turned bolts with bolts furnished to provide for a light driving fit. Furnish bolts with threads that are entirely outside of the holes. Provide a washer under the nut.

as specified in Section 1105.03(c ). When Turn- of-Nut Tightening Method is used, provide hardened washers as specified in Section 1105.02(d)5, under the element turned in tightening.

such as gaskets or insulation within the grip. Ensure that bolted steel parts solidly fit together after the bolts are tightened. Bolted steel parts may be coated or uncoated. Do not exceed a slope of 20:1 for the surfaces of parts in contact with the bolt head or nut with respect to a plane normal to the bolt axis.

adjacent to the bolt head and nut, are free of scale (except tight mill scale), dirt, or other foreign material. Remove burrs that would prevent solid seating of the connected parts. Paint is allowed on the faying surface in connections except for slip- critical connections as defined in Article 6.13.2.1.1 of the LRFD Specification. Prepare faying surfaces for slip-critical connections according to the following requirements, as applicable:

3.a Non-coated Joints. Exclude paint, including any inadvertent over spray, from the area within the bolt pattern and areas closer than one bolt diameter, but not less than 1 inch, from the edge of any hole.

3.b Joints with Painted Faying Surfaces. Blast clean joints specified to have painted faying surfaces. Except as specified in Section 1105.03(j)3.c, coat the joints with a Class A or B paint according to Section 6.13.2.8 of the LRFD Specification.

3.c Coatings with Low Slip Coefficient. If allowed and provided that the mean slip coefficient is established (tested according to Section 6.13.2.8 of the LRFD Specification) and the allowable slip load per unit area is achieved, the Contractor may use a coating providing a slip coefficient less than 0.33.

3.d Minimum Coating Curing Time. Do not assemble coated joints before the coating has cured for the minimum time used in the qualifying test.

3.e Galvanized Faying Surfaces. Hot-dip galvanize faying surfaces specified to be galvanized according to AASHTO M 111 (ASTM A123).

3.f Existing Field Surfaces. For connections to existing structures, provide surface conditions as indicated.

more than 5/8 inch thick that carry calculated stress.

cut edges according to the AASHTO/AWS D1.5M/D 1.5-2015.

are valid indefinitely unless application of the WPS results in consistently substandard welds. Submit WPS for review and acceptance not more than 60 months in advance of the production welding. WPS qualification welding must be witnessed by a Department representative unless otherwise approved by the Chief Structural Materials Engineer. For welding aluminum structures, conduct welding, welder qualification, prequalification of weld details and inspection of welds according to AWS D1.2M/D1.2-2014. For the purpose of establishing weld acceptance criteria, define all welded aluminum structures as ‘Class II’ structures. For welding sheet steel, conduct welding, welder qualification, prequalification of weld details and inspection of welds according to AWS D1.3M/D1.3-2008. For welding stainless steel or stainless steel to carbon steel, conduct welding, welder qualification, prequalification of weld details and inspection of welds according to AWS D1.6M/D1.6-2007. Unless otherwise indicated or specified, for tubular steel structures, conduct welding, welder qualifications, prequalification of weld details, and inspection of welds according to AASHTO/AWS D1.1M /D1.1-2015 subject to the following limitations:

• Use on low-hydrogen electrodes

• Provide a minimum preheat and interpass temperature of at least 50F.

Conduct welding, welder qualifications, prequalification of weld details, and inspection of welds according to the AASHTO/AWS D1.5M/D1.5-2015. Do not weld or tack brackets, clips, shipping devices or other material not indicated or specified in the special provisions to any member unless shown on the shop drawings and approved.

the following modifications:

• Section 1.1.3. Revise completely as follows:

• All references to acceptance or approval will denote acceptance or approval by the Engineer. The term Engineer refers to the Chief Bridge Engineer or the Chief Bridge Engineer's representative; namely, the Chief Structural Materials Engineer.

• Section 1.3.1. Delete reference to EGW. ESW may be used if approved by the Engineer.

• Section 1.3.3. Delete this section.

