Nu Cable Install Jul 08

8/3/2019 Nu Cable Install Jul 08

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NU-CABLECable Barrier Systems

I N S T A L L A T I O N M A N U A LF O R T E S T - L E V E L 3 & 4 A P P L I C A T I O N S

TM


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- NU-CABLE High-Tension Cable System Jul-08 V. 5.07 Page 2

C O N T E N T S

INSTALLATION CONSIDERATIONS ......................................... 4SYSTEM OVERVIEW ........................................................... 5

Current Configuration Summary ................................................................ 5SITE PREPARATION ........................................................... 6INSTALLATION OF THE BARRIER ........................................... 7

Line Post Overview .................................................................................. 7Line Post Installation ............................................................................... 7Cable-To-Post Connections ..................................................................... 12Cable Mounting Heights .......................................................................... 15Turnbuckles .......................................................................................... 16Field Applied Cable Attachment and Wedge Encasement ............................. 17Wedge Installation ................................................................................ 18System Splicing .................................................................................... 18Field Assembly of Strong-Back Turnbuckles and Quick-Grip Cable Ends .... 19Standard Cable Option ........................................................................... 19

INSTALLATION OF THE ANCHOR ......................................... 20CableGuard Terminal TL-3 ................................................................... 20CRP Anchor Three-Cable Systems ......................................................... 26CRP Anchor Four-Cable Systems ........................................................... 27CRP Anchor Installation .......................................................................... 28Connecting Cable Ends ........................................................................... 30

Soft Soil Foundations ............................................................................. 31

TENSIONING THE SYSTEM ................................................. 32 Tensioning Overview .............................................................................. 32Tensioning with Standard Turnbuckles ...................................................... 33Tensioning with Strong-Back Turnbuckles ............................................... 34Tensioning Considerations ...................................................................... 35Tension Table ....................................................................................... 36

DELINEATION ................................................................. 37REPAIR & MAINTENANCE .................................................. 38

Repeat Impacts ..................................................................................... 38Releasing Tension ................................................................................. 39Cutting Cables ...................................................................................... 39Pavement Overlays or Resurfacing ........................................................... 40Emergency Access ................................................................................. 40Materials for Maintenance ....................................................................... 40

INSTALLATION CHECKLISTS .............................................. 41


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Cable Checklist ..................................................................................... 41Post Checklist ....................................................................................... 42Terminal/Anchor Checklist ...................................................................... 42

APPENDIX ..................................................................... 43Tension Log 3-Cable Systems ............................................................... 44Tension Log 4-Cable Systems ............................................................... 45Post Spacing & Deflection Charts ............................................................. 46Line Post Detail - Test Level 3: Three-Cable .............................................. 47Line Post Detail - Test Level 3: Four-Cable ................................................ 48Line Post Detail - Test Level 4 ................................................................. 49Line Post Detail Driven Socket Option .................................................... 50System Detail TL-3: Three-Cable .......................................................... 51System Detail TL-4 or TL-3: Four-Cable ................................................. 52Anchor Detail CRP Anchor End Posts & Footer Reinforcement .................... 53Anchor Detail CRP TL-3: Three-Cable Anchor Line Posts ........................... 54Anchor Detail CRP TL-3: Four-Cable Anchor Line Posts ............................. 55Anchor Detail CRP TL-4 Anchor Line Posts .............................................. 56Anchor Detail CableGuard Terminal for TL-3 ........................................... 57Anchor Detail CableGuard Footing Reinforcement .................................... 58Component Detail NU-CABLE Strong-Back Turnbuckle ........................... 59Component Detail NU-CABLE Quick-Grip Cable End ............................... 60Component Detail Standard Turnbuckle ................................................. 61Component Detail Standard Cable End ................................................... 62Component Detail TL-4 Cable Hanger & Hanger Strap .............................. 63FHWA Memorandum Cable Barrier Considerations ................................... 64

TECHNICAL SUPPORT AND SALES ....................................... 67


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I N S T A L L A T I O N C O N S I D E R A T I O N S

This manual should be carefully reviewed prior to construction to ensure

proper installation of the NU-CABLE Cable Barrier System.

The NU-CABLE Cable Barrier System is a straight-forward barrier, which is easy toinstall and can be safely maintained with the information contained within this

installation manual.

The initial installation run for any new crew will need to be trained by a qualifiedNucor Distributor or Nucor Steel Marion Inc representative. It is also strongly

recommended that the first run for any new installation crew be completelyinstalled and tensioned before attempting to start other runs.

If there is ever any doubt about a part of the installation contact Nucor Steel Marion

Inc (800) 333-4011 or the appropriate Nucor Distributor immediately.

Distributor contact information is listed on the last page of this manual.

Nucor is not responsible for any certifications, licensing, or permits, such asenvironmental impact, that may be required in order to complete installation of this

or any roadside safety device.


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S Y S T E M O V E R V I E W

Current Conf igurat io n Summary

There are currently (2) main categories of the NU-CABLE Cable Barrier. This

manual covers the layout, components and installation instructions for bothsystems, including the available anchors for each type.

