Brifen Wire Rope Safety Barrier TL-3 & TL-4

Brifen Wire Rope Safety Barrier TL-3 & TL-4 Product and Installation Manual Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 1

Table of Contents Background 3 Design Considerations 4 Design Requirements 6 Post Foundations 8 Wire Rope Barrier Installation Procedure 10 Tensioning 12 Maintenance & Repair Procedures 13 Repair Sequence 15 Demounting & Reinstallation Procedures 16 New Installation Check List 18 Checklist for Use following Accident 21 Appendices Details of Ropes for NCHRP Systems - WR3000 22 Details of Posts & Foundations for NCHRP 350 - TL-4 Systems - WR3021 23 Details of Rope Heights for NCHRP 350 - TL-4 Systems - WR3022 24 NCHRP 350 - TL-4 Length of Need General Layout - WR3025 25 Details of Components for NCHRP 350 - TL-4 Length of Need - WR3026 26 Works Procedure - Installation 27 Works Procedure - Repair 34 Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 2

Background Brifen was the world s first high tension wire rope safety barrier, introduced in the 1960 s when it was installed as a median barrier on the M62 motorway in Northern England. It has been successfully crash tested in England, Sweden and the USA to every new standard introduced over the last 40 years, and is today approved to the following standards, o NCHRP 350 Test Levels 3 & 4 o EN 1317 Test Levels TB 22, TB 32 and TB 42 With NZTA adopting the NCHRP 350 crash test regime, this information is concerned only with the NCHRP 350 tested versions of Brifen, and all Brifen barriers supplied in New Zealand (and listed in NZTA specification M23 Appendix A) are crash tested and approved to NCHRP 350 TL-3 or TL-4. Anyone seeking information on Brifen for installation in countries other than New Zealand should contact the Brifen supplier in the country concerned. Brifen is currently in service in over 40 countries around the world, with over 4000km installed. Here in New Zealand, more than 140km of Brifen is in service as both median and verge barriers, and the earlier installations have now been in continuous service for over 20 years. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 3

Design Considerations Number of Ropes - all Brifen WRS barriers supplied in New Zealand use four cables, each one tensioned by CSP Pacific personnel during initial installation to approx. 20kN, the exact tension depending upon ambient temperature at the time of installation. Dynamic Deflection - based upon crash testing to NCHRP 350 Test Levels 3 & 4 by independent, internationally renowned test facilities in the UK and USA, Brifen WRS Barrier is approved by the NZTA for use in NZ as follows: Deflection Post Spacing Test Level 3 1.25m 1.0m 1.65m 2.4m 1.8m 3.2m Test Level 4 1.7m 3.2m Other post spacing/deflection combinations may be used, but NZTA National Office approval is required on a site specific basis. Horizontal Curvature - installing wire rope barriers around curves can result in deflections being higher than the figures obtained from crash tests performed on straight sections. However, this can be countered by reducing post spacing around bends, and/or by the use of intermediate anchors on the apex of a bend. Brifen s interwoven rope design makes it tolerant of curvature with a curvature greater than 300m radius can be easily accommodated by the barrier. The angle through which the barrier curves is also relevant, for example a 90 curve with 300m radius would be of more concern than a 15 curve with 150m radius. Therefore we recommend that designers contact CSP Pacific to discuss the most cost effective options to deal with any concerns regarding installations around curves. The absolute minimum for a Brifen WRS barrier is 100m radius. Vertical Sag Curves - wire rope barriers are sensitive to vertical sag curvature because of the possibility of cables lifting up due to the increase in cable tension while tensioning or during vehicle impact. For this reason we recommend that vertical sag curvature should be not less than 3000m radius. Set-back - the desirable minimum set-back, the distance from the carriageway edge-line to the traffic face of the Brifen WRS barrier, should normally be 1.2m or greater. This reduces the incidence of nuisance hits, where a vehicle strays beyond the carriageway edge-line but can regain control and return to the carriageway if a reasonable set-back is provided. However in many instances (such as narrow medians like Centennial Highway) it may not be feasible to provide 1.2m set-back, and designers may have to compromise with smaller setbacks. This does not have any adverse effect on the performance of the Brifen WRS barrier. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 4

