VicRoads

SECTION 675-CAST STEEL BARRIER RAILING POSTS

675.01GENERAL

This section covers the manufacture of cast steel barrier railing posts, the properties of the cast steel and the testing procedures required.

Cast steel for railing posts and sleeves shall conform to the requirements of AS 2074.

675.02MATERIALS SPECIFICATION

Cast steel with minimum yield stress of 245 MPa shall conform to AS 2074 Grade C4 1.

Cast steel with minimum yield stress of 340 MPa shall conform to AS 2074 Grade L1A.

Technical requirements for steel castings shall comply with AS 4738.1.

675.03HEAT TREATMENT

All castings shall be heat treated in accordance with Clause 2.3.2 of AS 2074.

675.04SHAPE AND TOLERANCES

The castings shall be made to the shape and dimensions shown on the drawings and within the tolerances specified:

thickness of members+2 mm / 0 mm

diameter of holes+2 mm / 0 mm

overall dimensions+2 mm / 0 mm

flatness of base2 mm maximum on convex surface

(measured along all edges and diagonals of base plan area)

The web centreline shall not be out of square with the plane of the base by more than 1 mm per 100 mm height of the web.

The recess for the rail shall not be out of parallel with the plane of the base by more than 1 mm per 100 mm width of the base.

All edges shall be smooth, true and rounded to 2 mm radius.

675.05IDENTIFICATION MARKS

Each casting shall be legibly marked, with a number or identification mark by which it can be traced to the cast and heat treatment batch from which it was made. All test samples, made in accordance with AS 2074, shall be similarly marked.

675.06ACCEPTANCE OF SURFACE FINISH QUALITY BY VISUAL INSPECTION

Steel castings shall be visually inspected by the Contractor in accordance with AS 3978 Non destructive testing - Visual inspection of metal products and components.


The texture and surface finish of all castings shall not exceed the following maximum levels of acceptable defect:

Surface Feature / Maximum acceptable level 1 / Source of acceptance criteria 2
Surface texture / Level I : A1 / ASTM A802/A802M - 95
Non metallic inclusions / Level I : B1 / ASTM A802/A802M - 95
Gas porosity / Level I : C2 / ASTM A802/A802M - 95
Metal removal marks
Thermal
Mechanical
Welds / Level I : G1
Level I : H1
Level I : J1 / ASTM A802/A802M - 95
Hot tears and cracks / None acceptable / MSS SP 55:2011
Shrinkage / Better than reference photograph a (Type II) / MSS SP 55:2011
Veining / Better than reference photograph a (Type V) / MSS SP 55:2011
Rat Tails / Better than reference photograph a (Type VI) / MSS SP 55:2011
Wrinkles, Laps, Folds and Coldshuts / Better than reference photograph a (Type VII) / MSS SP 55:2011
Scabs / Better than reference photograph a (Type IX) / MSS SP 55:2011
Chaplets / Better than reference photograph a (Type X) / MSS SP 55:2011

Note 1:The maximum acceptable levels are consistent with surface discontinuity comparators for a reduced discontinuity size, as described in AS 4738.1 (Appendix F).

Note 2:Sources of acceptance criteria are as follows:

●ASTM A802/A802M - 95 Standard Practice for Steel Castings, Surface Acceptance Standards, Visual Inspection, ASTM (2006)

●MSS SP 55:2011 Quality Standard for Steel Castings for Valves, Flanges and Fittings and Other Piping Components, - Visual Method for Evaluation of Surface Irregularities, Manufacturers Standardisation Society

675.07WORKMANSHIP

Where the maximum levels of acceptable defects as given in Clause 675.06 are exceeded, the defects in the castings shall be rectified. Where appropriate, castings may be welded in accordance with the requirements of AS 1988.1 Welding of ferrous castings - Steel castings. After welding, all weld repaired castings shall be given a stress relieving heat treatment.

675.08TESTING AND TEST CERTIFICATES

Testing for chemical composition and tensile properties shall be carried out for each cast or heat treatment batch. Charpy V-notch impact testing shall be carried out for the first batch cast, and then for at least every third batch. The Charpy impact average value, for testing of three specimens, shall be not less than the value nominated in AS 2074 for the relevant grade.

Test certificates which demonstrate compliance of the steel with chemical composition and mechanical property requirements of AS 2074 Grade C4 1 or Grade L1A cast steel, and the results of visual inspection shall be submitted to the Superintendent.

675.09PROTECTIVE TREATMENT

All cast steel posts shall be coated in accordance with the drawings and specification.