Quality Criteria and Inspection Standards ‘THIRD EDITION S eT0/TOOR American Institute of Steel Construction ‘One East Wacker Drive, Suite 3100 Abtenns tert maaee neeCopyright © 1988 by American Institute of Steel Construction, Inc. All rights reserved. This book or any part thereof ‘must not be reproduced in any form without the written permission of the publisher. Preface Since its founding in 1921, the American Institute of Steel Construction, Inc. has improved and advanced the use of fabricated structural steel through re- search and development, engineering, and promotion. ‘The American Institute of Steel Construction, the American Welding So- siety, the American Society for Testing and Materials, the Steel Structures Painting Council, the American Association of State Highway and Transporta- Officials and other organizations publish specifications that provide a prac. tical basis for quality standards necessary to meet the industry objective of providing serviceable structures. These commonly accepted standards for fabricated structural steel framing provide satisfactory criteria for workman- ship, fit and appearance, at minimum cost, for the vast majority of buildings and bridges. More restrictive tolerances, while sometimes justified by special ‘conditions of usage, can significantly increase the cost of fabrication. Accuracy ‘or perfection of finish that serves no useful function increases the cost, but not the quality, of steel framing. Yva ef :60 9002/92/80 This commentary has been prepared by the AISC Committee on Fabricat- ing Operations and Standards for owners, architects, engineers and inspectors who may not be familiar with the techniques and tolerances of standard stee! fabricating practice, nor with the economic effect of special workmanship re- quirements. It discusses some common problems and conflicts of interpretation ‘of standards involving fabricating tolerances and procedures and provides AISC recommendations for their clarification and resolution. This Quality Cri. teria and Inspection Standard should be used with existing specifications and codes to advance the twin goals of achieving serviceability and cost effective- ness of steel structures. ‘Owners, architects, engineets, inspection agencies, testing laboratories, steel fabricators and erectors are urged to submit recommendations and com. ments to the American Institute of Steel Construction for improvement in this standard, which will be periodically updated to permit full utilization of ad~ vances in engineering design and industry capability. ‘While every precaution has been taken to insure that all data and informa- presented is as accurate as possible, the Institute cannot assume responsi- bility for errors or oversights in the information published herein, the use of the information published or incorporation of such information in the prepara are recommen- applications of specific design Fecommendations applicable to a specific problem under the competent super. eT0/z008)Table of Contents rapter 1 — Preparation of Materials . vapter 2 — Fitting and Fastening .. tapter 3 — Dimensional Tolerances rapter 4 — Welding tapter 5 — Surface Preparation and Painting .. apter 6 — Non-destructive Exami lapter 7 — Special Fabrication Problems Page 13 19 3 41 \ 1 1 ' 1 ' 1 I! 1 ) Preparation of Material» § CHAPTER 1 Preparation of Material I. INTRODUCTION This chapter covers specific problem areas encountered in material prepara- tion, and makes recommendations for updating and clarifying applicable criteria, ‘The ASTM AG specification governs the delivery requirements for steels, provides for dimensional tolerances, delineates the quality requirements and outlines the type of mill conditioning. Material used for structural applications is usually furnished in the as rolled condition. The engineer should recognize that surface imperfections (seams, scebs, ete) acceptable under A6 may be present on the material re- ceived at the fabricating shop. Special surface finish quality, when needed in as-rolled products, should be specified in information furnished to bidders. ‘The commentary includes discussions and recommendations for work re- quired on material which does not meet the provisions of ASTM AG, or the Necessary work required to adjust the material to specified tolerances which are more restrictive than ASTM A6, It also includes preliminary fabrication operations of identification and cutting of stock material 1, MILL MATERIAL ‘A. Camber, flatness, straightness, sweep, crass section Permissible variations for steel as received from the rolling mill are established by ASTM A6. These standard tolerances have been developed historically and define the acceptable limits of variation from