Wisconsin WisDOT Standard Specifications (within FDM) — Section 506

Effective with the December 2018 Letting 247 2019 Standard Spec ifications Section 506 Steel Bridges

506.1Description

(1)This section describes fabricating, furnishing, casting, machi ning or preparing otherwise, delivering,

and erecting the steel and miscella neous metals required for st eel bridges, or metal parts of other bridges.

506.2Materials

506.2.1 General

(1)Furnish materials conforming to the specifications for the sev eral parts of the completed structure.

506.2.2 Structural Steel 506.2.2.1 General

(1)Furnish structural steel for highway structures conforming to the ASTM specifications the plans show.

For material that the plans do not indicate the ASTM specifications, furnish structural carbon steel conforming to ASTM A709 grade 36. Revise 506.2.2.1(2) to prohibit shearing or punched holes in members requiring Charpy testing.

(2)Ensure that girder flange plates, girder web plates, flange sp lice plates, hanger bars, links, rolled

beams, flange cover plates, and plates and angles connecting fl oor beams to girders conform to zone 2 toughness requirements for longi tudinal Charpy V-Notch tests specified in ASTM A709 . Sample and test according to ASTM A673. Use the (H) frequency of testing. Do not shear cut or punch full-sized holes in members requiring Charpy V-Notch testing.

(3)Ensure that structural steel members included in the structural design capacity, and that will be

welded, have a maximum carbon equivalent (CE) of 0.48. Steels c onforming to ASTM A709 HPS 50 or 70 with carbon contents 0.10 per cent or less are exempted fr om this rule. The engineer may allow steels with up to CE 0.58 only i f the contractor uses an engineer-approved adjusted welding procedure. Submit steel mill cert ifications indicating the comp osition of the steel provided under the contract. The engineer will calculate the carbon equivalent as follows: CE= C + (Mn+Si)/6 + (C r+Mo+V)/5 + (Ni+Cu)/15 506.2.2.2 Structural Carbon Steel

(1)For structural carbon steel 4 inches thick or thinner, conform to ASTM A709 grade 36. For structural

carbon steel over 4 inches thick, conform to ASTM A36 . 506.2.2.3 High-Strength Structural Steel

(1)Use high-strength structurals teel conforming to ASTM as follo ws:

HSLA columbium-vanadium steels of structural quality: 50 ksi minimum yield poi nt to 4 inches thick .................. ............................................. ASTM A709 , grade 50 HSLA weathering steel: 50 ksi minimum yield poi nt to 4 inches thick .................. .......................................... ASTM A709 , grade 50W High-yield-strength quenched and tempered alloy steel plate: Martensitic ................................................................................................... ASTM A709 , grade 100 or 100W Non-martens itic ............................................... ......................................................... ASTM A709 , grade 70W High Performance Steels: Up to 4 inches thick .......................................... .......................................... ASTM A709 HPS, grade 50 or 70 506.2.3 Miscellaneous Metals 506.2.3.1 Steel Castings

(1)If using carbon steel castings for bridges and general use, co nform to class 70 , 90, 120 of AASHTO

M192 and the following:

1.Furnish the specific class o f steel castings the plans show or are specified in the contract.

2.The plans will specify the nondestructive tests to perform and their extent.

3.Use steel castings that are true to pattern in form and dim ensions and free from def ects affecting strength

or service life.

4.The contractor may weld def ects using an engineer-approved process. Perform weld repairs before

annealing the ca sting. If the engineer requires, re-anneal castings after welding.

5.If the engineer requires, the c ontractor shall test castings by radiography or ultrasonic testing to determine

the presence of cracks, flaws, or other defects.

Effective with the December 2018 Letting 248 2019 Standard Spec ifications 6. Ensure that the me tal thickness remaining after completing the machining is not less than the thickness the plans show.

7.Thread the ends of the tens ile test specimens for at least 3/4 inch with 3/4-inch American N.C. threads.

506.2.3.2 Bronze Castings

(1)If using bronze casti ngs for bearings, trunnions, journals of bridges, and expansion plates, conform to

ASTM B22 , alloy No. C91100. 506.2.3.3 Cold-Finished Carbon Steel Shafting

(1)Use cold-finished carbon steel shafting conforming to AASHTO M 169, grades 1016 through 1030. If

used for structural pins, then conform to ASTM A434, grade BC, quenched and tempered. 506.2.3.4 Lubricated Bronze Plates

(1)Fabricate lubricated bronze plates as the plans show and with materials conforming to ASTM B100,

copper alloy No. C51000 or to ASTM B22 , alloy No. C91100.

(2)Provide to the engineer a certi fied report of test or analysis indicating the manufacturer’s test results

for the lubricated bronze plates on their chemical and physical properties, including the coefficient of friction of the material used.

(3)Bore or cast the surface of the lubricated bronze plates in a geometric pattern of recesses. Fill the

recesses with a lubricating compound consisting of graphite and metallic substances with a lubricating binder capable of withstanding the atmospheric elements. Hydrau lically press the compound into the recesses to form dense, non-plasti c lubricating inserts. Ensure the lubricated area is within a range of 25 to 33 percent, inclusive, of the bearing face with a coeffic ient of friction not gr eater than 0.1. Unless the plans show or the contract d irects otherwise, only lubricat e the top face of the bronze plate. 506.2.3.5 Steel Forgings

(1)Use steel forgings for pins, r ollers, trunnions, and other for ged parts conforming to the requirements

for class M quenched and tempered forgings of ASTM A668. Thread the ends of the tensile test specimens for at least 3/4 inch with 3/4-inch American N.C. threads. 506.2.3.6 Welded and Seamless Steel Pipe

(1)Furnish welded and seamless st eel pipe for general use conforming to ASTM A53 , type F, or type E,

grade B or typeS, grade B. Unless provided otherwise, use blac k, standard weight pipe. 506.2.3.7 Pipe Fittings

(1)Use malleable cast iron or pressed steel pipe fittings for required uses. If zinc coated fittings are

required, the coating shall conform to ASTM A123. 506.2.3.8 Sheet Lead

(1)Furnish lead in she et form conforming to ASTM B29 .

(2)Use lead sheets of uniform thi ckness throughout, free from cra cks, seams, slivers, scale, and other

surface defects.

(3)Unless the plans show otherwise, use sheet lead 1/8 inch thick with a tolerance of +/- 1/32 inch.

Ensure that the length and width are within 1/8 inch of the pla n dimensions. 506.2.3.9 Sheet Copper

(1)Furnish strip or sheet copper conforming to ASTM B152 and suitable for the pur pose intended. Unless

specified otherwise, use sheet c opper with a minimum thickness of 0.02 inch. 506.2.3.10 Sheet Zinc

(1)For sheet or plate zinc, conform to Prime Western Grade ASTM B6 .

(2)Use sheet and plate zinc of uniform thickness, free from cracks, seams, slivers, scale, surface

corrosion, adhering matter, and other surface defects.

(3)Use sheet and plate zinc of t he zinc gauge the plans show, wit h a thickness tolerance of +/- 6 percent.

Use sheets within 1/8 inch of t he length and width the plans sh ow. 506.2.4 Name Plates

(1)Furnish bronze nameplates for bridges, culverts, and retaining walls cast from material conforming to

ASTM B62 for copper alloy UNS No. C83600, common trade name 85-5-5-5. P rovide raised lettering in a block gothic font and polis h the raised surface of the lettering and borders.

Effective with the December 2018 Letting 249 2019 Standard Spec ifications 506.2.5 High-Strength Bolts 506.2.5.1 General

(1)Furnish high-strength A325 bolts conforming to ASTM F3125, nuts conforming to ASTM A563, and flat

washers conforming to ASTM F436. Use type 1 galvanized bolts, gal vanized grade DH nuts, and type 1 galvanized washers. For weathering steel connections use type 3 bolts, grade C3 or DH3 nuts, and type 3 washers.

(2)Hot-dip zinc-coat according to ASTM A153 supplemented by ASTM F2329 or mechanically zinc-coat

according to ASTM B695, class 50. Remove excess hot-dip zinc coating on threads by ce ntrifuging or air blasting immediately after withdrawal. Do not flame-chase. Ensure that the same zinc-coating process is used for bolts and nuts within a bolt/nut/washer ass embly.

(3)Ensure that the supplier lubricates zinc coated nuts with a lubricant containing dye that contrasts with

the color of the zinc coating according to ASTM A563 supplementary requirements S1 and S2.

(4)For, uncoated nuts use grade C, D, or C3 with a minimum Rockwe ll hardness of 89 HRB or minimum

Brinell hardness of 180 HB, or use heat treated grade DH or DH3.

(5)Furnish direct tension indicati ng (DTI) washers conforming to ASTM F959. Use zinc-coated type 325

DTIs in type 1 galvanized bolt/nut/washer assemblies and type 325-3 DTIs in type 3 weathering steel bolt/nut/washer assemblies. Ensur e that DTIs have identifying m arks applied by the manufacturer. 506.2.5.2 Bolt and Nut Dimensions

(1)Use high-strength bolts and nuts conforming to the dimensions the plans show and as specified in

ASTM F3125 . Determine the length as specified in 506.2.5.4 . 506.2.5.3 Washer Dimensions

(1)Use flat, smooth, and hardened ci rcular washers conforming to dimensions specified in ASTM F436.

