815Structural Metals and Metal Castings

Structural Metals and Metal Castings

815.1Structural Steel

1 Ensure the provision and use of structural carbon steel in accordance with ASTM A 709, grade 36 [ASTM A 709M, grade 250].

2 Ensure the provision and use of high-strength, low-alloy structural steel in accordance with ASTM A 709, grade 50, 50S, or 50W [ASTM A 709M, grade 345, or 345W].

3 Ensure the provision and use of high-performance steel in accordance with ASTM A 709, grade HPS70W [ASTM A 709M, grade HPS485W].

4 For non-fracture critical main girders for highway bridges, ensure the provision and use of structural steel for W-shape rolled beams, webs and all flanges of welded-plate girders, splice plates, and other primary members are in accordance with the impact test requirements of ASTM A 709 [ASTM A 709M], table 11 for zone 2.

5 For all fracture critical members, ensure the provision and use of structural steel in accordance with the impact test requirements of ASTM A 709 [ASTM A 709M], table 12 for zone 2.

815.2High-Strength Bolts and Fasteners

815.2.1 Bolts, Nuts, and Washers

1 Ensure the provision and use of high-strength bolts, nuts, and washers as follows:

maximum Rockwell C hardness of 33.

For unpainted ASTM A 709 grade 50W or HPS70W [ASTM A 709M, grade 345W or HPS485W] steel, use only type 3 bolts.

Mark bolts “A325” and with a symbol identifying the manufacturer; for type 3 bolts, underline the mark as follows: “ A325.” Mark metric bolts “A325M” and with a symbol identifying the manufacturer; for type 3 bolts, underline the mark as follows: “A325M.” Mark twist -off bolts “A325TC” and with a symbol identifying the manufacturer; for type 3 bolts, under the mark as follows: “A325TC”.

Structural Metals and Metal Castings SECTION 815

2.1Lubricate galvanized nuts with clean lubricant, dry to the touch, and dyed

to contrast with the galvanizing color.

2.2Provide grade and finish in accordance with Table 815.2.1-1, Nut Grade

and Finish Requirements.

Table 815.2.1-1 Nut Grade and Finish Requirements Bolt Type and Finish Grade Type 1 plain, uncoated A 563 C, Plain [Class 8S] Type 1 galvanized A 563 DH, Galv. [Class 10S] Type 3 plain, weathering A 563 C3 [Class 8S3]

2.3Mark nuts with the class shown above and a symbol identifying the

manufacturer.

[ASTM F 436M], and marked with symbols identifying the manufacturer. Mark type 3 weathering-grade washers with a “3.”

[ASTM F 959M], and marked with a symbol identifying the type and manufacturer, lot number, or private label distribution, as appropriate. Use galvanized washers for galvanized bolts. Use type 3 washers for type 3 bolts.

nut, and washer, in accordance with ASTM F 3125, grade F 1852. Use only type 3 assemblies for unpainted ASTM A 709, grade 50W or HPS70W [ASTM A 709M, grade 345W or HPS485W] structural steel. Provide nuts and washers for twist-off bolts from the same manufacturer as the bolts and lubricated in accordance with manufacturer’s recommendations.

if they meet the material, manufacturing, and chemical- composition requirements of ASTM F3125 [ASTM F3125M], grade A 325, the mechanical property requirements of the same specification in full-size tests and have a body diameter and bearing area under the head not less than those provided by the bolt of the same nominal dimensions. They may differ in other dimensions.

Ensure that each fastener provides a solid-shank body of sufficient diameter to provide tensile and shear strengths equaling or exceeding that of equivalent ASTM F3125 [ASTM F3125M], grade A 325 bolts. Use lock pins with a cold- forged, round head on one end, an annular breakneck groove and annular pull

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grooves on the other end, and a shank length suitable for the material thickness being fastened

Provide each fastener with a steel locking collar of proper size for the shank diameter used that when cold-swayed into the locking grooves, forms a head for the grooved end of the fastener after the pullse ction has been removed. Provide a flanged-type collar, with a tab to retain the collar on the pin during installation, that is a standard product of an established lock-pin-and-collar- fastener manufacturer; mark fasteners with the grade designation and a symbol identifying the manufacturer.

B18.2.4.6M and Table 815.2.1-2, Bolt and Nut Dimensions.

