Specification Template - Main Roads Western Australia

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MAIN ROADS Western Australia

Specification 830 Structural Steelwork

Page
1

of
24

Contract xxx/xx

Document 04/10141 Issue 23/09/08








SPECIFICATION
830

S
TRUCTURAL
S
TEELWORK

Copyright MAIN ROADS Western Australia



MAIN ROADS Western Australia

Specification 830 Structural Steelwork

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Document 04/10141 Issue 23/09/08




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


1 Aug 06

Whole
document

Complete revision of Issue
2.1 to new format

MCP



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Specification 830 Structural Steelwork

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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 MATERIA
LS

................................
................................
...............

6

830.06

SPECIFICATIONS FOR S
TEEL

................................
...............................

6

830.07

TEST CERTIFICATES AN
D IDENTIFICATION OF

MATERIAL

.............

8

830.08

TESTING OF STEEL

................................
................................
................

8

830.09

IDENTIFICATION MARKS

................................
................................
.......

9

830.10

STORAGE

................................
................................
................................

9

830.11

HANDLING AND STACKIN
G

................................
................................
...

9

830.12


830.20

NOT USED

................................
................................
..............

9

FABRICATION

................................
................................
................................
.........

9

830.21

GENERAL

................................
................................
................................

9

830.22

SHOP DRAWINGS
................................
................................
...................

9

830.23

PRECAMBER AND DISTOR
TIONS

................................
.......................

11

830.24

STRAIGHTENING AND CO
RRECTION OF DISTO
RTIONS

...............

11

830.25

CUTTING AND EDGE TRE
ATMENT

................................
.....................

11

830.26

SPLICES

................................
................................
................................

12

830.27

HOLES FOR BOLTING

................................
................................
..........

12

830.28

WELDING

................................
................................
..............................

12

830.29

STUD SHEAR CONNECTOR
S

................................
..............................

17

830.30

BOLTING
................................
................................
................................

17

830.31

HOLDING DOWN BOLTS

................................
................................
......

18

830.32

CERTIFICATION OF FAB
RICATION

................................
.....................

18

830.33
-

830.40

NOT USED

................................
................................
.............

18

ERECTION

................................
................................
................................
.............

18

830.41

GENERAL

................................
................................
..............................

18

830.42

BOLTED JOINTS

................................
................................
...................

19

830.43

CONSTRUCTION TOLERAN
CES

................................
..........................

19

830.44


830.80

NOT USED

................................
................................
............

20

AS BUILT AND HANDOVE
R REQUIREMENTS

................................
....................

20

830.81


830.90

NOT USED

................................
................................
............

20

CONTRACT SPECIFIC RE
QUIREMENTS

................................
.............................

20

830.91


830.99

NOT USED

................................
................................
............

20

ANNEXURE 830A

................................
................................
................................
..

21

STEEL ITEMS SUPPLIED

BY PRINCIPAL

................................
.........................

21



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Specification 830 Structural Steelwork

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SPECIFICATION
830

STRUCTURAL STEELWORK


GENERAL


830
.
01

SCOPE


1.

The w
ork under this specification consists of

the supply,
fabrication and erection of steel beams, box girders, columns and
associated struc
tural 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
,

M
AIN 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, th
e 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 a
nd 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
t
esting of
c
ar
bon
and
l
ow
a
llow





s
teel
p
late

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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Specification 830 Structural Steelwork

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AS 2837



Wrought Alloy Steels


Stainless Steel Bars and Semi
-
finished Products

AS 3828



Guideli
nes 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
c
arbon
steel electrodes for






manual metal
-
arc

welding of carbon

steels and carbon
-
manganese






s
teels

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


Fusio
n 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

S
pecifications


Specification 603

SAFETY & TRAFFIC BARRIER SYSTEMS

Specification 831

MINOR STEEL ITEMS

Specification 833

BRIDGE BALUSTRADES

Specification 835

PROTECTIVE TREATMENT OF STEELWORK

830.03

DEFINITIONS


830.03.01

TERMS


ITP

Detailed Ins
pection 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

WORKMANSH
IP


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
Contracto
r 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 shal
l 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 enabl
e the Superintendent to assess
and approve their suitability for that work.