(2)Install bolts with a washer under the nut or bolt head, whiche ver is turned to tighten. If the bearing

faces of the bolted parts have a slope of more than 1:20 with r espect to a plane normal to the bolt axis, use smooth, hardened, and beveled washers to compensate for lack of parallelism.

(3)If clearance is necessary, the contractor may clip washers on one side to a point no t closer than 7/8 of

the bolt diameter from center of washer. 506.2.5.4 Bolt Lengths

(1)The required bolt length is the gr ip, total thickness of the c onnected material, plus the tabulated length

added to the grip for each bolt size as follows: BOLT SIZE LENGTH A DDED TO THE GRIP 5/8-inch ...................................................... ...................................................................................... 1 1/16 inches 3/4-inch ...................................................... ...................................................................................... 1 3/16 inches 7/8-inch ...................................................... ...................................................................................... 1 5/16 inches 1-inch ........................................................ ....................................................................................... 1 9/16 inches 1 1/8 to 1 1 /4-inch ........................................... ............................................................................... 1 13/16 inches 1 3/8 to 1 1 /2-inch ........................................... ................................................................................. 2 1/16 inches

(2)The above values are generalized, with allowance for manufactu ring tolerances, to provide for a

washer and using a heavy nut, w ith adequate stic k-through at th e end of the bolt. For each required beveled washer, add 5/16 inch; for any additional washer, add 3 /16 inch; and for a load-indicating washer, add 1/8 inch. Adjust t he length determined from the above table increment and allowances for additional washers to the next 1 /4 inch length increment for bo lts up to 5 inches length and to the next 1/2 inch length increment for lengths over 5 inches.

(3)For bolt lengths determined as provided above, the full thread may extend into the grip not more than

3/8 inch for lengths of 5 inches or less, and not more than 5/8 inch for lengths over 5 inches. 506.2.5.5 Identification

(1)Ensure that the manufacturer pr ovides identification marks for high-strength bolts and nuts according

to ASTM F3125. 506.2.5.6 Testing and Reporting

(1)Test according to ASTM F3125, ASTM A563, and ASTM F436. For rotational-capacity testing conform

to Report No. FHWA SA-91-031 "Hi gh-Strength Bolts for Bridges." In addition perform rotational- capacity testing in the field c onforming to the procedures enum erated in department form DT2113.

Effective with the December 2018 Letting 250 2019 Standard Spec ifications (2) Furnish 2 copies of a certified report of test or analysis ind icating the results of required manufacturer/supplier tests. Als o verify the results of additio nal field testing required under FHWA SA- 91-031 by submitting 2 copies of department form DT2113. 506.2.6 Elastomeric Bearings 506.2.6.1 General Revise 506.2.6.1(1) to remove the reference to the bridge secondary item APL for non-laminated bearings.

(1)Furnish laminated bearings from the department's APL of laminated elastomeric bearings

(2)Manufacture bearings according to AASHTO M251 except replace the requirements of sections 4.1

and 4.2 with the following: - Use virgin crystallization resistant polychloroprene, or virgin natural polyisoprene as the raw polymer. Use only new material with no reclaimed material incorporated in th e finished bearing. - Provide elastomer with durometer hardness of 60 on the Shore “A” scale. Provide el astomer compounds classified as low-temperature zone D, grade 4 or 5, meeting the requirements of AASHTO LRFD Bridge Design Specifications, table 14.7.5.2-1. - Conform to the following physical properties: POLYISOPRENE POLYCHLOROPRENE (NATURAL RUBBER) (NEOPRENE) Grade (durometer) ........................................................................... 60±5 60±5 Physical properties Hardness ( ASTM D2240 ) ........................................................... 60+/-5 60+/-5 Tensile strength ( ASTM D412 ), psi ............................................... 2500 2500 Ultimate elongation, minimum percent ........................................... 400 400 Heat resistance (ASTM D573 ) 168 hrs. @ 158°F 70 hrs. @ 212°F Hardness, maximum points change ............................................... +10 +15 Tensile strength, maximum percent change .................................... -25 -15 Ultimate elongation, maximum percent change ................................ -25 -40 Compression set ( ASTM D395, method B) 22 hrs. @ 158°F 22 hrs. @ 212°F Maximum percent ......................................................................... 25 N.A. Maximum percent ........................................................................ N.A. 35 Low temperature brittleness ( ASTM D746 , procedure B) Brittleness at -54.4°F .............................................................. No Failure No Failure Laminated pad adhesion test ( ASTM D429 , method B) Bond strength, psi ........................................................................ 40 40 506.2.6.2 Non-Laminated Elastomeric

(1)Form non-laminated elastomeric be arings by casting or extrudin g rubber or neoprene in a single,

integral layer to the required plan thickness. Avoid heating or damaging the material if cutting. 506.2.6.3 Laminated Elastomeric

(1)Furnish alternate layers of ela stomer and steel reinforcement integrally bonded together, with

reinforcement spaced as the pl ans show and parallel to the pad top and bottom surfaces. Cover reinforcement edges with a minimum of 1/4 inch of elastomer. Se al edge cavities using heat bonded vulcanized patching or an engineer-approved elastomeric sealant .

(2)Conform to AASHTO M251 tolerances, dimensions, and configurati ons; except cover the top and

bottom steel plates with 1/4 inc h of elastomer with a +1/8 to - 1/16-inch thickness to lerance. Use rolled steel conforming to ASTM A36 or ASTM A1011 grade 36 or higher, for internal steel reinforcement.

(3)Ensure that the manufacturer mo lds their name or trademark int o the edge of each pad on a face

visible after structure erection. Revise 506.2.6.3(4) to require electr onic submittal of shop drawings to the department's fabrication library.

(4)Submit shop drawings to the engineer conforming to 105.2 with electronic submittal to the fabrication

library under 105.2.2 . 506.2.6.4 Testing

(1)Conform to the bearing testing and acceptance criteria specified in AASHTO M251, section 8 as

follows: - Determine compressive strain a ccording to section 8.8.1. Ensu re that compressive str ain in any layer of an elastomeric bearing does not exc eed 7 percent at 800 psi averag e unit pressure for the full size bearing.

Effective with the December 2018 Letting 251 2019 Standard Spec ifications - Proof load each bearing accordin g to section 8.8.2. Use a com pressive load of 1200 psi for non-laminated bearings and 1800 psi for laminated bearings.

(2)Provide a manufacturer's certified report of test or analysis to the engineer for each production lot of

bearings at least 30 days befores hipment to the contractor. Th e department may require additional test samples from the bearings to confirm manufacturer test res ults before shipment.

(3)Ensure that each bearing delivered to the project is labelled to clearly indicate its production lot and

can be tied to its assoc iated test results. 506.2.7 Welded Stud Shear Connectors

(1)For shear connector studs conform to ASTM A108, cold-finished bars, grades 1015, 1018, or 1020,

either semi- or fully killed. If u sing flux-retaining caps, use low carbon grade steel for the caps suitable for welding that comply with ASTM A109.

(2)Tensile properties, determined te sting bar stock after drawing , or of finished studs, shall conform to the

following: Minimum tensil e strength ...................................... ............................................................... ....................... 60 ksi Minimum yield strength[1] ............................................................................................................................ 50 ksi Minimum elongation ............................................................... ............................................ 20 percent in 2 in ches Minimum reduction of a rea ..................................... ............................................................... .............. 50 percent [1] As determined by the 0.2 percent offset method.

(3)Determine tensile properties according to ASTM A370. Perform tensile tests of finished studs on studs

welded to test plates using a te st fixture similar to figure 7. 2 of chapter 7 of A WS D 1.5. If fracture occurs outside the middle half of the gauge length, repeat the test.

(4)Ensure that finished studs are of uniform quality and condition, free from injurious laps, fins, seams,

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

(5)Furnish arc shield (ferrule) of heat-resistant ceramic or othe r material with each stud that does not

damage the welds, or does not c ause excessive slag, and will no t crumble or break due to thermal or structural shock before completing the weld.

(6)The contractor shall submit the following information on the studs to the engineer for approval before

installation: - The name of the manufacturer. - A detailed description of the stud and arc shield. - Documentation that the studs qualify as specified in AWS D 1. 5. 506.2.8 Bearing Assemblies 506.2.8.1 General

(1)Use bearing assemblies conforming to the material requirements , sizes, and details the plans show.

(2)Blast clean fabricated structural steel bearing components as specified in 506.3.31.3 before zinc

coating. After zinc coating, apply a wash primer to the compone nts and the coating sy stem in the color selected for the structural steel under the concrete. If using weathering steel, paint the bearing assemblies with one coat of or ganic zinc-rich primer and one sh op coat of high-bu ild brown epoxy paint. The contractor shall not b last clean, zinc coat, or pain t stainless steel and teflon surfaces. 506.2.8.2 Fixed Bearing Assemblies

(1)Zinc coat the complete bearing assembly, including anchor bolts, nuts and washers, but excluding

elements welded to the girder. Zin c coat the anchor bolts, nuts , and washers, according to ASTM A153, class C, supplemented by ASTM F2329. Zinc coat the remainder o f the assembly according to ASTM A123. 506.2.8.3 Expansion Bearing Assemblies

(1)An expansion bearing assembly unit consists of a top sole plat e, a bottom masonr y plate, a rocker

plate, a slide plate, side reta iners, anchor bolts with nuts an d washers, and a lead plate, all as described below and as the plans show.

