SECTION 824 — STRUCTURAL STEEL CONSTRUCTION — STRUCTURAL STEEL CONSTRUCTION
824.01 Description.
This work includes furnishing, fabricating, and erecting all structural steel at the required locations. Structural steel includes carbon, special alloy steels, steel forgings, steel and iron castings, and weldments. In addition to this Specification, ensure that all structural steel work conforms to the applicable requirements in the current editions of the AASHTO LRFD Bridge Design Specifications and the AWS D1.5 Bridge Welding Code.
824.02 Materials.
General. Use materials that conform to the following. Material Standard Specification Reference Structural Steels Subsection M05.05.1 Steel Bars and Forgings Subsection M05.05.2 Structural Tubing Subsection M05.05.3 Bolts, Nuts, Washers Subsection M05.05.4 Weld Metal Subsection M05.05.5 Shear Connectors Subsection M05.05.6 Low Alloy Nickel Copper Steel Pipe Subsection M05.05.7 Steel Forging and Shafting Subsection M05.05.8 Steel and Iron Castings Subsection M05.05.9 Shear Connectors. This work includes providing stud shear connectors welded to the flanges of steel beams or girders at the required locations. Ensure that the welded stud shear connectors comply with the AASHTO/AWS1.5M/D1.5 Bridge Welding Code provisions related to material, manufacturing, physical properties, certification, and welding. Ensure that shear connector studs have a design suitable for end-welding to steel beams and girders with automatically timed stud welding equipment. Ensure that finished studs are of uniform quality and condition, free from injurious laps, fins, seams, cracks, twists, bends, or other defects. Before placing orders for studs, submit to the Engineer for approval the following information on the studs to be purchased:
Part 800 — Bridge Structures August 2025
SECTION 824 — STRUCTURAL STEEL CONSTRUCTION 800-135 • The name of the manufacturer • A detailed description of the stud and arc shield to be furnished • A certification from the manufacturer that the stud to be furnished is qualified according to the currently adopted edition of the AASHTO LRFD Bridge Construction Specifications At the option of the Engineer, the manufacturer of the studs may be required at any time to submit requalification test data according to the procedure in Section 11 of the AASHTO LRFD Bridge Construction Specifications. Direct Tension Indicators (DTI). DTIs may be used in conjunction with bolts, nuts, and washers specified in Subsection M05.05.4. Ensure that the DTIs conform to ASTM F959, “Specification for Compressible-Washer Type Direct Tension Indicators for Use with Structural Fasteners, ” except as provided in the following paragraph. Subject to the approval of the Engineer, alternative design direct tension indicating devices may be used if they satisfy the requirements detailed in the specifications provided by the manufacturer.
824.03 Construction Methods.
Shop Drawings. Submit all Shop D rawings, erection diagrams, camber diagrams, and a list of bolts from the Plans furnished by the Department. The Engineer will review the submittals according to Subsection 105.02. Inspection and Testing.
a.Mill Orders. Furnish four copies of mill orders. Do not roll the material or perform work before the Engineer has been notified where the orders have been placed so that he/she 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. Furnish suitable testing equipment, properly calibrated. Prepare the pieces for the testing machine at no cost to the Department. The manufacturer shall perform all testing of materials. Furnish the Engineer with four copies of the mill report of the chemical and physical tests before starting work. Do not cut off any markings until the inspector has established the heat and designation and determined the method of continued identity. Perform inspection and testing that conforms to SECTION 106.
b.Shop. Notify the Engineer 48 hours in advance of the start of work in the shop so that an inspector can be on hand to inspect the material and workmanship.
