Chapter 17. Construction 17.1 General ITAL Scope of application ‘This chapter shall stipulate steel bridges designed on the basis of the provisions of chapters until Chapter 16 of “Part I: Steal Bridges” ‘When iti difficult to perform construction in accordance with the provisions of this chapter, the safety rate, etc, in design must be considered separately. ‘While tis chapter is applied to the construction of steel road brides centering on the weld struetue, the provisions ofthe chapters up to Chapter 16 (pertaining to design) are stipulated ‘on the assumption that the provisions in this chapter on construction have compliance ‘Accordingly, when the provisions stipulated in this chapter on construction do not have ‘compliance, or when itis dificult to follow the criteria of construction methods shown in this ‘chapter, the provisions on design shown in chapters up to Chapter 16, particularly the allowable sess, safety fctr, et, shall be considered separately. ‘There are four types of provisions shown inthis chapter on the construction of a sce bridge, 18 shown below: 1) Those that stipulate the criteria for acceptance or rejection when @ nondestrctive inspection is performed on a finished product and the soundness of the product is assessed; Examples: Visual inspection, intemal inspection (radiographic tet, ultrasonic tes), fabrication precision, et. ofthe welded par. 2). Those that show items that shall have compliance in each stage and standard methods of ‘onstruction, which ate made into te provisions in construction; Examples: Precaution for weld works, groove prevsion, seasoning of welding ‘consumables, preheating, cold-forming, hot-forming, high-strength bot works, te. 3) Those that stipulate construction methods by conducting a construction test each time ‘regarding the type of matcral and structure and the combination of construction methods ‘without showing standard construction methods such as those in 2), and that also stipulates the criteria on the results of a construction test in that regard; “MB.Example: Welding procedure test 4) Other items that should basically be retained in terms of quality contol Example: cleaning, drying te In 1), asa result ofthe nondestructive inspection, facelift repair is generally performed and the standard repair methods ae stipulated 2) is used to obiain products with presribed performance by stipulating the methods of construction s there are cases where a facelift may instead result insignificant defects or cases where it is dificult to determine the acceptanceitsjection of products by a nondestructive inspection, ‘The one that falls into 3) inthis specification is the welding procedure test, and it is advisable to refer Section 17.4.4 forthe details ‘Those that belong to 4) are basic items in the steel bridge construction for which compliance is required without exception 17.12 Construction in general The construction of a stel bridge stall be performed in such a way that various conditions considered as premises in design are saisied, to ensure tha the construction is performed in satisiction of various conditions considered as promises indesign, ee ‘The exceution plan is a generic term for the fabrication plan, welding procedure plan, erection plan ete 1743. Execution plan In construction, the execution plan shall be compiled in such a way that checks can be made When checking whether a product secures the prescribed performance or not by a quality inspection inthe final stage alone, there can be cases where although it is difficult to check the performance or although the performance isnot secured, i is also dificult to cope with such situations. Therefor, i is generally necessary to conduct appropriate quality contol in the middle of construction so that the prescribed performance ean ulimately be achieved. For these reasons itis necessary to plan in advance the methods by which to ensure ultimate Maeperformance, to compile an execution plan forthe purpose of recognizing the importance of ensuring quality in the middle of construction, and to show in these documents the methods of quality contro! during construction and its allowable values. Moreover, the main points of quality control are stipulated in the respective clauses of this ‘chapter. tis necessary to incorporate these provisions into the execution plan. ‘Additionally, the execution plan shall generally describe the instructions to show thatthe ‘construction to ensure the performance required in design onthe following items is carried out: 1) quality contol plan, 2) material and part, 3) production (processing and the assembly of members, 4) welding, 5) assembly, 6) rust and corrosion prevention (shop painting, ‘galvanizing, et), 7) tensportation, 8) erection, 9) high-strength bolt, 10) Noor deck work, and 11) fold painting. 1744 Inspection (1) In constuction it shall be checked by such appropriate means that the construction stisfying the items required in design is performed. (@) When conducting inspection by selecting inspection items from among the items 1) 109) in consideration of the difficulty level of constretion, types of material, etc. and confirming tht the construction is eartied out by the preseribed constriction methods, ‘Clause (1) may be deemed tobe satisfied 1) material, 2) bolt, ar stud dowel, 3) weld (welders, welding equipment, welding works, weld pur), 4) member and part (bearing, expansion joint, drainage appliance, ete), §) ‘member! assembly precision, 6) rust and coresion prevention, 7) erection (ld joint, size at the time of erection, ct), 8) lor deck (form, reinforcement, finishing precision ‘of loor desk), and 9) completion For quality contol, the following inspections are conducted in each stage of construction: 1) To inspect whether the product possesses the prescribed performance or not. 2) To check whether the eo ‘method oF no. suction is being performed in accordance with the prescribed. Te inspection referred to here isthe one that the constructor of a stel bridge construction conduets in order to check quality, and is basically the one the constructor of @ construction project carries out voluntary‘When deciding which inspections to cary out about the inspection items shown in this ‘chapter, it is advisable to choose either 1) or 2) above after considering the difficulty level of ‘construction, types of material, et. However, since itis not desirable 10 unnecessarily ‘complicate the inspetion, i is advisable to decide the frequency of inspection through careful consideration ‘Additionally, there used to be an item of temporary assembly as part of the standard of inspection items. However, what i alle temporary assembly is performed forthe purpose ‘of, among others, checking the assembly precision ofthe completed form ofthe bridge in the riddle of produetiontconstruction a the need arises. Fortis reason it is possible to skip it ‘when the required precision ean be ensuted, Therefore in this revision it has been changed ‘to-memberiassembly precision as an inspection item. 172. Steet (1) As for the steel used for a steel superstructure and pir structure, it shall be confirmed before the start of construction tat the steel complies withthe steel standard described in the design drawings, et. or, when a special performance is required, that it satisfies such requirement. (2) In storing steel, a consideration shall be taken so that th characteristics and qualities that the steel originally possesses will be maintained and secured. Moreover, when an event considered to have affected its charsteristics and qualities arises during the storage perio and its found thatthe stel doesnot satisfy the required performance as a result of ‘an assessment of the effet, the steel shall undergo repair or remedy by an appropriate, ‘non-damaging method. (9) The permissible variation ofthe thickness ofthe steel plate on the negative sie shall be within S percent of the nominal plate thickness withthe application of the permissible variation of thickness of the Table 4 of the JIS G 3193, “Dimensions, Mass and Permissible Variations of Hot-Rolled Stoel Plates, Sheets and Strips" and according 10 Remark 1 (4) There must be no haemful aw on the surface of the steel pte. (6) The surface smoothness of the steel plate shall be such that it poses no hindrance to cutting plan, marking, joint work, te. @ The steel used fora ste! superstructure and pier structure is generally brought into check With the items described in the steel inspection centfiate (mill sheet issued by a stel manufacturer. Moreover, it s verified that it complies withthe requited performance of oM6-@ the steel standard described in the design drawings, etc, and also with the required performance added asthe need arises fr design and producionlrecton. Additionally, these required performances of stel are generally according to the stipulated values 100 |ength (im) fee F lool agra aera SHAS ae St0415 40 Gas hil ar weing rig eee eee [Covered are welding by Tow Bydrogsn) No SMALGOW [pe elected erage Se OU SMASTOW [Submerged ar welding No} 39 | ae) Gas shield re welding prebesing [Unser conditions of nn peeing,” when te air ompertire (oom temperature the ete o dos) & 5°C or ess, ating approsimately 20°C perfome. 5) eat gain estretion 4) The heat gain per pass shall generally be controlled at 7,000 J/mm or less for '5MS70, SMASTOW, SMS20 and SMA490W, and 10,000 Jnm or less for 'SM490 and SM490Y. fi) When the heat gain of iter i) is exceeded, iti necessary to conduct a welding procedure test and confirm thatthe prescribed quality is obtained at the weld 5+6) Note for welding works a ip » (Cleaning and drying the member atthe weld zone 8) There shall be no haemful mill scale, rst, paint, oil, ete, on the part where ‘welding isto be conducted, 1) Before the welding is conducted, the part near the welding line must be sufficiently die, Weld tab 18) In the work of the groove welding and fillet welding ete, ofthe Mange and web plate of the main girder, the weld tab that possesses the same groove as ‘member shall generally be installed so that the start point and end point of| the weld may not interfere with the member tobe welded 1b) The weld tab shall be removed by the gas cutting method afte welding, and shall be finished with grinder. ‘Work of partial penetration groove welding ‘When working on continuous weld lies by two welding methods inthe work of the partial penertion groove welding the next welding shall be performed ance it is confirmed that there is no chipping or defect in the end portion of the previous weld bead, However, this provision shall not be applicable when | crater treatment is conducted inthe manual welding or semi-automatic welding. Work of illet welding snd partial penetration groove welding, 8) The fillet welding that ends at the comer potion of a material piece must be performed in a continuous manner by rotating the omer portion b) When using the submerged are welding method or other welding method, it is advisable not to cut the arc inthe middle of joint. Installment and removal ofsuspender and temporary member, ee, 48) The welding used to install a suspender, temporary member, et, to be used for transportation, erection, et, shall generally be performed within a factory, and its condition must be equal o or greater than the condition for shop welding, When installation is conducted on site out of novessity, it must be done carefully under sufficient control 1b) The removal of a suspender, temporary member, et. must be conducted ccareflly so that no harmful flaws will remain in base materia ‘Additionally, appropiate work needs to be performed corresponding to the member, ete. For example, the treatment of a removal mark must be caried out in consideration of the effect on pavement. 