ATTACHMENT C.pdf

709.2 Materials

709.2.1 Structural Steel

709.2.1.1 General

1 Ensure that all structural steel conforms to AASHTO M 270.

2 Thermo-mechanical control processed (TMCP) HPS 70W steel may be directly substituted for quenched and tempered (Q&T) HPS 70W steel for plate thicknesses up to 2 in.

3 Protect the stock steel to be used in the project such that all surfaces are free from heavy rust and rust pitted areas at the start of and during fabrication.

Division 700 Section 709 700-100

709.2.1.2 Notch Toughness of Weld Metal

1 Ensure that the Charpy V-Notch Toughness of weld metal complies with the AASHTO/AWS D1.5, Bridge Welding Code.

709.2.1.3 Charpy V-Notch Testing

1 Perform Charpy V-Notch testing of the following structural steel members.

Ensure that the longitudinal Charpy V-Notch results comply with the requirements of AASHTO M 270, Zone 2. Sample according to the requirements of AASHTO M 270. Perform testing according to ASTM E23.

709.2.1.3.1 Simple Span Rolled Beam

1 Perform Charpy V-Notch testing of the beam itself and the bottom cover plate, if applicable.

709.2.1.3.2 Simple Span Plate Girder

1 Perform Charpy V-Notch testing of the web, bottom flange plate, web splice plates, and bottom flange, excluding any filler plates.

709.2.1.3.3 Continuous Span Rolled Beam

1 Perform Charpy V-Notch testing of the beam itself and any top or bottom cover plate located in a tension region. In addition, test all web splice plates and top and bottom flange splice plates, excluding any filler plates.

709.2.1.3.4 Continuous Span Plate Girder

1 Perform Charpy V-Notch testing of all web plates, the top flange plates, and the bottom flange plates located in tension regions as indicated in the Plans. Also, perform testing on all web splice plates and top and bottom flange splice plates, excluding any filler plates.

709.2.1.4 Corrosion Resistant Steel (Weathering Steel)

1 Ensure that all welding produces weld metal with atmospheric corrosion resistance and coloring characteristics similar to that of the base metal according to AASHTO/AWS D1.5, Bridge Welding Code.

2 Clean all structural steel to the requirements of Near White Blast Cleaning according to SSPC-SP 10, Near White Blast Cleaning Method. Remove all contamination of the structural steel resulting from erection or concrete placement. Clean the structural steel by an acceptable method approved by the BCE, and restore the surface finish to the specified Near White Blast Clean condition.

Division 700 Section 709 700-101

3 Do not paint corrosion resistant steel unless specifically indicated on the Plans.

709.2.2 Shear Connector Studs

1 Provide shear connector studs conforming to AASHTO M 169 (ASTM A108) Cold-drawn Bar Grades 1015, 1018, or 1020, either semi or fully-killed. If flux-retaining caps are used, ensure that the steel for the caps is a low carbon grade suitable for welding and complies with ASTM A109.

2 Provide shear connector studs suitable for welding to steel beams and girders with automatically timed stud-welding equipment.

3 Ensure that studs are of the specified type, size or diameter, and length and are listed on Qualified Products List 25.

709.2.3 Welding Electrodes

1 Ensure that the electrodes used in welding structural steel conform to the AASHTO/AWS D1.5, Bridge Welding Code.

709.2.4 High Strength Structural Steel Fasteners

709.2.4.1 General

1 Furnish high strength bolts, nuts, washers, and direct tension indicators according to the appropriate ASTM materials specifications.

2 Ensure that additional requirements for the field or shop installation of ASTM F3125, Grade A325 high strength bolts are met.

3 Ensure that all bolts, nuts, washers, and Direct Tension Indicators (DTI) are marked according to the appropriate ASTM specifications.

4 Use galvanized bolts, nuts, washers, and DTIs where steel is to be painted. Use non-galvanized bolts, nuts, washers, and DTIs where steel is not to be painted.

709.2.4.2 Bolts

1 Provide bolts meeting ASTM F3125, Grade A325. Mechanically galvanize Type 1 bolts according to ASTM B695, Class 50. Use non-galvanized Type 3 bolts where steel is not to be painted.

709.2.4.3 Nuts

1 Furnish nuts meeting ASTM A563, Grade DH or DH3 as specified. Ensure that Grade DH nuts are mechanically galvanized according to ASTM B695, Class 50.

Ensure that plain nuts for Type 3 bolts are Grade DH3.

Division 700 Section 709 700-102

2 Provide galvanized nuts tapped oversize the minimum amount required for proper assembly. Ensure that the amount of over-tap in the nut allows the nut to assemble freely on the bolt in the coated condition and meets the mechanical requirements of ASTM A563 and the rotational-capacity tests SC-T-150 and

SC-T-151.

3 Provide all nuts with an additional lubricant that is clean and dry to the touch.

Ensure that the lubricant has a color that contrasts with the zinc coating of galvanized nuts.

709.2.4.4 Washers

1 Provide washers that meet ASTM F436 as revised by these specifications.

2 Mechanically galvanize washers for Type 1 bolts according to ASTM B695, Class 50. Use non-galvanized weathering steel washers for Type 3 bolts having equal or better corrosion resistance than the Type 3 bolts.

709.2.4.5 Direct Tension Indicators (DTIs)

1 Furnish DTIs complying with ASTM F959.

2 Mechanically galvanize the DTIs for Type 1 bolts according to ASTM B695, Class 50. Use non-galvanized weathering steel DTIs for Type 3 bolts having equal or better corrosion resistance than the Type 3 bolts.

