Nu Guard Product and Installation manual - CSP Pacific · Installation Manual: Nu-Guard® 31...

Installation Manual: Nu-Guard® 31 Guardrail System

Ph 0800 655 200 or visit www.csppacific.co.nz April 15 /

Nu-Guard® 31 Roadside and Median

Guardrail System

MASH TL-3 & NCHRP TL-4 Product & Installation Manual



Table of Contents NU-GUARD® 31 Introduction……………..……..…………………….. 3

System Overview…...……………………........................... 3

Limitations and Warnings……….………........................... 4

Before Installation……….………………............................ 4

Safety Statements………………………………………....... 4

Limited Warranty………...…………..…………..…………………….... 5

Geotechnical Warning..….…………..………..………………………... 5

Design Considerations……………………………..…………………… 6

System Design……….……………………………..…………………… 7

Parts Identification………….…………………….……………………… 9

Installation Preparation...….…..……………………………………….. 11

Roadside Installation Instructions……………..……………………..... 12

Median Installation Instructions……..…………………………………. 13

Installation Examples……………………………..…………………… 16

Installation Checklist.……………………...…………… ……………… 19

Maintenance & Repair…..………………………....………………….. 20

Frequently Asked Questions …………………………………………. 21

APPENDIX – Technical Drawings NU-GUARD® 31 W Beam Post (FX513) ..……..…………………….. 24 NU-GUARD® 31 System Assembly (FX514)…..…………………….. 25 NU-GUARD® 31 Median Assembly (FX525) ..…………………….. 26 NU-GUARD® 31 Curved Terminal Installation (FX566-1)………….. 27 NU-GUARD® 31 Rigid Barrier Transition (FX527-3)…………….. 28 NU-GUARD® 31 X-350 Ground Anchor (FX636)……………….. 29 NU-GUARD® 31 Transition to 27” High X-350 Timber Post (FX577) 30 NU-GUARD® 31 Transition to 31” High X-350 (FX608) ……………. 31 NU-GUARD® 31 Transition to Standard TL-4 Thrie-beam (FX609).. 32 NU-GUARD® 31 Transition to Trailing End Terminal (FX611) …… 33 NU-GUARD® 31 Transition to X-TENuator™ (FX606) ……………. 34 NU-GUARD® 31 Median Transition to 31” High X-350 Median (FX607) 35 NU-GUARD® 31 Thrie-beam TL-4 on Flange Based Posts (FX613) 36 NU-GUARD® 31 Area of Reduced Deflection (FX614)……………. 37



Introduction NU-GUARD® 31 roadside is a w-beam guardrail barrier comprising of unique ‘U’ shaped steel posts. The posts are driven, which allows for quick installation, and connect to w-beam guardrail panels on one side in the traditional manner at a height of 31” (787mm). The barrier has been designed and tested to meet the evaluation criteria of NCHRP 350 Test Level 4 (TL-4) & MASH (TL-3) for a longitudinal barrier. It is recommended that the ‘roadside’ NU-GUARD® 31 barrier is anchored using a single sided X-350 terminal end which is accepted to NCHRP 350 TL-3. System Overview NU-GUARD® 31 roadside barrier is designed and constructed to provide acceptable structural adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 & MASH for longitudinal barriers. When impacted with an 820kg, 2270kg and 8000kg vehicle at speeds of up to 100kph and side on entry angles up to 25 degrees, the impacting vehicle is re-directed in a safe manner. Nu-Guard® 31 Median Introduction NU-GUARD® 31 median is a w-beam guardrail barrier comprising of unique ‘U’ shaped steel posts. The posts are driven, which allows for quick installation, and connect to w-beam guardrail panels on both sides in the traditional manner at a height of 31” (787mm). The barrier has been designed and tested to meet the evaluation criteria of NCHRP 350 Test Level 4 (TL-4) & MASH (TL-3) for a longitudinal barrier. It is recommended that the ‘median’ NU-GUARD® 31 barrier is anchored using a X-350 Median terminal end or a X-TENuator™ crash cushion which is accepted to NCHRP 350 TL-3. System Overview NU-GUARD® 31 median barrier is designed and constructed to provide acceptable structural adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 & MASH for longitudinal barriers. When impacted with an 820kg, 2270kg and 8000kg vehicle at speeds of up to 100kph and side on entry angles up to 25 degrees, the impacting vehicle is re-directed in a safe manner.



