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Guard Rail Inspection

Guard Rail Inspection. Module 8 District 7- General Materials Training March 27, 2008. Inspection Equipment. Micrometer or Vernier Caliper Magnetic Gauge Tape Measure Platform Scale Strapping Tape Knife. Equipment Calibration. Need to ensure testing equipment is functioning properly:.

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Guard Rail Inspection

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  1. Guard Rail Inspection Module 8 District 7- General Materials Training March 27, 2008

  2. Inspection Equipment • Micrometer or Vernier Caliper • Magnetic Gauge • Tape Measure • Platform Scale • Strapping Tape • Knife

  3. Equipment Calibration • Need to ensure testing equipment is functioning properly:

  4. Inspection Procedures forGuard Rail Beams and Related Sheet Items • Check identification markings • Review mill test or certification, if required • Determine thickness • Determine weight of coating • Check dimensions • Check fabrication

  5. I. Check Identification Markings • To accept guard rail by Brand Registration and Guarantee, the markings shall match those shown in Section 1040, Table 1040.2.1.1,of the EPG. The markings shall match identically. If markings vary, contact the Construction and Materials Division immediately.

  6. I. Check Identification Markings • Markings shall not be obscured after erection but not easily visible to traffic. Markings facing traffic shall be placed in the valley of the center corrugation and shall be die imprinted with letters and numbers not exceeding 1 ¼ inches high

  7. I. Check Identification Markings • Markings for transition sections and terminal connectors may be on durable tag attached to individual pieces or a bundle of pieces. • Markings or tags are not required for end sections • Markings shall resist obliteration during storage, transportation and erection

  8. II. Review Mill Test or Certification • If accepting guard rail by Brand Registration and Guarantee, mill test and/or certification are not required • An acceptable mill test shall contain the following information: - Quantity of each item - Heating Number - Thickness - Coating Date - Weight of Coating Test Result - Yield, Tensile and Elongation Test Results

  9. II. Review Mill Test or Certification • An acceptable certification shall contain a statement which certifies that the material furnished conforms to Section 1040 and its supplements. The certification shall include or have attached physical, chemical and coating test results.

  10. II. Review Mill Test or Certification • Physical properties required for beams and transition sections: - Yield Point, minimum, 50,000psi (345MPa) - Tensile Strength, minimum, 70,000psi (483MPa) - Elongation, in 2 inches (50mm), minimum, 12% • Physical properties required for end and buffer sections: - Yield Point, minimum, 33,000psi (227MPa) - Tensile Strength, minimum, 45,000psi (310MPa)

  11. III. Determine Thickness • Need to determine thickness on 10% of the lots furnished • Pieces shall be selected from the lot at a rate of 1 per each 200 pieces in the lot

  12. At least 3 measurements are to be taken along the end of each piece Measurements shall be taken on the tangent portion of the cross-section and at least 3/8 inch from the edge. Avoid drip edge. Measure to the nearest 0.0001 inches Report to the nearest 0.001 inch III. Determine Thickness

  13. III. Determine Thickness • Required beam and related sheet thickness: Class Type Minus of of Thickness Tolerance BeamCoating(inch)(inch) A 1 0.108 0.009 2 0.111 0.009 B 1 0.138 0.010 2 0.141 0.010

  14. III. Determine Thickness • If any measurement is out of tolerance, double the amount of pieces to be measured. If any measurements taken on the re-sampled pieces are out of tolerance, reject the lot.

  15. IV. Determine Weight of Coating • Shall determine on each lot furnished • Test 1 pieces for every 200 pieces per lot • Can use either a magnetic gauge or an electronic thickness measuring device

  16. IV. Determine Weight of Coating • Perform 6 single spot test per specimen • Perform 3 single spot test on each side of the specimen • A single spot test is comprised of 5 readings taken in a small area and averaged together • Report in oz / sq. ft

  17. IV. Determine Weight of Coating • The weight of coating shall meet the following: Type 1 1.8 Oz per Sq. Ft * Type 2 3.6 Oz per Sq. Ft * * Double surface • Type 1 shall be galvanized by the continuous method

  18. IV. Determine Weight of Coating • If any measurement is out of tolerance, double the amount of pieces to be measured. If any measurements taken on the re-sampled pieces are out of tolerance, reject the lot.

  19. Shall determine on each lot furnished Test 1 pieces for every 200 pieces per lot May use same pieces used to determine the weight of coating V. Check Dimensions

  20. Nominal width W-beams = 19 in. Thrie beams = 29 ½ in. Tolerance of minus 1/8” from the nominal width Dimensions shall meet those shown in the standard drawings [Section 606.00] V. Check Dimensions

  21. VI. Check Fabrication • Shall determine on each lot furnished • Test 1 pieces for every 200 pieces per lot • May use same pieces used to determine the dimension • Fabrication should result in a uniform product showing good workmanship

  22. Beams shall not have any uncoated spots except along edges resulting from transverse shearing or punching of holes Coating shall be: - Smooth - Free of beads or sharp projections along the edge - Adhere tenaciously to the surface of the metal - Free from blisters and flux Warped and deformed beams will be rejected VI. Check Fabrication