709.2.4.6 Testing High Strength Bolt Assemblies

709.2.4.6.1 Bolts

1 Perform proof load tests according to ASTM F606, Method 1.

2 Perform wedge tests according to ASTM F606 on full size bolts. Perform tests after galvanizing. Perform testing at the minimum frequency specified in ASTM F3125, Grade A325.

3 Measure the thickness of the zinc coating on the wrench flats or top of the bolt head.

709.2.4.6.2 Nuts

1 Perform proof load tests according to ASTM F606. Perform testing at the minimum frequency specified in ASTM A563. Perform tests after galvanizing and lubricating.

2 Measure the thickness of the zinc coating on the wrench flats of the nut.

Division 700 Section 709 700-103

709.2.4.6.3 Washers

1 Perform hardness testing after galvanizing. Remove coating before taking hardness measurements.

2 Measure the thickness of the zinc coating.

709.2.4.6.4 Direct Tension Indicators (DTIs)

1 Test the DTIs according to SC-T-152, and ensure that the results comply with the Department’s specifications.

709.2.4.6.5 Assembly and Verification

1 Perform the rotational-capacity (R/C) test according to Subsection 709.3.3.10 for long bolts and/or Subsection 709.3.3.11 for bolts too short to be tested in a tension measuring device (TMD). Perform rotational-capacity tests on all structural fastener assemblies before shipping by the manufacturer or distributor.

Test galvanized assemblies after galvanizing.

2 Perform the rotational-capacity test on 2 assemblies of each possible combination bolt, nut, and washer production LOT. Assign a rotational-capacity LOT number to each combination of LOTs tested.

3 Ensure that the tension for the long bolts at the completion of the required rotation is equal to or greater than 1.15 times the required installation tension.

The installation tension and the tension for the turn tests are shown in the following table.

Minimum Installation Tension and Turn Test Tension for ASTM F3125, Grade 325 Bolts Bolt Diameter (inches) ½ ⅝ ¾ ⅞ 1 1⅛ 1¼ 1⅜ 1½ Minimum Installation Tension* 12 19 28 39 51 64 81 97 118 Minimum Turn Test Tension** 14 22 32 45 59 74 94 112 136

* Installation tension equals 70% × Min. Tensile Strength in kips.

** Turn test tension equals 1.15 × 70% × Min. Tensile Strength in kips.

4 Ensure that the measured torque is as follows:

Torque ≤ 0.25 × P × D

Where:

Torque = Measured torque (foot pounds) P = Turn test tension (pounds) D = Bolt diameters (feet) Division 700 Section 709 700-104

5 For test bolts that are too short for testing in a TDM, test in a steel joint. The tension requirement of paragraph 3 above need not apply.

6 Failure of any portion of the rotational-capacity (R/C) test for either of the two sample assemblies tested constitutes failure of the R/C LOT.

709.2.4.6.6 Reporting

1 Ensure that the manufacturer or distributor provides a record of the results of all tests (including the zinc coating thickness) required herein and in the appropriate ASTM specification on the appropriate document.

2 Report the location where tests are performed and date of tests on the appropriate document.

709.2.4.6.7 Witnessing

1 Ensure that the manufacturer or distributor that performs the tests certifies that the results reported are accurate.

709.2.4.6.8 Documentation

709.2.4.6.8.1 Mill Test Report (MTR)

1 Furnish MTRs for all mill steel used in the manufacture of the bolts, nuts, and washers. Ensure that each MTR indicates the place where the material has been melted and manufactured.

709.2.4.6.8.2 Manufacturer Certified Test Report (MCTR)

1 Ensure that the manufacturer of the bolts, nuts, and washers furnishes a MCTR for the items furnished. Ensure that the MCTR shows the relevant information required according to Subsection 709.2.4.6.6.

2 Ensure that the manufacturer performing the rotational-capacity test includes the following information on the MCTR:

• LOT number of each of the items tested;

• Rotational-capacity LOT number as required in paragraph 2 of

Subsection 709.2.4.6.5; and

• Results of the test required in Subsection 709.2.4.6.5, if performed by the manufacturer.

3 Provide a MCTR that certifies that the furnished DTIs meet Department specifications.

Division 700 Section 709 700-105

709.2.4.6.8.3 Distributor Certified Test Report (DCTR)

1 Include the MCTR for the various bolt assembly components in the DCTR.

Include in the DCTR the rotational-capacity test results if performed by a distributor instead of a manufacturer. Ensure that the DCTR certifies that the MCTRs conform to this specification and the appropriate ASTM specifications.

709.2.4.6.9 Shipping

709.2.4.6.9.1 Marking

1 Permanently mark on the side of each container the rotational-capacity LOT number such that identification is possible at any stage before installation.

709.2.4.6.9.2 Documentation

1 Supply the appropriate MTR, MCTR, or DCTR to the RCE or OMR.

709.2.5 Low Carbon Unfinished Turned and Ribbed Bolts

709.2.5.1 General

1 The requirements of this Subsection do not pertain to high-strength bolts.

2 For other than high strength bolts, provide bolts, nuts, and washers meeting ASTM A307, Grade A. Provide bolts with single self-locking nuts or double nuts.

Use beveled washers where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis.

709.2.5.2 Unfinished Bolts

1 Provide unfinished bolts unless other types are specified.

709.2.5.3 Turned Bolts

1 Ensure that the surface of the body of turned bolts meets the ANSI roughness rating value of 125. Furnish bolts with hexagonal heads and nuts with standard dimensions of the nominal size specified or the next larger nominal size. Ensure that the diameter of threads is equal to the body of the bolt or the nominal diameter of the bolt specified.

