On-Call_Guardrail_Repair_Services_-_Caltrans_Standard_Specifications_(Exhibit_A).pdf

83 RAILINGS AND BARRIERS

83-1 GENERAL

83-1.01 GENERAL

Section 83-1 includes general specifications for constructing railings and barriers.

Excavation and backfill must comply with section 19.

83-1.02 MATERIALS

83-1.02A General Reserved

83-1.02B Steel Parts and Hardware Welding must comply with AWS D1.1. Grind welds on exposed surfaces flush with the adjacent surfaces.

Galvanize completed steel parts and hardware for railings and thrie beam barrier under section 75-1.02B.

After galvanizing, the railing and barrier elements must be free of fins, abrasions, rough or sharp edges, and other surface defects and must not be kinked, twisted, or bent. If straightening is necessary, use an authorized method. Elements with kinks, twists, or bends may be rejected.

Clean and regalvanize (1) abraded or damaged galvanized surfaces of steel rail elements and posts and

(2) ends of steel rail elements cut after galvanizing. If authorized, you may repair the surfaces under section 75-1.02B instead of regalvanizing.

83-1.02C Mortar Mortar must comply with the specifications for mortar in section 51-1, except the mortar must consist of 1 part by volume of cement and 3 parts by volume of clean sand.

83-1.02D Markers Markers must comply with section 82.

83-1.03 CONSTRUCTION

83-1.03A General At locations exposed to traffic, schedule construction activities such that at the end of each day no post holes are open and no posts are installed without the blocks and rail elements assembled and mounted.

After constructing railings, barriers, terminal systems, crash cushions, and vegetation control, uniformly spread the surplus excavated material along the adjacent roadway where designated by the Engineer unless the material is hazardous.

83-1.03B Mortar Cure mortar by either the water method or the curing compound method using curing compound no. 6.

83-1.03C Median Barriers Trim existing median plantings to clear the work area for median barrier construction. Dispose of the trimmings.

Do not remove an existing median barrier more than 500 feet in advance of the barrier being constructed.

At the end of each day's activities, reset the existing median barrier without mesh or glare screen and anchor the barrier in an authorized way such that no gap is left between the reset barrier and the barrier being constructed. You may place Type K temporary railing instead of resetting the existing barrier.

83-1.04 PAYMENT

Except for midwest guardrail system and double midwest guardrail system, the payment quantity for railings is the length measured along the face of the railing, including end and intermediate posts, with no deductions for gaps in the railing for lighting and sign supports.

SECTION 83 RAILINGS AND BARRIERS

83-2 METAL RAILINGS AND BARRIERS

83-2.01 GENERAL

83-2.01A General 83-2.01A(1) General Section 83-2 includes specifications for constructing metal railings and barriers.

83-2.01A(2) Materials Plastic blocks for midwest guardrail systems and thrie beam barrier must be on the Authorized Material List for highway safety features.

Grease used to coat the inside surfaces of foundation tubes to receive wood posts must not melt or run at a temperature of 149 degrees F.

83-2.01A(3) Construction For midwest guardrail systems and thrie beam barrier, install posts, foundation tubes, and soil plates in soil.

83-2.01A(4) Payment Not Used

83-2.01B Minor Concrete Vegetation Control Reserved

83-2.02 MIDWEST GUARDRAIL SYSTEMS

83-2.02A General 83-2.02A(1) Summary Section 83-2.02 includes specifications for constructing midwest guardrail systems.

The reinforcing steel in the concrete anchors for Type CA end anchor assemblies must comply with section 52.

83-2.02A(2) Definitions Reserved

83-2.02A(3) Submittals Submit 2 certified copies of mill test reports as an informational submittal for each heat of steel from which the rail elements and steel posts are formed or fabricated.

For end anchor assemblies and rail tensioning assemblies, submit:

1. 2 certified copies of the mill test reports for each manufactured length of cable used.

2. 1 sample of the cable for testing. The cable must be 39 inches in total length and must be properly fitted with a swaged fitting and right-hand thread stud at both ends as specified in section 83- 2.02B(2), including a clevis if shown.

83-2.02A(4) Quality Assurance Reserved

83-2.02B Materials 83-2.02B(1) General 83-2.02B(1)(a) General Railing parts must be interchangeable with similar parts, regardless of the source.

83-2.02B(1)(b) Steel Components and Hardware Workmanship for steel components and hardware must be equivalent to good commercial practice.

Edges, bolt holes, and surfaces must be free of torn metal, burrs, sharp edges, and protrusions.

Fabricate the metal work in the shop. Do not punch, cut, or weld in the field.

Rail elements, end caps, and return caps must comply with AASHTO M 180 for Class A, Type I, W-beam guardrail, except within 0.5 miles of the coast the components must comply with AASHTO M 180 for Class A, Type II, W-beam guardrail.

Bolts, nuts, and other fittings must comply with AASHTO M 180.

Instead of the rolled steel section shown, you may substitute a welded section built up from structural steel plates if:

1. Depth, width, and average thicknesses of the welded section are at least equal to those of the rolled section

2. Steel plates of the welded section comply with ASTM A36/A36M

3. Flanges of the welded section are welded to the web with continuous fillet welds on each side of the web

The rail element metal must withstand a cold bend, without cracking, of 180 degrees around a mandrel of a diameter equal to 2.5 times the plate thickness.

If the radius of curvature of a rail element is 150 feet or less, shape the rail element in the shop. Stencil the radius of curvature on the back of each rail element in 2-1/2-inch-high numerals.

Fabricate steel posts from steel complying with ASTM A36/A36M.

Bolts must have shoulders of a shape that will prevent the bolts from turning. The holes in the rail elements must be of a shape similar to the bolt shoulder.

