8−120 below the pavement surface. The joint shall be tooled using a blunt instrument, so that it is slightly concave and approximately 1/4-inch below the adjacent surface. Tooling should be done within 10 minutes of application before a "skin" forms. No soap or oil shall be used as a tooling aid. Traffic shall be kept off the sealed lane for at least 30 minutes after sealant application.
822.03.1 Limitations. Silicone sealant is not intended for continuous water immersion, and it
should not be applied in totally confined spaces where the sealant is not exposed to atmospheric moisture. The sealant should never be applied to wet or damp surfaces nor should it be installed during inclement weather. 822.04 METHOD OF MEASUREMENT. "Silicone Highway Joint Sealant" will be measured by the number of linear feet of each type of joint actually installed in accordance with the Plans and/or as directed by the Engineer. 822.05 BASIS OF PAYMENT. The accepted quantities of "Silicone Highway Joint Sealant" of the various types will be paid at their respective contract unit prices per linear foot as listed in the Proposal. The prices so-stated constitute full and complete compensation for all silicone sealant, backer rods, bond breaker tape, primer, surface preparation, other materials, labor, tools, equipment, and all incidentals required to finish the work, complete and accepted by the Engineer.
823.01 DESCRIPTION. This work consists of the provision of various types of roadway joints, both
expansion and fixed, between bridge decks and abutment s or between sections of bridge decks at intermediate piers. Deck joints specified in this provision include co mpression type neoprene joints, strip seal joints, and asphaltic bridge deck joints. Other types of roadway joints, if required, will be specified in the Special Provisions. Deck joints shall be fabricated and installed in accordance with the details indicated on the Plans, or as directed by the Engineer, all in accordance with these Specifications. 823.01.1 Compression Type Neoprene Deck Joints. This type of joint consists of structural steel components anchored to the deck slab or abutment with preformed neoprene sealer placed between these structural elements. The neoprene seal er is approximately 1¼-inches wide for fixed joints and approximately 3 inches wide for expansion joints. 823.01.2 Strip Seal Expansion Joints. This type of joint consists of specially designed rolled steel sections that are anchored to the deck slab or abutment. The steel section contains a groove into which is inserted a pre-moulded neoprene strip seal. This deck joint system is a commercial product and must be installed in strict accordance with the manufacturer's recommendations. 8−121Manufacturers of this joint system are incl uded in the Department's Approved Materials List.
823.01.3 Asphaltic Expansion Joint System. This type of joint consists of the placement of a 20-
inch nominal width, or as otherwise indicated on the Plans, of a special asphalt material with unique elastic properties over concrete deck joints in t he space usually occupied by the bituminous wearing surface. This deck joint system is a commercial product and must be installed in strict accordance with the manufacturer's recommendations. Manufacturers of this joint system are included in the Department's Approved Materials List. 823.02 MATERIALS.
823.02.1 Compression Type Neoprene Deck Joints.
a.Structural Steel. Structural steel bars and plates shall conform to AASHTO M270, Grade 36, hot-dipped galvanized. Stud anchors shall conform to ASTM A108.
b.Sealer and Adhesive. The neoprene sealer shall be a preformed extruded type. The sealer and adhesive shall conform to the requirements of Subsection M.02.10.3 of these Specifications.
c.Aluminum Sheet Metal. The aluminum sheet metal shall conform to AASHTO M274.
d.All metal materials shall be hot-dipped galvanized or metalized except those that are in contact with concrete. 823.02.2 Strip Seal Expansion Joints. The materials for the strip seal joint are the same as those set forth above in Subsection 823.02.1 .
823.02.3 Asphaltic Expansion Joint System.
a.Backer Rod. The backer rod material shall be an expanded closed cell polyethylene foam capable of withstanding the temperature of t he hot binder material, sh all have a diameter 150 percent the width of the joint opening and shall have the following properties: Density - 2.0 lbs./cu.ft. min. ASTM D1622 Tensile Strength - 25 psi min. ASTM D1623 Water Absorption - 1 percent of weight max. ASTM C509
b.Binder Material. The binder material shall be a hot applied polymer modified bituminous material conforming to all specifications as detailed in ASTM D3405 and manufactured under strict quality control procedures as approved by the Engineer and conforming to the following: Softening Point, (ASTM D36) - 180 °F min.
c.Aggregate. The aggregate shall be of the Basalt, Gabbro or Granite groups, meeting the manufacturer’s size and gradation requirement s. All stones shall be double-washed, dried and 8−122 delivered to the site pre-weighed in labeled packs. When tested in accor dance with AASHTO T11, the material passing the #200 sieve will be no more than 0.3 percent by weight of the stone. The broadcast stone for the surface of the joint system will be basalt and shall be sized to pass the #8 sieve and be retained on the #16 sieve.
d.Steel Backing Plate. The backing plate shall conform to requirements of AASHTO M270, Grade 36 steel, minimum 1/4-inch thick and shall be galvanized in accordance with AASHTO M232. Holes for locating pins shall be approximatel y 1 foot center-to-center along the centerline of the plate, unless indicated otherwise on the Plans.
e.Locating Pins . Locating pins shall be 16d common nails or larger and shall be hot- dipped galvanized in accordance with ASTM A153.
f.Asphaltic Joint System. The materials for the joint system, both aggregate and binder, shall be provided by one of the manufacturers included in the Department's Approved Materials List. 823.03 CONSTRUCTION METHODS. 823.03.1 Compression Type Neoprene Deck Joints.
a.Fabrication. The steel frame shall be fabricated as detailed on the Plans. It shall be constructed to conform to roadway grade and cross slope.
b.Installation. The entire structural steel frame shall be assembled, erected and set to grade prior to placing deck (or abutment) concrete. Allowance shall be made for temperature conditions at the time of final setting. The joint assembly shall be clean and free of foreign material immediately prior to installation of the seal. The neoprene sealer shall be installed in the field by suitable hand or machine tools and thoroughly secured in place with the approved lubricant-adhesive. The adhesive shall cover both sides of the sealer over the full contact area with the sides of the metal joint. The adhesive may be applied to the metal or the sealer or both. The sealer shall be installed in a compressed condition in the position shown on the Plans within seconds after the application of the adhesive. The sealer shall be in one piece for the full width of transverse joints. No field splicing of the seal will be permitted in transverse joints. In longitudinal joints, the sealer shall be in practical lengths. Any joints in the sealer material shall be adequately sealed with additional adhesive.
c.Compliance. All sealer and adhesive to be employed in the work shall conform with the material that has been approved as the basis of test results. Each such shipment shall be identified with the manufacturer's name, address and trademar k and shall be accompanied by four copies of the manufacturer's standard test results and an affidavit attesting to full compliance with these Specifications.
823.03.2 Strip Seal Expansion Joint.
a.Fabrication. The steel frame shall be fabricated as detailed on the Plans. It shall be constructed to conform to roadway grade and cross slope. 8−123
b.Installation. The entire strip seal frame shall be assembled, erected and set to grade prior to placing deck (or abutment) concrete. Allowance shall be made for temperature conditions at the time of final setting. The joint assembly shall be clean and free of foreign material immediately prior to the installation of the seal. The neoprene strip seal shall be installed in the fi eld by suitable hand or machine tools. The seal shall be thoroughly secured in place with the approved adhesive in accordance with the manufacturer's recommendations. The strip seal shall be in one piece for the full width of the transverse joints. No field splicing of the seal will be permitted.
c.Compliance. Compliance requirements for strip seal joints are the same as those set forth above in Para. c of Subsection 823.03.1.
