Nu-Guard 31. Roadside and Median Guardrail System. MASH TL-3 & NCHRP TL-4 Product & Installation Manual

Transcription

1 Nu-Guard 31 Roadside and Median Guardrail System MASH TL-3 & NCHRP TL-4 Product & Installation Manual Ph or visit April 15 / Page 1

2 Table of Contents NU-GUARD 31 Introduction System Overview Limitations and Warnings Before Installation Safety Statements... 4 Limited Warranty Geotechnical Warning Design Considerations.. 6 System Design... 7 Parts Identification.. 9 Installation Preparation Roadside Installation Instructions Median Installation Instructions Installation Examples.. 16 Installation Checklist Maintenance & Repair Frequently Asked Questions. 21 APPENDIX Technical Drawings NU-GUARD 31 W Beam Post (FX513) NU-GUARD 31 System Assembly (FX514) NU-GUARD 31 Median Assembly (FX525) NU-GUARD 31 Curved Terminal Installation (FX566-1).. 27 NU-GUARD 31 Rigid Barrier Transition (FX527-3).. 28 NU-GUARD 31 X-350 Ground Anchor (FX636).. 29 NU-GUARD 31 Transition to 27 High X-350 Timber Post (FX577) 30 NU-GUARD 31 Transition to 31 High X-350 (FX608). 31 NU-GUARD 31 Transition to Standard TL-4 Thrie-beam (FX609).. 32 NU-GUARD 31 Transition to Trailing End Terminal (FX611) 33 NU-GUARD 31 Transition to X-TENuator (FX606). 34 NU-GUARD 31 Median Transition to 31 High X-350 Median (FX607) 35 NU-GUARD 31 Thrie-beam TL-4 on Flange Based Posts (FX613) 36 NU-GUARD 31 Area of Reduced Deflection (FX614). 37 Ph or visit April 15 / Page 2

3 Introduction NU-GUARD 31 roadside is a w-beam guardrail barrier comprising of unique U shaped steel posts. The posts are driven, which allows for quick installation, and connect to w-beam guardrail panels on one side in the traditional manner at a height of 31 (787mm). The barrier has been designed and tested to meet the evaluation criteria of NCHRP 350 Test Level 4 (TL-4) & MASH (TL-3) for a longitudinal barrier. It is recommended that the roadside NU-GUARD 31 barrier is anchored using a single sided X-350 terminal end which is accepted to NCHRP 350 TL-3. System Overview NU-GUARD 31 roadside barrier is designed and constructed to provide acceptable structural adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 & MASH for longitudinal barriers. When impacted with an 820kg, 2270kg and 8000kg vehicle at speeds of up to 100kph and side on entry angles up to 25 degrees, the impacting vehicle is re-directed in a safe manner. Nu-Guard 31 Median Introduction NU-GUARD 31 median is a w-beam guardrail barrier comprising of unique U shaped steel posts. The posts are driven, which allows for quick installation, and connect to w-beam guardrail panels on both sides in the traditional manner at a height of 31 (787mm). The barrier has been designed and tested to meet the evaluation criteria of NCHRP 350 Test Level 4 (TL-4) & MASH (TL-3) for a longitudinal barrier. It is recommended that the median NU-GUARD 31 barrier is anchored using a X-350 Median terminal end or a X-TENuator crash cushion which is accepted to NCHRP 350 TL-3. System Overview NU-GUARD 31 median barrier is designed and constructed to provide acceptable structural adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 & MASH for longitudinal barriers. When impacted with an 820kg, 2270kg and 8000kg vehicle at speeds of up to 100kph and side on entry angles up to 25 degrees, the impacting vehicle is re-directed in a safe manner. Ph or visit April 15 / Page 3

