Abu Dhabi, United Arab Emirates. STANDARD CONSTRUCTION SPECIFICATIONS (PART 2 - ROAD STRUCTURES, 2020)

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b. Vent ends shall be removed at least 25 mm below the concrete surface after the grout has

set.

c. Voids shall be filled with epoxy grout. All miscellaneous material used for sealing grout caps

shall be removed before carrying out further work to protect end anchorages.

22.8.8.9

Protection of End Anchorages

Permanent grout caps constructed from either stainless steel or fibre-reinforced polymer shall be
specified.

The following requirements apply:

a. Within seven days upon completion of the grouting, the anchorage of post-tensioning bars

and tendons shall be protected, as indicated in the Contract documents. The application of
the elastomeric coating may be delayed up to 90 days after grouting. Plastic or stainless steel
threaded caps shall be used to plug all grout in- and outlets. A sand-filled epoxy grout suitable
for machinery base plates shall be used to construct all pour-backs located at anchorages of
expansion joints or other areas exposed to the elements.

b. All laitance, grease, curing compounds, surface treatments, coatings, and oils shall be

removed by grit or water blasting, using a minimum 70 MPa nozzle pressure. The surface
shall be flushed with water and blown dry. Surfaces shall be clean, sound, and without any
standing water. In case of dispute, ACI 503 (1997) shall be followed for substrate testing and
a minimum of 1.2 MPa tension, or pull-off value, is developed.

c. Epoxy shall be mixed and applied as per the manufacturer's current standard technical

guidelines. All pour-backs shall be in leak-proof forms, creating neat lines. Epoxy grout
pumping shall be permitted for proper installation. Forms shall be constructed to maintain a
liquid head to insure intimate contact with the concrete surface. Vents shall be used as
needed to provide for the escape of air to insure complete filling of the forms.

d. Exposed pour-back or group cap surfaces, except on transverse tendons, shall be coated

with an elastomeric coating system having a thickness of 760

μm to 1,140 μm. Concrete,

grout caps, or other substrates shall be structurally sound, clean, and dry. Concrete shall be
a  minimum  of  28  days  old.  Laitance,  grease,  curing  compounds,  surface  treatments,
coatings, and oils shall be removed by grit or water blasting using a minimum 70 MPa nozzle
pressure  to  establish  the  anchor  pattern.  Surfaces  shall  be  blown  with  compressed  air  to
remove dust or water.

e. A 0.6 m by 1.2 m concrete test block shall be constructed with a similar surface texture to the

coated surfaces and a vertical face shall be coated with the elastomeric coating system
chosen. To achieve a coating thickness between 760

μm to 1,140 μm, without runs and drips,

the Contractor shall have to determine the number of coats needed. Elastomeric coatings
shall  be  mixed  and  applied  as  per  the  manufacturer's  current  standard  technical
specifications. Spray or roller  application may be permitted; spray application is preferred.
Coatings  shall  be  applied  using  approved  and  experienced  personnel  with  a  minimum  of
three years experience applying similar polyurethane systems. Credentials of these persons
shall be submitted to the Engineer for review and consideration for approval.

22.8.8.10 Construction Traffic and Operations Causing Vibrations

For the designated period of time after grouting of a tendon begins, vibrations from all sources

—

such as moving vehicles, jackhammers, compressors, and generators

— that are operating within

the affected bridge superstructure shall be eliminated and pile-driving and soil compaction within 90
m of the affected superstructure shall not be permitted. The designated period of time shall be taken
as four hours for prequalified anti-bleed grout and 24 hours for plain grout. The affected bridge

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superstructure shall be taken as that portion of the total superstructure that is 90 m up- or down-
station of the ends of the span in which grouting is taking place.

22.8.8.11 Grouting Trials

At least 56 days before the planned commencement of fixing ducts for the post-tensioning permanent
works, the Contractor shall carry out full-scale grouting trials. The trial shall comprise a 25m long
concrete beam 350mm wide and 1500mm deep, incorporating one tendon with a high point and a
low point in a profile to be instructed by the Engineer. All relevant details of ducts, vents, duct
supports, prestressing anchorages, prestressing strands, grout inlets and outlets shall be
incorporated.

The tendons shall be sufficiently tensioned such that the strands within the duct take up a
representative alignment. All personnel, system methods and materials are to be those proposed for
the permanent works, and shall have been submitted to the Engineer as part of the detailed method
statement required in Section 22.8.8.

Grouting and testing shall be carried out in accordance with the specification in this chapter.

After 3 days the Contractor shall carefully cut and expose cross-sections and longitudinal sections
of the duct and anchorages where directed by the Engineer to demonstrate that the duct is fully
grouted.

A report shall be prepared by the Contractor giving full details of the trial, testing results and
photographs of the cut sections.

Grouting of the ducts shall be shown to leave no void which has a radial dimension greater than 5%
of the diameter of the duct or which poses a risk to the protective system. The location of the voids
with respect to grout vents and their adequate grouting and subsequent sealing, and the disposition
of the steel tendons within the body of the grout shall be reported.

Post-tensioning of the permanent works will not be permitted without the written approval of the
Engineer to the grouting procedures and formal acceptance of the results of the grouting trial.

22.8.8.12 Field Testing of Grout for Quality Control

General Conditions

Field testing shall comprise suitability testing of the materials assessment, and acceptance testing
of the grouting trials and actual works operations.

Suitability testing shall wherever possible be carried out in the conditions of temperature and
humidity expected on site but in the absence of this data the conditions of temperature and relative
humidity at test shall be as follows:

•

Temperature:

20°C ± 2°C

•

Relative humidity:

> 65%

Variations in temperature and humidity on site are likely to cause variations in the test results and
shall be reported.

The temperature of the freshly mixed grout shall be given in all test reports.

Fluidity Test

1. Principle

The fluidity of the grout, expressed in seconds, is a measure of time necessary for a stated quantity
of grout to pass through the orifice of the cone, under stated conditions.

2. Apparatus

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The following apparatus is required for the test:

Cone - A cone of the dimensions given in Figure 22-1. It shall be robust and manufactured
from materials not reactive with any materials specified. A tap shall be fitted at the lower cone
orifice.

II.

Sieving medium - The sieving medium aperture shall be 1.5mm and the sieving medium shall
be fitted as shown in Figure 22-1, and be removable.

III.

Stopwatch - The stopwatch shall be accurate to 0.2 seconds in 60 seconds and shall show
time to 0.1 seconds.

IV.

Graduated cylinder of minimum 1 litre capacity.

3. Test Procedure

Mount the cone with its axis vertical and its largest diameter uppermost. Fix the sieving medium at
the position indicated in Figure 22-1: Cone for Fluidity Test. During the test, prevent the cone from
vibrating. Place the cylinder under the cone outlet. All surfaces of the cone shall be clean and shall
be dampened so that the surfaces are moist but without free water. Close the lower cone orifice.

Pour the grout through the sieving medium to fill the conical section of the cone. Pouring shall be
sufficiently slow to prevent the build-up of air in the grout in the cone. Open the lower cone orifice
and, at the same time, start the stopwatch. Measure the time taken to the nearest 0.5s to fill the
cylinder to 1 litre. The presence of lumps on the sieving medium shall be reported. For suitability
testing three tests shall be carried out, the first immediately after the grout is mixed and the remaining
two tests 30 minutes after the grout is mixed. The grout shall be kept agitated while awaiting testing.

Figure 22-1: Cone for Fluidity Test.

4. Reporting of Results

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Report the time to the nearest 0.5 s. Report also the presence of lumps. Report the result as the
average of the times determined to the nearest 0.5 of the second and third tests, separately from the
results of the first test.

For acceptance testing, the test shall be performed on grout from each anchorage outlet and from
the mixer at the start and end of grouting of each duct.

Bleeding Test

1. Principle

The test consists of measuring the quantity of water remaining on the surface of the grout which has
been allowed to stand protected from evaporation.

2. Apparatus

A transparent cylinder 50mm internal diameter and 200mm in height graduated in mm.

3. Test Procedure

Place the cylinder on a surface free form shocks or vibration. The grout used should be from the
same batch as that used for the fluidity test.

Pour grout into the cylinder to a height of approximately 150mm and seal the cylinder to prevent
evaporation. Note the height to the top of the grout (h) ignoring the meniscus. After 3 hours, measure
the depth of water on top of the grout (h1). After 24 hours, check whether the water has been
reabsorbed. The test is carried out on one sample of grout.

4. Reporting of Results

Bleeding at the end of 3 hours is given by:

h1 × 100(%)

where:

h1 is the height in mm of water on the surface of the grout after 3 hours.

h is the initial height in mm of grout.

The report shall state the range of air temperatures and the grout temperature at the time of test, the
bleeding at 3 hours and whether the water has been reabsorbed after 24 hours.

For acceptance testing, a minimum of two tests per day shall be performed.

Volume Change Test

1. Principle

The volume change is measured as a percentage of the volume of grout between the start and the
end of the test. The test measures mainly the volume change caused by segregation, contraction or
expansion.

The volume change test may be a continuation of the bleeding test.

2. Apparatus

A transparent cylinder 50mm internal diameter and 200mm in height graduated in mm.

3. Test procedure

Place the cylinder on a surface free from shocks or vibration. Fill it with grout to approximately
150mm and seal the cylinder to prevent evaporation. Note the height to the top of the grout h ignoring
the meniscus. 24 hours after filling the cylinder measure the height of the grout in the cylinder (h2).

