SPECIFICATION 830
STRUCTURAL STEELWORK
Copyright MAIN ROADS Western Australia
MAIN ROADS Western Australia
Contract xxx/xx
Specification 830 Structural Steelwork
Document 04/10141 Issue 23/09/08
Page 1 of 24
SPECIFICATION 830
STRUCTURAL STEELWORK
REVISION REGISTER
Date
Clause
Number
Description of Revision
Authorised
By
23 Sept 08
830.02
References - amendments to
Standards titles AS 1710 &
AS/NZS 1553.1
SDSE
6 Nov 06
830.28.05.2
Clause re-worded and made
into a HOLD POINT
SDSE
830.28.06.2
Amended
Whole
document
Complete revision of Issue
2.1 to new format
1 Aug 06
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Contract xxx/xx
Specification 830 Structural Steelwork
Document 04/10141 Issue 23/09/08
MCP
Page 2 of 24
CONTENTS
Clause
Page No
GENERAL ................................................................................................................ 4
830.01 SCOPE ..................................................................................................... 4
830.02 REFERENCES ......................................................................................... 4
830.03 DEFINITIONS ........................................................................................... 5
830.04 – 830.05 NOT USED .............................................................................. 6
PRODUCTS AND MATERIALS ............................................................................... 6
830.06 SPECIFICATIONS FOR STEEL ............................................................... 6
830.07 TEST CERTIFICATES AND IDENTIFICATION OF MATERIAL ............. 8
830.08 TESTING OF STEEL................................................................................ 8
830.09 IDENTIFICATION MARKS ....................................................................... 9
830.10 STORAGE ................................................................................................ 9
830.11 HANDLING AND STACKING ................................................................... 9
830.12 – 830.20 NOT USED .............................................................................. 9
FABRICATION ......................................................................................................... 9
830.21 GENERAL ................................................................................................ 9
830.22 SHOP DRAWINGS................................................................................... 9
830.23 PRECAMBER AND DISTORTIONS ....................................................... 11
830.24 STRAIGHTENING AND CORRECTION OF DISTORTIONS ............... 11
830.25 CUTTING AND EDGE TREATMENT ..................................................... 11
830.26 SPLICES ................................................................................................ 12
830.27 HOLES FOR BOLTING .......................................................................... 12
830.28 WELDING .............................................................................................. 12
830.29 STUD SHEAR CONNECTORS .............................................................. 17
830.30 BOLTING................................................................................................ 17
830.31 HOLDING DOWN BOLTS ...................................................................... 18
830.32 CERTIFICATION OF FABRICATION ..................................................... 18
830.33 - 830.40 NOT USED ............................................................................. 18
ERECTION ............................................................................................................. 18
830.41 GENERAL .............................................................................................. 18
830.42 BOLTED JOINTS ................................................................................... 19
830.43 CONSTRUCTION TOLERANCES .......................................................... 19
830.44 – 830.80 NOT USED ............................................................................ 20
AS BUILT AND HANDOVER REQUIREMENTS .................................................... 20
830.81 – 830.90
NOT USED ............................................................................ 20
CONTRACT SPECIFIC REQUIREMENTS ............................................................. 20
830.91 – 830.99
NOT USED ............................................................................ 20
ANNEXURE 830A .................................................................................................. 21
STEEL ITEMS SUPPLIED BY PRINCIPAL ......................................................... 21
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Document 04/10141 Issue 23/09/08
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SPECIFICATION 830
STRUCTURAL STEELWORK
GENERAL
830.01
SCOPE
1.
The work under this specification consists of the supply,
fabrication and erection of steel beams, box girders, columns and
associated structural steel work,.
2.
Minor steel items, balustrades and traffic barrier requirements
are covered in Specifications 831, 833 and 603 respectively.
830.02
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:
2.
All metal fabrication and welding shall comply with the
current edition of the relevant Standard or Code of Practice (including
amendments) specified in the Specifications or nominated on the
Drawings. The requirements of the relevant Standard / Code are
deemed to be the minimum standard applicable, unless otherwise stated
in the Contract Specification.
