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
Reserve d
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 galvani zing, 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
83-1.02C Mortar
Mortar must c omply 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
After constructing railings, barriers, terminal systems, crash cushions, and vegetation control, use the surplus excavated material to meet the grading requirements. Disposal of surplus material must comply with section 19-2.03B.
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, r eset 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 temporary barrier system instead of resetting the existing barrier.
83-1.03D Miscellaneous Construction
Where shown, paint the structure name, bridge number, year constructed, and other bridge identification information. Painting concrete must comply with section 78 -4.03C(3). Bridge identification on the bridge barrier must be (1) painted at each structure approach, (2) visible to approaching traffic, and (3) located near the paving notch, if applicable. For open bridge barrier rails, paint bridge identification on the widest rail element. For structures with adjacent retaining walls or approaches where metal beam bridge railings extend beyond the structure, paint bridge identification on the concrete end block of the barrier. SECTION 83 RAILINGS AND BARRIERS For bents and piers, paint bridge identification corresponding to the name and n umber shown, on the face of the bridge barrier directly above the centerline of each bent or pier.
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.
83-2 Metal Railings and Barriers
83-2.01 General
83-2.01A General
83-2.01A(1) General
Section 83 -2.01 includes general specifications for constructing metal railings and barriers. Locations shown are approximate. The Engineer will determine exact locations. Confirm layout with the Engineer prior to installation.
83-2.01A(2) Materials
W-beam elements, thrie beam elements, end caps, and return caps must comply with AASHTO M 180 for Class A, Type I, except within 0.5 miles of the coast the components must comply with AASHTO M 180 for Class A, Type II. 10-gauge rail elements for thrie beam elements and transition rai lings must comply with AASHTO M 180 for Class B, Type I, except within 0.5 miles of the coast the 10 -gauge rail elements must comply with AASHTO M 180 for Class B, Type II. Bolts, nuts, and other fittings for W -beam and thrie beam must comply with AASHTO M 180. A W6 x 8.5 Steel post may be substituted for a W6 x 9 steel post . 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 foun dation 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 , steel foundation tubes and soil plates in soil. Cut off any excess bolt that extends more than 0.5 inch beyond the nut. Metal beam railing must not be cut or modified in the field. Do not drill or punch new holes. Steel or wood posts must not be cut in the field to reduce length. Do not place posts in asphalt, conc rete or structural section. Do not install new wood posts or blocks with cracks wider than 1/4 inch with cracking evident through the wood to another side of the post or block. Install posts no more than 1 inch per foot out of plumb unless otherwise descri bed. Place rub rail guardrail element when height of guardrail is more than 3 inches above standard placement height. At locations exposed to traffic, schedule activities so that at the end of each day, no post holes are open and no posts are installed wit hout the blocks and rail elements assembled and mounted. Anchor both leading and trailing ends of all guardrail or barriers to a permanent or temporary terminal system, end anchor assembly or anchor block. You may anchor to existing guardrail if connected using a standard bolted rail element splice. SECTION 83 RAILINGS AND BARRIERS Identify steel posts longer than 6 feet by painting the post length as a 2 -inch-tall numeral in the web near the top of the post before installation. Before applying paint, ensure the post surface is free of all dirt, grease, oil, salt, or other contaminants by washing it with detergent or other suitable cleaner. Rinse thoroughly with fresh water and allow to fully dry. Use black metallic acrylic resin type paint.
83-2.01A(4) Payment
Not Used
83-2.01B Minor Con crete Vegetation Control
Reserved
83-2.02 Midwest Guardrail System S
83-2.02A General
83-2.02A(1) Summary
Section 83 -2.02 includes specifications for constructing midwest guardrail systems .
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 a ssemblies and rail tensioning assemblies, submit:
83-2.02A(4) Quality Assurance
Reser ved
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. The reinforcing steel in the concrete anchors for Type CA end anchor assemblies must comply with section 52.
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. Fabrica te the metal work in the shop. Do not punch, cut, or weld in the field. Instead of the rolled steel section shown, you may substitute a welded section built up from structural steel plates if:
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 an d 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 :
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 a nchor 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 A STM 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 f orming 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 SECTION 83 RAILINGS AND BARRIERS steel with a minimu m 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 s waged 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:
83-2.02B(3) Transition Railing s
Reserv ed
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:
83-2.02C(1)(b) Posts
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. P lace 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 o r 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 in Wood Posts and Cuts in Blocks
If copper naphthenate, Alkaline Copper Quaternary ammonium compound, or copper azole is used to treat wood posts and blocks, before inserting the bolts, fill the bolt hole s with grease. SECTION 83 RAILINGS AND BARRIERS You may field bore the 2 -3/8-inch-diameter holes shown for wood guardrail terminal posts and wood rail tensioning assembly posts. If you perform field cutting or boring after treatment, manually treat with preservative under 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 when 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 where shown. Install end caps flush with barrier face.
