487DIVISION 600 – INCIDENTAL CONSTRUCTION

601.01 Description This work shall consist of the fabrication, assembly, and installation of guardrail, guardrail components, guardrail transitions, guardrail end treatments, and impact

attenuators, all in accordan ce with 105.03 and as shown on the plans. This work may also consist of the extension of existing guardrail with new guardrail, the removal of existing guardrail, or adjusting the height of existing guardrail. MATERIALS 10

601.02 Materials

Materials shall be in acco rdance with th e following: Alternate Material Guardrail Blockouts ...................... 926.03 Guardrail Posts ............................................................ 910.10 Guardrail Accessories, Fittings, and Fasteners ............ 910.11 Guardrail and Guardrail Components .......................... 910.09 Steel Thrie-Beam Rail ................................................. 910.09 Steel W-Beam Rail ...................................................... 910.09 20 Timber Posts a nd Blockouts ........................................ 911.02(f) Guardrail end treatments shall be sel ected from the QPL of Guardrail End Treatments in accordance with 601.07. Impact attenuators shall be selected from the QPL of Impact Attenuators in accordance with 601.08. PCC in anchors, and in pads, or bases for impact attenuators shall be class A and in accordance with 702. Sheet signs and si gn posts shall be in accordance with 802. Barrels used in impact attenuators shall be yellow with black lids. The coarse 30 aggregate used in the barrels shall be size 93PG, class F or higher, in accordance with 904. All other impact attenuators shall have end reflectorization as shown on the plans or attached to the nose of the attenua tor in accordance with the attenuator manufacturer’s recommendation. W-beam or Midwest Guardrail System, MGS, W-beam guardrail, components, assembly, post spacing, post lengths, and installation for each location shall be as shown on the plans. Double-faced guardrail shall be required at the locations shown 40 on the plans. For W-beam guardrail, in locations where conditions will not allow the use of 7 ft posts, 6 ft posts may be substituted when approved. Timber posts may be 601.02 488 used within a run of MGS W-beam guardrail as shown on the plans. Timber posts shall not be used within a run of W-beam guardrail. The base metal thickness of the steel W- beam rail element for a curved guardrail system shall be 0.105 in. The base metal thickness of the steel W-beam terminal connector shall be 0.135 in. The controlled released terminal, CRT, timber breakaway posts shall be S4S timber and shall otherwise be in accordance with 911. The curved rail timber posts shall be in accordance with 911. All structural tubing shall be in 50 accordance with ASTM A500. The remaining st eel components shall be in accordance with 910. CONSTRUCTION REQUIREMENTS

601.03 General Requirements

Posts shall be installed plumb at the spacing and embedment depth shown on the plans. Posts shall be driven where subsur face conditions enable the use of normal driving equipment. Where subsurface conditions prohibit driving the posts, a 12 in. diameter hole shall be bored to the required embedment depth. The hole shall be 60 backfilled with suitable material in 6 in. maximum lifts, compacted as directed, and then the posts driven. Posts damaged during installation shall be repaired or replaced as directed with no additional payment. When new guardrail is being installed to replace existing guardrail and traffic is to be maintained during the work, the installation of the new guardrail shall follow the removal of the existing guardrail as closel y as practical. Adequate safety protection shall be provided as directed between the time that the existing guardrail is removed 70 and the time that the installation of the new guardrail is completed. When new guardrail is being installed where there is no existing guardrail and traffic is to be maintained during the work, the mounting of the blockouts and the rail elements to the posts shall be completed as soon as practical after the posts are installed. The time between the installation of the posts and the mounting of the blockouts and rail elements shall not exceed 24 h. Drums shall be placed to mark all installed guardrail posts left bare overnight. The spacing of these devices shall be numerically equal to the worksite speed limit, but not less than 20 ft. All damaged galvanized surfaces shall be coated in accordance with 910.11(a)4. W-beam guardrail shall be installed as shown on the plans with the W-beam rail element splice at the post. MGS W-beam guardrail shall be installed as shown on the plans with the W-beam ra il element splice at midspan. MGS W-beam guardrail installed with half or quarter post spacing shall be spliced as shown on the plans. The nested W-beam guardrail element sh all consist of two rail elements, one set 601.03 489 inside the other. The length of nested guardrail placed over a culvert shall not be spliced. 90

601.04 Guardrail Erection Blockouts and rail elements shall be erected in a manner resulting in a smooth, continuous installation. All bolts shall be of sufficient length to extend beyond the nuts and shall be drawn tight. Rail installed along a radius of 150 ft or less shall be shop curved. Rail elements shall be lapped as shown on the plans.

