b282 pot bearings - structural steel · description of revision . authorised by . date . ed1/rev0 ....

ROADS AND MARITIME SERVICES (RMS)

QA SPECIFICATION B282

POT BEARINGS – STRUCTURAL STEEL

NOTICE

This document is a Roads and Maritime Services QA Specification. It has been developed for use with roadworks and bridgeworks contracts let by Roads and Maritime Services or by local councils in NSW. It is not suitable for any other purpose and must not be used for any other purpose or in any other context.

Copyright in this document belongs to Roads and Maritime Services.

REVISION REGISTER

Ed/Rev Number

Clause Number Description of Revision Authorised

By Date

Ed1/Rev0 First Issued GM, CMS 03.05.91

Ed1/Rev1 1.1 Note regarding design of bearings. GM,CMS (per HJL)

17.12.91

1.2 Add AS 1449, delete AS 1554.1.

2 Requirement for "consulting" engineer changed.

3.1(b) Guides to be recessed and faced with stainless steel.

3.2(b) PTFE pad to be permanently lubricated.

3.2(d) Revised requirements for stainless steel.

3.3 Fabrication (new clause)

4.4 Bearings to be tested with lubricant. Table B282.2 - Friction coefficients reduced.

6 Include reference to B241.5 for galvanising.

8 Allowance for Bearing Installation (new clause).

Ed 2/Rev 0 Re-formatted with new clause numbers and reworded Hold Points. Converted to MS Word 6.0c.

GM, RNIC (W Ho)

25.07.97

1.2 References updated.

3.2.2 Hardness of resin changed.

Ed 2/Rev 1 Annexure B282/1

New schedule listing Identified Records GM, RNIC 04.05.00

Ed 3/Rev 0 Major technical changes Clauses & annexures rearranged

GM, RNIC 11.03.03

Ed 3/Rev 1 Changed fonts. GM, RNIC 07.08.03

1.3 Definitions transferred to 1.3

Edition 4 / Revision 2 ROADS AND MARITIME SERVICES April 2012

Ed/Rev Number


By Date

Ed 4/Rev 0 Various Text revised to direct imperative style. “Comply” changed to “conform”. ”Contractor” replaced by “you”. ”Superintendent” replaced by “Principal”. “Shall” replaced by “must”. Minor editorial and font changes.

GM, RNIC 20.12.04

Foreword New clause after Table of Contents

1.2.3 RTA G2 and G5 changed to RTA Q.

1.2.6 Both paragraphs modified.

1.3 Minor changes to definitions. Addition of Ra.

1.5 Requirements for bearing information expanded.

2.1, 2.2, 2.3 Requirements of AS 5100.4 called up for materials and testing.

Withdrawn Australian Standards replaced by ISO and ASTM equivalents.

2.4 Changes to internal seal requirements.

2.5 Testing accreditation by NATA replaced by reference to RTA Q.

3.1 Ultimate Limit State loads and movements specified in accordance with AS 5100.4. Bolt design changed to AS 5100.6.

3.2 Piston rim diameter reworded and requirements changed. Use of silicone sealant for sealing made more general.

3.3 Change to stainless steel thickness requirements and rewording for clarity.

3.4 Guide bar requirements amended. Change reference from Clause 6.3 to 3.3.

3.6, 3.7 AS 5100.4 design requirements called up. Requirements for PTFE pad thickness amended.

4.1, 4.2, 4.3. New subclause added. Straight edge testing now required in all directions. Now ULS not SLS loads and movements. Test loads and durations amended. Friction test amended and simplified.

5.2 ZP permitted for attachment plates.

8 B284 called up for installation.

Annexure B282/C

Merge Clauses C1 and C2. Transfer Clause C3 to C2.

ii

Ed/Rev Number


By Date

Ed 4/Rev 0 (cont’d)

Annexure B282/M

Change reference from ABDC (SAA HB 77) and AS 4100 to AS 5100.

Add missing references. Delete withdrawn Australian Standards and add equivalent ISO and ASTM standards.

Ed 4/Rev 1 1.3 Definition of “Ra” changed GM, IC 22.01.07

Ed 4/Rev 2 1.3 Use of approved structural steel pot bearings mandated and link to lists of RMS approved bridge proprietary products added. Subsequent clauses renumbered.

