615Steel Structures

615.1-GENERAL: 615.1.1-Description: The work shall consist of furnishing, fabricating, and erecting steel structures and structural steel portions of other structures in accordance with these Specifications, the Special Provisions, and the details shown on the plans. Fabricators of bridges that have welded shop splices shall be certified under the American Institute of Steel Construction’s (AISC) Quality Certification Program “Major Steel Bridges” category. The fabricators of fracture critical members shall be certified as category: “Maj or Steel Bridges” and, in addition, shall possess an “F” endorsement by AISC. Fabrication of grades HPS 50W and HPS 70W steel shall only be performed by fabricators possessing an “F” endorsement. Fabricators of rolled beam bridges shall be certified by A ISC in either the “Major Steel Bridges” category or the “Simple Steel Bridges” category. Ancillary bridge components such as expansion dams, drains, scuppers, and pedestrian handrail may be fabricated in shops that are AISC certified as “Bridge and Highwa y Metal Component Manufacturers.” The fabricator shall provide a quality control plan to the Engineer for approval. This plan shall contain information concerning the fabricator's internal control process. Information concerning the contents of the quality control plan can be found in the FHWA Region Three, Structural Committee for Economic Fabrication's Guidelines for the Development of a Quality Control Plan. The plan shall be approved by the Division prior to the start of fabrication. Structural components designated on the plans or in the special provisions as “fracture critical” shall conform to the provisions of Section 12 of the ANSI/AASHTO/AWS Bridge Welding Code D1.5. Painting shall conform to the provisions of Section 688. 615.1.2-Notice of Beginning of Work: The Contractor shall give the Engineer a minimum of two weeks notice prior to the beginning of work at the fabrication shop, so that inspection may be provided. No material shall be manufactured, or work done in the shop, befo re the Engineer has been so notified. Prior to beginning work, Engineer and Contractor representatives shall identify individuals who are responsible for the following functions: preparation, submittal, review, approval, and distribution of shop drawings ; submittal and control of material test reports (MTRs). The Engineer will identify individuals or agents responsible for handling shop detail drawings, approving welding procedures, providing quality assurance, and accepting proposed repairs. Before wor k begins a prefabrication meeting may be held at the discretion of the Engineer or if requested by the Fabricator or Contractor. 615.1.3-Inspection: Structural steel shall be inspected in the fabrication shop. The Contractor shall furnish the Engineer with a copy of all mill orders and shop lists showing heat numbers to be used for each piece. Mill test reports that document the chemical analysis and physical test results for each heat of steel to be used in the work shall also be furnished. Final approval of the material in the shop will not be given until the above data is approved. With the approval of the Engineer, certificates of compliance shall be furnished in lieu of mill test reports for material that normally is not supplied with mill te st reports, and for items 436 such as fills, minor gusset plates and similar material when quantities are small and the material is taken from stock. Certified mill test reports for steels with specified minimum impact values shall include, in addition to other test results, the results of Charpy V -Notch impact tests. When fine grain practice is specified, the test report shall confirm that the material was so produced. Copies of mill orders shall be furnished at the time orders are placed with the manufact urer. Certified mill test reports and Certificates of Compliance shall be furnished prior to the start of fabrication of material covered by these reports. The Certificate of Compliance shall be signed by the manufacturer and shall certify that the material is in conformance with the specifications to which it has been manufactured. Material to be used shall be made available to the Engineer so that each piece can be examined. The Engineer shall have free access at all times to any portion of the fabri cation shop where the material is stored or where work on the material is being performed. 615.1.4-Inspector's Authority: The Inspector shall have the authority to reject materials or workmanship which do not fulfill the requirements of these Specifications. In cases of dispute, the Contractor may appeal to the Engineer, whose decision shall be final. Inspection at the s hop is intended as a means of facilitating the work and avoiding error, and it is expressly understood that it will not relieve the Contractor of any responsibility in regard to defective material or workmanship and the necessity for replacing same. The acceptance of any material or finished members by the Inspector shall not be a bar to their subsequent rejection, if found defective. Rejected materials and workmanship shall be replaced as soon as practical or corrected by the Contractor. 615.2-WORKING DRAWINGS: Working drawings must be submitted in accordance with section 105.2. 