Table 815.2.1-2 Bolt and Nut Dimensions Heavy Hexagon Structural Bolts in [mm]

Nut Dimensions, Heavy Hexagon Nuts in [mm] Bolt Size D Width Across Flats F Height H Thread Length T Width Across Flats W Height H ⅝ [16] 1¹⁄₁₆ [27] ²⁵⁄₆₄ [10] 1¼ [31] 1¹⁄₁₆ [27] ³⁹⁄₆₄ [17] ¾ [19] 1¼ [34] ¹⁵⁄₃₂ [12] 1⅜ [36] 1¼ [34] ⁴⁷⁄₆₄ [20] ⅞ [22] 1⁷⁄₁₆ [36] ³⁵⁄₆₄ [14] 1½ [38] 1⁷⁄₁₆ [36] ⁵⁵⁄₆₄ [23] 1 [25] 1⅝ [41] ³⁹⁄₆₄ [15] 1¾ [44] 1⅝ [41] ⁶³⁄₆₄ [24] 1⅛ [28] 1¹³⁄₁₆ [46] ¹¹⁄₁₆ [17] 1¾ [44] 1¹³⁄₁₆ [46] 1⁷⁄₆₄ [27] 1¼ [31] 2 [50] ²⁵⁄₃₂ [19] 2 [50] 2 [50] 1⁷⁄₃₂ [30]

2 Provide hardened circular washers in accordance with ASTM F 436 [ASTM F 436M] and Table 815.2.1-3, Hardened Circular Washer Dimensions.

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Table 815.2.1-3 Hardened Circular Washer Dimensions Circular Washers in [mm] Bolt Size D Maximum Outside Diameter Minimum Diameter of Hole Thickness Minimum Maximum ⅝ [16] 1⁵⁄₁₆ [34] 11/16 [17] 0.122 [3] 0.177 [5] ¾ [19] 1¹⁵⁄₃₂ [42] ¹³⁄₁₆ [22] 0.122 [3] 0.177 [5] ⅞ [22] 1¾ [44] ¹⁵⁄₁₆ [24] 0.136 [3] 0.177 [5] 1 [25] 2 [50] 1¹⁄₁₆ [26] 0.136 [3] 0.177 [5] 1⅛ [28] 2¼ [56] 13/16 [30] 0.136 [3] 0.177 [5] 1¼ [31] 2½ [60] 1⅜ [33] 0.136 [3] 0.177 [5]

815.2.2 Testing

method 1, at least as frequently as specified in ASTM F 3125, 9.6.

The department requires wedge tests on full -size bolts in accordance with ASTM F 606 [ASTM F 606M], 3.5. Test after galvanizing, when applicable, and as frequently as specified in ASTM F 3125, 9.6.

When providing galvanized bolts, determine the zinc -coating thickness by measurements taken on the wrench flats or on top of the bolt head.

at least as frequently as specified in ASTM A 563 [ASTM A 563M] 9.3. For galvanized nuts, test after galvanizing, overlapping, and lubricating.

When providing galvanized nuts, determine the zinc-coating thickness by measurements taken on the wrench flats.

testing after galvanizing and after the zinc coating has been removed. Measure the zinc-coating thickness.

and washer assemblies (after galvanizing, for galvanized assemblies) before shipping.

Ensure that each production lot combination of bolts, nuts, and washers is tested as an assembly and that at least two assemblies are tested per rotational-capacity lot. Assign a rotational-capacity lot number to each combination of lots tested.

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Assemble the bolt, nut, and washer in a Skidmore-Wilhelm Calibrator or an acceptable equivalent device. Ensure a minimum rotation from a snug-tight condition (10 percent of the required installation tension) in accordance with Table 815.2.2-1, Minimum Rotation From Snug Tight Condition.

Table 815.2.2-1 Minimum Rotation From Snug Tight Condition Minimum rotation Bolt Length 240° ≤ 4 times the diameter of the bolt 360° > 4 diameters up to ≤ 8 diameters of the bolt 420° > 8 diameters of the bolt

Ensure that the tension reached at the above rotation is at least 1.15 times the required installation tension. Use an installation and turn-test tension in accordance with Table 815.2.2-2, Installation and Turn-Test Tension.