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, AGT But tress, anchor block, or barrier, form holes using galvanized metal HSS 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 spalle d 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 specification s 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 h as cured for at least 5 days.
83-2.02C(3) Transition Railings
Construct AGT using wood blocks with steel posts.
83-2.02C(4) Buried Post End Anchors
Alignment and elevation of the buried post end anchor will be established by the Engineer. Excavate into s lope and extend rail elements until there is 1 foot minimum of cover over the anchor post. A partial element may be used if needed to achieve required cover. Do not install blocks on posts where blocks will have contact with soil. Bolt the rail directly to the post. Backfill buried post end anchors and grade as shown. Provide drainage and conform to adjacent grading and other features. The guardrail element attached to the anchor post may be drilled in the field at the bolted connection. For buried post end anchor Type B -S, install longer posts if needed to maintain 3 -foot post embedment.
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, (4) a b uried post end anchor, or (5) 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. 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. SECTION 83 RAILINGS AND BARRIERS Rub rail will be measured from the first post connected to the rub rail to the last post connected to the rub rail and will be paid as additional length of MGS. 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.
83-2.03 Thrie Beam Barrier S
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. Thrie beam barrier work includes transition sections between W beam and thrie beam elements.
83-2.03B Materials
Use steel posts for thrie beam barrier Type M, except use wood posts for posts set in steel foundation tubes at trailing end anchors. Use wood or plastic blocks with steel posts. For thrie beam barrier on bridges:
83-2.03C Construction
If median barrier delineation is shown, match the barrier marker spacing to the raised pavement marker spacing on the adjacent median edge line 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 a transition railing. 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 p ay limits of a transition railing. 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 d ouble thrie beam barrier (bridge) and double thrie beam barrier is the face of the paving notch of the bridge.
83-2.04 Terminal System S
83-2.04A General
83-2.04A(1) General
Section 83 -2.04 includes general specifications for constructing terminal system s.
83-2.04A(2) Materials
Not Used SECTION 83 RAILINGS AND BARRIERS
83-2.04A(3) Construction
Not Used
83-2.04A(4) Payment
Not Used
83-2.04B Alternative In -Line Terminal System s
Reserved
83-2.04C Alternative Flared Terminal System s
Reserved
83-2.04D 83-2.04H Reserved
83-2.05 California Bridge Rail S
83-2.05A General
83-2.05A(1) Summary
Section 83 -2.05 includes specifications for constructing California bridge rail . California bridge rail consists of steel post and beam railing. Concrete must comply with section 51. Reinforcement must comply with section 52. ST-75SW and ST -76SW California bridge rails include the handrailings. Drill and bond the threaded rods us ing chemical adhesive system s under section 51 -1.
83-2.05A(2) Definitions
Reserved
83-2.05A(3) Submittals
Submit shop drawings for the California bridge rail. The shop drawings must include:
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:
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 quali ty. Formed steel sections must be uniform in appearance. SECTION 83 RAILINGS AND BARRIERS Stud bolts must comply with the specifications for studs in clause 9 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 s eries 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. Anchor bolts and threaded rods must comply with ASTM F1554, Grade 105. Bridge rail post plates and base plates must comply with one of the following:
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. Do not incorporate venting or pickup h oles on the traffic side of railing. 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 quanti ty 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 Railing S
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. SECTION 83 RAILINGS AND BARRIERS 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:
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 SECTION 83 RAILINGS AND BARRIERS
83-2.07 Cable Railing S
83-2.07A Gener al
Section 83 -2.07 includes specifications for constructing cable railings .
83-2.07B Materials
Concrete for the post footings must comply with the specifications fo r 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 wrou ght 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:
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 Railings
83-2.08A General
83-2.08A(1) Summary
Section 83 -2.08 includes specifications for constructing tubular railings. Tubular railing includes rail tubes, post tubes, pl ates, rail splice sleeves, and fasteners. For Type 85 concrete barrier, tubular bicycle railing includes the upper and lower tubular bicycle railing.
83-2.08A(2) Definitions
Reserved
83-2.08A(3) Submittals
Submit a certificate of compliance verifying tha t all components of the tubular railing comply with section
83-2 08b.
Submit shop drawings for tubular railing. Shop drawings must include:
83-2.08A(4) Quality Assurance
Reserved
83-2.08B Materials
The materials for tubular railing 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, Type 1 Threaded rods ASTM A449, Type 1 Nuts for bolts and threaded rods ASTM A563/A563M Washers for bolts and threaded rods ASTM F436/F436M, Type 1, including S1 supplementary Rail tubes must be shop bent or fabricated to fit the horizontal curve if the radius is less than 900 feet. If the vertical radius of the tubular railing is 30 feet or less, that portion o f 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. The difference between out -to-out rail splice sleeve dimensions and the clear i nside dimensions of the tubular steel rail elements must not exceed 3/16 inch after galvanizing. 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 .
