KANSAS DEPARTMENT OF TRANSPORTATION SPECIAL PROVISION TO THE STANDARD SPECIFICATIONS, 1990 EDITION

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1 Sheet 1 of 9 KANSAS DEPARTMENT OF TRANSPORTATION SPECIAL PROVISION TO THE STANDARD SPECIFICATIONS, 1990 EDITION SECTION STRUCTURAL STEEL CONSTRUCTION Page 392, subsection.01. Add the following bid items: Expansion Device (**) ** Type: Finger Joint Sliding Plate Page 392, subsection.03(a). Delete the last sentence of the first paragraph and replace with the following: Fabricators of bridge beams and girders shall be certified by the American Institute of Steel Construction in the appropriate category for the type of work being performed. Page 393, subsection.03(b). Delete the last sentence of the second paragraph and add the following to the third paragraph: These dimensions shall include but not be restricted to bearing-to-bearing lengths and vertical and horizontal curvature offsets at bearing points and splices. Page 395, subsection.05(b). Delete this subsection and replace it with the following: (b) Welding and Gas Cutting. Welding and gas cutting of structural steel shall be in accordance with the applicable requirements of the "Bridge Welding Code", ANSI/AASHTO/AWS D1.5-88, with the exceptions and/or additions listed below. Bearing devices, drainage systems, expansion devices, handrail, bridge rail, sign structures and other tubular structures shall be in accordance with applicable requirements of the "Structural Welding Code," ANSI/AWS D

2 Sheet 2 of 9 Page 398, subsection.05(l). Add the following after the first sentence: Blocking, sweep, and bearing-to-bearing measurements shall be checked by the fabricator s Quality Control personnel immediately before the inspector checks the assembly after it is completely set up. Page 409, subsection.07(k). Delete the first sentence of this subsection and replace with the following: Field welding of structural steel shall be in accordance with the applicable requirements of the "Bridge Welding Code", ANSI/AASHTO/AWS D1.5-88, with the exceptions and/or additions listed below. Pages 409, 412, and 416, subsections.08,.09, and.10. Make the following changes in these subsections: Change all references of the "Vinyl Finish Coat" to "Acrylic or Polyurethane Finish Coat". Unless otherwise noted on the Plans or in the Contract, the Contractor may use either an acrylic or a polyurethane finish coat. Refer to Special Provisions 90M-186 and 90M-187 (latest editions) for material requirements. In regard to stenciling the date of painting and the type of paint system on the completed work, use the code "A" for acrylic and "P" for polyurethane. Page 410, subsection.08(a). Delete the seventh paragraph on this page and replace it with the following: Galvanized drains shall have an application of a two component 98 percent solids polymeric epoxy amido-amine primer tiecoat of about mm dry film thickness prior to the application of the topcaat. The application and cure time before topcoating shall follow the manufacturer s recommendations. Page 421, Section. Add a new subsection.11 Weathering Steel. Subsequently renumber the existing subsections that follow:.11 WEATHERING STEEL. Whether the Plans designate weathering steel or whether the Contractor chooses the weathering steel alternate shown on the Plans, the structural steel will be furnished and erected according to this Section, with the following additions and exceptions: If the Plans provide an option for furnishing weathering steel, A709 Grade 50W may be substituted for A709 Grade 36. M270 Grade 50WT2 may be substituted for M270 Grade

