SPECIFICATION 831
MINOR STEEL ITEMS
Copyright MAIN ROADS Western Australia
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 1 of 14
SPECIFICATION 831
MINOR STEEL ITEMS
REVISION REGISTER
Date
Clause
Number
Description of Revision
Authorised
By
23 Sept 08
831.02
References - amendments to
Standards title AS/NZS
1553.1
SDSE
21 Dec 06
831.01
Reference to “sockets for
balustrades and traffic
barriers” deleted
SDSE
1 Aug 06
Whole
document
Complete revision of Issue
1.2 to new format
MCP
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 2 of 14
CONTENTS
Clause
Page No
GENERAL ................................................................................................................ 4
831.01 SCOPE ..................................................................................................... 4
831.02 REFERENCES ......................................................................................... 4
831.03 – 831.05 NOT USED .............................................................................. 5
PRODUCTS AND MATERIALS ............................................................................... 5
831.06 STRUCTURAL STEEL FOR PLATES, BARS AND SECTIONS ............... 5
831.07 BOLTS, NUTS, SCREWS AND WASHERS ............................................. 5
831.08 TESTING AND IDENTIFICATION OF MATERIAL.................................... 6
831.09 DAMAGED STEEL ................................................................................... 6
831.10 STORAGE OF MATERIALS ..................................................................... 6
831.11 ASSEMBLY PROCEDURES .................................................................... 7
831.12 ACCEPTANCE OF PROTOTYPE COMPONENTS .................................. 7
831.13 IDENTIFICATION MARKS ....................................................................... 7
831.14 – 831.25 NOT USED .............................................................................. 7
FABRICATION ......................................................................................................... 8
831.26 CUTTING AND EDGE TREATMENT ....................................................... 8
831.27 SPLICES .................................................................................................. 8
831.28 HOLES FOR BOLTING ............................................................................ 8
831.29 WELDING ................................................................................................ 9
831.30 STUD SHEAR CONNECTORS ................................................................ 9
831.31 CERTIFICATION OF FABRICATION ....................................................... 9
831.32 PROTECTIVE TREATMENT .................................................................... 9
831.33 TRANSPORT, HANDLING AND STORAGE .......................................... 10
831.34 – 831.80 NOT USED ............................................................................ 10
AS BUILT AND HANDOVER REQUIREMENTS .................................................... 10
831.81 – 831.90
NOT USED ............................................................................ 10
CONTRACT SPECIFIC REQUIREMENTS ............................................................. 10
831.91 – 831.99
NOT USED ............................................................................ 10
ANNEXURE 831A .................................................................................................. 11
SUPPLY OF MINOR STEEL ITEMS BY THE PRINCIPAL .................................. 11
831.91 SUPPLY OF ITEMS BY THE PRINCIPAL .............................................. 13
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 3 of 14
SPECIFICATION 831
MINOR STEEL ITEMS
GENERAL
831.01
SCOPE
1.
The work under this specification consists of the supply,
fabrication, protective treatment and delivery of steel expansion joint
protection angles and other minor steel items including dowels, bolts,
nuts, screws and washers.
831.02
REFERENCES
1.