3.

Establish and maintain an accredited quality management
system to AS/NZS ISO 900
1

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 MATERIA
LS


830.06

SPECIFICATIONS FOR S
TEEL


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 2
50LO 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 o
f AS

1163 and shall be grade C350.


5.

Bolts, Nuts, Screws and Washers
:
































































































a)

All bolts, nuts, screws and washers
sha
ll conform with
the

relevant Australian Standards.


b)

High strength bolt
s, with associated nuts and washers,

will comply with AS

4100. The length of the bolt
sha
ll be

as shown on the
D
rawings, or, if no length is shown,
sha
ll

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, stu
d 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
sha
ll
be as shown on the
D
rawings.


7.

Where stainless ste
el bolts are shown on the
D
rawings the
stainless steel used in the manufacture of non high strength bolts, nuts
and dowels
sha
ll
conform to AS

2837 Grade 316L for welded
components or Grade 316 otherwise. The stainless steel used in the
manufacture of hig
h strength bolts and nuts
sha
ll
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
a
r慷i湧猬

t桥y
獨s
汬l
扥 t桥 i湳nrt ty灥
having a nylon or similar plastic insert such as “Nyloc” nuts. Those used
wit栠捯hm敲捩el gr慤攠扯et猠潲or
-
扯lt猠
獨s
汬l
扥 獴r敮gt栠hr慤攠㘠潲o
桩g桥r.



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9.

Unless shown other
w
ise on the
D
rawings, the following
types of washer
s 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.

Washers are genera
lly not required under socket head cap
screws
.


11.

The Contractor
sha
ll
obtain a Certificate from a laboratory
with appropriate NATA registration stating that the bolt
s
, nuts screws
and washers comply with the appropriate standard.


830.
07

TEST CERTIFIC
ATES AND IDENTIFICAT
ION 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 shal
l 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 maint
ain 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 C
lause
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 Contrac
tor along all lines where welding
sha
ll
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 te
sted 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

IDE
NTIFICATION 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.


Mark
Number

830.1
0

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
sha
ll
be satisfac
tory.
Rusted or bent or damaged steel
sha
ll be rejected.


830.1
1

HANDLING AND STACKIN
G


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.

Identi
fication

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 packa
ge 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
D
rawings and in accordance with the requirements of AS 4100 and
AS
/NZS

1554.1 (SP quality) except as v
aried 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 DRAWIN
GS


1.

The Contractor shall prepare
s
hop

d
rawings for the
fabrication of all members.



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2.

Shop
d
rawings
shall show details of fabrication which are not
explicit in the
D
rawings. Details required include dimensions, angles
and weld preparation details an
d any
CONTRACT
S
PECIFIC

R
EQUIREMENTS

specified in Clauses 830.
91

to 830.
9
9
.


3.

The details shown on the
s
hop
d
rawings
shall be consistent
with the
D
rawings and shall comply with the following:
-


a)

The marking plan shall show the location of each part i
n
the structure.


b)

Shop
d
rawings
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 wel
ds shall be clearly shown on the
s
hop
d
rawings
. These
shop d
rawings 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
D
rawings shall be the required effective lengths.


g)

Each

member shall be clearly identified with the
identification marks shown on the
D
rawings. 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 joi
ning details shall be shown on the
s
hop
d
rawings
.


4.

Four copies of the
s
hop
d
rawings, certified by the Contractor
as complying with the above requirements, shall be submitted to the
Superintendent 7 working days before fabrication commences.


5.

Variat
ions of details shown on the
s
hop
d
rawings
shall not
be made without resubmission of appropriately amended
s
hop
d
rawings
at least 7 working days before fabrication of any affected component of
the Works.


6.

The Contractor shall be responsible for the cor
rectness of
the shop drawings. Acceptance of the
s
hop
d
rawings
by the
Superintendent shall not relieve the Contractor of
any

responsibility.



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830.
23

PRECAMBER AND DISTOR
TIONS


1.