GM, IC 20.04.12

iii

QA SPECIFICATION B282

POT BEARINGS – STRUCTURAL STEEL Copyright – Roads and Maritime Services

IC-QA-B282

VERSION FOR: DATE:

Edition 4 / Revision 2 ROADS AND MARITIME SERVICES April 2012

Pot Bearings – Structural Steel B282

CONTENTS

CLAUSE PAGE

FOREWORD ............................................................................................................................................... II RMS Copyright and Use of this Document ................................................................................... ii Revisions to Previous Version ....................................................................................................... ii Project Specific Changes ............................................................................................................... ii

1 GENERAL ........................................................................................................................................ 1 1.1 Scope .............................................................................................................................. 1 1.2 Structure of the Specification ......................................................................................... 1 1.3 Approved Bridge Components and Systems .................................................................. 2 1.4 Definitions ...................................................................................................................... 2 1.5 Quality Management System Requirements .................................................................. 2 1.6 Bearing Information ....................................................................................................... 2

2 PROPERTIES OF MATERIALS ........................................................................................................... 3 2.1 Ferrous Materials............................................................................................................ 3 2.2 Pot Sliding Pad and Strips .............................................................................................. 4 2.3 Elastomeric Disc............................................................................................................. 4 2.4 Internal Seals .................................................................................................................. 4 2.5 Lubricant ........................................................................................................................ 4

3 DESIGN AND FABRICATION REQUIREMENTS .................................................................................. 5 3.1 General ........................................................................................................................... 5 3.2 Pot and Piston ................................................................................................................. 5 3.3 Stainless Steel Sliding Surface ....................................................................................... 6 3.4 Guide Bars ...................................................................................................................... 6 3.5 Internal Seal .................................................................................................................... 7 3.6 PTFE Sliding Pad ........................................................................................................... 7 3.7 Elastomeric Disc............................................................................................................. 7

4 TESTING OF BEARINGS ................................................................................................................... 8 4.1 General ........................................................................................................................... 8 4.2 Geometrical Testing ....................................................................................................... 8 4.3 Proof Load Tests ............................................................................................................ 8 4.4 Failure to Meet Requirements ...................................................................................... 10

5 PROTECTIVE TREATMENT ............................................................................................................ 10 5.1 General ......................................................................................................................... 10 5.2 Coating Systems ........................................................................................................... 10 5.3 Surface Preparation ...................................................................................................... 11 5.4 Zinc Metal Spray .......................................................................................................... 11 5.5 Hot Dip Galvanizing..................................................................................................... 11 5.6 Paint Application .......................................................................................................... 11

6 BEARING REPORT ......................................................................................................................... 12

7 IDENTIFICATION AND DELIVERY .................................................................................................. 12

8 INSTALLATION .............................................................................................................................. 12

ANNEXURE B282/A – JOB SPECIFIC REQUIREMENTS ............................................................................ 13

Ed 4 / Rev 2 i

B282 Pot Bearings – Structural Steel

ANNEXURE B282/B – (NOT USED) ......................................................................................................... 13

ANNEXURE B282/C – SCHEDULES OF HOLD POINTS, WITNESS POINTS AND IDENTIFIED RECORDS ..... 13 C1 Schedule of Hold Points and Witness Points ............................................................... 13 C2 Schedule of Identified Records..................................................................................... 13

ANNEXURE B282/D – PLANNING DOCUMENTS ...................................................................................... 14

ANNEXURE B282/E – ZP COATING SYSTEM .......................................................................................... 15

ANNEXURES B282/F TO B282/L – (NOT USED) ..................................................................................... 16

ANNEXURE B282/M – REFERENCED DOCUMENTS ................................................................................ 16

LAST PAGE OF THIS DOCUMENT IS .......................................................................................................... 17

FOREWORD

RMS COPYRIGHT AND USE OF THIS DOCUMENT

Copyright in this document belongs to Roads and Maritime Services.

When this document forms part of a contract

This document should be read with all the documents forming the Contract.

When this document does not form part of a contract

This copy is not a controlled document. Observe the Notice that appears on the first page of the copy controlled by RMS. A full copy of the latest version of the document is available on the RMS Internet website: http://www.rms.nsw.gov.au/business-industry/partners-suppliers/specifications/index.html

REVISIONS TO PREVIOUS VERSION

This document has been revised from Specification RMS R282 Edition 4 Revision 1.

All revisions to the previous version (other than minor editorial and project specific changes) are indicated by a vertical line in the margin as shown here, except when it is a new edition and the text has been extensively rewritten.

PROJECT SPECIFIC CHANGES

Any project specific changes are indicated in the following manner:

(a) Text which is additional to the base document and which is included in the Specification is shown in bold italics e.g. Additional Text.

(b) Text which has been deleted from the base document and which is not included in the Specification is shown struck out e.g. Deleted Text.

ii Ed 4 / Rev 2

http://www.rms.nsw.gov.au/business-industry/partners-suppliers/specifications/index.html

(RMS COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

RMS QA SPECIFICATION B282

POT BEARINGS – STRUCTURAL STEEL

1 GENERAL

1.1 SCOPE

This Specification applies to the design, fabrication, testing, protective treatment, supply and installation of structural steel pot bearings and associated attachment plates.

1.2 STRUCTURE OF THE SPECIFICATION

This Specification includes a series of annexures that detail additional requirements.

1.2.1 Details of Work

Project specific requirements are shown in Annexure B282/A.

1.2.2 (Not Used)

1.2.3 Schedules of HOLD POINTS, WITNESS POINTS and Identified Records

The schedules in Annexure B282/C list the HOLD POINTS and WITNESS POINTS that must be observed. Refer to Specification RMS Q for the definitions of HOLD POINTS and WITNESS POINTS.