The bolted connection of the rail element to the post must withstand a 5,000 lb pull at 90 degrees to the line of the railing.

83-2.02B(1)(c) Wood Posts and Blocks The grade and species of wood posts and blocks must be no. 1 timbers, also known as no. 1 structural, Douglas fir or no. 1 timbers Southern yellow pine. Wood posts and blocks must be graded under section 57-2.01B(2), except allowances for shrinkage after mill cutting must not exceed 5 percent of the American Softwood Lumber Standard, PS 20, minimum sizes when installed.

Wood posts and blocks must be rough or S4S. The size tolerance of rough sawn blocks in the direction of the bolt holes must not exceed ±1/4 inch.

After fabrication, the wood posts and blocks must be pressure treated under section 57-2.01 and AWPA U1, Use Category UC4A, Commodity Specification A.

83-2.02B(1)(d) Bolt Hole Grease Grease used to fill bolt holes in wood posts and blocks must be recommended for corrosion protection by the manufacturer. The grease must not melt or run at a temperature of 149 degrees F.

83-2.02B(1)(e) Components for Connection to a Concrete Surface Components for connecting midwest guardrail systems to vertical concrete surfaces, such as bridge railings, barriers, retaining walls, and abutments, must comply with the following requirements:

1. Metal box spacers and plate washers must be fabricated from steel complying with ASTM A36/A36M.

2. Metal box spacers must be fabricated from separate plates and welded or press-formed and welded.

3. HS bolts must comply with ASTM F3125, Grade A325/A325M, or ASTM A449, or be fabricated from steel rods complying with ASTM A449. The bolts or rods must comply with the mechanical requirements in ASTM F3125, Grade A325/A325M after galvanizing. The nuts and washers must comply with ASTM F3125, Grade A325/A325M.

4. For connecting guardrail to existing bridge railings or barriers, the epoxy adhesive used in the sand and the epoxy adhesive mixture for repairing spalled or damaged areas around the anchor bolt holes must be a 2-component, commercial-quality epoxy adhesive manufactured especially for making epoxy-sand mortar.

83-2.02B(2) End Anchor Assemblies and Rail Tensioning Assemblies Section 83-2.02B(2) applies to end anchor assemblies and rail tensioning assemblies.

Concrete used to construct the anchors for end anchor assemblies must comply with the specifications for minor concrete.

Fabricate the metal components of anchor assemblies in compliance with good shop practice.

Fabricate the anchor plates, metal plates, foundation tubes, and soil plates from steel complying with

ASTM A36/A36M.

Fabricate the anchor rods from steel complying with ASTM A36/A36M, ASTM A572, or ASTM A576, Grade 1018, 1019, 1021, or 1026. Hot forge the eyes or form the eyes with CJP welds. After fabricating and before galvanizing, thermally stress relieve anchor rods with eyes that were formed with any part of the eye below 1,600 degrees F during forming or with eyes that were closed by welding. The completed anchor rod after galvanizing must develop a strength of 50,000 lb.

Instead of using built-up fabrication, you may press-form the anchor plates from steel plate with or without welded seams.

Bolts and nuts must comply with ASTM A307.

Anchor cables must be 3/4-inch, preformed 6 x 19 wire strand core or independent wire rope core, galvanized under Federal Specification RR-W-410, right regular lay, manufactured from improved plow steel with a minimum breaking strength of 23 tons. The overall length of each cable anchor assembly must be at least 6.5 feet.

Use cable clips and a cable thimble to attach the cable to the anchor rod where shown. Thimbles must be commercial-quality, galvanized steel. Cable clips must be commercial-quality, drop-forged, galvanized steel.

Swaged fittings must be machined from hot-rolled steel bars complying with AISI C 1035 and annealed suitable for cold swaging. Galvanize the swaged fitting before swaging. To keep the stud in the proper position, drill a lock pin hole through the head of the swaged fitting and install a 1/4-inch plated steel spring pin. Stamp the manufacturer's identifying mark on the body of the swaged fitting.

Before galvanizing, mill a 3/8-inch slot in the stud end for the locking pin. Studs must comply with ASTM A449 after galvanizing.

The swaged fittings, stud, and nut assembly must develop the specified breaking strength of the cable.

Ship cable assemblies as a complete unit, including studs and nuts.

Clevises must be drop-forged galvanized steel and must develop the specified breaking strength of the cable.

For anchor rods to be buried in earth, coat the portions to be buried with a 20-mil minimum thickness of one of the following:

1. Coal tar enamel complying with AWWA C 203

2. Coal tar epoxy complying with either of the following:

2.1. SSPC-Paint 16, Coal Tar Epoxy-Polyamide Black Paint

2.2. U.S. Army Corps of Engineers Specifications, Formula C-200a, Coal Tar-Epoxy (Black) Paint

83-2.02B(3) Type WB-31 Transition Railings Section 83-2.02B(3) applies to Type WB-31 transition railings.

Ten-gauge rail elements must comply with AASHTO M 180 for Class B, Type I, thrie beam element, except within 0.5 miles of the coast the 10-gauge rail elements must comply with AASHTO M 180 for Class B, Type II, thrie beam element.

Other rail elements and end caps must comply with AASHTO M 180 for Class A, Type I, thrie beam element, except within 0.5 miles of the coast the rail elements and end caps must comply with AASHTO M 180 for Class A, Type II, thrie beam element.

83-2.02C Construction 83-2.02C(1) General 83-2.02C(1)(a) General At locations where traffic is adjacent to midwest guardrail system work, all materials required to complete the guardrail work at a location must be available before you start work at the location.

Construct midwest guardrail systems using:

1. Wood or steel line posts.

2. Wood blocks for line posts. You may use plastic blocks for steel line posts where shown.

3. Only 1 type of post and block for any 1 continuous length of guardrail.

83-2.02C(1)(b) Posts Place the posts at equal intervals, except you may space the end posts closer to the adjacent posts if authorized.

