506STRUCTURAL STEEL

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5-85SECTIO N 506 – STRUCTURA L STEEL

506.0 1 DESCRIPTION . This work shall consist of furnishing, erecting, and , when specified, coating fabricated metal structures and structural components.

506.02MATERIALS . Materials shall meet the requirements of the following subsections:

Mortar, Type IV ................................ ................................ ................................ ......... 707.0 1(e) Powder Coating Systems ................................ ................................ ........................... 708.02 Structural Steel Coating Systems ................................ ................................ ............... 708.0 3 Grease Rustproofing Compound ................................ ................................ ................ 708.0 4 Structural Steel ................................ ................................ ................................ ........... 714.02 High -Strength Low -Alloy Structural Steel ................................ ................................ 714.03 Carbon Steel Bolts, Nuts , and Washers ................................ ................................ .....714.04 High -Strength Structural Bolts and Assemblies, 120 ksi ................................ ........... 714.05 High -Strength Structural Bolts and Assemblies, 150 ksi ................................ ........... 714.06 Anchor Bolts for Bearing Devices ................................ ................................ ............. 714.08 Welded Stud Shear Connectors ................................ ................................ ................. 714.10 Steel Tubing ................................ ................................ ................................ ............... 714.11 Direct Tension Indicators ................................ ................................ ........................... 714.12 Tension Control Assemblies ................................ ................................ ...................... 714.13 Galvanizing ................................ ................................ ................................ ................ 726.0 6 Metalizing ................................ ................................ ................................ .................. 726.0 7 Unless otherwise specified in the Contract, all steel shall be high -strength low -alloy structural steel conforming to the requirements of AASHTO M 270, Grade 345W (Grade 50W). All materials shall conform to the prescribed AASHTO or ASTM specifications and no substitutions will be allowed. 506.0 3 GENERA L FABRICATIO N REQUIREMENTS . Except as modified below, fabrication shall be performed in accordance with the applicable AASHTO design code, ANSI/AASHTO/AWS D1.5 (hereinafter designated as AWS D1.5 ), and interim specifications in effect on the date of Contract advertisement . Unless otherwise indicated in the Contract, the applicable AASHTO design code shall be the AASHTO LRFD Bridge Design Specifications .

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5-86Structural steel furnished under this section shall be fabricated in a plant having an AISC Certified Bridge

Fabricator – Advanced (ABR), or Intermediate (IBR) certification, and in a plant listed as a Category 1 fabricator on the Agency’s Pre-Qualified Fabricator List prior to Contract execution. Structural steel components such as bridge rail, bridge joints, bridge bearings, overhead sign structures , and compone nts for the repair of superstructures consisting of only cutting and drilling (no welding) which are fabricated under this section may be fabricated in a plant that does not have an ABR or IBR certification, provided that the fabrication plant has either a n AISC Certified Bridge Fabricator – Simple (SBR) certification or an AISC Bridge Component QMS certification, and is listed as a Category 2 fabricator on the Agency’s Pre-Qualified Fabricator List prior to Contract execution. Minor steel components, including, but not limited to, downspouts, scuppers, and pedestrian hand railings may be fabricated in a plant that does not have an AISC certification, provided that the fabrication plant is approved in writing by the Structural St eel Fabrication Engineer prior to Contract execution. All plants without certification shall have an organization, operation, and equipment capable of producing a product equal to a certified plant. These plants will be reviewed on a case -by-case basis. Structural steel that is to be painted or metalized under this section shall be coated in a plant having an AISC Sophisticated Paint Endorsement – Enclosed or SSPC -QP 3 – Enclosed Shop certification and which is listed as a Category 3 fabricator for the appl icable coating on the Agency’s Pre-Qualified Fabricator List prior to Contract execution. Structural steel that is to be galvanized or powder coated under this section shall also be coated in a plant listed as a Category 3 fabricator for the applicable coa ting on the Agency’s Pre-Qualified Fabricator List prior to Contract execution. The Agency’s Pre-Qualified Fabricator List can be found on the Agency ’s website. It is the responsibility of the fabricator to verify that they are on the list prior to bidding on work. It shall be known that being included on the list does not waive any certification requirements that are required for performing the intended work. Any fabricator who has been pre-qualified but does not perform any work for the Agency for a period of 5 years will be automatically removed from the list without notice. It is the fabricator’s responsibility to re -apply if they desire to be included on the list again . When certified fabrication or coating plants are required, the plant shall maintain certified status throughout the duration of the work under the Contract. The Agency reserves the right for the Structural Steel Fabrication Engineer to give written notification to any fabricator (regardless of certification level or status) restricting the types of items that they are approved to fabricate, up to and including restricting all structural steel fabrication for the Agency. Causes for such restrictions shall include concerns of quality, production, accountability, or any other cause that is deemed justifiable by the Agency.

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5-87The fabricator shall demonstrate full capability for fabricating materials meeting the requirements of the

Contract. Failure to meet Contract requireme nts will result in rejection of the material being fabricated and the termination of the ability to fabricate material for the Agency . Prior to performing any work under this section, the fabricator shall have received approval for all fabrication drawings , welding procedures , and any special Contract requirements and have notified the Agency’s Structural Steel Fabrication Engineer in writing at least 10 working days in advance of fabrication. The Contractor shall bear full responsibility and costs for all materials ordered, raw materials stockpiled, or for work performed prior to approval of the fabrication drawings or written authorization from the State Bridge Engineer. Except as noted in this subsection, all work shall be performed by the fabricator indi cated on the approved fabrication drawings, unless otherwise authorized in writing by the Structural Steel Fabrication Engineer. For coatings, if the fabricator intends to use a subcontractor, it shall be clearly outlined on the fabrication drawings to be submitted for review. At a minimum, the provided information shall include the subcontractor’s name and address; the name, phone number , and e -mail address of the quality control contact; and an acknowledgement of the Agency quality assurance inspection requirements which apply to the subcontractor. If the fabricator wishes to request the use of a subcontractor for material processing (e.g. cutting, drilling, bending, rolling, punc hing, machining, etc.), they shall include this information on the shop drawings that are submitted for review or they shall submit a set of the previously approved shop drawings to the Agency for review, with the requested changes and required information clearly marked and indicated (e.g. by making all additional notes red). At a minimum, the submittal shall include the subcontractor’s name and address; the name, phone numbers and e -mail address of the quality control contact; an acknowledgement of the Agency quality assurance inspection requirements which apply to the subcontractor; and clear information on the extent and limits of work to be performed by the subcontractor. Requests will be evaluated on a case -by-case basis and may be rejected by the Agen cy for any reason. Use of a subcontractor does not relieve the fabricator of any responsibilities or quality control requirements specified by the Contract. All steel fabrication plants shall satisfy the following minimum requirements:

publications:

A5.29, AWS C2.18, AWS C2.23, AWS D1.1, AWS D1.2, AWS D1.3, AWS D1.4, and AWS D1.5

506 5-88 (2) AASHTO Standard Specifications for Transportation Materials and Methods of Sampling and Testing, Part I and Part II

In addition to the above, access to the latest editions of any applicable ASTM standards is required.

burning, heating, welding, etc.), as well during as any operations that may affect the quality of the coating system.

inspection, testing and quality matters shall be qualified and certified in accordance with the provisions of AWS QC 1 .

506 5-89 b. Coating Inspectors . The fabricator’s coatings quality control manager shall possess a minimum classification as a NACE Coating Inspector Level 2 – Certified, SSPC Bridge Coatings Inspector (BCI) Level 2, or SSPC Protective Coatings Inspector

classification as a NA CE Coating Inspector Level 1 – Certified, SSPC Bridge Coatings Inspector (BCI) Level 1, or SSPC Protective Coatings Inspector (PCI) Level 1.

the approved welding procedures, including tacking, in accordance with the requirements of AWS D1.5 for all structural bridge items and AWS D1.1 for items not covered in AWS D1.5.

approved by the Structural Steel Fabrication Engineer . To meet minimum requirements, a plant shall have the following facilities:

at least 500 amps

of Subsection 506.14

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components requiring continuous welds over 2 feet in length shall also have the following

equipment:

applicable

components

be separate from the quality control facilities and shall include the following items:

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The Structural Steel Fabrication Engineer reserves the right to reject inadequate office

facilities and require suitable alternatives.

or quality assurance, the fabricator shall have available the necessary nondestructive testing

equipment for material or weld inspection (such as magnetic particle, radiograph, ultrasonic, or

dye penetrant) or employ an outside inspection firm to fulfill the necessary nondestructive test

requirements of the code. Nondestructive tests shall be performed in accordance with the

applicable code in effect on the date of Contract advertisement.

