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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Structural Steel
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

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Structural Steel
LEARNING OBJECTIVES:
•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:

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Shopdrawings
LEARNING OBJECTIVES:
•STRUCTURAL PLANS & SHOPDRAWINGS:
• Framing Plans
• Typical Transverse Section
• Permissible Field Splice
•STAY IN PLACE FORM
• Recommended SIP Detail (s)
• Applicable Plan Notes

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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 Structural Steel
Material - Section 407.02
Structural Steel
Shapes
•Section 226 / pp:230
•ASTM A709 (Grade 36
or Grade 50W )
Unpainted.

Structural Steel
Structural Steel Shapes Bf
W Shape Wide Flange Beam
Web
W 36 x 135
D

Flange
Weight = 135 lbs / LF
Depth = 36”

Rolled Beam

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 Structural Steel
S Shape Standard Beam 7/8”
7B f
S 24 x 106

D
Weight = 106 lbs. / LF
Depth = 24”
Bf = Flange Width = 7 7/8”

Structural Steel

C Shape – Std. Channel

D

C 15 x 33.9
Weight = 33.9 lbs./ LF
Depth = 15”

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 Structural Steel

Angle Shape t
L 5 x 3 x 3/8”
Leg Dimension = 5” & 3”

Structural Steel

Steel Plate Shape t

PL 9/16 x 32
D

Girder
Jacking
Stiffener

Sole Plate

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 Structural Steel
HP Shape H-Pile
Section 228 W
HP 10 x 42

D
Weight = 42 lbs / LF
Depth = 10” = Width

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

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 Structural Steel

Fabrication Procedures Section 407.04

• Shop Assembly
• Inspection

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 :
Field Weld Other side of joint
• Non-conforming welds determined by Notes
Weld all around joint
visual inspection or NDT
Arrow side of joint
• Shall be repaired if not possible shall Weld size
be removed, replaced and re-
inspected.
•Groove Weld shallbe Ground Flush. Fillet Weld

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 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
Weld Symbols

Structural
Structural SteelSteel
Types of Structural Welds

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 Structural
Structural SteelSteel
Types of Structural Welds

Structural Steel
Shop Full Penetration Weld:

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 Structural
Structural SteelSteel

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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Structural Steel
Upstation Horizontal Dimensions

Girder 1

Girder 2
Permissible Field Splice

Permissible Field Splice

Girder 3

Girder 4

Girder 5

Girder 6

Girder 7

Framing Plan

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Structural Steel

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

Looking Up-station

Beam Labeling

Structural Steel

Framing Plan / Bearings

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 Structural Steel

Structural Steel

Stiffeners and Plate Connectors

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 Structural Steel
Cross Frames

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Structural Steel
Stiffeners 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
Splice & Bolt Detail :

•Bolt layout
•Uniform / Staggered
Bolt Spacing

•Splice Plate Size

•Filler Plate Size
•Transition dimension
and detail.

High Strength Bolts

Section 226.02 (h)
•A325 Type 1 or 3
•A490 Type 1 or 3

Field Splice

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Structural Steel

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Structural Steel

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 Structural Steel
Bolt / Nuts / Washer / DTI :

Structural Steel
Stay In Place Forms Shopdrawings

Field Splice

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

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 Steel
Bridge Survey Stakeout

Field Splice

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 Structural Steel
Temporary Shoring

Sample of Temporary Shoring Detail

Structural Steel
Temporary Shoring

Steel Piles
• Section 228
• H-Piles
• Shell Piles
• Sheet Piles

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Structural Steel
Temporary Shoring

Slope
Failure

Structural Steel
Shopdrawings

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Structural Steel
FABRICATION:

Structural Steel
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. Figure 1
• Cover Plates. Bridge on Grade (Final)

Figure 2
Fabricated Beam Shape
and Final Erected Position

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 Structural Steel
FABRICATION:

Structural Steel
Steel Fabrication
Camber Diagram

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 Structural Steel
FABRICATION:

Before

After

Structural Steel
FABRICATION:

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 Structural Steel
FABRICATION:

Structural Steel
FABRICATION:

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 Structural Steel
Jacking Stiffeners

Field Splice

Structural Steel
Jacking Stiffeners

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 Structural Steel
Jacking 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:

Structural Steel

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 Structural Steel
FABRICATION:
•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 Steel
Handling, 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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 Structural Steel

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.

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Structural Steel
Handling, Storing and Shipping

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Structural Steel
Handling, Storing and Shipping

Structural Steel
Handling, Storing and Shipping

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Structural Steel
Handling, Storing and Shipping

Structural Steel
Handling, Storing and Shipping

Field Splice

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 Structural Steel
Handling, Storing and Shipping

Field Splice

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Structural Steel
Handling, Storing and Shipping

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 Structural Steel

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

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Structural Steel
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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Structural Steel
ERECTION PLAN:
Checklist:
10. Check crane specifications:
• Crane Radius
• Check Counter weights used.

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Structural Steel
Erection

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 Structural Steel
Erection

Field Splice

Structural Steel
Erection

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 Structural Steel
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

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Structural Steel
Erection Procedure Section

Abrasive Blast Cleaning

Weathering Finish Stainless Steel Finish

ASTM A-709 50W A1010

Structural Steel

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, when
specified, 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)
————————————————————————————————
Pay Item Pay Unit
————————————————————————————————
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

SAFETY
CONTRACTOR 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
SAFETY

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