A. Test Level 3 Cable Barrier & Anchorsa. High-Tensioned Cable Barrier for roadways up to 65 mph, in median &

roadside applications, using:

i. NUCOR U-Channel Sign Posts Driven, Socketed, or Driven-Sockets

ii. NUCOR Locking Hook Boltsiii. (3) Strands of 3 x 7 x 3/4 Pre-Stretched or Standard Wire

Rope, Field Tensioned for 6:1 Slope Applicationsiv. (4) Strands of 3 x 7 x 3/4 Pre-Stretched or Standard Wire

Rope, Field Tensioned for 4:1 (Steep) Slope Applications

b. Various post spacings to fit required design deflection, clear-zone

minimums & barrier working width requirements.c. Anchorage Options include:

i. Cable Release Post (CRP) TL-3 Anchor

ii. CableGuard TL-3 Anchor

B. Test Level 4 Cable Barrier & Anchors

a. High-Tensioned Cable Barrier for roadways up to 65 mph, with large

volumes of heavy vehicle (18,000 lb.) traffic, in median & roadsideapplications, using:

i. NUCOR U-Channel Sign Posts Socketed or Driven-Socketsii. NUCOR Locking Hook Bolts, Cable Hanger & Hanger Strap

iii. (4) Strands of 3 x 7 x 3/4 Pre-Stretched Wire Rope, Field

Tensioned forb. Various post spacings to fit required design deflection, clear-zone

minimums & barrier working width requirements.

c. Anchorage Options include:i. Cable Release Post (CRP) TL-4 Anchor

The installation instructions for each barrier type will be noted w ithin eachrelevant section in this manual. If there is no specific reference to one of

the barrier types, the stated installation instruction is intended for bothsystem types.

Both systems and their anchorages conform to Federal Highway Administration

NCHRP-350 crashworthiness standards for use on the National Highway System.

The NUCOR Rib-Bak U-Channel posts are also an acceptable post alternate

in the non-proprietary USDOT 3-Strand Low -Tension Cable Barrier system.


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S I T E P R E P A R A T I O N

The initial layout for the NU-CABLE High-TensionSystem should be free of hazards, obstacles, and

debris. The cross-slope should be 6:1 or flatter.Grading may be necessary.

It is important to note that the high-tension cablebarrier cannot be installed within a range of1 (305mm) to 8 (2.44m) from the bottom of a

median ditch according to FHWA memorandum. Thehigh-tension cable barrier can be installed in the

bottom of the median ditch or within a 1 (305mm)range either side of the median ditch. However, this

is not recommended because of potential waterdrainage issues and poor soil conditions.


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I N S T A L L A T I O N O F T H E B A R R I E R

L ine P os t Overv iew

A string line should be set to aid in properly placing the posts and cables. Mark

each run starting with the location of end treatments. Then mark the position foreach cable line post to be installed according to project plans to meet required

deflections. Please refer to project plans for job specific post spacing.

TEST LEVEL 3:

The line post spacing can be varied from 6-6 to 20 (2m to 6m) , dependingon desired deflection, ranging from 5 3 to 8 9 (1.6m to 2.6m).

TEST LEVEL 4:

The line post spacing is 20 (6m), with a resulting deflection of8 4 (2.55m).

Desired deflection under 8 4 available by reducing post spacing. See Appendix,

Deflection Graph, for more information

*All post spacings were derived from crash testing using a 300 test installation.

Actual deflections may vary based upon site variables, installation length and

impact conditions.

Please refer to the project plans and specifications to determine which post spacing

is required for the installation. FHWA recommends a maximum post spacing of 15

0 (4.6m) for all cable barriers. Varying post spacing can also be used whennecessary due to conflicts with utilities or culverts.

It is helpful to mark every 1000 (305m)* when laying out the system to aid in

turnbuckle placement as the cable is unspooled.

*Mark every 7 5 0 ( 2 2 9 m ) if using standard cable.

L ine Pos t I ns ta l la tion

TEST LEVEL 3:

Only the 20 TL-3 system uses the 5# Rib-Bak Line Post.

All other current TL-3 system options use 4# Rib-Bak Line Post.

The TL-3 system posts can be either directly embedded (driven) or installed in

either concrete-sockets or driven-sockets, depending upon project specifications.

TEST LEVEL 4:

The TL-4 system uses a 54 Long - 4# Rib-Bak Line Post.

The TL-4 system is designed for use in concrete-sockets, or driven-sockets perproject specifications.


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Opt ion 1 : D i rec t -Dr i ven L ine Post

The direct embedment method uses 72(1829mm) Rib-Bak Line Post with no soil

plate required. Direct driven line posts are driven into natural soil using a presetstring line to depth of39(991mm). The top of the line post should be 33

(838mm) above ground after installation.

Opt ion 2 A: Socke t ed Foun dat ion , Concre t e Foo t ing

The socketed method utilizes a 12 GA 4 OD x 15(102mm x 381mm) steel socket set into a 12

diameter x 30 deep [305mm x 768mm] concretefooting. The socket depth is assumed to be in NCHRP

350 strong soil. In weak soil or where the frost line isbelow 30(305mm) the depth of the socket should be

increased to accommodate.

TEST LEVEL 4:

The TL-4 system uses a 4 OD x 12 steel or plastic

socket.

The concrete foundation is strengthened with one #3 steel reinforcing ring andtwo #4 x 28steel dowels (dowel length may vary upon foundation depth). Thering is inserted to a depth of4; the dowels are inserted to a depth of2. The

dowels should be installed at approximately 25 degrees off center so that they are

in line against oncoming traffic. The steel reinforcement does not need to be tied.

Use a socket insertion tool (see photo) to install socket after steel reinforcement

has been placed. The top of the socket should normally be flush with the top of the

foundation concrete. To prevent runoff debris from entering the socket, thefoundation should be finished with up to 3/4" (19mm) taper to the outer edge.

This may not be required when the system is installed in a mow strip.