316oD Welder Because the quality of welding is greatly dependent onthe skills of the welder, itis a ‘common practice that qualified operators who have passed the presribed tests are assigned tothe welding stractre. ‘This speciticaion adopts JIS 7 3801, “Standard Qualification Procedure for Manual Welding Technique.” This standard is « combination of welding position (at position F, vertical position , horizontal position H and overhead position O), ‘welding works (thin plate 1, middle plate 2 an thick plate 3) and welding procedure (g25 welding G, are welding with backing stip A, and are welding without backing strip) and contains enormous numbers of test types. These have been designed t0 cope with all types of existing weld joins that are found in use, and itis not necessary foreach welder to pass all the tests ‘The are welding is used for the welding in a steel bridge fabrication, Because a single-sided reverse-side welding without a backing strip is rarely required, dhe arc welding with a backing strip shall be targeted as the welding procedure. Moreover, itis rare that a butt joint ofa thin plate o thick plate will be performed by welding, 0 it Is sulficent to cover the middle plate a¢ a division of welding operation ‘Ultimately itis suficient forthe welder to have passed A-2F, A-2V and A-20. Oa the other hand, when on-site but welding is performed to the bridge pier column of thick plate, an operator with an A-3H qualification must be assigned. Although there is currently no national standard of technieal qualification for submerged-are ‘welding, manual welding is fundamental to such welding; therefore, i is desirable for the operator to have passed atleast the test for A-2P. The semi-automatic welding refered to in this item is @ welding procedure to automatically supply a wie from the nozzle ofa blowpipe and to perform welding ‘through the manual operation of the welder, It ig a method used to shield the are generally with the CO> eas ofthe mixed gas of CO) and Ar and it does not contain so-called gravity welding For the qualification ofthe semi-automatic welding work, test items shall be selected fom among SA-2F, SA2V, SA-3H and SA-20 in JIS Z 3861, “Standard Qualification Procedure for Semi-Automatic Welding Technique” according to the ‘welding positon employed inthe actual work in the same manner as that in regard 10 manual welding, “am.2 ‘The onsite but welding generally uses the COzautomatie welding and submerged arc welding. Therefor, iti stipulated that a welder be qualified in repard to the ‘welding procedure a the location to which i is appli. Additionally, itis stipulated ‘thatthe division of welding operation and the welding position he not only assigned ‘sa welder but thatthe welder shall be one who has & work record on the welding procedure or one who has undergone sufficient traning including the operation of ‘automatic machines. Welding procedure test 9 Because the purpose of the welding procedure test isto determine the weld ability ofthe steels to be used and the applicability of welding procedures, tis stipulated thatthe steels and welding procedures curently with a small number ‘of usage records and those that require special care in working are targeted Moreover, when the welding procedure test of the test that targets the above ‘condition has been conducted with the same material, the same level of carbon ‘equivalent, the weld-racking sensitivity composition and special ingredient, as Wel as the same welding procedure and the sime welding technique, and when there are work experiences, iti stipulated that the welding work test ean be skipped in deference to the submittal and consideration of documents 18) Because the weld cracking sensitivity composition of the steels curently sed for steel brides is generally controlled tobe low even when the plate is thick, the procedure test in terms of the quality of material and plate thickness is stipulated to he skipped. However, the portion near @ weld bead in heat-treated see tends to lose the effect of quenching and annealing by the heat eyele, which therefore lead to softening and embrittlement. Therefore, when (Curren (amp) « Vokage (wots) 60 Heat gain Q (mm) = "Welding speed (eum/mi,) jis large, both the extent and range of alteration become large and the joint performance decreases, A numberof experiments have confirmed that no decrease in joint performance is found atthe heat gain of approximately 7,000 simen or less in SMS70, SMASTOW, SM520 and SMA490W and the submerged are welding method wsed inthe construction of a common steel bridge can be appropriately applied to the welding work with this heat gain ‘or less, For these reasons 7,000 Jim is stipulated to be the upper limit of 2378+» o ® ° 4 common welding work. When the heat gain exceeds 7,000 Jim in the groove welding of a thick plate due to the usage of a particularly high current, the usage of the tandem method, ete, it is stipulated that its applicability be investigated by means of a welding procedure test. ‘When the heat input exceeds 10,000 J/mm in SM490 and SM490Y, the Joint performance may decrease. Therefore, a welding procedure testis stipulated to be performed for checking Its stipulated thatthe manual welding by a covered electrode, submerged awe welding method and gas shield are welding method (C2 gas or mixed fas of Ar and CO:) are given a common teatment and other welding methods are mage the objects of the work test. Concering welding ‘methods for steel structures, MIG welding, self-shield are welding, lectroslag welding, clectro-gas are welding, gravity welding, ete, ar used Although these welding methods ae superior to manual welding in terms of ellcieney, they have yet to become so commonplace in terms of the traning of welders and the contol of aptitude conditions to such an extent ‘that they can be adopted without limitation. Thus particular problems may Therefore, these are stipulated to be aris, depending on the joint appli ‘checked by a welding peocodure test When there is no past record of steel bridge fabrication, a welding procedure test (in atual-size test pees if necessary) shall be conducted in order to confirm that there is no problem concerning the quality of the weld zone orn the form of completed work. ‘When materials are supplied fom a source that has no record of past usage, ‘a welding procedure esti stipulated wo be performed until an accumulation of liable test datas obtained. ‘The onsite welding is generally under disadvantageous conditions ‘compared to shop welding in tems of weather condition, welding position, ‘ove precision, ete. Moreover, in the on-site weing such as the one- sided welding of a steel deck, the horizontal welding of a pier or the reinforcement of an existing bridge, the work on joint itself is often extremely different ftom common shop welding as well. For these reasons, in the past a welding procedure test incorporating on-site conditions would generally be performed for on-site welding. However, since work records have increased it s stipulated tha a welding procedure 379test need not necessarily be conducted when quality is ensured. However, when adopting a work method that has no record of past usage, a check ‘mus be conducted by a welding procedure test. fi) Table 17.44 shows three types of tess: the groove welding fet, fillet welding testand stud welding test. However, it snot necessary to consider that each of these tests will always be performed in the welding procedure test, For example, while nearly all tests are to be conducted when the plate thickness exceeds the standard values as the characteristics ofthe sec ae the issue (when 8 stud isnot used, the stud welding is excluded), only the groove welding test is required when the welding falls unde only item ) or item), Moreover, the test contents shown here include elements strongly colored by ‘echnical qualifications (for example, the radiographic testing and stud welding test). However itis possible to check the quality-control system of the builder by these tests, so they are stipulated to be included once the meaning of the welding procedure testis broadly interpreted, [Even ifa crack is generated inthe puided bend test ofa groove welding test, ii considered as permissible, provided there is confirmation thatthe eause ofthe generation isa blowhole ora slag inclusion and when the length ofthe erack is ‘up approximately 3 mm. ‘Additionally, 3 mm is stipulated as the permissible limit of the length of the ‘rack in “IIS Z 3801 Standard Qualification Procedure for Manual Welding ‘Technique 3.2," “Ministry of Intemational Trade and Industry Technical Standards on the Welding of Electric Structures,” “AWS 5, 12, 1,2 Root, Face and Side-Bend Tests,” “ASME QW-1 Acceptance Criteria-Bend Tess,” ee ‘The provisions of item c have heen obtained once the consistency between the ‘welding procedure test and the execution work has been considered, The steel and welding consumables that will be setually used are stipulated to be adopted fora welding procedure test of dissimilar steels. ‘The decision to pass or fil inthis instance shall be made based on the standard values ofthe steel on the low-strength side ‘The impact test on the groove weld zone used to be conducted only about the deposited metal. However, to conduct a more definitive test, the impact test on the weld heataffected zone is added so that the toughness values of the base ‘material can be satisfied. Moreover, although the maximum hardness test used 2380.to be conducted in order to determine the necesity of preheating, the maximum Fharness test has been deleted from among the items ofthe welding procedure lest sine the previous time because preheating has been proscribed in the weld cracking sensitivity composition, 3) Assembly welding Although there are eases where al the assembly welding i remelted through regular ‘welding, part or most of it remains within the repular welding. Therefor, this item is stipulated so thatthe quality of the assembly welding may be made equal o that of regular welding. Moreover, although the term “tack welding” was formerly used, it ‘nas been changed to “assembly welding” because consideration for the prevention of ‘weld cracking in this welding process is as important as in the regular welding, Consequently, the expression “tek” is not necessarily appropriate. Because the assembly welding is performed atthe assembly stage, its welding control tends to be neglected. To avoid tis, itis important frst of al to engage the qualified welders. AWS stipulates to also conduct technical qualifications for the welders who are engaged in assembly welding. However, our country does not possess a ualificaion system for assembly welding slone, so itis necessary 10 engage in assembly welders who possess skills equivalent to those of the operators who perform regular welding, ‘The length of assembly welding (80 mm or more) is based on a research result that ‘hile cracking tends tobe generated from the root and along the bond when a fillet ‘welding of a short bea is applied to aT joint of steel of 490 Nim’, eracks cease to be generated when the bead length becomes 80 mm or more. However, recent research has revealed that no cracking is generated even if the length of assembly ‘welding is $0 mm, provided thatthe thickness of he thicker plate is 12 mm of ess oF {hat the carbon equivalent (Cg) of the steel is 0.36 percent of less. Moreover, there js largely the correlation between Ceg and Poy inthe stel of $70 Nim class for a bridge and the Poy equivalent 10 Ceg 0.36 is 0.22 percent. Is therefore stipulated ‘that the length of assembly welding can be 50 mm or more when Powis 0.22 percent orless. While the above-mentioned root crack doesnot appear on the surface of the bead in many eases othe types of assembly welding cracks often appear on the surface of the bead duc to the small cross section. When a crack is detected by a surface inspection at the end of assembly, messures can be taken at that stage ‘Accordingly, itis stipulate thatthe slag ofa bead in assembly welding is removed at the end of assembly and an inspection is performed on the surface ofthe bead. 384) Prebeating Recent research” has reveled tht itis better to use the weld eracking sensitivity ‘composition as an index of preheating rather than the carbon equivalent that has ‘conventionally been used, Moreover, in addtion tothe increase in plate thickness in the previous revision, the plate thickness applied to weathering steel has been increased t 100 mm in this revision. Correspondingly, it has become necessary to more accurately select the preheating condition in welding for the purpose of preventing the delayed cracking by hydrogen, so itis stipulated thatthe provisions of preheating are reviewed on the bass of Pou. [Based on the usage records of steels for bridges inthis county, Table C.17.42 has been obiained after reordering is made in accontance with Rey. On the other hand, the preheating temperature for crack prevention in accordance withthe Poy values of ‘the stel in the common joint of a bridge, the plate thickness and welding procedure are shovn in Table C.17.4.3, Ita been known that while the restriction ofa joint by welding ineeases asthe plate thickness inereases, that the increase peaks out when the plate thickness exceeds 400 mm to 50mm and that eracking can be prevented without increasing the preheating temperature above certain degrees. Because the usage records of steels with plate thickness of 50 mm or more have been ‘increasing, itis stipulated thatthe restriction becomes constant at the plate thickness fof $0 mm or more and that the preheating temperature is the same for the plate thickness of 40 mm to 100 mm of steels withthe same Pou. Additionally, the preheating temperature division has been simplified withthe distance of 20° to 30°C into “no preheating,” “SO°C", “80°C” and “100°C,” hereby aiming at the streamlining ofthe preheating contro. ‘Table C.17.42 Condition of Poy in Application of Preheating Temperature Standard oo ——Sisegpe [e00 ——[SHATOOW | Sw) ——TSsa0 —TSAOOW. see pial smasoy | sMsma_— | sMas70w thickest) —~ 25 ores Tt ortess [036 ores | Oars | 03 oem | Oar [Over2s and. otess [028 orless [0.24 orless [0267s [027 orlesr [0.77 oes ‘Over Sbd 100 orlss [0.24 orlss | 02¢ ores [O77 orless [0.29 rless [029 oleae “The preheating temperature standards in Table 17.4.5 inthe clause has been obtsined by ordering the preheating temperatures in reference tothe traditional experience, other standards, etc, on the basis of the amount of difusible hydrogen of the deposited metal and the joint condition of abridge where the restriction ofa join is standard from the relationship among Pew , plate thickness and preheating 382temperature of Table C.17.43, based on the assumption of the Pou conltion of the steels of Table C.17.42. Moreover, the preheating temperature of shield are welding other than the low- hydrogen