CSP Pacific | Barrier Field Manual | December 12
Barrier Field Manual
Barrier Field Manual - Index
Flexrail™ W Beam Highway & Bridge Barrier Brochure
Installation Checklist
FX54 Highway Flexrail – 12G – Half Rail
FX55 Bridge Flexrail – 10G – Half Rail
FX33 Highway Flexrail – 12G – Full Rail
FX34 Bridge Flexrail – 10G – Full Rail
FX360 Standard Guardrail Assembly – 12G on Timber Posts & Blockouts
FX283 Standard CSP Pacific Flexrail Posts
FX92 Standard Flange Mounted Steel Posts FX107 Standard Timber Post & Blockout
FX93 Standard Steel Post for Bridge Handrail
FX94 Standard Steel Flexrail Post
FX147 Standard Tested Necked Bolt
FX150 Standard Cast-In Brackets
FX91 Flexrail Steel Post Flange Mounted
FX253 Standard Flexrail Backing Piece
FX126 8 Hole Bridge Connector
FX146 Bullnose Terminal End – Single Piece
FX407 Flexrail Structure Connector
FX359 Buried-in-Backslope Assembly
04
07
08
08
09
09
10
11
12
12
13
13
14
14
15
15
16
16
17
17
Bridge Handrail
FX350-1 Flexrail Handrail – Sloping Termination
FX306-1 Handrail Standard Detail
18
19
X-350 Tangent & Flared End Terminal Brochure30
Installation & Maintenance instructions
31
Installation Checklist
37
FX538 Tangential Terminal End - Timber Post-Elevation
38
39
FX539 Tangential Terminal End - Timber Post
FX540 Tangential Terminal End - Steel Posts-Elevation
40
FX541 Tangential Terminal End - Steel Posts
41
Nu-Guard 31™ Steel Guardrail System Brochure42
43
Installation & Maintenance instructions
Installation Checklist
45
FX514 Nu-Guard 31 System Assembly
46
FX513 Nu-Guard 31 W-Beam Post
47
FX525 Nu-Guard 31 Median System Assembly
47
FX566-1 Nu-Guard 31 Curved Terminal Installation
48
FX577 Nu-Guard 31 Transition to 27” High X-350 Timber Post Option
49
FX608 Nu-Guard 31 Transition to 31” High X-350
50
FX609 Nu-Guard 31 Transition to Standard TL4 Thriebeam
51
FX611 Nu-Guard 31 Transition to Railing End Terminal
51
Trailing End Terminal
Installation Checklist
FX335 Curved Trailing Terminal Assembly - exploded view
52
53
CSP PACIFIC
2
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
Thriebeam™ Brochure20
Installation Checklist
22
FX382-1 Standard 12G Thriebeam Rail
23
FX497 W-Thrie Transition Section
23
24
FX408 Thriebeam Timber Post & Blockout
FX476 Standard Thriebeam Posts
24
FX459 Thriebeam Driven Post & Blockout
25
FX475 Thriebeam Bridge Post & Blockout
25
FX461 Thriebeam Structure Connector Assly
26
26
FX453 Thriebeam Structure Connector
FX495 Thriebeam Handrail-Sloping to Timber
27
FX495-2 Thriebeam Handrail-Sloping to Steel Base
28
FX495-1 Thriebeam Mounting Detail
29
FX553 Thriebeam Steel Post & Routered Timber Blockout
29
FX348-2 Curved Trailing Terminal Assembly
FX348-4 Straight Trailing Terminal Assembly
54
55
NZTA Standard Details
RSB-1 Buried-in-Backslope Terminal
RSB-2 Curved Terminal
RSB-3 M23 Terminal Grading Plan
RSB-4 Nested Guardrail Detail
RSB-5 TL4 Transition Detail
56
57
58
59
59
Drawings
FX33
FX34
FX54
FX55
FX91
FX92
FX93
FX94
FX107
FX126
FX146
FX147
FX150
FX253
FX283
FX306-1
FX335
FX348-2
FX348-4
FX350-1
FX359
FX360
FX382-1
FX407
FX408
FX453
FX459
FX461
FX475
FX476
FX495
FX495-1
FX495-2
FX497
FX513
FX514
FX525
FX538
FX539
FX540
FX541
FX553
FX566
FX577
FX608
FX609
FX611
RSB1
RSB2
RSB3
RSB4
RSB5
09
09
08
08
15
12
13
13
12
16
16
14
14
15
11
19
53
54
55
18
17
10
23
17
24
26
25
26
25
24
27
29
28
23
47
46
47
38
39
40
41
29
48
49
50
51
51
56
57
58
59
59
CSP Pacific | Barrier Field Manual | December 12
Barrier Field Manual - Index
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
3
FlexrailTM W-Beam Highway (12g) & Bridge Barrier (10g)
Flexrail™ complies with the requirements
of AASHTO, AS/NZS 3845 : 1999 TNZ
specifications M/23 and M/17P.