The
C
ontractor shall be aware that the specified construction
tolerances r
equire 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
D
rawings 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 CO
RRECTION 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 ens
ure 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
sha
ll
not be permitted unless written approval is obtained from the
Superintendent

prior to any heat application
.


830.25

CUTTING AND EDGE TRE
ATMENT


1.

Steelwork shall be cut only by sawing
,

thermal cutting
,

abrasive water jet cutting
o
r

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
D
rawing
s
, 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
D
rawings.


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
galvani
s
ing
is
specified,
the edge surface preparation shall conform to the
requirements
of

this Specification.


5.

Unless shown otherwise on the
D
rawings, 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
D
rawings
, shall be
suitably staggere
d 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 sh
all be drilled to a diameter 2mm larger than
the diameter of the bolt unless otherwise shown on the
D
rawings.


2.


Drilled holes shall be cylindrical and perpendicular to the
face of the member. Drilling shall be done by mechanical means.


830.28

WELDIN
G


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 WEL
DING PERSONNEL


830.28.02.01

W
elder


1
.

Welding shall only be carried out by welders meeting the
requirements of Clause 4.
1
2
.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 th
e 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 confi
rming each welder is
qualified for each welding procedure that they
sha
ll 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.
1
2
.1 of AS
/NZS

1554.1.


2.

Not less than 10 working days prior to commencement of
welding, the WSP shall identify the Welding Superv
isor who
sha
ll
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 comple
ted work.


830.2
8
.02.03

Welding Inspector


1.

All welding work
sha
ll
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 Wel
ding 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 w
ho
sha
ll
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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830.2
8
.03

EQUIPMENT


1.

Welding equipment and plant shall confor
m 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 ele
ctrodes, 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 weld
ing 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).


830.2
8
.04

WELDING CONSUMABLES


1.

All welding consumabl
es 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 worki
ng days prior to the
planned commencement of welding work to which the procedures
sha
ll
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 C
ontractor 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
/N
ZS

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
,

environmen
t,
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
sha
ll
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 sho
wn 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 o
f 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 we
lds 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 compl
eted 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 i
s 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 Insp
ection



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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 generall
y
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)

Te
sting 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 u
sing 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 p
rocedures
830.28.07.2.
(vii) and (viii) shall be
used where directed by the Superintend
ent.


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 retes
ted 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
.


830.2
8
.08

NON
-
CONFORMING W
ELDS


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
/NZ
S
1554.1.


2.

R
epairing 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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830.29

STUD SHEAR CONNECTOR
S


830.29.01

GENERAL


1.

Stud shear connectors and stud weldin
g shall comply with
the requirements of AS
/NZS

1554.2 except as varied by this
Specification.


830.29.02

OPERATOR QUALIFICATI
ON


1.

Operators shall be qualified in accordance with Section
4.
3
of AS
/NZS
1554.2.


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
/NZS
1554.2.

Distortion

830.29.04

TESTING


1.

The testing of welded studs shall b
e 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 DEFECT
IVE 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,
sha
ll
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
sha
ll
face in one direction and

away from the general view.

Generally


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2.

T
he following types of bolts with their tightening procedures
are designated on
S
tructural
D
rawings when required.


4.6/S, 8.8/S, 8.8/TF, 8.8/TB, 8.8X/TF an
d 8.8X/TB

W
here 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.

Types of
Bolts

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
-
tig
ht condition


b)

Bolting procedure 8.8/S refers to any bolt of strength
grade 8.8 tightened using a standard wrench to a snug
-
tight condition in the same way as for procedure 4.6/S.
T
he bolts used
sha
ll be high strength structural bolts of
grade 8.8 to A
S
/NZS
1252.


830.
31

HOLDING DOWN BOLTS



1.

All holding down bolts
sha
ll
, wherever applicable, be welded
into a cage to

ensure accurate placement. Bolts, nuts, washers and
cage assemblies
sha
ll

be hot
-
dip galvanised to give a coating of zinc of
not less
than 85 microns
thick
.


830.3
2

CERTIFICATION OF FAB
RICATION


1.