Clearance behind the barrier - ideally the clearance will always be greater than the design deflection of the barrier. But if designers automatically specify a barrier deflection less than the available clearance, the cost implications can be severe. For example, if a median is 3.0m wide the designer might specify a TL-3 or TL-4 deflection of 1.5m for a wire rope barrier. This will generally require significantly closer post spacing than if the TL-3 or TL-4 deflection was specified as, say, 1.8m. And closer post spacing can significantly increase the cost of the installation. Yet, the vast majority of impacts in real life will be at lower impact angles or lower impact speeds than the TL-3 or TL-4 crash test criteria, and therefore the resulting deflections will be lower. Even in the case of a full TL-3 or TL-4 impact which would be expected to result in 300 mm of intrusion into the opposing traffic lane in the above example, consider the following points, i) The intrusion would exist for only 200-300 milliseconds. ii) If a vehicle was in the opposing traffic lane during that 200-300 milliseconds, how likely is it to be travelling within 300 mm of the median edge-line. III) Even if there was contact with a vehicle in the opposing traffic lane it would only be a glancing impact thanks to the cables being pushed out ahead of the intruding vehicle. In-service experience with installations such as Centennial Highway and SH1 Rangiriri to Longswamp demonstrate that the Brifen WRS barrier can provide a cost effective solution to cross-median crashes, even though in those installations the TL-3 design deflection is 1.5m, while the available clearance is typically only 750mm. Side Slope - Ideally the ground in front of, and behind the barrier should be level. In reality this is often not possible, particularly the ground behind the barrier often has a side slope. The presence of a side-slope need not rule out the use of a Brifen WRS barrier, but side-slope should be avoided at the design stage where possible. For further information please contact CSP Pacific. Kerbs - the presence of kerbs in front of a safety barrier is not desirable because the kerb will cause instability in the vehicle trajectory prior to the vehicle contacting the barrier. However, a Brifen WRS barrier does have a degree of tolerance to an impacting vehicle having an upward trajectory, because as soon as the vehicle has contacted the ropes they are able to move vertically upwards with the vehicle and thus continue to restrain and redirect the vehicle. Therefore a Brifen WRS barrier may be installed up to a maximum of 1.5m behind the face of the kerb, subject to the height of the kerb above the carriageway being 110mm or less. Rope Heights - rope heights are generally measured from the mean ground level immediately beneath the ropes. However, if there is a kerb in front of the barrier, or some other feature causing a difference in ground level between the edge of the carriageway and the position of the barrier, then designers/contractors should contact CSP Pacific for advice before foundations are constructed. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 5

Design Requirements General The design of Brifen WRS barrier installations shall comply with the following layout and detailing requirements. Layout Layout requirements are as follows: (a) Set back at verge The desirable minimum set-back shall normally be not less than 1.2m. It may be reduced to: 1.0m adjacent to an obstruction; 0.6m adjacent to any hardshoulder, hardstrip or road having a speed limit not exceeding 50mph. (b) Set back at central reserve Where there are no obstructions and there is only one Brifen WRS Barrier installation between the carriageways and the support posts are at 3.2m centres, the minimum setback shall be 1.5m; In all situations other than above (e.g. two separate Brifen WRS Barrier installations) the set-back shall normally be not less than 1.2m. It may be further reduced to an absolute minimum of 1.0m adjacent to short obstructions and on long structures provided the support posts are spaced at 1.2m centres. (c) Clearance The minimum clearance shall normally be not less than: 1.5m when the support posts are at 3.2m centres; 1.3m when the support posts are at 1.2m centres; 1.1m when the support posts are at 1.0m centres. (d) Height of fence Where the horizontal distance from the traffic face of the fence to the edge of the adjacent paved surface is less than 1.5m, the heights of the ropes shall be measured from the level of the adjacent paved surface. Elsewhere the heights of the ropes shall be measured from the general ground level beneath the line of the safety fence. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 6

(e) Length of fence Where the Brifen WRS Barrier is provided in front of an obstruction, it shall be extended at full height not less than 30m in advance of the obstruction and shall continue at full height not less than 7.5m beyond the obstruction; On embankments 6m or more in height, the length of wire rope safety fence should be extended beyond the 6m high section to ensure that vehicles leaving the carriageway at places of lesser drop will not reach the 6m high section. On curves, further extension may be needed to reduce the risk of vehicles passing behind the fence. Detailing Detailing requirements are as follows: (a) Post foundations For initial detailing, foundations must be designed to resist the effects of a horizontal shear of 10.25 kn combined with a bending moment of 6.0 knm in a plane at right angles to the fence subject to the test loading requirements; The construction details for concrete foundations shall be specified wherever appropriate. However, specially designed foundations will be required to resist the loading requirements and where the standard details are not suitable due to poor ground conditions and/or where posts and foundations would interfere with cables, ducts or drainage systems; Where a socket is cast into an in-situ concrete foundation to facilitate post replacement, the foundation shall be of sufficient size to ensure that it is not displaced when the post is knocked down under vehicle impact. b) Anchors Where intermediate anchors are required, they shall be located not less than 30m apart longitudinally. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 7

