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 i ii 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 iii 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 iv 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 v 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 vi 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 vii 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 viii