Part 800 — Bridge Structures August 2025
800-136 SECTION 824 — STRUCTURAL STEEL CONSTRUCTION The fabricator shall furnish all facilities for inspecting and testing the weight and quality of workmanship at the shop where the material is fabricated. Provide suitable testing equipment, properly calibrated, for the Department Inspector. Provide full and safe access at all times and to all parts of the mills or shops where the material is being manufactured or fabricated.
c.S ite. The Engineer may waive shop inspections and instead inspect all fabricated material when delivered at the work site. However, if the Engineer rejects defective material, its repair or replacement will be performed at no additional cost to the Department, including any additional shipping costs. Furnish a minimum of four copies of shipping statements that include the weights of the individual members. Furnish a Certificate of Identification as defined in Subsection 11.4.1 of the AASHTO LRFD Bridge Construction Specifications.
d.Delegation of Authority. The Department may delegate inspection and testing to an independent, accredited 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 the decision to the Engineer whose decision will be final. Fabrication.
a.Storage of Materials. Store structural material, either plain or fabricated, at the bridge shop above the ground and on platforms, skids, or other supports. Keep the materials free from dirt, grease, and other foreign matter and protected from any corrosion that will degrade the performance of the element.
b.Ho les for High -Strength Bolts and Unfinished Bolts. ● General. Ensure that all holes for bolts are either punched or drilled. Material forming parts of a member composed of not more than five thicknesses of metal may be punched 1/16 in. larger than the nominal diameter of the bolts when the thickness of the material is not greater than ¾ in. for structural steel, ⅝ in. for high-strength steel, or ½ in. for quenched and tempered alloy steel. When there are more than five thicknesses or when any of the main material is thicker than ¾ in. for structural steel, ⅝ in. for high-strength steel, or ½ in. for quenched and tempered alloy steel, ensure that all holes are either subdrilled and reamed or drilled full size with sufficient tolerance to ensure that the standard size bolt pass es though all parts without interference. When required, ensure that all holes are either subpunched or subdrilled (subdrilled if thickness limitation governs) 3/16 in. smaller and, after assembling, reamed 1/16 in. larger or drilled full size to 1/16 in. larger than the nominal diameter of the bolts.
Part 800 — Bridge Structures August 2025
SECTION 824 — STRUCTURAL STEEL CONSTRUCTION 800-137 When shown on the Plans, enlarged or slotted holes are allowed with high-strength bolts. ● Punched Holes. Ensure that the diameter of the die does not exceed the diameter of the punch by more than 1/16-in. If any holes must be enlarged to admit the bolts, ream the holes. Ensure that the holes are clean cut without torn or ragged edges. ● Reamed or Drilled Holes. Ensure that reamed or drilled holes are cylindrical, perpendicular to the member, and comply with the requirements of Para. b, first bullet above for size. Where practical, direct reamers by mechanical means. Remove burrs on the outside surfaces and finish the holes with a slight chamfer . Perform reaming and drilling with twist drills, twist reamers, or rotobroach cutters. Assemble connecting parts requiring reamed or drilled holes that securely hold while being reamed or drilled and that are match marked before disassembling. ● Accuracy of Holes. Holes not more than 1/32 in. larger in diameter than the true decimal equivalent of the nominal diameter that may 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. This would have the 1/32-in. tolerance, with the minimum at the small end of the taper being at least a clearance fit. Ensure that the width of slotted holes that are produced by flame cutting or a combination of drilling or punching and flame cutting are not more than 1/32 in. greater than the nominal width. Grind smooth the flame cut surface.
c.A ccuracy of Hole Group. ● Accuracy Before Reaming. Ensure that all holes punched full size, subpunched, or subdrilled are accurately punched so that, after assembling (before any reaming is done), a cylindrical pin ⅛ in. 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 in. smaller in diameter than the nominal size of the punched hole, this will be cause for rejection. ● Accuracy After Reaming. When holes are reamed or drilled, ensure that 85 percent of the holes in any contiguous group, after reaming or drilling, show no offset greater than 1/32 in. between adjacent thicknesses of metal. Ensure that all steel templates have 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.
d.Holes for Ribbed Bolts, Turned Bolts, or other Approved Bearing-Type Bolts. Subpunch or subdrill all holes for ribbed bolts, turned bolts, or other approved bearing-type bolts 3/16-in. 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. Ensure that the finished holes provide a driving fit as specified.