(2)Zinc coat all structural steels urfaces, including anchor bolts, nuts and washers, that do not come in

contact with other structural st eel surfaces, or stainless stee l, or polytetrafluoroethylene (PTFE) surfaces, as specified in 506.2.8.2 for fixed bearing assemblies.

(3)For the stainless steel sheet fo r the top element of sliding b earings use type 304 conforming to ASTM

A240 and ensure it is not less than 1/ 16 inch thick after finishing . Make the finisheds tainless surface a plane within a tolerance of 1/32 inch and with a 2B finish as s pecified in ASTM A480.

Effective with the December 2018 Letting 252 2019 Standard Spec ifications (4) During welding, protect the surf ace of the stainless steel pla te from weld splatter.

(5)After fabrication, provide a near mirror finish on the surface of the stainless steel plate.

(6)Use PTFE materials that are virgin polytetrafluoroethylene flu orocarbon resin, unf illed conforming to

ASTM D4894 . The finished materials shall exhibit the following physical p roperties: REQUIREMENT TEST ME THOD UNFILLED VALUE Hardness at 78 F ASTM D2240 Shore "D" 50-65 Tensile strength, psi ASTM D1708 2800 Min. Elongation, percent ASTM D1708 200 Min. Specific gravity ASTM D792 2.16 +/- 0.03 Melting point ASTM D4591 621 +/- 18 F

(7)Ensure the finished PTFE shee t is not less than 1/16 inch or m ore than 3/32 inch thick.

(8)Bond the PTFE sheet to the 1/2-inch steel sheet with extreme c are using a proven high-temperature-

resistant epoxy bonding material. Use a 2-component, medium vis cosity epoxy resin conforming to ASTM D1763 for this purpose.

(9)The engineer may allow welding to steel plate that has a bonde d PTFE surface provided welding

procedures are established tha t restrict the maximum temperatur e reached by the bond area to less than 300 F. Monitor temperature us ing temperature-indicating cr ayons, liquids, or bimetal thermometers.

(10)If epoxy bonding PTFE sheets, ensure that one side of the PTFE sheet is factory treated by the

sodium naphthalene or sodium ammonia process by a department-ap proved manufacturer.

(11)Perform PTFE bonding at the beari ng manufacturer’s factory under controlled conditions and

according to the engineer-approved adhesive systems manufacture r’s written instructions. The bonding operation should produce a PTFE surface that is smooth and free from bubbles.

(12)At installation, ensure the stai nless steel sliding face of th e upper element and the PTFE sliding face of

the lower element have the surfac e finish specified and are cle an and free of dust, dirt, moisture, or any other foreign matter. 506.2.8.4 Preformed Fabric Pads, Class A

(1)Furnish fabric pads for use under steel bearings the plans sho w. Use preformed pads composed of

multiple layers of 8-ounce co tton duck impregnated and bound wi th natural rubber, or of equivalent and equally suitable materials compressed into resilient pads of uniform thickness. The number of plies shall produce the specified thickness after compression a nd vulcanizing. When tested according to MIL-C-882E, finished pads sha ll withstand comp ression loads of 10,000 psi or more perpendicular to the plane of the laminations without harmful extrusion or re duced thickness. 506.2.9 Steel Diaphragms

(1)Furnish steel diaphragms conforming to the plan details.

506.2.10 Zinc Coated Fabrication

(1)Conform to ASTM A385 for fabricating zinc coated work.

Delete 506.2.11 to move secondary fabr ication requirements to 506.3.1.2 now cal led fabricated bridge components.

506.3Construction 506.3.1 General

Revise 506.3.1 to clarify requirements for steel pr imary members and fabricated bridge components. 506.3.1.1 Primary Members

(1)Ensure that the following are f abricated by an approved fabrica tor selected from the department’s APL

for primary members: - Webs and flanges of tub and box gi rders, rolled beams, and thei r cover plates. - Main truss members (chords, verti cals, and diagonals of truss p anels, transverse wind bracing, floor system). - Floor beam webs and flanges. - Arch ribs. - Ties and hangers. - Pier diaphragm members for tub girders. - Splice plates for primary members. - Columns.

Effective with the December 2018 Letting 253 2019 Standard Spec ifications (2) Ensure that the fabricator does the following: - Submits department form DT2330 electronically to the department ’s fabrication library for eac h structure before fabrication. - Submits and updates weekly fabr ication progress reports on depa rtment form DT2172 electronically to the department’s fabrication library for each structure during fabr ication. 506.3.1.2 Fabricated Bridge Components

(1)Ensure that the following are f abricated by an approved fabrica tor selected from the department's APL

for fabricated bridge components: - Railing assemblies - Expansion devices - Bearing assemblies - Structural steel diaphragms for concrete girders

(2)Ensure that the fabricator does the following:

- Submits a fabrication progr ess report on department form DT2334 electronically to the department’s fabrication library. Update th is form weekly for each component in fabrication. 506.3.2 Shop Drawings

(1)Ensure that shop drawings confor m to the contract plans and provide additional details, dimensions,

computations, and other informati on necessary for completely fabricating and erecting the work. Include project and structure numbers on each shop drawing shee t. Revise 506.3.2(2) to clarify shop drawing submittal requi rements for primary members and fabricated components.

(2)Submit shop drawings to the engineer conforming to 105.2 with electronic submittal to the fabrication

library under 105.2.2 . Also certify that shop drawings conform to quality control standards before fabrication by submitting department form DT2333 for primary members and department form DT2327 for fabricated bridge components with each set of shop drawings . Department review does not relieve the contractor from responsibility for errors or omissions on shop drawings.

(3)Shop drawings are part of the co ntract. The department must ap prove differences between shop

drawings and contract plans. The contractor bears the costs of department-approved substitutions. Do not deviate from or revise drawings without notifying the depar tment and resubmitting revised drawings and an updated department form DT2333 .

(4)Ensure that the fabricator de livers 3 sets of shop drawings fo r railroad structures to the railroad

company upon contract completion. 506.3.3 Structural Steel Identification

(1)In addition to ordinary mill identification, paint the appropriate color, according to ASTM A6 , on all

structural steel, except steel conforming to ASTM A709 , grade 36 without toughness requirements, on each end of each piece before sh ipment from the mill. Before wo rking any piece in the shop, move the identifying paint marks a sufficient distance away from the end to ensure the identity of the piece during fabrication. Mark angles on the inside of a leg. Mark be ams and channels on the inside of a flange. Paint the ends of pieces if assembly will destroy or ma ke identification by the above methods impossible. If the contractor fails to exercise the above preca utions, the engineer will reject the piece. 506.3.4 Rolled Material 506.3.4.1 Straightening

(1)Ensure rolled material is str aight before being laid off or wo rked. If straightening is necessary, perform

it without injuring the metal. The engineer may reject material with sharp kinks and bends. 506.3.4.2 Camber

(1)If the plans show, camber rolled beams. The camber shall confo rm to a uniform, approximately circular

curve for the entire length o f the beam or between designated p oints. Ensure the designated camber is within the tolerance specified in the American Institute of Steel Construction Manual. The steel manufacturer may produce camber , or produce or correct it by lo cal heating. If the plans show camber less than the minimum camber likely to remain permanent as tabu lated in the Manual of Steel Construction of the American Inst itute of Steel Construction, produce the camber by applying heat.

(2)If cambering beams or correctin g camber by local heating, take care not to overheat the metal. The

contractor shall not heat the metal above 1200 F. Select the ar eas to heat so that no distortion other than the required camber occurs. F ollow a procedure that prevents beam flange warpage.

(3)Support the beam near its ends facing the side made concave upward. Apply propane, natural gas, or

other engineer-approved gas flame to areas selected so that no distortion other than the required

Effective with the December 2018 Letting 254 2019 Standard Spec ifications camber occurs. Apply heat by playing the flame over the section until the metal attains a maximum temperature of 1000 F to 1200 F. M onitor the temperature using temperature-indicating crayons, liquids, or bimetal thermometers. Notify the engineer before applying any heat.

(4)Heat the areas in generally w edge- or triangular-shaped areas with an included angle between 10 and

20 degrees. Locate the vertex of the angle on the web midway be tween flanges. Slowly play the flame over the area heated, commenci ng at the vertex of the angle and finishing at the widest part of the heated wedge, extending across the flange width. Manipulate the torch, or torches, to rapidly bring the total area heated to the proper temperature at the same time.