615.2.1-Erection Drawings: The contractor shall submit drawings illustrating fully their proposed method of erection. The drawings shall show details of all falsework bents, bracings, guys, dead-men, lifting devices, and attachments to the bridge members: sequence of erection, location of cranes and barges, crane capacities, location of all lifting points on the bridge members, and weights of the members. The plans and drawings shall be complete in detail for all anticipated phases and conditions during erection. Design calculations, sealed by a West Virginia Registered Professional Engineer, shall be submitted by the Contractor to the Engineer seven days prior to commencing work. Receipt of plans, drawings and calculations does not constitute review or approval or relieve the contractor of their responsibility to satisfactorily design the erection plan. The design calculations shall demonstrate that allowable stresses for falsework and steel members being erected are not exceeded and that member capacities and final geometry shall be correct. When the designated concrete deck overhang exceeds thirty (30) inches from the edge of the beam flange, the erection drawings submitted by the Contractor/fabricator shall include complete details of the forming and bracing for the over hang and shall transmit the concrete dead load to an area of the beam or stringer which will prevent distortion. 615.2.2-Camber Diagram: A camber diagram shall be furnished to the Engineer by the Fabricator, showing the camber at each panel point in th e cases of trusses or arch ribs, and at the location of field splices and fractions of span length (¼ points minimum) in the cases of 437 continuous beam and girders or rigid frames. The camber diagram shall show calculated cambers to be used in preassembly of the structure in accordance with Section 615.5.3. 615.3-MATERIALS: 615.3.1-Structural Steel: 615.3.1.1-Quality: Steel shall be furnished according to the following specifications. The grade or grades of steel to be furnished shall be as shown on the plans or as specified. Material meeting equivalent AASHTO and ASTM specifications may be supplied under either specification. All steel for use in main load -carrying member components subject to tensile stress, including splice plates, shall conform to Zone 2 Charpy V -Notch Impact Test requirements of AASHTO M 270. 615.3.1.2-Certifications and verification: Fabricators of structural steel shall provide certified mill test reports (MTRs) for all steel materials used in fabrication. MTRs must originate from the producer of the material and not a supplier. 615.3.1.3-High Performance Steel: Structural Steel designated on the plans as grades HPS 50W and HPS 70W shall conform to the requirements of AASHTO M 270. All fabrication for grades HPS 50W and HPS 70W must conform to the current edition of the AASHTO/AWS D1.5 2008 Bridge Welding Code and by the latest edition of the AASHTO Guide Specification for Highway Bridge Fabrication with HPS 70W Steel. Only submerged arc welding (SAW) and shielded metal arc welding (SMAW) are permitted when welding grade HPS 70W steel. 615.3.1.4-Non-Destructive Testing (NDT): All NDT shall be performed in accordance with the AASHTO/AWS D1.5 2008 Bridge Welding Code. Whenever magnetic particle testing (MT) is performed only the yoke technique will be allowed, as described in section 6.7.6.2 of AWS D1.5, modified to test using alternating current only. 615.3.1.5-Weld procedure qualification: The procedure qualification test record

Engineer for review and approval prior to the s tart of fabrication. In general, post weld heat treatment shall not be required. If proposed by the Contractor for production or repair welding, such post weld heat treatment must be included in the procedure qualification testing, or qualified by additional PQR’s, as appropriate. 615.3.2-High-Strength Fasteners: Bolts, nuts, and washers shall conform to Section

709.24and shall be mechanically galvanized in accordance with ASTM B695. Hot -dip

galvanizing or coating with a zinc rich primer may be used only when specified by the Contract documents. 615.3.2.1-Weathering Steel Bridges: High strength fasteners shall meet Section

and shall be Type 3 (weathering steel), per ASTM F3125 Grade A325. High

strength fasteners used in regions of the structure that require painting shall be Type 1, per ASTM F3125 Grade A325, and mechanically galvanized in accordance with ASTM B695. ASTM F3125, Grade A490, high strength fasteners shall only be used when indicated on the plans. 438 615.3.3-Welded Stud Shear Connectors: When design requires the use of welded stud shear connectors, they shall meet the requirements of Section 7 of the ANSI/AASHTO/AWS D1.5, Bridge Welding Code. The connectors shall be attached in the field. With the exception of worker fall protection as described in section 615.3.3.1, no shop installation of welded stud shear connectors shall be permitted. The field installation of the welded stud shear connectors shall not commence prior to the installation of the deck forms in the area surrounding the welded stud shear connectors. Overhanging deck forms may be installed after the welded stud shear connectors are installed. The welded stud shear connectors and deck forms shall be installed in a sequence that permits workers access th rough the deck area without walking through installed welded stud shear connectors. 615.3.3.1- Shear Studs for Worker Fall Protection: The Contractor may shop install shear studs to the beam or girder for the purpose of attaching a worker fall protection system. Only the shear studs required to properly install and support the worker fall protection system may be installed in the shop. The remaining shear studs at this location for an individual transverse row across the beam or girder flange may also be installed in the shop. All shop installed shear studs shall be shown on the drawings. 