Sentryline II Cable Barrier

Transcription

1 Product Manual Sentryline II Cable Barrier TL-3-3 Cable & TL-4-4 Cable Systems Proudly distributed by BJM(v6) ANOTHER ARMORFLEX DEVELOPMENT

2 Table of Contents Sentryline II Introduction 3 Deflection.. 5 Component Specification... 6 System Design. 7 Design Considerations 9 Special Circumstances Parts Identification.. 13 Installation Preparation Bill of Materials. 15 Installation Instructions.. 16 Maintenance and Repair 23 Installation Examples.. 24 Installation Checklist.. 25 Installation Checklist - Misc Frequently Asked Questions 27 Crash Test Results Summary 29 APPENDIX Technical Drawings Sentryline II TL-3-3 Cable Line Post Set Up Sentryline II TL-4-4 Cable Line Post Set Up Universal A.T.E Overlap. 31 Universal A.T.E (4 Cable Barrier) Universal A.T.E (3 Cable Barrier) Sentryline II TL-3 and TL-4 Cable Heights. 34 2

3 TL-3-3 Cable Barrier Introduction Sentryline II Introduction The Sentryline II TL-3 barrier is a 3 cable, high tension Cable Barrier. The system has been designed and tested to meet the evaluation criteria of NCHRP 350 Test Level 3 (TL-3) 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. Those conditions are an 820kg passenger car and a 2000kg pickup truck impacting at 20 and 25 degrees at a speed of 100kph. System Overview The Sentryline II TL-3-3 Cable Barrier is designed and constructed to provide acceptable structural adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 for cable barriers. When impacted with an 820kg and 2000kg vehicle at speeds of up to 100kph and side on entry angles up to 25 degrees, the impacting vehicle is redirected or contained in a safe manner. TL-4-4 Cable Barrier Introduction The Sentryline II TL-4 barrier is a 4 cable, high tension Cable Barrier. The system has been designed and tested to meet the evaluation criteria of NCHRP 350 Test Level 4 (TL-4) 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. Those conditions are an 820kg passenger car, 2000kg pickup truck and an 8000kg truck impacting at 20, 25 and 15 degrees at a speed of 100kph and 80kph. System Overview The Sentryline II TL-4-4 Cable Barrier is designed and constructed to provide acceptable structural adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 for cable barriers. When impacted with an 820kg, 2000kg and 8000kg vehicle at speeds of up to 100kph and side on entry angles up to 25 degrees, the impacting vehicle is redirected or contained in a safe manner. 3

4 Sentryline II Introduction cont. Limitations and Warnings Features The Sentryline II TL-3 and TL-4 Systems have 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 the Sentryline II TL-3 and TL-4 Systems 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 cable 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. Before Installation Design, selection and placement of the Sentryline II shall be in accordance with the local road authority guidelines and the details shown in the construction drawings. Installation shall be in accordance with the installation instructions supplied for this product. Depending on the application, post spacing and circumstances at the site, installation and assembly of the system should take a 2 person crew less than 2 hours to cast the piles, install the posts and place the cables for a 100m section. The Sentryline II 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. 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 authorized trained personnel should operate any machinery. Where overhead machinery is used, care must be taken to avoid any overhead hazards. Before auguring, always have the area checked for underground services by the appropriate service providers. Sentryline II Safety Statements All installers must be well clear of machinery while the holes are augured. The posts and components are easily lifted and positioned by hand, while the cable and reel are extremely heavy so it is recommended that the cable is run out on a heavy duty, single axis spindle. Avoid placing hands or fingers in and around moving parts when components are being lifted into place and cable is run out from the reel. Only trained personnel should use the tensioning machine. All installers must be extremely careful they are clear of moving parts when the hydraulic ram is being operated. 4