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For uneven terrain (see picture below), where the potential exists for line posts to

be pulled out of their sockets by the tensioning of the cable,set the socket in the

concrete with no more than 2(51mm) above ground level with no less than 13(330mm) embedment. After concrete has set, drill a 3/8(10mm) hole as close tothe base of the footing as workable to install a 5/ 16 x 1 (8mm) Grade 5 or

better bolt to hold the post in place. The socketed method requires a 48

(1219mm) Rib-Bak Cable Line Post. The top of the line post should be 33(838mm) above ground after installation.

Opt ion 2 B: Precast Socke t ed Foun dat ion , Concre t e Foo t ing

The precast line post socket follows the same detail as the standard socketed

concrete footing.

Use a 12 diameter x 30 deep [305mm x 768mm] form. Some contractors have

found that modifying a standard section of12 steel culvert pipe works well as areusable form. Place steel reinforcement as detailed on plan standard. Plumb postsand pour concrete.

Be sure to not leave more than 2(51mm) of the line post socket exposed abovethe ground line. It is easier to plumb the line post socket with a post temporarilyinserted in the socket. The back fill material needs to be strong soil compacted in

6(153mm) lifts with a hydraulic tamper.


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Opt i on 3 :D i rect -Dr i ve Socke t

Much like the direct driven post option, there is a steel tube socket option that canbe fitted for post-driving machines and does not require the use of any concrete.

This socket allows for the use of a shortened post.


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Laying Out Cable

The cable used in the NU-CABLE system is 3/ 4 diameter (19mm), 3x7construction, galvanized cable. It weighs 0.857 lbs/ ft, and is packaged in 2000or 3000(915m) per wooden reel. The empty reel weighs 260 lbs (118kg).

Shipping weight per reel is 2831 lbs (1284kg) for 3000reel. Illustrated beloware two different methods contractors have used to transport and pull cable.


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MEDIAN RIGHT-SIDE MEDIAN

Cab le-To-Post Connect ions

TEST LEVEL 3:

Each cable is attached to each post using a 5/ 16[8mm] diameter locking hook

bolt. Right-side-of-the-road applications have all 3 cables on the travel side of theline posts. When installing the TL-3 three-cable barrier in a median, the lower and

upper cables should be located on the post side closest to the roadway, and themiddle cable should be located on the opposite side.

If installing the TL-3 four-cable barrier in a median, the top and lower-middle cablesshould be located on the post side closest to the roadway, and the bottom and

upper-middle cables should be located on the opposite side.

Insert the special locking hook bolts (pictured at left) into theappropriate locations on the line posts to ensure correct

cable height and allow them to hang down such that they willaccept the cable when it is strung. As the cable is strung,

rotate the special hook bolts and attach the nut. Nuts needonly be finger-tight. The long hook bolt is used on median

applications only.

Test Level 3 Three Cable System


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Test Level 3 Four Cable System

All Test Level 3 systems, such as the four-cable option shown below, connect eachcable to the posts with the NUCOR locking hook bolts.

The configuration of the cables relative to the face of the post and roadway is

depicted below:

Please refer to the details in the Appendix for dimensions and placement

information.


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TEST LEVEL 4:

The TL-4 system uses the NUCOR locking hook bolts to connect the bottom two

cables and a cable hanger to connect the upper (2) cables of the system. A hanger

strap is to be situated above the top cable.


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Cab le Moun t ing He ights

TEST LEVEL 3: Three-Cable:

The TL-3: Three-Cable System cable heights measured at the middle of the cable

are as follows:

Top Middle Bottom

Median & Roadside 29.5 in 25.5 in 21.5 in

1 1 +0/-2

(750mm) (650mm) (545mm)

TEST LEVEL 3: Four-Cable:

The TL-3: Four Cable System heights measured at the middle of the cable are as

follows:

Top Upper-Mid Lower-Mid Bottom

Median & Roadside 29.5 in 25.5 in 21.5 in 15 in

1 1 1 1

(750mm) (650mm) (545mm) (380mm)

TEST LEVEL 4:

The TL-4 NU-CABLE High-Tension System cable heights measured at the middle ofthe cable are as follows:


Median & Roadside 35 in 31 in 27 in 15 in

1 1 1 1

(890mm) (790mm) (590mm) (380mm)

Please see the Cable Terminal End Installation details for terminal end cable heightswhich vary.


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Turnbuck les

Turnbuckles are used to achieve the appropriate tension in the system. By using

prestretched cable, turnbuckles are required to be installed every 1000(305m).If prestretched cable is used, the hardware must be 1D (25mm) to approach the

breaking strength of the cable. Note: More turnbuckles than the minimum amount

may be used if conditions require this option. Some maintenance crews havesuccessfully used turnbuckles in place of cable splices.

In a TL-3 system, if using standard cable, install one turnbuckle per cable every

750(229m). When using standard cable, the attachment hardware may be (19mm) or 1 (25mm) diameter. If the length of the run is 750long (229m),install the turnbuckle near the middle.

There are two options for the turnbuckle style used. The NU-CABLE system caneither be installed with:

TEST LEVEL 3:

Standard Turnbuckles and Wedge-Style Cable Fittings

TEST LEVEL 3 or TEST LEVEL 4:

Strong-Back Turnbuckles and Quick-Grip Cable Ends


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It is not recommend putting turnbuckles directly above each other in the same

section between two line posts (bay). They will be easier to tighten if they arestaggered. If a turnbuckle becomes positioned at a post, do not install a special

hook bolt at this post. This should be allowed for only one cable per post. If amaintenance crew strongly desires to place all of the turnbuckle in the same bay,

the result will have no adverse effect on the crash worthiness of the system.