Table 815.2.2-2 Installation and Turn-Test Tension Diameter in [mm] Required Installation Tension kip [kN] Turn-Test Tension kip [kN] ⅝ [16] 19 [94.2] 22 [108] ¾ [19] 28 [147] 32 [169] ⅞ [22] 39 [183] 45 [209] 1 [25] 51 [212] 59 [244] 1⅛ [28] 64 [274] 73 [315] 1¼ [31] 81 [337] 93 [388]

After exceeding the required installation tension above, take and record one reading of tension and torque. Ensure that the torque value does not exceed the following:

Torquemax = 0.25 PD, where:

Torquemax = measured torque in foot-pounds [newton•meters]

P = measured bolt tension in pounds [kilonewtons]

D = bolt diameter in feet [millimeters]

Bolts too short to assemble in a Skidmore-Wilhelm Calibrator may be tested in a steel joint; compute the maximum torque requirement using a value of P equal to the turn- test tension shown in the table above.

Examine bolts and nuts for stripping or failure; ensure that the nut finger-turns on and off the thread being tested. Assemblies with evidence of stripping fail the test.

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815.2.3 Reporting

1 Ensure that required test results, as well as the location and date of testing, are recorded on the appropriate document.

815.2.4 Witnessing

1 Tests need not be witnessed by an inspection agency; ensure that the manufacturer or distributor performing the tests certifies the accuracy of results recorded.

815.2.5 Additional Bolts for Testing

1 Provide additional bolts for testing by the Materials Program in accordance with Table 815.2.5-1, Required Test Bolts.

Table 815.2.5-1 Required Test Bolts Number of Bolts of Each Length Required for Project Number of Additional Test Bolts Required 0 to 150 2 151 to 280 2 281 to 500 3 501 to 1200 5 1201 to 3200 8 3201 to 10,000 13 over 10,000 20

815.2.6 Documentation

1 Provide mill test reports (MTR), showing where the material was melted and manufactured for mild steel used in manufacturing bolts, nuts, and washers.

2 For all bolts, nuts, and washers supplied, provide a manufacture r-certified test report (MCTR), showing results for required tests.

3 Ensure that the MCTR provided by the manufacturer performing rotational- capacity tests includes the following:

Structural Metals and Metal Castings SECTION 815

4 For bolt assembly components, ensure that the distributor-certified test report (DCTR) includes the MCTR; the rotational-capacity test may be performed by a distributor instead of a manufacturer, with results reported on the DCTR.

815.2.7 Shipping

1 Ensure that bolts, nuts, and washers from each rotational-capacity lot are shipped in the same container. If there is only one production-lot number for each size of nuts and washers, they may be shipped in separate containers. Permanently mark each container with the rotational -capacity lot number to allow identification at any stage before installation. Ensure the provision and receipt of two signed copies of the appropriate MTR, MCTR, or DCTR with each shipment.

815.3Sheet Metal

1 Ensure the provision and use of galvanized sheet metal in accordance with ASTM A 924 [ASTM A 924M] and ASTM A 653 [ASTM A 653M], coating designation G90 [Z275].

815.4Automatically-End-Welded Studs

1 Ensure the provision and use of automatically-end-welded studs in accordance with AASHTO/AWS D1.5 Bridge Welding Code, Clause 7, and with mechanical properties in accordance with the requirements for type B studs.

815.5Steel Pipe

1 Ensure the provision and use of steel pipe in accordance with ASTM A 53 or ASTM A 500, grade B for pipe with a nominal diameter greater than 2 in [50 mm]. For diameters less than or equal to 2 in [50mm], provide ASTM A 53, grace A, type F.

815.6Bolts and Fasteners

1 Other than high-strength bolts, ensure the provision and use of bolts and fasteners in accordance with ASTM A 307, grade A [ASTM F 568, class 4.6], or SAE, grade 2, with coarse threads.

815.7Steel Piles

1 For steel piles, provide rolled steel sections made from structural steel in accordance with ASTM A 709 grade 36, 50, or 50W [ASTM A 709M, grade 250, 345, 345W].

Structural Metals and Metal Castings SECTION 815

2 If used, ensure that splicer sections are made of steel meeting the same requirements as the corresponding piles. When specified, provide pile points made of cast steel in accordance with ASTM A 27, grade 65-35 [ASTM A 27M, grade 450-240], or ASTM A 148, grade 90-60 [ASTM A 148M, grade 620-415]; the State Bridge Engineer may approve alternative materials.

815.8Sheet Piling

1 Provide and use sheet piling made from structural carbon steel in accordance with ASTM A 328 [ASTM A 328M].

815.9Bridge Railing

1 Ensure the provision and use of structural-tube railing made from structural tubing in accordance with ASTM A 501 or ASTM A 500, grade A or B.

2 If ASTM A 500 structural-tube is used, ensure railing is tested in accordance with ASTM E 436, after galvanizing; ensure a testing temperature of 0 °F [- 18 °C]. Ensure six specimens from the longest side of the tube are used to determine the percentage shear area; do not use specimens containing a weld. The department will not accept material in which the average percent shear area is less than 50.