Drive wood posts with or without pilot holes, or place the posts in drilled holes. Backfill any space around the wood posts with selected earth that is free of rock. Place the earth in 4-inch-thick layers. Moisten and thoroughly compact each layer.

Drive steel posts with or without pilot holes. If pilot holes are used, backfill any space around the steel posts with dry sand or pea gravel after driving.

Drive steel foundation tubes with soil plates attached with or without pilot holes, or place them in drilled holes. Backfill any space around the foundation tubes with selected earth that is free of rock. Place the earth in 4-inch-thick layers. Moisten and thoroughly compact each layer. Coat the inside surfaces of the foundation tubes to receive wood terminal posts with grease. Insert the posts into the tubes by hand. Do not drive the posts. You may slightly round the post edges to facilitate insertion.

83-2.02C(1)(c) Bolt Holes and Cuts in Wood Posts and Blocks If copper naphthenate, ammoniacal copper arsenate, ammoniacal copper zinc arsenate, ammoniacal copper quat, or copper azole is used to treat wood posts and blocks, before inserting the bolts, fill the bolt holes with grease.

You may field bore the 2-3/8-inch-diameter holes shown for breakaway wood guardrail terminal posts.

If you perform field cutting or boring after treatment, thoroughly swab, spray, or brush the cuts and holes with 2 applications of the same type of preservative as initially used or treat the cuts and holes with copper naphthenate under AWPA Standard M4. Preservative application in the field must comply with the 1st and 2nd paragraphs of section 57-2.01C(3)(b).

83-2.02C(1)(d) Rail Elements The edges and center of the rail elements must contact each post block.

Splice the rail elements at 12.5-foot maximum intervals. Locate the splices at midspan between posts.

Rail element splices must be lapped at least 12-1/2 inches and bolted.

Lap the rail elements such that the exposed ends do not face approaching traffic.

The rail elements must have full bearing at joints.

Install end caps and return caps under the manufacturer's instructions.

83-2.02C(1)(e) Connection to a Concrete Bridge Railing or Barrier If connecting a midwest guardrail system to a new concrete bridge railing or barrier, drill anchor bolt holes in the concrete or form holes using metal or PVC sleeves.

If connecting a midwest guardrail system to an existing concrete bridge railing or barrier, drill anchor bolt holes in the concrete.

Repair any areas around the holes that were spalled or otherwise damaged during drilling using an epoxy adhesive and sand mixture in proportions of 1:4 to 1:6. The epoxy adhesive must comply with section 83- 2.02B(1)(e). Mix the 2 components and the epoxy-sand mixture under the manufacturer's instructions.

83-2.02C(1)(f) Anchor Bolts Set With Epoxy For anchor bolts set with epoxy, place the anchor bolts in holes filled with a 2-component epoxy mixture complying with the specifications for load bearing applications.

83-2.02C(2) End Anchor Assemblies Place the concrete for end anchors for Type CA end anchor assemblies against the undisturbed material of the excavated holes. If ordered, form the top 12 inches of the holes.

Tighten the anchor cables for Type CA end anchor assemblies after the concrete anchor has cured for at least 5 days.

Backfill the holes excavated in the slope to construct buried post end anchors with selected earth. Place the earth in layers approximately 1 foot thick. Moisten and thoroughly compact each layer.

83-2.02C(3) Type WB-31 Transition Railings Reserved

83-2.02D Payment Except for midwest guardrail systems located within the pay limits of (1) a terminal system, (2) a transition railing, (3) an end anchor assembly, or (4) a railing tensioning assembly, the payment quantity for midwest guardrail system is the length measured along the face of the rail element from end post to end post of the completed railing and includes buried post anchors. The point of measurement at the end post is the center of the bolt attaching the rail element to the end post. If midwest guardrail system is connected to a structure, barrier, wall, or abutment, the point of measurement is the midpoint between the 2 bolts attaching the rail element to the structure, barrier, wall, or abutment.

The payment quantity for double midwest guardrail system is the length measured from end post to end post along the center line of the guardrail.

An end anchor assembly (Type CA) with 2 cables attached to 1 concrete anchor is 1 measurement unit.

83-2.03 THRIE BEAM BARRIERS

83-2.03A General Section 83-2.03 includes specifications for constructing thrie beam barrier.

Thrie beam barrier must comply with the specifications for midwest guardrail systems in section 83-2.02.

Single thrie beam barrier work includes transition sections between W beam and thrie beam elements.

83-2.03B Materials Rail elements, terminal connectors, end caps, and return caps must comply with AASHTO M 180 for Class A, Type I, thrie beam guardrail, except within 0.5 miles of the coast the components must comply with AASHTO M 180 for Class A, Type II, thrie beam guardrail.

Ten-gauge rail elements for transition railings must comply with AASHTO M 180 for Class B, Type I, thrie beam element, except within 0.5 miles of the coast the 10-gauge rail elements must comply with AASHTO M 180 for Class B, Type II, thrie beam element.

Other rail elements and end caps for transition railings must comply with AASHTO M 180 for Class A, Type I, thrie beam element, except within 0.5 miles of the coast the rail elements and end caps must comply with AASHTO M 180 for Class A, Type II, thrie beam element.

Use steel posts for thrie beam barrier on bridges. Use wood posts for approach barrier transitions to connect to concrete structures and for posts set in steel foundation tubes at trailing end anchors. At all other locations, use either wood or steel posts. Use only 1 type of post in any 1 continuous length of barrier.

Use wood blocks with wood and steel posts. You may use plastic blocks with steel posts where shown.