F ie ld App l ied Cab le At tachment and W edge Encasement

Cable attachment hardware requires the wedge to be properly encased in the cablestrands and seated into the casting to insure that the cable will not slip out of the

hardware.

o The wedge must be seated into the cables such that the flutes in the wedge nestwith the three x strands of the cable. If not properly aligned cable slippage is

possible.

o The wedge needs to be, at a minimum, seated inside the cable strands such thatthe top of the wedge is flush with all three 7 x strands. If one strand of the

three 7 x strands is not at a minimum flush, then the wedge needs to be reset.The optimum seating for the wedge is such that there is 1 of cable is beyondthe wedge.

Strands in flute wedge


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o If slippage between the wedge and strands occurs reset the wedge deeper intothe strands.

o It is acceptable for the wedge to protrude up to 1/4 from the bottom of thecasting as long as the wedge has been seated properly. If the wedge protrudesmore it must be reset.

During the initial installation process the three 7x strands should be set in the body

of the casting such that the nut has just enough room to be inserted. This will helpinsure that the wedge is seated below the three 7 x strands.

W edge Ins ta l la tion

1. Some contractors choose to use a screw driver to open up the cable andseparate the three 7 x strands in preparation for wedge insertion. Once the

wedge is inserted into the cable it should be driven approximately 1 inch belowthe end of the cable.

2. Other contractors have chosen to insert the cable into the casting and twist the

casting until the strands pop open inside the casting opening up the cable lay.The wedge is inserted into cable strands approximately 1 inch below the end of

the cable. The casting is then twisted back so that the cable lay is returned tothe initial position.

3. Other installation methods are acceptable as long as the wedge placement &cable engagement is correct.

System Sp l ic ing

A splice may be used where needed. If an open

faced splice is needed, use a turnbuckle instead ofthe standard splice.


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F ie ld Assemb ly o f St rong-Back Turnbuck les and Qu ick-

Gr ip Cab le Ends

At the desired location, cut the cable. Push the cable end completely into the openmouth of the fitting.

Pull back on the fitting and then push in again. Repeat 2 or 3 times to completely

seat the cable into the fitting jaws.

Tip: The cable may have an oil residue on it and should be wiped with a cloth and

solvent before pushing it into the self-swagging fitting.

Standard Cab le Opt ion

Factory pre-stretched cable is the default cable type used in the NU-CABLE system;however, it is also permitted to use standard cable in the TL-3 configurations.

If factory pre-stretched cable is used, it is allowable to increase the distance

between turnbuckles to 1000 feet, while standard cable requires a turnbuckle every750 feet.

In addition, standard cable uses 3/4 cable turnbuckle & splice hardware, while pre-

stretched cable uses 1 hardware.


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I N S T A L L A T I O N O F T H E A N C H O R

C a b l e G u a r d Termina l TL-3


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Position of the three concrete footings which support the ground strut:

Fill the holes to the top with 25 Mpa concrete.Attach rebar cages and ground strut bracket

(B070515) to the ground strut as shown using1 - 8 UNC-2B nuts, one above and one belowthe ground strut. The hollow end of the strut is

the upstream end.

Direction of Traffic


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Place the ground strut into the concrete sockets.Push the plastic socket into the rear footing.

Place the trigger post into the plastic socket.Angle the socket so the top of the trigger post

is 4 in (100 mm) forward of vertical (towards theground strut).

Ensure that the plastic socket and the triggerpost are as close to the ground strut as possible,

using the ground strut bracket as a bearing surface

for alignment and positioning.

WAIT FOR THE CONCRETE TO CURE.


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This picture shows a fully installed CableGuard terminal.

Direction of Traffic


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CRP A nchor Three-Cab le Systems

TEST LEVEL 3: Three-Cable

Each Cable Barrier Terminal Section consists of

3 (2-part) Cable Release Posts (CRP) at 63post spacing and 6

line posts at 66post spacing.

The CRP terminal posts (#1, #2 & #3) are offset from thecenterline of the string line. The remaining terminal posts (#4

through #9) and all cable line posts should be centered on thestring line.

Installation tolerances of the CRP locations are as follows:

+/ - 12 inches parallel to the system

+/ - 6 inches perpendicular to the system*

*CRP posts may be in contact with cables leading to other posts, but may not causemore than inch deflection.

Note that the opposing end treatments on a particular run are mirrored in their

layout (see figure below).

Cable Height Placement:

Post 4 Post 5 Post 6 Post 7 Post 8 Post 9

Top:

Middle:Bottom:

28

2219

28

2219

28

2219

28

2219

28

2320

29.5

25.521.5

*See Details in Appendix for more information on layout & placement.


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CRP A nchor Fou r-Cab le Systems

TEST LEVEL 3: FOUR CABLE & TEST LEVEL 4

Both the TL-3: Four-Cable and TL-4 CRP Anchors are much the same as the TL-3version, but require (4) CRP posts one for each cable and has slightly different

cable placement on the post.

Mirrored Installation for Opposing Anchor:

TEST LEVEL 4

Cable Heights Post 5 Post 6 Post 7 Post 8 Post 9 Post 10

Top:Upper-Mid:Lower-Mid:

Bottom:

282219

15

282219

15

282219

15

282320

15

302520

15

353127

15

Terminal posts 5 shall be installed in a concrete footer.