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4. Reporting of Results

Volume change at the end of 24 hours given by:

(h2 − h) × 100(%)

where:

h is the initial height in mm of grout

h2 is the height in mm of grout after 24 hours.

The report shall state the range of air temperatures during the test and the volume change.

For acceptance testing the test shall be performed twice each day.

22.8.8.13 Admixtures

General

Admixtures shall be used to achieve a low water/cement ratio and impart good fluidity, minimum
bleed and volume stability or expansion to the grout to comply with Article 22.7.2.3. They should be
added on site during the mixing process and used in accordance with the manufacturer's
recommendations.

Types

Admixtures are divided into two types - expanding and non-expanding.

Expanding grout admixtures are supplied as powders which expand to ensure there is no decrease
in the volume of grout at the end of the hardening period. Non-expanding grout admixtures are
supplied in liquid or powder form and shall not exhibit any measurable decrease in volume after
curing.

Both types of grout admixture may also permit a reduction in water/cement ratio, improve fluidity,
reduce bleeding and retard the set of the grout.

Admixtures may be used singly or in combination to obtain the required grout performance.
Admixtures used in combination shall be checked for compatibility.

Chemical Composition

Admixtures shall not contain substances in quantities which will adversely affect the grout or the
corrosion protection of the prestressing steel. Thiocyanate, nitrates, formate, fluorides and sulphides
shall not be used in admixtures.

Material Requirements

The admixture shall not segregate and shall be uniform in colour. The composition shall not change
and the supplier shall operate a quality system complying with BS EN ISO 9001:2015. Where
appropriate, admixtures shall comply with BS 5075-1:1982 and BS 5075-3:1982.

Other admixtures shall be permitted provided they satisfy Sections 6, 7.1 and 7.3 of BS 5075-1:1982
and full account is taken of their effects on the finished product and their fitness for purpose. Data
on their suitability, including previous experience with such materials, shall be made available and
records of the details and performance of such materials shall be maintained.

Corrosion

Grout admixtures shall not cause the grout to promote corrosion of the prestressing steel by rusting,
pitting, stress corrosion or hydrogen embrittlement.

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Dosage

The optimum dosage of the admixture shall be determined by trial mixes with the cement to be used
in the grout. This dosage shall be expressed as percent by mass of cement. It shall be within the
range recommended by the supplier and shall not exceed 5% by mass of the cement.

The method of measuring dosage and checking weights of pre-packed dry materials shall be agreed
with the Engineer.

22.9

Structural Cable Members

This section of the specification shall apply to the supply, fabrication, delivery, testing, installation,
stressing, and permanent corrosion protection of the hanger cables forming the structural connection
between the concrete deck and the supporting structures, and any transverse tie cables connecting
the supporting structures.

Forming tubes, anchorage bearing plates together with any other material necessary to form a
complete hanger or tie system in accordance with the Contract plans and Contract documents, shall
also be subject to the requirements of this section.

The arrangement and details of the cables shown on the Contract plans are indicative only. Final
details and dimensions are to be determined by the Contractor and shall be subject to the approval
of the Engineer.

22.9.1

Description of System and General Requirements

The general arrangement of the cable systems shall be as shown on the Contract plans. Each cable
shall be comprised of an assembly of parallel, individually protected seven wire strands with wedge
anchorages, contained within an additional outer casing. The cable members shall be arranged to
enable the replacement of any cable, if required, on a strand by strand basis, with minimum
disruption to traffic using the bridge. To permit this, the space between the individual strands and
the outer casing shall not contain any filler material in the free length between the anchorage zones.

The  design  and  arrangement  of the cables  shall  include  provision  for the  measurement  and final
adjustment  of  their  tension  under  full  permanent  loading.  However,  during  construction,  initial
installation and tensioning of multi-strand cable members may be carried out on a strand by strand
basis  by  a  method  approved  by  the  Engineer.  After  completion  of  construction,  and  with  all
permanent dead load in place, the load in each complete hanger member shall be measured, and if
necessary  adjusted  using  a  calibrated  hydraulic  jack  or  equivalent  device.  The  associated  fine
adjustment of cable length shall be by means of a securing nut on an externally threaded anchor
member. The use of shimming to provide cable length adjustment shall not be permitted.

22.9.2

Strand for Structural Cables

22.9.2.1

Materials

The individual strands for cables shall be 15.24mm diameter seven wire low relaxation prestressing
strands conforming to AASHTO M 203M/M 203-12 (ASTM A416/ A416M - 12) Grade 1860 MPa or
15.7mm diameter seven wire low relaxation prestressing strands conforming to EN 10138

– BS

5896:2012 Grade 1770 MPa, together with the following additional requirements:

Zinc Coating

Before the final wire drawing operation, the wire for the strands shall be galvanized to give a uniform
zinc coating with an average weight of 280g/m

on the finished wires. The weight of zinc coating

shall have a minimum value of 220g/m

and a maximum value of 350g/m

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High Density Polyethylene (HDPE) Coating to Strand

The strand shall be completely coated with an HDPE sheath extruded over the strand and protective
filler material. The HDPE sheath shall have a minimum thickness of 1.5mm (thickness tolerance -0,
+0.25mm), and shall tightly follow the outer contours of the strand, so that the outer surface of the
HDPE sheath need not necessarily be circular. The HDPE coating material shall be virgin high
density polyethylene complying with the requirements of Article 22.9.3.1, and shall be coloured black.
The minimum longitudinal bond strength between the sheath and the strand wires shall be 1.0kN
per 300mm length of strand. The Manufacturer shall provide the Engineer with an evidence of having
such bond strength.

Protective Filler

All strands shall be further protected against corrosion by the application during fabrication of an
approved petroleum wax material containing anti-corrosive additives. This material shall have a
melting point of between 100

C and 120

C, and shall fill both the inter-wire voids, together with any

spaces between the wires and the HDPE sheath. Sufficient filler material shall be incorporated in the
strand to prevent the flow of water along it should the HDPE sheath be locally damaged.

Resistance of the HDPE Sheath to Accidental Damage

The HDPE sheath shall have a resistance to accidental damage determined by a falling weight test,
using a test apparatus and procedure similar to that described in ASTM G14-88 (1996)e1, but with
a specially shaped cup nose. This nose shall be wedge shaped with an included angle of 90

, an

edge radius of 1.0mm, and a length of 20mm. The edge of the nose shall be arranged to fall
perpendicular to the axis of the strand, which shall be positioned such that impact occurs on a single
wire. Perforation of the sheath shall not occur under an impact of 6.0 Newton metres.

Fatigue Resistance

Unless otherwise specified in the Contract documents, the strands shall have a fatigue resistance of
2 million cycles with a maximum force applied to the strands representing half its rated rupture load
and with a stress range of 280 MPa.

Ductility

The strand ductility shall be measured by the one-pin test specified in Appendix C of the Post
Tensioning Institute publication “Recommendations for Stay Cable Design, Testing, and Installation”.
The pin test efficiency (PTE) as measured by this deflected tensile test shall not be less than 80%.

Free Curvature of Strand

With a length of strand freely lying on a smooth flat surface, the maximum deviation from a one metre
long gauge length, measured on the inside of the strand shall not exceed 15 mm.

Environmental Resistance

The resistance to environmental exposure shall be such that after a 7000 hours duration xenon-arc
exposure to UV radiation:

•

No degradation in mechanical properties shall occur when tested in accordance with BS EN

ISO 527-1:2012.

•

The HDPE envelope shall completely prevent any penetration when exposed for 1000 hours

to salt mist as per ASTM B117 - 11.

•

The shore D hardness shall not be increased by more than 20 %.

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Protective Filler

The weight of wax per unit length of strand shall be specified by the stay cable Supplier, who shall
propose the range of permitted maximum and minimum  values. The minimum value shall ensure
that  any  possible  water  flow  or  passage  is  prevented,  and  the  maximum  value  shall  provide  for
sufficient  bond  between  the  wires  and  the  protective  coating.  The  test  procedure  shall  consist  of
weighing a suitable length of complete strand, followed by longitudinal cutting and removal of the
HPDE sheath. The weight of wax shall then be established by further weighing of the cleaned and
degreased wires and HDPE sheath. The stay cable supplier shall propose a water tightness test to
the approval of the Engineer at no cost to the Owner.

22.9.2.2

Production Testing of Strand

Unit of Production for Sampling

The unit of production shall be defined as a production lot of maximum 10-ton or fractions thereof
from which test pieces shall be selected.

Standard Properties

Tests for standard properties shall be carried out in accordance with AASHTO M 203M/M 203-12
(ASTM A416/ A416M - 12) or BS 5896:2012 and the requirements of Article 22.7.1.2.

Particular Properties

1. Weight of Galvanising

The weight of galvanizing shall be determined as per the ASTM A90/ A90M

– 11 method. The

frequency of testing shall be not less than one test per five production units.

2. Fatigue

Unless agreed otherwise, one fatigue test shall be carried out for each five units of production or
fraction thereof. For each test, 3 samples shall be taken. If the test fails two more tests are to be
done. If one of the two additional tests fails the quantity of strand represented by the 3 samples shall
be rejected.

3. Ductility

A "One-pin deflected tensile test" in accordance with Appendix C of the Post Tensioning Institute
publication “Recommendations for Stay Cable Design, Testing, and Installation” shall be carried out
for each five units of production.