506.04DRAWINGS AND PROCEDURES

fabrication drawings in accordance with the requirements of Subsection 105.06. Drawings, details,

and welding procedures shall be submitted as a complete package for each structure.

The Agency will review fabrication drawings, details, and procedures for their compliance with

the Contract. The Agency will refer to the requirements of AASHTO/NSBA G1.1, Section 4 and

use them as the basis for the review of structural steel fabrication drawings.

The Agency assumes no responsibility for dimensions and other information calculated by the

fabricator. The fabricator is responsible for the fit of all components. If errors occur that cause

problems during erection, the Contractor is responsible for making acceptable corrections.

The Agency is responsible for all principal dimensions and material properties contained in the

Contract. The fabricator and Contractor are responsible for bringing to the Agency’s attention any

errors or discrepancies they discover.

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The fabricator is responsible for dimensioning members and ordering material to compensate for

weld shrinkage, distortion, elastic deformation, sweep, slope, machining, waste from cutting, and

other incidentals that are affected by the fabrication process.

shall be developed by the fabricator.

The fabrication drawings shall provide a material list on each sheet for tabulating the number of

pieces, piece marks, description, dimensions, type of material, and weight of each piece. When the

Contract item pay unit is on a per pound basis, the weight of each piece shall be extended and

summarized for each sheet as specified in Subsection 506.22. Weight extensions (extended

weights) shall be submitted to the Agency upon completion of fabrication.

All welds shown on the fabrication drawings shall identify, by symbol, the applicable procedures

and appropriate nondestructive testing requirements. A separate symbol shall be used to identify

each approved welding procedure.

provisions of the applicable AWS, ANSI, and AASHTO code revisions and submitted in

accordance with the following:

along with each procedure. Heat input values during welding shall be shown for each

procedure (except for SMAW procedures). All weld procedure sheets shall identify the

project name, number, structure, and procedure qualification record or fillet weld

soundness test.

presented in a format similar to example forms as shown in AWS D1.5 and AWS D1.1 as

applicable.

D1.1 as applicable) unless otherwise approved by the Structural Steel Fabrication Engineer.

box including provision for the date of revision, symbol of revision number, revision made by, and

description of each revision. As changes or revisions are made to previously approved sheets, the

appropriate information shall be recorded, a revision number symbol placed adjacent to the

appropriate detail, and the sheet resubmitted for approval. It is the fabricator’s responsibility to

transfer all as noted corrections to the originals.

Revisions of welding procedures shall also be resubmitted as they occur.

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and any other procedures that are required to be submitted for approval, and are being used in

production, shall bear an Agency approved or approved as noted stamp.

506.05QUALITY ACCEPTANCE. Quality acceptance is inspection of fabrication by the Agency or the

Agency’s representative (quality assurance inspector), to verify compliance with these specifications.

Acceptance of materials, test results, or completed fabricated items by the quality assurance inspector or

Structural Steel Fabrication Engineer does not relieve the fabricator of any responsibility to meet Contract

requirements and specifications. The Contractor shall refer to the Agency’s Quality Assurance Manual

for Metal Fabrication for more information.

reports, and test results; the performance of tests specified; the evaluation of reports and tests; the

approval, disapproval, or rejection of materials, processes, quality of work, reports, and test results;

or other work specified or directed by the Engineer.

perform all the duties assigned and delegated to the Engineer in Section 105 as they pertain to the

Contract except for measuring quantities of materials and payment thereof. The inspector will

witness, interpret, and accept or reject all testing.

Inspection of the work will conform to the requirements of the applicable AWS, ANSI, and

AASHTO codes and specifications referenced in the Contract.

safety equipment. They may make use of any tools the fabricator is required to make available,

however, the fabricator is responsible for verifying that the equipment is properly calibrated and

in working order.

506.06QUALITY CONTROL

matters necessary for producing a product that conforms to the requirements of the Contract. The

fabricator is responsible for quality control.

The fabricator is responsible for performing all nondestructive tests required by the Contract and

any nondestructive tests necessary to determine the extent of metallurgical defects discovered in

the base metal.

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scheduled nondestructive testing so that all tests can be witnessed by an Agency quality assurance

inspector. Nondestructive tests shall be performed in accordance with the requirements of AWS

D1.5.

Personnel performing and interpreting nondestructive tests (radiographic (RT), magnetic particle

(MT), ultrasonic (UT), and dye penetrant (PT)) shall be NDT certified for Level II qualification in

accordance with ASNT SNT-TC-1A.

However, ultrasonic testing may be used by the fabricator to determine the extent of

discontinuities, laminations, and inclusions discovered in any weld or base metal.

of overhead traffic sign structures, mast arms, and strain poles shall be in accordance with the

AASHTO Standard Specifications for Structural Supports for Highway Signs, Luminaires, and

Traffic Signals as well as the following:

original lot shall be examined using MT. If any welds in the second 10% require a welded

repair, all welds in that production lot shall be tested using MT.

all remaining PJP welds in that production lot shall be tested using MT.

For the purposes of this subsection, a production lot shall be defined as a day’s production on any

given project.

506.07MATERIAL IDENTIFICATION

clearly identified at all times during the fabrication of the product. If fabrication operations could

obliterate the identity, the fabricator may use a low stress die stamp placed in an area not exposed

on the finished structure. The die stamp character size shall be a minimum of 1/8 inch and a

maximum of 1/4 inch. Nonmetallic materials shall be identified to the satisfaction of the Engineer.

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When requested, the Contractor shall furnish an affidavit certifying that throughout the fabrication

operation identification of the steel has been maintained in accordance with this specification.

When a steel stamp identification is used at a tension joint transition, the impression shall be placed

on the thicker of the members.

506.08BASE METAL REQUIREMENTS. When backing bars, extension bars, and runoff plates are part

of a welding process, the material used shall be of the same chemistry as the base metal.

Discontinuities, laminations, inclusions, or other anomalies discovered in the base metal during the

manufacturing process shall be individually evaluated. The Agency may require nondestructive testing to

determine the extent of the defect. Repair procedures or replacement will be approved on an individual

case basis.

Rolled beams shall be ordered from the mill without camber, unless pre-approved in writing by the State

Bridge Engineer.

Main members are defined as compression members, tension members, and members subject to reversals of

stress, including stringers, girders, cover plates, rigid frames, floor beams, gusset plates, and curved girder

cross frames. Other members may be indicated in the Contract as main members.

Material for main members shall be ordered and prepared so that the direction of rolling is parallel to the

stress in the member, in accordance with the requirements of AASHTO LRFD Bridge Construction

Specifications, Section 11.4.3.1. Charpy V-notch (CVN) testing shall be performed as required in

Subsection 714.01.

Members identified as fracture critical shall be subject to additional base metal requirements as specified

in Subsection 506.11.

506.09PREPARATION OF BASE METAL. Material flame cuts by any thermal cutting process shall be

made with an approved mechanically-guided torch.

The fabricator shall use preheating, post-heating, or control of the cutting process to ensure that flame-cut

edges of main members of structural steel are not flame-hardened. Flame-cut edges that will not be

included in a permanent weld shall have a Rockwell hardness value not greater than C30.

When pieces are to be bent during fabrication, bending shall be performed in accordance with the

requirements of AWS D1.5 and the applicable design code as defined in Subsection 506.03.

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Cold bending of main members will not be permitted without written approval of the Agency. This

approval may limit the radius of curvature and require nondestructive testing to verify that no internal

distress or separation has occurred. Expenses incurred in performing any such nondestructive test

examination shall be the responsibility of the fabricator.

506.10WELDING

shall conform to the requirements of the AWS D1.5. For welding items other than those covered in

AWS D1.5, the Contractor shall adhere to AWS D1.1, AWS D1.2, AWS D1.3, or AWS D1.4 as

applicable.

Welding will not be permitted without approved welding procedures and fabrication drawings

meeting the requirements of Subsection 506.04.

Welding and inspection of shear connectors shall conform to the requirements of Section 508.

Stitch welds are not permitted, however, the skip-and-fill technique may be used when applicable

to prevent distortion.

Prior to performing any corrective weld repairs to base metal, the fabricator shall do the following:

Engineer in writing. Corrective procedures for radiographed butt welds may be included in

the welding procedure.

an approved welding procedure may be authorized by the Agency’s quality assurance

inspector.

The fabricator will be permitted a maximum of two repairs on any given welded joint.

Should nondestructive test inspection indicate weld rejection after two repairs, the Agency

may reject the entire weld and require its removal.

D1.5, Section 1 shall be deemed prequalified. Submerged arc welding (SAW), flux core arc

welding (FCAW), and gas metal arc welding (GMAW) shall be subject to qualification testing as

described in AWS D1.5 prior to approval. Other processes may be approved, on a project-by-

project basis, provided procedure qualification results meet the specified acceptance criteria.