Terminal posts 8 through 10 shall be installed in concrete footers with the socket

exposed approximately 2 from the top of the concrete. The socket is to be field

drilled with a 3/8 hole and spray galvanized. The posts shall be fastened to thetop of the socket with a Grade 8, 5/16 x 1 1/2 galvanized bolt and nut, to prevent

post from lifting out of socket.

TEST LEVEL 3: Four-Cable

Cable Heights Post 5 Post 6 Post 7 Post 8 Post 9 Post 10

Top:

Upper-Mid:

Lower-Mid:Bottom:

28

22

1915

28

22

1915

28

22

1915

28

23

2015

30

25

2015

30

25

2115

**See Details in Appendix for more information on layout & placement.


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CRP Anchor I ns ta l la tion

There are t h r e e options for installing CRPs. They can be either cast-in-place in aconcrete footing or directly embedded (driven), depending upon project

specifications.

Opt i on 1 : D r i ven CRP pos ts w i th so i l p l ate

For permanent or temporary usage or where

soil is known to be very strong, there is an

option of installing CRP post without aconcrete footing. The CRP post base is 96

(2438mm) long and has a 1/ 4 x 18 x48 (6mm x 457mm x 1219mm) welded

soil plate. Attach the CRP top to the base withthe two 5/ 16 (8mm) breakaway bolts

provided. Where soils are weaker thanNCHRP 350 strong soil consult the

manufacturer for special CRP post anchorsthat can be designed to appropriately meet

the demands of the site soil conditions.

Opt ion 2 : CRP posts cas t - in - p lace

In strong soil conditions drill 18 (457mm) diameter x 5-0 (1524mm) deep

hole. Place steel reinforcement as detailed on plan standard. Plumb posts and pourconcrete. Be sure to not leave more than 4 (102mm) of the CRP post baseexposed above the ground line. It is easier to plumb the CRP bases with the CRP

top posts attached. Attach the CRP top to the base with the two 5/ 16 (8mm)

breakaway bolts provided.


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Opt ion 3 : Precast CRP posts

Use an 18 (457mm) diameter x 5-0 (1524mm) form. Some contractors have

found that modifying a standard section of 18 steel culvert pipe works well as areusable form. Place steel reinforcement as detailed on plan standard. Plumb posts

and pour concrete.

Be sure to not leave more than 4 (102mm) of the CRP post base exposed above

the ground line. It is easier to plumb the CRP bases with the CRP top postsattached. The back fill material needs to be strong soil, compacted in 6(162mm) lifts with a hydraulic tamper.


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Connect ing Cab le Ends

To connect the cables to the terminal, affix a cable end anchor to the end of each

cable. Grease is recommended on all threaded rods to ease tensioning.

Insert the cable end anchor into the CRP post and through the L-Bracket, and install

double nuts. The bottom cable shall be attached to CRP #3, the middle cable to CRP#2, and the top cable to CRP #1. Before putting final tension in system, ensure the

L-Bracket is properly situated as show below.

Leave nuts as far down on the threads aspossible to leave ample room for tensioning the

cables. Run the cable along the ground to the

respective turnbuckle location. Cut the cablesand affix to one end of the turnbuckle. Attach

the other end of the turnbuckle to the adjacentsegment of cable and then connect the

turnbuckle leaving the maximum amount ofthreads for tensioning. Repeat for all three

cables to end of run.

Remember to use 1 threaded rod & hardware if using pre-stretched cable, or 3/4hardware for standard cable.


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Sof t So i l Foun dat ions

CRP foundations in soft soil should be a minimum of8in depth with an 18

diameter shaft; use 12 rebar cage reinforced with #5s at 6O.C. with straps.Pouring a monolithic concrete pad for all three CRP post is also a viable option.

If full 8 0 embeddment is not available, use the following list to calculate therequired concrete footing for each CRP:

For em bedm en t l ess th an 5 : Use a 4wide x 3deep monolithic concrete

pad that spans the length of all of the CRP posts. It will need to extend 2past each end CRP Post; total length being approximately 16.5. Use #5steel reinforcement bars equally spaced at 6 O.C.

Fo r e m b e d m e n t d e p t h o f 5 t o 5 . 9 : Drill a 48diameter shaft. Use a 40rebar cage reinforced with #5s equally spaced at 6 O.C. with straps.

For em bedm en t dep th i s 6 - 6 .9 : Drill a 36diameter shaft. Use a 30

rebar cage reinforced with #5s equally spaced at 6 O.C. with straps.

Em bedm en t dep th i s 7 - 7 .9 : Drill a 24diameter shaft. Use an 18 rebarcage reinforced with #5s equally spaced at 6O.C. with straps.

All concrete should be 3000 psi minimum and should cure for at least 7 days

before tension is added to system.

Direct Driven CRP foundations are 8 in length with attached soil plate, andcan be tensioned immediately after installation.


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T E N S I O N I N G T H E SY S T E M

Tens ion ing Overv iew

The last step is setting the proper cable tension by using the turnbuckles. The cable

tensioning process is a dynamic process. Regardless of the cable type (pre-

stretched or standard) when the cable and cable attachment hardware are broughtup to the appropriate tension the following process will occur:

o Cable and wedges will be seated into the cable hardware for the turnbuckles,cable anchor ends, and splices.

o Cable can temporarily hang up on hook bolts or posts creating pinch points.

