HSM001 Hill & Smith Ltd Flexbeam Installation Manual Issue A HSM001 (Issue A) 2 Hill & Smith Ltd Flexbeam Installation Manual Hill & Smith Ltd Flexbeam Installation Posts All posts must satisfy the requirements of HSD002 to ensure that when impacted the system will perform as designed. There are various methods to install system posts: • Driven directly into the ground. • Placed into a punched hole with an aggregate backfill. • Placed into a precast foundation within a punched hole. • Cast directly into insitu concrete foundation. • Set into a socket (plastic/metal) cast into an insitu concrete foundation. • Set into a socket punched into a suitable substrate. • Surface mounted. In order to determine the strength of the ground into which a VRS is to be installed, a test shall be carried out as detailed in Hill & Smith Site Testing Requirements document HSD002. The frequency of tests is dictated by prevailing site conditions and as deemed necessary to satisfy the overseeing site engineer. The post and/or foundation is acceptable if: • FlexBeam 125 x 44 ‘Z’ post A Bending Moment of 6 kNm (6000Nm) is achieved without the deflection exceeding 100mm at the designated height. • FlexBeam PLUS 170 x 47.5 ‘Z’ post A Bending Moment of 9 kNm (9000Nm) is achieved without the deflection exceeding 150mm at the designated height. (note allowable deflection is reduced in the TranZFlex arrangement – see TranZFlex drgs for details) • FlexBeam PLUS 125 x 90 ‘Z’ post A Bending Moment of 9 kNm (9000Nm) is achieved without the deflection exceeding 150mm at the designated height. HSM001 (Issue A) Hill & Smith Ltd Flexbeam Installation Manual Progression through N2 Flexbeam systems W2 W3 W4 W5 Single sided 4m (2 pitches at 2m) 5.6m (2 pitches at 2.8m) 8m (2 pitches at 4m) 10m (2 pitches at 5m) Double sided 4.8m (3 pitches at 1.6m) 8m (2 pitches at 4m) 9.6m (2 pitches at 4.8m) Please refer to appendix C for further explanation 1. Posts installation When setting out post positions it is important that an accumulation of tolerance errors is avoided, this is to ensure that posts remain within the system tolerances,. From the setting out datum check the pitch to the first system post and ensure that it is within the system tolerances as shown on the relevant system drawings. (Subsequent posts are to be measured from the setting out datum). Continue this method for all posts and then, if necessary, re-datum and repeat as above. Ensure that the post is the correct type. Ensure that the post is in the correct orientation. Ensure post is set to the specified height. Ensure the system is within the tolerances for height, spacing and verticality. Note for driven posts: If the ground is too hard unacceptable damage to the top of the post will result. In these circumstances other options should be used, e.g. cored concrete foundations. Note for concrete foundations: Concrete specification to have minimum characteristic cube strength of 25MPa or cylinder strength of 30MPa and meet any additional site specific requirements. Note for surface-mounted posts: It may be necessary to use a suitable grout/mortar bed of between 10mm and 30mm underneath the surface mounted post feet to enable levelling of the system . All voids in anchorages, attachment systems and base plates should be filled with a non-setting passive filler to prevent the collection of water. Fixings should be M20 and must pass the requirements set out in HSD002 document. No part of the fixing should protrude more than 40mm above the underside of the foot. Some contracts call for stainless steel anchorage systems to be used, this is usually the case when attaching to structures i.e. bridges. 2. Beams Hang beams onto posts at the designated positions using the correct fixings as shown on the relevant system drawing hand tightened only. Couple beams together using the correct fixings as shown on the relevant system drawing. Fixings to be torqued as required before moving onto the next beam joint. Lap joint bolts must be tightened to their correct torque before post fixings are torqued to their final setting. Positioning of the posts is critical. Double check all dimensions before setting components in concrete. 