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Submerged arc welding (SAW) shall be used for all principal welds, as follows:

and attaching connection or stiffener plates to girder webs.

restricts the use of the automatic process.

The manual shielded metal arc welding process shall be limited to attaching connection plates to

rolled beams, welding bearing assemblies, repairs, tack welding, joints under 24 inches in length,

minor attachments, and other applications where the use of an automatic process is impractical.

When prior authorization has been granted, the GMAW and FCAW processes will be limited to

indoor shop welding of bridge rail, expansion joints, cross frames, bearing devices, scuppers, sign

fixtures, light fixtures, and low-stressed members or components. Gas metal arc welding-short

circuit arc (GMAW-S) will not be permitted.

Any gas shielded process subject to wind velocities in excess of 5 mph shall be protected using

draft barriers.

operators, and tackers qualified in accordance with the requirements of AWS D1.5. Requalification

may be required in accordance with the requirements of AWS D1.5. The requirements of AWS D1.1

shall be adhered to for welding of items not covered in AWS D1.5.

Groove welds shall be started and terminated with extension bars or runoff plates.

Fillet welds shall be performed in the flat or horizontal position unless restricted by member size

or physical position.

are on the Agency’s Pre-Qualified Welder List.

The requirements for field welding are contained in the Agency’s Field Welding Manual and shall

be adhered to. This manual may be obtained from the Agency’s website.

Welding performed in the field is subject to all of the requirements of Subsection 506.10. The

SMAW process is the only process approved for field welding.

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All welds used to attach miscellaneous construction fixtures to any portion of the bridge structure

shall be approved in writing by the Engineer. Welding to tension members or tension components

of members will not be allowed.

Welding of miscellaneous construction fixtures such as form supports, screed supports, and

reinforcing steel chairs to any portion of the bridge structure will not be permitted without

approved drawings and welding procedures. Any increase in material thickness made necessary

by reduced allowable stresses resulting from such welding shall be at the Contractor’s expense.

Approval for any welding requiring an increase in material thickness shall be obtained before the

affected structural steel is fabricated.

Shear connectors shall be installed in accordance with the requirements of Section 508.

qualified in accordance with the requirements of AWS D1.5.

Welding and testing of samples shall be witnessed by the Agency, or the Agency’s quality

assurance inspector, or an authorized representative of a testing agency that is AWS

certified in accordance with the provisions of AWS QC 1.

AWS D1.5. The requirements of AWS D1.1 shall be adhered to for items not covered in

AWS D1.5.

506.11FRACTURE CRITICAL MEMBERS. The Agency will identify in the Contract the members or

member components that are categorized as fracture critical.

Material for members or member components identified as fracture critical shall be furnished and

fabricated in conformance with the requirements of AWS D1.5 for fracture critical components.

Welding performed on fracture critical members or components, and testing, shall be witnessed by an

Agency representative. Qualification acceptance for any welding procedure shall be based on the results

of mechanical tests and chemical analysis of deposited weld metal. Procedure requirements and basis of

acceptance shall meet the requirements in AWS D1.5 for fracture critical components.

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506.12ASSEMBLY

drawings.

cutting the flange plates to the required curvature. Each plate shall be flame cut simultaneously on

both edges to reduce unbalanced shrinkage stresses. The flange plate lengths between shop splices

shall not be less than 20 feet. Web plates shall be aligned to the center of the flange plates.

If the final curvature is not as specified after the flanges have been welded to the web, the girder

shall be corrected by application of heat in accordance with an approved procedure.

measured only after the member has cooled. The member shall be supported in a manner that will

ensure accurate measurements for sweep and camber. The web shall be in a vertical position for

measuring curvature and in a horizontal position for measuring camber.

Heating shall be performed in such a manner that the temperature of the steel does not exceed

1,150°F. Any member heated to a temperature of more than 1,200°F shall be rejected.

Artificial cooling will not be permitted until a member has cooled to 600°F. Under no conditions

will water be permitted for cooling. Dry air may be used subject to the approval of the quality

assurance inspector.

to a minimum 1/16-inch radius by grinding.

provisions of Subsection 506.18.

may require different tolerances of fit. Terms used to define the fit of connections are as follows:

0.02 inch with a permissible variation of 1/16 inch for the remaining 50% of projected area.

0.01 inch with a permissible variation of 1/32 inch for the remaining projected area.

contact.

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maximum allowable gap of 1/16 inch.

written approval by the Agency. Procedures will be required describing in detail the distortion to

be corrected and all procedures for heating, cooling, verifying final dimensions, and nondestructive

tests.

506.13TOLERANCES. Rolled steel plates, shapes, and bars shall be supplied to the permissible

tolerances specified in ASTM A6. The camber and sweep of fabricated rolled members shall be subject to

the same dimensional tolerances specified for welded members in AWS D1.5.

The metal bearing surface of any masonry bearing plate shall be flat, with a maximum permissible

variation of 0.04 inch from a plane determined by any three of its corners.

The fabricator is responsible for straightening to specification tolerances any weldments that may have

been distorted through stress relieving during the galvanizing process.

506.14SURFACE PREPARATION. All materials shall be blast-cleaned to the specified grade as defined

by the SSPC Painting Manual and supplemented by reference to SSPC-VIS 1. Further preparation shall

conform to the following:

This work may be performed either before or after fabrication. The final surface appearance after

fabrication shall be clean and free from any contaminants or blemishes so as to allow the metal to

weather uniformly.

and prepared in accordance with the appropriate Contract specifications.

506.15MARKING, STORING, AND SHIPPING

identification mark on the approved fabrication drawings.

Identification marks may be painted on members that will receive field coats of paint.

Identification marks on unpainted steel shall be impressed into the member with a low-stress stamp

in a non-stressed or low-stressed area of the member. The fabricator shall identify to the Contractor

the procedure used for marking material.

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suitable supports. It shall be kept clean, properly drained, and protected from unwanted corrosion.

Free circulation of air shall be provided around all surfaces.

Girders and beams shall be stored in the upright position, supported at their ends or points of

bearing. Long members (e.g. columns and chords) shall be supported at sufficient points to prevent

damage from deflection.

Special care shall be taken for unpainted steel to ensure that it can weather uniformly.

In addition to the requirements specified above, material or raw material stockpile storage shall be

subject to any other storage criteria deemed necessary by the Engineer in accordance with the

requirements of Subsection 106.09.

shape prohibits shipment in the upright position, the fabricator shall submit a proposed method

and details of shipment to the Agency for approval.

The fabricator shall not ship any material, either to the project or to another manufacturer or

subcontractor, without the Agency’s approval. The Agency’s quality assurance inspector will place

a seal of approval on all material (or on the bill of lading) that has been accepted for shipment and

will accept the loading, positioning, and anchorage of all material being shipped. If the quality

assurance inspector is not available, the Structural Steel Fabrication Engineer shall be contacted

for approval to ship.

506.16FIELD HANDLING AND STORING. The Contractor is responsible for providing equipment

that is adequate to safely lift and place, without damage, all material furnished. Permanent distortion

caused by handling or storage will be cause for rejection.

The edges of nicks or bumps caused by handling shall be carefully ground to a 1/16-inch radius.

The storage requirements in Subsection 506.15 shall be applicable for all materials stored in the field.

506.17ERECTION

erection shall be of adequate design and capacity to safely erect, align, and secure all members and

components in their final positions without damage. The Contractor is solely responsible for the

methods and equipment employed for the erection of the structural steel. However, the Contractor

shall lift and erect curved girders so that the web of the girder is maintained vertical within a 10°

vertical tolerance.

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The Contractor shall submit construction drawings in accordance with the requirements of

Subsection 105.06 for the methods and sequence of structural steel erection, the temporary bracing,

and the equipment to be used for the erection. The Agency will use the requirements specified in

AASHTO/NSBA S10.1, Appendix B and AASHTO/NSBA S10.1, Appendix C, as the basis for review

of erection plans.

The erection plan shall include the necessary computations to indicate the magnitude of stress in

the segments during erection and to demonstrate that all of the erection equipment has adequate

capacity for the work to be performed. The erection plan shall contain provisions for all stages of

construction, including offloading, temporary storage conditions, and temporary stoppages.

The Contractor shall include additional information in the erection plan for curved girders as

indicated in AASHTO LRFD Bridge Construction Specifications, Section 11.8.2.

The structural steel may be used for support of equipment prior to placement of the deck only with

the written permission of the Engineer. The proposed use of structural steel for support of

equipment shall be detailed in the erection plan.