Part 800 — Bridge Structures August 2025
800-138 SECTION 824 — STRUCTURAL STEEL CONSTRUCTION
e.Preparation of Field Connections. Subpunch or subdrill holes in all field connections and field splices of main members of trusses, arches, continuous beam spans, bents, towers (each face), plate girders, and rigid frames 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. Subpunch and ream all holes for floor beam and stringer field end connections while assembled or drilled full size to a steel template. Perform reaming or drilling full size of field connection holes through a steel template after the template has been located in the correct position and angle and firmly bolted in place, using at least two holes previously drilled for the connection. Ensure that templates used for reaming matching members, or the opposite faces of a single member, are duplicates within 1/32 in. Accurately locate templates used for connections on like parts or members so 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, as an option, drill holes full size with all thicknesses or material assembled in the proper position with the hole locations matching the Plans/Shop Drawings. Bolts and Bolted Connections Using Unfinished, Turned, and Ribbed Bolts.
a.General. Ensure that bolts are unfinished, turned, or an approved form of ribbed bolts as designed. Ensure that bolts have hexagonal heads and nuts and are of a length that they will extend entirely thorough the nut but not more than ¼ in. beyond after completing torquing of the connection. Use beveled washers where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis. Ensure that bolts have single, self-locking nuts or double nuts.
b.Unfinished Bolts. Ensure that bolts in shear have not more than one thread within the grip. Ensure that the diameter of the unfinished bolt is not more than 1/16 in. smaller than the diameter of the hole.
c.Tur ned Bolts. Ream holes for turned bolts, and turn the bolts to a light driving fit, with threads entirely outside of holes, and use a washer. Use ¼ -in. nut locks on all turned bolts.
d.R ibbed Bolts. Special types of ribbed bolts, with drive fit, may be used if approved by the Engineer. If the bolt twists before drawing tight, remove the bolt , re-ream the hole, and replace with an oversized bolt. Size t he reamed hole to meet industry standard practices to hold the bolt in place at the required torque. Re-ream the hole to the minimum proper size to hold the next largest standard size bolt, which shall be used as a replacement.
Part 800 — Bridge Structures August 2025
SECTION 824 — STRUCTURAL STEEL CONSTRUCTION 800-139 Connections Using High-Strength Bolts.
a.General. This Subsection addresses the assembly of structural joints using ASTM F3125 Grade A325 and A490 high strength carbon steel bolts or equivalent fasteners, tightened to a high tension. The bolts are used in holes conforming to Subsection 824.03.3.
b.B olted Parts. Ensure that the slope of surfaces of bolted parts in contact with the bolt head and nut do not exceed 1:20 with respect to a plane normal to the bolt axis. Fit bolted parts solidly together when assembled and do not separate the bolts by gaskets or any other interposed compressible material. When assembled, ensure that all joint surfaces, including those adjacent to the bolt heads, nuts or washers, are free of scale, except tight mill scale, and are also free of dirt, loose scale, burrs, other foreign material and other defects that would prevent solid seating of the parts. Ensure that contact surfaces within friction-type joints are free of oil, paint, lacquer, rust inhibitor or galvanizing. After connection, ensure that primers and paint provide a moisture-tight joint.
c.Installation. Clean and lubricate the threads. Tighten each fastener to provide, when all fasteners in the joint are tight, at least the minimum bolt tension shown on the Bolt Tension Table in Para. f below. Tighten threaded bolts 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.
d.Washers. Provide all fasteners with 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, use a smooth beveled washer to compensate for the lack of parallelism. On diaphragm connections using oversized holes, use a washer over every oversized hole regardless of the part turned in tightening.