CSP Pacific supplies two standard types of
Flexrail™ W-beam guardrail:
» Highway Flexrail: 3810-12
» Bridge Flexrail: 4000-10
Flexrail™ is roll formed from coil steel and
sheared to length. It is then punched, slotted and
hot dip galvanised in accordance with
the appropriate standards.
Flexrail™ is generally available ex-stock in
standard net lengths of 3.81 metres and 1.905
metres for highway rail and 4.00 metres and 2.00
metres for bridge rail.
Highway (12g)
Bridge (10g)
3810
4000
Steel Thickness (mm)
2.7
3.4
Area of Cross Section
(mm2)
1350
1640
Major 80,000
Major 103,000
Minor 22,000
Minor 29,000
11.3
13.4
Effective Cover
Section Modulus (mm3)
Mass (kg per metre)
Profile
More information on Flexrail™ can be found at www.csppacific.co.nz or call 0800 655 200
4
CSP Pacific | Barrier Field Manual | December 12
Physical Properties
Flexrail™ W-Beam Highway (12g) & Bridge Barrier (10g)
Fish Tail
Backing Piece
(used on steel blockouts only)
Bullnose End Fitting
Rolled End Fitting
Structure Connector
Post
PostBolt
Bolt
Bolt Size
A mm
B mm
250
25
120
350
350
80
450
450
120
Wooden
WoodenPost
Post
Splice Bolt
More information on Flexrail™ can be found at www.csppacific.co.nz or call 0800 655 200
CSP Pacific | Barrier Field Manual | December 12
Steel Post
5
Flexrail™ W-Beam Highway (12g) & Bridge Barrier (10g)
Bridge Rail Dimensions (3.4mm Gauge)
Curved Flexrail™
The standard straight section will align to give a
smooth transition on curves with a radius greater
than 45m. Pre-curved Flexrail™ is required for
tighter radii and may be curved to traffic face
concave or convex.
NB: Only Highway Flexrail is available pre-curved.
Highway Rail
R
(metres)
α
(Deg)
C
(m)
H
(mm)
3
72.7656
3.559
585
4
54.5742
3.667
445
5
43.6594
3.719
359
6
36.3828
3.746
300
7
31.1853
3.763
258
8
27.2871
3.774
226
9
24.2552
3.782
201
10
21.8297
3.787
181
12
18.1914
3.794
151
14
15.5926
3.798
129
16
13.6436
3.801
113
20
10.9148
3.804
91
23
9.4912
3.806
79
29
7.5275
3.807
63
32
6.8218
3.808
57
35
6.2371
3.808
52
41
5.3243
3.809
44
46
4.7456
3.809
39
More information on Flexrail™ can be found at www.csppacific.co.nz or call 0800 655 200
6
CSP Pacific | Barrier Field Manual | December 12
Highway Rail (2.7mm Gauge)
Flexrail™ W-Beam Highway (12g) & Bridge Barrier (10g)
Installation Checklist
Checklist
Y
N
Assembly and installtion is to be generally in accordance with TNZ
M23, AS/NZS 3845:1999 and CSP Pacific drawing FX360 and/or the
Engineers specification.
The rail height (top) is in accordance with the plans (706mm above
the edge of the shoulder or the ground line).
Correct lapping of the rail should be away from the direction of traffic
to prevent snagging.
Timber blockouts should be nailed to timber post to prevent rotation.
Installation is aligned and level.
Posts are aligned at correct spacing and backfill compacted.
Post bolts are tight and a 50 x 50 square washer is fitted to back of
post.