type is stipulated tobe a stated previously, du to the reason that it eannot ‘be ordered using Pee ‘Because preheating is a means to perform a sound welding that does not generate crack, it snot suficent simply to always preheat tothe temperature show in these tables, It is necessary to take care of the work condition such as conducting the preheating of even higher temperature in order to prevent the generation of cracks depending on the Po the ste! the condition of joint restriction, ee. ‘Moreover, the preheating temperature can be decreased by reducing the Poy values of the steel. The preheating temperature in this instance shall be according t Table C1743. When using an electrode of extremely low hytrogen under a wel controlled condition, the preheating temperature can be lowered tothe same as the gnsshield are metal welding method. Adktionally, when crack prevention is guranced by the data ‘rom experiments such asthe welding crack test that simultes the actual structure, the preheating temperature canbe lowered below those show in Table 1745, Table C1743 Standard of Py Value and Preheating Temperature ‘raat temperature CC) Pow Welding metios at tikes division (rm) —_—_—_— 7s Berea | W272 100 a SAW ‘Noehesing | No prebet No preheating ‘GRIAW, SAW | No preheating | — No preeating = SMAW. No preteating | No preheat { TOMAW, SAW | "No peceatng | ~ No prbeat leaeeaes —_SMAW No prceaing | —No preening ‘GMAW. SAW No reat | — No preheat lagen 'SMAW. ‘No grcheating | —No preheating t GMAW, SAW | No preheating | No prebeating | No prebeating [es ‘SMAW. No pret 30 ‘0 ‘GRIAW, SAW | No preating | — No prea 30 one SMAW | Nopreeati 0 0 ‘GMAW, SAW | No peating | ~ Nore 0 oa SMAW. ‘0 0 a ‘GMAW, SAW | “Nope 30 0 oe SMAW. <0 a 100) GMAW, SAW 0 0 30 aa ‘SMAW. 0 100 100 ‘GMAW, SAW 0 a0 w Nas) ‘SMAW= Covered are weidng by low tndopen ppe dlskode GMAW: Gavstield are metal welding SAW: Submerged are welding -383-"Note: 1) In “no preheating.” when air temperature (room temperature in the ease of indoor) is $°C or less, warm up (heating t0 approximately 20°C) shall be performed in order to remove any condensation 2) Preheating temperature calculation formula T,CC)= 14407, -392 where ae Pee Poe Gy 0,000 3) The prcheating temperature in the table is calculated on the basis of the following assumptions: 8) Amount of difusible hydrogen in deposited metal (Hs) In low hydrogen covered are welding Hog =2 m0 In submerged are welding and gas-shield are metal welding Ho, "2 mV/100 g Two hundred times the plate thickness (#) is assumed for the average restition ofthe welded joint ofa bridge. K= 200. Nimm- mm Plate thikness shal be 50 mm in the ease of $0-mm or more 5) Heat gain restriction When the welding heat gain is increased in the welding work, the speed of the temperature decrease becomes slower once the temperature reaches the peak by ‘welding heat, and therefore the toughness and stength of the deposited metal and weld heavaffected zone (HAZ) are reduced, Consequently its necessary to ensure ‘that the heat input is restricted in acordance wit the steel and welding procedure so that the mechanical properties required for ajoint can be ensured. ‘The welding with excessive heat input is generally rare in the welding work ofa steel ‘ridge. However, there may be cases where toughness degradation in the weld bhea-affected one (ie, the HAZ) ofthe steel becomes 8 problem withthe adoption of the weld that generates excessive heat input in submerged arc welding, electro-ga5. are welding, te, for the purpose of improving the efficiency of welding work. Accordingly, to ensure the toughness ofthe zone afected by weld heat-affected zone (HAZ), the heat gain in submerged are welding shall generally be controlled to 7,000, 384o mm or less for SMS70, SMASTOW, SMS20 and SMA490W, and generally to 10,000 Jimm o less for SM490 and SMA9OY, When performing a welding that exceeds these heat gains, i is necessary to conduct a performance check through means ofa welding procedure test. Additionally, when conducting large-heatgain welding such as above, it is preferable to use appropriate materials according tothe heat gun, sine steels whose foughness in the weld heatafeted zone (HAZ) is good even in large-heat-gain welding have also been developed. On the other hand, with regard to. weld consumables itis necessary to select appropiate consumables that will ensure the performance ofthe deposited metal Note for welding work i) Cleaning and drying member before welding 8) The mil sale, rust, paint, oil, et, near the weld line can cause blowholes or cracks. However, the generation status of defects varies considerably, ‘depending on the amount of the foreign material and the welding procedure For example, the common pimer coating is nearly harmless inthe context of| ‘at manual welding, but itis panicularly harmful inthe case of fillet welding performed ata high speod, such as vertical downward welding. The state ‘where moisture is stached to the Weld line is stipulated to be prohibited, because suc a state obviously alfets the welding in negative manne. i), Weld ab ‘The start point and end point of a welded bead must use the weld tab sine they tend to generate defets, while the fillet welding at the end of a main girder is als stipulated to use the end tab. This is because the fillet welding ofthe main girder flange and web is presently performed by the submerged are welding ‘method, so it is not desirsble for a large erster particular to the automatic ‘welding to remain inthe end portion whee shear stress is great. However, the welding procedure without the stel weld tab (uch asthe ux tab) thas recently been developed. Such e method may be used when it is recognized tht the procedute can prevent the generation of defects atthe end of ‘4 eld zone in the same manner asthe steel weld tab, fil) Work of paral penetration groove welding “The crater generally artes atthe end ofa welded bead and the so-called cratercrack tends to be generated inthis portion. This tendency is particularly strong inecases where the groove angle i relatively small, such as in partial penetra groove welding. Accordingly, it is desirable inthe automatic welding method to perform the work on the weld line continuously without cutting the bead on the way. When euting the bead or changing the welding procedure on the way ‘based on necessity due to the change ofthe shape of the member or the change ofthe groove, et. its stipulated thatthe end ofthe previous bead be chipped away before the next welding i perfoemed, [No crater arses in manual welding when the end portion is treated carefully, nor {sa large crater generated in semi-automatic welding if a power source equipped ‘with a erater filler function is used and the end portion is teated by the crater- filler current. Therefore, in such eases it is not necessary to chip away the end portion Work of fillet welding and partial penetration groove welding ‘This provision is stipulated for the same reason as mentioned in item ii. When working on a long joint by the semi-automatic welding method, continuous ‘welding eannot be performed if the equipment layout or mobility is poor, itis desirable to make a sufficient arrangement for them in advance. stallment and removal of suspender and temporary member, ee Wis stipulated here thatthe welding used to install the suspender and temporary member, etc, be performed within a factory in consideration of the fat that it consttues welding f0 a primary member. On the other hand, when onsite welding is conducted out of necessity of the work, such as inthe case of (among, hanging rings) the floor deck type framed hanging ring installed to the top surface of the upper flange during the casting ofthe Noor deck, it is necessary for the welding (0 satisly the welding condition equivalent to that of shop welding When removing the suspender, temporary member, etc, consideration must be made not only in regard tothe effects of flaws, ete, on the base material, but also in regard tothe effects ofthe degree of finish, rong height of the removal mark, ete, on the work and quality of coating, bridge deck pavement, ete Accordingly, “Bridge Deck Pavement Standard (Plan), Honshu-Shikoku Bridge Authority, April 1983" can he used as reference in the degree of finish onthe pavement, ee. 3861745 » » (1) Upon the completion of welding, an inspection must be conducted on the bea form and appearance using the naked eye or other appropriate nondestructive inspection method in ‘order to confirm that the welding quality required of joint ‘Surface flaw inspection satisfied (@) Clause (1) may be doomed to be satisfied when the inspections are conducted in accordance with items 1) to 8), Weld crack inspection There must be no racking whatsoever in the weld bead or its vicinity, While the ‘rack inspection shall generally be conduted with the naked eye itis advisable to use the magnetic particle method or liquid penetrant method if any aw is suspected. Inspection of weld bead appearance and form |) Piton surface of weld bead ‘There must be no piting onthe surface ofa bead in a joint and comer joint constituting the but joint and cross section of a primary member. Up to three pits per joint or per meter of the joints length shall be allowed forthe filet, ‘welding and partial penetration groove welding in others. However, when the size of the pit is 1 mm or less, three pits shall be regarded as one pit in caleulation ii) Unevennesson te surface of weld ead ‘The unevenness on the surface of a bead shall be shown by the difference of elevation within 25 mm of the length of the bead, and there must be no unevenness exceeding 3 mm, iit) Undereut ‘The depth ofan undercut must be less than 0.5 mam, iv) Overlap ‘There must be no overlap, ¥) Size of filet welding The size and throat thickness of fillet welding must not under-run the size and throat thickness of a designated fillet. However, inthe portion excluding 50 rm ofboth ends of @ wel line within the range of up to 10 percent ofthe weld length, an error margin of -1.0 mm shall be allowed for both the size and throat thickness, 3873) Reinforcement and finish of groove weld In the groove weld having no paticular specification regarding finish in design, a reinforcement within the ange shown in Table 17.4.6 need not undergo finishing ‘When the reinforcement height exceeds the values shown in Table 17.46, the bead ‘orm, particularly its te portion, mus be finished smoathly. ‘Table 174.6 Groove Weld Reinforcement tam) etn [Warne a 36 nz Teac = 58 rr 4) Are stud inspection ') Visual inspection of are stud The visual inspection of are studs shall be performed for all pieces, and must satily Table 17.4.7 | ‘Table 174.7 Are Stud Visual Inspection Criteria Dele Criron “The weld einfrcensat aust around he whole cieumiirence Inked, ‘he one withthe eight of I mm of mare ap the Width of 0S mam or ere regarded asa Weld reinforcement regularity of weld reinforce fem Crack and ag Inclusion “There mist he none of hem. “Tere mist be no sharp lcs under or an underoot wha dep Undereut cxceeing 0.5mm. Hower, th ene whose rin ish aman all within (Sm shall pass afer iting. Fished eit of — Habel = am must nthe esos, Design value ii) Hammer impact inspection All the stud dowels that have fled a visual inspection shall undergo a bend inspection by hammer impact. The stud dowel that is nt surounded by a weld reinforcement shall be bent up to 15 degreesin the direction opposite its ovm ireeion. Moreover, 1 percent of the stud dowels that have passed a visual inspection shall undergo a sampling bend inspection. fil) As a result of the hammer impact inspection, those that have generated no defects such as cracks, ee, shall pass. Those that have generated no defects after being bent 15 degrees must remain bent without being restored 10 the original form. 388 -jv) When fil isthe result ofthe sampling bend inspection, ice the numberof the picces shall undergo a further inspection, and with all picces having passed it shal be considered a pass 5) Repair of defective portion ‘The repair ofa defective portion must be carried out carefully in consideration ofthe effet ofthe repair on the base materia ‘The methods to repair defects are shown in Table 17.4.8. In this rogard the length ‘of the bead of a repair weld shall be 40 mm ot more, and sufficient care for reheating, et. shall be used inthe repair work ‘Table 17.48 Method for Defect Repair Dateetigpe |" Repaitiog : “The prion on tbe suas af base male where ade fa bon generated 1 | Areseike shallbe inde ished afer overlaying. The ose with ny mark shall undergo oly he grinder nh, ‘fest in assy | The defective portion shall be ramoved with hearer goaeing, and weld necessary an asenbly welding shall be anced again Weld eck The cracking portion sal be completely removed, and avowed hall be prfomed afte th cus ofthe peoben sei, it on srfice of weld | Tat potion shall be removed with he ar ir gouging, and ve-wlIng Sal he be performed. ‘Over Tl be trimmed wih grinder and formed Tah ‘Unevenreson| 6 ae cag_| shale fished witha grinder fluo Teal beast nse with rnd, Gepening on We dees. ov all ‘be finshed witha rnd after welding 1) Weld crack inspection [Needless to say, no cracking can be allowed in a weld structure, but it is qui ficult wo detect ll cracks perfectly that may be present, Therefore, this provision {is stipulated for the purpose of allowing no cracks that can be detected from the surface. However, this does not mean nothing else needs to be done when the surface detectable cracks can be prevented, so the condition of execution must have solute compliance in order to prevent the generation oferacks. More specially, conceming the weld crack, it is the prime challenge to prevent its generation ‘Therefore, the maximum preventive efforts must be made in compliance with the provisions ofthe specifications. nthe other hand, the radiographic testing and ultrasonic testing methods are wsed to detect intemal laws. However, itis dificult to differentiate between the unvelded metal zone and a weld defect atthe root zone in the portion of the fillet weld portion -389-a ‘of a Toint or the partial penetration weld ofa comer joint, so these tet procedures have not ben included as inspection methods oferacks. Inspection of weld bead appearance and form Because the judgment of defects or otherwise conceing the appearance and form of awed bead vais among individuals, itis stipulated thatthe appropriate allowable amount ofthese are provided in his tem, techy enblishng the inspection etera With which an objective judgment can be made. While the reinforcement of a soove weld is referred o in item 3), oer factors that determine the quality ofthe appearance and form of a bead are the piting on the surfice, unevenness ofthe surfce, underout, overlap, the size of a fille weld, ce. The provisions are stipulated here onthe basis ofthe “Quantitative Inspection and Contol Ceiteia of the Appearance of Vessel’s Body” (eited by the Welding Work Commits, Shipbuilding Section, Japan Welding Engineering Society” and by adding various citeumstanes of ries tit {)_ its on the surface of @ weld bead are the vent holes ofthe gas generated from, foreign materils and moisture, Of these, small and sporadic ones do not affect the strength, but large ones and those occurring in clusters can cause stress concentration and are not desirable in appearance. Therefore, itis stipulated that these not be allowed in the primary joints but that some will be allowed in the secondary joints, ii) Unevenness on the surface of a weld bead appears mainly atthe joint of the bead, Because it becomes quite large when the rater treatment and the start point treatment are poor, its acceptance criteria is stipulated to be 3 mm fom the perspective of leting such treatment he carted out carefully and in ‘consideration of good appearance, il) Because undercuts ae the main eause ofthe stress concentration and lead tothe promotion of corosion, its acveptance criteria i stipulated tobe 0.S mm or less based on past records, tc. Additionally, in the case of the fillet welded joints ‘such as ribs and stiffeners, the undercut in the toe zone (on the lower-leg side of the filet weld) connecting with the main body stecture is particulary important fiom the standpoint of stress concentration, so the lower-leg side must be Inspected without fil ‘Moreover, there are cases where the requirements forthe undercut allowed in satisfying the prescribed fatigue strength prades ae stricter than the provision of -390this item; therefore, separate consideration is needed in such case, For matters Pertaining to fatigue, “Guideline of Fatigue Design for Steel Road Bridges” (apan Road Associaton)” canbe used as reference. iv) Overlaps are stipulated not to be recognized at all in consideration of the fact that no overlaps occur with recent welding materials unless under exceptionally poor conditions 'y)_ Recognizing, negative tolerance for the size and throat thickness of a fillet welding, i is stipulated that -.0 mm ig allowed for up to 10 percent of the length in the middle part of the weld line. This is a result of considering, among others, the fat thatthe strength of the welded metal in a fillet weld is considerably higher than that ofthe base material in general. Additionally, tis de to the judgment that ifthe target values are stipulated withthe lower limit of the variation of the work as the prescribed size, the average size will become unnecessarily large, causing disadvantages in deformation. 3) Reinforcement and finish of groove weld Because it is considered thatthe stress concentration by weld reinforcement is elated to the form ofthe toe zane of a bead but isnot direty related tothe height of the ‘center port of the weld reinforcement, a provision is stipulated as in Table 17.4.6 ‘withthe bead width adopted asthe acceptance criteria, Concerning the weld reinforcement that exceeds this provision, the excess part must be removed a8 a matter of course, However, in that instance, even if the eight is reduced by uimming the center part ony, the effet of the form ofthe toe zone will not be decreased, st is necessary to ensure tat the te zone is made particularly smooth “The stress concentration by the presence of the weld reinforcement i important for a Welded structure, and thee are eases where itis demanded from the standpoint of appearance thatthe weld reinforcement should undergo finishing, Therefore, the locations where the weld reinforcement finish is needed should be instructed in design drawings. During execution it s necessary to perform the work by carefully checking forthe existeneeof ths finish mark 5) Repair of defective portion Because the purpore of the repair isto ensure the sound fanetoning of the base material and welded joint portion, the repair method must be determined in careful 2391‘consideration ofthe effect on the entire member, and the repair must be conducted carefully inorder to provent unnecessary welding or heating. Particularly harmful defects tend tobe generated in the stat point and end point of reps welded portion. Therefore, care shouldbe taken, 17.46 Internal flaw inspection - ee (1) The inspection for the intemal flaw of a fullpenetration butt Welding joint must be conducted by an appropriate nondestructive inspection after the welding is completed, and it must be checked thatthe required weld quality is saistied, (2) When the inspection for the intemal Maw of a fullpenetation butt welding joint is conducted in accordance with the method shown below, Clause (I) may be deemed to be satisfied, 1) Inspection method ‘The nondestructive inspection is performed through radiographic testing and sltrasonie testing 2) Sampling inspection rate, cceptance criteria and judgment of acceptance |) Sampling inspection rate For a primary member, a sampling inspection of picking one joint per gz0Up shown in Table 17.4.9 shall be performed, However, of the full penetration butt welding joints that undergo site welding, forthe welded portion ofthe beam and column ofa steel bridge pie, tbe ange and web plate of a main girder and the steel deck plate, the inspection shall be conducted in aocordance with Table 174.0. | Additionally, when the allowable stess in other member is set to be the same value asthe joint ofthe same type that undergoes shop welding an inspection shall be caried out by # nondestructive inspection forthe entire length ofthe jin, 2392+‘Table 1749 Nondestructive Inspection Rate of Full Penetration Butt Welding Joint of Primary Member = Tamonroey | Ninian | Mb opie 4 a ingoupne enter frown” | ratopapic testing | rs sins Fas near : pea : oot end et) ae ma 5 Ope 7 iy | Teale age 1 Ones 7 F | Conese tng 5 Ones 1 8) Tiamat ; ‘re so one ’ | 2 | center toss: | Saecctensen 3 | [oii rate aecton ; Ones : tore ood pat) Sel ow desk : net (eluding end part) ! ‘Table 17.410 Nondestructive Inspection Rate of Full Penetration Butt Welding Joint ‘hat Undergoes Site Welding - Radiogapie esting, sone stig es Location to soot Tnsgeton lena "Head Solan of wel ge per ange af an gid eciong eee eee sie! Noor deck) and web plate cm coninoousy ate stat] point ad en point aint 40 | ‘Sao one locaton per eter a | ‘mide part (ne shot) and one | Tecation at wilt prion | {ne soo} in genera l Ortbeopicstel deck Entire length of join in general ii) Acceptance erteia “The sizeof the flaw detected inthe inspection must be te size allowed indesign orless, However, there must be no sheet flaws such as open cracks on the sufice, imespectve of size, (On the other hand, regarding the results ofthe test by the radiographic testing ‘withthe plate thickness of 25 mm o less, it may be deemed as having passed ‘when the following provisions are satisfied: 8) The welded portion receiving tensile stress shall be in Cass 2, as shown in [Appendix 4 of JS Z 3108 “Method for Classification of Flaw Image by Radiograph Photos," or more. 2193pos 1) The welded portion receiving compressive stress shall be in Class 3, as, shown in Appendix 4 of JIS Z 3104 “Method for Classification of Flaw Image by Radiographic Photos,” or more. | ii) Judgment of acceptance, treatment of filed portion ® ‘When the results of the nondestructive inspection in accordance with Table 17.4.9 do not satisy the provisions of item i), the following treatment shall be applied 8) When the group of the inspection lot consists of a joint, the joint that ‘underwent the test shall be filed. When the group of the inspection lot consists of two oF more joints, the nondestructive inspection shall be ‘conducted foreach ofthe remaining joints and it shall be judged to accept for reject. The whole of the falled joint must be inspected by the non- destructive test, and to the extent of defect determined the failed portion rust be repaired in accordance with the provisions of item 17.4.5 (2) 5) ‘The repaired portion must stisty the provisions of itm i) ‘When the results of the nondestrictve inspection in accordance with Table 17.4.10 given tothe fllpenetraton butt welding joint to be welded on site do not satisy the provisions of item i), the following treatment shall be applied 8) When te entire length ofthe joint was inspected, the inspected location that does not satisfy the provisions most be failed and repited in accordance ‘withthe provisions of item 17.45 (2) 5), Te repuired portion must satisfy the provisions of item i. 1b) When the sampling inspection was conducted by the radiographic testing, the range of 1 m each ffom both sides of the shoot location that does not satisfy the provisions shall be inspected. When these locations also fail to satisfy the provisions of item i), the whole ofthe remaining portion of the joint shall be inspected. The fled location must be repaired in ‘cordance with the provisions of item 17.45 (2) 8) afer the extent of the flaw is determined. The repaired portion must satisfy the provisions of item i), Incidentally, the joint mentioned here means the portion of joint from an edge to an intersection or ftom one intersection 10 another intersection. -394-1) Methods of testing for internal flaw of full penetration butt welding joint It is advisable t0 conduct the radiographic testing in accordance with JIS Z 3104, “Methods of Radiographic Examination for Welded Joints in Steel.” the ultrasonic testing in reference to Bibliography 6), 7), etc, and the manual flaw detecting in accordance with JIS Z 3060, “Method for Ultrasonic Examination for Welds of The applicable plate thickness ofthe nondestructive inspection shall be 8 mm to 100 ‘mm for the ultrasonic testing and 40 mm or less for the radiographic testing as a ‘guide, However, when sufficient data is available, radiographic testing can be used forthe plat thickness that exceeds 40 mm. ‘The ultrasonic testing shall generally be used forthe plate thickness of 40 mm or ‘more in consideration of the possibility of exceeding the detection capacity of radiographic testing. In this instance the testing shall be conducted by the ‘ultasonie automatic testing instrument whose reliability in the flaw-detection condition has been established in consideration of the plate thickness, welding condition, et, of the inspection target. Additionally, it is preferable tha the testing bbe performed by the testing personnel of Class 3 or higher who is qualified by the Japanese Society for Non-Destructive Inspection. Additionally, the ultrasonic automatic tester whose reliability has been established ‘means the ultrasonic automatic tester who has been confirmed in advance by verification tet, ete, including destructive inspections to satisfy the performance necessary for this inspection. It must have already been confirmed that component instruments and programs such asthe ultrasonic teste, probe, scanner, image display ‘unit and judgment support software installed in the instruments satisfy the necessary performance individually and inthe state where they aze combined, and it must also 'be confirmed that the performance will be maintained inthe process of inspection.” ‘The manual flaw detecting shall be used only inthe location where the ultrasonic tomatic testing cannot be applied, and inthis instance suficent data verified by the destructive inspection, etc, concerning the corelation between the area of flaw ‘cho height and the apparent flaw length and actual flaw length must be availble. The testing personnel engaged in the manual flaw deteting i stipulated to be one of Cass 2 oF higher who is qualified by the Japanese Society for Non-Destructive Inspection 398-2) Sampling inspection rate, acceptance criteria and judgment of acceptance a ‘Sampling inspection rate In this revision the inspection rates ofthe ultasonic