Product/Installation Manual Corporate Offices: 35 East Wacker Dr., 11 th Floor Chicago, IL 60601-2076, USA Tel: +1 (312) 467-6750 Fax: +1 (312) 467-1356 http://www.energyabsorption.com/ Quixote Europe Crown House, Crown Street Ipswich IP1 3HS, UK Tel: +44 (0) 1473 221105 Fax: +44 (0) 1473 221106 www.quixtrans.com
Table of Contents Important Introductory Notes... 2 Product Description... 2 Component Description... 3 Check Shipping List... 7 Tools Required for Installation... 7 P4 System Installation... 8 1.0 Determine Post Locations... 9 2.0 Post Installation... 12 3.0 Ground Anchorage Post Foundations... 17 4.0 Spacer and Rail Installation... 19 5.0 Head Assembly Installation... 22 6.0 Cable Installation... 23 P2 System Installation... 25 1.0 Determine Post Locations... 26 2.0 Post Installation... 29 3.0 Ground Anchorage Post Foundations... 33 4.0 Spacer and Rail Installation... 35 5.0 Head Assembly Installation... 37 6.0 Cable Installation... 38 Maintenance... 40 Limitations and Warnings... 40 P4 System Drawing [Driven Posts]... 41 P4 System Drawing [Concrete Sockets]... 43 P2 System Drawing [Driven Posts]... 45 P2 System Drawing [Concrete Sockets]... 47 Important Introductory Notes Proper design, installation, maintenance and repair of the Terminus CEN End Terminal system is essential to assure maximum performance. Take the time to review this manual thoroughly before performing any necessary work. Do not attempt to install any safety system without proper instructions. Product Description The Terminus CEN End Terminal is a crash worthy steel-post, energy absorbing terminal designed to enhance safety at the beginning and end of highway safety barrier. The Terminus CEN End Terminal has been successfully tested to the P4 performance class (110 km/h) and the P2 performance class (80 km/h) using the CEN criteria described in EN 1317-4. For a list of the tests, see the Limitations and Warnings section of this manual. The Terminus CEN End Terminal uses a 'directional' breakaway post concept to support the rail sections. The Lower Post, having a 'U' section is driven into the ground. The Upper Post, with its 'U' section, slides into the Lower Post and is secured using a steel Tension Bolt. During a head-on impact, longitudinal forces break the Tension Bolt, releasing the Upper Post. Energy absorption is achieved through clamping forces between the rails and deformation of the rail sections as they slide rearwards. During a side impact along the Terminus CEN End Terminal the Upper and Lower Posts are designed to remain together, laterally supporting the rail sections, so that the impacting vehicle is smoothly redirected. The P4 performance class system has a nominal length of 12.4 meters and a nominal rail height of 760 mm. The P2 performance class system has a nominal length of 4.4 meters and a nominal rail height of 760 mm. 2
Component Description COMPONENT PART NO. QTY. (P4 system) QTY. (P2 system) Head Rail Assembly 2770050-0000 1 1 Intermediate Rail 2770052-0000 1 1 Intermediate Rail with Fin 2770051-0000 4 0 End Rail with Fin 2770068-0000 1 1 Support Plate 2770053-0000 6 2 Spacer 2770058-0000 4 0 Spacer with Cable Anchor 2770060-0000 1 1 Spacer with Hole for Cable 2770059-0000 1 1 Upper Post 2770056-0000 6 2 Lower Post 2770055-0000 4 0 Front Lower Post 2770064-0000 2 2 Soil Plate 2770063-0000 1 1 Cable Strut 2770062-0000 1 1 Cable Assembly (P4 system) 3506351-0000 1 0 Cable Assembly (P2 system) 3506351-2000 0 1 Cable Strut Bolt Assembly 2680005-E005 2 2 Soil Plate Bolt Assembly 2680004-E004 2 2 Tension Bolt Assembly 2680006-E006 6 2 Rail Bolt Assembly 2680003-E001 41 13 Washer Bar 2708975-0000 5 1 Concrete Socket (OPTIONAL) 2770065-0000 6 2 Short Lower Post (OPTIONAL) 2770066-0000 4 0 Short Front Lower Post (OPTIONAL) 2770067-0000 2 2 WARNING! To ensure proper performance, only replacement parts supplied by Energy Absorption Systems, Inc. may be used to maintain or repair the Terminus CEN End Terminal. 3