4 Limitations and Warnings Installation Manual: Nu-Guard 31 Guardrail System NU-GUARD 31 barriers have been rigorously tested and evaluated per the evaluation criteria in the NCHRP 350 & MASH guidelines for longitudinal barriers. The impact conditions recommended in NCHRP 350 & MASH are intended to address typical in-service collisions. NU-GUARD 31 barriers allow an impacting vehicle to be re-directed in a safe and predictable manner under the NCHRP 350 & MASH impact conditions. It is imperative that the system is installed as per manufacturers specification. Vehicle impacts that vary from the NCHRP 350 & MASH 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 & MASH (weight, speed and angle) may result in system performance that may not meet these evaluation criteria s. Before Installation Design, selection and placement of NU-GUARD 31 must be in accordance with the Road Controlling Authority guidelines and the details shown in the construction drawings. Installation must be in accordance with the installation instructions supplied for this product. Note: Alternative installations techniques will need to be used if soil conditions on site do not meet the required level described in the manual. NU-GUARD 31 is a highly engineered safety device made up of a small number of parts. Before starting installation ensure that one is familiar with the make-up of the systems. Safety Statements General Safety All required traffic safety precautions should be complied with. All workers should wear required safety clothing (Examples, and not limited to, include: 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. Before installing the posts, always ensure that the area is clear of underground services. (The appropriate service providers may need to be contacted) NU-GUARD 31 Safety Statements All installers must be well clear of machinery when posts are being driven. The posts (15kg) and fixings are easily lifted and positioned by hand. While a highway rail panel (47kg approx.) should be moved and positioned by two personnel and care should be taken not to have fingers near the bolt holes while being manoeuvred. Ph or visit April 15 / Page 4

5 Limited Warranty Installation Manual: Nu-Guard 31 Guardrail System CSP Pacific has tested the impact performance of its barriers and crash cushion systems, and other highway safety hardware under controlled conditions. CSP PACIFIC does not represent nor warrant to the buyer (or any other person) that the Products and Parts as tested will necessarily avoid injury to persons or property. The use of the products and Parts is at the Buyer s sole risk. CSP PACIFIC EXPRESSLY DISCLAIMS ALL LIABILITY FOR CLAIMS OF ANY NATURE WHATSOEVER ARISING BY REASON OF DEATH OR PERSONAL INJURY OR DAMAGE TO PROPERTY RESULTING FROM ANY IMPACT, COLLISION OR HARMFUL CONTACT WITH OR USE OF THE PRODUCTS OR PARTS OR NEARBY HAZARDS OR OBJECTS BY ANY VEHICLE, OBJECTS OR PERSONS. CSP PACIFIC warrants solely that any product or component part manufactured by CSP PACIFIC will be free from defects in material or workmanship. THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER REPRESENTAIONS AND WARRANTIES NOT EXPRESSLY SET FORTH HEREIN, WHETHER EXPRESS OR IMPLIED BY OPERATION OF LAW OR OTHERWISE, INCLUDING BUT NOT LIMITED TO ANY IMPLIED REPRESENTATIONS OR WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE. CSP PACIFIC S LIABILITY UNDER THE FOREGOING WARRANTY IS EXPRESSLY LIMITED IN ALL RESPECTS AND AT AIL S SOLE ELECTION TO: A. THE REPLACEMENT FREE OF COST OF THE DEFECTIVE CSP PACIFIC PRODUCT OR PART SUPPLIED BY CSP PACIFIC ONLY (IN THE FORM AND THE TERMS ORIGINALLY SHIPPED). B. THE REPAIR OF THE DEFECTIVE CSP PACIFIC PRODUCT OR PART TO REMEDY ANY DEFECTS IN THE MATERIAL OR WORKMANSHIP. C. THE PAYMENT OF AN AMOUNT EQUAL TO THE ORIGINAL PURCHASE PRICE OF THE DEFECTIVE CSP PACIFIC PRODUCT OR PART. CSP PACIFIC SHALL NOT OTHERWISE BE LIABLE TO THE BUYER (OR ANY OTHER PARTY) FOR BREACH OF WARRANTY, NEGLIGENCE OR ANY OTHER RESPECT WHATSOEVER. WITHOUT LIMITATION, CSP PACIFIC SHALL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL LOSSES, DAMAGES OR EXPENSES OF ANY KIND, INCLUDING, WITHOUT LIMITATION, ANY SUCH LOSSES, DAMAGES OR EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM THE SALE, HANDLING OR USE OF THE PRODUCTS AND PARTS OR FROM ANY OTHER CAUSE RELATING THERETO, OR FROM PERSONAL INJURY OR LOSS OF PROFIT SUSTAINED IN RESPECT THEREOF. Any claim by the Buyer with reference to CSP PACIFIC Products or Parts sold hereunder for any cause shall be deemed waived by the Buyer unless CSP PACIFIC is notified in writing, in the case of defects apparent on visual inspection, within ninety (90) days from the delivery date, or, in the case of defects not apparent on visual inspection, within twelve (12) months from the delivery date. CSP PACIFIC Products and Parts claimed to be defective in material or workmanship under the foregoing warranty may be returned prepaid to CSP PACIFIC s plant for inspection in accordance with return shipping instructions that CSP PACIFIC shall furnish to the Buyer forthwith upon receipt of the Buyer s notice of claim. If the claim is established, CSP PACIFIC will reimburse that Buyer for all carriage costs incurred hereunder. The forgoing warranty benefits shall not apply to (i) any Products or Parts that have been subject to improper storage, accident, misuse or unauthorised alterations, or that have not been installed, operated and maintained in accordance with approved procedures and (ii) any Products or Parts manufactured or supplied by any party other than CSP PACIFIC (Including the Buyer). Geotechnical Warning NU-GUARD 31 posts require sufficient strength from the supporting soil to function as required and remain at the correct height. If it is determined that soil conditions on site do not meet these requirements, alternative installation options will need to considered. For further details contact CSP Pacific. Ph or visit April 15 / Page 5

