SECTION 9080 - CONCRETE STEPS, HANDRAILS, AND SAFETY RAIL
A.�� Construction of concrete steps.
B.�� Furnishing and installation of handrails.
C.�� Furnishing and installation of safety rail.
Comply with Division 1 - General Provisions and Covenants, as well as the following:
A.�� Submit color samples and product literature for primer, paint, and powder coating to be used on handrails and safety rail.
B.�� Submit shop drawings for handrails and safety rail.
Comply with Division 1 - General Provisions and Covenants.
1.05����� DELIVERY, STORAGE, AND HANDLING
Comply with Division 1 - General Provisions and Covenants.
1.06����� SCHEDULING AND CONFLICTS
Comply with Division 1 - General Provisions and Covenants.
1.07����� SPECIAL REQUIREMENTS
A.�� Provide 1 gallon of color matched exterior grade polyurethane paint for each color specified, for the Contracting Authority�s maintenance use.
B.�� Label each container with the manufacturer�s name, product number, and color number.
1.08����� MEASUREMENT AND PAYMENT
1.�� Measurement:� Measurement will be the area of concrete steps in square feet for each type of concrete step.� The length will be the horizontal length between expansion joints, and the width will include curbs.
2.�� Payment:� Payment will be at the unit price per square foot of concrete steps.
3.�� Includes:� Unit price includes, but is not limited to, reinforcement, expansion joint material, and preparation of subgrade.
1.�� Measurement:� Measurement will be in linear feet for each type of handrail, measured along the top of the handrail from end of rail to end of rail.
2.�� Payment: �Payment will be at the unit price per linear foot for each type of handrail.
3.�� Includes: �Unit price includes, but is not limited to, posts, mounting hardware or concrete grout, and finishing (painted, galvanized, or powder coated).
1.�� Measurement:� Measurement will be in linear feet for safety rail, measured along the top of the safety rail from end post to end post.
2.�� Payment:� Payment will be at the unit price per linear foot of safety rail.
3.�� Includes:� Unit price includes, but is not limited to, posts, pickets, mounting hardware, epoxy grout, and finishing (painted, galvanized, or powder coated).
A.�� Concrete:� Class C concrete complying with Section 6010, 2.02.
B.�� Reinforcing Steel:� Comply with Iowa DOT Section 2404.
C.�� Expansion Joint:� Comply with Iowa DOT Section 4136.03, A.
D.�� Forms: �Comply with Iowa DOT Section 2403.
1 1/4 to 2 inches in diameter; ensure post diameter matches handrail diameter.
A.�� Steel: �Welded or seamless black steel pipe and posts complying with ASTM A 53, Grade A or B.
B.�� Aluminum: �Aluminum-alloy extruded structural pipe complying with ASTM B 429, alloy 6061-T6 or 6063-T6, schedule 40 (if specified; for use with grouted connection only).
C.�� Bends: �Provide manufactured pipe bends and connections for handrail.� Do not field bend pipe.
A.�� Rails and Posts: �Provide 2 1/2 inch by 2 1/2 inch tubular high strength steel with 1/4 inch minimum wall thickness.� Comply with ASTM A 500, Grade B.
B.�� Pickets: �Provide 1 inch by 1 inch tubular high strength steel with 1/8 inch minimum wall thickness.� Comply with ASTM A 500, Grade B.
A.�� Painted:� Provide factory-mixed paint / primer.
1.�� Primer: �Provide single component, water-based rust and corrosion resistant primer specifically designed for use on steel surfaces.
2.�� Paint: �Provide water-based, abrasion-resistant paint specifically designed for use on steel surfaces.
B.�� Galvanized: �When specified in the contract documents, galvanize handrail and safety rail.
1.�� Provide zinc coating complying with ASTM A 123.
2.�� Hot-dip galvanize components after fabrication.
3.�� For hot-dip galvanized components that will be powder coated, utilize the dry-kettle (pre-fluxing) process.� Air cool galvanized components.� Do not quench in water or chromate.
C.�� Powder Coated:� Apply powder coat to steel, galvanized steel, or aluminum handrail and safety rail when specified in the contract documents.� Comply with the manufacturer�s recommendations for surface preparation, application of primer, and application of the powder coating, in addition to the following minimum requirements.
1.�� Surface Preparation:
a.�� Steel Substrate:
1)�� Remove oils and surface contamination by solvent cleaning.� Comply with the requirements of SSPC-SP 1.� Rinse thoroughly with hot water or water pressure and dry completely.
2)�� Remove loose rust, loose mill scale, and other foreign substances by hand or power tool cleaning.� Comply with SSPC-SP 2 or 3.
3)�� Remove all dirt, grease, rust scale, mill scale, paint, slag, and other foreign substances by blast cleaning.� Comply with SSPC-SP 6.
4)�� Remove all blast cleaning products by means of vacuuming or compressed air.
5)�� Chemically clean surface to remove residual contamination, apply conversion coating, and apply sealing agent to prepare the surface for powder coating.�
6)�� Begin powder coating as soon as possible after surface preparation to prevent the development of iron oxide on the surface of the steel.
b.�� Galvanized Steel Substrate:
1)�� Remove all tears, spikes, high spots, or other surface defects caused by the galvanizing process using hand or power tools.
2)�� Apply an alkaline solution, with a pH between 11 and 12, to remove traces of oil, grease, and dirt.
3)�� Remove residual zinc oxide by spraying surface with a mild acidic solution (pH of 3.5 to 4.5).
