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                        W-Beam Guardrail Repair: A Guide for Highway and Street Maintenance Personnel


            
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                APPENDIX A: ESTIMATING RESOURCES FOR W-BEAM GUARDRAIL REPAIR
APPENDIX A: ESTIMATING RESOURCES FOR W-BEAM GUARDRAIL REPAIR

1. EXAMPLE OF DAMAGE INSPECTION REPORT

***Damage inspection Report – New York State DOT***

Damage Inspection Report - New York State DOT

***Calculating Guardrail Radius (to complete form above)***

Traffice Face Convex

Diagram. This diagram shows where to acquire the measurements to calculate radius.



Table. This table shows the functions of a 12-foot, 6-inch circular arc.

2. ESTIMATING PARTS AND MATERIALS FOR STANDARD SECTION W-BEAM REPAIR

Typical elements of the W-beam guardrail (a standard 12-ft, 6-in rail length is assumed; if an agency allows a 25-ft rail length, then make appropriate adjustments) include the following:

12-ft, 6-in steel W-beam rail sections (matching existing material – gauge, galvanizing, treated, or "rusting steel", etc.).
	Eight each 5/8-in by 11⁄4-in galvanized buttonhead bolts with recessed nuts for each rail splice.
	One each, 5⁄8-in rail-to-post galvanized buttonhead bolt with round washer and recessed nut for fastening rail to post; length varies depending on the type of offset block and type of post:
	Wood block to wood post: 18 inches.
		Wood or approved block to steel post: 10 inches.
		Steel block to steel post: 2 inches (no washer on back + 2 each –11⁄2-in bolts to connect blockout to post).
	One each, 1-ft, 2-in wood offset block for wood post or approved offset block for steel post, to space the rail away from the post to minimize snagging.
	6-ft, 0-in posts. To agency standard (6 by 8 or 8 by 8 wood posts or W6 by 8.5 or W6 by 9 steel posts.
	12-in galvanized W-beam backup plate at intermediate steel post locations with steel offset block for placing behind rail where no rail splice occurs.
	10d to 16d galvanized nail(s) to keep wood offset block from rotating on wood post.Diagram. This diagram shows how to mount w-beam rail to wood posts with wood offset blocks.

Arrow pointing to the leftTraffic

***W-Beam with Wood Offset Block on Wood Post***

Diagram. This diagram shows how to mount w-beam rail to steel posts with approved offset blocks.

Arrow pointing to the leftTraffic

***W-Beam with Approved Offset Block on Steel Post***

Diagram. This diagram shows how to mount w-beam rail to steel posts with steel offset blocks.

Arrow pointing to the leftTraffic

***W-Beam with Steel Offset Block on Steel Post***

***Checklist of Materials for Repair***
	Item
			Compute
			Number neededW-beam galvanized steel rail sections

			12-ft, 6-in-long, desirably punched @ 3ft, 11⁄2 -in spacing
			Tally # of damaged

			Sections @ 12ft, 6 in5⁄8-in by 11⁄4 -in-long splice bolts with nuts
			(# sections x 8) + 85⁄8–in rail-to-post bolts with recess nuts and round washers for connecting rail to post and block
			(# sections x 2) + 16-ft , 0-in posts*
			(# sections x 2) + 1Offset blocks
			Same as # of postsFor wood block on wood post:

			10 16d galvanized nails
			(preferably two per offset block)
			2 x # of offset blocksFor steel block on steel post:

			12-in W-beam back-up plate
			Same as # of sectionsFor steel block on steel post:

			5⁄8 -in by 11⁄2 -in hex-head bolts to connect block
			2 x # of offset blocksGuardrail-mounted delineators
			Same as # of sectionsObject (hazard) markers
			1 for each end** If there is not adequate soil support behind the posts, use 7 ft or longer posts.*

This list indicates an exact number of parts. Be sure to take into account additional numbers of each part for damage, loss, etc.

A detailed list like this is not appropriate for end-treatment repair/replacement. The proprietary manufacturers' installation manuals contain bills of material for each model of their products. Check these when conducting a complete replacement installation or for the appropriate quantities based on the amount of repair/replacement.

3. ESTIMATING EQUIPMENT AND TOOLS

The following is a listing of equipment and tools that will be needed for guardrail repair. There are two lists: the first is from a typical state highway agency truck; and the second is from a typical guardrail contractor truck. Make sure you comply with OSHA or your local regulations when using this equipment.

