AASHTO M 306-2010 Standard Specification for Drainage Sewer Utility and Related Castings.pdf

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1、Standard Specification for Drainage, Sewer, Utility, and Related Castings AASHTO Designation: M 306-10 (2015) American Association of State Highway and Transportation Officials 444 North Capitol Street N.W., Suite 249 Washington, D.C. 20001 TS-4h M 306-1 AASHTO Standard Specification for Drainage, S

2、ewer, Utility, and Related Castings AASHTO Designation: M 306-10 (2015) 1. SCOPE 1.1. This specification is applicable to frames, grates, rings, and covers for inlets, manholes, and other structures for civil engineering use where items may be placed in traffic service and load bearing is a consider

3、ation. 1.2. The values stated in SI units are to be regarded as the standard. 2. REFERENCED DOCUMENTS 2.1. AASHTO Standards: M 105, Gray Iron Castings AASHTO LRFD Bridge Design Specifications, Sixth Edition 2.2. ASTM Standards: A48/A48M, Standard Specification for Gray Iron Castings A536, Standard S

4、pecification for Ductile Iron Castings A644, Standard Terminology Relating to Iron Castings 2.3. Federal Specification: CID A-A-60005, Frames, Covers, Gratings, Steps, Sump and Catch Basin Manhole 3. TERMINOLOGY 3.1. Definitions of Terms Specific to This Standard: 3.1.1. manufacturera producing foun

5、dry/facility where iron is melted and poured into molds. 3.1.2. supplieran agent, representative, or organization that provides castings that it did not manufacture. 3.1.3. purchaserthe end user of the casting. 3.2. The preceding terms and definitions are specific to this specification. ASTM A644 co

6、ntains other terms and definitions relating to gray iron castings. 4. MATERIALS 4.1. Gray iron castings shall conform to the requirements of M 105 Class 35B or ASTM A48/A48M Class 35B. 2015 by the American Association of State Highway and Transportation Officials.All rights reserved. Duplication is

7、a violation of applicable law.TS-4h M 306-2 AASHTO 4.2. Ductile iron castings shall conform to the requirements of ASTM A536 Grade 80-55-06, unless otherwise specified by the customer. 5. MANUFACTURE 5.1. Castings shall be manufactured true to pattern and component parts shall fit together in a sati

8、sfactory manner. They shall be smooth and well cleaned by shotblasting. Circular manhole frames, covers, and grates shall be furnished with machined horizontal bearing surfaces unless otherwise specified. All square and rectangular units shall be furnished with an as-cast bearing surface unless othe

9、rwise specified. 5.2. Permissible Variations: 5.2.1. As-cast dimensions may vary one half the maximum shrinkage possessed by the metal or 5.21 mm/m 1/16in./ft. 5.2.2. Mass weight 5 percent drawing/specification mass weight. 5.3. Performance and Other Requirements: 5.3.1. The cover or grate shall not

10、 rock when rotated to any position in the frame. 5.3.2. The cover or grate shall sit down into the frame so that the top surface of the cover or grate will be flush with the top surface of the frame. The difference in the level between the cover or grate shall not exceed 3.2 mm 1/8in. at any point w

11、hen placed in the frame. The cover or grate shall not sit higher than 1.6 mm 1/16in. over more than one fourth of the circumference when placed in the frame. 5.3.3. Welding, PluggingNot allowed. 5.3.4. No PaintingUnless specified by the customer. 5.4. Quality and Appearance: 5.4.1. The finished cast

12、ing shall show careful finished workmanship in all particulars. Castings that have been damaged either during manufacture or shipping may be rejected. Among others, the following defects may be considered as constituting poor workmanship. 5.4.1.1. Defects, Major (items that may affect casting load b

13、earing ability)Casting could be rejected or require proof that the defect is not injurious. Examples of such defects include: shrinkage, cracks, cold shuts, large cavities, major porosity episodes, or major sand inclusions. 5.4.1.2. Defects, Minor (items that may affect top surface appearance)Castin

14、g could be reworked and resubmitted. Examples of such defects include: dirt, scab, slag, minor surface porosity, or minor sand inclusions. 6. PROOF-LOAD TESTING 6.1. For first article inspection or when specified for quality conformance inspection, the frames and covers or gratings shall show no det

15、rimental permanent deformation when a proof load of 178 kN 40,000 lb is concentrated on a 229-by-229-mm 9-by-9-in. area placed at the center of the cover or grate. To distribute the load evenly in testing, an intermediate layer of material (i.e., fiberboard, felt, rubber, etc.) can be placed between