5 TL-3 Deflection Results: Sentryline II Deflection Deflection is from actual crash testing and the figure published is from the test involving a 2000kg pickup truck at a 25 degree angle and at 100kph. Test Post Spacing Deflection Working Width m 1.54m 1.54m Test Post Spacing Deflection Working Width m 3.27m N/A TL-3 Sentryline II Deflections (Actual) Deflection (m ) Actual Sentryline II Deflection (3m Test) Calculated Sentryline II Deflection Actual Sentryline II Deflection (9m Test) Post Spacing (m) TL-4 Deflection Results: Deflection is from actual crash testing and the figure published is from the test involving an 8000kg truck at a 15 degree angle and at 80kph. Test Post Spacing Deflection Working Width m 1.10m 2.15m NOTE: Deflection is influenced by a number of factors such as cable temperature, post spacing, soil stability, barrier length and barrier curvature. Consequentially, allowance should be made for barriers to deflect more than that shown during one particular test. The dynamic deflection shown in the test should only be used as an indication of what deflection approximately to expect. The above deflections are dynamic deflections. 5

6 Component Specification Steel Line Posts Posts are fabricated from a 42x97x3mm flat sided oval section. 1 slot is cut each side of the post and 1 slot cut into the top of the post. Posts are 1220mm long and Hot Dip Galvanised after cutting. Plastic socket Moulded from HDPE. Forms a 350mm deep socket in the concrete foundation, 5mm larger than the post. Plastic cap Moulded from glass reinforced Nylon and PVC with UV stabilisers. Cap is an extremely tight push fit into the top of the posts with two 340mm long sleeves protruding down the inside of the post on the outside of the 2 bottom cables. This Cap once installed correctly cannot be removed without tools. Barrier Cables All cables are constructed using 19mm 3x7 strand galvanized steel cable, pre-stretched by 35%. The ultimate tensile capacity of the cable is 205kN. Cable Grips The fittings used to grip the cable ends securely consist of 3 tapered jaws that fit inside a tapered casing with a threaded tail piece that screws into the rear of the casing. When the cable is pushed into the mouth of this fitting the jaws engage the cable and when tension is applied the wedges tighten further onto the cable. Strong Backs A turnbuckle-like device, fabricated from 10x20mm low tensile steel side arms welded to 30mm thick end washers. They are Hot Dip Galvanised after fabricated. Standard Line Post Foundation 300mm ø x 750mm deep holes at post spacing as per the construction drawings are filled with 25 MPA concrete. A D10 x 175mm ø rebar ring is placed in each foundation, 100mm down from the top. A plastic socket is pushed into the concrete so that top lip of the socket sits flush with the top of the concrete. Post o Ring A rubber o ring is used 350mm from the bottom of each post so that the 5mm gap with the socket is reduced and limits the amount of debris that can build up there. 6

7 System Design Footings Standard Pile Option Note: The use of this Standard Option is for when the piles will be installed in AASHTO Standard Soil with a fully compacted sub-base. Sentryline II has been tested with concrete piles. These consist of a 300mm ø by 750mm deep drilled (or punched) hole, filled with 25 mpa concrete. The theoretical volume of each hole is m³. (Footings may also be pre-cast and installed into drilled or punched holes) A 175mm ø rebar ring is inserted a minimum of 100mm below the surface of the concrete and a plastic socket inserted in the centre. Note: 20 holes will require approximately 1 m³ of concrete, but allowance must be made for holes being larger than the theoretical volume by the act of drilling and removing spoil. Footings Alternative Pile Options ONLY if the soil has been verified as a particular soil using a DCP (Dynamic Cone Penetrometer) or SV (Shear Vane) with results that match or exceed the parameters in the table below can the Alternative Pile Option be used. Assumptions: - Concrete is 25 mpa with a rebar ring placed 100mm down from the surface. - The soil has been verified as being a particular type. - Soil disturbed from drilling the footings is re-compacted after the concrete has been poured. How to use the tables: Select which soil type the intended installation is to be placed in by matching the description to the geotechnical report for the site. The recommended footing size is then given in the adjacent box. Cohesive Soils Soil Type Description Su (kpa) Foundation Pile Depth Firm < mm ø x 850mm Stiff mm ø x 600mm Very Stiff mm ø x 400mm Cohenionless Soils Soil Type Description Phi (0) Foundation Pile Depth Medium Dense < mm ø x 920mm Dense mm ø x 850mm Very Dense > mm ø x 750mm The majority of cable barrier installations will be in stiff, cohesive soil, which using the table above shows the minimum permissible footing depth to be 600mm. Footings Shallow Pile Option If the soil is cohesive with maximum shear strength of 50 kpa then the footing depth can be reduced to 450mm deep if the diameter is increased to 450mm. 7