4. Curvature of Strand

A straightness check shall be made for every unit of production.

22.9.2.3

Testing of HDPE Coating

Mechanical Resistance Test

One mechanical resistance test as per Sub-article d, Resistance of the HDPE sheath to accidental
damage, of Article 22.9.2.1 shall be carried out for each unit of production. The stay cable supplier
shall further demonstrate to the satisfaction of the Engineer that no cracking of the HDPE will occur
due to the calculated in service stress variations in the HDPE.

Resistance to Environment

At least one 7000 hours duration xenon-arc exposure test in accordance with BS EN ISO 4892-
2:2006+A1:2009 at a temperature of 60

C shall be carried out in a suitable chamber (Weather-0-

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meter or equivalent) to demonstrate compliance with the requirements of Sub-article h,
Environmental Resistance, of Article 22.9.2.1.

22.9.2.4

Petroleum Wax Filling

One test of void filling as per Sub-article i, Protective filler, of Article 22.9.2.1 shall be carried out for
each unit of production or fraction thereof unless otherwise directed by the Engineer.

22.9.2.5

Delivery and Storage of Strand

For delivery to the bridge site, lengths of strand shall preferably be supplied on either wooden or
steel reels. Supply of strand in unreeled coils shall only be acceptable provided the Contractor has
demonstrated to the satisfaction of the Engineer that the methods used for transport, unloading, and
handling of the coils will not cause any damage or deterioration of the strands.

The minimum diameter of reeled or coiled strand shall not be less than 50D, where D is the outside
diameter of the strand outer coating.

22.9.3

Outer Casing

The outer casing for the cables shall consist of a circular cross-section high density polyethylene
(HDPE) or stainless steel pipe conforming to the requirements of the following sections. The pipe
materials and dimensions shall be as shown in the Contract plans.

22.9.3.1

HDPE Pipe

HDPE casing pipe shall be manufactured from virgin HDPE material, and shall meet the specific cell
category requirements for PE 3408 material as defined by table X1 of ASTM D3350-12. The resultant
acceptable values of primary properties for the PE material shall be as follows.

Table 22-7: Acceptable values of primary properties for the PE material

Property

ASTM Test Method

Value

Density, g/cc

ASTM D1505 - 10

0.941 - 0.955

Melt Index

ASTM D1238 - 10

Max. of 1

Flexural modulus, Mpa

ASTM D790 - 10

550 ≤ 1100

Tensile Strength at Yield, Mpa

ASTM D638 - 10

21 ≤ 28

Environmental Stress Crack

Resistance, F

, hrs., min.

ASTM D1639 - 90(1996)e1

(Condition C)

192

Hydrostatic Design Basis, Mpa

ASTM D2837 - 11

8.62 (A)

•

Verification tests for mechanical and other properties on each size of pipe required shall be

carried out in accordance with ASTM D3350 - 12. The material shall meet the requirement of
a class C material: it shall be black, weather resistant, and contain not less than 2.3 percent
of carbon black and 1000 ppm of antioxidant.

The required length of the HDPE pipe shall be obtained by continuous extrusion or by fusion welding
of shorter lengths performed in accordance with ASTM D2657 - 07. The Contractor shall produce
sample welds to demonstrate the adequacy of the proposed fusion welding procedure. At least three
sample welds shall be made for each pipe size and wall thickness.

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The Contractor shall demonstrate the durability of the HDPE pipe by carrying out an accelerated
aging test of at least 7000 hours duration xenon-arc exposure test in accordance with BS EN ISO
4892-2:2006+A1:2009 at a temperature of 60

. The test shall be carried out in a suitable chamber

(Weather-0-meter or equivalent) to demonstrate that:

•

No degradation in mechanical properties shall occur when tested in accordance with BS EN

ISO 527-1:2012.

•

The HDPE envelope shall completely prevent any penetration when exposed for 1000 hours

to salt mist as per ASTM B117 - 11.

•

The shore D hardness shall not be increased by more than 20 %.

Procedures for packaging, handling and shipping the pipe shall ensure the pipe will not be damaged
when delivered to the site. A certificate of analysis shall be furnished for each shipment stating the
material meets this specification and showing results of tests.

22.9.3.2

Stainless Steel Pipe

Stainless steel casing pipe shall be Grade 316L. Pipe joints shall be welded before installation of the
cable strands. Pipe ends and details shall incorporate insulating devices to prevent bimetallic
contact. The Contractor shall propose suitable details for the pipe including jointing and installation
procedures which shall be subject to the Engineer’s approval. The pipe shall incorporate fixing
devices at intervals to allow for the possible installation of anti-vibration dampers.

22.9.4

Anchorages and Transition Zones

The cable anchorages shall be designed to anchor each strand individually by means of conical steel
wedges. These anchorages shall meet the acceptance criteria as specified in Section 6.1 of the 1993
edition of the Post-Tensioning Institute (PTI) "Recommendations for Stay Cable Design, Testing and
Installation" except as otherwise required by the Contract particular specifications.

Apart from the wedge anchor jaws, the steel wires of the strands shall not be in contact with any
other steel elements.

The angle of deviation of any strand in the anchorage or in the transition zone shall not be more than
0.025 radians. The anchorage and/or the transition zone shall include means to reduce the flexural
stress variations in the strand at the jaw due to cable oscillations and movement. The supplier of the
cable shall demonstrate the adequacy of such means to the satisfaction of the Engineer.

After completion of cable installation, and final adjustment of load, the anchor zones shall be
completely filled with a petroleum wax filler containing corrosion inhibiting additives. The type and
details of the filler material shall be proposed by the Contractor and shall be subject to the approval
of the Engineer.

The Contractor shall submit all material specifications, not specified herein or on the Contract plans,
to the Engineer for review and approval. The components of the assembly shall have, whenever
possible, an AASTHO or ASTM material and test designation numbers.

The Supplier of the stay cable system shall submit to the Engineer for review and approval assembly
drawings for each size and type of anchorages required by the Project, showing all dimensions and
materials of the main components.

All other components such as bearing plates, recess tubes, steel flanges, deviators and guides
shown on the Contract plans shall be of a type and strength suitable for the intended use. The
Contractor shall submit to the Engineer calculations for the justification of these components.

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22.9.5

Stay Cable Testing

The Contractor shall provide all materials, anchorages, stay cable specimens, strand specimens and
all labour and equipment, and carry out fatigue, ultimate strength, ductility and strand endurance
testing as follows.

Fatigue and ultimate strength of fully assembled cables for acceptance of the anchorage system,
unless evidence of previous testing is submitted and accepted by the Engineer, shall be as permitted
by Article 22.9.5.3.

Acceptance and other testing of individual strands and/or sheathing specimens shall be as required
by Article 22.9.2.2 and Article 22.9.2.3.

The specimen assemblies shall be tested by a recognized independent testing laboratory approved
by the Engineer. The Engineer shall be notified a minimum of 30 days in advance of any fabrication
or testing so that a representative of the Engineer may be present when the respective work is being
performed.

All testing data and testing results shall be submitted to the Engineer for approval.

Fabrication of anchorages or stay cable strands shall not begin until the required tests (or previous
tests reports) have been successfully completed and submitted and written approval has been given
by the Engineer.

22.9.5.1

Strand Acceptance Tests

The strand acceptance tests and frequency shall be as specified in Article 22.9.2.2.

22.9.5.2

Cable Acceptance Tests

Unless otherwise accepted by the Engineer, three complete fully assembled cable specimens shall
be fabricated for testing. One specimen shall be made representing the smallest cable required, a
mid-range cable and a large (the largest when the testing machine is of sufficient capacity) cable.
Each specimen shall be fully representative of all details and manufacturing processes for production
anchorages.

Cables shall be tested with their entire load bearing appurtenances. They shall include an active
anchorage and a passive anchorage. Strand deviations shall be representative of the actual installed
cable deviations. At the discretion of the Engineer, the anchorages of the test specimens may not
be injected with wax for the tests.

Test parameters and acceptance criteria shall be as detailed in Section 6.1 of the 1993 edition of the
Post-Tensioning Institute (PTI) "Recommendations for Stay Cable Design, Testing and Installation",
except that, in order to be consistent with the fatigue safety philosophy (Figure 5.1 of the above
reference), the stress range shall be equal to 210 MPa, corresponding to the specified component
fatigue stress range of 280 MPa.

22.9.5.3

Acceptance of Prior Tests of Cables

When at least three cable tests with the same specified stress range as in the Project have been
conducted for  previous projects  on  specimens  similar  to those  recommended for  the  Project  (not
necessarily of the same sizes, but at least half the size of the largest for the Project), the previous
tests may be used as the basis for stay cable approval, subject to review and acceptance by the
Engineer.  However,  the  quality  control  tests  required  by  Article  22.9.2.2  must  be  carried  out  to
establish  that  the  strand  supplied  for  the  Project  has  geometrical,  mechanical  and  fatigue
characteristics equal to the strand used in the acceptance tests of the stay cable specimens in the
previous projects. Further, the stay anchorage hardware must be the same as in the previous tests.

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22.9.6

Installation

Cables shall be installed in accordance with procedures prescribed by the cable system Supplier.
The Contractor shall submit for the Engineer’s approval a method statement fully describing the
installation operations. This shall include a description of the main items of the equipment required,
as well as an installation sequence prescribing the force and elongation of each cable.