Post Foundations 1. Procedures for Concrete foundations Plastic sockets supplied by CSP Pacific must be cast in-situ into all post foundations to provide a socket which Brifen posts will easily slide in and out of. A standard line post foundation is ø300mm x 750mm deep. The holes are usually drilled with an auger (or can be punched if the ground conditions are suitable). Then the holes should be filled with concrete (minimum 25mpa, or as specified by the engineer), ensuring a steel reinforcing ring is inserted 60mm below ground level. A post should then be placed into the plastic socket to help correctly position the plastic socket in the concrete. Avoid ramming the post into the socket to push it into position, as this could push the bottom out of the plastic socket. A 20mm crown should be formed on the top surface of the concrete. Note: The standard foundation size of ø300mm x 750mm deep is based upon the ground conditions being equivalent to or better than AASHTO soil specification M147. If the ground conditions are below the AASHTO specification then the foundation size may need to be increased. CSP Pacific has available free of charge the equipment necessary to carry out a pull test on post foundations. This will confirm that the chosen post foundation size is adequate. (Refer Section 3 Post Foundation Testing) 2. Setting Out A string line is normally used to ensure a good alignment of the post foundations. The string line can also helps to ensure that the tops of the posts are at the correct height, and have a good vertical alignment following the general contour of the road. A Brifen post should remain in the plastic socket until the concrete has cured. This ensures that the socket is not distorted by the pressure of the wet concrete and cause the post to be a tight fit. Also, the weight of the post prevents the socket from being lifted up by hydrostatic pressure if the concrete is on the wet side. 3. Post Foundation Testing A standard concrete post foundation of ø300mm x 750mm set in ground conditions that meet or exceed AASHTO soil specification M147 should be able to resist a bending moment of 6,000Nm. This can be easily checked by performing a pull test (figure A). Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 8

Figure A (pull test) Bending moment, BM, on a post/foundation is calculated as follows, BM = W x L Where: W is the load in Newtons which must be applied in a horizontal plane at right angles to the line of the barrier L is the distance in metres above ground level to the point at which the load is applied The equipment available from CSP Pacific includes a special saddle which is attached to the Brifen post. The load is then applied using a lever hoist attached to the saddle and anchored to a truck parked alongside. A load cell is also available from CSP Pacific to indicate the load being applied. A force of 10,000 N (approximately 1 tonne force) applied at a height of 600mm above ground level will give the required bending moment. If the foundation withstands a 6000Nm bending moment with no significant movement at ground level of the concrete foundation, then it has passed. If the top of the Brifen post deflects by more than 100mm, then it is deemed to have failed. Post foundations in areas which fail the pull test should be increased in size (e.g. to ø350mm x 950mm). It is usually unnecessary to perform another pull test using this larger foundation unless the ground conditions are unusually soft. If in doubt, perform another pull test. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 9

Wire Rope Barrier Installation Procedure 1. Once the end anchor blocks and post foundations have been marked out on-site, the total length of the section should be measured from end anchor to end anchor in the direction you intend on running the ropes. The position of any variation in post spacing should also be noted. Your measurements and any variations should be sent to CSP Pacific as soon as possible so, The rope lengths can be worked out. The ropes can be pre-stretched and measured. The fittings can be pressed on. The ropes can be wound on to the reel in such a way that when the ropes are run out on site they should line up exactly with the anchorage positions. 2. Prior to running the ropes, all steel posts complete with Z washer dirt excluder and bobbins should be placed into each of the concrete post foundations. Deflection posts (the ones with the welded lugs on each side) are positioned at each end anchorage. 3. The two lower ropes must always be installed first since they interweave between the posts. The two lower ropes are the first to come off the reel, and then the two upper ropes (check reel labels). The reel should be mounted on a reel stand (supplied by CSP Pacific) on the back of a truck or trailer making sure the ropes feed off the top of the reel. DO NOT lubricate the reel shaft, as the friction will help ensure the ropes remain reasonably taut while they are being run off. 4. Begin running out the first rope by connecting it into the end anchor as follows. Fit a safety check rope over the end of the rope and then fit a square polyethylene insert, steel backing plate and two nuts (or the mechanical fitting). Only screw on the nuts until a full thread has been obtained. Insert the rope into one of the slots in the outermost end anchor, so that the polyethylene insert is sandwiched between the steel backing plate and the anchor. CSP Pacific personnel will always be on-site to ensure all connections are done correctly. 5. Drive slowly alongside the barrier posts reeling off the rope. At least two people are needed to walk behind the truck weaving the rope between the posts and resting it on the plastic pegs. A join will be encountered approximately every 150 metres. When the join is reached, you will find that the next rope is taped and tied to it. After cutting away the tape and twine, the two ropes are then connected together by using a rigging screw. At this stage, only engage approximately 25mm thread, leaving the remaining thread for tensioning when all the ropes have been run out. Continue running the ropes fitting riggings screws to all joins until the end anchor is reached. Repeat this weaving the second lower rope and placing the last two ropes into the top slot. 6. Once all four ropes have been run out, you can then start to connect them to the end anchor. You will find that there is approximately two metres of surplus rope, and there is no threaded fitting swaged on the end. Fit a safety check rope, a square polyethylene insert and a steel backing plate to each rope. A lever hoist and rope grip (supplied by CSP Pacific) should now be used to pull through the slack. Before the lever hoist is released, the rope needs to be secured by a mechanical anchor fitting. The lever hoist can then be removed and the excess rope can be cut off. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 10

