structural steel & shop drawings

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Structural Steel & Shop Drawings

2018 Bridge Construction Inspection School

Eulogio “Jo” Javier II, P.E.

VDOT Staunton District

Assistant Structure & Bridge Engineer - Design

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LEARNING OBJECTIVES:

•MATERIALS

•WORKING DRAWINGS:

• Shop Drawing Submission

• Shop Drawing Review

• Contractor’s Responsibility

•FABRICATION PROCEDURE

• Workmanship, Finish, Fabrication and Welds

• Straightening and Curving

• Camber Procedures

• Bolt Holes

Structural Steel

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•HANDLING, STORING and SHIPPING MATERIALS:

• Marking & Shipping according to Erection Diagram

• Delivery Inspection and Checklist

•ERECTION PROCEDURE

• Structural Connections

• Bolt Tension

• Falsework

• Finishing and Protective Coating

•MEASUREMENT and PAYMENT:

Structural Steel

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•STRUCTURAL PLANS & SHOPDRAWINGS:

• Framing Plans

• Typical Transverse Section

• Permissible Field Splice

•STAY IN PLACE FORM

• Recommended SIP Detail (s)

• Applicable Plan Notes

Shopdrawings

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REFERENCE SPECIFICATIONS:•Section 101

DEFINITIONS OF ABBREVIATIONS, ACRONYMS and TERMS

•Section 105.10

PLANS and WORKING DRAWINGS

•Section 107.17

CONSTRUCTION SAFETY and HEALTH STANDARD

•Section 226

STRUCTURAL STEEL

•Section 233

GALVANIZING

•Section 228

STEEL PILES

•Section 407

STEEL and OTHER STRUCTURES

•Section 411

PROTECTIVE COATING OF METAL IN STRUCTURES

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Material - Section 407.02

Structural Steel Shapes

•Section 226 / pp:230

•ASTM A709 (Grade 36 or Grade 50W ) Unpainted.

Structural Steel

D

W Shape Wide Flange Beam

W 36 x 135

Weight = 135 lbs / LF

Depth = 36”

Rolled Beam

Structural Steel Shapes Bf

Web

Flange

Structural Steel

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S Shape Standard Beam

S 24 x 106

Weight = 106 lbs. / LF

Depth = 24”

Bf = Flange Width = 7 7/8”

D

Bf7 7/8”

Structural Steel

C Shape – Std. Channel

C 15 x 33.9

Weight = 33.9 lbs./ LF

Depth = 15”

D

Structural Steel

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Angle Shape

L 5 x 3 x 3/8”

Leg Dimension = 5” & 3”

t

Structural Steel

Steel Plate Shape

PL 9/16 x 32 D

t

Structural Steel

GirderJacking Stiffener

Sole Plate

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HP Shape H-Pile

Section 228

HP 10 x 42

Weight = 42 lbs / LF

Depth = 10” = Width

D

W

Structural Steel

Fabrication Procedures Section 407.04

•Workmanship, Finish and Fabrication Tolerance

•Complex Coating

•Fabrication and Welding

• Fracture Critical Components

• Other Structural and Miscellaneous Steel

• Welds

• Straightening and Curving

• Camber

• Bolt Holes

• Stud Shear Connectors

Structural Steel

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Fabrication Procedures Section 407.04

• Shop Assembly

• Inspection

Structural Steel

Field Weld

Weld all around joint

Weld size

Arrow side of joint

Other side of joint

Notes

Structural Steel

Fabrication:

Welds- Section 407.04 (a)

•Only welding or tack weld noted on the plans shall be performed Welds

• Partial penetration weld shall not be allowed.

• Electro-slag and Electro-gas welding shall be pre-approval in writing

• “Structural units shall not be used as worktable. Welding on other work shall be completed before parts are installed on units”

•Weld Checks :

• Non-conforming welds determined by visual inspection or NDT

• Shall be repaired if not possible shall be removed, replaced and re-inspected.

•Groove Weld shallbe Ground Flush. Fillet Weld

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Weld Symbols

Structural Steel

Welds•Certification :

• Certificate of qualification shall be for each welder, welding operator of tacker

• Certificate of qualification shall not exceed more that 3 months without performing satisfactory welding process.

• Qualification shall state Name / Name and tittle who conducted the examination and result of test.

