Barrier Field Manual. CSP Pacific Barrier Field Manual December 12

Transcription

1 Barrier Field Manual CSP Pacific Barrier Field Manual December 12

2 Barrier Field Manual - Index Flexrail W Beam Highway & Bridge Barrier Brochure 04 Installation Checklist 07 FX54 Highway Flexrail 12G Half Rail 08 FX55 Bridge Flexrail 10G Half Rail 08 FX33 Highway Flexrail 12G Full Rail 09 FX34 Bridge Flexrail 10G Full Rail 09 FX360 Standard Guardrail Assembly 12G on Timber Posts & Blockouts 10 FX283 Standard CSP Pacific Flexrail Posts 11 FX92 Standard Flange Mounted Steel Posts 12 FX107 Standard Timber Post & Blockout 12 FX93 Standard Steel Post for Bridge Handrail 13 FX94 Standard Steel Flexrail Post 13 FX147 Standard Tested Necked Bolt 14 FX150 Standard Cast-In Brackets 14 FX91 Flexrail Steel Post Flange Mounted 15 FX253 Standard Flexrail Backing Piece 15 FX126 8 Hole Bridge Connector 16 FX146 Bullnose Terminal End Single Piece 16 FX407 Flexrail Structure Connector 17 FX359 Buried-in-Backslope Assembly 17 Bridge Handrail FX350-1 Flexrail Handrail Sloping Termination 18 FX306-1 Handrail Standard Detail 19 Thriebeam Brochure 20 Installation Checklist 22 FX382-1 Standard 12G Thriebeam Rail 23 FX497 W-Thrie Transition Section 23 FX408 Thriebeam Timber Post & Blockout 24 FX476 Standard Thriebeam Posts 24 FX459 Thriebeam Driven Post & Blockout 25 FX475 Thriebeam Bridge Post & Blockout 25 FX461 Thriebeam Structure Connector Assly 26 FX453 Thriebeam Structure Connector 26 FX495 Thriebeam Handrail-Sloping to Timber 27 FX495-2 Thriebeam Handrail-Sloping to Steel Base 28 FX495-1 Thriebeam Mounting Detail 29 FX553 Thriebeam Steel Post & Routered Timber Blockout 29 X-350 Tangent & Flared End Terminal Brochure 30 Installation & Maintenance instructions 31 Installation Checklist 37 FX538 Tangential Terminal End - Timber Post-Elevation 38 FX539 Tangential Terminal End - Timber Post 39 FX540 Tangential Terminal End - Steel Posts-Elevation 40 FX541 Tangential Terminal End - Steel Posts 41 Nu-Guard 31 Steel Guardrail System Brochure 42 Installation & Maintenance instructions 43 Installation Checklist 45 FX514 Nu-Guard 31 System Assembly 46 FX513 Nu-Guard 31 W-Beam Post 47 FX525 Nu-Guard 31 Median System Assembly 47 FX566-1 Nu-Guard 31 Curved Terminal Installation 48 FX577 Nu-Guard 31 Transition to 27 High X-350 Timber Post Option 49 FX608 Nu-Guard 31 Transition to 31 High X FX609 Nu-Guard 31 Transition to Standard TL4 Thriebeam 51 FX611 Nu-Guard 31 Transition to Railing End Terminal 51 CSP Pacific Barrier Field Manual December 12 Trailing End Terminal Installation Checklist 52 FX335 Curved Trailing Terminal Assembly - exploded view 53 2

3 Barrier Field Manual - Index FX348-2 Curved Trailing Terminal Assembly 54 FX348-4 Straight Trailing Terminal Assembly 55 NZTA Standard Details RSB-1 Buried-in-Backslope Terminal 56 RSB-2 Curved Terminal 57 RSB-3 M23 Terminal Grading Plan 58 RSB-4 Nested Guardrail Detail 59 RSB-5 TL4 Transition Detail 59 Drawings FX33 09 FX34 09 FX54 08 FX55 08 FX91 15 FX92 12 FX93 13 FX94 13 FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX FX RSB1 56 RSB2 57 RSB3 58 RSB4 59 RSB5 59 CSP Pacific Barrier Field Manual December 12 3