(5)Space the heated sections to pr oduce uniform curvature. Heat n o less than 3 sections, and it may

require heating additional sections if the beam is unusually lo ng or heavily cambered. Do not use water to cool the metal, or hea t any area more than once. Air cool the heated metal slowly away from wind or drafts. The engineer may reject the beam if improper he ating or cooling occurs that might affect the strength or ductility of the metal. 506.3.5 Bolt Holes

(1)Punch or drill holes for bolts. T he contractor may punch bolt holes 1/16 inch larger than the nominal

diameter of the bolts in material forming a member made of no m ore than 5 metal thicknesses and if the metal is not thicker than 3 /4 inch for structural carbon st eel, 5/8 inch for high-strength structural steel, or 1/2 inch for quenched an d tempered alloy steel. For m ore than 5 thicknesses, or if the main material is thicker than 3/4 in ch for structural carbon steel, 5/8 inch for high-stre ngth structural steel, 1/2 inch for quenched and tem pered alloy steel, or if required otherwise, subpunch, or subdrill holes 3/16 inch smaller. After assembli ng, ream them 1/16 inch larger or drill from the solid to 1/16 inch larger than the nominal diameter of the bolts. The contractor m ay use oversized holes in secondary members if the engineer allows.

(2)The die diameter shall not excee d the punch diameter by more t han 1/16 inch. If enlarging holes to

admit the bolts, then ream the holes . Ensure clean-cut holes wi thout torn or ragged edges. The engineer may reject poorly matched holes.

(3)Make reamed or drilled holes cy lindrical, perpendicular to the member and not mor e than 1/16 inch

larger than the nominal diamete r of the bolts. If possible, dir ect the reamers by mechanical means. Remove burrs on the outside surfaces. Poor matching of holes sh all be cause for rejection. Perform reaming with tapered reamers. If r emoving burrs caused by drilling, take apart the assembled parts. For connecting parts that require reamed or drilled holes, asse mble them first and then hold securely during reaming or drilling. 506.3.6 Accuracy of Holes 506.3.6.1 Punched and Drilled Holes

(1)Ensure that holes punched full size, subpunched, or subdrilled are so accurate that after assembling

(before performing reaming) a cy lindrical pin 1/8 inch smaller in diameter than that of the punched hole can enter it, without drifting, i n at least 75 percent of the c ontiguous holes in the same plane. Failure to conform to this requirement will result in rejection of the badly punched pieces. In addition, the engineer will reject any hole t hat will not pass a pin 3/16 inc h smaller in diameter than that of the punched hole. 506.3.6.2 Reamed and Drilled Holes

(1)If holes are reamed or drille d, 85 percent of the holes in any contiguous group shall, after reaming or

drilling, show no offset greater than 1/32 inch between adjacen t thicknesses of metal.

(2)Use steel templates that have hardened steel bushings in the h oles, and are accurately dimensioned

from the connection centerlines as inscribed on the template. U se the centerlines to accurately locate the template from the milled or scribed ends o f the members. 506.3.7 Shop Assembly 506.3.7.1 General

(1)Unless specified otherwise, subpunch or subdrill, and ream while shop assembled bolt holes in

connections and splices (shop and field) of main truss or arch members, continu ous beams, floor beam connections to girder or truss, continuous plate girders, and rigid frames; or drill them full size from the solid while assembled at the shop. Subpunch or subdril l floor beam connections for plate girders and trusses and ream or drill full size from the solid in assembly. The contractor may use engineer-approved alternate procedures.

(2)Unless the engineer authorizes otherwise, assemble each indivi dual truss, arch, continuous beam, or

girder full length at the shop before reaming or drilling. Obta in approval of other than full-length assembly before submitting the shop drawings and show the engin eer-approved alternate assembly

Effective with the December 2018 Letting 255 2019 Standard Spec ifications procedure shall on the shop drawi ngs. During shop assembly, sup port members in a way that does not cause undesirable deflectio ns. The inspector will approve a ssembly, including camber, alignment, accuracy of holes, and milled jo ints, before drilling or reamin g.

(3)Conform to 506.3.27 for pickup points and girder handling equipment.

(4)Ensure that the component parts of a built-up member are straight and close fitting. Matchmark the

members and parts of the built-up members before disassembling. 506.3.7.2 Fitting for Bolting

(1)Clean the metal surfaces in c ontact with other each other befo re assembling. Before drilling, reaming,

or bolting, assemble the parts of a member, pin, and draw together. Take apart the assembled pieces in order to remove the burrs and shavings this operation produces. Ensure the member is free from twists, bends, and other deformation.

(2)During assembly tolerate only the drifting necessary to bring the parts into position and not sufficient to

enlarge the holes or distort the metal. 506.3.8 Flame Cutting

(1)The contractor may flame cut structural steel, provided this p rocess produces a smooth surface free

from cracks and notches and a me chanical guide is used to produce an accurate profile. The engineer must approve hand cutting.

(2)Flame cut plates in a direction that allows the stress in the plate, when assembled, to be parallel to the

direction the plate was rolled.

(3)Ensure that flame cutting is adjusted and manipulated to cut w ithin the prescribed lines. Flame cut

surfaces shall conform to the AN SI surface roughness value of 1 000 for material up to 4 inches thick and 1600 for material 4 to 8 inches thick, except that the ends of members not subject to calculated stress at the ends shall have a surface roughness value of 2000 . Round the corners of flame cut surfaces of members that carry c alculated stress to approximately a 1/16-inch radius by grinding after flame cutting.

(4)Cut re-entrant cuts to a rad ius of not less than one inch.

(5)Remove surface roughness exce eding the above values and occasional gouges not more than 3/16

inch deep on otherwise satisfactory flame cut surfaces by machi ning or grinding. Correct defects by flairing into the cut surface on a slope of at least 1 to 10. R epair gouges of flame cut edges more than 3/16 inch deep but not more than 7/16 inch deep by welding, if the engineer approves, with low- hydrogen electrodes not exceeding 5/32 inch in diameter and wit h a preheat of 250 F. Grind the completed weld smooth and flush with the adjacent surface. 506.3.9 Edge Planing

(1)Plane the sheared edge of pla tes more than 5/8-inch thick and carrying calculated stress to a depth of

1/4 inch. 506.3.10 Connections

(1)Unless specified otherwise, mak e connections with 3/4-inch A32 5 high-strength bolts conforming to

ASTM F3125 . 506.3.11 (Vacant) 506.3.12 Bolts and Bolted Connections 506.3.12.1 General

(1)Furnish sufficient bolts of eac h type, size, and length required with an ample surplus to replace those

lost or rejected.

(2)Perform shop assembly and matchmarking as specified in 506.3.7 .

(3)If assembled, ensure joint surf aces, including those adjacent to washers, are free of scale, dirt, oil,

burrs, pits, and other defects that prevent solid seating of th e parts. 506.3.12.2 Unfinished Bolts

(1)If using unfinished bolts for tem porary connections and other specifically allowed uses, use standard

bolts with hexagon heads and nuts . Ensure the bolt hole diamete rs are 1/16 inch greater than that of the bolt.

(2)Thread bolts transmitting shear so that not more than one thre ad is within the grip of the metal. Use

lock washers under the nuts for unfinished bolts used in perman ent connections.

Effective with the December 2018 Letting 256 2019 Standard Spec ifications 506.3.12.3 High-Strength Bolts

(1)Install bolts according to AASHTO LRFD Bridge C onstruction Spe cifications, Article 11.5.6.4, with the

following exceptions:

1.If connections are assembled, i nstall bolts wi th a hardened washer under the nut or bolt head, whichever is

the element turned in tightening.

2.If using oversized holes, 2 hardened washers are required, one under the bolt head and one under the nut.

3.Bring the bolted parts int o solid contact bearing before fi nal tightening. Use not l ess than 25 percent of the

total number of bolts in a join t to serve as fitting up bolts.

4.For steel diaphragms on prestressed concrete bridges do the following:

4.1For steel-to-steel connections within diaphragms:

- No field rotational capacity testing is required. Provide a cer tified report of test or analysis from the bolt supplier. The department may require field testin g to determine inspection torque. - Re-lubricate bolt threads wit h a wax-based lubricant. - Tension by the turn-of-nut method.

4.2For steel-to-concrete girder connections:

- No testing is required. - Tighten as the plan details specify.

(2)The contractor may use a flat w asher if the surface adjacent t o and abutting the bolt head or nut does

not have a slope of more than 1:20 with respect to a plane normal to the bolt axis. For slopes greater than 1:20, use smooth, beveled wa shers to produce parallelism.

(3)Tighten each fastener to provide, if all fasteners in the join t are tight, at least the minimum bolt tension

as follows: TABLE 506-1 BOLT TENSION BOLT SIZE REQUIRED MINIMUM BOLT TENSION[1] 1/2-inch ...................................................... ............................................................... .................... 12,050 pounds 5/8-inch ...................................................... ............................................................... .................... 19,200 pounds 3/4-inch ...................................................... ............................................................... .................... 28,400 pounds 7/8-inch ...................................................... ............................................................... .................... 39,250 pounds 1-inch ........................................................ ............................................................... ..................... 51,500 pounds 1 1/8-inch .................................................... ............................................................... ................... 56,450 pounds 1 1/4-inch .................................................... ............................................................... ................... 71,700 pounds 1 3/8-inch .................................................... ............................................................... ................... 84,450 pounds 1 1/2-inch .................................................... ............................................................... ................. 104,000 pounds [1] Equal to the proof load by the l ength measurement method as sp ecified in ASTM F3125 .

(4)Tighten threaded bolts by the turn-of-nut method or by the dir ect tension indicating washer method.

Tighten nuts while holding the bolt head. If clearance is an is sue, the contractor may tighten the bolt head while holding the nut.

