fails in some specific manner to demonstrate that the required accuracy is being obtained, further check a ssemblies may be required by the Engineer for which there shall be no additional cost to the Division.
615.5.3.4 -Field Welded Connections: For field welded connections the fit of members including the proper space between abutting surfaces shall be prepared and verified with the segment preassembled in accordance with Section 615.5.3.1.
615.5.3.5 -Assembly Verification: Each assembly, inc luding camber, alignment, accuracy of holes, and fit of milled or field welded joints, shall be approved by the Engineer before reaming or drilling is commenced or before an N/C drilled check assembly or field welded assembly is dismantled.
615.5.4 -Matc h Marking: Connecting parts preassembled in the shop to assure proper fit in the field shall be match -marked, and a diagram showing such marks shall be furnished to the Engineer.
615.5.5 -Connections Using Unfinished, Turned or Ribbed Bolts: 615.5.5.1 -General: When unfinished bolts are specified, the bolts shall be unfinished, turned, or ribbed bolts, conforming to the requirements of Grade A Bolts of the Specification for Low -Carbon Steel Externally and Internally Threaded Standard Fasteners , ASTM A307. Bolts shall have single self -locking nuts or double nuts unless otherwise shown on the plans or in the Special Provisions. Beveled washers shall be used where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis. The requirements of this Section do not pertain to the use of high -strength bolts. Bolted connections using high -strength bolts shall conform to Section 615.5.6.
615.5.5.2 -Turned Bolts: The surface of the body of turned bolts shall meet th e ANSI roughness rating value of 125. Heads and nuts shall be hexagonal with standard dimensions for bolts of the nominal size specified or the next larger nominal size. Diameter of threads shall be equal to the body of the bolt or the nominal diameter o f the bolt specified. Holes for turned bolts shall be carefully reamed with bolts furnished to provide for a tight driving fit. Threads shall be entirely outside of the holes. A washer shall be provided under the nut.
615.5.5.3 -Ribbed Bolts: The body of ribbed bolts shall be of an approved form with continuous longitudinal ribs. The diameter of the body measured on a circle through the points of the ribs shall be 5/64 inch greater than the nominal diameter specified for the bolts. Ribbed bolts shall be furnished with round heads conforming to ANSI B 18.5 unless otherwise specified. Nuts shall be hexagonal, either recessed or with a washer of suitable thickness. Ribbed bolts shall make a driving fit with the holes. The hardness of the ribs shall be such that the ribs do not mash down enough to permit the bolts to turn in the holes during tightening. If for any reason the bolt twists before drawing tight, the hole shall be carefully reamed and an oversized bolt used as a replacement.
450 615.5.6 -Connections Using High -Strength Bolts: 615.5.6.1 -General: This specification covers the assembly of structural connections using high -strength bolts and nuts with hardened washers where initial tension in the bolt produces friction on the contact surfaces o f the connected pieces sufficient in magnitude to resist shear.
615.5.6.2 -Bolted Parts: Surfaces of bolted parts in contact with the bolt head and nut shall not have a slope of more than 1 to 20 with respect to a plane normal to the bolt axis. Bolted p arts shall fit solidly together when assembled and shall not be separated by gaskets or any other interposed compressible material. Holes may be punched, subpunched, reamed or drilled and shall be of nominal diameter not more than 1/16 inch in excess of the nominal bolt diameter. When assembled, all joint surfaces, including those adjacent to the washers, shall be free of dirt, oil, loose scale, burrs, pits, and other defects that would prevent solid seating of the parts. All bolted surfaces shall be pai nted in accordance with Section 688 .