4 Flexrail TM W-Beam Highway (12g) & Bridge Barrier (10g) Flexrail complies with the requirements of AASHTO, AS/NZS 3845 : 1999 TNZ specifications M/23 and M/17P. CSP Pacific supplies two standard types of Flexrail W-beam guardrail:» Highway Flexrail: » Bridge Flexrail: Flexrail is roll formed from coil steel and sheared to length. It is then punched, slotted and hot dip galvanised in accordance with the appropriate standards. Flexrail is generally available ex-stock in standard net lengths of 3.81 metres and metres for highway rail and 4.00 metres and 2.00 metres for bridge rail. Physical Properties Highway (12g) Bridge (10g) Effective Cover Steel Thickness (mm) Area of Cross Section (mm 2 ) Section Modulus (mm 3 ) Major 80,000 Major 103,000 Minor 22,000 Minor 29,000 Mass (kg per metre) Profile More information on Flexrail can be found at or call CSP Pacific Barrier Field Manual December 12 4

5 Flexrail W-Beam Highway (12g) & Bridge Barrier (10g) Backing Piece (used on steel blockouts only) Fish Tail Rolled End Fitting Bullnose End Fitting Structure Connector Post Post Bolt Steel Post Wooden Post Wooden Post Bolt Size A mm B mm Splice Bolt More information on Flexrail can be found at or call CSP Pacific Barrier Field Manual December 12 5

6 Flexrail W-Beam Highway (12g) & Bridge Barrier (10g) Highway Rail (2.7mm Gauge) Bridge Rail Dimensions (3.4mm Gauge) Curved Flexrail Highway Rail The standard straight section will align to give a smooth transition on curves with a radius greater than 45m. Pre-curved Flexrail is required for tighter radii and may be curved to traffic face concave or convex. NB: Only Highway Flexrail is available pre-curved. R (metres) α (Deg) C (m) H (mm) More information on Flexrail can be found at or call CSP Pacific Barrier Field Manual December 12 6

7 Flexrail W-Beam Highway (12g) & Bridge Barrier (10g) Installation Checklist Checklist Y N Assembly and installtion is to be generally in accordance with TNZ M23, AS/NZS 3845:1999 and CSP Pacific drawing FX360 and/or the Engineers specification. The rail height (top) is in accordance with the plans (706mm above the edge of the shoulder or the ground line). Correct lapping of the rail should be away from the direction of traffic to prevent snagging. Timber blockouts should be nailed to timber post to prevent rotation. Installation is aligned and level. Posts are aligned at correct spacing and backfill compacted. Post bolts are tight and a 50 x 50 square washer is fitted to back of post. Steel Post Systems (Post Type FX91, FX92, FX93 & FX94) Backing pieces to be fitted at the intermediate post only. Post bolts are tight using a spring washer and then locked with a lock nut. Necked bolts are installed with washer as specified and are installed tight. Notes: Location: Installed by: Date: Inspected by: Date: More information on Flexrail can be found at or call CSP Pacific Barrier Field Manual December 12 7

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18 Bridge Handrail (Not for use on State Highways) CSP Pacific Barrier Field Manual December 12 18

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20 Thriebeam Thriebeam has been available for more than 25 years as a natural addition to the guardrail family of products. Thriebeam has an added corrugation that gives it an advantage for use in transitions to bridges and along high volume, high speed roadways. Thriebeam derives its name from the general cross-sectional shape of the beam. The product is roll formed from coil steel and sheared to length. It is punched and slotted to suit the particular configuration, then hot dip galvanised prior to despatch. Thriebeam complies with the requirements of AS/NZS 3845:1999 and TNZ M23. Thriebeam is available ex-stock in standard net lengths of 4 metres with post spacing at 1m centres. Profile DIMENSIONS & MECHANICAL PROPERTIES 2.7mm Gauge Beam Width Minimum (mm) 508 Beam Depth Minimum (mm) 76 Cross Sectional Area (mm2) 2,013 Moment of Inertia (mm2) 1,555,000 Section Modulus (mm3) 36,400 Weight (approx) (kg/m) 16.7 More information on Thriebeam can be found at or call CSP Pacific Barrier Field Manual December 12 20

