1200 New Jersey Ave., SE Washington, D.C. 20590

August 18, 2011

In Reply Refer To: HSST/ CC-75D Mr. Gerrit A. Dyke, P.E. Vice President of Engineering and R & D Barrier Systems, Inc. 3333 Vaca Valley Parkway, Suite 800 Vacaville, CA 95688 Dear Mr. Dyke: This letter is in response to your request for the Federal Highway Administration (FHWA) acceptance of a roadside safety system for use on the National Highway System (NHS).

Name of system: Universal TAU-IIR Crash Cushion Systems Type of system: Redirecting Crash Cushion/Impact Attenuator Test Level: NCHRP Report 350 Test Levels 2 and 3 (TL-2 and TL-3) Testing conducted by: Safe Technologies, Inc. Date of request: December 30, 2010 Date initially acknowledged: January 4, 2011 Task Force 13 designator: SCT 01c

You requested that we find this system, in its various configurations, acceptable for use on the NHS under the provisions of the National Cooperative Highway Research Program (NCHRP) Report 350. Requirements Roadside safety devices should meet the guidelines contained in NCHRP Report 350 if tested prior to December 31, 2010. Devices tested after that date must follow the guidelines contained in the American Association of State Highway and Transportation Official’s (AASHTO) Manual for Assessing Safety Hardware (MASH). The FHWA memorandum “ACTION: Identifying Acceptable Highway Safety Features” of July 24, 1997, provides further guidance on crash testing requirements of roadside features, including crash cushions. Decision The various configurations of the TAU-IIR crash cushion shown in Enclosure 1 are acceptable for use on the NHS at the impact speeds listed.

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Description The TAU-IIR crash cushion uses the same framework as that used in the TAU-II crash cushion configurations that were accepted by the FHWA in letters CC-75 through CC-75C. Specifically, the structural diaphragms, Thrie-beam side panels, slider bolts, backstop assemblies, cables, and anchoring systems are the same as those originally accepted for use on the NHS. The TAU-IIR design uses different energy absorbing cartridges that can be partially self-restoring after some impacts, thereby reducing the need for immediate repairs. These cartridges are made from proprietary hyperelastic (HE) polyurethane and are identified as Type1, 2, or 3 depending on the wall thickness of the cylindrical elements. Dimensions for each type are shown in Enclosure 2. A typical TL-3 installation is shown in Enclosure 3. Crash Testing Since only the energy-absorbing elements were changed from the TAU-II design, it was mutually agreed that only the end-on tests were needed to verify acceptable crash performance. Tests were conducted on specific configurations to determine the occupant risk factors for narrow parallel designs, moderately flared designs and wide designs for TL-2 and TL-3 impact speeds. One test was run with an impact speed of 110 km/h (70 mph). Using finite element analysis (FEA) and the results of the full-scale tests that were run, a report prepared by Roadsafe LLC for Barrier Systems, Inc. concluded that the various configurations shown in Enclosure 1were likely to produce acceptable compliance with Report 350 evaluation criteria for end-on impacts. The following summaries describe the tests that were conducted by Safe Technologies, Inc. on specific configurations of the TAU-IIR: Narrow (parallel) at TL-2 NCHRP Report 350 tests 2-30 and 2-31 were conducted on a narrow unit at 70 km/h (42 mph) to assess the capacity and occupant risk factors associated with a lower speed impact by both test vehicles. For test 2-30, the unit was anchored to an AC base; in test 3-31, a concrete base was used. The TAU-IIR design for both tests consisted of a 4-bay unit with one Type 3 element nose piece, two Type 1 elements in bay 1, and two Type 2 elements in both bays 3 and 4. Enclosures 3 and 4 show the crash cushion design and the test summaries for the small car and the pickup truck, respectively. Narrow (parallel) at TL-3 Tests 3-31 and 3-32 were conducted on a narrow, parallel-sided 8-bay design. The tested configuration consisted of a Type 3 element nose piece, three bays containing two Type 1 elements per bay, and five bays containing two Type 2 elements per bay. Enclosure 5 shows the tested crash cushion design and the summary sheets for both tests. This tested TL-3 configuration does not use any Type 3 elements in its interior bays. Narrow (parallel) at TL-3 Test 3-30 was conducted on a narrow, parallel-sided crash cushion to determine its crashworthiness at an impact speed of 110 km/h (70 mph). The tested configuration was a 10-bay unit, consisting of a Type 3 nose piece, three bays containing two Type 1 elements per bay, four bays containing two Type 3 elements per bay, and three bays containing two Type 2 elements per bay. Enclosure 6 shows the tested design and the crash test summary sheet.