Steel Post Systems (Post Type FX91, FX92, FX93 & FX94)
Backing pieces to be fitted at the intermediate post only.
Post bolts are tight using a spring washer and then locked with a
lock nut.
Necked bolts are installed with washer as specified and are installed
tight.
Location:
Installed by:
Date:
Inspected by:
Date:
More information on Flexrail™ can be found at www.csppacific.co.nz or call 0800 655 200
CSP Pacific | Barrier Field Manual | December 12
Notes:
7
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
8
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
9
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
10
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
11
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
12
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
13
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
14
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
15
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
16
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
17
(Not for use on State Highways)
CSP Pacific | Barrier Field Manual | December 12
Bridge Handrail
CSP PACIFIC
18
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
19
Thriebeam™
Thriebeam™ has been available for more than
25 years as a natural addition to the guardrail
family of products. Thriebeam™ has an added
corrugation that gives it an advantage for use in
transitions to bridges and along high volume, high
speed roadways.
Thriebeam™ derives its name from the general
cross-sectional shape of the beam. The product is
roll formed from coil steel and sheared to length.
It is punched and slotted to suit the particular
configuration, then hot dip galvanised prior to
despatch.
Thriebeam™ complies with the requirements of
AS/NZS 3845:1999 and TNZ M23.
Thriebeam™ is available ex-stock in standard net
lengths of 4 metres with post spacing at
1m centres.
DIMENSIONS & MECHANICAL PROPERTIES
2.7mm Gauge
Beam Width Minimum (mm)
508
Beam Depth Minimum (mm)
76
Cross Sectional Area (mm2)
2,013
Moment of Inertia (mm2)
Section Modulus (mm3)
Weight (approx) (kg/m)
1,555,000
36,400
16.7
More information on Thriebeam™ can be found at www.csppacific.co.nz or call 0800 655 200
20
CSP Pacific | Barrier Field Manual | December 12
Profile
Thriebeam™
Structure connector
Post options and detail
Thriebeam™ rail elevation
Backing plate
More information on Thriebeam™ can be found at www.csppacific.co.nz or call 0800 655 200
CSP Pacific | Barrier Field Manual | December 12
Transition section
21
Thriebeam™ (12g) Barrier
Installation Checklist
Checklist TL-3 Timber Post System
Y
N
Y
N
Assembly and installation is to be generally in accordance with TNZ M23,
AS/NZS 3845:1999 and/ or Engineers specification.
The rail height (top) is in accordance with the plans (805mm above the
edge of the shoulder or the ground line).
Correct lapping of rail away from the direction of traffic to prevent snagging.
Timber blockouts nailed to timber post to prevent rotation.
Installation is aligned and level.
Post are aligned, at correct spacing and backfill compacted.
Two post bolts per post and block.
Post bolts are tight and a 50 x 50 square washer is fitted to back of post.
Checklist TL-4 Steel Post System
Assembly and installation is to be generally in accordance with TNZ M23,
AS/NZS 3845:1999, CSP Pacific drawing FX495-1 and/ or Engineers
specification.
The rail height (top) is in accordance with the plans (865mm above the
edge of the shoulder or the ground line).
Correct lapping of rail away from the direction of traffic to prevent snagging.
Modified Blockout is fixed to I-Post with 2 M16 x 50 Eng bolt and nut
diagonally.
Backing pieces at fitted at the intermediate post only.
Installation is aligned and level.
Post bolts are tight using a spring washer and then locked with a lock nut.
Posts are aligned at correct spacing.
With a flange based post the necked bolts are installed with washer as
specified and are tight.
Location:
Installed by:
Date:
Inspected by:
Date:
More information on Thriebeam™ can be found at www.csppacific.co.nz or call 0800 655 200
22
CSP Pacific | Barrier Field Manual | December 12
One post bolt per post and modified blockout required only. To be installed
in the top post hole.