601.05 Curved W-Beam Guardrail Systems

This work shall consist of the fabrication, assembly, and installation of specified types of curved W-beam guardrail connector system or curved W-beam guardrail 100 terminal system in accordance with the requirements herein and as shown on the plans. The installation of the terminal end buffer may utilize an alternate single piece having similar dimensional shape to the terminal end buffer as shown on the plans, and which mates with the W-beam guardrail. Where the W-beam terminal connector is lapped on the outside of the guardrail, a galvanized 1 in. inside diameter, 2 in. outside diameter, 0.134 in. thick, narrow plain washer shall be placed under the splice bolt heads. Nuts for the anchor cable assembly shall be hand tightened, plus one complete turn at the anchor plate end. All other nuts shall be torqued to 50 ft lb. The installation of the Type 5 anchor sh all include tightening the cable with the swaged end to e liminate all slack. The W-beam rail in the Type 5 anchor shall be attached to the steel pipe with 5/8 in. diameter by 1 1/4 in. button head bolt with no washer. Connection to the post will not be required.

601.06 Guardrail Transitions Guardrail transitions shall be required to connect guardrail to bridge rail, guardrail to piers, and new W-beam guardrail to existing rub rail type guardrail. The required

type of guardrail transition shall be as shown on the plans. An MGS guardrail transition, with or without curb, shall be required to connect guardrail to bridge rail and guardrail to piers. An MGS height transition shall be required to connect MGS W-beam guardrail to existing W-beam or existing rub rail type guardrail. The required type of guardrail transition shall be as shown on the plans. The fabrication, assembly, and installation of thrie-beam rail, W-beam rail components, and posts and blockouts for guard rail transitions will be required for the locations shown on the plans. 601.06 490 601.07 Guardrail End Treatments Guardrail end treatments shall terminate guardrail installations at the locations shown on the plans. Type I guardrail end treatment shall be as shown on the plans or selected from the QPL of Guardrail End Treat ments. Type II guardrail end treatment shall be as shown on the plans. Type OS or Type MS guardrail end treatments shall be selected from the QPL of Guardrail End Treatments. The grading requirements shall 140 be as shown on the plans. Assembly and installation or resetting shall be supervised or performed at all times by an installer trained and certified by the unit’s manufacturer, and shall be in accordance with the manufacturer’s recomme ndations. The installer shall be included on the Department’s list of Qualified Guar drail End Treatment and Impact Attenuator Installers prior to the start of work. The Contractor shall provide the Department with original copies of all necessary current manufacturer’s installation manuals and working drawings in accordance with 150

105.02 Double facing of guardrail end treatment Type I shall be required when it is used in conjunction with double faced guardrail.

When installing end treatments to existing rub rail type guardrail, the rub rail, if spliced at the last existing post, shall be cut and the end repositioned behind the flange of the post. If the rub rail is spliced at the last existing post, the existing splice material shall be removed and the end of the rub rail repositioned behind the flange of the post. In both cases, the rub rail shall be conn ected to the post as shown on the plans. 160 Guardrail end treatments shall be installed within 24 h of the completion of the guardrail installation to whic h they are to be attached . Drums in accordance with

801.09 shall be placed for overnight marking of the bare end of the guardrail when the

installation of the end treatment will not be completed until the day following the completion of the guardrail installation to which it is to be attached.

601.08 Impact Attenuators Impact attenuators shall be placed or re set to obtain the proper height as shown

on the plans. The unit for each new location shall be of the width recommended by the 170 manufacturer and for the test level specified and shall be selected from those shown on the QPL of Impact Attenuators. Each unit shall be placed in accordance with the manufacturer’s recommendations on a PCC pad. Assembly, installation, or resetting of the impact attenuators shall be supervised or performed by an installer trained and certified by the unit’s manufacturer and shall be in accordance with the manufacturer’s re commendations at the locations shown on the plans. The installer shall be included on the Department’s list of Qualified Guardrail End Treatment and Impact Attenuator Installers prior to the start of work. 180 601.07 491 The Contractor shall provide the Department with original copies of all necessary current manufacturer’s installation manuals and working drawings in accordance with 105.02. Transition panels and all other necessary hardware shown in the manufacturer’s recommendations for bi-directional traffic protection shall be included in the installation or resetting, if the unit is installed at a location where traffic is passing the unit on both sides in opposite directions.