615.3.4-Steel Forgings and Steel Shafting: 615.3.4.1-Steel Forgings: Shall conform to subsection 709.13.1. 615.3.4.2-Cold Finished Carbon Steel Shafting: Shall conform to 709.13.2. 615.3.5-Steel Castings: Shall conform to subsection 709.14. 615.3.6-Iron Castings: Shall conform to subsection 709.10. 615.3.7-Coating of Anchor Bolts, Nuts and Washers: All anchor bolts, nuts and washers shall be hot dip galvanized in accordance with AASHTO M 232 after fabrication. 615.4-FABRICATION: 615.4.1-Identification and Traceability: Ensure that all structural steel materials are identified in accordance with ASTM A6. Maintain heat numbers on all primary bridge materials until the material is permanently joined into a piece-marked member. Use low stress steel die stamps or a firmly attached tag. Maintain documentation of all primary member material for shop records and provide this documentation to the Quality Assurance Inspector

615.4.2-Storage of Materials: Steel members must not be gouged, scratched, dented, or allowed to rub against other members that would result in damage to the steel member or coating. Members shall be handled using softeners and slings instead of chokers and chains. Store members in the fabrication shop and on the project site in such a manner as to be kept free and clean of all foreign substances such as grease, oil, mortar and concrete splatter , chalk and crayon marks, paint, and dirt. All storage must be above ground and sloped to allow free drainage of m elted snow, rainwater, and dew. If the members are stored for periods longer than three months, the members must be placed on metal supports. For a period of storage up to three months, members may be placed on clean, untreated wood timbers. Do not allo w treated lumber or treated timber to contact steel members. 439 Store plate girders and rolled beams with the web in the upright position. The members may be stacked on metal or wood supports provided, as noted above; individual members must be kept separate. Under no circumstances shall members be nested together or bundled. 615.4.3-Plates: 615.4.3.1-Direction of Rolling: Unless otherwise shown on the plans, steel plates for main members and splice plates for flanges and main tension members, nots econdary members, shall be cut and fabricated so that the primary direction of rolling is parallel to the direction of the main tensile and/or compressive stresses. 615.4.3.2-Plate Cut Edges: 615.4.3.2.1-Edge Planeing: For primary members more than 5 /8 inch in thickness, 3/16 inch shall be planed off sheared edges that remain exposed after fabrication. 615.4.3.2.2-Thermal Cutting: Shall conform to the requirements of the ANSI/AASHTO/AWS Bridge Welding Code D1.5. 615.4.3.2.3-Visual Inspection and Repair of Plate Cut Edges: Shall conform to the requirements of ANSI/AASHTO/AWS Bridge Welding code D1.5. 615.4.3.3-Bent Plates: 615.4.3.3.1General: Unwelded, load -carrying, rolled -steel plates to be bent shall conform to the following: They shall be so taken from the stock plates that the bend line will be at right angles to the direction of rolling, except that cold-bent ribs for orthotropic-deck bridges may be bent with bend lines in the direction of rolling if permitted by the Engineer. Before bending, the corners of the plates shall be rounded to a radius of approximately 1/16 inch throughout the portion of the plate at which the bending is to occur. 615.4.3.3.2-Cold Bending: Do not cold bend fracture critical materials. Cold bending shall be such that no cracking of the plate occurs. Visibly inspect all load points, and check any suspected damage by magnetic particle testing. Material with non -specified kinks or sharp bends, cracks, large dents, or visible reduction of section shall be rejected. Minimum bend radii, measured to the concave face of the metal, are shown in Table 615.4.3.3.2. TABLE 615.4.3.3.2 Minimum Cold-Bending Radii Material Radius in Terms of Plate Thickness, t (in.) ASTM Specification Grade t<(1) (1) <t< (2) (2)<t A36 --- 1.5t 1.5t 2.0tA572 42 A709 36 A572 50 1.5t 2.0t 2.5tA588 --- A709 50, 50W A572 55 1.5t 2.5t 3.0t A709 70W 440 Allowance for springback of Grades 100 and 100W steels should be about three times that for Grade 36 steel. For break press forming, the lower die span should be at least 16 times the plate thickness. Multiple hits are advisable. 615.4.3.3.3-Hot Bending: If a radius shorter than the minimum specified for cold bending is essential, the plates shall be bent hot at a temperature not greater than shown in Table 615.4.7. 615.4.4-Fit of Stiffeners: Bearing stiffeners for girders and stiffeners intended as supports for concentrated loads shall have full bearing (either milled, ground or on weldable steel in compression areas of flanges, welded when shown on the plans or specified) on the flanges to which they transmit load or from which they receive load and shall meet the requirements of paragraph 3.5.1.9 of the 2008 ANSI/AASHTO/AWS Bridge Welding Code D1.5. Intermediate stiffeners not intended to support concentrated loads, unless shown or specified otherwise, shall have a tight fit against both flanges wh ich is defined as having a gap of no more than 1/16 inch between stiffener and flange. Diaphragm, crossframes or floorbeam connection plates shall be welded to both top and bottom flanges. 