Safe Barriers Defender 100LDS, Installation Manual

Page 1: ...Defender 100LDS MASH TL 3 Low Deflection Temporary Steel Safety Barrier Anchored Product Design and Installation Manual Safe Barriers Pte Ltd Reference D100LDS M 1804 April 18 ...

Page 2: ...m Local Information Australia 1800 169 799 New Zealand 09 9507186 USA 1 888 215 4535 Email All Locations info safebarriers com Rev No Author Reviewed Approved Description Date Name Signature 1 C Lee R Hood Draft Issue 30 April 2017 2 D Moule R Hood Ver 1 0 21 Sept 2017 3 D Moule R Hood Ver 1 1 16 Jan 2018 4 D Moule R Hood Ver 1 2 22 Jan 2018 5 D Moule R Hood Ver 1 3 15 March 2018 6 D Moule R hood ...

Page 3: ...ersonal injury hazards All safety messages that have this image attached shall be followed to ensure injury and death does not occur DANGER Symbol This symbol defines a situation that is hazardous and which if cannot be avoided will result in death or serious injury WARNING Symbol This symbol defines a situation that is hazardous and which if cannot be avoided could result in death or serious inju...

Page 4: ...itions and Anchorage Requirements 13 2 4 1 Pavement Conditions 13 2 4 2 Anchorage 13 3 Installation Procedure 14 3 1 Planning 14 3 1 2 Length of Need Anchor Layout Requirements 14 3 1 3 Terminal Anchor Layout Requirements 15 3 2 Lifting and Loading 16 3 3 Loading Unloading Sequence 17 3 4 Site Activities 18 3 4 1 Unloading Sequence 18 3 4 2 Connection of the Units 18 3 4 3 Anchor Pin Installation ...

Page 5: ...iagram 11 Figure 2 4 Defender 100LDS Clear Zone Requirements 12 Figure 2 5 Ground Anchor Pin Installation Location 13 Figure 3 1 Defender 100LDS Anchor Layout 15 Figure 3 2 Top Rail Slot with Lifting Plate 16 Figure 3 3 Loaded Truck 16 Figure 3 4 Sequence of Unit Connection 19 Figure 3 5 Correct Pin Installation 20 Figure 3 6 Incorrect Pin Installation 20 Appendices Appendix A Product Drawings 23 ...

Page 6: ...of a connection pin to secure each unit in place The cross section of the unit is detailed within Figure 1 1 below and consists of a 680mm width base with an 800mm height which results in a centre of gravity at 342mm Each single unit is 3959mm in length with an effective barrier length of 3900mm and weighs 303kg or 77 7kg per lineal meter Figure 1 1 Defender 100LDS Cross Section The Defender 100LD...

Page 7: ...t 3 11 Figure 1 2 Barrier Installation Setup for 3 11 LDS Crash Test 1 2 Delineation Barrier installations whether they are permanent or temporary may require delineation to be attached for the duration of the installation The type shape colour of this delineation will vary dependant on the local regulatory requirements Local regulations should be reviewed to ensure correct delineation is attached...

Page 8: ...governing road authority in your state or country Proper site design and deployment of the Defender 100LDS is essential to assure performance If you have any questions about the deployment of the Defender 100LDS please contact Safe Barriers before deploying the barrier Incorrect installations can lead to outcomes different from the laboratory certification test outcomes ...

Page 9: ...o 1 0 degree of horizontal movement per joint This movement allows each section to create a bend in the alignment resulting in the ability to curve the barrier along the roadway to accommodate the road environment The sliding pulling of the units to achieve the required radius can potentially damage the barrier and or roadway Care must be taken during this process Vertical Design The Defender Barr...

Page 10: ...chor locations The pins are placed directly opposite each other in the same barrier drain location Each barrier has two 2 sets of symmetrically opposed ground anchor pin locations pre cut into the barrier drain Please refer to drawing D100 within Appendix A for more details Figure 2 1 Standard Barrier Unit 3900 150 1350 220 3959 680 800 200 342 Center of Gravity ITEM DRAWING NO DESCRIPTION QTY 1 D...

Page 11: ... Crash cushions can be used for both uni directional and bi directional traffic flows The TAU II crash cushion has been crash tested for use with the Defender 100LDS system Figure 2 2 below shows the TAU II crash cushion The connections and transition details can be found within Appendix B The use of a terminal system may be required on both approach and departure ends of the barrier as per local ...

Page 12: ...2 1 Design Deflection Table MASH16 Deflection Table Defender 100LDS Test Level 3 2 270 kg Pickup Truck 100kph 25o 0 93 The above deflection value is the tested deflection on the Length of Need of the Defender 100LDS anchored at every second barrier to a maximum of 9 15 metres between intermediate anchors Trailing point of need Leading point of need Direction of travel 2 Direction of travel 1 Safet...

Page 13: ...Defender 100LDS Product Manual Version 1 4 12 Safe Barriers Pte Ltd Figure 2 4 Defender 100LDS Clear Zone Requirements ...

Page 14: ...t surface 150mm 150mm asphaltic concrete over granular subbase 2 4 2 Anchorage The Defender 100LDS System is anchored at every second barrier to a maximum of 9 15m between anchor locations using two symmetrically installed 30mm x 500 mm steel ground anchor pins The pins are placed in the pre cut slot in the barrier drain at the base of the Defender 100 LDS barrier Figure 2 5 Ground Anchor Pin Inst...

Page 15: ...Pins must be placed in the first available holes after the Approach Terminal and before the Departure Terminal Refer Appendix A BSI 1707033 AP From the pins installed in the first Length of Need Barrier measure a maximum of 9 15 meters to install the next set of pins in the sequence In other words after the first barrier is pinned put pins in every second barrier refer Appendix A D100LDS Installat...

Page 16: ...per Drawings referenced in point 2 Otherwise terminate in a locally approved manner The minimum installation length between terminals is 78 meters 20 barrier units Should it be necessary to install a shorter system due to site conditions contact Safe Barriers 3 9 m TRAFFIC FLOW ANCHOR SPACING 1 28 m 9 15 m BETWEEN PINS CONTINUATION OF STD 3 9m UNITS 1XD7 PIN EACH SIDE TRAFFIC FLOW 1XD7 PIN EACH SI...

Page 17: ...ure 3 2 Top Rail Slot with Lifting Plate Figure 3 2 below shows a fully loaded truck with the maximum number of layers available for transport Generally a standard transportation vehicle 19m flat bed semi trailer will be able to accommodate three 3 layers consisting of three 3 units per layer This typical stack can be mounted on a standard truck three 3 times resulting in a maximum of 27 units per...

Page 18: ...r of 9 units is loaded 2 Timber dunnage is installed 3 2nd layer of 9 units is loaded 4 Timber dunnage is installed 5 3rd layer of 9 units is loaded The unloading of the truck is done from the rear and done by unloading the full top layer then moving to the 2nd layer and finally the bottom layer When un loading ensure site safety rules are adhered Special consideration should be given to the proxi...

Page 19: ...ced level on the ground with each footing section having contact with the surface In most cases the installation process will begin with the upstream approach end of the barrier being installed first Once the first unit is placed each consecutive unit can be lowered onto the joint of the previously placed unit to create a secure connection at the male female joints Once the run has been installed ...

Page 20: ...Defender 100LDS Product Manual Version 1 4 19 Safe Barriers Pte Ltd Part 3 Shows the internal connection before the pin is inserted of the Male and Female joints Figure 3 4 Sequence of Unit Connection ...

Page 21: ...he anchor pin is 60mm diameter Refer Appendix A D7 Anchor Pin Installation 1 At the desired location drill a minimum 28mm to maximum32 mm hole into the road 2 Drive the Pin into the hole It may be necessary to hit it with a small sledge hammer or use a cup ended jack hammer as a driver if a hole smaller than 32 mm is drilled 3 When installed the pin head must be flush to the barrier Pins left prou...

Page 22: ...klist in Appendix D 3 5 2 System Maintenance Due to the product construction the main reason for barrier maintenance would be due to an impact If an impact were to occur a system inspection should be undertaken to ensure the barrier is of sound structural capacity to continue use The following is a list of observations that would warrant the replacement of a section of barrier Toe foot sections be...

Page 23: ...the Defender 100LDS any pin with visible movement in the asphalt surface should be relocated to the anchor location nearest to the previous anchor location 3 5 4 End of Useful Life All Defender Barrier are made of recyclable mild steel We recommend sending the barriers to your local steel recycler at the end of useful life ...

Page 24: ...D100 DEFENDER 100 D HOT DIP GALVANISED SEE PARTS TABLE RH APPROVED RM CHECKED DC DRAWN BY DRAWING REF DRAWING DESCRIPTION 15 Dec 2016 DATE MM DIMENSIONS FINISH MATERIAL Tolerances unless otherwise stated Machining up to 300mm 0 50 300 to 0 80 Fabrication up to 300mm 2 00 300 to 1000mm 3 00 1000 to 6 00 Angular all 2 0 APPRD DRAWN DESCRIPTION DATE REV 4 3 C B A 4 3 2 1 D C B A 1 2 SHEET 1 of 1 WEIG...

Page 25: ...o 6 00 Angular all 2 0 APPRD DRAWN DESCRIPTION DATE REV 4 3 C B A 4 3 2 1 D C B A 1 2 SHEET 1 of 1 WEIGHT 3 2 KG GALV NOTES 1 REMOVE ALL BURRS AND SHARP EDGES 60 465 500Ref 20 4 5 6 1 2 ITEM DRAWING NO DESCRIPTION QTY 1 D7 1 ANCHOR PIN CAP 1 2 D7 2 ANCHOR PIN BODY 1 D7 ANCHOR PIN D MILL FINISH SEE PARTS TABLE RH APPROVED RM CHECKED DC DRAWN BY DRAWING REF DRAWING DESCRIPTION 15 Dec 2016 DATE MM DI...

Page 26: ... D6 DRAIN 2 5 D9 ANGLE IRON 2 6 D1 1 RIB PLATE 1 4 7 D1 2 RIB PLATE 2 4 8 D1 3 RIB PLATE 3 4 9 D1 4 RIB PLATE 4 4 10 D11 REINFORCING PLATE 2 D1 TAU APPROACH DEFENDER APPROACH D HOT DIP GALVANISED SEE PARTS TABLE RH APPROVED RM CHECKED DC DRAWN BY DRAWING REF DRAWING DESCRIPTION 15 Dec 2016 DATE MM DIMENSIONS FINISH MATERIAL Tolerances unless otherwise stated Machining up to 300mm 0 50 300 to 0 80 ...

Page 27: ...TING PLATE 2 5 D6 DRAIN 2 6 D9 ANGLE IRON 2 7 D1 1 RIB PLATE 1 4 8 D1 2 RIB PLATE 2 4 9 D1 3 RIB PLATE 3 4 10 D1 4 RIB PLATE 4 4 11 D11 REINFORCING PLATE 2 D1 TAU DEPARTURE DEFENDER DEPARTURE D HOT DIP GALVANISED SEE PARTS TABLE RH APPROVED RM CHECKED DC DRAWN BY DRAWING REF DRAWING DESCRIPTION 15 Dec 2016 DATE MM DIMENSIONS FINISH MATERIAL Tolerances unless otherwise stated Machining up to 300mm ...

Page 28: ...Defender 100LDS Product Manual Version 1 4 27 Safe Barriers Pte Ltd Appendix B End Terminal ...

Page 29: ...ummary Defender 100LDS Crash Test Summary Test Test Number Test Setup Length Impact Point Deflection MASH 3 10 131393MDS 3 10 20 Barriers 78 0m Barrier 9 0 56m MASH 3 11 131393MDS 3 11 20 Barriers 78 0m Barrier 9 0 93m MASH 3 21 131393 3 21 TAU II 14 Barriers 62 6m Transition Barrier 1 0 310m ...

Page 30: ...her with approval attached Terminals Absorb 350 TAUII Not required according to plan Approach Terminal Departure Terminal Both Ends Terminal Install Terminal Installed according to manufacturer s Instructions TAUII is pinned and transition installed Absorb 350 is water filled and transition installed Name Signature Date Defender Barrier TM Installation Checklist NOTES Report any installation issue...

Page 31: ...Defender 100LDS Product Manual Version 1 4 30 Safe Barriers Pte Ltd Appendix E State Local Approvals ...