Limitations and Warnings NU-GUARD® 31 barriers have been rigorously tested and evaluated per the evaluation criteria in the NCHRP 350 & MASH guidelines for longitudinal barriers. The impact conditions recommended in NCHRP 350 & MASH are intended to address typical in-service collisions. NU-GUARD® 31 barriers allow an impacting vehicle to be re-directed in a safe and predictable manner under the NCHRP 350 & MASH impact conditions. It is imperative that the system is installed as per manufacturers’ specification. Vehicle impacts that vary from the NCHRP 350 & MASH impact conditions described for longitudinal barriers may result in significantly different results than those experienced in testing. Vehicle impact characteristics different than, or in excess of, those encountered in NCHRP 350 testing & MASH (weight, speed and angle) may result in system performance that may not meet these evaluation criteria’s. Before Installation Design, selection and placement of NU-GUARD® 31 must be in accordance with the Road Controlling Authority guidelines and the details shown in the construction drawings. Installation must be in accordance with the installation instructions supplied for this product. Note: Alternative installations techniques will need to be used if soil conditions on site do not meet the required level described in the manual. NU-GUARD® 31 is a highly engineered safety device made up of a small number of parts. Before starting installation ensure that one is familiar with the make-up of the systems. Safety Statements General Safety

• All required traffic safety precautions should be complied with. All workers should wear required safety clothing (Examples, and not limited to, include: high visibility vests, steel capped footwear, gloves etc.) • Only authorised trained personnel should operate any machinery. Where overhead machinery is used, care must be taken to avoid any overhead hazards. • Before installing the posts, always ensure that the area is clear of underground services. (The appropriate service providers may need to be contacted) NU-GUARD® 31 Safety Statements

• All installers must be well clear of machinery when posts are being driven. • The posts (15kg) and fixings are easily lifted and positioned by hand. While a highway rail panel (47kg approx.) should be moved and positioned by two personnel and care should be taken not to have fingers near the bolt holes while being manoeuvred.