Head Rail Assembly* Intermediate Rail Intermediate Rail with Fin 2770050-0000 2770052-0000 2770051-0000 End Rail with Fin Support Plate Spacer 2770068-0000 2770053-0000 2770058-0000 Spacer with Cable Anchor Spacer with Hole for Cable Upper Post 2770060-0000 2770059-0000 2770056-0000 *Note: The Head Rail Assembly is symmetrical and can be used on the upstream and downstream ends of highway safety barrier and on either side of the roadway. 4
Lower Post Front Lower Post Soil Plate 2770055-0000 2770064-0000 2770063-0000 Cable Strut Cable Assembly Cable Strut Bolt Assembly 2770062-0000 3506351-0000 (P4) 3506351-2000 (P2) 2680005-E005 Soil Plate Bolt Assembly Tension Bolt Assembly Rail Bolt Assembly 2680004-E004 2680006-E006 2680003-E001 5
Washer Bar Concrete Socket (OPTIONAL) Short Lower Post (OPTIONAL) 2708975-0000 2770065-0000 2770066-0000 Short Front Lower Post (OPTIONAL) 2770067-0000 6
Check Shipping List Carefully uncrate all components. Check the component parts list against parts received to verify that all items were received. Tools Required for Installation Traffic Control Equipment 24mm Wrench 19mm Wrench 17mm Wrench Chalk Line Tape Measure Marking Paint Straight Edge 16mm Alignment Tool 160 Nm Torque Wrench 90 Nm Torque Wrench Protective Eyewear Gloves Steel-Toed Boots Note: The above list of tools is a general recommendation. The actual number of tools required will depend on specific site conditions and the complexity of the installation. CAUTION: Read and understand all instructions before beginning installation. IMPORTANT! Positioning of the posts is critical. Measure each post center and relevant distance back from the road carefully. Double check all measurements before installing the lower posts into the ground. 7
P4 System Installation Towards Existing Guardrail (Downstream) Back of System Upstream Post 6 Post 5 Post 4 Post 3 Front of System Post 2 Post 1 Figure 1 8
P4 System Installation (cont d.) 1.0 Determine Post Locations 1.1 Using a straight edge or plumb line down the existing guardrail face (i.e., traffic side) to the ground, create a datum line (DT1) on the ground. Ensure that this line is parallel with the existing guardrail face. Extend this line ~14 meters upstream of the end of the existing guardrail. Verify that the datum (DT1) remains parallel to the existing guardrail. [Refer to Figure 2] Existing Guardrail Straight Edge or Plumb Line DT1 Figure 2 9
P4 System Installation (cont d.) 1.2 A new guardrail post must be driven into the ground at the end of the guardrail panel. The edge of this new guardrail post must be offset from the datum line DT1 towards the existing guardrail by a distance of 210mm (this offset is needed in order to attach a Spacer between the guardrail post and the guardrail panel). It should be noted that the centerline of this new guardrail post may not align with the existing guardrail posts or with the Terminus CEN End Terminal posts. [Refer to Figure 3] 1.3 Measure perpendicular from the datum line (DT1) towards the existing guardrail 250mm and make a mark (M1) near the first guardrail post. [Refer to Figure 3] Note: Any variation of system post pitch at the end of the guardrail system caused by the addition of the new guardrail post must be evened out to reduce pocketing effects. If the dimensions to the end guardrail post is greater than the system post pitch then adjust by not more than one working width difference the adjacent downstream post. First Guardrail Post DT1 M1 210mm to edge of first guardrail post 250mm to mark M1 Figure 3 10