(5)The contractor may propose an alternate tightening method but the engineer must approve it before

use.

(6)During installation, regardless of the tightening method used, exercise care to snug all bolts according

to AASHTO LRFD Bridge Constructi on Specifications, Article 11.5 .6.4.1.

(7)Do not reuse zinc coated A325 bol ts. The contractor may reuse uncoated A325 bolts, if the engineer

approves, but not more than onc e. The department will not consider re-tightening previously tightened bolts that become loosened by the tightening of adjacent bolts as reuse.

(8)Perform the rotational-capacity test on each rotational-capaci ty lot before beginning bolt installation.

Hardened steel washers are required as part of the test althoug h the actual installation procedures may not require them.

(9)Provide and use a Skidmore-Wilh elm Calibrator or an acceptable equivalent tension measuring device

at each job site during erecti on. The contractor may test bolts too short for the Skidmore-Wilhelm Calibrator using direct tension indicators calibrated in the Sk idmore-Wilhelm Calibrator using longer bolts. Perform pre-installation testing in the field conforming to the procedures enumerated in department form DT2114 . Provide the engineer with the test results by submitting 2 co pies of department form DT2114 .

(10)Install bolt, nut, and washer combinations from the same rotat ional-capacity lot.

Effective with the December 2018 Letting 257 2019 Standard Spec ifications (11) Check zinc coated nuts to verif y that a visible dyed lubricant is on the threads and at least one bolt face.

(12)Ensure that uncoated bolts are oily to the touch over their en tire surface when delivered and installed.

(13)Clean and re-lubricate weathered or rusted bolts or nuts not c onforming to the requirements above

before installation. Retest all re-cleaned or re-lubricated bol t/nut/washer assemblies before installation. 506.3.12.3.1 Turn-of-Nut Method

(1)Snug bolts to ensure connection faying surfaces are in firm co ntact. Snug-tight is defined as the

tightness attained by a few impac ts of an impact wrench or the full effort of a perso n using an ordinary spud wrench. Snug systematica lly from the most rigid part of th e connection to free edges repeating until all bolts in the connection are snug-tight. Then tighten all bolts in the connection by the nut rotation specified in table 506-2 . Ensure the part not turned by the wrench does not rotate. TABLE 506-2 NUT ROTATION FROM SNUG-TIGHT CONDITION[1]

DISPOSITION OF OUTER FACES OF BOLTED PARTS Bolt length measured from underside of head to extreme end of point Both faces norma l 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 than 1:20 from normal to bolt axis(bevel washers not used) Up to and including 4 diameters 1/3 turn 1/2 tu rn 2/3 turn Over 4 diameters but not exceeding 8 diameters 1/2 turn 2/3 tu rn 5/6 turn Over 8 diameters but not exceeding 12 diameters [2] 2/3 turn 5/6 turn 1 turn [1] Nut rotation is relative to bolt regardless of the element, nu t, or bolt, being turned. For bolts installed by 1/2 turn and less, the tolerances hould be +/- 30 degrees; for bolts installed by 2/3 turn and more, the tolerance should be +/- 45 degrees. [2] No research work has been perf ormed by the Research Council on Riveted and Bolted Structural Joints to establish the turn-of-nut proce dure when bolt lengths exceed 12 diameters, therefore, determine the required rotation by actual tests in a suitable tension device simulatin g the actual conditions. 506.3.12.3.2 Direct Tension Indicating Washer Method

(1)If using DTIs, install the DTI on the bolt with the protrusions facing away from the connected materials.

Install bolt/nut/washer assemblies with DTIs in the same config uration used for pre-installation testing.

(2)Tighten conforming to department form DT2114 to provide the correct insta llation tension. During the

operation, ensure no rotation o f the part not turned by the wrench. Snug systematically from the most rigid part of the connection to the free edges. Repeat until th e full connection is in a snug condition and the faying surfaces are in firm contact. Systematically tig hten the connection required number of refusals is achieved. If the gaps on the DTI are completely clo sed, discontinue tightening. 506.3.12.3.3 Contractor QC Testing 506.3.12.3.3.1 General

(1)Notify the engineer before performing the required field rotat ional-capacity and pre-installation testing.

Do not begin bolt installation without the engineer's approval. The engineer may verify bolt installation by periodically testing with a c alibrated torque wrench for bol ts tensioned by turn-of-the-nut or with a feeler gauge for bolts tensioned using DTIs. 506.3.12.3.3.2 Turn-of-Nut Method QC

(1)In the presence of the engineer, use a torque wrench to perfor m QC testing for each completed bolted

connection.

(2)Calibrate the torque wrench using 3 bolt/nut/washer assemblies of the same rotational-capacity lot and

condition as those undergoing QC te sting. Place a washer under the part turned and tighten each bolt in a contractor-furnished bolt t ension calibration device to th e minimum inspection tension required on department form DT2114 using a torque wrenc h. Average the 3 tests to determine the in spection torque for that rotational-capacity lot.

(3)Perform QC testing on a minimum of 10 percent of the bolts, bu t not less than 2 bolts, selected

randomly in each connection. Test bolts by applying the inspection torque determined in the pre- installation test in the tight ening direction. If any nut or bolt turns, check all bolts in that connection, or

Effective with the December 2018 Letting 258 2019 Standard Spec ifications alternatively, the fabricator o r erector may re-tighten all bol ts in the connection and retest the retightened connection at the pres cribed QC testing frequency. 506.3.12.3.3.3 Direct Tension I ndicating Washer Method QC

(1)If using DTIs, use a 0.005-inch metal feeler gauge to perform QC testing for each completed bolted

connection in the presence of the engineer. Test a minimum of 1 0 percent of the bolts, but not less than 2 bolts, selected rand omly in each connection.

(2)If the number of refusals require d is achieved, the engineer w ill accept the connection as properly

tightened. If for any bolt the requi red number of refusals is n ot achieved, tighten all bolts in the connection. 506.3.13 Abutting Joints

(1)Mill or saw cut abutting joints i n compression members of trus ses and in columns to give a true and

square cut.

(2)Openings at abutting joints in tension members in continuous I -beams and plate girders shall not

exceed 3/8 inch. 506.3.14 Facing of Bearing Surfaces

(1)Make the top and bottom surfaces of steel slabs and the base p late and cap plates of columns and

pedestals straight, smooth, and free from warp and must bear ev enly throughout.

(2)If necessary, plane the bases of welded steel bearings after w elding to secure an even bearing.

(3)Plane the bases of cast steel bearings after annealing to secu re an even bearing.

(4)Ensure that the sole plates o f beams and girders have full contact with the flanges, and that the

bearing surface is smooth, true , and perpendicular to the web of the member. Ensure that curved sole plates make full line bearing wit h masonry or bearing plates, a nd that the line is at right angles to the axis of the member and perpendicu lar to the web of the member u nless the plans show otherwise.

(5)If planing the curved surfaces of expansion bea rings, operate the tool so that the cut is in the

expansion direction. If the cut of t he tool is at right angles, make the finished sur face the true arc of a circle, smooth and free from ridges.

(6)Finish contact steel surfaces subject to sliding motion in the direction of motion as specified in ANSI

No. 125.

(7)Machine finish surfaces that the plans show to receive a surface finish.

(8)Polish finish the surfaces of b ronze bearing plates intended f or sliding contact.

(9)If using lubricated bronze plates, cover the finished surface of the expansion plate assembly in contact

with the lubricated bronze plate with a plastic or other engineer-approved coating after machining. Before erecting the girder, re move this coating and coat the surface with graphite. 506.3.15 Web and Flange Plates

(1)At bolted splices, the clearanc e between the ends of the web a nd flange plates shall not exceed 3/8

inch.

(2)If the plans show camber for wel ded girders, pro duce the cambe r by machine flame cutting the web

plate. Cut cambers on a continuo us smooth curve. If the enginee r approves, correct moderate deviations from specified camber by a carefully supervised appl ication of heat.

(3)For welded girders, if detailed to a horizontal curve greater than 3 degrees, cut the flange plates to a

continuous smooth curve by machine flame cutting. If the curve is 3 degrees or less, curve the girder by either heat curving methods that the engineer approves, unless the plans specify otherwise. The contractor may curve the girder by machine flame cutting.

(4)Assemble the web and flange plates in the work so that the dir ection of stress in the plate, as

assembled, is parallel with the direction that the plate was ro lled. 506.3.16 Fit of Stiffeners

(1)Ensure that the end stiffeners of girders and stiffeners intended as supports for concentrated loads

bear fully on the flanges that t hey transmit load to or from wh ich they receive load. Obtain full bearing by milling, or grinding, or in the case of weldable steel in co mpression areas, by welding as the plans show or as specified.

(2)If the clearance between the end of the stiffener and the flan ge for stiffeners is not intended to support

concentrated loads, then the gap shall not exceed 1/16 inch unl ess the plans show or the contract specifies otherwise.

Effective with the December 2018 Letting 259 2019 Standard Spec ifications 506.3.17 Pin and Roller Details 506.3.17.1 Pins and Rollers

(1)Turn pins and rollers to the dimensions the plans show and mak e them straight, smooth, and free from

flaws.