e.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 that are assumed to relate torque to tension are not acceptable. When calibrated wrenches are used for installation, set the wrenches to provide a tension not less than 5 percent in excess of the minimum tension specified in the Bolt Tension Table in Para. f below. Calibrate the installation procedures by verification testing at least once each working day for each bolt diameter, length, and grade using fastener assemblies that are being installed in the work. Perform the verification testing in a device capable of indicating the actual bolt tension by tightening three typical bolts of
Part 800 — Bridge Structures August 2025
800-140 SECTION 824 — STRUCTURAL STEEL CONSTRUCTION each diameter, length, and grade from the bolts being installed and with a hardened washer from the washers being used in the work under the element turned in tightening. Recalibrate wrenches when a significant difference is noted in the surface condition of the bolts, threads, nuts, or washers. Perform the verification during the actual installation in the assembled steel work so 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. f below. If manual torque wrenches are used, turn nuts in the tightening direction when torque is measured. When calibrated wrenches are used to install and tension bolts in a connection, install the bolts with hardened washers under the element turned in tightening bolts in all holes of the connection and bring to a snug tight condition. Following this initial tightening operation, tighten the connection using the calibrated wrench. Ensure that t ightening progresses systematically from the most rigid part of the joint to its free edges. Return the wrench to touch up previously tightened bolts that may have been relaxed as a result of the subsequent tightening of adjacent bolts until all bolts are tightened to the prescribed amount.
f.Turn-of-Nut Tightening. Perform the 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 at the start of work in a device capable of indicating bolt tension. Ensure that this verification test demonstrates that the method for estimating the snug tight condition and controlling the turns from snug tight to be used by the bolting crew develops a tension not less than 5 percent greater than the tension required by the Bolt Tension Table below. Perform periodic retesting when ordered by the Engineer. Bolt Tension Table Minimum Bolt Tension In Pounds* Bolt Size, in Inches A325 Bolts A490 Bolts ½ 12,000 15,000 ⅝ 19,000 24,000 ¾ 28,000 35,000 ⅞ 39,000 49,000 1 51,000 64,000 1⅛ 64,000 80,000 1¼ 81,000 102,000 1⅜ 97,000 121,000 1½ 118,000 148,000 * Equal to 70 percent of specified minimum tensile 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. After snug tightening fasteners and fully compacting the connection, further tighten all bolts in the connection by the applicable amount of rotation specified in the Nut Rotation Table below. During the tightening operation, do not allow any rotation of the part not turned by the wrench. Tighten by progressing systematically from the most rigid part of the joint to its free edges.
Part 800 — Bridge Structures August 2025
SECTION 824 — STRUCTURAL STEEL CONSTRUCTION 800-141 Nut Rotation from the Snug Tight Condition a,b Geometry of Outer Faces of Bolted Parts Bolt length measured from underside of head to end of bolt Both faces normal to bolt axis One face normal to bolt axis and other face sloped not more than 1:20. Bevel washer not used Both faces sloped not more than1:20 from normal to bolt axis. Bevel washers not used Up to and including 4 diameters ⅓ turn ½ turn ⅔ turn Over 4 diameters but not exceeding 8 diameters ½ turn ⅔ turn 5/6 turn Over 8 diameters but not exceeding 12 diameters c ⅔ turn 5/6 turn 1 turn Notes: a Nut rotation is relative to bolt, regardless of the element (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 ⅔ 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 on Riveted and Bolted Structural Joints to establish the turn-of-nut procedure when bolt lengths exceed 12 diameters. Therefore, the required rotation must be determined by actual tests in a suitable tension device simulating the actual conditions.
g.Inspection. The Engineer will approve the procedure for calibration of wrenches and installation of bolts and will further observe the field installation to determine that these procedures are followed. Spot checks will be made with a manual torque wrench that has been calibrated as previously specified. Welding.
a.General. Ensure that all welding, welder qualifications, prequalification of weld details, and inspection of welds conform to ANSI/AASHTO/AWS D1.5 Bridge Welding Code. Do not weld or tack brackets, clips, shipping devices, or other material not required by the Contract to any member unless shown on the Shop Drawings and approved by the Engineer in writing.