21 Thriebeam Structure connector Post options and detail Thriebeam rail elevation Transition section Backing plate More information on Thriebeam can be found at or call CSP Pacific Barrier Field Manual December 12 21

22 Thriebeam (12g) Barrier Installation Checklist Checklist TL-3 Timber Post System Y N Assembly and installation is to be generally in accordance with TNZ M23, AS/NZS 3845:1999 and/ or Engineers specification. The rail height (top) is in accordance with the plans (805mm above the edge of the shoulder or the ground line). Correct lapping of rail away from the direction of traffic to prevent snagging. Timber blockouts nailed to timber post to prevent rotation. Installation is aligned and level. Post are aligned, at correct spacing and backfill compacted. Two post bolts per post and block. Post bolts are tight and a 50 x 50 square washer is fitted to back of post. Checklist TL-4 Steel Post System Y N Assembly and installation is to be generally in accordance with TNZ M23, AS/NZS 3845:1999, CSP Pacific drawing FX495-1 and/ or Engineers specification. The rail height (top) is in accordance with the plans (865mm above the edge of the shoulder or the ground line). Correct lapping of rail away from the direction of traffic to prevent snagging. Modified Blockout is fixed to I-Post with 2 M16 x 50 Eng bolt and nut diagonally. Backing pieces at fitted at the intermediate post only. Installation is aligned and level. One post bolt per post and modified blockout required only. To be installed in the top post hole. Post bolts are tight using a spring washer and then locked with a lock nut. Posts are aligned at correct spacing. With a flange based post the necked bolts are installed with washer as specified and are tight. Location: Installed by: Inspected by: More information on Thriebeam can be found at or call Date: Date: CSP Pacific Barrier Field Manual December 12 22

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30 X-350 Tangent and Flared Guardrail End Terminal X-350 Tangent Features» Approved to NCHRP 350 TL-3» Lower cost» Fully re-directive» Cost effective, life saving device» Length of need (LoN) at post one» Improved vehicular control» Impact force held in tension less chance of kinked rail» Little or no debris scatter» Ease of installation and maintenance» 3 x Standard highway rails 12 gauge» Impact head weighs only 25 kgs» Flared of tangent terminal end» Designed & manufactured in NZ» Patented technology X-350 Flared Specifications: NCHRP 350 TL-3» Speed: 100kph» Length: 11.4m (3rails)» Offset: mm» Post 1: Steel» Posts 2 6: Breakaway timber or steel» Run out 22.5m x 6m» LoN starts at Post 1» Max grade 10:1» All steel components hot dipped galvanised More information on X-350 Tangent and Flared Guardrail End Terminals can be found at or call CSP Pacific Barrier Field Manual December 12 30

31 X-350 Tangent & Flared Installation Instructions Step 1 - X-350 parts identification Impact head (1 required) Friction plate (1 required) Soil anchor (1 required) Slider panel (1 required) Slider bracket + angle bar (1 required roadside) Cable bracket (1 required) Cable assembly (2 required) Post 1 top (1 required) Post # 2 (1 required) (roadside can be CRT timber) Ground strut (1 required) Standard steel line Post (3-6) (roadside can be CRT timber) Post # 1 bottom (1 required) Standard highway rail (3 required roadside) Shear bolts (8 required) Blockout (plastic or timber) (5 required) Hardware set Step 2 - Installing posts 6-2 Install posts 6 to 2 at standard highway rail Spacing 1905mm, to the correct height. Top of post to be either 710mm or 805mm above ground level depending on the guardrail system being attached to. Posts #6 to #3 are either standard I beam posts OR timber CRT posts. Note: Only standard I beam posts can be installed at the higher height of 805mm. Timber posts must be 710mm above ground level. Post 2 is either the Special I beam post or a timber CRT. For the I beam post at 805mm above ground, the embedment of this post must only be 1025mm. Posts may be directly driven, or in stiff soils a 150mm diameter hole drilled, and the post then driven into the hole. The post may also be placed in an oversized augured hole but care must be taken to ensure the backfill is properly compacted. Figure 1. Pull a string line with the desired offset Figure 2. Bolt the blockout prior to attaching the rail CSP Pacific Barrier Field Manual December 12 31