Limited Warranty CSP Pacific has tested the impact performance of its barriers and crash cushion systems, and other highway safety hardware under controlled conditions. CSP PACIFIC does not represent nor warrant to the buyer (or any other person) that the Products and Parts as tested will necessarily avoid injury to persons or property. The use of the products and Parts is at the Buyer’s sole risk. CSP PACIFIC EXPRESSLY DISCLAIMS ALL LIABILITY FOR CLAIMS OF ANY NATURE WHATSOEVER ARISING BY REASON OF DEATH OR PERSONAL INJURY OR DAMAGE TO PROPERTY RESULTING FROM ANY IMPACT, COLLISION OR HARMFUL CONTACT WITH OR USE OF THE PRODUCTS OR PARTS OR NEARBY HAZARDS OR OBJECTS BY ANY VEHICLE, OBJECTS OR PERSONS. CSP PACIFIC warrants solely that any product or component part manufactured by CSP PACIFIC will be free from defects in material or workmanship. THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER REPRESENTAIONS AND WARRANTIES NOT EXPRESSLY SET FORTH HEREIN, WHETHER EXPRESS OR IMPLIED BY OPERATION OF LAW OR OTHERWISE, INCLUDING BUT NOT LIMITED TO ANY IMPLIED REPRESENTATIONS OR WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE. CSP PACIFIC’S LIABILITY UNDER THE FOREGOING WARRANTY IS EXPRESSLY LIMITED IN ALL RESPECTS AND AT AIL’S SOLE ELECTION TO: A. THE REPLACEMENT FREE OF COST OF THE DEFECTIVE CSP PACIFIC PRODUCT OR PART SUPPLIED BY CSP PACIFIC ONLY (IN THE FORM AND THE TERMS ORIGINALLY SHIPPED). B. THE REPAIR OF THE DEFECTIVE CSP PACIFIC PRODUCT OR PART TO REMEDY ANY DEFECTS IN THE MATERIAL OR WORKMANSHIP. C. THE PAYMENT OF AN AMOUNT EQUAL TO THE ORIGINAL PURCHASE PRICE OF THE DEFECTIVE CSP PACIFIC PRODUCT OR PART. CSP PACIFIC SHALL NOT OTHERWISE BE LIABLE TO THE BUYER (OR ANY OTHER PARTY) FOR BREACH OF WARRANTY, NEGLIGENCE OR ANY OTHER RESPECT WHATSOEVER. WITHOUT LIMITATION, CSP PACIFIC 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 THE SALE, HANDLING OR USE OF THE PRODUCTS AND PARTS OR FROM ANY OTHER CAUSE RELATING THERETO, OR FROM PERSONAL INJURY OR LOSS OF PROFIT SUSTAINED IN RESPECT THEREOF. Any claim by the Buyer with reference to CSP PACIFIC Products or Parts sold hereunder for any cause shall be deemed waived by the Buyer unless CSP PACIFIC is notified in writing, in the case of defects apparent on visual inspection, within ninety (90) days from the delivery date, or, in the case of defects not apparent on visual inspection, within twelve (12) months from the delivery date. CSP PACIFIC Products and Parts claimed to be defective in material or workmanship under the foregoing warranty may be returned prepaid to CSP PACIFIC’s plant for inspection in accordance with return shipping instructions that CSP PACIFIC shall furnish to the Buyer forthwith upon receipt of the Buyer’s notice of claim. If the claim is established, CSP PACIFIC will reimburse that Buyer for all carriage costs incurred hereunder. The forgoing warranty benefits shall not apply to (i) any Products or Parts that have been subject to improper storage, accident, misuse or unauthorised alterations, or that have not been installed, operated and maintained in accordance with approved procedures and (ii) any Products or Parts manufactured or supplied by any party other than CSP PACIFIC (Including the Buyer).

Geotechnical Warning NU-GUARD® 31 posts require sufficient strength from the supporting soil to function as required and remain at the correct height. If it is determined that soil conditions on site do not meet these requirements, alternative installation options will need to considered. For further details contact CSP Pacific.



Design Considerations Curves

NU-GUARD® 31 can accommodate curved w-beam guardrails panels like other guardrails systems if conditions on site require. For radii below 25m the Nu-Guard® 31 must be anchored at the start and the end of the curve by using an intermediate anchor and/or a trailing terminal end. There should be no bolts holding the rail at the apex of the curve with the rail instead sitting on a shelf angle. For further details refer to drawings FX566-1 and FX636 in the appendix of this manual. Slopes

A maximum slope of 1:10 is preferable. On slopes greater than this, follow the Road Controlling Authority guidelines. Curbs

As with all road side safety hardware, NU-GUARD® 31 has been designed and tested so that the centre of gravity of the impacting vehicle is at a constant height in relation to the barrier. For this reason, it is preferred that curbs or channels are not installed in front of the barrier as they will result in altering the height of the vehicle at impact. If there is no option but to install a curb or if it is already present consult Road Controlling Authority guidelines re curb height and design, and barrier offset distance. Undulating Ground Conditions

Site specific grading may be necessary to ensure that there are no ‘humps’ or ‘hollows’ that may significantly alter the impacting vehicles stability or substantially alter the barrier height in relation to the ground. Ditches

If the slope of the ditch is greater than 10:1 then follow the Road Controlling Authority’s guidelines.