Australian Standards
AS 1100
Technical Drawing
AS 1101.3
Graphical Symbols for General Engineering - Welding and Non-destructive
Examination.
AS 1111
ISO Metric Hexagon Bolts and Screws – Product Grade C
AS 1163
Structural Steel Hollow Sections
AS 1275
Metric Screw Threads for Fasteners
AS 1710
Non-destructive Testing – Ultrasonic testing of carbon and low allow
steel plate and universal sections - Test Methods and Quality Classification
AS 1796
Certification of Welders and Welding Supervisors
AS 1858
Electrodes and Fluxes for Submerged-arc Welding
AS 1966
Electric Arc Welding Power Sources
AS 2203
Covered Electrodes for Arc-welding – Ferritic Steel Electrodes
AS 2812
Welding, Brazing and Cutting of Metals – Glossary of Terms
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AS 2837
Wrought Alloy Steels – Stainless Steel Bars and Semi-finished Products
AS 3828
Guidelines for the Erection of Building Steelwork
AS 4100
Steel Structures
AS 5100
Bridge Design
Australian/New Zealand Standards
AS/NZS 1252
High Strength Bolts with Associated Nuts and Washers for
Structural Engineering
AS/NZS 1553.1
Covered Electrodes for Welding - Low carbon steel electrodes for
manual metal-arc welding of carbon steels and carbon-manganese
steels
AS/NZS 1554.1
Structural Steel Welding -Welding of Steel Structures
AS/NZS 1554.2
Structural Steel Welding - Stud Welding (Steel Studs to Steel)
AS/NZS 1995
Welding Cables
AS/NZS 3678
Structural Steel – Hot-rolled Plates, Floorplates and Slabs
AS/NZS 3679
Structural Steel – Hot Rolled Bars and Sections
AS/NZS ISO 3834
Quality Requirements for Welding – Fusion Welding of Metallic
Materials
AS/NZS ISO 9001
Quality Management Systems - Requirements
Other Standards
WTIA TN03
Welding Technology Institute of Australia, Technical Note 3, Care
and Conditioning of Arc Welding Consumables
MAIN ROADS Specifications
Specification 603
Specification 831
Specification 833
Specification 835
830.03
SAFETY & TRAFFIC BARRIER SYSTEMS
MINOR STEEL ITEMS
BRIDGE BALUSTRADES
PROTECTIVE TREATMENT OF STEELWORK
DEFINITIONS
830.03.01 TERMS
ITP
Detailed Inspection and Test Plan(s) for the Works
MDR
Manufacturer’s Data Report
WSP (Welding Service Provider)
The Contractor or an approved Subcontractor (approval in writing to be
obtained from the Superintendent) to undertake the Works.
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Specification 830 Structural Steelwork
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830.03.02
WORKMANSHIP
1.
All work shall be carried out by competent and qualified
personnel under the supervision of experienced and competent
supervisors to fully satisfy the requirements of this Specification.
830.03.03
PROVISION FOR AUDIT INSPECTION
1.
The Contractor shall lay out and arrange the individual
members or units to be inspected so that identification marks on each
may be readily distinguished and so that each member or unit is
accessible for audit inspection by the Superintendent.
2.
The Contractor shall assist the Superintendent by turning the
members or parts to permit examination of all sides. The Contractor
shall supply all labour, plant, tools and scaffolding required to facilitate
full inspection.
830.03.04
QUALITY ASSURANCE
The WSP shall:
1.
Be responsible for all quality control and assurance activities
necessary to ensure that the completed Works comply with the specified
requirements.
2.
Provide prior information to the Superintendent in respect of
any proposed subcontract work to enable the Superintendent to assess
and approve their suitability for that work.
3.
Establish and maintain an accredited quality management
system to AS/NZS ISO 9001 and AS/NZS ISO 3834 (or to an alternative
approved by the Superintendent) and to ensure that any Subcontractors
are subject to the same requirements.
4.
Submit a Quality Plan to the Superintendent detailing how
the Quality Assurance requirements are to be applied to each element
of the Works.
