606Guardrail and Median Barrier

Guardrail and Median Barrier

606.1DESCRIPTION

1 This section describes the requirements for:

guardrail, MGS/corrugated and box beam median barrier, and end terminals.

guardrail components and associated hardware, when required.

at the reverse ends of bridges on multi-lane, divided highways.

606.2MATERIALS

1 Provide materials in accordance with the following: Material Subsection Admixtures 801.4 Aggregate for Concrete 803 Box Beam Barrier 813.3 Bolts, Nuts and Washers 815.6 Fly Ash 801.2 Galvanized Coating 815.14 Guardrail or Median Barrier Posts 813.6 Guardrail Hardware 813.2 High-Strength Bolts and Fasteners 815.2 MGS/Corrugated Beam Rail 813.1 MGS Guardrail (Weathering Steel) and Corrugated Beam Guardrail (Self-Oxidizing) 813.4 Portland Cement 801.1 Reflective Sheeting 816.4 Sheet Metal 815.3 Structural Steel 815.1 Timber Posts and Blockouts 813.6.2 Water 814.1 Wire Cable 811.3 WYBET End Terminals 813.5

Guardrail and Median Barrier SECTION 606 2 Where “Guardrail Bolts” are specified, provide bolts of the button head design with an oval shoulder and that meet the requirements of Subsection 815.6, Bolts and Fasteners.

606.3EQUIPMENT

1 Ensure that equipment meets the following: E quipment Subsection Batch Plant 513.3.1 Mixers 513.3.2 Placing Equipment 513.3.3

606.4CONSTRUCTION

606.

4.1General

1 Use fabricated components with corners, edges, and burrs ground smooth before galvanization. Repair damaged galvanized components in accordance with Subsection 501.4.2.9, Repair of Galvanizing. 2 Use new, shop- fabricated guardrail components g alvanized af ter w elding. Whe n fabricating or modifying after galvanization, clean cut edges and welded joints with a wire brush. Paint the cleaned area in accordance with Subsection 501.4.2.9, Repair of Galvanizing. After cleaning, give bolt holes one coat of paint. 3 Avoid gouges, scratches or dents to steel parts. Do not allow foreign material, including paint, grease, oil, or crayon, to contact the surface. Do not use damaged steel parts. Position steel parts allowing for free drainage and air circulation during shipping and storage. The department will allow natural oxide formation on steel surfaces. 4 Remove existing guardrail in accordance with Subsection 202.4.3, Removal of Guardrail, Barrier, Bridge Railing, and Pedestrian Railing. 5 Before installing guardrail, complete grading and shoulder construction through the top course to match the specified slopes. 6 Fabricate box beam guardrail in accordance with Subsection 501.4.1.2, Fabricator Certification. 606.

4.2Shop Drawings and Fabrication

1 Submit shop drawings for new box beam guardrail and median barrier to the Highway Development Program for review in accordance with Subsection105.2, Working Drawings. Include layout diagrams, shop details and dimensions, piece marks, thicknesses of material, and other data necessary to fabricate and install rail elements. To aid in

Guardrail and Median Barrier SECTION 606 identification and erection, ensure that box beam railing has clearly visible piece marks corresponding to the approved “Final” shop drawings. 2 When shop-bending of box beam rail elements is required, indicate the locations, limits, and curving method on the shop drawings. 3 Use box beam rail elements with a nominal length of at least 18 ft [5.5 m]. Unless physical constraints require odd lengths, provide elements in nominal lengths enabling from 3 to 6 post spaces. Use a standard post spacing of 6.0 ft [1.8 m] and a minimum of 4.0 ft [1.2 m]. Provide rail elements so that a joint occurs at the point of tangency (PT) of the flare. 4 Place expansion splices in box beam installations over 300 ft [90 m] in length and at intervals not exceeding 500 ft [150 m]. Space them approximately equally in the guardrail run. 5 Galvanize WYBET end anchorages in accordance with Subsection 501.4.1.25, Galvanizing. Ensure that the outer rail of a WYBET end anchorage slides freely over the inner rail after galvanization. 606.

