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4 Jacking of Track (3.27) Get track geometry reading before jacking Do no jacking at crossovers or next to switch locations for x--brace replacement .instead install x--bracing at a lower elevation, using a 5/8 thick clip angle attached to the vertical legs of the top flange angles

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5 Jacking of Track Jack one rail at a time, 2 max, for ea increment Maintain track alignment: install temp guide angles tight to top flanges under wood ties just outside installation area at both ends prior to jacking

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Jacking of Track Before jacking: disconnect conduits, air-lines, grease lines, etc., attached to track 6 After completion: reconnect

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Jacking of Track At abutments: Elevated track runs into ballast area Loosen rails from ties in ballast Disconnect at nearest joint, if possible 7 Remove spikes/ pandrol clips Keep ballasted ties, in place Track profile wont change

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Contact Rail Safety Working under live C/R: -nail continuous 18 wide strip of plywood to bottom of ties to 6 beyond repair area prior to start 8 In winter weather: remove the boards after ea workday to avoid snow accumulation under C/R

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Contact Rail Safety GO Work at track level near live C/R : wrap C/R w rubber mat to 6 beyond repair area 9 Working near C/R w power off: have light bank & audible alarm connected

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Welding (3.16 a c) Not permitted for members or connections subject to impact or fatigue loading Shop welding otherwise allowed 10 Field welding not permitted except for bldgs (no groove welds) Stiffeners welded to compr flange & web only not tension flange Electric arc / lo hydrogen electrodes

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Welding (3.16 c e) Per Amer Railway Engrg / MOW/ AISC Workmanship : AWS 11 All welded joint procedures shall be pre- qualified per D1.1 sect 4 however. submit weld procedure for approval on Annex E forms

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12 Welding (3.16 c e) All welds: visual inspection All shop & field fillets: magnetic particle (E709) All shop groove: ultrasonic (E164) Consultant for field welds: full time; 5 yr exp; provides weld certification & test reports Take coupons of existing steel & test (3.27g)

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WELDING SYMBOLS Solid flag = a field weld 13

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WELDING filet weld required at point of the arrow 14

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WELDING 15 Weld on both sides of the joint

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WELDING 16 Circle = weld all around

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WELDING Quarter inch = length of weld leg Called the weld size 17

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WELDING actual throat - shortest distance betw weld root & face of a fillet weld 19 TOE

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WELDING 20 effective throat -minimum distance minus any convexity betw weld root & face of a fillet weld

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WELDING 21 root opening: separation at joint root betw the work pieces

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WELDING 22 Triangles not aligned: welds are staggered 2-8 = 2 welds spaced 8 apart

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23 WELDING May be easier to weld gusset to column in field vs a fabricated bolted connection

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24 Field Welding Rules-of-thumb : no welds where calculated stress exceeds 50% of working stress no transverse welds across tension members no welds where calculated stress exceeds three ksi unless shored make all welds parallel to stress lines

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25 Weldability of Old Steel Cut/drill samples from redundant parts of existing steel Test mechanically for ductility Test chemically for carbon content, phosphorus (increased brittleness) & hi sulfur (porous welds) take from thickest parts of members (usually exhibit greatest property fluctuation) lo-hydrogen electrodes & preheating can improve weldability of most base metal

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Weldability OnSite Test Weld deforms w/o fracturing: weldable 26 Weld separates from base metal at junction of weld & base: base metal subject to hardening (hi carbon content Separation exhibits a gray granular surface & follows profile of heat affected zone, appearing as a shallow crater in base metal

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Avoid Undercutting 27 Undercut potential: have undercut occur in new matl Undercut member in tension or subject to fatigue: grind out/ fill w sound metal/ grind smooth Keep grind marks // to stress lines or reduce grind profile by finishing w lt press

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HAZ 28 Heat Affected Zone: 1/8 - 3/16 width betw molten weld rod + base metal (1,250 - 2,700F range) In HAZ, changes in molecular & steel grain structure Cracks ~ dont start in HAZ but in unsound weld metal nearby & travel into base metal Steel melts ~ 2,800F 1,333F +: austenitic changes 1,500F: yield ~ 0; loses magnetic properties 1,200F: max for heat cambering or straightening 500-600F: max strength, but loss of ductility

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29 Quiz #5 How should you deal with repair plate interference w existing steel? How to deal w gussets hidden under ties? What deliverables should post design include? How do you keep track aligned when jacking it?

