Steel Construction Manual

315 Pages·4.783 MB·English

by  Paterson D.A., Glynn A.C.

NEW YORK STATE

STEEL CONSTRUCTION
MANUAL
3RD EDITION

DAVID A. PATERSON ASTRID C. GLYNN
GOVERNOR COMMISSIONER

Department of Transportation, Office of Structures
March 2008
NEW YORK STATE

STEEL CONSTRUCTION
MANUAL
rd
3 Edition

NEW YORK STATE DEPARTMENT OF TRANSPORTATION
ENGINEERING DIVISION
OFFICE OF STRUCTURES

G.A. CHRISTIAN PREPARED BY THE METALS ENGINEERING UNIT
DEPUTY CHIEF ENGINEER STRUCTURE S N. PAUL RIMMER, SUPERVISOR

March 2008
STEEL CONSTRUCTION MANUAL
LIST OF SECTIONS

Section Title

1 Introduction
2 Drawings
3 Inspection
4 General Fabrication Requirements
5 Base Metal
6 Preparation of Base Metals
7 Welding
8 Qualification
9 Fracture Control Plan
10 Bolting
11 Shop Assembly
12 Dimensional Tolerances for Fabricated Members
13 Cleaning and Protective Coatings
14 Storage, Transportation, & Erection
15 Heat Curving, Cambering, and Straightening
16 Radiographic Testing
17 Ultrasonic Testing
18 Magnetic Particle Inspection
19 Dye Penetrant Inspection

