403 SECTION 607 GUARDRAIL
607.1 -DESCRIPTION : This work shall consist of the construction or reconstruction of guardrail in accordance with these Specifications and in reasonably close conformity with the lines and grades shown on the Plans or established by the Engineer. The types of guardrail are designated as follows: Type 1: Galvanized Steel Deep Beam Type Guardrail or Zinc -Aluminum - Magnesium Alloy -Coated Steel Deep Beam Type Guardrail Type 2: Blank Type 3: Blank Type 4: Blank Type 5: Galvanized Steel Double -Faced Guardrail (Deep Beam Type) or Zinc - Aluminum -Magnesium Alloy -Coated Steel Double -Faced Guardrail (Deep Beam Type)
All installations of Type 1 & 5 Guardrail will be classified according to one of the designations specified. The guardra il class will be indicated in the pay items and on the Plans, Class I: 6 feet - 3 inches post spacing with blocks Class II: 12 feet - 6 inches post spacing with blocks Class III: 12 feet - 6 inches post spacing without blocks. Class IV: 3 feet - 1½ inches post spacing without blocks. Class V: 3 feet - 1½ inches post spacing with blocks.
The construction of the guardrail shall include the complete furnishing, assembling and erecting of all component parts and materials at the location shown on the Plans or directed by the Engineer.
607.2 -MATERIALS : Materials shall meet the requirements of the following Subsections of Division 700:
MATERIAL SUBSECTION Concrete for Footers 715.12 Galvanized Steel Deep Beam Type Guardrail Fasteners and Anchor Bolts 712.4 Miscellaneous Concrete 715.12 Offset Blocks 710.3, 710.5 * Pressure Treated Wood Guardrail Posts 710.3, 710.5 Retroreflective Sheeting for Traffic Control 715.9.2.8 Steel Guardrail Posts 709.45 Zinc-Aluminum -Magnesium Alloy -Coated Steel Deep Beam Type Guardrail 712.5 Zinc Rich Primer (Galvanized Repair) 711.21
* Other material types may be substituted from the division’s approved list.
404 All materials must be protected from damage during storage and handling. All materials, including materials which have been approved previously, will be subject to inspection by the Engineer as to condition at any time prior to or during incorporation of the material in the work. Materials which have been damaged shall not be used.
CONSTRUCTION METHODS
607.3 -SETTING POSTS AND PLACING FOOTERS : 607.3.1 -General: Unless one type is specified, posts may be of steel, or wood, and the Contractor shall indicate at the preconstruction conference the type of post the Contractor elects to use and that type shall be used throughout the Project. Post dimensions and deta ils shall conform to the requirements shown on the Plans. Guardrail posts shall be placed as shown on the Plans. Posts shall be set plumb in holes dug by hand or mechanically. When posts are driven, the manner of driving shall be such as to avoid batte ring or distorting of posts. Post holes shall be backfilled with acceptance material placed in maximum six (6) inch loose layers and thoroughly compacted. All posts damaged during erection or driving shall be removed and replaced without additional cost. Any damage to post galvanizing shall be repaired by a material meeting the requirements of subsection 711.21. Painting, when called for, shall not be done in damp or freezing weather and shall only be done when the posts are thoroughly dry.
607.3.2 -Steel Posts: Galvanized steel posts shall not be painted except for touch up painting with zinc primer as specified.
607.3.3 -Pressure Treated Wood Posts: All wood posts shall meet the requirements of
607.3.4 : Blank
607.3.5 -Offset Blocks: Offset blocks shall be used when called for by the Plans.
607.3.6 -Footers for Breakaway Cable Terminal and Special Trailing End Terminal: Footers for breakaway cable terminal and special trailing end terminal shall be constructed of cast-in-place concrete meeting the requirements of subsection 715.12. Concrete shall be placed promptly and without segregation after mixing. Concrete footers shall be carried down to at least the depth, and shall be not less than the dimensions shown on the Plans. The top of all footers shall be not less than the dimensions shown on the Plans. The top of all footers shall be flush with the ground line and shall be troweled to a smooth finish with a slope to drain away from the post. After excavating f or the footer, the earth coming in contact with the concrete must be moistened to a depth of at least two ( 2) inches just prior to placing the concrete in the hole. No curing will be required other than the placing of not less than four ( 4) inches of loos e moistened earth, free from clods or gravel, over the top of the footer immediately after placing the concrete. All excess excavation from footers and loose material used for curing shall be disposed of in a manner satisfactory to the Engineer.