16、 the test block and the casting to be tested. This layer shall 2015 by the American Association of State Highway and Transportation Officials.All rights reserved. Duplication is a violation of applicable law.TS-4h M 306-3 AASHTO not be larger than the area of the test block. The load shall be applie

17、d at a constant rate between 45 kg/sec and 454 kg/sec between 100 lb/sec and 1000 lb/sec. The castings shall be tested in a frame. If the product is not installed with a frame, or if proof-load testing in a frame is unfeasible, the cover or grate shall be supported in such a fashion as to simulate h

18、ow an item would be supported following installation. The specified load shall be applied and held for a period of 1 min by a suitable testing machine. Upon removal of the load, the cover or grating and frame shall be examined for cracks or detrimental permanent deformation. Permanent deformation sh

19、all not exceed 3.2 mm 1/8in. Any cracks shall be cause for rejection. Any permanent deformation that exceeds 3.2 mm 1/8in. shall be cause for rejection. All testing shall occur in the United States on a testing machine calibrated in accordance with and traceable to National Institute of Standards an

20、d Technology (NIST) standards. All castings that are subjected to the proof-load test shall be destroyed. For items that are smaller than a 229-by-229-mm 9-by-9-in. footprint, or where a 229-by-229-mm 9-by-9-in. footprint would transfer load directly to the frame, an alternate proof load test shall

21、be used. For H-20 or HS-20 loading, the applied load shall be the product of 3.39 MPa 494 psi multiplied by the area of the cover/grate, but not to exceed 178 kN 40,000 lb. For H-25 or HS-25 loading, the applied load shall be the product of 4.23 MPa 617 psi multiplied by the area of the cover/grate,

22、 but not to exceed 222 kN 50,000 lb. The footprint size shall not exceed 229 mm 9 in. in any direction and shall be smaller than the corresponding frame clear opening. Example 1: Given loading is H-20. Therefore, use 3.39 MPa 494 psi. Given cover diameter is 203 mm 8 in., which equates to a cover ar

23、ea of 0.0324 m250.3 in.2. Given frame has a clear opening of 152 mm 6 in. Therefore, the required loading is 0.0324 m2 50.3 in.2 multiplied by 3.39 MPa 494 psi, or 110 kN 24,850 lb. This value does not exceed the 178 kN 40,000 lb specified in the standard; therefore, it shall be the applied load. Th

24、e footprint size must be smaller than 152 mm 6 in. in diameter for the given frame clear opening. Example 2: Given loading is HS-25. Therefore, use 4.23 MPa 617 psi. Given grate size is 203 mm 8 in. wide and 610 mm 24 in. long, which equates to a grate area of 0.124 m2192 in.2. Given frame has a cle

25、ar opening of 152 mm 6 in. Therefore, the required loading is 0.124 m2192 in.2 multiplied by 4.23 MPa 617 psi, or 525 kN 118,465 lb. This value exceeds the maximum allowed load of 222 kN 50,000 lb. As a result, 222 kN 50,000 lb shall be the applied load. The footprint size shall be smaller than 152

26、mm 6 in. by 229 mm 9 in. Note that the footprint size cannot exceed 229 mm 9 in. in any direction; consequently, even though the length is 610 mm 24 in., the maximum value of 229 mm 9 in. is used. 6.2. The 178-kN 40,000-lb proof-load requirement listed in Sections 6.1 and 6.2 represents a safety fac

27、tor of 2.5 for H-20 or HS-20 loading. A 222-kN 50,000-lb proof load should be used in Sections 6.1 and 6.2, which represents a safety factor of 2.5 for H-25 or HS-25 loading. 6.3. Precision and BiasNo statement is made about the precision or the bias for the proof-load test method described in Secti

28、ons 6.1 and 6.2 for measuring the ultimate strength of the casting. The result merely states whether there is conformance to the criteria for success specified in the procedure outlined in Sections 6.1 and 6.2. 2015 by the American Association of State Highway and Transportation Officials.All rights

29、 reserved. Duplication is a violation of applicable law.TS-4h M 306-4 AASHTO 7. MATERIAL TESTING 7.1. Test bar testing shall be conducted in accordance with the applicable inspection requirements of Section 8. Test bar preparation and tensile testing shall be in accordance with the applicable materi

30、al specification listed in Section 4. Failure to meet the material specifications shall be cause for rejection. 8. INSPECTION 8.1. Unless otherwise specified in the contract or purchase order, the supplier/manufacturer shall be responsible for carrying out all the tests and inspections required by t

31、his specification, using purchaser approved reliable facilities, and he shall maintain complete records of all such tests and inspections. Such records shall be available for review by the purchaser. Three separate and alternative bases of acceptance are permitted: If the producing foundry is locate