P4 System Installation (cont d.) 1.4 Locate the first post of the Terminus CEN End Terminal (i.e., Post 1, refer to Figure 1): First measure from mark (M1) a distance of 12m upstream and make a second mark (M2) which is perpendicular to datum line (DT1). Verify the perpendicular distance of 250mm from mark (M2) to the datum (DT1). Adjust mark (M2) if necessary. [Refer to Figure 4] 1.5 Chalk or stake a line from mark (M1) to mark (M2). This will be the centerline for the posts. [Refer to Figure 4] 1.6 From location (M2), measure off the rest of the post locations (i.e., Posts 2 to 6, refer to Figure 1), towards the first guardrail post, at 2.0m intervals (6 total post locations). [Refer to Figure 4] 2.0m 2.0m M1 DT1 12m 2.0m 2.0m 2.0m 2.0m 250mm M2 Figure 4 11
P4 System Installation (cont d.) 2.0 Post Installation 2.1 Using two E004 fastener assemblies (i.e., two 10mm x 80mm Soil Plate Bolts and two 10mm Hex Nuts), attach the Soil Plate to one of the Front Lower Posts. [Refer to Figure 5] Note: This will be Post 1. [Refer to Figure 1 on page 8] Soil Plate Two Hex Nuts Two E004 fastener assemblies Front Lower Post (Post 1) Figure 5 12
P4 System Installation (cont d.) 2.2 Starting with the post location closest to the existing guardrail (i.e., Post 6), install one Lower Post, orient as shown. [Refer to Figure 6] The center of the Tension Bolt hole should be approximately 15mm above the ground. [Refer to Figure 7] Note: Post spacing is 2.0m. [Refer to Figure 4 on page 11] Refer to Section 3.0: Ground Anchorage Post Foundations Lower Post (Post 6) M1 DT1 Guardrail Figure 6 15mm Ground Lower Post Figure 7 2.3 Repeat step 2.2 for the remaining three Lower Posts (i.e., Posts 5, 4 and 3). 13
P4 System Installation (cont d.) 2.4 Next, install one Front Lower Post (i.e., Post 2), orient as shown. [Refer to Figure 8] The center of the Tension Bolt hole should be approximately 15mm above the ground. [Refer to Figure 9] Note: Post spacing is 2.0m. [Refer to Figure 4 on page 11] Lower Post (Post 3) Front Lower Post (Post 2) DT1 Figure 8 15mm Ground Front Lower Post (Post 2) Figure 9 14
P4 System Installation (cont d.) 2.5 Install the final Front Lower Post with Soil Plate attached (i.e., Post 1) at the last post location (i.e., farthest from the existing guardrail). The center of the Tension Bolt hole should be approximately 15mm above the ground. [Refer to Figure 10] 15mm Ground Front Lower Post (Post 1) Soil Plate Figure 10 2.6 Insert an Upper Post into the Lower Post. Note: Be sure to clear all dirt in between the Upper Post and Lower Post. Bolt the two posts together using one E006 fastener assembly (i.e., one 12mm x 50mm Tension Bolt and two 12mm Hex Nuts). [Refer to Figure 11] Upper Post Lower Post Two Hex Nuts E006 fastener assembly Figure 11 15
P4 System Installation (cont d.) 2.7 Tighten the E006 fastener assembly to a torque of 90Nm using a torque wrench. Note: The torque is applied using a single Hex Nut. Once the required torque is achieved attach the second Hex Nut and tighten. 2.8 Repeat steps 2.6 through 2.7 for all remaining Lower Posts and Front Lower Posts. 16
P4 System Installation (cont d.) 3.0 Ground Anchorage Post Foundations Note: It is essential the Terminus posts are installed in suitable ground/soil/foundations that will allow the system to fully perform in accordance with the design specification. Suitability of the ground foundation can be ascertained using the following test. 3.1 Ground anchorage testing shall be carried out on a sacrificial post. On completion of the testing, the test post(s) must be removed along with any foundations. 3.2 A horizontal load shall be applied to the top of the post by means of a hydraulic ram with a calibrated load cell. The load is to be applied to the side of the Upper Post near the front face to avoid twisting of the post during testing. [Refer to Figures 12 and 13] Upper Post Load, L (N) Figure 12 Upper Post Load, L (N) Datum peg or tripod Ground 600mm height for deflection measurement Height of load point, H (m) Lower Post Figure 13 3.3 The load shall be applied by pushing on the post. The hydraulic ram must be supported against a rigid/non-moving part of the work vehicle. 17
