Category:1040 Guardrail, End Terminals, One-Strand Access Restraint Cable and Three-Strand Guard Cable Material

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This article establishes procedures for inspecting, sampling, accepting and reporting of guardrail and guard cable material specified in Sec 1040.

For Laboratory testing and sample reporting procedures, refer to EPG 1040.5 Laboratory Testing Guidelines for Sec 1040.

Contents

1040.1 Apparatus

(a) Scales accurate to within 0.5 percent of the weight (mass) of the sample to be weighed.
(b) Magnetic gauge, reading range of 0-40 mils (0-1000 \mu\,m).
(c) Micrometer or vernier caliper capable of measuring to 0.0001 in. (0.00254 mm) and accurate to within at least 0.001 in. (0.0254 mm).
(d) Rule with suitable graduations to accurately measure the material to be inspected.
MGS Information
Current General Services Specifications (MGS) By Subject
(e) Fiber-reinforced strapping tape.

1040.2 Procedure

1040.2.1 Guardrail Beam and Related Sheet Items

Guardrail beams, end sections, bufferends, end shoes, back-up plates and related steel sheet items may be accepted on the basis of Brand Registration and Guarantee when furnished by those fabricators who have filed an acceptable Brand Registration and Guarantee, as listed in Table 1040.2.1.1. If the guardrail fabricator has not filed an acceptable Brand Registration and Guarantee, an acceptable mill test report or certification will be required. Regardless of the type of documentation furnished, field inspection performed shall include examination of mill test reports or certifications, if not accepted on Brand Registration and Guarantee; checking identification markings and fabrication; determination of thickness, weight (mass) of coating, and dimensions. Samples shall be submitted to the Laboratory when requested by Construction and Materials or when field inspection indicates questionable compliance with the specifications. When samples are taken, they are to be taken at the frequency and of the size shown in Table 1040.2.1.2.


Table 1040.2.1.1 List of Prequalified Guardrail Fabricators Brand Registration and Guarantee on File