3

Flared at TL-3 Test 3-31 was conducted to verify the crashworthiness of a flared side-panel layout. The TAU-IIR configuration tested was a seven bay design consisting of a Type 3 nose piece, three bays containing two Type 1 elements per bay, one bay containing two Type 2 elements, and three bays containing four Type 2 elements per bay. Enclosure 7 shows the tested design and the crash test summary sheet. Wide (flared) at TL-3 Tests 3-30 and 3-31 were conducted on a wide-flared unit. The tested design was a 7-bay unit with a Type 3 nose piece, three bays containing two Type 1 elements per bay and four bays containing four tyle2 elements per bay. Enclosure 8 shows the tested design and the crash test summary sheet. Findings Based on our review of the information you submitted, the TAU-IIR designs described above and detailed in the enclosed drawings are acceptable for use on the NHS under the range of conditions tested, when such use is acceptable to a highway agency. In addition, any of the configurations depicted in Enclosure 1 are also acceptable for use on the NHS. The five TAU-IIR configurations that were crash-tested were used to validate the FEA model from which the “family” of designs was created. In comparing the model results to the full-scale crash tests, it was seen that the model predictions were almost always conservative (i.e., they over-predicted the occupant risk factors). Consequently, the non-tested TAU-IIR configurations may be used with confidence that they will perform acceptably under the impact speeds listed. Transportation agencies specifying the 10-bay 110 km/h (70 mph) design should be advised that this unit met all NCHRP Report 350 evaluation criteria only for a head-on impact with the 2000P pickup truck at that speed. The remaining high-speed configurations were developed through analysis and should be equally acceptable for the head-on crash with the pickup truck. However, no assumption should be made that the remaining Report 350 tests for a crash cushion would meet all appropriate evaluation criteria at a 110 km/h (70 mph) impact speed. There is no federal requirement to specify crash cushions that exceed TL-3 capacity. Please note the following standard provisions that apply to FHWA letters of acceptance:

• This letter includes an AASHTO/ARTBA/AGC Task Force 13 designation that should be used when drafting new or revised Task Force 13 drawings.

• This acceptance is limited to the crashworthiness characteristics of the systems and does not cover their structural features, or conformity with the Manual on Uniform Traffic Control Devices.

• Any changes that may adversely influence the crashworthiness of the system will require a new acceptance letter.

• Should the FHWA discover that the qualification testing was flawed, that in-service performance reveals unacceptable safety problems, or that the system being marketed is significantly different from the version that was crash tested, we reserve the right to modify or revoke our acceptance.

• You will be expected to supply potential users with sufficient information on design and installation requirements to ensure proper performance.

4

• You will be expected to certify to potential users that the hardware furnished has essentially the same chemistry, mechanical properties, and geometry as that submitted for acceptance, and that it will meet the crashworthiness requirements of the FHWA and NCHRP Report 350.

• To prevent misunderstanding by others, this letter of acceptance is designated as number CC-75D and shall not be reproduced except in full. This letter and the test documentation upon which it is based are public information. All such letters and documentation may be reviewed at our office upon request.

• The Universal TAU-IIR family of crash cushions are patented products and considered proprietary. If proprietary devices are specified by a highway agency for use on Federal-aid projects, except exempt, non-NHS projects, (a) they must be supplied through competitive bidding with equally suitable unpatented items; (b) the highway agency must certify that they are essential for synchronization with the existing highway facilities or that no equally suitable alternative exists; or (c) they must be used for research or for a distinctive type of construction on relatively short sections of road for experimental purposes. Our regulations concerning proprietary products are contained in Title 23, Code of Federal Regulations, Section 635.411.

• This acceptance letter shall not be construed as authorization or consent by the FHWA to use, manufacture, or sell any patented system for which the applicant is not the patent holder. The acceptance letter is limited to the crashworthiness characteristics of the candidate system, and the FHWA is neither prepared nor required to become involved in issues concerning patent law. Patent issues, if any, are to be resolved by the applicant.

Sincerely yours, Michael S. Griffith

Director, Office of Safety Technologies Office of Safety

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Test IJeaignallon ............................................ NCHRP Rcpor1 ~ H1 Te:stNo ........................................................ $1'1 T.stOTAMS

Date ............................................................ 11/Sl2010

Tat Altic:"' Type ................................................................. Ctash ~ Nllll'llt ............................................................... TAU.UR O~ons ........................................................ Length: 8.9 m (29.1 ft)

Si2e M'tJ/tlt dimension and matarlal ................. Height: 829 mm (32.6') cf key elements ........................................... Wdth: 877 mm (34S)

TGStVtllide Type ......................................................... ~Mociel Designa1lon ............................................... 2000!' Model ....................................................... 2004 Cblnlralet 3'4 Ton Picltup Masa(kg)