8 System Design Cont. Cable Heights Cable # Sentryline II, 3 Cable System (mm) Sentryline II, 4 Cable System (mm) 1 (bottom) N/A 790 Note: When measured from ground to the centre of the cable. (Tolerance ± 30mm) Tension It is important that when tensioning the Sentryline II cables that the Tension Machine is set to make allowance for the temperature at the time of installation. On colder days the cables will have shrunk so more tension is required. Alternatively days that are hotter than 25 C will require less tensioning. The Tensioning Machine is usually set to 25kN s but advice should be sought on all installations from your Sentryline II distributer. Note: Temperature refers to air temperature. Temp ºC Tension kn s (As with all Cable Barrier Systems it is recommended that 2 weeks after the barrier is tensioned for the first time, it should be re-tensioned to remove any construction creep. Also, as with all Cable Barrier Systems it is recommended that the tension on the cables is checked annually.) Tension Bays Required at a minimum of every 450m or as often as is necessary to correctly tension the system. Note: Do not place two Strong Backs within 30m of each other when on the same cable. When installing the Strong Backs, care must be taken to cut the cables mid span between posts so that the installed Strong Backs do not coincide with posts. Terminal End Treatments It is recommended that the Sentryline II Cable Barrier is terminated using the Universal Armorwire Terminal End. For details on design and installation of this Terminal End System refer to the Universal A.T.E Product Manual. 8

9 Design Considerations Curves Horizontal Minimum allowable curve is a 200m radius. Curve Multiplying Factor Table - Multiply the deflection of the barrier by the appropriate factor from the table below to calculate the likely deflection of the barrier on a curve. Note: The multiplying factor only applies to convex curves. Convex Curve Radius (m) Length (m) Vertical Maximum allowable vertical sag of 1400m radius. This maximum does not apply to crests of hills. Flared The preference is to not flare the system. If this is unavoidable then the maximum flare rate should be 30:1. Slopes A maximum slope of 1:10 is preferable. On slopes greater than this, follow the local road authorities guidelines. Barrier Length Minimum 25m: measured from the upstream length of need (LoN) to downstream length of need (LoN). When using the Universal A.T.E. this 25m excludes the terminal ends. Note: A shorter barrier may not have sufficient length to fully redirect an errant vehicle. Maximum No theoretical limit if the barrier is essentially straight in both horizontal and vertical alignment. However, when a barrier is impacted, the ability of the barrier to resist subsequent impacts before repair is not guaranteed. For this reason, the barrier length should be limited to a maximum of 1000m between anchors. 9

10 Design Considerations Cont. Intermediate Anchors Intermediate anchors should be placed at a minimum of every 1000m to properly anchor the ends of each run and maintain tension. (refer Maximum Barrier Length). Additionally, intermediate anchors may be used to create shorter, effective runs, within a continuous run, in order to counteract the effect that a curve has of increasing the deflection of the barrier. ie: A shorter length between anchors on a curve helps lower deflection. (See Curve Multiplying Factor Table on page 9 of this manual.) To create an intermediate anchor, simply overlap one barrier run with the next. A minimum 300mm gap between the barriers is required. Terminate each barrier with a terminal end so that the lengths of need (LoN s) line up. A Universal A.T.E is recommended. (See drawing in the Appendix on page 31) Note: There is no requirement for installers or maintenance personnel to stand or position themselves between the overlapping runs of barrier. Median and Roadside Applications The Sentryline II Cable Barrier can be impacted from either side of the post with no difference in performance. Therefore the barrier can be used in both median and roadside situations. There is no requirement for post orientation in relation to impacting vehicles. Transitions Transitions from Sentryline II to other types of barriers are available on request. Please contact your local Sentryline II distributer. Curbs As with all road side safety hardware, the Sentryline II 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 terminal end 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, local authority guidelines re curb height and design and barrier offset distance from it should be followed. 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 cable heights in relation to the ground. Ditches If the slope of the ditch is greater than 1:10 then follow the local road authorities guidelines. 10

