TL-2 Plastic Water Filled Barrier

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1 TL-2 Plastic Water Filled Barrier Product Manual ANOTHER AMORFLEX DEVELOPMENT

2 Table of contents Introduction 3 System overview 3 Before installation 3 Limitations and warnings 4 Safety statements 4 System design and design considerations 5 Parts identification 7 Bill of materials 7 Installation preparation 8 Installation instructions 9 Installation examples 12 Installation checklist 13 Maintenance and repair 14 Frequently asked questions 15 Crash test results summary 17 APPENDIX Technical Drawings Plan and elevation 18 Isometric end #1 19 Isometric end #2 20 Twin pin connector 21 Approval letter 22 Ph or visit January 2011 Page 2

3 Introduction TL-2 Plastic Water Filled Barrier made up of plastic units that when joined together using a steel connector and filled with water provide positive work zone barrier protection to temporary construction sites and other miscellaneous roadside activities. TL-2 Plastic Water Filled Barrier has been designed and tested to meet the evaluation criteria of NCHRP 350 Test Level 2 (TL-2) for a longitudinal barrier. When correctly installed it is capable of stopping, containing or redirecting an errant vehicle in a safe manner under NCHRP 350 impact conditions. TL-2 Plastic Water Filled Barrier is the world s first 100% polyethylene water filled barrier (no steel reinforcement) to have been judged to have satisfied the evaluation criteria of NCHRP 350 Test Level 2 (TL-2). The unique TL-2 Plastic Water Filled Barrier polyethylene composition, profile design and twin pin connector allow the barrier to be installed straight or down to a minimum radius of 28m if required. System overview TL-2 Plastic Water Filled Barrier is designed and constructed to provide acceptable structural adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 for longitudinal barriers. When impacted with an 820kg or 2000kg vehicle at speeds of up to 70kph and angles up to 25 degrees, the impacting vehicle is stopped, redirected or contained in a safe manner. Before installation Placement of TL-2 Plastic Water Filled Barrier shall be in accordance with the design as provided for the temporary work zone. Installation shall be in accordance with the installation instructions supplied for this product. Depending on the circumstances at the site, installation including the filling of a unit (using a truck mounted water tanker) should take no more than 1 minute for each 2.0m unit. TL-2 Plastic Water Filled Barrier is a highly engineered safety device made up of a relatively small number of parts. Before starting installation ensure that one is familiar with the make up of the system. Ph or visit January 2011 Page 3

4 Limitations and warnings Product Manual: TL-2 Plastic Water Filled Barrier TL-2 Plastic Water Filled Barrier has been rigorously tested and evaluated per the evaluation criteria in the NCHRP 350 guidelines for a longitudinal barrier. The impact conditions recommended in NCHRP 350 are intended to address typical in-service collisions. When properly installed and maintained TL-2 Plastic Water Filled Barrier allow an impacting vehicle to be stopped, contained or redirected in a safe and predictable manner under the NCHRP 350 impact conditions. Vehicle impacts that vary from the NCHRP 350 impact conditions described for longitudinal barriers may result in significantly different results than those experienced in testing. Vehicle impact characteristics different than, or in excess of, those encountered in NCHRP 350 testing (weight, speed and angle) may result in system performance that may not meet the NCHRP 350 evaluation criteria. TL-2 Plastic Water Filled Barrier can be installed with the ArmorZone End Treatment. If this treatment is not used then the end of the barrier must be shielded or flared as per NZTA requirements. Please contact CSP Pacific if you require further assistance. Safety statements General safety All required traffic safety precautions should be complied with. All workers should wear required safety clothing (high visibility vests, steel capped footwear, gloves etc.) Only authorised trained personnel should operate any machinery. Where overhead machinery is used, care must be taken to avoid any overhead hazards. Gloves should be worn at all times. Safety statements All installers must be well clear of the water tanker when the units are being filled. TL-2 Plastic Water Filled Barrier is a stand alone barrier and does not require at any stage during installation that the surrounding soil is dug or drilled in anyway. The empty units weigh 50kg each and should be unloaded by two personnel. Do not attempt to lift a unit which contains water. Final positioning of the empty units and placement of the steel connectors should be done by 1 personnel so as to remove the risk of hands and fingers being caught between the components. Ph or visit January 2011 Page 4