3 Sheet 3 of 9 50T2. When substituting weathering steel for the structural steel shown on the Plans, furnish the same size plate or rolled member that is shown on the Plans. In the shop, blast clean all surfaces of all weathering steel, including all faying surfaces of bolted connections, to meet SSPC-SP6 specifications. Painting of weathering steel includes blast cleaning (to SSPC-SP10 specifications), prime coat (inorganic zinc), and top coat (waterborne acrylic) unless otherwise noted. The brown top coat will be equivalent to Federal Standard No. 595a, Color No (Carboline No. 2248). Where girder ends are embedded in the abutment, blast clean and prime coat the entire embedded portion of the girder, including diaphragms, plus an additional distance of 50 mm. Blast clean and prime coat the top and sides (if in contact with concrete) of the top flanges, including shear studs. Blast clean and prime coat both sides of fill plates less than 12 mm thick. Note: Fill plates need not be weathering steel. Paint all structural steel surfaces (not included above) within a distance of two times the depth of the girder (2D) on either side of an expansion joint. A nearby stiffener would be a convenient location to stop painting. When drainage is allowed over the side of the deck on a plate girder bridge, and the exterior girder is to be painted: blast clean all surfaces of the exterior girder; prime and top coat the exterior surfaces, including the bottom of the bottom flange, of the exterior girder only. When drainage is allowed over the side of the deck on a rolled beam bridge, painting the exterior beam is not required. If a uniform appearance is desired, blast clean the entire exterior facia of unpainted exterior girders after erection. Blast to meet SSPC- SP6 specifications. Use drip plates (see details in KDOT Bridge Design Manual) attached to the bottom flange of a girder to divert water off the structure before it runs onto another bridge component (check fatigue). Do not use weathering steel in rocker bearing devices (or any component with finished surfaces), expansion devices, or expansion device armoring. Sole plates may be weathering steel when used with elastomeric expansion devices. Protect all substructure concrete on structures where the substructure is highly visible (i.e. grade separations). Protect concrete by applying a protective coating to prevent absorption of the stain during the initial weathering of the unpainted steel (see Special Provision 90M-71, latest revision). In addition to the protective coating, wrap the concrete substructure in plastic from the time the steel is erected until the deck concrete is placed. This work is subsidiary to the weathering steel.

4 Sheet 4 of 9 Page 422, subsection.11. Renumber this subsection to.12. Delete this subsection and replace with the following:.12 METHOD OF MEASUREMENT. Painting of new structures will not be measured or paid for directly but shall be cnsidered subsidiary to structural steel. Painting of old existing structures shall be measured by the lump sum for "Bridge Painting" which price shall include all cleaning and painting of areas designated to be painted. Maintenance of traffic, where required, will not be measured and paid for directly but shall be considered subsidiary unless the Contract contains the item "Traffic Control". Headed Stud Anchors shall be measured per each. Structural Steel, Cast Steel, Cast Iron and Bearing Devices shall be measured by the kilogram, complete in place. The mass of structural steel, cast steel, cast iron and bearing devices, for which payment is made, shall be the net as shown on the Plans. When the Plans have been altered for changes in design, or when disagreement exists between the Contractor and the Engineer as to the accuracy of the plan quantities in any part of the entire Project, either party shall have the right to request and cause the quantities involved to be measured. The computed mass will be obtained by use of the following rules: Mass of Structural Steel 7840 kg per cu. m Mass of Bronze 8720 kg per cu. m Mass of Cast Iron 7200 kg per cu. m No allowance will be made for fasteners including erection bolts, button head bolts used for filing erection bolt holes, high strength bolts for permanent connections, temporary laterals or similar items. No measurement shall be made of weld metal deposited in fillets, or otherwise outside the lines and surfaces of the connected parts; but no deductions shall be made from the computed quantities of such work to allow for material that is removed by beveling or other cutting and subsequently replaced with weld metal. Unless shown as bid items on the Plans, structural steel expansion devices will be included in the sum of structural steel shown on the Plans. When shown on the Plans as bid items, expansion devices shall be measured by the meter along the centerline of the expansion device as shown on the Plans. Page 423, subsection.12. Renumber this subsection to.13. Delete the first paragraph of this subsection and replace with the following: The amount of completed and accepted work, measured as provided above, shall be paid for at the Contract lump sum price for "Bridge Painting" or at the Contract unit price per kilogram for "Structural Steel", "Cast Steel", "Cast Iron", or "Bearing Devices" or at the Contract unit price per each for "Headed Stud Anchors" or at the Contract unit price per meter for the various types of "Expansion Device", which prices shall be full compensation for furnishing, fabricating, welding, delivering, erecting, radiographic inspection, painting and placing all materials, for all labor, equipment, tools, and incidentals necessary to complete the work.