615.4.5-Abutting Joints: When specified by the contract plans, butting joints in compression members of trusses and columns shall be milled or saw-cut to give a square joint and uniform bearing. At other joints, not required to be faced, the opening shall not exceed 3/8 inch. 615.4.6-Facing of Bearing Surfaces: The surface finish of bearing and base plates and other bearing surfaces that are to come in contact with each other or with concrete shall meet the ANSI surface roughness requirements as defined in ANSI B46.1, Surfac e Roughness, Waviness and Lay, Part I: Steel slabs ANSI 2,000 Heavy plates in contact in shoes to be welded ANSI 1,000 Milled ends of compression members, milled ANSI 500 or ground ends of stiffeners and fillers Bridge rollers and rockers ANSI 250 Pins and pin holes ANSI 125 Sliding bearings ANSI 125 615.4.7-Straightening Material: The straightening of plates, angles, other shapes, and built-up members, when permitted by the Engineer, shall be done by methods that will not produce fracture or other injury to the metal. Straighten bridge member parts, such as plates, angles or shapes, before the parts are assembled. If members are cold straightened, follow the applicable provisions of Section 615.4.3.3.2. Distorted members shall be straightened by mechanical means or, if approved by the Engineer, by carefully planned procedures an d supervised application of a limited amount of localized heat, except that heat straightening of Grades 70W, 100 and 100W steel members shall be done only under rigidly controlled procedures, each application subject to the approval of the Engineer. In n o case shall the maximum temperature exceed values shown in Table 615.4.7. 441 TABLE 615.4.7 Maximum Heat Straightening and Hot Bending Temperature Grade 70W > 6" from weld 1,075° F Grade 70W < 6” from weld 900° F Grade 100 or 100W > 6” from weld 1,125° F Grade 100 or 100W < 6” from weld 950° F In all other steels, the temperature of the heated area shall not exceed 1,200° F as controlled by temperature indicating crayons. Parts to be heat straightened shall be substantially free of stress and from external forces, except stresses resulting from mechanical means used in conjunction with the application of heat. Evidence of fracture following straightening of a bend or buckle will be cause for rejection of the damaged piece. 615.4.8-Bolt Holes: 615.4.8.1-Holes for High -Strength Bolts and Unfinished Bolts: (See Section 615.5.5 for bolts included in designation "Unfinished Bolts"). 615.4.8.1.1-General: All holes for bolts shall be either punched or drilled. Material forming parts of a member composed of not more than five thicknesses of metal may be punched 1/16 inch larger than the nominal diameter of the bolts whenever the thickness of the material is not greater than ¾ inch for structural carbon steel, 5/8 inch for high-strength steel or ½ inch for quenched and tempered alloy steel, unless subpunching and reaming are required under Section 615.4.8.5. When there are more than five thicknesses or when any of the main material is thicker than ¾ inch for structural carbon steel, 5/8 inch for high -strength steel, or ½ inch for quenched and tempered alloy steel, all holes shall either be subdrilled and reamed or drilled full size. When required, all holes shall be either subpunched or subdrilled (subdrilled if thickness limitation governs) 3/16 inch smaller and, after assembling reamed 1/16 inch larger or drilled full size to 1/16 inch larger than the nominal diameter of the bolts. When shown on the plans, enlarged or slotted holes are allowed with high -strength bolts. 615.4.8.1.2-Punched Holes: The diameter of the die shall not exceed the diameter of the punch by more than 1/16 inch. If any holes must be enlarged to admit the bolts, such holes shall be reamed. Holes must be clean cut without torn or ragged edges. Do not punch holes full size in primary members. Apply these maximum thickness limits when punching: Grade 36-3/4 inch; Grade 50/50W-5/8 inch; Grade HPS 70W-1/2 inch. 615.4.8.1.3-Reamed or Drilled Holes: Shall be cylindrical, perpendicular to the member, and shall comply with the requirements of Section 615.4.8.1.1 as to size. Where practical, reamers shall be directed by mechanical means. Burrs on the outside surfaces shall be removed. Reaming and drilling shall be done with twist drills, twist reamers or rotobroach cutters. Connecting parts requiring reamed or drilled holes shall be assembled 442 and securely held while being reamed or drilled and shall be match marked before disassembling. Parts shall not be held by welding. 615.4.8.1.4-Accuracy of Holes: Holes not more than 1/32 inch larger in diameter than the true decimal equivalent of the nominal diameter that may result from a drill or reamer of the nominal diameter are considered acceptable. The slightly conical hole that naturally results fro m punching operations is considered acceptable. The width of slotted holes which are produced by thermal cutting or a combination of drilling or punching and thermal cutting shall be not more than 1/32 inch greater than the nominal width. The thermal cut surface shall be ground smooth. Do not thermally cut holes in quenched and tempered steel. 615.4.8.2-Accuracy of Hole Group: 615.4.8.2.1-Accuracy Before Reaming: All holes punched full size, subpunched, or subdrilled shall be so accurately punched so that after assembling (before any reaming is done) a cylindrical pin 1/8 inch smaller in diameter than the nominal size of the punched hole may be entered perpendicular to the face of the member, without drifting, in at least 75 percent (75%) of the conti guous holes in the same plane. If the requirement is not fulfilled, the improperly punched pieces will be rejected. If any hole will not pass a pin 3/16 inch smaller in diameter than the nominal size of the punched hole, this will be cause for rejection. 