859.1 General Description
This section includes the requirements for Guardrail components, such as: • Guardrail elements, terminal sections, and fittings • Cable end anchor assemblies • Steel Guardrail posts and offset blocks • Wood Guardrail posts and offset blocks
859.1.01 Related References
A. Standard Specifications Section 106—Control of Materials Section 863—Preservative Treatment of Timber Products B. Referenced Documents ASTM AASHTO A 123/ A 123M A 153/ A 153 M A 449 A 575 A 576 A 709/A 709M A 741 A 769/A 769M B 209 (B 209M) B 211 (B 211M) F 568 M 180 1994 SPIB rules, paragraph 402 QPL 8
859.2 Materials
859.2.01 Guardrail Elements, Terminal Sections, and Fittings
A. Requirements Steel Guardrail Use Guardrail parts that meet AASHTO M 180 requirements and are composed of the following elements: Bridge railing Class B, Type II beams Roadway Guardrail Class A, Type II beams Use Guardrail from suppliers found on QPL 8. Aluminum Guardrail Use rail elements made from aluminum alloy alclad 2024-T3 sheet that meets ASTM B 209 (B 209M) requirements. Use the following fittings: Fittings Material Requirements Aluminum bolts Alloy 2024-T4 [ASTM B 211(B 211M)] with 30-minute anodize and 30-minute seal Hex nuts Aluminum alloy 6061-T6, not anodized Washers May meet ASTM B 209 (B 209M) Alclad 2024-T4, not anodized Certification Submit a certification as in Subsection 106.05, Materials Certification. B. Fabrication General a. Make highway Guardrail elements according to the plans. b. Ensure that all Guardrail elements, terminal sections, and fittings are interchangeable with similar parts, regardless of the source or manufacturer. c. If constructing Guardrail on curves with a radius of 150 ft. (45 m) or less, curve the rail elements in the shop to the radius on the road side of the rail, either concave or convex, as required. Aluminum Guardrail Elements a. Form the rail elements into beams at least 1 ft. (300 mm) wide and 3 in. (75 mm) deep, and at least 0.156 in. (3.96 mm) thick. b. Form the terminal ends from the same material as the beams or from Alclad 2024-T42. C. Acceptance Steel Guardrail The Department will accept the material based on the provisions of AASHTO M 180 or ASTM B 209 (B 209M). Aluminum Guardrail The Department will accept the material based on the manufacturer’s QPL status or on tests conducted by the Department. D. Materials Warranty Steel Guardrail: Ensure that the manufacturer’s logo and heat numbers remain legible for at least 5 years after galvanizing.
859.2.02 Cable and Anchor Assembly
A. Requirements Type Ensure that the cable and anchor materials meet the following requirements, unless shown otherwise on the Plans: Material Requirements Anchor and metal plates Steel, ASTM A 709 (A 709M), Grade 36 (250) Anchor rod Steel, ASTM A 575 or A 576, Grade 1020 Anchor cable Preformed, galvanized wire rope, ASTM A 741, Type II, 3/4 in. (19 mm), 6 x 19, with right regular lay Cable clips and cable thimble Commercial quality, galvanized, drop-forged steel Material Requirements Bolts and nuts ASTM F 568 Swaged fittings Steel, ASTM A 576, Grade 1035; annealed, galvanized, suitable for cold swaging Ensure the swaged fittings and stud assembly develop at least 100% of the breaking strength of the cable. Galvanized stud Steel, ASTM A 449 Concrete deadman Precast Class A concrete, according to the plans Certification Submit a certification for these materials according to Subsection 106.05, Materials Certification. B. Fabrication Fabricate and assemble according to the plans. Anchor/Metal Plates Build up anchor plates and other metal plates, as shown on the plans, or form them on a press, with or without welded seams. Anchor Rod Drop-forge or form the eye of the anchor rod with a full penetration weld that develops 100 percent of the rod strength. Metal Components: a. Galvanize all metal components of the assembly, except the anchor cable, according to ASTM A 123/A 123M. b. Galvanize bolts, washers, etc., as stated in ASTM A 153/A 153M. C. Acceptance The Department will accept material based on the certification. D. Materials Warranty General Provisions 101 through 150.
859.2.03 Steel Guardrail Posts and Offset Blocks
A. Requirements Type Use steel posts of the dimensions and shapes shown on the Plans for Guardrails. Unless the plans show otherwise, use posts that meet the requirements of ASTM A 709 (A 709M), Grade 36 (250) or ASTM A 769 (A 769M) Class I, Grade 40 (380), and found in QPL 8. Certification Submit a certification according to Subsection 106.05, Materials Certification. B. Fabrication Galvanize steel posts and offset blocks according to ASTM A 123/ A 123M. C. Acceptance The Department will accept the material based on the certification. D. Materials Warranty General Provisions 101 through 150.
859.2.04 Wood Guardrail Posts and Offset Blocks
A. Requirements Grade Use posts and offset blocks that meet the requirements for No. 1 timbers, paragraph 402, of the 1994 SPIB rules. Do not use offset blocks with splits longer than 3 in. (75 mm). B. Fabrication Tolerances Ensure that the posts do not vary from the specified length by more than ± 1 in. (± 25 mm). If the plans specify a slope for the top, ensure that the slope does not vary more than ±1/4 in. (± 6 mm). Seasoning and Preservative Treatment Bore and frame posts, then treat the posts and offset blocks according to the requirements of Section 863. C. Acceptance The Department will accept the material based on tests conducted by the Department or on the manufacturer’s QPL status. D. Materials Warranty General Provisions 101 through 150.
859.2.05 Plastic Offset Blocks
A. Requirements Type Use only plastic offset blocks that are listed on QPL 8. Use plastic offset blocks that consist of 70 percent low density polyethylene and approximately 30 percent high density polyethylene with a trace of other plastic. Other compositions may be used if approved by the Office of Materials and Research. Certification Submit a certification according to Subsection 106.05, Materials Certification. B. Fabrication General Provisions 101 through 150. C. Acceptance The Department will accept the material based on the manufacturer’s certification. D. Materials Warranty General Provisions 101 through 150.
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