3. Repairs When setting components in wet concrete, ensure that they remain in the correct position, using temporary support framework where necessary. Beams and posts that are visually seen to be distorted, split, buckled or otherwise damaged shall be replaced. It is not acceptable to straighten damaged components due to work hardening effects. All fasteners in the impact zone shall be replaced with new FlexBeam specified fasteners irrespective of obvious damage. Ideally slope concrete away from post/socket to prevent formation of corrosion pockets. It is important that foundations have vertical sides as this considerably improves their overturning resistance. Beam lap holes either side of the damaged VRS area shall be examined closely for splitting or malformed shape (hole ovality, etc) and such beams will be unacceptable for re – use. 3 4 HSM001 (Issue A) Hill & Smith Ltd Flexbeam Installation Manual If a post is leaning but with no evidence of bending in the post at or near ground level, then it is likely that the foundation has moved. Movement of driven or socketed posts in individual concrete foundations (whether affected directly by impact or not) will require that the posts/foundations are removed and the ground locally dynamically compacted to the satisfaction of the overseeing Engineer with reference made to the pushpull test requirement for Flexbeam posts (see Hill & Smith document HSD002) before posts are re - driven or replaced. Where posts are in socketed foundations and there is no damage to the foundation, a new post can be refitted to the socket. Prior to the replacement of a surface mounted post, the holding down fixings should be inspected for any visible movement. Any movement or adjacent structural damage to the concrete will render the fixings unsuitable for re-use and they should be replaced with suitable fixings which are capable of withstanding the loads generated by the deforming of the ‘Z’ post section as specified by the overseeing Engineer. Breakage or movement of any concreted foundations of posts or End Anchorages will necessitate replacement. Impacts local to a terminal (within 50m) dictates inspection of the anchorage block and correction to the requirements of the overseeing Engineer. If the impact is within 50 m of a terminal then the anchor block and tension bolt assemblies should be inspected for damage/movement. Reconstruction using a larger block may be needed if any movement has occurred. 3.1 Repairing damaged Zinc coatings Damaged coatings can be repaired by the removal of any rust from the steel and the application of a 150 micron coat of high (> 89%) Zinc solids paint. This procedure complies with EN ISO 1461. 3.2 Component Replacement Any damaged beam, fixings, brackets or posts should be replaced with new components conforming with current Hill & Smith Ltd specification. Before any re-driving of posts in new positions is undertaken a check should be made on any underground services or cable positions. 4. Historical Information Hill & Smith Limited have policy of continual improvement and updates to VRS’s and their installation manuals/ drawings. Current information may not reflect what has been installed therefore it is recommended that you refer back to the job specific contract file for any system details at that time or deviations used. If versions of previous installation manuals or drawings are required then contact Hill & Smith Ltd for copies. For further information please visit the Hill & Smith Xtranet. An information portal designed for quick access to drawings & technical documents. 