32 X-350 Tangent Installation Instructions Step 2 - Installing posts 6-2 Hint: Offset Post 3 back from the string line 40-50mm to make it easier to push rail 1 and Slider Panel over rail 2. When driving steel posts, ensure that a driving cap with timber or plastic insert is used to prevent damage to the galvanising on the top of the posts. Bolt the blockout to the post at post 3, prior to attaching to the rail (Figure 3). Step 3 - Post 1, ground strut & soil anchor Place the roadside face of post 1 bottom anchor, 200mm towards the roadway to compensate for the lack of blockout (Figure 3). Post 1 bottom the Ground Strut and the Soil Anchor are then placed parallel to the string line at this roadside offset position. Drive or place the bottom of post 1 in the augured hole so that no more than 75mm (100mm max), protrudes above ground level (Figure 4). Use the Ground Strut as a template to place the Soil Anchor in the correct place. The Soil Anchor can then be driven into place or placed in an augured hole and backfilled. The Ground Strut should be level or lower at the anchor end than at the post 1 bottom end (Figure 5). Place post 1 top in the post 1 bottom anchor ensuring that the post bolt notches are at the top and facing the Soil Anchor (Figure 5). Use M16 x 200mm hex head bolt with nut and washers. Figure 3. Measure 20cms towards roadway Figure 4. Drive Soil Anchor 1 into augured hole Note: There is a choice of 2 height settings at the bottom of post #1 top. Ensure that the correct one is selected so that centre of impact head is at the correct height above ground level. Step 4 - Hang rail 3 & cable anchor bracket Rail 3 is installed like standard guardrail with post 6 at the centre of the rail and blockouts between the rail and post. Place the Cable Anchor Bracket on the back of the rail at the joint between rail 3 and rail 4 (post 7). The two boxes on the cable bracket should be on the impact head side of the splice joint. Attach rails to post with post bolt and splice rail 3 to rail 4 with 8 standard splice bolts (Figure 6). Note: Do not over tighten bolt. Figure 5. Post 1 top in post bottom Figure 6. Splice rail 3 to rail 4 with 8 standard splice bolts CSP Pacific Barrier Field Manual December 12 32

33 X-350 Tangent Installation Instructions Step 5 - Hang rail 2 and shear bolts Before installing rail 2 double check that the blockout is already bolted to post 3. Bolt rail 2 to the post and blockouts at posts 4 and 5 with the appropriate post bolt (Figure 7). DO NOT BOLT THE RAIL TO POST 3. Splice rail 2 to rail 3 with the 8 special shear bolts (yellow) supplied (Figure 8). Put the washer and nut on inside of rail. IMPORTANT NOTE: DO NOT USE STANDARD SPLICE BOLTS AT POST 5 SPLICE Figure 7. Bolt rail 2 to post and blockouts Figure 8. Splice rail 2 to rail 3 with 8 special shear bolts Step 6 - Attach slider bracket to Rail 2 Bolt the Slider Bracket to the end of rail 2 at post 3 (Figure 9). Use 4 standard splice bolts. The angle bar end should be closest to the Impact Head end. Remove the angle bar and 2 x M20 x 40mm bolts (Figure 10). Figure 9. Bolt Slider Bracket to end of rail 2 at post 3 Figure 10. Remove angle bar bolts Step 7 - Assemble slider panel onto Rail 1 Start by sitting rail 1 on a blockout or post so that it is raised off the ground as shown (Figure 11). Slide the Slider Panel onto the downstream end of rail at post 3 location (Figure 12) and bolt into place using 4 standard splice bolts, pushing the bolt through from the inside of the slider to the outside so that the nut is on the traffic face. The curved and reinforced (post breaker) end of Slider Panel sits at the rail end. Use guardrail pin bar or crow bar to assist with lining up splice holes. Step 8 - Hang rail 1 Lift rail 1 with Slider Panel attached and push the slider end over rail 2 (Figure 13). Overlap the rails as per a standard splice joint overlap. Bolt rail 1 and blockout to post 2 using a standard post bolt that is supplied (Figure 14). Re-attach the angle bar to the slider bracket on the backside of the rail (Figure 15). Figure 11. Sit rail 1 so it is raised off the ground Figure 12. Slide the Slider Panel onto downstream end CSP Pacific Barrier Field Manual December 12 Figure 13. Push Slider Panel over rail 2 Figure 14. Bolt rail 1 and blockout to post 2 33