823.03.3 Asphaltic Expansion Joint System.
a.Excavation. Bituminous concrete wearing surface shall be excavated from those areas where asphaltic joint material is to be placed. The joint shall be excavated by the use of saws and pneumatic hand tools. Saws shall be set to cut the full depth of the bituminous concrete and any membrane present. Variations in the thickness of the bituminous concrete across the road should be considered to insure, where possible, that the deck is not damaged.
b.Joint Preparation.
1.Cleaning. The entire joint must be thoroughly cleaned and dried using a Hot Compressed Air Lance immediately prior to tanking. All loose debris shall be removed from the gap. Care must be taken to ensure that the sawcut surfaces have been thoroughly cleaned of any dust or wet paste from the cutting operation.
2.Caulking. The joint gap shall be caulked with a backer rod as shown on the Plans. It shall be placed in such a manner as to allow for the appropriate placement of the required binder material.
3.Tanking. Immediately after cleaning/caulking, the bottom of the blockout area shall be coated with a layer of hot binder that has been heated in accordance with the manufacturer's recommendations. If any delay gr eater than one (1) hour occurs between cleaning and tanking, the joint shall be re-cleaned using a Hot Compressed Air Lance as described above.
4.Plating. The gap shall be bridged with three-to-four foot long steel backing plates. Steel plates shall be located with pins along the centerline. The plates shall be butted to each other and shall not be overlapped. Immediately coat the walls of the blockout area and the bridging plates with binder, making sure that the plate is entirely encapsulated by the binder.
c.Asphaltic Joint Material Preparation.
1.Aggregate. The aggregate must be dried, cleaned and heated in a drum mixer by hot compressed air. The stone shall be heated to a temperature between 375 OF (190OC) and the maximum safe binder temperature as specified by the manufacturer. The temperature shall be monitored with a calibrated infrared thermometer. Under no circumstances shall the binder be mixed with the aggregate if its temperature is above the maximum. All tangible signs of dust must 8−124 be removed prior to mixing of the binder with the aggregate.
2.Binder. The binder shall be heated to the manufacturer's recommended placement temperature in excess of 350OF (177OC). At no time shall the manufacturer's recommended safe heating temperature be exceeded.
d.Material Installation. The method used shall be according the manufacturer’s recommended procedure. Variations from the manufac turer’s procedure or from this Specification must be approved by the Engineer prior to commencement of work.
1.Placement of the Aggregate/Binder Mix into the Blockout Area. Binder material shall be added to the mixer just sufficient to thoroughly coat the aggregate. The coated aggregate shall be placed into the blockout in layers as recommended by the joint material manufacturer. The blockouts shall be overfilled with coated aggregate as required to compensate for compaction. Equipment for compaction shall be capable of sufficient compaction force as recommended by the joint manufacturer. Additional binder material s hall be screeded over the compacted joint to fill any surface voids.
2.Surface Layer. Accurately measured quantities of hot aggregate shall be mixed with the binder in an unvented rotating drum mixer. The binder should be at the approved temperature to insure complete coating of all the stone. This mix shall be transferred to the joint and leveled to be slightly higher than the adjacent road surface.
3.Compaction. Compaction should take place after the joint has cooled to approximately OF (71OC) using a vibratory plate or roller, and the joint surface made flush with the existing road surface.
4.Screeding. Prior to the final screeding, the surface of the joint and surrounding road shall, if necessary, be dried and cleaned with a Ho t Compressed Air Lance. Immediately thereafter a single screed of hot binder shall be applied to fill all surface voids.
5.Joint Sealing. The interface between the joint and the pavement shall be sealed with a 2-inch wide band of the binder, centered on the interface, for the entire length of the joint on both the leading and trailing edges, relative to traffic. The surface adjacent to the interface shall be heated with a Hot Compressed Air Lance to promote adhesion of the binder. Immediately after the application, while the binder is still hot, basalt st one shall be broadcast onto the band. It shall cover 75 percent of the surface of the band.
6.Opening to Traffic. The joint shall not be opened to traffic before the surface reaches a temperature of 120 OF or 30 minutes has elapsed from placing the basalt stone.
e.Equipment. The following equipment is required for the proper installation of asphaltic bridge deck joints.
1.A manually propelled, high speed water cooled saw with diamond tipped blades capable of cutting to the full depth required in one pass.
2.A pneumatic compressor of 185 CFM capacity to power drills and breakers of various sizes with suitable size bits. 8−1253. Two Hot Compressed Air Lances (HCA Lances), each capable of delivering a flame retarded air stream with a temperature of 3,000OF (1,648OC), at a speed of 3,000 feet per second. The use of a torch rather than a Hot Air Lance to heat the block out surfaces is not allowed.
4.A 200-gallon air-jacketed, trailer-mounted melter with two flame baffled L.P. ribbon type burners rated a minimum output of 175,000 BTU which shall apply indirect heat to the melting chamber. The unit shall have automatic temperature controls which can accurately maintain the material temperatures between 100OF and 650OF (38OC and 343OC). A temperature gauge, calibrated to ± 10OF of actual, must be provided and mounted such that the temperature is clearly visible to the operator and the Engineer. The burner system shall have a safety pilot capable of shutting off the base supply in the event of a flame-out. The melter shall be equipped with a horizontally mounted double-paddle, full sweep reversible agitation system which runs the length of the melting chamber and is driven hydraulically by a dedicated engine and compressor. Material delivery shall be by an angled 3-inch discharge port. The electrically braked trailer shall be rated at a minimum of 6,000 pounds and shall meet all ICC regulations with regards to running lights, brake lights and stop lights.
5.Storage tanks capable of holding a minimum of 600 pounds propane, 600 pounds oxygen, and 200 pounds acetylene.
6.A dedicated drum mixer, with compressed hot air apparatus sufficient to heat the aggregate and aggregate/binder mix in the drum to the specified temperature range.
7.Acetylene cutting torches.
8.An arc welder powered by a suitable generator.
9.500-gallon capacity water tank fitted with suitable spigots.
10.A hand-held infrared thermometer, calibrated to ±10 OF.
11.A vibratory plate compactor.
12.A powered roller sufficient to span the width of the joint system in a single pass.
13.In the event of equipment failure during installation, backup equipment must be available, or in the case of a major breakdown, replacement equipment should be on site within 48 hours.
f.Temporary Bituminous Joint System. A temporary bituminous joint system must be installed if the contractor is unable to complete the installation of the asphaltic expansion joint system prior to the ambient temperature falling below the minimum manufacturer recommendation. The temporary joint system must include the galvanized steel backing plate and be filled with compacted bituminous asphalt. A joint one-half the depth of the wearing surface shall be sawed and sealed along the temporary joint centerline from curb to curb. 8−126 The contractor shall remove and dispose of all unnecessary materials, repair any damage caused by the installation or removal of the temporary system and leave the joint in a condition acceptable for the installation of the final joint system per the manufacturer’s recommendations. The contractor may elect to reuse the steel backing plate(s) if the warranty standards can be met; otherwise the Engineer will determine if the plate(s) may be reused or must be replaced.
823.04 METHOD OF MEASUREMENT. 823.04.1 Compression Type Neoprene Deck Joints. "Compression Type Neoprene Deck Joints" will be measured by the number of linear feet of such joints actually installed in accordance
with the Plans and/or as directed by the Engineer. 823.04.2 Strip Seal Expansion Joints. "Strip Seal Expansion Joints" will be measured by the number of linear feet of such joints actually installed in accordance with the Plans and/or as directed by the Engineer. 823.04.3 Asphaltic Expansion Joint System. "Asphaltic Expansion Joint System" will be measured by the number of linear feel of such joints actually installed in accordance with the Plans and/or as directed by the Engineer.
a.Curbs. In each of the above three statements the measured length will include the vertical rise at curbs.
