ITEM 501 STRUCTURES—GENERAL
501.01 General
501.02
Verification of Dimensions
501.03
Notification of Fabricator
501.04 Shop
Drawings
501.05
Submittal of Working Drawing and Calculations
501.06 Test
Reports
501.01 General. This specification includes the
general requirements for building the various items that constitute the
completed structure.
Perform the
work, including fabrication, erection, and construction, so that the entire
structure and all its component parts will function as designed.
501.02 Verification of Dimensions. Verify
that all dimensions established by the Engineer are correct.
501.03 Notification of Fabricator. When
furnishing materials under Items 513, 515,
516, 517, and 518,
select a fabricator from the pre-qualified fabricators list in effect the date
of the Contract letting. Before or at the preconstruction conference,
provide a written notification to the DCA and Office
of Materials Management of the selected steel fabricators and precast
concrete fabricators.
501.04 Shop Drawings. Provide shop drawings
detailing structural steel, metal structural elements, prestressed
concrete members, precast concrete structural elements, and other similar
materials requiring either shop or field fabrication according to the
appropriate AASHTO Standard Specifications for Highway Bridges and Item 501.
A. Contractor Acceptance of Shop Drawings
for Items 513 and 515. After preparing
the shop drawings for Items 513 and 515,
submit the drawings to the Office
of Materials at least 3 days before the pre-fabrication meeting, or
before the start of fabrication on Item 513, UF Level.
For structures
carrying railroad traffic, submit four copies of the prepared shop drawings at
least 40 days prior to the pre fabrication meeting to each railroad company
involved for review and approval. Resolve all railroad comments prior to
supplying the letter of written acceptance to the Department. The acceptance
submission to the Department shall include one set of shop drawings approved by
each railroad company involved; copies of all documentation between the
railroad(s) and the Contractor; and four sets of Contractor accepted shop
drawings for each railroad company involved.
Include in the shop drawing submission a written acceptance letter and
four copies of each drawing, unless additional copies are requested. For
structures carrying railroad traffic, furnish 4 additional sets of shop
drawings for each railroad company involved. Also, furnish the fabricator’s
quality control specialist with one additional set of these drawings before the
pre-fabrication meeting.
Prepare the shop drawings by or under direct supervisory control of an
Ohio Registered Engineer having personal professional knowledge of AASHTO Standard Specifications for Highway Bridges,
and Items 513 and 515. The Registered
Engineer shall seal and date each drawing. Have a second Ohio Registered
Engineer check, sign, seal and date each drawing, confirming that the drawings
meet the intent of the plan (as designed). The preparer and checker shall be
two different Engineers. Have all questions and comments addressed before
submitting the shop drawings.
The Contractor’s written acceptance letter shall document acceptance of
the shop drawings including confirmation of field verification, as required,
and descriptions of issues resolved between the Contractor, the fabricator, or
the Department.
By accepting these shop drawings, the Contractor represents to the
Department that all dimensions and elevations of existing conditions shown on
the plans have been field measured and verified, and that these shop drawings
comply with all the materials requirements, construction requirements, contract
requirements, and performance criteria. The Contractor further represents
that these drawings have been coordinated and verified with the details of the
work to be performed by other fabricators and entities on the project.
The Department will not make any allowance for additional cost or delays to the
Contractor for incorrect fabrication as a result of failure to coordinate or
perform this acceptance.
If the Department
requests changes on these shop drawings, or the Contractor makes changes in
addition to those expressly requested, ensure that the shop drawings are
accepted as above with suitable revision marks to identify the changes.
Schedule the
pre-fabrication meeting after the Director receives the drawings.
Fabrication may begin after the pre-fabrication meeting is complete or after
receipt of Item 513, UF Level
drawings.
B. Fabricator
Coordination of Shop Drawings for Items 516, 517, and 518. The Contractor and fabricator must coordinate
these shop drawings. Ensure that shop drawings meet requirements for
materials, field measurements, construction requirements, contract
requirements, performance criteria, and similar data. The coordination
must also include details of the work to be performed by other fabricators and
entities on the project. The Department will not make allowance for
additional cost or delays to the Contractor for incorrect fabrication as a
result of failure to coordinate or perform this coordination.