1600 SS N2 W1 2000 2800 4000 5000 SS N2 W2 SS N2 W3 SS N2 W4 SS N2 W5 With Rubbing Rail 1200 Post Crs mm SS N2 W1 CE marked Flexbeam VRS PD-CEFB05 PD-CEFB04 PD-CEFB23 PD-CEFB22 PD-CEFB21R PD-CEFB21 Drawing reference 5000 4000 4000 4000 4000 4000 Beam mm Beam CM059 CM023 CM023 CM023 CM023 CM023 Item ref. CM031 CM031 CM047 CM047 CM047 CM047 Beam to post fixing Appendix A: System component guide 710 710 735 735 735 735 Height to top of post mm 450 450 450 450 450 450 470 470 470 470 470 470 Depth of socket Overall socket in ground mm length mm Assumed ‘level’ ground 1160 1160 1185 1185 1185 1185 Length mm CM011A CM011A CM301A CM301A CM301A CM301A Item ref. Socketed/cast-in post CM011B CM011C CM011D 1900 2100 CM011D 2100 1700 CM011C 1900 2050 CM011B CM301C CM301D 1850 1700 CM301B CM301D 2050 1650 CM301B CM301C 1850 2050 1650 CM301C CM301D 1850 CM301B CM301D 2050 1650 CM301B CM301C 1850 Item ref. 1650 Length mm Driven post CM077BV CM077BC 610 CM077AC 610 710 CM077AV CM077BC 710 CM077BV 610 CM077AC 610 710 CM077AV CM302BC 635 710 CM302BV CM302AC 635 735 CM302AV CM302BC 635 735 CM302BV CM302AC 635 735 CM302AV CM302BC 635 735 CM302BV CM302AC 635 735 CM302AV CM302BC 635 735 CM302BV CM302AC CM302AV Item ref. 635 735 735 Height mm Surface mounted post Hill & Smith Ltd Flexbeam Installation Manual HSM001: Appendix (Issue A) 5 1600 4000 4800 1600 2000 2000 1600 DS N2 W3 DS N2 W4 SS H1 W3 SS H1 W4 SS H2 W5 DS H2 W5 Post Crs mm DS N2 W2 CE marked Flexbeam VRS PD-CEFB95 PD-CEFB85 PD-CEFB64 PD-CEFB63 3200 4000 4000 3200 4000 4000 4000 CM001 CM023 CM023 CM001 CM023 CM023 CM023 Beam Beam mm Item ref. CM053 CM048 CM048 CM047 CM031 CM031 CM031 Beam to post fixing 1075 1075 1075 735 785 785 785 450 450 450 450 375 375 375 470 470 470 470 400 400 400 CM043AC CM043AV 1525 CM043AV 1525 CM043AC 1525 CM043AV 1525 1525 CM043AC CM301A CM011A CM011A CM011A 1525 1185 1160 1160 1160 Assumed ‘level’ ground Socketed/cast-in post Height to top Depth of socket Overall socket of post mm in ground mm length mm Length mm Item ref. 2120 2120 CM043B CM043B CM043B CM301D 2050 2120 CM301B CM301C CM011D 2100 1850 CM011C 1900 1650 CM011B CM011D 2100 1700 CM011B CM011C CM011D 2100 1900 CM011C 1900 1700 CM011B 1700 Driven post Length mm Item ref. CM049BC 975 CM049BC 975 CM049AC CM049BV CM049BC 1075 975 975 CM049AV CM049BV 975 1075 CM049AC 1075 CM049AV CM049BV 975 1075 CM049AC 1075 CM049AV CM302BC 635 1075 CM302BV CM302AC 635 735 CM302AV CM058BC 735 CM058BV 685 CM058AC 685 785 CM058AV CM058BC 685 785 CM058BV CM058AC 685 785 CM058AV CM058BC 785 CM058BV 685 CM058AC CM058AV 685 785 785 Surface mounted post Height mm Item ref. HSM001: Appendix (Issue A) PD-CEFB14 PD-CEFB13 PD-CEFB12 Drawing reference Appendix A: System component guide (continued) 6 Hill & Smith Ltd Flexbeam Installation Manual HSM001: Appendix (Issue A) Hill & Smith Ltd Flexbeam Installation Manual 7 Appendix B: Permissible system post positions (for post deviation rule please see product detail sheets (PD-CEFB….)) 4.0m Beam 4.0m Beam Post Crs systems (mm) N2 W1 S/S 1600 N2 W1 S/S 1200 N2 W2 S/S 2000 N2 W3 S/S 2800 N2 W4 S/S 4000 N2 W2 D/S 1600 N2 W3 D/S 4000 N2 W4 D/S 4800 H1 W4 S/S 2000 H2 W5 S/S 2000 1 2 3 4 5 6 7 8 9 10 1 8 4 4 4 8 8 8 8 4 4 4 4 8 4 8 4 8 4 8 8 8 4 8 4 8 8 8 8 8 8 4 4 8 4 8 4 8 4 8 8 8 4 8 4 8 8 8 8 8 8 4 4 4 4 4 4 4 4 4 4 8 4 8 4 8 8 8 8 8 8 4 4 8 4 8 4 8 4 8 8 8 4 8 4 8 8 8 8 8 8 4 4 8 4 8 4 8 4 8 8 8 4 4 4 8 8 8 8 4 4 3.2m Beam 3.2m Beam Post Crs systems (mm) H1 W3 S/S 1600 H2 W5 D/S 1600 1 2 3 4 5 6 7 8 1 4 4 8 8 8 8 8 8 4 4 8 8 8 8 8 8 4 4 5.0m Beam 5.0m Beam Post Crs systems (mm) 1 2 1 N2 W5 S/S 8 4 8 5000 For further information please visit the Hill & Smith Xtranet. An information portal designed for quick access to drawings & technical documents. 2,000 SS N2 W2 to N2 W1 (1.2m) 6 1,600 2,000 1,600 10 10 1,200 1 1,200 1,600 3 1,200 4 4 1,200 6 1,600 7 1,200 8 1,200 9 1,200 10 1,600 2 2 1,200 5 1,200 8 HSM001: Appendix (Issue A) 2,000 SS N2 W2 to N2 W1 (1.6m R) Holes counted in examples, from left to right. The following drawings show the various post positions allowed when progressing through the working in the Flexbeam system. IMPORTANT Appendix C 8 Hill & Smith Ltd Flexbeam Installation Manual 2 3 2,800 2,800 SS N2 W3 to N2 W2 8 9 10 2,800 2,800 2,800 5 6 7 2,400 2,000 2,800 2,000 4 2,800 1 For further information please visit the Hill & Smith Xtranet. An information portal designed for quick access to drawings & technical documents. 