Australian Standards, MAIN ROADS Western Australia
Standards and MAIN ROADS Western Australia Test Methods are
referred to in abbreviated form (e.g. AS 1234, MRS 67-08-43 or WA
123). For convenience, the full titles are given below:
Australian Standards
AS 1110
(Precision)
ISO Metric Hexagon Bolts and Screws - Product Grades A & B
AS 1111
ISO Metric Hexagon Bolts and Screws - Product Grades C (Commercial)
AS 1112
ISO Metric Hexagon Nuts - Including Thin Nuts, Slotted Nuts and Castle
Nuts
AS 1163
Structural Steel Hollow Sections
AS 1214
Hot-dip Galvanised Coatings on Threaded Fasteners
AS 1237
Plain Washers for Metric Bolts, Screws and Nuts for General Engineering
Purposes
AS 1275
Metric Screw Threads for Fasteners
AS 1420
ISO Metric Hexagon Socket Head Cap Screws
AS 1789
Electroplated Zinc (Electrogalvanised) Coatings - on Ferrous Articles
(Batch Process)
AS 1897
Electroplated Coatings on Threaded Components (Metric Coarse Series)
AS 2837
Wrought Alloy Steels - Stainless Steel Bars and Semi-finished Products
AS 4100
Steel Structures
Australian/ New Zealand Standards
AS/NZS 1252
High Strength Steel Bolts with Associated Nuts and Washers for
Structural Engineering
AS/NZS 1554
Structural Steel Welding
AS/NZS 1554.2
Structural Steel Welding – Stud Welding (steel studs to steel)
AS/NZS 3678
Structural Steel - Hot Rolled Plates, Floorplates and Slabs
AS/NZS 3679
Structural Steel - Hot Rolled Bars and Sections
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 4 of 14
MAIN ROADS Specifications
Specification 835
831.03 – 831.05
PROTECTIVE TREATMENT OF STEEL
WORK
NOT USED
PRODUCTS AND MATERIALS
831.06
STRUCTURAL STEEL FOR PLATES, BARS AND
SECTIONS
1.
Structural steel for plates, bars and sections shall conform to
the requirements of AS/NZS 3678, Grade 300, and AS 3679/NZS grade
300 unless noted otherwise on the Drawings or the Specification.
2.
Structural steel hollow sections shall conform to the
requirements of AS 1163, Grade 350 unless noted otherwise on the
Drawings.
831.07
BOLTS, NUTS, SCREWS AND WASHERS
1.
All bolts, nuts, screws and washers shall conform with the
relevant Australian Standards listed in Clause 831.02.
2.
High strength bolts, with associated nuts and washers, shall
be manufactured in accordance with AS/NZS 1252 and installed in
accordance with AS 4100. The length of the bolt shall be as shown on
the Drawings, or, if no length is shown, shall be in accordance with
AS 4100.
3.
All screw threads shall conform to the ISO coarse pitch
series thread in accordance with AS 1275.
4.
Unless shown otherwise on the Drawings, nuts other than
those for high strength bolts shall be "normal" size. The strength grade
of normal nuts to be associated with each strength grade of the bolt, Ubolt, screw, stud or other threaded component shall be as follows:
Grade of bolt, U-bolt etc.
Strength Grade of Nut
4.6
5
5.8
5
8.8
8
10.9
10
5.
The strength grade required for precision bolts and screws
shall be as shown on the Drawings.
6.
The stainless steel used in the manufacture of non-high
strength bolts, nuts and dowels shall conform to AS 2837 Grade 316L
for welded components or Grade 316 otherwise. The stainless steel
used in the manufacture of high strength bolts and nuts shall conform to
SS2343 (American Iron and Steel Institute Grade 316 Mo+) and have a
minimum ultimate tensile strength of 800MPa.
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 5 of 14
7.
Prevailing torque locknuts, also known as "self-locking nuts",
shall be the insert type having a nylon or similar plastic insert, such as
"Nyloc" nuts or similar approved by the Superintendent. Those used
with commercial grade bolts or U-bolts shall be strength grade 6 or
higher.
8.
Unless shown otherwise on the Drawings the following types
of washers shall be used:a) With precision bolts - bright metal washers, normal
series
b) With commercial bolts - black metal washers, normal
series
c) With stainless steel bolts - stainless steel washers
Grade 316, normal series.
9.
screws.
Washers are generally not required under socket head cap
10.
The Contractor shall obtain a Certificate from a laboratory
with appropriate NATA registration stating that the bolts, nuts, screws
and washers comply with the appropriate standard.
831.08
TESTING AND IDENTIFICATION OF MATERIAL
1.
The Contractor shall ensure that all materials or parts
conform with the tests required by the standards and with other tests
specified in this Part of the Specification.