  23. Inspection Procedures forGuard Rail Post and Other Steel Items • Review fabricators certification or mill test • Determine weight per linear foot • Determine weight of coating • Check dimensions • Check fabrication

  24. I. Review Fabricators Certification or Mill Test • Fabricators Certification shall include the following: - Source of material - Grade of Structural Steel - Quantity - Size - Heat or Mill Order Number - Statement that material galvanized in accordance with AASHTO M111 • Fabricators Certification signed by an authorized representative

  25. I. Review Fabricators Certification or Mill Test • Mill Test shall include the following: - Size - Quantity - Grade of Steel - Heat or Mill Order Number - Physical Test Results - Chemical Test Results - Statement that material galvanized in accordance with AASHTO M111 - Weight of Coating Test Results

  26. Table 1 - Certification Requirements Item Galvanizing Steel Grade Other Standard Wood Post and Blocks - - a Steel Posts, Plates and AASHTO M 111 AASHTO M 270, Grade 36 b Brackets Plastic Blocks - - g Guardrail Beam Sec 1040.3 Sec 1040.3 b, c Bolts, N uts and Washers AASHTO M 232 ASTM A 307 End Terminals Systems - - f End Anchors - Tubes AASHTO M 111 ASTM A 500/ASTM A 501 b - Transition Cap Rail AASHTO M 111 AASHTO M 270, Grade 36 b One - Strand Access Restraint Cable - Cable AASH TO M 30 AASHTO M 30 b - Hardware AASHTO M 232 AASHTO M 102/ b ASTM A 220 Three Strand Guard Cable b - Cable AASHTO M30 AASHTO M 30 & AASHTO M 269 d - Hardware AASHTO M 232 AASHTO M 102/ d ASTM A 220 d - Cast Steel Components AASHTO M 232 AASHTO M 103 - Malleable Iron AASHTO M 232 ASTM A 47 e Castings - Anchor Brackets AASHTO M 111 AASHTO M 270 - Cable Brackets AASHTO M 111 AASHTO M 270, Grade 36 d - Hook and Hex Bolts AASHTO M 232 ASTM A 307 - Hook Nuts AASHTO M 232 ASTM A 563 - Hooked Anchor Studs AASHTO M 232 AASHTO M 314 I. Review Fabricators Certification or Mill Test • Physical and Chemical test results shown on the mill test should be checked for compliance with the AASHTO or ASTM Specifications • See Table 1 in Section 1040 for the appropriate AASHTO and ASTM Specifications

  27. II. Determine Weight per Linear Foot • Only need to weigh post • A minimum of 3 specimens are to be weighed • Use a calibrated scale to determine the weight • Weigh to the nearest 0.1 pounds

  28. II. Determine Weight per Linear Foot • Required post weights shown on the standard drawings [Section 606.00] • Tolerance is +/- 2.5% from the specified weight • If test results less than this, determine the theoretical weight as per Sec 1044 of the EPG

  29. III. Determine Weight of Coating • Determine on 10% of the lot furnished • Test 1 pieces for every 200 pieces per lot • Can use either a magnetic gauge or an electronic thickness measuring device

  30. Perform 6 single spot test per specimen A single spot test is comprised of 5 readings taken in a small area and averaged together For blocks & post connector, it is acceptable to have less than 6 single-spot test results Report in oz / sq. ft III. Determine Weight of Coating

  31. All Specimens Tested, Steel Thickness Range (Measured), mm [in.] <1.6 1.6 to <3.2 3.2 to 4.8 >4.8 to <6.4 >6.4 1 1 1 1 3 3 1 1 Material Category [< / ] [ / to < / ] [ / to / ] [> / to < / ] [> / ] 16 16 8 8 16 16 4 4 Structural shapes and Plate 45 65 75 85 100 Strip and Bar 45 65 75 85 100 Pipe and Tubing 45 45 75 75 75 Wire 35 50 60 65 80 a Table 1 — Coa ting Thickness Grade 2 2 m Coating Grade g/m mils oz/ft m 35 35 245 1.4 0.8 45 45 320 1.8 1.0 50 50 355 2.0 1.2 55 55 390 2.2 1.3 60 60 425 2.4 1.4 65 65 460 2.6 1.5 75 75 530 3.0 1.7 80 80 565 3.1 1.9 85 85 600 3.3 2.0 100 100 7 05 3.9 2.3 a m m The values in micrometers ( m) are based on the Coating Grade. The other values are based on conversions using the following formulas: mils = m 2 2 m m × 0.03937; oz/ft = m × 0.02316; g/m = m × 7.067. III. Determine Weight of Coating • Weight of coating shall conform to AASHTO M111

  32. III) Determine Weight of Coating • If any measurement is out of tolerance, double the amount of pieces to be measured. If any measurements taken on the re-sampled pieces are out of tolerance, reject the lot.