32、d within the United States of America, and operates in accordance with an acceptable quality system approved by the purchaser, all castings must adhere to the inspection criteria listed in Sections 8.1.1 and 8.1.2. If the producing foundry is not located within the United States of America, or if th

33、e producing foundry is located within the United States of America and it is not operating in accordance with an acceptable quality system approved by the purchaser, all castings must adhere to the inspection criteria listed in Sections 8.1.1 and 8.1.3. 8.1.1. Acceptance on the Basis of Proof-Load T

34、estsAcceptability of the castings produced in accordance with this specification shall be determined by the results of the proof-load test as listed in Sections 6.1, 6.2, and 6.3. The producing foundry shall provide information about the ultimate strength of the castings to the purchaser upon reques

35、t. 8.1.2. Acceptance on the Basis of Separately Cast Test BarBefore supplying any castings to a purchaser, the manufacturer must first submit to the purchaser for acceptance documentation that a quality system is in place to ensure material compliance. Thereafter, acceptability of the castings produ

36、ced in accordance with this specification shall be by certification of the results of material tests conducted on separately cast test bars, and by inspection of the finished castings for freedom from defects. The manufacturer shall provide certification that the test bars furnished for testing repr

37、esent the castings furnished for the order. If there are more than three test-bar failures in one calendar year, the producing facility shall immediately report the three failing test results to the purchaser and shall discontinue supplying product. In order for the producing foundry to resume suppl

38、ying product, documentation that a new quality system is in place to ensure material compliance must be submitted to and accepted by the purchaser. The purchaser shall also have the option of allowing production under Section 8.1.3. 8.1.3. Acceptance on the Basis of Cast-On Test BarsA test bar for d

39、etermining the class of iron shall be cast on each member at a place where it can be easily broken off with a breakage pattern remaining on the member. Test bars are to be removed only after receipt of permission from the purchaser. Test bars shall be of sufficient size to produce a machined test sp

40、ecimen complying with the dimensional requirements for a Type B test bar as shown in Table 2 of M 105. For lots of 15 or fewer, 30 percent of the test bars selected at random from castings shall be tested by the supplier/manufacturer. For lots of 16 to 100, 10 percent or a minimum of 5 test bars, wh

41、ichever is greater, selected at random from castings shall be tested by the supplier/manufacturer. For lots greater than 100, a minimum of 10 percent of all test bars selected at random from castings shall be tested by the supplier/manufacturer. All test bars shall conform to the strength requiremen

42、ts specified. If any of those test bars fail to conform to the strength requirements herein specified because of surface or internal defects, additional testing shall be performed at the direction of the purchaser. For lots of 15 or fewer, all remaining test bars must be tested. For larger lots, an

43、additional 10 or 10 percent, whichever is greater, of the remaining test bars selected at random from the entire lot must be tested. All test results from this additional testing must conform to the 2015 by the American Association of State Highway and Transportation Officials.All rights reserved. D

44、uplication is a violation of applicable law.TS-4h M 306-5 AASHTO strength requirements of this specification for the lot of castings to be acceptable. Each casting that has a test bar removed from it and evaluated must be inspected for mass weight and dimensions by the supplier/manufacturer. If the

45、casting does not conform to the mass weight and dimensional requirements, the casting will be rejected. If a casting fails to conform to the mass weight or dimensional requirements, all remaining castings shall be inspected and all must conform to the requirements for the lot of castings to be accep

46、table. If the purchaser elects to select a casting for verification of test results, the member shall be furnished by the supplier/manufacturer at no cost to the purchaser. All test specimen preparation and testing shall be paid for by the supplier/manufacturer. 9. CERTIFICATION 9.1. All shipments t

47、o the purchaser shall include appropriate certification from the producing foundry. The certification shall state that the castings have been produced in facilities operating in accordance with the applicable laws and regulations of the United States and the appropriate state, province, or local uni

48、t of government. This certification shall also state that all samples representing each lot have been tested, inspected, and have been found to meet the requirements of this specification and the applicable AASHTO or ASTM material specifications listed in Section 4. Certifications shall also state c

49、ountry of origin of the castings. If specified in the order, a report of the test results shall be furnished. 10. MARKING 10.1. Each individual casting shall be identified by the foundry, showing the following: 10.1.1. Name of producing foundry and country of manufacture preceded by the words “Made in,” such as “Made in USA”; 10.1.2. AASHTO designation or ASTM designation number; 10.1.3. Class by a number followed by a letter indicating the minimum tensile strength