11 Design Considerations Cont. Batter Hinge Point NCHRP 350 recommends that the lateral extent of the soil, outside an envelope of the embedded portion of the test article, be approximately 1.3 times the embedment length. ie: The standard Sentryline II footing is 750mm deep therefore requiring a minimum of 1 metre supporting soil outside the line of posts.(shown in Figure A) Note: If the batter hinge point is reduced to only 600mm, then increase the standard footing depth to 1000mm. (shown in Figure B) For NSW installations the RTA require a minimum 1.7m (shown in Figure C) Figure A. Figure B. Figure C. Length of Need The Length of Need (LoN), determined from NCHRP crash tests on the Sentryline II TL-3 and TL-4 Systems, is at post #5 where post #1 is the Trigger Post. Posts #2 - #5 are always at 2m spacing; therefore the LoN is 8m downstream of the Trigger Post. (shown in Figure D) Downstream from the LoN the Sentryline II Cable Barrier Systems can shield fixed objects, provide edge of road protection and in median application, prevent cross median accidents. (As per the LoN design section of the local road authority guidelines, care must be taken when calculating the actual length of the barrier required versus the theoretical length of the LoN. The physical placement of the Universal A.T.E must be with post #5 positioned at or upstream from the LoN) Figure D. 11

12 Special Circumstances Cutting Cables AVOID CUTTING CABLES THAT ARE UNDER TENSION Release the tension using the Strong Back Assembly before cutting cables. If a vehicle is entrapped in the cables it may be causing greater tension than otherwise would be present. In this situation extreme care must be taken in cutting the cables using a rotating cutting blade such as a metal cut off wheel in a hand held grinder. Only in worst case should a bolt cutter with long handles be used and care must be taken to ensure that no one is near the cutting area either up or downstream. Emergency Access Sentryline II can simply be lowered to the ground with no need to de-tension the system. Simply remove the caps from posts and lift the cables out of the slots in the posts. The posts can then be removed from the sockets and when a sufficient number taken the unsupported cables will drop to the ground. This will create a gate in the system where vehicles can ride over the barrier. To reinstate: Place the posts back into the sockets making sure that the slot orientation is consistent. Lift and place the cables back into their respective slots so they fit under the notches. Push the caps firmly back into place taking care that the cap sleeves are on the outside of the cables in the side slots. 12

13 Sentryline II - Parts Identification Line Post & O Ring Cable Grip (required as per spacing specified) (6 required per tension bay) Post Cap Strong Back Post Socket (1 required per post) (3 required per tension bay) (1 required per post) 3 Cable Barrier 4 Cable Barrier Rebar Ring (3x length of barrier required) (4x length of barrier required) (1 required per post) All steel components used in the Sentryline II are hot dipped galvanized, except the Rebar Ring which are cast into the concrete piles. 13

14 Getting Started Sentryline II - Installation Preparation It is essential that the Sentryline II is installed correctly. Please carefully read and understand the following instructions before installing the Sentryline II. These instructions relate only to the installation of Sentryline II and are for standard installations only. The Sentryline II Cable Barrier is designed so that the TL-3 and TL-4 Systems have the same post design and pile setup. For all installations, start downstream from the terminal end at the calculated Length of Need (LoN). The 4 line posts between the terminal end Trigger Post and the Cable Barrier must always be at 2m spacing. Between the 2 LoN s the post spacing will be as per the construction drawings. Preparation Before installing a Sentryline II Cable Barrier, ensure that all components required for the system are on site and have been identified. The Sentryline II is 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 Bill of Materials and Parts Identification sections in this manual for more information. Ensure that the area where the Sentryline II 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 barrier s cables. Minor site grading may be required. Soil Conditions The Sentryline II can be installed in median or edge of road locations where AASHTO Standard Soil with fully compacted sub-base conditions are met. It is recommended that soil tests are carried out at the location the Sentryline II is to be installed. More information on the soil requirements and corresponding footing pile options can be found under Footings in the System Design section of this Product Manual. Tools Required The tools required to install the Sentryline II cable barrier are: Auger for drilling 300mm holes Machinery capable of lifting the cable reel and a single axle spindle 300mm Wrench Measuring tape and marker pen String line Cut off saw Tensioning Machine 14