823.05 Basis of Payment.
823.05.1 Compression Type Neoprene Deck Joints. The accepted quantities of "Compression
Type Neoprene Deck Joints" of various widths will be pai d for at their respective contract unit prices per linear foot as listed in the Proposal. The prices so-stated constitute full and complete compensation for all labor, materials and equipment, and all incidentals required to finish the work, complete and accepted by the Engineer. 823.05.2 Strip Seal Expansion Joints. The accepted quantities of "Strip Seal Expansion Joints" of various widths will be paid for at their respective contract unit prices per linear foot as listed in the Proposal. The prices so-stated constitute full and complete compensation for all labor, materials and equipment, and all incidentals required to finish the work, complete and accepted by the Engineer.
823.05.3 Asphaltic Expansion Joint System. The Accepted quantities of “Asphaltic Expansion
Joint System” of various widths will be paid for at t heir respective contract uni t prices per linear foot as listed in the Proposal. The prices so-stated constitute full and complete compensation for all labor, materials and equipment, the temporary bituminous joint, including the sawed and sealed joint, and for all incidentals required to finish the work, complete and accepted by the Engineer. 8−127SECTION 824 STRUCTURAL STEEL CONSTRUCTION
824.01 DESCRIPTION. This work consists of furnishing, fabricating, and erecting all structural
steel at the locations and to the details indicated on the Plans, or as directed by the Engineer, all in accordance with these Specifications. Structural steel includes, but is not limited to, carbon, special alloy steels, steel forgings, steel and iron castings and weldments. 824.01.1 Surface Preparation for Weathering Steel. This work also includes the cleaning and protection of weathering structural steel during both fabrication and after erection.
824.01.2 Applicable Specifications. In addition to this Specification, all structural steel work shall
conform to the applicable requirements of the re spective current editions of the AASHTO Standard Specifications for Highway Bridges and the AWS D1.5 Bridge Welding Code. 824.01.3 Related Items of Work Covered Elsewhere. Related items of work covered in other Sections of these Specifications include the following:
a.SECTION 825; PAINTING STRUCTURAL STEEL
b.SECTION 827; THERMAL SPRAYED ZINC COATING for NEW STRUCTURAL STEEL
824.01.4 Shear Connectors. This work shall consist of the provision of stud shear connectors
welded to the flanges of steel beams or girders at the locations indicated on the Plans or as directed by the Engineer, all in accordance with these Specifications.
a.General Requirements . Shear connector studs shall be of a design suitable for end- welding to steel beams and girders with automatically timed stud welding equipment. The type, size or diameter, and length of stud shall be as shown, specified or ordered. Finished studs shall be of uniform quality and condition, free from injurious laps, fins, seams, cracks, twists, bends, or other injurious defects. Finish shall be as produced by cold drawing, cold rolling, or machining. Before placing orders for studs, the Contractor shall submit to the Engineer for approval the following information on the studs to be purchased.
1.The name of the manufacturer.
2.A detailed description of the stud and arc shield to be furnished.
3.A certification from the manufacturer that the stud to be furnished is qualified in accordance with the latest AASHTO Standard Specifications for Highway Bridges.
4.If requested by the Engineer, a copy of t he qualification test report as certified by the testing laboratory. 8−128 824.02 MATERIALS.
824.02.1 Structural Steels shall conform to the requirements of Subsection M.05.04.1 of these
Specifications.
824.02.2 Steel Bars and Forgings shall conform to the requirements of Subsection M.05.04.2 of
these Specifications.
824.02.3 Structural Tubing shall conform to the requirements of Subsection M.05.04.3 of these
Specifications.
824.02.4 Bolts shall conform to the requirements of Subsection M.05.04.4 of these Specifications.
824.02.5 Weld Metal shall conform to the requirements of Subsection M.05.04.5 of these
Specifications.
824.02.6 Shear Connectors shall conform to the requirements of Subsection M.05.04.6 of these
Specifications.
824.02.7 Low Alloy Nickel Copper Steel Pipe shall conform to the requirements of Subsection
M.05.04.7 of these Specifications.
824.02.8 Steel Forging and Shafting shall conform to the requirements of Subsection M.05.04.8
of these Specifications. 824.04.9 Steel and Iron Castings shall conform to the requirements of Subsection M.05.04.9 of these Specifications. 824.03 CONSTRUCTION METHODS. 824.03.1 Shop Drawings. The Contractor shall prepare all shop drawings, erection diagrams, camber diagrams, and list of field rivets and bolts, from plans furnished by the State. Shop drawings and erection diagrams shall be submitted by the Contractor and reviewed by the Engineer in accordance with the requirements of Subsection 105.02 of these Specifications.
824.03.2 Inspection and Testing.
a.Mill. The State shall be furnished complete copies of mill orders in quadruplicate. No material shall be rolled, or work done, before t he Engineer has been notified where the orders have been placed so that he may arrange for the inspection. The manufacturer shall furnish all facilities for inspecting and testing the weight and quality of all material at the mill where it is manufactured. Suitable testing equipment, properly calibrated, shall be furnished. The pieces shall be prepared for the testing machine, at no cost to the State. Where no mill inspection is made, the Contractor shall furnish the Engineer with four copies of the mill report of chemical and physical tests prior to starting work. No markings shall be cut off until the inspector has established the heat and designation and determined the method of continued identity. Inspection and testing shall conform the SECTION 106; CONTROL OF 8−129MATERIAL, of these Specifications.
b.Shop. The Engineer shall be notified well in advance of the start of the work in the shop, in order that an inspector shall be on hand to inspect material and workmanship. The fabricator shall furnish all facilities for inspecting and testing the weight and quality of workmanship at the shop where the material is fabricated. Suitable testing equipment, properly calibrated, shall be provided. When an inspector is furnished by the State to in spect materials at the mills or at the shops, full access shall be provided at all times and to all parts of the mills or shops where the material is being manufactured or fabricated. The inspector shall have the authority to reject any material or work which does not meet the requirements of these Specifications. In case of dispute the Contractor may appeal to the Engineer, whose decision shall be final. The acceptance of any material or finished members by the inspectors shall not be a bar to their subsequent rejection, if subsequently found defective. Rejected material and workmanship shall be replaced promptly and made good by the Contractor.
c.Site. The Engineer may waive shop inspection and may make inspection of all fabricated material when the same is delivered at the site of the work. The Contractor shall furnish the Engineer with a minimum of four copies of shipping statements. The weights of the individual members shall be shown on the statement. The Contractor shall furnish the Engineer with a Certificate of Identification as defined in Subsection 11.4.1 of the AASHTO Standard Specifications for Highway Bridges (15th Edition).
d.Delegation of Authority. The State may delegate inspection and testing to an independent laboratory or testing company. This agency shall have all the prerogatives as previously mentioned for the Engineer except that in the event of a disagreement of substance the Contractor may appeal a decision to the Engineer whose decision shall be final.
824.03.3 Fabrication.
a.Quality of Workmanship. Workmanship and finish shall be equal to the best general practice of modern bridge shops.
b.Shop Storage of Materials. Structural material, either plain or fabricated, shall be stored at the bridge shop above the ground upon platforms, skids, or other supports. It shall be kept free from dirt, grease and other foreign matter, and shall be protected as far as practicable from corrosion.
c.Holes for High-Strength Bolts and Unfinished Bolts.