Prior to dispatch of work from the shop t
he Contractor
shall provide the Superintendent with certification that each item
fabricated conforms to the requirements of the
D
rawings and the
Spec
ification.

HOLD
POINT

830.3
3

-

830.
40

NOT USED


ERECTION


830.4
1

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
D
rawings.


2.

Upon completio
n of erection all temporary bracing shall be
removed and holes plugged and steel made good.



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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 hole
s 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.

Unl
ess otherwise shown on the
D
rawings, 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 AN
D TIGHTENING


1.

High Strength Bolts shall be installed and tightene
d in
accordance with AS 4100 and all bolts shall be installed and tightened in
accordance with procedures detailed in the
D
rawings.


830.
43

CONSTRUCTION TOLERAN
CES


1.

Measurements of length shall be checked with a standard
steel measuring tape or band c
orrected 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 specifie
d
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
i
n
any direction

b)

Le
ngth 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)

Maximum permitted angular rotation of

any
cross
-
section relative to its specified location

0.6




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830
.
44



830
.80

NOT USED


AS BUILT AND HANDOVE
R

REQUIREMENTS


830
.8
1



830
.90

NOT USED


CONTRACT SPECIFIC RE
QUIREMENTS


830
.9
1



830
.99

NOT USED






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ANNEXURE
830
A

STEEL ITEMS SUPPLIED

BY PR
INCIPAL


Description

Number

L
ocation

Time of Availability

(Weeks after
Commencement of
Contract)













Suppliers


y慲a

䙡扲楣bt潲o


y慲a




(
Delete Annexure if not applicable


refer Guidance Notes
)

MAIN ROADS Western Australia

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S
PECIFICATION
830

GUIDANCE

NOTES

DELETE
THESE

GU
IDANCE
NOTES FROM FINAL DOCUMENT AFTER USING FOR
REFERENCE

All edits to downloaded TD
P

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 i
talics 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 revie
w, 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

(C
lause 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 be
ams. 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 arrangeme
nts 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
C
ontract is for
erection only.



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CONTRACT SPECIFIC REQUI
REMENTS 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 PRINCIP
AL


1.

The Principal
sha
ll
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
M
aterials








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SPECIFICATION AMENDMENT
CHECKLIST


Specification Name:

No:

830
Re
vision

No:

______
Title:

STRUCTURAL
STEELWORK


Project Manager:

Name:

___________
__
Signature
:
________________Date:___
___





Checked By:

Name: ___________
____
Signature:
_______________Date:
_
____
_



Contract

No:

_
____
C
ontract
Description
:

______________
___
_____________
_
_____


ITEM

DESCRIPTION

SIGN
OFF

Note:

All changes/amendments
must
be shown in Tracked Change mode until
approved.

1.

Project Manager has reviewed Specification and identified
Additions and Amendments.


2.

CONTRACT SPECIFIC REQUIREMENTS

addressed?


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p灥捩fi捡瑩c渠n畩摡湣n k潴敳of潲og畩摡湣n).




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mr潪散琠j慮慧敲㼠


if “Yes” provide details at 15.




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m敮摥搿


MUST SEEK

approval from
MCP.


5.

Clause deletions shown as ‘NOT USED’.




A灰r潰ri慴攠
INSPECTION & TESTING

parameters included in
Spec 201 (Test Methods, Minimum Testing Frequencies
verified).


7.

ANNEXURES
completed (Refer
Specification Guid
ance

Notes).


8.

HANDOVER

and
AS BUILT

requirements addressed.


9.

Main Roads Q
S has approved changes to
SMM
.


10.

Project Manager certifies completed Specification reflects intent
of the design.


11.

Completed Specification


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慲a慮g敤 批
mr潪散琠j慮慧敲


ㄲN

Project Manager’s review completed.


ㄳN

SPECIFICATION GUIDANCE NOTES

deleted.


14.

TABLE OF CONTENTS

updated.


15

Supporting information prepared and submitted to Project
Manager.


Further action necessary:



Signed:







(Project Manager)


Date:_______________