System Design

Roadside and Median Applications

NU-GUARD® 31 can be used in both roadside and median applications. The single sided system is to be used on the edge of road, while the ‘back to back system, is required in a median situation.

Terminal End Treatments

It is recommended that NU-GUARD® 31 systems are anchored using a X-350 Tangent or Flared, X-350 Median end terminals or X-TENuator™ crash cushions. For further information on these terminal ends and crash cushions contact CSP Pacific. Transitions

To connect NU-GUARD™ 31 systems to other types of barriers or terminal ends consult the transition drawings contained in the Technical Drawing Appendix of this manual. If the situation is not covered in these drawings contact CSP Pacific for advice. Batter Hinge Point

It is recommended that there is a minimum of 600mm of soil between the post and the batter hinge point. Note: For installations where there is less than 600mm or ‘other’ issues are present, contact CSP Pacific.

Length of Need (LoN)

The Length of Need (LoN) of NU-GUARD® 31 system is dependent on the terminal end used to anchor the barrier as all LoN’s are contained within the terminal end itself. Note: As per the LoN design section of the Road Controlling Authority’s guidelines, care must be taken when calculating the actual length of barrier versus the theoretical length of the LoN. NU-GUARD® 31 when connected at either end to an X-350 end terminal creates a fully re-directive barrier, and therefore the actual length of the barrier is the same as the theoretical length of the LoN. The use of ‘other’ terminal ends may require addition length of barrier ‘upstream’ and ‘downstream’ of the LoN to achieve the same protection.



Deflections

Deflection measurements from actual crash testing can be useful when assessing a products suitability to perform as required at a given location. The below distance measurements are from NCHRP 350 and MASH compliance testing on the ‘roadside’ and ‘median’ systems respectively. Note: The MASH pickup truck has the highest impact severity of all the tests results below. TL-3 Deflection Results Test 3-11: 2270kg pickup truck, 25 degree angle at 100kph (MASH TL-3) Post Spacing Dynamic Deflection Permanent Deflection 1.905m 1.05m 0.80m Test 3-10: 820kg car, 20 degree angle at 100kph1 (NCHRP 350 TL-3) Post Spacing Dynamic Deflection Permanent Deflection 1.905m 0.68m 0.39m 1 Test 3-10 was run on the back to back NU-GUARD® 31 ‘median’ system.

TL-4 Deflection Results Test 4-12: 8000kg truck, 15 degree angle at 80kph (NCHRP 350 TL-4) Post Spacing Dynamic Deflection Permanent Deflection 1.905m 1.22m 0.80 Note: If tests 3-11 and 4-12 were run on the back to back NU-GUARD® 31 ‘median’ system, the deflection results would be expected to be lower than those listed above. Soil Conditions

For NU-GUARD® 31 to perform as intended and remain at the correct height it must be installed in soil conditions that have sufficient strength to support the posts as required. The ground conditions need to be able to withstand a push test of 1kN at 635mm above ground level. Soil conditions should meet the requirements of AS/NZS 3845:1999 and Specification TNZ M/4 2006.



Parts Identification - Components

Standard highway rail NU-GUARD™ 31 Post

Splice (Guardrail) Bolts 90mm Diameter Washer

M16x90mm Bolt & Nut M16x100mm Bolt, washer & Nut All NU-GUARD® 31 steel components are hot dipped galvanised.

Accessories

Post Cap Protector Protective Driving Insert (Plastic) (Nylon)



Bill of Materials

‘Roadside’ Barrier For every linear 3.81m of barrier the following components are required: • Standard highway rail 1 required • 1980mm NU-GUARD® Post 2 required

• Splice Bolts 8 required

• 90mm Coach Bolt and Splice Bolt Nut 2 sets required

• 90mm Diameter Washer 2 required ‘Median’ Barrier For every linear 3.81m of barrier the following components are required: • Standard highway rail 2 required

• 1980mm NU-GUARD® Post 2 required

• Splice Bolts 16 required

• 100mm Coach Bolt, round washer and Splice Bolt Nut 2 sets required

• 90mm Diameter Washer 4 required NB: Above descriptions are only for calculating total amount of components required.