theoretical dimension, camber, ross section, flatness, straightness or sweep for tolled sections prior to fabrica’ tion, Standard design practice should always allow and accept these structurally acceptable variations, unless bid documents specifically restrict them. When job specifications require more restrictive tolerances than allowed by ASTM A6, or when material received from the mill does not conform to the requirements of A6, the acceptability of methods available to the fabricator for adjusting these conditions is sometimes subject to varying interpretation. Yyva 08:60 9002/92/80 eT0/c008)+l Oteny ieee dnspenen Handrne | ' aD 1 AISC Recommendation: The fabricator shall be allowed to use controlled heating, mechanical straightening, or a combination of both methods, consistent with manufacturer recommendations, to adjust camber, cross section, flatness, straightness or sweep if: (1) The material as received from the mill does not meet ASTM A6 permissible variations, or (2) The specified tolerances are more restrictive than ASTM AG, B. Surface condition ASTM A6 defines permissible variations in the surface condition of structural steel plates and shapes as they are produced at the rolling mill, and specifies corrective reconditioning procedures that the mill producer may perform be- fore shipment to the steel fabricator. The surface reconditioning limitations of ‘AG are intended to apply only to operations performed at the rolling mill. They are not intended to apply to surface reconditioning or repairs in the shop of the steel fabricator, where qualified welders and special equipment are available, and where surface variations or defects exceeding those permitted in A6 can be repaired satisfactorily. It should be remembered material purchased to meet the requirements of ASTM A6 is subject to acceptance or rejection on the basis of visual inspection at the mill and at the time of receipt by the fabricator, Occasional surface imperfections will appear after fabrication and blast cleaning that were not visible beforehand. Because of the higher finishing tem- peratures and special problems of producing heavyweight cross sections, and the inherent surface finish problems associated with certain steel chemistries (e.g, ASTM A588 weathering steels), the finish of these materials cannot be expected to be as fine as thinner materials, materials of other chemistries or 1. Any special requirements, re restrictive tol lace. condone thn thaw peri by _ASTM AG, stipulated in the contract an 2. Corrective procedures described in ASTM A6, Sect. 9, for recondi- tioning the surface of structural steel plates and shapes before ship- ment from the producing mill may be performed by the fabricator, at his option, when variations described in A6 are discovered or occur after receipt of the material frfm the rolling mill, When surface variations are discovered or occur after receipt of the ‘material from the rolling mill, which exceed those permitted in ASTM ‘A6 and require repair by welding, the reconditioning or repair may be performed by the fabricator, provided the work is done by qualified welders and by welding procedures appropriate to the material being repaired. } i } Preperation of Material © 7 92/80 Surface variations discovered, or which occur after receipt of the ma terial from the rolling mill, or surface imperfections discovered after biast cleaning which are determined to be non-detrimental to the ‘strength of the member, need not be repaired or removed for cosmetic & reasons, unless otherwise specifically stated within the contract docu- = ments. Responsibility for such repairs should be a contractual agree- = ment, clearly understood by all parties involved, including the general & contractor (owner), fabricator, erector and painter. 4, Surface imperfections inherent in heavyweight sections and weather- ing steel which are parallel to the line of stress and not detrimental to the end use of the member, should be acceptable. The surface may ap- pear mottled, pockmarked, pitted, with washboard ridges or with alligatoring, etc. However, if these imperfections are detrimental to isintended service they maybe repaired bythe fabricator by gin or welding, C. Edge discontinuities - Article 3.2.3 of AWS D1.1 provides criteria for inspection and repair of cut edges of plates, when the edges are prepared for deposition of weld metal ‘These criteria were developed on the basis of the effect of discontinuities, zen- erally parallel to the applied stress, on the soundness of the welded joints. Often, criteria are needed for evaluating discontinuities discovered dur- ing fabrication on cut and rolled edges other than those being prepared for welding. AISC Recommendation: Article 3.2.3 of AWS D1. 