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TABLE OF CONTENTS

SECTION 1 INTRODUCTION...................................................................................................1
SECTION 2 DRAWINGS............................................................................................................3
201. CONTRACT DRAWINGS..........................................................................................3
201.1 Definition................................................................................................................3
201.2 Requests for Clarification.......................................................................................3
201.3 Dimensions.............................................................................................................3
201.4 Errors.......................................................................................................................3
201.5 Principal Controlling Dimensions and Material Properties....................................3
202. SHOP DRAWINGS......................................................................................................4
202.1 Preparation..............................................................................................................4
202.2 Type and Size..........................................................................................................4
202.3 Project Information Required on Shop Drawings...................................................5
202.4 NYSDOT Review of Shop Drawings.....................................................................5
202.5 Shop Drawing Submittal Procedure........................................................................6
202.5.1 Electronic Submittal........................................................................................6
202.5.2 Hard Copy Submittal......................................................................................7
202.6 Preliminary Review & Approval............................................................................8
202.7 Signature Review and Approval.............................................................................9
202.8 Revisions.................................................................................................................9
202.9 Distribution of Signature Approved Shop Drawings..............................................9
202.10 Archiving..............................................................................................................10
202.11 Submittal to Railroad Companies and Other Agencies........................................10
202.12 Contractor’s Responsibility..................................................................................10
202.13 Detention of Shop Drawings.................................................................................10
202.14 Consultant Engineering Review...........................................................................11
202.15 Cost of Shop Drawing Prints/ Reproducibles and Microfilm...............................11
203. DETAILING REQUIREMENTS FOR SHOP DRAWINGS................................11
203.1 AASHTO Requirements.......................................................................................11
203.2 AREMA Requirements.........................................................................................11
203.3 Detailing for Welded Fabrication.........................................................................11
203.4 Girder Details........................................................................................................12
203.5 Field Splices in Stringers and Girders..................................................................12
203.6 Location of Shop Welded Splices in Fabricated Members...................................13
203.7 Bearing Stiffeners.................................................................................................13
203.8 Intermediate Stiffeners and Connection Plates.....................................................14
203.9 Longitudinal Stiffeners.........................................................................................15
203.10 Lateral Bracing and Diaphragm Connections.......................................................15
203.11 Bearing Sole Plates...............................................................................................16
203.12 Curved Girders......................................................................................................16
203.13 Bolt Spacing and Edge Distance...........................................................................16
203.14 Seal Spacing..........................................................................................................16
203.15 Shop Drawing Requirements for Multi-Dimensional Framing with Numerically
Controlled Drilling................................................................................................................17
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204. ERECTION DRAWINGS..........................................................................................17
204.1 General..................................................................................................................17
204.2 Required Information [Drawings].........................................................................17
204.3 Required Information [Calculations]....................................................................19
205. REPAIR PROCEDURE DRAWINGS.....................................................................19
205.1 General..................................................................................................................19
205.2 Required Information............................................................................................19
206. TRANSPORTATION DRAWINGS.........................................................................20
206.1 General..................................................................................................................20
206.2 Required Information............................................................................................20
207. HEAT CURVING DRAWINGS................................................................................21
207.1 General..................................................................................................................21
SECTION 3 INSPECTION........................................................................................................23
301. GENERAL...................................................................................................................23
302. QUALIFICATION OF INSPECTORS....................................................................23
303. RESPONSIBILITIES OF INSPECTORS................................................................24
303.1 General..................................................................................................................24
303.2 Inspection of Materials.........................................................................................24
303.3 Inspection of Welding Procedure, Qualification and Equipment.........................24
303.4 Inspection of Welder, Welding Operator and Tacker Qualifications...................24
303.5 Inspection of Work and Records...........................................................................25
303.6 Photographs and Drawings...................................................................................25
303.7 Inspector's Mark of Acceptance for Shipment......................................................25
303.8 Report of Shipment of Structural Material (Form B and GC 4b).........................26
303.9 Shipment of Rejected Material or Material Not Offered for Shop Inspection.....26
304. FACILITIES FOR INSPECTION............................................................................26
305. INSPECTOR'S AUTHORITY..................................................................................26
306. OBLIGATIONS OF THE CONTRACTOR............................................................26
307. NONDESTRUCTIVE TESTING..............................................................................27
307.1 General..................................................................................................................27
307.2 Personnel Qualification.........................................................................................27
308. MILL AND SHOP INSPECTION............................................................................28
SECTION 4 GENERAL FABRICATION REQUIREMENTS.............................................29
401. FABRICATOR REQUIREMENTS..........................................................................29
401.1 General Requirements...........................................................................................29
401.2 Level of Work.......................................................................................................29
401.3 DCES Approval....................................................................................................29
402. MINIMUM SHOP FACILITIES FOR FABRICATION.......................................30
403. ORDERING OF MATERIALS.................................................................................31
404. COMMENCEMENT OF SHOP WORK.................................................................31
SECTION 5 BASE METAL......................................................................................................33
501. GENERAL...................................................................................................................33
502. APPROVED BASE METALS...................................................................................33
502.1 Specifications........................................................................................................33
502.2 Additional Requirements......................................................................................33
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503. STEEL FOR PINS, ROLLERS AND EXPANSION ROCKERS..........................34