**EXAMPLE 1– A TYPICAL STATE HIGHWAY AGENCY TRUCK**
	***Supervisor Truck Supplies***3⁄8-in drive ratchet and socket set (end treatments have small nuts and bolts)
			3⁄4-in drive ratchet and socket set (bridge connections and anchor terminals)1⁄2-in drive ratchet and socket set with 3-in and 10-in extensions
			7/16 to 11⁄8" sockets5 to 11⁄4" bell sockets
			4-in to 1⁄2-in drive socketsFour - splice pins, 2 pinch bars / pry bars
			Open end and box wrench set 5/16 to 11⁄4 inchTwo 1⁄2-in impact wrench
			Two 5/16-in impact socketsTwo 11⁄8-in impact socket
			Three 11⁄4-in impact bell socketTwo 11⁄4-in Impact Deep Bell SocketOne 15-in adjustable wrench
			One 20-in adjustable wrenchFour vise grip pliers
			Two 4-lb hammersOne 18 lb sledge hammer
			One 10-lb sledge hammerTwo flat shovels
			Two round shovelsTwo post hole digger
			Two digging barsOne post puller
			Cut-off saw, extra bladesChain saw, bar oil
			Mix oil for saws2- or 3-gal mix gas can
			2 5-gal gas cansHilti concrete drill set
			Hilti 1⁄2, 5⁄8, 7⁄8, 1-in bits3 7/8–inch-hole saws
			EpoxyLong heavy-duty jumper cables
			Ink markersAcetylene torch set
			Two chisels3500-watt generator
			Two 100-ft electric cordsTwo1/2-in VSR drills
			Two 1-in step bitsPaint & cold galvanizer
			Penetrating oil / sprayTwo- Line levels
			String lineLine pins
			200-ft steel tapeG/R Standards and Specifications
			Construction Log BookAccident Investigation Reports
			Two Pull bindersMaintenance of Traffic Standards
			Work zone signs & standsSTOP / SLOW paddles
			ConesHard hats, safety vests, safety glasses, gloves,
			hearing protection, dust masks
			MSDS Manual, Hazard Communication, Safety ManualsFirst-aid kit
			Blood-Born Pathogen KitFirst-Aid Reports
			Wasp and bee spray5-gal water cooler
			Quantity sheetsRespirators
			CameraClipboard
			TimesheetsCell phone
			Credit cardsGuardrail-mounted delineators
			Object Markers*Post Pounder Truck / Rail Truck*Add to Supervisor Truck Supplies:Truck-mounted post pounder – holds 30 posts – grease gunAir compressor, 92 CFM
			Two air hosesHydraulic cylinder (pulling)
			Three chainsCanvas strap for lifting
			One 60-lb jack hammerTwo vehicle battery chargers
			Two Dewalt 18-volt wrenches

**EXAMPLE 2– A TYPICAL GUARDRAIL CONTRACTOR REPAIR TRUCK**
	***Foreman Truck Supplies***3⁄8-in drive ratchet and socket set (end treatments have small nuts and bolts)3⁄4-in drive ratchet and socket set (bridge connections and anchor terminals)1⁄2-in drive ratchet and socket set with 3" and 10-in extensions7/16-in to at least 11⁄8inch sockets
			One 20-in adjustable wrenchFive 11⁄4-in bell sockets
			110-lb sledge hammer41⁄2-in drive sockets
			118-lb sledge hammerFour splice pins
			115-in adjustable wrenchFour vise grip pliers
			Combo open end and box wrench set 5/16 to 11⁄4 inchTwo 4lb. hammersPost puller
			Chain sawTwo flat shovels
			Cut-off sawTwo round shovels
			Saw bladesTwo digging bars
			Mix oil for sawsTwo- post-hole diggers
			Bar oilLong, heavy-duty jumper cables
			Two or three gallon mix gas cansTwo 5-gal gas cans
			Acetylene Torch SetInk markers
			3500-watt generatorTwo 100-ft electric cord
			Two 1⁄2-in VSR drillsTwo 1-in step bits
			Three 7⁄8-in hole sawsTwo 1⁄2-in impact wrenches
			Two 1⁄2-in impact wrenchesTwo 1⁄2-in impact wrenches
			Four swivel socketsTwo 5/16-in impact sockets
			Two 11⁄8-in impact socketThree 11⁄4-in impact bell socket
			Two 11⁄4-in impact deep bell socketsHILTI concrete drill set with bits 1⁄2, 5⁄8, 7⁄8, 1 inch
			Clipboard, time sheets, quantity sheetsEpoxy
			Dust maskLine levels
			Construction Log BookLine pins
			G/R Standards and SpecificationsString line
			Cell phoneCredit cards
			Paint & cold galv.Accident Investigation Reports
			Two pull bindersCamera
			Proper work zone signs & stands200-ft steel tape
			STOP / SLOW paddles / conesFirst-aid kit
			Blood-born pathogen kitFirst-Aid Reports
			M.O.T. Standards5 gal water cooler
			Penetrating oil / sprayWasp and bee sprayMSDS manual, hazard communication, safety manualsHard hats, safety vests, safety glasses, gloves, hearing protection4. ESTIMATING TIME NEEDED FOR REPAIR