P4 System Installation (cont d.) 3.4 A datum peg is to be driven into the ground in line with the post and the center line of the hydraulic ram with a height approximately equal to that of the test post (a simple tripod can be constructed for this purpose). [Refer to Figure 13] 3.5 The load is to be applied in increments of 1000N and the deflection of the post in reference to the datum peg is to be measured and recorded within ±1mm. The deflection of the post should be measured 600mm above the ground level. [Refer to Figure 13] 3.6 The applied bending moment is calculated by multiplying the load (L) measured in Newtons and the load height (H) measured in meters. [Refer to Figure 13] 3.7 The post/foundation is deemed satisfactory if the post is able to withstand a 9000Nm bending moment and the measured deflection is less than 150mm. In addition there shall be no apparent movement of the concrete foundation (if used). Examples of recommended ground anchorage options can be found in the Terminus Anchorage Guidelines published by Energy Absorption Systems, Inc. 18
P4 System Installation (cont d.) 4.0 Spacer and Rail Installation 4.1 Refer to system drawings on pages 41-44 of this manual for assistance in locating parts. 4.2 Use one E001 fastener assembly (i.e., one 16mm x 50mm Rail Bolt, one 16mm Washer, and one 16mm Hex Nut), or the existing guardrail manufacturer s hardware to attach the Spacer with Cable Anchor to the first guardrail post. All of the Spacers have two slots on the inside for mounting, orient as shown. [Refer to Figure 14 (Guardrail panel not shown for clarity)] Downstream Spacer with Cable Anchor First Guardrail Post E001 fastener assembly or guardrail manufacturer s hardware Figure 14 4.3 Working from the guardrail to the front of the Terminus CEN End Terminal, use one E001 fastener assembly (i.e., one 16mm x 50mm Rail Bolt, one 16mm Washer, and one 16mm Hex Nut) and one Washer Bar to attach the Spacer to the upper hole located in the Upper Post Posts 6, 5, 4 and 3. All of the Spacers have two slots on the inside for mounting, orient as shown. Note: The Washer Bar needs to lie between the E001 bolt head and the Spacer. [Refer to Figure 15] Spacer Upper Post (Posts 6, 5, 4 and 3) Washer Bar E001 fastener assembly Figure 15 19
P4 System Installation (cont d.) 4.4 Next use one E001 fastener assembly (i.e., one 16mm x 50mm Rail Bolt, one 16mm Washer, and one 16mm Hex Nut) and one Washer Bar to attach the Spacer with Hole for the Cable to the middle hole located in the second Upper Post. All of the Spacers have two slots on the inside for mounting, orient as shown. [Refer to Figure 16] Note: Post 1 does NOT receive a Spacer. [Refer to Figure 19 on page 22] Spacer with Hole for Cable Upper Post (Post 2) Washer Bar E001 fastener assembly Figure 16 4.5 Begin with the End Rail with Fin and the rear Intermediate Rail with Fin. Attach the End Rail with Fin over the existing guardrail panel and the rear Intermediate Rail with Fin over the End Rail with Fin (i.e., the End Rail with Fin is located in between the existing guardrail panel and the rear Intermediate Rail with Fin). You may have to use the alignment tools to aid in aligning the holes. Attach using four E001 fastener assemblies and one Support Plate as shown. Note: The Support Plate needs to lie between the E001 bolt heads and the Intermediate Rail. [Refer to Figure 17] First Guardrail Post Existing Guardrail Panel End Rail with Fin Rear Intermediate Rail with Fin Support Plate and four E001 fastener assemblies Fin Figure 17 20