The records listed in Annexure B282/C are Identified Records for the purposes of RMS Q Annexure Q/E.

1.2.4 Planning Documents

The PROJECT QUALITY PLAN must include each of the documents and requirements listed in Annexure B282/D and must be implemented.

1.2.5 (Not Used)

1.2.6 Referenced Documents

Unless specified otherwise or is specifically supplied by the Principal, the applicable issue of a referenced document is the issue current at the date one week before the closing date for tenders, or where no issue is current at that date, the most recent issue.

Codes, standards, specifications and test methods are referred to in abbreviated form (e.g. AS 1234). For convenience, the full titles are given in Annexure B282/M. Whenever a part of a standard is referenced, the common title of the standard is mentioned in Annexure B282/M as a separate entry with that part of the standard referred to only by its particular title.

Ed 4 / Rev 2 1



1.3 APPROVED BRIDGE COMPONENTS AND SYSTEMS

Unless approved otherwise by the Principal, use only RMS approved structural steel pot bearings. Details of RMS approved bridge proprietary products can be found at: http://www.rms.nsw.gov.au/business-industry/partners-suppliers/documents/tenders-contracts/listofapprovedbridgecomponentssystems.pdf

1.4 DEFINITIONS

The following definitions apply to this Specification:

(a) Bearing Exposed Surfaces. The pot bearing surfaces remaining after exclusion of the bearing internal surfaces.

(b) Bearing Internal Surfaces. The internal surfaces of the pot, the face of the piston in contact with the elastomeric disc, the rim of the piston and the areas covered by the stainless steel plates and the polytetrafluoroethylene (PTFE) pads and strips.

(c) Elastomer. A macromolecular material that rapidly regains its approximate original dimensions after release of a weak stress that has caused its substantial deformation.

(d) Elastomeric Disc. A disc of rubber fitted with internal seals around its perimeter that allows relative rotation of the top and bottom parts of the bearing.

(e) External Seal. The component used to seal the gap between the piston and the pot.

(f) Internal Seal. The sealing ring(s) recessed into the face of the elastomeric disc and in contact with the piston that prevents the disc from extruding from the pot.

(g) Nominal Dimension. The distance between any two points.

(h) Pot Bearing. A high-load multi-rotational bearing comprising a steel pot and a close fitting piston separated by an elastomeric disc, together with a sliding plate where applicable.

(i) PTFE Seal. The component which is fixed around the perimeter of the PTFE pad to prevent moisture and debris from reaching the pad.

(j) Sliding Plate. A steel plate faced on one side with a smooth stainless steel sheet and fitted with guide bar(s) faced with smooth stainless steel strips, where applicable.

(k) Surface Roughness Parameter (Ra). Measurement of roughness of a surface being the arithmetic average of a profile above and below a reference line taken within a sampling length as specified in ISO 3274.

1.5 QUALITY MANAGEMENT SYSTEM REQUIREMENTS

The design and fabrication of the bearings must be carried out by a bearing supplier that has a third party certified quality management system to AS/NZS ISO 9001, including the design clauses and documented procedures for the design.

1.6 BEARING INFORMATION

Submit one (1) electronic and one (1) hard copy of the following information for each bearing type:

2 Ed 4 / Rev 2

http://www.rms.nsw.gov.au/business-industry/partners-suppliers/documents/tenders-contracts/listofapprovedbridgecomponentssystems.pdf

http://www.rms.nsw.gov.au/business-industry/partners-suppliers/documents/tenders-contracts/listofapprovedbridgecomponentssystems.pdf



(a) Name of the bearing supplier;

(b) Confirmation of all load cases (axial and shear loads, and rotation and movement in each direction);

(c) Drawings of the assembled bearing and attachment plates to scale with overall dimensions;

(d) Calculations detailing elastomer pressure, elastomer thickness, PTFE mean and peak pressures, maximum bearing stress on substructure and superstructure giving method of calculation, and forces on bolts and dowels with required sizes and grades;

(e) Basis of deriving the rotational stiffness used in the calculations;

(f) Calculations and methods for sealing the gap between piston and cylinder, accounting for all rotations;

(g) Evidence of internal sealing ring performance;

(h) PTFE thickness, dimpling pattern, grease type, and method of bonding to steel;

(i) Specification for machine polishing and method of attachment of stainless steel sliding surfaces;

(j) Treatment of skew and taper if applicable;

(k) Surface protection including colour, thickness and grit blasting details;

(l) Test loads, loading arrangement and evidence of NATA accreditation of testing facilities;

(m) Lifting and transportation arrangements; and

(n) Deviations from the Drawings or Specification.

Forward a certificate (including design calculations from a professional engineer experienced in the design of structural bearings) that details the information required in this Clause and which verifies that all bearings and attachments comply with the requirements of the Drawings and this Specification.