601.09 Extension of Existing Guardrail 190

Extension of existing rub rail type guardrail with new W-beam guardrail shall require adjusting the post heights in the last 25 ft of existing rub rail type guardrail adjacent to the extension as shown on the plans. Guardrail transition Type VH shall be used to make this adjustment. The post spacing of the guardrail transition Type VH shall equal that of the last 25 ft of ex isting rub rail type guar drail adjacent to the extension. The rub rail shall be terminated at the last existing post in the transition in accordance with 601.06. Extension of existing rub rail type or W-beam guardrail with new MGS W-beam guardrail shall require adjusting the splice location and post height in the last 37 ft 6 200 in. of the existing rub rail type or W-beam guardrail as shown on the plans. MGS height transition shall be used to make this adjustment. The rub rail shall be terminated at the last existing post in the transition in accordance with 601.06. 601.10 Removal of Existing Guardrail Removal of existing guardrail shall be in accordance with the applicable requirements of 202 and these requirements. The locations shall be as shown on the plans. When it is specified that the removed guardrail is to become the property of the Department, the rail elements, posts, and blockouts shall be removed without being damaged. The removed material shall be stored as directed. 210

601.11 Adjusting Existing Guardrail Height

The height of the existing guardrail shall be adjusted by the use of moveable blockouts as shown on the plans. The height shall be measured to the top of the rail element along the face of the rail. Existing fixed blockouts shall be replaced with moveable blockouts installed at the proper height. Existing moveable blockouts shall be disconnected from the posts and re-mounted at the proper height.

601.12 Resetting Guardrail This work shall consist of the remova l of existing guardrail and if necessary, 220

storing and then re-erecting where shown on the plans or as directed.

601.13 Method of Measurement

Guardrail, guardrail with rub rail, shop curved guardrail, adjusting guardrail height, guardrail removal, and resetting guardrail will be measured by the linear foot along the top of the rail element, complete in place. Nested guardrail will be measured 601.13 492 per each 100 lft run placed. Modified posts for nested guardrail will be measured per each, complete in place. MGS structure top-mounted posts will be measured per each, complete in place. Long span MGS W-beam guardrail will be measured per each for the type specified and corresponding run length between outermost CRT posts. 230 Guardrail transitions, W-beam and MGS W-beam guardrail cable terminal anchors, and guardrail end treatments will be measured per each, complete in place. Guardrail buried end treatments Type II will be measured per each. Impact attenuators and resetting impact attenuators will be measured per each for the type and width and test level, complete in place. The curved W- beam guardrail connector system and the curved W-beam guardrail terminal system will be measured per each for the type specified. Grading at guardrail end treatment s, the reflectorization of guardrail end treatments, and concrete used in anchoring guardrail end treatments will not be measured for payment. 240 Aggregate used to fill gravel barrel impact attenuators will not be measured for payment.

