455 NOISE BARRIERS

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455.01 DESCRIPTION
Construct noise barriers. The Standard Noise Barrier System consists of precast concrete panels, steel or concrete posts, concrete foundations, fire hose connections, doors, and hardware necessary to construct a noise barrier. Either steel or concrete posts may be used, but use the same type of post throughout an entire noise barrier system.
When drilled shafts (caissons) are specified, refer to Section 412.
Bidders may view samples of the proposed panel finishes by contacting the Office of Highway Development, Director’s Office.
455.01.01 Special Bidding Instructions. When the Contract Documents permit optional post spacings, place the bid in the appropriate items for the post spacing selected. Only bid the items pertaining to the selected post spacing. Fill in as "$0.00" all remaining items pertaining to the alternate post spacings not selected. Only one alternate post spacing may be bid per barrier.
455.01.02 Preapproved Alternate Noise Barriers. Alternate noise barriers may only be used when specified. Only those noise barriers specified will be permitted. All other noise barriers, even though they are preapproved or have been previously used on Administration projects, shall not be used on the project. The Administration will not consider any other alternate noise barriers as a value engineering change proposal.
Enforcement. These requirements will be enforced on all projects.
Preapproved Alternate Noise Barrier List. Alternate noise barriers are selected from the list of Preapproved Alternate Noise Barriers, which is maintained by the Office of Structures. Procedures for adding products to the prequalified list may be obtained from the Office of Structures.
Alternate noise barriers that have been previously used on Administration projects without complying with the preapproval requirements shall be formally submitted through these procedures before they will be added to the Preapproved Lists for consideration to be used on future projects. These and other noise barrier systems may be submitted for addition to the Preapproved Lists, but the Administration will not permit these submittals to be used on an advertised or awarded project.
Deviations. Any proposed deviation in materials, design, post size or shape; panel size or shape; reinforcing type, size, and spacing; or placement from what is shown on the Plans or from any preapproved alternates allowed on this project will be reviewed by the Administration’s noise barrier consultant. All costs for these reviews, whether the details are accepted or rejected, shall be at no additional cost to the Administration and the costs will be deducted from monies due to the Contractor. Any fabrication or creation of any noise barrier element that is a deviation and is made prior to written approval of the Administration is not acceptable.
455.01.03 Contract Documents for Preapproved Alternate Systems or Alternate Post Spacing. When the Contract Documents permit and the Contractor elects to use preapproved alternate noise barrier systems or alternate post spacing not shown on the Plans, the Administration will furnish substitute Plans and specifications to the Contractor within 30 days after issuing Notice to Proceed. Only one type noise barrier may be used per barrier.
The substitute Plans may include other pertinent modifications and aesthetic changes necessitated by the selection such as: requiring tapered panels; grade beams or offset brackets; doublewide panels; larger or smaller caissons; additional grade beams and offset brackets or doublewide panels; or higher panels, if the changes in elevation between adjacent panels are determined to be too severe. No additional compensation will be given to the Contractor due to revisions detailed in the substitute Plans and specifications.
The substitute Plans will be issued as a Contract revision replacing the advertised Plans. All work under this Section, including any changes required in grading, drainage, paving, utility locations, and permits that are a direct result of the substitute Plans, shall be done at no additional cost to the Administration.
After substitute Plans are issued as a redline revision, submit working drawings bearing the fabricator or supplier’s title block as specified in Section 499.
455.02 MATERIALS
Concrete Structure       Section 420
Production Plants       Section 915
Reinforcing for Concrete Structure       421.02
Concrete Stain       902.18, Color No. as specified
Concrete       Section 902
Pretensioning Strand       908.11, 1/2 in. diameter seven wire
Elastomeric Bearing Pads       910.02.01
Elastomeric Shims       911.12
Fusion Bonded Polyester Powder Coating       917.03, Color as specified for stain on highway side of roadway
Anchor Assembly
     Plate       A36
     Rods       F1554, Grade 55, S 1 (Chemical Composition and Carbon Equivalent)
Nuts       A563
Washers       F436
Steel Posts (Including Plates and Shapes)       A709, Grade 50W
Organic Zinc Rich Paint       912.05
Galvanizing       A123
Galvanizing Repair       A780
Aggregate       M 43
Concrete Stain. Select the stain from the Qualified Products List (QPL) maintained by the Office of Materials Technology.