Buffalo Specialty Products, Inc., Buffalo, New York.
Brand Registration relates to guard rail beams marked in the following manner:
BSP Identification Code M-180 Class Type
The markings will appear on each beam element on the center corrugation of the traffic face and will consist of 1/4 in. (6 mm) tall letters embossed into the metal forming the rail element. Identification Code is a 2-letter marking code that refers to a specific heat number lot on file with the Buffalo Specialty Products, Inc. The Date and Shift of galvanizing will be in yellow waterproof ink on the back of the rail in the valley. This document also relates to back-up plates, end sections, buffer ends, end shoes and hardware. Markings for these items will be on durable tags to each bundle (or on labels affixed to at least one section in each bundle). Bolts and nuts for Types 1, 2 and 3 beams are certified as manufactured to comply with the requirements of ASTM A 307 and galvanized to comply with the requirements of AASHTO M 232. Bolts and nuts for Type 4 beams will be corrosion resistant steel and conform to the requirements of ASTM A 307.
Central Fabricators, Inc., Kosciuski, Mississippi
Brand Registration relates to guardrail beams marked in the following manner:
(Brand) CF M-180, Heat Number, Coating Lot, Class-Type
The markings will appear in the approximate center on each beam element on the center hump on the back side. The markings will consist of 5/16 in.-tall letters embossed into the metal forming the rail element. Heat number is 6 to 10 digits, alpha-numeric. Coating Lot is week (one or two digits) and Year as two digits. This document also relates to back-up plates, end sections, buffer ends, end shoes, and hardware. Markings for these items will be on durable tags to each bundle (or on labels affixed to at least one section in each bundle). Bolts, nuts and washers are certified as manufactured to comply with the requirements of ASTM A 307 and galvanized to comply with the requirements of ASTM A 153.
Contech Construction Products, Inc., Middletown, Ohio
Brand Registration relates to guardrail beams marked in the following manner:
CONTECH Flex-Beam Identification Code M-180 Class Type (W-BEAM SHAPE)
C Flex-Beam Identification Code M-180 Class Type (THRIE BEAM SHAPE)
The markings will appear on each beam element on the center corrugation and on the side opposite the traffic face. The markings will consist of 1/4 in. (6 mm) tall letters embossed into metal forming the rail element. Identification Code will appear on the beams as a heat number and stock card number. This document also relates to back-up plates, end sections, buffer ends and end shoes. Markings for these items will be on durable tags attached to each bundle (or on labels affixed to at least one section in each bundle). All splice bolts and post bolts furnished in conjunction with guardrail beam are certified as manufactured to comply with the requirements of ASTM A 307 and galvanized to comply with the requirements of ASTM A 153.
Gregory Highway Products, Inc., Canton, Ohio
Brand Registration relates to guardrail beams marked in the following manner:
GH M-180, Class-Type, Heat Number, Coating Lot
The markings will appear every 2 ft. 0 in. (600 mm) on each beam element on the center corrugation. The markings will consist of ½ in. (12 mm) tall letters embossed into the metal forming the rail element. This document also relates to back-up plates, end sections, buffer ends and end shoes. Markings for these items will be on durable tags attached to each bundle (or on labels affixed to at least one section in each bundle). All bolts and nuts furnished in conjunction with guardrail beam are certified as manufactured to comply with the requirements of ASTM A307 and galvanized to comply with the requirements of ASTM A 153. Washers will be galvanized to meet ASTM A 153.
Highway Safety Corp., Glastonbury, Connecticut
Brand Registration relates to guardrail beams marked in the following manner. The oval shown in the center of the marking represents the post bolt slot.
HSDateM-180ClassTypeimage:1040.2.1.2 highway.jpgHeat Number
The markings will appear every 6 ft. 3 in. (1905 mm) on each beam element on the center corrugation of the traffic face, centered around the post bolt slot, and will consist of 1/4 in. (6 mm) tall letters embossed into the metal forming the rail element. This document also relates to back-up plates, end sections, buffer ends, end shoes and hardware. Markings for these items will be on durable tags to each bundle (or on labels affixed to at least one section in each bundle). Bolts are certified as manufactured to comply with the requirements of ASTM A 307 and galvanized to comply with the requirements of ASTM A 153. Nuts are certified as manufactured to comply with the requirements of ASTM A 563 and galvanized to comply with the requirements of ASTM A 153.
Trinity Industries, Inc., Dallas, Texas
Registration relates specifically to standard and T-31 guardrail beams marked in the following manner. Markings for internal use in addition to those shown below may appear on the rail. The plant names shown to the left of the Logo are for information only, these names will not appear in the marking. (W-BEAM, THRIE-BEAM)
Fort Worth, TXimage:1040.2.1.2 trinity.jpg M-180Class & TypeHeat CodeIdentification CodeLot NumberF
Girard, OHimage:1040.2.1.2 trinity.jpgM-180Class & TypeHeat CodeIdentification CodeLot NumberG
Centerville, UTimage:1040.2.1.2 trinity.jpgM-180Class & TypeHeat CodeIdentification CodeLot NumberU
Lima, OHimage:1040.2.1.2 trinity.jpg M-180Class & TypeHeat CodeIdentification CodeLot NumberL
Orangeburg, SCimage:1040.2.1.2 trinity.jpgM-180Class & TypeHeat CodeIdentification CodeLot NumberO
The markings will appear on each beam element, on the center corrugation of the rail element for W-beam rail, and on the top corrugation for thrie-beam rail. Identification Code is the Mill Heat Number and Galvanized Lot, that is traceable to the galvanizing date (i.e., 01234567 08 00, where 01234567 is the heat number, 08 is the week of the year and 00 is the year). Longitudinal location along the rail and frontside/backside location will vary depending on plant. Brand Registration also applies to end sections, back-up plates, and guardrail accessories. Bolts, nuts, and washers are certified to meet or exceed specification requirements of AASHTO M 180.


