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FHWA Resource Center

STRUCTURES TEAM

Structural Committee for Economic Fabrication (SCEF)

MEETING MINUTES FROM JUNE 1, 2008 SCEF MEETING HELD AT THE DAVID L. LAWRENCE CONVENTION CENTER; PITTSBURGH, PA.

ITEM 1 - INTRODUCTIONS OF SCEF MEMBERS PRESENT
This meeting was held in conjunction with the International Bridge Conference.

ITEM 2 – APPROVAL OF MINUTES FROM PREVIOUS MEETING
Jamie Hilton motioned to approve the minutes of the previous meeting. Claude Napier 2nd the motion. Motion passed.

ITEM 3- AISC CERTIFICATION PROGRAM by Lou Triandafilou - FHWA
Program balloted by Certification Committee
30 Comments with one or two negatives that require resolution
Will be re-balloted in next couple of weeks
Task Force: SCEF members included Bruce Abernathy, Joe Bracken, Jon Edwards,
Barry Glassman, Jamie Connor
No other comments or questions

ITEM 4- SSPC UPDATE by Michael Damiano - SSPC

Michael Damiano discussed various training programs now offered by SSPC. These include:

Coatings inspection program similar to NACE
-6 days of intense training. Initiated August 2007
List of certified coatings inspectors is available on-line
CA, FL and KY have adopted the inspector certification program
AASHTO Bridge Coating Inspection Program
4 day course – 3rd year
Bridge Steel (new steel in shop & field) + maintenance
Concrete Coatings Inspection Course
Program in 3rd year
QC Training for shops 40-50 hrs training
Applicators formally certified

Several Standards were also mentioned and ANSI accreditation applied.
Thick film polyurethane
Non-ferrous metals
Sponge Abrasives
SSPC/NSBA

SSPC/AISC
-Certification for shops that paint steel
-Joint standard on how to qualify shops
-Unified standard
-Available by October
-Standard & audit criteria
-End of 2008
Lead Paint Removal

Mike’s presentation will be posted on the FHWA FTP website.

ITEM 5 – PERFORMANCE OF TERMARUST COATINGS by Craig Ballinger – Termarust Technologies

Mr. Ballinger was not available for this meeting; however, there was a short discussion on the topic. Maryland and Virginia each had one project. Both had issues with tacky surface due to lengthy, 4 to 6 week, curing time. Dust was adhering to the surface. Virginia witnessed some corrosion at a few joints.

We will invite Mr. Ballinger to speak at the next SCEF meeting, and to bring the group up to date on any outstanding issues with Termarust projects.

Mr. Triandafilou updated the group on a MDSHA coatings project incorporating rapid deployment techniques. The project was completed on MD Route 650 in the Wheaton area between May and August 2001. The contractor was Seaway Coatings of Baltimore and the single pack, zinc-filled, moisture-cured urethane primer and conventional polyurethane finish coat were supplied by Sherwin Williams. Blasting media was recycled grit. Coatings appear to be in good condition based on a recent visual inspection.

ITEM 6 – RESULTS OF HIGH STRENGTH BOLT SURVEY by Aaron Gillispie - WVDOT

Mr. Gillispie discussed problems with loose bolted connections in the field that were found in many web splices ranging from 14’ to 20’ deep on the new Martinsburg Bridge. Tapping on the bolt and listening to the sound was the quickest method to locate loose bolts. Loose bolts were replaced rather than removed and re-lubricated. The turn-of-the-nut method was used on the new bolts, no DTI’s. When bolts were tightened others would loosen. A larger number of loose bolts were found than had been originally replaced.

 

Based on the above experience, the State surveyed other SCEF states for guidance on how to check fasteners after installation, especially in very deep connections. They were
also interested in finding out whether other states encountered a similar situation where tightening loose bolts resulted in even more loose bolts.

Responses included the need to have plates in full contact with each other, then achieving a snug-tight condition first, working from the most rigid part of the connection out to the free edge. After obtaining snug-tight, repeat the procedure and do random testing with a torque wrench. TxDOT does further tightening using the turn-of-the-nut method. They also use fit-up bolts. Bolts should also be checked for uniform stickout—MD and VA check 10 % of the connections to ensure this. PA uses Test Method 429- requiring the Contractor to do verification testing in the State’s presence.