615.4.8.2.2-Accuracy after Reaming: When holes are reamed or drilled, 85 percent (85%) of the holes in any contiguous group shall, after reaming or drilling, show no offset greater than 1/32 inch between adjacent thickness of metal. All steel templates shall have hardened steel bushings in holes accurately dimensioned from the centerlines of the connection as inscribed on the template. The centerlines shall be used in locating accurately the template from the milled or scribed ends of the members. 615.4.8.3-Numerically-Controlled Drilled Field Connections: In lieu of subsized holes and reaming while assembled, or drilling holes full -size while assembled, the Contractor shall have the option to drill or punch bolt holes full-size in unassembled pieces and/or connections including templates for use with matching subsized and rea med holes by means of suitable numerically controlled (N/C) drilling or punching equipment. Full - size punched holes shall meet the requirements of Section 615.4.8.1. If N/C drilling or punching equipment is used, the Contractor, by means of check assemblies, will be required to demonstrate the accuracy of this drilling or punching procedure in accordance with the provisions of Section 615.5.3.3. Holes drilled or punched by N/C equipment shall be drilled or punched to appropriate size either through indivi dual pieces, or drilled through any combination of pieces held tightly together. Pieces shall not be held by welding. 615.4.8.4-Holes for Ribbed Bolts, Turned Bolts, or Other Approved Bearing Type Bolts: All holes for ribbed bolts, turned bolts, or other approved bearing-type bolts shall be subpunched or subdrilled 3/16 inch smaller than the nominal diameter of the bolt and reamed when assembled, or drilled to a steel template or, after assembling, drilled from the solid at the option of the Fabricator. In any case the finished holes shall provide a driving fit. 443 615.4.8.5-Preparation of Field Connections: Holes in all field connections and field splices of main members of trusses, arches, continuous beam spans, bents, towers (each face), plate girders, and rigid frames shall be subpunched or subdrilled and subsequently reamed while assembled or drilled full size to a steel template. Holes for field splices of rolled beam stringers continuous over floor beams or cross frames may be drilled full size unassembled to a steel template. All holes for floor beams or cross frames may be drilled full size unassembled to a steel template. All holes for floor beam and stringer field end connections shall be subpunched and reamed while assembled or drilled full size to a steel template. Reaming or drilling full size of field connection holes through a steel template shall be done after the template has been located with utmost care as to position and angle and firmly bolted in place. Templates used for reaming matching members, or the opposite faces of a single member, shall be exact duplicates. Templates used for connections on like parts or members shall be so accurately located that the parts or members are duplicates and require no match-marking. For any connection, in lieu of subpunching and reaming or subdrilling and reaming, the fabricator may, at his option, drill holes full size with all thicknesses or material assembled in proper position. 615.4.9-Pins and Rollers: 615.4.9.1-General: Pins and rollers shall be accurately turned to the dimensions shown on the drawings and shall be straight, smooth, and free from flaws. Pins and rollers more than nine (9) inches in diameter shall be forged rollers and annealed. Pins and rollers nine (9) inches or less in diameter may be either forged and annealed or cold -finished carbon-steel shafting. In pins larger than nine (9) inches in diameter, a hole not less than two (2) inches in diameter shall be bored full length along the axis after the forging has been allowed to cool to a temperature below the critical range, under suitable conditions to prevent damage by too rapid cooling, and before being annealed. 615.4.9.2-Boring Pin Holes: Pin holes shall be bored true to the specified diameter, smooth and str aight, at right angles with the axis of the member and parallel with each other unless otherwise required. The final surface shall be produced by a finishing cut. The diameter of the pin hole shall not exceed that of the pin by more than 1/50 inch for pins five (5) inches or less in diameter, or by 1/32 inch for larger pins. The distance outside to outside of end holes in tension members and inside to inside of end holes in compression members shall not vary from that specified more than 1/32 inch. Boring of pin holes in built -up members shall be done after the member has been assembled. 