4.3Installation

606. 4.3.1 General 1 After erection, thoroughly clean damaged galvanized surfaces with a wire brush to remove damaged spelter coating and repair in accordance with Subsection 501.4.2.9, Repair of Galvanizing. 606. 4.3.2 Posts 1 Use the same type and shape of posts and blockouts throughout the project. 2 Establish line and grade between the end anchorage systems, and correct misalignment or sags in elevation. Set posts plumb. Install as follows:

of at least 18 in [450 mm]. Set posts on undisturbed or thoroughly compacted material. Backfill in 6-inch [150 mm] lifts and thoroughly compact without moving posts from the correct alignment.

t Placement by Driving. Guide driven posts laterally and protect the tops to avoid battering. Posts may be driven using pilot holes formed with an auger or rock punch. Make pilot holes no less than the diameter of the post and extend the depth to within 6 in [150 mm] of the final grade. Drive posts the last 6 in [150 mm] to final elevation. If adverse or rocky soil conditions hinder driving, the depth of the pilot holes may be increased.

Guardrail and Median Barrier SECTION 606 3 After placing posts, place material around each post to match the depth and type of existing surfacing material. Set the initial height of posts for MGS/corrugated beam guardrail to provide the specified rail mounting height with blockouts mounted in the lowest set of mounting holes. 606. 4.3.3 Rail Elements 1 Erect rail elements to provide a smooth, continuous installation. Ensure that bolts in the finished rail are snug-tight and extend beyond the nuts. 2 Place reflective sheeting on both sides of the reflector tabs. Use white sheeting for shoulder installations and yellow for median installations. 3 The following apply when installing MGS/corrugated beam guardrail:

use washers between the head of the post bolt and rail element.

606. 4.3.4 End Anchorages 1 Use precast concrete end anchorage blocks or cast in place. Use class B concrete in accordance with Subsection 513.4.4, Mix Design. The engineer may approve a local commercial mix. Form, place, and cure concrete in accordance with applicable portions of Subsection 513.4, Construction. 2 When using precast blocks, install lifting devices to avoid damaging the anchor bolts during lifting or setting. Do not use anchor bolts for lifting. Do not place reflector tabs on end anchorages. 606.4.

3.5WYBET End Terminal

1 The department will allow intermediate spacers for WYBET end terminals to be painted with two coats of a zinc-rich paint in accordance with Subsection 501.4.2.9, Repair of Galvanizing, in lieu of galvanization. 2 Slide the inner rail inside the outer rail using only manual labor. Before completion of the installation, demonstrate to the engineer that the outer tube slides freely over the inner tube’s entire length without binding.

Guardrail and Median Barrier SECTION 606

3 Cover the impact plate with black and yellow reflective sheeting. Do not place reflector tabs on WYBET end terminals.

606.4.3.6 Bridge Rail and Concrete Barrier Connections

1 Construct MGS/corrugated beam and box beam transition sections and connections to bridge railing and concrete barrier as specified . Bridge rail connections include plates, sleeves, special end shoes, and associated hardware necessary to complete installation. If required, weld the connection sleeve or plate to the steel bridge railing in accordance with Subsection 501.4.2.5, Field Welding.

606.4.4 Reset/Upgrade Guardrail

1 Reset or upgrade existing guardrail installations in accordance with the following:

grade. If necessary, raise or lower posts in accordance with Subsection 606.4.3.2, Posts. Provide and install additional bolts, nuts, washers, post mounting brackets, and angles as necessary. Provide and install new reflective tabs for the length of the reset rail except on end terminals and end anchorages.

guardrail components, and modify removed salvaged components to provide the specified length. When the upgrade causes post spacing to vary more than 24 in [600 mm] from specified spacing, adjust posts, including those outside the upgrade section.

2 After post removal, backfill and compact holes in 8-inch [200 mm] lifts up to ground or shoulder surface. Backfill holes in plant mix with new plant mix up to the existing surface.

3 Cut rail, drill holes, and touch up exposed steel surfaces with two coats of zinc- rich paint in accordance with Subsection 501.4.2.9, Repair of Galvanizing, to accommodate required modifications in guardrail configuration.

606.4.5 Temporary Guardrail

1 When required, install temporary guardrail as specified. Obtain the engineer’s approval before installing undamaged, used guardrail elements, posts, and hardware. Replace unsatisfactory materials at no additional cost to the department. Remove guardrail when it is no longer required.

2 When specified, modify existing bridge railing for connecting temporary guardrail . Before welding, remove galvanizing in areas to be welded. Field- weld a steel plate to the existing bridge rail end as specified and in accordance with Subsection 501.4.2.5, Field Welding. If the end terminal will be reused or remain in place, galvanize the steel plate and affected areas in accordance with Subsection 501.4.2.9, Repair of Galvanizing.