Supply fire hose connections, fire doors, miscellaneous hardware, etc., as specified.
Quality Control. The manufacturer is solely responsible for all aspects of quality control and the delivery of products meeting specification to the jobsite, regardless of any inspections made by the Administration. The manufacturer is required to notify the Office of Materials Technology (OMT), any time there is a non-compliance in manufacturing procedures or a test failure of any material or product. The manufacturer must not deviate from or alter any terms of their plant Quality Control Plan (QCP) without the written approval of the Administration’s Engineer and OMT. Failure to obtain approval may result in rejection of any products produced during the period in which the plant was out of compliance with the approved QCP.
Records. The manufacturer must keep complete and accurate records of all material approvals, materials delivered, samples and tests taken, materials produced, and production units fabricated. In addition, the manufacturer must make, and keep, complete and accurate records of all pre- and post- pour inspections. All records must be available for inspection by the Administration’s Engineer and OMT representative immediately upon request. Any failure to maintain such records may result in the rejection of any units produced during the period for which the records are unavailable.
Quality Control Technician. The manufacturer must have on site during all phases of production at least one employee holding a minimum of a Level I Plant Quality Control Technician from the Precast/Prestressed Concrete Institute (PCI LI). The PCI LI technician will be responsible for ensuring that all production complies with the QCP and the Specifications, Plans and other relevant Contract Documents.
Sources. All materials must be obtained from approved sources. Approval of a source does not indicate approval of a specific material originating from that source. All materials must be submitted for approval by the Administration’s Engineer and OMT prior to use.
Mix Designs. All mix designs must be trial batched and approved by the Administration’s Engineer and OMT.
No changes may be made to any materials or mix designs without the approval of the Administration’s Engineer and OMT. Submit material change requests to the Administration in writing. Do not implement any changes without written approval from the Administration.
455.02.01 Hardware. No material substitutions will be permitted for anchor rods, nuts, and washers. Hot dip galvanize per A153.
455.02.02 Epoxy Organic Zinc Rich Primer. As specified in 465.03.01(b)
455.02.03 Precast Concrete Panels. Cast each panel with an embossed or impressed, legible, unique, permanent, indelible identification number located on a portion of the panel that will not be visible in the completed structure. A sample identification number will be included on each sample panel for approval by Administration’s Engineer and OMT. Panels will be rejected at any phase if identification numbers appear to have been tampered with or altered in any manner. Use Mix No. 6 concrete, except use a design compressive strength of 5000 psi.
The layout of stacked noise barrier panels shall ensure that the seams/joints between panels are consistent with the specified aesthetic design. This applies to all panels within the proposed noise barrier system, not just the panels between two posts. Do not alternate full height panels and stacked panels on a continuous section of a noise barrier. If full height panels are required at certain locations adjacent to stacked panels, provide a false joint to give the appearance of stacked panels.
Form liner seams/joints shall be as specified and shall not be visible in the noise barrier system unless they are an integral part of the noise barrier system’s aesthetic design. This applies to all components of the noise barrier system (panels, posts, etc.) and applies to both full height and stacked panel designs.
Caulking and coating material shall be compatible with the aesthetic aspects and acoustical requirements of the proposed noise barrier system.
Textures. Consider all panel surfaces as having architectural finishes and carefully produce a consistent, high quality finish as specified in Section 456. When stacked panel systems are used, ensure that the panels stacked within a single frame match in quality and appearance. Make aesthetic inspections for all panels in outdoor lighting conditions as specified in 456.03.03. Panels failing to conform to these requirements may be rejected.
Unless otherwise specified, the finishes for the panels shall be as follows:
(a) Produce exposed aggregate finishes on the bottom side of each panel in the precast form.
(b) Produce double rake finishes on the top side of each panel.
Sample Panels. Refer to Section 456 - Architectural Treatment for preliminary sample panel requirements. Provide a unique identification number on each sample panel.
Review and approve the concrete mixture by the Engineer prior to the production of the sample panel(s).
