629HIGH-TENSION CABLE BARRIER SYSTEM

629.1DESCRIPTION —This work is furnishing and installing a high -tension cable barrier system, with

concrete post foundations, steel sockets, and end anchor terminals, at locations indicated on the plans or as directed by the Representative, including all appurtenances and hardware.

629.2MATERIAL—Furnish all material needed to complete a continuous segment of high -tension cable

barrier system including, but not limited to, end anchor terminals, pre-stretched cables, turnbuckles, cable ends, intermediate anchor assemblies, bolts, nuts, and other hardware required by the manufacturer. Galvanize all hardware, including steel sockets, as specified in Section 1105.02(s) , and conforming to AASHTO M 111. Furnish posts in steel sockets which are encased in concrete foundations, according to manufacturer's recommendations.

• Pre-stretched

• 3/4-inch diameter minimum, 3 × 7 galvanized steel wire rope, AASHTO M 30, Type 1, Class A coating

• Minimum breaking strength = 39,000 pounds

• Minimum breaking strength = 36,800 pounds

• Galvanized after fabrication conforming to ASTM A153

Bulletin 15. System is to be crashworthy according to the 2016 AASHTO Manual for Assessing Safety Hardware (MASH). Proprietary cable systems must have a determination by an ISO 17025 accredited testing laboratory stating that the cable barrier system has either passed a full suite of tests or all critical crash tests per the MASH crash testing matrix and is compliant with the 2016 AASHTO MASH. MASH 2009 is also allowed on level terrain and slopes up to 4(H):1(V) if crash tested before 2016. System is to meet the following requirements:

• Test Level 4 (TL-4) for cross slopes of 10(H):1(V) or flatter.

• Test Level 3 (TL-3) for cross slopes steeper than 10(H):1(V) but no steeper than 4(H):1(V).

• Systems to be installed on cross slopes steeper than 10(H):1(V) but no steeper than 4(H):1(V) must be compliant with MASH TL-4 on level terrain and MASH TL-3 for 4(H):1(V) slopes.

• The maximum dynamic deflection/working width is 10 f eet based on the MASH Test 4 -11 with the 2270P pickup truck test vehicle on level terrain.

• The installed post spacing is determined from either method below; but regardless, the post spacing must not be greater than the post spacing used during the MASH 3 -17 and MASH 4 -17 sedan penetration crash test or 18 feet, whichever is less.

ͦ If the MASH 4-11 crash test with the 2270P test vehicle on level terrain was performed on a range of post spacings, then the installed post spacing is interpolated to meet the deflection requirement. ͦ If the MASH 4-11 crash test with the 2270P test vehicle on level terrain was performed at only one post spacing, then the installed post spacing must match the post spacing during crash testing. Also, the deflection determined during the crash testing must be less than the maximum required deflection.

System is to be crashworthy according to the 2016 AASHTO MASH. Proprietary end anchor terminals must have a determination by an ISO 17025 accredited testing laboratory stating that the end anchor terminal has either passed a full suite of tests or all critical crash tests per the MASH crash testing matrix and is compliant with the 2016 AASHTO MASH. End anchor terminal is to meet the following requirements:

• Test Level 3 (TL-3)

• Cross Slope = 10(H):1(V) or flatter

629.3CONSTRUCTION—

At a minimum, include the following in the shop drawings to cover all runs of high-tension cable barrier.

• General notes and construction specifications

• Height of each cable in the system from ground line and top of foundation

• Installation tolerances

• Post length and height of each post with respect to the ground level.

• Post spacing along entire length of system.

• Diameter and depth of line post foundations

• Detailed drawings of all posts, hardware, concrete, and reinforcement bars

• Maximum length between turnbuckles, not to exceed 1,100 feet.

• Minimum depth of the line post foundations, as specified in Section 629.3(b)6.

• Minimum diameter of 12 inches for the line post foundations

Provide Form CS-4171, Certificate of Compliance, for the associated components of the entire high - tension cable barrier system. Include the breaking strength, modulus of elasticity, and amount of force used to elongate the wire rope.

the soil type. Prepare shop drawings as specified in Section 105.02(d).