709.2.5.4 Ribbed Bolts

1 Provide ribbed bolts with a body of an approved form with continuous longitudinal ribs and with the diameter of the body measured on a circle through the points of the ribs that is 5/64 in. greater than the nominal diameter specified for the bolts.

Division 700 Section 709 700-106

2 Furnish ribbed bolts with round heads conforming to ANSI B18.5. Provide nuts that are hexagonal, either recessed or with a washer of suitable thickness.

Ensure that ribbed bolts make a driving fit with the holes. Ensure that the hardness of the ribs is such that the ribs do not deform to permit the bolts to turn in the holes during tightening.

709.2.6 Miscellaneous Metals

1 Provide steel forgings meeting AASHTO M 102 (ASTM A668), Class C, D, F, and G.

2 Furnish steel castings meeting AASHTO M 103 (ASTM A27) as designated on the Plans.

3 Provide iron castings meeting AASHTO M 105, Class No. 30B. Ensure that the test bars are Type B and are made and tested according to AASHTO M 105.

4 Furnish malleable castings meeting ASTM A47, Grade 35018.

5 Provide bronze castings meeting ASTM B22, Alloy C91100 or C91300.

6 Furnish other miscellaneous metals conforming to the AASHTO LRFD Bridge Design Specifications.

7 Furnish a certification for the above listed metals stating that the materials meet all SCDOT specifications. Ensure that the certification indicates the project SC File No. and the number of pieces being furnished.

709.2.7 Elastomeric Bearing Pads

1 Furnish elastomeric bearing pads as specified in Section 724.

709.2.8 Paint

1 Provide the paint and paint system as specified in Section 710.

709.3 Construction

709.3.1 Shop Fabrication

709.3.1.1 General

1 Generally, shop weld structural members and field bolt structural members.

2 Provide the falsework and all tools, machinery, and appliances, including drift pins and fitting-up bolts, necessary for the expeditious handling of the work.

Division 700 Section 709 700-107

709.3.1.2 Notice of Beginning of Work

1 Provide the OMR ample notice (14 days minimum) before beginning work at the fabrication shop and in the rolling mill or foundry when specified so that inspection may be conducted. Do not perform any work before the OMR has been notified and the inspection is completed.

709.3.1.3 Quality of Workmanship

1 Provide workmanship and finish equal to the best general practice in modern bridge shops. Neatly finish portions of the work exposed to view. Perform shearing, flame cutting, and chipping carefully and accurately.

2 Ensure that all structural steel fabrication is performed by a fabricator certified according to the American Institute of Steel Construction (AISC) Quality Certification Program for the category of work required.

709.3.1.4 Storage of Materials

1 Store structural materials, both plain and fabricated, at the fabricating shop above the ground and on platforms, skids, or other supports. Keep materials free of dirt, grease, and other foreign matter, and protect as practical from corrosion.

709.3.1.5 Facilities for Inspection

1 Furnish facilities for the inspection of material and workmanship in the mill and shop, and allow the Department's inspectors free access to all parts of the work.

709.3.1.6 Inspector’s Authority

1 The Department's inspectors have the authority to reject any materials or work that does not meet the requirements of the Contract. In case of dispute, the Contractor may appeal to the BCE. The acceptance of any material or finished members by the Department’s representative does not preclude their subsequent rejection, if found defective. Materials and workmanship, whether previously inspected or not, will be inspected after its delivery to the site of the work or after being erected in the structure. Promptly replace or make satisfactory rejected material or workmanship at no additional cost to the Department.

709.3.1.7 Mill Test Reports and Shipping Statements

1 Furnish the OMR with complete, certified mill test reports showing the chemical analysis and the physical tests for each heat of steel for all members. Furnish the OMR with shipping statements.

Division 700 Section 709 700-108

709.3.1.8 Identification of Steel during Fabrication

1 Properly identify each piece of steel to be fabricated to the Department’s inspector. Before cutting pieces of steel into smaller pieces, legibly mark each smaller piece with the heat number and piece mark. Individually marked pieces of steel, which are used in furnished size or are reduced from furnished size only by end or edge trim, may be used without additional identification if the original heat number is legible.

2 The Contractor may furnish from stock material that can be identified by heat number and mill test report. When separated from the full size piece furnished by the supplier, mark any excess materials placed in stock for later use with the project SCDOT File No., the MTR number, and the AASHTO/ASTM specification identification.

709.3.1.9 Straightening Material

1 If straightening is required, use Department approved methods that do not damage the metal. If heat is applied, do not allow the maximum temperature of the steel to exceed 1100ºF. Sharp kinks and bends are cause for rejection of the material.

709.3.1.10 Flame Cutting

1 Ensure that flame cutting of structural steel conforms to the AASHTO/AWS D1.5, Bridge Welding Code.

709.3.1.11 Edge Planing

1 Plane, mill, grind, or thermal cut to a depth of ¼ in. the sheared edges of plates more than ⅝ in. in thickness and which carry calculated stress.

709.3.1.12 Fit of Stiffeners

1 Ensure that end stiffeners of girders and stiffeners intended as supports for concentrated loads have full bearing on the flanges to which they transmit load or from which they receive load. Obtain full bearing by milling, grinding, or welding as shown on the Plans. Ensure that stiffeners not intended to transfer load, unless shown or specified otherwise, fit sufficiently tight to exclude water after being painted.

709.3.1.13 Flange Bearing Area

1 Ensure that flange surfaces bearing on sole plates conform to the tolerances specified in the AASHTO/AWS D1.5, Bridge Welding Code. In addition, do not allow the remaining contact area between the flange and sole plate to deviate more than 1/16 in. from a plane measured perpendicular to the web. Ensure Division 700 Section 709 700-109 that the field fit-up of the flange to the sole plate does not produce a gap exceeding ⅛ in. Correct gaps exceeding ⅛ in. in fit-up by a method approved by the BCE before welding the flange to the sole plate.