1 is reasonable and workable and should be fol- lowed for cut edges of plates or shapes, when the edges are prepared for welding, For cut-rolled edges that are not prepared for welding, the criteria for in- spection and repair depend on whether the member is considered to be Uy, ically loaded or statically loaded: Bridges (dynamically loaded) structures: ‘The criteria of AWS Art. 3.2.3 shall be applicable, except as modified by the following: 1. With the approval of the purchaser, discontinuities need not be ex- plored to a depth greater than | in. When depth of discontinuities ex- ceed 1 in., the discontinuity shall be gouged out to a depth of 1 in, and repaired by disposition of weld metal to form a block-off. 2. For discontinuities over 1 in. in length, with depth more than % in., ‘but not greater than 1 in., the discontinuity shall be removed and re. S paired, but no single repair shall exceed 20% of the length of the edge being repaired. & oR[Om fiver’ rspes—amee Buildings (statically loaded) structures: 1. In statically Joaded structures, more liberal criteria may be accept able. 2. In the event there is a need for more restrictive permissible edge dis- continuities in plate, such as in loading applied perpendicular to the thickness, the bidding documents must specify clearly the limit of such edge discontinuities. ‘The repair procedure to be used will be subject to the owner’s or architect/engineer’s approval. >. Internal exploration Decasionally, severe service conditions may make desirable a non-destructive “xploration to verify a high degree of soundness of the parent material. Ultra- ‘onic inspection techniques are suitable for such investigation; however, stan lard criteria for such investigations do not exist. AISC Recommendation: In the event non-destructive inspection of internal soundness of material ‘stequired by the bid documents, a clear set of acceptance criteria and a defini- ion of the areas to be tested shall be included in the specifications, If no acceptance criteria are specified, acceptance criteria applied shall not sxceed that permitted in ASTM A435. In undefined areas, no exploration is te- wired. ‘W. FABRICATED MATERIAL \cgittermal-cut edge roughness Thermal cutting (oxygen, arc, etc.) is a common method for cutting steel. In- idvertent notches or gouges of varying magnitude may occur in thermal-cut sdges, depending on the cleanliness of the material surface, the adjustment ind manipulation of the cutting head and various other factors AWS DL, Art. 3.2.2, specifies tolerances for such imperfections in sur- aces upon which weld is tobe deposited and stipulates the methods to be used or correcting defects of various magnitudes. However, the AWS requirements ‘ometimes are impractical for other thermal cut edges and do not take into a¢- ‘ount the end use of the product or the cost of the required procedures AISC Recommendation: 1. Structural steel may be cut by any of the acceptable thermal pro- cesses, either by hand or mechanically guided means, Except for cuts, copes, blocks, holes other than fastener holes and similar cuts where ‘machine guided cutting is not feasible, thermal cutting shall prefera- bly be done by machine. 2. Thermal-cut edges shall conform to the following requirements for surface condition: 1 : 1 I ' | Prep wb of on a. If subject to design tensile stress, edges shall, in general, have a surface roughness value not exceeding 1,000, as defined in ANSI ASME B46.1-1985. 'b. Machine-guided thermal-cut edges not subject to design tensile stress shall have a surface roughness value not exceeding 2,000, as, defined in ANSVASME B46,1-1985. ¢. Hand-guided thermal-cut edges not subject to design tensile stress shall have a roughness not exceeding 1/16 i 4. All thermal-cut edges shall be free of notches” and reasonably free of geluges:** Occasional gouges not more. be pertilted. Gouges great than 376 PLT ee re - 3. Roughness exceeding the criteria in Paragraph 2 above, and notches not more than 3/16 in, deep, may be removed by machining or grind- ing and fairing in at a slope not exceeding 1:24 4. Notches or gouges greater than 3/16 in. deep may be repaired by weld- ing, providing: 1, The bid document does not require specifically the approval of the engineer for such repair. b, The discontinuity is suitably prepared for good welding. . The welding is performed with low-hydrogen electrodes not ex- ceeding 5/32 in. diameter. 4. The other applicable welding requirements of AWS DI.1 are observed, . The repair is made flush with the adjacent surface in a workman- like manner. f. The repair is inspected to assure soundness. 