405 607.4 -ERECTING RAIL ELEMENTS : 607.4.1 -General: Rail elements shall be erected in a manner resulting in a smooth, continuous installation. All bolts, except where otherwise required, such as expansion joint bolts and adjustment bolts, shall be drawn tight. Bolts through expansion joints shall be dr awn up as tight as possible without being tight enough to prevent the rail elements from slipping past one another longitudinally. Bolts shall be sufficiently long to extend at least ¼ inch beyond the nuts. Except where required for adjustment, bolts sha ll not extend more than ½ inch beyond the nuts. Bolts through variable thickness posts shall be cut off a maximum of ½ inch beyond the nuts. All metal guardrail elements shall be fabricated in the shop. Field punching, cutting, and drilling of all guardrail elements other than rail may be permitted after it has been demonstrated that it will not result in damage to the surrounding metal and if approved by the Engineer. When additional slotted holes are required in W -beam to secure rail to post, sl otted hole shall be per Standard Details Volume I. Slotted hole shall be field punched or shop fabricated so that they are free from tears, jagged edges and damage to the surrounding metal. Drilling to create slotted holes is prohibited. It shall be pe rmissible to join Galvanized and Zinc -Aluminum -Magnesium Alloy -Coated Guard Rail together. Additionally, it shall be permissible to use galvanized fasteners and end terminals with Zinc -Aluminum -Magnesium Alloy -Coated Guard Rail beams. Galvanized or zinc-aluminum -magnesium alloy -coated surfaces which have been abraded so that the base metal is exposed, any field welded surfaces, threaded portions of all fittings and fasteners, and cut ends of bolts shall be protected with zinc rich primer or by field galvanizing, when approved by the Engineer.
607.4.2 -Type 1 Guardrail (Galvanized Steel Deep Beam / Zinc -Aluminum - Magnesium Alloy -Coated Steel Deep Beam): The rail shall be erected so that the bolts at expansion joints will be located near the centers of th e slotted holes. The rail elements shall be spliced by lapping in the direction of traffic. The rail elements at each splice shall make contact throughout the area of the splice. Shop -curved rail shall be used on curves with radii less than 150 feet. Any surface damage to galvanized beams or zinc -aluminum -magnesium alloy -coated beams shall be repaired with a material meeting the requirements of subsection 711.21. When called for, guardrail end terminals conforming to the details shown on the Plans sh all be constructed.
607.4.3 through 607.4.4: Blank
607.4.5 -Type 5 Guardrail (Galvanized Steel, Double -Faced / Zinc -Aluminum - Magnesium Alloy -Coated Steel, Double -Faced): This rail shall be erected in accordance with the requirements of 607.4.2 and as shown on the Plans.
607.5 -GUARDRAIL REMOVED AND REBUILT OR STORED : This item shall consist of carefully dismantling, removing, and reerecting or storing, at the location specified on the Plans, of existing guardrail. Rebuilt units shall be of the same type, spacing of members, etc., as original guardrail. New materials pecified on the Plans shall conform to the requirements for the construction of new guardrail of the type being reset. It shall be permissible to join Galvanized and Zinc - Aluminum -Magnesium Alloy -Coated Guard Rail beams.
406 All salvageable materials shall b e removed and re -erected (or stored if so specified) with reasonable care. Posts, rails, fabric, and cables for reerected rails shall be obtained from salvage sources, but the Contractor shall furnish whatever additional bolts, clips, or incidental hardwa re as may be necessary to complete the guardrail. Methods of re -erection shall conform to the requirements for the construction of new guardrail of the type being reset, except as modified on the Plans. Where removal and storage is specified, the bolts, cables, and other hardware shall be carefully removed from all rails, posts, and other members, and all parts shall be sorted and stored at the locations specified. Rails shall be properly stacked, cable shall be free from kinks and rewound on the cables pools, and all such reasonable care shall be exercised in the handling, storing, and preserving of materials as will insure the maximum salvage value for the entire operation.