Submit two copies of the shop drawings to the Engineer with the
materials delivered to the project. Do not incorporate material into the
work until after submitting the drawings. Department approval of these
shop drawings is not required.
C. Shop Drawing General
Requirements. Specific
requirements are specified in Item 513, 515,
516, 517, or 518.
Shop drawings shall be neatly and accurately drawn on 11 x 17 inch or
22 x 34-inch (280 x 432 mm or 559 x 864 mm) sheets. The shop drawings may be
submitted electronically in pdf format or by mail.
After all fabrication is completed for Item 513
and 515, furnish, to the Director, a copy of each final
Contractor accepted shop drawing on a digital media storage device according to
Supplement 1002.
For structures carrying railroad traffic, furnish an additional digital media
storage device or, at the option of each railroad, furnish a set of full-size
drawings on Mylar.
501.05
Submittal of Working Drawings and Calculations. Design
and perform all procedures as directed by the AASHTO Standard Specifications for Highway Bridges
or the AASHTO LRFD Bridge Design Specifications except as modified below:
Perform
daily inspections to ensure the work governed by the working drawing is
functioning as designed. Report malfunctioning work to the
Engineer immediately.
A. Projects with Railroad Involvement. Prepare and provide working drawings listed in this
section as follows:
Have an Ohio
Registered Engineer prepare, sign, seal and date each working drawing. Submit
working drawings to all involved railway companies at least 50 days before
construction begins. Obtain acceptance from all involved railroad companies.
Furnish the Engineer copies of all correspondence with the railroad,
documentation of railroad acceptance and the working drawings accepted by the
railroad. Department acceptance is not required. The absence of Department
acceptance does not supersede the Engineer’s authority as defined in 105.01.
Perform all work in
accordance with the accepted working drawings. Immediately cease all operations
that deviate from the accepted working drawings. If a deviation is necessary,
furnish the Engineer a copy of a revised working drawing including
documentation of acceptance from all involved railroad companies as least 24
hours before construction on deviated work begins. The revised working drawing
shall be sealed and dated by an Ohio Registered Engineer. Department acceptance
of revised working drawings is not required. The absence of Department
acceptance does not supersede the Engineer’s authority as defined in 105.01.
The Department will
consider delays resulting from working drawing deviations as non-excusable in
accordance with 108.06.E.
This section applies
to working drawings for the following:
1.
Bracing adjacent to the railroad tracks. Perform work according to 501.05.B.1.
2.
Demolition of structures over or within 14 feet of railroad tracks. Perform
work according to 501.05.B.2.
3.
Erection of structural members over or within 14 feet of railroad tracks.
Perform work according to 501.05.B.4.
B. Projects without Railroad Involvement. Prepare and provide working drawings listed in this
section as follows:
Have an Ohio
Registered Engineer prepare, sign, seal and date each working drawing. Have a
second Ohio Registered Engineer check, sign, seal and
date each working drawing. The preparer and checker shall be two different
Engineers.
Submit the working
drawing to the Engineer at least 7 days before construction begins. Department
acceptance is not required. The absence of Department acceptance does not
supersede the Engineer’s authority as defined in 105.01.
Perform all work in
accordance with the prepared working drawings. Immediately cease all operations
that deviate from the prepared working drawings. If a deviation is necessary, furnish
the Engineer a copy of a revised working drawing at least 24 hours before
construction on the deviated work begins. The revised working drawing shall be
signed, sealed and dated by an Ohio Registered Engineer and checked, signed and
sealed and dated by a Second Ohio Registered Engineer. Department acceptance of
revised working drawings is not required. The absence of Department acceptance
does not supersede the Engineer’s authority as defined in 105.01.
The Department will
consider delays resulting from working drawings deviations as non-excusable in
accordance with 108.06E.
This section applies
to working drawings for the following:
1. Excavation Bracing, impacting active
traffic, or with an exposed height over eight feet, except when a complete
design is already shown in the plans. Perform all work as specified
below:
a.
Locate Excavation Bracing according to the contract, if shown.
b.
Maintain temporary horizontal and vertical clearances according to the
contract.
c.
Include the effects of AASHTO live and dead load
surcharges as necessary.
d.