2 PROPERTIES OF MATERIALS

2.1 FERROUS MATERIALS

Fabricate pot, piston, sliding plate, guide bars and all attachment plates from structural steel conforming to AS/NZS 3678 and/or AS/NZS 3679.1.

Make sliding surfaces on the sliding plates and the guide bars from austenitic stainless steel conforming to ASTM A240M Grade 316 L with 2B-mill surface finish.

Bolts, nuts, screws and washers must conform to Specification RMS B240.

Ed 4 / Rev 2 3



2.2 POT SLIDING PAD AND STRIPS

Sliding pads and strips must be 100% virgin polytetrafluoroethylene (PTFE) conforming to ISO 13000-1 Grade 1, and etched on the side bonded to the steel.

Manufacture the sliding pad from unfilled PTFE dimensionally stabilised moulded sheet that is dimpled and lubricated in accordance with Clause 14.2 of AS 5100.4 on the face in contact with the sliding surface.

The sliding strips on the guide faces must be a durable filled PTFE with fillers being either milled glass fibre (25% maximum) or carbon fibre (25% maximum). Alternatively, sliding strips may be a multilayered composite material e.g. for a three layer composite; a bronze backing strip, a sintered interlocking porous impregnated matrix, and an overlay of PTFE/lead, graphite/lead or similar mixture.

Provide a current Certificate of Compliance verifying that each batch of the material complies with this Clause.

2.3 ELASTOMERIC DISC

The elastomer used in the elastomeric disc must comprise 100% virgin natural rubber (polyisoprene). The elastomer must be plain, not laminated or fibre reinforced.

The elastomer and its testing must conform to Type 53H of Appendix B of AS 5100.4. Provide certification that the raw material and manufacturing process for the elastomeric disc conform to the elastomer tested.

2.4 INTERNAL SEALS

Internal seals must be made from rectangular brass sections conforming to AS/NZS 1567 (half-hard). Where the zinc content in the brass is greater than 15%, the brass must be inhibited against dezincification.

Alternatively, internal seals may be made from stainless steel strips conforming to ASTM A204M Grade 316 L.

2.5 LUBRICANT

The lubricant used for filling the lubrication reservoirs in the dimpled face of the PTFE sliding pad, and for lubrication of the top and bottom surfaces of the elastomeric disc, must be made from silicone compounds. It must retain its consistency at room temperature over a temperature range of –40°C to +200°C. The lubricant must be compatible with all the components in contact with it. The lubricant must comply with the requirements of Table B282.2.

Submit test reports in accordance with Annexure Q/L of RMS Q showing conformity of the proposed lubricant with the requirements of Table B282.2.

4 Ed 4 / Rev 2



Table B282.2 – Properties of Lubricant

Property Requirements Method of Test

Penetration worked 60 stroke < 260 ASTM D217

Evaporation - 24 h at 200°C < 2% ASTM D972

3 DESIGN AND FABRICATION REQUIREMENTS

3.1 GENERAL

HOLD POINT

Process Held: Commencement of fabrication of bearings.

Submission Details: All details in accordance with Annexure B282/D at least five (5) working days before the proposed commencement of fabrication of the bearings.

Release of Hold Point: The Principal will consider the submitted documents for compliance with this Specification, prior to authorising the release of the Hold Point.

Pot bearings must be designed for Ultimate Limit State (ULS) effects and any associated sliding contact surfaces must be dimensioned to accommodate ULS movements. The design of the bearings must comply with the requirements of AS 5100.4 unless otherwise specified.

Where ultimate loads are required for design, and these loads have not been specified, then the relevant loads must be the Serviceability Limit State (SLS) loads multiplied by a factor of 1.5.

Bolts must be designed to AS 5100.6.

Allow for construction tolerances during the design and fabrication of the bearings and attachment plates, when required by the construction method adopted.

The bearings must be designed to allow removal for replacement using a maximum jacking lift of 5 mm.

All sharp edges, corners and sharp crests of welds must be rounded to a minimum radius of 1.5 mm. Edges of drilled holes must be smooth and rounded. Fabricated items must be free from defects, including weld spatter.

3.2 POT AND PISTON

The cylinder and base plate of the pot must be fabricated from one piece of steel. Welding of a separate base plate to the cylinder may be approved if supporting design calculations and/or experimental evidence are submitted showing that the strength of the welded component is equivalent to that made from a single piece of steel.

The piston must be machine-cut from a single piece of steel.

Ed 4 / Rev 2 5



The piston rim must have a nominal diameter not less than 1.0 mm less than the internal diameter of the pot. The vertical contact rim of the piston, which bears against the cylinder wall, can be flat in cross-section only where SLS rotation angle is less than or equal to 0.025 radians and where its thickness is less than or equal to 15 mm. The vertical contact rim of the piston must be bevelled or curved if the SLS rotation is greater than 0.025 radians or if its thickness is greater than 15 mm.

Internal surfaces of the bearing must be finished to a flatness not more than 0.005 times the nominal dimension and to a maximum surface roughness Ra of 6.3 µm.