Part 800 — Bridge Structures August 2025
800-142 SECTION 824 — STRUCTURAL STEEL CONSTRUCTION
b.Qualification of Welders. Ensure that a ll work is according to the best modern practices using qualified welding operators. Use the same type of equipment as required for the execution of the actual construction work in qualifying welders and welding operators. If the Contractor prequalifies its metal -arc welding operators according to the standard qualification procedures 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 the operator has been performing satisfactory welding of the required type within the three -month period previous to the subject work. Submit a certification for each operator and for each Project, stating the: ● Name of the operator ● Name and title of the person who conducted the examination ● Type of specimens ● Positions of welds ● Results of the test ● Date of the examination ● Identifying steel stamp symbol assigned The prequalification certification may also be accepted as proof that an operator of field welding is qualified, if the Contractor who submits the certificate is properly staffed and equipped to conduct such an examination or if the examining and testing is performed by a recognized agency that is staffed and equipped for this purpose. The qualification of a welder shall not prohibit his/her subsequent removal from the job for poor workmanship in the execution of welds. The welder shall place his identification stamp near the welds that he/she has made. Perform shop welding in areas sheltered from wind and weather with an ambient minimum temperature of 50°F.
c.Qualification of Welding Procedure. Submit a complete welding procedure specification for welding all primary members and other members on which welds are subject to calculated stress before proceeding with fabrication.
d.P rocedures for Manual Shielded Metal -Arc Welding. Position the work for flat position welding when practical. Inspection of Welds.
a.General. All welding, both shop and field, will be subject to inspection by the Engineer according to the ANSI/AASHTO/AWS D1.5 Bridge Welding Code, as amended herein. A minimum routine inspection program is outlined in Table 1. However, do not construe the inspection to be limited to the program described.
b.V isual Inspection of Welds and Welding Operations . Allow unlimited, safe access to the site of welding operations to allow the Engineer to observe the procedure and techniques used on all welds.
Part 800 — Bridge Structures August 2025
SECTION 824 — STRUCTURAL STEEL CONSTRUCTION 800-143
c.Non-Destructive Testing. Implement a routine program of non -destructive testing on all welds (shop and field) carrying calculated stress as indicated in the Table on the next page. Non-destructive testing will be performed by the Department. Radiograph and furnish one set of films of shop butt welds and furnish all equipment and an operator at no cost to the Department for making magnetic particle tests of shop fillet welds. Furnish all labor and equipment required to move and position the various members for inspection. Machining. Ensure that the steel fabricator machines all steel according to the ASIC Quality Certification Program, the American Society for Nondestructive Testing, and the Steel Structures Technology Center Structural Bolting Handbook. Marking, Shipping, Delivering, and Handling. Paint or mark each member with an erection mark for identification that is suitably durable or permanent. Furnish an erection diagram showing these marks. Furnish as many copies of material orders, shipping statements, and erection diagrams as the Engineer may direct. Record the weights of the individual members on the statements. Ensure that members weighing more than 3 tons have the weights marked thereon. Load structural members on trucks or cars with proper dunnage and support so that they can be transported and unloaded at their destination without being excessively stressed, deformed, or otherwise damaged. Ship bolts, nuts, and washers (where required) from each rotational -capacity lot 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. Ship pins, small parts and packages of bolts, washers, and nuts in boxes, crates, kegs, or barrels, but ensure that the gross weight of any package does not exceed 300 lb. Clearly mark a list and description of the contained materials on the outside of each shipping container. Conduct the loading and delivery of the structural material so that the metal and its coating will remain clean and free from damage. Keep girders and beams upright and shored. Support long members on skids spaced to prevent damage from deflection. Erection.
a.General. 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, inform the Engineer as to the method of erection, and the amount and character of equipment proposed to be used, which is subject to the approval of the Engineer.