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
23
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
24
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
25
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
26
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
27
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
28
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
29
X-350 Tangent and Flared Guardrail End Terminal
Features
» Approved to NCHRP 350 TL-3
» Lower cost
» Fully re-directive
» Cost effective, life saving device
» Length of need (LoN) at post one
» Improved vehicular control
» Impact force held in tension – less chance of
kinked rail
» Little or no debris scatter
» Ease of installation and maintenance
» 3 x Standard highway rails 12 gauge
» Impact head weighs only 25 kgs
» Flared of tangent terminal end
» Designed & manufactured in NZ
» Patented technology
X-350 Tangent
Specifications: NCHRP 350 TL-3
» Speed: 100kph
» Length: 11.4m (3rails)
» Offset: 0 – 1200mm
» Post 1: Steel
» Posts 2 – 6: Breakaway timber or steel
» Run out – 22.5m x 6m
» LoN starts at Post 1
» All steel components hot dipped galvanised
X-350 Flared
More information on X-350 Tangent and Flared Guardrail End Terminals
can be found at www.csppacific.co.nz or call 0800 655 200
30
CSP Pacific | Barrier Field Manual | December 12
» Max grade 10:1
X-350 Tangent & Flared Installation Instructions
Step 1 - X-350 parts identification
Impact head
Friction plate
Soil anchor
Slider panel
Slider bracket + angle bar
Cable bracket
(1 required)
Cable assembly
Post 1 – top
Post # 2 (1 required)
(roadside can be CRT timber)
Ground strut
Standard steel line Post
(3-6) (roadside can be
Post # 1 bottom
(1 required)
(2 required)
(1 required)
(1 required)
(1 required)
(1 required)
(1 required)
(1 required roadside)
(1 required)
CRT timber)
Standard highway rail
(3 required roadside)
Shear bolts
(8 required)
Blockout (plastic or
timber) (5 required)
Hardware set
Step 2 - Installing posts 6 - 2
Install posts 6 to 2 at standard highway rail Spacing
1905mm, to the correct height. Top of post to
be either 710mm or 805mm above ground level
depending on the guardrail system being attached to.
Note: Only standard “I” beam posts can
be installed at the higher height of 805mm.
Timber posts must be 710mm above
ground level.
Figure 1. Pull a string line with the
desired offset
Figure 2. Bolt the blockout prior to
attaching the rail
Post 2 is either the Special “I” beam post or a
timber CRT. For the “I” beam post at 805mm above
ground, the embedment of this post must only be
1025mm.
Posts may be directly driven, or in stiff soils a
150mm diameter hole drilled, and the post then
driven into the hole. The post may also be placed
in an oversized augured hole but care must be
taken to ensure the backfill is properly compacted.
CSP Pacific | Barrier Field Manual | December 12
Posts #6 to #3 are either standard “I” beam posts
OR timber CRT posts.
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
31
X-350 Tangent Installation Instructions
Step 2 - Installing posts 6 - 2
Hint: Offset Post 3 back from the string line
40-50mm to make it easier to push rail 1 and
Slider Panel over rail 2.
When driving steel posts, ensure that a driving
cap with timber or plastic insert is used to prevent
damage to the galvanising on the top of the posts.
Bolt the blockout to the post at post 3,
prior to attaching to the rail (Figure 3).
Step 3 - Post 1, ground strut & soil anchor
Place the roadside face of post 1 bottom anchor,
200mm towards the roadway to compensate for the lack
of blockout (Figure 3). Post 1 bottom the Ground Strut
and the Soil Anchor are then placed parallel to the string
line at this roadside offset position. Drive or place the
bottom of post 1 in the augured hole so that no more
than 75mm (100mm max), protrudes above ground level
(Figure 4).
Figure 3. Measure 20cms towards
roadway
Figure 4. Drive Soil Anchor 1 into
augured hole
Note: There is a choice of 2 height
settings at the bottom of post #1 top.
Ensure that the correct one is selected
so that centre of impact head is at the
correct height above ground level.
Step 4 - Hang rail 3 & cable anchor bracket
Rail 3 is installed like standard guardrail with post 6 at
the centre of the rail and blockouts between the rail
and post.
Place the Cable Anchor Bracket on the back of the rail
at the joint between rail 3 and rail 4 (post 7).
The two “boxes” on the cable bracket should be on the
impact head side of the splice joint.
Attach rails to post with post bolt and splice rail 3 to rail
4 with 8 standard splice bolts (Figure 6).
Figure 5. Post 1 top in post bottom
Figure 6. Splice rail 3 to rail 4 with
8 standard splice bolts
Note: Do not over tighten bolt.