6 Design Considerations Curves NU-GUARD 31 can accommodate curved w-beam guardrails panels like other guardrails systems if conditions on site require. For radii below 25m the Nu-Guard 31 must be anchored at the start and the end of the curve by using an intermediate anchor and/or a trailing terminal end. There should be no bolts holding the rail at the apex of the curve with the rail instead sitting on a shelf angle. For further details refer to drawings FX566-1 and FX636 in the appendix of this manual. Slopes A maximum slope of 1:10 is preferable. On slopes greater than this, follow the Road Controlling Authority guidelines. Curbs As with all road side safety hardware, NU-GUARD 31 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 curbs or channels are not installed in front of the barrier as they will result in altering the height of the vehicle at impact. If there is no option but to install a curb or if it is already present consult Road Controlling Authority guidelines re curb height and design, and barrier offset distance. 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. Ditches If the slope of the ditch is greater than 10:1 then follow the Road Controlling Authority s guidelines. Ph or visit April 15 / Page 6

7 System Design Roadside and Median Applications NU-GUARD 31 can be used in both roadside and median applications. The single sided system is to be used on the edge of road, while the back to back system, is required in a median situation. Terminal End Treatments It is recommended that NU-GUARD 31 systems are anchored using a X-350 Tangent or Flared, X-350 Median end terminals or X-TENuator crash cushions. For further information on these terminal ends and crash cushions contact CSP Pacific. Transitions To connect NU-GUARD 31 systems to other types of barriers or terminal ends consult the transition drawings contained in the Technical Drawing Appendix of this manual. If the situation is not covered in these drawings contact CSP Pacific for advice. Batter Hinge Point It is recommended that there is a minimum of 600mm of soil between the post and the batter hinge point. Note: For installations where there is less than 600mm or other issues are present, contact CSP Pacific. Length of Need (LoN) The Length of Need (LoN) of NU-GUARD 31 system is dependent on the terminal end used to anchor the barrier as all LoN s are contained within the terminal end itself. Note: As per the LoN design section of the Road Controlling Authority s guidelines, care must be taken when calculating the actual length of barrier versus the theoretical length of the LoN. NU-GUARD 31 when connected at either end to an X-350 end terminal creates a fully redirective barrier, and therefore the actual length of the barrier is the same as the theoretical length of the LoN. The use of other terminal ends may require addition length of barrier upstream and downstream of the LoN to achieve the same protection. Ph or visit April 15 / Page 7