4)�� Apply conversion coating to the surface and apply sealing agent to prepare the surface for powder coating.
c.�� Aluminum Substrate:
1)�� Clean surface by power washing to remove contaminants.
2)�� Clean surface with an aqueous alkaline solution by immersion or scrubbing with a soft brush.� Do not scrub with a steel bristle brush.� Dry completely after cleaning.
3)�� Remove oils and surface contamination by solvent cleaning.� Comply with the requirements of SSPC-SP 1.
4)�� Remove light deposits of aluminum reaction by-products by hand or power tool cleaning.� Comply with SSPC-SP 2 or 3.
5)�� Remove aluminum oxide by sweep blasting or chemical treatment:
a)�� Sweep Blasting:
i)��� Utilize oil-free compressed air to prevent contamination of cleaned surface.
ii)��� Utilize blast media with a MOH hardness of 5 or less, or utilize organic media such as corn cobs or walnut shells.� Do not roughen surface.
iii)�� Powder coat surface within 60 minutes of sweep blasting to prevent re-formation of aluminum oxide.
b)�� Chemical Treatment: Comply with ASTM D 1730 for Type B treatment.
6)�� Chemically clean surface to remove residual contamination, apply conversion coating, and apply sealing agent to prepare the surface for powder coating.
2.�� Priming:� Apply as recommended by coating manufacturer for specific substrate to all surfaces, unless specifically not required by coating manufacturer.
3.�� Coating:
a.�� General:
1)�� Provide complete multi-coat systems formulated and recommended by the manufacturer for the application indicated.
2)�� Provide urethane, TGIC polyester, polyester wrinkle, or non-TGIC polyester based powder coatings as recommended by the powder coating manufacturer to provide long term exterior durability.
b.�� Application:
1)�� Apply coating to the thickness specified by the coating manufacturer.� Comply with coating manufacturer�s recommendations for application of powder coating.
2)�� Apply coating in uniform thickness coats without runs, drips, pinholes, brush marks, or variations in color, texture, or finish.� Finish edges, crevices, corners, and other changes in dimension with full coating thickness.
4.�� Curing:� Cure the powder coating at the temperature and for the time recommended by the powder coating manufacturer.
1.�� Anchor plate: �1/4 inch thick, 5 inch by 8 inch steel anchor plate with a 46,000 psi yield strength.� Paint or galvanize anchor plate to match handrail or safety rail.
2.�� Bolts: �Provide 3/8 inch galvanized anchor bolts or threaded rod with length as required to provide a 3 inch embedment.� Comply with ASTM A 36.
3.�� Adhesive Anchoring Material:
a.�� Epoxy complying with ASTM C 881, Type IV.� Provide appropriate epoxy class based upon concrete temperature at time of installation.
b.�� Grout on approved products list in Iowa DOT Materials I.M. 491.11, Appendix C.
1.�� Polymer Grout: �Comply with Iowa DOT Materials I.M. 491.11.
2.�� Non-shrink Grout: �Comply with Iowa DOT Materials I.M. 491.13.
3.01����� INSTALLATION OF STEPS
A.�� Prepare Subgrade:� In fill areas, construct and compact subgrade to 95% of maximum Standard Proctor Density.
B.�� Forming: �Comply with Iowa DOT Article 2403.03, B.
C.�� Concrete: �Comply with Section 6010, 3.02.� Deposit concrete for the full depth of the steps in one operation.
D.�� Reinforcing Steel:� Comply with Iowa DOT Section 2404.� Provide a minimum 2 inches of cover on all reinforcing steel.
3.02����� INSTALLATION OF RAIL
1.�� Install rail continuously with no gaps or breaks along the length specified in the contract documents.
2.�� Use welded connections between rail components.� Grind connections to remove sharp or abrasive edges and to remove other irregularities.
B.�� Handrail: �Install the top rail between 34 inches and 38 inches above the nose of the step tread.� Maintain a consistent height above the step treads.� Install the bottom rail midway between the nose of the step and the top rail.
1.�� Rails: �Install the top rail a minimum of 42 inches above the finished grade.� Install the bottom rail a maximum of 4 inches above finished grade.
2.�� Pickets: �Locate pickets in the center of the top and bottom rails and space evenly between posts.� Provide a maximum clear opening between pickets of 4 inches.
D.�� Posts: �Install posts at a maximum spacing of 8 feet.� Attach handrail posts in one of following two ways.
1.�� Bolted Connection:
a.�� Weld anchor plate to the bottom of the handrail posts.
b.�� Layout location and drill four 7/16 inch holes for anchor bolts at each post attachment point.� Drill holes with a carbide drill bit; do not core drill anchor bolt holes.
c.�� Apply adhesive anchoring material according to manufacturer�s published recommendations and install threaded rod or anchor bolts.
2.�� Grouted Connection:
a.�� Form a 6 inch deep hole in the concrete curb 1 inch larger than the outside diameter of the post.� Alternatively, hole may be core drilled in hardened concrete.
b.�� After the concrete hardens, set handrail posts into holes and temporarily secure.
c.�� Fill the void between the post and holes with non-shrink or polymer grout.
Do not paint hot dipped galvanized or aluminum handrail or safety rail.
A.�� Mix paint and/or primer to correct consistency in accordance with manufacturer's instructions before application.� Do not reduce, thin, or dilute coatings or add materials to paint unless such procedure is specifically described in manufacturer's product instructions.
B.�� Shop coat handrail, safety rail, posts, pickets, and anchor plates with primer following fabrication.
C.�� Apply two field coats of paint upon completion of installation.
END OF SECTION