CSP PACIFIC
32
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
Use the Ground Strut as a template to place the Soil
Anchor in the correct place. The Soil Anchor can then
be driven into place or placed in an augured hole and
backfilled. The Ground Strut should be level or lower at
the anchor end than at the post 1 bottom end (Figure 5).
Place post 1 top in the post 1 bottom anchor ensuring
that the post bolt notches are at the top and facing the
Soil Anchor (Figure 5). Use M16 x 200mm hex head
bolt with nut and washers.
X-350 Tangent Installation Instructions
Step 5 - Hang rail 2 and shear bolts
Before installing rail 2 double check that the blockout is
already bolted to post 3.
Bolt rail 2 to the post and blockouts at posts 4 and 5 with
the appropriate post bolt (Figure 7).
DO NOT BOLT THE RAIL TO POST 3.
Splice rail 2 to rail 3 with the 8 special shear bolts
(yellow) supplied (Figure 8). Put the washer and
nut on inside of rail.
IMPORTANT NOTE: DO NOT USE STANDARD
SPLICE BOLTS AT POST 5 SPLICE
Figure 7. Bolt rail 2 to post and
blockouts
Figure 8. Splice rail 2 to rail 3
with 8 special shear bolts
Figure 9. Bolt Slider Bracket to
end of rail 2 at post 3
Figure 10. Remove angle bar bolts
Figure 11. Sit rail 1 so it is raised
off the ground
Figure 12. Slide the Slider Panel
onto downstream end
Figure 13. Push Slider Panel over
rail 2
Figure 14. Bolt rail 1 and blockout
to post 2
Step 6 - Attach slider bracket to Rail 2
Bolt the Slider Bracket to the end of rail 2 at post 3
(Figure 9). Use 4 standard splice bolts. The angle bar
end should be closest to the Impact Head end.
Remove the angle bar and 2 x M20 x 40mm bolts
(Figure 10).
Step 7 - Assemble slider panel onto Rail 1
The curved and reinforced (post breaker) end of Slider
Panel sits at the rail end. Use guardrail pin bar or crow
bar to assist with lining up splice holes.
Step 8 - Hang rail 1
Lift rail 1 with Slider Panel attached and push the slider
end over rail 2 (Figure 13). Overlap the rails as per a
standard splice joint overlap.
Bolt rail 1 and blockout to post 2 using a standard post
bolt that is supplied (Figure 14).
Re-attach the angle bar to the slider bracket on the
backside of the rail (Figure 15).
CSP Pacific | Barrier Field Manual | December 12
Start by sitting rail 1 on a blockout or post so that it
is raised off the ground as shown (Figure 11). Slide
the Slider Panel onto the downstream end of rail at
post 3 location (Figure 12) and bolt into place using 4
standard splice bolts, pushing the bolt through from the
inside of the slider to the outside so that the nut is on
the traffic face.
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
33
X-350 Tangent Installation Instructions
Step 9 - Attach Impact Head
Place Impact Head on upstream end of rail 1 and attach
using 8 standard splice bolts with nuts on traffic face
(Figure 16).
Hint: Place bottom two bolts first then use guardrail pin
bar to lever head up snug onto rail.
Bolt head and rail 1 to post 1 using the supplied
M16 x 50mm guardrail post bolt.
Use a 50mm x 50mm washer under the nut on the
inside of post 1 (Figure 17).
Figure 16. Attach Impact Head to
rail 1
Figure 17. Bolt head and rail 1 to
post 1 with washer
Step 10 - Place the Cables
Push the cables under the steel strap on the Ground
Strut (Figure 18) and forward through the holes at the
top of the anchor. Lay the cables out parallel to the
guardrail, downstream from the anchor.
Ensure that bottom cable (closest to road) has half the
thread protruding through the anchor, as shown. Ensure
the top cable has the nut wound on a least two turns
past the end of the thread (Figure 19).
Figure 18. Push cables under
steel strap on Ground Strut
Figure 19. Thread the nuts as
shown
Step 11 - Installing the Cables
Now thread the cable down the backside of the rail
following the bottom trough of the W-beam and attach
to the bottom “box” on the Cable Bracket at post 7.
Repeat this process with the other cable but push it
through the top hole and thread it along the top trough
of the W-beam.