5. Reentrant corners shall provide a smooth transition between adjacent surfaces, but need not be cut to a circular profile. Correction criteria of paragraphs 3 and 4 above shall apply. NB. Heat straightening, curving and cambering The application of controlled localized heat for straightening, curving or cam- bering structural steel members sometimes is denied arbitrarily the fabricator, despite sufficient experience and evidence to justify it use. AWS, DI.1, Art. 3.7.3, permits heat straightening of members distorted by welding and stipulates rules for this procedure. These rules are equally ap- plicable for all heat straightening or curving Defined as a V-shaped indentation or hollow **Defined as a groove or cavity having a curved shape 1002/82/80 eT0/c00R)| Guene Citera and dnspection ftandao4- 5 1 ' 1 1 ) AISC Recommendation: Both AWS D1.1 Art, 3.7.3 and AISC Stecl Construction Manual Sect. 6 ermit heat straightening of members distorted by welding and stipulate rules x this procedure. These rules are applicable equally to heat straightening, eat curving or heat forming, and the process shall not be denied the fabri ator, In addition, since the maximum temperature permitted by AWS D1.1 is low any critical metallurgical temperature for the material being heated, use compressed air, water mist or a combination thereof may be used to acceler. te the final cooling of the heated material, unless prohibited specifically in the id documents, For bridge work, such accelerated cooling shall not be com: ‘enced until the temperature has dropped below 600°F. Traceability or identification of material asicaly, identification implies the ability to determine that the specified mate- al grade and size is being used; traceability implies a responsibility for being dle to identify a specific piece of sel in a structure for the life of the structure ith regard to source, material specification designation, heat number and spe- fic material test report. Because traceability systems are significantly more expensive than identifi- ttion systems, the owner should understand clearly the difference between the ‘stems, their limitations and their relative costs. AISC Recommendation: 1. Identification system: The AISC Specification requires that the fabricator shall be able to demonstrate, by written procedure and by actual practice, a method ‘of getting the right material in the right place, through the “fit-up” op- eration, for the main stress-carrying elements of a shipping piece ‘The identification method shall be capable of verifying proper mate- tial application as it relates to: a. Material specification designation b, Heat number, if required © Material test reports for special requirements, if required 2. Traceability system: Traceability is not required by the AISC Specification. In the event the owner requires traceability, the requirement must be clearly speci- fied in the bid documents. Elements of traceability which have significant impact on cost, and which therefore should be selected only as needed, are: a. Lot vs, piece traceability b. Main material vs. all material traceability ©. Consumables traceability 4. Record retention: what, who, how, when, where €. System record retention: foolproof vs. fraud proof I 1 Prep lof dat ) D. Sawing Equipment ‘The AISC Specification for the Design Fabrication and Erection of Struct Steel for Buildings in Sect. 1.23, Fabrication, states that compression j which depend on contact bearing shall have the bearing surfaces o fabricated pieces prepared to a common plane by milling, sawing or other suit- able mears. Likewise, the AISC Code of Standard Practice in Sect. 6, Fabrica: © tion and Delivery, states any fabricating technique such as friction sawing, cold #! sawing, milling ete. that produces a finish having a maximum ANSI roughness ~~ value of 500 for surfaces noted as “finished” on drawings may be used. = AISC Recommendation: State-of-the-art, cold-sawing equipment produces cuts more than satisfac- lieu of “milling.” Therefore, cold sawing should be allowed in lieu of if as generally specified by engineers and as contained in the AISC Speci Jication and Code of Standard Practice. eT0/9008)“terns with a high des ' I 1 ' ' 1 Frain, Foster. 