5 System design and design considerations Slopes A maximum slope of 1:10 is preferable. On slopes greater than this, follow the local road authorities guidelines. Kerbs As with all road side safety hardware, TL-2 Plastic Water Filled Barrier has been designed and tested so that the centre of gravity of the impacting vehicle is at a constant height in relation to the barrier. For this reason, it is preferred that kerbs or channels are not in front or behind the barrier as they will result in altering the height of the vehicle at impact. If there is no option but to install in front or behind of a kerb advice should be followed from the local authorities guidelines. Undulating ground conditions Site specific grading may be necessary to ensure that there are no humps or hollows that may significantly alter the impacting vehicles stability or substantially alter the barrier height in relation to the ground. Median and roadside applications TL-2 Plastic Water Filled Barrier can be used in both roadside and median applications. Length of need The length of need (LoN) of TL-2 Plastic Water Filled Barrier is 14m. Ensure that when installing the barrier that it is of sufficient length. For further details consult the local authority guidelines. Ph or visit January 2011 Page 5

6 Terminal end treatments TL-2 Plastic Water Filled Barrier is a free standing plastic barrier that if terminated inside the clear zone will require either an ArmorZone End Treatment fitted or the end of the barrier shielded or flared as per NZTA requirements. Soil conditions TL-2 Plastic Water Filled Barrier is installed above ground so soil conditions on site are not applicable. However it is recommended TL-2 Plastic Water Filled Barrier is installed on a compacted surface. Deflection Test kg pickup truck, 25 degree angle at 70kph Dynamic deflection Permanent deflection Working width 2.10m 2.10m 2.10m Test kg car, 20 degree angle at 70kph 1.05m 1.05m 1.05m Note: Results are from actual crash testing and the test article length was 50m. Results from Test 2-11 are the published TL-2 Deflection. Ph or visit January 2011 Page 6

7 Parts indentification Product Manual: TL-2 Plastic Water Filled Barrier 2.0m TL-2 Plastic Filled Barrier unit Twin Pin connector (100% polyethylene) (hot dipped galvanised) Bill of materials For every 2.0m (linear) of temporary barrier the following components are required: 2.0m TL-2 Plastic Water Filled Barrier unit 1 required Twin Pin steel connector 1 required Water 560 litres required Ph or visit January 2011 Page 7

8 Installation preparation Getting started Product Manual: TL-2 Plastic Water Filled Barrier It is essential that TL-2 Plastic Water Filled Barrier is installed correctly. Please carefully read and understand the following instructions before installing. Note: These instructions relate only to the installation of TL-2 Plastic Water Filled Barrier and are for standard installations only. TL-2 Plastic Water Filled Barrier is designed so that it has exactly the same components and barrier setup whether in a roadside or median application. For all installations, start at one end and connect the units together until the correct barrier length and position is achieved. Preparation Before installing TL-2 Plastic Water Filled Barrier, ensure that all components required for the system are on site and have been identified. TL-2 Plastic Water Filled Barrier are a highly engineered safety device made up of relatively small number of parts. Before starting installation ensure that one is familiar with the make up of the system. Refer to the Parts identification and Bill of materials section in this manual for more information. Ensure that the area where TL-2 Plastic Water Filled Barrier is to be installed is flat enough and compacted so that the ground conditions will not significantly alter the height of the vehicle in relation to the height of the barrier. Minor site grading may be required. Tools required There are no tools required to install the components of TL-2 Plastic Water Filled Barrier. The plastic units can be manually lifted and positioned by 2 personnel and the twin pin used to connect the units is simply dropped into position. Each unit requires approx 560L of water and it is recommended that a large truck mounted tanker is sourced for fast barrier construction. A hose of up to 100mm in diameter can be used to fill the units. Ph or visit January 2011 Page 8

9 Installation instructions Standard installation Step 1 Site preparation Product Manual: TL-2 Plastic Water Filled Barrier It is preferred that TL-2 Plastic Water Filled Barrier is installed on compacted flat, level ground. Ensure that sufficient width and traffic control is available before installing TL-2 Plastic Water Filled Barrier. Due to the bulky nature of the units, deployment will be from a flat deck truck or similar. Each unit requires 560L of water and it is recommended that a large truck mounted tanker is used. TL-2 Plastic Water Filled Barrier should be installed in a tangent position to the direction of travel. TL-2 Plastic Water Filled Barrier units are dispatched in stacks of 15 with a unique triple strapped configuration to ensure safe unloading of each different tier. (Shown in figure 1) Using a fork hoist or similar the rows of 5 units can be lowered to ground level and from there manually moved into position. (Shown in figure 2). Figure 1 Figure 2 Ph or visit January 2011 Page 9

10 Step 2 Placement of the barrier units Unload the units and set out in a row along the intended barrier position. Make sure the configuration of the ends will fit together where they join. (shown in Figure 3) Lifting the units is a 2 person job; they weigh 50kg each when empty. Slide the units into position. (Shown in figure 4). The units must fit flush together so that the vertical holes on each unit line up. (Shown in figure 5 & 6). Note: None of the units are fixed to the ground in any way. Figure 5 Figure 6 Ph or visit January 2011 Page 10