615.4.9.3-Threads for Bolts and Pins: Threads for all bolts and pins for structural steel construction shall conform to the Unified Standard Series UNC ANSI B1.1, Class 2A for external threads and Class 2B for internal threads, except that pin ends having a diameter of 1-3/8 inches or more shall be threaded six threads to the inch. 615.4.10-Eyebars: Pin holes may be thermal cut at least two (2) inches smaller in diameter than the finished pin diameter. All eyebars that are to be placed side by side in the structure shall be securely fastened together in the order that they will be placed on the pin and bored at 444 both ends while so clamped. Eyebars shall be packed and match -marked for shipment and erection. All identifying marks shall be stamped with steel stencils on the edge of one head of each member after fabrication is completed so as to be visible when the bars are nested in place on the structure. Steel die stamps shall be low stress type. The eyebars shall be straight and free from twists and the pin holes shall be accurately located on the centerline of the bar. The inclination of any ba r to the plane of the truss shall not 0.5 percent (0.5%). The edges of eyebars that lie between the transverse centerline of their pin holes shall be cut simultaneously with two mechanically operated torches abreast of each other, guided by a substantial template, in such a manner as to prevent distortion of the plates. 615.4.11-Annealing and Stress Relieving: Structural members which are indicated in the contract to be annealed or normalized shall have finished machining, boring, and straightening done subsequent to heat treatment. Normalizing and annealing (full annealing) shall be as defined in ASTM A941. The temperatures shall be maintained uniformly throughout the furnace during the heating and cooling so that the temperature at no two points on the member will differ by more than 100° F at any one time. Members of Grades 100/100W or Grade 70W (690/690W or Grade 480W) steels shall not be annealed or normalized and shall be stress relieved only with the approval of the Engineer. A record of ea ch furnace charge shall identify the pieces in the charge and show the temperatures and schedule actually used. Proper instruments, including recording pyrometers, shall be provided for determining at any time the temperatures of members in the furnace. The records of the treatment operation shall be available to and meet the approval of the Engineer. The holding temperature for stress relieving Grades 100/100W and Grade 70W (690/690W and Grade 480W) steels shall not exceed 1,125° F and 1075° F, respectively. Members, such as bridge shoes, pedestals, or other parts that are built up by welding sections of plate together shall be stress relieved in accordance with the ANSI/AASHTO/AWS Bridge Welding Code D1.5 when required by the plans, specifications, or special provisions governing the contract. 615.4.12-Curved Girders: 615.4.12.1-General: Flanges of curved, welded girders may be cut to the radii shown on the plans or curved by applying heat as specified in the succeeding Sections providing the radii is not less than allowed by Article 10.15.2 of Division I of the AASHTO Standard Specifications for Highway Bridges. 615.4.12.2-Heat Curving Rolled Beams and Welded Girders: 615.4.12.2.1-Materials: Blank 615.4.12.2.2-Type of Heating: Beams and girders may be curved by either continuous or V-type heating as approved by the Engineer. For the continuous method, a strip or intermittent strips along the edge of the top and bottom flange shall be heated simultaneously depending on flange widths and thicknesses; the strip shall be of sufficient width and temperature to obtain the required curvature. For V -type heating, the top and bottom flanges shall be heated in truncated triangular or wedge -shaped areas having their base along the flange edge and spa ced at regular intervals along each flange; the spacing and temperature shall be as required to obtain the required curvature, and heating shall progress along the top and bottom flange at approximately the same rate. 445 For V-type heating, the apex of the truncated triangular area applied to the inside flange surface shall terminate just before the juncture of the web and the flange is reached. To avoid unnecessary web distortion, special care shall be taken when heating the inside flange surfaces (the surfaces that intersect the web) so that heat is not applied directly to the web. When the radius of curvature is 1,000 feet or more, the apex of the truncated triangular heating pattern applied to the outside flange surface shall extend to the juncture of th e flange and web. When the radius of curvature is less than 1,000 feet, the apex of the truncated triangle heating pattern applied to the outside flange surface shall extend past the web for a distance equal to one-eighth of the flange or three (3) inches, whichever is less. The truncated triangular pattern shall have an included angle of approximately 15 to 30 degrees, but the base of the triangle shall not exceed ten (10) inches. Variations in the patterns prescribed above may be made with the approval of the Engineer. For both types of heating, the flange edges to be heated are those that will be on the inside of the horizontal curve after cooling. Heating both inside and outside flange surfaces is only mandatory when the flange thickness is 1¼ inches or greater, in which case, the two surfaces shall be heated concurrently. The maximum temperature shall be prescribed as follows. 