615.5.6.3 -Installation: Fasteners shall be protected from dirt and moisture at the job site. Only the fasteners anticipated to be installed and tightened during a work shift shall be removed from protected storage. Fasteners not used shall be returned to protected storage at the end of the shift. Lot identification of all components shall be maintained at all times. Galvanized and zinc coated nuts shall be checked to verify that a visible lubricant is on the threads and nut faces. Fasteners shall not be cleaned of lubricant that is present in the delivered condition. Where galvanized fasteners must be tensioned by turning the bolt head, a visible lubricant that meets the requirements of ASTM F3125, shall be applied to the washer that will be placed under the bolt head. The lubricant may be applied to the washer by the manufacturer prior to shipment, by the fabricator at the fabrication shop, or by the erector in the field. Fasteners which have accumulated rust, dirt or have been wet, shall be cleaned and relubricated, prior to installation. Bolt, nut and washer combinations as installed shall be from the same rotational -capacity lot. A tension measuring device and torque wrench, suitable to the Enginee r, shall be provided and maintained by the Contractor at all job sites where high -strength fasteners are being installed. The tension measuring device shall be used to confirm: (1) the suitability to satisfy the requirement of Table 615.5.6.3A of the com pleted fastener assembly, including lubricant, to be used in the work, (2) rotational capacity testing requirements, and (3) that the bolting crew understands proper installation procedures. The tension measuring device and torque wrench shall be calibrated by an approved testing agency at least yearly. Documentation of calibration shall be provided to the Engineer. Immediately prior to installation in the fabrication shop or on the project site, all high - strength fasteners shall be subjected to rotational-capacity testing by the fabricator or the contractor. Testing shall be in accordance with Section 709.24.5 and shall be conducted at a frequency of two assemblies per rotational -capacity lot number as identified on the shipping containers. Test results shall meet the requirements of Section 709.24.5. When fasteners have been cleaned and relubricated , the rotational -capacity testing, on the affected fasteners, shall be reconducted. The Engineer may request additional tests as necessary to provide assu rance of product compliance. Bolts shall be installed with a hardened washer under the nut or bolt head, whichever is the element turned in tightening. A flat washer may be used when the abutting surface adjacent to the bolt head or nut does not have a s lope of more than 1 to 20 with respect to
451 a plane normal to the bolt axis, a smooth beveled washer shall be used to compensate for the lack of parallelism. The threaded end of bolts shall be placed on the inside, where practicable, to protect them from th e weather. All fasteners shall be tightened to give at least the required minimum bolt tension shown in Table 615.5.6.3A on completion of the joint. Tightening shall be done by the Turn -of-Nut Method .
TABLE 615.5.6.3 A FASTENER TENSION Bolt Size (inches) Required Minimum Fastener Tension (kips) 1/2 12 5/8 19 3/4 28 7/8 39 1 51 1-1/8 56 1¼ 71 1-3/8 85 1½ 103
Impact wrenches shall be of adequate capacity and sufficiently supplied with air to perform the required tightening in approximately 10 seconds. Tightening may be done by turning the bolt while the nut is prevented from rotating when it is impractical to turn the nut. A representative sample of not less than three bolt, nut and washer assemblies of each diameter, length, and grade to be used in the work shall be checked at the start of work, by the contractor, in a device capable of indicating bolt tension. The test shall demonstrate that the method for estimating snug tight condition, and controlling th e turns from snug tight to be used by the bolting crew will develop a tension at least 5 percent (5%) greater than the tension required by Table 615.5.6.3A. All additional fasteners (bolts, nuts, and washers) necessary for inspection and testing shall be provided by the Contractor as required by Section 105.5. Bolts shall be installed in all holes of th e connection and brought to "snug tight" condition. Snug tight is defined as that tightness which exists when the plies of the joint are in firm contact and a tension is induced in the bolts of approximately 40 -50 percent (40-50%) of the required tension specified in Table 615.5.6.3A. Snug tightening shall progress systematically from the most rigid part of the connection to the free edge, and then the bolts of the connection shall be again retightened to snug tight in a similar systematic manner untilal l bolts are simultaneously snug tight and the connection is fully compacted. Following this initial operation, all bolts in the connection shall be tightened further by the applicable amount of rotation in Table 615.5.6.3B. During the tightening operatio n, there shall be no rotation of the part not turned by the wrench. Tightening shall progress systematically from the most rigid part of the joint to its free edges.