5 Sheet 5 of 9 THE REFERENCES CITED IN THE PARAGRAPHS BELOW ARE TO ANSI/AASHTO/AWS D UNLESS OTHERWISE STATED. UNTIL SUCH TIME AS THE ANSI/AASHTO/AWS D IS REVISED TO METRICS UNITS, THE UNITS SHOWN BELOW WILL REMAIN AS ENGLISH UNITS. SECTION 1. GENERAL PROVISIONS. Delete paragraph and add the following: Electroslag or electrogas welding shall not be used. Add two new paragraphs as follows:.10 EQUIPMENT CHECK: Each DC generator shall have a service check by an NEWA member, a commercial electrical equipment company or by the fabricating plant s electrical maintenance engineer once each year. A service certificate shall be issued with each equipment check and shall be available for inspection by the Engineer at all times TEMPORARY WELDING AND TACKING: The attachment of temporary fabrication, erection and construction items to main members by welding or tacking is prohibited except by written permission from the Engineer. Permissible locations for such welds and tacks shall be only at locations shown on approved shop drawings or at locations designated by the Engineer in writing. All such tacks or temporary welds shall be made in accordance with Paragraphs and and welders and/or tackers shall be qualified in accordance with AWS requirements. Delete paragraph and add the following: All corners of main stress carrying members and all corners to be painted or galvanized shall be rounded to a 1/16th inch radius. SUBSECTION 3.5 DIMENSIONAL TOLERANCES. Delete paragraph and add the following: Permissible variations in specified camber and blocking of welded beams or girders regardless of cross section shall not exceed: -0, +1/4 inch for spans 0 thru 100 feet -0, +1/2 inch for spans greater than 100 feet Add a new paragraph as follows: Permissible variation in length of assembled beams or girders between the center line of bearing devices shall not exceed plus or minus 1/4 inch for any one span or plus or minus 3/8 inch for any two or more spans within the assembled unit. The actual centerline of any bearing device shall lie within the thickness of the bearing stiffener.

6 Sheet 6 of 9 SECTION 4. TECHNIQUE. Add the following notes to Table 4.1: 8. Only low hydrogen electrodes shall be used. 9. E 8 Electrodes may be used for shop fillet welds except for the attachment of gusset plates and bearing stiffeners to girders, bearing stiffeners to beams, web to flange welds and for welding floor beam truss assemblies. Horizontal and flat position welding only. SECTION 6. INSPECTION, PART A. Delete paragraphs 6.7.1, , and and add the following: Groove welds in main members as identified in contract documents shall be QC tested by nondestructive testing. Unless otherwise specified, radiographic testing shall be used on butt joints Radiographic testing of welds shall be performed in accordance with the following requirements: (1) 100% of all welded girder and rolled beam flange butt joints. (2) All except the middle 1/3 of all welded girder or rolled beam web butt joints. (3) The requirements for Radiographic Testing and Ultrasonic Testing apply equally to shop and field welds. Add paragraph : Bearing device inspection will require one piece in 10, or fraction thereof, to be tested 100%. Delete paragraphs 6.7.6, , , , , and and add the following: When magnetic particle testing is used, the procedure and techniques shall be in accordance with the dry powder magnetic particle examination of welds using the yoke method The yoke method shall be performed in accordance with ASTM E709, and the standard of acceptance with 9.25 of the Code. (1) The yoke method shall be performed using half-wave rectified direct current. (2) Electromagnetic yokes shall have a lifting force of at least 40 lb. (18 Kg) at the maximum pole spacing that will be used Prior to magnetic particle testing, the surface shall be examined, and any adjacent area within at least 1 in. (25 mm) of the surface to be tested, shall be dry and free of contaminants such as oil, grease, loose rust, loose sand, loose scale, lint, paint, welding flux, and weld spatter. Cleaning may be accomplished by detergents, organic solvents, descaling solutions, paint removers, vapor degreasing, sand or grit blasting, and ultrasonic cleaning methods The poles shall be oriented in two directions approximately 90 degrees apart at each inspection point, to detect both longitudinal and transverse discontinuities. The pole