P4 System Installation (cont d.) 4.6 Working from the rear Intermediate Rail, attach the next Intermediate Rail to the system using six E001 fastener assemblies and one Support Plate. Be sure to overlap the panels in the correct way, the upstream panel is on top of the downstream panel. [Refer to Figure 18] Rear Intermediate Rail with Fin Intermediate Rail with Fin Support Plate and six E001 fastener assemblies Figure 18 4.7 Tighten E001 fastener assemblies to a torque of 160Nm using a torque wrench. 4.8 Repeat steps 4.6 and 4.7 until all of the Intermediate Rails are attached. Note: The final Intermediate Rail to be installed (at the front of the system) does NOT have a fin. 21
P4 System Installation (cont d.) 5.0 Head Assembly Installation 5.1 Using a forklift or other lifting method, position the Head Rail Assembly on the posts. Attach using a total of seven E001 fastener assemblies and one Support Plate. Note: The Head Rail Assembly attaches to the Head Post through the lowest hole in the Upper Post. [Refer to Figure 19] Spacer with Hole for Cable Post 2 Intermediate Rail (without fin) Post 1 Support Plate and six E001 fastener assemblies Head Rail Assembly Figure 19 5.2 Tighten E001 fastener assemblies to a torque of 160Nm using a torque wrench. 22
P4 System Installation (cont d.) 6.0 Cable Installation 6.1 Using two E005 fastener assemblies (i.e., two 10mm x 130mm Cable Strut Bolts and two 10mm Hex Nuts) attach the Cable Strut between the two Front Lower Posts, orient as shown. [Refer to Figure 20 (Head Assembly not shown for clarity)] Cable Strut Hex Nut Post 1 Hex Nut E005 fastener assembly E005 fastener assembly Figure 20 6.2 Attach the Cable to the Cable Strut using the Cable Shackle. [Refer to Figure 21 (Head Assembly not shown for clarity)] Cable Post 1 Cable Shackle Figure 21 23
P4 System Installation (cont d.) 6.3 Feed the Cable up through the hole located on the bottom of the Spacer with Hole for the Cable. Next feed the Cable through each of the Spacers. [Refer to Figure 22] Intermediate Rail (without fin) Spacer Post 3 Spacer with Hole for the Cable Post 2 Figure 22 Cable 6.4 Insert the threaded end of the cable through the Spacer with Cable Anchor. Secure the Cable using one 24mm Washer and one 24mm Hex Nut. Tighten nut until slack is removed from the Cable. [Refer to Figure 23 (End Rail with Fin, guardrail panel and first guardrail post not shown for clarity)] Rear Intermediate Rail with Fin 24mm Hex Nut and Washer Spacer with Cable Anchor Figure 23 Threaded Cable End 24
P2 System Installation Towards Existing Guardrail (Downstream) Back of System Upstream Front of System Post 2 Post 1 Figure 24 25
P2 System Installation (cont d.) 1.0 Determine Post Locations 1.1 Using a straight edge or plumb line down the existing guardrail face (i.e., traffic side) to the ground, create a datum line (DT1) on the ground. Ensure that this line is parallel with the existing guardrail face. Extend this line ~6 meters upstream of the end of the existing guardrail. Verify that the datum (DT1) remains parallel to the existing guardrail. [Refer to Figure 25] Existing Guardrail Straight Edge or Plumb Line DT1 Figure 25 26
P2 System Installation (cont d.) 1.2 A new guardrail post must be driven into the ground at the end of the guardrail panel. The edge of this new guardrail post must be offset from the datum line DT1 towards the existing guardrail by a distance of 210mm (this offset is needed in order to attach a Spacer between the guardrail post and the guardrail panel). It should be noted that the centerline of this new guardrail post may not align with the existing guardrail posts or with the Terminus CEN End Terminal posts. [Refer to Figure 26] 1.3 Measure perpendicular from the datum line (DT1) towards the existing guardrail 250mm and make a mark (M1) near the first guardrail post. [Refer to Figure 26] Note: Any variation of system post pitch at the end of the guardrail system caused by the addition of the new guardrail post must be evened out to reduce pocketing effects. If the dimensions to the end guardrail post is greater than the system post pitch then adjust by not more than one working width difference the adjacent downstream post. First Guardrail Post DT1 M1 210mm to edge of first guardrail post 250mm to mark M1 Figure 26 27