830.04 – 830.05
NOT USED
PRODUCTS AND MATERIALS
830.06
SPECIFICATIONS FOR STEEL
1.
All materials supplied by the Contractor shall be new and
shall conform to the Standards specified below.
New Steel
2.
Unless otherwise specified, steel plate used in box girders
shall meet the requirement of Grade 250LO in accordance with AS/NZS
3678.
Standards
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3.
Unless otherwise specified, all structural steel sections
except hollow sections shall be Grade 300 in accordance with AS/NZS
3679.
4.
Structural steel hollow sections shall conform to the
requirements of AS 1163 and shall be grade C350.
5. Bolts, Nuts, Screws and Washers:
a) All bolts, nuts, screws and washers shall conform with
the relevant Australian Standards.
b) High strength bolts, with associated nuts and washers,
will comply 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
c) All screw threads will conform to the ISO coarse pitch
series thread in accordance with AS1275.
d) Unless otherwise shown on the Drawings, nuts other
than those for high strength bolts will be “normal” size.
The strength grade of normal nuts to be associated with
each strength grade of the bolt, U-bolt, screw, stud or
other threaded component will 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
6.
The strength grade required for precision bolts and screws
shall be as shown on the Drawings.
7.
Where stainless steel bolts are shown on the Drawings 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.
8.
Where prevailing torque locknuts, also known as “self locking nuts” are shown on the Drawings, they shall be the insert type
having a nylon or similar plastic insert such as “Nyloc” nuts. Those used
with commercial grade bolts or U-bolts shall be strength grade 6 or
higher.
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Document 04/10141 Issue 23/09/08
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9.
Unless shown otherwise on the Drawings, the following
types of washers will 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.
10.
screws.
Washers are generally not required under socket head cap
11.
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.
830.07
TEST CERTIFICATES AND IDENTIFICATION OF
MATERIAL
1.
Steel shall be identified in accordance with Clause 15 of
AS/NZS 3678 or Clause 14 of AS/NZS 3679 as appropriate. This
identification shall be maintained during all phases of fabrication.
2.
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.
3.
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, and shall form part of the
MDR.
Certificates
4.
All materials or parts used in the Works shall be traceable to
the Test Certificates. 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, and shall
form part of the MDR.
830.08
TESTING OF STEEL
1.
If steel manufacturer's certificates in accordance with Clause
830.07 are not available, then the Contractor shall prepare specimens
and carry out tests in accordance with the relevant Australian Standards.
Testing
2.
Prior to fabrication, all plates of thickness in excess of 30mm
shall be tested by the Contractor along all lines where welding shall be
carried out using continuous ultrasonic testing to establish that the
plates are free from laminations and defects. The method of testing
shall be in accordance with AS 1710.
3.
A written report on each line tested shall be forwarded direct
from the NATA registered testing laboratory to the Superintendent within
24 hours of completion of the test. The location and extent of inclusions
and/or laminations shall be detailed and sketched in the report.
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830.09
IDENTIFICATION MARKS
1.
Each item of structural steelwork shall have its own item
mark number which shall be used on all related schedules and
documents. This mark shall be clearly indicated on all members by
durable identification marks to enable accurate identification on site.
830.10
Mark
Number
STORAGE
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 timber gluts under cover shall be satisfactory.
Rusted or bent or damaged steel shall be rejected.
830.11
HANDLING AND STACKING
1.
Before and after fabrication and during transit and on the
Site all structural steelwork shall be handled and stacked in such a way
that it is not damaged.
Identification
2.
All bolts and nuts and washers and plates under 300mm
maximum dimension and small articles generally shall be packed
separately in watertight containers.
3.
Identification marks as specified in Clause 830.09 shall be
stencilled on each package in a conspicuous position.
830.12 – 830.20
NOT USED
FABRICATION
830.21
GENERAL
1.
All structural steelwork shall be fabricated as shown on the
Drawings and in accordance with the requirements of AS 4100 and
AS/NZS 1554.1 (SP quality) except as varied by this Specification.
2.