601.14 Basis of Payment

W-beam and MGS W-beam guardrail will be paid for at the contract unit price per linear foot for the specified post spacing. Thrie-beam and thrie-beam double faced guardrail will be paid for at the contract unit price per linear foot for guardrail, thrie-beam and guardrail, thrie-beam, double faced, complete in place. Nested guardrail will be paid for at the contract unit price pe r each 100 lft run, complete in place for guardrail, W-beam, nested. Long span MGS guar drail will be paid for at the contract 250 unit price per each type specified and corresponding run length between outermost CRT posts, complete in place for guardra il, MGS, long span. W-beam and MGS W- beam guardrail cable terminal anchor will be paid for at the contract unit price per each, complete in place. Modified posts for nested guardrail will be paid for at the contract unit price per each for modified posts, nested guardrail. Structure top- mounted posts will be paid for at the contr act unit price per each for guardrail, MGS, structure top-mounted posts. W-beam guardrail with rub rail will be paid for at the contract unit price per linear foot for guardrail, WR-beam complete in place. Shop curved guardrail, adjusting 260 guardrail height, guardrail removal, and resetting guardrail will be paid for at the contract unit price per linear foot. Guardrail transitions and guardrail end treatments will be paid for at the contract unit price per each for the type specified. Guardrail buried end treatments Type II will be paid for at the contract unit price per each, complete in place. Impact attenuators and resetting impact attenuators will be paid for at the contract unit price per each for the type and width, and test level specified. The curved W-beam guardrail connector system and curved W-beam guardrail system will be paid for at the contract unit price per each for th e type specified, complete in place. 270 Where existing guardrail height is adjusted, such work will be paid for at the contract unit price per linear foot. The cost of removal, all necessary storage, new 601.14 493 adjustable post brackets, attachment of rail section, and miscellaneous nuts and bolts as required shall be included in the cost of adjust guardrail height. Payment will be made under: Pay Item Pay Unit Symbol 280 Guardrail Connector System, W-Beam, Curved, _____............ EACH type Guardrail End Treatment, _____ ............................................... EACH type Guardrail Height Transition, MGS ............................................ EACH Guardrail Height Transition, VH, ____ ft ____ in. Spacing ...... EACH Guardrail Transition, _____ ...................................................... EACH type Guardrail Transition, MGS, _____ ............................................ EACH type 290 Guardrail, Adjust Height ........................................................... LFT Guardrail, MGS W-Beam, ____ ft ____ in. Spacing ................. LFT Guardrail, MGS W-Beam, Cable Terminal Anchor .................. EACH Guardrail, MGS W-Beam, Double Faced, _____ ft _____ in. Spacing ................................................ LFT Guardrail, MGS W-Beam, Shop Curved, _____ ft _____ in. Spacing ................................................. LFT Guardrail, MGS, Long Span, _____ .......................................... EACH type Guardrail, MGS, Structure Top-Mounted Posts ........................ EACH 300 Guardrail, Remove .................................................................... LFT Guardrail, Reset ......................................................................... LFT Guardrail Terminal System, W-Beam, Curved, _____ ............. EACH type Guardrail, Thrie-Beam .............................................................. LFT Guardrail, Thrie-Beam, Double Faced ...................................... LFT Guardrail, W-Beam, ____ ft ____ in. Spacing .......................... LFT Guardrail, W-Beam, Cabl e Terminal Anchor ............................ EACH Guardrail, W-Beam, Double Faced, _____ ft _____ in. Spacing ................................................ LFT 310 Guardrail, W-Beam, Nested ...................................................... EACH Guardrail, W-Beam, Shop Curved, _____ ft _____ in. Spacing ................................................ LFT Guardrail, WR-Beam ................................................................. LFT Impact Attenuator, ________, _______ _ .................................. EACH type-width test level Impact Attenuator, Reset, ________, ____ ____ ....................... EACH type-width test level Modified Posts, Nested Guardrail ............................................. EACH 601.14 494 320 For W-beam guardrail, the substitution of 6 ft posts for 7 ft posts where conditions will not allow the use of the longer post will be at the same contract unit price of the longer post. The substitution of W 6 x 8.5 for W 6 x 9 steel posts, in MGS W-beam guardrail, will be at the same contract unit price for heavier post. The cost of resetting guardrail shall include the removal, necessary storage, resetting, and replacement of damaged or missing parts and new posts as required. 330 The cost of reflectorization of impact attenuators and guardrail end treatments shall be included in the respective pay items. The cost of all grading required for the guardrail buried end treatment shall be included in the cost of guardrail end treatment, Type II. The cost of earthwork, grading, trans ition panel, if required, and PCC pad shall be included in the cost of the impact attenuator. The cost of aggregate used to fill gravel barrel impact attenuators shall be in cluded in the cost of the impact attenuator. The cost of excavation, concrete footi ngs, reinforcement, and structural steel tubing required for modified posts, nested guardrail, shall be included in the cost of the pay item. The cost of all materials, including replacing damaged or missing parts, labor, and necessary incidentals required to reset impact attenuators, shall be included in the cost of impact attenuator, reset. Where guardrail transition Type TGB is used with bridge railing Type TR, the cost of eliminating the thrie-beam terminal connector and driving the posts to the 350 height above ground shown on the plans shall be included in the cost of the guardrail transition.