607.6 -METHOD OF MEASUREMENT : The quantity of work done will be measured in linear feet of guardrail of the type indicated on the Plans, complete in place and accepted, measured along the face of the rail from center to center of end posts. The linear feet of double -faced guardrail will be measured along the face of one rail only. When end terminals or attenuators for steel beam type guardrail are used, they will be measured separately and will be the actual number of end terminals or attenuators constructed, complete in place and accepted. Where twenty -five ( 25) feet sections of steel deep beam guardrail having three ( 3) feet - 1½ inches or six ( 6) feet – three ( 3) inches post spacings are utilized at bridges, they will be measured and paid for as six (6) feet – three ( 3) inches post spacing with blocks (Class I) and in accordance with their appropriate guardrail type. Where eighteen ( 18) feet – nine ( 9) inches sections of guardrail -bridge transitions, having three ( 3) feet- 1½ inches and one ( 1) foot - 6 ¾ inches post spacings, are utilized at bridges or in conjunction with other structures, these sections shall be measured and paid for as W -Beam Guardrail Bridge T ransition. The cost of the double, top w -beam ( twelve ( 12) feet – six (6) inch section ), bottom w -beam (rubrail), guardrail end special hardware, connectors and incidentals utilized in guardrail - bridge transit shall be included in W -Beam Guardrail Brid ge Transition. Where w -thrie beam guardrail -bridge transitions consisting of two nested thrie beam panels and a transition section from w -bearn to the thrie hewn guardrail having a total length of eighteen ( 18) feet – nine ( 9) inches are utilized at bridges or in conjunction with other structures, these sections shall be measured, and paid for as Thrie Beam Guardrail Bridge Transition. The cost of the double thrie beam twelve ( 12) feet – six (6) inch sections, the six (6) feet – three ( 3) inches section o f w-thrie beam transition, the six ( 6) feet – six ( 6) inches length steel posts, guardrail terminal connectors, and all special hardware, connectors, and incidentals utilized in this guardrail - bridge transition shall be included in Thrie Beam Guardrail Bridge Transition. Where guardrail end terminals , per the Division Approved Source/Product Listing, are utilized on projects, these terminals shall be measured and paid for as Flared End Terminal or Tangent End Terminal as shown in the plans. The cost of all hardware shown on the pre -approved shop drawings for the end terminals and the reflective sheeting on the nose of the terminal shall be included in the cost of the Flared End Terminal, per each or Tangent End Terminal, per each.
407 607.6.1 -Tangent End Terminal Components: Tangent End Term inal Repair will be measured from the percentage shown in tables 607.6.1A and 607.6.1B for the parts that are used and accepted. The Tangent End Terminal (TET) has two approved manufactures. The different components of each system along with how much perc entage each part is to the entire system can be found in the following tables:
TABLE 607.6.1A (SKT 350) Approval #1318593A Part # Component Description Value in Percentage (per each) S3000 Impact Head 41.6% S1303 / 1305 #1 Deep Beam Guardrail 12 GA. 12.5’ or 25’ 2.1% G1203 / 1205 #2 Deep Beam Guardrail 12 GA. 12.5’ or 25’ 5.8% E735 Foundation Soil Tube 6” x 8” x 4’ -6” 3.3% SP600 Soil Plate 24” x 18” x ¼” 1.3% E740 Pipe Sleeve 0.3% E750 Bearing Plate 8” x 8” x 5/8” 0.8% E760 Cable Anchor Box 2.3% E770 BCT Anchor Cable Assembly 2.4% E780 Ground Strut 2.1% P650 Wood Posts 5.5” x 7.5” x 45” 1.2% P675 Timber Blockout 6” x 8” x 14” 0.4% E3151 Impact Face Object Marker 1.5%
TABLE 607.6.1A (SKT 350) Approval #1318593A -Hardware Package: Part # Component Description Value in Percentage (per each) B580122 Splice Bolt 5/8” Dia. x 1 ¼” 4.5% B580754 Hex Bolt 5/8” Dia. x 7 ½” B581004 Hex Bolt 5/8” Dia. x 10” B581002 H.G.R Bolt (Post 2 Only) 5/8” Dia. x 10” B581802 H.G.R Bolt (POST 3 -8) 5/8” Dia. x 18” N050 H.G.R Nut (Splice 16/32, soil tubes 22, Strut 2, Post 2 -8, 7) 5/8” Dia. W050 H.G.R Washer 5/8” Dia. N100 Anchor Cable Hex Nut 1” W100 Anchor Cable Washer 1” E350 Lag Screw 3/8” x 3” SB58A Cable Anchor Box Shoulder Bolts N055A A325 Structural Nut 1/2 ” W050A A325 STR. Washer 1-1/16” OD x 9/16” ID
408 TABLE 607.6.1B (ET -2000) Approval #1318592A Part # Component Description Value in Percentage (per each) 62G #1 Deep Beam Guardrail 12 GA. 9% 60G #2 Deep Beam Guardrail 12 GA. 5% 740G Steel Tube 6” x 8” x 54” x 3/16 ” 3.3% 766G Soil Plate 24” x 18” x ¼” 1.3% 782G Bearing Plate 8” x 8” x 5/8” 1.2% 704A Cable Anchor Bracket 5.6% 3000G Cable Assembly/ With Hex Nut & Washer 3/4” x 6’6” 3.5% 985A Guardrail Extruder 63% 9918A Offset Strut 2.8% 705G Pipe Sleeve 2” Std. x 5 ½” 0.4% 4147B Wood Posts 5.5” x 7.5” x 45” 1.4% 4063B Wood Posts 6” x 8” x 6’ 2.4% 4148B Wood Block 5.5” x 7.5” x 14” 0.5% 3177A Object Marker
TABLE 607.6.1B (ET -2000) Approval #1318592A -Hardware Package: Part # Component Description Value in Percentage (per each) 3478G Hex Bolt (Soil Plate) 5/8” Dia. x 7 ½” 0.6% 3497G Hex Bolt (Top Of Tube) 5/8” Dia. x 9 ½” 3360G H.G.R Splice Bolts 5/8” Dia. x 1 ¼” 3580G H.G.R Post Bolt 5/8” Dia. x 18” 3340G H.G.R Nut (Splice 16, tubes 24A/12B, gr -7) 5/8” Dia. 3300G Washer (2 At Tubes 1 & 2 + 7 Posts) 5/8” Dia. 4228G Lag Screw 3/8” x 4”
607.6.2 -Flared End Terminal Components: The Flared End Terminal (FET) has three (3) approved manufactures. The different components of each system along with how much percentage the part is to the entire system can be found in the following tables:
409 TABLE 607.6.2A (FLEAT 350) Approval #1318589A Part # Component Description Value in Percentage (per each) S3000 Impact Head 40.4% F1303 W-Beam Guardrail End Section, 12 GA 2.8% F1304 W-Beam Guardrail Center Section, 12 GA 3% G1203 W-Beam Guardrail, 12 GA 7.8% S730 Foundation Soil Tub e Note 1 6” X 8” X 6’ 5.8% Note 1 Post 1 and 2 Foundation Tubes maybe substituted with the following options:
Part # Component Description S730 Split Foundation Tubes 6’-0” E371 Solid Foundation Tubes 6’-0” SP600 Foundation Tubes S375 W/Soil Plates 5’-0” SP600 Foundation Tubes E735 W/Soil Plate 4’-6” E740 Pipe Sleeve 0.5% E750 Bearing Plate 8” X 8” X 5/8” 1% E760 Cable Anchor Box 3.1% E770 BCT Cable Anchor Assembly 3.3% E780 Ground Strut 2.8% P650 Wood Posts 5.5” X 7.5” X 45” 1.6% P671 Wood CRT Posts 6” X 8” X 6’ 2.3% P675 Timber Blockout 6” X 8” X 14” 0.5%
TABLE 607.6.2A (FLEAT 350) Approval #1318589A -Hardware Package: Part # Component Description Value in Percentage (per each) B580122 Splice Bolt 5/8” DIA. X 1 ¼” 4.9% B580754 Hex Bolt 5/8” DIA. X 7 ½” B581004 Hex Bolt 5/8” DIA. X 10” B581002 Bolt (Post 2 Only) 5/8” DIA. X 10” H.G.R B581802 H.G.R. Bolt (Post 3 -7) 5/8” DIA. X 18” N050 H.G.R. Nut (Splice 24, Soil Tubes 2, Strut 2, Post 2, 1; Post 3 Thru 7, 5.) 5/8” DIA W050 H.G.R. Washers N100 Anchor Cable Hex Nut 1” W100 Anchor Cable Washer 1” E350 Lag Screw 3/8” X 3” SB58A Cable Anchor Bow Shoulder Bolts N055A A325 Structural Nuts 1/2” N050A A325 Str. Washer 1-1/16” OD X 9/16” ID
410 TABLE 607.6.2B (SRT 350) Approval # 1318590A Part # Component Description Value in Percentage (per each) 3G Backup (Guardrail) 12 GA 12” 2.4% 34G SRT-1 (Guardrail) 12 GA 12’6” 12.8% 63G SRT-350 (Guardrail) 12 GA 25’/6’3 16.2% 9G (Guardrail) 12 GA 12’6/6’3 5% 35G SRT-2 (Guardrail) 12 GA 12’6/6’3 12.8% 700A Cable Anchor Bracket 2.6% 705G Pipe 2” Ø x 5 ½” 0.5% 736G Tube Sleeve 5’ 8.2% 766G Soil Plate 24” x 18” x ¼” 2.4% 775G Bearing Plate 8” x 6” x 5/8” 2.6% 923G 12 GA/Barrier (Terminal) 98” 2.6% 3000G Cable With Nut And Washer 3/4 x 6’6 6.4% 9852A Strut Assembly 5.1% 4075B Block 6” X 8” X 14” 1% 4063B Posts 6” X 8” X 6’ 4.4% 9960A Slot Guard 2.1% 4147B Wood Posts 5.5” X 7.5” X 45” 2.6%
TABLE 607.6.2B (SRT -350) Approval # 1318590A -Hardware Package: Part # Component Description Value in Percentage (per each) 3360G Splice Bolts 5/8” Dia. x 1 ¼” 10.3% 3500G Post Bolt 5/8” Dia. x 10” 3580G Post Bolt 5/8” Dia. x 18” 3340G Hex Nut 5/8” Dia. 3300G Washer 5/8” Dia. 3320G Washer 3/16 x 1 ¾ x 3” 3478G Hex Head Bolts 5/8” Dia. x 7 ½” 3380G Hex Head Bolts 5/8” Dia. x 1 ½” 3497G Hex Head Bolts 5/8” Dia. x 9 ½” 9961G Plate Washer 3/8 x 3 x 4 5968G 16d Standard Nail 3900G Washer 1” 3910G Hex Nut 1”
411 TABLE 607.6.2C (REGENT) Approval # 318591A Part # Component Description Value in Percentage (per each ) PTE05 Foundation Tube, ST, G 10.5% PLS03 Soil Plate, St, G 1.5% PFP01 Strut & Yoke Assemble, ST, G 4.5% Regent Post 1 Regent Post 1 11% Regent Post 2 Regent Post 2 4% FAC PLT WLD Regent Face Plate Weldment 3.5% Rein Panel Regent Rein Panel Weldment 4.4% Brace Brace Ch Standard 4% Brace Support Brace Support ¼ x 5” Bent With Holes 4% FPA01 Cable Anchor Box 2% FCA01 Cable Anchor, Nut And Washers 1.5% CBL Arch SLV Cable &Anchor Sleeve 3.5% Bearing SLV Regent Bearing Sleeve, Half 6% Regent Line Po Regent Line Post, Mod 2 ½” Holes 2% PDB01 Timber Post Blockout 4% Regent Rail 1 Regent Rail 1 (Mod Twm14a) 12% Regent Rail 2 Regent Rail 2 (Mod Twm14a) 8% Rwm04a Regent Rail 3 (Rwm04a Or Rwm02a) 5.5% Fpp02 “L” Shelf Angel Bracket 1.5% Rwb01a W-Beam Backup Plate 1.5%