P2 System Installation (cont d.) 1.4 Locate the first post of the Terminus CEN End Terminal (i.e., Post 1, refer to Figure 24): First measure from mark (M1) a distance of 4m upstream and make a second mark (M2) which is perpendicular to datum line (DT1). Verify the perpendicular distance of 250mm from mark (M2) to the datum (DT1). Adjust mark (M2) if necessary. [Refer to Figure 27] 1.5 Chalk or stake a line from mark (M1) to mark (M2). This will be the centerline for the posts. [Refer to Figure 27] 1.6 From location (M2), measure off the rest of the post locations (i.e., Post 2, refer to Figure 24), towards the first guardrail post, at 2.0m intervals (2 total post locations). [Refer to Figure 27] 4m 2.0m M1 DT1 2.0m 250mm M2 Figure 27 28
P2 System Installation (cont d.) 2.0 Post Installation 2.1 Using two E004 fastener assemblies (i.e., two 10mm x 80mm Soil Plate Bolts and two 10mm Hex Nuts), attach the Soil Plate to one of the Front Lower Posts. [Refer to Figure 28] Note: This will be Post 1. [Refer to Figure 24 on page 25] Soil Plate Two Hex Nuts Two E004 fastener assemblies Front Lower Post (Post 1) Figure 28 29
P2 System Installation (cont d.) 2.2 Starting with the post location closest to the existing guardrail (i.e., Post 2), install one Front Lower Post, orient as shown. [Refer to Figure 29] The center of the Tension Bolt hole should be approximately 15mm above the ground. [Refer to Figure 30] Note: Post spacing is 2.0m. [Refer to Figure 27 on page 28] Refer to Section 3.0: Ground Anchorage Post Foundations Guardrail Lower Post (Post 2) M1 DT1 Figure 29 15mm Ground Front Lower Post (Post 2) Figure 30 30
P2 System Installation (cont d.) 2.3 Install the final Front Lower Post with Soil Plate attached (i.e., Post 1) at the last post location (i.e., farthest from the existing guardrail). The center of the Tension Bolt hole should be approximately 15mm above the ground. [Refer to Figure 31] 15mm Ground Front Lower Post (Post 1) Soil Plate Figure 31 2.4 Insert an Upper Post into the Front Lower Post. Note: Be sure to clear all dirt in between the Upper Post and Front Lower Post. Bolt the two posts together using one E006 fastener assembly (i.e., one 12mm x 50mm Tension Bolt and two 12mm Hex Nuts). [Refer to Figure 32] Upper Post Front Lower Post Two Hex Nuts E006 fastener assembly Figure 32 31
P2 System Installation (cont d.) 2.5 Tighten the E006 fastener assembly to a torque of 90Nm using a torque wrench. Note: The torque is applied using a single Hex Nut. Once the required torque is achieved attach the second Hex Nut and tighten. 2.6 Repeat steps 2.4 through 2.5 for the remaining Front Lower Post. 32
P2 System Installation (cont d.) 3.0 Ground Anchorage Post Foundations Note: It is essential the Terminus posts are installed in suitable ground/soil/foundations that will allow the system to fully perform in accordance with the design specification. Suitability of the ground foundation can be ascertained using the following test. 3.1 Ground anchorage testing shall be carried out on a sacrificial post. On completion of the testing, the test post(s) must be removed along with any foundations. 3.2 A horizontal load shall be applied to the top of the post by means of a hydraulic ram with a calibrated load cell. The load is to be applied to the side of the Upper Post near the front face to avoid twisting of the post during testing. [Refer to Figures 33 and 34] Upper Post Load, L (N) Figure 33 Upper Post Load, L (N) Datum peg or tripod Ground 600mm height for deflection measurement Height of load point, H (m) Lower Post Figure 34 3.3 The load shall be applied by pushing on the post. The hydraulic ram must be supported against a rigid/non-moving part of the work vehicle. 33