113 CHAPTER 2 Fitting and Fastening 1. INTRODUCTION In this commentary, fitting is defined as the positioning of the component parts of the total fabricated piece, including shop assembly of main members (fre quently required in the fabrication of structural steel for bridges). Fastening is defined as the bolting or riveting of these component parts to form the total ‘member. Connection by welding is discussed in Chapter 4. Fastening with high-strength bolts is covered by the Specification for Siruc- tural Joints Using ASTM A325 or A490 Bolis, approved by the Research Coun- cil on Structural Connections of the Engineering Foundation; although document is generally workable, it does not presently incorporate provisions {for clarifying certain misunderstandings which occur in current installation and inspection procedures. This commentary will discuss specific problem areas encountered in fitting and fastening, with recommendations for updating and clarifying criteria for fastening with bolts or rivets. I, FITTING A. Requirement for shop assembly Many modern punches and drills consistently produce and duplicate hole pat- of dimensional accuracy. Some specifications fail to recognize this capability and stil require matching hole patterns be produced by drilling or reaming chrough a steel template. AISC Recommendation: In lieu of template, or assembly drilling or reaming, the fabricator shall be allowed to demonstrate his capability to fabricate component structural mem bers to the tolerance and accuracy specified so that further shop assembly to as- sure proper fit and alignment would be an unnecessary requirement. Responsi- bility for final fit stll rests with the fabricator. ‘The 1983 AASHTO Standard Specifications for Highway Bridges, Arts. 2.10.10.13 and 2.10.14 FI, sustains this recommendation, ‘Squareness of connection attachments . Projecting elements of high-strength-bolted, slip-critical connection attach- ments, such as clip angles or end plates, often are not flat in the connecting va 28:60 9002/92/80 eT0/2008)JOuat “feria "popeer” “nda” 1 I ine because of profile variations due to the mill as-rolled tolerances or from 1d distortion. For example, in clip-angle construction, the outstanding legs the clip angles frequently tend to bend back toward the centerline of the an, The full slip resistance value of the total number of bolts will be devel- ed, regardless of the initial position of the projecting elements of the connec- 1, if the following conditions are met: (1) Some part of the connection is in tact with the support before the bolts are tightened, (2) The bolts are prop- y tensioned and (3) The faying surfaces come into contact at the bolts within > area of the bolt head or nut (see Fig. FFI). Figure FF AISC Recommendation: The fabricator shall not be required to straighten connection attachments the plane of connection, if he can demonstrate in the shop that high-strength its, properly tensioned, will provide contact between faying surfaces when italied in the Geld See also Sect. 6.3.1 of the AISC Code of Standard Practice (9/1/86). Crimped stiffeners though there is no structural reason for requiring that girder stiffeners be rmped instead of straight, bid documents sometimes still require erimped ffeners for riveted girders, AISC Recommendation: ‘Where crimped stiffeners for riveted girders are called for on design draw- 38, the fabricator shall have the option of using straight stiffeners with fil ates. Fitting aid welds and tack welds tuctural fabrication involves the use of temporary fitting aids attached by Iding, as well as tack welds which are, in some cases, not incorporated into manent welds. Questions sometimes arise as to the need to femove such ds, 1 I It ' ' Lint Fran 1s 18, AISC Recommendation: AWS D1.1 Arts. 3.3.7 (Tack Welds), 8.14 (Temporary Welds—Buildings) and 9.24 (Temporary Welds—Bridges) adequately address the disposition of fitting aid welds and tack welds not incorporated into permanent welds. When such welds are made they should be in full accordance with AWS Di.1 and these articles. Generally, they require such welds to be removed on bridge (dy- namically loaded) structures, but permit them to remain on building (statically loaded) structures, unless provided otherwise in contract documents, Welds not made in accordance with the provisions of AWS D1LI shall not be permitted. II], FASTENING A, Rivet heads Specifications often contain vague terms to define the acceptability of rivet heads, such as “badly iormed” and “otherwise defective,” which leave consi erable room for subjective interpretation. AISC Recommendation. Not more than 20% of the rivet heads in any member shail have variations beyond the limits in Table FF-1, except all rivet heads in any member may have full or partial collaring, up to and including 3/32 in., measured radially B. Quality of high-strength bolts, nuts and washers, ‘The manufacturing quality requirements for high-strength bolts, nuts and washers are adequately covered in the Standard Specifications for High ‘Strength Bolts for Structural Sieel Joints, ASTM A325, Standard Specification for Heat-treated Steel Structural Bolts, 150 ksi Minimum Tensile Strength, ‘ASTM A490, Standard Specifications for Carbon and Alloy Sieel Nuts, ASTM. ‘A363, and Standard Specifications for Hardened