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Gtos:t Stalie .......................................... 2020

Impact Cond"ltiom

Speed(kpll) ·-···· ...................................... 1110 Angle (Cfet) ............................................... 0 lmPaC1 SevctUr (II.I) ..................... - ............. 776.0

Exit Conditions

Speecl (kph) ................................................ NIA Anglo(dcg} HaU•HIOU•U•t•H•••tA••H•H••••••tHtlUH 'WA

Occu.-it Risk Valuos 1""8Cl Velcdty {mfs)

le-direction ... -· ................................ 9 y.direetion ...................................... 0

RidedoVm Acceleration (g's)

lC-ditedicn ................................. _ ... 19 Y'(l1rection ...................................... 3

Test Article Oe&ctlon (111111)

Dynamic ..................................................... NIA Pemlll1eflt ................................................. NIA

Vehlcle Damago

Exteficr VOS .................................................... 12-Fc-2

CDC ................................................... 12FDEW1 Interior

OCOI ................................................... FSllOOQQOO Post-hllpictVoblculllr Boh:avior(doa ·GYl'O @e.111

Maximum Roa Angle ..................................... 4 Maximum Pitch Angle ... ... • .. ... ............ ....... ••• 14 MaximumYawAngle ................................... 2

L: ~· :I II l]Ill ffil JI I] I lll]Ill l!I II Otrn m llIHill DUii rnJ r r- 379 I t__ __ [96:-1 )

2S [705]

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r• ., ........... "'u.>o11• 11. .. ,~·1 .. ~"'" I XJJ°'-m I ' " """ll~U~M'~l.l~'\Cf..._.._, .M:!_

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Ut.llVERSAl TAU.UR l IOkph SYSTEM COMPACT BACKSTOP. CONCRETE ANCHORING

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l Typical 30" 11G kpll CcmcMD Anchoring TAU-'IR,. CC

- 34.5 :,. ran ,.,, .... J

; I ~ f :t~i! §1:1 lijlmj:1;1.tni1;i! .-- lflllm u 11!Pllu18l1mtl!Ul11[lllm IBID I I ID J_

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~d i i k Q i ~ i ~ I ~ t ~ I I 4C~.2 ;,, [102!n -nmJ

Test Agenr;r" ........ •••••••••••••-••• ......................... SAiFE 1'ECHN(>l..Oc;IES, INC. Test Designation .......................................... - NCHIU" Repoit 350 ~1 (MGdlfiedtl 10 kpb)

Test No ...... - ................................................ sn Tl!lt•TAR12 Date ............................................................ 1ZJ&'2010

TestAltlde Type ................................................. _ .............. Crash Cushlen

Name ................................................... _ ... , ...... TAU·llR

Clmetllllats .................. _ ................................... Ll!ng1h: 1G.3 m (33.811)

Size ancl'or dimmllon and matedal ..... rn ......... Heigtit: 829 mn ~8 in) of laey elemerds ........................................... VVldlh: ffr7 mm (34.5 in)

Test Vettlc:le TyPe .•..•.•.•.•...•.•••••••.•. ; ............................. Produdion MOdel ~Cll1 ............................................... 2000P

MOdel ............... -············· ......................... 2000 Ctlewclet 314 Ten Plckllp Mua(leg)

C&l:lb ............................................ , •••••••• 2t7'7 Test lnertisl .................................... --.... 2013 Dummy(&) ............................................. NIA

Gloss Stetio ............... ,_ ........................ 201 & Imp.Kt Ccndl1ielm

Spe.d ~) ............................................. 10G

Ang1e (deg) •••.•...•••.•...•...••........ •··••• ........... 0 ~ Sevoetlty (le.I) .................................... 91•.3

l!)dt Condiliomi

Speed (lcph) ............................................... NJA

Angfe (cleg) ·······-···-························· ••.•.••.• NJA Occupant Risk 'Values

lmpact\lelodty (mis)

>Clln!CUOn ·········-····· .. •••••••• .. -·-· .. •• 10 y.cltrec:don ..................... - ............. -0

Rldedovm Ac:cotetatlon (g's)

x-dh!ctlon •••.• - .......................... --·· 17

y-diec:tion ···-······ ......................... 2

Test ArtJcl9 Daftac1lon (mm)

Oyne.iril; ..................................................... NJA

Permanent ............................ -·· ................. NIA VollicJo Damago

Exterior VOS ................. - ................................. 12.fC.2 CDC ................................................... 1~CEW1

Interior OCOI ................................................... FSOOOOOOO

PDGOl'lpKlV.tllc:utar Boflnior (deg• S»'rD @c:..g)