452 TABLE 615.5.6.3B NUT ROTATION FROM SNUG TIGHT CONDITION a, b Disposition Of Outer Faces Of Bolted Parts Bolt Length in Diameters (measured from underside of head to end of bolt) Both faces normal to bolt axis One face normal to bolt axis other face sloped not more than 1:20 (bevel washers not used) Both faces slope d not more than 1:20 from normal to bolt axis (bevel washers not used) Up to & including 4 1/3 turn ½ turn 2/3 turn Over 4 but not exceeding 8 ½ turn 2/3 turn 5/6 turn Over 8 but not exceeding 12 c 2/3 turn 5/6 turn 1 turn
installed by ½ turn and less, the tolerance shall be plus or minus 30 degrees; for bolts installed by 2/3 turn and more, the tolerance shall be plus or minus 45 degrees.
lengths exceeding 12 diameters. Therefore, the required rotation must be determined by the Contractor by actual test in a suitable tension measuring device which simulates conditions of solidly fitted steel. Testing is subject to appr oval by the Engineer
615.5.6.4 -Inspection: The Engineer will determine the following requirements are met in the work. Before the installation of fasteners in the work, the Engineer will check the markings, lot identifications, surface condition and l ubrication, storage of all bolts, nuts and washers and the faying surfaces of joints for compliance with requirements of Sections 615.3.2, 615.5.6.2, 615.5.6.3 and 709.24.9. The Engineer will observe calibration and testing procedures required in Section 615.5.6.3 to confirm the procedure is properly used and, when so used with the fastener assemblies supplied, the tensions specified in Table 615.5.6.3A are provided. The Engineer will observe the installation of fasteners in the work to assure the procedu re, as demonstrated in the initial testing to provide specified tension, is routinely properly applied. Bolts installed by the turn -of-nut method may reach tensions substantially above the values given in Table 615.5.6.3A, but this shall not be cause for rejection.
615.5.7 -Welding: Fabrication of welded members, welding, welder qualifications, prequalification of weld details and inspection of welds shall conform to the requirements of the ANSI/AASHTO/AWS Bridge Welding Code D1.5. Ultrasonic testing (UT) may be used for nondestructive testing of butt welded joints in lieu of radiographic testing (RT) at the Contractor's option. No field welding is permitted unless shown on the plans or approved by the Engineer. Exercise caution while making field or shop welds while an elastomeric bearing pad is in contact with the steel. In no case shall the elastomer or elastomer band be exposed to instantaneous temperatures greater than 400 °F. Any damage to the elastomeric bearing due to
453 welding will be cause for rejection. The tem perature shall be monitored by heat crayons furnished by the Contractor. Brackets, clips, shipping devices or other material not required by the plans or Special Provisions shall not be welded or tacked to any member unless shown on the shop drawings and approved by the Engineer. All of the above requirements apply equally to both shop and field welding operations.
615.6 -ERECTION : 615.6.1 -General: The Contractor shall provide all tools, machinery, and equipmen t necessary to erect the structure. The Contractor shall submit to the Engineer, plans for falsework or for changes in the existing structure necessary for maintaining traffic prior to commencing work. The falsework shall be properly designed and substan tially constructed and maintained for the loads which will come upon it (see 615.2. 1). Submission of the Contractor’s plans shall not be considered as relieving the Contractor of any responsibility. In addition to the above, the Contractor’s West Virgini a Registered Professional Engineer shall certify to the Engineer that the falsework system has been assembled according to the falsework drawings, prior to placing loads on the falsework.
615.6.2 -Handling and Storing Materials: Material to be stored at the job site shall be placed on skids above the ground. It shall be kept clean and properly drained. Girders and beams shall be placed upright and shored. Long members, such as columns and chords, shall be supported on skids placed near enough together to prevent damage from deflection. If the contract is for erection only, the Contractor shall check the material against the shipping lists and report promptly in writing any shortage or damaged discovered. The Contractor shall be responsible for the loss of any material while in their care, or for any damage caused to it after being received by the Contractor.