For thrie beam barrier on bridges:

1. Threaded rods must comply with ASTM A307

2. Anchor bolts must comply with ASTM F1554, Grade 55

3. Plates must comply with section 55

83-2.03C Construction Toenailing wood blocks to wood posts is not required.

If the spacing between the posts must be varied from the standard spacing, you may modify the rail elements at the job site if authorized. Repair damaged galvanizing under section 75-1.02B.

For thrie beam barrier on bridges:

1. If cored or drilled holes for anchor bolts must be offset to avoid existing main reinforcing steel, the corresponding base plate anchor bolt holes may be slotted to adjust to the new anchor bolt locations.

Slotting must not reduce the edge distance of the hole to less than 7/8 inch.

2. Drilling of anchor bolt holes and bonding of bolts must comply with the specifications for drilling and bonding dowels in section 51-1.03E(3).

If median barrier delineation is shown, match the barrier marker spacing to the raised pavement marker spacing on the adjacent median edgeline pavement delineation.

83-2.03D Payment The payment quantity for single thrie beam barrier is the length measured from end post to end post along the face of the rail element of the installed barrier. The quantity does not include any portion of single thrie beam barrier within the pay limits of transition railing (Type STB).

The payment quantity for single thrie beam barrier constructed on each side of a bent underneath a structure or on each side of other obstructions is the length measured along each face of the installed barriers.

The payment quantity for double thrie beam barrier is the length measured from end post to end post along the center line of the installed barrier. The quantity does not include any portion of double thrie beam barrier within the pay limits of transition railing (Type DTB).

The point of measurement at the end posts of single and double thrie beam barriers is the center of the bolt or rod attaching the rail element to the end post.

If a single thrie beam barrier is constructed on each side of a median obstruction and the single barriers merge into a double barrier, the post with 2 blocks attached is the end post for measuring the length of the single and double thrie beam barriers.

The division point for determining the payment quantities of double thrie beam barrier (bridge) and double thrie beam barrier is the face of the paving notch of the bridge.

83-2.04 TERMINAL SYSTEMS

83-2.04A General 83-2.04A(1) General Section 83-2.04 includes specifications for constructing terminal systems.

83-2.04A(2) Materials Not Used

83-2.04A(3) Construction Not Used

83-2.04A(4) Payment Not Used

83-2.04B Alternative In-Line Terminal Systems Reserved

83-2.04C Alternative Flared Terminal Systems Reserved

83-2.04D–83-2.04H Reserved

83-2.05 CALIFORNIA BRIDGE RAILS

83-2.05A General 83-2.05A(1) Summary Section 83-2.05 includes specifications for constructing California bridge rail.

Concrete must comply with section 51.

Reinforcement must comply with section 52.

California ST-20S bridge rail work includes the handrailing.

83-2.05A(2) Definitions Reserved

83-2.05A(3) Submittals Submit shop drawings for the California bridge rail. The shop drawings must include:

1. Details for venting and pickup holes in rails and sleeves

2. Railing layout

3. Complete details for the construction of the work, including construction methods, sequence of shop and field assembly, and installation procedures

Submit 7 copies of the shop drawings. Allow 25 days for review. Upon authorization, the Engineer returns 2 copies to you for use during construction.

83-2.05A(4) Quality Assurance Reserved

83-2.05B Materials 83-2.05B(1) General Reserved

83-2.05B(2) Reinforced Concrete In freeze-thaw areas:

1. Concrete must contain at least 675 pounds of cementitious material per cubic yard

2. Bar reinforcing steel must comply with section 52-2.02

83-2.05B(3) Metal Components Structural shapes, structural tubing, plates, bars, bolts, nuts, and washers must comply with section 55-

1.02. Other fittings must be commercial quality.

Formed steel sections must be uniform in appearance.

Stud bolts must comply with the specifications for studs in clause 7 of AWS D1.1.

Ferrous metal parts must be galvanized under section 75-1.02B.

Railings must conform to the curvature by means of a series of short chords, from center-to-center of rail posts, except (1) tubing for railings described as conforming to the curvature must be shop bent to fit the curvature and (2) tubing with a horizontal curve radius less than 900 feet must be shop bent or fabricated to fit the curvature. Joints must be matchmarked.

83-2.05B(4) Coatings Organic zinc-rich primer used to paint the exposed bolt threads must be on the Authorized Material List for organic zinc-rich primers.

83-2.05C Construction Railings must present a smooth, uniform appearance in their final position, conforming closely to the horizontal and vertical lines shown or ordered.

Erect railings carefully and true to line and grade. Posts must be normal to the profile grade. Transverse to the profile grade, railings must be plumb within a tolerance not to exceed 0.02 foot in 10 feet. Adjacent rail elements must align with each other within 1/16 inch.

In freeze-thaw areas, cure concrete by the water method.

After installing the rail, paint the exposed bolt threads with 2 applications of organic zinc-rich primer.

83-2.05D Payment The payment quantity for California bridge rail is the length measured from end to end along the face of the railing, including reinforced concrete end blocks and intermediate posts.

83-2.06 CHAIN LINK RAILINGS

83-2.06A General Section 83-2.06 includes specifications for constructing chain link railings.

83-2.06B Materials Structural shapes, plates, bars, and bolts must comply with section 55-1.02.

Structural tubing steel must comply with ASTM A500/A500M or A501.

Frame members carrying electrical conductors must be rigid metal conduit manufactured of mild steel complying with UL 6, Electrical Rigid Metal Conduit - Steel. Hot dip galvanize the interior and exterior surfaces of the rigid metal conduit.

Truss rods, post tops, and other required fittings and hardware must be steel, malleable iron, or wrought iron. Post tops and other closures must be watertight. Fittings and hardware must fasten properly to the posts and other members.