testing have been added to Table 17.4.9 and Table 174.10. Due to the difference in the characteristics of inspection methods, the unit inspection length is stipulated to be the entire length ofa joint in the ultrasonic testing compared to 30 em in the radiographic testing. This isa result of considering, among others, the fact thatthe records ‘of ultrasonic testing are not yet sufficient, although the provisions have recently ‘een stipulated, along with the fact tat iis difficult to determine the fa type jn the curent situation. Moreover, attention must be paid to the fact that ultrasonic testing is greatly dependent on the competence of the testing personnel CConceening the inspection rate of the compressive member in Table 17.4.9, about which a demand for intemal faws is shown after conducting the fatigue design as a condition to satisly the prescribed fatigue strength, since it can be considered that there is no difference about the generation of fatigue erack between the compressive member and the tensile member duc to the effect of residual tess, a separate consideration must be made such as rendering it into the same inspection rte as that ofthe tensile member. Included among the conditions affecting the weld qualities are the joint type, material quality, plate thickness, welding condition, the accuracy of the groove and assembly, the cleanliness of the groove, the control of preheating, post- heating and interlaminar temperature, competence of welders, ete. Therefore, ‘the welded joints in the same welding condition shall be regarded asthe same in terms of quality control, and the aggregate of such joints is tumed into an inspection lot. For example, when ten butt joints withthe same pte thickness ‘are welded by the same welding method, these ten joints shall constitute one inspection ot. However, one joint mentioned here means the join between the plates but not the joint between members. Accordingly, when a member that is ‘welded continuously at one time is later cut into ten pieces, they will be considered as one joint. Subsequently, this lot shall be divided into groups according tothe maximum numbers of joints shown Table 17.49, and one joint shal be taken from each group for inspection. “The location of the sampling inspection represents the group, so if it fils the ‘soup shall fail as well. Tn the case of failure, an inspection similar to those of =396-Table 17.4.9 shall be conducted foreach joint of the group and the pass or fail status of each joint shall be determined. Moreover, in the sampling inspection an appropriate inspection lot and the locaton ofthe sampling inspection must be ‘determined in onder to ensure the quality of the welded portion, The phrase of (including end part in the column of “umber of photo shoot in radiographic testing” in Table 17.4.9 means shooting photos inclusive ofthe beginning part or ‘ending part ofthe weld ‘The inspection method forthe Fullpenetration butt welding joint tht undergoes the site welding is clearly stipulated. Paricularly, because the welded portion of ‘the beam and column ofa ste! bridge pcr, the flange and web plate of a main tinder and the orthotopic steel deck constitute the welded portion of a primary ‘member, nd because it is important to ensure quality, the inspection method is stipulated on the basis of quality control ofthe records of site welding and itis stipulated thatthe inspection results must satisfy the provisions of item i), The inspection ofthe lange and web plate of a main gder and the pier of a steel bridge is stipulated to be performed generally forthe entre length ofthe joint ‘Concerning the radiographic testing of the fll penetration butt welding joint in ‘he orthotopic stel deck, the shooting locations are stipulated tobe distributed evenly along one weld line. However, because defects tend to be generated at the start and end parts as well asthe intersection potion aad wire joint portion fof the weld line, these portions are stipulated to be inspected by priority. Additionally, when « work method other than automatic welding is adopted a at the location where the groove condition or welding condition exceeds the control values it is preferable to conduct inspection regardles af thi provision Examples of the locations of shooting in an orthotropic steal deck with an site ‘welding joint are shown in Figure C.17.44, Moreover, when there is a aw that has filed inthe inspection, i is stipulated thatthe generation statu ofthe ‘aw be determined by further inspecting the range of 1 m from the location of the flaw on both sides in onder to decide whether itis a local Maw oF ‘continuous flaw. When there is no Maw that has filed the inspection in the ditional inspection portion, the original aw is stipulated tobe considered as a local defect. On the other hand, when there is a flaw that has filled the inspection inthe additional inspection zone as well the entite length of the joint is stipulated tobe inspected, Additionally, in the case ofthe ultrasonic testing the entire length ofthe joint is stipulated tobe inspected. -397-Weld ine sem wo fms) , Figure C1744 Example of the Location of Xray Shooting in Deck Plate of and Orthotropie Steel Deck i) Acceptance criteria ‘The size of the internal flaw allowed forthe fullpenetation butt welding joint is sotto be 1/3 the plate thickness or less, in aevordance with the results of the latest research on fatigue by the Ministry of Land, Infastructure, Transport and ‘Tourism, ete. This size is fixed with or without the bead finishing, Moreover, ‘conceming so-called adjacent Daws and cluster blowkoles where multiple Naws exist in close proximity, this provision can be applied to the size once the conversion toa single aw is made. Additionally, the allowable value forthe size of internal flaw in the welded portion where a good execution was conducted in accordance with the provisions of this specification may also be considered to be 1/3 the plate thickness. However, ina joint that can be considered subject to the effect of fatigue, the size of the fla allowable in satisfying the preseribed fatigue strength may be smaller than this value, so in this instance separate consideration is needed, For matters pertaining to fatigue, such asthe qualities required by fatigue strength, “Guideline of Fatigue Design for Steel Road Bridges” Qpan Road Association) can be used as reference. “Moreover, while the exiting specifications did not recognize the existence ofthe crack regardless ofits size, the lntest research results have not found a signet Aiference in fatigue stength depending on te flaw type. Therefore, it may be considered that the allowable actual flaw size can be applied regardless of the flow type. However, since any flaw that is quite close to the surface and can therefore he detected by the magnetic particle testing isnot allowed regardless of its size like the case where there isan opening onthe surface, it must be repaired ‘even fits size is less than the allowable Naw size Inthe case of ultrasonic testing there are cases where the echo is detected for -398-reasons other han a aw at a high level, depending on the form of the weld ‘bead. This makes it difficult to determine a flaw, and in this instance it is necessary to determine the echo carefully, Particularly attention must be paid in cases where there isa bead form in which a crack is suspected to exist based fon appearance. When itis dificult to determine flaw in detail trough ‘ultrasonic testing, the fina check shall be made by means of magnetic particle testing. In the radiographic testing, the determination has so far been made by marks based on the flaw type and size in accordance with Acceptance Criteria Appendix 4 of JIS Z. 3104, “Methods of Radiographic Examination for Welded Joins in tee.” However, because this acceptance criteria did not originate from the consideration of fatigue, it can be considered that it is not necessarily consistent with the sceptance criteria for ultrasonic testing. However, given the consistency wit the existing acceptance criteria, etc, itis stipulated tat the radiographic testing that targets the plate thickness of 25 mm or ess may be based on the existing acceptance criteria, Nevertheless, when the plate thickness exceeds 25 mm it s necessary to apply tothe radiographic testing the same acceptance criteria as that of ultrasonic testing, and to make an estimation ‘based on the converted flaw size that includes the single flaw and adjacent flaw ‘without discriminating between the types of flaws In regard fo ultrasonic automatic testing, while an acceptance erteria by the law echo height and apparent flaw length that correspondingly applies Appendix 6 of HS 7.3060, "Method for Ultrasonic Examination for Welds of Fertc Stel,” has customarily been used, in tis revision it has been changed into making an assessment based on the actual size of the law. The validity of the methods used to assess the actual flaw size must be determined for the respective ultrasonic automatic testing instruments in accordance with their characteristics. “Moreover, the validity of thee assessment methods must be verified in advance ‘through reliable methods. Attention must be paid to the fact that much of the judgment work inthe curent ultrasonic automate testing depends on the skill ‘of the competence ofthe testing personnel Additionally, concerning the period of nondestructive inspection, itis generally performed within 24 hours from the completion of welding, However, when it is novestary to consider the delayed fracture in relation tO the material quality and plat thickness, consideration must be made in order to conduct the testing aftr appropriate time has passed since the completion of welding =399-17S High strength bolt 175.1 High strength bolt work in general In the tightening work of the high strength bolt, the following items must be considered sulicently and the work must be executed appropriately in order to ensure the qualities required ofa join. 1), Joint type and characterises 2) Type ofigh strength bol andits qualities 3) Method of tightening, contr of tightening axial free and inspection method 4) Method of weatment of joint surfce 5) Assembly accuracy of material piove tobe tightened “The methods of connecting high strength bolt joint include tietion grip conection, bearing connection and tensile connection, and there are different mechanisms for the transfer of stress. Accordingly, based on 2 sufficient understanding of the features of the tightening ‘work, an execution plan to ensure the qualities required of a joint must be compiled forthe tightening work, and the work must be carried out in strict accordance withthe plan. ‘The fiction grip connection tightens together the members constituting a joint using high strength bots, taking advantage of the high axial force, and transfers force with the fiction free generated on the contact surface between the material pioces. Therefore, it is necessary in the work to ensure the tightening axial fore, slip coeficent of the contact surface and contact density between the tightened material pices. ‘The bearing connection transfers force by means of the bering force between the holes of members constituting joint and the bolt axes through the shear resistance of the bolts ‘When using the hammering type of high strength bolt that generates no relative displacement inthe joint portion, the drilling accuracy and the generation of hole mismatch in the joint potion must be checked prior to performing the tightening work in order to prevent any ‘problems from taking place in the tightening work, Additionally, the tightening axial force is generally given witha view to improving the joint performance, and inthis instance an execution management similar to that of the fiction grip connection i required ‘The high strength bolt tensile connection employs the style of transferring the Force in the direction ofthe bolt axis by generating the contact stress on the joint surface. Given this \ype of connection, it is necessary fo ensure the tightening axial force ofthe bolt a well as fo secure the fatness on the contact surface of the joint and the contact density after the =400-lightening, Moreover, since itis sometimes necessary even in the tensile connection to resist the shear foree with the fietion force on the connection surface, an execution management ‘equivalent to that ofthe fretion grip connection is required in this instance ‘The tightening methods include the tomue control method, angle contol method, torque aradient control method, ete, depending on the method to contro the tightening axial force. [Because there are cases where particular bolts and tightening equipment are used, depending fn the parcular method, the tightening work and its quality control must be performed after sufficiently grasping the types of the bolts and charateristics ofthe equipment to be wed Additionally, the assembly accuracy of members concerning the inconsistency among ‘members at the joint portion, the degree of the lap gap between material pieces, hole mismatch, ete, must be checked before implementing the tightening work, and appropriate tweatments must be conducted so that no problems will arise inthe performance of the joint afer the tightening and in the implementation of the tightening work. 1752 Quality control and storage of high strength bolt (1) Concerning the bolts, nuts, washers and their ses, tests and inspections to ensure their | characteristics and quality must be conducted at the time of factory shipment and verification that they conform to the specifications must be performed. Moreover, a checkup with the inspection report must be conducted atthe time of delivery to the site, and it must be verified that they are bolt sets whose characteristics and quality are guaranteed @ Aitention must be paid tothe packing and site storage of the bot ses so tht their quality atthe time of factory shipment may be maintained untl the execution ofthe work onsite. (1) The bigh strength bolt must conform to the specifications preseribed in design. In executing the work it must be verified that the mechanical properties and shape and size ofthe bolts, nuts, washers and their sts, torque coefficient values, tightening axial force values, ete, conform to the prescribed specifications atthe time of factory shipment. “Moreover, it must be verified thatthe delivered bolts are those guaranted of thelr quality by checking them off withthe atached inspection report at te time of delivery to the sive ‘When the bolts require special performance and specifications in terms of their rmechanical characteristics, chemical components, manufacturing, methods, et. those qualities must be verified through tess nd inspections, and it must be confirmed that the results are stated in the inspection report. 