23.6.10

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STANDARD CONSTRUCTION SPECIFICATIONS PART 2 – ROAD STRUCTURES

and on the nut, and then tighten the nut the amount of rotation specified in Table 23-11. The
Engineer will accept the connection as fully tightened when all of the following conditions are
met:
· Rotation specified in Table 23-11 has been achieved
· There are no loose assemblies in the connection
· All plies of the connection are in firm contact
· There are no indications that excessive stretching or yielding has occurred in the
fastener assembly
· Bolt stick-through is consistent per lot

q. Direct Tension Indicator Tightening for High-strength Fasteners


Before bringing the connection to a snug-tight condition, the Contractor shall verify in the presence
of the Engineer that the ‘dimples’ of the DTI are not deformed or damaged. Bring the connection to
a snug-tight condition and tighten in accordance with the requirements of Article 23.6.9.6. The
Engineer will accept the connection as fully tightened when all of the following conditions are met:
1. the requirements of Article 23.6.9.6 have been achieved
2. there are no loose assemblies in the connection
3. all plies of the connection are in firm contact
4. there are no indications that excessive stretching or yielding has occurred in the fastener
assembly
5. Bolt stick-through is consistent per lot

23.6.10 Welding for Steel Structures


Except as noted in the Contract documents, shop and field welding, welder qualifications,
prequalification of weld details, and inspection of welds shall conform to the requirements of the
current AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code.
Brackets, clips, shipping devices, or other material not required by the Contract documents shall not
be welded or tacked to any member unless specified in the Contract documents and approved by
the Engineer.
Additional or alternate requirements for hollow steel structural sections and non-dynamically loaded
members or components are listed below.
Welding shall be a metal arc process in accordance with BS EN 1011-2:2001 and BS EN 1011-
8:2004, as appropriate, together with other clauses contained in this section, unless otherwise
specifically permitted by the Engineer.
Welding consumables used shall be chosen to ensure that the mechanical properties of the weld
metal are not less than those required for the parent metal.
Joints shall be prepared in accordance with BS EN 1011-2:2001. Precautions shall be taken to
ensure cleanliness of the connection prior to welding.

23.6.10.1 Welding on Non-dynamically Loaded Elements


The Contractor shall perform welding on miscellaneous components and other statically (non-
dynamically, noncyclically, etc.) loaded structural elements in accordance with the AWS D1.1,
Structural Welding Code, or the AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code. Unless
otherwise specified in the Contract documents or as approved by the Engineer, follow the Bridge
Welding Code for weld inspection and welder certifications.

23.6.10.2 Electroslag Welding


The Contractor shall use Narrow-Gap Improved Electroslag Welding (NGI-ESW) for joining non-
fracture critical members or components up to 75mm thick. These members or components may be
subjected to tension, compression or stress reversal. Inspect 100% of all NGI-ESW welds subject to
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CHAPTER 23: STEEL STRUCTURES First Edition -January 2018
STANDARD CONSTRUCTION SPECIFICATIONS PART 2 – ROAD STRUCTURES

tension stresses or reversal of stress by both UT (ultrasonic examination as described in Section 6,


Part C of the AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code) and RT (radiographic
examination as described in Section 6, Part B of the AASHTO/AWS D1.5M/D1.5:2010, Bridge
Welding Code).
Perform NGI-ESW welding in accordance with the AASHTO/AWS D1.5M/D1.5:2010, Bridge
Welding Code. Supplemented by the recommendations from the following references:
· Report No. FHWA-SA-96-053, “Technical Information Guide for Narrow.Gap Improved
Electroslag Welding”.
· Report No. FHWA-SA-96-052, “Process Operational Guide for Narrow-Gap Improved
Electroslag Welding”.

23.6.10.3 Welding of Hollow Structural Steel Sections (Pipes and Tubes)


Except as noted in the Contract documents, the Contractor shall perform all shop and field welding
of Hollow Structural Shapes in accordance with the ANSI/AWS D1.1/D1.1M:2010, Structural Welding
Code – Steel, as amended herein.

a. Welding Highway Signs, Luminaires and Traffic Signals


For structural steel sign structures, lighting poles, and traffic signal poles, the Contractor shall comply
with the additional requirements of AASHTO Standard Specification for Structural Steel Supports for
Highway Signs, Luminaires and Traffic Signals, 5th Edition, Section 1.4.2, Welding of Steel
Structures.