(2)Forge and anneal pins and rollers more than 9 inches in diameter. For pins and rollers 9 inches or less

in diameter use either forged and annealed or cold-finished, carbon-steel shafting.

(3)In pins larger than 9 inches in diameter, bore a hole, not less than 2 inches in diameter and full length

along the axis after the forging cools below the critical range under conditions suitable to prevent injury by too rapid cooling a nd before annealing.

(4)Use standard recessed pin nuts for nuts in connection with pin s.

506.3.17.2 Pinholes

(1)Bore pinholes true to the specified diameter, smooth, straight , at right angles with the axis of the

member, and parallel with each other unless required otherwise. Produce the final surface by using a finishing cut.

(2)The pinhole diameter for pins without bushings shall not exceed the pin diameter by more than 1/50

inch for pins 5 inches or less in diameter, or 1/32 inch for la rger pins. For pins wi th bushings, follow the manufacturer’s recommendations for tolerances of pins and bushi ngs. 506.3.17.3 Threads for Bolts and Pins

(1)Threads for bolts and pins for s tructural steel constructions hall conform to the Unified Standard Series

UNC-ANSI B1.1, Class 2A for exte rnal threads and Class 2B for i nternal threads, except that pin ends with a diameter of 1 3/8 inch or more shall have 6 threads per one inch. 506.3.18 Finished Members

(1)Make finished members true to line and ensure they are free from twists, bends, and open joints.

506.3.19 Welding 506.3.19.1 General

(1)Weld steel structures as the pl ans show and conforming to the AWS D 1.5, Bridge Welding Code.

Furnish welders or welding operators certified to the requireme nts of AWS D 1.5. If the engineer questions a welder or welding operator's ability, requalificati on tests are required under AWS D 1.5. A department-approved i ndependent testing agenc y will perform req ualification testing. Revise 506.3.19.1 to require an inspector from the contr actor's current field welding plan described in (DT2337).

(2)Visually inspect and certify t he quality of field welds as fol lows:

1 . Designate an inspector listed in the current contractor field w elding plan described in department form DT2337.

2.Have the desig nated inspector comp lete department form DT2320 and submit to the engi neer for inclusion

in the permanent project record. 506.3.19.2 Procedures

(1)Submit welding procedures required under AWS D 1.5 to the engi neer electronically for approval

before fabricating the structural steel.

(2)Use automated submerged arc welding for primary shop welds in the flat position unless the engineer

approves another welding process . Place joint designations indicating "automatic welding" by each primary weld on the shop drawin gs. Primary shop welds are defined as flange and butt welded splices in I-beams, box members, and plate girders; plate girder or box flange to web groove and fillet welds; and cover plate to flange fillet welds.

(3)Do not use electroslag or electrogas weld.

(4)Grind flange butt welds flush. G rind web butt welds to 1/6 of the web depth beginning at the point of

maximum tension,1/6 of the web depth beginning at the point of maximum compression, and grind the entire outside surface of exterior girders. Ground surfaces tha t require grinding before performing radiographic or ultrasonic insp ection. Grind plates with a surf ace or surfaces in the same plane flush. Grind plates with surfaces not in the same plane smooth.

(5)Ensure that weld metal for fillet and groove welds for exposed , bare, unpainted applications of ASTM

A709 grade 50 steel possess similar atmospheric corrosion resistance and the same coloring characteristics as that of the base metal. 506.3.19.3 Procedure Qualifications

(1)Ensure that procedure qualific ations conform to Section 5 of A WS D 1.5.

Effective with the December 2018 Letting 260 2019 Standard Spec ifications (2) Complete qualification tests of the welding procedures and obt ain the engineer's ac ceptance of them before beginning steel fabrication or field welding. Submit revisions in the welding procedure specifications to the engineer for approval and qualify them in the presence of the department's inspector to qualify for acceptance.

(3)Before the starting qualifying welding procedures, the contrac tor and the department's inspector shall

confer to ensure reaching an agreement regarding the procedure details, the welding sequence, the handling of materials to be insp ected, the status of welders an d welding inspectors qualifications, and the approval of electrodes, wire, flux, and other welding mater ials and equipment.

(4)Assign each welder or welding operator an identification mark for them to paint on the pieces welded.

The welder or welding operator sh all use these identification m arks for the duration of the contract. 506.3.19.4 Shop Welding Inspection

(1)Inspect shop welding according to AWS D 1.5. Unless specified otherwise, test bu tt welds in main

members by either the radiogra phic or the ultrasonic method.

(2)Test fillet welds and groove welds not covered otherwise in ma in members in a non-destructive

manner by the magnetic particle method according to ASTM E709, utilizing the yoke method. This includes, but is not limited to, a minimum of 12 inches in ever y 10 feet or portion thereof of each weld connecting web to flange, bearing stiffener to web or flange, f raming connection bar to web or flange, and longitudinal stiffener to web or vertical bar. 506.3.20 Stud Shear Connectors

(1)Use studs for shear connectors if the plans show. Weld conforming to chapter 7 of AWS D 1.5 except

as follows:

1.Fillet welds varying in size from 3/16 to 5/16 inch are sat isfactory provided the studs pass all other required

tests. Make adequate pr ovision in structural member fabrication to compensate for ca mber loss due to shear connector welding.

2.Ensure the studs are free from rust, scale, rust pits, and oil at the time of welding and immediately before

placing the concrete.

3.Longitudinal and lateral spacing of studs with respect to e ach other and to edges of beam or girder flanges

shall not vary more than 1/2 in ch from the dimensions the plans show, except that the engineer will allow a variation of one inch if required to avoid obstr uction of other attachments on the beam , or if welding a new stud to replace a defective one. E nsure a minimum distance from the edge of a stud shank to the edge of a beam or plate of one inch exists, but preferably 1 1/2 inch o r more.

4.Notify the engineer promptly of any changes in the welding procedure at any time during construction.

5.If welding the studs reduces their height to less than normal, immediately stop welding and do not resume

until correcting the cause.

6.After welding the studs to the beams, perform a visual inspection and give each stud a light blow with a

hammer. Bend test studs withou t a complete 360-degree end weld, studs that do not ring when given a light blow with a hammer, studs repaired by welding, or studs r educed to less than normal in height due to welding. The bend test consists o f bending the stud 15 degrees from its correct install ation axis by striking with a hammer. In cases of a def ective or a repaired weld, bend the stud in the direction that places the weld’s defective portion in th e greatest tension. Replace studs that crack either in the weld or in the shank.

7.The engineer may select addi tional studs to subject to the bend test specified in item 6 above.

506.3.21 Mill Inspection and Tests

(1)Unless directed otherwise, the fabricator of structural steel shall furnish the engineer with 2 copies of a

certified report of test or analysis showing both physical and chemical tests of the material for each heat of material. Submit these inspection and test reports to the inspector for examination and before requesting the fabrication shop inspection or when requesting t he material prepayment inspection. The engineer will not approve prepayment for material that mill test reports are not submitted. 506.3.22 Shop Inspection

(1)The engineer or an independent inspection agency under department contract may inspect all

structural steel and miscellaneo us metals furnished. The department will provide t he contractor with monthly consultant inspection invoices and identify any quality deficiencies at the fabrication facility.

(2)Give the engineer ample notice of the beginning of the shop wo rk.

(3)Before requesting an inspector , the fabricator shall submit a list of main stress-carrying members and

the heat number of the material fr om which fabricating the member. Preserve the heat number, as marked by the rolling mill, for i dentification by the inspector . If fabrication hides, cut s off, or obliterates otherwise the original number or marking, the fabricator shall paint the number on the material at a conspicuous location.

Effective with the December 2018 Letting 261 2019 Standard Spec ifications (4) Furnish facilities in the shop fo r inspecting ma terial and work quality and allow the inspectors necessary access to a ll parts of the work. T he facilities shall include adequate office space at the fabricating plant for the inspec tor's use during fabrication, a ssembly, cleaning, and painting. At the plants of all major fabricators , as the engineer determines, en sure this office space has at least 100 square feet of floor space and is furnished with at least 2 des ks, or a desk and table, a file case, and other necessary furniture. Provi de adequate lighting, heating, and ventilation and ensure cleanliness. Provide office space that is a completely partitioned area separated from the fabricator's activities, has a separate door equipped with a s uitable lock and key; or is pa rt of a larger facili ty set aside for the exclusive use of outside inspection personnel. Make available t elephone service and adequate sanitary facilities in the imm ediate area. The engineer may rev ise the foregoing requirements to accommodate the number of inspect ors necessary to inspect the volume of work.

(5)The inspector may reject any mat erial or work that does not co nform to the specific ation requirements.

(6)The inspector’s acceptance of any material or finished members will not preclude their subsequent

rejection if found defective.

(7)Inspection at the shop is intended as a means of facilitating the work and avoiding error. It shall not

relieve the contractor of responsibility for imperfect material , or technique, or for replacing the same. 506.3.23 Marking and Shipping

(1)Paint or mark each member with an erection mark for identification and furnish an erection diagram

showing the erection marks. Mark members weighing more than 3 t ons with their weight. Load structural members on trucks or cars in a way that transports a nd unloads them at their destination without being excessively stres sed, deformed, or damaged otherw ise. Ship girders and rolled beams in a standing position, maintain this position in subsequent op erations. The fabricator may ship haunched sections of built-up girders in an inverted position.