Figure 20. Pass the cable through
the bottom hole
Figure 21. Place the nuts and
washer on the cables at the Cable
Bracket end but only turn them a
few turns
Place the nuts and washer on the cables at the Cable
Bracket end but only run them a few turns (Figure 21).
Do not tighten cables at this stage
(or the Friction Plate will not turn)
Figure 15. Reattach the angle bar
CSP PACIFIC
34
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
Install the Friction Plate in the top of the Impact Head,
adjustment hole up. Take the cable closest to the
road, pick up the downstream cable fitting and walk to
the head, passing the cable through the bottom hole,
through the Friction Plate (Figure 20) and out the
backside of the Impact Head.
X-350 Tangent Installation Instructions
Step 12 - Turning the Friction Plate
Put a crow bar through the hole at the top of the friction
plate (Figure 22) and turn it in slot as far as it will go.
Using a socket spanner tighten the 4 - M20 x 75mm
bolts on the side of the impact head to lock the bar in
the turned position (Figure 23).
Figure 22. Use crow bar to turn
Friction Plate
Figure 23. Use socket to lock bar
in the turned position
Step 13 - Tightening the Cables
Only tighten the cables using the nuts at the Cable
Bracket end (post 7) (Figure 24). Do not tighten the
cable nuts at front of the Ground Anchor.
Tighten the cables until they are taut, i.e. they rest in the
backside of the W-beam and do not visibly sag between
posts (Figure 25). There is no torque requirement for
the cables.
Figure 24. Tighten cables at Cable
Bracket end (post 7)
Figure 25. Tighten cables until
they are taut
Figure 26. Attach nose using nylon
push rivets
Figure 27. Nut Protectors fitted on
Impact Head
Step 14 - Attach Nosing and Nut Protectors
The X-350 Plastic Nut Protectors are available for all
X-350 Terminal Ends. They protect pedestrians and
cyclists from exposed splice bolt nuts and threads. Fit 8
Nut Protectors on the Impact Head (Figure 27) and 4
on Slider Panel (Figure 28).
CSP Pacific | Barrier Field Manual | December 12
Push nosing into place on the front of the impact head.
Attach using the supplied nylon push rivets (Figure
26). Delineation to be attached to nosing as per Local
Authority requirements.
Figure 28. Nut Protectors fitted to
Slider Panel
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
35
X-350 Flared Installation Instructions
X-350 - Flared Installation Instructions
0 - 1.2m
This section deals with installation of a Flared X-350
system in a roadside guardrail terminal
end application.
Apart from the initial set out, the flared X-350 and
installation procedure is identical to the Tangent
system, the only difference being the amount of offset
used.
Site preparation
The Flared terminal may be installed either parallel to
the edge of the roadway (tangent) or with the impact
head end of the rail offset by up to 1.2m away from the
road (Figure 29) in a straight flare, over the length of
the system. No parabolic curve is required.
Ensure that the area where the X-350 is to be installed
is flat enough so that the anchor will not protrude more
than 75 mm (100 mm max) above ground level, when
measured with a straight line over a 1.5m cord. Minor
site grading may be required.
Figure 29. Pull string line to follow roadside
edge of post. Maximum offset is 1.2m
Step 1 - Set Out
Pull a string line out with the desired offset 0 -1.2m. Note
that the flare is a straight flare, over the length of the
system (11.4m).
All the posts except post 1 have a blockout so take care
to place the roadside face of post 1, 200mm towards the
roadway (Figure 30).
Post 1 bottom; the Ground Strut and the Soil Anchor are
then placed parallel to the string line on the roadside of
it (Figure 31).
Figure 30. Place roadside face of
post 1 towards roadway
Figure 31. Place ground strut
parallel to string line
Now follow steps 2 – 14 in the Tangent
installation instructions.
Note: The “kink” in the line of rail between rail
3 and rail 4 (at post #7) is formed by simply
pushing the rails around to follow the flared
line of posts. This is not factory bent.
CSP PACIFIC
36
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
The string line should be set to follow the roadside edge
of the posts (Figure 29).