15 Sentryline II - Bill of Materials Components required for each post: 1x Galvanised Line Post (powder coating is optional) 1x Plastic Cap 1x Plastic Socket 1x Rebar Ring 1x Rubber o Ring Cable required for both TL-3 and TL-4 Systems: TL-3-3 Cable Barrier 3x the total length of the barrier of 19mm cable TL-4-4 Cable Barrier 4x the total length of the barrier of 19mm cable Note: It pays to be conservative with these lengths. Strong Backs required for both TL-3 and TL-4 Systems: TL-3-3 Cable Barrier 3x Strong Backs for each Tension Bay TL-4-4 Cable Barrier 4x Strong Backs for each Tension Bay Note: There may be more than 1 Tension Bay per barrier run depending on the length or design of the barrier. Cable Grips and associated components: TL-3-3 Cable Barrier 6x Cable Grips c/w M20 Nuts for each Tension Bay TL-4-4 Cable Barrier 8x Cable Grips c/w M20 Nuts for each Tension Bay Note: There may be more than 1 Tension Bay per barrier run depending on the length or design of the barrier. Concrete required for each post: 1x 0.053m³ 25 mpa concrete Note: This is the theoretical volume only and that allowance must be made that the holes may be larger than this due to the act of drilling and removing spoil. 15

16 Sentryline II - Installation Instructions Step 1 Site Preparation It is preferred that the Sentryline II is installed on flat, level ground with sufficient distance behind the foundation piles as described in the Batter Hinge Point section of this Product Manual. The Sentryline II barrier starts at post #5 (where post #1 is the Trigger Post) of the Universal A.T.E with post spacing as described in the construction drawings. The Sentryline II is a continuation of the Universal A.T.E and should be installed in a tangent position. If this is not possible, a maximum flare rate of 30:1 is preferred. Before drilling always have the area checked for underground services Step 2 Drilling the holes Standard Footing Pile Using an auger, drill 300mm diameter holes 750mm deep (shown in Figure 1 & 2) at the spacing as shown in the construction drawings. Theoretical volume of concrete required for each pile is 0.053m³. N.B. Due to the drilling and removing spoil, the actual amount of concrete required is likely to be larger than the theoretical volume. Figure 1. Figure 2. NOTE: If the conditions on site don t allow for a 750mm hole it may be possible to use a Shallow Option. Soil tests will need to be carried out and the required soil strength present. For more details on this Shallow Option and all other Alternative Options consult the Footings section under Design Considerations in this Product Manual. 16

17 Sentryline II - Installation Instructions Step 3 - Construction Fill the holes to within 100mm of the top with 25mpa concrete, place the rebar ring in the centre of the footing taking care to ensure that the ring is centred in the hole and level. (shown in Figure 3) A string line and level are useful to ensure this. Fill the remainder of the hole with concrete until flush with grade. (shown in Figure 4) Figure 3. Figure 4. Push plastic socket into centre of the footing until the top edge of the socket is flush with the top of the concrete. (shown in Figure 5) Alignment of the socket is important so use of a string line and level, or some other suitable installation method, is required. Note: To prevent the possibility of a socket floating use a stiff mix of concrete or place a post in the socket. (shown in Figure 6) Figure 5. Figure 6. 17

18 Sentryline II - Installation Instructions Step 4 - Installing the Posts Push a rubber o ring onto the bottom of the post by approximately 350mm. This will prevent debris from building up in the socket which can make removal difficult. (shown in Figure 7) Slide a post into the socket once the concrete has set and adjust the o ring so that it fills the gap between the post and post socket. (shown in Figure 8) Ensure that the side slots in the post are aligned so that the orientation of the two slots are consistent. (shown in Figure 9) Figure 7. Figure 8. Figure 9. 18

19 Sentryline II - Installation Instructions Step 5 - Installing the Cables Using a truck or trailer fitted with a cable reel frame, run the cables out to the desired length. (shown in Figure 10) One or more of the cables may be run out at the same time depending on the installer s equipment. (shown in Figure 11) Figure 10. Figure 11. For a 3 cable system place the bottom 2 cables into the bottom slots on either side of the post and the top cable into the top slot. (shown in Figure 12) For a 4 cable system place the bottom 2 cables into the bottom slots on either side of the post and the top 2 cables into the top slot. Ensure that the cable is pushed fully down to the bottom of the slots. (shown in Figure 13) Figure 12. Figure