The cable installation procedure shall be compatible with the bridge construction sequence, and the
Engineer’s approval of the Contractor's erection sequence and equipment shall not relieve the
Contractor from his responsibility for performing the work required by the Contract documents.

Stay cables may be fabricated into fixed length cables or erected in-situ.

The Contractor shall be responsible for the determination of and monitoring of forces, and deflections
in the permanent structure at all erection stages as are caused by his proposed erection process.

22.9.6.1

Handling and Installation

The Contractor shall work in accordance with procedures developed to ensure that the cables and
associated components will not be damaged during handling and installation. These procedures
shall be subject to the approval of the Engineer.

All cables and associated components shall be protected from corrosion, excessive heat, abrasion
and other harmful effects throughout the fabrication and installation.

During fabrication, transport, storage, and installation, HDPE outer casing pipes shall at no stage be
bent to radiuses of less than 60 times their outside diameter.

All damage to cables or associated components shall be evaluated by the Engineer and remedied
prior to installation of the cables. Any damaged strand or load carrying components shall be
replaced. Minor damage to non load-carrying components may be repaired to the Engineer's
satisfaction prior to installation.

22.9.6.2

Stressing

Jacks and gauges for cable installation shall be calibrated using a load cell or calibrated static load
machine within one month prior to the beginning of the cable installation, and every 6 months
thereafter, for the duration of cable installation. The 6-month recalibration may be performed using
a master gauge, provided that the master gauge is calibrated with the field gauges at the time of
initial jack calibration.

Prefabricated cables shall only be tensioned as a full unit. For cables prefabricated at the bridge site,
pre tensioning of individual strands may be allowed up to 10 percent of the final installation force
called for in the cable. Procedures shall be developed to ensure that the pretension in all strands is
equalized within a range of 2.5%.

In-situ installed hanger cables may be tensioned one by one provided that it can be demonstrated,
to the satisfaction of the Engineer, that the final tension and elongation of each strand is equalized
within a range of 2.5 %. Tensioning of strands one by one by applying forces to the strands deduced
from calculations based on the deformation of the structure shall not be permitted. The preferred
method shall be the so-called "isotension" method. All stressing must be recorded automatically with
a computer system connected to load cells. The use of pressure gauges for strand load
measurement will not be permitted.

Cables shall be capable of being tensioned, de-tensioned or re-tensioned more than once during
and after the construction of the structure. These operations may be carried out either by full jacking
of the live anchorage and adjustable ring setting, or strand by strand. If de-tensioning strand by
strand in such a way that the "gripping" zone is incorporated in the stressed portion of the stay, it
shall be demonstrated by testing that a single strand anchored and fitted with the jaws and the strand

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used in the Project can withstand without rupture 0.1 million cycles with a stress range of 350 MPa
and at an upper stress equal to 55 percent of the guaranteed ultimate tensile stress. It is not permitted
to de-tension or re-tension strand by strand in such a way that already "gripped" and newly "gripped"
lengths overlap. No "gripped" lengths of strand shall permanently be left on the stressed portion of
the stay. Maximum cable tension during construction shall not exceed 55 percent of the cable
guaranteed ultimate tensile strength.

22.9.6.3

Finishing Operations

Completion of the anchorage and transition zones (removal of surplus strand length; wax injection
of the anchorage zone; installation of guides, deviators, vibration dampers etc.) shall not be
commenced until the tension of each cable has been finally adjusted to the satisfaction of the
Engineer. The Contractor shall carry out these operations in accordance with a detailed procedure
approved by the Engineer.

22.9.6.4

Re-stressing

The cable tensions shall be re-measured and adjusted to the specified tensions at the following times
after the initial installation and tensioning of the cables:

•

1 year after initial installation

•

5 years after initial installation

22.9.7

Vibration Damping

The Contractor shall design, supply and install a suitable number and type of dampers to limit cable
oscillations for the prescribed cable layouts and tensions for the full range of design wind speed from
0 to 45 metre per second. The damping system shall be chosen to have minimum visual impact and
shall be subject to the Engineer’s approval. It shall be easily replaceable during the life of the bridge.

The acceptance criteria for cable vibrations shall be that the maximum amplitude of vibration shall
not exceed the lesser of the following:

•

± 5 cm

•

± L / 500

where L is the free length of the cable between its effective anchor points.

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NDEX

Admixtures, 22-39
allowable stresses, 22-1
ambient temperature, 22-34
Anchor plates, 22-22
anchorage assemblies, 22-1, 22-19
anchorages, 22-1, 22-7, 22-9, 22-11, 22-13,

22-17, 22-19, 22-20, 22-22, 22-25, 22-26,
22-29, 22-30, 22-33, 22-34, 22-35, 22-36,
22-40, 22-44, 22-45

beam, 22-1, 22-36
bleeding, 22-15, 22-38, 22-39
Bleeding, 22-3, 22-15, 22-17, 22-37, 22-38
Bond transfer lengths, 22-11
cable vibrations, 22-46
Cables, 22-28, 22-40, 22-45, 22-46
caps, 22-17, 22-26, 22-33, 22-35
CARES certificate, 22-9
cast-in-place, 22-1, 22-20
Chemical composition, 22-28
coefficients, 22-1, 22-21
column, 22-1
concrete placement, 22-17, 22-19, 22-24, 22-

25, 22-26

cone, 22-15, 22-17, 22-36, 22-37
constant delivery pressure, 22-32
corrosion, 22-1, 22-16, 22-17, 22-22, 22-27,

22-29, 22-30, 22-39, 22-40, 22-44, 22-45

Corrosion inhibitors, 22-30
Coupling, 22-19
damp atmosphere, 22-27
dampers, 22-43, 22-46
degradation, 22-41, 22-43
Department of Transport, iii
design procedures, 22-1
Draped pretension tendons, 22-21
draped strand, 22-22, 22-23
duct profile, 22-25
ducts, 22-1, 22-7, 22-8, 22-9, 22-11, 22-17,

22-18, 22-19, 22-21, 22-23, 22-24, 22-25,
22-26, 22-27, 22-30, 22-31, 22-32, 22-33,
22-34, 22-36

dynamic test, 22-11
elongation measurements, 22-22, 22-23
fatigue resistance, 22-41
Field testing, 22-15, 22-36
fluidity, 22-15, 22-32, 22-34, 22-36, 22-38, 22-

friction, 22-1, 22-19, 22-20, 22-21, 22-22, 22-

gauges, 22-1, 22-10, 22-11, 22-20, 22-45, 22-

girder, 22-1, 22-6, 22-26
grout, 22-1, 22-11, 22-14, 22-15, 22-17, 22-19,

22-26, 22-27, 22-30, 22-31, 22-32, 22-33,
22-34, 22-35, 22-36, 22-37, 22-38, 22-39

Grout openings, 22-24
grouting operations, 22-6, 22-14, 22-30, 22-31
hanger cables, 22-1, 22-39, 22-46
HDPE sheath, 22-40, 22-41, 22-42
hot weather, 22-34
humidity, 22-36
hydrogen embrittlement, 22-39
individual mould system, 22-21
injection tubes, 22-33
inlets, 22-19, 22-26, 22-31, 22-33, 22-36
jacks, 22-10, 22-11, 22-19, 22-20
load cell, 22-20, 22-45
local zone, 22-12, 22-27
lot number, 22-14, 22-28
low points, 22-19, 22-25, 22-30
mandrels, 22-24
mechanical resistance, 22-42
Moderate atmosphere, 22-27
multiple-strand stressing, 22-21
nonbleeding characteristic, 22-15
optimum dosage, 22-39
outlets, 22-15, 22-19, 22-25, 22-26, 22-33, 22-

35, 22-36

petroleum wax material, 22-40
physical damage, 22-29, 22-30
Plant Certification, 22-6
post-tensioning, 22-1, 22-7, 22-8, 22-9, 22-10,

22-12, 22-14, 22-19, 22-20, 22-22, 22-23,
22-24, 22-25, 22-27, 22-30, 22-32, 22-35,
22-36

precast, 22-1, 22-6, 22-24
pressure gauge, 22-20, 22-24, 22-32
prestress losses, 22-1
prestressing, 22-1, 22-3, 22-5, 22-6, 22-7, 22-

8, 22-9, 22-11, 22-14, 22-17, 22-19, 22-20,
22-21, 22-22, 22-23, 22-26, 22-27, 22-28,
22-29, 22-30, 22-31, 22-36, 22-39, 22-40

prestressing strands, 22-23, 22-36, 22-40
prestressing system, 22-1, 22-7
pretensioning, 22-1, 22-21, 22-22
rust, 22-27, 22-29, 22-30
saltwater environment, 22-18
Sheathing, 22-17
skin reinforcement, 22-12, 22-13

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Chapter 23: Steel Structures

ABLE OF

ONTENTS

Table of Contents............................................................................................................................. i

List of Tables .................................................................................................................................. iii

Steel Structures ............................................................................................................... 23-1

23.1

Terminology for Steel Work .......................................................................................... 23-1

23.2

General Requirements for Steel Structure Work .......................................................... 23-2

23.2.1

Reference Standards and Codes .......................................................................... 23-2

23.2.2

Mill Inspection and Tests for Steel Structures ....................................................... 23-9