Installation Preparation

Getting Started NU-GUARD® 31 barriers have virtually the same components and barrier setup for the ‘roadside’ or ‘median’ systems. For all installations, whether edge of road or median locations, start from the last post of the adjacent system. NU-GUARD® 31 post spacing between the systems for a standard installation is 1.905m.

Preparation Before installing NU-GUARD® 31, ensure that all components required for the system are on site and have been identified. NU-GUARD® 31 is a highly engineered safety device made up of small number of parts. Before starting installation ensure that one is familiar with the make up of the system. Refer to the Parts Identification and Bill of Materials section in this manual for more information. Ensure that the area where NU-GUARD® 31 is to be installed is flat enough so that the ground conditions will not significantly alter the height of the vehicle in relation to the height of the w-beam guardrail panels. Minor site grading may be required.

Soil Conditions NU-GUARD® 31 can be installed in ‘Roadside’ and ‘Median’ locations where soil conditions that exist are essentially a fully compacted sub-base. Refer to the Soil Conditions section in this manual for more information. It is recommended that soil tests are carried out at the location the NU-GUARD® 31 is to be installed.

IF SOIL CONDITIONS ON SITE DO NOT MEET OR EXCEED THE REQUIRED STRENGTH DETAILED IN THIS MANUAL DO NOT INSTALL THE SYSTEM. CONTACT CSP PACIFIC FOR

FURTHER ADVICE.

Tools Required The tools required to install NU-GUARD® 31 are:

• Wrenches and sockets (32mm) commonly used to install w-beam guardrail. (A small specialised socket wrench is required for the ‘median’ system) • Podger bar • Measuring tape and marker pen • String line and fluorescent spray paint • Tampers or Post Rammer commonly used for driving posts • Protective inserts for driving cap • Impact Wrench and portable compressor – optional



Nu-GUARD® 31 Post in hard surfaces NU-GUARD® 31 posts should be installed in soil conditions that meet the requirements of AS/NZS 3845:1999 and TNZ M/4 2006. However due to its smaller footprint and no blockout requirement NU-GUARD® 31may need to be installed in areas that have thick asphaltic layers or even a concrete footpath. As concrete or thick asphalt surrounding the NU-GUARD® 31 post has no flexibility, unlike soil, it can create a pinch point. In a vehicle impact this may cause the post installed in the hard surface to snap very quickly and as a result not give enough support to the highway rail to perform as designed. The recommended treatment involves creating a hole in the hard surface around the post to remove the possibility of any pinch point and fill with a low strength concrete/grout or flexible asphalt. A hole in the hard surface material of 300 x 300mm square is to be keep clear around each NU-GUARD® 31 post in a side of road installation. The post sits centrally in the hole but at the front face closest to the road as shown in Figure 1. The post can sit against the hard surface at the front of the hole as the top of the post will only rotate backwards but the post area below ground will not rotate forward as with a timber post. The NU-GUARD® 31 post is installed in compacted soil under the pavement surface that meets the requirements of AS/NZS 3845:1999 and TNZ M/4 2006. After installation of the NU-GUARD® 31 post, the widened hole in the surfacing is filled with a grout mixture to a maximum depth of 150mm. This grout mixture is a recipe by volume of seven parts sand, two parts water and 0.5 parts cement. The compressive strength should be about 1 MPa. It must not be a concrete mix (i.e. no graded aggregate composition) but rather a uniform sand and cement matrix. This is the same mixture as per recommendation for around timber posts in the NZTA Technical Memorandum TM-2005.