A pinch point is defined when there is difference is cable tension between cablebays. Over time the cable tension will over come these pinch points and benormalized over the entire run.

o If a pinch point is recognized it can be manually released by adjusting the hook

bolt to allow the cable to freely move. Pinch points may become visually evident

when a line post is out of plum or a hook bolt is bent.o Over time the fact that the cable is under tension will in itself remove the

construction stretch from the cable.

o Time under tension will also physically change the cable in a fashion similar to

yield hardening. This process will occur more with standard cable then pre-stretched.

Each of these processes will cause the cable to physically lengthen. Cable

lengthening will cause the initial tension to decrease. Because these processes are

dynamic it may take a number of temperature cycles/changes of season before the

cables consistently hold tension. Longer runs may take more time for this processto occur than shorter runs. The use of pre-stretched cable will decrease the numberof temperature cycles to get cable to hold tension, but its use will not eliminate the

processes above from occurring. Vehicle impacts may aid in this stabilizationprocess to some degree too.

The amount of tension in the cable barrier will affect system performance. The

cables should be tensioned to the values given in the Tension Table, based uponthe temperature of the cable. The tension in the cables will vary with ambient

temperature changes.


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Tens ion ing w i th S tandard Turnbuck les

It is best to use a cable pull to get the majority of the tension into the system.

Attach the cable pull to a suitable vehicle (truck, skid steer, etc.), pull the cabletaut, install the cable end, and attach to the CRP. An alternate method is to attach

both cable ends to the CRPs and make the final connection at the turnbuckles.Using a hydraulic puller, tension the system, install the turnbuckle, and release the

hydraulic puller. Plan to pull approximately 1 per 1000from taut to

approximately 6000 pounds tension.

The final tension is achieved by tightening the turnbuckles.The tension should bechecked between every turnbuckle to ensure proper tension has been met

throughout system.

Be sure to leave a minimum of6 of clear throw in each turnbuckle after

tensioning. Do not bottom out the turnbuckles during initial installation.


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Tens ion ing w i th St rong-Back Turnbuck les

The NU-CABLE Strong-Back Turnbuckles requires installation with an in-linecable tensioning device. This device may optionally be used to install standard

turnbuckles.

Instead of relying on torquing the nut on the threaded rod to compress theturnbuckle, this pnuematic tool pulls the cable and fittings together into the strong-

back turnbuckle, allowing for easier and faster connections.

When the appropriate tension is reached, the nuts are then spun down to thebottom of the threaded cable end fittings, thus setting the turnbuckles at the

correct position.

The remote control (orange) is used to expand/contract the tensioning device,releasing the turnbuckle which has been set to the correct position for the tension

required.


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Tens ion ing Cons iderat ions

If using standard (non-prestretched) cable, the initial tension on a new cable

installation should be approximately 15% higher than the desired tension indicatedin the temperature/tension table below, to allow for cable creep. The tension

tolerance is + 15-20% or up to 2500 lbs. over desired tension maximum. Most

tension meters have an accuracy of about 200-300 lbs. The system should bechecked 2 weeks to 3 months after installation, and then periodically over the

first year, especially after seasonal changes.

After a significant impact it is recommended to check the tension. Also, checktension if an impact occurs close to an end terminal.

If tension needs to be taken up, make sure that at least 6-12 of throw is left

on the turn buckles. This may require that some length of the cable is removed.Cable should be removed adjacent to any of the attachment hardware (turnbuckles,

cable anchors or cable splices.) The attachment hardware can be re-used.

Once a cable has been in service for approximately one to tw o years, thereis no need to use the 15% creep factor after the cable has stabilized.


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3500

4500

5500

6500

7500

8500

9500

10500

11500

12500

-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120

Cable Temperature Degrees Fahrenheit (Not ambient Temp)

Tension(

Lbs

Force)

3/4" Cable - Standard & Pre-Streatched

Tens ion Tab le

After one year, the system should be tensioned per the table above. When the

cables are properly adjusted, the cables will maintain acceptable tension overexpected temperature ranges. Tension should be checked annually as a part of a

standard maintenance schedule.

A Tension Log Sheet is provided in the Appendix for accurate record keeping. It isrecommended that the contractor and DOT keep accurate, signed records of tension

for any future reference.

CableMaterial

TemperatureF

InitialTensionw/ 15%

ExpectedTension

120 4,624 4021

110 4,986 4336

100 5,350 465290 5,713 4968

80 6,077 5284

70 6,440 5600

60 7,167 6232

50 7,894 6864

40 8,619 7495

30 9,346 8127

20 10,073 8759

10 10,800 9391

0 11,525 10,022

-10 12,252 10,654

-20 12,979 11,286-30 13,706 11,918


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D E L I N E A T I O N

System delineation is not typically supplied with the NU-CABLE barrier system dueto the wide variety of delineation specifications between states. Delineation should

be installed as shown on the Tension Cable standard drawing or as directed by theengineer.

Adhesive delineators shall be 3M High Intensity Prismatic #3931 ReflectiveSheeting. Primer shall be 3M #94 Primer.

The bonding surface must be relatively clean and dry. Contaminated surfacesshould be cleaned with a 50-50 Isopropyl Alcohol and water mixture. Use a lint-

free cloth. Substrate temperature must be above 50 degrees F for properadhesion.

#94 Primer should be shaken well before using. Apply a thin, uniform coating to

the bonding surface using the minimum amount that will fully coat the surface.Allow to dry completely before applying tape.

Remove backing from pressure-sensitive reflective sheeting and apply pressure by

rolling or rubbing to ensure good contact.