Submittal of the erection plan is for documentation purposes only and shall in no way be construed

as approval of the proposed method of erection. Unless otherwise directed by the Engineer, the

Contractor shall follow the erection plan as submitted.

drawings, following match marks when provided. Material shall be carefully handled so

that no members or pieces will be bent, broken, or damaged. Hammering that will injure

or deform members will not be permitted. Bearing surfaces and contact surfaces shall be

clean.

Only light drifting will be permitted. Any member subjected to drifting that results in

distortion of the member or elongation of the holes will be rejected. Cylindrical erection

pins, the same size as the hole, shall be used at least in the extreme corners of all main

member connections.

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Main members shall be match marked by the fabricator and should fit together easily.

Main members shall not be reamed larger than the hole size indicated on the approved

fabrication drawings without written authorization from the Project Manager. Secondary

members may be subjected to limited field reaming with the written approval of the

Engineer. Assembled parts that have been approved for field drilling or reaming shall be

disassembled to remove any burrs, shavings, oils, or lubricants.

Pins used for hinged connections and bearings shall be inserted with care and aligned so

the members take full and even bearing. Nuts shall be adequately tightened and locked in

position either by upsetting the threads or tack welding the nut to the bolt.

the Engineer. The Engineer shall approve any corrective action prior to it occurring.

506.18BOLTING AND CONNECTIONS

requirements of Subsection 714.05 unless otherwise specified. Bolts and nuts shall be furnished

by the same supplier. Bolts, nuts, and washers shall be packaged and shipped so they are kept dry.

When not in transit, bolts, nuts, and washers shall be stored indoors under dry, ventilated

conditions.

All bolts and nuts shall be adequately and uniformly lubricated. Bolts and nuts not properly

lubricated shall be cleaned and re-lubricated prior to installation in accordance with applicable

specifications.

Bolt holes are specified as 1/16 inch larger in diameter than the bolt. Bolt holes shall be fabricated

to the requirements of the AASHTO LRFD Bridge Construction Specifications, Section 11.4.8,

except that holes shall not be punched full-size unless otherwise permitted in the Contract or

approved by the Structural Steel Fabrication Engineer.

gaskets or other interposed compressible material. All joint contact surfaces and areas adjacent to

bolt holes shall be free of scale, burrs, dirt, and other foreign material that may prevent solid seating

of the parts.

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Unless otherwise specified in the Contract, faying surfaces of bolted connections shall have a Class

B slip coefficient value of not less than 0.50 as specified by AASHTO.

Splices and field connections of main members shall have all holes filled with high-strength bolts

or cylindrical drift pins, with bolts snug-tightened before external support systems are removed.

Cylindrical drift pins shall be used in the extreme corners of all main member connections to ensure

alignment and shall remain until all bolts in the connection have been fully tightened.

element. Hardened steel washers shall be used under both the head and the nut when bolts are used

for the following connections:

shall not be allowed unless approved in writing by the Engineer)

Where an outer face of the bolted parts has a slope of 1:20 (V:H) or steeper with respect to a plane

normal to the bolt axis, a smooth beveled washer shall be used to compensate for the lack of

parallelism.

Bolts installed with the stem oriented vertically shall have the heads up. Bolts installed with the

stem oriented horizontally shall have the head towards the weather unless clearance restrictions

dictate otherwise.

Normally the nut will be the turned element. However, if the position of bolt entering or wrench

operation clearances prohibit this procedure, the bolt may be the turned element.

Tightening of a bolt group shall progress systematically from the most rigid part of the joint to its

free edges.

Previously tightened bolts shall be re-tightened until all bolts in the connection are tightened to the

minimum required tension.

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Recalibration of the tightening wrench may be required any time there appears to be a significant

change in the bolt tightening conditions.

All bolts in a connection shall first be brought to a snug tight condition. Snug tight is defined as

initial tension sufficient to bring all the plies of the connection into firm contact while the drift

pins remain in the connection. Snugging shall progress systematically, beginning at the most rigid

part of the connection and progressing to the free edges until the connection is fully compacted.

All high-strength bolts shall be tightened to the specified tension as soon after installation as

feasibly possible. Under no circumstances shall bolts be left untightened for more than 5 days after

installation unless specific requirements to do so are indicated in the Contract or directed by the

Engineer. Bolts left in place beyond five days without specific requirements in the Contract or as

directed by the Engineer shall be removed and replaced with new bolts at the Contractor’s expense.

Bolts shall be tightened to develop a tension not less than 5% more than the minimum bolt tension

specified in Table 506.18A. Unless otherwise indicated on the Plans, ASTM F3125 Grade A325

hex head bolts shall be used.

Engineer using one of the following methods:

control bolt with a spline end and a suitable nut and washer. This method shall be employed

when installing button-headed or dome-headed high-strength bolts. This method shall only

be used when required by the Contract.

All bolts shall be tightened by the application of torque to the nut and counter-torque to the

spline end of the bolt using an approved spline drive installation tool. A random sample of

not less than three tension control assemblies of each diameter, length, grade, and type to

be used in the work shall be checked a minimum of once each working day in a device

capable of indicating bolt tension.

The test shall be performed to verify that the spline twist-off develops a tension at least 5%

greater than the minimum bolt tension specified in Table 506.18A. Additional verification

of the tension control assemblies shall be performed as directed by the Engineer. Separate

checks will be required for each diameter fastener with hardened washers placed under the

nut or bolt head as they will be used in the structure. Variations in the number or location

of washers will require separate checks.

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washers capable of indicating that a specified minimum bolt tension has been attained.

DTIs installed with high strength bolts to indicate bolt tension shall be subjected to field

verification testing prior to installation and the installation requirements specified in this

subsection.

DTIs installed with high-strength bolts to indicate bolt tension shall be placed under the

head of the bolt with the protrusions facing the head of the bolt, and the nut shall be turned,

with a hardened washer underneath it, to tension the fastener. Additional hardened washers

shall be provided if required by the DTI manufacturer for their specific product. If for

reasons of wrench operations clearance it is necessary to place the DTI under the turned

element, the DTI shall be oriented so that the protrusions face outward from the work, and

a hardened washer shall be placed between the DTI and the turned element. Placement of

the DTI under the turned element will only be allowed when approved by the Engineer.

The bolt, DTI, hardened washer, and nut assembly used in the verification testing device

and installed in the work shall be such that at least three and preferably not more than five

threads are in the grip. The grip is defined as the distance between the bearing face of the

nut and the bolt head.

The Contractor shall supply 5-mil tapered feeler gauges, a calibrated bolt tension-

measuring device and equipment necessary to perform field verification testing and

inspection of tensioned bolts. The feeler gauges, fasteners, and impact and manual

wrenches shall be the same as that to be used in the work.

The Contractor shall obtain the services of a qualified technical advisor employed by the

DTI manufacturer to make at least one site visit to assist the Contractor and to ensure the

proper installation and use of DTIs. This requirement may be waived by the Engineer if

the Contractor can demonstrate to the Agency’s satisfaction successful use of DTIs on

previous projects for the Agency.

Verification testing shall be performed in a calibrated bolt tension measuring device, such

as a Skidmore-Wilhelm Calibrator, with a special flat insert (supplied by the Contractor)

replacing the normal bolt head-holding insert. The special insert allows the DTI to be

located on the flat front face of the tension measuring device for ease of observation and

improved access for measuring the DTI gap during testing. The Contractor shall supply

hardened steel spacers as needed for testing longer bolts in the bolt tension measuring

device. Stacked washers will not be permitted as a substitute for hardened steel spacers.

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The purpose of verification testing is to validate the DTI assembly’s ability to indicate

installation tension above the minimum. The verification tension specified in Table

A is 5% higher than the minimum required installation tension in Table 506.18A

The increase provides confidence that the installation tension can be achieved for the lot.

Three verification tests are required to be performed on random samples of each

combination of fastener rotational-capacity lot, DTI lot and DTI position (under the nut or

bolt head) used on the project. All three tests must pass for the DTI and assembly

combination to be approved. Testing shall be performed at the project site by the Contractor

and witnessed by the Engineer.

When testing for the normal DTI position, the nut shall be turned from the rear of the

tension measuring device, with the bolt head against the DTI restrained from turning with

another wrench. When testing with the DTI under the turned element, the turned element

shall be placed on the flat front face of the tension measuring device and the unturned

element will be in the rear held by another wrench.

A for the grade and size of fastener. If an impact wrench is used,

tension to a load two-thirds below the required load and use a manual

wrench to attain the required tension.

spaces between the protrusions. When using galvanized or epoxy coated

DTIs under the turned element, there shall be at least one entry of the feeler

gauge.

The DTI lot will be rejected if the number of entries is less than the value

in column 2 of Table 506.18B. If coated DTIs are used under the turned

element, the DTI lot will be rejected if there are no entries.

the range in column 3 of Table 506.18B.