• Other applicable AWS codes:

• AWS D1.4 = welds for rebars, include tack welds

• AWS D1.2 = Welding for Aluminum

• AWS D1.1 = Welding for Tubular Structures

Structural SteelStructural SteelTypes of Structural Welds

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Structural SteelStructural SteelTypes of Structural Welds

Structural SteelShop Full Penetration Weld:

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Structural SteelStructural Steel

Non-Conforming Weld

Structural Steel

Damages cause by faulty field Welds

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Structural Steel

Shop Or Working Drawings Sections 407.03 & 105.10 (c) • Contractor’s Responsibility

• Shall Submit the Engineering Working Drawing for Engineer’s Review :

• Shop Drawing Items for Review:• Structural Steel (Framing Plan, Camber etc.)• Bridge Stakeout• Anchor Device• Bearing Assemblies• Deck Drain Assembly• Railing Assemblies• Tooth Expansion Joints• Stay-in-Place Forms• Falsework• Signal Poles• Miscellaneous Shop drawings (i.e. Temporary Shoring)

Structural Steel

• Contractor’s Responsibility• Stamped by an Engineer license to practice in Virginia.• Provide 30 days from receipt turn around time for review. • 45 Days if Rail Road, municipality or other entities are

involved.• Section 105.10 - Contractor may authorize the Fabricator to act

on the Contractor’s behalf.• Shall be Submitted to the District ACE• Shop plans will be stamped reviewed with appropriate

comments.• Hard copies shall furnish 9 sets with detail required unless

indicated in the contract.• Staunton District S&B allows electronic file submission.

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Structural Steel

FRAMING PLAN

•Labeling of Beams / Girders

•Horizontal Dimension

•Location of Permissible Field Splices

•Assembly of Structural Connection using H.S. Bolts

•Types of Structural Steel Beams

Structural Steel

Framing Plan

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Structural Steel

Transverse Section

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Girder 1

Girder 2

Girder 3

Girder 4

Girder 5

Girder 6

Girder 7

Horizontal Dimensions

Per

mis

sibl

e F

ield

Spl

ice

Per

mis

sibl

e F

ield

Spl

ice

Upstation

Framing Plan

Structural Steel

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Girder 1 Girder 2 Girder 3 Girder 4 Girder 5 Girder 6 Girder 7

Beam Labeling

Looking Up-station

Structural Steel

Structural Steel

Framing Plan / Bearings

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Structural Steel

Structural Steel

Stiffeners and Plate Connectors

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Cross Frames

Structural Steel

36 Structural SteelStiffeners and Connectors

Bearing Stiffener / Connector Plate

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Structural Steel

Shear Connector Detail

Structural Steel

Flange Detail

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Structural Steel

Field Splice Detail

Structural Steel

Field Splice

•Bolt layout

•Uniform / Staggered

•Splice Plate Size

•Filler Plate Size

•Transition dimension and detail.

Splice & Bolt Detail :

Bo

lt S

pac

ing

High Strength Bolts

Section 226.02 (h)

•A325 Type 1 or 3

•A490 Type 1 or 3

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42 Structural Steel

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Structural Steel

Bolt / Nuts / Washer / DTI :

Structural Steel

Field Splice

Stay In Place Forms Shopdrawings

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Stay in Place Form Notes:Support angles and beam straps shall be assembled and welded away from the girder on a worktable. No welding to or on top of the flange shall be permitted. Extreme care shall be taken to avoid even accidental contact between the electrode and the flange. The grounding clamp shall be positioned so that the current will not flow between the flange and support assemblies when welding the clips. All welding shall be done by certified welders in accordance with Sec. 407.04 of VDOT Specifications and the requirements of AASHTO/AWS DI.5 Bridge Welding Code.

Structural SteelStructural Steel

Section 407.04 (a)“Structural units shall not be used as a worktable. Welding on other work shall be completedbefore parts are installed on units”

Structural Steel

Field Splice

Bridge Survey Stakeout

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Structural Steel

Sample of Temporary Shoring Detail

Temporary Shoring

Steel Piles

• Section 228

• H-Piles

• Shell Piles

• Sheet Piles

Structural SteelTemporary Shoring

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Structural Steel

Temporary Shoring

Slope Failure

Structural Steel

Shopdrawings

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51 Structural SteelFABRICATION:

Figure 1Bridge on Grade (Final)

FABRICATION:Structural Steel Fabrication and

Camber Section 407.04 (a)

• Bridge Length (plan dimension); correct beam length for grades.

Camber• Shall be heat curved• Camber compensation.• Cover Plates.

Structural Steel

Figure 2Fabricated Beam Shape

and Final Erected Position

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Structural SteelFABRICATION:

Steel FabricationCamber Diagram

Structural Steel

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Structural Steel

Before

After

FABRICATION:


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Structural Steel

Field Splice

Jacking Stiffeners

Structural SteelJacking Stiffeners

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Structural SteelJacking Stiffeners

Structural Steel

FABRICATION:

Bolt Holes – Section 407.04 (d)

•Shall be punched, drilled, or reamed as specified, but not flame or electrode cut

•Finished holes shall be 1/16 inch larger than the nominal bolt size.

•Oversized holes needs permission from the Engineer or in accordance with Section 407.06(b).

•Tolerance for finished holes is 1/16th inch:

• Plan gage and match mating holes shall not exceed tolerance.

• Offset not > the above tolerance.

•Burrs shall be removed from holes.

•Punched holes:

• Not on Carbon Steel with Fy < 36 ksi or thicker that ¾”.