The gap between the pot and the piston must be sealed against dust and moisture using either a small compression seal supplied and installed in accordance with Specification RMS B310 or a neutral cure silicon sealant with at least 50% movement accommodation factor. The seal must remain effective at the maximum serviceability rotation and must not be damaged at this rotation.

3.3 STAINLESS STEEL SLIDING SURFACE

The stainless steel sheet in the assembled bearing must completely cover the PTFE pad and extend beyond the specified limits of translation by no less than 25 mm except in the dimension normal to the direction of movement for guided bearings.

Stainless steel sheets with the larger plan dimension being less than 800 mm must be at least 1.5 mm thick. For larger plan dimensions greater than 800 mm, the minimum sheet thickness must be at least 2.5 mm.

Sheets must be mechanically polished using automated machinery to a mirror finish with a maximum surface roughness Ra of 0.4 µm.

Attach sheets to the backing plate by continuous welds along the edges. Design welds to resist the design frictional forces. The backing plate must extend beyond the stainless steel sheet to accommodate the welds. The PTFE must not come in contact with the weld perimeter.

Welding must conform to AS/NZS 1554.1 Category GP. Where used, electrodes must be of corrosion resistant material complying with AS/NZS 1553.3 or AS 2717.3 as appropriate. The weld size must not exceed the thickness of the stainless steel sheet.

Submit welding procedures prior to welding. Only use prequalified welding procedures in accordance with AS/NZS 1554.1. The welding procedures must detail the welding sequence necessary to eliminate distortion and to ensure flatness of the sheet and its full contact with the backing plate.

After welding, the flatness of the sliding sheet must not be more than 0.001 of the sheet’s larger plan dimension.

All welds and heat affected zones of the stainless steel sheet must be passivated and the sheet repolished to a maximum surface roughness Ra of 0.4 µm.

3.4 GUIDE BARS

Design guide bars to keep the guided surfaces of the pot parallel with the guide bars and within the guides at the specified limits of translation and rotation of the bearing.

Manufacture each guide bar from one piece of steel. Where the guide bar is of structural steel, face it with stainless steel strip welded as specified in Clause 3.3. Guide bars must be recessed into the

6 Ed 4 / Rev 2



sliding plate and must be designed to withstand the lateral forces shown on the drawings. The two contact surfaces of the guide bars must be parallel and flat to within 0.001 of the nominal dimension.

The maximum gap between a guide and its corresponding sliding surface must not exceed 3 mm when the other side is in full contact.

3.5 INTERNAL SEAL

The internal seal must consist of a number of split rings formed to fit snugly in recesses in the elastomeric disc and within the inside surface of the pot. Each ring must have one vertical cut at 45° to the tangent, with a maximum gap of 1 mm. These cuts must be staggered a minimum of 90° relative to one another when the rings are fitted to the elastomeric disc.

The rings must have a minimum thickness of 1.5 mm, with a minimum width of 6 mm for ring diameters less than or equal to 300 mm, and 10 mm for ring diameters larger than 300 mm. The minimum number of rings must be two, except where the outside diameter of the ring is greater than 700 mm or the specified rotational capacity is greater than 0.025 radians, when it must be three.

The rings must have a maximum surface roughness Ra of 6.3 µm.

3.6 PTFE SLIDING PAD

The PTFE pad for sliding bearings must have a minimum thickness of 6 mm for pads with any dimension larger than 650 mm, and 4 mm for smaller dimensions. The pad must be restrained by adhesive bonding and recessing into the backing material to a depth of half the thickness of the PTFE, to prevent its extrusion. The average adhesion-in-peel strength of the adhesive compound must not be less than 30 N when tested under standard conditions to ASTM Test Method C794.

The backing material to the PTFE and the mating surface must be sufficiently flat and rigid to ensure that the PTFE layer is uniformly loaded. The flatness of the PTFE pad must not be more than 0.002 of the pad diameter. The shoulder of the recess into the backing material must be sharp and square to resist extrusion of the PTFE. There must be no gap between the inner face of the recess and the PTFE.

The PTFE stresses must not exceed the values specified in AS 5100.4.

The PTFE pad must be permanently lubricated in accordance with Clause 14.2 of AS 5100.4. The lubricant used must meet the requirements of Clause 2.5 of this Specification.

3.7 ELASTOMERIC DISC

Each elastomeric disc must be made from one piece of elastomer, individually moulded or machine-cut from the moulded rubber slab. Discs must not be layered or stacked.

Proportion each bearing to achieve the design requirements specified in AS 5100.4.

Lubricate the disc with a silicone compound complying with the requirements of Clause 2.5 of this Specification.

In unloaded condition, the lateral clearance between the pot and the elastomeric disc must not exceed 0.2% of the diameter of the pad or 0.5 mm, whichever is greater.

Ed 4 / Rev 2 7



4 TESTING OF BEARINGS

4.1 GENERAL

The number of representative bearings to be tested from each type supplied for the Contract must be in accordance with Table B282.3.