Additionally, after the small sample panels and working drawings are approved, erect a full-size frame set panel (a single full height panel or a complete set of stacked panels assembled full height) between two posts at the precasting site, and prepare them for visual inspection. The frame set panel will be used to determine conformance with the Contract Documents for finishes, and to determine the quality of the fit and finish. This frame set panel shall have the textures specified in (a) and (b) above on the appropriate highway and residential sides as well as caps or any other specified finishes. Make the frame set panel available outdoors with both sides visible for inspection. Provide a second full-frame set panel, equal in appearance to the approved sample panel at the precasting site, and place it at the construction site as a visual quality control reference device. Upon written approval by the Administration, produce all subsequent panels equal in appearance to the approved panel at the plant. Transport the plant full-frame set panel to the project site and use it and the project full-frame set as panels in the noise barrier after all other panels have been accepted.
Supply sample panels and frame set panels for inspection for each barrier finish type on the project.
Sample Panel Digital Photograph Inspection. Refer to Section 456 - Architectural Treatment.
Reinforcement. All deformed steel reinforcing bars used in the production of noise barriers must be Grade 60 epoxy coated. Use supports for epoxy coated reinforcing steel as specified in 420.02.02.
455.02.04 Concrete Posts. Use Mix No. 6 concrete except use a design compressive strength of 5000 psi. When concrete posts include base plates, galvanize plates and all hardware to meet A123 and A153.
Textures. Unless otherwise specified, finish the posts as follows:
(a) Produce exposed aggregate finish on the bottom side of posts in the precast form.
(b) Produce Double Rake finish on the top side of posts.
Sample Posts. When concrete posts are used, submit a 24 in. long sample of the concrete post to the construction site for approval. Submit the sample with the panel samples as specified in 455.02.03. Ensure that the sample post exhibits the specified finishes.
Reinforcing. All deformed steel reinforcing bars used in the production of noise barrier posts must be Grade 60 epoxy coated.
455.03 CONSTRUCTION
Refer to Section 450 for additional requirements for noise barriers mounted on top of retaining walls. Perform all welding according to AWS D1.1.
455.03.01 Galvanizing. As specified in 465.03. Complete all holes and welding required in the hardware before galvanizing.
455.03.02 Anchor Assemblies. Assemble anchor assemblies and place them at the specified elevation and spacing. Use templates for proper alignment and spacing of all anchor assemblies prior to concrete placement. Ensure that the threads of the anchors are long enough to provide room for a 1 in. concrete encasement, leveling nuts, washers, base plate, and at least a 1/2 in. protrusion through the top of the top nut when the noise barrier is properly installed.
455.03.03 Posts. Erect all posts plumb at the specified alignment, and at the appropriate spacing.
Embedded Concrete Posts. Erect posts using a temporary support system to ensure the vertical and horizontal alignment and specified elevation. Temporary support systems shall include fixed ties between the post being set and a previously set post. Submit the design of the temporary support on the concrete post working drawings prior to erection. Leave the support system in place for at least 40 hours after completing the concrete placement for the drilled shaft that encases the post.
Polyester Powder Coated Steel Posts. As specified in 465.03.01(b). Completely fabricate steel posts, including base plates and all holes drilled, before application of the polyester coating system.
455.03.04 Precast Concrete Panels. Fabricate and install precast concrete panels as specified.
Submit working drawings that provide for all accessories, additional reinforcing steel, materials, and methods not specifically indicated, but that are essential for transportation, handling, installation, or construction of the panels.
Show the size, shape, and location of all panels and include complete reinforcement and connection details. When specified, show the method and sequence of erection, method of plumbing panels and adjusting connections, and the loads and movements due to erection.
Provide all lifting devices and inserts used externally, or installed in the panel, that are 4 times stronger than the loads anticipated during the course of manufacture, storage, delivery, and erection. Include all inserts on the working drawings. When no longer needed, remove lifting inserts, grout insert areas and install elastomeric pad according to with the Contract Documents.
Place concrete as specified in 420.03.04. When placing concrete, the temperature conditions of 420.03.04(f) apply. Cure all concrete as specified in Section 420.03.08. Provide cold weather protection as specified in 420.03.13. Panels that have not been cured per specification may be subject to rejection regardless of appearance or test result. In addition, do not remove panel and appurtenance forms until the concrete has achieved at least 75 percent of design strength, or as specified by the Engineer. Provisions of 420.03.02(o) apply. Panels that have not been stripped per specification may also be subject to rejection regardless of appearance or test result.