7 Sheet 7 of 9 position shall overlap as testing progresses to insure 100 percent inspection of the areas to be tested. Discontinuities are best detected when their axis is normal to the magnetic lines of force. Therefore, the yoke technique is most sensitive to discontinuities whose major access is normal to a line drawn between the two poles A report of magnetic particle examination shall be prepared and furnished to the owner. (1) The report shall include the following minimum information: (a) Part identification (b) Examination procedure number (if applicable) (c) Date of examination (d) Technicians name, certification level, and signature (e) Name and signature of contractors or owners, Inspectors, or both who witnessed the examination (f) Examination results (g) Equipment make and model (h) Yoke spacing using (i) Particles (manufacturer s name) and color (2) One copy of the report shall be furnished to the contractor for the owner. Delete paragraph and add the following: For detecting discontinuities in non_magnetic materials including stainless steel to stainless steel or stainless steel to carbon steel, liquid penetrate inspection will be used in lieu of magnetic particle inspection. The standard methods, set forth in ASTM E165 shall be used for liquid penetrate, and the standards of acceptance shall be in accordance with 9.25 of this code. SECTION 6. INSPECTION, PART B. Delete paragraph and add the following: FILM SIZE - When the joint thickness is less than 3 inches, radiographs shall be 4 1/2 inches x 17 inches in size. When the length of the joint is such that more than one radiograph is required,_one of the films may be shortened to 4 1/2 inches x 10 inches if the contractor elects to do so. When joint thicknesses are 3 inches or greater, the minimum film size shall be 7 inches x 17 inches. Larger radiographs may be required in areas where there have been excessive repairs or where there are joints with unusual dimensions. Delete paragraph and add the following: One radiograph identification number shall be painted on the steel no closer than 3/4 inch from the weld edge at each radiograph location. Corresponding lead numbers shall be superimposed on the painted numbers to produce an image on the radiograph. A combination of letters and numbers may also be used. Two location dots shall be painted on the steel at each radiograph location no closer than 3/8 inch from the weld edge. The dots shall be placed at a

8 Sheet 8 of 9 random distance from the steel plate edges which are perpendicular to the length of the weld. The dots shall be placed in different locations for each radiograph location. One lead arrow shall be placed so that its tip is superimposed on each of the two location dots. A location letter shall be painted immediately under each arrow and a lead letter shall be superimposed on each painted letter. When radiographs are viewed, only those films representing the same joint should have location arrows and location letters perfectly superimposed. Any additional information shall be produced on the radiograph no less the 3/4 inches from the edge of the weld either by pre-printing or by placing lead letters and numbers on the steel. See Fig. 1 and Fig. 2. Delete paragraph and add the following: Information required to be shown on the radiograph shall include: the complete KDOT bridge number, initials of the radiographic inspection company, initials of the fabricator, the fabricator s shop order number, the radiographic identification number, the date, and the weld repair number if applicable. Add a new paragraph : Unless otherwise noted on the shop plans all butt welds will be evaluated as tension welds BD(BS) (LR)

9 Sheet 9 of 9 FIGURE 1 ITEMS TO BE PAINTED FOR RADIOGRAPHIC IDENTIFICATION /2 weld edges random spacing - location dot A - location letter W99 B radiograph I.D. number FIGURE 2 LEAD CHARACTER PLACEMENT FOR RADIOGRAPHIC IDENTIFICATION SLTL Stupp Image Quality Indicator (IQI) 3/4 min. 4-1/2 weld edges 3/8 min. - location dot - location arrow 3/4 A - location letter W 99 B min.