Guardrail and Median Barrier SECTION 606 3 Bolt the W-beam terminal connector to the steel plate as specified. Make bolts snug- tight in accordance with Subsection 501.4.2.3.4.5, General Installation.

606.5MEASUREMENT and PAYMENT

606.

5.1General

1 The engineer will measure as follows:

x Beam Guardrail, Box Beam Med Barrier, Corr Beam Guardrail, Corr Beam Guardrail (Self-Oxidizing), and Corr Beam Med Barrier by the foot [meter].

Guardrail and Reset Box Beam Med Barrier by the foot [meter], and will include the lengths of end anchorages and bridge rail connections in the measured length for resetting barrier or guardrail.

Beam Guardrail, and Upgrade Box Beam Med Barrier by the foot [meter].

___ (Self-Oxidizing), Corr Beam Med Barrier Term, Box Beam Guardrail End Anch Type ___, and Box Beam Med Barrier End Anch Type___ by the each.

x Beam End Term (WYBET), Box Beam End Term (WYBET) Mod, Box Beam Med Barrier End Term (WYBET), and Reset Box Beam End Term (WYBET) by the each.

porary Guardrail by the each, which includes the work at both sides of the bridge end. 2 The department will pay as follows: Pay Item Pay Unit Measure to the Nearest Pay to the Nearest Box Beam End Term (WYBET) EA [Ea] EA [Ea] EA [Ea] Box Beam End Term

EA [Ea] EA [Ea] EA [Ea] Box Beam Guardrail FT [m] 0.1 ft [0.05 m] FT [0.5 m] Box Beam Guardrail End Anch Type ____ EA [Ea] EA [Ea] EA [Ea] Box Beam Med Barrier FT [m] 0.1 ft [0.05 m] FT [0.5 m]

Guardrail and Median Barrier SECTION 606 Pay Item Pay Unit Measure to the Nearest Pay to the Nearest Box Beam Med Barrier End Anch Type ____ EA [Ea] EA [Ea] EA [Ea] Box Beam Med Barrier End Term (WYBET) EA [Ea] EA [Ea] EA [Ea] Corr Beam Guardrail FT [m] 0.1 ft [0.05 m] FT [0.5 m] Corr Beam Guardrail (Self-Oxidizing) FT [m] 0.1 ft [0.05 m] FT [0.5 m] Corr Beam Guardrail End Anch Type ____ EA [Ea] EA [Ea] EA [Ea] Corr Beam Guardrail End Anch Type ____ (Self-Oxidizing) EA [Ea] EA [Ea] EA [Ea] Corr Beam Med Barrier FT [m] 0.1 ft [0.05 m] FT [0.5 m] Corr Beam Med Barrier Term EA [Ea] EA [Ea] EA [Ea] MGS Guardrail FT [m] 0.1 ft [0.5 m] FT [0.5 m] MGS Guardrail Special FT [m] 0.1 ft [0.5 m] FT [0.5 m] MGS Guardrail (Weathering Steel) FT [m] 0.1 ft [0.5 m] FT [0.5 m] MGS Median Barrier FT [m] 0.1 ft [0.5 m] FT [0.5 m] MGS Terminal Type I EA [Ea] EA [Ea] EA [Ea] MGS Terminal Type II EA [Ea] EA [Ea] EA [Ea] MGS Terminal Type I (Weathering Steel) EA [Ea] EA [Ea] EA [Ea] MGS Terminal Type II (Weathering Steel) EA [Ea] EA [Ea] EA [Ea] Reset Box Beam End Term (WYBET) EA [Ea] EA [Ea] EA [Ea] Reset Box Beam Guardrail FT [m] 0.1 ft [0.05 m] FT [0.5 m] Reset Box Beam Med Barrier FT [m] 0.1 ft [0.05 m] FT [0.5 m] Reset Corr Beam Guardrail FT [m] 0.1 ft [0.05 m] FT [0.5 m] Reset Corr Beam Med Barrier FT [m] 0.1 ft [0.05 m] FT [0.5 m]

Guardrail and Median Barrier SECTION 606 Pay Item Pay Unit Measure to the Nearest Pay to the Nearest Temporary Guardrail EA [Ea] EA [Ea] EA [Ea] Upgrade Box Beam Guardrail FT [m] 0.1 ft [0.05 m] FT [0.5 m] 606.

5.2Referenced Sections for Direct Payment

1 When specified, the engineer will measure and pay for Removal of Guardrail in accordance with Section 202, Removal; however , when reset is specified, removal is incidental to resetting.