• Section 1.3.4 Add: Electrosag Welding (ESW) may be used if preapproved by the Engineer.

• Section 1.3.7. Welding of Ancillary Products. Delete this section.

• Section 2.3.3. Plug and Slot Welds. Delete this section.

• Section 2.9. Details of Plug and Slot Welds. Delete this section.

• Section 2.17.6.1. Revise second sentence as follows:

• Design connections or splices made with fillet welds for the average of the calculated stress and the strength of the member, but no less than 75% of the strength of the member.

• Section 3.5.1.6(2). Revise completely as follows:

• Use web flatness tolerances for all girders according to the following equation and the Web Flatness Tolerance Table below.

          − + 150

1 75 . 0t D t

Where, D = web depth, in. t = web thickness, in.

Verify w eb flatness in all girder panels in the presence of the Department inspector. Flatness variations and locations exceeding the allowable tolerance must be documented. Submit a repair procedure to the Chief Structural Materials Engineer for review and approval before repair.

Web Flatness Tolerance Table Web Thickness, in. Web Depth, in. 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 5/16 1/4 5/16 5/16 5/16 3/8 3/8 7/16 7/16 7/16 1/2 1/2 9/16 9/16 9/16 5/8 5/8 3/8 5/16 5/16 5/16 3/8 3/8 7/16 7/16 7/16 1/2 1/2 9/16 9/16 9/16 5/8 5/8 11/16 7/16 5/16 3/8 3/8 3/8 7/16 7/16 1/2 1/2 1/2 9/16 9/16 5/8 5/8 5/8 11/16 11/16 1/2 3/8 3/8 3/8 7/16 7/16 1/2 1/2 1/2 9/16 9/16 5/8 5/8 5/8 11/16 11/16 3/4 9/16 3/8 7/16 7/16 7/16 1/2 1/2 9/16 9/16 9/16 5/8 5/8 11/16 11/16 11/16 3/4 3/4 5/8 7/16 7/16 7/16 1/2 1/2 9/16 9/16 9/16 5/8 5/8 11/16 11/16 11/16 3/4 3/4 13/16 3/4 1/2 1/2 1/2 9/16 9/16 5/8 5/8 5/8 11/16 11/16 3/4 3/4 3/4 13/16 13/16 7/8 7/8 9/16 9/16 9/16 5/8 5/8 11/16 11/16 11/16 3/4 3/4 13/16 13/16 13/16 7/8 7/8 15/16 Note: For actual dimensions not shown, use the next higher value. For values beyond the table dimensions shown, calculate web flatness according to the equation above and round to the next higher 1/16-inch increment.

• Section 3.5.1.9. Revise the first paragraph in this section completely as follows: Fit bearing stiffeners as specified in Section 1105.03(u) . Flatness tolerance of sole plates after welding as specified in Section 1111.03(c), Class B.

• Section 4.1.6. Delete this section.

• Table 4.2. Matching Filler Metal Requirements for WPSs Qualified according to 5.13. Delete all references to electroslag welding.

• Clause 4. Part E, Electrogas Welding (EGW). Delete this part.

• Clause 4. Part G, Plug and Slot Welds. Delete this part.

• Section 5.3. Duration. Add the following. Submit WPS for review and acceptance not more than 60 months in advance of the production welding.

• Section 5.14. Electrogas Welding. Delete this section.

• Table 5.4. Additional PQR Essential Variable Changes Requiring WPS Requalification for Electroslag or Electrogas Welding. Delete this table.

• Section 5.7.7.1. Delete this section in its entirety. FCAW-s is not allowed.

• Section 5.16.4. Delete EGW in Item (2).

• Section 5.19.5.2. Delete reference to EGW Specimens.

• Clause 6, Part B. Radiographic Testing (RT) of Groove Welds in Butt Joints. Digital Radiography is allowed with the approval of the Chief Structural Materials Engineer. If approved, code variations from Clause 6 will be incorporated into a formal procedure and included in the QC Plan.

• Section 6.7.1. Revise completely as follows: Non-destructively test complete penetration groove welds as specified in Section 1105.03(m)8.