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verification tension load in Table 506.18A. If the actual pretension

developed in the fastener is less than the verification tension load specified

in Table 506.18A, the causes shall be determined and resolved before the

fasteners are used in the work. Cleaning, lubrication, and retesting new

fasteners is permitted for this step provided that all fastener assemblies are

treated in the same manner.

If the bolts are too short to be tested in the tension measuring device, the verification

test for the DTI shall be conducted on longer bolts supplied by the Contractor. The

longer bolts shall be new, meet the requirements of Subsection 714.05, and be of

the same type as the DTI being tested. Three verification tests are required as

specified above.

Bolts and DTIs used in verification tests shall be marked and shall not be reused in

the work.

TABLE 506.18A – BOLT TENSION VALUES FOR ASTM F3125 BOLTS

Nominal Bolt

Diameter (in.)

Minimum Bolt Tension (kips) Verification Tension (kips)

Grade A325 Grade A490 Grade A325 Grade A490

1/2 12 15 13 16

5/8 19 24 20 25

3/4 28 35 29 37

7/8 39 49 41 51

1 51 64 54 67

1-1/8 64 80 67 84

1-1/4 81 102 85 107

1-3/8 97 121 102 127

1-1/2 118 148 124 155

Equal to 70% of the specified minimum tensile strength of bolts.

Verification tension is 1.05 times the minimum bolt tension.

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follows:

condition. Snugging shall progress systematically beginning at the most

rigid part of the connection and progressing to the free edges until the

connection is fully compacted. At the snug-tight condition all of the DTIs

shall be inspected with the feeler gauge to verify that they meet the number

listed in column 2 of Table 506.18B.

If the number of entries is less than the values specified in Table 506.18B,

the fastener shall be removed and another DTI installed, followed by re-

snugging of the fastener. This is required because a fastener’s tension may

have relaxed during the snugging of adjacent fasteners. A compressed DTI

does not rebound if the fastener tension is reduced. If a DTI which has fewer

entries were left in place, it would give a false indication of bolt tension.

point that the number of entries for a 5-mil feeler gauge meets the number

listed in column 3 of Table 506.18B. Tightening shall progress

systematically beginning at the most rigid part of the connection and

progressing to the free edges. Drift pins shall be removed during this

process, with the exception that drift pins in the extreme corners of main

member connections shall remain in place until all other bolts are fully

tensioned. Several cycles may be required.

The Contractor shall use the minimum amount of force necessary to achieve

the number of entries listed in column 3 of Table 506.18B. If DTIs are

consistently being tensioned to a point where there are zero entries of the

feeler gauge, the amount of force applied to the bolt shall be reduced.

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TABLE 506.18B – NUMBER OF DTI ENTRIES FOR ASTM F3125 BOLTS

Number of

Spaces Between

DTI Protrusions

Verification -

Required Number

of DTI Entries 1, 2

Installation -

Required Number

of DTI Entries 1, 3

4 2 – 4 0 – 1

5 3 – 5 0 – 2

6 3 – 6 0 – 2

7 4 – 7 0 – 3

8 4 – 8 0 – 3

9 5 – 9 0 – 4

An entry occurs when a 5-mil tapered feeler gauge fits into

the space between DTI protrusions and touches the bolt

shank.

For coated DTIs under the turned element, at least one

entry is required.

For coated DTIs under the turned element, 0 – 1 entries are

required.

observed to determine if the tightening procedure is working properly and the correct tension has

been achieved

The Contractor shall provide a tension measuring device, such as a Skidmore-Wilhelm Calibrator,

which has been calibrated within the last year and is accompanied by a certificate verifying its date

of calibration.

Before the installation of fasteners in the work, the Engineer shall check the marking, surface

condition, and storage of bolts, nuts, and washers and the faying (contact) surfaces of joints for

compliance with the Contract requirements.

Bolt tension for fasteners with DTIs shall be verified using 5-mil tapered feeler gauges provided

and operated by the Contractor.

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All bolts installed using DTIs shall be inspected after snug tightening and again after full

tensioning, with 100% of the bolts inspected visually and 10% of the bolts in any connection (but

not less than two) inspected by feeler gauge. If the installation of inspected bolts is accepted, then

the connection shall be accepted as properly tensioned.

If any bolt in a connection does not pass inspection, then all (100%) of the bolts in that connection

shall be inspected with the feeler gauge. Any bolt which does not pass inspection as described

herein shall be further tensioned if required.

If the Engineer suspects that the Contractor is using an excessive amount of force on fasteners with

DTIs, the Engineer may require a sample of no less than three fasteners to be removed from the

work in one or more locations for further inspection. All costs for further inspection, including

replacement fasteners, shall be at no additional cost to the Agency. Further inspection shall be

performed as follows for each sample of fasteners:

full length of the threads, excluding thread runout. If this is successful for all fasteners, the

fasteners represented by the sample will be accepted and new fastener assemblies and DTIs

shall be installed in the work where the sample fasteners were removed. If the nut cannot

be turned down the full length of the threads by hand on all fasteners, proceed to Step 2.

tensioned to the verification tension load in Table 506.18A. The bolt tension measuring

device shall be supplied with short bolt plates and bushings as needed for testing shorter

bolts and hardened steel spacers as needed for testing longer bolts. Stacked washers will

not be permitted as a substitute for hardened steel spacers, with the exception that

additional flat washers may be used in combination with hardened steel spacers if necessary

to achieve the appropriate grip length. The complete fastener assembly that was removed

from the work, excluding the DTI, shall be installed in the calibrated bolt tension measuring

device with a grip length equal to or greater than the grip length when installed in the work.

If this is successful for all fasteners, the fasteners represented by the sample will be

accepted and new fastener assemblies and DTIs shall be installed in the work where the

sample fasteners were removed. If all fasteners cannot be tensioned to the verification

tension load in Table 506.18A, the Contractor shall replace all fasteners in the work

represented by the sample as determined by the Engineer.

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Bolts installed using tension control assemblies shall be visually inspected for consistent twist-off

and thread stick-out.

Undamaged fasteners may only be reinstalled with the approval of the Engineer. Galvanized bolts,

ASTM F3125 Grade A490 bolts, tension control assemblies, and DTIs shall not be reinstalled.

An additional required inspection step is to check the bolt thread stick-out on the nut side after

installation to the final specified gap to look for inconsistency of pattern. Any stick-outs greater

than the other bolts shall be investigated and discarded (e.g. if necking down of the bolt has

occurred or the wrong length bolt was used). The end of the properly installed bolt shall be at least

flush with the nut.

The Engineer shall be provided with safe access in accordance with the requirements of Section

105 to conduct all inspection deemed necessary during and after the installation of the bolts. If the

Engineer determines that the access provided is unsafe, work will be ordered to halt until such time

that the access is made safe. Any delays incurred by the unsafe access will not be cause for a

monetary, material, or delay claim.

506.19RIVET REMOVAL. When the Plans specify existing rivets to be removed, they shall be removed

without damaging the base metal. The rivets identified for removal shall have the rivet head ground flush

with the base metal and the shaft drilled for removal. If necessary, the rivet head on the opposite side shall

be removed in the same manner. The use of pneumatic rivet breakers and punching of rivet shanks will

not be allowed, unless approved in writing by the Engineer. Flame cutting, performed by a certified welder

on the Agency’s Pre-Qualified Welder List, will be allowed if approved by the Engineer. Each worker

performing rivet removal work shall successfully demonstrate the process on scrap metal to the

satisfaction of the Engineer prior to each worker performing any rivet removal work on the bridge. If it is

necessary to pierce the shaft of rivets with a torch, the outer surface of the rivet shank shall remain intact

during this process.

Absolutely no gouging or other damage to the structural steel will be permitted on any member that will

remain in service after the rivet is removed. If the rivet removal process causes any damage to structural

steel, the damaged member shall be repaired or replaced in a manner satisfactory to the Engineer at the

Contractor’s expense. If any gouging or other damage to structural steel occurs, the rivet removal work

shall stop immediately, and the Engineer shall be notified. At the discretion of the Engineer, the Contractor

may be required to obtain the services of a professional engineer to assess the structural capacity of the

damaged member prior to restoring traffic. All costs associated with assessing damage caused by this

removal process will be at the Contractor’s expense.

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Where rivets are specified to be replaced, they shall be replaced with high-strength bolts meeting the

requirements of Subsection 506.18 unless otherwise specified in the Contract. Rivets shall be replaced

one at a time, unless otherwise specified in the Plans or approved by the Project Manager. Use of

temporary bolts to replace a rivet will only be allowed with written approval from the Engineer, and

provided that temporary bolts meet the requirements of Subsection 506.18.