7. The remaining slack in the ropes will gradually be taken out by the tightening up each of the rigging screws (Tensioning). This should be done in stages so that the slack is taken up evenly along the full length of the barrier, and ensuring that there is at least 50mm of engagement between the threaded fittings and rigging screws. Also ensure that the rope fittings are pressed down and sitting correctly in the anchor slots. Tensioning and all termination checks of new Brifen WRS Barriers are always performed by CSP Pacific personal. 8. A tension meter supplied by CSP Pacific will be used to check the tension of all new installations. The tension meter can be quickly attached to the rope to ensure correct tension is achieved. The final tension will be determined by the ambient temperature at the time of tensioning. (Refer Table A shown in tensioning) 9. Once tensioning is complete, plastic caps can be fitted to all posts and reflectors attached as per contract. Denso tape (greased tape) can be used to wrap all exposed threads to help keep them free from corrosion, thus making any re-tensioning in future years easier. This is optional but recommended in harsh environments. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 11

Tensioning CSP Pacific personnel will always be on-site to help with the running of the ropes and to perform the final tensioning. rigging screws along each of the four ropes shall be adjusted equally to achieve the required tension. The required tension shall be determined at the time of tensioning and is dependant on the current ambient temperature as shown in Table A. Ambient Temperature Rope Tension C kn -10 36.00-5 33.25 0 30.50 5 27.75 10 25.00 15 22.25 20 19.50 25 16.75 30 14.00 Table A Relationship Between Rope Tension and Ambient Temperature Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 12

Maintenance & Repair Procedures Maintenance 1. A periodic drive-by inspection should be performed to detect vehicle impact damage, vandalism or damage due to any other cause. The replacements of missing caps and/or reflectors needs no further explanation, but for any other repair procedures see below. 2. Periodic check on rope heights if vehicle impact repairs are being performed correctly, there should be no reason for the rope heights to have changed since installation unless the road surface has been raised or lowered. 3. The rope heights will be automatically be correct if the top of the Brifen posts are the correct height above ground level, as follows, For Brifen WRS Barrier installed since NZTA M23 (NCHRP 350 TL3) was introduced (approx. 2002) 770mm ±30mm For earlier Brifen WRS Barrier installations 680mm ± 30mm 4. It is recommended that removal of debris from around anchorages be performed as required. This build up of soil/sand can retain moisture and increase corrosion rates. 5. Periodic check on rope tensions should not be necessary for approximately 10 years, unless the ropes have been de-tensioned for some unexpected reason, or unless the barrier has been subjected to exceptionally big impact (e.g. a particularly major impact by a heavy truck). When rope tensions are checked, a visual inspection should also be made to ensure that there is no serious corrosion of any components which are under tension. 6. Checking & adjustment of rope tensions require special equipment, and should only be carried out by CSP Pacific personnel Repair Procedures 1. Brifen posts are designed to fold on impact, and typically from 5 to 20 posts will be damaged when a vehicle hits the barrier. The system is designed to enable the damaged posts to be replaced without the need to de-tension the ropes. 2. In the section headed Brifen Repair Sequence this shows 9 photographs taken before, during and after a typical impact repair. The job can be made even easier by using a simple spreader bar to spread the ropes apart. existing maintenance contractors already have spreader bars. Further details regarding spreader bars can be obtained from CSP Pacific. 3. It is important to ensure that the top of any new posts are at the correct height above ground level. Therefore if any gravel/debris has fallen into a post socket, it may be necessary to remove it to ensure that the post is at the correct height. 4. Plastic bobbins to locate the lower interwoven ropes, plastic Z washer dirt excluders, and plastic caps must always be fitted to every post. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 13

5. In the unlikely event of impact damage occurring to the Brifen end terminals, or to the end post immediately next to the end terminal, de-tensioning of the ropes may be necessary and CSP Pacific should be contacted for advice and/or assistance. 6. Special posts are used adjacent to the end anchors and intermediate anchors. Although the vast majority of vehicle impacts will only require standard posts to be replaced, it is always important to ensure that the replacement post is of the same type as the damaged post. 7. Where a single block Brifen terminal is installed, the first 19 posts closest to a terminal will be special posts and it is important to ensure that the replacement post is of the same type as the damaged post. 8. Training of maintenance crews in repair procedures can be arranged by contacting CSP Pacific. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 14