• Section 6.7.1.1. Delete EGW.

• Section 6.7.1.2(2). Revise completely as follows: Twenty-five percent of each joint subject to compression or shear.

• Section 6.7.1.2(2)(d). Delete this section.

• Section 6.7.2.1. Revise the first sentence as follows: At least 12 inches will be tested in every 10-foot length and 12 inches of such welds less than 10 feet length of each size of weld and type joint in primary members including the end connections of such members.

• Section 6.7.8. Can be used if approved.

• Section 6.13.2. add “Steel produced with the Thermo- Mechanical Control Process (TMCP) are considered a variation and require submittal of independent procedures with performance mock-ups”.

• Annex K: use of PAUT must be approved by the Chief Structural Materials Engineer.

• Section 12.6. Consumable Requirements. Delete all references to optional supplemental diffusible hydrogen designator H16.

• Section 12.7.4. Period of effectiveness: 36 Months for all FCM WPS’s, 60 Months for PQR’s and fillet weld soundness test.

1.a Grades HPS 70W and HPS 100W. Conform to Section 1105.03(m)1 and the following additional requirements. For final welds, only use the submerged arc and shielded metal arc welding processes. Remove all mill scale by grinding or blasting from the weld area of the Grade HPS 70W and Grade HPS 100W steel before welding. Processes other than shielded metal arc welding ( SMAW) may be approved, including GMAW , when the manufacturer’s consumable certification shows that the deposited weld metal has a diffusible hydrogen level equivalent of H4 or less.

1.b Filler Metal Requirements.

1.b.1 Use filler metals that conform to AASHTO/AWS D1.5M/D1.5-2015, Table 4.1, Hydrogen control level H8 or less for AASHTO M 270/ASTM A709, Grade 50W, Grade HPS 50W or Grade HPS 70W, as applicable, for the base metal for all fillet welds, unless otherwise required by design or noted on the plans. Use "undermatched" welds for flange-to-web welds of Grades HPS 70W or HPS 100W when welded to Grade 50W or Grades HPS 50W and HPS 70W respectively. Use only electrodes with the designator "HZ” or “R", where “HZ” indicates the diffusible hydrogen level of either H4 or H8 depending on the preheat and where “R” indicates a moisture-resistant coating. The higher preheat and interpass temperatures listed in Table 1 also apply to H8 electrodes.

1.b.2 Make all 5/16 inch and smaller fillet welds in a single pass. Make all fillet welds larger then 5/16 inch with a root pass of sufficient size to prevent cracking.

1.b.3 Conform to the requirements for Grade 50W or Grade HPS 50W base metal, as listed in AASHTO/AWS D1.5M/D1.5-2015, Table 4.1, or those listed in Section 1105.03(m)1.c, at the Fabricator's option, for filler metals in all full penetration groove welds connecting a Grade HPS 70W plate to a Grade 50W or Grade HPS 50W plate. Similarly, conform to the requirements for Grade HPS 70W base metal, as listed in AASHTO/AWS D1.5M/D1.5-2015, Table 4.1, or those listed in Section 1105.03(m)1.c, at the Fabricator's option, for filler metals in all full penetration groove welds connecting a Grade HPS 100W plate to a Grade HPS 70W plate.

1.c Groove Weld Requirements-Matching Base Metals. Conform to the following requirements for either two Grade HPS 70W plates or two Grade HPS 100W plates.

1.c.1 SAW Consumables. Use SAW consumables meeting the hydrogen control level of H4, as discussed in AASHTO/AWS D1.5M/D1.5-2015, Annex G, Section G6.2.2.1. Follow the minimum preheat and interpass temperature limits and other conditions listed in Table 1. Fabricators with multiple plants under a common umbrella of welding equipment, welding training and supervision, need to perform the Hd testing only once per combination of consumables for each location. Plants audited as a single facilit y by the AISC as part of their Quality Certification Program are considered one location. Multiple plants not falling under the AISC Single Facility audit definition are considered separate facilities and additional WPS and Hd tests are required.