Cable used in the frame must:

1. Be wire rope

2. Be 5/16 inch in diameter

3. Have a minimum breaking strength of 5,000 lb

4. Be galvanized under Federal Specification RR-W-410

Crimped sleeve clamps and stud socket assemblies must:

1. Be metal

2. Develop the strength of the cable

3. Be the same color as the cable

Tension wires must be at least 7-gauge coil spring steel.

Post clips must be at least 9-gauge steel.

Wire ties or hog rings must be 9-gauge, commercial-quality steel wire.

Galvanize the tension wires, post clips, wire ties, and hog rings under ASTM A116, Coating Type Z, Class 3.

You may substitute one of the following for the steel wire ties or hog rings:

1. 6-gauge (0.192-inch minimum diameter) aluminum wire ties complying with ASTM B211 or B211M, Alloy 1100-H18

2. 6-gauge (0.192-inch minimum diameter) aluminum hog rings complying with ASTM B211 or B211M, Alloy 6061-T94 or Alloy 5052-H38

Chain link fabric must be 11 gauge and must comply with one of the following:

1. AASHTO M 181, Type I, Class C

2. AASHTO M 181, Type IV, Class A

3. ASTM F1345, Class 2

Chain link fabric must be woven into approximately 1-inch mesh.

All of the railings for a single structure must be the same color.

83-2.06C Construction Give wire ties at least 1 complete turn. Bend the wire tie ends away from pedestrian traffic.

Tighten truss rods and cables with turnbuckles or other fittings.

Install a thimble at each cable loop.

Stretch and fasten the chain link fabric securely to the posts, other members, and tension wires. Stretch the tension wires tightly.

Wherever necessary to conform to horizontal or vertical curvature, rework and fit the fabric to present a smooth, neat, and workmanlike appearance.

Provide openings in the fabric as required by other facilities. Reinforce the openings with at least 1 turn of 6-gauge wire.

Attach pipe handrailing to chain link railing where shown. Pipe handrailing must comply with section 83- 2.09.

83-2.06D Payment Not Used

83-2.07 CABLE RAILINGS

83-2.07A General Section 83-2.07 includes specifications for constructing cable railings.

83-2.07B Materials Concrete for the post footings must comply with the specifications for minor concrete.

Pipe for posts and braces must be standard steel pipe or pipe complying with section 80-3.02B.

Truss rods, post tops, cable clamps, eye bolts, thimbles, and other required fittings must be commercial-quality steel, malleable iron, or wrought iron. Post tops must be watertight. The eye of the eye bolts must be either drop forged or formed with a complete penetration weld. The eye must develop 100 percent of the bolt strength.

Turnbuckles must:

1. Be commercial quality

2. Have jaw or eye ends

3. Have a minimum breaking strength of 2,700 lb

4. Be steel pipe type or drop-forged steel

Crimped sleeve clamps and stop sleeve clamps must:

1. Be nonferrous metal

2. Develop the strength of the cable

3. Be the same color as the cable

Cables must:

1. Be wire strand or rope

2. Have a minimum diameter of 1/4 inch

3. Have a minimum breaking strength of 1,800 lb

4. Be galvanized under Federal Specification RR-W-410

83-2.07C Construction Tension the cables to provide taut railings between posts.

Install a thimble at each cable loop.

83-2.07D Payment Not Used

83-2.08 TUBULAR HANDRAILINGS

83-2.08A General Section 83-2.08 includes specifications for constructing tubular handrailings.

83-2.08B Materials The materials for tubular handrailing components must comply with the specifications shown in the following table:

Material Specification Rail and post tubes ASTM A500/A500M, Grade B Rolled bars and plates ASTM A36/A36M Rail splice sleeves ASTM A36/A36M Bolts ASTM F3125, Grade

A325/A325M Threaded rods ASTM A449 Nuts for bolts and threaded rods ASTM A563/A563M Washers for bolts and threaded rods ASTM F436/F436M

Bolts and threaded rods furnished under ASTM A449 must comply with the mechanical requirements specified in ASTM A449 after galvanizing.

If the vertical radius of the tubular handrailing is 30 feet or less, that portion of the railing must be either shop bent or built up from 1/4-inch-thick structural steel plates. The built-up tubular rail elements must match the seamless tubing in appearance.

83-2.08C Construction

Before the tubular handrailing parts are assembled, clean the bearing surfaces and surfaces to be in permanent contact. If the railing is mounted on a concrete surface, the post bases must be true and flat to provide uniform bearing.

Adjust the vertical position of the tubular handrailing to compensate for the camber and dead load deflection of the superstructure. The Engineer determines the adjustment amount before the railing is installed.

Carefully handle the materials such that no parts are bent, broken, abraded, or otherwise damaged. Do not use manufacturing, handling, or installation methods that damage or distort the members or damage the galvanizing.

Tubular handrailings must present a smooth, uniform appearance in their final position, conforming closely to the horizontal and vertical lines shown or ordered.

The difference between out-to-out rail splice sleeve dimensions and the clear inside dimensions of the tubular steel rail elements must not exceed 3/16 inch after galvanizing.

Rail tubes must be shop bent or fabricated to fit the horizontal curve if the radius is less than 900 feet.

The metal railing posts to which the chain link railing attaches must fit the mounting brackets, pipe sleeves, and other connection fittings.

Where necessary, install shims at posts and rail elements to provide uniform bearing and conformance with the horizontal lines and vertical grade lines. Shims at steel posts must be commercial-quality, galvanized sheet steel.

83-2.08D Payment Not Used

83-2.09 PIPE HANDRAILINGS

83-2.09A General Section 83-2.09 includes specifications for constructing pipe handrailings.

83-2.09B Materials Rail elements must be commercial-quality standard steel pipe.

Brackets, bolts, nuts, and other fittings must be commercial-quality structural steel, except standard steel pipe fittings may be used where shown.