1.General. All holes for bolts shall be either punched or drilled. Material forming parts of a 8−130 member composed of not more than five thicknesses of metal may be punched 1/16-inch larger than the nominal diameter of the bolts whenever the thickness of the material is not greater than 3/4-inch for structural steel, 5/8-inch for high-strength steel of ½-inch for quenched and tempered alloy steel. When there are more than five thicknesses or when any of the main material is thicker than 3/4-inch for structural steel, 5/8-inch for high-strength steel, or ½-inch for quenched and tempered alloy steel, all holes shall either be subdrilled and reamed or drilled full size. When required, all holes shall be either subpunched or subdrilled (subdrilled if thickness limitation governs) 3/16-inch smaller and, after a ssembling, reamed 1/16-inch larger or drilled full size to 1/16-inch larger than the nominal diameter of the bolts. When shown on the Plans, enlarged or slotted holes are allowed with high-strength bolts.
2.Punched Holes. The diameter of the die shall not exceed the diameter of the punch by more than 1/16-inch. If any holes must be enlarged to admit the bolts, such holes shall be reamed. Holes must be clean cut without torn or ragged edges.
3.Reamed or Drilled Holes. Reamed or drilled holes shall be cylindrical, perpendicular to the member, and shall comply with the requirements of Para. c.1 , above, as to size. Where practical, reamers shall be directed by mechanical means. Burrs on the outside surfaces shall be removed. Reaming and drilling shall be done with twis t drills, twist reamers or rotobroach cutters. Connecting parts requiring reamed or drilled holes shall be assembled and securely held while being reamed or drilled and shall be match marked before disassembling.
4.Accuracy of Holes. Holes not more than 1/32-inch larger in diameter than the true decimal equivalent of the nominal diameter that ma y result from a drill or reamer of the nominal diameter are considered acceptable, the slightly conical hole that naturally results from punching operations is considered acceptable. The width of slotted holes which are produced by flame cutting or a combination of drilling or punching and flame cutting shall generally be not more than 1/32-inch greater than the nominal width. The flame cut surface shall be ground smooth.
d.Accuracy of Hole Group.
1.Accuracy Before Reaming. All holes punched full size, subpunched, or subdrilled shall be so accurately punched that after assembling (before any reaming is done) a cylindrical pin 1/8- inch smaller in diameter than the nominal size of the punched hole may be entered perpendicular to the face of the member, without drifting, in at least 75 percent of the contiguous holes in the same plane. If the requirement is not fulfilled, the badly punched pieces will be rejected. If any hole will not pass a pin 3/16-inch smaller in diameter than the nominal size of the punched hole, this will be cause for rejection.
2.Accuracy After Reaming. When holes are reamed or drilled, 85 percent of the holes in any contiguous group shall, after reaming or drilling, show no offset greater than 1/32-inch between adjacent thicknesses of metal. All steel templates shall have hardened steel bushings in holes accurately dimensioned from the centerlines of the connection as inscribed on the template. The centerlines shall be used in locating accurately the template from the milled or scribed ends of the members. 8−131
e.Holes for Ribbed Bolts, Turned Bolts, or Other Approved Bearing-Type Bolts. All holes for ribbed bolts, turned bolts, or other approved bearing-type bolts shall be subpunched or subdrilled 3/16-inch smaller than the nominal diameter of the bolt and reamed when assembled, or drilled to a steel template or, after assembling, drilled from the solid at the option of the fabricator. In any case the finished holes shall provide a driving fit as specified on the Plans or in the Special Provisions.
f.Preparation of Field Connections. Holes in all field connections and field splices of main members of trusses, arches, continuous bean spans, bents, towers (each face), plate girders, and rigid frames shall be subpunched or subdrilled and subsequently reamed while assembled or drilled full size to a steel template. Holes for field splices of rolled beam stringers continuous over floor beams or cross frames may be drilled full size unassembled to a steel template. All holes for floor beams or cross frames may be drilled full size unassembled to a steel template. All holes for floor beam and stringer field end connections shall be subpunched and reamed while assembled or drilled full size to a steel template. Reaming or drilling full size of field connection holes through a steel template shall be done after the template has been located with utmost care as to position and angle and firmly bolted in place. Templates used for reaming matching members, or the opposite faces of a single member, shall be exact duplicates. Templates used for connections on like parts or members shall be so accurately located that the parts or members are duplicates and require no match-marking. For any connection, in lieu of subpunching and reaming or subdrilling and reaming, the fabricator may, at his option, drill holes full size wi th all thicknesses or material assembled in proper position. 824.03.4 Bolts and Bolted Connections Using Unfinished, Turned and Ribbed Bolts.
a.General. Bolts shall be unfinished, turned or an approved form of ribbed bolts as designed. Bolts shall have hexagonal heads and nuts and shall be of such length that they will extend entirely thorough the nut but not more than 1/4-inch beyond. Beveled washers shall be used where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis. Bolts shall have single self-locking nuts or double nuts.
b.Unfinished Bolts. Bolts in shear shall have not more than one thread within the grip. The diameter of the unfinished bolt shall be not more than 1/16-inch smaller than the diameter of the hole.
c.Turned Bolts. Holes for turned bolts shall be carefully reamed and the bolts turned to a light driving fit, with threads entirely outside of holes, and a washer shall be used. One-quarter inch nut locks shall be used on all turned bolts unless otherwise specified on the Plans.
d.Ribbed Bolts. Special types of ribbed bolts, with drive fit, may be used if approved by the Engineer in writing, for special purposes or for field rivets in locations where, in the opinion of the Engineer, it is impractical to drive rivets. In the event that the bolt twists before drawing tight, it shall be removed, the hole rereamed and an oversize bolt used in replacement. 8−132 824.03.5 Connections Using High Strength Bolts.
a.General. This Subsection covers the assembly of structural joints using ASTM A325 high strength carbon steel bolts or equivalent fasteners, tightened to a high tension. The bolts are used in holes conforming to the requirements of Subsection 824.03.3 of this Section.
b.Bolts, Nuts and Washers. Bolts, nuts and washers shall conform to the requirements of Subsection M.05.04.4; Fasteners, of these Specifications.
c.Bolted Parts. The slope of surfaces of bolted parts in contact with the bolt head and nut shall not exceed 1:20 with respect to a plane normal to the bolt axis. Bolted parts shall fit solidly together when assembled and shall not be separated by gaskets or any other interposed compressible material. When assembled, all joint surfaces, including those adjacent to the bolt heads, nuts or washers, shall be free of scale, except tight mill scale, and shall also be free of dirt, loose scale, burrs, other foreign material and other defects that would prevent solid seating of the parts. Contact surfaces within friction-type joints shall be free of oil, paint, lacquer, rust inhibitor or galvanizing.
d.Installation. Each fastener shall be tightened to provide, when all fasteners in the joint are tight, at least the minimum bolt tension shown on the Bolt Tension Table in Para. g of this Subsection. Threaded bolts shall be tightened with properly calibrated wrenches or by the turn-of-the nut method. If required because of bolt entering and wrench operation clearances, tightening by either procedure may be done by turning the bolt while the nut is prevented from rotating. Impact wrenches, if used, shall be of adequate capacity and sufficiently supplied with air (minimum 100 psi at tool for 7/8-inch bolts) to perform the required tightening of each bolt in approximately ten seconds.
e.Washers. All fasteners shall have a hardened washer under the element (nut or bolt head) turned in tightening. Where an outer face of the bolted parts has a slope of more than 1:20 with respect to a plane normal to the bolt axis, a smooth beveled washer shall be used to compensate for the lack of parallelism. On diaphragm connections using oversized hol es, a washer must be used over every oversized hole regardless of part turned in tightening.
