Barrier Systems X-TENSION XTGTSM1, Installation And Maintenance Manual

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

Page 2: ...al Nose Cover 23 Installation Checklist 24 MAINTENANCE Traffic Face Impacts 25 Head on Impacts 26 APPENDIX Drawings XTGTSS1 Roadside Imperial Wood Blockout Wood Post 27 XTGTSS2 Roadside Imperial Wood Blockout Steel Post 28 XTGTSS3 Roadside Imperial Composite Blockout Steel Post 29 XTMTSS2 Median Imperial Wood Blockout Steel Post 30 XTMTSS3 Median Imperial Composite Blockout Steel Post 31 XTGTSM1 R...

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: ...iteria Safety Statements General 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 us...

Page 5: ...ication Impact Head Friction Plate Soil Anchor 1 Required 1 Required 1 Required B061072 B061058 B061104 Slider Bracket Angle Bar Cable Bracket Cable Assembly 1 Required Roadside 2 Median 1 Required 2 Required B061079 B061083 B061109 Slider Panel Post 1 Top Ground Strut 1 Required Roadside 2 Median 1 Required 1 Required B061088 B061099 B061094 ...

Page 6: ...Post 1 Bottom Roadside can be CRT Timber CRT Timber Posts allowed roadside 1 Required B061100 4002338 B061098 Standard Highway Rail 12 6 Median Radius Rail 1 12 6 Median Secondary Head 3 Required Roadside 5 Median 1 Required Shop Curved 1 Required 4002018 B070233 B070219 Shear Bolts Blockout Plastic or Timber Hardware Set 8 Required Roadside 16 Median 5 Required Roadside 10 Median Roadside K080123...

Page 7: ...ines will vary from State 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 termi...

Page 8: ...ly an 11 4m 38 ft continuation 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...

Page 9: ...nto 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 that a driving cap with timber or plastic insert is used to pre vent damage to the galvanizing on the to...

Page 10: ...Strut should be level or lower at the 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 i...

Page 11: ...L TO POST 3 Splice rail 2 to rail 3 with the 8 special 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...

Page 12: ...urved 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 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 j...

Page 13: ...ing the supplied M16 x 50mm 5 8 in x 2 in guardrail post bolt Use a 50mm x 50mm 2 in x 2 in washer under the nut on the inside of post 1 Figure 18 Step 10 Place the Cables Push the cables under the steel 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 closest ...

Page 14: ... 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 22 Do not tighten cables at this stage or the Frict...

Page 15: ... until they are taut i e they 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 riv ets Figure 27 Delineation ...

Page 16: ...ed 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 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...

Page 17: ... 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 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...

Page 18: ...a Median X Tension system as a Median guardrail terminal end application Site preparation The Median X Tension 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 mea sured...

Page 19: ...arallel with the median barrier posts The string line should be set to follow the side of the posts on the side that it is desired to install the tangent X Tension 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 ...

Page 20: ...he 25mm 1 in pin and pin lynch or 2 M24 x 50mm 1 in X 2 in bolts as 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 la...

Page 21: ...eam end of rail 2 Figure 40 Angle bar end should be closest to Impact 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 traff...

Page 22: ...der end over rail 2 Bolt rail 1 and blockout to post 2 using supplied 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 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 Brac...

Page 23: ...ush rivets Figure 47 Delineation to be attached to 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 ...

Page 24: ...h 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 Shear Bolts c...

Page 25: ...will help Undo nuts at ground anchor end and remove cables 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 pull out post For all oth...

Page 26: ...ll 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 bolt...

Page 27: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 27 X Tension System ...

Page 28: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 28 Installation and Maintenance MANUAL ...

Page 29: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 29 X Tension System ...

Page 30: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 30 Installation and Maintenance MANUAL ...

Page 31: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 31 X Tension System ...

Page 32: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 32 Installation and Maintenance MANUAL ...

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 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 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 36: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 36 Installation and Maintenance MANUAL ...

Page 37: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 37 Page Left Intentionally Blank ...

Page 38: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 38 Page Left Intentionally Blank ...

Page 39: ...Lindsay Transportation Solutions Sales and Services Inc 888 800 3691 U S toll free or 1 707 374 6800 39 Page Left Intentionally Blank ...

Page 40: ...00 U S Toll 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 Barrier Systems Sales and Service Lindsay Transportation Solutions XT06 041112 ...