8 Deflections Deflection measurements from actual crash testing can be useful when assessing a products suitability to perform as required at a given location. The below distance measurements are from NCHRP 350 and MASH compliance testing on the roadside and median systems respectively. Note: The MASH pickup truck has the highest impact severity of all the tests results below. TL-3 Deflection Results Test 3-11: 2270kg pickup truck, 25 degree angle at 100kph (MASH TL-3) Post Spacing Dynamic Deflection Permanent Deflection 1.905m 1.05m 0.80m Test 3-10: 820kg car, 20 degree angle at 100kph 1 (NCHRP 350 TL-3) Post Spacing Dynamic Deflection Permanent Deflection 1.905m 0.68m 0.39m 1 Test 3-10 was run on the back to back NU-GUARD 31 median system. TL-4 Deflection Results Test 4-12: 8000kg truck, 15 degree angle at 80kph (NCHRP 350 TL-4) Post Spacing Dynamic Deflection Permanent Deflection 1.905m 1.22m 0.80 Note: If tests 3-11 and 4-12 were run on the back to back NU-GUARD 31 median system, the deflection results would be expected to be lower than those listed above. Soil Conditions For NU-GUARD 31 to perform as intended and remain at the correct height it must be installed in soil conditions that have sufficient strength to support the posts as required. The ground conditions need to be able to withstand a push test of 1kN at 635mm above ground level. Soil conditions should meet the requirements of AS/NZS 3845:1999 and Specification TNZ M/ Ph or visit April 15 / Page 8

9 Parts Identification - Components Standard highway rail NU-GUARD 31 Post Splice (Guardrail) Bolts 90mm Diameter Washer M16x90mm Bolt & Nut M16x100mm Bolt, washer & Nut All NU-GUARD 31 steel components are hot dipped galvanised. Accessories Post Cap Protector (Plastic) Protective Driving Insert (Nylon) Ph or visit April 15 / Page 9

10 Bill of Materials Roadside Barrier Installation Manual: Nu-Guard 31 Guardrail System For every linear 3.81m of barrier the following components are required: Standard highway rail 1 required 1980mm NU-GUARD Post 2 required Splice Bolts 8 required 90mm Coach Bolt and Splice Bolt Nut 2 sets required 90mm Diameter Washer 2 required Median Barrier For every linear 3.81m of barrier the following components are required: Standard highway rail 2 required 1980mm NU-GUARD Post 2 required Splice Bolts 16 required 100mm Coach Bolt, round washer and Splice Bolt Nut 2 sets required 90mm Diameter Washer 4 required NB: Above descriptions are only for calculating total amount of components required. Ph or visit April 15 / Page 10

11 Installation Preparation Getting Started Installation Manual: Nu-Guard 31 Guardrail System NU-GUARD 31 barriers have virtually the same components and barrier setup for the roadside or median systems. For all installations, whether edge of road or median locations, start from the last post of the adjacent system. NU-GUARD 31 post spacing between the systems for a standard installation is 1.905m. Preparation Before installing NU-GUARD 31, ensure that all components required for the system are on site and have been identified. NU-GUARD 31 is a highly engineered safety device made up of 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 NU-GUARD 31 is to be installed is flat enough so that the ground conditions will not significantly alter the height of the vehicle in relation to the height of the w- beam guardrail panels. Minor site grading may be required. Soil Conditions NU-GUARD 31 can be installed in Roadside and Median locations where soil conditions that exist are essentially a fully compacted sub-base. Refer to the Soil Conditions section in this manual for more information. It is recommended that soil tests are carried out at the location the NU-GUARD 31 is to be installed. IF SOIL CONDITIONS ON SITE DO NOT MEET OR EXCEED THE REQUIRED STRENGTH DETAILED IN THIS MANUAL DO NOT INSTALL THE SYSTEM. CONTACT CSP PACIFIC FOR FURTHER ADVICE. Tools Required The tools required to install NU-GUARD 31 are: Wrenches and sockets (32mm) commonly used to install w-beam guardrail. (A small specialised socket wrench is required for the median system) Podger bar Measuring tape and marker pen String line and fluorescent spray paint Tampers or Post Rammer commonly used for driving posts Protective inserts for driving cap Impact Wrench and portable compressor optional Ph or visit April 15 / Page 11