Part 800 — Bridge Structures August 2025
800-144 SECTION 824 — STRUCTURAL STEEL CONSTRUCTION Non-Destructive Testing Program Type of Weld Percentage (Number, Quantity) of Weld(s) to be Tested Inspection Remarks Flange to flange butt welds – tension 100% Radiographic Flange to flange butt welds – compression 50% (selected at random by the Engineer) Radiographic If any radiographed joint is rejected, radiograph all compression grooved welds of this member 100%. Web to web butt welds One-third of depth closest to tension flange of each weld Radiographic If quality of the portion radiographed is unsatisfactory, radiograph entire weld. Flange plate to cover plate fillet weld 10% (each end of each weld and other locations to be selected at random by the Engineer) Approved magnetic particle Increase quantity of weld to be inspected if quality of initially inspected weld proves unsatisfactory. (See AWS D.2.0 as amended by Circular Memo). Flange to web fillet welds 10% (each end of each weld and other locations to be selected at random by the Engineer) Approved magnetic particle Increase quantity of weld to be inspected if quality of initially inspected weld proves unsatisfactory. (See AWS D.2.0 as amended by Circular Memo). Repair of flame out edge with greater than 3/16 in. gage. 100% Radiographic Radiographing and laboratory report no expense to the Department.
b.Storage of Materials at Site. Place material to be stored on skids above the ground. Keep the material clean, free of graffiti, and properly drained. Place girders and beams upright and shored. Support long members, such as columns and chords, on skids placed close enough together to prevent injury from deflection. If the Contract is for erection only, check the material against the shipping lists and report promptly in writing any shortage or injury discovered.
c.Fal sework . Design the falsework, and construct and maintain the falsework for the applicable loads. Prepare and submit to the Engineer for approval in writing plans for falsework or for changes in an existing structure necessary for maintaining traffic. Approval of the plans does not relieve the Contractor of its primary responsibility for the adequacy of the design.
d.S traightening Bent Material (Field). Perform the straightening of plates, angles, other shapes, and built-up members, when permitted by the Engineer, by methods that will not produce fracture or other injury to the metal. Straighten distorted members by mechanical means or, if approved by the Engineer, by effective procedures and the supervised application of a limited amount of localized heat. As an exception, perform the heat straightening of AASHTO M270 (ASTM A709) Grades 70W, 100, and 100W steel members only under rigidly controlled procedures, with each application subject to the
Part 800 — Bridge Structures August 2025
SECTION 824 — STRUCTURAL STEEL CONSTRUCTION 800-145 approval of the Engineer. Do not allow the maximum temperature to exceed the values in the following table. Grade Max. Temp Grade 70W > 6 in. from weld 1050°F Grade 70W < 6 in. from weld 900°F Grade 100 or 100W > 6 in. from weld 1100°F Grade 100 or 100W < 6 in. from weld 950°F In all other steels, do not allow the temperature of the heated area to exceed 1200°F, as controlled and monitored by temperature indicating crayons, liquids, or bimetal thermometers or by other methods as approved by the Engineer . Heating in excess of the limits shown shall be cause for rejection, unless the Engineer allows testing to verify material integrity. Ensure that parts to be heat straightened are substantially free of stress and from external forces, except stresses resulting from mechanical means used in conjunction with the application of heat. Evidence of fracture following straightening of a bend or buckle will be cause for rejection of the damaged piece.
e.Assembling Steel. Handle the materials so that no parts are bent, broken, or otherwise damaged. When hammering material, avoid damage or distortion of the members. Repair all damage to coatings according to SECTION 825 at no additional cost to the Department. Clean bearing surfaces and surfaces to be in permanent contact before the members are assembled. Ensure that splices and field connections have one-half of the holes filled with bolts and cylindrical pins (half bolts and half pins). Use fitting -up bolts that are the same nominal diameter, and ensure that cylindrical erection pins are 1/32 in. larger.