f.Calibrated Wrench Tightening. Calibrated wrench tightening may be used only when installation procedures are calibrated on a daily basis and when 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 they shall be set to provide a tension not 8−133less than 5 percent in excess of the minimum tension specified in the Bolt Tension Table in Para. g of this Subsection. The installation procedures shall be calibrated by verification testing at least once each working day for each bolt diameter, l ength and grade using fastener assemblies that are being installed in the work. This verification testing shall be accomplished in a device capable of indicating actual bolt tension by tightening three typical 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. Wrenches shall be recalibrated when significant difference is noted in the surface condition of the bolts, threads, nuts or washers. It shall be verified 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 permitted in the Nut Rotation Table in Para. g of this Section. If manual torque wrenches are used, nuts shall be turned in the tightening direction when torque is measured. When calibrated wrenches are used to install and tension bolts in a connection, bolts shall be installed with hardened washers under the element turned in tightening bolts in all holes of the connection and brought to a snug tight condition. Following this initial tightening operation, the connection shall be tightened using the calibrated wrench. Tightening shall progress systematically from the most rigid part of the joint to its free edges. The wrench shall be returned to "touch up" previously tightened bolts which may have been relax ed as a result of the subsequent tightening of adjacent bolts until all bolts are tightened to the prescribed amount.
g.Turn-of-Nut Tightening. Verification testing using a representative sample of not less than three bolt and nut assemblies of each diameter, length and grade to be used in the work shall be performed at the start of work in a device capable of indicating bolt tension. This verification test shall demonstrate that the method for estimating the snug tight condition and controlling the turns from snug tight to be used by the bolting crew dev elops a tension not less than 5 percent greater than the tension required by the Bolt Tension Table. Periodic retesting shall be performed when ordered by the Engineer. After snug tightening fasteners and fully compacting the connection, all bolts in the connection shall be tightened further by the applicable amount of rotation specified in the Nut Rotation Table. During the tightening operation, there shall be no rotation of the part not turned by the wrench. Tightening shall progress systematically from the most rigid part of the joint to its free edges. Bolt Tension Table Minimum Bolt Tension in Pounds * Bolt Size, in Inches A325 Bolts ½ 12000 5/8 19000 3/4 28000 7/8 39000 1 51000 1 1/8 56000 1¼ 71000 1 3/8 85000 1½ 103000 8−134 *Equal to 70 percent of specified minimum tens ile strength of bolts (as specified in ASTM Specifications for tests of full-size A325 bolts with UNC threads loaded in axial tension) rounded to the nearest kip. Nut Rotation Table Nut Rotation from the Snug-Tight Condition a,b Geometry of Outer Faces of Bolted Parts One face normal to Both faces bolt axis sloped not and other more than Bolt length face sloped 1:20 from measured from not more normal to underside of Both faces than 1:20. bolt axis. head to end normal to Bevel washer Bevel washers of bolt. bolt axis. not used. not used. Up to and including 4 diameters 1/3 turn ½ turn 2/3 turn Over 4 diameters but not exceeding 8 diameters ½ turn 2/3 turn 5/6 turn Over 8 diameters but not exceeding 12 diameters C 2/3 turn 5/6 turn 1 turn Notes: a Nut rotation is relative to bolt, regardless of the el ement (nut or bolt) being turned. For bolts installed by ½ turn and less, the tolerance should be plus or minus 30 degrees; for bolts installed by 2/3 turn and more, the tolerance should be plus or minus 45 degrees. b Applicable only to connections in which all material within grip of the bolt is steel. c No research work has been performed by the Research Council Riveted and Bolted Structural Joints to establish the turn-of-nut procedure when bolt lengt hs exceed 12 diameters. Therefore, the required rotation must be determined by actual tests in a suitable tension device simulating the actual conditions.
h.Inspection. The Engineer will determine that all requirements of this Specification are satisfied. The Engineer will approve the procedure for calibra tion of wrenches and installation of bolts and will further observe the field installation to determine that these procedures are followed. 8−135Spot checks will be made with a manual torque wrench that has been calibrated as previously specified.
i.Load Indicator Devices. Load indicating devices may be used in conjunction with bolts, nuts and washers specified in Subsection M.05.04.4. Load indicating devices shall conform to the requirements of ASTM Specification for Compressible-Washer Type Direct Tension Indicators for Use with Structural Fasteners, ASTM F959, except as provided in the following paragraph. Subject to the approval of the Engineer, alternate design direct tension indicating devices may be used provided they satisfy the requirements detailed in specifications provided by the manufacturer. 824.03.6 Welding.
a.General. Unless specified otherwise herein, all welding, welder qualifications, prequalification of weld details and inspection of welds shall conform to the requirements of the current ANSI/AASHTO/AWS D1.5 Bridge Welding Code. Brackets, clips, shipping devices or other material not required by the Plans or Special Provisions shall not be welded or tacked to any member unless shown on the shop drawings and approved by the Engineer.
b.Qualification of Welders. All work shall be in accordance with the best modern practice using qualified welding operators. The same type of equipment as required fo r the execution of the actual construction work shall be used in qualifying welders and welding operators. If the Contractor prequalifies his metal-arc welding operators according to the standard qualification procedure of the American Welding Society and certifies to the Engineer that an operator working on the structure has been prequalified previously, the Engineer may consider such operator qualified. This certificate shall state that such operator has been doing satisfactory welding of the required type within the 3-month period previous to the subject work. A certification shall be submitted for each operator and for each project, stating the name of the operator, the name and title of the person who conducted the exam ination, the kind of specimens, the positions of welds, the results of the test, the date of t he examination and the identifying steel stamp symbol assigned. Such a certification of prequalification may also be accepted as proof that an operator of field welding is qualified, if the Contractor who submits it is properly staffed and equipped to conduct such an examination, or if the examin ing and testing is done by a recognized agency which is staffed and equipped for such purpose. The qualification of a welder shall not prohibit his subsequent removal from the job for poor workmanship in execution of welds. The welder shall place his identification stamp near the welds that he has made. Shop welding shall be done in areas sheltered from wind and weather with an ambient minimum temperature of 50 OF, unless otherwise permitted by the Engineer.
c.Qualification of Welding Procedure. The Contractor shall submit a complete welding procedure specification for welding all primary members and other members on which welds are subject to calculated stress prior to proceeding with fabrication. 8−136 d. Procedures for Manual Shielded Metal-Arc Welding. The work shall be positioned for flat position welding whenever practicable.
824.03.7 Inspection of Welds.
a.General. All welding, both shop and field, shall be subject to inspection by the Engineer, in accordance with ANSI/AASHTO/AWS D1.5 Bridge Welding Code, as amended herein. The principal method of inspection shall be non-destructive testing, which may be carried out by radiographic, magnetic particle, dye penetrant or ultrasonic methods, or any other methods designated by the Engineer. A minimum routine inspection program is outlined in Table 1 . However, inspection shall in no way be construed to be limited to the program described. A routine inspection program shall be established to which all welding shall be subject. This program shall involve two types of inspection.
b.Visual Inspection of Welds and Welding Operations. The Engineer shall have unlimited access to the site of welding operations, and shall be free to observe the procedure and techniques used by the Cont ractor on all welds. The program of visual inspection will be adapted to job conditions. The cost of visual inspection shall be borne by the State.
c.Non-destructive Testing. A routine program of non-destructive testing will be carried out on all welds (shop and field) carrying calculated stress as indicated in Table 1 of this section. All non-destructive testing will be performed by the St ate, except that the Contractor shall, at his own expense, radiograph and furnish the State one set of films of shop butt welds above specified and shall furnish all equipment and an operator at his own expense for the making of magnetic particle tests of shop fillet welds as above specified. All other costs of non-destructive inspection shall be borne by the State except that the Contractor shall furnish all labor and equipment required to move and position the various members for inspection. No additional compensation shall be granted to t he Contractor for moving, handling, rehandling or positioning the members to facilitate testing.
824.03.8 Machining.
a.Edge Planing. Sheared edges of plates more than 5/8-inch in thickness and carrying calculated stress shall be planed to a depth of 1/4-inch. Re-entrant cuts shall be filleted before cutting.
b.Oxygen Cutting. Steel and weld metal may be oxygen cut, provided a smooth and regular surface free from cracks and notches is se cured, and provided that an accurate profile is secured by the use of a mechanical guide. Hand cutting shall be done only where approved by the Engineer. Mill scale and extraneous material shall be remo ved from the torch side of A514/A517 steel plates along the lines to be flame cut, when necessary to obviate excessive notches. All oxygen cutting shall be in accordance with AW S D.1.5, except that occasional notches or gouges in edges of A514/A517 steel shall not be repaired by welding except under the following conditions: 8−138 1. Cutting defects not more than 3/16-inch deep in plate edges which will form the faces of a groove weld joint and which will subsequently be completely fused with t he weld may be repaired by welding. Nonmetallic stringers or pipes opening to these edges shall be removed to a depth of 1/4-inch below the surface by grinding or chipping and the gouge repaired by welding. Laminations opening to these edges shall be removed to a depth of ½-inch below the surface by grinding and chipping and the gouge repaired by welding.
2.Cutting defects not more than 3/16-inch deep in plate edges which will form a fillet- welded corner joint shall be repaired by welding only on the part of the edge which will become the facing surface for the joint and the fusion zone of the fillet weld. The part of the defect outside the toe of the completed fillet weld shall be removed by machining or grinding, and faired with the surface of the cut on a bevel of 1 to 6 or less.
3.All welding for these repairs shall be made by suitably preparing the defect, welding with low hydrogen electrodes not exceeding 5/32-inch in diameter, and grinding the completed weld smooth and flush with the adjacent surface to produce a workmanlike finish. Oxygen cut edges of ASTM A440 steel and ½-inch or greater in thickness
1.shall be removed to a depth of at least 1/8-inch by machining or grinding except that machine flame cut edges may be used without such removal if the edges are softened after cutting; (a) by heating the cut edge uniformly and progressively to a red heat, visible in ordinary shop light (1,150 to 1,250 OF) to a depth of at least 1/16-inch; or (b) by means of a post heating torch attached to and following the cutting torch with the tips, gas pressure, speed or travel, and the distance of the post heating torch from the kerf regulated to the thickness of the steel. Bend test specimens 1½-inches wide and of the full thickness of the material or with thickness reduced to 3/4-inch in accordance with Para. 6.8 of ASTM A6 and having edges flame cut and flame softened in accordance with this article shall meet the bend test requirements specified in ASTM A440 for the thickness of material under consideration. Oxygen cut surfaces of members carrying ca lculated stress shall have their corners rounded to 1/16-inch radius by grinding after cutting. Note (1): ASTM A242 steel not approved for welded construction requires this treatment of oxygen cut edges in all thicknesses and with bend tests, as applicable, conforming to ASTM A242 for the thickness of material under consideration.
c.Facing of Bearing Surfaces. The top and bottom surfaces of steel slabs and base plates and cap plates of columns and pedestals shall be straight and true to provide full bearing between contact areas. Sole plates of beams and girders shall have full contact with the flanges. Cast pedestals shall be machined on surfaces to be in contact wi th steel and shall be rough finished on surfaces to be in contact with masonry. Surfaces of bronze bearing plates intended for sliding contact shall be finished. The surface of expansion bearings shall be machined in the direction of the major expansion. The surface finish of bearing and base plates and ot her bearing surfaces that are to come in contact with each other or with concrete shall meet the ANSI surface roughness requirements as 8−139defined in ANSI B46.1, Surface Roughness, Waviness and Lay, Part I: Bearing Surfaces Roughness Requirements Steel slabs ANSI 2,000 Heavy plates in contact in shoes to be welded ANSI 1,000 Milled ends of compression members, milled or ground ends of stiffeners and fillers ANSI 500 Bridge rollers and rockers ANSI 250 Pins and pin holes ANSI 125 Sliding bearings ANSI 125
d.Abutting Joints. Abutting joints in compression members and girder flanges, and in tension members where so specified on the drawings, shall be faced and brought to an even bearing. Where joints are not faced, the opening shall not exceed 3/8-inch.
e.End Connection Angles. Floor beams, stringers and girders having end connection angles shall be built to exact length back to back of connection angles. If end connections are faced, the finished thickness of the angles shall not be less than that shown on the detail drawings.
f.Pins and Rollers. Pins and rollers shall be accurately turned to the dimensions shown on the drawings and shall be straight, smooth and free from flaws. The final surface shall be produced by a fine finishing cut as specified. Pin holes shall be bored true to the specified diameter, smooth and straight, at right angles with the axis of the completed member. The distance outside to outside of holes in tension members and inside to inside of holes in compression members shall not vary from that specified more than 1/32-inch. Boring of holes in built-up members shall be done after the riveting and welding is completed. The diameter of the pin hole shall not exceed that of the pin by more than 1/50-inch for pins 5 inches or less in diameter, or 1/32-inch for pins of larger size. Threads for all bolts and pins for structural steel construction shall conform to the American National Coarse Thread Series, Class 2, free fit, except that the pin ends having a diameter of 1 _- inches or more shall be threaded six threads to the inch. Finished members shall be true to line and free from twists, bends and open joints. Shearing and chipping shall be done carefully and accurately.
g.Fit of Stiffeners. End stiffeners, stiffeners over intermediate supports of girders, and stiffener angles intended as supports for concentrated loads shall be milled or ground to secure an even bearing against the flange. Intermediate stiffeners shall fit sufficiently tight to exclude water after being painted. Fillers under stiffeners shall fit within 1/4-inch at each end.
h.Annealing and Stress Relieving. Structural members which are indicated in the Contract to be annealed or normalized shall have finished machining, boring, and straightening done subsequent to heat treatment. Normalizing and annealing (full annealing) shall be as specified in ASTM E44. The temperatures shall be maintained uniformly throughout the furnace during the heating and cooling so that the temperature at no two points on the member will differ by more than 100 OF at any one time. 8−140 Members of AASHTO M270 (ASTM A709) Grades 100/100W or Grade 70W steels shall not be annealed or normalized and shall be stress relieved only with the approval of the Engineer. A record of each furnace charge shall identify the pieces in the charge and show the temperatures and schedule actually used. Proper instruments, including recording pyrometers, shall be provided for determining at any time the temperatures of members in the furnace. The records of the treatment operation shall be availabl e to and meet the approval of the Engineer. The holding temperature for stress relieving Grades 100/100W and Grade 70W steels shall not exceed 1100 OF and 1050OF, respectively. Members, such as bridge shoes, pedestals, or other parts which are built up by the welding sections of plate together shall be stress-relieved in accordance with the procedure of the American Welding Society Section 4.4 of the current ANSI/AASHTO/AWS D1.5 Bridge Welding Code when required by the Plans or Specifications. 824.03.9 Marking, Shipping, Delivering and Handling. Each member shall be painted or marked with an erection mark for identification and an erection diagram showing these marks shall be furnished to the Engineer. The Contractor shall furnish to the Engineer as many copies of material orders, shipping statements, and erection diagrams as the Engineer may direct. The weights of the individual members shall be shown on the statements. Members weighing more than 3 tons shall have the weights marked thereon. Structural members shall be loaded on trucks or cars in such a manner that they may be transported and unloaded at their destination without being excessively stressed, deformed, or otherwise damaged. Bolts, nuts and washers (where required) from each rotational-capacity lot shall be shipped in the same container. If there is only one production lot number for each size of nut and washer, the nuts and washers may be shipped in separate containers. Pins, small parts and packages of bolts, washers, and nuts shall be shipped in boxes, crates, kegs, or barrels, but the gross weight of any package shall not exceed 300 pounds. A list and description of the contained materials shall be plainly marked on the outside of each shipping container. The loading and delivery of the structural material shall be conducted so that the metal will be kept clean and free from injury. Girders and beams shall be kept upright and shored. Long members shall be supported on skids spaced to prevent injury from deflection. 824.03.10 Erection.