11 Step 3 Connecting the barrier units Once the units are flush fit aligned, the twin pin connector can be positioned down the 2 vertical alignment holes. (Shown in figure 7 & 8). The connector sits in the vertical holes under its own weight only and is not connected to the barrier units in any other way. Note: If slight curvature of the barrier is required, position as required at this point. Figure 7 Figure 8 Step 4 Filling the barrier units Lifting the flap on the top of the unit will allow access to the 125mm diameter Water Fill Hole. (Shown in figure 9). Using a truck mounted tanker fill each unit to the top with water. (Shown in figure 10). Check that there are no leaks before filling the next unit. If there is a leak the unit must be replaced. It may be possible to fix at a later stage depending on the damage. Figure 9 Figure 10 Ph or visit January 2011 Page 11

12 Installation examples Product Manual: TL-2 Plastic Water Filled Barrier TL-2 Plastic Water Filled Barrier Standard installation (straight) TL-2 Plastic Water Filled Barrier Standard Installation (curved) Note: A minimum 28m radius curvature can be achieved when the flush fit connection is made between TL-2 Plastic Water Filled Barrier units. This positioning should be done before the units are filled with water. Ph or visit January 2011 Page 12

13 TL-2 Plastic Water Filled Barrier Installation Y/N Y/N The units are positioned on level ground. The set-out of the barrier is as per the design instructions. The lugs of each unit have a flush fit with each other and the twin pin steel connector is positioned through both vertical holes in the lugs of each unit. The lid and bung are attached to each unit correctly so as to ensure the units will remain full of water as intended. Each unit is filled to the top with water. (approx 560L) Check for leaks. The barrier is not fixed to the ground or any other device in any way. The end of the barrier is installed with an AmorZone End Treatment or shielded/flared as per NZTA requirements. Location: Installed by: Inspected by: Date: Date: For more information contact CSP Pacific on Ph or visit Installation Checklist January

14 Maintenance and repair Maintenance Product Manual: TL-2 Plastic Water Filled Barrier TL-2 Plastic Water Filled Barrier is maintenance free. Although it is recommended that inspections are carried out on barriers that are installed for long periods of time. Each unit has a lid and filter assembly to ensure that the barrier is only filled with water. However, in extreme conditions it may be possible for evaporation to take place and it is important that the units remain full. Repair After a typical impact Recommended tools: Flat deck truck A truck mounted water tanker A crow bar or similar Replacement parts required for a severe impact: TL-2 Plastic Water Filled Barrier units Steel Twin Pin connectors 560l of water for each unit Key steps: Separate the damaged components by removing the steel connector. Drain any units that are partially damaged. Assess which components are damaged and replace with new parts accordingly. Connect replacement units to the undamaged section of the barrier and align as required. Fit the replacement steel connectors between each unit. Fill all the units with water. For further information consult TL-2 Plastic Water Filled Barrier - Installation Instructions section in this Product Manual. After fire damage TL-2 Plastic Water Filled Barrier is made of polyethylene and joined together using steel connectors. It is possible that under extreme conditions, like Australian bushfires, that the components of the system can be damaged. If this is the case replace the components as described above and as outlined in TL-2 Plastic Water Filled Barrier Installation Instructions. Ph or visit January 2011 Page 14

15 Frequently asked questions Product Manual: TL-2 Plastic Water Filled Barrier 1) What type of equipment is required to install TL-2 Plastic Water Filled Barrier? The units are 50kg each when empty so can be unloaded and positioned by hand by 2 personnel. To connect the units together a steel connector is used and again fitted manually. Each unit requires approx 560L of water so it is recommended that a truck mounted water tanker is available. 2) Does your company provide spare parts? What is the lead-time for supply? It is important to fix a damaged barrier as soon as possible because it most probably won t perform as required when damaged. Replacement components are available from CSP Pacific and can be available between 1 and 3 working days. 3) On average, how long does it take to install a TL-2 Plastic Water Filled Barrier? Depending on the application and circumstances at the site, installation and assembly of the system should take a 2 person crew approx. 1 hour to install a 120m section. 4) What about vandalism, can TL-2 Plastic Water Filled Barrier be easily damaged? The units are constructed using a very strong polyethylene and would not easily be damaged. The construction is similar to other water filled barriers and this is not considered an issue. 5) How easily can TL-2 Plastic Water Filled Barrier be restored after impact? The system is made up of very few components and is a modular so easily repaired. A flat deck truck, crow bar and water tanker will be required to reinstate. 6) What maintenance does TL-2 Plastic Water Filled Barrier require? TL-2 Plastic Water Filled Barrier barrier is maintenance free barrier. For barriers installed for long periods of time and in extreme conditions, cyclic checks may be required to check that the units remain full of water. 7) What is the deflection of TL-2 Plastic Water Filled Barrier? The maximum deflection recorded during actual crash testing at TL-2 was 2.1m. 8) What is TL-2 Plastic Water Filled Barrier connected to? TL-2 Plastic Water Filled Barrier is a free standing system and neither anchored or connected to other systems. 9) Is the performance of TL-2 Plastic Water Filled Barrier jeopardised when the water is frozen? Testing on the TL-2 Plastic Water Filled Barrier has been carried out only with water in a liquid state and CSP Pacific believe the performance of the barrier may not be as intended if the water freezes. If conditions are below zero degrees the following additives will reduce the temperature at which the barrier will freeze. For percentages required, cost, environmental impact and reduced temperature consultation will be required with a third party. Sodium Chloride, Calcium Chloride, Ethylene/Propylene Glycol, Liquid CMA and Liquid Potassium Acetate. Ph or visit January 2011 Page 15