Repair Sequence Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 15

Demounting & Reinstallation Procedures Demounting Procedure In the event that a section of Brifen WRS Barrier needs to be lowered to the ground in order to provide emergency access, the following procedures should be followed. UNDER NO CIRCUMSTANCES should tensioned wire ropes be cut. This applies to tensioned wire ropes in any situation. Cutting them could result in the ends flailing around unpredictably which could cause serious injury to the person cutting them or someone close by. It is not generally necessary to detension a Brifen WRS Barrier in order to lower the ropes to the ground. This means that the barrier can subsequently be reinstated without the need to carry out any retensioning. 1. The first step is to lift the two upper ropes out of the short slot in the top of the Brifen posts and place them one either side of the of the posts making sure they run parallel through the section to be lowered. Because the slots in the Brifen posts are very shallow, one person can easily carry out this procedure unaided. 2. Most maintenance crews carry a simple spreader bar which they use to speed up the replacement of Brifen posts following vehicle impacts. If one of these spreader bars is available, it will also speed up the following steps. 3. If a spreader bar is available, insert it alongside one of the Brifen posts, and turn the spreader bar through 90 degrees in order to spread the Brifen ropes apart. The post can then be lifted upwards clear of the ropes. The spreader bar is then removed. After the first post has been removed, the barrier will appear as shown in fig. 2. 4. If a spreader bar is not available, the ropes can be spread apart by hand, although this may sometimes require two men spreading the ropes while a third person lifts out the Brifen post. The easiest way to spread the ropes is to pull the ropes away from one side of the post, while using one or both feet to push the ropes away from the opposite side of the post. After the post has been removed, care should be taken to release the pressure on the ropes slowly. If possible, gloves should be worn to protect the fingers. 5. Repeat step No. 3 with the second post along, i.e. not with the immediately adjacent post. Continue to remove every second post until approximately 10 posts have been removed. The barrier will now appear as shown in fig. 3. 6. The ropes will no longer be interwoven around the posts which have been left in position. Now lift the ropes off the plastic pegs and allow the ropes to fall to the ground. The remaining posts can then simply be lifted out. 7. The posts which have been removed can now be stacked up at each end of the emergency crossing point in order to hold the ropes on the ground. If a longer crossing area is needed, more posts can be removed using the above steps. Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 16

Reinstallation Procedure 1. The first step is to identify the two lower ropes and ensure that they are lying on the ground without any crossing over. Then, every second post can be replaced in its socket, such that the two lower ropes appear as shown in fig. 3. The two upper ropes should also run along one side of the posts. 2. Lift up the 2 lower ropes and hang them on the plastic bobbins. The upper ropes are best left lying on the ground until step 5. 3. Starting from one end, the remaining posts can now be installed, one at a time. To do this, if a spreader bar is available, use the spreader bar to make the two lower ropes cross over. By turning the spreader bar through 90 degrees, the ropes are then spread apart enough to allow the post to be replaced. 4. If a spreader bar is not available, the 2 lower ropes can be crossed over and spread apart manually, as outlined in step 3 of the demounting procedures. 5. Repeat step 3 to replace each of the remaining posts. 6. Finally the two upper ropes can now be repositioned in the slot in the top of each post. The plastic caps can then be replaced, and the Brifen WRS Barrier is fully operational. Fig. 1 Befor Fig. 2 After Fig. 3 After removing Remov e Remove every Second Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 17

Brifen Wire Rope Safety Barrier Installation Checklist 1. END / INTERMEDIATE ANCHORAGES Y N 1.1 Excavations - dimensions as per drawings as supplied by CSP Pacific - vertical sides 1.2 Anchor frame - correctly positioned in accordance with drawings 1.3 Concrete to grade 25 Mpa (minimum) 1.4 Compaction using internal vibration 1.5 Trowelled finish to all exposed surfaces, & top surface formed as per drawings supplied 2. POST FOUNDATIONS Y N 2.1 Excavation minimum 300mm diameter and 750mm deep when ground conditions meet or exceed AASHTO standard soil with a fully compacted base. (refer test 2.6) 2.2 Concrete to grade 25 Mpa (minimum) 2.3 Reinforcing ring 60mm below ground level 2.4 20mm crown on top surface for drainage 2.5 Trowelled finish to top surface 2.6 Satisfactory pull/push test to establish the foundation s resistance to bending moment (if required by Engineer) 2.7 Post spacing in accordance with the contract 2.8 Notes: Alignment - with all posts inserted is a good alignment achieved? Height variation less than ± 10mm in any 10m length More information on Brifen Wire Rope Safety Barrier can be found at www.csppacific.co.nz or call 0800 655 200 CSP Pacific Brifen Wire Rope Safety Barrier Checklist April 12