a.General. The Contractor shall provide the falsework and all tools, machinery and appliances, including drift pins and fitting bolts necessary for the expeditious handling of the work. Before starting work, the Contractor shall inform the Engineer fully as to the method of erection he proposes to follow, and the amount and character of equipment he proposes to use, all of which shall be subject to the approval of the Engineer. The approval of the Engineer shall not be considered as relieving the Contractor of the respons ibility for the safety of his method or equipment or from carrying out the work in full accordance with the Plans and these Specifications.
b.Transportation of Materials. The Contractor shall make the necessary arrangements for the unloading and the transporting and bear all charges for such unloading and hauling of the 8−141steel from the designated place of delivery to the point of placement. The Contractor shall unload promptly upon delivery any material delivered on railroad cars which he is required to unload, and shall be responsible for demurrage charges.
c.Storage of Materials at Site. Material to be stored shall be placed on skids above the ground. It shall be kept clean and properly drained. Girders and beams shall be placed upright and shored. Long members, such as columns and chords, shall be supported on skids placed near enough together to prevent injury from deflection. If the contract is for erection only, the Contractor shall check the material turned over to him against the shipping lists and report promptly in writing any shortage or injury discovered. The Contractor shall be responsible for the loss of any material while in his care, or for any damage caused to it after being received by him.
d.Falsework. The falsework shall be properly designed and substantially constructed and maintained for the loads which will come upon it. The Contractor shall prepare and submit to the Engineer for approval, plans for falsework or for changes in an existing structure necessary for maintaining traffic. Approval of the Contractor's plans shall not be considered as relieving the Contractor of his primary responsibility for the adequacy of the design.
e.Straightening Bent Material (Field). The straightening of plates, angles, other shapes, and built-up members, when permitted by the Engineer, shall be done by methods that will not produce fracture or other injury to the metal. Distorted members shall be straightened by mechanical means or, if approved by the Engineer, by carefully planned procedures and supervised application of a limited amount of localized heat, except that heat straightening of AASHTO M270 (ASTM A709) Grades 70W, 100 and 100W steel members shall be done only under rigidly controlled procedures, with each application subject to the approval of the Engineer. In no case shall the maximum temperature exceed values in the following table. Grade Max. Temp. Grade 70W > 6" from weld 1050 OF Grade 70W < 6" from weld 900OF Grade 100 or 100W > 6" from weld 1100OF Grade 100 or 100W < 6" from weld 950OF In all other steels, the temperature of the heated area shall not exceed 1,200 OF as controlled by temperature indicating crayons, liquids , or bimetal thermometers. Heating in excess of the limits shown shall be cause for rejection, unless the Engineer allows testing to verify material integrity. Parts to be heat straightened shall be substantially free of stress and from external forces, except stresses resulting from mechanical means used in conjunction with the application of heat. Evidence of fracture following straightening of a bend or buckle will be cause for rejection of the damaged piece.
f.Assembling Steel. The parts shall be accurately a ssembled as shown on the Plans and any match-marks shall be followed. The materials shall be carefully handled so that no parts will be 8−142 bent, broken or otherwise damaged. Hammering which will injure or distort the members shall not be done. Bearing surfaces and surfaces to be in permanent contact shall be cleaned before the members are assembled. Splices and field connections shall have one-half of the holes filled with bolts and cylindrical pins (half bolts and half pins) before riveting. Fitting-up bolts shall be of the same nominal diameter as the rivets, and cylindrical erection pins shall be 1/32-inch larger.
g.Bolted Connections. Surfaces of metal in contact shall be cleaned before assembling. The parts of a member shall be assembled, well pinned, and firmly drawn together before drilling, reaming, or bolting is commenced. Assembled pieces shall be taken apart, if necessary, for the removal of burrs and shavings produced by the operation. The member shall be free from twists, bends, and other deformation. The drifting done during assembling shall be only such as to bring the parts into position and not sufficient to enlarge the holes or distort the metal. For high-strength bolted connections, see Subsection 824.03.5 of this Section.
h.Field Welding. When field welding is specified, it shall be performed by the electric arc process and shall conform to the same requirements as noted under Subsection 824.03.6 with the following modifications: Unless approved by the Engineer, welding shall not be undertaken when the ambient temperature is lower than 32 OF, when surfaces are wet or exposed to rain, snow or high wind nor when the welders would be exposed to inclement conditions.
i.Misfits. The correction of minor misfits involving non-harmful amounts of reaming, cutting and chipping will be considered a legitimate part of the erection. However, any error in the shop fabrication or deformation resulting from handling and transportation which prevents the proper assembling and fitting up of parts by the moderate us e of drift pins or by a moderate amount of reaming and slight chipping or cutting, shall be reported immediately to the Inspector and his approval of the method of correction obtained. The correction shall be made in his presence. The Contractor shall be responsible for all misfits, errors and injuries and shall make all the necessary corrections and replacements.
j.Removal of Falsework. Upon completion of the erection and before final acceptance, the Contractor shall remove all falsework, excavated or useless materials, rubbish and temporary buildings and restore in an acceptable manner a ll property, both public and private which may have been damaged during the prosecution of this work, and shall leave the bridge site and adjacent highway in a neat and presentable condition satisfactory to the Engineer. 824.03.11 Surface Preparation for Weathering Steel.
a.Cleaning After Fabrication. After completion of fabrication operations all steel surfaces shall be blast cleaned in accordance with the requirements of Steel Structures Painting Council Surface Preparation Specification No. 6 - "Commercial Blast Cleaning," SSPC-SP 6. Particular attention shall be given to all exposed surfaces including the outside face and bottom side of fascia girders and all exposed fascia welds. 8−143
b.Handling. All cleaned steel is to be handled carefully to keep it clean. The steel is to be treated with the care and concern that is required for any finished architectural product. Exposed steel shall be kept free and clean of all foreign material such as grease, oil, concrete spatter, chalk marks, crayon marks, dirt, etc. Natural oxidation of the steel shall not be considered foreign matter.
c.Final Cleaning. After the deck is in place and all formwork has been removed, the steel surfaces will be inspected for stains, discoloration, and any other deleterious materials which may affect the weathering of the steel in a uniform manner. Stains, discoloration, and any other deleterious materials on exterior surfaces of fascia girders shall be removed by high pressure (5000-10,000 psi) water cleaning. It may be necessary to add a chemical cleaning agent, with the approval of the Engineer, to the high-pressure cleaning to remove staining. If high pressure water cleaning does not remove the stains, the Contractor shall propose an alternate cleaning method, subject to the approval of the Engineer. Once the final cleaning is accomplished no further use of the structural steel for attachment or support will be allowed. 824.03.12 Shear Connectors.
