Installation Manual for Gate Guard Fast Opening Barrier Gate for Emergencies and Contra Flow Innovative safety technology from SGGT of Germany
TABLE OF CONTENTS Page Number Preface 3 Introduction 3 System Overview 3 Equipment and Tools 4 Before Installing 5 Components 6-14 Preparing the Site 14 Installation 15-18 Appendices a. General System Drawing plan and profile (no.: SGGT 145001-e page 1-3)
Preface Page 3 The SGGT GateGuard barrier gate incorporates the latest engineering techniques and processes and has been tested and approved to the European norms contained in EN1317-2 at test level H2. It is robust enough to safely contain vehicles up to 13,000 kgs traveling at 70 km/h and impacting at a 20 degree angle. As with all roadside safety devices, the GateGuard system must be correctly installed to ensure proper performance. Thoroughly review and understand the installation instructions before starting to install. Do not start without the proper plans and tools required. Should you need further information or have any queries, please contact the SGGT Customer Service Department on +49 6824 308 171. Introduction The GateGuard system is a semi rigid barrier gate designed to safely redirect impacting vehicles when closed acting in a similar to normal road barriers but to be quick and easy to open when required, providing safe channeling of traffic. It is ideal for all dual carriageways (divided roads). The system is modular and is supplied in 4 metre long sections. The sections can be connected forming gates of any length up to 40 metres per gate. Sometimes turning point are too short and it is advisable to lengthen them by modifying existing civil works to improve ease of turning for emergency vehicles or contra flow traffic. SGGT will also supply transition sections to link the GateGuard to existing barriers. These would be purpose made and tailored to each individual site. System Overview The GateGuard system is designed and constructed to provide acceptable structural adequacy, minimal occupant risk and safe vehicle trajectory as set forth in EN 1317-1 & 2. It is a fully crashworthy gate constructed of galvanized steel with a barrier height of 900mm. The upper part resembles box beam. The system s broad base gives maximum stability and safety. The system consists of five primary parts: o eight fixed anchored end sections, o two gates and, o one connecting section between the two gates.
Page 4 Equipment & Tools Flatbed truck with lifting equipment Core drilling tool capable of drilling a core 32 and 45 mm in diameter and to a depth of 400mm. Power generator Compressor Rotohammer for drilling holes in concrete Drills bits 18/32 and 35/57 Tape measure and chalk line Long handle crow bar Sledgehammer Saw for cutting metal Screw driver, hammer, broom and other miscellaneous tools Pipe wrench, large adjustable spanner (preferably two or three sets) Safety equipment for workers (steel capped boots, high visibility jackets, gloves, protective glasses) and, Traffic control items road (traffic cones, warning signs, etc.) First aid kit Note: The tool list is a general recommendation. Depending on the specific characteristics of the work site, more or less tools may be required.
Page 5 Before Installation 1. Please send site details to SGGT or its local agent so that we can provide recommendations and detailed drawings. 2. Let us know what is on either end of the proposed gate site so that we can recommend transitions from GateGuard to existing barriers. 3. Let us know what type of road surface there is at the site. We would prefer to install onto concrete but it might be possible to install onto asphalt. SGGT or its local agent will be able to advise you. 4. We also need to know if there are any expansion joints or storm water drains or other obstacles running across or near the proposed site. 5. The site should be prepared for installation before the system is delivered to site. This might include removing existing barriers, pouring concrete foundations and modifying civil works. 6. All traffic control devices should be in place before arrival of the system. 7. The GateGuard can be installed in one day or less if there is an experienced crew with the right tools. However, it is better to allow two days for installation if this is the first time you have carried out an installation. 8. The GateGuard is a highly engineered road safety device made up of a relatively small number of parts. Before starting to assemble, become familiar with the basic elements that make up the system. The GateGuard components are illustrated on the following page.
Page 6 Components (Photos with each item) General photo of system
Page 7 Installation photos
Gate in open position Page 8 Gate section
Page 9 Gate hinge Fixed end section with hinge
Page 10 Hinge pin Upper box beam Lower box beam
Anchor poles Page 11 Box beam end caps
Page 12 Steel pins Safety clip
Page 13 Lifting rod Threaded Spindle
Page 14 Wheels Preparing the Site a) Make sure traffic control/safety devices are positioned around the worksite in accordance with local safety regulations before work begins. b) In most cases, systems will be dispatched in containers when shipped to destinations outside of Europe. Assembly is typically done on site. Before beginning assembly, check the packing list against system components to ensure all parts are present. c) Make sure location where the GateGuard is to be installed is flat without unevenness or significant changes in cross gradient and is clear of dirt and other debris. If there is a significant unevenness, this should be rectified before installing. Unevenness can create problems when opening the gate. d) If concrete foundations are to be laid at the anchor points, this should be done at least 5 days before installation. e) It is important to determine the system s intended position in accordance to the drawings provided. Mark with a chalk line the position. Also, mark the exact centre. f) Additionally, mark 13 cm either side of the centre. (Gates have a 26 cm gap between them).