615.6.3 -Bearings and Anchorage’s: Masonry bearing plates shall not be placed upon bridge -seat bearings which are improperly finished, defor med, or irregular. Bearing plates shall be set level in exact position and shall have a full and even bearing upon the masonry. Preformed fabric pads, of the thickness shown on the Plans, shall be placed between the bearings and the masonry. The preformed fabric pads or other material when specified, shall be included in the price bid for structural steel. The Contractor shall drill the holes and set the anchor bolts, except where the bolts are built into the masonry. The bolts shall be set accurately and fixed with Portland cement groutompletely filling the holes. The location of anchor bolts in relation to the slotted holes in the expansion shoes shall correspond with the temperature at the time of erection. The nuts or anchor bolts at the expansio n ends of spans shall be adjusted to permit the free movement of the span.
615.6.4 -Erection Procedure: 615.6.4.1 -Conformance to Drawings: The erection procedure shall conform to the erection drawings submitted in accordance with Section 615.2. 1. Any modifications to or deviations from this erection procedure shall require revised drawings and verification of stresses and geometry by the Contractor's registered West Virginia Professional Engineer. The proposed revisions shall be approved by a West Virginia Registered Professional Engineer.
454 615.6.4.2 -Erection Stresses: Any erection stresses that are induced in the structure as a result of the use of a method of erection or equipment which differs from that shown on the plans or specified, and which will remain in the finished structure as locked -in stresses shall be accounted for by the Contractor. The Contractor may provide additio nal material at their expense to keep both temporary and final stresses within the allowable limits used in design. The Contractor will be responsible for providing temporary bracing or stiffening devices to accommodate handling stresses in individual mem bers or segments of the structure during erection.
615.6.4.3 -Maintaining Alignment and Camber: During erection the Contractor will be responsible for supporting segments of the structure in a manner that will produce the proper alignment and camber in t he completed structure. Cross frames and diagonal bracing shall be installed as necessary during the erection process to provide stability and assure correct geometry. Temporary bracing, if necessary at any stage of erection, shall be provided by the Con tractor.
615.6.5 -Field Assembly: The parts shall be accurately assembled as shown on the plans or erection drawings, and any match -marks shall be followed. The material shall be carefully handled so that no parts will be bent, broken, or otherwise d amaged. Hammering which will damage or distort the members shall not be done. Bearing surfaces and surfaces to be in permanent contact shall be cleaned before the members are assembled. Splices and field connections shall have all holes filled with high strength bolts before snug tightening begins. Snug tightening and final tightening shall be in accordance with Section 615.5.6.3. Fitting -up bolts may be the same high -strength bolts used in the installation provided all requirements of Section 615.5.6 are strictly adhered to. If other fitting -up bolts are used they shall be of the same nominal diameter as the high -strength bolts, and cylindrical erection pins shall be 1/32 inch larger.
615.6.6 -Pin Connections: Pilot and driving nuts shall be used in driving pins. They shall be furnished by the Contractor without charge. Pins shall be so driven that the members will take full bearing. Pin nuts shall be screwed up tight and the threads burred at the face of the nut with a pointed tool.
615.6.7 -Misfits: The correction of minor misfits involving minor amounts of reaming will be considered a legitimate part of the erection. However, any error in the shop fabrication or deformation resulting from handling and transporting will be cause for rejecti on. The Contractor shall be responsible for all misfits, errors, and damage and shall make the necessary corrections and replacements. The Engineer's approval shall be obtained by the Contractor before any reaming of holes or other corrections are under taken.
615.6.8 -Removal of Falsework and Cleaning Up of Site: Upon completion of the erection and before final acceptance, the Contractor shall remove all falsework, excavated or useless materials, rubbish, and temporary buildings, shall restore, in an acceptable manner, all property which may have been damaged during the prosecution of the work, and shall leave the structure site and adjacent highway in a neat and presentable condition, satisfactory to the Engineer. All falsework or other obstructions placed in stream beds shall be removed by the Contractor.