X-350 Installation Instructions
Installation Checklist
Checklist
Y
N
Ground strut is flush to ground surface
No more than 100mm to protrude above ground surface
Bolted to post # 1 at base of post
Impact head has rail bolted with all 8 nuts on the face of the rail
Locking bar is turned fully in slot and secured with 4 x 8.8HT
bolts only
Post # 2 is a steel I beam breakaway (weakened) or timber CRT
post with blockout
Post # 3 is not bolted to rail
Post # 3 to 6 are steel I beam line posts (not weakened) or
timber CRT posts with blockouts
Slider panel is attached to rail # 1 with all four nuts on the face of rail
Slider bracket is attached to rail # 2 with all four nuts inside the
rail
Angle bar is bolted to the slider bracket with the flat section
facing post # 3 at the impact head side
Cables are tensioned up “taut” with no visible sag over the 11.4m
span
8 x yellow shear bolts are bolted at rail # 2 and # 3 with the spacers
washers between the nut and rail depending on guardrail system.
Note that steel posts must be used if at 635mm high.
Guardrail height is 550mm or 635mm from the finished road surface
to the centre of the rail depending on guardrail system. Note that
steel posts must be used if at 635mm high.
Location:
Installed by:
Date:
Inspected by:
Date:
CSP Pacific | Barrier Field Manual | December 12
Flare rate 0 - 1200mm from the tangent 11.43m
37
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
38
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
39
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
40
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
41
Nu-Guard 31™ Steel Guardrail System
A smaller footprint, lighter weight and no
requirement for a blockout means the
Nu-Guard 31™ steel post guardrail system
is comparable in cost to wooden post
systems and is simpler and quicker
to install.
Features
» System has a smaller footprint and no blockout
» NUCOR™ steel posts, with no blockout, enables
faster installation
» It is possible for one post to be installed per
minute using a post rammer
» NUCOR™ steel posts are lighter and smaller in
area than traditional posts
» High tensile galvanised NUCOR™ steel post is
designed for easy after-impact repair of system
» Environmentally friendly - manufactured using
recycled steel
» Uses standard highway rail and fixings
» A median or roadside barrier
» NUCOR™ steel posts will split on impact to avoid
guardrail tearing, reducing the incidence of wheel
snagging
» Only NCHRP350 TL-4 tested and approved
system using standard highway rail
Specifications
» Tested and approved to MASH-1 TL-3
and NCHRP 350 TL-4
» Post weight: 14.78 kg
» Post length: 1980mm
» Height to centre of rail: 635mm
» Maximum system deflection is 1200mm for
roadside applications
» No blockouts required
» Standard highway rail and fixings
» All components hot dip galvanised
» Posts are manufactured from high tensile steel
More information on Nu-Guard 31™ can be found at www.csppacific.co.nz or call 0800 655 200
42
CSP Pacific | Barrier Field Manual | December 12
» Post footprint: 0.0375m2
Nu-Guard 31™ Installation Instructions
Install Posts
Use standard guardrail procedures to mark out and
align the posts. Post spacing is the same as standard
rail at 1905mm.
The Nu-Guard 31™ posts are 1980mm long with a slot
at the top.
For roadside installations, ensure that the flanges are
facing to the side the rail will be installed on and that
they are parallel to the line of the rail.
For median installations ensure the posts are
alternated between flanges forward and then flanges
back.
When driving steel posts, ensure that a driving
cap with timber or plastic insert is used to prevent
damage to the galvanising on the top of the posts.
The top of the post should be 812mm above the
nominal ground line. This places the centre of the rail at
approximately 635mm from the nominal ground line.
Posts may be driven or in stiff soils a 100 dia. hole
drilled and the post then rammed into the hole. The
post may also be placed in an oversized augured hole
but care must be taken to ensure the backfill is properly
compacted.
Install Rail
The rail is installed the same as standard guardrail with
a splice join being at a post.
It is generally easiest to lift one rail at a time and while
it’s held in place, fit the post bolt in the centre of the rail
to hold the rail in place.
CSP Pacific | Barrier Field Manual | December 12
Use the M16 x 90mm coach bolt to fix rail to post,
ensuring that the 90mm diameter washer is fitted
between the rail and post as detailed below.
Secure on back of post with a standard splice nut (no
washer).
Lap rails in direction of traffic.
The top of the post must be a minimum of 20mm above
the top of the guardrail.