Table 1040.2.1.2 Sampling Requirements

ItemSample FrequencySample Size, Submitted For
Guard Rail Beams 1/200 pieces / Lot Each sample is to consist of 1 piece full width of beam and 18 in. (450 mm) in length, free of holes. Flame cutting to procure this sample is permitted -Thickness, Dimensions (Shape), Weight (mass) of Coating, Mechanical Tests.
End Sections, buffer Ends, End Shoes and Back-up Plates 1/200 pieces / LotEach sample is to consist of 1 entire unit - Thickness, Dimensions, Weight (mass)of Coating, Mechanical Properties.
Steel Guard Rail Posts and Cable Posts3/1000 posts or fraction thereof/LotEach sample is to consist of 3 specimens, each 2 in. (50 mm) in length cut from one post, cut one specimen approximately 4 in. (100 mm) from each end of the post and one from near the middle - Weight (mass) of Coating.
Steel Post Blocks, Steel Post Connectors, Anchor Plates, Bearing Plates, Soil Plates, Steel Tube for BCT and End Anchor 3/1000 pieces or fraction thereof/Lot Each sample is to consist of 1 entire unit - Weight (mass) of Coating
Splice or Post Bolts, Nuts and Washers 3 for lots of 0 to 800 pcs., 6 for lots of 801 to 8,000 pcs., 9 for lots of 8,001 to 22,000 pcs., 15 for lots of 22,001 pcs. + Each sample is to consist of one bolt, nut and washer. - Dimensions, Weight (mass) of Coating, Mechanical Properties.
1/2 in. and ¾ in. Guard Cable 2 for lots of 0 to 5,000 ft., 3 for lots of 5,001 to 30,000 ft., 4 for lots of 30,001 to 150,000 ft., 5 for lots of 150,000 ft. +Each sample is to be 5 ft. [1500 mm] in length - Weight (mass) of Coating, Dimensions and Fabrication, Mechanical Properties
Turn Buckles, Anchor Sockets, Cable Clips, Cable Clamps and Screw Type Anchors1/Lot Each sample is to consist of 3 units - Weight (mass) of Coating.
Miscellaneous Nuts, Bolts, Lag Screws and Washers used for Guard Cable Assembly- Same as Splice or Post Bolts, Nuts and Washers
Rod for Cable Anchor Assembly and Cable End Assembly 1/Lot Each sample is to consist of 3 specimens each 6 in. (150 mm) in length and cut from different pieces. Do not sample fully threaded rods. - Weight (mass) of Coating.
A lot shall be the quantity of material offered for inspection at one time, of the same type and size, or of the same heat number – as applicable.

An acceptable mill test report is to include the quantity of each item, thickness, heat number, results of tests for yield, tensile and elongation, coating date and results of tests for coating weight (mass). An acceptable certification is to include a statement certifying that all materials furnished conform to Sec 1040 and its supplements. The certification shall include or have attached, specific results of laboratory tests for all specified physical, chemical and coating properties as determined from samples taken from the lot or lots of material being furnished.

An examination of the identification markings on beam elements and the identification tags or markings on end sections, buffer ends, end shoes and back-up plates is to be made to determine if the markings conform to the requirements of Sec 1040.3.4. If material is being inspected for acceptance by Brand Registration and Guarantee, the marking shall be as shown in Table 1040.2.1.1.

Field measurement of thickness on beams and sheet items is to be taken on at least 10 percent of the lots furnished. After a lot has been selected for measurement of thickness, pieces shall be selected from that lot for measurement at the rate of one per 200 pieces in the lot. Thickness measurements are to be made with a micrometer to the nearest 0.0001 in. (2.5 \mu\,m) and reported to the nearest 0.001 in. (2.5 \mu\,m) and shall be taken on the tangent portion of the cross section at least 3/8 in. (10 mm) from the edge of the metal across the end of the sheet item. Care is to be taken to avoid drip ends. At least three measurements are to be taken across the end of each piece selected for measurement. The average of all measurements and the minimum single measurement are to be reported. If any measurement is found to be deficient by more than the specified tolerance, double the number of pieces is to be selected from that lot and thickness measurements made. If any measurement taken on the resample pieces fails to comply, the lot of material represented is to be rejected.

Field determination of weight of coating.

Field determination of weight of coating is to be made by magnetic gauge on each lot of material furnished. The magnetic gauge is to be operated and calibrated in accordance with ASTM E376. Specimens for field-testing are to be selected from each lot at the frequency shown in Table 1040.2.1.2, but in no case is the number of specimens to be less than three. A single-spot test is comprised of at least five readings of the magnetic gauge taken in a small area and those readings averaged to obtain a single-spot test result. Three such areas should be tested on each side of the specimen being tested. This would yield six single-spot results for that specimen. Test each specimen in the same manner. Average all single-spot test results from all specimens to obtain the average coating weight to be reported. The minimum single-spot test result would also be selected and reported from all readings. For those items that have a specified coating weight as the total amount of coating on both sides, the test result that is to be reported should be doubled so the reported test result can be applied directly to the specifications. Material may be accepted or rejected for galvanized coating on the basis of magnetic gauge. If a test result fails to comply with the specifications, that lot should be re-sampled at double the original sampling rate shown in Table 1040.2.1.2. Reject lots having any of the re-sampled specimens failing to comply with the specification. The contractor or supplier is to be given the option of sampling for Laboratory testing, if test results are within minus 15 percent of the specified coating weight.