12 Nu-GUARD 31 Post in hard surfaces NU-GUARD 31 posts should be installed in soil conditions that meet the requirements of AS/NZS 3845:1999 and TNZ M/ However due to its smaller footprint and no blockout requirement NU-GUARD 31may need to be installed in areas that have thick asphaltic layers or even a concrete footpath. As concrete or thick asphalt surrounding the NU-GUARD 31 post has no flexibility, unlike soil, it can create a pinch point. In a vehicle impact this may cause the post installed in the hard surface to snap very quickly and as a result not give enough support to the highway rail to perform as designed. The recommended treatment involves creating a hole in the hard surface around the post to remove the possibility of any pinch point and fill with a low strength concrete/grout or flexible asphalt. A hole in the hard surface material of 300 x 300mm square is to be keep clear around each NU- GUARD 31 post in a side of road installation. The post sits centrally in the hole but at the front face closest to the road as shown in Figure 1. The post can sit against the hard surface at the front of the hole as the top of the post will only rotate backwards but the post area below ground will not rotate forward as with a timber post. The NU-GUARD 31 post is installed in compacted soil under the pavement surface that meets the requirements of AS/NZS 3845:1999 and TNZ M/ After installation of the NU- GUARD 31 post, the widened hole in the surfacing is filled with a grout mixture to a maximum depth of 150mm. This grout mixture is a recipe by volume of seven parts sand, two parts water and 0.5 parts cement. The compressive strength should be about 1 MPa. It must not be a concrete mix (i.e. no graded aggregate composition) but rather a uniform sand and cement matrix. This is the same mixture as per recommendation for around timber posts in the NZTA Technical Memorandum TM Figure 1 SECTION A-A The top of the hole can also be filled with a topping asphalt with a maximum depth of 75mm. If the depth of the hole is greater than 75mm then a suitable compacted fill such as GAP20 should be used to bring the surface to the correct height before applying the asphalt. The same applies for a median installation except the NU-GUARD 31 post is placed centrally in the 450mm x 450mm hole in the hard surface. Ph or visit April 15 / Page 12

13 Installation Instructions Roadside Application Installation Manual: Nu-Guard 31 Guardrail System Step 1 Site Preparation and General Information It is preferred that NU-GUARD 31 is installed on flat, level ground with sufficient distance behind the posts as described in the Batter Hinge Point section. The barrier itself must be connected (anchored) at either end to either an approved terminal end, transition section or w- beam guardrail in order to perform as designed and tested. Post spacing is 1.905m, further details will be shown in the construction drawings on how to mark the appropriate locations at which the posts are to be installed. Before driving posts, always ensure that the posts are clear of underground services. Note: During the construction period NU-GUARD 31 should be installed in a way so that the exposed end of the w-beam guardrail is located at the downstream end, and not dangerous to other road users. Protective techniques commonly used when installing other types of w- beam guardrail can also be used for NU-GUARD 31. Ph or visit April 15 / Page 13

14 Step 2 Driving the Posts Installation Manual: Nu-Guard 31 Guardrail System Drive posts at predetermined position to the required depth using suitable machinery. The top of the post should be 812mm above the nominal ground line. Post spacing is 1.905m from the last post of the terminal end, transition section or w-beam guardrail. (shown in Figures 1, 2 & 3) For the roadside installation only make sure that the post flanges face the back of the rail. Traditional installation methods used when installing other w-beam guardrail utilising a string line, measuring tape and marker paint are also useful when applied to NU-GUARD 31. Protect the galvanising on top of the posts by using a protective insert Figure 1 Figure 2 Figure 3 Note: If the conditions on site don t allow for the posts to be driven, contact CSP Pacific for alternative accepted installation methods. Step 3 Joining the W-Beam Guardrail Panels The centre of the guardrail is 635mm above the nominal ground line. Lap the w-beam guardrail panels on the side of the posts with the direction of the laps the same as the direction of the traffic flow. (shown in Figures 4, 5 & 6) Each splice joint requires the w-beam guardrail panels to be joined using 8 splice bolts and tightened with a wrench or socket. (An impact wrench is optional) Figure 4 Figure 5 Figure 6 Ph or visit April 15 / Page 14

15 Step 4 Connecting the W-Beam Guardrail Panels to the Posts Once the w-beam guardrail panels have been joined together on the traffic side of the posts they can be attached to the post. Insert the 90mm M16 coach bolt through from the face of the guardrail with the 90mm diameter round washer positioned between the back of the rail and the flanges on the post. (shown in Figure 7) The bolt can then be secured at the back of the post with the splice bolt nut and tightened with a spanner ONLY. (shown in Figure 8) The post bolt position in the vertical slot in the post may vary and may not be at the bottom of the slot. Ensure the top of the post is at 812mm and the centre of the w-beam guardrail panel is at 635mm relative to the ground. (shown in Figure 9) Figure 7 Figure 8 Figure 9 Step 5 Repeat Steps 2, 3 and 4. Repeat these steps until the barrier is the required length and joined to a terminal end, transition section or w-beam guardrail at the other end. During construction of NU-GUARD 31 ensure that the exposed end of the w-beam guardrail is ALWAYS at the downstream end of the installation and/or protected using a suitable technique if road users are present. Step 6 Delineation. Delineation may be required as per the Road Controlling Authority Guidelines. For further details including type, location and placement contact the Road Controlling Authority or CSP Pacific. Ph or visit April 15 / Page 15