709.3.1.14 Abutting Joints

1 Face and bring to even bearing abutting joints in compression members designed to transfer stress. Where joints are not required elsewhere to be faced or brought to even bearing, do not allow the opening to exceed ¼ in.

709.3.1.15 End Connection Angles

1 Build floor beams, stringers, and girders having end connection angles to the exact length back to back of connection angles. If end connections are faced, do not allow the finished thickness of the angles to be less than that shown on the detailed drawings.

709.3.1.16 Web Splices

1 At bolted web splices, cut the ends of the beams or girders and grind smooth.

During shop assembly, do not allow the clearance between the ends of the members (web and flanges) to exceed ¼ in., +⅛ in., -3/16 in.

709.3.1.17 Bent Plates

1 Obtain unwelded, cold-bent, load-carrying, rolled-steel plates from the stock plates.

2 Ensure that bending does not cause cracking of the plate. Do not use less than the minimum bend radii, measured to the concave face of the metal. Satisfy the following requirements (where t is the plate thickness):

• Where the bend lines are oriented perpendicular to the direction of final rolling, use 5.0t.

• Where the bend lines are oriented parallel to the direction of final rolling, use 7.5t.

• For cross frame and diaphragm connection plates up to ¾ in., use 1.5t.

3 For break press forming, ensure that the lower die span is at least 16 times the plate thickness. Multiple hits are advisable.

4 If a shorter radius is essential, hot bend the plates at a temperature not greater than 1100ºF. Reject plates from all ASTM or AASHTO designations inadvertently heated above 1100ºF, or re-quench and re-temper the plates using the correct ASTM procedures.

Division 700 Section 709 700-110

5 Before bending, round the corners of the plate to a radius of 1/16 in. throughout the portion of the plate at which the bending will occur.

709.3.1.18 Camber

1 Furnish to the OMR a camber diagram prepared by the fabricator, showing the camber at each panel point for trusses or arch ribs, and at the location of field splices and fractions of span length (¼ points minimum, 1/10 points maximum) for continuous beams and girders or rigid frames. When the shop assembly is full truss or girder assembly or special complete structure assembly, ensure that the camber diagram shows the camber measured in the assembly. When any of the other methods of shop assembly is used, ensure that the camber diagram shows the calculated camber.

2 Camber girders before heat curving. Camber for rolled beams may be obtained by heat-cambering methods approved by the OMR. Camber girders and rolled beams according to the camber diagram as shown in the Plans. Camber for rolled beams may be obtained by heat cambering methods or by cold bending with hydraulic rams. Moderate deviations from the specified camber may be corrected by a carefully supervised application of heat when approved by the OMR. Ensure that horizontal heat curving does not change the vertical camber.

This effect may be more pronounced when the top and bottom flanges are of unequal width on a given transverse cross section.

709.3.1.19 Shop Assembly

709.3.1.19.1 General

1 Clean metal contact surfaces before assembling. Assemble the field connections of main members of arches, continuous beam spans, bents, towers (each face), plate girders, and rigid frames in the shop with milled ends of compression members in full bearing, and ream the sub-size holes to the specified size while the connections are assembled.

2 Ensure that each assembly, including camber, alignment, accuracy of holes, and fit of milled joints, is approved by the Department’s inspector before commencing reaming or before a computer numerically controlled (CNC) drilled check assembly is dismantled.

709.3.1.19.2 Progressive Truss or Girder Assembly

1 Unless otherwise specified, use progressive girder assembly. Ensure that the assembly contains at least one “carry over” longitudinal segment of the previous assembly, repositioned for accurate alignment (i.e., providing the advancing assembly the proper relative rotation, horizontal, and vertical position) plus one or more longitudinal segments at the advancing end. For entire structures with lengths up to 150 ft, assemble the entire line. The sequence of assembly may Division 700 Section 709 700-111 start from any location in the structure provided that the preceding requirements are satisfied. For structures longer than 150 ft, ensure that each assembly is not less than 150 ft long regardless of the length of individual continuous panels or sections.

709.3.1.19.3 Check Assemblies with Computer Numerically

Controlled (CNC) Drilled Field Connections 1 When using CNC drilling with progressive assembly, produce a check assembly for each major structural type of each project, unless otherwise specified.

2 Base check assemblies on the proposed order of erection, joints in bearings, special complex points, and similar considerations.

3 Ensure that each check assembly is the first section of each major structural type to be fabricated, unless otherwise agreed to by the Department’s shop inspector.

4 No shop assemblies other than the check assemblies are required.

5 If the check assembly fails to demonstrate that the required accuracy is being obtained, further check of the assemblies may be required by the Department’s shop inspector at no additional cost to the Department.

709.3.1.20 Match Marking

1 Match-mark connecting parts assembled in the shop for reaming holes in field connections, and furnish a diagram identifying the marks to the Department’s shop inspector.

709.3.1.21 Finished Members at Fabrication Shop

1 Ensure that finished members are true to line and free from twists, bends, and open joints. For box member dimensional tolerance issues, including twists, contact the BCE for guidance.

709.3.1.22 Weighing Members

1 When specified that any part of the material is paid for by actual weight, weigh the finished work in the presence of the Department’s inspector. In this case, supply satisfactory scales and perform all work involved in handling and weighing the various parts.

709.3.1.23 Marking and Shipping

1 Paint or mark each member with an erection mark for identification, and furnish an erection diagram with erection marks shown thereon.