Dimensions and fabrication are to be field inspected on specimens selected from the lot at the frequency shown in Table 1040.2.1.2. It may be convenient to perform this inspection on the same specimens selected for determining the weight of coating.

Dimensions are to conform to those shown on the Standard drawings. Fabrication should result in a uniform product showing good workmanship.

1040.2.2 Bolts, Nuts, and Washers

Bolts, nuts and washers intended for use in beam connections and splices may be accepted by Brand Registration Guarantee or by an acceptable certification. Regardless of the type of acceptance documentation, field inspection performed shall include an examination of certifications and testing for weight (mass) of coating and dimensions. It will only be necessary to submit samples to the Laboratory when requested by Construction and Materials or when field inspection indicates questionable compliance. When samples are taken, take them at the frequency and size shown in Table 1040.2.1.2.

Post and splice bolts, nuts and washers furnished by a fabricator listed in Table 1040.2.1.1 require no additional documentation. Those not covered by Brand Registration and Guarantee must be accompanied by a certification or mill test report. Bolts and nuts specified meeting the requirements of ASTM A307 shall be accompanied by a manufacturer's certification statement that the bolts and nuts were manufactured to comply to the requirements of ASTM A307 and galvanized to comply to the requirements of AASHTO M 232 or were mechanically galvanized and meet the coating thickness, adherence, and quality requirements of AASHTO M 232, Class C.

Markings are not required on bolts and nuts meeting ASTM A307. All bolts and nuts should be identifiable as to type and manufacturer whether the information is shown on a container or on the bolts and nuts.

Field determination of weight (mass) of coating is to be made on each lot of material furnished. Test procedures and conditions of acceptance or rejection shall be as described in Field determination of weight (mass) of coating with the following modifications:

Due to the size and shape of the material being tested, it will only be necessary to obtain a minimum of three readings of the magnetic gauge on a bolt to determine a single-spot test result and at least five readings on a nut or washer. Since the minimum sampling frequency is three bolts or three nuts or three washers, it will always be possible to obtain at least three single-spot test results from which to calculate an average coating weight (mass) and minimum coating weight (mass) for reporting and applying the specification requirements.

Dimensions of bolts, nuts and washers are to be as shown on the Standard Drawings or as specified.

1040.2.3 Guardrail Posts, Guard Cable Posts, Blocks, Post Connectors Anchor Plates, Bearing Plates, Soil Plates, and Steel Tube for Breakaway Cable Terminal and End Anchor

Wood posts and blocks are to be inspected and reported in accordance with EPG 1050 Lumber, Timber, Piling, Posts and Poles.

Plastic blocks are to be inspected for dimensional requirements shown in the standard plans by randomly sampling and measuring at least 3 blocks. The sampled blocks should also be visually inspected to ensure that the blocks are solid and homogeneous with a uniform texture and that they are reasonably free from cracking, chipping, flaking, peeling or splintering. A manufacturer’s certification stating that the blocks provided are the same as those that were qualified and NCHRP 350 tested shall be furnished at the time of inspection. If the visual inspection identifies a concern with the dimensions or fabrication of the block, the blocks may be rejected or one of the sampled blocks may be submitted to the lab for confirmation of the results. A block should not be submitted to the lab if, in the opinion of the inspector, the failing dimension or fabrication issue is clear and obvious without subjective interpretation and there is no evidence produced during the visual inspection that would indicate that the block might have unacceptable voids.

Steel guardrail posts and guard cable posts, blocks, post connectors anchor plates, soil plates and steel tube for breakaway cable and end section may be accepted on the basis of an acceptable Fabricator's Certification and field inspection. If a Fabricator's Certification is not provided, a mill test report shall be furnished. Regardless of the type of documentation, field inspection shall be performed and shall consist of checking the Fabricator's Certification or mill test report; checking dimensions and fabrication; weight (mass) per linear ft. (m); and weight (mass) of coating. It will only be necessary to submit samples to the Laboratory when requested by Construction and Materials or when field inspection indicates questionable compliance with the specifications. When samples are taken, they shall be taken at the size and frequency shown in Table 1040.2.1.2. The number of specimens selected for field inspection should never be less than three.

An acceptable Fabricator's Certification should indicate the source of supply, grade of structural steel, number of pieces, size, heat or mill order number and a statement that the material was galvanized in accordance with AASHTO M 111. The heat or mill order number is to be such that mill tests may be obtained from the fabricator when desired. The Fabricator's Certification is to be signed by an authorized representative of the fabricator and it need not be notarized. An acceptable mill test report shall show size and quantity, grade of steel, heat or mill number, complete physical results, complete chemical analysis, and shall include or have attached a certification statement that the material was galvanized in accordance with AASHTO M 111 and results of tests performed to determine weight (mass) of coating.