16 Median Application Installation Manual: Nu-Guard 31 Guardrail System Step 1 Site Preparation & General Information It is preferred that NU-GUARD 31 is installed on flat level ground. NU-GUARD 31 must be connected (anchored) to either an approved terminal end, transition section or w-beam guardrail at either end in order to perform as designed and tested. Post spacing is 1.905m, further details will be shown in the construction drawings on how to mark the appropriate locations at which the posts are to be installed. Before driving posts, always ensure that the posts are clear of underground services. Ph or visit April 15 / Page 16

17 Step 2 Driving the Posts Installation Manual: Nu-Guard 31 Guardrail System Drive the posts at predetermined position to the required depth using suitable machinery. The top of the post should be 812mm above the nominal ground line. Post spacing is 1.905m from the last post of the terminal end, transition section or w-beam guardrail. (shown in Figures 10, 11 & 12) For the median installation only make sure that the post flanges alternate. (see page 24) Traditional installation methods used when installing other w-beam guardrail utilising a string line, measuring tape and marker paint are also useful when applied to NU-GUARD 31. Protect the galvanising on top of the posts by using a protective insert Figure 10 Figure 11 Figure 12 Note: If the conditions on site don t allow for the posts to be driven, contact CSP Pacific for alternative accepted installation methods. Step 3 Joining the W-beam Guardrail Panels Together The centre of the guardrail is 635mm above the nominal ground line. Lap the w-beam guardrail panels on each side of the posts with the direction of the laps the same as the direction of the traffic flow. (shown in Figures 13, 14 & 15) Each splice joint requires the w-beam guardrail panels to be joined using 8 splice bolts and tightened with a wrench or socket. There is limited access when connecting the second side of w-beam guardrail and a small specialised socket wrench is required. Figure 13 Figure 14 Figure 15 Ph or visit April 15 / Page 17

18 Step 4 Connecting the W-Beam Guardrail Panels to the Posts Once the w-beam guardrail panels have been joined together on either side of the posts they can be attached to the posts. Insert the 100mm M16 Coach Bolt through from the face of the rail with a 90mm diameter round washer positioned between the back of the w-beam guardrail panel and post on each side. (shown in Figure 16) Bolt orientation is consistent with post. Consult the drawing in the Appendix for further detail. The bolt can then be secured on the face of the guardrail with a small round washer under the M16 nut and tightened with a wrench or socket ONLY. (shown in Figure 17) The post bolt position in the vertical slot in the post may vary and may not be at the bottom of the slot. Ensure the top of the post is at 812mm and the centre of the W-beam guardrail panel is at 635mm relative to the ground. (shown in Figure 18) Figure 16 Figure 17 Figure 18 Step 5 Repeat Steps 2, 3 and 4. Repeat these steps until the barrier is the required length and joined to a terminal end, transition section or w-beam guardrail at the other end. During construction of Nu-Guard 31 ensure that the exposed end of the w-beam guardrail is ALWAYS at the downstream end of the installation and/or protected using a suitable technique if road users are present. Step 6 Delineation. Delineation may be required as per the Road Controlling Authority Guidelines. For further details including type, location and placement contact the Road Controlling Authority or CSP Pacific. Ph or visit April 15 / Page 18

19 NU-GUARD 31 Installation Examples NU-GUARD 31 Roadside Application NU-GUARD 31 Median Application Ph or visit April 15 / Page 19