455 615.6.9 -Final Cleaning of Weathering Steel Bridges: Upon completion of all concrete curing operations, the contractor shall clean all steel surfaces to remove all grease, oil, concrete residue, dirt, and other foreign substances to the satisfaction of the Engineer. Upon completion of all concrete curing operations, the contractor shall clean all steel surfaces to remove all grease, oil, concrete residue, dirt, and other foreign substances in accordance with SSPC SP 1, Solvent Cleaning, to the satisfaction of the Engineer. Do not use acids to remove stai ns. Areas of the shop applied paint system which are damaged during erection and high strength bolted connection areas that were only prime painted shall be properly cleaned and painted according to Section 688 of the Specification and to the satisfactio n of the Engineer. After completion of all tightening operation, mechanical galvanized fasteners shall be solvent cleaned and field painted as specified for the structural steel. For integral or semi -integral abutment structures, the crevice/interface between the embedded steel and the concrete shall be suitably chamfered to provide for placement of a sealant. Sealant material shall meet the requirements of ASTM C920, TypeS, Grade NS, Class 25, Uses NT and M. Sealant shall be suitable for bonding betw een concrete and the top coat of the specified paint system. Acid -cure sealants shall not be permitted.
615.7 -MEASUREMENT AND PAYMENT : 615.7.1 -General: Structural steel will be measured on a lump sum basis or on a pound basis, as required by the terms of the Contract, but it will be on a lump sum basis unless stipulated otherwise on the Plans. Under contracts containing an item for structural steel, a ll metal parts, other than metal reinforcement for concrete, such as anchor bolts, nuts, shoes, rockers, rollers, bearing, and slab plate, pins and nuts, bolts embedded in concrete cradles and brackets, railing and railing posts, waterstops, preformed fabr ic or other type of bearing pads, and roadway drainage system when this material is connected to the metal work, will be paid for as structural steel unless otherwise noted, stipulated, or listed as separate pay items. Steel grid flooring will be measure d and paid for as structural steel only if noted on the Plans.
615.7.2 -Lump Sum Contracts: In the case of a lump sum bid, it shall be the Contractor's responsibility to determine the weight on which he bases his bid, for the weight of structural steel shown on the Plans is approximate only. In the event of discrepancy between the Plan weight and the actual weight, no increase or decrease in the Contract lump sum price bid for the item will be made on account of such discrepancy.
615.7.3 -Pound Price Contracts: 615.7.3.1 -General: The payment in pound -price contracts will be based on the computed net weight of metal in the fabricated and erected structures, or on certified scale weights when so specified on the Plans. The weight of temporary erection bolts, drift pins, shop and field paint, boxes, crates and other containers used for shippin g, and materials used for supporting members during transportation and erection will not be included.
615.7.3.2 -Computed Weights Net: The weight of the metal work to be paid for under the Contract for structural steel will be computed on the following b asis:
456 Unit Weights Per Cubic Foot Aluminum cast or wrought 173.0 Bronze, cast 536.0 Copper -alloy 536.0 Copper sheet 558.0 Iron, cast 445.0 Iron, malleable 470.0 Iron, wrought 487.0 Lead, sheet 707.0 Steel: rolled, cast, copper bearing, silicon, nickel and stainless 490.0 Zinc 450.0
per foot as shown on the drawings or listed in the handbooks. The weights of plates will be computed on the basis of the nominal weight of the width and thickness as shown on the drawings, plus an estimated overrun computed as one -half of the "Permissible Variation in Thickness and Weight" as tabulated in AASHTO M 160. ii. The weights of castings will be computed from the di mensions shown on the approved shop drawings, deducting for open holes. To this weight will be added five percent (5%) allowance for fillets and overrun. Scale weights may be substituted for computed weights in the case of castings or of small complex pa rts for which accurate computations of weight would be difficult. iii. For members comprising both carbon steel and other special steel or material, when separate unit prices are provided for such members, the weight of each class of steel in each such member w ill be separately computed and paid for at the Contract unit price. iv. In computing pay weight on the basis of computed net weight, the following additional stipulations will apply:
The weight of all high -strength bolt heads, nuts, single washers and thread stick - throughs, both field and shop, will be included on the basis of Table 615.7.3.2.
TABLE 615.7.3.2 Nominal Diameter of High - Strength Bolt in Inches Weight Per 100 Units In Lb Bolt Head, Nut, One Washer and Stick -Through 1/2 22 1/8 33 3/4 55 7/8 84 1 120 1-1/8 169 1¼ 216
The weight of weld metal will be computed on the basis of the theoretical volume from dimensions of the welds.