Bridge Manual - Part I - May CHAPTER 6 SHOP DRAWINGS, CONSTRUCTION PROCEDURES, AND OTHER SUBMISSIONS

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1 Bridge Manual - Part I - May CHAPTER 6 SHOP DRAWINGS, CONSTRUCTION PROCEDURES, AND OTHER SUBMISSIONS 6.1 APPROVAL PROCESS General The official MassHighway procedure for submission of and approval of shop drawings is set forth in the Commonwealth of Massachusetts Department of Public Works (former name of the Massachusetts Highway Department) Standard Operating Procedure No. HED , Approval Of Shop Drawings, dated May 3, This chapter is a supplement to the referenced S.O.P. If there are conflicts between the two, the information in this Chapter shall take precedence. Drawings or plans for which the Contractor is responsible for the original design, such as for, but not limited to: steel sheeting; cofferdams; sign, signal and lighting supports; temporary structures; erection drawings; demolition drawings; and computations submitted by the Contractor for approval shall bear the seal of a Professional Engineer of the appropriate discipline registered in Massachusetts Responsibility It will be the responsibility of the Resident Engineers and Project Engineers to advise respectively the Contractors and Designers concerning the proper procedures to be followed with regard to submitting and distributing shop drawings. Shop drawings not submitted in compliance with these procedures shall be returned immediately by the Resident or Project Engineer to the Contractor for resubmission in accordance with the established procedure. The Designer, as part of their review of shop drawings, must verify that the fabricators of metal elements, such as structural steel, steel railings, and aluminum protective screen, are on MassHighway s Approved Fabricator List when the shop drawings are first received. An up to date copy of the Approved Fabricator List may be obtained from the MassHighway website at In addition, the MassHighway Research and Materials Engineer shall be contacted to verify that the fabricator of precast concrete elements is approved by MassHighway. The Designer shall not review and approve cement concrete mix designs, welding procedures, and other materials-related submittals. All welding procedures shall be forwarded to the MassHighway Bridge Section for review and approval. All other materials-related submittals shall be forwarded to the MassHighway Research and Materials Engineer for review and approval Approval of Shop Drawings MassHighway policy does not allow for the approval of shop drawings with an "APPROVED AS NOTED" stamp. Shop drawings will either be approved as submitted or else they will be returned for corrections On shop drawings for structural steel, prestressed beams, steel or iron castings, bronze or wrought iron plates, metals railing and machinery, and structural timber the Designer shall make sure that the following notation is on the shop drawings before approval is given:

2 Bridge Manual - Part I - May INSPECTION TO BE PERFORMED BY THE MASSACHUSETTS HIGHWAY DEPARTMENT OR DESIGNATED REPRESENTATIVE The Designer shall affix his/her own approval stamp to every sheet of all shop drawings approved. For all projects designed by private consultant firms, the Designer shall be the consultant firm as indicated on the Contract Drawings. For projects designed by MassHighway, the Designer may be the District, the Bridge, Highway or Traffic Engineer depending on the origin of the design If catalog cuts or manufacturer's specifications are submitted in lieu of or in addition to shop drawings, the number of copies required for distribution shall be in accordance with Table In case a Railroad is involved, the following procedures shall be followed: Highway Over Railroad: Railroad will not approve shop drawings. Railroad Over Highway: Railroad will approve all drawings of the structure Approval of Construction Materials, Products, and Fabrication Procedures The Designer shall verify that all AASHTO or ASTM material designations on the shop drawings comply with the material specifications in either the MassHighway Standard Specifications, Supplemental Specifications, or Special Provisions. The MassHighway Research and Materials Engineer will approve the use of all products and materials other than metals whose use requires preapproval or material certification for conformance with the MassHighway Approved Products List or the MassHighway Standard Specifications, Supplemental Specifications, or Special Provisions. Examples of such products and materials include, but are not limited to: concrete mix designs for both redi-mix concrete and precast concrete products; concrete patch materials; grouts; epoxies; concrete sealers; membranes; joint sealers and fillers; geotextiles; mechanical reinforcing bar splicers; and coatings. The MassHighway Metals Control Engineer will approve all welding procedures, metal certifications, and any metal repair procedures for any fabrication related errors Telephone Calls from Contractors, Fabricators, and Suppliers Contractors, Fabricators, and Suppliers often directly call the Designer with inquiries. In order to avoid confusion and potential claims, all answers to the Contractor shall be made through the appropriate MassHighway District Construction personnel, except in cases where the inquiry is related to resolving review comments on shop drawings. Direct communication between the Contractor, Fabricator, or Supplier and the Designer is encouraged for the timely and effective resolution of review comments on shop drawings.