f.Bolted Connections. Clean the surfaces of metal in contact before assembling. Assemble the parts of a member and ensure that the parts are well pinned and firmly drawn together before drilling, reaming, or bolting is commenced. Take apart assembled pieces, if necessary, for the removal of burrs and shavings produced by the operation. Ensure that the member is free from twists, bends, and other deformations. Ensure that the drifting performed during assembly is only that needed to position the parts and does not enlarge the holes or distort the metal. For high strength bolted connections, see Subsection 824.03.5.
g.Field Welding. When field welding is specified, perform the welding by the electric arc process, and ensure that it conforms to the same requirements in Subsection 824.03.6 with the following modifications.
Part 800 — Bridge Structures August 2025
800-146 SECTION 824 — STRUCTURAL STEEL CONSTRUCTION Unless approved by the Engineer, do not undertake welding when the ambient temperature is lower than 32°F, when surfaces are wet or exposed to rain, snow, or high wind, nor when the welders would be exposed to inclement conditions.
h.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, report immediately to the Engineer if any error in the shop fabrication or deformation resulting from handling and transportation that prevents the proper assembling and fitting up of parts by the moderate use of drift pins or by a moderate amount of reaming and slight chipping or cutting, and secure his/her approval of the method of correction. Make the correction in his/her presence. Surface Preparation for Weathering Steel.
a.Cleaning After Fabrication. After completion of fabrication operations, blast clean all steel surfaces according to SSPC-SP 6, “Steel Structures Painting Council Surface Preparation Specification No. 6 - Commercial Blast Cleaning.” Emphasize the inspection of all exposed surfaces, including the outside face and bottom side of fascia girders and all exposed fascia welds.
b.H andling. Ensure that all steel remains clean. Ensure that exposed steel remains clean of all foreign material such as grease, oil, concrete spatter, chalk marks, crayon marks, dirt, etc. Natural oxidation of the steel is not considered foreign matter.
c.Fi nal Cleaning. After the deck is in place and all formwork has been removed, inspect the steel surfaces for stains, discoloration, and any other deleterious materials that may affect the weathering of the steel in a uniform manner. Remove stains, discoloration, and any other deleterious materials on exterior surfaces of fascia girders by high pressure (5000 - 10,000 psi) water cleaning. If necessary, 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, propose an alternative cleaning method, subject to the approval of the Engineer in writing. Ensure that the surrounding area is protected from contamination. Avoid any damage to the adjacent concrete. Once the final cleaning is accomplished, do not use the structural steel for attachment or support. Shear Connectors.
a.Welding. End-weld stud shear connectors to steel beams or girders (on axes parallel to the transverse reinforcement) with automatically timed stud welding equipment connected to a suitable power source. Ensure compliance with Subsection 824.03.7. If two or more stud welding guns will be operated from the same power source, interlock the gunsso 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. Do not perform welding when the ambient temperature is below 32°F or when the surface is wet or exposed to rain or snow.
Part 800 — Bridge Structures August 2025
SECTION 824 — STRUCTURAL STEEL CONSTRUCTION 800-147 While in operation, hold the welding gun in position without movement until the weld metal has solidified. Ensure that longitudinal and lateral spacings of studs with respect to each other and to edges of beam or girder flanges do not vary more than ½ in. from the dimensions shown on the Plans, except that a diagonal variation of 1 in. 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. Ensure that the minimum distance from the edge of a stud to the edge of a beam is 1 in. but preferably not less than 1½ in. Bend the first two studs welded on each beam or girder, after being allowed to cool, to 45° by striking the stud with a hammer. If failure occurs in the weld of either stud, correct the procedure and attain two successive studs successfully welded and tested before any more studs are welded to the beam or girder. Promptly inform the Engineer 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, cease welding immediately and do not resume until the cause has been corrected. Before welding a new stud where a defective one has been removed, ground smooth and flush the area or, for a pullout of metal, fill the pocket with weld metal using the shielded metal-arc process with 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 that does not show a full 360-degree weld, any stud that has been repaired by welding, or any stud in which the reduction in height due to welding is less than normal, strike the stud with a hammer and bend the stud 15 degrees off the vertical. For studs showing less than a 360-degree weld, ensure that the direction of bending is opposite to the lack of weld. Replace studs that crack either in the weld or the shank. 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 remain in the bent position.