Brifen Wire Rope Safety Barrier Installation Checklist 3. POSTS Y N 3.1 Correct placement of deflection posts at end and intermediate anchorages 3.2 Post caps in place 3.3 Reflectors in accordance with contract 3.4 Side pegs/hooks in place to support the lower ropes 3.5 Plastic Z-washer in place to prevent debris entering the socket 3.6 Driven posts to have no measurable damage to the slot in the top of the post 3.7 Surface mounted posts adequately bolted down (if used) 4. ROPES Y N 4.1 Lower ropes correctly interwoven between posts 4.2 Top ropes positioned in the slots in the top of each post 4.3 Safety check ropes fitted at each anchor and clevis fittings secured with split pins 4.4 Rope heights as per Brifen WRS Barrier drawings subject to ± 30mm tolerance 4.5 No evidence of broken wires, or other damage to ropes 4.6 Ropes correctly attached to anchors using steel backing plates and HDPE inserts Notes: More information on Brifen Wire Rope Safety Barrier can be found at www.csppacific.co.nz or call 0800 655 200 CSP Pacific Brifen Wire Rope Safety Barrier Checklist April 12

Brifen Wire Rope Safety Barrier Installation Checklist 5. RIGGING SCREWS Y N 5.1 Minimum of 25mm of thread engaged at each threaded terminal 5.2 Densotape or waterproof grease applied to all exposed threads to prevent corrosion and enable easy re-tensioning in the future (optional) 5.3 No signs of damage to threaded fittings or rigging screws 6. TENSION Y N 6.1 Rope tension checked at regular intervals and in accordance with Tensioning Table A on page 12 of Product & Install Manual Notes: Location: Installed by: Date: Inspected by: Date: More information on Brifen Wire Rope Safety Barrier can be found at www.csppacific.co.nz or call 0800 655 200 CSP Pacific Brifen Wire Rope Safety Barrier Checklist April 12

Brifen Wire Rope Safety Barrier CHECKLIST FOR USE FOLLOWING ACCIDENT 1. Did the impact cause any visible damage to an anchorage or any posts adjacent to an anchorage? (If yes, then give details in Q.10) 2. How many posts needed replacing? 3. Did any post foundations suffer damage? (If yes, then give details in Q.10) 4. Are the tops of the replacement posts the same height as the undamaged posts either side of the impact zone? (If the new posts are too high, there is likely to be debris in the post socket which needs to be removed) 5. Have the black plastic Z washer dirt excluders been fitted to all new posts? 6. Have black plastic bobbins been fitted to all new posts to support the lower ropes? 7. Have caps (and reflectors where applicable) been fitted to all new posts? 8. Have all 4 ropes been correctly positioned on the new posts, with the 2 lower ropes interweaving around the posts, and the 2 upper ropes sitting in the slots in the top of the posts? 9. Was there any visible damage (such as broken wires or kinks) to any of the ropes? (If yes then give details in Q.10) 10. Please detail any damage re. Q.1, Q.3 and Q.9, list any other concerns or inspection / maintenance work you consider needs attention: Company and Branch performing Repair Time and Date of Repair Supervisor/Team leader Supervising Repair More information on Brifen Wire Rope Safety Barrier can be found at www.csppacific.co.nz or call 0800 655 200 CSP Pacific Brifen Wire Rope Safety Barrier Checklist May 12

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Pt No Type Length WR1059A Concrete In Line Post 1430 WR1059B Standard Driven Line Post 1900 WR1059C Long Driven Line Post 2100 Ph 0800 655 200 or visit www.csppacific.co.nz June 2012 / Page 26

Works Procedure Installation of Wire Rope Barrier Activity Definition works associated with the installation of Brifen roadside wire rope barrier furniture. Unit of Measurement Metres Average Daily Production Specification or Restoration Standard The wire rope barrier shall be installed to the CSP Pacific Product & Install Manual and Road Controlling Authority Guidelines. Procedure Steps Hazard Additional PPE Details / Issues Resp. Officer 1. Locate work area Identify the proposed job site from Works orders or as directed Evaluate other site specific conditions Manual Handling Are there any changes required for the environment? Are there any changes required for safety? Check for above and under ground services Dial before you dig 2. Daily Pre-start Meeting Keep clear of moving plant Determine where Spotter will be required. Nominate Spotter from team for days work PPE as per Site policy Spotter to be nominated and recorded on daily pre-start form Ensure Spotter is aware of exclusion zones requirements for plant 3. Establish Traffic Control Erect signs and other traffic control devises in accordance with requirements Record sign layout and time of erection Are there any changes required for traffic management? Refer Roadworks signing Guide 4. Determine the Work Area Mark out site 5. Mark Out Wire Rope Footings / Posts Excavate footings / anchors Drill footing for wire rope barrier Dispose of waste as directed Crush by reversing vehicles Environmental control Spoil to be removed from site or spread Pothole. High traffic volume Muscular strains/bending

