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RCSC Section 6 tells you everything you need to know about washers. There's no impact on capacity, but they are definitely required under the head in certain circumstances. https://www.aisc.org/publications/steel-standards/rcsc/

Yeah, case 3 is not appropriate here. By following case 3 you have Hb equal to zero, Hc equal to 72.6k, and are dumping significant moment into the column. This does not match the assumptions in example 5.12. I'd try starting over with the general UFM case, with the workpoint set at the...

Can you post a picture of your mathcad analysis? I do not believe special case 3 applies to the gusset-to-base plate case, which has connections to both the horizontal and vertical interface. I think you'd need to use the general UFM case where "e" would be the beam eccentricity "eb" but with a...

The intent is that the top chord has local bending capacity as if you treated it like a beam spanning from panel point to panel point, to carry the 100# load. Anything in excess should have a field installed diagonal web member bringing the load back to a panel point (i.e. carried only by axial...

Draw a shear/moment diagram for the uniform load the joist is capable of supporting. As long as the induced shear/bending from the 100# loads does not create a larger bending moment or shear load than the envelope, it would be acceptable.

OSHA laying the blame on the contractor: Link I'll save my thoughts on PEMBs, but they are extremely scary while they're going up. Hopefully OSHA publishes the results of its investigation soon.

And from a general flag performance, expect this thing to get bound up on a daily basis. There's a big reason flag poles are round.

That whole thing really screams "retrofit opening in existing masonry wall with insufficient lintel".

EORs that write "full moment capacity" for connection designers should be fired into the sun.

Hung directly under a mechanical duct, oops!

Slope stability failure maybe?

Republicans overturned Roe V. Wade, so I guess they've made some political progress in reducing per capita footprint.

This book has some useful "boots on the ground" information, with some war stories included: Temporary Structures in Construction, Third Edition

Improper ventilation during galvanizing?

No, that'll raise the per capita carbon emissions. Everyone needs to have 8 kids to do their part.

Any reason slip critical bolts aren't being considered? Seems like that would be the most straightforward way to keep this as a bolted connection while transferring both shear and tension across the joint.

Check out ASCE 37, design loads on structures during construction. This allows you to reduce the design wind speed for short durations of exposure. I believe this document also states all temporary works should use risk category II, regardless of the structure.

Is it galvanized? Might be hydrogen assisted cracking. Best way to see if water is the culprit is to drill a 1/4" weep hole near the base plate, water will come out if that is the problem. I've seen this issue in the past, but the cracks were enormous and there wasn't much question as to why...

Sounds like a lap joint, limited by the 3/8" thick plate. AISC limits the leg size to 1/16" less than the thickness of the lapped plate, i.e. 5/16".

Too many bundles of deck stacked too early. Trusses look like custom fabrications as well, not a typical SJI bar joist.