824.04 Method of Measurement.
Structural Steel is measured by the pounds of each type and configuration provided. Castings, forgings, wrought iron, special alloy steels, weld metal, and special shapes for expansion joints, shear connectors, drainage fixtures, or railing are considered as structural steel even when made of other materials. Compute the weight of metal based on the following unit weights expressed in pounds per cubic foot:
Part 800 — Bridge Structures August 2025
800-148 SECTION 824 — STRUCTURAL STEEL CONSTRUCTION Metal Unit Weights (lb/cu ft) 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 Steel, cast, or rolled, including alloys, copper bearing, and stainless 490.0 Zinc 450.0 For the estimated overrun, compute the weight of steel shapes and plates based on their nominal weights and dimensions as shown on the approved Shop Drawings and after deducting for open holes. An estimated overrun computed as one-half the “Permissible Variation in Thickness and Weight” as tabulated in ASTM A6 will be added to all universal mill and sheared plates and slabs. For high strength bolts and nuts, compute the weight based on the following weights: Diameter of Bolt Bolts in Inches Weight per 100 Bolts in Pounds ½ 19.7 ⅝ 31.7 ¾ 52.4 ⅞ 80.4 1 116.7 1⅛ 165.1 1¼ 212.0 1⅜ 280.0 1½ 340.0 Compute the weight of weld metal to the net length called for on the Shop Drawings based on the following table: Size of Fillet in Inches Weight in Pounds Per Foot of Weld 3/16 0.08 ¼ 0.14 5/16 0.22 ⅜ 0.30 ½ 0.55 ⅝ 0.80 ¾ 1.10 ⅞ 1.50 1 2.00
Part 800 — Bridge Structures August 2025
SECTION 824 — STRUCTURAL STEEL CONSTRUCTION 800-149 If the Contract does not include erection by the fabricator, field welds will not be included. The weight of temporary erection bolts, shop, and field paint, galvanizing, and material used for shipping and erection will not be included. Compute the weight of castings from the dimensions shown on the approved Shop Drawings, deducting for open holes. Add a 5 percent allowance for fillets and overrun. Scale weights may be substituted for computed weights for castings or for small complex parts for which accurate computation of weights is difficult. Surface preparation for weathering steel will not be measured separately for payment. Welded Stud Shear Connectors will be measured by the number of each piece welded to steel flanges.
824.05 Basis of Payment.
The Department will pay for the completed and accepted quantities as follows. Pay Item Pay Unit Structural Steel LB Welded Stud Shear Connectors EA Structural Steel. The price constitutes full compensation for all labor, materials, and equipment, including fabricating, delivering, erecting, shop and field painting, and all incidentals required to finish the work, complete and accepted. No separate payment will be made for surface preparation for weathering steel. This work is included with the payment, and at the Contract unit price, per pound for Structural Steel; Weathering. No additional compensation will be granted to the Contractor for moving, handling, rehandling or positioning the members to facilitate testing. Welded Stud Shear Connectors. The price constitutes full compensation for all labor, materials, and equipment, and all incidentals required to finish the work, complete, and accepted.
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Source: Standard Specifications for Road and Bridge Construction (Blue Book), 2022 (Aug 2025 compilation) Edition. Pages 503–518 of 951. View official source ↗