Table B282.3 – Sampling Requirements

Number of Bearings of Each Type ≤ 10 ≤ 25 ≥ 50

Number to be tested 1 2 3

Test representative bearings in accordance with the Clauses 4.2 and 4.3.

Carry out testing in a laboratory certified by NATA for the test.

The direction of loads/rotations applied in all the tests must replicate the in-service conditions.

Test bearings as fabricated, excluding the seal between the pot and piston.

On completion of tests, each bearing tested must be dismantled and inspected for the defects listed in Clause 4.4.

Where a bearing complies with the specified requirements, it may be used in the Works. Lubricate all sliding surfaces and elastomeric discs before final reassembly and install the seal between the pot and piston.

4.2 GEOMETRICAL TESTING

The geometrical parameters to be tested are flatness, surface roughness, and clearances. These parameters must comply with the requirements of Clause 3.

Measure flatness in all directions using a precision straight edge sliding on the surface and feeler gauges.

4.3 PROOF LOAD TESTS

WITNESS POINT Proof Load Testing

Process Witnessed: First proof load test for each bearing type.

Submission Details: At least five (5) working days’ notice to the Principal of the date and location of bearing tests.

Proof loading test requirements are detailed in Table B282.4 and the following Clauses.

8 Ed 4 / Rev 2



Table B282.4 – Proof Loading Test Requirements

Bearing Type Vertical Lateral Friction Rotation

Fixed Yes Yes No Yes

Free sliding Yes No Yes Yes

Guided sliding Yes Yes Yes Yes

4.3.1 Vertical Proof Load Test

Bearings must be loaded in compression to the maximum ULS vertical load shown on the Drawings. The load must be maintained for one (1) minute, then released, reapplied and maintained for a minimum of three (3) minutes (the loading period must be the time the bearing sustains a test load of at least 95% of the initial load). Visually inspect the bearing whilst under the second loading.

4.3.2 Lateral Proof Load Test

Test bearings which are required to resist lateral forces as follows:

(a) the maximum ULS lateral load while loaded in compression to the minimum ULS vertical load shown on the Drawings; and

(b) the maximum ULS lateral load while loaded in compression to the maximum ULS vertical load shown on the Drawings.

In both cases, apply vertical load firstly, followed by gradual application of the lateral loads. Maintain the test loads for a minimum of three (3) minutes during which time visual inspection of the bearing must be carried out.

4.3.3 Coefficient of Friction Test

Determine the coefficient of friction using a vertical load corresponding to the factored down permanent vertical load on the bearing, at an ambient air temperature between 5°C and 35°C.

The test displacement must be equal to the design displacement value but not more than 50 mm. The vertical load must be applied and maintained for three (3) minutes before starting the test. The test sliding speed must be in the range of 2.5 to 25 mm/minute.

The maximum measured coefficient of friction must not exceed the values specified in Table B282.5 for the relevant stresses on the PTFE.

Table B282.5 – Coefficient of Friction for Sliding Surfaces

Bearing Pressure 5 MPa 15 MPa 20 MPa ≥ 30MPa

Coefficient of Friction 0.04 0.025 0.02 0.015

Note: Friction values must be linearly interpolated for intermediate bearing pressures.

4.3.4 Rotation Capacity Test

Test the bearing at the design rotation specified on the Drawings to 0.7 times the maximum ULS vertical load shown on the Drawings (refer to Clause 4.3.1).

Maintain the applied test load and rotation for at least three (3) minutes.

Ed 4 / Rev 2 9



4.4 FAILURE TO MEET REQUIREMENTS

Bearings failing to meet the dimensional requirements of Clause 4.2 and the proof loading requirements of Clause 4.3 must be rejected.

Bearings tested must be rejected if they exhibit any signs of damage visible to the naked eye such as, but not restricted to:

(a) splitting, extrusion or permanent deformation of the elastomer;

(b) opening, extrusion or permanent deformation of the external seal;

(c) tearing, cracking or permanent deformation of the PTFE sliding surfaces;

(d) cracking, indentation or permanent deformation of the internal seal or other part of the bearing;

(e) abrasive marks indicating abnormal contact between the metal surfaces of the bearing plates or piston, and the pot; or

(f) failure or permanent deformations of guide bars.

If a bearing is rejected, test two additional bearings from the batch it represents. If both bearings meet the requirements of this Specification, the remaining bearings in the Lot must be accepted. Otherwise, test each bearing remaining in the Lot for compliance.

5 PROTECTIVE TREATMENT

5.1 GENERAL

Unless specified otherwise, all work required for the protective treatment must comply with the requirements of AS/NZS 2312.

Apply protective treatment under factory conditions prior to assembly of the bearings. Carry out repairs to damaged coatings in accordance with the paint manufacturer’s recommendations.

Stainless steel sliding surfaces and bearing internal surfaces must not receive protective treatment and care must be taken to protect these surfaces from being damaged or coated during the application of the protective treatment to adjacent areas.