83-2.09C Construction Erect pipe handrailings carefully and true to line and grade.

83-2.09D Payment Not Used

83-2.10–83-2.14 RESERVED

83-3 CONCRETE BARRIERS

83-3.01 GENERAL

83-3.01A Summary Section 83-3 includes specifications for constructing concrete barriers and wildlife passage ways in concrete barriers.

Concrete must comply with section 51.

Reinforcement must comply with section 52.

Drill and bond dowels under section 51.

Concrete barrier work includes:

1. Bar reinforcing steel, including the length that extends from the barrier into decks, walls, and footings

2. Constructing Type L wildlife passage ways

3. Constructing steel plate barriers at overhead sign foundations, electroliers, drainage structures, and other locations shown

For Type 80SW concrete barriers:

1. Tubular handrailing and tubular lower rail must comply with the specifications for tubular handrailings in section 83-2.08

2. Threaded rods for the tubular handrailing and resin capsule anchors for the tubular lower rail must comply with section 75-3

Type K concrete barrier must comply with the specifications for Type K temporary railing in section 12-

3.20 and the plans for Type K temporary railing, except removable panels must not be used and the barriers must remain in place at the completion of the work.

Thrie beam barrier elements, end caps, and hardware required to construct Type M wildlife passage ways must comply with section 83-2.03.

83-3.01B Definitions Reserved

83-3.01C Submittals If the extrusion or slip form method is to be used and the reinforcement is not fixed in place before placing the concrete, submit a QC plan for the extrusion or slip form construction method. The QC plan must include:

1. Contingency plan for correcting problems in production, transportation, or placement

2. Procedure for splicing concrete barrier reinforcement

3. Procedure for positioning reinforcement during extrusion or slip form operations

4. Test procedure for verifying the final positions of the longitudinal reinforcement

5. Test report form to be used that shows the station of the test, the position of the reinforcement relative to the top of the barrier, and the clearance cover from the faces of the barrier to the reinforcement

Submit the test report forms within 48 hours after constructing the concrete barrier.

Submit a certificate of compliance for a new or used Type 60K portable concrete barrier that is not cast on the job site.

For the tubular handrailing on a Type 80SW concrete barrier, submit 2 copies of the threaded rod layout before placing the barrier reinforcement.

83-3.01D Quality Assurance 83-3.01D(1) General Reserved

83-3.01D(2) Quality Control 83-3.01D(2)(a) General s

Reserved

83-3.01D(2)(b) Barrier Smoothness Test the smoothness of the top and exposed faces of barriers using a 10-foot straightedge laid on the surfaces.

83-3.01D(2)(c) Barrier Reinforcement Positions For the extrusion or slip form construction method, if the reinforcement is not fixed in place before placing the concrete, verify the final positions of the horizontal reinforcement at 100-foot intervals, evaluated a minimum of 20 feet behind the trailing extrusion or slip form edge, by testing the position of the reinforcement relative to the top of the barrier and the clearance cover from the faces of the barrier to the reinforcement.

83-3.01D(3) Department Acceptance The Department rejects concrete barriers with any reinforcement that does not comply with section 83- 3.03A(6)(c)(iii).

83-3.02 MATERIALS

83-3.02A General Reserved

83-3.02B Concrete 83-3.02B(1) General Concrete for Type 60 series concrete barriers must comply with the specifications for minor concrete, except the concrete must contain at least 550 pounds of cementitious material per cubic yard.

In non-freeze-thaw areas, concrete for concrete barriers other than Type 60 series must contain at least 590 pounds of cementitious material per cubic yard.

In freeze-thaw areas, concrete for concrete barriers must contain at least 675 pounds of cementitious material per cubic yard.

For Type 60F, 60GE, and 60SF concrete barriers, the concrete paving between the tops of the 2 walls of the barrier and the optional concrete slab at the base between the 2 walls of the barrier must comply with the specifications for minor concrete.

83-3.02B(2) Concrete for Extrusion or Slip form Methods Minor concrete for extruded or slip formed concrete barriers must comply with the following:

1. Maximum aggregate size must be no larger than 1-1/2 inches and no smaller than 3/8 inch.

2. If the 3/8-inch maximum size aggregate is used, the concrete must contain at least 675 pounds of cementitious material per cubic yard.

3. Combined aggregate gradation must produce concrete of the shape and surface texture specified.

4. Consistency must be such that after extrusion or slip forming, the concrete maintains the shape of the barrier without support.

You may make the concrete by continuously batching the materials by volume and mixing in a continuous mixer under the batching and mixing requirements in ASTM C685/C685M.

83-3.02C Bar Reinforcing Steel In freeze-thaw areas, bar reinforcing steel for concrete barriers must be epoxy coated under section 52- 2.02.

83-3.02D Steel Plates and Hardware Structural steel plates and hardware required to join the concrete barrier at gaps caused by overhead sign foundations, electroliers, drainage structures, and at other locations shown must comply with section 75-3.02A.

83-3.02E Granular Backfill For Type 60F, 60GE, and 60SF concrete barriers, the granular material for backfill between the 2 walls of concrete barrier must:

1. Be earthy material suitable for the purpose intended

2. Have no rocks, lumps, or clods exceeding 1-1/2 inches in greatest dimension

83-3.02F Type K Concrete Barrier Reflectors Type K concrete barrier reflectors must be Type K temporary railing reflectors on the Authorized Material List for signing and delineation materials.

The adhesive used to mount reflectors on a Type K concrete barrier must comply with the manufacturer's instructions.

83-3.02G Connection of a Concrete Barrier to a Structure Sheet metal, neoprene strip, and grease at the connection of a concrete barrier to a structure must comply with the following:

1. Sheet metal must be commercial-quality galvanized sheet steel that is smooth and free of kinks, bends, or burrs. Joints in the sheet metal must be butt joints sealed with plastic duct-sealing tape.