2,000 Hill & Smith Ltd Flexbeam Installation Manual HSM001: Appendix (Issue A) 9 SS N2 W4 to N2 W3 4,000 2,800 3,200 4,000 6 3,600 3 4 5 2,800 2,800 2,800 10 1 2 2,800 2,800 2,800 7 8 9 HSM001: Appendix (Issue A) 4,000 Holes counted in examples, from left to right. The following drawings show the various post positions allowed when progressing through the working in the Flexbeam system. IMPORTANT Appendix C (continued) 10 Hill & Smith Ltd Flexbeam Installation Manual 8 DS N2 W3 to N2 W2 DS N2 W3 to N2 W2 4,800 10 4,800 4,000 4,000 2 6 4,800 1,600 4 2,400 10 4,800 2 1,600 6 1,600 4,000 8 For further information please visit the Hill & Smith Xtranet. An information portal designed for quick access to drawings & technical documents. 1,600 4 Hill & Smith Ltd Flexbeam Installation Manual HSM001: Appendix (Issue A) 11 For further information on any of our products please call: +44 (0)1902 499400 Hill & Smith Limited Springvale Business & Industrial Park Bilston, West Midlands WV14 0QL Tel: +44 (0)1902 499400 Fax: +44 (0)1902 499419 Email: barrier@hill-smith.co.uk sales@hill-smith.co.uk www.hill-smith.co.uk HSD002 Hill & Smith Ltd Site Testing Requirements 2 HSD002 (Issue A) Hill & Smith Ltd Site Testing Requirements 1. General To enable our systems to perform as designed it is imperative that the post can yield. When using driven post start with the shortest working to the longest to determine the most suitable length. Concrete foundations can have two functions the first being ground strengthening (these foundations have an allowable amount of movement) and the second is to enable repair of the VRS without having to repair the ground when this is the case posts should be installed in sockets and the destructive test carried out to ensure the post yields before the foundation moves. When surface mounted posts are installed on a bridge deck or structure with known overturning capacitates only the anchorage test needs to be carried out and the push test need not be carried out, however in all other cases the anchorage and push test must be completed. 1.1 Push test The post must be vertical in both planes and installed to the specified installation height. Testing should be carried out at the location where the posts are to be installed, in the direction of anticipated deflection and at a time when the ground is likely to have least resistance. Where concrete foundations are to be used adequate time must be allowed for curing. A horizontal load is applied to the top of the post by means of a hydraulic ram with a calibrated load cell. The load is to be applied in the direction it would be loaded in service. The load is applied by pushing the post. the ram must be reacted against a rigid/non-moving part of the reaction vehicle, The correct cap should be chosen for the post being tested with the ram attached to this post cap. The dimension of the horizontal centre line of the ram above the ground is to be measured and recorded. A datum peg is to be driven into the ground in line with the post and the centre line of the ram with a height approximately equal to that of the test post. (A simple tripod can be constructed for this purpose). Datum peg/tripod must be placed independent of the foundation/surrounding soil to ensure datum is not subjected to any movement due to foundation movement/ground heave. The load is to be applied in increments of 1000N and the deflection of the post in reference to the datum peg is to be measured and recorded within ± 1mm. The applied bending moment is calculated by multiplying the load in Newton’s (N) and the load height (L) measured in (d) in meters. The ground/foundation is deemed satisfactory if the bending moment and post deflection criteria are not exceeded as detailed in Specific Hill & Smith Vehicle Restraint System installation manuals. 2. Loading Apply test load to the post in the direction in which it would be loaded in service or, in the case of double-sided safety fence, in the direction of weakest foundation. 3. Push mode 1 Place appropriate post cap onto the post. 2 Screw yoke (A) onto the cylinder (B). 3 Connect the hydraulic pipes to the cylinder (B) and pump (Q). 4 Attach yoke (A) to the post cap with screw pins (E1). 5 Screw the slip lock (F) to the cylinder (B). 