  33. Dimension determined on at least 3 specimens from the furnished lot Dimensions shall meet those shown in the standard drawings [Section 606.00] Size and spacing of holes should be measured IV. Check Dimensions

  34. V. Check Fabrication • Fabrication check on at least 3 specimens from the furnished lot • May use same pieces used to check the dimension • Fabrication should result in a uniform product showing good workmanship

  35. Coating shall be: - Smooth - Free of beads or sharp projections along the edge - Adhere tenaciously to the surface of the metal - Free from blisters and flux Material shall not have any uncoated spots VI. Check Fabrication

  36. Inspection Procedures ForPlastic Blocks • Plastic Block on Qualified List • Check certification • Check dimensions • Check fabrication

  37. I) Material on Qualified List • Shall use plastic blocks shown in Field Section 1040, Table 1040.4.4, of the EPG • The following is required in order to be placed on the qualified list: - Copy of FHWA acceptance letter - Copy of NCHRP 350 test results - Manufacturer’s name - Brand name or model number - Material Safety Data Sheet - Plastic block sample • Send to construction and Materials Division

  38. II) Check Certification • Need a manufacturer’s certification • Certification states that the blocks provided are the same as the ones qualified and NCHRP 350 tested

  39. III) Check Dimensions • Plastic blocks shall meet the dimension requirements shown on the plans [Standard Drawing 606.00] • Check at least 3 blocks randomly selected

  40. IV) Check Fabrication • Blocks shall have no cracking, chipping, flaking, peeling or splintering after fabrication

  41. IV) Check Fabrication • Blocks shall be a homogeneous product with a uniform texture • Blocks will not be considered homogeneous if there are more than five voids larger than 5/8 inch or any voids larger than 3/4 inch on any cut face

  42. Inspection Procedures forBolts, Nuts and Washers • Review certification or mill test, if required • Determine weight of coating • Check dimensions • Check identification markings

  43. I) Review Certification or Mill Test • Bolts, nuts and washers may be accepted by Brand Registration and Guarantee. If not, need to have an acceptable certification. • Bolts and nuts meeting ASTM A307 must be accompanied by a manufacturers certification statement which states that the bolts and nuts meet ASTM A307 and that they were galvanized to meet AASHTO M232 (If not by Brand Registration and Guarantee)

  44. Need to determine the weight of coating for each lot furnished Test 1 pieces for every 200 pieces per lot Can use either a magnetic gauge or an electronic thickness measuring device II) Determine Weight of Coating

  45. A minimum of 3 single-spot tests are to be taken For nuts and washers, a single spot test is comprised of 5 readings taken in a small area and averaged together. For bolts, a single-spot test will be comprised of 3 readings The weight of coating shall conform to AASHTO M232 Report in oz / sq. ft II) Determine Weight of Coating

  46. II) Determine Weight of Coating • Weight of coating shall conform to AASHTO M232 Mass[Weight] of Zinc Coating, Coating Thickness, g/m2 (oz/ft2) of Surface, Minimum microns [mils], Minimum Average of Any Average of Any Specimens Individual Specimens Individual Class of MaterialTested Specimens Tested Specimens Class A – Castings - Malleable iron, steel 610 [2.00] 550 [1.80] 86 [3.4] 79 [3.1] Class B – Rolled, pressed, and forged articles (except those which would be included under Classes C & D) B-1 – 4.75 mm (3/16 in.) and over in thickness and over 610 [2.00] 550 [1.80] 86 [3.4] 79 [3.1] 380 mm (15 in.) in length B-2 – Under 4.75 mm (3/16 in.) in thickness and over 458 [1.50] 381 [1.25] 66 [2.6] 53 [2.1] 380 mm (15 in.) in length B-3 – any thickness and 380 mm (15 in.) and under in length 397 [1.30] 336 [1.10] 56 [2.2] 48 [1.9] Class C – Fasteners over 9.5 mm (3/8 in.) in diameter and 381 [1.25] 305 [1.00] 53 [2.1] 43 [1.7] Similar articles. Washers 4.75 mm and 6.35 mm (3/16 in. and 1/4 in.) in thickness Class D – Fasteners 9.5 mm (3/8 in.) and under in diameter, 305 [1.00] 259 [0.85] 43 [1.7] 36 [1.4] Rivets, nails, and similar articles. Washers under 4.75 mm (3/16 in.) in thickness ____________________________________________________________________________________________________ Note 1: Length of the pieces, stated in Classes B-1, B-2, and B-3, refers to the finished dimension of the piece after fabrication

  47. II) Determine Weight of Coating • If any measurement is out of tolerance, double the amount of pieces to be measured. If any measurements taken on the re-sampled pieces are out of tolerance, reject the lot.

  48. III) Check Dimensions • Dimensions are to be checked on 3 specimens selected from the lot • Dimensions shall meet those shown in the standard drawings or as specified [i.e. length and diameter] • Try placing the nuts on the appropriate size bolts to ensure that they are compatible

  49. IV) Check Identification Markings • All bolts and nuts should be identifiable as to type and manufacturer whether the information is shown on the container or on the material itself • Markings are NOT required on bolts or nuts meeting ASTM A307

  50. Crashworthy End Terminals • Crashworthy system on Qualified List • Check certification • Check weight of coating • Check fabrication

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