Borings and soil testing for line post foundations may be performed according to Publication 222 at no additional cost to the Department. At a minimum, include the following to cover all locations for end anchor terminals:

• Borings and Soil Testing.

ͦ Perform drilling by a prequalified geotechnical drilling contractor listed in Publication 222 . ͦ Prepare and deliver the boring inspection information according to Publication 222, Section 4.11. ͦ Obtain each boring within 25 feet horizontally of each proposed end anchor terminal location. If two end anchor terminals are close enough that one boring is within 25 feet of both end anchor terminals, then the same boring may be used for both end anchor terminals. ͦ If end block anchorage is proposed for the high -tension cable barrier system, drill each boring to a minimum depth of 15 feet into soil, or a minimum of 5 feet into rock, whichever is encountered first. If a drilled shaft is proposed for the high-tension cable barrier system's end block anchorage, drill each boring to a minimum depth of 25 feet into soil or a minimum of 10 feet if rock is encountered, whichever occurs first. Any additional borings or additional depth of boring required because of change in proposed end anchorage are at the Contractor's expense. ͦ At each boring location, laboratory testing must include soil classification, soil strength and rock strength testing to determine the required in situ soil/rock parameters for design of the foundation. ͦ Testing must be performed by a certified AASHTO Materials Reference Laboratory (AMRL). Show water table on boring log.

• End Anchor Terminal Foundation Design. Provide design for end anchor terminal foundations based on site specific soils for each end anchor terminal location.

ͦ Design the block anchor or drilled caisson (shaft) anchor according to Publication 15M, Design Manual Part 4, and the AASHTO LRFD Bridge Design Specifications, including overturning, sliding (block anchor only), and reinforcement steel. Design each end anchor terminal foundation for the Service Limit State including the cable tension force, a nd the Extreme Event (Collision) limit state using a minimum impact/collision force of 31 kips. Use the most conservative limit state, either Service or Extreme Event (Collision), for the end anchor terminal foundation design. Design cable median barrier a nchorage connections into the end block foundations for the controlling Strength or Extreme Event (collision) limit state. ͦ Support or resistance provided by the top 1 foot of soil is discounted and must not be included in the design of the end anchor terminal foundation. ͦ Design the end anchor terminal foundation for longitudinal deflection of 1 inch. The contractor is to inspect the end anchor terminal foundation upon completion of the entire project. If the end anchor terminal longitudinal deflection exceeds 1 inch (is ou t of plumb by 1 inch in the direction of the cable), the contractor is responsible for tensioning or repairing the cable median barrier system to ensure proper cable tension and system functionality. ͦ Base the minimum design load for the cable end terminal to cable connections on the theoretical cumulative tension expected at -25F. ͦ Design the bottom elevation of the end anchor terminal foundations to 6 inches below the minimum frost depth. Determine the depth of frost penetration according to Publication 242, Section 9.3, Item 2, Maximum Potential Serviceability Loss Due to Frost Heave . Add 6 inches to that depth and round up the resulting value to the nearest 6-inch increment. ͦ One foundation design may be submitted for one or more end anchor terminal locations based on the most conservative roadway boring information.

to the Representative at least 30 calendar days before planned construction and have them signed and sealed by a Professional Engineer, registered in the State. Include manufacturer's product brochure, specifications, and requirements. Within 16 calendar days after receipt, the Representative will notify the Contractor in writing of all additional information required and/or necessary changes. Submit the additional information and/or necessary changes within 7 calendar days of receiving comments from the Representative. The Representative will notify the

Contractor within 7 calendar days, after receipt of the additional information, of the Department's acceptance or rejection.

than 60 calendar days after the Notice to Proceed Date. Field verify the exact locations of the end anchor terminals and the high -tension cable barrier with at least one individual in attendance from the following organizations:

• Contractor

• District Representative

• District Senior Inspector-in-Charge

• District Guide Rail Mentor (Optional)

• Bureau of Bridge (Optional)

Before the preinstallation review, place temporary markings (paint, stakes, or flags) indicating planned locations of all permanent high-tension cable barrier and end anchor terminals to be installed as part of the project.

specified in Section 629.3(a) have been accepted in writing by the Representative.

and during installation of posts, cable, and hardware.