6 Connect extension tube (H), extension rod (J), adaptors (K and L) and flat base (M) together and screw into the slip lock (F). Hill & Smith Ltd Site Testing Requirements HSD002 (Issue A) Figure 1 Push mode for steel posts 7 Fully retract the cylinder (B) with switch valve on the pump (Q) on “Pull” mode. Do not overload pull load indicator (S2) when retracting the cylinder. Position the switch valve to neutral position at end of this operation. (See figure 1) 13 Measure and mark the position on the post where deflection measurement is to be taken. 8 Locate the reaction vehicle in a suitable position ensuring the contact point formed between the flat base (M) and the vehicle (via adjusting extension tube (H), extension rod (J) and slip lock (F)) is perpendicular to the load direction. Note: It is possible to push against the rear wheels with timber baulk between the wheel and flat base (M). 15 Apply incremental load (in steps of 1,000N approximately). Record the load and the deflection of the post within ± 1 mm at each increment until one of the conditions below is reached: 9 Ensure that the load is applied perpendicular and central to axis of post. 10 Switch the valve on the pump (Q) to “Push” mode. (See figure 1) 11 Place the datum tripod (T) in line with the direction of loading, ensuring it is isolated from foundation movement. 12 Measure the height of loading (L) 14 Record the distance between the post and the datum tripod (T). 16 The required bending moment for the specific Hill and Smith VRS is achieved; the post deflects to the required limit at measuring position (see specific VRS Manual). Note: The pump (Q) should be operated with a smooth and continuous action and readings taken immediately the increment value is reached. When all results are completed, operate the pump (Q) in the pull mode to retract the cylinder. 3 4 HSD002 (Issue A) Hill & Smith Ltd Site Testing Requirements Figure 2 Calculation for the traffic face of the fence within and over 1.5 m of the edge 4. Calculations 5. Destructive Post Testing Results should be recorded on form ‘VRS Standard Post Foundation Test Results’ on page 6 of this document Used to determine special ‘non-moveable’ concrete foundations, if required by overseeing Engineer, e.g. adjacent to cable ducts where foundation movement may not be permitted. The deflection of the post should be measured 600 mm above either: (See figure 2) a)the edge of the paved surface*, if the traffic face of the fence is within 1.5 m of the edge; or b)the finished ground level at the base of the post or top of the concrete footing, whichever is higher, when the traffic face of the fence is more than 1.5 m from the edge of the paved surface*. Bending moment, BM, on the post/foundation is calculated from the following equation. BM = W × L where: W is load in Newtons indicated on the load indicator; L is the height in meters between the point of loading at either a)the edge of the paved surface, if the traffic face of the fence is within 1.5 m of the edge; or b)the finished ground level or top of the concrete footing, whichever is smaller, when the traffic face of the fence is more than 1.5 m from the edge of the paved surface*. The post foundation is acceptable if the bending moment and deflection criteria for system are achieved (see relevant installation manual) * Paved surface is defined as that which comprises carriageway and hardshoulder/hardstrip. Testing procedure follows the basic post foundation and soils testing details as clauses 1, 2, 4 & 5 of this document, except that the post is tested to failure. Due to the higher loads that need to be applied to fail the post, a higher load capacity calibrated gauge will be required. A 55kN gauge to suit the standard post testing cylinder will be needed. (It is critical that the gauge area matches the pump area). In addition, the reaction vehicle will need to be larger to resist the increase in the test loads applied to the post. The applied loading is likely to be twice the load requirement as for the Standard Post Foundation & Soil Test for the relevant given post type. Apply incremental load (in steps of 1,000N approximately). Record the load at each increment until no more load can be taken by the post. Results