1.c.1.a Grade HPS 70W SAW Consumables. Use electrodes conforming to Table 4.1 of AASHTO/AWS D.1.5M/D1.5-2015.

1.c.1.b Grade HPS 100W SAW Consumables. Use LA100 electrode with Mil800HPNi flux manufactured by Lincoln Electric Company.

1.c.1.c Alternate Grade HPS 100 SAW Consumables. In stead of the filler metals for SAW in Section 1105.03(m)1. c.1.a and Section 1105.03(m)1.c.1.b, request approval of alternate consumables from the Engineer. In addition to the requirements for WPS, qualification according to AASHTO/AWS D1.5M/D1.5-

2015, when using "alternate" consumables, perform diffusible hydrogen (Hd) tests on the weld metal. Provide the full range of weld tests as required by AASHTO/AWS D1.5M/D1.5- 2015 Section 12.6. Use minimum preheat and interpass temperatures with "alternate" consumables according to AASHTO/AWS D1.5M/D1.5-2015, Table 4.4. Provide a diffusible hydrogen level equivalent to 4 mL/100g or less in the deposited weld metal. Prepare Hd test specimens at the fabrication plant. Test specimens according to AWS A4.3. Test results in excess of 4 mL/100g are unacceptable, and a retest is required, with or without revised welding procedures. AASHTO/AWS D1.5M/D1.5-2015, Section 5.7.6, Exemption from Further Testing, is applicable, but WPS or Hd results are not transferable from fabricator-to-fabricator.

1.c.2 SMAW Consumables.

• Grade HPS 70W: E9018M-HZR (H8 or less)

• Grade HPS 100W: E110M-HZR (H4 only)

The designator "R", for moisture- resistant coating, is required for all SMAW electrode used for welding Grade HPS 70W and Grade HPS 100W. Use SAW consumables and SMAW electrodes producing weld deposits meeting the requirements of AASHTO/AWS D1.5M/D1.5-2015, Table 4.3, except for single pass fillet welds (up to 1/4 inch maximum for SMAW and up to 5/16 inch for SAW) , or welds that will be fully incorporated into a finished weld with satisfactory weathering characteristics.

1.d Qualification Testing. Filler Metal Procedure Qualification Test Requirements for groove

matching (groove) welds using Grade HPS 100W, meet the minimum properties equal to or greater than Base Metal requirements, according to ASTM A709 for Qualification, Pretest and Verification Test Requirements. Filler metal qualification test requirements for all hybrid designs and undermatched fillet welds are listed in AASHTO/AWS D1.5M/D1.5-2015, Table 4.1, for the lowest strength base metal used in the hybrid design, as applicable. Individually qualify WPSs for joint welding combinations of different strength Grades such as Grade HPS 70W to Grade 50W or Grade HPS 50W; or Grade HPS 100W to Grade HPS 70W according to AASHTO/AWS D1.5M/D1.5-2015, Clause 5. For example, when welding Grade 50W webs to Grade HPS 70W flanges will require a procedure plate composed of half Grade 50W and half Grade HPS 70W. In addition to radiographic testing, all Procedure Qualification tests must be ultrasonically tested in conformance with the requirements of AASHTO/AWS D1. 5M/D1.5-2015, Clause 6, Part C. Evaluate according to AASHTO/AWS D1. 5M/D1.5-2015, Table 6.3 Ultrasonic Acceptance - Rejection Criteria - Tensile Stress. Disregard indications found at the interface of the backing bar regardless of defect rating.

1.e. Preheat and Interpass Temperature:

1.e.1 Matching Strength Welds. Use minimum preheat and interpass temperatures for "matching strength" fillet and groove welding for two Grade HPS 70W steel plates using consumables listed in Sections 1105.03(m)1.b.4.1 and .03(m)1.b.4.2, according to Table 1. Limit the maximum interpass temperature for welding Grades HPS 70W and HPS 100W steel to 450F and 400F respectively. For hybrids, welds joining both grades, limit the maximum interpass temperature to 400F.