***General guidelines:***

Include travel time to and from the repair site when this is a maintenance activity scheduled from a central garage.
	Plan about 30 to 45 minutes to place the traffic control devices. It will take about the same time to gather the control devices after repair work is completed.
	Allow 30 minutes for final inspection of guardrail after finishing the repair and for recording the repair job.
	The time needed to make ANY repair depends on the experience and skill of the crew. The number of workers for the job and the amount of power-assisted tools available will also affect the time required.**Repairing *cosmetic* damage to guardrail installations**--Should your agency want to repair the very minor type of damage mentioned earlier in this handbook, the actual repair (which may only be painting or minor straightening of a dented rail) should not require more than 30 minutes to 1 hour.

**Repairing damage that still permits the guardrail to function** --When the inspection of the damage at the site indicates:

Only a few posts are broken.
	Only a few posts are pushed badly off line.
	A rail is bent out of line less than 18 inches.Or other conditions exist that permit routine scheduling of the repair (rather than emergency repair), plan for 1 to 2 hours of repair time, plus traffic control, inspection, and recording.

**Repairing major damage requiring prompt attention**--When the guardrail damage is extensive, such as four or more posts are knocked out or several rail beam sections are broken, plan on one half day time requirement, including the traffic control setup, inspection, and recording.

FOR AGENCIES WITH MAINTENANCE MANAGEMENT SYSTEMS THAT GIVE A MORE DETAILED TIME BREAKDOWN, USE THAT TO ESTIMATE TIME.

5. ESTIMATING CREW SIZE

The crew size will depend upon the extent of the damage and the needs for traffic control. Two workers and a person in charge should be enough to repair minor damage where the guardrail is allowed to remain assuming the guardrail would function satisfactorily while the repair was scheduled. This assumes the work involves only a few posts or rail beam sections. When four or more posts are involved, or more than two rail beam sections are to be replaced, expect to need a crew of four. If a wide range of power-assisted tools is available, then a crew of three should work well.

Traffic control crew needs are as follows:

If no person is to be assigned to flag traffic through the repair work zone, then no additional workers are needed. Workers repairing the rail can place and collect the traffic control devices. There can be situations causing short-term encroachment on the road to move equipment or to make brief repairs. Provide warning to traffic in such cases.
	Assign one worker as a flagger when the traffic cones or temporary barricades around the repair site restrict the road or street to alternating one-way traffic. USE ONE FLAGGER WHEN THAT WORKER CAN CLEARLY SEE TRAFFIC APPROACHING THE REPAIR SITE FROM BOTH DIRECTIONS AND THE FLAGGER SIGNAL CAN BE SEEN BY DRIVERS WELL IN ADVANCE OF THE REQUIRED STOP POINT.
	ssign two workers as flaggers for any other work zone conditions where traffic cones or barricades create alternating one-way traffic flow around the repair.IF YOUR MAINTENANCE MANAGEMENT SYSTEM GIVES MORE DETAILED CREW SIZE INFORMATION BY WORK TASK FOR GUARDRAIL REPAIR, THEN USE THAT CREW SIZE ESTIMATE.

6. EXAMPLE W-BEAM GUARDRAIL REPAIR LOG

***W-beam guardrail repair log***

Image. This is a scanned copy of a sample w-beam guardrail repair log.\
      
  Book traversal links for APPENDIX A: ESTIMATING RESOURCES FOR W-BEAM GUARDRAIL REPAIR
      ‹ REFERENCES
                    Up
                    APPENDIX B: VIRGINIA DOT REPAIR GUIDANCE ›
                
                Book:W-Beam Guardrail Repair: A Guide for Highway and Street Maintenance Personnel
              I. INTRODUCTION: INTENT AND CONTENT
                II. IDENTIFY PROBLEMS AND PLAN APPROPRIATE ACTION
                III. REPAIR SEQUENCE GUIDANCE
                IV. REPAIR RECORD
                REFERENCES
                APPENDIX A: ESTIMATING RESOURCES FOR W-BEAM GUARDRAIL REPAIR
                APPENDIX B: VIRGINIA DOT REPAIR GUIDANCE
                APPENDIX C: MAINTENANCE GUIDANCE
                APPENDIX D: CLEAR ZONE DESCRIPTION U.S. DEPARTMENT OF TRANSPORTATION

**Federal Highway Administration**

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