should be recorded on form ‘VRS Destructive Post Test Results’ on page 7 of this document. The post foundation is acceptable if there is no apparent movement of the concrete foundation. For further information please visit the Hill & Smith Xtranet. An information portal designed for quick access to drawings & technical documents. Hill & Smith Ltd Site Testing Requirements HSD002 (Issue A) Notes: 6. Surface-mounted posts Surface Mounted Posts using Anchorages and Attachment Systems Anchorages for securing surface mounted posts which utilise drilled holes have been known to fail due to either the lack of cleanliness of the hole or the excessive tolerance in the size of the hole. The manufacturer of the anchorages should provide details of the maximum tolerances permitted. Where anchorages and attachment systems are used, the bolts or nuts should be tightened adequately, in accordance with the manufacturer’s instructions, to ensure that effective shear transfer will occur between the post base plate and the base. In addition, it is important to ensure an adequate length of thread engagement. The surrounding concrete should be appropriately reinforced to prevent shear cone failure, particularly where an anchorage is close to the edge of the concrete. Where safety barriers, terminals and transition posts are to be installed on bridge decks an anchorage and attachment system should be used. Care should be taken to avoid damaging bridge deck waterproofing systems when installing anchorages in drilled holes. Normally, an anchorage and attachment system, which avoids this problem, should be used. In exceptional circumstances, where damage to the waterproofing is unavoidable a compatible sealing system agreed with the Overseeing organisation to prevent ingress of water and avoid corrosion should be provided. Note: Surface mounted posts not mounted on bridge deck structures must also be subjected to a post push test. Loads for individual anchorages in drilled holes for use with Hill and Smith Ltd Surface Mounted Posts, attachment fixings to be M20. anchorage type, fixing torque settings, threads engagement, length of anchorage and thickness of bedding mortar to be as specified by the anchorage designer. The Contractor shall carry out on-site tensile load tests on anchorages in drilled holes. Where anchorages are tested they shall be loaded incrementally in tension to ensure that they shall be capable of resisting a test load equal to 10 per cent above the nominal tensile load at post failure. The nominal tensile load is shown on the product detail drawing. The total movement of the anchorage shall not exceed 1.0 mm during the test. Any evidence of slip during loading as demonstrated by a significant change in the slope of the load/extension curve, shall constitute failure. The testing frequency must be agreed with the designer / contractor. Note: 5 HSD002: Appendix (Issue A) 6 Hill & Smith Ltd Site Testing Requirements VRS Standard Post Foundation Test Results Date Order number Job number Site Test number Push / Pull* Details of post Load (N) Post type: 0 Post size: 1000 Set back: 2000 Max BM – 6000/9000Nm* 3000 Ht to load point (L): Max load required (BM-/L): metres 4000 N 5000 Location Offset Remarks (mm) 6000 7000 8000 Max Deflection: 9000 10000 11000 12000 13000 14000 15000 16000 *Delete as appropriate Test undertaken by Print name Date Hill & Smith Ltd Site Testing Requirements HSD002: Appendix (Issue A) VRS Destructive Post Test Results Date Order number Job number Site Test number Push Details of post Load (N) Post type: 0 Post size: 1000 Set back: 2000 Ht to load point (L): Max Load achieved (M Load): Max BM achieved (M Load x L): Location metres 3000 N 4000 Nm 5000 Movement of foundation Remarks 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000 25000 Test undertaken by Print name Date 7 For further information on any of our products please call: +44 (0)1902 499400 Hill & Smith Limited Springvale Business & Industrial Park Bilston, West Midlands WV14 0QL Tel: +44 (0)1902 499400 Fax: +44 (0)1902 499419 Email: barrier@hill-smith.co.uk sales@hill-smith.co.uk www.hill-smith.co.uk