TABLE 607.6.2C (REGENT) Approval # 318591A –Hardware Package: Part # Component Description Value in Percentage (per each) FBB01 Guardrail Bolt & Rail Nut 5/8” Dia. x 1 ¼” 5.1% FBB03 Guardrail Bolt & Nut, Hex Head 5/8” Dia. x 10” FBB04 Guardrail Bolt & Nut, Hex Head 5/8” Dia. x 18” FBX16a1 Hex Bolt & Hex Nut 5/8 x 1 9/16 FBX16a2 Hex Bolt & Hex Nut 5/8 x 7 7/8 FBX16a3 Hex Bolt & Hex Nut 5/8 x 9 7/8 FWC16a Flat Washer, G 11/16” ID x 1 ¾” OD FW4R03 Rectangular Guardrail Washer Standoff Standoff 7/8 x 5/8 x ¼ C Bracket C Bracket Bent With Hole 1/4 x 6” Post Breaker FTB ST With Holes 1/4 x 3 x 16 Post Breaker ANG ST With Hole 1/4 x 3 x 3x 9 N16D Nail, 16D, G
412 607.7 -BASIS OF PAYMENT : The quantities, determined as provided above, will be paid for at the contract unit prices bid for the items listed below, which prices and payments shall constitute full compensation for furnishing, preparing, placing, and erecting all materials, and all labor, tools, equipment, supplies such as nuts, bolts, washers, cables and any other incidentals ne cessary to complete the work. Tangent End Terminal Repair and Flared End Terminal Repair will be paid for at the percentage calculated above of the unit price bid for that item. Payment for Cut Slope Terminal Type A shall include extra -length guardrail p osts as required, rubrail, excavating and backfilling the trench, reshaping, seeding and mulching of the cut slope, and either concrete block or soil plate anchor complete and in place. Payment for Cut Slope Terminal Type B shall include extra -length guar drail posts as required, drilling holes into the cut slope, and furnishing and installing rock bolts (2), end shoes (2), rubrail, and all other necessary hardware to complete the installation.
607.8 -PAY ITEMS : ITEM DESCRIPTION UNIT 607001 -* Type 1 Guardrail, Class “class” Linear Foot 607005 -* Type 5 Guardrail , Class “class” Linear Foot 607006 -* Thrie Beam Guardrail Bridge Transition Each 607007 -* W-Beam Guardrail Bridge Transition Each 607009 -* “Type” Guardrail, Removed and Reset Linear Foot 607010 -* “Type” Guardrail, Removed and Stored Linear Foot 607010 -* Guardrail Removal Linear Foot 607011 -* Reset “Type” Guardrail, “class” Linear Foot 607025 -* Cut Slope Terminal , Type “type” Each 607030 -* Special Trailing End Terminal Each 607035 -* Guardrail Element Each 607036 -* Guardrail End Shoe Each 607037 -* Buffer End Section Each 607039 -* 6 x 6 x 14 inch Treated Wood Block Each 607040 -* 8 x 6 x 14 inch Treated Wood Block Each 607041 -* 13 foot – 6.5 inch Curved Rail Element Each 607042 -* 6 foot Steel Post Each 607043 -* 8 foot Steel Post Each 607044 -* 8 x 6 x72 inch Treated Wood Post Each 607045 -* 5.5 x 7.5 x 44 inch Treated Wood Post Each 607046 -* 7 inch Round x 6 foot Treated Wood Post Note 1 Each 607047 -* 10 x 10 inch x 6 foot Treated Wood Post Each 607048 -* Structure Mounted Post, Anchored Each 607049 -* 10 foot Steel Post Each 607050 -* 8 x 6 inch x 5 foot Steel Tube Sleeve Each 607051 -* Remove And Reset Guardrail Post Each 607065 -* Flared End Terminal Each 607066 -* Tangent End Terminal Each 607081 -* Tangent End Terminal Repair , “system name” Each 607082 -* Flared End Terminal Repair , “system name” Each * Sequence number Note 1: For repair and replacement of existing round treated wood post only.