Barrier Systems X-MAS Installation And Maintenance Manual Download

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Lindsay Transportation Solutions Sales and Services, Inc

(888) 800-3691 [U.S. toll free] or +1 (707) 374-6800

X-TENSION

SYSTEM

X-Tension Maintenance (Head on Impacts)

Head on Impacts

Key Repair Steps:

1. Remove the cables

2. Pull the rails back

3. Remove components from rails

4. Remove damaged posts

5. Assess damage

6. Reassemble

Step 1: Remove Cables

After a head on impact the cables may appear to be slack but may in fact still retain some tension

from the impact. Care must be taken when removing the cables. DO NOT UNDO THE CABLES

FROM TH E GROUND ANCHOR END FIRST, ALWAYS UNDO THE CABLES FROM THE C ABLE

BRACKET (post 7) FIRST.

Undo nuts at downstream cable bracket (post 7). Take out the bolts on the side of the impact head that

hold the friction plate in place and turn the friction plate back. Pull one cable at a time from the front

side of the impact head and completely remove them. Rotating the cables as you pull them will help.

Undo nuts at ground anchor end last and remove cables.

Step 2: Pull Rails Back Out

Attach a chain or two ton strap to the front of the impact head and pull upstream to its’ original position

with a light truck or utility vehicle. The components are easier to unbolt when the rails are separated.

Step 3: Remove X-Tension Components

All components are attached to the rails with standard splice bolts. Unbolt and remove parts.

Step 4: Remove Posts

Undo the bolt at the bottom of Post 1 and pull out post. For all other damaged line posts, attach a

chain to the top half of the post and pull out of the ground with either a crane truck or digger. Note it is

sometimes possible to remove steel posts by hand.

Step 5: Assess The Damage

Any part that cannot be reused must be replaced with a new part. In minor impacts (rails telescoped

less than 3 meters (10 feet ) the cables can be reused by turning them end for end. If additional dam-

age has occurred, replace the cables. Generally, all the specialized components of the system such

as the head and brackets should be undamaged.

Step 6: Reassemble

Reassemble as per system installation instructions.

Summary of Contents for X-MAS

Page 1: ...INSTALLATION AND MAINTENANCE MANUAL X TENSION X MAS NCHRP 350 TL 3 Tangent Flared End Terminal and Median Attenuator ...

Page 2: ...Tools Required 8 Before Starting 8 X Tension Tangent Installation 9 X Tension Flared Installation 17 X MAS Median Installation 19 Optional Nose Cover 24 Installation Checklist 25 Traffic Face Impacts 26 Head on Impacts 27 APPENDIX Drawings XTGTSS1 Roadside Imperial Wood Blockout Wood Post 28 XTGTSS2 Roadside Imperial Wood Blockout Steel Post 29 XTGTSS3 Roadside Imperial Composite Blockout Steel Po...

Page 3: ...r systems Even head on high angle 15o during testing impacts on the nose resulted in the vehicle being redirected and controlled System Overview The X Tension Guardrail End Terminal is designed and constructed to provide acceptable struc tural adequacy minimal occupant risk and safe trajectory as set forth in NCHRP 350 for guard rail terminal ends When impacted head on with an 820 2000kg 1800 4400...

Page 4: ...ING WITH LTS SPECIFICATIONS OR AT LTS ELECTION TO THE REPAYMENT OF AN AMOUNT EQUAL TO THE PURCHASE PRICE OF SUCH PRODUCTS OR PARTS WHETHER SUCH CLAIMS ARE FOR BREACH OF WARRANTY OR NEGLIGENCE LTS SHALL NOT BE LIABLE FOR ANY INCIDENTAL CONSEQUENTIAL OR SPECIAL LOSSES DAMAGES OR EXPENSES OF ANY KIND INCLUDING WITHOUT LIMITATION ANY SUCH LOSSES DAMAGES OR EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM ...

Page 5: ...ral Safety All required traffic safety precautions should be complied with All workers should wear required safety clothing high visibility vests steel capped footwear gloves hard hats safety glasses etc All underground services must be located before installation of any posts Only Authorized trained personnel should operate any machinery Where overhead machinery is used care must be taken to avoi...

Page 6: ...AINTENANCE MANUAL Impact Head 1 Required B061072 Friction Plate 1 Required B061058 Soil Anchor 1 Required B061104 Slider Bracket Angle Bar 1 Required Roadside 2 Median B061079 Cable Bracket 1 Required B061083 Cable Assembly 2 Required B061109 Slider Panel 1 Required Roadside 2 Median B061088 Post 1 Top 1 Required B061099 Ground Strut 1 Required B061094 ...

Page 7: ...llowed roadside BSI 1012078 00 Post 1 Bottom 1 Required B061098 W Beam Guardrail RWM02a 3 Required Roadside 5 Median 4000443 Median Radius Rail 1 12 6 1 Required Shop Curved B070233 Median Secondary Head 1 Required B070219 Shear Bolts 8 Required Roadside 16 Median K080123 Blockout Plastic or Timber 5 Required Roadside 10 Median B090534 Hardware Set Roadside K070202 K070204 X Tension Parts Identifi...

Page 8: ...to State Tools Required The same tools required to install standard highway guardrail will also install an X Tension Spe cifically Sockets commonly used in Guardrail Drill Wrenches Large Crow Bar String line Level Augers Tampers and Post Pounders commonly used in driving posts Before Starting For all applications begin the installation from the downstream end of the terminal at the point where it ...

Page 9: ...tion of the standard guardrail run Pull a string line out with the desired offset 0 450mm 0 1 5 ft over the length of the system in a straight flare Figure 1 The system should not be installed on parabolic curve The string line should be set to follow the roadside edge of the posts All the posts except post 1 have a blockout so take care to place the roadside face of post 1 200mm 8 in towards the ...

Page 10: ...s may be directly driven or in stiff soils a 150mm 6 in 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 Hint Offset Post 3 back from the string line 40 50mm up to 2 in to make it easier to push rail 1 and Slider Panel over rail 2 When driving steel posts ensure ...

Page 11: ...he anchor end than at the post 1 bottom end 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 6 Use M16 x 200mm 5 8 in x 8 in hex head bolt with nut and washers Do not over tighten bolt Figure 4 Measure 8 in towards roadway Figure 5 Drive post 1 into augured hole Figure 6 Post 1 top in post bottom Step 4 Hang Rail 3 an...

Page 12: ... shear bolts yellow supplied Figure 9 Put the washer and nut on inside of rail IMPORTANT NOTE DO NOT USE STANDARD SPLICE BOLTS AT POST 5 SPLICE DO NOT USE AN AIR IMPACT WRENCH TO TIGHTEN SHEAR BOLTS SHEAR BOLTS WILL BREAK IF OVER TIGHTEND Figure 8 Bolt rail 2 to post and blockouts Figure 9 Splice rail 2 to rail 3 with 8 special shear bolts Step 6 Attach Slider Bracket to Rail 2 Bolt the Slider Bra...

Page 13: ...end of Slider Panel sits at the rail end Use guardrail pin bar or crow bar to assist with lining up splice holes Figure 12 Sit rail 1 so it is raised off the ground Step 8 Hang Rail 1 Figure 13 Slide the Slider Panel onto downstream end Lift rail 1 with Slider Panel attached and push the slider end over rail 2 Figure 14 Overlap the rails as per a standard splice joint overlap Bolt rail 1 and block...

Page 14: ...l strap on the Ground Strut Figure 19 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 Cable B in Diagram 1 has half the thread protruding through the an chor as shown Ensure the top cable has the nut wound on a least two turns past the end of the thread Figure 20 Cable A should always pass throu...

Page 15: ... 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 22 Do not tighten cables at this stage or the Friction Plate will not turn Figure ...

Page 16: ...hey rest in the backside of the W beam and do not visibly sag between posts Figure 26 There is no torque requirement for the cables Figure 25 Tighten cables at Cable Bracket end post 7 Figure 26 Tighten cables until they are taut Step 14 Attach Nosing Push nosing into place on the front of the impact head Attach using the supplied nylon push rivets Figure 27 Delineation to be attached to nosing as...

Page 17: ...rminal 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 4 ft away from the road Figure 28 in a straight flare over the length of the system The system should not be installed on parabolic curve Ensure that the area where the X Tension is to be installed is flat enough so that the anchor will not protrude more than 75 m...

Page 18: ... rails around to follow the flared line of posts This is not factory bent Step 1 Set Out Pull a string line out with the desired offset 0 1 2m 0 4 ft Note that the flare is a straight flare over the length of the system 11 4m 38 ft 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 ...

Page 19: ... a median guardrail terminal end application Site preparation The X Tension Median Attenuator System is installed parallel to the standard median barrier therefore no offset is used Figure 32 Ensure that the area where the X Tension is to be installed is flat enough so that the soil anchor will not protrude more than 100mm 4 in preferred 75 mm 3 in from ground level when measured with a straight l...

Page 20: ...X Tension Median Attenuator should always be installed on the side with approach traffic See Diagram 2 Figure 33 Essentially a tangent system installed parallel to median barrier Figure 34 Small number of additional components Step 2 Installing Tangent X Tension Portion Follow steps 2 13 in the Tangent installation instructions with the following exceptions 1 DO NOT set post 3 back 30 50mm 1 2 in ...

Page 21: ... shown Figure 36 Step 4 Attach Backside Rail 3 and Rail 2 Rails 3 and 2 are installed like standard guardrail with blockouts between the rail and post Figure 37 Attach rails to post 2 4 5 and 6 with blockouts and post bolts supplied do not bolt the rail to post 3 and splice rail 3 to rail 4 with 8 standard splice bolts At post 7 lap rail in the direction of traffic as per standard median barrier E...

Page 22: ...ct Head Step 6 Assemble Slider Panel onto Backside Rail 1 Raise the straight end of the curved backside rail 1 and fit the Slider Panel onto the downstream straight end of rail Figure 41 and bolt into place using 4 standard splice bolts pushing the bolt through from the inside of the slider to the outside so the nut is on the traffic face Figure 42 The curved and reinforced post breaker end of Sli...

Page 23: ...d standard post bolt and 50x50mm 2 in x 2 in washer on inside of post bolt notch on the backside of post 2 Figure 43 The bolt should pass through the notch on the approach end of the system Re attach the angle bar to the Slider Bracket Figure 44 on the backside of the rail at post 3 Figure 43 Bolt rail 1 and blockout to post 2 using the square washer Figure 44 Re attach the angle bar to the Slider...

Page 24: ...nosing as per Local Authorities requirements Optional Nose Cover Install High Visibility Nose Cover Attach the High Visibility Nose Cover to the Impact Head using the supplied hardware The nose cover is attached using 4 bolts two on each side of the Impact Head and a wire tether To attach the wire tether pass the tether through the Nose Cover and the Friction Plate Figure 48 Figure 48 Tether Insta...

Page 25: ... straight with flare as per design offset between 0 to 1 2m 0 to 4 ft Slider Panel is connected to end of first rail All 4 holes bolted with nuts on traffic face Slider Bracket affixed to back of rail 2 with 4 bolts and nuts on backside of rail Angle bar is fitted closest to impact head end Bolts MUST be wrenched tight Guardrail for terminal end i e 3 lengths is 2 7mm 12 gauge highway rail Yellow ...

Page 26: ...les as you pull them will help Undo nuts at ground anchor end and remove ca bles Step 2 Remove Rails Unbolt the splice bolts first Then unbolt the post bolts and lower rails to ground Step 3 Remove X Tension Components All the X Tension components are attached to the rails with standard splice bolts Unbolt and re move the components Step 4 Remove Posts Undo the bolt at the bottom of Post 1 and pul...

Page 27: ...do nuts at ground anchor end last and remove cables Step 2 Pull Rails Back Out Attach a chain or two ton strap to the front of the impact head and pull upstream to its original position with a light truck or utility vehicle The components are easier to unbolt when the rails are separated Step 3 Remove X Tension Components All components are attached to the rails with standard splice bolts Unbolt a...

Page 28: ... T Y L B M E S S A E L B A C S S A P N E H T T U R T S D N U O R G D A E H T C A P M I N I E L O H R E W O L H G U O R H T D N A E T A L P N O I T C I R F H G U O R H T D N A T N E M D L E W D A E H T C A P M I E H T F O E D I S K C A B E H T T U O O T Y L B M E S S A E L B A C D N O C E S R O F T A E P E R D A E H T C A P M I N I E L O H R E P P U H G U O R H T S S A P T N E M D L E W Y A W A 8 3...

Page 29: ... M G N I K C O L T S N I A G A T C A P M I F O E D I S N O 2 M E T I O P S T L O B X 4 G N I S U T N E M D L E W D A E H 1 T S O P T A T U O K C O L B O N D A E H T C A P M I G N I T N U O M N E H W E R U S N E L I A R D R A U G O T T N E M D L E W E R A 3 M E T I O P S T U N X E H T A H T E D I S C I F F A R T N O D A E H D L O H O T S T U O K C O L B E S U G N I T L O B E L I W P U T N E M D L E...

Page 30: ... T S N I A G A T C A P M I F O E D I S N O 2 M E T I O P S T L O B X 4 G N I S U T N E M D L E W D A E H 1 T S O P T A T U O K C O L B O N D A E H T C A P M I G N I T N U O M N E H W E R U S N E L I A R D R A U G O T T N E M D L E W E R A 3 M E T I O P S T U N X E H T A H T E D I S C I F F A R T N O D A E H D L O H O T S T U O K C O L B E S U G N I T L O B E L I W P U T N E M D L E W D N A L E N A...

Page 31: ...E W 3 M E T I O P T U O K C O L B X 5 T S O P X 4 3 M E T I G N I S U E C A L P N I E R U C E S 8 M E T I O P L E N A P S U I D A R L E N A P L I A R D R A U G X 3 3 M E T I O P 5 8 M E T I O P T U O K C O L B R E B M I T X 5 8 M E T I O P L E N A P L I A R D R A U G X 2 8 S T U N X E H T A H T E R U S N E E D I S C I F F A R T N O E R A Y L N O E D I S S I H T 0 1 3 6 3 6 3 6 3 6 3 6 6 1 9 7 2 X ...

Page 32: ... T S O P X 4 3 M E T I G N I S U E C A L P N I E R U C E S 8 M E T I O P L E N A P S U I D A R L E N A P L I A R D R A U G X 3 3 M E T I O P 8 M E T I O P T U O K C O L B E T I S O P M O C X 5 8 M E T I O P L E N A P L I A R D R A U G X 2 2 A 1 A L I A T E D E E S D E S S E C E R E L B U O D T A H T E R U S N E E D I S C I F F A R T N O E R A S T U N Y L N O E D I S S I H T 5 7 0 1 R O H C N A L I...

Page 33: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 33 X TENSION SYSTEM Page Left Intentionally Blank ...

Page 34: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 34 INSTALLATION AND MAINTENANCE MANUAL Page Left Intentionally Blank ...

Page 35: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 35 X TENSION SYSTEM Page Left Intentionally Blank ...

Page 36: ...Free 888 800 3691 www barrriersystemsinc com Installation manual details for the X Tension System are subject to change without notice to reflect improvements and upgrades Additional information is available from Lindsay Transportation Solutions Sales and Service Lindsay Transportation Solutions XTENSION 061515 v9 ...

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