The steelwork shall be fabricated where applicable with all
necessary temporary brackets and straps and gussets and cleats and
fixings and lifting eyes and the like necessary for erection and assembly.
830.22
SHOP DRAWINGS
1.
The Contractor shall prepare shop drawings for the
fabrication of all members.
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2.
Shop drawings shall show details of fabrication which are not
explicit in the Drawings. Details required include dimensions, angles
and weld preparation details and any CONTRACT SPECIFIC
REQUIREMENTS specified in Clauses 830.91 to 830.99.
3.
The details shown on the shop drawings shall be consistent
with the Drawings and shall comply with the following:a) The marking plan shall show the location of each part in
the structure.
b) Shop drawings shall conform to AS 1100.
c) Welding and cutting definitions shall conform to AS
2812.
d) Welding symbols shall conform to AS 1101.3.
e) Complete information regarding the location, type, size
and extent of all welds shall be clearly shown on the
shop drawings. These shop drawings shall clearly
distinguish between shop and field welds.
f)
Joints or groups of joints in which it is especially
important that the welding sequence and technique of
welding be carefully controlled to minimise shrinkage
stresses and distortion shall be noted on the shop
drawings. Joints where no welding is permitted shall
also be clearly indicated. Weld lengths specified on the
Drawings shall be the required effective lengths.
g) Each member shall be clearly identified with the
identification marks shown on the Drawings. Each type
of component shall be further identified to readily
distinguish it from all other types.
h) For assemblies, all associated bolting, accessories
and/or joining details shall be shown on the shop
drawings.
4.
Four copies of the shop drawings, certified by the Contractor
as complying with the above requirements, shall be submitted to the
Superintendent 7 working days before fabrication commences.
5.
Variations of details shown on the shop drawings shall not
be made without resubmission of appropriately amended shop drawings
at least 7 working days before fabrication of any affected component of
the Works.
6.
The Contractor shall be responsible for the correctness of
the shop drawings. Acceptance of the shop drawings by the
Superintendent shall not relieve the Contractor of any responsibility.
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830.23
PRECAMBER AND DISTORTIONS
1.
The Contractor shall be aware that the specified construction
tolerances require making due allowance for pre-camber and distortions
due to fabrication and erection processes and for careful matching of
angles and dimensions at field joints.
2.
The Drawings show pre-camber due to dead load. The
Contractor shall allow for all other aspects of the construction method
affecting pre-camber.
830.24
STRAIGHTENING AND CORRECTION OF
DISTORTIONS
1.
All plates shall be flattened and all sections shall be
straightened and made free from twist before any work is done on them
to ensure assembled surfaces shall be flat within specified tolerances
and adjacent surfaces shall be in close contact throughout. The
methods adopted for such flattening and straightening shall be such as
not to damage or mark the material. Heating of plates and all sections
shall not be permitted unless written approval is obtained from the
Superintendent prior to any heat application.
830.25
CUTTING AND EDGE TREATMENT
1.
Steelwork shall be cut only by sawing, thermal cutting,
abrasive water jet cutting or laser cutting. After cutting, cut edges shall
be ground to remove burrs, dross and slag, and to clean up any
roughness (including gouge marks and unintentional bevel).
2.
Unless required otherwise for welding, or where shown
differently on the Drawings, any surfaces produced by cutting shall be
finished square (unless a bevelled edge is called for) and smooth and
true to the required dimensions.
3.
Ends of web stiffener plates shall be cut and finished to fit
snugly and uniformly to girder flanges unless otherwise shown on the
Drawings.
4.
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 of this Specification.
5.
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.
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830.26
SPLICES
1.
The location of any splices required in the flanges or webs of
the box girder, additional to those shown on the Drawings, shall be
suitably staggered and away from zones of high stress (typically not
within 1m of beam bolted splice connection points and located near the
contraflexure points away from pier centrelines) as approved by the
Superintendent.
830.27
HOLES FOR BOLTING
1.
All bolt holes shall be drilled to a diameter 2mm larger than
the diameter of the bolt unless otherwise shown on the Drawings.
2.