Design Excavation Bracing in accordance with the latest AASHTO Guide Design Specifications for Bridge Temporary
Works, Section 4
2. Demolition of structures over or
adjacent to active traffic. Perform all work as specified below:
a.
Provide temporary devices or structures necessary to protect traffic during all
demolition activities. Provide traffic protection when demolition is located
less than 12' horizontally from active traffic on structures of less than 25'
vertical clearance. Increase the 12' minimum horizontal distance 1 foot for
each 2 feet of additional height greater than 25'.
b.
Never lift the portions of structure being removed over active traffic. Before
releasing traffic make the remaining structure stable.
c.
Design traffic protection devices or structures for a minimum load of 50 pounds
per square foot plus the weight of equipment, debris and any other load to be
carried. Include any portion of the deck that cantilevers beyond the fascia
beams or girders.
d.
In lieu of temporary devices or structures required in “a”
above, provide a vertical barrier. Design the vertical barrier with rigid or
flexible materials specifically designed for demolition containment. Extend the
enclosure up to the bottom of the deck and down to the ground. Maintain all
materials free of tears, cuts and holes.
e.
Maintain temporary horizontal and vertical clearances according to the
contract.
f.
Locate structural members to be reused before performing any removal
operations.
g.
Do not damage structural members being reused during any removal operation.
h.
Perform work so that all members are stable during all operation and loading
conditions.
i.
Perform work according to 501.05.B.6.
3. Falsework
for cast-in-place concrete slab bridges. Perform all work according to 508 and as specified below:
a.
Provide a camber table to account for the deflection of the falsework
loaded with its self weight and the weight of wet
concrete. Also include in the table, the specified camber to compensate for
slab deflection after the falsework is released.
b.
Maintain temporary horizontal and vertical clearances according to the
contract.
c.
As a minimum design falsework over waterways for a
five year flood or with 75 percent of the effective waterway opening of the
proposed structure. The Contractor is responsible for any damages caused by
upstream flooding due to insufficient temporary structure size or the
accumulation of debris or sediment in the channel.
d.
Support falsework foundations located within the ten
year flood limits on rock, shale or piles driven to a minimum depth of 15
feet, and to sufficient penetration to carry superimposed loads or until
refusal on rock.
e.
The incorporation of structural steel shapes, used as temporary support
members, into a finished concrete slab superstructure is prohibited.
f.
Design falsework in accordance with the latest AASHTO Guide Design Specifications for Bridge Temporary
Works, Section 2.
4. Erection of steel or precast concrete
structural members as specified below:
a.
Never lift structural members over active traffic. Before releasing traffic
make structural members stable.
b.
Supply any temporary supports or braces necessary to maintain structural
stability and prevent lateral movement until completion of all construction
activities.
c.
Perform work according to 501.05.B.6, 513 or 515.
d.
Do not field weld temporary members to permanent steel members.
e.
Maintain temporary horizontal and vertical clearances according to the
contract.
f.
Provide drawings with at least the following
information:
(1)
Site Plan of the work area showing permanent support structures (piers and
abutments); roads; railroad tracks; waterways; overhead and underground
utilities; and other information pertinent to erection.
(2)
Erection sequence for all members, noting any temporary support conditions,
such as holding crane positions, temporary supports, falsework
etc. Member reference marks, when reflected on the erection plans, should be
the same used on the shop drawings.
(3)
Primary member delivery location and orientation.
(4)
Maintenance of Traffic during erection operations.
(5)
Location of each crane for each primary member pick, showing radius and crane
support (barges, mats, etc.).
(6)
Capacity chart for each crane configuration and boom length used in the work.
(7)
Center of gravity locations for primary member.
(8)
Rigging weights, capacity and arrangement for primary member picks.
(9)
Lifting weight of primary member picks, including all rigging and pre-attached
elements.
(10) Details of
any temporary lifting devices to be bolted or welded to permanent members,
including method and time (shop or field) of attachment; capacity; and method,
time, and responsibility for removal.
(11) Blocking
details for bridge bearings.
g.
Provide calculations for the following:
(1) Load capacity and
stability of temporary supports and crane(s) for each pick and release.
(2) Structural adequacy
and stability of members for each step of erection.