2. Neoprene strip must comply with the specifications for neoprene in section 51-2.04.

3. Grease must comply with SAE AS8660.

Expanded polystyrene at the connection of a concrete barrier to a structure and at a concrete barrier transition at a bridge column must comply with section 51-2.01B(1).

83-3.02H Type 60K Portable Concrete Barriers Type 60K portable concrete barrier must consist of interconnected new or undamaged used PC portable concrete barrier units.

For Type 60K portable concrete barrier:

1. Concrete must comply with the specifications for minor concrete, except weighmaster certificates and certificates of compliance are not required.

2. Steel plates must comply with ASTM A36/A36M. After fabrication, galvanize the steel plates under section 75-1.02B.

3. Connection pins must be round bars complying with ASTM A36/A36M.

83-3.03 CONSTRUCTION

83-3.03A General 83-3.03A(1) General Reserved

83-3.03A(2) Closing Gaps in Concrete Barriers During construction on highways open to traffic, if a gap is left in the concrete barrier, such as for equipment or special drainage features, close the gap by temporary or permanent means when work is not actively in progress at the location of the gap.

83-3.03A(3) Adjusting Barrier Height If the concrete barrier height is adjusted, the Engineer determines the adjustment amount before the concrete is placed.

If a concrete barrier is constructed on AB, adjust the barrier height to compensate for irregularities in the surface of the finished AB.

For a concrete barrier constructed on a recently completed bridge, adjust the barrier height to compensate for the camber and dead load deflection of the superstructure. Construct the barrier after the falsework has been released and as long after the superstructure construction as the progress of the work will allow.

For a concrete barrier constructed on existing pavement or on an existing structure, adjust the barrier height to compensate for irregularities in the existing grade.

83-3.03A(4) Locating Expansion Joints Locate concrete barrier expansion joints at deck, pavement, and principal wall joints. The expansion joint filler material must be the same size as the joint or a minimum of 1/2 inch.

83-3.03A(5) Placing Barriers The concrete barrier must present a smooth, uniform appearance in its final position, conforming closely to the horizontal and vertical lines shown or ordered. The barrier must be free of lumps, sags, or other irregularities.

You may place the portion of the barrier that is below finished grade to the neat lines of the excavation.

83-3.03A(6) Barrier Construction Methods 83-3.03A(6)(a) General Construct Type 60 series concrete barriers by one of the following methods:

1. Cast-in-place-with-fixed-forms method

2. Extrusion or slip form method

3. Combination of both methods

Construct concrete barriers other than Type 60 series by the cast-in-place-with-fixed-forms method.

83-3.03A(6)(b) Cast-In-Place-with-Fixed-Forms Method Concrete barriers constructed by the cast-in-place-with-fixed-forms method must comply with section 51.

Do not use PC mortar blocks to support the reinforcing steel on the traffic side of barriers.

83-3.03A(6)(c) Extrusion or Slip form Method 83-3.03A(6)(c)(i) General Reserved

83-3.03A(6)(c)(ii) Placing Concrete For concrete barriers constructed using an extrusion or slip form machine or other similar type of equipment, the concrete must be well compacted and dense and the exposed surfaces must comply with section 51. You may be required to submit evidence of successful operation of the extrusion or slip form machine or other equipment.

Feed the concrete to the extrusion or slip form machine at a uniform rate. Operate the machine under enough uniform restraint to the forward motion to produce a well-compacted concrete mass free from surface pits larger than 1 inch in diameter and requiring no further finishing other than that specified in section 83-3.03A(7).

83-3.03A(6)(c)(iii) Placing Reinforcing Bars For concrete barriers constructed using extrusion or slip form methods, place the horizontal reinforcing bars continuously.

If the reinforcement is not fixed in place before placing the concrete, the reinforcement must not deviate more than 1 inch from the positions shown when tested under section 83-3.01D(2)(c).

83-3.03A(6)(c)(iv) Maintaining Barrier Grades The grade for the top of concrete barriers constructed using extrusion or slip form methods must be indicated by an offset guide line set from survey marks established by the Engineer. The forming portion of the extrusion or slip form machine must be readily adjustable vertically during the forward motion of the machine to conform to the predetermined grade line. A grade line gauge or pointer must be attached to the machine such that a continual comparison can be made between the barrier being placed and the established grade line as indicated by the offset guide line.

Instead of the above method for maintaining the barrier grade, the extrusion or slip form machine may be operated on rails or forms set at a uniform depth below the predetermined finished top of the barrier grade or on existing pavement or bridge decks.

83-3.03A(6)(c)(v) Constructing Expansion Joints For concrete barriers constructed using extrusion or slip forming methods, construct expansion joints using one of the following methods:

1. Comply with section 51.

2. Saw through the barrier section to its full depth. Insertion of joint filler is not required.

If you saw or form the joints before the concrete has hardened, firmly support the adjacent portions of the barrier with close fitting shields.

If you saw or form the joints after applying curing compound, treat the exposed barrier faces in the vicinity of the joint with curing compound after sawing or forming the joints.

83-3.03A(7) Finishing Before applying the curing compound, the surface finish of Type 60 series concrete barriers must be free from surface pits larger than 1 inch in diameter and you must give the surface a final soft brush finish with strokes parallel to the line of the barriers. Do not finish the surface with a brush application of grout.

To facilitate finishing, remove fixed forms for CIP Type 60 series concrete barriers as soon as possible after the concrete has set enough to maintain the barrier shape without support.

At least 7 days after placing Type 60 series concrete barriers, give the exposed surfaces a light abrasive blast finish to achieve a uniform appearance.