Drilled holes shall be cylindrical and perpendicular to the
face of the member. Drilling shall be done by mechanical means.
830.28
WELDING
830.28.01
GENERAL
1.
All welding shall comply with AS/NZS 1554.1 or AS/NZS
1554.2 as appropriate. All welding shall be category SP (Structural
Purpose) in accordance with AS/NZS 1554.1.
830.28.02
QUALIFICATION OF WELDING PERSONNEL
830.28.02.01
Welder
1.
Welding shall only be carried out by welders meeting the
requirements of Clause 4.12.2 of AS/NZS 1554.1
2.
Not less than 10 working days prior to planned
commencement of welding, the following information on each welder
shall be provided to the Superintendent:
a) Documentary evidence of the qualification/certification
currently held;
b) Trade training background;
c) Duration of employment with current employer;
d) Nature of current employment duties; and,
e) Documentary evidence confirming each welder is
qualified for each welding procedure that they shall apply
to the Works.
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3.
The WSP shall:
a) Maintain records clearly identifying the welders to each
completed weld, weld repair and/or fabricated
assembly/unit. All records shall be available to the
Superintendent; and
b) On completion of the welding work, a weld map showing
the welds completed by each welder shall be part of the
MDR.
830.28.02.02
Supervisor / Welding Coordinator
1.
All welding shall be carried out under the supervision of the
Contractor's Welding Supervisor who shall be qualified in accordance
with the requirements of Clause 4.12.1 of AS/NZS 1554.1.
2.
Not less than 10 working days prior to commencement of
welding, the WSP shall identify the Welding Supervisor who shall be
responsible for the coordination of all operations in respect of the
welding work. The WSP shall provide to the Superintendent details of
the Welding Supervisor’s qualifications, certification and experience. The
Welding Supervisor shall have delegated authority to deal directly with
the Superintendent on all issues relating to the welding work, including:
a) Welding procedure management;
b) Welding quality management;
c) Inspection and testing activities; and
d) Sign-off of completed work.
830.28.02.03
Welding Inspector
1.
All welding work shall be inspected by a suitably qualified
Welding Inspector in accordance with Clause 7.2 of AS/NZS 1554.1,
and who holds:
a) Current WTIA Welding Inspection Certification, either as
a Welding Inspector or as a Structural Welding
Supervisor; or,
b) Other current qualification / certification acceptable to
the Superintendent.
2.
Not less than 10 working days prior to commencement of
welding, the WSP shall identify the Welding Inspector who shall be
responsible for the inspection of the welding work. The WSP shall
provide to the Superintendent details of the Welding Inspector’s
qualifications, certification and experience.
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830.28.03
EQUIPMENT
1.
Welding equipment and plant shall conform to AS 1966 and
AS/NZS 1995, and shall be maintained at all times in good condition. It
shall be of an appropriate type for the intended purpose and shall only
be used in the circumstances and in the manner recommended by the
manufacturer for size of electrodes, currents, voltages, speeds of travel,
position of welding and fixtures and jigs shall be as laid down for the
particular class of work.
2.
Where a machine or a method is not of a conventional type,
the machine or method shall be used in the welding procedure
qualification.
3.
Where welding is required to be done in conditions of a high
risk of electric shock the welding equipment shall be fitted with a Voltage
Reduction Device (VRD).
830.28.04
WELDING CONSUMABLES
1.
All welding consumables to be used in welding procedures
and for the Works shall comply with the relevant Standards. Electrodes
used for manual welding shall conform to AS/NZS 1553.1. Flux cored
electrodes used for semi-automatic welding shall conform to AS 2203.
Electrodes and fluxes used for submerged arc-welding shall conform to
AS 1858.
2.
The WSP shall store and handle welding consumables, in
particular hydrogen controlled electrodes, in compliance with the
recommendations in WTIA Technical Note 3.
830.28.05
WELDING PROCEDURES
1.
Welding procedures for all fillet and butt welds, or any
combination of either, shall be proven qualified by the WSP, who shall
submit to the Superintendent a schedule of all proposed welding
procedure qualifications, not less than 10 working days prior to the
planned commencement of welding work to which the procedures shall
apply.