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Steel Erection 30

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FRAMING Spandrel (girt) is on perimeter & transmits exterior wall loads to columns 31

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FRAMING 32 Rafters: *closely spaced beams *support roof *run // to slope Purlins span between Flat roofs: rafters- called joists

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Opening thru a Floor 33

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Erection: Column / Footing Prep 34 Use multiple shim plates with heavy columns

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35 Erection: Column / Footing Prep Mark footing w C/Ls in ea direction Mark ea column base plate w C/Ls Line them up when setting column LEVELING SHIMS

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OSHAGuidelines for a Site-specific Erection Plan Controlling contractor must provide written notice to steel erector ensuring that [1926.752(a)]: Concrete ftgs, piers & walls are cured to level to 36 provide adequate strength to support any forces imposed during steel erection [1926.752(a)(1)] Anchor bolt repairs, replacements & mods were done w approval of project Structural Engineer of Record (SER) [1926.752(a)(2) & 1926.755(b)(1)]

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OSHAGuidelines for a Site-specific Erection Plan Controlling contractor must provide & maintain [1926.752(c)]: Access roads into & thru site that are adequate for 37 safe delivery & movement of: derricks, cranes, trucks & other necessary equipment & matl Hold conferences & site inspections between erector & controlling contractor & fabricator before start of steel erection

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38 OSHA: Site-specific Erection Plan Components : Sequence of erection, develop w contractor: *Material deliveries: staging / storage *Coordination w other trades Crane selection & placement procedures: *Site preparation/ Path for overhead loads *Critical lifts, incl rigging supplies/ equipment

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39 OSHA: Site-specific Erection Plan Erection activities/ procedures : Stability requiring temporary bracing & guying Erection bridging terminus point Anchor bolt notifications: repair/replacement/modifications Column / beam installation incl joists/ purlins

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40 OSHA: Site-specific Erection Plan Erection activities/ procedures contd: Connections incl Ornamental /misc iron Fall protection procedures Falling object protection Special procedures for hazardous non-routine tasks Certification for ea employee trained for steel erection operations

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OSHA: Site-specific Erection Plan Erection activities/ procedures contd: List the qualified & competent persons 41 Describe rescue or emergency response procedures Have plan signed & dated by the qualified persons responsible for its preparation & modification

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Erection Sequence (1.13) F1, 1.1, 2 E1, 2 B5A13 B532, 510 B511, 5A6 B512 B513, 514 D18,25,20 D30,43,21 D32,45,21 D24,23,20 42

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Erection Sequence Work out sequence w fabricator early Make a tier sequence listing w foreman Lay out steel in sequence to be installed 43 Mark left side/west side of beam or bottom of a column to allow iron worker to know correct end position Fabrs Bolt sched- ea conn: B5A13-B512: #; dia; length; grade; nuts; washers; grip Mark info from bolt list on ea end/ea piece

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Column Lifting 44

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Column Lifting 45 Tag line - used to pull pin out of shackles after weight is off

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Second Tier and up Put in stairs & handrails before starting next tier 46 Easier & safer for workers to get to upper levels

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Life on the 50 th Tier (50-65 pcs/day) 47

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Erection Crew (3.24) 48 Lightly drifts holes for drawing together; not for fair aligning Install 50% bolts min

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Bolt- -Up Crew Plumbs frame using turnbuckles Fills all holes w permanent bolts Reams unfair holes Also for stabilizing frame 49

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50 Reaming- rehab work No lubricant needed All holes: 1/16 >specd bolt Can use a regular drill - makes a mess Reamed, oblong hole: 3/16 max, larger than bolt used (3.27e4) Use next size drill bit & larger bolt: may slip in smaller bolt Drill shavings at ironworkers feet: hes been reaming

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Reaming- new assemblies All holes: 1/16 > specd bolt No lubricant needed Ream together 51 1/32max offset between plies of a new assembly (3.9). same size bolt allowed If hole is larger: must be re-drilled & next larger dia. bolt used Burrs removed w tool making 1/16 fillet (3.6)

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Holes If more than 3 unfaired holes that require reaming per connection, get new piece of steel 52 Check holes in new & old steel to see if they match Catch at beginning of installation vs taking new piece down

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Before installing bolts Ensure proper seating by preparing surfaces w power grinding tool (3.25c) Washer under element to be turned: A325 53 Washers on both sides: A490

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Bolt Lubrication Prevents thread lock & reduces twisting force introduced into bolt 54 Stick waxes can be used in field to lubricate fastener assemblies if soluble lubricant was washed away due to improper storage

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. Bolt w stripped threads A proper fastener assembly will fail by fracture thru the threads of the bolt outside the nut 55

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Bolt Lubrication Black, lubricated bolts & nuts: oily to touch when delivered & installed 56 Galvanized nuts should be lubricated w a visible lubricant

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Using ASTM A325 or A490 Bolts BOLTED PARTS Slip Critical Joints Faying surfaces, incl filler plates & finger shims shall be: free of scale, except for tight mill scale free of coatings in areas closer than 1 bolt diameter but not less than 1 from edge of any hole free of coatings in all areas w/i bolt pattern 57

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58 Only area local to bolt influences slip behavior Portions outside striped areas will not influence slip performance of connection

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Faying Surfaces Loose scale or rust must be removed prior to making connection 59 Removal should be done by blasting or wire brushing

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60 PRE INSTALLATION VERIFICATION Required Testing: 3 min. complete fastener assemblies of ea diam, length, grade & lot: check at install site in hydr tension calibrator (Skidmore) (table II note 3) Verify: pre-tension method develops pre-- tension = or >1.05 X spec for pretension values (table II note 1). Use washers as in the work If actual pretension is