Installation Manual. DUO-GATE double. Containment level H2-W3-C in acc. with DIN EN

Transcription

1 Installation Manual DUO-GATE double mechanical operation Containment level H2-W3-C in acc. with DIN EN Read through this installation manual precisely before starting assembly! The restraint system DUO-GATE double serves as an opening of the median strip and can be used as emergency opening for fire brigades and rescue workers. Die DUO-GATE double is intended for installation at public roads in accordance with the national regulations. Stand page 1 of 11

2 Installation Manual DUO-GATE double Content Page 1. General Storage and transport Foundation System assembly Bolting Transitions Implementing / Preparations Briefing 9 9. Release for traffic Operating instructions Training Auxiliary equipment Durability Repairing, inspection and maintenance Reusability of parts.. 11 Stand page 2 of 11

3 1. General National regulations must be observed, e.g. occupational safety, dangerous goods, load securing, securing of construction sites, etc. In Germany the regulation Richtlinien zur Sicherung von Arbeitsstellen (RSA) or corresponding instructions of the principal apply. In order to achieve the performance declared in the crash test reports, the following requirements must be fulfilled during installation and assembly. A deviation of these requirements without consulting the manufacturer means that the liability for defects is transferred from the manufacturer to the assembly operator. The securing of traffic and construction site must be arranged in accordance with the requirements of the principal and coordinated with the scheduled process of unloading prior to the delivery of DUO-GATE double. The responsible installation teams must comply with the following qualifications: min. 1 locksmith (skilled worker) with hydraulic expert knowledge If you are experienced with the system, 1 working day with 3 installers can be planned. If it is the first installation we recommend to plan with 2 working days. The installation must be accompanied by the manufacturer or a person authorized by the manufacturer. An installation in Germany is independent from the ambient temperature during this time. In regions with a minimal outside air temperature Tmin in acc. with EN /NA under -24 C, installation may be carried out only with the written confirmation of the manufacturer. For an effective installation we recommend the following equipment and tools on site: 1. A crane to lift the delivered maximum weights (a truck with a crane may be sufficient). 2. Installation vehicle with conventional equipment for the installation of machines (altimeter, wrenchs with sizes up to 75). 3. Drilling tools matching ground conditions in order to make the following holes: - Ø 28 mm, L = 400 mm 4. A ramming device, if DUO-GATE double shall be connected to steel restraint systems. 5. Threaded rods M24 L=350mm 8.8 DIN 975 and injection mortar HILTI HIT HY 200 for fixing the anchors on the existing foundations, as well as anchor and resin capsules for a potentially required connection to concrete restraint systems. Stand page 3 of 11

4 If the system is delivered in a container, the unloading must be carried out on a nearby storage area. Thus, delivery to the construction site can be made just in time then. We recommend checking the completeness of the delivery by dint of attached item lists and/or delivery notes. 2. Storage and transport The system DUO-GATE double is built modularly of DUO-RAIL elements with supplementary constructions. In order to optimize installation on site, the components are delivered in four preassembled units. The preassembled units are connected at the swivel-joints. The weight of the heaviest part is about 1500 kg. The delivery of the elements to the construction site should be carried out by a truck that is equipped with hoisting machine. Sling gear and suspension points are given by the manufacturer. All components must be stored and handled professionally. They must be protected from contamination, corrosion and damaging. 3. Foundation / Ground conditions Provided documentation: - Fundamentplan - Fundamentstatik - Detailzeichnung Klebeanker Building the foundation: Foundations respectively the anchorage of the gate on already existing foundations shall be carried out in accordance with the foundation plan and the corresponding static calculation. The setting time of the foundations depends on the concrete quality. In general we recommend keeping a setting time of 28 days. The designated location must be paved with concrete (foundation) and asphalt. The anchored, rigid elements of DUO-GATE double must be positioned on the concrete foundations. Only under the movable part of Duo Gate double may be the asphalt track bed. The asphalt must comply with the load capacity of the road surface. Make sure that the installation site is free of impurities. Local conditions concerning longitudinal or cross inclination, torsion of the central reserve, unevenness, connection to concrete, drainage, expansion joints or other obstacles within the operational area of DUO-GATE double must be agreed with the manufacturer during the order process and prior to installation. Stand page 4 of 11