Division 700 Section 709 700-112

2 Furnish material orders, shipping statements, and erection diagrams as requested by the OMR. Provide the weights of the individual members on the statements. Mark the weight on members weighing more than 3 tons.

3 Load structural members on trucks or cars so that the members may be transported and unloaded at their destination without being excessively stressed, deformed, or otherwise damaged.

4 Pack bolts of one length and diameter and loose nuts or washers of each size separately. Protect all hardware from damage in transit. Post a plainly marked list and description of the contained material on the outside of each shipping container.

709.3.2 Structural Welding

709.3.2.1 General

1 Ensure that the welding of steel structures and all subsequent references to welding conform to AASHTO/AWS D1.5, Bridge Welding Code, the Plans, and the Special Provisions. In addition, adhere to the provisions of Subsection 709.3.2.2 through 709.3.2.6.

709.3.2.2 Preheat and Interpass Temperatures

1 Obtain the pre-heat and interpass temperatures required for welding structural steel as specified in the AASHTO/AWS D1.5, Bridge Welding Code.

709.3.2.3 Restricted Welded Processes

1 Do not use gas metal arc and flux cored arc welding without written approval of the OMR. If authorization is granted, perform the procedure and provide operator qualifications according to the AASHTO/AWS D1.5, Bridge Welding Code. Do not use electro-slag and electro-gas.

709.3.2.4 Welding Shear Studs

1 Weld shear connector studs conforming to the AASHTO/AWS D1.5, Bridge Welding Code.

2 Do not allow longitudinal and lateral spacing of studs with respect to each other and to the edges of beam or girder flanges to vary by more than ½ in. from the dimensions shown on the Plans. Spacing may vary by up to 1 in. to avoid conflicts with other attachments on the flange or where a new stud is being welded to replace a defective one.

3 After welding, ensure that the studs are free from any defect or substance that may interfere with their function as shear connectors.

Division 700 Section 709 700-113

709.3.2.5 Field Welding

709.3.2.5.1 General

1 Consider all field welding as structural welding, except for the welding of reinforced pile tips, temporary falsework (unless specified), SIP formwork, armor plate at bridge ends, and armor plate at expansion joints. Ensure that personnel performing the structural welding of structural steel, steel reinforcement, steel pile splices, and other types of field structural welds are SCDOT-certified welders and are qualified to perform structural welding according to the qualification procedures of the AASHTO/AWS D1.5, Bridge Welding Code modified as follows:

A. A welder or tacker (hereafter known as “welder”) may be qualified by preparing test specimens in the 2G position (horizontal groove) for limited thickness groove welding and in the 2F position (horizontal fillet) for fillet welding as a minimum.

B. The above testing is a minimum and will qualify the welder for field welding at the job site. The welder may choose to qualify for additional positions and unlimited metal thickness as part of the above testing.

Specialized welding and welding positions at the job site may require additional welder qualification testing if required by the Department.

C. Ensure that testing is administered by an independent laboratory listed on Qualified Products List 26. Prepare the test specimens in the presence of, and test and evaluate the specimens by, an OMR authorized independent laboratory person qualified as a Welding Inspector. Perform radiographic, non-destructive testing by an ASNT Level II or III technician. Have the independent laboratory furnish a welder qualification test report on company letterhead stationery stating the type of welding approved and the name of the welder and a statement that the welder is duly qualified as a field welder according to the SCDOT requirements. Ensure that the report shows the name of the independent laboratory technician(s) making the evaluation and that the report is signed by the independent laboratory manager. Submit a copy of the report to the OMR.

D. The welder will be given a SCDOT certification valid for 2 years and renewable every 2 years if the welder has been engaged in welding procedures during the preceding 2-year period. The list of certified structural steel field welders are included in Qualified Products List 41.

709.3.2.5.2 Submittals and Notifications

1 Notify the RCE and the SME at least 14 days before performing any field welding of any items incorporated into the structure by completing Form 700.16 (SCDOT Welding Procedure Specification) and submitting the form to the RCE Division 700 Section 709 700-114 and the SME. The Department’s review and acceptance are required before any field welding will be permitted. Submit to the RCE and OMR for review and acceptance a Structural Field Welding Quality Control (QC) Plan for all structural field welding a minimum of 30 days before performing any field welding. Ensure that the Plan conforms to the AASHTO/AWS D1.5, Bridge Welding Code. Do not perform any structural field welding before the Department’s review and acceptance of the Structural Field Welding QC Plan.

2 Within 14 days after receipt of the QC Plan, the Contractor will be notified of QC Plan acceptance or any additional information required and/or changes that may be necessary to meet the requirements of the Plans and Specifications. If any parts of the QC Plan are unacceptable and rejected, resubmit the changes for re-evaluation. The Contractor will be notified of their acceptance or rejection within 7 days after receipt of the proposed changes.

3 Coordinate and schedule structural field welding with the Department’s inspector or Department authorized inspection agency’s inspector a minimum of 14 days before welding. The inspector may be present any time the Contractor performs structural field welding. The inspector will perform the Department’s Quality Assurance (QA) nondestructive testing.

709.3.2.6 Inspection of Welds

709.3.2.6.1 General

1 Ensure that the structural steel fabrication and construction assembly, including all shop and field welding, is performed according to the AASHTO/AWS D1.5, Bridge Welding Code except as noted herein. Fabrication and welding quality assurance (QA) inspection in the fabricating shops will be performed by the Department's representative, either an OMR inspector or an inspector from a commercial testing laboratory acting for the Department.