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R E P A I R & M A I N T E N A N C E

The NU-CABLE System, regardless of installation method, is very easy to repair

after an impact. The longitudinal elements (the cables) of the barrier will rarelyneed to be replaced. Visually inspect the cables, and if necessary, use cable splices

to replace damaged cable.

Damaged posts and hook bolts should be replaced.

In the case of driven posts, the damaged posts must be removed and groundrepaired before driving a new post.

After a significant impact it is recommended to check the tension. Also, check

tension if an impact occurs close to an end terminal.

The many factors contributing to increased deflections can also lead to maintenanceand performance issues. The NU-CABLE High-Tension System is a low-maintenancecable barrier system. Checking the tension of the cables on an annual basis, or

after a severe impact, should be adequate. If impacted, a slack cable will result in

increased lateral deflections. If the slack allows for a cable to become incorrectlypositioned, the propensity for vehicle under-riding may increase. After all impacts,

the system requires inspection and replacement or repair of damaged parts.

Repeat Impacts

High-Tension Cable barrier systems have shown capabilities of withstanding

additional vehicular impacts on a damaged barrier. Due to the high tension, thecables typically do not fall to the ground as is the case with low-tension cablesystems.


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Re leas ing Tens ion

In certain circumstances, it may be necessary to release the tension in the system.

Those may include the need to perform a repair, or a vehicle has becomeentangled.

There are three common ways to release thetension in the system.

1. On a short run, in a non-emergencysituation, the easiest method to releasetension is to open several turnbuckles to

their maximum length1. This methodallows the detensioning and the

retensioning to be done with hand tools.

2. Using a cable grip and a vehicle ofsufficient size, attach the cable grip tothe longest end of the run not affected by the accident. Drive the vehicle

towards the accident to release tension. A worker can then either take out a

turnbuckle or cable splice, unscrew the terminal end connector from the CRP,

or cut the cable.

3. Using a ratchet come-along (note capacity2) and two cable grips, pull thecable grips toward each other to release tension. Once tension is safely

removed from the section of cable to repair, remove the nearest turnbuckleor cable splice, unscrew the terminal end connector from the CRP, or cut the

cable.

4. In emergency situation, the CRPs can be longitudinally run over (slowly) witha truck. The CRPs will simply lay down and release the tension. The CRP

posts can be reused. It will then be needed to replace the two 5/16 (8mm)breakaway bolts.

1

Completely unscrewing the turnbuckle or cable anchor end, or unscrewing the cable splice at all,without first removing the tension can be unsafe. The cables will move rapidly when the threads stripout of the connection. This method is not recommended.

2 Most construction come-alongs are only 2000# capacity. Capacity of come-along and cable grip mustbe equal or greater to the amount of tension in system. Typically 8000# to 12,000# capacity will beneeded.

Cutt ing Cab les

Although it can be done, cutting cables under

tension should be done with caution. It is

best to first release tension in the cables byusing the turnbuckles if at all possible. Avehicle becoming entrapped in the system

can create a higher-than-normal tension. In

an emergency, the cables CAN be cut, byusing great care, with an abrasive wheelsaw. Make sure no one is near the cutting point upstream or downstream. Use

gloves and safety goggles and cut very carefully. Pay particular attention whenthere are only a few strands left, at the final stage of cutting. In worst case, use a

bolt cutter with long handles.


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P avement Over lays o r Resur fac ing

Cable heights are critical to performance of the system. If the roadway has

experienced an overlay, ensure cable heights are correct, and that the slope to thebarrier does not exceed the maximum allowed. For significant overlays, it may benecessary to install extra-height posts.

Where it is anticipated that future roadway construction will require increases in the

roadway surface elevation, a pro-active solution is to install extra-height posts inthe original installation to allow for vertical adjustment of the cables. This option isonly available in Test Level 3 systems.

Emergency Access

A temporary crossover for emergency vehicles or temporary traffic control can bemade at any location of the installed cable barrier by removal of the special locking

hook bolts and/or cable hanger straps, thus allowing the cables to slacken. The

number of posts necessary for removal depends on the tension and temperature,but normally 15-40 posts will be enough. The weight of the cable will provideenough slack for passing over with vehicles.

Mater ia l s fo r Ma in tenance

A regional distributor may carry an inventory of replacement parts for the NU-CABLE system. However, it is recommended that DOTs keep repair parts on hand

for quick repair of an impacted system.

A general rule of thumb is for DOTs to stock 2% to 4% of the total project, roundedup to the minimum order quantities (below).

Line Posts = 50 piece bundles

Small Hook Bolts = 100 piecesLarge Hook Bolts = 50 pieces

Cable Hanger & Retainer Strap

= 50 BundlesCRP/Trigger posts = 3 or 4 pairs

Turnbuckles = 3 or 4 pairsCable Anchor Ends = 3 or 4 piecesCable Spool = 2000 ft.

Please contact the appropriate distributor, see list in back of manual, for up to datequotes on products.


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I N S T A L L A T I O N C H E C K L I S T S

Cab le Check l i s t

Is there anything in front of the cable barrier that might cause a vehicle

to vault the barrier or make the barrier ineffective? Items to look for

include vegetation, rough ground, debris, or hard packed snow. These

items should be removed if present.

Has the roadside grading been completed correctly?

Is there enough clearance between the barrier and the hazard for the

expected barrier deflection? Minimum clearance is dependent upon post

spacing.

Is the cable barrier the correct height?