615.4.12.2.3-Temperature: Bring the steel within the planned temperature as rapidly as possible without overheating. The heat-curving operation shall be conducted in such a manner that the temperature of the steel does not exceed 1200°F for grade 36 and grade 50 steel, and 110 0° F for grades HPS 70W and HPS 100/100W steel as measured by temperature indicating crayons, pyrometers, or infrared non -contact thermometers. Measure the temperature 5-10 seconds after the heating flame leaves the area to be tested. The girder shall no t be artificially cooled until after naturally cooling to 600°F. Cooling with dry compressed air after the steel has cooled to below 600° F is permitted. Do not cool the steel with water or mist. Allow steel to cool below 250° F before applying another set of heating patterns. Do not handle, support, or load the member in a manner that causes material to yield without the application of heat. 615.4.12.2.4-Position for Heating: The girder may be heat -curved with the web in either a vertical or a horizontal position. If the radius is less than 1000 feet, heat curve only with the web in the horizontal position or preload to induce stress prior to heating. Do not heat curve portions of members where the required radius of curvature is less than 1000 feet and the flange width exceeds thirty (30) inches. When curved in the vertical position, the girder must be braced or supported in such a manner that the tendency of the girder to deflect laterally during the heat-curving process will not cause the girder to overturn. When curved in the horizontal position, the girder must be supported near its ends and at intermediate points, if required, to obtain a uniform curvature; the bending stress in the flanges due to the dead weight of the girder must not exceed the usual allowable design stress. When the girder is positioned horizontally for heating, intermediate safety catch blocks must be maintained at the mid -length of the girder within two (2) inches of the flanges at all times during the heating process to guard against a sudden sag due to plastic flange buckling. 615.4.12.2.5-Sequence of Operations: The girder shall be heat -curved in the fabrication shop before it is painted. The heat curving operation may be conducted either before or after all the required welding of transverse intermediate stiffeners is completed. 446 However, unless provisions are made for girder shrinkage, connection plates and bearing stiffeners shall be located and attached after heat curving. If longitudinal stiffeners are required, they shall be heat-curved or oxygen-cut separately and then welded to the curved girder. When cover plates are to be attached to rolled beams, they may be attached before heat curving if the total thickness of one flange and cover plate is less than 2½ inches and the radius of the curvature is greater than 1,000 feet. For other rolled beams with cover plates, the beams must be heat -curved before the cover plates are attached; cover plates must be either heat curved or oxygen-cut separately and then welded to the curved beam. 615.4.12.2.6-Camber: Girders shall be cambered before heat curving. Camber for rolled beams may be obtained by heat-cambering methods approved by the Engineer. For plate girders, the web shall be cut to the prescribed camber with suitable allowance for shrinkage due to cutting, welding, and heat curving. However, subject to the approval of the Engineer, moderate deviations from specified camber may be corrected by a carefully supervised application of heat. 615.4.12.2.7-Measurement of Curvature and Camber: Horizontal curvature and vertical camber shall be measured for final acceptance after all welding and heating operations are completed and the flanges have cooled to a uniform temperature. Horizontal curvature shall be checked with the girder in the vertical position. 615.4.13: Blank 615.4.14-Full Size Tests: When full size tests of fabricated structural members or eyebars are required by the contract, the Contractor shall provide suitable facilities, material, supervision, and labor necessary for making and recording the required tests. The members tested in accordance with the contract shall be paid for in accordance with Section 615.7.2. 615.4.15-Marking and Shipping: Each member shall be painted or marked with an erection mark for identification and an erection diagram showing these marks shall be furnished to the Engineer. The Contractor shall furnish to the Engi neer as many copies of material orders, shipping statements, and erection diagrams as the Engineer may direct. The weights of the individual members shall be shown on the statements. Members weighing more than 3 tons shall have the weights marked thereon. Structural members shall be loaded on trucks or railcars in such a manner that they may be transported and unloaded at their destination without being excessively stressed, deformed, or otherwise damaged. High strength bolts, nuts, and washers shall be packaged as required by Section 709.24.9.1. Pins and small parts shall be shipped in boxes, crates, kegs, or barrels, but the gross weight of any package shall not exceed 300 pounds. A list and description of the contained material shall be plainly marked on the outside of each shipping container. 615.5-ASSEMBLY: 615.5.1-Bolting: Surfaces of metal in contact shall be clean before assembling. The parts of a member shall be assembled, well pinned, and firmly dr awn together before drilling, reaming, or bolting is commenced. Assembled pieces shall be taken apart for the removal of burrs and shavings produced by the operation. The member shall be free from twists, bends and other deformation. 447 The drifting done during assembling shall be only such as to bring the parts into position and not sufficient to enlarge the holes or distort the metal. 615.5.2-Welded Connections: Surfaces and edges to be welded shall be smooth, uniform, clean and free of defects which would adversely affect the quality of the weld. Edge preparation shall be done in accordance with ANSI/AASHTO/AWS Bridge Welding Code D1.5. 