709.3.2.6.2 Nondestructive Testing of Welds and Metals

1 Perform radiographic, ultrasonic, magnetic particle, and dye penetrant testing of welds conforming to the AASHTO/AWS D1.5, Bridge Welding Code with the following exceptions:

A. Test all girder flange butt welds radiographically, whether in tension or compression.

B. Interpret Quality Assurance (QA) and Quality Control (QC) nondestructive testing as referenced in AASHTO and AWS as follows:

QA nondestructive testing required by the Contract Documents will be performed by the Department's inspector or authorized inspection agency's inspector acting for the Department. At the discretion of the Department's inspector or authorized representative, QC nondestructive Division 700 Section 709 700-115 testing performed by the Contractor in the presence of the Department's inspector may be used to satisfy like nondestructive testing requirement(s) specified for QA. The observing inspector will maintain test result records of the work performed.

2 The cost of the QC nondestructive testing is borne by the Contractor regardless of the Department's acceptance for QA testing. The cost of Department-performed QA testing will be borne by the Department.

3 The cost of re-testing repaired welds is borne by the Contractor.

709.3.2.6.3 Inspection of Welded Studs

1 After welding the first 2 studs on the flange and after the material is allowed to cool, strike with a hammer and bend to 45 degrees off the vertical. If failure occurs in the weld of either stud, correct the welding procedure, then weld and successfully test 2 successive studs before any more studs are welded to the beam or girder. Promptly inform the SME of any changes in the welding procedure.

2 When the temperature of the base metal is below 32°F, test 1 stud in each 100 studs welded in addition to the first 2 specified above.

3 If visual inspection reveals a stud that does not show a full 360-degree weld, or has been repaired by welding, or has had a reduction in height (due to welding) less than normal, test the stud by striking with a hammer and bending 15 degrees off the vertical. For studs showing less than a 360-degree weld, bend in the direction opposite to the lack of weld. Replace studs that crack in either the weld or the shank.

4 After welding, select 10 studs at random along each beam or girder or 10% of the studs along other structural members. Hammer these studs 30 degrees out of line. Ensure that none of the test studs shows any signs of failure.

5 If any of the studs fail, then hammer all studs on the member (but not necessarily bent to the full 30 degrees) and replace all that fail. Before replacing the stud, grind the area free of any metal left from the old weld or, for a pocket, fill with E-7018 weld metal and grind flush.

6 In addition to the above test, if any of the studs in any group of studs checked show the need for additional all-around welding due to faulty operation of the welding gun, remove all studs in the group as required in the paragraph above and replace.

7 The studs tested that show no sign of failure may remain in the bent position.

8 If during the progress of the work, inspection and testing indicates, as determined by the Department’s representative, that the shear connections being obtained are not satisfactory, make the required changes in the welding Division 700 Section 709 700-116 procedure, welding equipment, and type of shear connector as necessary to secure satisfactory results at no additional cost to the Department.

709.3.3 Bolted Connections

709.3.3.1 Bolt Holes

709.3.3.1.1 Bolt Holes for High Strength Bolts

1 Punch or drill holes for high strength bolts. Unless sub-punching and reaming are required under Subsection 709.3.3.7, material forming parts of a member composed of not more than five pieces of metal may be punched 1/16 in. larger than the nominal diameter of the bolts when the thickness of any of the pieces is not greater than ¾ in. for structural steel, ⅝ in. for high-strength steel, or ½ in.

for quenched and tempered alloy steel.

2 When there are more than 5 pieces of metal or when any of the main material is thicker than ¾ in. for structural steel, ⅝ in. for high-strength steel, or ½ in. for quenched and tempered alloy steel, either sub-drill or drill full-size holes.

3 When required under Subsection 709.3.3.7, sub-punch or sub-drill (sub-drilled if thickness limitation governs) all holes 3/16 in. smaller and, after assembling, reamed 1/16 in. larger or drilled full size to 1/16 in. larger than the nominal diameter of the bolts.

4 When permitted by the BCE, enlarged or slotted holes are allowed with high-strength bolts.

709.3.3.1.2 Holes for Ribbed Bolts, Turned Bolts, or other

Approved Bearing Type Bolts 1 For holes for ribbed bolts, turned bolts, or other approved bearing-type bolts, sub-punch or sub-drill 3/16 in. smaller than the nominal diameter of the bolt and ream. Assemble or drill with a steel template or, after assembling, drill from the solid at the option of the fabricator. Provide a driving fit in the finished holes as specified.

709.3.3.2 Punched Holes

1 Do not use a die with a diameter more than 1/16 in. greater than the diameter of the punch. Ream any holes that must be enlarged to admit the bolts. Clean out holes and ensure that there are no torn or ragged edges. Poor matching of holes is cause for rejection.

709.3.3.3 Reamed or Drilled Holes

1 Ensure that reamed or drilled holes are cylindrical, perpendicular to the member, and comply with Subsection 709.3.3.1 as to size. Where practical, direct Division 700 Section 709 700-117 reamers by mechanical means. Poor matching of holes will be cause for rejection. Perform reaming and drilling with twist drills.

2 Assemble and securely hold the connecting parts that require reamed or drilled holes while being reamed or drilled, and match-mark before disassembling.

3 Remove burrs on the outside surfaces. If required by the Department’s shop inspector, take apart assembled parts for removal of burrs caused by drilling.

709.3.3.4 Accuracy of Punched, Sub-punched or Sub-drilled

Holes 1 Ensure that holes punched full-size, sub-punched, or sub-drilled are accurately punched, so that, after assembling (before any reaming is done), a cylindrical pin, ⅛ in. smaller in diameter than the nominal size of the punched hole can be entered perpendicular to the face of the member, without drifting, in at least 75% of the contiguous holes in the same plane. If this requirement is not fulfilled, inaccurately punched pieces will be rejected. If any hole will not pass a pin, 3/16 in. smaller in diameter than the nominal size of the punched hole, this will be cause for rejection.