Action Item #1: The Bolting Subcommittee was requested to draft regional guidance that the States could incorporate into their Construction Manuals, and to report on their progress at the next SCEF meeting.

ITEM 7 – ELECTROSLAG WELDING PROJECT IN FLORIDA by Jamie Hilton, KTA-Tator, Inc.

Mr. Hilton gave a general presentation on the use of electroslag welding (ESW) by Florida Structural Steel - Tampa. The project was owned by Florida DOT and included 2” thick steel. The DOT now allows ESW to be used on non-fracture-critical steel up to 3” thick up to three inches. The fabricator estimated they saved about 16,000 welding man-hours per year on the project, which is equivalent to 8 welders. There were no UT- or RT-tested rejects of the welded material.

Virginia mentioned that they have one fabricator qualified to perform ESW, but no project has been selected to date. High Steel Structures is currently fabricating one project for the New York State Thruway using ESW.

Mr. Hilton’s presentation will also be posted on the FHWA FTP website.

ITEM 8 – UPDATE ON FHWA HPS RESEARCH PROGRAM by Lou Triandafilou of FHWA.

Mr. Triandafilou discussed several items included in the HPS program:

Optimized welds
-Hybrid
-Test specimens by High Steel
-Delaware River Port Authority

Corrosion-Resistant Steel
-Mittal has lab trials with Lehigh and Northwestern Universities
Performance of Weathering Steel
-Effect of vertical clearance under the bridge
Lab Testing 1-coat paint systems
-Final report end of this year
100-yr paint systems
Modular Bridge Concepts
-Organize workshop
Rapid construction
Modernizing Fracture Control Plan
-For fabrication & inspection
Laser Measuring components to eliminate shop assembly
-3D laser technology
-High Steel interested
Laser welding techniques – PLS plant in ME very promising
Software

Handout will be attached to the distribution of minutes.

ITEM 9 – ANCILLARY STRUCTURES SUBCOMMITTEE REPORT by Karl Larson - VDOT

Karl is the new chair of this subcommittee; taking over for Brandon Motuk of Penn DOT. We thank Brandon for all his efforts in guiding the group these past few years.

Steel procurement is an issue as prices are up 42%. VDOT has found problems with some mast arm and light poles. Aluminum casting was found cracked on a high percentage of structures, possibly due to bolt tightening. Torque values have been adjusted.

The group has reached agreement on mast arm standards.

We will invite Dr. Sougata Roy, Lehigh University, to make a presentation at our next meeting, on research he is conducting on cost-effective connections for ancillary structures.

Minutes of recent meeting will be attached to the distribution of minutes.

ITEM 10 – SCEF WELDER CERTIFICATION PROGRAM REPORT by Bruce Abernathy - MDSHA
Mr. Abernathy gave an update on the SCEF welder certification program, based on a February 28th meeting with AWS. Several changes have been made to facilitate the use of the program and acceptance by AWS. Representing AWS, Messrs. Bob Wiswesser and Stan Raymond spoke about how the acceptance can be accomplished. Under the proposed changes, contractors can send a properly trained CWI to administer the weld test in the field and send the plates to AWS. Qualified welding procedures will be used. An accredited test facility still has to conduct bend tests of the samples.

A 10-14 day turnaround of results is anticipated. Welders will no longer be required to go to a testing facility. For identification, a welder certification “passport” will be issued with the welder’s photograph. The passport will be updated every 3 years to show continuity of experience. Goal is to reduce the expense of testing welders. Beta-testing of the program is expected to take place by the end of the summer. AWS is soliciting State DOT representatives to participate in this program.

CWI endorsements are also being offered for bolting and seismic inspection.

Action Item #2: Mr. Abernathy will revise the current SCEF welder qualification procedures for SMAW, FCAW-G and FCAW-S, to be in line with the above discussion. A ballot will be distributed to committee members by the end of June. Pending a positive outcome of the balloting, the program should be elevated to the AASHTO/NSBA Steel Bridge Collaboration level.

Action Item #3: State DOTs are requested to contact AWS to express their interest in participating in the beta-testing program described above.