1.e.2 Undermatched Fillet Welds/ Fillet Welds on Hybrid Members. Use preheat/interpass temperature requirements according to Note (b) of Table 1.

1.e.3 Drying Preheat. As an absolute minimum for all permanent welds, apply to the joint a drying preheat sufficient to remove any existing moisture before to welding.

Table 1 Minimum Preheat and Interpass Temperature Thickness of Thickest Part at Point of Welding Grade Welding Process (Base Metal) To 3/4 in. inclusive Over 3/4 in. to 1-1/2 in. inclusive Over 1-1/2 in. to 2-1/2 in. inclusive Over 2-1/2 in. HPS 70W; HPS 100W SAW; SMAW 50 125 175 225 Notes:

during development of the WPS and increased preheat temperatures are used to produce a satisfactory PQR, use the higher preheat temperature during bridge fabrication used for the PQR.

minimum preheat and interpass temperature from above or from Table 4.4 in AASHTO/AWS D1.5M/D1.5-2015.

requirements of AASHTO/AWS D1.5M/D1.5-2015, Chapter 12.

1.f Heat Input (HI).

1.f.1 SAW. For HPS Grade 70W or hybrid combinations of HPS Grade 70W and HPS Grade 100W, limit heat input to 40 kilojoules per inch, minimum; 90 kilojoules per inch maximum according to AASHTO/AWS D1.5M/D1.5-2015, Section 5.12. Heat inputs about 90 kilojoules per inch for Grade HPS 70W or hybrid Grade HPS 70W to Grade HPS 50W joints where multiple wire SAW applications are used may be approved if qualified according to the provisions listed herein. For HPS Grade 100W, limit heat input to 40 kilojoules per inch, minimum; 70 kilojoules per inch maximum according to AASHTO/AWS D1.5M/D1.5-2015, Section 5.12.

1.f.2 SMAW. Use welding heat input parameters recommended by the individual consumable manufacturer.

1.g Backing. Whenever possible, use steel backing material for WPS test plates from the s ame grade as the weld test plates. For Production and Qualification welding of Grade HPS 70W, steel backing material for WPS test plates that is either Grades 50W or HPS 70W may be used. For Production and Qualification welding of Grade HPS 100W, steel backing material for WPS test plates that are either Grades 50W, HPS 70W, or 100W may be used. For all cases, limit the maximum sulfur content of the backing material to 0.025% maximum.

the shop drawings.

bar supports, or deck-forming devices, to beams, girders, or other main members, unless permitted. Identify locations of such welds on the shop drawings.

6.a Primary Load Carrying Bridge Members. Do not use the GMAW or FCAW processes (including tack welding except as otherwise approved herein) for any of the following conditions:

• web-to-web welds 5;

• web-to-flange welds5;

• flange-to-flange welds5; and

• welds on truss members and gusset plates5.

Note 5: Including rolled shapes.

For stiffener and connection plate welds to flanges and webs and for X-frames and diaphragms considered primary members, the fabricator may use the FCAW-G (gas shielded) process and the GMAW process, subject to the following restrictions:

• Use only GMAW spray and constant voltage pulsed spray transfer modes.

• Use only metal cored electrodes for GMAW on fracture critical members.

• Use only GMAW equipment with the following features:

ͦ A ‘lock out’ feature to prevent the operator from adjusting the equipment outside the approved WPS parameters. ͦ An adaptive mode capable of automatically correcting amperage, etc. due to operator variations (stick-out, etc.) to maintain the desired transfer mode.

• Single-pass GMAW tack welds and root passes are allowed for all joints on all primary members provided the Contractor can demonstrate that such welds are completely re-melted by subsequent SAW passes.

• Other applications may be allowed by the Engineer if prior approval is received.

6.b Secondary Members and Other Welded Structures. Either the GMAW or FCAW-G process may be used for welding bridge drainage material, expansion dams, bearings, bracing, those X-frames and diaphragms not considered main members, soldier piles, sound barrier posts, and other welded structures. Both Globular and Short Circuit GMAW transfer modes are prohibited unless otherwise specifically approved or specified.