Figure 1 SECTION A-A The top of the hole can also be filled with a topping asphalt with a maximum depth of 75mm. If the depth of the hole is greater than 75mm then a suitable compacted fill such as GAP20 should be used to bring the surface to the correct height before applying the asphalt. The same applies for a median installation except the NU-GUARD® 31 post is placed centrally in the 450mm x 450mm hole in the hard surface.



Installation Instructions ‘Roadside’ Application Step 1 – Site Preparation and General Information It is preferred that NU-GUARD® 31 is installed on flat, level ground with sufficient distance behind the posts as described in the Batter Hinge Point section. The barrier itself must be connected (anchored) at either end to either an approved terminal end, transition section or w-beam guardrail in order to perform as designed and tested. Post spacing is 1.905m, further details will be shown in the construction drawings on how to mark the appropriate locations at which the posts are to be installed. Before driving posts, always ensure that the posts are clear of underground services.

Note: During the construction period NU-GUARD® 31 should be installed in a way so that the exposed end of the w-beam guardrail is located at the ‘downstream’ end, and not dangerous to other road users. Protective techniques commonly used when installing ‘other’ types of w-beam guardrail can also be used for NU-GUARD® 31.



Step 2 – Driving the Posts Drive posts at predetermined position to the required depth using suitable machinery. The top of the post should be 812mm above the nominal ground line. Post spacing is 1.905m from the last post of the terminal end, transition section or w-beam guardrail. (shown in Figures 1, 2 & 3) For the roadside installation only make sure that the post ‘flanges’ face the back of the rail. Traditional installation methods used when installing ‘other’ w-beam guardrail utilising a string line, measuring tape and marker paint are also useful when applied to NU-GUARD® 31.

Protect the galvanising on top of the posts by using a protective insert

Figure 1 Figure 2 Figure 3 Note: If the conditions on site don’t allow for the posts to be driven, contact CSP Pacific for alternative accepted installation methods.

Step 3 – Joining the W-Beam Guardrail Panels The centre of the guardrail is 635mm above the nominal ground line. Lap the w-beam guardrail panels on the side of the posts with the direction of the laps the same as the direction of the traffic flow. (shown in Figures 4, 5 & 6) Each ‘splice joint’ requires the w-beam guardrail panels to be joined using 8 splice bolts and tightened with a wrench or socket. (An impact wrench is optional)

Figure 4 Figure 5 Figure 6



Step 4 – Connecting the W-Beam Guardrail Panels to the Posts Once the w-beam guardrail panels have been joined together on the traffic side of the posts they can be attached to the post. Insert the 90mm M16 coach bolt through from the face of the guardrail with the 90mm diameter round washer positioned between the back of the rail and the ‘flanges’ on the post. (shown in Figure 7) The bolt can then be secured at the back of the post with the splice bolt nut and tightened with a spanner ONLY. (shown in Figure 8) The post bolt position in the vertical slot in the post may vary and may not be at the bottom of the slot. Ensure the top of the post is at 812mm and the centre of the w-beam guardrail panel is at 635mm relative to the ground. (shown in Figure 9)

Figure 7 Figure 8 Figure 9 Step 5 – Repeat Steps 2, 3 and 4. Repeat these steps until the barrier is the required length and joined to a terminal end, transition section or w-beam guardrail at the other end.

During construction of NU-GUARD® 31 ensure that the exposed end of the w-beam

guardrail is ALWAYS at the ‘downstream’ end of the installation and/or protected using a suitable technique if road users are present.

Step 6 – Delineation. Delineation may be required as per the Road Controlling Authority Guidelines. For further details including type, location and placement contact the Road Controlling Authority or CSP Pacific.



‘Median’ Application Step 1 – Site Preparation & General Information It is preferred that NU-GUARD® 31 is installed on flat level ground. NU-GUARD® 31 must be connected (anchored) to either an approved terminal end, transition section or w-beam guardrail at either end in order to perform as designed and tested. Post spacing is 1.905m, further details will be shown in the construction drawings on how to mark the appropriate locations at which the posts are to be installed. Before driving posts, always ensure that the posts are clear of underground services.