2401(2) Conceming the storage of bolt sets, they must be stored as they were packed in the acory if citeumstances allow; and with care tht they will not be exposed to moisture such as rain and night dew. Additionally, it must be ensured thatthe quality atthe time of factory shipment is maintained until the execution of the work on site, Because quality tends to diminish after unpacking due to moisture such as rain and night dew, the occurence of rust, adhesion of dust, sand, et. 10 the screw portion, and damage in the screw portion due to rough handling, the package must preferably be unpacked immediately before the execution of work. It is therefore necessary to conduct the systematic delivery of the bolts to the work location and to ensure that unnecessary ‘unpacking isnot performed, —Adtonally, to maintain the quality atthe time of factory shipment until the execution ofthe work, it is desirable to be aware ofthe above points and make an arrangement to limit, a5 much as possible, the period from the factory shipment tothe execution ofthe work onsite 1753 Connection surface treatment (1) An appropriate treatment must be applied to the contact surface ofthe material piece that i connected by the frction grip coonection so thatthe required slip coefficient may be obtained. (2) When the following treatments are applied, i may be considered that the slip coefficient of 04 of mor is obained 1) When the contact surface is not painted, the mil seale shall be removed from the contact surface, turing it into a rough surfce, In tightening a material piece the loose rust, oil, mud, ete, shall be removed from the contact surface through sulficent cleaning. 2) When the contact surface is painted, the high build type inorganic zine-rich paint shall be used in accordance with the conditions shown in Table 17.5.1. 3) When a treatment other than as specified in item 1) or item 2) is applied to the contact surface, careful consideration shall be made so thatthe slip coefficient of 04 ‘ormore may be obtained. 402+‘Table 175.1 Condition in Applicaton of High Build Type Inorganie Zine-Rich Paint Tem Conon ‘Minimum ay Hi icknes por ede oF conact 5 ay 310 ym rare “Tal dey i kes oT cornet sae 90200 Zia ewer indy aM armor ‘Grain diameter of ine powder aig aad ‘Approx 10 ym or mare (2) The sip strength ofa Sietion grip joint is calulated by assuming the slip coefficient of the contact surftce, so an appropriate treatment must be applied to the contact surface so ‘that the slip coefficient assumed in design may be ensured in the work, Moreover, when the tightening axial force is applied to the bolt in order to improve the Joint performance in the bearing connection and accordingly the transfer of force by the fietion fore is hoped for, or when the shear force is transfered by the fiction force of ‘the contact surface in the tensile connection, a treatment similar to the one in the fetion stip connection must be applied to the contact surface {@) thas been conventionally known that a sufficient slip coefficient of 04 or more can be secured in a joint whose contact surface is tumed into a rough surface through the removal of mill sale, However, even if such a treatment is applied during shop fabrication it is difficult to ‘maintain this status until the connection is performed onsite, andthe loose rust, oil, md, te, are often attached to the connection surface, In such a case itis important to remove them by suffiiently cleaning the connection surface immediately before the connection is cartied out on sit, However, because the weights ofthe splice plates increase as bridges grow in size, the operation t remove the loose rst, et, onsite is becoming dificult and the paint in the ‘connection portion tend to ecome a weakness aller completion in terms of resistance 10 rust and corrosion. Thus the aplication of a surface treatment such as paint to the ‘connection surface has heen considered ‘Concerning the paint specification used to secute the slip coefficient of 04 or more, it has ‘been revealed that the slip coeticient of 0.4 oF more can be secured™” ifthe paint is performed according t the conditions shown inthe text of tem (2) 2), so the conditions ‘in applying the high build type inorganic zine-sich paint are stipulated. Different kinds ‘of high build type inorganic zin-rich paints must not be applied to each of the contact 403 -surfaces, aor must other paints be used concomitantly, The high build type inorganic ‘inetich pain shall be directly applied following surface treatment. When the high build type inorganic zine-rich paint is applied only to the fiction grip connection surface but other types of paints are used for other portions, it is necessary to pay attention fo the treatment on the boundary zone and to give due consideration in advance so that no averse effeet may be exerted on ether paint. Adkltionlly, contol ofthe film thickness shall be performed sufficiently. ‘When a rust and corrosion prevention other than as specified inthe texts of items (2) 1) tnd 2) is applied to the contact surface, it may not be possible to secure the sl coefficient of 04 or more depending on the type and thickness of the pant film, and the creep of the paint film may cause a decrease inthe bolt axial foree. Therefore, such a ‘weatment must be used after eareil consideration (including the question ofits necessity) ismade. Moreover, it is advisable to apply a blast treatment tothe connection surface that has been applied with @ galvanizing treatment as part of «hot dip galvanized bridge, and to secure a slip coecient of 04 of more. However, beeause there are eases where the slip coefficient of 04 or more cannot be obtained depending on the type ofthe blast material, itis advisable to refer to Bibliography 10) ete. A7S4 Bolt tightening (1) In tightening bolts, the operation must be performed so as to obtain the design bolt axial force @) Tightening bolts must be performed in such a way that contact density between the respective material pieces is ensured and sufficient stress is transfered (3). When the provisions of tems 1) to S) are applied, the Clauses (1) and (2) may be deemed to be satisied, 1) Boletightening i) The introduction of the bot axial force is generally performed by rotating the ‘nat, When the head rotation is conducted out of necasiy, the change of the torque coefficient shall be checked, ii) When the tightening of bolts is performed through the torque contol method, the tightening torque shall be adjusted in such a way thatthe axial fore of bolt, tightening is introduced uniformly to each bolt. 404) When the torque shear type high strength bolts are used, a special tighteer shal | tb employed fo the final tistening iv) When the tightening of bolts is performed by the angle control method, the Lightening with the tongue wrench o with the assembly spanner using all one's might shal be carted out, o the extent that he lap gap ofthe contact surface Aisappears. Then the rotational angles show below shall be given However, the angle control method shall be aplied to FRT and BST only. 8) When the length of bolt is $ times its diameter or less: 1/3 tum (120 degrees) #30 degrees 1) When the Jena of bolt excceds 5 times its lamer the target rotational angle shall be determined by the preliminary test tha is consistent with the ‘work condition, ¥) When the tightening of bolts is performed through the torque gradient control ‘method, the high strength bolts stipulated in item 6.3.2 (3) 3) shall be used and te final tightening shall be conducted by means ofthe special tghtener. vi) The tightening of the hammering type of high strength bolt is performed by hammering bolts until the nuts reach the serew portion of the bolls and then palling inthe bolts by rotating the nuts. 2). Calibration of Machinery and Device The calibration of bolt tighteners and measuring instruments shall be conducted at appropriate periods, and ther precision shall be checked. 3) Tightening bolt axial force 4) The bolt fo be used for the fiction grip connection, bearing connection and | tensile connection shall be tightened in such a way thatthe design bolt axial force shown in Table 17.5.2 an be obtained. =405-poo ‘Table 172 Design Bolt Axial Force aos) [OT Rem ceinar | paar ii) The tightening bolt axial force in the case of tightening by means of the torque control method shall generally be 10 percent greater than the design bolt axial force. i) Concerning the tightening bot axial force ofthe torque shear type high strength bolt at normal temperature (10°C - 30°C), the average value of testing five sampling set randomly selected from one production lot must fll within the range of the bolt axial force shown in Table 17.5.3, ‘Table 1753 Average Value of Tightening Bolt Axial Foree at Normal Temperature (10°C - 30°C) Set | Nominal dexigaaion] Avene vale of fgtimicg bolt ial owe ‘otiead ofthe et of on rodton fat RN) ‘zo 1202, sir ay 212~249 Ma 2A ~290 jw) Concerning the tghtoning bolt axial force in the case of tightening by the ‘onque gradient contol method, the average value of testing five sampling sets randomly selected from one production lot forthe tightener to be wsed must all, within the range ofthe bolt axial fore shown in Table 17.5.4 = 406Table 175.4 Average Value of Tightening Bolt Axial Force by Torque Gradient Control Method se Nomina designation | Average value oftihtning bol ain force cotthead| ofthe sea ane prodaton lo (kN) M20 0. 196 0,~0. 221 07 Flor Mae 0.242 0,~0.273 07 Mae 0. 282 o)~0. 818 07 —| ‘2: Proof rss oftoit te pece (Nin) (based on JIS tet lee No. 4) 4) Tightening order ‘Tightening bolts shall be performed by starting from the bolt atthe center of the splice plate and making forthe bolts at the end portion, and the second tightening shall be conducted (Figure 17.51). Additionally, marking shall generally be applied to bolts, nuts and washers so that failed tightening and dragged rotation can be readily identified after the preliminary tightening. Figure 175.1 Order of Bott Tightening 5) Lap gap of joint The member and splice plate or the mutually connected material pioces shall be attiched to exch other by means of tightening leaving no room for the lap joint, @) 1) Botesightening ‘The method of tightening bolts in a fietion grip joint is generally categorized into ‘the torque control method, angle control method and torque gradient control method, depending on the manner used to control the tightening bolt axial force. Considering the torque contol method, because the torque coefficient value is stipulated in the case where tightening is performed by rotating the mut, the bolt sightening shall generally be conducted by rotating the nt. When rotating the bolt head out of necessity due to the work procedure, itis nacessary to check the value =407-again. On the other hand, when the surfaceteated washer is used to decrease the torque coefficient value, care must be taken to use it on the side being rotated. ‘When using the torque control method, the tightening torque must be selected before ‘the work in order to achieve the bolt sxil foree that matches the work standard ‘mentioned in tem 3). When using the torque shear ype high strength bolt «special tghtener shall he adopted, The angle contro! method controls the bolt axial force arising from the tightening by the elongation of the bolt, and the elongation ofthe bolt appears asthe amount of aut rotation, The amount of nut rotation stipulated in item iv) has been determined in order to secure the standard bolt axial force and with an allowance forthe bolts clongation after fracture. When this rotational amount is given, the bolt axial force teaches the degree exceeding the yield point. However, based on the existing ‘experience and the results of @ numberof experiments!" is determined that such tightening is safe withthe BT bolt and therefor it is stipulted