504. BACKING, EXTENSION BARS, AND RUN OFF PLATES................................34
504.1 Backing.................................................................................................................34
504.2 Extension Bars and Run Off Plates.......................................................................34
505. INTERNAL SOUNDNESS OF PLATES AND SHAPES.......................................34
505.1 Laminar Defects at Edges and Ends.....................................................................34
505.2 Laminar Defects at Tension Groove Welds..........................................................34
506. STRAIGHTENING MATERIAL PRIOR TO FABRICATION...........................36
507. DIRECTION OF ROLLING.....................................................................................36
508. IDENTIFICATION OF MATERIAL.......................................................................36
SECTION 6 PREPARATION OF BASE METALS...............................................................39
601. CUTTING – GENERAL............................................................................................39
602. THERMAL CUTTING OF HIGH STRENGTH (70,000 psi minimum yield
strength)...................................................................................................................................39
603. SURFACES AND EDGES TO BE WELDED.........................................................39
604. FLANGE PLATES.....................................................................................................40
605. WEB PLATES.............................................................................................................40
606. TRUSS MEMBERS....................................................................................................40
607. STIFFENERS AND CONNECTION PLATES.......................................................40
608. LATERAL GUSSET PLATES..................................................................................40
609. SPLICE PLATES AND GUSSET PLATES............................................................41
610. SHEARED EDGES.....................................................................................................41
611. BENDING OF STRUCTURAL STEEL PLATES..................................................41
612. MACHINING OF CONTACT SURFACES............................................................41
612.1 Bearing Surfaces...................................................................................................41
612.2 Abutting Joints......................................................................................................42
612.3 End Connection Angles........................................................................................42
613. BOLT HOLES IN STEEL MEMBERS....................................................................42
613.1 General..................................................................................................................42
613.2 Bolt Holes in Primary Members...........................................................................44
613.3 Bolt Holes in Primary Members...........................................................................44
614. BOLT HOLES IN SECONDARY MEMBERS AND COMPONENTS................45
614.1 General..................................................................................................................45
614.2 Size of Holes in Secondary Members...................................................................45
615. PINS AND ROLLERS................................................................................................45
615.1 General..................................................................................................................45
615.2 Boring Pin Holes...................................................................................................45
615.3 Pin Clearances.......................................................................................................45
615.4 Pin Threads...........................................................................................................45
615.5 Pilot and Driving Nuts..........................................................................................45
616. BRONZE SURFACED EXPANSION BEARINGS................................................46
SECTION 7 WELDING Part A – Design of Welded Connections........................................47
SECTION 7 WELDING Part B – Workmanship and Technique.........................................49
704. GENERAL...................................................................................................................49
705. APPROVED WELDING PROCESSES...................................................................51
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706. FILLER METAL REQUIREMENTS......................................................................51
706.1 General..................................................................................................................51
706.2 Requirements for Weathering Steels....................................................................51
706.3 Manufacturer’s Certification.................................................................................51
707. WELDING WEATHERING STEELS.....................................................................54
708. PREHEAT AND INTERPASS TEMPERATURE..................................................54
708.1 General Requirements...........................................................................................54
708.2 Preheating for Tack Welding................................................................................55
709. HEAT INPUT REQUIREMENT FOR A709-50W (A588) AND A709-HPS70W
STEELS...................................................................................................................................55
710. STRESS RELIEF HEAT TREATMENT.................................................................56
711. REQUIREMENTS FOR MANUAL SHIELDED METAL ARC WELDING.....57
711.1 Electrodes for Manual Shielded Metal Arc Welding............................................57
711.2 Procedures for Manual Shielded Metal Arc Welding...........................................57
711.2.1 General..........................................................................................................57
711.2.2 Size of Electrodes.........................................................................................57
711.2.3 Size of Weld Passes......................................................................................57
711.2.4 Direction of Welding....................................................................................58
711.2.5 Gouging Root of Weld..................................................................................58
711.2.6 Restrictions...................................................................................................58
711.2.7 Field Welding................................................................................................58
712. REQUIREMENTS FOR SUBMERGED ARC WELDING...................................58
712.1 General..................................................................................................................58
712.2 Electrodes and Fluxes for Submerged Arc Welding.............................................59
712.3 Procedures for Submerged Arc Welding with a Single Electrode........................60
712.4 Procedures for Submerged Arc Welding with Parallel Electrodes.......................60
712.5 Procedures for Submerged Arc Welding with Multiple Electrodes.....................61
713. REQUIREMENTS FOR FLUX CORED AND GAS METAL ARC WELDING 62
713.1 Electrodes..............................................................................................................62
713.2 Procedures for FCAW and GMAW......................................................................62
714. EXTENSION BARS AND RUNOFF PLATES.......................................................63
715. GROOVE WELD BACKING...................................................................................63
715.1 Bridge Structures..................................................................................................64
715.2 Buildings and Tubular Structures.........................................................................64
716. TEMPORARY AND TACK WELDS.......................................................................64
717. CONTROL OF DISTORTION AND SHRINKAGE STRESSES.........................65
718. PEENING....................................................................................................................65
719. ARC STRIKES............................................................................................................65
720. CAULKING.................................................................................................................65
721. WELD CLEANING....................................................................................................66
721.1 In Process Cleaning...............................................................................................66
721.2 Cleaning of Completed Welds..............................................................................66
722. WELD PROFILES AND FILLET WELD SIZES..................................................66
723. QUALITY OF WELDS (Bridges).............................................................................67
723.1 Visual Inspection..................................................................................................67
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723.2 Other Nondestructive Inspection..........................................................................67
723.3 Limits of Porosity.................................................................................................69
724. QUALITY OF WELDS (Buildings)..........................................................................69
725. REPAIRS.....................................................................................................................69