Place Class AA Cement Concrete and reinforcement for high-tension cable barrier end anchor terminals.

finished ground or up to 1 inch above finished ground if allowed according to manufacturer's recommendations. Construct the bottom elevation of the line post foundations to the greater of the manufacturer's minimum depth or to 6 inc hes below the minimum frost depth penetration determined according to Publication 242, Section 9.3, Item 2 , Maximum Potential Serviceability Loss Due to Frost Heave . Add 6 inches to that depth and round up the resulting value to the nearest 6-inch increment. In areas where random boulders, hardpan, or bedrock are encountered, and the specified steel socket cannot be constructed to full depth, drill a minimum diameter and minimum depth hole as specified by the manufacturer. Fill excavation completely with the same class of cement concrete used in the foundation.

plans. Do not install high-tension cable barrier between 4 feet and 20 feet from the hinge point if the cross slope is 6(H):1(V) or steeper.

as indicated on the plans. Install high-tension cable barrier end anchor terminal with an offset between it and the paved surface of the median crossover as indicated on the plans. High-tension cable barrier may be installed at a minimum flare rate of 50:1 to avoid existing barriers and for deceleration lanes of median crossovers.

concrete footing for the line post foundation, conforming to the accepted preconstruction submittals, and meeting manufacturer's guidance for tolerance. Ensure that cables are set to the proper height.

Any further reduced post spacing or extra posts installed for performance in horizontal or vertical curves, to reduce deflection or for any other reason, is included in the price.

at no additional cost to the Department.

barrier end anchor terminals, according to the manufacturer's requirements. Install delineation devices to not exceed the spacing requirements for guide rail delineation as shown on Standard Drawing TC-8604. In locations where a high -tension cable barrier end anchor terminal is near a permanent median crossover, install delineation devices on every line post within 100 feet of the end anchor terminal. Provide a minimum of 120 square inches of reflective sheeting on the end anchor terminal. Provide a minimum of 8 square inches of reflective sheeting attached directly on or attached to the posts. Place reflective sheeting as high as possible on the line posts. Delineation is required on the side closest to traffic. Delineation is also required on the other side if the cable barrier is within the clear zone of traffic on the other side. Verify that the reflective sheeting of all delineation devices is visible to approaching traffic. In locations where high -tension cable barrier overlaps another roadside barrier, provide delineation only on the barrier system closest to traffic. Provide delineation on every other post when any individual run of the system is within 4 feet of edge of traveled way.

tension cable barrier end anchor terminals, as specified in Section 804.

placed for line post foundations. Mold one set of concrete QC cylinders to be tested for compressive strength for concrete that is placed for end anchor terminals. Acce ptance of cylinders is as specified in Section 704.1(d)5, except lots established daily.

terminals has cured for a minimum of 3 days, and the concrete for the end anchor terminals has achieved a minimum compressive strength of 3,500 pounds per square inch. Cable tension must meet manufacturer's guidance and be within tolerance for different tensions for various temperature ranges. Follow the manufacturer's instructions for tensioning near turnbuckles. After a minimum of 3 days but no more than 14 days after initial tensioning, recheck cable tension and adjust, if necessary, according to the manufacturer's instructions. Prepare and submit tension logs to the Representative with, at a minimum, the following:

• Date tensioning was performed.

• Temperature of wire cable at the time of tensioning.

• The segment and offset of each end terminal and near each turnbuckle being tensioned .

• A diagram showing the number assigned to each of the cables.

• The wire cable number being tensioned.

• The initial tension load in each cable (Optional).

• The final tension load applied to each cable.

• Any applicable installation notes.

• The name and signature of person conducting the tension testing.

and high-tension cable barrier end anchor terminals at no additional cost to the Department.

629.4MEASUREMENT AND PAYMENT—

For the cross slopes indicated. Costs associated with placement of the temporary markings, and attendance at the preinstallation review are incidental to other items of work, and no separate payment will be made. Revisions to contract quantities of high-tension cable barrier will be paid as specified in Section 110.

Each. Roadway borings and laboratory testing for line post foundations are incidental.