709.3.3.5 Accuracy of Reamed and Drilled Holes

1 When holes are reamed or drilled, ensure that, after reaming or drilling, 85% of the holes in any contiguous group demonstrate no offset greater than 1/32 in.

between adjacent thicknesses of metal.

2 Ensure that steel templates have hardened steel bushings in holes accurately dimensioned from the centerlines of the connection as inscribed on the template.

Use the centerlines to accurately locate the template from the milled or scribed ends of the members.

709.3.3.6 Preparation of Field Connections

1 Unless otherwise specified in the Special Provisions or on the Plans, sub-punch holes (or sub-drill if sub-drilling is required according to Subsection 709.3.3) in field connections and field splices of main members of continuous beam spans and plate girders, and subsequently ream while assembled onto a steel template, as required by Subsection 709.3.1.19. 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.

2 Sub-punch and ream holes for floor beams and stringer field end connections to a steel template or ream while assembled. Perform reaming or drilling full size field connection holes through a steel template after the template has been located accurately as to position and angle and firmly bolted in place. Ensure that the templates used for reaming matching members, or the opposite faces of a single member, are exact duplicates. Ensure that templates used for Division 700 Section 709 700-118 connections on like parts or members are accurately located so that the parts or members are duplicates and require no match-marking.

3 Unless otherwise authorized by the Department’s shop inspector, assemble the adjacent panels or sections of each individual truss, arch, continuous beam, or girder in the shop before reaming or full drilling is commenced. Block up and set the parts that make up the joint to be reamed or drilled to the exact relative position and grade that such parts will be in the completed bridge, and fasten the parts securely in position before and during the reaming or drilling of the holes in the joint.

4 For any connection, instead of sub-punching and reaming or sub-drilling and reaming, the fabricator may drill holes full size with all thickness or material assembled in proper position.

5 Perform additional sub-punching and reaming as specified.

6 For any connection or splice designated above, in lieu of sub-sized holes and reaming while assembled or drilling holes full-size while assembled, the fabricator may drill or punch holes full-size in unassembled pieces and/or connections including templates for use with matching sub-sized and reamed holes using suitable CNC drilling or punching equipment, subject to the specific provisions contained in this Subsection. Ensure that full-size punched holes meet Subsection 709.3.3.1.

7 Unless otherwise specified in the Special Provisions or on the Plans, when CNC drilling or punching equipment is used, the SME may require that the Contractor, by means of check assemblies, demonstrate that the drilling or punching procedure consistently produces holes and connections meeting Subsections 709.3.3.5 and 709.3.1.19.

8 Submit to the SME for approval a detailed outline of the procedure to accomplish the work from initial drilling or punching through check assembly, if required.

Include in the outline the specific members of the structure that will be CNC drilled or punched, the sizes of the holes, the location of common index and other reference points, composition of check assemblies, and all other pertinent information.

9 Drill or punch holes with CNC equipment to the appropriate size through individual pieces or through any combination of pieces held tightly together.

709.3.3.7 Fitting for Bolting

1 Clean contact surfaces of metal before assembling. Ensure that the parts of a member are assembled, well pinned, and firmly drawn together before drilling, reaming, or bolting is commenced. Take apart assembled pieces, if necessary, for the removal of burrs and shavings produced by the operation. Ensure that the members are free from twists, bends, and other deformations.

Division 700 Section 709 700-119

2 Perform drifting during assembling only to bring the parts into position without causing holes to enlarge or metal to distort.

709.3.3.8 Installation of High Strength Bolts

1 The following requirements apply to the installation of high strength bolts installed in the shop or field.

2 Install bolt, nut, and washer combinations from a LOT represented by an accepted rotational-capacity test as certified by the manufacturer or distributor.

Install structural bolts with a DTI on each assembly to verify proper tensioning.

3 Assemble fastener components of appropriately assigned rotational-capacity test LOT numbers together. Store assembled fasteners in buildings or similar enclosures to protect the fasteners from dirt and moisture at the job site. Take only as many fasteners as are anticipated to be installed and tightened during a work shift from protected storage. Protect fasteners not used and return them to storage at the end of the shift. Do not remove lubricant from fasteners that is required to be present in as-delivered condition. Clean, re-lubricate, and retest before installing fasteners for slip-critical connections that accumulate rust or dirt resulting from job site conditions.

4 Perform the rotational-capacity test as required in Subsection 709.3.3.10 or

709.3.3.11 on each rotational-capacity LOT before the start of bolt installation.

Perform the rotational-capacity tests in the shop or field on the LOTs as shipped to the job site with certifications by the manufacturer or distributor. Test 2 assemblies consisting of a nut, bolt, and washer from each LOT. Provide hardened steel washers as part of the test. Reject fastener assemblies that fail any part of the rotational-capacity test.

5 Provide a TMD and a dial type torque wrench of suitable range at each job site during the erection of structural steel.

6 Conduct periodic re-testing as directed by the RCE to confirm that storage has not reduced the effectiveness of the lubricant on the material.

7 Provide the galvanized nuts with a lubricant containing a visible dye. When the bolt head is the turned element in the assembly, apply a manufacturer recommended lubricant to the washer face of the bolt or to the washer. Use lubricant waxes such as bee’s wax or stick waxes for use on metal. Water/wax emulsions for use on fasteners may also be used. Apply the waxes by dipping the nuts or, when necessary, the washers in the water/wax emulsion or warmed bee’s wax or stick wax. Remove the nuts and washers from the wax, allow the excess wax to drain and cool as necessary, and place the hardware back into protected storage until they are needed for installation.