Therefore the position of the M16 x 90mm post bolt in
the slot may vary slightly.
M16 x 90mm coach bolt c/w splice nut
90mm Dia. washer between rail and post flanges
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
43
Nu-Guard 31™ Installation Instructions
Assemble Rails
Splice the rails together in the standard manner,
ensuring that all eight splice bolts are used and
fully tightened at every joint.
For Median Installations Only
It may be easier to hang the rails on one side, two
or three panels ahead of the other, holding them
temporarily in place with the centre post bolts.
Then as the panels on the other side are placed, secure
them into place bolting both sides of rail with one bolt at
the splice joins.
The temporarily placed centre bolts can then be
removed and pushed through both sides of rail as well.
Washers are placed between the post rail on both sides
of the post in median situations.
In median installations, if more than 20mm of bolt
protrudes past nut on backside, cut off
and treat with cold galvanising paint.
System Maintenance
Nu-Guard 31TM is maintained exactly the same as
standard timber post and block-out guardrail.
CSP Pacific | Barrier Field Manual | December 12
If the rail and/ or the post is damaged and/or bent then
it must be replaced.
CSP PACIFIC
44
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
Nu-Guard 31™ Steel Guardrail System
Installation Checklist
Checklist
Y
N
Height to centre of rail is 635mm
There is no blockout
When driving post, use a driving cap with timber or plastic insert
to avoid damage to the post
Top of post should be a minimum of 20mm above top of guardrail
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
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 terminations
are correct
Location:
Installed by:
Date:
Inspected by:
Date:
CSP Pacific | Barrier Field Manual | December 12
Notes:
45
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
46
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
47
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
48
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
49
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
50
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
51
Trailing End Terminal
Installation Checklist
Checklist
Y
N
Assembly and installation is to be generally in accordance
with AS/NZS 3845:1999, TNZ M23 and CSP Pacific drawing
FX348-2
The rail height (top) is in accordance with the plans
(706mm above the edge of the shoulder or the ground line)
The steel tubes/posts do not protrude more than 100mm above
the ground line (measured by the AASHTO 1.5m cord method, site
grading may be necessary to meet this requirement
The bolts at the top of the steel tubes are not over tightened
and the walls of the steel tubes are not collapsed/distorted.
The 200mm x 200mm bearing plate at post 1 is correctly
positioned and the anchor cable is taut and correctly installed
(it should be rechecked after installation to be sure it hasn’t
relaxed)
Blockouts have been toe nailed to the posts
The backfill material around the posts is properly compacted
The rail panel is not attached to the post at post No. 2 the rail sits
on the shelf angle only
Location:
52
Installed by:
Date:
Inspected by:
Date:
CSP Pacific | Barrier Field Manual | December 12
Notes:
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
53
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
54
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
55
NZTA Standard Details
CSP Pacific | Barrier Field Manual | December 12
The following drawings are the property of the New Zealand Transport Agency and are subject to amendment.
The latest version is available on www.nzta.govt.nz
CSP PACIFIC
56
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
57
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
58
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
CSP Pacific | Barrier Field Manual | December 12
CSP PACIFIC
A | 306 Neilson St, Onehunga
P | PO Box 12 949, Penrose, Auckland 1642, New Zealand
W | www.csppacific.co.nz
59
Copyright and Limited Reproduction:
The design of and all content appearing in this brochure are the copyright of CSP Pacific. No part of this brochure may be:
» distributed or copied for any commercial purpose, nor incorporated in any other work or publication (whether in hard
copy, electronic or any other form); or
» resold, published, copied, reproduced, transmitted or stored (including in any other brochures or other electronic form)
except that you may print, or copy only for your own use (or for use in any document, proposal or presentation for the
purpose of specifying products manufactured or supplied by CSP Pacific), without the express permission of CSP
Pacific.
Disclaimer:
This Brochure contains files which were current at the time of printing. Latest drawings and informations are available in
PDF format from our web site www.csppacific.co.nz
Issue: Barrier Field Manual V8 December 2012
CSP Pacific – A member of the Fletcher Building Group
306 Neilson Street, Onehunga, Auckland 1061
PO Box 12 949, Penrose, Auckland 1642
Ph: 0800 655 200 or 09 634 1239 Fax: 09 634 4525
www.csppacific.co.nz