23.2.3

Notice of Beginning Steel Structure Work ........................................................... 23-10

23.2.4

Shop Inspection for Steel Structures ................................................................... 23-10

23.2.5

Material Traceability and Shipping for Steel Structures ....................................... 23-10

23.2.6

Handling and Storing Materials for Steel Structures ............................................ 23-12

23.2.7

Field Inspection for Steel Structures ................................................................... 23-13

23.2.8

Falsework for Steel Structures ............................................................................ 23-13

23.2.9

Continuous Members of Steel Structures ............................................................ 23-13

23.3

Drawings for Steel Structures .................................................................................... 23-14

23.3.1

Shop Drawings for Steel Structures .................................................................... 23-14

23.3.2

Erection Drawings for Steel Structures ............................................................... 23-14

23.3.3

Camber Diagrams for Steel Structures ............................................................... 23-15

23.3.4

Transportation Drawings for Steel Structures ...................................................... 23-15

23.4

Materials for Steel Structures ..................................................................................... 23-15

23.4.1

Structural Steel ................................................................................................... 23-15

23.4.2

High-strength Fasteners for Steel Structures ...................................................... 23-17

23.4.3

Other Structural Fasteners .................................................................................. 23-19

23.4.4

Welded Stud Shear Connectors .......................................................................... 23-20

23.4.5

Steel Forgings for Steel Structures ..................................................................... 23-21

23.4.6

Cold-finished Carbon Steel Shafting for Steel Structures .................................... 23-21

23.4.7

Mild Steel Castings for Steel Structures .............................................................. 23-21

23.4.8

Chromium Alloy-steel Castings for Steel Structures ............................................ 23-21

23.4.9

Iron Castings for Steel Structures ....................................................................... 23-21

23.4.10

Galvanising Steel Structures ............................................................................... 23-22

23.4.11

Welding Steel Structures .................................................................................... 23-22

23.5

Fabricating Steel Structures ....................................................................................... 23-23

23.5.1

Cutting, Shearing, and Machining for Steel Plates .............................................. 23-23

23.5.2

Cold Bending Steel Plates .................................................................................. 23-24

23.5.3

Straightening Steel ............................................................................................. 23-25

23.5.4

Applying Heat to Steel ........................................................................................ 23-25

23.5.5

Bolt Holes for Steel Structures ............................................................................ 23-31

23.5.6

Contact and Bearing Surfaces for Steel Structures ............................................. 23-34

23.5.7

Cleaning and Coating Steel Structures ............................................................... 23-35

23.5.8

Geometry for Members of Steel Structures ......................................................... 23-35

23.5.9

Surface Condition ............................................................................................... 23-37

23.5.10

Pins and rollers for Steel Structures .................................................................... 23-38

23.5.11

Eye Bars for Steel Structures .............................................................................. 23-38

23.5.12

Stiffeners for Steel Structures ............................................................................. 23-38

23.5.13

Abutting Joints for Steel Structures ..................................................................... 23-39

23.5.14

Fabrication of Stainless Steel .............................................................................. 23-39

23.5.15

Orthotropic-deck Superstructures ....................................................................... 23-39

23.5.16

Full-size Tests for Steel Structures ..................................................................... 23-40

23.6

Assembly of Steel Structures ..................................................................................... 23-40

23.6.1

Shop Assembly for Steel Structures .................................................................... 23-40

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23.6.2

Evaluation of Steel Structure Assemblies............................................................ 23-42

23.6.3

Certification of Members or Components of Steel Structures .............................. 23-42

23.6.4

Bolting Steel Structures ...................................................................................... 23-43

23.6.5

Welded Connections for Steel Structures............................................................ 23-43

23.6.6

Preassembly of Field Connections for Steel Structures....................................... 23-43

23.6.7

Match-marking Connecting Parts for Steel Structures ......................................... 23-45

23.6.8

Steel Structure Connections Using Unfinished, Turned, or Ribbed Bolts ............ 23-45

23.6.9

Steel Structure Connections Using High-strength Bolts ...................................... 23-46

23.6.10

Welding for Steel Structures ............................................................................... 23-56

23.7

Erecting Steel Structures ........................................................................................... 23-59

23.7.1

Pre-erection Requirements ................................................................................. 23-59

23.7.2

Special Requirements to Resist Steel Weathering .............................................. 23-59

23.7.3

Aligning Steel Structure with Substructure .......................................................... 23-60

23.7.4

Placing Anchor Rods for Erection of Steel Structure ........................................... 23-60

23.7.5

Preparing Bearing Areas and Setting Bearings for Erection of Steel Structure .... 23-61

23.7.6

Tightening Anchor Rod Nuts for Erection of Steel Structure ................................ 23-61

23.7.7

Bearings for Erection of Steel Structures ............................................................ 23-61

23.7.8

Procedure to Erect a Steel Structure ................................................................... 23-61

23.7.9

Field Assembly for Erection of a Steel Structure ................................................. 23-62

23.7.10

Connection of Pins for an Erected Steel Structure .............................................. 23-62

23.7.11

Correcting Misfits in an Erected Steel Structure .................................................. 23-63

23.8

Expansion Joints for Steel Structures ........................................................................ 23-63

23.9

Inspection and Final Acceptance for Steel Structures ................................................ 23-63

23.10

Additional Provisions for Curved Steel Girders........................................................... 23-64

23.10.1

Contractor’s Construction Plan for Curved Girder Bridge .................................... 23-64

23.10.2

Fabricating Materials for Curved Girder Bridges ................................................. 23-64

23.10.3

Transportation Plan for Curved Girders .............................................................. 23-66

23.10.4

Erecting Steel for Curved Girder Bridges ............................................................ 23-67

23.10.5

Erecting Decks for Curved Girder Bridges .......................................................... 23-67

23.10.6

Reporting Modification to Construction Plan for Curved Girder Bridge ................ 23-68

23.11

Post-weld Treatment for Steel Structures ................................................................... 23-68

23.11.1

Ultrasonic Impact Treatment for Steel Structures ................................................ 23-68

23.12

Additional Requirements for Steel Structures ............................................................. 23-69

Index ........................................................................................................................................... 71

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23 STEEL STRUCTURES

This  chapter  outlines  standards  and  requirements  for  furnishing,  fabricating,  assembling,  and
erecting steel structures and structural steel portions of other structures for the Project. This chapter
also  outlines  requirements  for  non-destructive  testing  for  steel  structures  and  structural  steel
components  of  other  structures. When  performing such  work for  the  Project,  the  Contractor  shall
comply with the specifications in this chapter and in the Contract documents.

The Contractor shall fabricate and test steel structures and structural steel components of other
structures in accordance with these specifications and in compliance with the

American Association

of State Highway and Transportation Officials

(AASHTO)

Standard Specifications for Transportation

Materials and Methods of Sampling and Testing,

and the

American Society for Testing and Materials

(ASTM), or the British Standards (BS) and European Standards (BS EN). Where steel structures
and steel components are fabricated and tested by standards other than AASHTO/ASTM, products
conforming to equivalent or higher standards will be acceptable if proven to be suitable.

23.1

Terminology for Steel Work

This section defines terminology that occurs throughout this chapter and that applies to work with
steel structures.

Main or Primary Load-Carrying Member or Component:

Any part of a steel structure, including

the following, that supports the primary load for such a structure:

•

Longitudinal or transverse rolled beams or fabricated girders (I or box, curved or straight)

•

All truss members not designated as cross frames

•

Cross frames, diaphragms and connection plates of horizontally curved beams or girders

•

Rib members of steel arches

•

Bracing members subjected to and specifically designed for traffic live load and/or other loads

•

Cross frames or diaphragms at pier and abutment supports of tub or box girders (trapezoidal

members) and their connection plates

•

Attachments and components of the above such as splice, cover, cross frame and diaphragm

connection and gusset plates, but not transverse and bearing stiffeners (unless acting as a
cross frame or diaphragm)

•

Cables, moment release pins and links, and hangers

•

All steel substructure members except those designated as secondary in the Contract

documents

•

Other members as may be identified in the Contract documents

Miscellaneous Components:

Any other components of a steel structure, which includes but is not

limited to the following:

•

Ladders

•

Platforms

•

Bearings

•

Railings

•

End Wall Grates

•

Roadway Gratings

•

Metal Drainage Components

•

Steel Expansion Joint and Components

Design details shall conform to the requirements for the American Association of State Highway and
Transportation Officials (AASHTO), as outlined in the AASHTO Load and Resistance Factor Design
(LRFD) Bridge Design Specifications, and Road Structures Design Manual (ADQCC TR-516), as
applicable.

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Falsework used in the erection of structural steel shall conform to the provisions of Section 1.20.8 of
Chapter 01, General Requirements.

Welding and weld qualification tests shall conform to the provisions of the current AASHTO/ AWS
D1.5M/D1.5:2010,

Bridge Welding Code

23.2

General Requirements for Steel Structure Work

This section outlines general standards and requirements for steel structure work.