P2 System Installation (cont d.) 3.4 A datum peg is to be driven into the ground in line with the post and the center line of the hydraulic ram with a height approximately equal to that of the test post (a simple tripod can be constructed for this purpose). [Refer to Figure 34] 3.5 The load is to be applied in increments of 1000N and the deflection of the post in reference to the datum peg is to be measured and recorded within ±1mm. The deflection of the post should be measured 600mm above the ground level. [Refer to Figure 34] 3.6 The applied bending moment is calculated by multiplying the load (L) measured in Newtons and the load height (H) measured in meters. [Refer to Figure 34] 3.7 The post/foundation is deemed satisfactory if the post is able to withstand a 9000Nm bending moment and the measured deflection is less than 150mm. In addition there shall be no apparent movement of the concrete foundation (if used). Examples of recommended ground anchorage options can be found in the Terminus Anchorage Guidelines published by Energy Absorption Systems, Inc. 34
P2 System Installation (cont d.) 4.0 Spacer and Rail Installation 4.1 Refer to system drawings on pages 45-48 of this manual for assistance in locating parts. 4.2 Use one E001 fastener assembly (i.e., one 16mm x 50mm Rail Bolt, one 16mm Washer, and one 16mm Hex Nut), or the existing guardrail manufacturer s hardware to attach the Spacer with Cable Anchor to the first guardrail post. All of the Spacers have two slots on the inside for mounting, orient as shown. [Refer to Figure 35 (Guardrail panel not shown for clarity)] Downstream Spacer with Cable Anchor First Guardrail Post E001 fastener assembly or guardrail manufacturer s hardware Figure 35 4.3 Next use one E001 fastener assembly (i.e., one 16mm x 50mm Rail Bolt, one 16mm Washer, and one 16mm Hex Nut) and one Washer Bar to attach the Spacer with Hole for the Cable to the middle hole located in the second Upper Post. All of the Spacers have two slots on the inside for mounting, orient as shown. [Refer to Figure 36] Note: Post 1 does NOT receive a Spacer. [Refer to Figure 38 on page 37] Spacer with Hole for Cable Upper Post (Post 2) Washer Bar E001 fastener assembly Figure 36 35
P2 System Installation (cont d.) 4.4 Begin with the End Rail with Fin and the Intermediate Rail. Attach the End Rail with Fin over the existing guardrail panel and the Intermediate Rail over the End Rail with Fin (i.e., the End Rail with Fin is located in between the existing guardrail panel and the Intermediate Rail). You may have to use the alignment tools to aid in aligning the holes. Attach using four E001 fastener assemblies and one Support Plate as shown. Note: The Support Plate needs to lie between the E001 bolt heads and the Intermediate Rail. [Refer to Figure 37] First Guardrail Post Existing Guardrail Panel End Rail with Fin Intermediate Rail Support Plate and four E001 fastener assemblies Figure 37 4.5 Tighten E001 fastener assemblies to a torque of 160Nm using a torque wrench. 36
P2 System Installation (cont d.) 5.0 Head Assembly Installation 5.1 Using a forklift or other lifting method, position the Head Rail Assembly on the posts. Attach using a total of seven E001 fastener assemblies and one Support Plate. Note: The Head Rail Assembly attaches to the Head Post through the lowest hole in the Upper Post. [Refer to Figure 38] Spacer with Hole for Cable Post 2 Intermediate Rail Post 1 Support Plate and six E001 fastener assemblies Head Rail Assembly Figure 38 5.2 Tighten E001 fastener assemblies to a torque of 160Nm using a torque wrench. 37