506.20STRAIGHTENING BENT MATERIAL. Damaged, bent, or misaligned structural steel may only

be straightened or corrected by procedures approved by the Agency. The method of repair proposed by

the Contractor shall be submitted as construction drawings for approval in accordance with the

requirements of Subsection 105.06. No corrective work shall be performed without Agency approval.

Heating limitations and procedures shall conform to the requirements of Subsection 506.12.

Members or parts to be heat straightened shall be free of stress from external forces other than those

necessary and used in conjunction with the application of heat. Following straightening, the surface of the

metal shall be free of any evidence of distortion or fracture. Required nondestructive tests shall be

performed by NDT Level II or NDT Level III personnel at the Contractor’s expense.

506.21FIELD CLEANING. When assembly of the fabricated structural components is complete, any

rust, scale, dirt, grease, or other foreign material shall be removed from the metal components. The cost

of such necessary cleaning will not be paid for directly but will be considered incidental to the Section

items in the Contract.

506.22STEEL SURFACES AND COATINGS. All welding and anticipated hot work shall be completed

prior to applying any coatings on a given item unless approved in writing by the Structural Steel

Fabrication Engineer.

surfaces of unpainted steel during storage, erection, and construction of the deck.

due to oxide formation on the steel.

beams and bottom surface of their lower flanges shall be cleaned of all foreign material to

a uniform appearance. The Engineer may require the exposed surfaces to be blast cleaned

to meet SSPC-SP 10. The use of acids for cleaning is prohibited.

726.06and the following:

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furnished to the quality assurance inspector (or the Structural Steel Fabrication Engineer,

if there is no quality assurance inspector assigned to the project) prior to shipment from the

galvanizer’s plant. Certifications shall include a report of all test results and measurements.

approved otherwise by the Engineer. Products containing aluminum shall not be used.

treated with chromate conversion coatings.

seal coated in accordance with Subsection 726.07.

accordance with the requirements of this subsection.

grade powder meeting the requirements of Subsection 708.02.

105.06for construction drawings, which includes the following information. The

submittals shall be made sufficiently in advance of coating work to allow for review,

resubmittals, and approval.

methods of surface preparation and types of equipment to be used. The plan shall

identify the solvents proposed for solvent cleaning.

blast cleaning.

product manufacturer’s recommendations for coating thickness, curing, and

product data sheets for each and every coating product.

temperature, the thickness of each coat to be applied, and the curing time and

temperature for each coat, and shall be in accordance with the manufacturer’s

recommendations.

506

inspections. The personnel performing any QC tests shall be trained in coatings inspection

and the use of the testing instruments. Documentation of training shall be provided upon

request. Reports for all quality control testing and observations shall be completed and

provided to the QA inspector on a daily basis unless otherwise authorized by the Structural

Steel Fabrication Engineer.

Fabricator QC inspections shall include, but are not limited to, the following:

etc.).

numbers.

with the manufacturer’s recommendations. At a minimum, the steel surface shall be

prepared by SSPC-SP 1 followed by SSPC-SP 7.

When powder coating is to be applied over galvanizing, the galvanized surface shall be

prepared by SSPC-SP 1, followed by SSPC-SP 16, and in accordance with ASTM D7803.

Surface grinding in accordance with SSPC-SP 11 and ASTM D7803 will be permitted in

areas where SSPC-SP 16 is not achievable or practical.

2 mils for galvanized steel shall be produced. If the profile requirements of the coating

manufacturer are more restrictive, the fabricator shall advise the Structural Steel

Fabrication Engineer and comply with the more restrictive requirements.

The surface profile produced by the fabricator’s surface preparation procedures shall be

determined by replica tape and spring micrometer and in accordance with SSPC-PA 17.

Areas having unacceptable measurements shall be further tested to determine the limits of

the deficient area. The replica tape shall be attached to the daily report.

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When unacceptable profiles are produced, work shall be suspended. The fabricator shall

make the necessary adjustments to ensure that the correct surface profile is achieved on all

surfaces. The fabricator shall not resume work until the new profile is verified by the QA

observations and they confirm that the profile is acceptable.

but shall be applied within 8 hours of the completion of blast cleaning.

with SSPC-PA 2 and shall be within the manufacturer’s recommended thickness range. The

minimum total DFT of the powder coating shall not be less than 5.0 mils.

in accordance with the requirements of this subsection.

of Subsection 708.03.

Shop applied systems may have isolated areas where the coatings were damaged during

shipping or erection and will have areas around faying surfaces that may need field applied

primer, intermediate, and top coatings. Thus, any coating system that is used in the shop

shall be acceptable for the field conditions that are expected to be encountered.

When the plans specify paint to be applied over galvanizing, a galvanized coating applied

in accordance with Subsection 506.22(b) shall be used in place of the prime coat of the

three coat system. The first coat of paint applied over the galvanizing (intermediate coat)

shall be recommended for application over galvanizing by the manufacturer. Any and all

galvanizing repair products used prior to painting shall be compatible with the intermediate

coat.

for construction drawings, which includes the following information. The

submittals shall be made sufficiently in advance of coating work to allow for review,

resubmittals, and approval.

shall include the specified methods of surface preparation and types of equipment

to be used for removal of rust, mill scale, or foreign matter.

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The plan shall identify the solvents proposed for solvent cleaning, together with the

solvent safety data sheets (SDS). If any detergents, additives, or inhibitors are

incorporated into the water used for any coating work operations, the plan shall

include the names of the materials and their SDS.

The plan shall also include the methods of coating application, including any

required stripe coats, and all equipment to be used.

The plan shall also identify all applicable QC/QA hold points. Specific inspection

items throughout these specifications are designated as hold points. These hold

points are for the QA inspector to perform inspections. QA inspections will be

performed only after a proper QC inspection by the fabricator. Permission to

proceed beyond a hold point without a QA inspection will be granted solely at the

discretion of the Structural Steel Fabrication Engineer, and only on a case-by-case

basis. If re-work is necessary, as determined by a QA inspection, it shall be

accomplished and a new hold point for the re-work shall be observed as defined

above.

blast cleaning and their SDS. For expendable abrasives, the Contractor shall

provide certification from the abrasive supplier that the abrasive meets the

requirements of SSPC-AB 1. For steel grit abrasives, the certification shall indicate

that the abrasive meets the requirements of SSPC-AB 3.

product manufacturer’s application and thinning instructions, SDS, and product

data sheets for each and every coating, thinner, sealer, and grease rustproofing

compound. Specific attention shall be drawn to storage temperatures and the

temperatures of the material, surface, and ambient air at the time of application.

Recommended minimum ambient weather conditions during curing shall also be

included A letter or written instructions from the coating manufacturer shall be

provided indicating the length of time that each coat must be protected from cold

or inclement weather (e.g. exposure to rain) during the drying/curing period.

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When the Agency accepts the submittals, the fabricator will receive written

notification. The fabricator shall not construe Agency acceptance of the submittals

to imply approval of any particular method or sequence for conducting the work,

or for addressing health and safety concerns. Acceptance of the submittals does not

relieve the fabricator from the responsibility to conduct the work according to the

requirements of federal, state, or local regulations, this specification, or to

adequately protect the health and safety of all workers involved in the project and

any members of the public who may be affected by the project. The fabricator

remains solely responsible for the adequacy and completeness of the programs and

work practices, and adherence to them.

inspections. The personnel performing any QC tests shall be trained in coatings inspection

and the use of the testing instruments. Documentation of training shall be provided upon

request. Painters shall perform wet film thickness measurements, with the quality control

inspector conducting random spot checks of the wet film. Reports for all quality control

testing and observations shall be completed and provided to the QA inspector on a daily

basis.

cleaning, etc.).

sweat-in time, and wet/dry film thickness).

spray, pinholes, shadow-through, skips, misses, etc.).

product batch numbers.

506

perform QC inspections:

and relative humidity, together with all necessary tables or psychrometric

charts.

3 SSPC-VIS 1 and SSPC-VIS 3, as applicable.

a width between 1 and 3 inches.

painting, and inspection activities.

work.

The instruments shall be calibrated within 12 months of the date of project usage or

according to the equipment manufacturer’s recommendations and the fabricator’s QC

Program if they require a shorter duration.

any or all phases of the work. The presence or activity of QA inspector observations in no

way relieves the fabricator of the responsibility to provide all necessary daily QC

inspections and to comply with all requirements of this specification.

The Structural Steel Fabrication Engineer has the right to reject any work that was

performed without adequate provision for QA observations.

506

where natural light is inadequate, to allow proper cleaning, inspection, and painting.

Illumination for inspection shall be at least 30 foot-candles.

include gauges capable of accurately measuring fluid and air pressures and shall have

valves capable of regulating the flow of air, water, or paint as recommended by the

equipment manufacturer. The equipment shall be maintained in proper working order.