(2)Ship high-strength bolts, nuts , and washers (if required) from each rotational-capacity lot in the same

container. If there is only one production lot number for each size of nut and was her, the supplier may ship the nuts and washers. Pack separately non-high-strength bo lts of one length and diameter, and the loose nuts and washers supplied for each size of bolt, exce pt ship zinc coated bolts, nuts, and washers of the same size in the same containers. Ship bolts, nu ts, washers, pins, and small parts in boxes, crates, kegs, or barrels, but the gross weight of any co ntainer shall not exceed 300 pounds. Clearly and permanently, mark a list on the outside of each shi pping container that describes the contained material. Clearly and pe rmanently, mark on the outsid e of each shipping container of bolts, nuts, and washers the rotational-capacity lot number, in additi on to a list and description of the contained material. 506.3.24 Handling and Storing

(1)Place material to be stored on skids above the ground. Keep it clean and properly drained. Place

girders and beams upright, shore , and tie or brace to preclude tipping or overturning if exposed to high winds. Support long members, such as columns and chords, on ski ds placed near enough together to prevent injury from deflection. Loss of any material, or any da mage caused after receiving it is the contractor’s responsibility.

(2)Store bolts, nuts, and washers in closed containers in a prote cted shelter to protect them from dirt and

moisture until used. Maintain fa stener system components as nea rly as possible in the as- manufactured condition until installed. Remove from storage onl y as needed and promptly return unused components to storage. 506.3.25 Field Inspection

(1)Erections are subject to inspection and the cont ractor shall f urnish facilities for in spection of material

and work quality. The inspector w ill inspect material and work quality not previously inspected after its delivery to the work site. 506.3.26 Falsework

(1)The contractor may furnish used materials for falsework. Ensur e proper design, construction, and

maintenance of falsework in order to handle the loads placed up on it. Falsework shall provide the required construction camber.

(2)Submit detailed plans for falsework to the engineer if requested. The engineer's approval of these

plans, or acceptance in work c onstructed according to them shal l not relieve the contractor of responsibility for succ essful erection or s atisfactory results.

(3)If building falsework over a s tream or lake subject to boating use, construct it to provide horizontal and

vertical clearance adequate for passage of rowboats and small p owerboats. If building falsework over

Effective with the December 2018 Letting 262 2019 Standard Spec ifications a highway or street used by traffi c provide a minimum clearance , unless the plans or special provisions require otherwise, o f 22 feet horizontal and 13 1/2 feet vertical.

(4)After completing the work, remov e falsework piles down to at l east 2 feet below streambed or finished

ground line. Remove entirely any temporary bents, mudsills, and footings.

(5)Do not attach overhang bracket form supports to the girder web.

506.3.27 Erection

(1)Do not apply any part of the st eel superstructure load to any concrete substructure unit until the

concrete in that unit cures f or at least 48 hours. Do not apply loads to beams of open-type structure units until the end of the require d period for falsework support of these beams.

(2)Unless specified otherwise the minimum number of pickup points are as follows:

GIRDER LENGTH MINIMUM NUMBER OF PICKUPS 50 feet and over .............................................. ............................................................... ........................2 or more

(3)Use an appropriate balance beam or spreader bar for 2 or more pickup points with a single crane.

Locate pickup points to avoid damage to the girder and to balance the load at each point.

(4)The contractor shall not place any bent or twisted member unti l correcting its defects. The engineer

will reject any members seriously damaged in handling or transp orting. 506.3.28 Straightening Bent Material

(1)Notify the engineer before strai ghtening structural steel plates, angles, or other shapes. Describe the

process that will be used. Do no t proceed with the repair unless the engineer allows that process.

(2)If heating, do not exceed 1200 F, a dull red condition, and mo nitor temperature using temperature-

indicating crayons, liquids, or a bimetal thermometer. Ensure that parts to be heated are substantially free of stress and external forces, except for stresses resulting from mechanical means used in the application of heat. After heating, cool the metal as slowly as possible away from drafts. Do not use water for cooling.

(3)After straightening a bend or b uckle, inspect the repair and n otify the engineer if any evidence of

fracture is identified. 506.3.29 Field Assembling and Bolting

(1)Conform to the foregoing requirements for shop assembling. Mak e field connections, unless specified

otherwise, with high-strengt h bolts as specified in 506.3.12 .

(2)Unless the engineer allows, do not use a burning torch to make adjustments or cuts as an aid to field

assembling.

(3)Before beginning the field bol ting on a continuous span, adjus t the span and the immediately adjacent

continuous spans to the correct g rade, construction camber, and alignment.

(4)Complete field bolting, except fo r compression joints in trusses, connections for laterals and railings,

and connections for those nominal members the plans or contract specifically designates, before releasing and swinging free any part of the span from its suppo rting falsework.

(5)Swing the span free from falsework before making connections f or laterals.

(6)After placing and curing the concrete floor, and sidewalks if any, on all spans of the structure, make

the connections for those nominal members as the plans show or the contract specifically designates. Erect, align, and fasten t he railings in place.

(7)For splices and field connections using high-strength bolts, f ill at least 25 percen t of the holes with

cylindrical erection pins before placing the permanent high-str ength bolts. Fill at least 25 percent of the holes with erection bolts for te mporary connections. Place all bolts before proceeding with final tightening as specified in 506.3.12 .

(8)Ensure that erection bolts are the same nominal diameter as th e high-strength bolts and that

cylindrical erection pins are 1/32 inch larger.

(9)The contractor may assemble girders or portions of girders or other units on cribbing to the required

blocking before erection or pl acement in the structure, if the engineer approves. Any necessary adjustments in the joints or splices of the assembled units after erection or placement are the contractor’s responsibility. 506.3.30 Bearings and Anchorage

(1)Do not place masonry bearing plates on bridge seat bearing are as improperly finished, deformed, or

irregular.

Effective with the December 2018 Letting 263 2019 Standard Spec ifications (2) Set the bearing plates level in exact position and have full and even bearing on the masonry. Unless required otherwise, place them on bearing pads conforming to 506.2.6 .

(3)After properly aligning and finally connecting the steel in th e superstructure, drill the holes in the

concrete and set the anchor bolts except if the bolts are built into the masonry.

(4)Set anchor bolts in an engineer -approved, premixed, non-shrink commercial grout, except during

freezing weather, or in an epoxy conforming to 416.2.3.2 . Place the grout according to the manufacturer's instructions and fill the hole before ramming th e bolt in place. Overfill the hole with just enough grout or epoxy to produce a watertight fit when the bearing plate is installed. Remove excess grout or epoxy from the bolt and bearing area. 506.3.31 Cleaning of Surfaces 506.3.31.1 General

(1)Blast clean the surfaces of st ructural steel to remove rust, m ill scale, dirt, oil, or grease and other

foreign substances until obtaining the specified finish.

(2)Blast clean all non-machined su rfaces of a casting before mach ining the casting.

506.3.31.2 Coated Surfaces

(1)As specified in 506.3.32 , blast clean structural steel and ferrous metal products to be coated as

specified for blast cleaning in 517.3.1.3.3 to a near-white finish accordi ng to SSPC-SP 10 . Blast clean steel that will be encased in con crete to SSPC-SP 6 standards o r cleaner. 506.3.31.3 Unpainted Weathering Steel

(1)Blast clean all surfaces of weathering steel, unless designate d for coating, until obtaining a finish as

described for commercial blast cleaning in SSPC-SP 6. Perform b last cleaning with sand, grit, or steel shot as described for SSPC-SP 6.

(2)Keep or place the following markings on material shipped to th e field:

- Weights of members we ighing 3 tons or more. - Piece marks. - Matchmarks if required.

(3)Place weight markings on interior surfaces of exterior girders and on interior girders in locations

inconspicuous after erection and their removal are not required except if the engineer directs.

(4)After erection, clean steel in the completed structure by hand, until free of oil, dirt, grease, mortar and

other foreign substances. 506.3.32 Painting Metal

(1)Unless the contract provides otherwise, apply 3 coats of paint to structural steel and ferrous metal

products. Furnish and apply paints according to the epoxy system or as specified in the special provisions. The requirements for this system are set forth in 517.

(2)For structural steel, includi ng weathering steel, and miscella neous metals that w ill be encased in

concrete, paint as specified in 517.3.1 .

(3)Use the 3-coat epoxy system to paint the end 6 feet of structural weathering stee l at the abutments,

the 6 feet on each side of piers , joints, downspouts, hinges, a nd zinc-coated bearings in contact with weathering steel. Use a coat of brown urethane matching Federal Standard 595 - FS 20059. Apply one coat of zinc-rich paint to sur faces of expansion joint assemblies and other surfaces not in contact with the weathering steel but inac cessible after assembly or er ection.

(4)Do not paint structural steel to be welded before completing w elding. If welding only in the fabricating

shop and subsequently erecting by bolting, coat it after completing shop welding. Apply one coat of weldable primer or other engineer -approved protective coating to steel surfaces to be field welded after completing shop welding and shop fabrication. Protect mac hine-finished surfaces that do not receive a paint or zinc coating from contamination during the c leaning and painting process.