20 Sentryline II - Installation Instructions Step 6 Placing the Post Caps Slide the cap down the inside of the post and push down until cap is pushed hard home onto the top of the post. (shown in Figure 14) Note: Make sure that cap sleeves are on the outside of the 2 cables in the bottom slots. (shown in Figure 15) Figure 14. Figure 15. Step 7 Connecting to the Cable Barrier Terminal End Connect the cables to the terminal end as per the manufacturer s instructions. The Universal A.T.E is the recommended terminal end for Sentryline II Cable Barriers. (shown in Figure 16) Figure

21 Sentryline II - Installation Instructions Step 8 Connecting the Cable Grips At the desired location, cut the cable using a cut off wheel in a grinder. (treat cut end of cables with a zinc containing paint) Mark the cable with a marker pen 75mm from the cut end. (shown in Figure 17 & 18) Now push the cable end into the Cable Grip and jiggle a few times until hard home and the mark previously placed on the cable is flush with the mouth of the fitting. (shown in Figure 19) Note: If the cable has just been unwrapped and still has an oily residue on it, wipe with a cloth before fitting the Cable Grip. It is acceptable for the cable to ease out of the Cable Grip up to 10mm when tensioned. If the cable has eased out more than 10mm, remove the Cable Grip and refit. (shown in Figure 20) Figure 17. Figure 18. Max 10mm Figure 19. Figure

22 Sentryline II - Installation Instructions Step 8 Tensioning the Barrier Ensure full tension machine training, including safe use, has been completed before using the following methodology to tension the Cable Barrier. Tension Machine and training is available from your local Sentryline distributer. It is recommended that the supplied Sentryline II Tension Machine is used. Tensioning is achieved by pulling the cables together using an appropriately placed Strong Back and Cable Grip assembly. Place the Cable Grips and Strong Back into the Tension Machine ensuring that the cable is held in place by the safety catches. Once all personnel s hands are clear, activate the Tension Machine so that it contracts, pulling the Cable Grips together and hence tensions the cables. The Tension Machine is pre-set to stop at 25kN. Note: Tension is dependant on temperature, therefore it may be necessary to adjust the tension applied to suit the temperature. (refer to the System Design section of this manual under Tension ) Run nuts up onto the threaded section of the Cable Grips inside the Strong Backs by using a ring spanner. (shown in insert below) Take care not to place fingers between nut and turnbuckle end. Extend the Tension Machine so that the Cable Grip and Strong Back are holding the cable under tension. Remove the Tension Machine and repeat until all cables have been tensioned using the same technique. 22

23 Maintenance Sentryline II Maintenance and Repair Sentryline II is a maintenance-free high tension Cable Barrier. However it is recommended that all Cable Barrier Systems are checked annually to ensure that the tension is maintained. Follow the Tensioning section in Installation Instructions in this manual to do this. Repair After a typical impact Recommended tool Crow bar Replacement parts required for an average impact Posts Caps Remove all damaged caps. Remove and replace all damaged posts with new ones. Note: Making sure that the slots on the side of the posts match the configuration of the rest of the intact barrier. Place the cables back into the appropriate slots. Put new caps onto the posts. Note: Making sure that the caps are pushed hard home and are on the outside of the 2 cables in the bottom slots. Non-Standard Impacts If for whatever reason a cable is damaged (any one strand or more are severed) then that cable must be replaced. For further details consult the Installation Instructions in this manual for methodology. If the impact was at or near an end anchor or intermediate anchor, tension should be rechecked. To do this, place the Tension Machine (available from your Sentryline Distributer) over the Strong Backs and Cable Grips and tensioned as per the Tensioning section in Installation instructions in this manual. If properly installed, the footings should not move or be damaged. 23

