-4.07 COMPOSITE COLUMNS CASINGS

60-4.07 COMPOSITE COLUMNS CASINGS

60-4.08 PRESTRESSING STEEL GIRDERS

60-4.09 BRIDGE JOINT RESTRAINERS

60-4.09A General

60-4.09A(1) Summary

Bridge joint restrainers must comply with the specifications for miscellaneous bridge metal in section 75-3.

60-4.09A(2) Definitions

60-4.09A(3) Submittals

60-4.09A(3)(a) General

60-4.09A(3)(b) Cable-Type Restrainers

Submit 2 certified copies of the mill test and heat treating reports for each heat of bars used for cable yield indicators.

Submit at the manufacturer's plant:

1. 1 cable-type restrainer test sample for each 200 restrainers or fraction thereof produced. The sample restrainer must:

1.1 Consist of a cable fitted with a swaged fitting and right hand thread stud at both ends

1.2 Be 3 feet in total length

2. 1 turnbuckle fitted with an 8-inch stud at each end for each 200 turnbuckles or fraction thereof.

3. Greater of 1 percent or 8 of the cable yield indicators produced from each mill heat.

4. 2 disc springs of each size produced from each mill heat.
Items to be submitted at the manufacturer's plant must be submitted with all manufacturer's plant-applied coatings.

60-4.09A(3)(c) Pipe-Type Restrainers

60-4.09A(4) Quality Assurance

Notify the Engineer:

1. When materials have been delivered to the fabrication site

2. At least 10 days before starting fabrication

60-4.09B Materials

60-4.09B(1) General

60-4.09B(2) Cable Type Restrainers

60-4.09B(2)(a) General

Cables must be galvanized, 3/4-inch preformed, 6 by 19, wire strand core or independent wire rope core, complying with Federal Specification RR-W-410, right regular lay, manufactured of improved plow steel with a minimum breaking strength of 23 tons.

Each swaged fitting must:

1. Be machined from hot-rolled steel bars complying with AISI C-1035

2. Be annealed, suitable for cold swaging

3. Have a hole drilled through the head to accommodate the locking pin

4. Have the manufacturer's identifying mark stamped on the body
The locking pin must be a 1/4-inch-diameter, zinc-plated steel spring pin. The pin must keep the stud in proper position.

Before galvanizing, mill a 3/8-inch slot for the locking pin in the stud end. Each stud must comply with ASTM A449 after galvanizing.

Nuts must comply with ASTM A563, including appendix X1, except lubrication is not required.

Each cable yield indicator must:

1. Be machined from hot-rolled steel bars complying with AISI C-1035

2. Be annealed, suitable for cold swaging

3. Have the heat number and manufacturer's identifying mark stamped on the end surface
Disc springs must be made from steel complying with ASTM A684/A684M, Grade 1075.

Turnbuckles must be steel pipe type. Pulls for turnbuckles must consist of a swaged fitting and stud assembly.

Steel parts must comply with ASTM A36/A36M or A576, Grade 1030 (AISI 1030) and must not be rimmed or capped steel.

Pipe sleeves must be commercial-quality welded steel pipe.

Concrete for filling cable drum units must either (1) comply with the specifications for minor concrete or (2) be a concrete mix with a 3/8-inch maximum combined aggregate grading and at least 675 pounds of cementitious material per cubic yard.

Elastomeric bearing pads must comply with section 51-3.02 except pads may consist of only elastomer and laminated reinforcement is not required.

PVC must be commercial quality.

Bond breaker on PVC pipe must be a mortar-tight wrapping of plastic or rubber sheet at least 0.010 inch thick.

Expanded polystyrene and hardboard must comply with section 51-2.01B(1).

Neoprene sheets must comply with the specifications for neoprene in section 51-2.04. The sheets must be smooth, free from pinholes and surface blemishes, and show no evidence of delamination.

