2475Metal Railing

2475.1DESCRIPTION

Furnish and install metal railing, including anchorages and fittings. Adhesive anchorages consist of a continuously threaded rod, per Standard Plate 8400 , secured by an adhesive.

2475.2MATERIALS

B Pipe and Pipe Sleeves C Threaded Rods, Bolts, Nuts, and Washers C.1 Galvanized ............................................................................................... 3391 and 3392 C.2 Electroplate ............................................................. 3391 and ASTM B633, Type III, SC 4 D Part of a proprietary anchorage assembly E Adhesives ............................... APL, Bridge, “Concrete Anchorages – Threaded Rod Applications”

2475.3CONSTRUCTION REQUIREMENT

A General Perform the Work in accordance with the applicable requirements of 2433, “Structure Renovation,” 2402, “Steel Bridge Construction,” 2471, “Structural Metals,” 3321, “Gray Iron Castings,” the Plans, and the following: Before the start of Work, the supplier will be qualified on Approved Suppliers for Fabricated Structural Metals Products list as maintained by the Structural Metals Engineer on the Bridge Office website or become qualified. To become qualified, the supplier is to submit a Quality Manual (QM) to the Bridge Engineer for review and acceptance, at least 60 Calendar Days before beginning Work. The QM is to meet the requirements of the MnDOT Supplier Qualification Standard which will be the basis for acceptance by the Bridge Engineer. Upon acceptance of the QM, a supplier is qualified and will be listed on the Approved Suppliers for Fabricated Structural Metals Products list . In addition to routine inspections, the Bridge Engineer will audit suppliers with approved QMs on a biannual or annual basis or as otherwise directed by the Bridge Engineer to ensure the implementation of the QM. The Department will invoke its Corrective Action Process if the routine inspections or audits indicate non-conformance. Corrective actions deemed appropriate by the Bridge Engineer, are effective immediately and apply to any Work remaining on a current and future Projects. If the Bridge Engineer determines that Work does not comply with the QM or that fabrication does not follow approved fabrication procedures, the Bridge Engineer will deem the Materials as non-conforming in accordance with 1503, “Conformity with Contract Documents,” and 1512, “Unacceptable and Unauthorized Work.” If the Bridge Engineer finds non-conforming Work, direct the supplier to immediately correct the procedure

and submit a written Nonconformance Report, containing data required by the Bridge Engineer to ensure compliance with the QM, Specifications, and drawings. Perform additional testing as required by the Bridge Engineer, at no additional cost to the Department. For repeat offences or negligence, the Department will require corrective action of hiring a third-party Quality Control Inspector, at no additional cost to the Department. The Contractor may obtain a copy of the Department’s Corrective Action Process from the Bridge Engineer. B Fabrication and Inspection Requirements Fabricate metal railing in accordance with 2471, “Structural Metals,” the Plan, and the AWS D1.1, Structural Welding - Steel. Submit Welding Procedure Specifications (WPSs) to the Bridge Engineer for approval in writing, prior to the start of fabrication. Mark metal railing components during fabrication with individual piece marks. Identify the marking and its location on the shop drawings. Identify the proper location on the Bridge for piece marks on an erection drawings [with shop drawing submittal]. Markings should not be readily visible to the public when the railing is in the installed position. Ensure piece marks are durable markings which will be readily visible after galvanizing (e.g. welded numbers/letters with 1-1 1/2 inch height). Ensure markings represent good workmanship as to not degrade the aesthetics of th e product. For standard post/rail designs, mark post pieces near the bottom of the post [near the base plate] on the exterior post side and mark railing panels on the bottom side of the bottom rail. For special rail designs, mark railing panels and posts in locations which are underneath or toward the exterior of the B ridge in locations which minimize their view. Identify/tag bundled pieces, prior to shipping/storage, with the following identification information: individual piece marks included in bundle, Bridge and/or Project number(s), fabricator name. The Department QA shop inspections are not intended to supplement or replace the f abricator’s Quality Control (QC). The Contractor is ultimately responsible for the correction of errors and faulty workmanship or for the replacement of non-conforming Materials. The fabricator will visually inspect parts of the fabrication and have the inspections documented by QC personnel. The fabricator will ensure that the rail meets a straightness tolerance of 1/8 inch in 10 feet. The fabricator will perform and document any nondestructive testing required by the Contract documents using an ASNT-TC-1A Level II qualified Inspector. Fabricator shall supply QA/QC documentation to the Engineer and Metal Railing Installer verifying that all fabricated railing components are within the necessary tolerances for proper fit up and installation of the railing, including measurements between railing base plates that indicate that the as fabricated base plate hole locations are within 1/8 inch of the specified plan dimensions, based on the plan specified rail post spacing. Document parts found to be in nonconformance by using a Nonconformance Report form (NCR), and describe in detail the fabrication error and the proposed repair procedure(s) in accordance with the QCP. Repair(s) performed are subject to the written approval of the Bridge Engineer . C Galvanizing Requirements for Metal Railing Galvanize railing Material in accordance with 3394, “Galvanized Structural Shapes.” D Pipe Railing Anchorage Adhesive anchorage installers must hold current ACI Adhesive Anchor Installer Certification credentials, and are required to check the depth, diameter, and condition of the drilled hole; clean the hole; and install the anchorage per the Manufacturer’s Printed Installation Instructions (MPII). Record the name(s) of all certified installers on the “Record of Contractor/Installer ACI Certification” form which can be downloaded from the web at http://www.dot.state.mn.us/bridge/construction.html under “Construction Forms and Tools.”

Conduct a pre-installation meeting inviting the Engineer, Inspectors, and certified installers to review the installation process and requirements. Submit the following to the Engineer:

Adhesive Anchor Installer Certification card

Certification card

in the Plans. Furnish only one of the adhesives listed on the APL, Bridge, “Concrete Anchorages – Threaded Rod Applications.” Verify that the adhesive has an uncracked characteristic bond strength as specified in the Plans. Install all anchors as specified by the MPII. Install to the depth on the Plans or as specified by the manufacturer, whichever is greater, in sound concrete and a minimum of 1 1/2 inches from bottom of concrete element. Meet the following conditions prior to installation and testing:

compressed air and allow a minimum of 24 hours dry-out time before cleaning the hole and installing the anchorage.

Fill the hole to the top of the concrete surface in which the anchorage is installed. Do not permit the adhesive to overtop the concrete surface in a way that will interfere with the placement of the base plate. An independent testing agency, not affiliated with the Contractor, must complete testing. The independent testing Inspector is required to be ACI Adhesive Anchor Inspector Certified. Verify the anchor strength and installation procedures by proof testing anchorages. Perform all tension testing in accordance with ASTM E 488, Standard Test Methods for Strength of Anchors in Concrete Elements. No portion of the tension testing device will bear on the concrete surface within a distance equal to one and a half times the anchorage embedment depth. Test anchorages to not less than the required proof load as provided in the Plans. Sustain the pr oof load for a minimum of 60 seconds prior to release of the proof load. Failure criteria of an anchorage test is defined in ASTM E 488. Proof test one anchorage in every set of 12 anchorages installed. If a set contains less than 12 anchorages test at least one. If a failure occurs while testing the anchorages in a set, test an additional anchorage within the set. If two of the anchorages in a set fail in concrete breakout, stop testing, notify the Engineer, and provide a non-conformance anchorage replacement Plan, to be accepted by the Engineer. Once accepted by the Engineer, remove and replace the remaining untested anchorages according to the approved replacement Plan and test new anchorage installations as outlined in this provision. Concrete breakout failure is defined as: a spall a minimum of two inches in diameter by one inch deep. Notify the Engineer immediately after any failure. Remove all anchors that fail the field test without damage to the surrounding concrete. Remove any remaining adhesive bonding material in the hole. Replace and test anchors using the method listed above, at no cost to the Department.

Prior to repairing concrete damaged during testing, provide a repair procedure to the Engineer for approval. Repair all damage to the concrete at no cost to the Department in accordance with the procedure approved by the Engineer.

2475.4METHOD OF MEASUREMENT

Unless otherwise shown on the Plans, the Engineer will measure the length based on the sum of the lengths of the various sections as shown on the Plans and as measured at the base of the rail.

2475.5BASIS OF PAYMENT

The Contract Unit Price for metal railings includes the cost of fabrication, surface preparation, coating, galvanizing, metal posts, fittings, castings, anchor bolts, accessories required for erection, and installation. The Department will pay for metal railings on the basis of the following schedule: Item No. Item Unit

2475.503 Ornamental Metal Railing ___ linear foot

3 Structural Tube Railing Design ___ linear foot

3 Pipe Railing ___ linear foot