83-2.08C Construction
83-2.08C(1) General
Before the tubular railing parts are assembled, clean the bearing surfaces and surfaces to be in permanent contact. If the railing is mounted on a con crete surface, the post bases must be true and flat to provide uniform bearing . Tubular railings must present a smooth, uniform appearance in their final position and conform closely to the horizontal and vertical lines as shown.
83-2.08C(2) Tubular Handrailing
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. 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 v ertical grade lines. Shims at steel posts must be commercial -quality, galvanized sheet steel.
83-2.08C(3) Tubular Bicycle Railing
If authorized as alternative to cast -in threaded rods, you may cast sleeves for the threaded rods, or drill and bond the thre aded rods using chemical adhesive systems under section 51 -1. SECTION 83 RAILINGS AND BARRIERS Erect railing 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. Ad jacent rail elements must align with each other within 1/16 inch.
83-2.08D Payment
Not Used
83-2.09 Pipe Handrailing S
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, exc ept 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:
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:
83-3.01D Quality Assurance
83-3.01D(1) General
Reserved
83-3.01D(2) Quality Control
83-3.01D(2)(a) General
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 t hat 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 60M series concrete barriers must comply with the specifications for minor concrete, except the co ncrete must contain at least 550 pounds of cementitious material per cubic yard. In non -freeze -thaw areas, concrete for concrete barriers other than Type 60M series must contain at least 590 pounds of cementitious material per cubic yard. In freeze -thaw ar eas, concrete for concrete barriers must contain at least 675 pounds of cementitious material per cubic yard. For Type 60 MF, 60 MGF, and 60 MSF concrete barriers, the concrete paving between the tops of the 2 walls of the barrier and the optional concrete sl ab 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 form ed concrete barriers must comply with the following:
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 must comply with section 55-1.02D. Hardware, including concrete anchorage devices, must comply with section 75 -3. Galvanize d structural steel plates and hardware must comply with section 75 -1.02B.
83-3.02E Granular Backfill
For Type 60 MF, 60 MGF, and 60 MSF concrete barriers, the granular material for backfill between the 2 walls of concrete barrier must:
83-3.02F Reserved
83-3.02G Connection of a Concrete Barrier to a Structure
Sheet metal, neoprene strip, and grease at the connection of a con crete barrier to a structure must comply with the following:
83-3.02H Type 60K Portable Concrete Barrier s
Type 60K portable concrete barrier must consist of interconnected new or undamaged used PC portable concrete barrier units. For Type 60K portable concrete barrier:
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. SECTION 83 RAILINGS AND BARRIERS
83-3.03A(3) Adjusting Barrier Height
If the concrete barri er height is adjusted, the Engineer determines the adjustment amount before the concrete is placed. 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 su perstructure. 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 or new pavement or on an existing or new 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 e xpansion 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 barrie r 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. Construct concrete barrier footings on a minimum of 90 percent compacted material . Construct concrete barrier on a minimum of 4 inches of AC or concrete.
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:
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 b e 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 mot ion 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 con structed using extrusion or slip form methods, place the horizontal reinforcing bars continuously. SECTION 83 RAILINGS AND BARRIERS 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 tes ted under section 83 -3.01D(2)(c).
83-3.03A(6)(c)(iv) Maintaining Barrier Grade s
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 suc h 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 operat ed 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 formin g methods, construct expansion joints using one of the following methods:
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, an d you must give the surface a 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. The surface finish of Type 60 series concrete barriers must be Class 1 surface finish if cured by the forms -in-place method. At least 7 days after placing Type 60 ser ies concrete barriers, give the exposed surfaces a final 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. Any alternative method of final surface finishing must be authorized. Class 1 surface finish must comply with section 51 -1.03F(3).
83-3.03A(8) Curing
Cure the exposed surfaces of concrete barriers by the curing compound method using curing compound no. 6. For concrete barriers on bridges and walls that do not support soundwalls, you may cure the formed surfaces of the barriers by keeping the forms in place for at least 12 hours after placing the concrete. No further curing is required after the forms are removed. SECTION 83 RAILINGS AND BARRIERS For Type 60 series concrete barriers not using the forms -in-place curing method, apply the curing compound using a mechanical sprayer capable of applying the curing compound to at least one entire side and the top of the concrete barrier in one application at a uniform rate of coverage. Protect the spray against wind. In freeze -thaw areas, cure concrete barriers on bridges and walls by the water method. For Type 85 and Type 86 series concrete barriers, cure the formed surfaces of the barriers by keeping the forms in place fo r at least 36 hours after placing the concrete. No further curing is required after the forms are removed.