20 Nu-Guard 31 Steel Guardrail System Installation Checklist Checklist Y N Height to centre of rail is 635mm Height to the top of the post is 812mm Top of post should be a minimum of 20mm above top of guardrail There is no blockout When driving post, use a driving cap with timber or plastic insert to avoid damage to the post Post is aligned with flanges rail (for road side applications) and alternating between flanges forward and back for median applications There is a 90mm dia. washer between rail and post. Position of M16 x 90mm post bolt in post slot may vary. It is not always located in the bottom of the slot. Rail is lapped in the direction of traffic All bolts are fully tightened Nut on backside of post is a splice nut If a median installation-excessive bolt length is cut off on backside That transition details to existing guardrail or terminations are correct Notes: Location: Installed by: Inspected by: Date: Date: CSP Pacific Nu-Guard 31 Steel Guardrail System April 15

21 Maintenance and Repair Maintenance NU-GUARD 31 barriers are maintenance free. It is however recommended that an annual inspection is carried out on the terminal ends, if applicable, to check that the anchor tension is maintained by the cables as per Manufacturer s Specifications. Repair After a typical impact Recommended tools: Wrenches and 32mm sockets Podger bars Vertical Plate lifting clamp Machinery to remove the damaged posts and install new ones Replacement parts required for an average impact: 1980mm NU-GUARD 31 Posts 3.81m W-Beam Guardrail Panels Post Bolt sets as per application Splice Bolts Key Steps: Separate the components by undoing the splice bolts and post bolts Remove any damaged posts (machinery may be required as detailed above) Assess which components are damaged and replace with new parts accordingly Drive new posts and install new guardrail as per the Installation Instructions in this manual for the type of barrier system being repaired. Replace Post Caps (if required) After Fire Damage A NU-GUARD 31 barrier is made entirely of galvanised steel components and it is possible that under extreme conditions, like bushfires, that the components of the system or the galvanising can be damaged. If this is the case replace the components as described above and as outlined in the NU-GUARD 31 Installation Manual. Ph or visit April 15 / Page 21

22 Frequently Asked Questions 1) What type of equipment is required to install NU-GUARD 31? Standard tools required include 32mm sockets and wrenches, podger bars, measuring tape and a string line. Machinery includes post rammer commonly used in driving posts. If installing the median system a specialised small socket wrench is recommended. 2) On average, how long does it take to install a NU-GUARD 31 Barrier? Depending on the application and circumstances at the site, installation and assembly of the system should take a three person crew less than two hours to install a 50m section. 3) When driving the posts what can be used to prevent damage to the galvanising on the top of the posts? It is recommended that a timber, plastic or brass insert is fitted to the device being used to drive the posts. (Experience has shown that a brass insert will last the longest) 4) How easily can NU-GUARD 31 be restored after impact? The system is made up of very few different components and is easily repaired. Machinery will be required to lift out the damaged posts and drive the new ones. The remainder of the barrier requires only a wrench and 32mm socket to take apart and reinstate. 5) 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 may not perform as required when damaged. For this reason it is recommended that spare NU-GUARD 31 key components are held by maintenance contractors along with the standard w-beam guardrail hardware. 6) What maintenance does NU-GUARD 31 require? NU-GUARD 31 is maintenance free barrier. 7) Are the same posts used for both the TL-3 and TL-4 Barriers? Yes, there are no differences in any components or installation characteristics between the systems. In summary, the same barrier has passed NCHRP criteria for both MASH TL-3 and NCHRP350 TL-4. 8) What is the maximum Deflection of NU-GUARD 31? The maximum deflection recorded during actual crash testing at TL-4 was 1.22m on an edge of road system. An assumption can be made then that on a median installation the deflection will be lower than this due to the barrier having guardrail panels on both sides and providing a stiffer system. The dynamic deflection that should be used when comparing the performance of w-beam barrier is 1.05m with the MASH pickup truck. (2270kg, 100kph & 25 Degrees) Ph or visit April 15 / Page 22

23 9) What can NU-GUARD 31 be connected to? NU-GUARD 31 must be anchored at either end by either an approved terminal end, transition section or w-beam guardrail. A fully re-directive X-350 End Terminal is the recommended terminal end for both Roadside and Median applications. For further information consult the NU-GUARD 31 recommended transition drawings in the Technical Drawing Appendix of this manual. 10) What about vandalism, can NU-GUARD 31 be easily damaged? The system can be dismantled using a wrench; however NU-GUARD 31 barriers are held together using similar nuts and bolts to other systems in which vandalism is not considered an issue. Ph or visit April 15 / Page 23

24 APPENDIX Technical Drawings Ph or visit April 15 / Page 24

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