(3) Capacity of
fabricated rigging, such as lift beams, welded lugs, spreader beams, beam clamps, etc. Submit manufacturers’ certifications of
catalog cuts for pre-engineered devices.
5. Jacking and support of existing
structures as specified below:
a.
Support the structure on temporary supports and brace as necessary to maintain
structural stability and prevent lateral movement until completion of the
permanent supports. Do not use jacks alone to support the structure except
during the actual jacking operation. Remove all temporary supports upon
completion of the jacking procedure.
b.
Maintain a maximum differential jacking height of 1/4 inch between any adjacent
beam lines.
c.
Maintain a maximum differential jacking height of 1 inch between any adjacent
abutments or piers.
d.
Place jacks and any load plates at least 2 inches from the edges of any
concrete substructure seats.
e.
Do not field weld temporary members to permanent steel members.
f.
Maintain temporary horizontal and vertical clearances according to the
contract.
6. When the total load applied to a
structure during construction, (new or structure being rehabilitated), exceeds
75 percent of the legal limit, (The Legal Limit is 80,000 lbs. or percentage
thereof if posted), the load effects on the structure shall be analyzed based
on the operating level calculated by the Load Factor Rating Method as given in
the AASHTO Manual for Bridge Evaluation.
7. Structures for maintaining traffic in
accordance with Item 502.
a.
For structures located over or within 14 feet of railroad tracks, submit plans
in accordance with 501.05.A.
b.
Perform work according to 501.05.B.6.
C. Welded Attachments. Prepare and provide a detailed request showing
weld size, length, type and location for welding permanent or temporary
attachments to main structural members not shown or permitted by contract.
Submit request to the Office of Structural Engineering for acceptance at least
20 days before construction begins. Perform work according to 501.05.B.6 and 513.
D. Corrective Work. Unless otherwise noted, before performing corrective
work on structure items, 507,511,513,515,516,517 and 524, prepare a Corrective Work
Plan (CWP) including supporting calculations. Submit
three copies of the CWP to the Engineer for
acceptance at least 30 days before construction begins. Have an Ohio Registered
Engineer prepare, sign, seal and date each CWP.
Obtain Department acceptance before beginning corrective work.
Perform all work in
accordance with the accepted CWP. Immediately cease
all operations that deviated from the accepted CWP.
If a deviation is necessary, furnish the Engineer three copies of a revised CWP. The revised CWP shall be signed,
sealed and dated by an Ohio Registered Engineer. Obtain Department acceptance
of revised CWP prior to performing corrective work.
Perform all
corrective work, including the preparation of the CWP
and revisions at no expense to the Department. The Contractor shall reimburse
the Department for all CWP review costs of the
Designer of Record. The Department will consider delays resulting from all
corrective work as non-excusable in accordance with 108.06E.
A. Contractor Acceptance of Materials for
Item 513.
Submit certified test data to the Director showing compliance with the
requirements of Item 711. Accompany all
certified test data with copies of mill shipping notices or invoices showing
the quantity and size of material being accepted.
Check this material
data and provide a letter of written acceptance. Submit the material data
and letter of written acceptance to the Director so that the Director receives
them at least 7 days before final shop inspection Item 513,
Levels 1 through 6 or before final shop inspection Item 513,
UF Level.
Submit a single copy
of this material data for each structure, except where the structure carries
railway traffic. Submit one additional copy to each railway company
involved.
Additionally for Item
513, Levels 1 through 6 structural steel members, submit
one copy of main material, certified test data with a letter documenting the QCFS acceptance to the QA shop inspector before the
material passes check point one.
The Department will
not accept materials for final inspection at the fabrication shop until the
Director receives the Contractor accepted material data.
B. Fabricator Certification of Materials
for Items 516, 517, and 518. Ensure
that a letter of certification accompanies the fabricated material shipped to
the job site, in a format approved by the Director, stating all materials
conform to contract requirements. For these materials, the fabricator
must retain certified test data, copies of mill shipping notices, or invoices
showing the quantity and size of material being accepted. This data shall
provide complete traceability to the producing mill and proof of domestic
origin, as required by ORC 153.011.
Do not deliver
materials to the project without the certification letter.