When steel posts are used, protect the inner-coated steel surfaces from being scratched, marred, or chipped during panel installation. The protective material shall not be visible in the finished structure. Do not use grease or similar lubricants.
Defects and Tolerances. Place concrete in a manner so that there are no cold joints. Cracked panels or panels determined by the Engineer to be non-repairable or do not conform to the following tolerances will be rejected, and replaced with acceptable panels.
(a) Within 3/16 in. for panel dimensions except for panels with an effective thickness of less than 4 in. where the thickness shall be within 1/8 in.
(b) Within 1/2 in. for panel squareness for rectangular panels.
(c) Panel surface defects on textured-finished surfaces shall not exceed 5/16 in. per 5 ft.
(d) Within 1/8 in. of the dimensions specified for tongue and groove joints.
Shipping, Handling, and Erection. The Engineer and the manufacturer’s Quality Control representative shall review the panels for initial/shipping acceptance. Mark panels clearly for acceptance or rejection. The Engineer shall make the final determination regarding acceptance or rejection of panels. Clearly mark rejected panels as “rejected” and destroy or store in predetermined area in the manufacturer’s yard. List and document all rejected panels with a unique identification number. Storage for rejected components will not be paid by the Administration.
Protect panels by padding or other means to prevent cracking, staining, chipping, or spalling of the concrete during handling, storage, transporting, and erection. Support or brace panels during installation to ensure safety. Maintain bracing or supports until proper alignment and adequate permanent support has been provided. Do not leave any panel in an unsafe support condition.
The Engineer will evaluate damaged panels to determine whether they can be used. If acceptable, repair damaged panels in an approved manner.
Erect panels centered between posts. Where a panel cannot be erected within the tolerances assumed in the connection design, notify the Office of Structures. The structural adequacy of the installation will be checked by the Office of Structures, and the connection design shall be modified as required. Make changes, other than adjustments within the specified tolerances, only after approval.
Panels will be inspected again after erection for final aesthetic approval and to determine if they have been damaged. Damaged panels will be evaluated for structural integrity and reparability. The producer will submit a repair procedure to the Engineer for review and approval determination. Perform all repairs at no additional cost to the Administration. Panels that are determined to be unrepairable will be removed and replaced at no additional cost.
455.03.05 Concrete Stain. Apply prior to backfilling. For concrete posts, use water blasting or other mechanical means to provide a surface for improved adhesion. Apply two coats according to the manufacturer’s recommendations and as directed. Apply to the top and full height of the panels, but do not apply to exposed aggregate surfaces. Before application, ensure that all surfaces are defect free, structurally sound, clean, dry, fully cured, and free from dirt, dust, curing agents and form release agents, efflorescence, scale, and other foreign materials.
455.04 MEASUREMENT AND PAYMENT
The payment will be full compensation for all material, labor, equipment, tools, and incidentals necessary to complete the work. Modifications such as an increase or decrease in the size or number of grade beams, drilled shafts (caissons), or retaining walls, special anchorages, conflicts with utilities or other obstructions when the utilities or obstructions were noted in the Contract Documents, or any other modifications required due to the Contractor’s selection of an alternate spacing, or a preapproved alternate noise barrier when permitted, will be incidental to the item.
455.04.01 Noise Barrier System will be measured and paid for at the Contract unit price per square foot of barrier including posts and panels and samples thereof, architectural and noise absorptive finishes, stains and coatings, base plates, anchor assemblies (except when noise barriers are mounted on retaining walls), construction templates, temporary supports, steel post protection during panel installation, doors, fire hose connections, excavation, backfill, caulking, double wide panels, earth retaining panels, special panels and posts, cast in place portions of noise barriers, block wall portions of noise barriers, underwall gabions and associated drainage systems, stairs, noise wall access door and hydrant signs, and hardware. Measurement will be based on the as-planned dimensions, using the length along the face of the barrier times the panel height. The cost of any reviews for proposed deviations as specified in 455.01.02 will be deducted from the monies due the Contractor.
455.04.02 Grade Beams and Offset Brackets will not be measured but will be paid for at the pertinent Contract lump sum price, which also includes excavation, reinforcement, concrete, and backfill.
455.04.03 Drilled Shafts (Caissons) will be measured and paid for as specified in 412.04.
455.04.04 Retaining walls will be measured and paid for as specified in 450.04.