5 Enquiries about supply lines (cables, pipes, lines) shall be made prior to the start of work. The cable protection instructions of the supplier must be observed. In the event that DUO-GATE double is to be connected to a pile-driven steel restraint system, the installation manual of that system must be observed. An installation of DUO-GATE double in curved areas is not feasible. The central axis of all parts must fall in line in order to guarantee a proper opening and closing of the gate as well as to provide for the correct function of the lock. 4. System assembly Documentation: - Drawings of the single components - Assembly drawings for steel component and hydraulic components - Parts lists Prior to the start of installation, all relevant measurements mentioned in the planning documents shall be checked with the ones on site. If there are no deviations outside tolerances, the installation can start. DUO-GATE double is basically composed of 4 main construction groups. For a proper installation it is important that these construction groups are assembled in correct order. Passive element Aktive element 2 Aktive element 1 Passive element Stand page 5 of 11

6 The installation of DUO-GATE double is divided in 5 steps: 1. Mounting of the passive elements The passive elements are mounted on the concrete foundations. At this stage, the elements are not yet fixed with the chemical anchors. This is to be carried out after the proper adjustment of the opening point s locking mechanism. 2. During the second step, the active element 2 is to be slidden into the passive element and set up flat on the ground. Prior to sliding the active element 2 into the hinge of the passive element, the bearing plates must be inserted on both sides. (left picture) Hinge with inserted bearing plates Passive element and active element 2 connected and rotating axis secured When the active element 2 has been inserted into the fixed bearing, the rotating axis must be mounted and secured with the rotary protection and the corresponding bolts. (right picture) After the second step, the first passive element and active element 2 are connected. 3. The third step is the same as step 2. The active element 1 must be connected with the other passive element. As well, this is to be done with the rotating axis and rotary protection with the corresponding bolts. (pictures step 2) 4. Now that the main components are connected with each other, the distance within the locking must be adjusted. This depends on the outside temperature and must be adjusted individually. X The left picture shows the closed but not yet locked gate. The distance X must be ca. 15mm within an outside temperature range of 5-40 C Stand page 6 of 11

7 The left picture shows the closed and locked gate. At this stage it must be checked if the locking bolt can be pushed back and forth without canting. 5. The last step for the time being is to drill the holes in the foundation through the locating holes at the foot of both passive elements. The nuts on the threaded rods must be tightened only after the complete setting time of the adhesive. The specifications of the adhesive manufacturer concerning setting time are binding. The depth of the hole shall be ca. 350mm. The threaded rod must be glued in the hole with at least 350mm. Attention: The gate may not be opened before the adhesive is entirely hardened. In the event of a one-sided connection to an existing construction (e.g. concrete wall or tunnel portal) the installation shall begin at this place. Please note: The orientation clearly refers to a driving direction as shown in the drawings provided by the manufacturer. If project drawings and location do not correspond with each other, the manufacturer is to be contacted prior to installation. In the event of a connection on both sides (e.g. between concrete wall and tunnel portal or concrete wall) the processes depend on the chosen solution. (see para. 6. Transitions) 5. Bolting - Bolting must be carried out professionally - Used bolting may not be utilized Bolting torque - Bolting must be hot-dip galvanized or stainless steel, electrolytically galvanized bolts may not be used - The instructions of the manufacturer for anchors and adhesive must be observed Stand page 7 of 11

8 Bolt size Quality min. tightening torque max. tightening torque M hand-tight 5 Nm M hand-tight 10 Nm M hand-tight 22 Nm M hand-tight 48 Nm M Nm 140 Nm M Nm 140 Nm Threaded rod M Nm 200 Nm 6. Transitions DUO-GATE double can be connected to steel restraint systems or, by a connection cap, to a concrete wall. In any case, the connection must be carried out professionally and adjusted to the situation on site. In case of doubt, the manufacturer t be consulted. If chemical anchors are used, the mounting instructions of the manufacturer must be followed consequently. The mounting must only be carried out by trained staff. In genereal the following guidelines shall be observed: The depth of the hole (=anchoring depth) must be kept. The threaded rod may not be shortened due to potential obstacles. Edge and joint distances must be kept. The hole must be blown at least 4x with a hand pump or oil-free compressed air (ISO , Tab. 7.3, oil class 4, < 5mg/m³) and potentially existing water must be removed completely. The minimum waiting times until assembly must be kept subject to the temperature of the ground in accordance with mounting instructions of the anchor manufacturer. The screwed portion of the threaded rod may not protrude the nut by more than 15mm. 7. Implementing / Preparations Documentation: - Hydraulic plan The supplied hydraulic hoses shall be connected to the corresponding junctions of cylinder and hand pump as shown in the hydraulic plan. Only after having checked the proper connection of the supply lines, both tanks in the passive elements shall be filled with hydraulic fluid. These steps are only required if the gate is not delivered preassembled to the site due to a different agreement with the manufacturer concerning the delivery status. The locking device at the opening point shall be tested for correct closing. After activation of the opening mechanism (e.g. by a small ax) the cover plate shall be opened. Pic.: closed cover plate Stand page 8 of 11