Works Procedure Installation of Wire Rope Barrier Procedure Steps Hazard Additional PPE Details / Issues Resp. Officer 6. Layout Posts and Anchors Set posts / anchors into concrete footings / Manual Handling Exposure to concrete Correct height Fit reo rings into concrete as you set the posts. Fit dust covers before wire rope. 7. Lay out wire rope and swag turn buckles at tension points / spacers / bobbins / caps / reflectors Lay out the rope to specs Swage bolts to wire rope as you lay out the rope 8. Tensioning Check the lay of rope and or height at anchors. Tension wire rope to CSP Pacific Product & Install Manual 9. Check the work against the standards Audit site 10. Re-establish Road Furniture Check Signs Ensure signs are clean 11. Leave Work Site Safe and Tidy Remove all loose material Dispose of all materials to designated site 12. Remove Traffic Control Remove signs and other traffic control devices in accordance with requirements Record time of removal 13. Complete and hand in relevant paperwork

Works Procedure Installation of Wire Rope Barrier Project Specific Details - There no additional procedures to follow the above. Project: Project Manager: Step # Procedure Steps Hazard Additio nal PPE Details / Issues Resp. Officer 1 Consider potential hazards, control measures and appropriate PPE associated with loading and/or unloading equipment and material. Struck by moving object Crushed by vehicle, plant or object Manual handling Pre-start site safety meeting Refer to Work Method Statement "Moving Powered Mobile Plant at the Workplace" and "Working on, or Adjacent to a Road or Railway". Refer to specific state "Plant Code of Practice" PPE as per department policy High Visibility Clothing Manual handling training A recommended lifting weight of 20kg for a single person 2 Ensure plant has been serviced and adjusted. 2.1 Use of unsafe plant Slips, Trips, Falls 2.2 Contaminant s spill for example, motor oil, hydraulic liquid, fuel and so on. Plant servicing and pre-start checks to be carried out and recorded in logbooks Housekeeping Bioactive absorbent material and/or spill kit to be on site Environmental controls as per sate requirements 3 Establish traffic management devices 3.1 Struck by passing traffic Pre-start site safety meeting Traffic control setup and devices utilized as per TMP's Qualified personnel PPE as per departmental policy Where possible exit vehicle on opposite side to passing traffic If exiting vehicle on traffic side always check for approaching vehicles Vehicles are to display arrow boards (when available) Work Using a Truck Mounted Attenuator (TMA) Consider the use of a TMA as per Traffic Management Diagrams and Work Instructions included in the "Guide for Use of TMA's." If a TMA is required then use in

Works Procedure Installation of Wire Rope Barrier Project: Project Manager: accordance with the above Guide. TMA to shadow personnel and vehicle placing traffic control devices TMA should be used on all M/way & H/way job sites 3.2 Muscular Strain while handling warning devises Manual handling training A recommended lifting weight of 20kg for a single person 3.3 Cuts and bruises Store signs in easy to reach locations PPE as per state policy Speed Environment High Vehicle Volumes Environment Pre-start site safety meeting do not cross any multi lane carriageways on foot Keep clear of moving plant or vehicles 4 Determine the work area: From supervisor s instructions Mark out site Drill / Excavate Struck or Crushed by plant or passing traffic UV Radiation Underground and overhead power line Environmental risks Spotter for overhead power lines PPE as per state policy High Visibility Clothing Check with "Dial Before You Dig" Environmental controls as per state requirements Refer to Work Method Statement "Moving Powered Mobile Plant at the Workplace" and "Working on, or Adjacent to a Road or Railway". Refer to specific state "Plant Code of Practice" Refer to Work Method Statement Work near overhead or underground power lines. Overhead and/or underground power lines may be required to have power isolated Spotters for plant Pothole if necessary. 5 Lay out Materials Posts /Swages / Dust Covers / Anchors. 5.1 Manual handling Sprains and strains Hand tools/cuts or striking injuries Slips, Trips, Falls Manual handling training A recommended lifting weight of 20kg for a single person Maintain hand tools in good condition PPE as per state policy Gloves while handling Wire Rope and post components

Works Procedure Installation of Wire Rope Barrier Project: Project Manager: Maintain a clean worksite Visual check of site 5 5.3 Struck or Crushed by plant or passing traffic Keep clear of moving plant or vehicles PPE as per state policy Traffic management in accordance with approved "Traffic Management Plans" Work vehicles and plant warning devices (Flashing lights, Reversing beepers,spotters while reversing,lights and work area lighting for night work) to be checked and working Refer to Work Method Statement "Moving Powered Mobile Plant at the Workplace" and "Working on, or Adjacent to a Road or Railway". Refer to specific state "Plant Code of Practice" 5.4 Contaminant s spill for example, motor oil, hydraulic liquid, fuel and so on. Bioactive absorbent material and/or spill kit to be on site Environmental controls as per state requirements. 6.1 Manual handling Sprains and strains Manual handling training A recommended lifting weight of 20kg for a single person 6 Concrete Anchors/ Footings/Posts. Hand tools/cuts or striking injuries Slips, Trips, Falls Noise PPE as per state policy Gloves while handling Wire Rope post components Maintain a clean worksite 6.2 Struck or Crushed by plant or passing traffic Keep clear of moving plant or vehicles PPE as per state policy Traffic management in accordance with approved "Traffic Management Plans" Work vehicles and plant warning