34 X-350 Tangent Installation Instructions Step 9 - Attach Impact Head Place Impact Head on upstream end of rail 1 and attach using 8 standard splice bolts with nuts on traffic face (Figure 16). Hint: Place bottom two bolts first then use guardrail pin bar to lever head up snug onto rail. Bolt head and rail 1 to post 1 using the supplied M16 x 50mm guardrail post bolt. Use a 50mm x 50mm washer under the nut on the inside of post 1 (Figure 17). Figure 16. Attach Impact Head to rail 1 Figure 17. Bolt head and rail 1 to post 1 with washer Step 10 - Place the Cables Push the cables under the steel strap on the Ground Strut (Figure 18) and forward through the holes at the top of the anchor. Lay the cables out parallel to the guardrail, downstream from the anchor. Ensure that bottom cable (closest to road) has half the thread protruding through the anchor, as shown. Ensure the top cable has the nut wound on a least two turns past the end of the thread (Figure 19). Figure 18. Push cables under steel strap on Ground Strut Figure 19. Thread the nuts as shown Step 11 - Installing the Cables Install the Friction Plate in the top of the Impact Head, adjustment hole up. Take the cable closest to the road, pick up the downstream cable fitting and walk to the head, passing the cable through the bottom hole, through the Friction Plate (Figure 20) and out the backside of the Impact Head. Now thread the cable down the backside of the rail following the bottom trough of the W-beam and attach to the bottom box on the Cable Bracket at post 7. Repeat this process with the other cable but push it through the top hole and thread it along the top trough of the W-beam. Place the nuts and washer on the cables at the Cable Bracket end but only run them a few turns (Figure 21). Do not tighten cables at this stage (or the Friction Plate will not turn) Figure 20. Pass the cable through the bottom hole Figure 21. Place the nuts and washer on the cables at the Cable Bracket end but only turn them a few turns CSP Pacific Barrier Field Manual December 12 Figure 15. Reattach the angle bar 34

35 X-350 Tangent Installation Instructions Step 12 - Turning the Friction Plate Put a crow bar through the hole at the top of the friction plate (Figure 22) and turn it in slot as far as it will go. Using a socket spanner tighten the 4 - M20 x 75mm bolts on the side of the impact head to lock the bar in the turned position (Figure 23). Figure 22. Use crow bar to turn Friction Plate Figure 23. Use socket to lock bar in the turned position Step 13 - Tightening the Cables Only tighten the cables using the nuts at the Cable Bracket end (post 7) (Figure 24). Do not tighten the cable nuts at front of the Ground Anchor. Tighten the cables until they are taut, i.e. they rest in the backside of the W-beam and do not visibly sag between posts (Figure 25). There is no torque requirement for the cables. Figure 24. Tighten cables at Cable Bracket end (post 7) Figure 25. Tighten cables until they are taut Step 14 - Attach Nosing and Nut Protectors Push nosing into place on the front of the impact head. Attach using the supplied nylon push rivets (Figure 26). Delineation to be attached to nosing as per Local Authority requirements. The X-350 Plastic Nut Protectors are available for all X-350 Terminal Ends. They protect pedestrians and cyclists from exposed splice bolt nuts and threads. Fit 8 Nut Protectors on the Impact Head (Figure 27) and 4 on Slider Panel (Figure 28). Figure 26. Attach nose using nylon push rivets Figure 27. Nut Protectors fitted on Impact Head CSP Pacific Barrier Field Manual December 12 Figure 28. Nut Protectors fitted to Slider Panel 35