• Not on HS-Steel with Fy > 36 ksi. Or thicker that 5/8”.

•Full size holes punched in structural members identified in Section 407.04 (k) or in the Plans, SP or any primary members is not permitted.

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Structural Steel

FABRICATION:

•Reamed and drilled holes:

•Cut Edges of Plates and Shapes:

•Facing of Bearing Surfaces:

•Bend Plates:

•Annealing and Stress Relieving:

•Stud Shear Connectors:

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•Shop Assembly:

• Holes for field connections and field splices in the following main units shall be drilled.

• Girders and Rolled Beams

• Trusses, Arches and Towers

• Bent and Rigid Frames

• Diaphragm, Cross-Frames

• Members designate and

• Main (primary) Members identified in the Plans, SP or Contract.

• Holes for floor-beam and stringer-end

• Surfaces of metal in contact

• Drift Pins.

• Connecting parts assembled in the shop

• Inspection:

Structural SteelHandling, Storing and Shipping Section 407.05

• Material Storage:

• Placed 4” above ground

• Properly Supported

• Original Containers / Protective Storage

• Protected from other material contamination

• Contractor Responsibility

• Shall be responsible for loss and damage after shipment.

• Shall check materials delivery against shipping list.

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Handling, Storing and Shipping Section 407.05

•Marking and Shipping

• Each unit shall be identified with erection mark and diagram

• Contractor shall furnish copies of shipping statements and erection diagram.

• Proper transportation

• Main structural units shall be properly supported.

• Bolts, loose nuts and washers of similar length and sizes shall be packed separately.

• Small parts (pins, bolts , nuts and washers) shall be properly packaged.

Structural Steel

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Handling, Storing and Shipping

Structural Steel

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Structural Steel

Structural SteelHandling, Storing and Shipping

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Structural Steel

Structural Steel

Field Splice


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Structural Steel

Field Splice


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Erection Procedure Section 407.06

•Contract for erection only, the Contractor:

• Will receive the designated materials.

• Loaded or unloaded where specified.

• Shall promptly unload material

•Erection Plan shall be submitted to the Bridge Office for approval

•No work shall be started until such approval has been obtained.

•The Contractor shall erect steel, remove temporary construction, and perform all work required to complete the structure(s), including removing the old structure(s).

• Field Welding: shall be performed in accordance with Section 407.04.

• Misfits Field Assembly:

• Drift pins

Structural Steel

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ERECTION PLAN:

Checklist:

1. Check feasibility or conflicts of staging plan

2. Check procedure, sequence and method of setting: • Bracing Methods.• Procedure and sequence of diaphragm installation.• Staging for truck delivery• Crane locations (check for distances vs. crane radius)• Temporary support tower.

3. For single traffic lanes during construction, make sure that the flow of traffic is not heavily impeded by sequencing the traffic flow with delivery of girders.

4. Check compression flanges against allowable.

5. Check beam against allowable deflection.

6. Bending Stresses

7. Bending at flanges due to clamps

8. Possibility of sliding if spreaders are not used.

9. Check cable capacity.

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77 Structural Steel

ERECTION PLAN:

Checklist:

10. Check crane specifications:

• Crane Radius

• Check Counter weights used.

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Erection

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Field Splice

Structural SteelErection

Erection

Structural Steel

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Erection

Structural Steel

Erection Procedure Section 407.06

•Assembly of Structural Connections Using High-Strength Bolts:

• Bolts, nuts and washer

• Bolted Parts

• Installation Method of High Strength Bolts

•Inspection: The Engineer will observe the installation and tightening of bolts.

• Alignment at Bearings and Transverse Connections:

•Falsework:

•Straightening Material in the Field:

•Assembling Steel

•Finishing

•Protective Coating

Structural Steel

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83 Structural Steel

Weathering FinishASTM A-709 50W

Stainless Steel FinishA1010

Erection Procedure Section

Abrasive Blast Cleaning

Measurement and Payment Section 407.07

Structural steel, including beams, girders, and misc. steel Will be paid for at the contract lump sum price or, whenspecified, in pounds of the specified metal in the fabricated structure, including bolts shipped, as weighed on a shop scale.

Fabrication of structural steel,

Erection of structural steel, The cost of testing unit(s)

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Pay Item Pay Unit

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Structural steel (Type) Lump sum or Pound

Fabrication of structural steel (Type) Lump sum

Erection of structural steel (Type) Lump sum

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Structural Steel

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SAFETYCONTRACTOR IS REQUIRED TO PROVIDE AND USE FALL

PROTECTION.• 407.04 (j)

• Section 107.17 – Const. Safety and Health Std.

• IIM-CD-2013-01.01

• 29 CFR 1926.501(b)(2) - Each worker constructing a leading edge 6 feet or more above a lower level must be protected.

– Guardrail System

– Safety Net System

– Personal Fall arrest System

Structural Steel

Structural SteelSAFETY

structural steel & shop drawings

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