24 Sentryline II Installation Examples Sentryline II TL-3 3 Cable Barrier Sentryline II TL-4 4 Cable Barrier 24

25 Location Installed By Inspected By TL-3-3 Cable Barrier INSTALLATION CHECKLIST FOR THE Sentryline II Cable Barriers Date Date Ground is level and the top of the pile is flush. The plastic socket is cast in correctly and a rebar ring is positioned 100mm down from the top. If installed near a steep slope, at least 1000mm of supporting soil is outside the line of the posts. (1700mm in NSW) Spacing between the posts are as per the Construction Drawings. Posts are installed with slot orientation consistent for the entire length of the barrier. Top cable is positioned in the top slot while the bottom 2 cables sit at the bottom of the slots on either side of the post. An o ring seal is positioned on all posts at the top of the socket. All posts have a plastic Cap inserted in the top pushed hard home. (make sure each cap sleeve is on the outside of the bottom cables) Cable heights, 530mm, 650mm and 770mm. (± 30mm) Each of the 3 cables has been tensioned correctly. TL-4-4 Cable Barrier Ground is level and the top of the pile is flush. The plastic socket is cast in correctly and a rebar ring is positioned 100mm down from the top. If installed near a steep slope, at least 1000mm of supporting soil is outside the line of the posts. (1700mm in NSW) Spacing between the posts are as per the Construction Drawings. Posts are installed with slot orientation consistent for the entire length of the barrier. Top 2 cables are positioned in the top slot while the bottom 2 cables sit at the bottom of the slots on either side of the post. An o ring seal is positioned on all posts at the top of the socket. All posts have a plastic Cap inserted in the top pushed hard home. (make sure each cap sleeve is on the outside of the bottom cables) Cable heights, 530mm, 650mm, 770mm and 790mm. (± 30mm) Each of the 4 cables has been tensioned correctly. Comments: Y/N N/A 25

26 Location Installed By Inspected By INSTALLATION CHECKLIST FOR THE Sentryline II Cable Barriers - Misc Date Date Y/N N/A Intermediate Anchors Minimum of 300mm gap between Cable Barriers when overlapping. The correct distance is met overlapping. (for the Universal A.T.E it is necessary for the LoN s to line up, i.e. 16m total cable overlap) Maintenance Check the tension of the Cable Barrier annually using a Tension Machine or a Tension Measuring device. (Details on this procedure are in the Tension section of this manual under System Design ) Repair Remove and discard all damaged posts, caps and o rings. Place new posts into sockets with new o rings. (making sure that the post slot orientation pattern is maintained) Reinstate Cables: TL-3 - Top cable is positioned in the top slot while the bottom 2 cables sit at the bottom of the slots on either side of the post. TL-4 Top 2 cables are positioned in the top slot while the bottom 2 cables sit at the bottom of the slots on either side of the post. Insert a plastic Cap in the top of the Post and push hard home. (make sure each cap sleeve is on the outside of the bottom cables) Reflectors replaced in accordance with local authority guidelines. Tensioning should be checked if impact was near the Terminal End. Emergency Access Remove Posts Caps spanning the desired access area. Lift all cables out of the post slots. Remove posts and stack in a safe area. When a sufficient amount of posts have been removed the cables will lie on the ground and allow vehicles to ride over. (dependant on post spacing, temperature and curvature) Reinstate all components as per steps above in the Repair section. AVOID CUTTING CABLES THAT ARE UNDER TENSION Release tension in a controlled manner using the Strong Backs Clear area when cutting the cables and always use a cutting wheel. 26

27 Sentryline II Frequently Asked Questions 1) What type of equipment is required to install the Sentryline II? Standard tools required include a wrench, measuring tape and a string line. Machinery includes an Auger for drilling holes 300mm in diameter and 750mm deep. A cut off saw (cutting wheel) is required to cut the cables and a Tension Machine to tension the System. 2) How much concrete is required to install the footings on a Sentryline II and what strength does it need to be? The theoretical volume for each default pile is 0.053m³. Therefore for every 20 piles approximately 1m³ is required. The concrete must be 25mpa. (Due to the drilling and removing spoil the actual amount may be larger than this) 3) Is there a curing period for the concrete before the cable barrier can be tensioned? Yes, it is recommended that the system is not tensioned until 7 days after all concrete piles have been poured. 4) Does your company provide spare parts? What is the lead-time for supply? It is important to fix a damaged Cable Barrier as soon a possible because it most probably won t perform as required when damaged. For this reason it is recommended that spares are held by Maintenance Contractors. (the concrete piles are very unlikely to be damaged) 5) On average, how long does it take to install a Sentryline II Barrier? Depending on the application and circumstances at the site, installation and assembly of the system should take a two person crew less than 2 hours to cast the piles, install the posts and place the cables for a 100m section. 6) What about vandalism, can the Sentryline II be easily damaged? No, once the system has been tensioned it is an extremely rigid system and tampering without the use of heavy duty tools or machinery is very unlikely to damage or affect the performance of the system. 27