ITEM 11 – “MODULAR STEEL BRIDGES – FAST, EASY & ECONOMICAL” by Dave Rogers - Big R Manufacturing, LLC

Mr. Rogers gave an excellent presentation on use of short-span, modular steel bridges for fast installation, cost savings and aesthetic value. Approximately 15,000 such structures have been erected nationwide, one of which is a 230’ span pedestrian bridge over a NJ tollway.

Big R’s system consists of a 2-beam modular system supporting a 4-1/4” deep corrugated steel decking with an asphalt or Portland cement concrete overlay. Corrugations are filled to the top first, then a layer of geotextile is placed, then a final layer of AC is placed. The company performs the structural design of the system. Multiple manufacturers can bid projects. Galvanized decking has performed well to date for 30 years. Polymer coatings can be applied to the decking to increase durability and service life.

Bridge railing used with the AC system has not been crash-tested, but has been with the concrete overlay system.

A copy of his presentation will be posted on the FHWA FTP website.

ITEM 12 – EXPANSION JOINT SUBCOMMITTEE REPORT by Marv Blimline - MDSHA

Ms. Patti Kiehl spoke on Mr. Blimline’s behalf. The committee is currently working on a final submission of details and expects to have them completed in time for balloting at the next meeting.

Action Item #4: Details to be submitted to the SCEF chair by October 1st of this year.

ITEM 13 – “NEWARK AIRPORT PREFABRICATED STEEL PROJECT” by Michael Hebor – HDR, Inc.

Mr. Hebor gave an excellent presentation on the elevated people mover system constructed at the Newark International Airport for the Port Authority of NY and NJ. The system has been in place since 2001 and is operating well. There were many challenges with the prefabricated steel pier design considering full reversal of stress and higher than expected fatigue considerations. Extra thickness was built into the design to account for milled bearing areas.

The Grade 50 structure was fabricated in Canada and has a 3-coat system on the outside and metalizing on the inside. A similar structure now 8 years old was erected in Singapore, and is showing no signs of fatigue cracking.

A copy of Mr. Hebor’s presentation will be posted on the FHWA FTP website.

ITEM 14 – DESIGN DETAILING SUBCOMMITTEE REPORT by Ronnie Medlock – High Steel Structures

Mr. Medlock was not available for this meeting; items will be reviewed at the next meeting. Ms. Kiehl discussed the need to revisit the design details of intersecting longitudinal and transverse stiffeners, based on the latest fatigue considerations.

Action Item #5: The subcommittee is requested to convene prior to the next SCEF meeting and resolve any necessary revisions to these details. Coordination with the AASHTO/NSBA Steel Bridge Collaboration is recommended.

ITEM 15 – STANDARD DIAPHRAGM DETAILS FOR CURVED GIRDERS by Jeffrey Hill - VDOT

Mr. Hill discussed the following items:
-SCEF Standard 203-2, Intermediate Diaphragm Details does not include
anything on Curved Girders
-VDOT progressing to LRFD
-Purpose of this task is to develop ideas for details
-VDOT allows field welding for erection of cross frames
-Discussed bolting to bottom flange
-VDOT cross frames will not be bolted to flange
-PA does not permit welding in the field

ITEM 16 – REVIEW OF SCEF ADOPTED STANDARDS

Mr. Triandafilou distributed a revised index of SCEF details developed over the years and asked for comments on any needed revisions. Details were formerly posted on the AASHTO/NSBA website. It was noted that Inspection Handrail details needed to be added to the list.

Handout attached with these minutes.

Action Item #6 – The SCEF membership is requested to review this handout and send any comments to the Chair by September 1, 2008.

ITEM 17- OTHER ISSUES

Ms. Kiehl noted that the SCEF HLMR Bearing specifications were up to date with the respect to the AASHTO LRFD specifications.

Action Item #7 – The Subcommittee will review the SCEF Elastomeric Bearing Details used in design examples for prestressed concrete and steel girder bridges and update them to be consistent with the current AASHTO LRFD specifications. They will report their progress at the next SCEF meeting.

ITEM 18- MEETING ADJOURNED

Meeting was adjourned at 10:00 pm.

Next meeting will be held in Ocean City, Maryland on Tuesday, February 10, 2009, 8 am to noon, preceding the Mid-Atlantic States Quality Assurance Workshop.

PREPARED BY:

ROCHELLE AND ROBERT STACHEL
HRV CONFORMANCE VERIFICATION ASSOCIATES, INC.

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