36 X-350 Flared Installation Instructions X Flared Installation Instructions This section deals with installation of a Flared X-350 system in a roadside guardrail terminal end application. Apart from the initial set out, the flared X-350 and installation procedure is identical to the Tangent system, the only difference being the amount of offset used m Site preparation The Flared terminal may be installed either parallel to the edge of the roadway (tangent) or with the impact head end of the rail offset by up to 1.2m away from the road (Figure 29) in a straight flare, over the length of the system. No parabolic curve is required. Ensure that the area where the X-350 is to be installed is flat enough so that the anchor will not protrude more than 75 mm (100 mm max) above ground level, when measured with a straight line over a 1.5m cord. Minor site grading may be required. Figure 29. Pull string line to follow roadside edge of post. Maximum offset is 1.2m Step 1 - Set Out Pull a string line out with the desired offset 0-1.2m. Note that the flare is a straight flare, over the length of the system (11.4m). The string line should be set to follow the roadside edge of the posts (Figure 29). All the posts except post 1 have a blockout so take care to place the roadside face of post 1, 200mm towards the roadway (Figure 30). Post 1 bottom; the Ground Strut and the Soil Anchor are then placed parallel to the string line on the roadside of it (Figure 31). Now follow steps 2 14 in the Tangent installation instructions. Note: The kink in the line of rail between rail 3 and rail 4 (at post #7) is formed by simply pushing the rails around to follow the flared line of posts. This is not factory bent. Figure 30. Place roadside face of post 1 towards roadway Figure 31. Place ground strut parallel to string line CSP Pacific Barrier Field Manual December 12 36

37 X-350 Installation Instructions Installation Checklist Checklist Y N Ground strut is flush to ground surface No more than 100mm to protrude above ground surface Bolted to post # 1 at base of post Impact head has rail bolted with all 8 nuts on the face of the rail Locking bar is turned fully in slot and secured with 4 x 8.8HT bolts only Post # 2 is a steel I beam breakaway (weakened) or timber CRT post with blockout Post # 3 is not bolted to rail Post # 3 to 6 are steel I beam line posts (not weakened) or timber CRT posts with blockouts Slider panel is attached to rail # 1 with all four nuts on the face of rail Slider bracket is attached to rail # 2 with all four nuts inside the rail Angle bar is bolted to the slider bracket with the flat section facing post # 3 at the impact head side Cables are tensioned up taut with no visible sag over the 11.4m span 8 x yellow shear bolts are bolted at rail # 2 and # 3 with the spacers washers between the nut and rail depending on guardrail system. Note that steel posts must be used if at 635mm high. Guardrail height is 550mm or 635mm from the finished road surface to the centre of the rail depending on guardrail system. Note that steel posts must be used if at 635mm high. Flare rate mm from the tangent 11.43m Location: Installed by: Inspected by: Date: Date: CSP Pacific Barrier Field Manual December 12 37

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42 Nu-Guard 31 Steel Guardrail System A smaller footprint, lighter weight and no requirement for a blockout means the Nu-Guard 31 steel post guardrail system is comparable in cost to wooden post systems and is simpler and quicker to install. Features» System has a smaller footprint and no blockout» NUCOR steel posts, with no blockout, enables faster installation» It is possible for one post to be installed per minute using a post rammer» NUCOR steel posts are lighter and smaller in area than traditional posts» High tensile galvanised NUCOR steel post is designed for easy after-impact repair of system» Environmentally friendly - manufactured using recycled steel» Uses standard highway rail and fixings» A median or roadside barrier» NUCOR steel posts will split on impact to avoid guardrail tearing, reducing the incidence of wheel snagging» Only NCHRP350 TL-4 tested and approved system using standard highway rail Specifications» Tested and approved to MASH-1 TL-3 and NCHRP 350 TL-4» Post weight: kg» Post length: 1980mm» Height to centre of rail: 635mm» Post footprint: m 2» Maximum system deflection is 1200mm for roadside applications» No blockouts required» Standard highway rail and fixings» All components hot dip galvanised» Posts are manufactured from high tensile steel More information on Nu-Guard 31 can be found at or call CSP Pacific Barrier Field Manual December 12 42