23.2.1

Reference Standards and Codes

Standards and codes for materials of steel structures and related construction works shall be as
specified in this section, in the Contract documents, if any, and the following, in their latest edition:

AASHTO LRFD

American Association of State Highway and Transportation Officials -
Load and Resistance Factor Design, Bridge Construction
Specifications;

AASHTO LRFD

American Association of State Highway and Transportation Officials -
Load and Resistance Factor Design, Bridge Design Specifications;

AASHTO

Standard Specifications for Highway Bridges, 17th Edition, Design
Specifications;

AASHTO

Standard Specifications for Transportation Materials and Methods of
Sampling and Testing;

AASHTO

Guide Specifications for Highway Bridge Fabrication with HPS70W
Steel, 2

Edition;

AASHTO/AWS

Bridge Welding Code; D1.5M/D1.5:2010

AASHTO

Standard Specification for Structural Steel Supports for Highway
Signs, Luminaires and Traffic Signals, 5th Edition;

ADQCC (TR-516)

Road Structures Design Manual;

ANSI

American National Standards Institute;

ANSI ASME

Metric Screw Threads: M Profile; B1.13M-2005

ANSI/ASME

Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy

Hex,

B18.2.1-2010

Hex Flange, Lobed Head, and Lag Screws (Inch Series);

ANSI/ASME

Nuts for General Applications: Machine Screw Nuts, Hex, Square,
Hex

B18.2.2-2010

Flange, and Coupling Nuts (Inch Series);

ANSI/ASME

Surface Texture, Surface Roughness, Waviness and Lay; B46.1-
2009

ANSI/AWS

Specification for Carbon Steel Electrodes and Fluxes for Submerged

Arc

A5.17/A5.17M-97

Welding; (R2007)

ANSI/AWS A5.18

Specification for Carbon Steel Electrodes and Rods for Gas Shielded
Arc

/A5.18M:2005

Welding;

ANSI/AWS A5.28

Specification for Low-Alloy Steel Electrodes and Rods for Gas
Shielded

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/A5.28M:2005

Arc Welding;

ANSI/AWS A5.24

Zirconium and Zirconium Alloy Welding Electrodes and Rods;

/A5.24M:2005

ANSI/AWS

Structural Welding Code

– Steel;

D1.1/D1.1M:2010

API

American Petroleum Institute;

API RP 2X:2004

Recommended practice for ultrasonic and magnetic examination of
offshore structural fabrication and guidelines for qualification of
technicians, 4th Edition;

ASME

American Society of Mechanical Engineers;

ASME/ANSI

Metric Heavy Hex Structural Bolts;

B 18.2.3.7M-2006

ASME/ANSI

Metric heavy hex nuts;

B 18.2.4.6M-2010

ASME/ANSI

Round head short square neck bolts;

B 18.5-2008

ASTM

American Society for Testing and Materials;

AWS

American Welding Society;

AWS A5.1/

Specification for Carbon Steel Electrodes for Shielded Metal Arc

Welding;

A5.1M-2004

AWS A5.5/

Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc

A5.5M:2006

Welding;

AWS A5.23/

Specification for Low-Alloy Steel Electrodes and Fluxes for
Submerged

A5.23M:2011

Arc Welding;

AWS D 1.6/

Structural Welding Code - Stainless Steel;

D 1.6M: 2007

British Standards;

BS EN

European Standards;

FHWA

U.S. Department of Transportation, Federal Highway Administration;

OSHA

Occupational Safety and Health Administration;

Report No.

Technical Information Guide for Narrow-Gap Improved Electroslag

FHWA-SA-

Welding;

96-053

Report No.

Process Operational Guide for Narrow-Gap Improved Electroslag

FHWA-SA-

Welding;

96-052

SSPC

Society for Protective Coatings;

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SSPC-SP 10/

Near-White Blast Cleaning;

NACE No. 2

SSPC-SP 6/

Commercial Blast Cleaning;

NACE No. 3

Table 3.2

Prequalified Minimum Preheat and Interpass Temperature;

ANSI/AWS D1.1

/D1.1M:2010

UNC

Unified Coarse Thread;

UNC Thread

Specifications of International Thread Standards.

ANSI B1.1

Table 23-1 and Table 23-2 presents American Association of State Highway and Transportation
Officials (AASHTO), American Society for Testing and Materials (ASTM), British (BS), and European
(BS EN) Standards that are related to materials for steel structures. It also includes designations and
titles.

Table 23-1: Designations and titles for AASHTO and ASTM standards that apply to steel

structures construction works

AASHTO
Designation

ASTM
Designation

Title

AASHTO M
270M/M 270-
12

ASTM A709 /
A709M - 11

Standard Specification for Structural Steel for Bridges

ASTM A675 /
A675M -
03(2009)

Standard Specification for Steel Bars, Carbon, Hot-
Wrought, Special Quality, Mechanical Properties

ASTM A663 /
A663M

– 12

Standard Specification for Steel Bars, Carbon, Merchant
Quality, Mechanical Properties

ASTM A673 /
A673M -
07(2012)

Standard Specification for Sampling Procedure for Impact
Testing of Structural Steel

ASTM A501 -
07

Standard Specification for Hot-Formed Welded and
Seamless Carbon Steel Structural Tubing

ASTM A500 /
A500M - 10a

Standard Specification for Cold-Formed Welded and
Seamless Carbon Steel Structural Tubing in Rounds and
Shapes

AASHTO M
164-05

ASTM A325 -
10

Standard Specification for Structural Bolts, Steel, Heat
Treated, 120/105 ksi Minimum Tensile Strength

AASHTO M
253-05

ASTM A490 -
12

Standard Specification for Structural Bolts, Alloy Steel,
Heat Treated, 150 ksi Minimum Tensile Strength

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AASHTO
Designation

ASTM
Designation

Title

ASTM F606 -
11a

Standard Test Methods for Determining the Mechanical
Properties of Externally and Internally Threaded Fasteners,
Washers, Direct Tension Indicators, and Rivets

AASHTO M
291-09

ASTM A563 -
07a

Standard Specification for Carbon and Alloy Steel Nuts

AASHTO M
293-10

ASTM F436 -
11

Standard Specification for Hardened Steel Washers

ASTM F959 -
09

Standard Specification for Compressible-Washer-Type
Direct Tension Indicators for Use with Structural Fasteners

AASHTO M
298-10

ASTM B695 -
04(2009)

Standard Specification for Coatings of Zinc Mechanically
Deposited on Iron and Steel

AASHTO M
232M/M 232-
10

ASTM A153 /
A153M - 09

Standard Specification for Zinc Coating (Hot-Dip) on Iron
and Steel Hardware

ASTM F1852 -
11

Standard Specification for “Twist Off” Type Tension Control
Structural Bolt/Nut/Washer Assemblies, Steel, Heat
Treated, 120/105 ksi Minimum Tensile Strength

AASHTO M
169-09

ASTM A108 -
07

Standard Specification for Steel Bar, Carbon and Alloy,
Cold-Finished

ASTM A109 /
A109M - 08

Standard Specification for Steel, Strip, Carbon (0.25
Maximum Percent), Cold-Rolled

AASHTO T
244-12

ASTM A370 -
12

Standard Test Methods and Definitions for Mechanical
Testing of Steel Products

AASHTO M
102M/M 102-
06 (R2011)

ASTM A668 /
A668M -
04(2009)

Standard Specification for Steel Forgings, Carbon and
Alloy, for General Industrial Use

ASTM A781 /
A781M - 12a

Standard Specification for Castings, Steel and Alloy,
Common Requirements, for General Industrial Use

AASHTO M
103M/M 103-
12

ASTM A27 /
A27M - 10

Standard Specification for Steel Castings, Carbon, for
General Application

AASHTO M
163M/M 163-
07 (2012)

ASTM A743 /
A743M -
06(2010)

Standard Specification for Castings, Iron-Chromium, Iron-
Chromium-Nickel, Corrosion Resistant, for General
Application

AASHTO M
105-09

ASTM A48 /
A48M -
03(2008)

Standard Specification for Gray Iron Castings

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AASHTO
Designation

ASTM
Designation

Title

ASTM A536 -
84(2009)

Standard Specification for Ductile Iron Castings

ASTM A47 /
A47M -
99(2009)

Standard Specification for Ferritic Malleable Iron Castings

AASHTO M
111M/M 111-
11

ASTM A123 /
A123M

– 12

Standard Specification for Zinc (Hot-Dip Galvanized)
Coatings on Iron and Steel Products

ASTM A6 /
A6M

– 12

Standard Specification for General Requirements for Rolled
Structural Steel Bars, Plates, Shapes, and Sheet Piling

ASTM A36 /
A36M

– 08

Standard Specification for Carbon Structural Steel

ASTM A588 /
A588M

– 10

Standard Specification for High-Strength Low-Alloy
Structural Steel, up to 50 ksi [345 MPa] Minimum Yield
Point, with Atmospheric Corrosion Resistance

ASTM E165 /
E165M

– 12

Standard Practice for Liquid Penetrant Examination for
General Industry

ASTM E709

–

Standard Guide for Magnetic Particle Testing

ASTM A941 -
10a

Standard Terminology Relating to Steel, Stainless Steel,
Related Alloys, and Ferroalloys

ASTM A307

–

Standard Specification for Carbon Steel Bolts and Studs,
60 000 PSI Tensile Strength

ASTM F568M-
07

Standard Specification for Carbon and Alloy Steel
Externally Threaded Metric Fasteners (Withdrawn)

ASTM A276 -
13

Standard Specification for Stainless Steel Bars and Shapes

Table 23-2: Designations and titles for BS and BS EN standards that apply to steel

structures construction works

BS
Designation

BS EN
Designation

Title

BS 4-1:2005

Structural steel sections. Specification for hot-rolled sections

BS 7079:2009

General introduction to standards for preparation of steel
substrates before application of paints and related products