Notwithstanding the requirements of Clause 5.2, attachment plates attached to steel girders must receive the same protective treatment used for the girders.

All paints must be supplied by a single manufacturer and must comply with the specified Australian Paint Approval Scheme as per Annexure B282/E. Record details of paint used.

5.2 COATING SYSTEMS

Unless specified otherwise, coating systems for the bearing and attachment plates must be as shown in Table B282.6.

10 Ed 4 / Rev 2



Table B282.6 - Coating System for Bearing and Attachment Plates

Component Bearing- External Surfaces

Bearing - Internal Surfaces

Attachment Plates Fasteners Stainless

Steel Sheet

System ZP No treatment HDG or ZP HDG No treatment

where: ZP: Zinc metal spray and paint system as detailed in Annexure B282/E HDG: Hot dip galvanizing in accordance with AS/NZS 4680 (for attachment plates), AS 1214 (for fasteners) and this Specification

5.3 SURFACE PREPARATION

All steelwork to receive protective treatment, except that to be galvanized, must be abrasive blast cleaned in accordance with AS 1627.4 using crushed sharp angular metallic abrasive grit.

Before abrasive blast cleaning, clean all areas contaminated with oil, grease, fingerprints, salt residues or other contaminants using alkaline solutions in accordance with AS 1627.1.

Surface preparation for galvanized steelwork must be in accordance with AS/NZS 4680 and AS 1214 as appropriate.

5.4 ZINC METAL SPRAY

Apply zinc metal using an electric arc spray method for melting the zinc wire. Apply zinc metal spray to dry, dust free and abrasive blast cleaned surfaces before any discolouration or contamination of these surfaces and no later than 24 hours after blast cleaning. The temperature of the steelwork must be at least 3°C above the dew point.

The specified coating thickness must be the minimum local thickness on the significant surface of a single component in the bearing. Seal the zinc metal coating by an appropriate sealer prior to application of top coat.

5.5 HOT DIP GALVANIZING

Quench all galvanized items in a passivating chromate solution immediately after galvanizing.

5.6 PAINT APPLICATION

Paint must be applied using airless or air assisted airless spraying methods and must be applied to zinc sprayed steelwork no later than 24 hours after the zinc spraying. All edges of surfaces to be painted must receive a stripe coat of paint prior to spraying. Brush shadowed areas before spraying.

Apply paint coats under the environmental conditions specified by the paint manufacturer. Cure finished paintwork for a minimum of three days before dispatch of bearings to site, unless recommended otherwise by the manufacturer.

Ed 4 / Rev 2 11



6 BEARING REPORT Forward to the Principal a bearing report with test results demonstrating that all bearings supplied comply with the requirements of this Specification.

7 IDENTIFICATION AND DELIVERY All bearings must be clearly marked to identify their type and location in the bridge.

HOLD POINT

Process Held: Delivery of bearings to Site.

Submission Details: Bearing report in accordance with Clause 6 at least ten (10) working days before the proposed delivery of bearings to site.

Release of Hold Point: The Principal will consider the submitted documents for compliance with this Specification, prior to authorising the release of the Hold Point.

Supply mating parts of bearings in sets held together at the correct preset and skew, with metal transit clips and/or bolts, to prevent misalignment and/or damage of the components during transport and erection. Do not remove the transit clips and/or bolts until after completion of installation in the bridge. Protect bearings must be protected with dust and moisture resistant wrappings after assembly and during transportation to Site.

Deliver bearings to Site only after submission of the bearing report to the Principal.

8 INSTALLATION Install bearings in accordance with RMS B284 at the positions and orientations shown on the Drawings.

Install bearings level or at the grades shown on the Drawings, within a tolerance of 0.5% of level or the design grade respectively.

Where required, determine the anticipated hog or camber of the girders at the time of erection and make appropriate allowances during erection to ensure that the bearings are installed to the required tolerances.

12 Ed 4 / Rev 2



ANNEXURE B282/A – JOB SPECIFIC REQUIREMENTS

Paint System Colour of Paint Coat

ANNEXURE B282/B – (NOT USED)

ANNEXURE B282/C – SCHEDULES OF HOLD POINTS, WITNESS POINTS AND IDENTIFIED RECORDS

Refer to Clause 1.2.3.

C1 SCHEDULE OF HOLD POINTS AND WITNESS POINTS

Clause Point Description

3.1 Hold Commencement of fabrication of bearings

4.3 Witness Testing of first bearing of each type

7 Hold Delivery of bearings to site

C2 SCHEDULE OF IDENTIFIED RECORDS

The records listed below are Identified Records for the purposes of RMS Q Annexure Q/E.

Clause Description of Identified Record

1.6 Certificate and calculations from an Engineer which verifies that all bearings and attachments comply with the requirements of this Specification

6 Bearing report with test results

Ed 4 / Rev 2 13



ANNEXURE B282/D – PLANNING DOCUMENTS Refer to Clause 1.2.4.