28 FAQ s (continued) 7) How easily can the Sentryline II be restored after impact? The system is easily repaired after impact as the foundations and ground strut should not be damaged in anyway. The damaged posts can be removed using a crow bar and new posts positioned in the sockets. If the impact was near a Terminal End it is recommended that the cable tension is checked. If the system has been de-tensioned or Trigger Post damaged, a hydraulic Tension Machine and trained personnel will be required to re-tension the system. 8) What maintenance does the Sentryline II require? The Sentryline II is maintenance free barrier as the cables used are prestretched. It is however recommended that the Cable Barrier is included in routine inspections and the cable tension checked annually. 9) Apart from the configuration of the cables, are there any other differences between installing a TL-3-3 Cable or TL-4-4 Cable Barrier? No, the setup of the Sentryline II is always the same. (The only variance that can happen, and not related to whether it is a 3 or 4 Cable Barrier, is the depth of the footings may change due to the soil conditions that exist at that location) 10) What is the Deflection rating of the Sentryline II? Deflection is from actual crash testing and the figure published is from the test involving a 2000kg pickup truck at a 25 degree angle and at 100kph. The Sentryline II at 3.0m post spacing has a Dynamic Deflection of 1.54m. 11) The Calculated Deflection was derived using which formula? Dc (Calculated Deflection) = Dm * Mt (Vt * sinθt)² Mm (Vm * sinθm)² Dm: Maximum Measured Dynamic Deflection (m) Mm: Measured Test Total Mass (kg) Vm: Measured Test Velocity (kph) θm: Measured Test Angle (deg) Mt: Total Test Mass (kg) Vt: Test Velocity (kph) θt: Test Angle (deg) 28

29 Sentryline II Crash Test Results Summary A total of 4 crash tests where completed on the Sentryline II to NCHRP 350. Test 3-11 Test Article 3 Cable Sentryline II (length 114m) Post Spacing 3m Test Vehicle. Speed Impact Angle 2000 kg Pickup Truck (2000P) 100 kph 25 deg ` Test 3-11 Test Article 3 Cable Sentryline II (length 119m) Post Spacing 9m Test Vehicle. Speed Impact Angle 2000 kg Pickup Truck (2000P) 100 kph 25 deg 29

30 Sentryline II Crash Test Results Summary cont. Test 4-12 Test Article 4 Cable Sentryline II (length 114m) Post Spacing 3m Test Vehicle. Speed Impact Angle 8000 kg Truck (8000S) 80 kph 15 deg Test 4-10 Test Article 4 Cable Sentryline II (length 119m) Post Spacing 3m Test Vehicle. Speed Impact Angle 820 kg Car (820C) 100 kph 20 deg For all 4 tests the vehicles where safely redirected by the Sentryline II cable 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-3 and TL-4. 30

31 APPENDIX Technical Drawings 3 Cables Line Post Set Up 4 Cables Line Post Set Up Universal A.T.E Overlapping Sentryline II Cable Barriers 31

32 APPENDIX Technical Drawings (continued) Universal A.T.E Connecting to a Sentryline II TL-4-4 Cable Barrier 32

33 APPENDIX Technical Drawings (continued) Universal A.T.E Connecting to a Sentryline II TL-3-3 Cable Barrier 33

34 APPENDIX Technical Drawings (continued) Sentryline II TL-3 3 Cable Barrier Cable Heights (measured in mm to the centre of the cable) Sentryline II TL-4 4 Cable Barrier Cable Heights (measured in mm to the centre of the cable) 34