9 Afterwards, the bolt within the construction shall be pulled out as far as it will go to the right. Otherwise the active element can not be lifted. Pic.: drawn-in bolt (arrow shows moving direction) As long as the bolt is pulled out, the cover plate can not be closed. This is only possible if the bolt is drawnin again. Pic.: pulled out bolt If the construction is properly locked, the bolt shall be drawn-in again and the cover plate shall be closed. Pic.: cover plate closed by small ax 8. Briefing Documentation: - Acceptance form - Check list During the briefing, the responsible mounting team shall demonstrate the proper functionality to the customer and the required steps in order to open and close the DUO-GATE double. By filling in and signing the acceptance form and check list the handover of DUO-GATE double is completed. Stand page 9 of 11

10 9. Release for traffic Concerning the release for traffic respectively the leaving oft he construction site it must be secured that all the bolting has been tightened with the corresponding torque. Redundant bolts or connection parts are to be removed. The construction site must be cleared. The self-monitoring report for DUO-GATE double shall be filled in and signed. It shall be provided to the customer if requested. 10. Operating instructions The operating instructions of DUO-GATE double shall be handed over to the customer prior to the acceptance. 11. Training We recommend a training of the local rescue service and fire departments on site. 12. Auxiliary equipment The attachement of auxiliary equipment (e.g. glare shield) requires the written confirmation of the manufacturer. 13. Durability Results obtained from scientific analyses have established that the corrosive stress on galvanized coatings by the atmosphere has reduced considerably in recent years. The consequence of this is a substantially longer period of protection provided by such galvanized coatings. The guardrail parts must be classified in the corrosion class C4 in accordance with ISO This means an average erosion of the galvanized coating of 2.0 to 4.0 µm/year. Hotdip galvanization guarantees a corrosion protection of more than 20 years for steel guardrails Corrosivity Class Type of Exposure to Ø Zinc abrasion as per ISO 9223 atmosphere corrosion per year C1 indoor; dry very low < 0,1 µm/year C2 indoor; occasional condensate formation low 0,1 to 1,0 outdoor; rural atmosphere µm/year C3 indoor; high humidity, average clime average 1,0 to 2,0 outdoor; industry or urban clime, coastal clime µm/year with low salt content C4 indoor; swimming pools, chemical plants high 2,0 to 4,0 outdoor; industry clime, coastal clime with high salt content µm/year Our products are galvanized in galvanizing plants that have been certified in general and approved by us in accordance with DIN EN ISO Stand page 10 of 11

11 Regarding the regulations for the coating thicknesses, as a member in the registered association of quality manufacturers of steel crash barrier systems, we align ourselves with the current RAL-RG 620, according to which batch-galvanized RAL parts with 3 mm nominal thickness must continue to have a galvanized coating thickness of 70 µm, as compared to the requested 55 µm specified in DIN EN ISO Repairing, inspection and maintenance All works must be carried out in accordance with the corresponding accident prevention regulations. Prior to any repairs and disassembly the gate must be closed and the mounted hydraulic components without pressure and locked. Generally, all components with a permanent (plastic) deformation shall be exchanged. If damaged parts are exchanged, there must be careful attention in the transitional area to the undamaged parts. After the disassembly, the remaining parts may not be damaged by using an angle grinder, pin tap or hammer. If DUO-GATE double is installed or repaired on roads that are already under traffic, the construction site must be secured. The hydraulic supply lines must be controlled by visual inspection once a year. Further on we recommend, as for all safety-relevant devices, an annual functional test. Within the framework of this test (preferably after the winter period), existing pollutant and salt residues should be removed 15. Reusability of parts Components of DUO-GATE double may be reused in case of reconstruction and /or modification if: - the components do not show any visible deformations and/or damages (e.g. torn or burnt out holes), - the construction parts still have a zinc thickness of at least 15 μm, - the manufacturer s label and the label of the inspection period are still clearly identifiable. Used fixing materials (Bolts, nuts, washers, anchor pins)schrauben, Muttern, Scheiben, Erdnägel) may not be used again. New materials must always be used, also in case of repairs of accidental damages. Construction parts that can not be reused shall be dismantled, e.g. by cutting off parts or fragmentation. They shall be disposed together with the dismounted fixing materials. Stand page 11 of 11