Dimensions of steel posts, blocks, and brackets; and weight (mass) of posts and blocks are to be as shown on the plans. Size and spacing of holes should be measured.

Weight (mass) per linear ft. (m) on posts and blocks is obtained by weighing to the nearest 0.1 lb. (45 g) and dividing by the measured length. A weight (mass) tolerance of ±2.5 percent from the specified weight (mass) is allowed on posts and blocks. If test results indicate the weight [mass] to be below the specified limit, the theoretical weight (mass) should be calculated by adding the weight (mass) of steel that has been punched out to form holes and deducting the theoretical weight (mass) of galvanizing. An example of this type calculation may be found in EPG 1044 Posts for Markers and Delineators.

Field determination of weight (mass) of coating is to be made on a minimum of 10 percent of the lots of material furnished. Test procedures and conditions of acceptance or rejection shall be as described in Field determination of weight (mass) of coating except a smaller number of single-spot test results would be acceptable on steel blocks and post connectors.

1040.2.4 Guard Cable and Fittings

Guard cable and fittings are to be accepted by certification, if applicable, accompanied by field inspection and sampling if necessary. Field inspection is to consist of an examination of certifications, checking dimensions and fabrication and weight of coating. Samples shall be submitted when requested by the State Construction and Materials Engineer, when field inspection indicates questionable compliance; or when the item is of a size or shape that weight (mass) of coating cannot be determined by magnetic gauge.

Certifications are required for the cable, eyebolts, turnbuckles and clips for cable-to-cable connections. Certifications are to contain a statement that material furnished was manufactured to conform to the requirements of the applicable ASTM or AASHTO specifications specified in Sec 1040. Certifications are not required on other items.

Dimensions and fabrication are to be as shown on the plans.

Field determination of weight (mass) of coating may be determined on nearly all fittings but not on cable. Samples of cable are to be taken at the frequency and of the size shown in Table 1040.2.1.2. Test procedures for determining weight [mass] of coating and conditions of acceptance or rejection for items other than cable is to be as described in Field determination of weight (mass) of coating.

1040.2.5 Three-Strand Guard Cable System

The components of a three-strand guard cable system will be inspected and accepted in accordance with their applicable specification. However, complete three-strand guard cable systems will be accepted on the basis of the system having successfully completed NCHRP 350 Test Level 3 testing and the manufacturer having received a letter of acceptance from the FHWA. A list of qualified three-strand guard cable systems can be found in Qualified Systems for JSP Median Guard Cable FS-1040 Table 8. The manufacturer shall request to be placed on the qualified list by submitting to Construction and Materials a letter stating their request and certifying that their system has completed NCHRP 350 Test Level 3 testing, and a copy of the FHWA acceptance letter.

1040.3 Report (Records)

SiteManager is to be used to identify samples sent to the Laboratory and to create the inspection report. The report is to show a Status of “Accepted/Complete” or “Rejected/Fail.” If a sample is submitted to the Laboratory for testing, the Laboratory will perform the designated tests and complete the SiteManager record. If all tests are performed and acceptance is made in the field, the inspector should complete the entire report.

1040.4 Crashworthy End Terminal and Qualified Plastic Guardrail Block


For the listings of Types A, B, C, D and E crashworthy end terminals as well as of sand barrels and miscellaneous barrier systems, please refer to End Terminals and Barrier Systems and scroll down the page to Crashworthy End Terminals.

For a listing of qualified plastic guardrail block manufacturers, refer to Table 1040.4, below.


Table 1040.4 Qualified Plastic Guardrail Blocks

Brand NameManufacturer
MONDOBlock Mondo Polymer Technologies, P.O. Box 250, Reno, OH 45773
Polylumber Ramco International, P.O. Box 9625, Pittsburgh, PA 15226
Eco-Composite Guardrail Offset Block Eco-Composite, LLC, 17169 Hayes Rd., Grand Haven, MI 49417
Anro Recylced Plastic Guardrail Offset BlockAnro Products, Inc., 7887 Ashwood Drive, SE, Ada, MI 49301
King BlockTrinity Highway Products, PO Box 568887, Dallas, TX 75356-8887
P Block Monroeville Industrial Moldings, 75 Ontario Street, Norwalk, OH 44857

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