Hand tools, power tools, abrasive blast cleaning equipment, brushes, rollers, and spray

equipment shall be of suitable size and capacity to perform the work required. All power

tools shall be equipped with vacuums and high efficiency particulate air (HEPA) filtration.

Appropriate filters, traps, and dryers shall be provided for the compressed air used for

abrasive blast cleaning and conventional spray application. Paint pots shall be equipped

with air operated continuous agitation devices unless prohibited by the coating

manufacturer. The air discharge from power tools and air motors shall be directed away

from steel surfaces. If this is not possible a filtering device shall be appropriately placed.

and other contaminants. The fabricator shall control operations to ensure that dust, dirt, or

moisture does not come in contact with surfaces cleaned or painted that day. The following

ambient conditions shall be met:

during final surface preparation operations.

above dew point, and the maximum relative humidity shall be less than or equal to

85% during the application and cure/dry time of each coat of the paint system. If

the manufacturer’s published literature is more restrictive it shall be followed for

specific temperature, dew point, and humidity conditions during the application

cure/dry of each coat. The cure/dry time shall be measured as the time following

application when the ambient conditions are within the ranges above.

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The fabricator shall monitor and document temperature, dew point, and relative

humidity at the beginning of each work day and every 4 hours during surface

preparation and coating application, in the specific areas where the work is being

performed. The frequency of monitoring shall increase if weather conditions are

changing. If the weather conditions are forecast to be borderline relative to the

limits established by the manufacturer, monitoring shall continue at a minimum of

4 hour intervals throughout the curing/drying period. The Structural Steel

Fabrication Engineer has the right to reject any work that was performed under

unfavorable weather conditions. Rejected work shall be removed, re-cleaned, and

repainted at the fabricator’s expense.

blowing down the surfaces, and painting with conventional spray, the fabricator shall verify

that the compressed air is free of moisture and oil contamination in accordance with the

requirements of ASTM D4285. The tests shall be conducted at least one time each shift for

each compressor system in operation. If air contamination is evident, the fabricator shall

change filters, clean traps, add moisture separators or filters, or make other adjustments as

necessary to achieve clean, dry air. The fabricator shall also examine the work performed

since the last acceptable test for evidence of defects or contamination caused by the

compressed air. Affected work shall be repaired at the fabricator’s expense.

abrasive blast cleaning to meet the requirements of SSPC-SP 10.

When the Plans specify paint to be applied over galvanizing, the galvanized surface

shall be prepared prior to applying the intermediate coat. The galvanized surface

shall be prepared by SSPC-SP 1 followed by SSPC-SP 16, and in accordance with

ASTM D 6386. Surface grinding in accordance with SSPC-SP 11 and ASTM D6386

will be permitted in areas where SSPC-SP 16 is not achievable or practical.

abrasives (other than silica sand), or recyclable steel grit abrasives. Expendable

abrasives shall be used one time and disposed of. The fabricator shall verify that

recycled abrasives are free of oil contamination by conducting oil content tests in

accordance with SSPC-AB 2 on a daily basis.

506

that the abrasive will produce a uniform surface profile of 1.5 mils to 3.5 mils for

bare steel and 1 mil to 2 mils for galvanized steel. If the profile requirements of the

coating manufacturer are more restrictive, the fabricator shall advise the Structural

Steel Fabrication Engineer and comply with the more restrictive requirements. For

recycled abrasives, an appropriate operating mix shall be maintained in order to

control the profile within these limits.

The surface profile produced by the fabricator’s surface preparation procedures

shall be determined by replica tape and spring micrometer and in accordance with

SSPC-PA 17. Areas having unacceptable measurements shall be further tested to

determine the limits of the deficient area. The replica tape shall be attached to the

daily report.

When unacceptable profiles are produced, work shall be suspended. The fabricator

shall make the necessary adjustments to ensure that the correct surface profile is

achieved on all surfaces. The fabricator shall not resume work until the new profile

is verified by the QA observations and they confirm that the profile is acceptable.

degrees of cleaning immediately prior to painting and shall be painted before

rusting appears on the surface. If rust appears or bare steel remains unpainted for

more than 8 hours, the affected area shall be prepared again at the expense of the

fabricator.

All surface preparation cleaning residue on steel surfaces shall be removed prior to

painting.

The quality of surface preparation and cleaning of surface dust and debris shall be

accepted by the QA inspector prior to painting. The Structural Steel Fabrication

Engineer has the right to reject any work that was performed without adequate

provision for QA observations to accept the degree of cleaning. Rejected coating

work shall be removed and replaced at the fabricator’s expense.

according to these specifications and as specified in the paint manufacturer’s written

instructions and product data sheets for the paint system used. In the event of a conflict

between these specifications and the coating manufacturer’s instructions and data sheets,

the fabricator shall advise the Structural Steel Fabrication Engineer and comply with the

most restrictive requirements.

506

published instructions, including handling, minimum and maximum temperatures,

and warming as required prior to mixing. All coatings shall be supplied in sealed

containers bearing the manufacturer’s name, product designation, batch number,

and mixing/thinning instructions. Leaking containers shall not be used. The paint

shall be stored in a secure fireproof location.

Mixing shall be performed according to the manufacturer’s instructions. Thinning

shall be performed using thinner provided by the manufacturer, and only to the

extent allowed by the manufacturer’s written instructions. In no case shall thinning

be permitted that would cause the coating to exceed the local volatile organic

compound emission restrictions. For multiple component paints, only complete kits

shall be mixed and used. Partial mixing is not allowed.

The ingredients in the containers of paint shall be thoroughly mixed by mechanical

power mixers according to the manufacturer’s instructions, in the original

containers before use or mixing with other containers of paint. The paint shall be

mixed in a manner that will break up all lumps, completely disperse pigment, and

result in a uniform composition. Paint shall be carefully examined after mixing for

uniformity and to verify that no unmixed pigment remains on the bottom of the

container.

Excessive skinning or partial hardening due to improper or prolonged storage will

be cause for rejection of the paint, even though it may have been previously

inspected and accepted. Manufacturer recommended induction/sweat-in times and

temperature of mixed coatings shall be observed.

Multiple component coatings shall be discarded after the expiration of the pot life.

Single component paint shall not remain in spray pots, paint buckets, etc. overnight

and shall be stored in a covered container and remixed before use.

coat of paint shall be applied as a continuous film of uniform thickness free of

defects including, but not limited to, runs, sags, overspray, dry spray, pinholes,

voids, skips, misses, and shadow-through. Defects such as runs and sags shall be

brushed out immediately during application.

506

Unless prohibited by the coating manufacturer’s written instructions, paint may be

applied by spray methods, rollers, or brushes. If applied with conventional or airless

spray methods, paint shall be applied in a uniform layer with overlapping at the

edges of the spray pattern.

The painters shall monitor the wet film thickness of each coat during application.

The wet film thickness shall be calculated based on the specified dry film thickness

using the solids by volume of the material and the amount of thinner added.

When brushes or rollers are used to apply the coating, additional applications may

be required to achieve the specified thickness per layer.

considered dry for re-coating according to the re-coat time/temperature/humidity

criteria provided in the manufacturer’s instructions, and when an additional coat

can be applied without the development of film irregularities such as lifting,

wrinkling, or loss of adhesion of the under coat.

an additional stripe coat to edges, crevices, welds, and similar surface irregularities

for the prime coat and intermediate coat. The stripe coat shall be applied by brush

or roller, as per the manufacturer’s recommendations, such that the coating is

thoroughly worked into or on the irregular surfaces. The stripe coat shall extend

onto the surrounding steel a minimum of 1 inch in all directions. The purpose of

the stripe coat is to build additional thickness and to ensure complete coverage of

these areas.

The stripe coat shall not be applied as part of the application of the full coat. The

stripe coat shall be applied and dried separately according to the manufacturer’s

recommended drying times. Also, the color of the stripe coat shall contrast with the

colors used for the full coats immediately preceding and succeeding the stripe coat.

applied as follows:

Once the full prime coat has dried, the prime stripe coat shall be applied.

stripe coat shall be applied and allowed to dry, followed by the full

intermediate coat.

506

be applied.

measured in accordance with SSPC-PA 2. If the manufacturer’s upper or lower thickness

limit is more restrictive, it shall be followed instead.

and 5.0 mils dry film thickness.

mils and 6.0 mils dry film thickness.

dry film thickness. The top coat color shall be according to Contract.

under certain conditions. Amine blush often appears as a yellowish milky or blotchy

residue on the coating surface and is a deterrent to the adhesion of subsequently applied

coating layers. If amine blush is detected, the Contractor shall provide the Engineer with

written procedures from the coating manufacturer for complete removal prior to the

application of additional coating layers.

newly installed coating system, at no cost to the Agency. If the damage extends to the

substrate, the damaged areas shall be prepared to meet SSPC-SP 3.