Steel Washers, ASTM F436. ‘Sometimes, the owner or his representative arbitrarily applies acceptability requirements other than those of the ASTM specifications. AISC Recommendation: ASTM A325 and A490 bolts, nuts and washers shall be accepted, based on the criteria of the applicable ASTM specifications. Additional requirements shall not be imposed upon the fabricator or erccto. C. Tightening of high-strength bolts The RCSC Specification for Structural Joints Using ASTM A325 and A490 Bolts includes provisions for tightening high-strength bolts by turn-of-nut method, with calibrated wrenches, alternate fastener designs, or by load- dicating devices. Use of these procedures will produce properly tensioned bolts. However, tightening by the calibrated wrench method gives less con- tent results, due to variations in air pressure, humidity, lubrication and other factors. This tightening method is subject to more variation than the turn-of-nut method, alternate fastener designs or direct tension indicators. yva €8:60 9002/92/80vob Quay Ever unk Ieper Stanaeas | Dest eee AISC Recommendation: To provide maximum consistency in the tightness of high-strength-bolted joimts, it is recommended the turn-of-nut method, alternate fastener designs (ditect tension indicator bolts) or load indicating devices be used in preference to the calibrated wrench method. In addition, regardless of the method used, tightening of the bolts in a joint should commence at the most rigidly fixed or stiffest point and should progress toward the free edges, both in the initial snugging up and in the final tightening. Table FF-1 Condition Acceptable Limits Jockey cap cA re rot LOL Slee © Head ot 4 BS be snark Burst or crack y ed a Sew Indents [Y_L® Heumerence at ab max. coptn = © a ean cota EF Shon 1 ! I \ a d D. Inspection torque wrenches Inspection torque wrenches have been widely accepted as the proper measur-® ing instruments for checking tightness of bolts when disputes must be arbi- = trated, However, as a simplification, so-called “approximate equivalent torque = values” for inspection wrenches are sometimes used as a measure of bolt tight- ness. Such values do not take into account varying conditions of bolt installa: tion and, therefore, have no relationship to bolt performance. 2 z/80 i AISC Recommendation: The use of any so-called “approximate equivalent torque values” for in- spection torque wrenches shall be prohibited. The provisions of Sect. 9 of the RCSC Specification for Structural Joinis Using ASTM A325 or A490 Bolts, which clearly defines the inspection procedures and determination of “inspec- tion torque” to be used, shall be followed, Reference should also be made to Sects. C8 and C9 of the Commentary of the above specification. Ya E. Reuse of high-strength bolts Section 8{e) of the 1985 RCSC specification permits the reuse of A325 bolts, if approved by the engineer responsible, but prohibits the reuse of A490 and gal- vanized A325 bolts. However, “reuse” is not defined clearly and is subject to misunderstanding. AISC Recommendation: A325 bolts (except if galvanized) shall be considered satisfactory for reuse regardless of previous use, if the nuts can be placed on the threads and run down the full length of the thread by hand. ‘A490 bolts and galvanized A325 bolts shail not be reused if they have once been tightened by the procedures approved in Sect. 8 of the RCSC specifica tion, As stipulated in Sect. 8(c) of the RCSC specification, retightening previ ously tightened bolts which may have been loosened by the tightening of adja cent bolts shall not te considered as reuse. A325 and A490 bolts used for fitup bolts may be left in place and subse quently tightened as the permanent bolts in @ connection, since fit-up bolts are not tightened to specified minimum tension. F. High-strength belt thread engagement and stick-through. The allowable (maximum or minimum) amount of high-strength bolt stick through beyond the nut is subject to many interpretations, due to permissible ‘manufacturing variables of material thicknesses, washer thicknesses and bol lengths. AISC Recommendation: . The 1985 RCSC Specification and its Commentary cover adequately th requirements for bolt stick-through. 