2.
Test certificates showing the results of mechanical tests and
chemical analysis (where applicable) of the material or parts used in the
Works shall be retained by the Contractor.
3.
All materials or parts used in the Works shall be identified
with the tests. The Contractor shall establish and maintain a
comprehensive system of identification records. Copies of all these
records shall be forwarded to the Superintendent on request.
831.09
DAMAGED STEEL
1.
Steel which is bent (except as required for fabrication),
damaged or excessively rusted shall not be used in the Works.
831.10
STORAGE OF MATERIALS
1.
All steel, whether fabricated or not, shall be stored in such a
manner that corrosion is minimised. Generally, storage at least 200mm
above the ground on platforms, slabs, or other supports under cover will
be satisfactory.
2.
Bolts, nuts, screws and washers not promptly incorporated
in the work shall be stored in a waterproof shelter clear of the ground,
and protected from damage.
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 6 of 14
831.11
ASSEMBLY PROCEDURES
1.
Details of the procedures for assembly and fabrication shall
be submitted with the Contractor's Quality Plan. These procedures shall
be comprehensive and shall cover all aspects of the work. The
procedures shall include, but not be limited to:-
Quality Plan
a) Assembly procedures, including dimensional control and
details of manufacturing jigs
b) Welding procedures
c) Qualification of welds, including stud welding
d) Qualification and identification of welders
e) Qualification of welding supervisors
f)
System of identification of welders with work
g) Quality control measures
h) Quality control check lists and forms
i)
System for identification of components
j)
Procedures for trial assembly
k) Procedures for repair of non-conforming materials,
components and assemblies
l)
Procedures for transport, handling and storage,
including measures to prevent distortion and damage to
the steelwork and its protective coating
m) Procedure for curving
2.
At least one week prior to commencing fabrication, the
Contractor shall submit a programme to the Superintendent
showing the proposed sequence of operations.
831.12
ACCEPTANCE OF PROTOTYPE COMPONENTS
1.
The Contractor shall give 5 working days' notice in
writing before commencing work, and this shall be allowed for in
the programme. For the first item of any component fabricated the
Contractor shall make a thorough dimensional check. The
Contractor shall submit to the Superintendent details of this
dimensional check, and certification that the dimensions are in
conformity with the requirement of the Drawings and the
Specification. No further fabrication work on similar items shall be
carried out until submission of this certification.
831.13
HOLD
POINT
HOLD
POINT
IDENTIFICATION MARKS
1.
Each component shall be metal stamped with an
identification mark which remains recognisable after protective
treatment, but which is located in a hidden or inconspicuous position
after erection. Each type of component shall be designated with a mark
which is readily distinguishable from the marks for all other types.
831.14 – 831.25
Identification
NOT USED
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 7 of 14
FABRICATION
831.26
CUTTING AND EDGE TREATMENT
1.
Steelwork may be cut by flame cutting, sawing or guillotining
unless specified otherwise. Surfaces produced by such cutting shall be
finished square (unless a bevelled edge is called for) and true to the
required dimensions. Shearing by nibbling action shall not be
permitted.
2.
Cut edges shall be finished as specified in AS 4100.
Guillotined plates shall be cut to an oversize sufficient for the correct
dimensions to be achieved after edge finishing. Where galvanising is
specified the edge surface preparation shall conform to the
requirements specified in this Part of the Specification.
3.
Unless shown otherwise on the Drawings, all corners on cut
edges shall be rounded to a radius of approximately 1.5mm, except
where such edges are subsequently to be welded. Rolled edges need
not be rounded provided the corners have a similar radius.
831.27
SPLICES
1.
Except where shown on the Drawing, splices shall not be
permitted.
831.28
HOLES FOR BOLTING
1.
The diameters of the bolt holes shall be 2mm greater than
the diameters of the bolts shown on the Drawings unless otherwise
specified.
2.
Holes may be either drilled full-size or reamed to full-size
after sub-drilling or sub-punching. In all cases, sub-drilling may be
substituted for sub-punching, and holes may be drilled from the solid
metal instead of being sub-punched or sub-drilled and reamed, provided
such drilling is done with the material assembled in the same manner as
is required for reamed work.
3.
Sub-punched and sub-drilled holes shall be smaller in
diameter than the nominal diameter of bolts by 3mm.
4.
For sub-punched holes the diameter of the die shall not
exceed the diameter of the punch by more than 1mm. Holes shall be
clean cut, without torn or ragged edges. Reamed or drilled holes shall
be cylindrical and perpendicular to the face of the member. Reaming
and drilling shall be done by mechanical means.
5.
Connecting parts shall be assembled and held securely
while being reamed or drilled and shall be match-marked before
separating the parts. Burrs on the outside surfaces shall be removed.
6.
Holes for field connections may be sub-punched or subdrilled and reamed or drilled from the solid to a hardened steel template
not less than 25mm thick, and all corresponding holes in the members
to which they connect shall be reamed or drilled to the same template.
Alternatively these connections may be reamed or drilled with the
members assembled.
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 8 of 14
831.29
WELDING
1.
All welding shall conform to AS/NZS 1554.1 or AS/NZS
1554.2 as applicable, unless otherwise specified.
2.
Weld quality shall be as nominated on the Drawings. All
weld spatter, shall be removed before protective treatment is applied.
831.30
STUD SHEAR CONNECTORS
1.
Stud shear connectors and stud welding shall comply with
the requirements of AS/NZS 1554.2 except as varied by this
Specification.
2.
Operators shall be qualified in accordance with Section 3 of
AS/NZS 1554.2.
Operator
Qualifications
3.
Any stud welds not meeting the requirements of
AS/NZS 1554.2 shall be rejected. Repairs to defective welds, except
where allowed for in AS 1554.2, shall not be allowed.
831.31
CERTIFICATION OF FABRICATION
1.
Prior to dispatch of work from the fabrication shop, the
Contractor shall provide the Superintendent with certification that
each item fabricated conforms to the requirements of the
Drawings and the Specification.
831.32
831.32.01
HOLD
POINT
PROTECTIVE TREATMENT
GENERAL
1.
All minor items of steelwork shall be hot dip galvanised
unless otherwise specified.
Galvanise
2.
All protective treatment including hot dip galvanising shall be
in accordance with Specification 835 PROTECTIVE TREATMENT OF
STEEL WORK unless otherwise specified.
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 9 of 14
831.32.02
1.
PROTECTIVE TREATMENT FOR BOLTS, NUTS, ETC.
Stainless steel items do not require protective treatment.
2.
Unless shown otherwise on the Drawings, all other bolts, Ubolts, screws, nuts and washers shall be protected with the following
protective treatment:Item to be Protected
Protective Treatment
High strength bolts and associated
nuts and washers, and Commercial
bolts, screws and U-bolts and
associated nuts and washers
Hot-dip galvanised in accordance with
AS 1214
Precision bolts and screws and
associated nuts and washers &
Prevailing torque locknuts
Electroplated with zinc in conformity with the
principles of AS 1897, or for sizes over M16,
of AS 1789 - Classification Fe/Zn 12c
Type C
Socket head cap screws
Blue-black or chemical black finish plus a
residual coating of light oil. Prior to placing
into position in the bridge, socket head cap
screws shall be de-greased and coated with
approved zinc rich epoxy based primer.
831.33
TRANSPORT, HANDLING AND STORAGE
1.
The Contractor shall ensure that loading, transport,
unloading, stacking and handling operations are carried out in such a
way that the items are protected from distortion and that galvanised
surfaces are protected from damage. The Contractor shall store
components in such a manner that the freshly galvanised surfaces are
protected from the attack of "white rust".
