facture, fabrication or erection under any one contract. The bend test specimen shall be flame cut while the material is at the lowest temperature at which material under the contract will be flame cut. The material subject to the bend test shall conform to the bending property requirements of the governing material specifications when bent with the flame cut surface on the outside of the bend. The width and depth of the bend test specimen shall be equal to the thickness of the material except that for material over 11⁄2 inches in thickness or diameter the specimen depth may be 4 inch or more. The corners of the specimen may be rounded to a radius not greater than 1/16 of the width of the test specimen. When the specimen does not meet the pertinent bend test requirements additional tests shall be made of material cut with a revised procedure or at higher material temperatures until a minimum preheat temperature, at which the flame cut specimen will meet the bend test, is determined for the procedure used. In lieu of preheating, the flame cut edges shall be removed to a depth of at least 8 inch by milling, or grinding, or in the case of machine flame cutting, the edges may be flame softened after cutting: (a) by heating the cut edge uniformly and progressively to a red heat, visible in ordinary shop light (1.150° to 1,250° F) to a depth of at least 1/16 inch; or (b) by means of a post heating torch attached to and following the cutting torch with the tips, gas pressure, speed of travel, and the distance of the post heating torch from the kerf regulated to the thickness of the steel. Bend tests of specimens so cut and flame softened shall meet the bend test requirements of the basic specifications for the material of the thickness cut.

611.05 Finishing and Shaping. Finished members shall be true to line and free from twists, bends, and open joints.

(a) Edge planing.—Sheared edges of plates more than 5/8 inch in thickness and carrying calculated stresses shall be planed to a depth of 4 inch. Re-entrant cuts shall be filleted before cutting.

(b) Facing of bearing surfaces.-The surface finish of bearing and base plates and other bearing surfaces that are to come in contact with each other or with concrete shall meet the United States of America Standards Institute surface roughness requirements as defined in USASI B-46.1-47, surface roughness, waviness, and lay, part I:

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(c) Abutting joints.-Abutting joints in compression mem bers and girder flanges, and in tension members where so specified on the drawings, shall be faced and brought to an even bearing. Where joints are not faced, the opening shall not exceed 1/4 inch.

(d) End connection angles.-Floor beams, stringers, and girders having end connection angles shall be built to plan length back to back of connection angles with a permissible tolerance of plus 0 inch to minus 1/16 inch. If end connections are faced, the finished thickness of the angles shall not be less than that shown on the detail drawings, but in no case less than 3/8 inch.

(e) Lacing bars.—The ends of lacing bars shall be neatly rounded unless another form is required.

(f) Web plates.-(Riveted or Bolted). In girders having no cover plates and not to be encased in concrete, the top edge of the web shall not extend above the backs of the flange angles and shall not be more than % inch below at any point. Any portion of the plate projection beyond the angles shall be chipped flush with the backs of the angles. Web plates of girders having cover plates may be not more than 1⁄2 inch less in width than the distance back to back of flange angles. Splices in webs of girders without cover plates shall be sealed on the top by welding.

At web splices, the clearance between the ends of the web plates shall not exceed % inch. The clearance at the top and bottom ends of the web splice plates shall not exceed 14 inch.

plates.-Cold-bent

load-carrying

(g) Bent
plates shall conform to the following:

rolled-steel

(1) They shall be so taken from the stock plates that the bendline will be at right angles to the direction of rolling. (2) The radius of bends, measured to the concave face of the metal, shall not be less and preferably shall be greater than shown in the following tabulation, in which T is the thickness of the plate.

Angle through which plate is bent

61-90 degrees

91-120 degrees

121-150 degrees

Minimum radius

1.0 T

1.5 T

2.0 T

Radii given above are for material with specified yield points to 40,000 psi, inclusive. Tabulated minimum radii shall be increased 2 T for material with specified yield points from 40,000 psi to 50,000 psi, inclusive.

If a shorter radius is essential, the plates shall be bent hot. Hot-bent plates shall conform to requirement (1) above. (3) Before bending, the corners of the plate shall be rounded to a radius of 1/16 inch throughout that portion of the plate where the bending is to occur.

(h) Fit of stiffeners.—End stiffener angles of girders and stiffener angles intended as supports for concentrated loads shall be milled or ground to secure an even bearing against the flange angles. Intermediate stiffener angles shall fit sufficiently tight to exclude water after being painted. Fillers under stiffeners shall fit within 4 inch at each end. Welding will be permitted in lieu of milling or grinding if noted on the plans or in the special provisions. Ends of stiffeners and other attachments may be welded to flanges only at points where the flanges carry compressive stress or where the tensile stress does not exceed 75 percent of the maximum allowable stress permitted by the applicable general specification.

(i) Eyebars.-Pin holes may be flame cut at least two inches smaller in diameter than the finished pin diameter. All eyebars that are to be placed side by side in the structure shall be securely fastened together in the order that they will be placed on the pin and bored at both ends while so clamped. Eyebars shall be packed and match marked for shipment and erection. All identifying marks shall be stamped with steel stencils on the edge of one head of each member after fabrication is completed so as to be visible when the bars are nested in place on the structure. The eyebars shall be straight and free from twists and the pin holes shall be accurately located on the centerline of the bar. The inclination of any bar to the plane of the truss shall not exceed 1/16 inch to a foot.