2.
Prior to the commencement of any welding procedure
where the essential variables, vary outside the limits specified in
Table 4.11(A) of AS/NZS 1554.1, the Contractor shall submit to the
Superintendent a copy of the new procedures proven qualified by
the WSP.
HOLD
POINT
3.
Suitable run-on and run-off tabs shall be used for all butt
welds. The tabs shall have the same thickness and preparation as the
parts to be joined. Each weld pass shall terminate at least 20mm
beyond the edges of the parts to be joined. Welds shall be continuous
for the full length.
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4.
All welding for the work shall be shown in a detailed Welding
Procedure Sheet in accordance with AS/NZS 1554.1. Each welding
procedure shall be qualified by way of test pieces and/or assemblies in
accordance with AS/NZS 1554.1.
5.
Test pieces and/or assemblies shall represent the actual
conditions in the work in regard to location, weather, environment,
geometric arrangement, plate thickness, joint preparation and
equipment and be of a minimum size recommended by AS/NZS 1554.1,
but of adequate size to carry out all testing.
6.
The Superintendent shall be given at least 3 working days
notification of the time and place where the welding and testing of all test
pieces and/or assemblies shall be carried out.
7
The WSP shall obtain any test and/or Inspection Certificates
from a laboratory with appropriate NATA registration, with all relevant
results shown and a statement that the results comply with AS/NZS
1554.1.
830.28.06
CLEANING OF FINISHED WELDS
1.
All run-on and run-off tabs shall be removed after the joint
has cooled and the ends of the welds shall be finished smooth and flush
with the faces of the abutting parts.
2.
Slag shall be removed from completed welds. The weld and
adjacent base material shall be cleaned by brushing or other suitable
means to remove spatter and foreign material. Welded joints shall not
be painted until after the welds have been inspected and tested in
accordance with Clause 830.28.07.
3.
Where butt welds form part of a faying or contact surface,
the surfaces of the butt welds shall be dressed in accordance with
Clause 5.12 of AS/NZS 1554.1.
830.28.07
INSPECTION AND TESTING OF WELDS
1.
Inspection of welds will be carried out in accordance with
AS/NZS 1554.1. The WSP shall produce an Inspection and Test Plan
(ITP) for all welding work, which shall contain the necessary elements
and hold points to ensure the completed welding work complies with
AS/NZS 1554.1 or other specified requirements. The WSP shall submit
ITPs to the Superintendent not less than 10 working days prior to
commencement of the welding work.
2.
The WSP shall ensure that testing of all welds is carried out
in accordance with AS/NZS 1554.1. Test Certificates issued by a NATA
registered laboratory shall be available to the Superintendent and shall
be part of the MDR. The testing procedures to be used are:
i) Visual Scanning
ii)
Visual Inspection
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iii) Radiographic Testing
iv) Ultrasonic Testing
v) Magnetic Particle Inspection
vi) Dye Penetration Testing
vii) Hardness Testing
viii) Microstructure Replica Examination
3.
The extent of testing and inspection of welds shall generally
be in accordance with the recommendations in Table 7.4 of AS/NZS
1554.1, but also as follows:
a) Visual inspection of all weld preparations prior to
welding.
b) Inspection of all weld quality using testing procedures
830.28.07.2.(i) and (ii).
c) Testing of all full strength butt weld splices in tension
and compression using testing procedure
830.28.07.2.(iii).
d) For all other butt welds test 10% of the length of all
welds longer than 1m and one in twenty of all welds
which are less than 1m long using a combination of
testing procedures 830.28.07.2.(iii) and (iv).
e) 10% of fillet welds tested using testing procedures
830.28.07.2.(v) and/or (vi).
f)
Testing procedures 830.28.07.2.(vii) and (viii) shall be
used where directed by the Superintendent.
4.
The Contractor shall allow for all labour and plant required to
lay out and arrange items for inspection and testing and carry out any
necessary weld preparation including allowance for lost production time.
5.
