New York State Steel Construction Manual March 24, 2008

3rd Edition

SECTION 12
DIMENSIONAL TOLERANCES FOR FABRICATED MEMBERS
1201. GENERAL

The provisions of this Section shall apply to all members, independent of cross section, whether straight or
curved. Members heat-curved under the provisions of Section 15, Heat-Curving, Cambering and
Straightening shall meet the dimensional tolerances of this section. Before welding, dimensions of shapes
and plates shall conform to the tolerances described in ASTM Designation A6. After the start of any
fabrication and after welding has been completed, all members shall conform to the dimensional tolerances
of these specifications. All measurements shall be compared to the dimensions shown on the approved
shop drawings.

1202. DEVIATION FROM DETAILED LENGTH

Members with ends milled for bearing and members with faced-end convection angles may deviate from
the detailed length by [1/32 inch [1 mm] maximum. All other members may vary from the detailed length
by [ inch [6 mm] maximum, unless otherwise approved by the DCES.

1203. DEVIATION FROM DETAILED WIDTH.

The width of members (flanges, coverplates, etc.) may deviate from the detailed width by inch [3 mm].
This does not apply to the areas allowed by Section 601 for ground gouge repairs.

1204. DEVIATION FROM SPECIFIED DEPTH

The maximum deviation from the specified depth of welded beams and girders, measured at the web
centerline, shall not exceed the following:

For depths up to 36 inches, inclusive ................................................................................................. inch

For depths over 36 inches to 72 inches, inclusive ............................................................................. 3/16 inch
For depths over 72 inches ................................................................................................. + 5/16 inch, -3/16 inch

1205. LOCATION OF WELDED BUTT JOINTS

Welded butt joints shall not be placed more than inch from the detailed location.

1206. INTERMEDIATE STIFFENERS

1206.1 Location. Intermediate stiffeners may vary inch [12 mm] from the detailed location.

1206.2 Deviation from Straightness and Fit of Intermediate Stiffeners. The deviation from
straightness of intermediate stiffeners shall not exceed inch in the length of the stiffener. The edge
of the stiffener that is welded to the web of the girder shall be straight and, when fit to the web, shall
have no gaps in excess of 3/32 inch [2 mm] between the web and the stiffener. Where tight fit of
intermediate stiffeners is specified, a gap of up to 1/16 inch between stiffener and flange is allowed.

1207. BEARING STIFFENERS

1207.1 Deviation from Straightness of Bearing Stiffeners. The out-of-straightness of bearing

stiffeners shall not exceed inch for stiffeners up to 6 feet in length and inch for lengths over 6 feet.

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 The centerline of the attached stiffener shall lie within the dimensional boundaries of a perfectly
straight stiffener of the same thickness. They shall fit to the web as described in Section 1206.2.

1207.2 Ends in Bearing. The bearing ends of bearing stiffeners shall be flush and square with the web
and at least 10 percent of the area at the bearing end shall be in intimate contact with the flange. The
remaining portion may have a gap not exceeding 0.040 inch.

1208. BEARING AT POINTS OF LOADING

The maximum gap between abutting parts at any bearing point shall be 0.040 inch. When mill to bear
(MB) is specified at a point of bearing, the surfaces shall be plane and true within 0.010 inch.

1209. WARPAGE AND TILT OF FLANGES

The combined warpage and tilt of flanges of welded beams or girders shall be determined by measuring the
offset at the toe of the flange from a line normal to the plane of the web, through the intersection of the
centerline of web, with the outside surface of the flange plate. This offset shall not exceed 1/100 of the
total width of the flange or inch, whichever is greater. This deviation does not apply to bearing areas at
points of loading. At bearing points the flange shall be perpendicular to the web and shall be flat so that
bearing will be achieved between abutting parts as required in Section 1208.

1210. WEB TO FLANGE OFFSET

The lateral deviation between centerline of web and centerline of flange of fabricated girders shall not
exceed inch.

1211. DEVIATION FROM FLATNESS OF GIRDER WEBS

1211.1 Girders with Intermediate Stiffeners and/or Connection Plates. The maximum deviation
from flatness of girder webs shall be determined by measuring offsets from a straight edge whose
length is not less than the least dimension of any panel. The straight edge shall be placed in any
position within the panel necessary to measure the maximum deviation of the web. A panel is defined
as the web area bounded by flange plates or horizontal stiffeners and any two adjacent vertical
stiffeners or connection plates, regardless of side to which attached.

The maximum deviation from web flatness shall be determined by applying the following formula to
each panel:

maximum deviation = d where d is the least panel dimension in inches.

100

Table 1211.1 lists values obtained using the above formula.

TABLE 1211.1 - MAXIMUM DEVIATION FROM WEB FLATNESS FOR GIRDERS WITH
INTERMEDIATE STIFFENERS AND/OR CONNECTION PLATES

Least Panel
Dimension 12 18 25 31 37 44 50 56 62 69 75 81 87 94 100
(in.)

Allowable
Deviation 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1
(in.)

144 March 24, 2008

 1211.2 Girders With No Full-Depth Web Attachments. The maximum deviation from web flatness
of shafts (girders with no full-depth web attachments which may stiffen the web) shall be determined
by applying the following formula:

maximum deviation = d where d is the depth of the web in inches.

