Appendix E – continued Table 2 – Acceptable Guardrail Conditions Condition Number Comments/Notes Repairable? Repair Method Spikes, Icicles 14-20 The guardrail is acceptable unless sharp points provide a safety hazard during handling or roadside operations Yes. Remove spikes with sander or file. If spikes break off leaving bare spots, repair following procedure for bare spots. Excess Buildup of Material 21-22 The guardrail is acceptable unless sharp points provide a safety hazard during handling or roadside operations Yes. Remove excess buildup with sander or file. If bare spots occur, repair following procedure for bare spots. Lumpiness and Runs 23-25 The guardrail is acceptable unless Lumpiness and Runs interfere with mating surfaces or by prior agreement. None Dull Gray Coating 26-29 - - General Roughness 30-34 The guardrail is acceptable unless General Roughness interferes with mating surfaces or by prior agreement. None Dross Protrusions 35 Acceptable unless the Dross None
Causes: Storage of close packed pieces under damp conditions. Packing pieces while damp. Lack of ventilation during storage. Effect: Protective value of coating lessened in extreme cases due to prevention of formation of protective film of zinc carbonates. Light staining will eventually wear off due to weathering with no effect on the protective value of the coating. Rejectable Guardrail Conditions Continued Wet Storage Stains (White Rust) Continued Photo 73 Condition: Wet Storage Stains (White Rust) Causes: Storage of close packed pieces under damp conditions. Packing pieces while damp. Lack of ventilation during storage. Effect: Protective value of coating lessened in extreme cases due to prevention of formation of protective film of zinc carbonates. Light staining will eventually wear off due to weathering with no effect on the protective value of the coating. Rejectable Guardrail Conditions Continued Wet Storage Stains (White Rust) Continued Photo 74 Condition: Wet Storage Stains (White Rust) Causes: Improper storage. The material should not be in contact with the ground surface or decaying matter.
Photographs Listed in Table 4 – Guardrail Material Storage Proper Storage Procedures Photograph 87 Photo 87 Proper storage of guardrail material. All materials are placed on pallets and all containers have lids. Photographs Listed in Table 5 – Examples of Good Guardrail Production and Installation Photographs 88-95 Clean Rail Elements and End Pieces Stored on Site Photographs 88-90
Safety Concerns: Vehicular Traffic Sharp Edges 3. Heavy Equipment/Backing Incidents Equipment Required for Guardrail Inspection: Tape Measure Magna gage (Calibrated Annually by Materials and Tests Unit Chemical Lab) Micrometer Calculator Pen or Pencil Guardrail Inspection Field Worksheets Material Inspector’s Duties for Guardrail Inspection: Periodically review the Guardrail Inspection SOP. Review Section 862 of the NCDOT Standard Specifications and AASHTO M 180 Review contract special provisions and/or plans for type of guardrail and anchor units to be inspected. No inspection will be made without Bill of Lading. All guardrail inspections will be inspected after installation. Pre-Inspection Process M&T technician will be contacted by Engineer or project inspector administrating the contract to inspect guardrail and/or anchor units. Determine the location and amount of guardrail and/or anchor units to be inspected. Technician will record approximate locations of rail and/or anchor to be inspected on Guardrail Field Worksheet. Review contract special provisions and/or project plans for type of rail and anchor units to be inspected. Alternates for the anchor units will be listed in the contract special provisions. Installation plans and parts list will be furnished by installer for each style of anchor unit. FHWA approval letter will be furnished with each type of anchor unit. Inspection Process Guardrail Inspection (Straight Rail) Test lot for straight rail is 25 LF for every 2000 LF or fraction thereof. Technician will randomly select a 25 LF section of rail for inspection for every 2000 LF of installed rail.