8 Perform installation verification tests for each possible rotational-capacity LOT in combination with each LOT of DTIs. Perform the installation verification test according to the procedures in this Subsection.

Division 700 Section 709 700-120

9 During installation, regardless of the tightening method used, ensure that the snug tight condition is achieved. Snug tight is defined as the tightness that exists when the plies of the joint are in firm contact. Provide hardened washers under the turned element for all installation methods.

10 Conduct periodic retesting as directed by the RCE to confirm that storage has not reduced the effectiveness of the lubricant. Ensure that the retesting is witnessed by the Department’s representative. Reject any LOT with failing assemblies.

11 Check galvanized nuts to verify that a visible lubricant is on the threads. When the bolt head is the turned element in assembly, add a lubricant approved by the Department to the washer face under the bolt head or to the washer.

12 Reject bolts or nuts not satisfying the requirements above. Reject bolts, nuts, or washers that are weathered, rusty, or dirty. Submit for approval a procedure for cleaning and re-lubricating rejected fastener LOTs. Retest recleaned or relubricated bolt, nut, and washer assemblies before installation.

709.3.3.9 Procedures for Verification and Installation of High Strength Bolt DTIs

709.3.3.9.1 Verification of DTI Performance

1 Verify DTI performance according to SC-T-152 before installation of bolts in the work. In bridge work, the manufacturers typically specify smaller gaps in the space between the protrusions on the washer than is normally used in other construction or than is specified for testing in the product specification ASTM F959. The basic principle used in this verification test is to ensure that there is a DTI gap when the test tension is 1.05 times greater than the job installation tension requirement. Test 3 bolts from each rotational-capacity LOT and position of DTI.

709.3.3.9.2 Test Equipment

1 Use equipment for DTI verification and testing as outlined in SC-T-152.

709.3.3.9.3 Verification Test Procedure

1 Perform the DTI verification test procedure according to SC-T-152.

2 The DTI fails the verification test if the 0.005-in. feeler gauge is refused in half or more of the gaps during the test procedure.

3 The DTI and assembly pass the test if the nut on the bolt assembly is unable to turn the full length of the threads of the bolt at the completion of SC-T-152, and the load at the minimum DTI gap is less than 95% of the bolt tension recorded at the nut rotation required in SC-T-150 for the rotational-capacity test. If the nut Division 700 Section 709 700-121 cannot be run the full thread length, but the load at the smallest gap condition is greater than the 95% of the bolt tension recorded at the nut rotation required for the rotational-capacity test, the load required for the smallest gap is too large.

Reject the LOT if this occurs.

4 Test bolts from rotational-capacity LOTs that are too short to fit in the tension measuring device according to SC-T-151 by tightening to the minimum DTI gap measured and check according to paragraph 3 above. Do not use the 95% alternative because short bolts are not tested in the tension-measuring device for rotational capacity. Check the DTI used with the short bolt according to SC-T-152 using a longer bolt in the tension measuring device.

709.3.3.9.4 Installation of DTI

1 The use of a DTI under the unturned bolt head requires that the element bearing against the DTI does not turn. Use two workers to install the DTI: one to operate the wrench and the other to prevent turning of the element with the DTI and to monitor the gap. If the DTI is used under the turned element, provide an additional hardened washer between the turning element and the protrusion on the DTI.

2 Tighten the bolts systematically to the inspection gap. For uncoated DTIs used under a stationary or turned element and for coated DTIs used under a stationary element, further tension the bolts until the number of refusals of the 0.005-in.

feeler gauge is equal to or greater than the number shown in the following table.

For coated DTIs used under a turned element, ensure that the 0.005-in. feeler gauge is refused in all spaces. If the bolt is tensioned so that no visible gap in any space remains, remove the bolt and DTI and replace with a new properly tensioned bolt and DTI.

Inspection Criteria Number of spaces in washers 4 5 6 7 8 9 Minimum spaces gauge is refused* 2 3 3 4 4 5

* Refuse the gauge in all spaces when a coated DTI is used under the turned element.

709.3.3.10 Procedure for Performing Rotational Capacity Test

(Long Bolts in TMD) 1 Perform the rotational-capacity (R/C) test on the long bolts meeting ASTM F3125, Grade A325 according to the testing procedure in SC-T-150.

Division 700 Section 709 700-122

2 Ensure that the measured bolt tension is equal to or greater than the values shown in the following table. Assemblies that do not meet this tension fail the test (value is 115% of minimum installation tension).

Turn Test Bolt Tension Bolt Diameter

(inches) ½ ⅝ ¾ ⅞ 1 1⅛ 1¼ 1⅜ 1½ Tension (kips) 14 22 32 45 59 74 94 112 136 3 Assemblies that have evidence of stripping fail the test.

4 Ensure that the measured torque is as follows:

Torque ≤ 0.25 × P × D

Where:

Torque = Measured torque (foot pounds) P = Turn test tension (pounds) D = Bolt diameters (feet) Assemblies with torque values exceeding this calculated value fail the test.

709.3.3.11 Procedure for Performing Rotational Capacity Test on Bolts Too Short to Fit TMD 1 Perform the R/C test on bolts too short to fit a TMD according to the testing procedure in SC-T-151.

2 Ensure that the measured torque does not exceed the values listed in the following table. Assemblies that exceed the listed torque fail the test.

Torque* Bolt Diameter (inches) ½ ⅝ ¾ ⅞ 1 1⅛ 1¼ 1⅜ 1½ Torque (ft-lb) 150 290 500 820 1230 1730 2450 3210 4250

* Ensure that the measured…