Works Procedure Installation of Wire Rope Barrier Project: Project Manager: devices (Flashing lights, Reversing beepers, lights and work area lighting for night work) to be checked and working Spotter while reversing. Refer to Work Method Statement "Moving Powered Mobile Plant at the Workplace" and "Working on, or Adjacent to a Road or Railway". Refer to state specific "Plant Code of Practice" 6 6.3 Contaminant s spill for example, motor oil, hydraulic liquid, fuel and so on. Bioactive absorbent material and/or spill kit to be on site Environmental controls as per state requirements. 7 Lay out Wire Rope Tension rope. Swage bolts 7.1 Manual handling Sprains and strains Hand tools/cuts or striking injuries Struck by the use of a overhead crane Slips, Trips, Falls Noise Manual handling training A recommended lifting weight of 20kg for a single person Use of crane truck Hard Hats to be wear while the crane is been used Keep others away from area while the crane is in use PPE as per state policy Gloves while handling Wire Rope post components Maintain a clean worksite Spotter for overhead power lines Tiger Tails Visual check of site 7.2 Overhead power line Refer to Work Method Statement Work near overhead or underground power lines. Overhead and/or underground power lines may be required to have power isolated 7.3 Keep clear of moving plant or vehicles Struck or Crushed by plant or passing traffic PPE as per state policy Traffic management in accordance with approved "Traffic Management Plans" Experience in Swaging Machine.

Works Procedure Installation of Wire Rope Barrier Project: Project Manager: Work vehicles and plant warning devices (Flashing lights, Reversing beepers, lights and work area lighting for night work) to be checked and working Spotters for reversing 7.4 Contaminant s spill for example, motor oil, hydraulic liquid, fuel and so on. Bioactive absorbent material and/or spill kit to be on site Environmental controls as per state requirements. Dispose of waste / excess material: 8 Dispose waste material at an environmentally approved site Store excess material for future work at an environmentally approved site 8.1 Manual handling Sprains and strains Syringes Manual handling training A recommended lifting weight of 20kg for a single person Dispose of syringes in sharps containers Sharps awareness training Recycle old material 8.2 Overhead power line Spotter for overhead power lines Tiger Tails Visual check of site 8.3 Recyclable material Recycle material Environmental controls as per state requirements. 9 Check the work against the restoration standard Audit Site Project Team 10 Leave work site safe and tidy Remove all loose material Manual Handling Sprains and strains Manual handling training A recommended lifting weight of 20kg for a single person Approved by Project Manager: Signature / / Date

Works Procedure Repair Wire Rope Barrier Activity Definition works associated with the repair of damaged Brifen roadside wire rope barrier furniture Unit of Measurement Metres Average Daily Production Specification or Restoration Standard The wire rope barrier shall be reinstated to CSP Pacific Product & Install Manual. Procedure Steps Hazard Additional PPE Details / Issues Resp. Officer 1. Locate work area Identify the proposed job site from Works orders or as directed Evaluate other site specific conditions Manual Handling Are there any changes required for the environment? Are there any changes required for safety? Check for above and under ground services 2. Establish Traffic Control Erect signs and other traffic control devises in accordance with requirements Record sign layout and time of erection Are there any changes required for traffic management? Refer Roadworks signing Guide 3. Determine the Work Area Mark out area if required. 4. Remove Damaged Components Dispose of waste as directed Environmental control Crush by reversing vehicles High traffic volume Muscular strains/bending 5. Install posts Replace in sockets Manual Handling Correct height Refer work instruction in Install Wire Rope Barrier 6. Re-Instate wires Determine level of impact of need to retension Ensure correct placement of wires to Hill & Smith Manual Gloves must be worn.

Works Procedure Repair Wire Rope Barrier Procedure Steps Hazard Additional PPE Details / Issues Resp. Officer 8. Tensioning Check the lay of rope and or height at anchors. Tension wire rope to CSP Pacific product & Install Manual 9. Check the work against the restoration standards Audit site 10. Re-establish Road Furniture Check Signs & guideposts Ensure signs are clean 11. Leave Work Site Safe and Tidy Remove all loose material Dispose of all materials to designated site 12. Remove Traffic Control Remove signs and other traffic control devices in accordance with requirements Record time of removal 13. Complete and hand in relevant paperwork Project Specific Details The following details are in addition to the standard Works Procedure instructions above and are specific to this project only. Project: Project Manager: Step # Procedure Steps Hazard Additional PPE Details / Issues Resp. Officer 1. 2 Approved by Project Manager: Signature / / Date