P2 System Installation (cont d.) 6.0 Cable Installation 6.1 Using two E005 fastener assemblies (i.e., two 10mm x 130mm Cable Strut Bolts and two 10mm Hex Nuts) attach the Cable Strut between the two Front Lower Posts, orient as shown. [Refer to Figure 39 (Head Assembly not shown for clarity)] Cable Strut Hex Nut Post 1 Hex Nut E005 fastener assembly E005 fastener assembly Figure 39 6.2 Attach the Cable to the Cable Strut using the Cable Shackle. [Refer to Figure 40 (Head Assembly not shown for clarity)] Cable Post 1 Cable Shackle Figure 40 38
P2 System Installation (cont d.) 6.3 Feed the Cable up through the hole located on the bottom of the Spacer with Hole for the Cable. [Refer to Figure 41 (Guardrail panel and first guardrail post not shown for clarity)] Intermediate Rail Spacer with Cable Anchor Head Rail Assembly Spacer with Hole for Cable Post 2 Cable Figure 41 6.4 Insert the threaded end of the cable through the Spacer with Cable Anchor. Secure the Cable using one 24mm Washer and one 24mm Hex Nut. Tighten nut until slack is removed from the Cable. [Refer to Figure 42 (End Rail with Fin, guardrail panel and first guardrail post not shown for clarity)] Rear Intermediate Rail 24mm Hex Nut and Washer Spacer with Cable Anchor Figure 42 Threaded Cable End 39
Maintenance Visual Inspection - Weekly The purpose of the visual inspection is to spot any conditions that would prevent the system from functioning as designed. These conditions may include an unrecorded impact, misalignment, loose fasteners, corrosion, vandalism, etc. 1. Check for any buildup of trash or dirt around the system that could interfere with proper operation. Limitations and Warnings The Terminus CEN End Terminal has been tested and evaluated in accordance with European Standard EN 1317-4 (Terminals and Transitions). While the tests are intended to represent a range of in-service impact conditions, they do not represent or encompass all possible in-service impact conditions. The following tests have been conducted on the Terminus CEN End Terminal and all test criteria have been successfully met. Physical Inspection - Annually 1. Clear and dispose of any debris on the site. 2. Be sure all fasteners are tight. 3. Verify that all E001 fastener assemblies (i.e., Rail Bolts) are torqued to 160Nm. 4. Check to see that the E006 fastener assemblies (i.e., Tension Bolts) in each post are still intact. Test 1 Test 2 Test 3 Test 4 Test 5 Head-on 1/4 offset Head-on center 15 side 2/3 L 165 side 1/2 L Head-on 1/4 offset 900 kg vehicle 1500 kg vehicle 1500 kg vehicle 900 kg vehicle 900 kg vehicle 100 km/h 110 km/h 110 km/h 100 km/h 80 km/h 5. Verify that all E006 fastener assemblies (i.e., Tension Bolts) are torqued to 90Nm. 6. Check to see that slack is removed from the cable (tighten nut on threaded cable end if necessary). 40
P4 System Drawing [Driven Posts] 41
P4 System Drawing [Driven Posts] (cont d.) 42
P4 System Drawing [Concrete Sockets] 43
P4 System Drawing [Concrete Sockets] (cont d.) 44
P2 System Drawing [Driven Posts] 45
P2 System Drawing [Driven Posts] (cont d.) 46
P2 System Drawing [Concrete Sockets] 47
P2 System Drawing [Concrete Sockets] (cont d.) 48
Customer Service Department USA Phone: 1-888-323-6374 Fax: 1-312-367-1356 Asia Pacific Phone: +65 6276 3398 Fax: +65 6276 6218 Europe Phone: +44-1473-221-105 Fax: +44-1473-221-106 35 East Wacker Dr., 11 th Floor Chicago, IL 60601-2076 Engineering and Manufacturing Facilities: Rocklin, California and Pell City, Alabama Rev. A 12/18/09 Part No. 2735921-0000 2009 Energy Absorption Systems, Inc. 49