a.Welding . Stud shear connectors shall be end-welded to steel beams or girders (on axes parallel to the transverse reinforcement) with automatically timed stud welding equipment connected to a suitable power source. If two or more stud welding guns are to be operated from the same power source, they shall be interlocked so that only one gun can operate at a time and so that the power source has fully recovered from making one weld before another weld is started. At the time of welding, the studs and beams shall be free from moisture, rust, rust pits, scale, oil or other deleterious matter which would adversely affect the welding operation. Welding shall not be done when the ambient temperature is below 32 OF, or when the surface is wet or exposed to rain or snow. While in operation, the welding gun shall be held in position without movement until the weld metal has solidified. Longitudinal and lateral spacings of studs with respect to each other and to edges of beam or girder flanges shall not vary more than one-half inch from the dimensions shown on the Plans, except that a diagonal variation of 1 inch will be permitted where required to avoid obstruction with other attachments on the beam or where a new stud is being welded to replace a defective one. The minimum distance from the edge of a stud to the edge of a beam shall be 1 inch, but preferably not less than 1½-inches. The first two studs welded on each beam or girder , after being allowed to cool, shall be bent O by striking the stud with a hammer. If failure occurs in the weld of either stud, the procedure shall be corrected and two successive studs successfully welded and tested before any more studs are welded to the beam or girder. The Engineer s hall be promptly informed of any changes in the welding procedure at any time during construction. If the reduction in the height of studs as they are welded becomes less than normal, welding shall be stopped immediately and not resumed until the cause has been corrected. 8−144 Before welding a new stud where a defective one has been removed, the area shall be ground smooth and flush, or in the case of a pullout of metal, the pocket shall be filled with weld metal using the shielded metal-arc process wi th low-hydrogen welding electrodes and then ground flush. In compression areas of flanges, a new stud may be welded adjacent to the defective area in lieu of repair and replacement on the existing weld area.
b.Inspection . If visual inspection reveals any stud which does not show a full 360- degree weld, any stud which has been repaired by welding, or any stud in which the reduction in height due to welding is less than normal, such stud shall be struck with a hammer and bent 15 degrees off the vertical. For studs showing less than 360-degree weld, the direction of bending shall be opposite to the lack of weld. Studs that crack either in the weld or the shank shall be replaced. The Engineer may select additional studs to be subjected to the bend test specified above. The studs tested that show no sign of failure may be left in the bent position. If, during the progress of the work, inspection and testing indicate in the judgment of the Engineer, that the shear connectors being obtained are not satisfactory, the Contractor will be required at his expense to make such changes in welding procedure, welding equipment and type of shear connector as necessary to secure satisfactory results. At the option of the Engineer, the manufacturer of the studs may be required at any time to submit requalification test data in accordance wi th the procedure as set forth in AASHTO Standard Specifications for Highway Bridges.
824.04 Method of Measurement.
824.04.1 General. "Structural Steel" of the various types and configurations described in this
Section will be measured by the number of pounds of each such type and configuration actually provided in accordance with the Plans and/or as directed by the Engineer. For the purpose of measurement, such items as castings, forgings, wrought iron, special alloy steels, weld metal and special shapes for expansion joints, shear connectors, drainage fixtures, or railing shall, unless otherwise covered by Special Provisions, be considered as structural steel even when made of other materials. 824.04.2 Unit Weights. The weight of metal shall be computed on the basis of the following unit weights expressed in pounds per cubic foot: Metal Unit Weights Aluminum, cast or rolled 173.0 Bronze or copper alloy 536.0 Copper, sheet 558.0 Iron, cast 445.0 Iron, wrought 487.0 Iron, malleable 470.0 Lead, sheet 707.0 8−145Steel, cast or rolled, including alloys, copper bearing and stainless 490.0 Zinc 450.0
a.Estimated Overrun. The weights of steel shapes and plates shall be computed on the basis of their nominal weights and dimensions as shown on the approved shop drawings and after deducting for open holes. To the nominal theoretical weight of all universal mill and sheared plates and slabs, there shall be added an estimated overrun computed as one-half the "Permissible Variation in Thickness and Weight" as tabulated in ASTM A6.
b.High Strength Bolts. The weight of high strength bolt heads and nuts shall be included on the basis of the following weights: Diameter of Bolt Weight per 100 Bolts in Inches in Pounds ½ 19.7 5/8 31.7 3/4 52.4 7/8 80.4 1 116.7 1/8 165.1 1¼ 212.0 13/8 280.0 1½ 340.0
c.Weld Metal. The weight of weld metal to the net length called for on the drawings shall be included based on the following table: Size of Fillet Weight in Pounds in Inches per Foot of Weld 3/16 .08 1/4 .14 5/16 .22 3/8 .30 ½ . 5 5 5/8 .80 3/4 1.10 7/8 1.50 1 2.00 If the Contract does not include erection by the fabricator, field welds shall not be included. The weight of temporary erection bolts, shop and field paint, galvanizing and material used for shipping and erection shall not be included.
d.Castings. The weight of castings shall be computed from the dimensions shown on the approved shop drawings, deducting for open holes. To the weight will be added a 5 percent 8−146 allowance for fillets and overrun. Scale weights may be substituted for computed weights in the case of castings or of small complex parts for which accurate computation of weights would be difficult. 824.04.3 Surface Preparation for Weathering Steel. This work will not be measured separately for payment. 824.04.4 Shear Connectors. “Welded Stud Shear Connectors” will be measured by the number of each such piece actually welded to steel flanges in accordance with the Plans and/or as directed by the Engineer.
824.05 Basis of Payment.
824.05.1 Structural Steel; Furnish, Fabricate and Erect. The accepted quantity of "Structural Steel; Furnish, Fabricate and Erect" will be paid for at the contract unit price per pound as listed in the Proposal. The price so-stated constitutes full and complete compensation for all labor, materials, and equipment, including fabricating, delivering, erecting, shop and field painting unless specified otherwise, and all incidentals required to finish the work, complete and accepted by the Engineer. 824.05.2 Structural Steel; Furnish and Fabricate. The accepted quantity of "Structural Steel;
Furnish and Fabricate" will be paid for at the contract unit price per pound as listed in the Proposal. The price so-stated constitutes full and complete compensation for all labor, materials and equipment, including fabricating, delivering, and all incidentals required to finish the work, complete and accepted by the Engineer. 824.05.3 Structural Steel; Erect. The accepted quantity of "Structural Steel; Erect" will be paid for at the contract unit price per pound as listed in the Proposal. The price so-stated constitutes full and complete compensation for all labor, materials and equipment, including erection and all incidentals required to finish the work, complete and accepted by the Engineer. 824.05.4 Surface Preparation for Weathering Steel. No separate payment will be made for this work. Rather, payment will be included with the payment, and at the contract unit price per pound as listed in the Proposal, for "Structural Steel; Weathering."
824.05.5 Shear Connectors. The accepted quantity of “Welded Stud Shear Connectors” will be
paid for at the contract unit price as listed in the Proposal. The price so-stated constitutes full and complete compensation for all labor, materials, and equipment, and all incidentals required to finish the work, complete, in place and accepted by the Engineer.
Source: Rhode Island Standard Specifications (Bluebook), 2024 Edition. Pages 454–480 of 826.