3 Provide standard and expansion sleeves made from structural steel in accordance with ASTM A 709, grade 36 [ASTM A 709M, grade 250], and galvanized in accordance with Subsection 501.4.1.25, Galvanizing, and Subsection 815.14, Galvanized Coating.

4 Provide posts made from structural steel in accordance with ASTM A 709 grade 36 [ASTM A 709M, grade 250].

5 For bridge railing, provide anchor bolts in accordance with Subsection 815.18, High- Strength Anchor Bolts.

6 Provide anchor bolts, posts, and railing galvanized or cadmium-coated in accordance with Subsection 501.4.1.25, Galvanizing, and Subsection 815.14, Galvanized Coating.

7 For concrete anchorage, provide and use uncoated hardware consisting of steel bars in accordance with ASTM A 709, grade 36 [ASTM A 709M, grade 250].

815.10Bronze Bearing Plates

1 When specified, provide self-lubricating bronze bearing plates made of cast bronze alloy in accordance with AASHTO M 107 (ASTM B 22), Copper Alloy, UNS No. C91100, with contact surfaces finished in the direction of movement to a maximum roughness of No. 125 [3 µm] in accordance with ANSI B 46.1. Ensure that the lubricated surface has trepanned recesses and that hydraulic pressure has been use to press a lubricating compound made of graphite, metallic substance, and binder into the recesses to form

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dense, nonplastic, lubricating inserts comprising at least 25 percent of the plate’s total area. Ensure that steel surfaces in contact with bronze plates are coated during assembly with an approved lubricant. Ensure that the coefficient of friction between contact surfaces does not exceed 0.1.

815.11Steel Pins and Rollers

1 For pins and rollers with diameters equal to or less than 9 in [230 mm], provide and use in accordance with AASHTO M 169 or ASTM A 108 , grades 1016 to 1030, inclusive. Ensure a minimum Rockwell Scale B hardness of 85, or the development of a minimum tensile strength of 72,000 psi [500 MPa] with a minimum yield strength of 36,000 psi [250 MPa].

815.12Steel Castings

1 For highway-bridge components, provide and use steel castings, of the class specified, in accordance with ASTM A 148 [ASTM A 148M].

815.13Gray Iron Castings

1 Provide gray iron castings in accordance with ASTM A 48, class No. 35B, true to pattern in form and dimensions, free from pouring faults, sponginess, cracks, blow holes and other defects affecting their intended use. Ensure that castings are boldly-filleted at angles, with sharp and perfect arises, and with clean, smooth, uniform surfaces.

815.14Galvanized Coating

1 As specified, ensure that products made from rolled, pressed, and forged steel shapes, plates, bars, and ⅛ in [3 mm] and thicker strip are zinc (hot-dipped galvanized) coated in accordance with AASHTO M 111 or ASTM A 123.

2 As specified, provide and use iron and steel hardware galvanized in accordance with ASTM A 153 [ASTM A 153M], ASTM B 633, or ASTM F 2329, or cadmium-coated in accordance with ASTM B 766, class 8, type II or III; ensure that type II cadmium coating is bronze or brown.

815.15Preformed Fabric Pads

1 Provide and use preformed fabric pads made of multiple layers of cotton duck, impregnated and bound with rubber, compressed to uniform thickness, and in accordance with Military Specification MIL-C-882. Ensure the use of enough plies to achieve the specified thickness after compression and vulcanizing and that finished pads withstand compression loads perpendicular to the plane of laminations of at least 10,000 psi [70 MPa] without detrimental extrusion or reduction in thickness.

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815.16Elastomeric Bearing Pads

1 Ensure laminated elastomeric bearings conform with AASHTO M 251, Appendix X1 . Ensure the use of grade-4, 50-durometer hardness elastomer.

2 Ensure the provision and use of uncoated sheet metal in accordance with ASTM A 1011.

815.17Welding Materials

.1 General

1 For manual shielded-metal arc welding, provide and use electrodes in accordance with AWS A5.1 [A5.1M] or A5.5 [A5.5M].

2 For submerged arc welding, provide and use electrodes in accordance with AWS A5.17 [A5.17M] or A5.23 [A5.23M] Provide and use an electrode-flux combination as recommended by the electrode manufacturer.