Step 2 – Driving the Posts Drive the posts at predetermined position to the required depth using suitable machinery. The top of the post should be 812mm above the nominal ground line. Post spacing is 1.905m from the last post of the terminal end, transition section or w-beam guardrail. (shown in Figures 10, 11 & 12) For the median installation only make sure that the post ‘flanges’ alternate. (see page 24) Traditional installation methods used when installing ‘other’ w-beam guardrail utilising a string line, measuring tape and marker paint are also useful when applied to NU-GUARD® 31.

Protect the galvanising on top of the posts by using a protective insert

Figure 10 Figure 11 Figure 12 Note: If the conditions on site don’t allow for the posts to be driven, contact CSP Pacific for alternative accepted installation methods. Step 3 – Joining the W-beam Guardrail Panels Together The centre of the guardrail is 635mm above the nominal ground line. Lap the w-beam guardrail panels on each side of the posts with the direction of the laps the same as the direction of the traffic flow. (shown in Figures 13, 14 & 15) Each ‘splice joint’ requires the w-beam guardrail panels to be joined using 8 splice bolts and tightened with a wrench or socket. There is limited access when connecting the second side of w-beam guardrail and a small specialised socket wrench is required.

Figure 13 Figure 14 Figure 15



Step 4 – Connecting the W-Beam Guardrail Panels to the Posts Once the w-beam guardrail panels have been joined together on either side of the posts they can be attached to the posts. Insert the 100mm M16 Coach Bolt through from the face of the rail with a 90mm diameter round washer positioned between the back of the w-beam guardrail panel and post on each side. (shown in Figure 16) Bolt orientation is consistent with post. Consult the drawing in the Appendix for further detail. The bolt can then be secured on the face of the guardrail with a small round washer under the M16 nut and tightened with a wrench or socket ONLY. (shown in Figure 17) The post bolt position in the vertical slot in the post may vary and may not be at the bottom of the slot. Ensure the top of the post is at 812mm and the centre of the W-beam guardrail panel is at 635mm relative to the ground. (shown in Figure 18)

Figure 16 Figure 17 Figure 18 Step 5 – Repeat Steps 2, 3 and 4. Repeat these steps until the barrier is the required length and joined to a terminal end, transition section or w-beam guardrail at the other end.

During construction of Nu-Guard® 31 ensure that the exposed end of the w-beam guardrail is ALWAYS at the ‘downstream’ end of the installation and/or protected using

a suitable technique if road users are present. Step 6 – Delineation. Delineation may be required as per the Road Controlling Authority Guidelines. For further details including type, location and placement contact the Road Controlling Authority or CSP Pacific.



NU-GUARD® 31 – Installation Examples

NU-GUARD® 31– ‘Roadside’ Application

NU-GUARD® 31 – ‘Median’ Application

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Nu-Guard® 31 Steel Guardrail System

Location:

Installed by: Date:

Inspected by: Date:

Checklist Y N

Height to centre of rail is 635mm

Height to the top of the post is 812mm

Top of post should be a minimum of 20mm above top of guardrail

There is no blockout

When driving post, use a driving cap with timber or plastic insert to avoid damage to the post

Post is aligned with flanges rail (for road side applications) and alternating between flanges forward and back for median applications

There is a 90mm dia. washer between rail and post. Position of M16 x 90mm post bolt in post slot may vary. It is not always located in the bottom of the slot.

Rail is lapped in the direction of traffic

All bolts are fully tightened

Nut on backside of post is a splice nut

If a median installation-excessive bolt length is cut off on backside

That transition details to existing guardrail or terminationsare correct

Installation Checklist

Notes:



Maintenance and Repair

Maintenance NU-GUARD® 31 barriers are maintenance free. It is however recommended that an annual inspection is carried out on the terminal ends, if applicable, to check that the ‘anchor’ tension is maintained by the cables as per Manufacturer’s Specifications.