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BS
Designation

BS EN
Designation

Title

BS 4190:2001

ISO metric black hexagon bolts, screws and nuts.
Specification

BS 3692:2001

ISO metric precision hexagon bolts, screws and nuts.
Specification

BS 2583:1955

Specification for podger spanners

BS 4872-
1:1982

Specification for approval testing of welders when welding
procedure approval is not required. Fusion welding of steel

BS 7419:2012

Specification for holding down bolts

BS 4933:2010

Specification for ISO metric black cup and countersunk
head bolts and screws with hexagon nuts

BS 4929-
1:1973

Specification for steel hexagon prevailing-torque type nuts.
Metric series

BS 4320:1968

Specification for metal washers for general engineering
purposes. Metric series

BS EN 10163-
1:2004

Delivery requirements for surface condition of hot-rolled
steel plates, wide flats and sections. General requirements

BS EN
10164:2004

Steel products with improved deformation properties
perpendicular to the surface of the product. Technical
delivery conditions

BS EN
10160:1999

Ultrasonic testing of steel flat product of thickness equal or
greater than 6 mm (reflection method)

BS EN 10025-
1:2004

Hot rolled products of structural steels. General technical
delivery conditions

BS EN 10025-
2:2004

Hot rolled products of structural steels. Technical delivery
conditions for non-alloy structural steels

BS EN 10025-
3:2004

Hot rolled products of structural steels. Technical delivery
conditions for normalized/normalized rolled weldable fine
grain structural steels

BS EN 10025-
4:2004

Hot rolled products of structural steels. Technical delivery
conditions for thermomechanical rolled weldable fine grain
structural steels

BS EN 10025-
5:2004

Hot rolled products of structual steels. Technical delivery
conditions for structural steels with improved atmospheric
corrosion resistance

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BS
Designation

BS EN
Designation

Title

BS EN 10025-
6:2004+A1:2009

Hot rolled products of structural steels. Technical delivery
conditions for flat products of high yield strength structural
steels in the quenched and tempered condition

BS EN 10210-
1:2006

Hot finished structural hollow sections of non-alloy and fine
grain steels. Technical delivery requirements

BS EN 10210-
2:2006

Hot finished structural hollow sections of non-alloy and fine
grain steels. Tolerances, dimensions and sectional
properties

BS EN 10219-
2:2006

Cold formed welded structural hollow sections of non-alloy
and fine grain steels. Tolerances, dimensions and sectional
properties

BS EN
10346:2009

Continuously hot-dip coated steel flat products. Technical
delivery conditions

BS EN
10143:2006

Continuously hot-dip coated steel sheet and strip.
Tolerances on dimensions and shape

BS EN
10029:2010

Hot-rolled steel plates 3 mm thick or above. Tolerances on
dimensions and shape

BS EN 10056-
1:1999

Specification for structural steel equal and unequal angles.
Dimensions

BS EN
10034:1993

Structural steel I and H sections. Tolerances on shape and
dimensions

BS EN
10051:2010

Continuously hot-rolled strip and plate/sheet cut from wide
strip of non-alloy and alloy steels. Tolerances on
dimensions and shape

BS EN
14399:2005

High-strength structural bolting for preloading.

BS EN 1993-1-
8:2005

Eurocode 3. Design of steel structures. Design of joints

BS EN 1011-
2:2001

Welding. Recommendations for welding of metallic
materials. Arc welding of ferritic steels

BS EN 1011-
8:2004

Welding. Recommendations for welding of metallic
materials. Welding of cast irons

BS EN 287-
1:2011

Qualification test of welders. Fusion welding. Steels

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BS
Designation

BS EN
Designation

Title

BS EN ISO
15614-
1:2004+A2:2012

Specification and qualification of welding procedures for
metallic materials. Welding procedure test. Arc and gas
welding of steels and arc welding of nickel and nickel alloys

BS EN ISO
17637:2011

Non-destructive testing of welds. Visual testing of fusion-
welded joints

BS EN ISO
9934-1:2001

Non-destructive testing. Magnetic particle testing. General
principles

BS EN ISO
3452-1:2013

Non-destructive testing. Penetrant testing. General
principles

BS EN ISO
17640:2010

Non-destructive testing of welds. Ultrasonic testing.
Techniques, testing levels, and assessment

BS EN ISO
4157-1:1999

Construction drawings. Designation systems. Buildings and
parts of buildings

BS EN ISO
4157-2:1999

Construction drawings. Designation systems. Room names
and numbers

BS EN ISO
6284:1999

Construction drawings. Indication of limit deviations

BS EN ISO
8560:1999

Construction drawings. Representation of modular sizes,
lines and grids

BS EN ISO
9431:1999

Construction drawings. Spaces for drawing and for text, and
title blocks on drawing sheets

BS EN ISO
4063:2010

Welding and allied processes. Nomenclature of processes
and reference numbers

BS EN
22553:1995

Welded, brazed and soldered joints. Symbolic
representation on drawings

BS EN ISO
7042:2012

Prevailing torque type all-metal hexagon high nuts. Property
classes 5, 8, 10 and 12

BS EN ISO
2320:2008

Prevailing torque type steel nuts. Mechanical and
performance properties

23.2.2

Mill Inspection and Tests for Steel Structures

Unless directed otherwise, the Fabricator of structural steel shall give the Engineer two copies of a
certified report of test or analysis showing both physical and chemical tests of the material for each
heat of material. The Fabricator shall submit these inspection and test reports to the Engineer for
examination and before requesting the fabrication shop inspection.

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23.2.3

Notice of Beginning Steel Structure Work

The Contractor shall give the Engineer ample notice of the beginning of work at the mill or in the
shop to enable inspection. The Contractor shall not manufacture any material or do any work in the
shop until providing such notice to the Engineer.

23.2.4

Shop Inspection for Steel Structures

The Engineer may inspect all structural steel and miscellaneous metals furnished at fabrication site.
Before requesting inspection, the Fabricator shall submit a list of main stress-carrying members and
the heat number of the material from which fabricating the member. The Fabricator shall preserve
the heat number, as marked by the rolling mill, for identification by the  Engineer and inspectors. If
fabrication  hides,  cuts  off,  or  otherwise  obliterates  the  original  number  or  marking, the  Fabricator
shall paint the number on the material at a conspicuous location.

The Fabricator shall furnish facilities in the shop for inspecting material and work quality and allow
the Engineer and inspectors necessary access to all parts of the work. Such facilities shall include
adequate office space at the fabricating plant for the inspectors use during fabrication, assembly,
cleaning,  and  painting.  At  the  plants  of  all  major  Fabricators,  as  the  Engineer  determines,  the
Contractor shall ensure this office space has at least 10 square metres of floor space and at least
two  desks  (or  a  desk  and  table),  a  file  case,  and  other  necessary  furniture.  The  Contractor  shall
provide  adequate  lighting,  heating,  and  ventilation  and  ensure  cleanliness.  The  Contractor  shall
provide office space that is completely partitioned and separated from the Fabricator's activities, with
a separate door equipped with a suitable lock and key. This may be part of a larger facility that is set
aside for the exclusive use of outside inspection personnel.

The Contractor shall make available telephone service and adequate sanitary facilities in the
immediate area. The Engineer may revise the foregoing requirements to accommodate the number
of inspectors necessary to inspect the volume of work. The inspector may reject any material or work
that does not conform to the specification requirements. The

inspector’s acceptance of any material

or finished members shall not preclude the rejection of such materials later if they are defective.

Inspection at the mill and shop facilitates the work and avoids error. It shall not relieve the Contractor
of responsibility for imperfect material, or technique, or for replacing the same.

23.2.5

Material Traceability and Shipping for Steel Structures

This section outlines requirements for tracing and shipping materials for steel structures.

23.2.5.1

Marking

The Con

tractor’s system of assembly-marking individual pieces, and the issuance of cutting

instructions to the shop shall be such as to maintain identity of the original piece.

The Contractor may furnish material that can be identified by heat number and mill test report from
stock.

During fabrication, up to the point of assembling members, each piece of steel, other than Grade 36
(Grade 250) steel, shall show clearly and legibly its specification.

Any piece of steel, other than Grade 36 (Grade 250) steel, which will be subject to fabricating
operations such as blast cleaning, galvanizing, heating for forming, or painting which might obliterate
marking prior to assembling into members, shall be marked for grade by steel die stamping or by a
substantial tag firmly attached. Steel die stamps shall be low stress-type.

The Contractor shall properly identify all materials that arrive at the shop, in accordance with the
requirements of

ASTM’s Standard Specification for

General Requirements for Rolled Structural Steel

Bars, Plates, Shapes, and Sheet Piling

(ASTM A6 / A6M

– 12) or BS EN’s

General Technical Delivery

Conditions for Hot Rolled Products of Structural Steels

(BS EN 10025-1:2004). The Fabricator shall

document all main load-carrying member material, high-strength fastener assemblies, and weld
materials incorporated into the work through the entire fabrication process. The Contractor shall

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document this material traceability in a report that correlates heat numbers to their respective
locations in the completed members. The Contractor shall also provide diagrams and sketches, as
requested by the Engineer for clarity.