3 6. SHOP DRAWINGS 6..1 Structural Bridge Manual - Part I - May General. The procedure outlined below shall be followed for the following shop drawings: 1. Prestressed Concrete Beams.. Structural Steel. 3. Elastomeric Bearings. 4. Steel or Iron Castings. 5. Bronze or Wrought Iron Plates. 6. Grid Decking. 7. Metal Railings and Protective Screens. 8. Machinery (When used on Bridges). 9. Reinforcing Steel. 10. Structural Timber 11. Stay-In-Place Forms 1. Strip Seal Bridge Joint Systems Approval Procedure. The Fabricator or Supplier shall send three sets of prints of the shop drawings to the Contractor who shall then send two sets of these prints directly to the Designer for comments or approval. The Contractor shall send a copy of this transmittal to the appropriate District Office, to the attention of the District Construction Engineer. The Designer, after checking the prints and making any necessary comments, shall return one set of marked-up prints through the Contractor to the Fabricator for correction, retaining one set for backchecking to see that the comments have been reconciled. The Designer shall send a copy of this transmittal to the appropriate District Office, to the attention of the District Construction Engineer. After the Fabricator or Supplier has reconciled all of the comments on the shop drawings with the Designer, he/she shall send to the Designer as many sets of prints as are required for distribution, as specified in Table Required Project Information on Shop Drawings. All shop drawings submitted for the approval of the Designer shall feature a title block that contains all of the project information presented in Figure Traffic General. Overhead, cantilever, and ground mounted signs, light standards, and traffic signal assemblies shall be designed by the Contractor. The design calculations and shop drawings shall be reviewed by the Engineer. Signs supported on bridges or walls shall be designed by the Designer of record for those structures.

4 Bridge Manual - Part I - May Sign Supports. Unless the structures have been pre-approved by MassHighway, complete design calculations must be prepared for all structures and must accompany the shop drawing submittals. The design calculations must include analysis of the sign structure, foundations, and all connections Light Standards, Traffic Signal Assemblies, and High Mast Lighting Assemblies. The requirements of Paragraph 6... shall apply, except that for High Mast Lighting Assemblies the following criteria shall also be met: 1. The lowering device motor must have a sufficient rating to withstand the torque imposed on it by the ring assembly as it is lowered or raised.. The lowering device housing must be made of a material able to withstand the shear and tensile stresses imposed on it by the lowering and raising of the ring assembly. 3. Two () copies of the Manufacturer s test results must be submitted with the shop drawings as documentary proof that the aforementioned requirements are met. If designed by the Contractor, two () copies of shop drawings and two () copies of design calculations shall be submitted to the Designer for review and comment. After the comments have been reconciled, the required number of shop drawings and two () copies of design calculations shall be returned to the Engineer for approval and distribution. For bridge mounted sign supports designed by the Designer, the same procedure as outlined in Subsection 6..1 shall be followed Distribution Only after the shop drawings have received the FINAL approval by the Designer, the shop drawings will be distributed as shown in Table 6.1. All distributions will be made by the Designer. Copies of transmittal letters will be sent to respective MassHighway Engineers concerned. MassHighway will not distribute any shop drawings on projects handled by Design Consultants. 6.3 EFFECT OF CONTRACT DRAWING REVISIONS ON SHOP DRAWINGS When Contract Drawings are revised after the contract has been awarded for construction and the revision affects the work of a supplier or fabricator, the following procedures shall apply: 1. Where shop drawings have not been prepared, the drawings shall be processed in accordance with the standard procedure incorporating the revisions.. Where part of a series of related shop drawings is in the process of approval and a revision relative to this series is made to the Contract Drawings, those shop drawings of this series not yet submitted for approval shall include and make note of such Contract Drawing revisions. Those drawings, already approved shall be revised as outlined below (3).

5 Bridge Manual - Part I - May Where the shop detail drawings have been approved prior to a revision to the Contract Drawings, revised shop drawings shall be made and processed in accordance with the standard procedure. A note shall be shown on the shop drawings to include the date and nature of revision. When it becomes necessary to issue revised shop drawings after the approved prints have been distributed, the Designer shall notify the Construction Engineer as to the extent of the revisions and the probable time of issuance of the revised drawings. The Construction Engineer will then notify the District Highway Director that revisions are being made. The District Highway Director will, in turn, inform the Resident Engineer. 6.4 CONSTRUCTION PROCEDURES General Approval Where a Railroad is Not Involved. See Table 6. for a description of each construction procedure category and the required distribution. All Construction Procedure submittals shall be initially forwarded by the Contractor through the District. For Category 1 procedures, the Designer will review these submittals for structural adequacy and conformance with the project specifications and will inform the District accordingly. When all comments have been resolved, the Designer shall notify the District that the submission is acceptable. For Category and 3 procedures, the Designer will review these submittals and return them to the Contractor for resolution of comments. When all comments have been resolved and the submittal is found acceptable, the Designer will approve and distribute the submittals. For Category 4 procedures, the District will perform all reviews, approvals and distributions Approval Where a Railroad is Involved. See Table 6. for a description of each construction procedure category and required distribution. All submittals shall be initially forwarded by the Contractor through the District. The railroad will approve demolition procedures, erection procedures, sheeting procedures, and anything concerning the safety of railroad traffic and personnel. The District shall forward the Contractor's submittals under Categories 1 and to the railroad for their review. The District shall also coordinate the railroad comments with those made by the Designer in order to ensure that all comments are resolved and the required approvals are obtained.