3 For flux-cored arc welding, provide and use electrodes in accordance with AWS A5.20 [A5.20M] or A5.29 [A5.29M].

4 For gas-metal arc welding, provide and use electrodes in accordance with AWS A5.18 [A5.18M] or A5.28 [A5.28M].

5 For welding bare, unpainted steel in accordance with ASTM A 709, grade 50W or HPS70W [ASTM A 709M, grade 345W or HPS485W], provide and use electrodes in accordance with table 4.2 of AASHTO/AWS D1.5 or table 3.4 of AWS D1.1, as applicable.

6 Provide a cl assification of electrodes and electrode-flux combinations that produces weld metal with a minimum-impact strength of 20 ft-lb [20 J], Charpy V- notch, at a temperature of 0 °F [-18 °C] or less.

7 Provide certified copies of test reports for all tests specified in AWS A5.1 [A5.1M], A5.5 [A5.5M], A5.17 [A5.17M], A5.18 [A5.18M], A5.20 [A5.20M], A5.28 [A5.28M], or A5.29 [A5.29M], whichever is applicable, made on the electrodes or flux-electrode combinations of the same classification, size, and brand, manufactured using the same process and materials as those provided. If the electrodes used are of a size for which tests are not required by applicable specifications, provide test reports for electrodes of the size nearest and of the same classification and brand. The tests may be for process qualification or quality control. Ensure that the tests were done less than one year before the manufacture of the electrodes and fluxes provided and that the report includes all pertinent information concerning the required tests.

8 Provide certification that the gas or gas mixture used for flux-cored arc welding and gas- metal arc welding is suitable for the intended application and meets the dew point requirement.

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9 When galvanizing weldments after welding, provide and use a type or brand of filler metal that will deposit weld metal with a maximum silicon content of 0.4 percent to avoid possible weld disintegration during galvanizing.

10 For submerged-arc welding, provide and use a flux that is nonhygroscopic, dry, and free of foreign contamination.

.2 High Performance Steel

1 For welding steel in accordance with ASTM A 709, grade HPS70W [ASTM A 709M, grade HPS485W], the following apply:

AASHTO/AWS D1.5 when welding to ASTM A 709, grade 50 or 50W [ASTM A 709M, grade 345 or 345W] steel. Ensure that consumables are in accordance with diffusible hydrogen requirements of the AWS filler-metal specifications optional supplemental moisture-resistance designator, H4 or H8.

use consumables in accordance with the AASHTO/AWS D1.5 with HPS70W Steel for matching strength welds. To use alternate consumables, submit a request to the State Bridge Engineer for approval including documentation of successful welding in accordance with AASHTO/AWS D1.5 and diffusible hydrogen tests as described in Clause 12.6.1.1 of AASHTO/AWS D1.5 that conclude the deposited weld metal, under proposed fabrication shop conditions, has a di ffusible hydrogen level of H4 or less.

elding procedures qualified in accordance with Clause 5.12 of AASHTO/AWS D1.5. Perform qualification tests for strength, toughness, and ductility, and evaluate results in accordance with Clause 5.19 of AASHTO/AWS D1.5. Include ultrasonic testing in accordance with AASHTO/AWS Clause 6, Part C and evaluate in accordance with table 6.3 of AASHTO/AWS D1.5. Disregard indications found at the interface of the backing bar.

815.18High-Strength Anchor Bolts

1 As specified, provide and use cast-in high-strength anchor bolts or threaded anchor rods in accordance with ASTM A 449 or ASTM F 1554; supply ASTM A 563 nuts of appropriate grade and finish in accordance with Table 815.2.1-1, Nut Grade and Finish Requirements to match the anchor bolts [AASHTO M 164M or ASTM F 568, class 8.8, with ASTM A 563M, class 12 nuts].

2 Ensure that galvanized bolts have an ultimate tensile strength no greater than 150,000 psi [1 034 214 kPa].

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815.19Anchor Bolts Other Than High-Strength

1 Provide and use anchor bolts in accordance with ASTM A 307 [ASTM F 568]; supply nuts in accordance with ASTM A 563 and of a matching grade and finish in accordance with Table 815.2.1-1, Nut Grade and Finish Requirements. Ensure that galvanized bolts are hot-dipped.

815.20Frames, Grates, and Covers

1 Ensure frames, gates, and covers are designed for an AASHTO HL93 loading.

2 For fabricated grates, use structural steel in accordance with Subsection 815.1, Structural Steel. The department will allow the ⅝-inch [16 mm] diameter cross bars to be fillet welded, resistance welded, or electroforged to the bearing bars.