thatthe angle control thod can be wed. Moreover, since the under-head length ofthe bolt commonly used is five times its 4iameter oF less, the rotational angle in the ease of five times or less is stipulated. ‘When using the bolt longer than this, itis stipulated thatthe rotational amount is checked by means of preliminary test. Although the 1OT bolt shows deformation characteristics similar to those ofthe 8T bolt in the results of experiments, the angle control method is stipulated as being applied only tothe BT due to the lack of data on delayed fracture, Moreover, the bolt axial fore atthe start point of measuring the amount of rotation is important as well. “Therefore, the amount of rotation shall be measured on the ‘basis ofthe state of tightening with the assembly spannee with all one's might or by tightening with the impact wrench othe extent of giving the first impact so thatthe lap gap between the material pieces will disappear. ‘The torque gradient control method is tightening method where the management is performed by the tghtener capturing the property that the relationship between the introduced axial force atthe time of tightening the high stength bolt and the nut ‘tational amount becomes nonlinear neae the proof stress, whereby the prescribed axial force is introduced. Although the site management of this method is easy and ‘there is minimal variation inthe introduced axial fore, its introduced axial force is 4082 high compared to the torque control method. Therefore, the property of resistance to delayed fracture is enhanced by stipulating the chemical components, mechanical properties, etc, of the bol to be used more strictly than JIS B 1186, as shown in Section 63.2. This tightening method has numberof past records inthe Honshu- Shikoku Bridge ete." ‘When using the hammering type high strength bolts inthe beating connection, the hole diameter and the mismatch ofthe holes must be checked prior to tightening in order to prevent problems from taking place in the workability ofthe hammering-in (Gitfcuty level of hammering-in), Additionally, care mast be taken so thet no Iharmful flaws will be generated in the vicinity of the holes atthe time the bots are ‘bammered in, Calibration of Machinery and Devi ‘The calibration ofthe device mentioned here refers to periodic calibration, not daily on-site calibration, ‘The axial force meters consist of the type used to measure the axial force by the change of oil pressure and the load-cell type using a strain gauge. These meters rust always be in such a state that they can be used at the prescribed level of precision. Accordingly, itis necessary to check their precision prior to the site work by performing a calibration once immediately before delivery tothe site and then periodically afer that. Because the precision of the axial force meter is less affected by the handling than the torque wrench, etc, its periodic calibration can generally be performed once ina three-month period Moreover, the stiffness of the potion of the axial force meter tightened by the bots is not necessarily the same a the stiffness of the actual member. For this reason there are cases where there is some difference in the introduced bolt axial force hetween the tightening of the axial force meter and the tightening of the actual ‘member under the same output tongue. It is therefore desirable to use the axial force meter that possesses a degre of sess as close as possible to that of the actual member While there are several types of tonue wrenches~such as the one that reads the torgue with the seale ofa dial gauge, the one that reads the scale by the deflection of ‘the torque wrench, and the ratchet type—each type tends to give rise to regularities if handled roughly. Accordingly, it is advisable to conduct the calibration of a torque wrench onee at the time of delivery to the site and then generally once a 409 -» month after the delivery, or t determine the time of the periodic calibration separately depending on the frequency of usage. ‘The tightener has the electric motor type and hydraulic type. Since either has @ good ability to sustain tightening precision, their calibration may be performed once ‘before delivery tothe site andthe periodic calibration after the delivery can generally ‘be conducted once every three months. Since the tighlener whether eletrie motor type or hydraulic model is used in combination of the gun and control device or a Inydraulic pressure adjustment device, the periodic calibration shall be performed on ‘he combination. Moreover, inthe case ofthe torque control method, the precision of the output torque shall be calfbrated in several stages ofthe range of torque values, {In addition to the above-mentioned tghteners there isthe electrical torque controled impact wrench. However, because it presents difficulty in terms of fine adjustment and cannot easily sustain tightening precision, itis advisable not to use it for final tightening However, since the preliminary tightening does not require such a high tightening precision a torque controlled impact wrench with good operating efficiency may be used ‘The socket portion of the tightener of torque shear type high strength bolts consists of two sockets that hold a mut and a pinta espoctvely. tis system in which the ‘outer socket holds the nut and applies the tightening torque, while the inner socket holds the pintail and transfers the reaction force of the tightening torque, The sockets rotate in opposite directions relative to each othe, snd they continue to rotate ‘until the tightening torque reaches the fracture torgue of the facture groove to Because in this way the tightening torque is controlled by eutting the pital, the special tightener offers no funtion to control the tongue. It only provides the torque, s0 there is no need to calibrate it and consequently only the maintenance and inspection procedures need tbe performed. Tighening bolt axial force ‘The design bolt axil force of Table 17.5.2 is the bolt axial fore in design that is necessary to satay the prescribed allowable force, as mentioned in the commentary ‘of Section 3.23 (2) -410-In tightening the bolt, the tightening is performed in order to obtain the above- mentioned design bolt axial foree. However, taking into consideration further the effects of the variation ofthe torque coeicient, creep and relaxation, variation of slip coefficient, ete, the bolt axial force at the time of the work is generally stipulated to be 10 percent greater than the design bot axial force On the other hand, in the angle control method, the tightening bolt axial force is secured if the nut rotational amount stipulated in I) is provided. Inthe ease of the torque shear high strength bol, as stated in above-mentioned commentary, the tighlener possesses no control system but the tightening bolt axial foree equivalent to that of the high strength bolt for friction grip connection is secured by the bolt set. Additionally, while the tightening force is adjusted using the shove-mentioned devices in tightening the bolt, inthis instance one must pay attention tothe fact that the torque coefficient obtained on site is fundamentally different from the torque coefficient of the product in a factory stipulated in Section 6.3.2. When using the torque shear type high strength bolt, the tightener possesses no fanetion to contol the tone as was mentioned in the commentary of item 2), the tightening axa free varies depending onthe performance of the bolt. Therefore, it must be checked thatthe average value of the tightening bolt axial force atthe time of factory shipment flls within a certsin range and that the performance is ‘maintained from the ime of factory shipment to the time of work atthe site, For this reason it is necessary to check the performance ofthe bolts using Table 17.5.3 ‘before the bolls are tightened, Additionally, in the on-site test ofthe tightening axial force it is sometimes difficult to administer the test to the bots with every kind of under-hesd length due to the {unetional constraints on the inspection equipment to be used for the test. In this instance the performance ofthe bolts to be used may be guaranteed by selecting the bolts with the under-head lengths that can be tested from among the bolts with the same nominal diameter and delivered during the same period to the site from the same manufacturer as that ofthe bolts tobe used that have been kept under the same storage environment. This is done by condueting the tightening test on these bots and thus by verifying thatthe performance a the time of factory shipment has been maintained sine detivery to the site <4Because the torque coeficient value ofthe bolt changes according to temperature, the tightening bot axial force changes as well. When the test is conducted outside ‘the range of the normal temperature (0°C = 10°C, 30°C - 60°C), the range of the bolt axial force shown in Table C 175.1 shall be applied ‘Table C.17.5. Average Value of Tightening Bolt Axial Force Outside Range of ‘Normal Temperature (0°C:- 10°C, 30°C - 60°C) ‘Average val of ihaning bol al ors eee ‘Ofte set of oe prodaction kx RN) | 1er~2ii sioT 207~261 241~304 When tightening is performed through means ofthe torgue gradient contol method as wells necessary to check before the work is done, in accordance with the text, that the average value ofthe contol ction axial force of the tghtener falls with a certain range. Moreover, when itis difficult to perform the tightening axial force test on site, such as inthe case ofthe torque shear high strength bal, a test similar to that of the torque shear high strength bolt shall be conducted 4) Order of ightening ‘When the bolt axial force within a joint is uneven, the slip strength may decrease For that reason this item stipulates the provision to tighten the group of bots as evenly as possible. When the bolts are tightened fom the outer end of the join, the splice plate tends to be rsised, leading to poor contact density, so the hols shall be tightened from the center outward Generally, when the tightening is performed up to the required axial fore at one time, the bolts tightened earlier tend to become loose, so it is stipulated thatthe tightening is generlly tobe conducted in twice, Its advisable for the preliminary tightening to achieve approximately 60 percent of the tightening bolt axial free. (On the other hand, when the tightening is performed inthe besinning to the extent that the Lap gap i eliminated in the case of the angle control method, the tightening force becomes large enough to render unnecessary the secondary tightening as ‘mentioned above, 42-5). Lap gap of joint ‘This item stipulates the treatment used to suficiently transfer the stress due to the Fetion of respective material pieces constituting a member in the state in which the tightening is completed. The generation ofa lap gap inthe vicinity of @ bot hole prevents the transfer of stress 9 care must be taken not to generate such alap gap in tightening bots, When the lp gop is generated only in the edge portion away fom the bolt hole it cannot necessarily be sai that there isa problem in terms of stress transfer. However, even in sucha cas it is necessary to consider the resistance to rust and corrosion. The lap gap between material pieces occurs in such eases where thee is a difference in plate thickness or where there is inconsistency among members. The difference in plate thickness mentioned here is what arises from the plate thickness tolerance, $0 for the treatment tothe ease where members with diferent nominal plate thicknesses are splied, the design must consider measures such as eliminating the difference in plate thickness with the installation of a fll, Concerning the plate thickness tolerance, the tolerance increases asthe thickness ofthe stel increases, and there is ‘the possiblity that a lap gap may be generated after the tightening, Thus the ‘existence ofa lap gap must be checked atthe time ofthe preliminary tightening of a joint, and in the ease where the lap gap is expected to remain after the final tightening, appropriate treatments such as installing a filler plate and attaching a ‘taper to the material tobe tightened must be applied. ‘Conceming the inconsistency, itis difficult to remedy the inconsistency on site, ‘Therefore, i is important to pay attention to fabrication methods, et. atthe time of shop fabrication 50 that no inconsistency may arise, and when a temporary assembly is performed, iti important to check that there is no inconsistency, and to conduct appropriate repair when @ lap gap accompanying. the inconsistency is found, Additionally, when a splice plate is tightened in the state of inconsistency, careful ‘measures must be taken since thee are cases where harmful deformation occurs (0 the spice plate a31755 Inspection after completion of tightening (1) The bolt shall undergo inspection afer tightening t confirm that the presribed tightening has been performed. (2) In the ease of rejection in inspection, an appropriate treatment shall generally be applied in order to secure the prescribed quality. (@) When the provisions of items 1) and 2) are applied, the Clauses (1) and (2) may be ‘deemed to be satisfied. 