b. Welding Bridge Structures


For tubular bridge structures including pedestrian bridges, the Contractor shall comply with the
requirements of the ANSI/AWS D1.1/D1.1M:2010, Structural Welding Code – Steel, as amended by
the following:
1. Qualify all welding processes in accordance with the AASHTO/AWS D1.5M/D1.5:2010,
Bridge Welding Code. Comply with all qualification criteria including production thickness and
position limitations. Use ASTM A709 / A709M - 11 Grade 50 for this test.
2. UT NDE technicians performing inspection of TKY welds are to be qualified to the
requirements and recommendations for operator qualification specified in API RP 2X:2004,
Recommended practice for ultrasonic and magnetic examination of offshore structural
fabrication and guidelines for qualification of technicians, 4th Edition, including a practical
test with mockup tubular welds containing built-in flaws.
3. Perform nondestructive testing of all tubular complete joint penetration groove welds in main
members using Ultrasonic Testing in accordance with the ANSI/AWS D1.1/D1.1M:2010,
Structural Welding Code – Steel.
Perform ultrasonic testing at the following frequency:
· One hundred percent of each joint subject to tension or reversal of stress.
· Twenty-five percent of each joint subject to compression or shear.
If unacceptable discontinuities are found in the joint, the remainder of the joint shall be tested.
Perform Magnetic Particle Testing on 300mm in every 3.0 metre on each fillet and partial penetration
groove welds in main members but no less than 300mm on welds less than 3.0 metre.

23.6.10.4 Non-destructive Testing of Welds


a. Record of Testing
The test results shall be recorded and be available for inspection by the Engineer.

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STANDARD CONSTRUCTION SPECIFICATIONS PART 2 – ROAD STRUCTURES

b. Visual Inspection of Welds


Visual inspection shall be made in accordance with guidance given in BS EN ISO 17637:2011 over
the full length of the weld and before NDT inspection is performed. Any welds which will be rendered
inaccessible by subsequent work shall be examined in prior to the loss of access.
A suitably qualified person for visual inspection of welds may be a welding inspector or a welder who
can provide evidence of having been trained and assessed for competence in visual inspection of
the relevant types of welds.

c. Surface Flaw Detection


Where a closer examination of a weld surface is required, magnetic particle inspection (MPI) shall
be used in accordance with the recommendations given in BS EN ISO 9934-1:2001.
If magnetic particle inspection equipment is not available, dye penetrant inspection (DPI) may be
used in accordance with the recommendations given in BS EN ISO 3452-1:2013.
Final surface flaw detection of a welded joint shall be carried out not less than 16 hours from the
time of completion of the weld to be inspected, or not less than 40 hours in the case of welds to
Design Grade 55 material. The Contractor shall note that where a welding procedure requires an
inspection after initial weld runs before further welding is performed, such inspections may be carried
out when the weld metal has cooled to ambient temperature.
A suitably qualified person for surface flaw detection of welds may be a welding inspector or a welder
who holds a current certificate of competence in surface flaw detection of the relevant types of work,
from a recognised authority.

d. Ultrasonic Examination
Where ultrasonic examination is required, it shall be made in accordance with BS EN ISO
17640:2010, Level 2B. Examination shall be carried out not less than 16 hours from the time of
completion of the weld to be inspected, or not less than 40 hours in the case of butt welds thicker
than 40 mm or any welds to Design Grade 55 material.
Operators carrying out final ultrasonic examination of the weld shall hold a current certificate of
competence from a recognised authority.

23.6.10.5 Field Welding


The Contractor shall field weld only with the approval of the Engineer. Provide any additional field
welding procedures as requested by the Engineer for review.

23.6.10.6 Tack Welding


The Contractor shall not weld or tack any fill plates, brackets, clips, shipping devices, or other
materials not required by the Contract documents or allowed by the AASHTO/AWS
D1.5M/D1.5:2010, Bridge Welding Code.
1. Tack welds shall be made using the same procedures as for the root runs of main welds. The
length of the tack shall be the lesser of 4 times the thickness of the thicker part or 50 mm,
unless demonstrated by a weld procedure qualification.
2. Tack welds which are not defective may be incorporated into main welds provided that the
welder is qualified as in Article 23.4.11.3 of this chapter. However, where joints are welded
using an automatic or mechanised process, the suitability of the tack weld used for
incorporation into automatic processes shall be demonstrated in the weld procedure
qualification.
3. Where tack welds are made in circumstances other than those identified above, they must
be removed.

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CHAPTER 23: STEEL STRUCTURES First Edition -January 2018

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