All repaired welds shall be retested and for welds tested
under (d) above two extra samples of either 10% or one in twenty shall
be tested as appropriate. All repairing and retesting defective welds and
additional testing shall be at no cost to the Principal.
830.28.08
NON-CONFORMING WELDS
1.
Any welds not meeting the requirements of this Specification
shall be rejected. The WSP shall document all NCRs and shall submit
proposals to the Superintendent for correcting defective welds. All
corrective work shall be in accordance to AS/NZS1554.1.
2.
Repairing or correcting defective welds and any additional
work or material required to repair defective welds shall be at no cost to
the Principal.
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Document 04/10141 Issue 23/09/08
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830.29
830.29.01
STUD SHEAR CONNECTORS
GENERAL
1.
Stud shear connectors and stud welding shall comply with
the requirements of AS/NZS 1554.2 except as varied by this
Specification.
830.29.02
OPERATOR QUALIFICATION
1.
Operators shall be qualified in accordance with Section 4.3
of AS/NZS1554.2.
830.29.03
WELDING
1.
After stud welding, all beams shall comply with the
tolerances given in Clause 830.60 "Construction Tolerances". Quality
control for all stud welding shall be maintained in accordance with
AS/NZS1554.2.
830.29.04
Distortion
TESTING
1.
The testing of welded studs shall be in accordance with
AS/NZS 1554.2. In addition, the Superintendent shall select an
additional five per cent of the remaining studs which shall also be tested.
All other studs shall be ring tested.
830.29.05
CORRECTION OF DEFECTIVE STUD WELDS
1.
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/NZS 1554.2, shall not be allowed.
830.30
BOLTING
1.
All bolts, nuts and washers are to be hot-dip galvanised
unless otherwise noted. Use one nut only to each bolt. Project the
threaded portion of the bolt a minimum of one thread and a maximum of
five threads through the nut. Use washers, tapered where necessary, to
give nuts and bolts satisfactory bearing. All nuts and washers in each
joint shall face in one direction and away from the general view.
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Document 04/10141 Issue 23/09/08
Generally
Page 17 of 24
2.
The following types of bolts with their tightening procedures
are designated on Structural Drawings when required.
Types of
Bolts
4.6/S, 8.8/S, 8.8/TF, 8.8/TB, 8.8X/TF and 8.8X/TB
Where 8.8 bolts are designated, the washers and nuts shall also be
hardened as for the bolt.
Where 8.8X bolts are designated, keep the thread portion of the bolt
outside the shear plane of the parts being joined.
3.
The tightening of bolts shall be carried out to the following
procedures according to the grade of bolt.
Bolt
Tightening
a) Bolting procedure 4.6/S refers to commercial bolts of
strength grade 4.6 manufactured to AS 1111, tightened
using a standard wrench to a snug-tight condition
b) Bolting procedure 8.8/S refers to any bolt of strength
grade 8.8 tightened using a standard wrench to a snugtight condition in the same way as for procedure 4.6/S.
The bolts used shall be high strength structural bolts of
grade 8.8 to AS/NZS1252.
830.31
HOLDING DOWN BOLTS
1.
All holding down bolts shall, wherever applicable, be welded
into a cage to ensure accurate placement. Bolts, nuts, washers and
cage assemblies shall be hot-dip galvanised to give a coating of zinc of
not less than 85 microns thick.
830.32
CERTIFICATION OF FABRICATION
1.
Prior to dispatch of work from the shop the Contractor
shall provide the Superintendent with certification that each item
fabricated conforms to the requirements of the Drawings and the
Specification.
830.33 - 830.40
HOLD
POINT
NOT USED
ERECTION
830.41
GENERAL
1.
Where applicable, erection procedures shall comply with the
requirements of –AS 3828. The erection sequence assumed in the
design is shown on the Drawings.
2.
Upon completion of erection all temporary bracing shall be
removed and holes plugged and steel made good.
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Document 04/10141 Issue 23/09/08
Page 18 of 24
3.
During erection, no steel shall be cut or heated or welded or
drilled. Drifting may only be used for bringing parts into position and not
to match unfair holes or enlarge holes or distort metal.