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) :
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 s pecifications for drilling and bonding dowels in section 51 -1.
83-3.03A(11) Installing Barrier Markers
Cement the markers to the barrier under the manufacturer's instructions. Match the barrier marker spacing to the raised pavement marker spacing on the a djacent median edge line pavement delineation.
83-3.03A(12) Reserved
83-3.03A(13) Placing Granular Backfill
For Type 60 MF, 60 MGF, and 60 MSF concrete barriers, place the granular material for backfill between the 2 walls of the concrete barrier must be pl aced 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 existin g 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:
83-3.03E Type 60K Portable Concrete Barrier s
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 abut ting 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). SECTION 83 RAILINGS AND BARRIERS 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 locat ed 12 inches or less above the bottom of the rail panel. Cure the exposed surfaces of concre te 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 r equired 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 60 MF, 60MGF, and 60 MSF is the length measured along the top of the barrier. The payment quantity for Type 60 MF, 60 MGF, and 60 MSF concrete barriers is the length measured once along the centerline between the 2 walls of the barrier. The payment quantity for con crete barriers includes the length of gaps in the concrete barrier where steel plate barrier is attached to the concrete barrier. The payment quantity for concrete barriers includes barrier markers.
83-4 Crash Cushions
83-4.01 General
83-4.01A General
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 83-11.01 includes general specifications for performing work on existing railings, barriers, terminal systems, and crash cushions.
83-11.01B Materials
Concrete must comply with the specifications for minor conc rete. Reinforcement must comply with section 52. SECTION 83 RAILINGS AND BARRIERS
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:
83-11.01D Payment
The payment quantities for removing, salvaging, reconstructing, relocating, and resetting existing railings and barrie rs are measured as specified for measuring new railings and barriers.
83-11.02 Existing Guardrail S
83-11.02A General
83-11.02A(1) General
Section 83-11.02 includes specifications for performing work on existing guardrail.
83-11.02A(2) Materials
Not Used
83-11.02A(3) Construction
Not Used
83-11.02A(4) Payment
Not Used
83-11.02B Remove Guardrail s
83-11.02B(1) General
Section 83 -11.02B includes specifications for removing guardrail which includes specifications for removing terminal systems, end anchors, and transitions .
83-11.02B(2) Materials
Not Used
83-11.02B(3) Construction
Where removing guardrail, remove any concrete anchors and steel foundation tube s.
83-11.02B(4) Payment
The payment quantity for removing W -beam, thrie beam, a terminal system, end anchor, or transition is the length measured along the face of the rail elements.
83-11.02C Salvage Guardrail s
83-11.02C(1) General
83-11.02C(2) Materials
Not Used
83-11.02C(3) Construction
Remove, disassemble, clean, prepare, mark, bundle, package, tag, haul, and stockpile the guardrail to be salvaged. Comply w ith the requirements for number per bundle for the guardrail components shown in the following table: Component Number per bundle Rail 25 Steel posts 10 Plastic blocks 50 SECTION 83 RAILINGS AND BARRIERS Tag incomplete bundles and show the quantity contained.
83-11.02C(4) Payment
Not Used
83-11.02D Reconstruct Guardrail s
Reserved
83-11.02E Adjust Guardrail s
Reserved
83-11.02F 83-11.02J Reserved
83-11.03 Existing Metal Bridge Railing S
83-11.03A General
83-11.03A(1) General
Section 83-11.03 includes specifications for performing work on existing metal bridge railings.
83-11.03A(2) Materials
Not Used
83-11.03A(3) Construction
Not Used
83-11.03A(4) Payment
Not Used
83-11.03B Reconstruct Metal Bridge Railing s
83-11.03B(1) General
83-11.03B(1)(a) Summary
Section 83 -11.03B includes specifications for reconstructing metal bridge railings .
83-11.03B(1)(b) Definitions
Reserved
83-11.03B(1)(c) Submittals
Submit 2 copies of shop drawings showing the details of the refabrication of the removed materials and the fabrication of the new materials. Include a list of the new materials, the type of metal, and the metal specifications.
83-11.03B(1)(d) Quality Assurance
Reserved
83-11.03B(2) Materials
Not Us ed
83-11.03B(3) Construction
Remove, refabricate, and install the metal bridge railing of the type shown. Refabrication of removed material, fabrication of new material, and installation of the railing must comply with the specifications for a new metal b ridge railing of the type being reconstructed. Perform aluminum welding by the inert -gas-shielded arc welding process. Finish exposed aluminum welds to a neat surface. Repair abraded and damaged galvanized surfaces on the removed material under section 75-1.02B .
83-11.03B(4) Payment
The payment quantity for reconstruct metal railing (bridge) is the length measured along the face of the reconstructed railing and includes the length of gaps in the railing for lighting and sign supports. SECTION 83 RAILINGS AND BARRIERS