Closed-cell expanded neoprene material must be commercial quality and comply with the stiffness requirements in ASTM D1056 for Class SC, Grade SCE43 material or firmer.

60-4.09B(2)(b) Corrosion Protection

60-4.09B(2)(c) Fabrication

60-4.09B(2)(c)(i) General

Each swaged fitting, turnbuckle, stud, and nut assembly must develop the specified breaking strength of the cable.

Machine the wall of the reduced section of the cable yield indicator such that the indicator yields at a load of from 36,000 to 38,000 pounds when tested in compression along the major axis at a test speed of at most 1/2 inch/minute.

Clean and paint disc springs the described color using a paint recommended by the manufacturer of the disc springs. Disc springs do not need to be galvanized.

The minimum size of fillet welds must comply with AWS D1.1 except as follows:

The finish coat must match color no. 26373 of FED-STD-595.

Securely wrap each free end of restrainer-unit cables to prevent separation.

Ship cable-type restrainers as complete units.

60-4.09B(2)(c)(ii) Applying Corrosion Protection

Reserved

60-4.09B(3) Bar Type Restrainers

Bar-type restrainers consist of HS bars, bearing plates, couplers, anchorage devices, and incidentals.

You must determine the required length of each bar-type restrainer.

Bar-type restrainers must comply with the specifications for bar prestressing steel in section 50.

Each anchorage device and coupler must develop the specified minimum ultimate tensile strength of the steel bar and include locking devices to prevent turning or loosening.

Bearing plates must comply with ASTM A36/A36M.

Elastomeric bearing pads must comply with section 51-3.02 and must be bonded to bearing plates with adhesive complying with Federal Specification MMM-A-121.

Ship each bar-type restrainer as a complete unit, including anchorage device and coupler.

60-4.09B(4) Pipe Type Restrainers

Pipe-type restrainers consist of double extra-strong steel pipe and associated hardware.

Double extra-strong pipe for pipe-type restrainers must comply with ASTM A53/A53M, Grade B.

Grout for bonding the pipe to the existing concrete must comply with section 60-4.06B(2).

60-4.09C Construction

60-4.09C(1) General

Place new concrete adjacent to restrainers before installing them.

Where removing and replacing restrainers, remove at most 50 percent of the restrainers at any joint and replace them with an equal proportion of new restrainers before subsequent removal activities. Perform all removal and replacement symmetrically about the centerline of the existing bridge.

If paint removal or welding at connections to existing steel is not described at restrainer locations, wash loose dirt and dust from existing contact surfaces of HS bolted connections without disturbing the existing paint. Clean and paint existing contact surfaces of HS bolted connections that contain rust, loose paint, or other foreign substances other than dirt and dust. Cleaning and painting existing contact surfaces is change order work.

Repair painted areas of existing structural steel damaged (1) by your operations or (2) from drilling holes through existing steel members. Repairing painted areas must comply with the specifications for repairing damaged galvanized surfaces in section 75-1.02B.

60-4.09C(2) Cable Type Restrainers

Notify the Engineer at least 2 days before tightening and setting cable-type restrainer units.

60-4.09C(3) Bar Type Restrainers

Clean and paint new metal surfaces of bar-type restrainer units after fabrication as specified for new structural steel in section 59-2, except:

1. SSPC-QP 1, SSPC-QP 2, and AISC-420-10/SSPC-QP3 certifications are not required

2. Blast-cleaned surfaces require only a single undercoat of inorganic zinc primer

60-4.09C(4) Pipe Type Restrainers

Bond pipe-type restrainers to existing concrete by completely filling the void between the pipe and the cored hole with grout within the limits shown. Provide filler material and seals along the sides of the pipe to prevent grout from entering the bridge hinge joints. The filler material and seals must not restrict joint movement.

60-4.09D Payment

The payment quantity for miscellaneous metal (restrainer) does not include the weight of nonmetallic materials used in constructing the restrainers.

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