501.02 Verification of Dimensions
501.03 Notification of Fabricator
501.05 Submittal of Construction Plans
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 DCE 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 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 Director at least 7 days before the pre-fabrication meeting, or before the start of fabrication on Item 513, UF Level. Department approval of these shop drawings is not required.
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 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.
Make the prints from tracings, neatly and accurately drawn on 22 ´ 34-inch (559 ´ 864 mm) sheets.
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 Construction Plans and Calculations. Do not begin work until after complying with the acceptance criteria and work limitations specified below.
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
herein:
A. Prepare and provide plans listed in this section as follows:
Have an Ohio Registered Engineer prepare, sign, seal and date each plan. Submit plans that will be accepted to all involved railway companies at least 50 days before construction begins. Obtain acceptance from all involved railroad company(s). Furnish the Engineer with copies of all correspondence with the railroad, documentation of railroad acceptance and the plans accepted by the railroad. Department acceptance is not required.
This section applies to construction plans for the following:
1. Sheeting and bracing of excavations adjacent to the railroad tracks.
2. Demolition of structures over or within 14 feet of railroad tracks.
3. Erection of structural members over or within 14 feet of railroad tracks or that carry railroad traffic.
B. Prepare and provide plans listed in this section as follows:
Have an Ohio Registered Engineer prepare, sign, seal and date each plan. Have a second Ohio Registered Engineer check, sign, seal and date each plan. The preparer and checker are two different Engineers. Include the following statement on the plans:
“This plan was prepared in compliance with contract documents.”
Submit the plan to the Engineer at least 7 days before construction begins. Department acceptance is not required.
This section applies to construction plans for the following:
1. Sheeting and bracing adjacent to active traffic when required by contract. Perform all work as specified below:
a. Locate sheeting and bracing per contract.
b. Maintain temporary horizontal and vertical
clearances per contract.
c. Design sheeting or bracing to support the
roadbed including the effects of AASHTO live and dead load surcharges.
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 per 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 per 501.05.B.6.
3. Falsework for cast-in-place concrete bridges over 20 feet (6.1 m) in span. Perform all work per 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 per contract.
c. As a minimum design falsework over waterways for a five year flood or with 75% 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.
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 per 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 per contract.
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 per contract.
6. Placing or moving equipment having a gross weight in excess of 60,000 pounds (27,000 kg) on or across a structure as follows:
a. Do not allow equipment having a gross weight in excess of the posted limit to be placed on or driven across a structure.
b. Do not allow erection and construction methods, or use or move erection or construction equipment on or across the uncompleted or completed structure, to subject any part of the structure to unit stresses that exceed by more than one-third the allowable unit stresses, as given in AASHTO Standard Specifications for Highway Bridges.
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 per 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 per 501.05.B.6 and 513.
501.06 Test Reports.
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.