16 Note: There is no internal steel in TL-2 Plastic Water Filled Barrier so if used corrosion is not an issue. 10) Can TL-2 Plastic Water Filled Barrier units be moved when full? It is possible and extreme care must be taken, a full unit weighs 610kg. Each unit is equipped with fork hoist holes through the barrier and must be used with the appropriate machinery and safety equipment. Ph or visit January 2011 Page 16

17 Crash test results summary Product Manual: TL-2 Plastic Water Filled Barrier A total of 2 official crash tests where completed on the TL-2 Plastic Water Filled Barrier to NCHRP 350 Test 2-10 Test Article TL-2 Plastic Water Filled Barrier (length 50mm) Post Spacing n/a Test Vehicle. Speed Impact Angle 820 kg Car (820C) 70 kph 20 deg Test 2-11 Test Article TL-2 Plastic Water Filled Barrier (length 50mm) Post Spacing n/a Test Vehicle. Speed Impact Angle 2000 kg Car (2000P) 70 kph 25 deg For both tests the vehicles where safely redirected by the TL-2 Plastic Water Filled Barrier. The vehicles did not penetrate, underride or override the test installations. The test article was judged to have satisfied the requirements of NCHRP Report 350 criteria TL-2. Ph or visit January 2011 Page 17

18 Appendix Technical drawings Plan and elevation Ph or visit January 2011 Page 18

19 Isomeric end #1 Ph or visit January 2011 Page 19

20 Isomeric end # 2 Ph or visit January 2011 Page 20

21 Twin Pin steel connector Ph or visit January 2011 Page 21

22 July 2010 Interim Acceptance for Safety Barrier Product Product: Armorflex P2 TL-2 Plastic Barrier Safety Barrier - Temporary Expiry Date: 30 June 2011 The Armorflex P2 TL-2 plastic barrier system has been tested in accordance with NCHRP Report 350 and is deemed to comply with the required evaluation criteria for Test Level 2 (TL-2). Pending further updates to the NZTA s M23 Specification for Roads Safety Barrier Systems, the Armorflex P2 system is granted interim acceptance by the New Zealand Transport Agency for use on the state highway network, with the following conditions: Product Identification Conditions of Use The Armorflex P2 temporary barrier system must be installed and maintained in accordance with the product installation/maintenance manual and relevant NZTA specifications. NZTA specifications and standards shall prevail where there is discrepancy between the product manual(s) and the NZTA specifications and standards. Installers must ensure that they are familiar with relevant conditions, requirements and limitations of the system, particularly with regard to the appropriate length of need, minimum installation length and test deflection. Vehicle impacts that vary from the NCHRP Report 350 impact conditions may result in significantly different results than those experienced in testing.

23 The Armorflex P2 temporary barrier system has been evaluated in accordance with the Test Level 2 criteria presented in NCHRP Report 350 under the following test conditions: 820kg small car impacting at an angle of 20º and a nominal speed of 70kph; 2,000kg pick-up truck impacting at an angle of 25º and a nominal speed of 70kph. Units MUST be connected with the appropriate steel connecting pin and filled with water when in use. Since there is currently no crashworthy terminal for the Armorflex P2, its ends should be flared away from approaching traffic or adequately shielded. A copy of this Interim Acceptance Letter must be appended to the Installation Manual. Expiry of Acceptance This acceptance expires on 30 June 2011 and replaces any previous acceptance. New installations of the Armorflex P2 must not be deployed on the state highway network after the expiry date of acceptance unless a further period of acceptance is granted or the product has been formally included in the M23 Specification for Roads Safety Barrier Systems, in which case the M23 specification would replace this interim acceptance. The New Zealand Transport Agency reserves the right to rescind or modify, at any time, acceptance of the Armorflex P2 temporary barrier system. Authorised by the National Traffic and Safety Manager 2

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