The surrounding coating at each repair location shall be feathered for a minimum distance

of 1-1/2 inches to achieve a smooth transition between the prepared areas and the existing

coating.

If the bare steel is exposed, all coats shall be applied to the prepared area. If only the

intermediate and finish coats are damaged, the intermediate and finish coats shall be

applied. If only the finish coat is damaged, the finish coat shall be applied.

All hold points and specifications are applicable to the repair of damaged areas and areas

concealed by containment.

506

Contractor may request that the Engineer waive the requirements for NACE certification

and SSPC-QP 1 certification for the necessary field painting of the bolted connection areas.

Requests will be reviewed on a case-by-case basis and will only be considered on projects

with limited amounts of required field painting such as diaphragm and cross frame

connections. If the Engineer grants the request, all other requirements for certifications,

inspections, quality control, supplying inspection equipment, hold points, etc. will remain

in effect.

Contract requires installation of bolts that are to be painted. This work shall occur after bolt

tensioning has been completed. All exposed oils, lubricants, and wax on the bolts, nuts,

washers, and surrounding surfaces to be painted shall be completely removed by solvent

cleaning. This also includes any foreign material that has come out of the DTIs during the

tensioning process. Light hand wire brushing or scrubbing with bristle brushes is allowed.

Use of power tools is not allowed.

For galvanized hardware, the Contractor shall remove the colored lubricant from the nuts.

The galvanizer may be able to provide information to the Contractor on the most effective

solvent cleaner to remove the colored lubricant (common examples include methyl-ethyl-

ketone (MEK), foaming glass cleaners containing ammonia, and foaming alkaline-type

household cleaners). It is not necessary to remove 100% of the dye, and it is acceptable for

some staining to remain after cleaning. A white cloth wipe test with no color transfer can

be used to confirm that all lubricant and non-absorbed dye has been removed, leaving only

the residual stain on the surface. The final cleanliness shall be acceptable to the Engineer.

shall be performed in accordance with Subsection 708.04.

Grease rustproofing compound shall be uniformly applied in a single coat by brush or spray at an

approximate rate of 20 square feet per gallon to the steel as specified. This shall occur after all

concrete form work has been removed, and after the final coat of paint, including repairs, has fully

cured. A fully cured condition has occurred when a thumbnail driven into the coating surface does

not leave an impression and when a thumb firmly pushed against the surface and twisted does not

disturb the coating.

Surfaces adjacent to areas being grease coated shall be protected against over-spray. Non-metallic

and stainless steel surfaces shall not be coated.

506

506.23METHOD OF MEASUREMENT

item, to be measured for payment will be the number of pounds used in the complete and accepted

work. The weight of the material to be measured for payment under this item will be computed

based on the approved fabrication drawings, as follows:

specified in Table 506.23A.

TABLE 506.23A – MATERIAL DENSITIES

Material Density (lbs/ft )

Aluminum, Alloy 173

Bronze, Cast 536

Copper, Alloy 536

Copper, Sheet 558

Iron, Cast 445

Iron, Wrought 487

Lead, Sheet 707

Steel – Rolled, Cast, Copper

Bearing, Silicon, Nickel, or Stainless 490

For any material not listed in Table 506.23A, the material will be paid for by actual weight

as measured on a certified scale.

foot as shown on the Plans or, if not shown on the Plans, by the weights shown in the AISC

Steel Construction Manual.

The weight of rolled shapes will be based on the overall net length shown on the approved

fabrication drawings, with no allowance for milling, finishing, or overrun, and with no

deduction for cuts, clips, copes, or open holes.

fabrication drawings, with no allowance for milling, finishing, tolerance, or overrun, and

with no deductions for copes, clips, and open holes. The weights of beveled plates or curved

surface plates will be based on the finished maximum thickness shown on the approved

fabrication drawings.

506

For gusset plates, scupper components, slotted plates, and similar minor fixtures the net

finished dimensions will be the minimum rectangular dimensions from which the parts are

cut, except when it is practical to cut the parts in multiples from pieces of larger dimensions,

in which case the weight will be based on the dimensions of the larger pieces, making

necessary allowance for the material lost in cutting.

The net finished dimensions of flange plates will be the nominal width and the finished

length measured along the centerline of the flange without deduction for width transitions,

bevels, or chamfers.

The net finished dimensions of the webs of all girders and of the webs of rigid frame legs

will be the actual area of the web as detailed on the approved fabrication drawings.

will be made for the weight of weld metal used.

incorporated into the structure and temporary erection bolts, nuts, and washers shall be

incidental to the Structural Steel item and no measurement will be made for weight of the

bolts, nuts, direct tension indicators, and washers.

item, to be measured for payment will be on a lump sum basis in the complete and accepted work.

number of existing rivets replaced with high strength bolts in the complete and accepted work.

Rivets measured for replacement will be made in only the locations specified in the Contract and

in any other locations identified for replacement by the Engineer. Unless otherwise specified in

the Contract, rivet removal and installation of new fasteners associated with structural steel repairs

will not be measured for payment as Rivet Replacement.

506.24BASIS OF PAYMENT. The accepted quantity of Structural Steel will be paid for at the Contract

unit price per pound or at the Contract lump sum price for the items specified in the Contract. Payment

will be full compensation for furnishing, detailing, handling, transporting, and placing the materials

specified, including nondestructive testing of welds; for preparing the surface of new steel to be painted,

galvanized, metalized, or to remain unpainted; for necessary field cleaning; and for painting, metalizing,

sealing, galvanizing, or grease coating of surfaces, unless otherwise paid for. Payment will also be full

compensation for furnishing and implementing the erection plan, nondestructive testing, quality control

activities, and for furnishing all labor, tools, equipment, and incidentals necessary to complete the work.

506

The Engineer may authorize partial payments in the following manner:

approved for fabrication.

completed and accepted in accordance with the approved fabrication drawings, stored in a location

and manner accepted by the Structural Steel Fabrication Engineer, and all applicable material

certifications have been approved.

falsework removed, and painting of connections and touch-up completed where required.

of all work under this section, including extended weights being received and checked.

The accepted quantity of Rivet Replacement will be paid for at the Contract unit price for each. Payment

will be full compensation for performing the work specified and for furnishing all labor, tools, equipment,

and incidentals necessary to complete the work.

Payment will be made under:

Pay Item Pay Unit

506.5000 Structural Steel, Rolled Beam ...................................................................Pound

506.5500 Structural Steel, Plate Girder ....................................................................Pound

506.5600 Structural Steel, Curved Plate Girder........................................................Pound

506.5700 Structural Steel, Truss ...............................................................................Pound

506.6000 Structural Steel ..........................................................................................Pound

506.7500 Structural Steel ..........................................................................................Lump Sum

506.8500 Rivet Replacement ....................................................................................Each

507

5-130SECTIO N 507 – REINFORCIN G STEEL

507.0 1 DESCRIPTION . This work shall consist of furnishing and placing bar reinforcement of the level specified, dowels, wire, welded wire reinforcement (WWR), and mechanical bar connectors. Levels and associated types of reinforcing steel are specified as follows:

coated reinforcing steel.

continuously -galvanized , low -carbon chromium, and hot-dipped galvanized reinforcing steel.

reinforcing steel. The location, level, and when specified, type of reinforcing shall be as indicated on the Plans. Reinforcing supplied shall meet the requirements of the level specified or any higher level. Only one type of reinforcing steel shall be used for each level for the Contract work, unless permitted in writing by the Engineer. 507.0 2 MATERIALS . Materials shall meet the requirements of the following subsections: Mortar, Type IV ................................ ................................ ................................ ......... 707.0 1(e) Bar Reinforcement ................................ ................................ ................................ .....713.01 Mechanical Splices for Bar Reinforcement ................................ ............................... 713.02 Welded Wire Reinforcement ................................ ................................ ..................... 713.0 3 507.0 3 FABRICATIO N AND SHIPMENT . Bar reinforcement shall be deformed bar cold bent to the shapes required. Bar reinforcement shall be fabricated, bundled, tagged, marked, and shipped in accordance with the CRSI Manual of Standard Practice . The fabricator shall maintain records that will provide traceability of identifying heat numbe rs for all material being fabricated for Agency projects or Contract orders referencing materials covered under this section . 507.0 4 PROTECTIO N OF MATERIAL . Reinforcing steel shall be protected from damage at all times by storing it on blocking, racks, or platforms. When multiple levels of reinforcing steel are used on a project, they shall be stored separately, including during transport in order that there is no direct contact between the bars. When placed in the work, the reinforcing steel shall be free from dirt, detrimental scale, paint, oil, previously placed concrete, or other foreign substances.