The edges of eyebars that lie between the transverse centerline of their pin holes shall be cut simultaneously with two mechanically operated torches abreast of each other, guided by a substantial template, in such a manner as to prevent distortion of the plates.

(j) Annealing and stress relieving.-Structural members which are indicated in the contract to be annealed or normalized shall have finished machining, boring and straightening done subsequent to heat treatment. Normalizing and annealing (full annealing) shall be in accordance with ASTM Designation E 44. The temperatures shall be maintained uniformly throughout the furnace during heating and cooling so that the temperature at no two points on the member will differ by more than 100° F. at any one time.

A record of each furnace charge shall identify the pieces in the charge and show the temperatures and schedule ac

tually used. Proper instruments including recording pyrometers, shall be provided for determining at any time the temperatures of members in the furnace. The records of the treatment operation shall be available to and meet the approval of the Engineer.

Members, such as bridge shoes, pedestals, or other parts which are built up by welding sections of plate together shall be stress relieved in accordance with the provisions of subsection 611.12 (p) when required by the plans, specifications or special provisions governing the contract.

(k) Tests. When full size tests of fabricated structural members or eyebars are required by the contract, the plans or specifications will state the number and nature of the tests, the results to be attained and the measurements of strength, deformation or other performance that are to be made. The Contractor shall provide suitable facilities, material, supervision and labor necessary for making and recording the tests. The members tested in accordance with the contract will be paid for in accordance with subsection 611.28. The cost of testing, including equipment, handling, supervision, labor and incidentals for making the tests shall be included in the contract price for the fabrication or fabrication and erection of structural steel, whichever is the applicable item in the contract, unless otherwise specified. 611.06 Pins and Rollers. Pins and rollers shall be accurately turned to the dimensions shown on the plans and shall be straight, smooth, and free from flaws.

In pins larger than 9 inches in diameter, a hole not less than 2 inches in diameter shall be bored full length along the axis after the forging has been allowed to cool to a temperature below the critical range under suitable conditions to prevent injury by too rapid cooling, and before being annealed.

Pin holes shall be bored true to the specified diameter, smooth and straight, at right angles with the axis of the member and parallel with each other unless otherwise required. The final surface shall be produced by a finishing cut.

The distance outside to outside of holes in tension members and inside to inside of holes in compression members shall not vary from that specified more than 1/32 inch. Boring of holes in built-up members shall be done after the riveting is completed.

The diameter of the pin hole shall not exceed that of the pin by more than 1/50 inch for pins 5 inches or less in diameter, or 1/32 inch for larger pins.

Two pilot nuts and two driving nuts for each size of pin shall be furnished, unless otherwise specified.

611.07 Fastener Holes (rivets and bolts). All holes for

rivets shall be either punched or drilled. Material forming parts of a member composed of not more than five thicknesses of metal may be punched 1/16 inch larger than the nominal diameter of the fasteners whenever the thickness of the metal is not greater than 4 inch for structural steel or % inch for alloy steel.

When there are more than five thicknesses or when any of the main material is thicker than 4 inch in carbon steel, or 5% inch in alloy, steel, or when required under other provisions of this subsection, all the holes shall be subpunched or subdrilled 3/16 inch smaller and, after assembling, reamed 1/16 inch larger, or drilled from the solid to 1/16 inch larger, than the nominal diameter of the fasteners. For punched holes the diameter of the die shall not exceed the diameter of the punch by more than 1⁄416 inch. If any holes must be enlarged to admit the fasteners they shall be reamed. Holes shall be clean cut, without torn or ragged edges. Poor matching of holes will be cause for rejection.

Reamed holes shall be cylindrical, perpendicular to the member, and not more than 1/16 inch larger than the nominal diameter of the fasteners. Where practicable, reamers shall be directed by mechanical means. Drilled holes shall be 1/16 inch larger than the nominal diameter of the fasteners. Burrs on the outside surfaces shall be removed. Poor matching of holes will be cause for rejection. Reaming and drilling shall be done with twist drills. If required by the Engineer, assembled parts shall be taken apart for removal of burrs caused by drilling. Connecting parts requiring reamed or drilled holes shall be assembled and securely held while being reamed or drilled and shall be match marked before disassembling.

Unless otherwise specified, holes for all field connections and field splices of main truss or arch members, continuous beams, towers (each face), bents, plate girders, and rigid frames shall be subpunched (or subdrilled if subdrilling is required) and subsequently reamed while assembled in the shop in accordance with subsection 611.08.

All holes for floor-beam and stringer field end connections shall be subpunched and reamed to a steel template reamed while assembled.

Reaming or drilling full size of field connection through templates shall be done after the templates have been located with the utmost care as to position and angle and firmly bolted in place. Templates used for the reaming of matching members, or of the opposite faces of one member, shall be exact duplicates. Templates for connections which duplicate shall be so accurately located that like members are duplicates and require no match-marking.