Repair After a typical impact Recommended tools: • Wrenches and 32mm sockets • Podger bars • Vertical Plate lifting clamp • Machinery to remove the damaged posts and install new ones Replacement parts required for an average impact: • 1980mm NU-GUARD® 31 Posts • 3.81m W-Beam Guardrail Panels • Post Bolt sets as per application • Splice Bolts Key Steps: • Separate the components by undoing the splice bolts and post bolts • Remove any damaged posts (machinery may be required as detailed above) • Assess which components are damaged and replace with new parts accordingly • Drive new posts and install new guardrail as per the Installation Instructions in this manual for the type of barrier system being repaired. • Replace Post Caps (if required) After Fire Damage A NU-GUARD® 31 barrier is made entirely of galvanised steel components and it is possible that under extreme conditions, like bushfires, that the components of the system or the galvanising can be damaged. If this is the case replace the components as described above and as outlined in the NU-GUARD® 31 Installation Manual.



Frequently Asked Questions 1) What type of equipment is required to install NU-GUARD® 31? Standard tools required include 32mm sockets and wrenches, podger bars, measuring tape and a string line. Machinery includes post rammer commonly used in driving posts. If installing the ‘median’ system a specialised small socket wrench is recommended. 2) On average, how long does it take to install a NU-GUARD® 31 Barrier? Depending on the application and circumstances at the site, installation and assembly of the system should take a three person crew less than two hours to install a 50m section. 3) When driving the posts what can be used to prevent damage to the galvanising on the top of the posts? It is recommended that a timber, plastic or brass insert is fitted to the device being used to drive the posts. (Experience has shown that a brass insert will last the longest) 4) How easily can NU-GUARD® 31 be restored after impact? The system is made up of very few different components and is easily repaired. Machinery will be required to lift out the damaged posts and drive the new ones. The remainder of the barrier requires only a wrench and 32mm socket to take apart and reinstate. 5) Does your company provide spare parts? What is the lead-time for supply? It is important to fix a damaged barrier as soon as possible because it may not perform as required when damaged. For this reason it is recommended that spare NU-GUARD® 31 key components are held by maintenance contractors along with the standard w-beam guardrail hardware. 6) What maintenance does NU-GUARD® 31 require? NU-GUARD® 31 is maintenance free barrier. 7) Are the same posts used for both the TL-3 and TL-4 Barriers? Yes, there are no differences in any components or installation characteristics between the systems. In summary, the same barrier has passed NCHRP criteria for both MASH TL-3 and NCHRP350 TL-4. 8) What is the maximum Deflection of NU-GUARD® 31? The maximum deflection recorded during actual crash testing at TL-4 was 1.22m on an ‘edge of road’ system. An assumption can be made then that on a ‘median’ installation the deflection will be lower than this due to the barrier having guardrail panels on both sides and providing a ‘stiffer’ system. The dynamic deflection that should be used when comparing the performance of w-beam barrier is 1.05m with the MASH pickup truck. (2270kg, 100kph & 25 Degrees)



9) What can NU-GUARD® 31 be connected to? NU-GUARD® 31 must be anchored at either end by either an approved terminal end, transition section or w-beam guardrail. A fully re-directive X-350 End Terminal is the recommended terminal end for both ‘Roadside’ and ‘Median’ applications. For further information consult the NU-GUARD® 31 recommended transition drawings in the Technical Drawing Appendix of this manual. 10) What about vandalism, can NU-GUARD® 31 be easily damaged? The system can be dismantled using a wrench; however NU-GUARD® 31 barriers are held together using similar nuts and bolts to other systems in which vandalism is not considered an issue.



APPENDIX – Technical Drawings

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