Page 15 Installation Step 1 a) When the truck arrives on site, offload the gate centre (diagonal) sections first placing the tip of the lower ends at the 13 cm marks. This will form a V shape. b) Then offload the gate sections. The base plates overlap one another with part of the base sliding under the other. It is important to ensure the sections are the right way round to order to do this. Use the truck s crane and crow bar to maneuver them into position. These sections are heavy and caution should be taken in keeping heads, feet and hands out of the way when offloading and positioning. Note: one section has a hinge. This section must be the last gate section with the hinge facing outwards. c) After the gate sections are in position, offload the end (fixed) sections. The hinge should be facing towards the centre and should marry up to the last gate section. Using the crane and crow bar, insert the hinge pin. d) Lastly, offload the transition sections. These are likely to have been specially made for the site and will differ in length and type. e) Other parts of the system should be left to one side for the moment. f) Check that the system fits the space allocated and there are no problems with the positioning. Step 2 The sequence of installation may change depending on site conditions but in normal circumstances, we recommend that installation starts at one end and continues towards the middle and onto the other end. DON T START AT BOTH ENDS AT ONCE. The transitions can be the difficult part of the installation. SGGT recommends that one starts with the more complicated end (if there is one). Therefore, attach one of the transitions to existing barrier and to the GateGuard fixed end. All bolts, nuts and washers are supplied and the drawings will clearly mark which ones to use. In some cases, chemical adhesive is required to secure the bolts in place. Please read the instructions detailed on the cans carefully. If adhesive is used, do not tighten the bolts for at least 6 hours. Note: Some small adjustments to the positioning of the system may be necessary either to avoid rebar or to give a better visual appearance to the transitions. Minor adjustments do not create problems.
Page 16 Step 3 Next, secure the end (fixed) sections to the road surface. Use the section s base as a template and drill holes through it into the road surface to the depth and diameter shown on the drawings. Clean loose dirt from the holes using compressed air and/or brush. Place a nut on an anchor bolt and drop it into each hole ensuring that the holes are deep enough for the bolt s length. Then half fill holes with adhesive supplied and insert a bolt into each hole. We recommend that a nut with washer is placed on each bolt so that the right height is achieved. To ensure good bonding, twist the bolt backwards and forwards when installing until the bolt is to the correct depth. Note: Don t attempt to tighten nuts for at least six hours to allow the adhesive to cure. Step 4 The gate sections must now be bolted together. There are many bolts and one should have several people working on tightening them. The drawings will indicate which size of bolt is required. Bolts in the base plate are smaller. Take care in lining up the lower sections before attempting to insert the bolts. Minor adjustments to the sections position may be necessary. Ensure all bolts are tightly done up. Step 5 There are two box beam rails which connect the two gates at the centre. They are held in place by steel pins. Each pin has a safety clip. The longer beam goes on top and the shorter below. Install them now. Note: One of the gate sections has a metal rod passing vertically through the top and bottom parts of it. It is not fixed in any way. Look for it. It can be removed and placed through the box beams. It is long enough for two people to use it to lift the beams. The rod simply facilitates ease of movement when one needs to move them from the closed to the open position and back. The beams will slide along the top of the gates and are secured with the steel pins. You will find holes in the first sections of the gates for this purpose. Step 6 Bolt up the second gate in exactly the same way as the first.
Page 17 Step 7 Install the second fixed end section as the first. Step 8 Install the second transition. In some cases, there is the need to shorten or lengthen the transition slightly to fit accurately the space available. This is usually fairly easy to do. If modifications are necessary, the site engineer should be consulted. If new holes are drilled or beams cut, the steel parts should be treated with galvanizing paint to protect them against corrosion. Step 9 a) Remove the centre box beam. Remove the plates at the base of each gate. These cover a circular hole. Mark the position the holes with chalk and move gates to one side. Using the core drilling tool, drill holes to the diameter and depth shown on the drawings. b) After removing the core, insert the metal anchor sleeve. This is sometimes a tight fit. A sledge hammer can be used to install it to the correct depth. c) Move the gates back into their original position and insert the anchor poles. d) Remove all dirt, gravel or sand which the cores may have created. The GateGuard installation for the closed position is completed. Step 10 The final step is the make the holes in the lanes to secure the gate open when required. a) Along the lower section of each gate section is a black cap. Remove them. Beneath, is a threaded spindle with a large nut. By turning this nut, the wheels can be lowered, raising the gate off the ground. Raise each wheel to the same height. b) Remove the anchor poles which are securing the gates in the closed position. Swing the gates open both to the left and right. This can easily be accomplished by one or two people. With the assistance of the site engineer, determine what positions are required when the gate is open. Depending on gate length, one will normally make holes at the outer edges of the first and second lanes closest to the GateGuard. Make a chalk marks using the gate to determine exact positions and drill_holes.
Page 18 c) There are several lane anchoring solutions and one should consult the drawings for the type being used on your project. In most cases, metal sleeves are inserted into the road surface at the points drilled. A cap is supplied to stop dirt getting into it. The centre anchor poles are usually used to hold the gates open. Final Checks o Close gates. o Insert anchor pins in closed position. o Replace cover plates above anchor pins. o Replace upper and lower box beams. o Replace the lift rod o Clean all dirt from site If there are any queries or the need for some help, please contact our local agent or SGGT. Our contact details are: SGGT Strassenausstattungen GmbH Customer Service Dept. Bahnhofstrasse 35 66564 Ottweiler Germany Tel.: +49 6824 308 0 Fax: +49 6824 308 231 Email: export@sggt.com