Cable heights measured to the middle of the cable are as follows:

TEST LEVEL 3:

The TL-3 NU-CABLE High-Tension System cable heights measured at the middle of

the cable are as follows:

Top Middle Bottom

Median & Roadside 29.5 in 25.5 in 21.5 in

1 1 +0/-2

(750mm) (650mm) (545mm)

TEST LEVEL 4:

The TL-4 NU-CABLE High-Tension System cable heights measured at the middle of

the cable are as follows:


Median & Roadside 35 in 31 in 27 in 15 in

1 1 1 1

(890mm) (790mm) (590mm) (380mm)

Are the cables properly tensioned? Are there irregular curves or joints where an errant vehicle might snag?

Is there evidence of corrosion or damage to the cable? The cable should

be scheduled for repair if either of these circumstances exists.

Check to see that nuts are installed on the special locking hook bolts.

Check that there is enough thread at the cable connections to allow for

future tensioning or repairs.


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Post Check l i s t

Is there sufficient soil behind the posts to prevent them from being pushed

out when the barrier is hit? Eroded or disturbed soil should be replaced and

recompacted.

Is the post spacing correct?

Is there evidence of corrosion or damage to the posts? The posts should

be replaced if either of these circumstances exists.

TEST LEVEL 4:

Has the quick-release clip been installed properly at the top of the post?

Has the clip retainer strap been installed over the quick-release clip?

Termina l / Anchor Check l i s t

Is there soil erosion around the end anchor? Eroded or disturbed soil

should be replaced and recompacted.

Was the L-bracket installed with the CRP Posts?

Did the CRP foundation move after tensioning the cable?

Is the embankment depth such that no more than 4 of the base of theCRP post is exposed above ground level?

CableGuard:

Has the anchor post been installed at the correct angle in the system?


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A P P E N D I X


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Tens ion Lo g 3-Cab le Systems


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Tens ion Lo g 4-Cab le Systems


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P ost Spac ing & Def lect ion Charts

Test Level 3 Direct Drive vs. Concrete Socket

Test Level 3 vs. Test Level 4


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L ine P ost Deta i l - Test Leve l 3 : Three-Cab le


48/68


L ine P ost Deta i l - Test Leve l 3 : Four-Cab le


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L ine P ost Deta i l - Test Leve l 4


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L ine P ost Deta i l Dr iven Socket Opt ion


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System Detai l TL-3: Three -Cable


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System Detai l TL-4 or TL-3: Four -Cable

DirectDrive

PostOption

(No

Sock

et)Is

Ava

ilable

forallTL-3

versions.


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Anchor Deta i l CRP Anchor End Pos ts & Foote r

Re in fo rcement

In soft soil conditions, use aconcrete footer with an 8 0[2438] embedment depth.


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Anchor Deta i l CRP TL-3: Three-Cab le Ancho r L ine P osts


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Anchor Deta i l CRP TL-3: Four-Cab le Anchor L ine P osts


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Anchor Deta i l CRP TL-4 Anchor L ine P os ts


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Anchor Deta i l C a b l e G u a r d Termina l for TL -3


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Anchor Deta i l C a b l e G u a r d Foot ing Re in fo rcement


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Component Deta i l NU-CABLE Strong-Back Turnbuck l e


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Component Deta i l NU-CABLE Qu ick -Gr ip Cab le End


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Component Deta i l Standard Turnbuck l e

*Source NCDOT


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Component Deta i l Standard Cab le End

*Source AASHTO Barrier Guide

May besupplied with

only (1)washer.


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Component Deta i l TL-4 Cab le Hanger & Hanger Strap


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FHW A M emorandum Cab le Bar r ie r Cons idera t ions


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T e c h n i c a l S u p p o r t a n d S a l e s

Contact Information

M anu fac tu re r :

NUCOR Stee l Ma r i on , I nc .

www.nsmarion.com

Corpora te Headquar te r s

Steve Conw ay

Sales Manager Highway Products Division

(800) 333-4011 ext. [email protected]

Mailing Address:912 Cheney Ave.

Marion, OH 43301

Manufactu r e r Represen ta t i ves NUCOR Steel Marion, Inc.

Rick Mauer

National Sales Representative(603) 430-9350

[email protected] Address:

PO Box 837Greenland, NH 03840-0837

Chris Sanders

District Sales Manager

(740) 383-9637

[email protected] Address:912 Cheney Ave.

Marion, OH 43301


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Dis t r i bu to rs :

Clover leaf Corpor at ionAlabama, Florida, Georgia

www.cloverleafcorp.com

Matthew Schindler

(888) 388-1882(813) 645-5577 [email protected]

GSI High Tension Cable LPArkansas, Colorado, Kansas, Nebraska,Texas, Oklahoma, Wyoming

www.hightensioncable.com

John Williams

(972) 225-1660 ext. 11

(972) 225-6662 [email protected]

Gul f I n dus t r i es In c .Louisiana, Mississippi, Tennessee

www.gulfindustriesinc.com

Quinn Boylen(800) 960-7788

(985) 892-0707 fax

Hi ghw ay Sa fet y Corpora t i on Connecticut, Delaware, Maine,

Massachusetts, New Hampshire, NewJersey, New York, North Carolina,

Pennsylvania, Rhode Island, Vermont,Virginia, Washington D.C.

www.highwaysafety.net

Roy Riedl

(860) 633-9445


Hi ghw ay Supp l y

Arizona, New Mexico

www.highwaysupply.net

Denis R idef for d (505) 345-8295

(505) 980-7160 fax

[email protected]

John Thomas I nc .Illinois, Wisconsin

www.crashcushions.com

John Dvorak(888) 447-7263


Nu Cable Install Jul 08

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