4.
Permanent bolting of the box girder shall not be carried out
until the correct alignment and level has been obtained including any
pre-camber allowance necessary.
830.42
BOLTED JOINTS
830.42.01
GENERAL
1.
Unless otherwise shown on the Drawings, all bolts and nuts
for field joints shall be High Strength Friction Grip Bolts, complying with
AS/NZS 1252 Grade 8.8.
830.42.02
BOLT INSTALLATION AND TIGHTENING
1.
High Strength Bolts shall be installed and tightened in
accordance with AS 4100 and all bolts shall be installed and tightened in
accordance with procedures detailed in the Drawings.
830.43
CONSTRUCTION TOLERANCES
1.
Measurements of length shall be checked with a standard
steel measuring tape or band corrected to a standard temperature of
20°C.
2.
The Contractor shall allow in the fabrication of the girders for
all weld distortion so that on completion of erection the dimensions of
the fabricated members shall be correct within the tolerances specified
in AS 4100 and in addition shall not exceed the following:
a) Deviation from flatness and straightness of
all exposed plate surfaces and edges
(or from specified surface in the case of
curved surfaces).
+3mm in 2m straight
edge in any direction
b) Length of beam
+5mm
c) Deviation from specified alignment at points
of support
+5mm
d) Deviation from specified alignment elsewhere
+10mm
e) Deviation from specified profile measured
along edge of box girder
+10mm
f)
0.6
Maximum permitted angular rotation of any
cross-section relative to its specified location
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Document 04/10141 Issue 23/09/08
Page 19 of 24
830.44 – 830.80
NOT USED
AS BUILT AND HANDOVER REQUIREMENTS
830.81 – 830.90
NOT USED
CONTRACT SPECIFIC REQUIREMENTS
830.91 – 830.99
NOT USED
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Document 04/10141 Issue 23/09/08
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ANNEXURE 830A
STEEL ITEMS SUPPLIED BY PRINCIPAL
Description
Number
Location
Time of Availability
(Weeks after
Commencement of
Contract)
Suppliers’ yard
Fabricators’ yard
(Delete Annexure if not applicable – refer Guidance Notes)
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Document 04/10141 Issue 23/09/08
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SPECIFICATION 830 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.
PRINCIPAL SUPPLIED STEEL (Clause 830.91)
1.1
If there are to be Principal Supplied Items, insert Clause 830.91 and
complete Annexure 830A.
1.2
If the Principal is to pre-supply steel:
Annexure 830A is provided for listing Principal supplied items such as pre-supplied
rolled steel beams. The description should include identification with items shown on
the drawings as well as the length and weight and whether items are fabricated with
shear studs, bolt holes etc. or unfabricated. The location may need to be changed to
suit arrangements made.
1.3
Note that the last column in Annexure 830A should be deleted if the
paragraph on timing in Clause 830.91 is included unaltered.
1.4
Clause 830.06 should generally be retained unless the Contract is for
erection only.
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Document 04/10141 Issue 23/09/08
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CONTRACT SPECIFIC REQUIREMENTS TO ADD OR DELETE
The following clauses are to be placed under the CONTRACT SPECIFIC
REQUIREMENTS as required.
830.91
SUPPLY OF STRUCTURAL STEEL BY THE PRINCIPAL
1.
The Principal shall make available free of charge to the
Contractor structural steel as listed in Annexure 830A.
2.
The Contractor shall provide for all cranage, handling and
loading and a means of transport for the structural steel.
Handling
3.
The structural steel will be available at the commencement
of the Contract.
Timing
4.
The Contractor shall supply all other material in accordance
with the Specification necessary for fabricating, connecting and
supporting the structural steel.
Associated
Materials
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Document 04/10141 Issue 23/09/08
Page 23 of 24
SPECIFICATION AMENDMENT CHECKLIST
Specification Name: No: 830 Revision No: ______Title: STRUCTURAL
STEELWORK
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 830 Structural Steelwork
Document 04/10141 Issue 23/09/08
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