D1.5M/D1.5-2015. Unless otherwise indicated or specified, use radiographic testing on butt joints. Use radiographic or ultrasonic testing for corner or “T” joints. Use magnetic particle testing according to AASHTO/AWS D1.5M/D1.5-2015, Section 6.7.2.

8.a Grade HPS 70W and HPS 100W. For non-fracture critical members, radiographically test 100% of all complete penetration groove welds for Grade HPS 70W steel plates, regardless of the type of stress in the plate. Test fillet welds according to AASHTO/AWS D1. 5M/D1.5-2015, Section 6.7.2.1, on Grade HPS 70W and HPS 100W steel by magnetic particle testing. Use the yoke technique as described in AASHTO/AWS D1. 5M/D1.5-2015, Section 6.7.6.2, as specified in Section 1105.03(m)1. The prod technique is not allowed. For non-fracture critical members, perform testing not less than 48 hours after completion of welding. For fracture critical members, comply with the above including any additional requirements of AASHTO/AWS D1.5M/D1.5-2015, Chapter 12.

critical members will conform to the diffusible hydrogen requirements of the AWS filler metal specifications optional supplemental designator H4 or H8 only.

Do not repair individual locations more than three times without written permission of the Engineer. Following the third unsuccessful attempt, submit a proposed repair procedure for review.

connections for luminaire supports, traffic signal supports, and sign structure supports more than one time without written permission of the Engineer.

only, refer to Publication 135 for pre-approved base metal repair procedures and heat correction procedures. The fabricator may use the pre-approved procedures after the Department’s inspector has verified that the discontinuity to be repaired is covered by the specific procedure. Any repairs performed are subject to inspection by the Department’s inspector.

arc, or oxygen plasma arc processes. Conduct cutting for all processes according to the AASHTO/AWS D1.5M/D1.5-2015. Do not submerge base metal in water during any process unless otherwise indicated.

Structural Materials Engineer.

bearing surfaces in contact with each other or concrete conform to the ANSI surface roughness requirements defined in ANSI/ASME B46.1 and listed below:

• Steel slabs ANSI 2 mils

• Heavy plates in contact with shoes to be welded ANSI 1 mil

• Milled ends of compression members, finished-to-bear (milled or ground) ends of stiffeners and fillers ANSI 0.5 mil

• Bridge rollers and rockers ANSI 0.25 mil

• Pins and pin holes ANSI 0.13 mil

• Sliding bearing ANSI 0.13 mil

• Sliding bearings—Stainless Steel to Polytetrafluoroethylene (PTFE) ANSI 0.008 mil

Fabricate bearing surfaces according to the following additional requirements:

• Machine sliding bearings having a surface roughness of 0.063 mil or rougher so the lay of the cut is parallel to the direction of movement.

• Provide machined surfaces plane and true, conforming to the indicated dimensions.

• For surfaces designed to be flat, machine surfaces to within 0.01 inch of flatness. Determine flatness as specified in Section 1111.03(c).

• Maintain uniform and even contact when assembling adjacent bearing surfaces. Unless a closer tolerance is indicated or specified, do not exceed a gap of 0.040 inch between bearing surfaces. Machine all sliding surfaces of base plates.

• Do not machine any surfaces of fabricated members until all fabrication and welding of the assembly or subassembly is complete. Machine heat-treated components after completion of heat treating.

obtain a square joint and uniform bearing. Do not allow the opening at other joints not required to be faced to exceed 3/8 inch.

fabricate steel plates for primary members and splice plates for flanges and main tension members (not secondary members) so that the primary direction of rolling is parallel to the direction of the main tensile and compressive stresses. Unless otherwise indicated or specified, fabricate I -shaped beams and girders so that when erected and under their own weight, the webs are within the allowable tolerance of vertical. Provide flanges normal to the web, unless otherwise indicated.