43 Nu-Guard 31 Installation Instructions Install Posts Use standard guardrail procedures to mark out and align the posts. Post spacing is the same as standard rail at 1905mm. The Nu-Guard 31 posts are 1980mm long with a slot at the top. For roadside installations, ensure that the flanges are facing to the side the rail will be installed on and that they are parallel to the line of the rail. For median installations ensure the posts are alternated between flanges forward and then flanges back. When driving steel posts, ensure that a driving cap with timber or plastic insert is used to prevent damage to the galvanising on the top of the posts. The top of the post should be 812mm above the nominal ground line. This places the centre of the rail at approximately 635mm from the nominal ground line. Posts may be driven or in stiff soils a 100 dia. hole drilled and the post then rammed into the hole. The post may also be placed in an oversized augured hole but care must be taken to ensure the backfill is properly compacted. Install Rail The rail is installed the same as standard guardrail with a splice join being at a post. It is generally easiest to lift one rail at a time and while it s held in place, fit the post bolt in the centre of the rail to hold the rail in place. Use the M16 x 90mm coach bolt to fix rail to post, ensuring that the 90mm diameter washer is fitted between the rail and post as detailed below. Secure on back of post with a standard splice nut (no washer). Lap rails in direction of traffic. The top of the post must be a minimum of 20mm above the top of the guardrail. Therefore the position of the M16 x 90mm post bolt in the slot may vary slightly. M16 x 90mm coach bolt c/w splice nut 90mm Dia. washer between rail and post flanges CSP Pacific Barrier Field Manual December 12 43

44 Nu-Guard 31 Installation Instructions Assemble Rails Splice the rails together in the standard manner, ensuring that all eight splice bolts are used and fully tightened at every joint. For Median Installations Only It may be easier to hang the rails on one side, two or three panels ahead of the other, holding them temporarily in place with the centre post bolts. Then as the panels on the other side are placed, secure them into place bolting both sides of rail with one bolt at the splice joins. The temporarily placed centre bolts can then be removed and pushed through both sides of rail as well. Washers are placed between the post rail on both sides of the post in median situations. In median installations, if more than 20mm of bolt protrudes past nut on backside, cut off and treat with cold galvanising paint. System Maintenance Nu-Guard 31 TM is maintained exactly the same as standard timber post and block-out guardrail. If the rail and/ or the post is damaged and/or bent then it must be replaced. CSP Pacific Barrier Field Manual December 12 44

45 Nu-Guard 31 Steel Guardrail System Installation Checklist Checklist Y N Height to centre of rail is 635mm There is no blockout When driving post, use a driving cap with timber or plastic insert to avoid damage to the post Top of post should be a minimum of 20mm above top of guardrail 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 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 Barrier Field Manual December 12 45

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52 Trailing End Terminal Installation Checklist Checklist Y N Assembly and installation is to be generally in accordance with AS/NZS 3845:1999, TNZ M23 and CSP Pacific drawing FX348-2 The rail height (top) is in accordance with the plans (706mm above the edge of the shoulder or the ground line) The steel tubes/posts do not protrude more than 100mm above the ground line (measured by the AASHTO 1.5m cord method, site grading may be necessary to meet this requirement The bolts at the top of the steel tubes are not over tightened and the walls of the steel tubes are not collapsed/distorted. The 200mm x 200mm bearing plate at post 1 is correctly positioned and the anchor cable is taut and correctly installed (it should be rechecked after installation to be sure it hasn t relaxed) Blockouts have been toe nailed to the posts The backfill material around the posts is properly compacted The rail panel is not attached to the post at post No. 2 the rail sits on the shelf angle only Notes: Location: Installed by: Inspected by: Date: Date: CSP Pacific Barrier Field Manual December 12 52

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56 NZTA Standard Details The following drawings are the property of the New Zealand Transport Agency and are subject to amendment. The latest version is available on CSP Pacific Barrier Field Manual December 12 56

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60 Copyright and Limited Reproduction: The design of and all content appearing in this brochure are the copyright of CSP Pacific. No part of this brochure may be:» distributed or copied for any commercial purpose, nor incorporated in any other work or publication (whether in hard copy, electronic or any other form); or» resold, published, copied, reproduced, transmitted or stored (including in any other brochures or other electronic form) except that you may print, or copy only for your own use (or for use in any document, proposal or presentation for the purpose of specifying products manufactured or supplied by CSP Pacific), without the express permission of CSP Pacific. Disclaimer: This Brochure contains files which were current at the time of printing. Latest drawings and informations are available in PDF format from our web site Issue: Barrier Field Manual V8 December 2012 CSP Pacific A member of the Fletcher Building Group 306 Neilson Street, Onehunga, Auckland 1061 PO Box , Penrose, Auckland 1642 Ph: or Fax: