1086SOUND BARRIERS

1086.1DESCRIPTION—This work is the construction of either structure mounted, g round mounted, or

offset sound barrier walls.

1086.2MATERIAL—

• Structural Steel Shapes and Plates. Section 1105.02(a)2

• Structural Steel Tubing. ASTM A53/A53M, Grade B, Type E

• Anchor Bolts, Nuts, and Washers. Section 1105.02(c)3, galvanized as specified in Section 1105.02(s).

• Oversize Washers. Section 1105.02(a)2 galvanized and painted after fabrication as specified in Section 1105.02(s) and Section 1060.2(b).

• Welded Studs. Section 1105.02(e)

• Welding Material. Section 1105.02(t)

• Galvanizing. Section 1105.02(s)

• Paint. Section 1060.2(b)

• Class AA Cement Concrete, Modified. Provide cement concrete as specified in Section 704; except, with a minimum 28-day compressive strength of 5,000 pounds per square inch.

• Structural Steel Base Plates. Section 1105.02(a)2 galvanized after fabrication as specified in Section 1105.02(s).

• Anchor Bolts, Nuts, and Washers. Section 1105.02(c)3, galvanized as specified in Section 1105.02(s).

• Oversize Washers. Section 1105.02(a)2 galvanized after fabrication as specified in Section 1105.02(s).

• Deformed Reinforcement Bars. Section 1002

• Deformed Welded Wire Fabric. Section 709.4

• Class AA Cement Concrete, Modified. Provide cement concrete as specified in Section 704; except, with a minimum 28-day compressive strength of 5,000 pounds per square inch.

ͦ Provide light weight concrete in the structure mounted sound barrier panels when specified to achieve a maximum oven dry density of 115 pounds per cubic foot. Verify the oven dry density of concrete in accordance with ASTM C567 during qualification of the mix design. Following mix

design approval, perform oven dry unit weight testing in accordance with ASTM C567 for each lot. Proportion mix design in accordance with ACI 211 for structural lightweight concrete.

• Deformed Reinforcement Bars. Section 1002

• Steel Welded Wire Fabric. Section 709.3

proposal. Color and texture to be uniform from panel to panel and post to post.

• Class A Cement Concrete. Section 704

• Deformed Reinforcement Bars. Section 1002

Mounted Sound Barrier Walls.

• Bolts. Section 1105.02(c)1

• Nuts. Section 1105.02(c)2.a

• Washers. Section 1105.02(c)2.b

• Galvanize and Paint all bolts, nuts, washers, and other hardware as specified in Sections 1105.02(s) and 1060.2(b).

• Galvanized Steel Flexible Wire Rope. 3/8-inch 7 x 19 with a minimum breaking strength of 35.6 8 kips.

• Thimbles. Galvanized Heavy-Duty for 3/8-inch wire rope meeting the requirements of Federal Specification FF-T-267B, Type II.

• Galvanized Wire Rope Clips. 3/8 inch.

• Steel Pipe. ASTM A53/A53M, Grade B, Type E galvanized as specified in Section 1105.02(s).

• Stainless Steel (Type 302 or 304) Flexible Wire Rope (Aircraft Cable). 3/8-inch 7 x 19 in accordance with MIL-W-83420 with a minimum breaking strength of 12 kips.

• Stainless Steel (Type 302 or 304) Internally Threaded Terminals. 5/8 inch outside diameter, swedged to cable, in accordance with MIL-T-6117. Provide compression fittings with a minimum breaking strength equal to or greater than the cable.

• Stainless Steel (Type 304) Hex Head Cap Screws. 1/2 inch - 13 UNC.

• Stainless Steel (Type 304) Washers.

• PVC Pipe (Schedule 40). Section 1101.09(b)1.

• Structural Steel Angles. Section 1105.02(a)2 galvanized after fabrication as specified in Section 1105.02(s).

• Anchor Bolts, Nuts, and Washers. Section 1105.02(c)2 galvanized as specified in Section 1105.02(s).

• Thru Bolts. Section 1105.02(c)1 galvanized as specified in Section 1105.02(s).

• Nuts. Section 1105.02(c)2.a galvanized as specified in Section 1105.02(s).

• Washers. Section 1105.02(c)2.b galvanized as specified in Section 1105.02(s).

• PVC Pipe (Schedule 40). Section 1101.09(b)1

• Door and Frame. As manufactured by Windsor Republic Doors, Steelcraft, Pioneer Industries, or and approved equal. Refer to Standard Drawings for additional information.

• Adhesive. As required and as specified by the manufacturer.

• Joint Sealing Material. Section 705.4(a)

• Caulking Compound. Section 705.8(b)

• Joint Backing Material (Backer Rod). Section 705.8

• Epoxy Bonding Compound. Section 706.1

• Non-shrink Grout. Section 1080.2(c)

• Closed Cell Neoprene Sponge. Section 1085.2(m)

• Unreinforced, Plain Neoprene Bearing Pads. Sections 1113.02(a), 1113.03(a), (d), and (g). Mark each bearing pad in indelible ink or flexible paint with at least one of the following: order number, lot number, or any unique identifier marking traceable to a specific lot of bearing pad material. Markings may be on any surface of the bearing pad. Sample the completed bearing pads according to PTM No. 312, except reduce the sampling rate to three bearing pads per structure.

• Integral Color Pigmentation (Where Indicated). See Special Provisions in the proposal.

• Lifting Inserts. Galvanized and as specified by Fabricator.

• Paint Color (Where Indicated). See Special Provisions in the proposal.

1086.3CONSTRUCTION—Before fabrication, obtain acceptance of shop drawings. Construct as indicated

on the contract drawings, Standard Drawings, as shown on the accepted shop drawings, and as follows:

adequate reinforcement around panel openings to prevent cracking. Show reinforcement details, in accordance with the Standard Drawing, on the shop drawings. Submit design calculations , for acceptance, for the precast concrete panels in accordance with the requirements of the Standard Drawings. Submit design calculations, for acceptance, for the panel and post lifting inserts for actual strength of concrete at time of stripping, transportation, and erection in accordance with the requirements of the Standard Drawings.

ground and acoustical profile elevations. Protect final ground elevations, established in the field, for the duration of the project and do not adjust without prior acceptance.

and acoustical profile elevations.

fabrication details and handling and transportation procedures for all wall elements including connections. Submit shop drawings for the posts and panels concurrently.

with the shop drawings.

(if applicable):

• Name of Manufacturer

• Pattern name and number.

• Minimum, maximum, and average relief

• Joint Widths

• Liner material type

• Schematic drawing of Form Liner layout for each panel type

• Name of Manufacturer.

• Specification

• Product Name, number and lifting capacity.

• Minimum concrete strength for lifting insert.

• Design information and calculations.

• Name of Manufacturer

• Product number and color number

• Specification

• Name of Manufacturer

• Product number and color number

• Specification

Sound Barrier Wall.

1.a. Drilled Caissons. Construct drilled caisson foundations as specified in Section 1006.3, and as follows: Construct embankments and/or cut existing grade to the top of caisson elevations before construction of the caissons. Provide vertical and tie reinforcement for the full height of the shaft. If the bottom of the caisson elevation is lower than required, then either provide additional vertical and tie reinforcement, at no additional cost to the Department, or suspend the reinforcement cage such that the reinforcement is in the proper position relative to the top of caisson elevation. Provide test holes and probe holes only as indicated. When permanent casing is used, drill, drive, or vibrate casing so soil is in full contact with the outside of the casing. Alternatively, place casing in an oversized hole and grout the annular space between the permanent casing and the surrounding soil to establish lateral support. Grout after the concrete has obtained its initial set but no later than 24 hours after placement of the concrete. Where excavation is stable and not subject to rapid degradation, the 24- hour period may be extended to 72 hours, as allowed. Use a pressurized grouting method capable of completely filling the open area. Provide grout as specified in Section 1108.03(f)1, except testing is not required. When temporary casing is used, remove casing as specified in Section 1006.3(i). If unexpected construction conditions require the casing to remain in place, perform grouting as specified for permanent casing to fill cavities surrounding the casing. Place caisson concrete within 24 hours of the completion of excavation and within 3 hours of final inspection of the drilled shaft. Where excavation is stable and not subject to rapid degradation, the 24 hour period may be extended to 72 hours, as allowed.

1.b. Spread Footings. Construct concrete spread footings as indicated , as specified in Section 1001.3, and as follows: Construct embankments and/or cut existing grade to the top of footing elevations. Excavate and backfill foundation areas as specified in Section 204.3; and compact using a mechanical tamper. If unsuitable foundation material is encountered, remove all unsuitable material at least 12 inches or as specified or directed below the bottom of spread footing elevation and backfill with compacted No. 2A Coarse Aggregate or Class C Cement Concrete as specified or directed.

2.a. Precast Concrete Posts and Panels. Fabricate precast concrete posts and panels as specified in Section 714, as indicated on the accepted shop drawings, and as follows: Use only pre-approved Fabricators listed in Bulletin 15.

Obtain acceptance of the concrete mix design before fabrication. Obtain initial acceptance of any architectural surface treatments before production of Test Posts and Panels. Fill all holes in the precast concrete posts and panels , resulting from fabrication, wi th an accepted non-shrink grout (color to match panel/post). Ensure that precast concrete posts and panels are cast in one continuous lift to eliminate cold joints. Fabricate panels in a manner that will produce a secure and vibration free installation. Provide a smooth finish on the portions of panels , being placed in post flanges or in contact with adjacent panels, as shown in the Standard Drawing. Furnish full height panels or stacked panel sections with tongue and groove or interlocking joints that provide “light tight” conditions at the joints and prevent direct transmission of sound. Furnish top panels with a smooth finish on the top side. Furnish bottom panels with a smooth finish on the bottom side. Repair defects in accordance with Publication 145. Replace cracked or damaged posts and panels which cannot be repaired to the satisfaction of the Representative.

2.b. Steel Cables (in precast concrete panels) and Accessories. Assemble three sample connections and submit for testing and acceptance before panel fabrication. Samples must be assembled by the same process that is used for production panels. Galvanized Wire Rope Clips. Tighten nuts evenly in accordance with the manufacturer’s recommendations. Confirm tension via torque verification.

2.c. Threaded Reinforcement Bars in Precast Concrete Posts with Base Plate Connections. Provide either epoxy coated or galvanized reinforcement bars. Thread end of bar or provide upset threads as specified. Fabricate in accordance with the following procedure: Cut threads on one end of bar. Clean any cutting lubricant from threads and bar and apply two coats of zinc oxide paint meeting the requirements of ASTM A780 to the threaded portion of the bar. Assemble reinforcement and base plate assembly. Overtap n uts, if required, to accommodate the additional material on the bolt threads.

2.d. Structural Steel Posts. Fabricate steel posts as specified in Section 1105.03, as indicated on the accepted shop drawings, and as follows: Use only pre-approved Fabricators listed in Bulletin 15. Furnish posts which are galvanized and painted as specified in Section 1105.02(s) and Section 1060.2(b). Furnish paint color as indicated or directed.

2.e. Steel Cables and Accessories for Offset Sound Barrier Walls. Assemble three sample connections and submit for testing and acceptance before panel fabrication. Samples must be assembled by the same process that is used for production panels.

2.f. Test Posts and Panels. Fabricate Test Posts and Panels (samples) for acceptance before normal fabrication and after acceptance of the shop drawings and catalog cuts for the panels and posts. Ground Mounted Sound Barrier Walls and Structure Mounted Sound Barrier Walls . Fabricate and erect a sample wall consisting of a minimum of three posts and two panel sections. Provide post heights that meet or exceed the average post height for the sound barriers on the project. Provide sufficient number of panels to match the height of the posts. Offset Sound Barrier Walls . Fabricate and erect a sample wall consisting of a minimum of three panel sections (lengths) Provide sections that meet or exceed the average wall height for the sound barriers on the project. Fabricate samples using the same process and materials that will be used for production. Erect sample walls at the place of manufacture and store outdoors to allow proper lighting for comparisons during manufacturing and inspection. Apply penetrating stain, where specified, to one half of wall, per side, to show the final finish after the sample wall is constructed.

Use test sections to determine the acceptability of the various surface treatments, uniform color, free of surface blemishes, quality of construction, and overall appearance of both the roadway and residential sides of the sound barrier wall. Provide integrally colored posts and panels that are uniform in color consistency and free from discoloration and blemishes. Galvanize and paint structural steel posts as specified. View architectural treatments for the sample wall and subsequent production for acceptance at a distance of 30 feet, unless otherwise specified. Notify the Department, at least 14 days before the construction of the Test Panels and Posts, so the appropriate Department representatives may be present to determine acceptability. Department representatives may include the Environmental Manager, Project Manager, Design Staff, Construction Staff, and any other project team member designated by the Department. Department representatives will determine whether the color and various surface treatments of the posts and panels are acceptable. Produce additional samples until an acceptable product is produced if initial test sections are found to be unacceptable. Acceptable samples fabricated according to the accepted shop drawings are allowed to be incorporated into the project in the final stage of construction, after all production has been completed and accepted. Production panels and posts not conforming to the accepted test sections will be rejected.

according to the manufacturer’s recommendations. Provide cranes that are sized to handle the posts and panels safely at the required height and reach. Erect posts truly vertical. Erect panels truly vertical in a manner that will provide a secure and vibration free system installation. Pack or place non-shrink grout in locations as shown. Do not pour or inject grout. Provide joints and connections with no visible openings or gaps to decrease sound attenuation. Fill all lifting inserts, in all concrete panels and posts, with an accepted non-shrink grout (color to match panel/post). Seal all open joints and holes with joint sealing material or caulking compound. Apply penetrating stain when indicated. Stain to extend a minimum of 6 inch below finished ground line. Construct finished ground as indicated or directed. Use only hand -operated compaction equipment within 4 feet of the sound barrier when backfilling. Contractor is responsible for overall fit of wall.

at least 48 hours after placing the final portion of the foundation.