(5)Upon fabrication and acceptance , coat pins and pinholes with a plastic or other engineer-approved

coating before removing from the shop.

(6)Mark members weighing 3 tons or more with their weights on are as that will be encased in concrete,

or paint with a compatible pain t on zinc-rich primer, or mark w ith soapstone on an epoxy-coated surface. Wait until material is dry, inspected, and approved for shipment before loading for shipment. 506.3.33 Name Plates

(1)Install nameplates conforming to 506.2.4 at the locations the plans show. Embed in concrete as

specified in 502.3.11 ; do not bolt to steel components. Except for survey benchmarks , do not attach other permanent plates or markers to a structure.

Effective with the December 2018 Letting 264 2019 Standard Spec ifications 506.3.34 Steel Diaphragms

(1)Install steel diaphragms as the plans show.

506.4Measurement

(1)The department will measure Structural Steel Carbon, Structural Steel HS, the Castings bid items,

Forgings Steel Carbon, Lubricated Plates Bronze, and the Sheet bid items by the pound acceptably completed based on plan quantit ies the department-approved brid ge plans show.

(2)The department will use the following unit weights to compute the weight of metals:

MATERIAL UNIT WEIGHT Steel: structural carbon, high-strength structural, castings, o r forgings .................................................. 4 90 lb/ft3 Bronze plate and castings ..................................... ............................................................... .................. 536 lb/ft3 Sheet copper 0.02 inches thick ................................ ............................................................... ............... 0.93 lb/ft2 Sheet zinc No. 12 zinc gauge, 0.028-inch ..................................................................................... ........ 1.05 lb/ft2 Sheet zinc No. 18 zinc gauge, 0.055-inch ..................................................................................... ........ 2.06 lb/ft2 Sheet zinc No. 20 zinc gauge, 0.070-inch ..................................................................................... ........ 2.62 lb/ft2

(3)Compute the weights of rolled shapes based on their nominal we ights and dimensions. Compute the

weights of plates, including t hose of zinc and copper based on their nominal weights and dimensions and make full deduction for cuts except interior cuts, beveled cuts on edges for butt welding, and cuts made by machining to provide other than plane surfaces.

(4)The department will not include t he weight of paint, zinc coating, or weld metal in the computed

weight.

(5)The department will include the weight of heads, nuts, single washers, and threaded stick-through of

high-strength bolts and heads, based on the following weights: BOLT DIAMETER WEIGHT PER 100 BOLTS 1/2-inch ...................................................... ............................................................... ........................ 19.7 pounds 5/8-inch ...................................................... ............................................................... ........................ 31.7 pounds 3/4-inch ...................................................... ............................................................... ........................ 52.4 pounds 7/8-inch ...................................................... ............................................................... ........................ 80.4 pounds 1-inch ........................................................ ............................................................... ....................... 116.7 po unds 1 1/8-inch .................................................... ............................................................... ..................... 165.1 po unds 1 1/4-inch .................................................... ............................................................... ..................... 212.0 po unds

(6)The department will not measure DTIs for payment.

(7)Compute the weight of castings from their dimensions and add 3 percent for fillets and overruns,

however, if the scale weight of any casting is less than the co mputed weight, the department will pay for the weight of that casti ng at the scale weight. If the scal e weight of any casting is less than 97 percent of the computed weight, the department may reject the c asting.

(8)If the computed weights of metals, from engineer-approved shop drawings, varies more than one

percent from those the engineer-a pproved bridge plans show for an individual structure, the department will base quantities for that structure on those computed from the engineer-approved shop drawings. The exception is if the contractor elects, with the e ngineer's permission, to use equivalent sections of greater weight than th ose the engineer-approved bri dge plans show, then the contractor shall bear all additional costs.

(9)The department will measure Beari ng Pads Elastomeric Non-laminated and Bearing Pads Elastomeric

Laminated as each individual pad acceptably completed.

(10)The department will measure the Welded Stud Shear Connectors b id items as each individual stud

acceptably completed. The department will measure the total num ber of studs incorporated in the work and accepted.

(11)The department will measure the St eel Diaphragms bid items as each individual diaphragm acceptably

completed.

(12)The department will measure the Be aring Assemblies bid items a s each individual bearing acceptably

completed.

506.5Payment

(1)The department will pay for measured quantities at the contrac t unit price under the following bid

items: ITEM NUMBER DESCRIPTION UNIT

Effective with the December 2018 Letting 265 2019 Standard Spec ifications 506.0105 Structural Steel Carbon LB

506.0605 Structural Steel HS LB

506.1000 - 1099 Castings (type) LB

506.1105 Forgings Steel Carbon LB

506.1405 Lubricated Plates Bronze LB

506.1500 - 1599 Sheet (type) LB

506.2105 Bearing Pads SF

506.2605 Bearing Pads Elast omeric Non-Laminated EACH

10 Bearing Pads Elastomeric Laminated EACH

506.3000 - 3099 Welded Stud Shear Connectors (diameter x length ) EACH

506.4000 Steel Diaphragms (structure) EACH

506.5000 Bearing Assemblies Fixed (structure) EACH

506.6000 Bearing Assemblies Expansion (structure) EACH

(2)Payment for Structural Steel C arbon, Structural Steel HS, the Castings bid items, Forgings Steel

Carbon, Lubricated Plates Bronze, and the Sheet bid items is fu ll compensation for providing, fabricating, casting, machining or otherwise preparing, transpo rting, and erecting materials; for providing name plates; and for furnishing radiographic films to the inspector.

(3)Payment for Bearing Pads Elast omeric Non-Laminated and Bearing Pads Elastomeric Laminated is

full compensation for providi ng the pads, and for testing.

(4)Payment for the Welded Stud Shear Connectors bid items is full compensation for providing the shear

connectors.

(5)Payment for the Bearing Assemb lies bid items is full compensation for providing bearing assemblies,

including the anchor bolts, and for fabricating and installing the assemblies.

(6)Payment for the Steel Diaphragms bid items is full compensatio n for providing, fabricating, zinc

coating, transporting, and erecting.

(7)The contractor shall perform mi scellaneous work that the plans show or is specified otherwise and

included within the scope of this c ontract but not listed as bi d items as a part of and included in the contract price for other bid items, except as follows: - If the contract does not contai n the Welded Stud Shear Connec tors, Bearing Assemblies Fixed, or Bearing Assemblies Expansion bid item, and the contract requires this w ork, the department will pay for this work as Structural Steel Carbon. - The department will pay for painting structural steel and mis cellaneous metals as specified in 517.5 .

(8)The department will limit costs for inspections conducted unde r 506.3.22 to $0.05 per pound of

material and deduct costs in excess of that amount from payment due the contractor. The department will determine costs for in-hous e inspections based on hourly r ates for department staff plus overhead and use invoiced costs for contracted-out inspections. The depa rtment will administer deductions for the contractor's share of the to tal inspection cost under the E xcess Costs For Fabrication Shop Inspection administrative item.

Effective with the December 2018 Letting 266 2019 Standard Spec ifications Section 507 Timber Structures

507.1Description

(1)This section describes furnishi ng, framing, treating, deliveri ng, erecting, and painting if required,

treated lumber and timber required for timber bridges and other timber structures, or lumber and timber parts of other b ridges or structures.

507.2Materials

507.2.1 General

(1)Furnish hardware required to erect the lumber and timber. Furnish materials conforming to the

following: Structural steel .............................................. ............................................................................................... 506.2 Miscellaneous metals .......................................... ........................................................................................ 506.2 507.2.2 Lumber and Timber 507.2.2.1 General

(1)If ordering lumber and timber i n multiple lengths, grade them after cutting to length.

(2)The engineer will only accept sound pieces free from decay. The engineer will reject pieces

exceptionally light in weight.

(3)There is no heartwood requirem ent for lumber and timber treate d with a preservative and no limit on

the quantity of sapwood it can cont ain. Preservative treatment of lumber and timber shall conform to 507.2.2.6 .

(4)Ensure that there are no unso und knots or knot holes. Also ensure that there are no tight knots of a

diameter exceeding one-quarter of the greater dimension at the point where they occur. Measure a knot by taking its diameter a t right angles to the length of th e timber. Ensure that the sum of sizes of all knots in any one-foot length does not exceed 2 times the size o f the largest allowed single knot. The engineer will treat cluster knots as if they were a single knot . A cluster knot is 2 or more knots grouped together, with the fibers of the wood deflected ar ound the entire unit. 507.2.2.2 Wood Species

(1)Furnish one of the following species for treated structural lu mber and timber:

- Douglas Fir-Coastal - Southern Pine - Hem-Fir 507.2.2.3 Manufacture

(1)Ensure structural lumber and ti mber are straight, sawed square at the ends, and have opposite

surfaces parallel.

(2)Saw rough structural lumber and timber to the nominal dimensio ns specified in 507.2.2.3(4) .

Occasional slight variation is permissible, however, ensure tha t the specified minimum dressed dimensions are met everywhere along the length.

(3)The manufacturer may surface str uctural lumber and timber orde red rough, if thicker than specified, to

a rough stock thickness.

(4)Manufacture lumber and timber according to the nominal and min imum dimensions in the following

table:

Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 256–274 of 601.

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505 Steel Reinforcement

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