At the fabrication facility, the Fabricator shall maintain records of all relevant material testing and
certification processes and identification of all components and parts. The Fabricator shall maintain
such vital project records for at least two years from the latest date on which they shipped such
materials from their facility. The Contractor shall provide a copy of these records to the Engineer.

On any item that weighs more than three tons, the Fabricator shall mark the

item’s weight on the

member in a visible location.

The Contractor shall mark matching members and assemblies.

The Fabricator shall match mark all connecting members or parts that have been reamed or drilled
while assembled. The Fabricator shall also provide a diagram showing all marks and clearly indicate
the location of all the marks on the shop drawings.

The  Fabricator  shall  use  painted  marks,  attached  metal  tags,  other  durable  methods  that  do  not
degrade the finish of the piece, or low-stress type steel die stamps to identify and match mark pieces.
Steel  die  stamps,  if  used,  shall  be  blunt  nosed  or  interrupted  dot  dies,  manufactured  to  produce
impressions that are rounded at the bottom of the impression. Depressions caused by such stamps
shall  not  exceed  0.8  mm.  Character  heights  from  such  stamps  shall  not  exceed  12.5  mm.  The
Fabricator shall remark coated type markings as necessary to maintain continuity in traceability.

The Fabricator shall mark splice plates and girders so that upon erection, the mark on the splice
plate is located opposite a matching mark on the girder. The Fabricator shall adhere to the following
instructions for marking splice plates:

a. Place the mark on web splice plates, midway down the long side of the plate, on either the

right or left side, to correspond with the girder to which the splice plate will be temporarily
attached for shipping to the erection site. Make a matching stamp on the girder web opposite
the mark on the splice plate.

b. Place the mark on top or bottom flange splice plates, on the right or left end of the plate,

corresponding to the girder to which the plate will be attached for shipment to the erection
site. Place a corresponding mark on the girder flange opposite the mark in the splice plate.

c. As an alternate location for tub girder bottom flange splice plates, place the mark midway

down the long side of the plate, on either the right or left side, to correspond with the girder
to which the splice plate will be temporarily attached for shipping to the erection site. Make a
matching mark on the girder flange opposite the mark on the splice plate.

The Fabricator shall mark girders and beams on the left end, according to the orientation shown in
the shop drawings, near the top flange. Diaphragms shall be marked in the middle upper portion of
the web. Cross frames shall be marked in the middle of the top or bottom horizontal member. The
Fabricator shall not use die stamps on fracture critical members or use die stamps near edges of
members or components subject to tensile stresses as specifically noted in the Contract plans or as
directed by the Engineer.

The Fabricator shall ensure that, during fabrication, the heat number remains painted on each
primary load-carrying component until each component is permanently joined into a piece-marked
member or assembly.

Upon request by the Engineer, the Contractor shall furnish an affidavit certifying that throughout the
fabrication operation the identification of steel has been maintained in accordance with this
specification.

23.2.5.2

Shipping Structural Members

The Fabricator shall load structural members on trucks or cars in a way that transport to their
destination and unloading at their destination shall not cause excessive stress, deformation, or
damage. All girders and rolled beams shall be shipped in a standing position. The Contractor shall

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ensure that girders and beams remain in such standing positions in subsequent operations. The
Fabricator may ship haunched sections of built-up girders in inverted positions.

23.2.5.3

Shipping Bulk Materials

The Contractor shall ensure that all bulk materials, such as shear studs, are stored together in
individual LOTs and that the outside of each container has a list and description of the contents.
Maintain a separate list of the weights of all tools and erection materials.

23.2.5.4

Shipping Fastener Assemblies

Either the Contractor or the Fabricator shall transport and store fastener assemblies in sealed,
watertight containers, in accordance with the following procedural directions.

a. Label the side of each container with the supplier

’s name and LOT identification number, and

marked to identify the contents and size of the fastener components. Ensure that all surfaces
of the nuts are lubricated before their placement in watertight containers.

b. Provide containers for components that are capable of protecting them from moisture and

other  harmful  materials.  Maintain  such  containers  in  their  sealed  conditions  until  they  are
opened for use at their assembly locations. Do not remove more fastener assemblies from
the  protected  area  than  can  be  installed  and  tightened  during  a  work  shift.  Leave  the
containers unopened until needed for assembly.

c. At the end of the work shift, return unused fastener assemblies to the protected storage area

for future use. Protect opened storage containers from contamination.

The Fabricator shall separately pack non-high-strength bolts of different lengths and diametres. They
shall also pack the loose nuts and washers supplied for each size of bolt separately, except that zinc
coated bolts, nuts, and washers of the same size shall be shipped in the same containers. Bolts,
nuts, washers, pins, and small parts shall be shipped in boxes, crates, kegs, or barrels. A container

’s

gross weight shall not exceed 136 kg.

23.2.5.5

Shipping Anchor Rods and Nuts

The Contractor shall ship anchor rods and nuts as an assembly. Washers may be shipped separate
from an assembly.

23.2.6

Handling and Storing Materials for Steel Structures

When handling, transporting, and storing plates, shapes, assemblies, fastener components and
other parts, the Contractor shall protect such items from damage. They shall also ensure that such
items remain safe during subsequent inspections. The Contractor shall provide storage that keeps
materials, assemblies, parts, and other components clean. While stored, such materials shall remain
free from dirt, grease, other foreign matter, unacceptable corrosion or coating deterioration, and all
other adverse environmental conditions.

The Contractor shall place material to be stored at a job site on platforms, skids, or other supports
above the ground to keep materials clean and properly drained. Girders and beams shall be placed
upright,  shored,  and  tied  or  braced  to  prevent  high  winds  from  tipping  or  overturning  them.  Long
members, such as columns and chords, shall be supported on skids that are near enough to each
other  to  prevent  damage  and  injury  from  deflection.  If  the  Contract  documents  only  apply  to  the
erection of a steel structure, the Contractor shall check the material received against the shipping
lists and promptly report, in writing, any shortage or damage. The Contractor shall be responsible
for any loss of material and for any damage to those materials after receiving them.

The Contractor shall store bolts, nuts, and washers in their original containers and protect them from
dirt and moisture until using them. Storage of high-strength fasteners shall conform to Article
23.6.9.6.

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The Contractor shall store coatings in accordance with Section 24.3.8 of Chapter 24, Painting, and
the Manufacturer

’s recommendations. The Contractor shall notify the Engineer if the Manufacturer’s

recommendations vary from those provided in the Contract documents.

23.2.7

Field Inspection for Steel Structures

Erections are subject to inspection and the Contractor shall provide facilities in which the Engineer
can inspect material and work quality. The Engineer shall inspect only material and work quality that
was not already inspected after its delivery to the work site.

23.2.8

Falsework for Steel Structures

Falsework used for the erection of structural steel shall conform to the provisions in Section 1.20.8
of Chapter 1, General Requirements, of these standard specifications, except that dead loads shall
consist of the mass of the structural steel and any other portions of the structure that are supported
by the falsework.

The Contractor shall properly design, construct, and maintain falsework to ensure that it can handle
the loads placed upon it. Falsework shall provide the required construction camber.

If  asked  to  do  so,  the  Contractor  shall  submit  detailed  plans  for  falsework  to  the  Engineer.  The
Engineer's approval of these plans, or acceptance of work constructed according to them, however,
shall  not  relieve  the  Contractor  of  responsibility  for  successful  erection  of  a  steel  structure  and
otherwise satisfactory results.

When building falsework over seawater that is subject to boating use, the Contractor shall construct
such  falsework  to  provide  adequate  horizontal  and  vertical  clearance  for  rowboats  and  small
powerboats to pass. Such clearance shall also comply with the requirements of related authorities.
Falsework  that  resides  over  a  highway  or  street  that  is  used  by  traffic  shall  provide  a  minimum
horizontal clearance of 7.5 metres and minimum vertical clearance of 6.5 metres, unless the plans
or special provisions require otherwise.

After completing a steel structure, the Contractor shall remove falsework piles down to at least 600
mm below seabed or finished ground line. The Contractor shall also entirely remove any temporary
bents, mudsills, and footings.

Overhang bracket form supports shall not attach to the girder web.

Falsework and forms that support concrete work on steel structures shall be constructed so that any
loads applied to girder webs shall be applied within 150 mm of a flange or stiffener and shall be
distributed to prevent local distortions of the web. As necessary, temporary struts and ties shall resist
lateral loads that are applied to the girder flanges and shall prevent appreciable relative vertical
movement between the edge of a deck form and the adjacent steel girder.

23.2.9

Continuous Members of Steel Structures

If erection procedures to be used will provide the designed girder continuity for dead load, then the
Contractor shall provide a statement of the intended steel erection procedures to the Engineer for
review and approval. This statement shall include calculations in sufficient detail to substantiate that
girder geometry will be correct. The Contractor shall preassemble members with field joints in a
horizontal or an upright position and with no load.

If erection procedures to be used will result in steel girders not attaining the continuity for dead load
assumed in design, then the Contractor shall provide a statement of steel erection procedures to the
Engineer. This statement shall include calculations in sufficient detail to substantiate that girder
capacity and geometry will be correct.

After erection, a steel structure shall have a load carrying capacity at least equal to the designed
structure, as shown on the Contract plans. With the Engineer

’s approval, the Contractor may

increase the cross-sectional area or change the grades of steel to provide the specified load carrying
capacity. The Contractor may also use any additional steel or higher strength steels to accommodate

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