10/6008)J ric pan Si I, COMPLETED STRUCTURE TOLERANCES A. Establishing member working lines Deviations from true straightness and dimension of individual members, within AISC acceptable tolerances, may be compensated for during erection, because of the flexibility of the members relative to the total frame of which they are el- ‘ements. In some structures using heavy rigid cross sections, the stiffness of the member may preclude any adjustment of camber or sweep which, although within allowable limits, can prevent tight ft-up connections. This situation frequently occurs in multistory building columns and may cause difficulty in erecting the floor framing members. Normal detailing prac- tices may compensate in part for this problem; however, special shop layout practices are essential for heavy, rigid framing, AISC Recommendation: ‘To compensate for allowable camber or sweep in heavy rigid framing, spe- cial shop layout techniques to establish straight theoretical working lines be- tween member ends as defined by AISC Code of Standard Practice (9/1/86) 7.11.2(4) should be used. B. Accumulation of individual member tolerances While individual member tolerances are usually self-compensating and of minor significance in the overall structure, the possibility exists these toler- lances may accumulate and lead to misalignments that are difficult to correct in the field, Asan example of the effect individual member tolerance may have on the total structure, consider the tolerances on columns and beams, Figure DT-1 shows individual column and beam members with their respective permissible tolerances. These tolerances come from several sources: ASTM, A6 and AWS D1.1 specify permissible camber and sweep: AISC specifies the permissible variation from detail length for members framed to other steel parts; Fig. 1 of the commentary on the AISC Code of Standard Practice (9/1/86) illustrates mill tolerances on cross-sectional dimensions. Figure DT-2 illustrates a case where individual members fabricated within permissible tolerances could make it impossible to erect a heavy two-story col- ‘umn within the allowable plumbness tolerance of + 1:500, or 0.72 in., for a 30 ft long column. Although the condition shown would be unusual, and is the worst that could occur ifall permissible member tolerances accumuiated in one direction, leading to an unworkable situation, itis evident the accumulation of tolerances is a real problem requiring special consideration. Special detailing, fabrication and erection techniques may be used to minimize the effects, but details for material supported by the steel framing must provide for toler- ances. Other possible examples are: end-plate connections to columns, framing- angle connections to columns, attached shelf or spandrel angles and other simi- lar conditions. | Shimerounid Toten! + 21 Derail dimension #%’when L £ 30-0 Detail dimension #8 when Detail Dimension ?& when L >30%0 Actual ¢ i ip feotegts pe pen goto 2 Baer epee || ae dine ig. DT-1. AISC fabscaton tolerances for bets and columns va p$:60 9002/92/80 eTO/0TORFt 7 fle” yond = tion yds I ' 1 Permissible out- Plumb line © * 300) Working tine Plumb line Actuot out-of - plumb, if” a (E+ U Actuot € 1 lax? Actual ¢ Actual ¢ i ¢.foc. Working line ‘er Detail dim.+ (frye FF) 2 ‘col. mbar) eee are detail dim. +e Working Wi Fig. OT-2, Possible effect of accumulation of allowable member tolerances ‘when delais ae located from actual centeines ' i ' I Dime Ton b+ 2 ) AISC Recommendatic The use of oversized holes, short-slotted holes and long-slotted holes, as® provided for by the AISC Specification, isa satisfactory method for achieving S erection within tolerances (see Figs. D1-3 and DT-4). Finger shims, shop lay. $ ut to working lines and recogniti details for collateral material, such as stonework, etc., are also satisfactory methods. 8 The + 1/16 in. tolerance, where applicable on overall length of members ®1 framed to other steel parts, or the 1/16 in. clearance on size of standard holes, = shall not be construed as implying that the tolerance = 1/16 in, also applies to= the maximum tolerance on hole location within a pattern of holes, the position of intermediate connections, the position of intermediate stiffeners, the depths of girders and trusses, etc. z/80 Il. INDIVIDUAL MEMBER TOLERANCES (WELDED MEMBERS) A. Flatness of girder webs Under static loading conditions, web flatness does not affect the structural tegrity of a girder. Therefore, in buildings and other statically loaded struc tures, the 1978 AISC Specification takes exception to AWS D1.1, Art. 8.13.2, and does not provide a limitation on maximum out-of-latness of girder webs (See the Commentary to the AISC Specification, Sect. 1.17). Problems arise when these tolerances are applied to thin girder webs. In ‘uirder webs less than 5/16 in. thick, the provisions of Art. 8.13.2.do not account realistically for operational difficulties caused by shrinkage resulting from web: to-flange welds and/or welds that attach stiffeners to the web. In some cases flatness within required tolerances cannot be practically provided. AISC Recommendation: ‘Under static loading, the dimensional tolerance for devi of a girder web less than 5/16 in. thick, with stiffeners one side, both sides o1 no stiffeners, shall be as determined by AWS D1.1, Art. 813.2, or @ in whichever is greater. farchitectural considerations require special flatness tolerances, such spe cial requirements must be identified on the engineering drawings and stipulatec in the bid documents. ion from flatness B. Curved girders Article 3.5.1.4 of AWS D1L1 stipulates the permissible variation in sweep fog, horizontally curved welded girders, but does not clearly define how the sweefs dimension is to be measured. As a result, tolerance is sometimes applied to the = ‘wrong dimension. 