1.a. Reinforced Precast Concrete Posts and Panels. Section 714 and as indicated in Publication 145.

1.b. Structural Steel Posts. ASTM A6

1.c. All Others.

ENGLISH Panels (inch) Post (inch) Height: ±1/4 Length: ±1/4 Length: ±1/4 Width: ±1/4 Thickness: ±1/4 Depth: ±1/4 Out of Flatness: Slot Depth: ±1/8 • Lengths to 8 feet: 1/8 Slot Width: ±1/8 • Lengths over 8 feet: 1/4 Out of Flatness: • Lengths to 8 feet: 1/8 • Lengths over 8 feet: 1/4

1.d. Steel Base Plate Flatness. Machine surfaces to within 0.01 inch of flatness. Determine flatness as specified in Section 1111.03(c).

1.e. Galvanized Lifting Inserts. Set inserts within ± 1 inch of the indicated location.

1.f. Steel Pipe in Precast Concrete Panels. Set steel pipe, for thru bolt, in precast concrete panels within ± 1/8 inch of the indicated location.

1.g. PVC Pipe in Offset Sound Barrier Panels. Set PVC pipe, for cable connection, in precast concrete panels ± 1/2 inch of the indicated location.

2.a. General. Provide architectural surface treatment patterns that are continuous and uninterrupted across horizontal joints in stacked panels.

2.b. Vertical Alignment for Stacked Panels (top-to-bottom). Provide a tolerance of ± 1/2 inch for the vertical alignment of the architectural surface treatment pattern between stacked panels.

2.c. Horizontal Alignment between Adjacent Panels (side-by-side panels). Provide a tolerance of ± 2 inch for the horizontal alignment of the architectural surface treatment pattern at adjacent panels.

2.d. Seam Lines between Form Liners. Assemble non-continuous form liner sections such that seams lines or match lines are not apparent when viewing the completed panels.

3.a. Vertical Alignment.

Height of Wall Vertical Alignment of Walls and Posts ≤ 10 feet 1/4 inch ≤ 20 feet 1/2 inch > 20 feet 3/4 inch

3.b. Horizontal Alignment. Horizontal alignment for walls and posts to be within ± 1/2 inch of the indicated location.

3.c. Posts. Set posts within ± 1/2 inch of the indicated location.

3.d. Post Rotation. Set orientation of post within ± 2 degrees of the indicated location.

3.e. Anchor Bolts. Set anchor bolts within ± 1/4 inch of the indicated location.

3.f. Top of Barrier, Wall, Caisson, Footings, Pedestals, and Raised Panel Seat Elevations. Set elevations within ± 1/2 inch of the indicated location.

3.g. Grout Depth under Base Plate. Set grout depth within ± 1/4 inch of the indicated thickness.

• Production panels and posts not conforming to the accepted test sections.

• Fractures and cracks passing through the panel or post.

• Defects that indicate proportioning, mixing, and molding not in compliance with the specifications or as indicated.

• Honeycombed open texture.

• Damaged ends where such damage would prevent making a satisfactory joint.

• Twenty-eight-day cylinder strength is less than design concrete strength.

• Defective welding.

• Dimensions not conforming to the allowable tolerances specified.

Panels and posts may be rejected either at the fabrication shop or at the construction si te, even after installation, but before acceptance of project. Mark the rejected post or panel “Rejected for the Department’s Use” with waterproof paint.

1086.4MEASUREMENT AND PAYMENT—

The price includes excavation, foundation, post, base plate, bearing pads, and all associated hardware.

Measured to equal the total area of the panel including areas concealed by posts or finished ground. The unit price includes all joint sealing materials and all associated hardware.

Measured to equal the total area along the Sound Barrier Control line disregarding the offset. The barrier height will be measured from the top of wall to the bottom of wall (top of footing). The barrier length will be measured from begin to end of wall. The price includes excavation, foundation, bearing pads, joint sealing material, and all associated hardware.

The price includes installation of door in wall panel and all associated hardware .

Class 3 Excavation required for the over excavation of unsuitable material below the bottom of spread footing elevation as indicated or directed.

Backfill over excavated area with compacted No. 2A Coarse Aggregate or Class C Cement Concrete as indicated or directed.