6 6.4. Erection of Structural Steel Bridge Manual - Part I - May The following procedure for the erection of structural steel is taken from the Commonwealth of Massachusetts Department of Public Works (former name of the Massachusetts Highway Department) Standard Operating Procedures No. CSD , Procedures For Erection Of Structural Steel, dated December 1, As soon as possible after being assigned to a project, the Resident Engineer shall determine the ratio of the span to width of the compression flange, (L/B), for main load-carrying structural steel members of each bridge, if not already shown on the plans. This determination shall be documented as part of the project records. Each structure will then be classified in one of the following three groups: GROUP DEFINITION I. Members with L/B ratios of less than 80 II. Members with L/B ratios between 80 and 100 III. Members with L/B ratios over 100 Where: L = length of beam being erected; B = width of compression flange. For continuous spans, the span length shall be considered as the distance between the dead load points of contraflexture GROUP I represents structures whose main load carrying members are comparatively rigid and which are relatively easy to erect. Approval for the erection procedures to be used shall be given at the project level by the Resident Engineer. Control of traffic around and under these structures will be as directed by the Resident Engineer GROUP II represents structures whose main load carrying members are less rigid and are more difficult to erect. Approval for the erection procedures to be used shall be given at the District level by the District Construction Engineer. Control of traffic around and under these structures will be as directed by the District Construction Engineer GROUP III represents structures whose main load carrying members are unstable without sufficient lateral support and require extreme care and caution during erection. Final approval for the erection procedures and provisions for control of traffic around and under the structure shall be vested with the Construction Engineer (Boston Construction Office). Traffic will be allowed to flow under a structure in this group only after a representative from the Boston Construction Office has made an inspection and given approval Nothing contained herein shall supersede the project specifications Erection of Prestressed Concrete If the Contractor wants to use any previously erected span to erect subsequent spans, the procedure shall be reviewed and approved by the Designer.

7 Bridge Manual - Part I - May TABLE 6.1 SHOP DRAWING DISTRIBUTION DRAWING CONTRACTOR NUMBER OF APPROVED COPIES REQUIRED FOR DISTRIBUTION BY THE DESIGNER RESEARCH & MATERIALS ENGINEER METALS CONTROL ENGINEER BRIDGE ENGINEER DESIGNER TRAFFIC ENGINEER DISTRICT HIGHWAY DIRECTOR STRUCTURAL STEEL, METAL BRIDGE RAILINGS, PROTECTIVE SCREENS, METAL CASTING, METAL PLATES AND MACHINERY, STRUCTURAL TIMBER 1 1 PRECAST AND/OR PRESTRESSED CONCRETE STRUCTURAL UNIT 1 1 REINFORCING STEEL AND STEEL S.I.P. FORMS 1 1 ELASTOMERIC BEARINGS 1 1 STRIP SEAL BRIDGE JOINT SYSTEMS 1 1 SPECIAL NON-TRAFFIC PRECAST CONCRETE UNITS (PIPES, MANHOLES, ETC.) TRAFFIC: PRECAST CONCRETE UNITS, SIGNS, SUPPORTS, CASTINGS, SIGNAL MECHANISMS, HIGHWAY LIGHTING, ETC. SPECIAL METAL PIPES, PIPE ARCHES, STRUCTURAL PIPES, PLATE PIPES, AND PLATE ARCHES * * * If drawings are for steel or aluminum structures, they shall be sent to the Metals Control Engineer. All other drawings shall be sent to the Research and Materials Engineer.

8 Bridge Manual - Part I - May TABLE 6. DISTRIBUTION OF CONSTRUCTION PROCEDURES CATEGORY 1 NUMBER OF APPROVED COPIES REQUIRED FOR DISTRIBUTION DESCRIPTION DISTRICT DESIGNER STEEL BEAM ERECTION PRESTRESSED CONCRETE BEAM ERECTION BRIDGE DEMOLITION DECK REMOVAL & SHIELDING DESIGN 6 * (9) 3 SHEETING / COFFERDAM DESIGNS TEMPORARY BRIDGES BEAM OR PIPE JACKING PROCEDURE PILE DRIVING (WAVE EQUATION METHOD) PILE LOAD TESTS DRILLED SHAFT CONSTRUCTION PROCEDURES EMBANKMENT SETTLEMENT SIGN SUPPORTS / STRAIN POLES 6 ** (9) 6 ** 4 PILE CAPACITY (UNDER 100 KIPS) SCHEDULES & CONSTRUCTION EQUIPMENT 3 5 ERRORS AND CHANGES See: CSD ( ) Number of copies when a Railroad is involved. * District shall distribute as follows: 1 to Designer, 1 to Resident Engineer, 1 to District Construction Office, 3 to Contractor, 3 to Railroad (if involved). ** Designer shall distribute. Distribution shall be the same as for *.

9 Bridge Manual - Part I - May FIGURE 6.1: PROJECT INFORMATION REQUIRED ON SHOP DRAWING TITLE BLOCKS