the bend lines will be at right angles to the direction of rolling. If allowed, cold-bent ribs for orthotropic-deck bridges may be bent with bend lines in the direction of rolling. When bend lines must be oriented parallel to the direction of the plate, increase the bend radii specified in Section 1105.03(t)2 by an additional factor of 1.5, unless otherwise specified or approved. Before bending, round the corners of the plate where bending is to occur to a radius of 1/16 inch.

provide a minimum bend radii, measured to the concave face of the metal, of 5.0t for all grades and thickness of AASHTO M 270 (ASTM A 709) steel, including material substitutions allowed for AASHTO M 270 (ASTM A709), where t is the thickness of the plate in inches. For cross-frames, diaphragm connection plates up to 0.75 inches thick that are not considered main members, the minimum bending radii may be taken as 1.5t. When bend lines are oriented parallel to the final rolling direction, increase the minimum bend radius to not less than 7.5 times the plate thickness. For all other Grades of steel, provide minimum bend radii according to the applicable material specification, where provided or as follows:

Thickness (t) in inches Up to 1.0 Over 1.0 to 2.5 Over 2.5 to 4.0 Bend radii 2.5t 3.5t 4.0t

Provide allowance for springback of Grade HPS 100W steels of about three times that for Grade 36 steel. For break press forming, provide a lower die span of at least 16 times the plate thickness. Multiple hits are advisable. Cold Bending of fracture critical members is prohibited without the approval of the Chief Structural Materials Engineer.

bend bars and plates at a temperature not less than 800F and not greater than 1,200F. Submit the heating and bending procedure to the Chief Structural Materials Engineer for review and approval. Limit hot bending temperatures for Grade HPS 100W steel plates to not greater than 1,100F.

and stiffeners intended as supports for concentrated loads have full bearing on the flanges that they transmit load to or receive load from. Full bearing is defined as a gap not exceeding 0.005 inch. The maximum gap between the bearing stiffener and the flange on the remaining 25% may not exceed 1/32 inch. Mill or grind the ends of bearing stiffeners to achieve the required bearing on the flanges. For weldable steel in compression areas of flanges, weld stiffeners as indicated or specified. Provide a tight fit against the compression flange for intermediate stiffeners not intended to support concentrated loads unless otherwise indicated or specified. Tight fit is defined as a gap not exceeding 1/16 inch.

Securely fasten together all eyebars that are to be placed side by side in the structure in the order that they will be placed on the pin and bore both ends while clamped. No welding is allowed on eyebars or to secure adjacent eyebars. Pack and match-mark eyebars for shipment and erection. Stamp all identifying marks on the edge of one head of each member with steel stencils after fabrication is completed so that the marks are visible when the bars are nested in place on the structure. Provide low stress type steel die stamps. Furnish eyebars straight and free from twists. Accurately locate pin holes on the centerline of the bar. Limit inclination of any bar to the plane of the truss to 1/16 inch to a foot. Simultaneously cut the edge of eyebars that lie between the transverse centerline of their pin holes with two mechanically operated torches abreast of each other and guided by a substantial template. Prevent distortion of the plates.

according to ASTM A941. Finish machining, boring, and straightening structural members subsequent to heat treatment. Maintain the temperature uniformly throughout the furnace during heating and cooling so that the temperatures of any two points on the member differ by no more than 100F at any one time. Do not anneal or normalize members consisting of Grades HPS 70W and HPS 100W steel. Stress relieve these members only if permitted. Do not allow the holding temperatures for stress relieving Grade HPS 100W or Grade HPS 70W steels to exceed 1,100F and 1,050F, respectively. Furnish a record of each furnace charge identifying the pieces in the charge and showing the temperature and schedule actually used. Provide proper instruments, including recording pyrometers, to determine the temperatures of members in the furnace at any time. Submit the records of the treatment operation for approval. When indicated or specified, stress relieve members such as bridge shoes, pedestals, or other parts that are built up by welding sections of plate together according to Section 4.4 of the AASHTO/AWS D1.5M/D1.5- 2015.