831.34 – 831.80
NOT USED
AS BUILT AND HANDOVER REQUIREMENTS
831.81 – 831.90
NOT USED
CONTRACT SPECIFIC REQUIREMENTS
831.91 – 831.99
NOT USED
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 10 of 14
ANNEXURE 831A
SUPPLY OF MINOR STEEL ITEMS BY THE PRINCIPAL
Description
Number
MAIN ROADS Western Australia
Contract xxx/xx
Location
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Time of Availability
(Weeks after
Commencement of
Contract)
Page 11 of 14
SPECIFICATION 831 GUIDANCE NOTES
DELETE THESE GUIDANCE NOTES FROM FINAL DOCUMENT AFTER USING FOR
REFERENCE
All edits to downloaded TDP documents shall be tracked (most word processing
software allows this to be done automatically). Deletions shall be struck through e.g.
example. Insertions shall be in italics e.g. example. If all information relating to a clause
is deleted then the clause number should be retained and the words "NOT USED"
should be inserted.
The proposed documents with tracked changes shall be submitted to the Project
Manager for review, prior to printing the final batch of documents. When this final
printing is carried out, the tracked changes option is to be turned off.
The Custodian of this specification is the Structures Design and Standards Engineer.
1.
SUPPLY BY THE PRINCIPAL (Clause 831.91)
1.1
If the Principal will pre-supply steel, include Clause 831.91 and complete
Annexure 831A.
1.2
Annexure 831A is provided for listing Principal supplied items. The
description should include identification with items shown on the Drawings, and the
location for pick-up of items.
1.3
If not applicable, delete Annexure 831A.
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 12 of 14
CONTRACT SPECIFIC REQUIREMENTS TO ADD OR DELETE
The following clauses are to be placed under the CONTRACT SPECIFIC ITEMS as
required.
831.91
SUPPLY OF ITEMS BY THE PRINCIPAL
1.
The Principal will make available free of charge to the
Contractor steel items as listed in Annexure 831A.
2.
The Contractor shall provide for all cranage, for handling
and loading and a means of transport for these items.
Handling
3.
The Contractor shall supply all other material necessary for
completing the Works.
Associated
Materials
MAIN ROADS Western Australia
Contract xxx/xx
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
Page 13 of 14
SPECIFICATION AMENDMENT CHECKLIST
Specification Name: No:
831 Revision No: ______Title: MINOR STEEL ITEMS
Project Manager: Name:
_______________Signature: ____________Date:______
Checked By: Name: _______________Signature: _______________Date:______
Contract No: ______Contract Description: ___________________________________
ITEM
DESCRIPTION
SIGN
OFF
All changes/amendments must be shown in Tracked Change mode until
Note:
approved.
1.
Project Manager has reviewed Specification and identified
Additions and Amendments.
2.
CONTRACT SPECIFIC REQUIREMENTS addressed? –
Contract specific materials/products/clauses added? (Refer
Specification Guidance Notes for guidance).
3.
Any unlisted Materials/Products proposed and approved by the
Project Manager? – if “Yes” provide details at 15.
4.
Standard Clauses amended? – MUST SEEK approval from
MCP.
5.
Clause deletions shown as ‘NOT USED’.
6.
Appropriate INSPECTION & TESTING parameters included in
Spec 201 (Test Methods, Minimum Testing Frequencies
verified).
7.
ANNEXURES completed (Refer Specification Guidance Notes).
8.
HANDOVER and AS BUILT requirements addressed.
9.
Main Roads QS has approved changes to SMM.
10.
Project Manager certifies completed Specification reflects intent
of the design.
11.
Completed Specification – independent verification arranged by
Project Manager
12.
Project Manager’s review completed.
13.
SPECIFICATION GUIDANCE NOTES deleted.
14.
TABLE OF CONTENTS updated.
15
Supporting information prepared and submitted to Project
Manager.
Further action necessary:
Signed:
MAIN ROADS Western Australia
Contract xxx/xx
(Project Manager)
Date:_______________
Specification 831 Minor Steel Items
Document 04/10142 Issue 23/09/08
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