615.5.3-Preassembly of Field Connections: 615.5.3.1-General: Field connections of main members of trusses, arches, continuous beams, plate girders, bents, towers and rigid frames shall be preassembles prior to erection to verify the geometry of the completed structure of un it and to verify or prepare field splices. Attaining accurate geometry is the responsibility of the Contractor and they shall propose and appropriate method of preassembly and submit the plan to the Engineer. The method and details of preassembly shall b e consistent with the erection procedure shown on the erection plans and camber diagrams prepared by the Contractor and submitted to the Engineer. Receipt of plans, drawings and calculations does not constitute review or approval or relieve the contractor of their responsibility to satisfactorily design the erection plan. As a minimum, the preassembly procedure shall consist of assembling three contiguous panels accurately adjusted for line and camber. Successive assemblies shall consist of at least on e section or panel of the previous assembly (repositioned if necessary and adequately pinned to assure accurate alignment) plus two or more sections or panels added at the advancing end. In the case of structures longer than 150 feet, each assembly shall be not less than 150 feet long regardless of the length of individual continuous panels or sections. At the option of the fabricator, sequence of assembly may start from any location in the structure and proceed in one or both directions so long as the preceding requirements are satisfied. 615.5.3.2-Bolted Connections: For bolted connections, holes shall be prepared as outlined in Section 615.4.8. Where specified by the contract documents, major components shall be assembled with milled ends of compression members in full bearing and then shall have their subsized holes reamed to the specified size while the connections are assembled. 615.5.3.3-Check Assembly-Numerically Controlled Drilling: When the Contractor elects to use numerically controlled dr illing, a check assembly shall be required for each major structural type, unless otherwise designated on the plans or in the special provisions, and shall consist of at least three contiguous shop sections or, in a truss, all members in at least three contiguous panels but not less than the number of panels associated with three contiguous chord lengths (i.e., length between field splices). Check assemblies should be based on the proposed order of erection, joints in bearing, special complex points, and similar considerations. Special points could be the portals of skewed trusses, for example. More than one check assembly may be required by the Engineer. The check assemblies shall include the first sections of each major structural type to be fabricated and additional assemblies as required by the Engineer. Shop assemblies other than the check assemblies will not be required. 448 If the check assembly fails in some specific manner to demonstrate that the required accuracy is being obtained, further check assemblies 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-Match 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 the 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. 449 615.5.6-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 of 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 parts 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 painted 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 Engineer, 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 assurance 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 450 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 the 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 615.5.6.3A 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. 451 TABLE 615.5.6.3B a, b NUT ROTATION FROM SNUG TIGHT CONDITION 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 sloped 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 lubrication, 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 452 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 Virginia 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. 453 615.6.4.2-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 Contractor. 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 rejection. 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 undertaken. 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. 454 615.6.9-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 stains. 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 satisfaction 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 between 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 fabric 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 basis: 455 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 dimensions 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 parts 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 will 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. 456 615.8-BASIS OF PAYMENT: The quantities, determined as provided above, will be paid for at the contract unit prices bid for the items listed below, which prices and payments shall be full compensation for furnishing all the material and doing all the work herein prescribed in a workmanlike and acceptable manner including all labor, tools, equipment, supplies, falsework, painting, and incidentals necessary to complete the work. 615.9-PAY ITEMS: ITEM DESCRIPTION UNIT 615001-* Steel Superstructure Lump Sum 615002-* Prefabricated Steel Bridge Superstructure Lump Sum 615003-* Fabricated Structural Steel Lump Sum 615004-* Fabricated Structural Steel Pound * Sequence number 457