smooth, and free from flaws. Forge and anneal pins and rollers more than 9 inches in diameter. Either forge and anneal or use cold-finished, carbon-steel shafting for pins and rollers 9 inches or less in diameter. In pins larger than 9 inches in diameter, bore a hole not less than 2 inches in diameter full length along the axis of the pin after the forging has cooled to a temperature below the critical range and before annealing. Bore the hole under suitable conditions to prevent damage by cooling too rapidly.

with the axis of the member and parallel with each other unless otherwise indicated or specified. Produce the final surface by a finishing cut. Do not allow the diameter of the pin hole to exceed that of the pin by more than 1/50 inch for pins 5 inches or less in diameter, or by more than 1/32 inch for pins larger than 5 inches in diameter. Do not allow the distance outside to outside of end holes in tension members and inside to inside of end holes in compression members to vary more than 1/32 inch from that indicated or specified. Bore pin holes in built- up members after the member has been assembled.

conforming to Unified Standard Series UNC ANSI B1.1, Class 2A for external threads and Class 2B for internal threads, except furnish pin ends having a diameter of 1 3/8 inches or threaded more than six threads to 1 inch.

specified, provide suitable facilities, material, supervision, and labor necessary for making and recording the required tests.

an erection diagram to the Representative indicating the location of the erection marks on each member, so that the marks can be located in the field. Furnish copies of material orders, shipping statements, and erection diagrams to the Representative. Show the weights of the individual members on the statements. Mark the weights of members with a weight greater than 3 tons on the members. Load structural members on trucks or cars in such a manner that they

may be transported and unloaded at their destination without being excessively stressed, deformed, or otherwise damaged. Pack bolts of one length and diameter and loose nuts or washers of each size separately. Ship pins, small parts and packages of bolts, washers, and nuts in boxes, crates, kegs, or barrels, but do not allow the gross weight of any package to exceed 300 pounds. Plainly display a list and description of contents on the outside of each shipping container.

Include the manufacturer of the complete self -curing inorganic zinc system consisting of the primer, intermediate tie, and finish coats on the shipping papers.

and issuing cutting instructions to the shop (generally by cross -referencing the assembly-marks indicated on the shop drawings with the corresponding item covered on the mill purchase order) that maintains the identity of the original piece. Only furnish steel from stock material that can be identified by heat number and mill test report. During fabrication, up to the point of assembling members, clearly and legibly show the grade designation on each piece of steel other than Grade 36 steel. Either write the grade designation on the piece or submit an alternate marking procedure to the Chief Structural Materials Engineer for approval . Use low stress d ie stamp or firmly attach a substantial tag to identify the grade designation of those pieces of steel, other than Grade 36 steel, that before being assembled into members will be subjected to fabricating operations such as blast cleaning, galvanizing, heating for forming, or painting that might obliterate paint color code markings. If requested by the Representative, furnish an affidavit certifying that the identification of the steel was maintained according to this specification throughout the fabrication operation.

and free of defects that would adversely affect the quality of the weld. Prepare edges according to the AASHTO/AWS D1.5M/D1.5-2015.

• Provide surfaces plane and true, within the specified tolerances.

• Variations for surfaces designed to be flat: Conforming to ASTM A6, Tables A1.13, A1.14, and A1.15, unless otherwise indicated or specified.

• Complete all welded attachments to bolted surfaces before machining surfaces to required tolerances.

• Grind only on surfaces less than 2 inches wide, unless otherwise allowed.

• Use milling or other acceptable procedures to correct plate flatness to within the specified tolerances.

• Provide plate thickness as indicated.

• Identify each plate and the methods used to correct plate flatness to the specified tolerances.

• Replace rejected plates at no additional cost to the Department.

Furnish surfaces having flatness as determined by the following method:

• Place a precision straightedge that is a minimum of 6 inches longer than the surface to be measured in contact with and as parallel as possible to the surface. The straightedge may be located in any position on the surface being evaluated and not necessarily at 90 degrees to the edge.

• Attempt to insert a feeler gage having the required tolerance under the straightedge.

• Flatness is acceptable if the feeler gage does not pass between the straightedge and the surface.