150

Table 1211.2 lists values obtained using the above formula.

TABLE 1211.2 - MAXIMUM DEVIATION FROM WEB FLATNESS FOR GIRDERS WITHOUT
INTERMEDIATE STIFFENERS, CONNECTION PLATES OR OTHER FULL
DEPTH ATTACHMENTS THAT MAY STIFFEN THE WEB.

Depth of
19 28 37 47 56 66 75 84 94 103 113 122 131 141 150
Web (in.)

Allowable
1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1
Deviation (in.)

1211.3 Web Flatness at Bolted Ends. Webs of plate girders that are shop assembled and have
shrinkage distortion at the bolted end in excess of the flatness requirements specified may be shipped
to the project site for erection provided shop assembly has demonstrated that the splice material will
straighten the web to acceptable tolerances when less than 25 percent of the required splice bolts were
installed.

1212. DEVIATION FROM STRAIGHTNESS OF WELDED COLUMNS

a) Length of 45 feet and under:

inch x No. of feet of test length, but not over inch

10

b) Lengths over 45 feet:

inch + inch x No. of feet of total length 45

10
The above deviations do not apply to guide columns in vertical lift bridges. Guide columns shall be
straight within the limits specified on the Plans or ordered by the DCES.

1213. DEVIATION FROM HORIZONTAL ALIGNMENT

Deviation from specified horizontal alignment (sweep) in curved beams and girders and deviation from
straightness in beams and girders with no specified sweep shall not exceed the following:

a) inch x Total no. of feet between supports,

10

or

b) inch x No. of feet from the nearest end

10

145 March 24, 2008

 If the top and bottom flange deviations are on opposite sides of the theoretical centerline, the total deviation
(top flange plus bottom flange) shall not exceed either of the values computed by a) or b) above.

This maximum deviation may only be used when the member has sufficient lateral flexibility to permit the
attachment of diaphragms, cross frames, lateral bracing, etc., without damaging the structural member or its
attachments.

1214. DEVIATION FROM SPECIFIED CAMBER

1214.1 General. Camber measurements shall be made in the shop prior to shipment and in the field
after erection to insure conformance with the Contract documents.

All camber measurements in the shop shall be made by the Fabricator in the presence of the NYS QA
inspector. The camber of each single erection piece, after fabrication, shall be in accordance with the
approved shop drawing and submitted to the DCES for review. When shop assembly is required, full
line camber measurements shall also be made on the assembled members in accordance with the
approved shop drawing and the results submitted to the DCES for review prior to drill the splices.

Final camber measurements shall be made by the Contractor after erection. The Contractor shall notify
the Engineer-In-Charge in advance so that camber measurements may be witnessed. After erection,
each member shall have all of the specified camber, less the dead load deflection of the steel, within
the tolerance specified herein.

When members do not conform to these requirements, either in the shop or in the field, the DCES may
order camber correction by the heat-shrink process submitted for approval to the DCES in accordance
with Section 15. Negative camber deficiencies are unacceptable and may only be corrected by heat-
shrink procedures approved by the DCES. Camber deviations that cannot be corrected by the heat-
shrink technique without adversely affecting the structural steel, in the opinion of the DCES, shall be
cause for rejection and replacement of the steel at no cost to the State.

1214.2 Deviation from Specified Camber of Single Erection Pieces.

a) Stringers, girders and floorbeams:

1) at bearing locations " (3 mm)

2) at midpoint -0, + inch [19 mm]

3) at intermediate points -0, + inch x No. of feet from nearest end or + inch, whichever is less
10

Note: The fabricator may elect not to check piece camber for stringers, girders and floorbeams when
span assembly for these pieces is performed. Span assembly shall meet the piece camber requirements
shown above.

b) Truss chord, web members and built-up hanger members:

inch x No. of feet of total length, or inch, whichever is less

10

c) Arch members and rigid frames:

inch x No. of feet of total length, or inch, whichever is less

10

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 Measurements to verify conformance with the above requirements shall be made with the member
lying on its side in the no-load condition or, when blocked in the no-load position, as approved by the
DCES.

1214.3 Deviation from Specified Camber in Assembly

-0, + x No. of feet of length from nearest support (bearing or pin), or inch, whichever is less
10

1214.4 Deviation from Specified Camber of Erected Steel Bridge Superstructures.

a) cantilever sections

-0, + x No. of feet of length from nearest support (bearing or pin), or inch, whichever is less
10

b) between substructure supports

-0, + x No. of feet of length from nearest support (bearing or pin), or 1 inch, whichever is less
10

Unless otherwise specified, all measurements shall be taken when the steel erection is complete and the
superstructure is subject to steel dead load stresses only.

1215. DEVIATION FROM VERTICAL ALIGNMENT OF GIRDER WEBS

The maximum deviation of girder webs from vertical at points of support shall be inch or 3/32 inch/foot [6
mm/m] of web depth, not to exceed inch [19 mm]. The deviation of girder webs from vertical at mid-
span locations may exceed the above requirements subject to the approval of the DCES.

1216. TOLERANCES FOR JOINT FIT-UP IN WELDED CONNECTIONS

See AWS D1.5 Figure 2.5 for PJP and Section 1101.1 for fillet welds.

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