3nt fire and pons pas i 1 &" (Nominal -vary in field to suit. condition) ~o<« ; ¢ | f + ; Locate ain rom kK working line af. Florence's f* __ Horizontally elongated Actual € —| or oversize holes for HS.bolts }—Working tine Maximum camber Fig. DT-3. Adjustments fer column camber in bearsto-column connections I ' ' Dime Toh | + 2 Locote details from warking line pf col Tolerance 2 Flonge connection plate Horizontally slotted or oversize holes For HS. bolts length +3 Locate details from working ling of col. Tolerance * §" }— Sweep Working line Actual € Fg. DT-4. Adjustments for column sweep in bearmto.coumn connections 8:60 900z/9z/80 wa eT0/zT0Rpe pen dh pases | | ' ' AISC Recommendation: ‘The permissible variation indicated in Art. 3.5.1.4 is the deviation of the theoretical mid-ordinate from a chord through the ends of a single fabricated irder section. It should be remembered most girders have sufficient lateral flexibility to casily permit the attachment of diaphragms, lateral bracing, etc., even if this tolerance is exceeded. C. Girder depth at bolted splices Article 3.5 of AWS D1.1 is silent on girder depth at bolted splices. The follow- ‘ng recommendation is made to establish a standard tolerance. AISC Recommendation: ‘The permissible deviation for depths of girders as described in AWS D1.1, Art. 3.5, shall also include specifically the depth of girder at bolted splices. Any difference within the prescribed tolerances at such a bolted joint shall be taken up, if necessary, by fill plates. D. Spacing of stiffeners Article 3.5 of AWS D1.1 is silent in regard to permissible variations in the lo- cation of intermediate and longitudinal stiffeners. ‘When intermediate stiffeners are spaced at a distance approximately equal to the gitder depth, welding shrinkage up to % in. in a 100-ft length of girder is not uncommon. Further, thermal expansion or contraction in a like length of fitder, due toa temperature differential of SOF, can cause changes in length up to ¥ in, Similarly, there is need for an allowable variation in the location of longi- tudinal stiffeners. AISC Recommendation: Intermediate stiffeners may deviate from their theoretical location +? in (as measured from the girder end). Diaphragm and other connection stiffeners may deviate from their theoretical location by no more than twice the thickness of the stiffener. Longitudinal stiffeners may deviate from their theoretical location by a distance equal to 1% of the girder depth. If longitudinal stiffeners are inter- rupted by vertical stiffeners, the ends shall not be offset more than ¥4 the thick- ness of the stiffeners. E. Welded box members Neither AWS D1.1 or AISC currently provides a tolerance for allowable twist of box columns and box girders. In the absence of such a tolerance, inspectors sometimes attempt to apply the p: is of ASTM A500, and ASTM A6, a structural tubing specification, to fabricated box members. lnensione Yoterances!« 27 ) AISC Recommendation: Designers of fabricated box members should permit use of connection de- tails which accommodate twist in the completed member. ‘The provisions of ASTM AG and ASTM A500 should not be applied di- rectly or indirectly to fabricated members. If required for appearance reasons, ‘a twist tolerance should be clearly stipulated in contract documents, If twist of a fabricated member exceeds this tolerance, decisions as to whether to attempt correction should be made on a case-by-case basis, as correction in a closed box is nearly impossible and carries the potential for damage. F. Other tolerances not specified —_ Many tolerances of assemblies are not covered under any standard code, Ex- amples are tolerances on shop assembled bents, frames, platforms, pairs of sirders, ete. AISC Recommendation: Article 3.5.1.13 of AWS D1.1 requires that dimensi covered in Art. 3.5 must be determined individually and mutually agreed upon by the fabricator and the owner, with proper regard for erection requirements and the erection tolerances of the AISC Code of Standard Practice. This proce- dure should also be applied to bolted shop assemblies. 8:60 900z/9z/80 wa eTo/eTOR