The following documents are a summary of documents that must be included in the PROJECT QUALITY PLAN. The requirements of this Specification and others included in the Contract must be reviewed to determine documentation requirements in addition to the following:

(a) Workshop drawings, bearing information and certificate (refer to Clause 1.6);

(b) Technical procedures for welding and polishing the stainless steel sheet (refer to Clause 3.3);

(c) Technical procedure for bonding and lubricating the PTFE pad (refer to Clause 3.6);

(d) Technical procedure for dismantling and reassembly of test bearings (refer to Clause 4.3);

(e) Technical procedures for protective treatment (refer to Clause 5);

(f) Any variations from the drawings or specifications that have been accepted by the Principal.

14 Ed 4 / Rev 2



ANNEXURE B282/E – ZP COATING SYSTEM

Surface preparation 1. Abrasive blast cleaned to Class 3 / AS 1627.4

2. Nominal surface profile of 75µm

3. The surface profile measured in accordance with Method A / AS 3894.5

Material 1. Zinc wire: Zn 99.99 / ISO 752

2. MIO Epoxy: a two pack micaceous iron oxide pigmented polyamide cured epoxy coating conforming to GPC-C-29 / 7A

3. HB polyurethane: a full gloss two component, high build recoatable, acrylic modified polyurethane enamel, excluding two pack acrylic, included in a system conforming to GPC-C-29 / 11A

4. Sealer: a proprietary low viscosity sealer compatible with the top coat

Zinc Coat 1. Minimum local thickness of 150 µm

2. Local coat thickness measured in accordance with AS 2331.1.3.

Wet Paint Coating Systems Applied to Zinc Coating 1. The paint systems given in Table B282.7

2. Paint System A is the default system

3. System B only applied as a job specific requirement as per Annexure B282/A

4. Minimum DFT is the minimum dry film thickness measured in accordance with Magnetic Induction Method B/AS 3894.3

Table B282.7 – Properties of Wet Paint Coating

System A System B

Paint Min DFT (µm) Paint Min DFT (µm)

MIO Epoxy 125 HB Polyurethane 125

Colours

System A:

RMS Bridge Grey to Colours Card for MIO Pigmented Paints produced by the NSW State Paint Group of the APAS, June 1993, unless otherwise specified on Drawings or Annexure B282/A

System B:

Colour N35 “Light Grey” to AS 2700 unless otherwise specified on Drawings or Annexure B282/A

Ed 4 / Rev 2 15



ANNEXURES B282/F TO B282/L – (NOT USED)

ANNEXURE B282/M – REFERENCED DOCUMENTS Refer to Clause 1.2.6.

RMS Specifications

RMS Q Quality Management System

RMS B240 Supply of Bolts, Nuts, Screws and Washers

RMS B284 Installation of Bridge Bearings

RMS B310 Compression Seal Expansion Joints

Australian Standards

AS 1214 Hot-dip galvanized coatings on threaded fasteners (ISO metric coarse thread series)

AS/NZS 1553 Covered electrodes for welding

AS/NZS 1553.3 Corrosion-resisting chromium and chromium- nickel steel electrodes

AS/NZS 1554 Structural steel welding

AS/NZS 1554.1 Welding of steel structures

AS/NZS 1567 Copper and copper alloys - Wrought rods, bars and sections

AS 1627 Metal finishing – Preparation and pretreatment of surfaces

AS 1627.1 Removal of oil, grease and related contamination

AS 1627.4 Abrasive blast cleaning

AS/NZS 2312 Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings

AS 2331 Methods of test for metallic and related coatings

AS 2331.1.3 Local thickness tests – Magnetic method

AS 2700 Colour Standards For general purposes

AS 2717 Welding - Electrodes - Gas metal arc

AS 2717.3 Corrosion-Rresisting chromium and chromium-nickel steel electrodes

AS/NZS 3678 Structural steel - Hot-rolled plates, floorplates and slabs

AS/NZS 3679 Structural steel

AS/NZS 3679.1 Hot-rolled bars and sections

AS 3894 Site testing of protective coating

AS 3894.3 Determination of dry film thickness

AS 3894.5 Determination of surface profile

AS/NZS 4680 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles

16 Ed 4 / Rev 2



AS 5100 Bridge design

AS 5100.4 Bearings and deck joints

AS 5100.6 Steel and composite construction

AS/NZS ISO 9001 Quality management systems- Requirements

ASTM Standards

ASTM A240M Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM C794 Standard Test Method for Adhesion-in-Peel of Elastomeric Joint Sealants

ASTM D217 Standard Test Methods for Cone Penetration of Lubricating Grease

ASTM D972 Standard Test Method for Evaporation Loss of Lubricating Greases and Oils

ISO Standards

ISO 752 Zinc Ingots

ISO 3274 Surface texture: Profile method - Nominal characteristics of contact (stylus) instruments

ISO 13000 Plastics-Polytetrafluoroethylene (PTFE) Semi-Finished Products

ISO 13000-1 Requirements and designation

Ed 4 / Rev 2 17