The final surface finish of concrete barriers other than Type 60 series must be a Class 1 surface finish complying with section 51-1.03F(3). Any alternative method of final surface finishing must be authorized.

83-3.03A(8) Curing Cure the exposed surfaces of concrete barriers under section 90-1.03B by the curing compound method using curing compound no. 6. For concrete barriers on bridges and walls that do not support soundwalls, you may instead cure the formed surfaces of the barriers by the forms-in-place method if you keep the forms in place for at least 12 hours after placing the concrete.

For Type 60 series concrete barriers, apply the curing compound using a mechanical sprayer capable of applying the curing compound to at least 1 entire side and the top of the concrete barrier in 1 application at a uniform rate of coverage. Protect the spray against wind.

In freeze-thaw areas, cure concrete barriers on bridges and walls under section 90-1.03B by the water method.

For Type 80 series concrete barriers, keep the forms in place for at least 36 hours after placing the concrete.

83-3.03A(9) Smoothness The top and exposed faces of barriers must comply with the following smoothness requirements when tested under section 83-3.01D(2)(b):

1. For Type 60 series concrete barriers, the top must not vary more than 0.02 foot from the edge of the straightedge and the faces must not vary more than 0.04 foot from the edge of the straightedge.

2. For concrete barriers other than Type 60 series, both the top and faces must not vary more than 0.02 foot from the edge of the straightedge.

83-3.03A(10) Installing Tubular Handrailings For a tubular handrailing mounted on a Type 80SW concrete barrier, drill and bond the threaded rods under the specifications for drilling and bonding dowels in section 51-1.

83-3.03A(11) Installing Barrier Markers Where concrete barrier markers are shown, cement the markers to the barrier under the manufacturer's instructions. Match the barrier marker spacing to the raised pavement marker spacing on the adjacent median edgeline pavement delineation.

83-3.03A(12) Installing Reflectors Where shown, install reflectors on Type K concrete barriers. Mount the reflectors using an adhesive complying with section 83-3.02F.

83-3.03A(13) Placing Granular Backfill For Type 60F, 60GE, and 60SF concrete barriers, place the granular material for backfill between the 2 walls of the concrete barrier must be placed without compaction.

83-3.03B Concrete Barriers at Existing Structures For a concrete barrier constructed on an existing structure, bond the dowels in drilled holes in the existing concrete.

For a concrete barrier constructed to the face of an existing concrete structure, match the existing weep holes.

83-3.03C Connection of a Concrete Barrier to a Structure At the connection of a concrete barrier to a structure, apply a uniform film of grease to the upper surface of the neoprene strip before placing the sheet metal.

83-3.03D Concrete Barrier Transitions For a concrete barrier transition:

1. Remove portions of the existing concrete barrier where shown

2. Roughen the contact surfaces of the existing concrete barrier

3. Drill and bond dowels into the existing concrete barrier

83-3.03E Type 60K Portable Concrete Barriers Set Type 60K portable concrete barriers on a firm, stable foundation. Grade the foundation to provide uniform bearing throughout the entire barrier length.

Place and maintain the abutting ends of the PC concrete units in alignment without substantial offset to each other. Position the PC concrete units straight on tangent alignments and on a true arc on curved alignments. The minimum curve radius for horizontal alignments is 164 feet.

The final surface finish of Type 60K portable concrete barriers must comply with section 51-1.03F(2).

Place the fabrication date and your name or logo on each panel. The fabrication date and name or logo must be 4 inches or less in height and must be located 12 inches or less above the bottom of the rail panel.

Cure the exposed surfaces of concrete elements by the water method, the forms-in-place method, or the curing compound method. Curing compound must be curing compound no. 1.

83-3.03F Wildlife Passage Ways Construct wildlife passage ways in concrete barriers where shown.

Construct the passage way opening by forming the opening in the concrete barrier or, after the concrete barrier is constructed, by saw cutting the outline of the opening and removing the concrete and bar reinforcing steel within the limits of the opening.

The completed opening for the wildlife passage way must be clear and unobstructed for the dimensions shown.

For a Type M wildlife passage way, you may be required to remove concrete barrier. Before removing the concrete barrier, make a saw cut of approximately 1 inch in depth on the face of the barrier along the removal limits.

83-3.04 PAYMENT

The payment quantity for concrete barriers other than Types 60F, 60GE, and 60SF is the length measured along the top of the barrier.

The payment quantity for Type 60F, 60GE, and 60SF concrete barriers is the length measured once along the centerline between the 2 walls of the barrier.

The payment quantity for concrete barriers includes the length of gaps in the concrete barrier where steel plate barrier is attached to the concrete barrier.

83-4 CRASH CUSHIONS

83-4.01 GENERAL

83-4.01A General Section 83-4 includes specifications for constructing crash cushions.

83-4.01B Materials Not Used

83-4.01C Construction Not Used

83-4.01D Payment Not Used

83-4.02–83-4.10 RESERVED

83-5–83-10 RESERVED

83-11 EXISTING RAILINGS AND BARRIERS

83-11.01 GENERAL

83-11.01A General Section 83-11 includes specifications for performing work on existing railings, barriers, terminal systems, and crash cushions.

Work performed on existing railings, barriers, terminal systems, and crash cushions must comply with section 15.

83-11.01B Materials Concrete must comply with the specifications for minor concrete.

Reinforcement must comply with section 52.

83-11.01C Construction If a portion of a guardrail or thrie beam barrier is to remain in place, removing, salvaging, reconstructing, relocating, or resetting work includes:

1. Resetting end caps, return caps, and buried post anchors

2. Providing connections to existing and new facilities, including connections to concrete

83-11.01D Payment The payment quantities for removing, salvaging, reconstructing, relocating, and resetting existing railings and barriers are measured as specified for measuring new…