1) The tightening inspection shall be performed immediately ater the bolt ightening 2). The inspection of the tightening axial force and the treatment in the case of rejection shall be performed as follows 5) In the case of the torque control method the tightening inspection shall be performed using a torque wrench on 10 percent of each group of bolts as the standard number of bolts. For acceptance erteria in this instance, when the tightening tomue value is within + 10 percent ofthe tonue value stipulated at the time of calibration, it shall pss the test. Concerning the rejected group of bolts, double the numberof bolts shall be picked up for re-inspeetion, and inthe case of rejection inthe e-inspection the entre number of bolts shal be inspected. Those bolts whose tightening torque is below the presribed tightening torque shall be further tightened (© the presribed torque, and those bolts whose tightening torque is more than 10 percent above the prescribed tightening torque shall he replaced with new bolt sets for retightening. li) Im the case of the torshear type high strength bolt, the check of the pin tail severance ad the appearance inspection by marking shall be conducted. When a skipped tightening is identified, tightening shall be performed, and ‘when 2 simultaneous rotation is recognized it shall be replaced with a new bolt set forretightening. fil) Inthe case of the tur-of-nut method, the appearance inspection by marking shall be conducted for the whole number, and it shall be confirmed that the tightening rotational angle i within the range stipulated in Section 17.54 ‘Those lacking in the rotational angle shall be further tightened tothe prescribed rotational angle. Those with an excessive rotational angle shall be replaced With anew bot st for retightening. 414iv) In the case of the torque gradient control method, the appearance inspection by marking shall be conducted for the entire number, and the rotational angle arising ftom the slippage between the bolt and marking shall be measured on five bolts randomly selected from each bolt group, and it shall be confirmed that the whole number ofa group of bolts is within the range of $30 degrees of the average value. Inthe case the range of $30 degrees is exceeded, a replacement ‘ith a new bolt set shall be performed for reightening (@) This clause stipulates the inspection methods after the bolt tightening as well as judgments by the inspection methods. 1) In the case ofthe torque contol method, the torque coefficient value changes when left unattended for along time after tightening, so the inspection shall generally be performed immediately after tightening 2) The tightening inspection on the bolts tightened by means of the torque-control ‘method shall be conducted on the standard number of 10 percent of each bolt eroup using @ torque wrench whose precision bas been checked in the periodic calibration The inspection bolt shall be further tightened with th torque wrench, and the torque value atthe time when the nut begins to rotate shall be st as the tightening torque ‘When this torque value is within the range of #10 percent of the torque value stipulated at the time of calibration, the bolt shall be determined to have passed the tes. ‘The phrase “each bolt group” mentioned here refer to a series of bolt groups when the bolts with the same size are tightened on the same day with the same tightening device. These groups may be generally considered fo refer to the bolt groups within the respective material pieces such as flanges and webs that constitute the cxoss- section ofa member. Tn the inspection after the tightening ofthe trshear type high strength bolt, it can be ‘considered that an appropiate tightening has been performed when the pin tail is severed, so the check of the severance of the pin tall and the inspection of the Simultaneous rotation by marking may be conducted. “The bot ightened by the tum-of-ut method or torque gradient control method may be inspected by marking to sce whether it possesses the prescribed rotational angle or not. In the case ofthe torque gradient control method, inorder to confirm that there jis no variation among the rotational angles in each group, it is stipulated that i is oais-confirmed by an inspection thet the rotational angles are within the prescribed range agains the average value ofthe rotational angles ofthe bots tightened normally 17.6 Work of welding and high strength bolt fiction connection atthe same time in ‘member mainly receiving bending moment ———E (2) When the welding and the high strength bolt fition connection ae usd atthe same time {inthe cross section ofa joint in a member that mainly receives the bending moment, the ‘work shall generally be performed in such a way thatthe restaint on the welding is reduced and the strength does not decrease following the welding deformation @ @) When welding and high strength bolt fetion connection are respectively used in the lange portion and web plate portion that mainly receive the bending. moment, the high strength bolt shall generally be tightened after the completion of welding, However, | ‘when the weld is applied tothe upper Mange ofthe girder withthe I section or box section | and the high strength bolt connection is applied to the web plate and lower flange, the bot ofthe eb plate inthe vicinity of the lower flange and the bolt of the lower flange ‘When the provision of Clause (3) is applied, Cause (1) may be deemed tobe satisfied. ‘may be tightened before the upper flange is welded © “This text stipulates the work procedure when the join in which the flange is made to be a Dutt joint and the web plate and rib are made to be a fiction grip connection joint is adopted within a erss section in the member that mainly receives the bending moment of girder withthe I section, the box section andthe like @ Although, ftom the standpoint of reducing the deformation accompanying the welding, there is an argument that bolt tightening should be performed first, the tightening ofthe bolt is stipulated to be performed generally after the welding in order to reduce the restraint on the weld and to prevent the decrease inthe slip strength due o deformation following the welding. In this instance there are cases where the misalignment of the bolt hole location between the connecting plate and the base material the camber change ofthe girder, te, may arise ftom the deformation accompanying the weld shrinkage. Therefore, consideration shall generally be made in advance at the time of design regarding the effect ofthe weld deformation, and if necessary measures suchas the use of an enlseged hole shall be taken ‘When the welding is performed after the high strength bolt is tightened the internal stress is introduced to the joint portion due to the fact thatthe shrinkage deformation om welding is restrained, and depending on the welding condition and the extent of the 416.restrain, a erack may be generated in the welded portion. Moreover, the partial sip and local out-of plane deformation may arse inthe portion ofthe joint with the high strength bolt tightened prior to welding [Not enough has been clarified regarding the stength of the joint to which the internal stress has been introduced or regarding the strength where partial slippage-bas taken place. ‘Therefore, in adopting a work procedure like this itis necessary to carefully investigate the mechanical bchavior ofthe joint though analysis experimentation using large-size test pieces, and it shall not be adopted lightly. Moreover, because problems as mentioned above may arse when a bolt joints temporarily tightened before welding in order to secure the groove precision and member form, sufficient consideration shall _geneally be given regarding the extent of tightening axial force andthe tightening aa at the time ofthe temporary tightening. Generally, the tightening axial force of bot at the time of temporary tightening shall be approximately that of preiminary tightening, and the final tightening shall not be performed. Moreover, the area of the temporary ‘tightening shall be determined in such a way that te deformation accompanying welding i not restrained, and the high strength bolt that is temporarily tightened shall be replaced after welding wit a new bol for final ightening. When welding is applied tothe upper Mange (including the orthotropic steel deck) and high stength bok fiction connection is applied to the web plate and lower flange in a ‘common stel girder with an I section or box section, experience to date has confirmed that when the lower Mlange and the web plate in its vicinity are tightened prior to the ‘welding ofthe upper lange, thatthe effet of the restraint willbe small. Therefore, in the work of such ajoin itis stipulated that she lower lange and the high strength bot in the vicinity ofthe lower flange may be tightened prior tothe welding ofthe upper Mange. ‘Moreover, the web plate portion in the vicinity of the lower flange may be considered as the area below the neutral axis of the member and approximately one-third the height of the web plate. ‘Concerning the ease of the joint where welding is applied to the upper and lower flange ‘and high stength bot fiction connection is applied tothe web plat, andthe case of the joint where high strength bolt ition connection is applied to the flange portion and ‘welding is applied to the web plate, there have been not many usage record for them and ‘rious points about their work procedure have not been known, Therefore in the work ‘of such a joint, sufficient consideration shall generally be made in advance regarding the effet ofthe work method on the performance of joint, -417-1747 Breeton 177.1 Work basie [Eretion shall generally be performed in accordance with the erection method and erection sequence that are the premises of design, When the method differing from the erection ‘method or erection sequence considered at the lime of design ie used, the stess and ‘deformation during erction shall generally be considered anew, and its safety shall be checked. ‘he erection of a steel bridge shall generally be performed by the erection work that was sssumed at the time of design, Depending on the various erection methods, the same structure will have different dead load stresses arising from the steel dead load. Among the ‘2008 examples are erection by the bent method, erection bythe eantilever erection method. ‘and erection by the lauching method, Therefore, in making an erection plan, considering the design caleulation sheet of the main body and understanding on what assumptions the dead Toad stress arising from the steel dead load has been calculated, one shall carry out the erection workin such a way that no erection stress that i not considered inthe design is left ‘once the erection i complete. Given the use of an erection method fering from the one assumed in design, & larze Aiference will arise in the deformation of the bridge body when the dead load stress from the stool dead load varies significantly, and this may lead toa situation in which the closure af the last member eannot be performed. When such # method neods to be adopted out of necessity, the stress of the bride body during erection and at te time of completion shall be verified in sdvance, safety shall be confirmed, and the closure of the member shall be performed by ‘concomitantly using the metho, et. of moving up and down te bearing, among others. Aitionally, when pavement is placed on the orthotropic steel dec, the effets arising due to the fat thatthe members become hot and the fact hat the temperature ofthe members differs ‘extremely, ete, may sometimes be generated, In such cases as well, if necessary, the saety inthe effect on each part of the bridge shall generally be confirmed in advance 41817.7.2. Confirmation of erection location (1) Im the erection of a steel bridge, the total structure shall generally be erected on the prescribed location and height onthe substructure (@) When all the supports ofthe superstructure are erected on the prescribed locations and Ineights, Clause (1) may be deemed to be satistid ‘These are the most important items in determining the completed form of the superstructure of a bridge. To properly work on the height and plane figure of the road surface, it is presumed thatthe supports of the main girder or the main structure are erected atthe proper locations. The finished work of the substructure shall generally be messured prior to the ‘erection, and when there are errors exceeding the allowable values countermeasures shall enerally be taken before the work of erecting the superstructure is performed, 17.73 Ensuring the quality of erection member (1) The prescribed quality ofthe members that have been received onsite shall generally be ‘maintained until the completion of erection (@) When the provisions of tems 1) to 4) are applied in terms of the temporary storage and assembly ofthe members, Clause (1) may be deemed to he satitie, 1) The members shall be kept from the ground and shall be suiciently protected so that ro damage by the fall fom the temporary storage table or by touching other ‘members and the like may arse, 2) The long chord and diagonal members shall be sufficiently supported so that they will receive no damage due to stack placement. 3) When the temporary storage lasts a long time, appropriate measures to prevent

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