725.1 General..................................................................................................................69
725.2 Written Repair Procedures....................................................................................70
725.3 Methods of Repair.................................................................................................70
SECTION 7 WELDING Part C – Stud Welding.....................................................................71
SECTION 7 WELDING Part D – Welding of Reinforcing Steel...........................................73
735. GENERAL...................................................................................................................73
736. BASE METAL............................................................................................................73
737. WELD PROCESSES..................................................................................................73
738. FILLER METAL........................................................................................................73
739. PERMISSIBLE STRESSES......................................................................................73
740. EFFECTIVE DESIGN DIMENSIONS.....................................................................73
740.1 Direct Butt Splices................................................................................................73
740.2 Flare-Bevel and Flare-V-Groove Welds...............................................................74
741. JOINT DETAILS........................................................................................................75
741.1 General..................................................................................................................75
741.2 Direct Butt Splice Details.....................................................................................75
741.3 Indirect Butt Splice Details...................................................................................76
741.4 Direct Lap Splice Details......................................................................................76
741.5 Indirect Lap Splice Details....................................................................................76
742. PREHEAT AND INTERPASS TEMPERATURES................................................81
743. PREPARATION OF MATERIAL............................................................................82
744. ASSEMBLY.................................................................................................................82
745. QUALITY OF WELDS..............................................................................................82
746. QUALIFICATION.....................................................................................................84
747. INSPECTION..............................................................................................................84
SECTION 8 QUALIFICATION Part A – Welding Procedure Qualification......................85
801. GENERAL...................................................................................................................85
802. BASE METAL AND ITS PREPARATION.............................................................90
803. TEST POSITIONS......................................................................................................90
804. TEST SPECIMENS....................................................................................................90
805. LIMITATION OF VARIABLES..............................................................................95
805.1 Submerged Arc Welding.......................................................................................95
805.2 Flux Cored and Gas Metal Arc Welding..............................................................95
806. METHOD OF TESTING SPECIMENS...................................................................96
807. TEST RESULTS.........................................................................................................96
807.1 Reduced Section Tension Tests............................................................................96
807.2 Side Bend Tests.....................................................................................................96
807.3 All Weld Metal Tension Test................................................................................96
807.4 Charpy V-Notch Impact Test................................................................................96
807.5 Chemical Analysis................................................................................................96
807.6 Radiographic Test.................................................................................................96
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807.7 Macroetch Specimen.............................................................................................96
808. RETESTS.....................................................................................................................96
808.1 General..................................................................................................................96
808.2 Impact Specimens.................................................................................................96
808.3 Test Plates.............................................................................................................97
SECTION 8 QUALIFICATION Part B Welder, Welding Operator, and Tacker
Qualification................................................................................................................................99
809. GENERAL...................................................................................................................99
810. TEST POSITIONS......................................................................................................99
810.1 Groove Welds.......................................................................................................99
810.2 Fillet Welds.........................................................................................................100
811. WELDER QUALIFICATION.................................................................................105
811.1 Welder’s Classification.......................................................................................105
811.2 Tests Required....................................................................................................105
811.3 Position Qualified...............................................................................................109
811.4 Welding Procedure..............................................................................................109
811.5 Preparation of Test Specimens............................................................................109
811.6 Method of Testing Specimens............................................................................109
811.7 Test Results.........................................................................................................110
811.8 Retests.................................................................................................................110
811.9 Period of Effectiveness.......................................................................................110
811.10 Records...............................................................................................................110
812. WELDING OPERATOR QUALIFICATION.......................................................110
812.1 Tests Required....................................................................................................110
812.2 Welding Procedure..............................................................................................113
812.3 Preparation of Test Specimens............................................................................113
812.4 Method of Testing Specimen..............................................................................113
812.5 Test Results.........................................................................................................113
812.6 Retests.................................................................................................................113
812.7 Period of Effectiveness.......................................................................................113
812.8 Records...............................................................................................................113
813. TACKER QUALIFICATION.................................................................................113
813.1 Tests Required....................................................................................................113
813.2 Positions Qualified..............................................................................................115
813.3 Welding Procedure..............................................................................................115
813.4 Method of Testing Specimens............................................................................115
813.5 Test Results Required.........................................................................................115
813.6 Retests.................................................................................................................116
SECTION 9 FRACTURE CONTROL PLAN.......................................................................117
901. GENERAL.................................................................................................................117
902. SHOP DRAWING REVIEW...................................................................................117
903. FABRICATOR QUALIFICATION........................................................................117
904. BASE METAL REQUIREMENTS........................................................................117
904.1 General................................................................................................................117
904.2 Toughness Requirements....................................................................................118
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