MaximumRc!llAngla ..................................... 11 Mmdlnum Pl!d\ Angle ............ ...... .•. •.•••.• .•. ••• 3

Maximum Yflrt Angle .................................... 12

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APPROVALS to"IJJt t•L"9-0f~,1J..t. t(JUJ':""'"l'irTW~

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UNIVERSAL TAU-llR 66in n .3 SYSTEM WIDE FLANGE BACKSTOP. CONCRffi ANCHORING

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Tat~ .. ··••••••••••••••••• ............................. -SAF'E'1ECHNOLOGIES, INC.. Test DaJsnatkm. ........................................... NCH RP Roport 350 wt TestNo ........................................................ STITest•TAR13

Dato_. .......... "''' ........................................... 1219/2010 TostAniclo ~ ................................................................. Cr.1st! Cusnlcn

Name ....................................... - ...................... TALHIR Clmensians ... ._ ................................. _ ............... l...eaglh:7.7rn(25.2ft)

SiZe "IWJI« dimension elld matefiGI ......... -······ Hei§llt 844 mm (33.2 in) ar ICiiy elements ......... ·-............................... \Mdlh: 2049 nm (80.7 In)

Test Vehicle Type -· ..................................................... Production Maciel Desigr"llil'lton ............................ _ ...... - ........ 20ClOJ'

McdGI -····················-···-·-·--· ................. 200-t Chllvrolat 314 Ton Pic:lcup M8Sfl (leg)

Cun> .................................................... ~1 Test rnertW ........................................... 2009 DunTny(a) .......................................... -.NIA GIOSS Sla1lc: ................................. -· ...... 2009

Impact Conc8tlms Speed (kph) •.• ••• •.• ••• ..• ..• .. . ... .••• ... ..... ... ... ••• 102

A"9le (deg) ............................... .-............. 0 '""DCtSewetlty (lW) .................................... 806.2

~ ; II 111 s1u:r1J:11m11111:

Typlelt 66"" TI.-3 TAIMll\"' CC

i S0.7 In [2C"9 r.1m} )1$11111:1nilm11ttttmro l

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N -Exit Conditions

Sp«!ed (kflll} •••.•••....•.••••..•••.••.•..•••••••.••.••.•.... NIA

Aslf/te (deg} ••••.•.•..•..••.......•..•.......•.. ·- .•..••••• NIA Occupant RJslc vatues I~ Vctoeity (m's)

x-diredion ............................ -··· .•••. D ~ ...................................... o

Rldeclo\wl Accclera&in (g'a)

x-clitediotl ••• _ ...... - ......... rn.·•····-···20 y.diteelioft ... _ ......... ·····················- 3

Test Artlcle Dellectlon (mm)

Dynamic .................................................... NJA Pecn'Wlnent ....................................... ~ ... -···· NIA

Vohiclo i>MASO' ect.ior

VOS .................................................... 12-FC-Z CDC .................................. , .................. 12fCEW1·

llltericr OCDI ................................................. FSOOOOOOO

Poltolmpact Vehicular Beflavlor(dlg •BJ10@c:.g}

Maximum Roi Angle ........................... " ........ 2 Maximum P'rtl:h AJ9e ......... ... ........ ........... ... 7 MaxlmumYawAngle .................................... 5

27& 1/~ t--~~~~~~~- (7~CJ ~~~~~~~~~

( y,:~~)") - ----- - --

t ;}2 ~ t ~ ~ ; § __ [ I j 341 / 7 l :l!

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:!.:~·~~· :-::~;~, .. 1-:.i:ir):v'~.~M~t~ !;;li,. ~ I, .... •t • ~-- - ,~-~ 0 .... , ..

APPROVALS ~., .. ...

"El"' -:-.-..,,,,. :¥11 12,117/10 ~, .. G"D ........ ,, .. .., 12117/10

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UNIVfRSAl TAU·lllt 7'in fi·!I SYSTEM WIDE fl.ANGE &ACKSTO~. CONCIE!f ANCHORING

... 1 <t0 t.\1Jt' l.Mlt l) , ,10111 1 ·t: ( "l'l '\'.'. t.;.

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Tesl .Agency ................................................ _ SAP£ TECHNOLOGIES, INC.

Test Deslgnalion. ........................................... NCHRP Report 35D W1

Test No. ....................................................... S11 Test'# TAR07 Date ............................................................ 1111912011>

Test Ankle Type ................................................................. Crash Cushicn Nan .................................... ~ ........... - ............ TAU-llR Dimensions ........................................

Size and/a' dimension and material _ ............. Lengln: 7.4 m CZ.S.-'tl) ................. Hefght 844 mm (33.2 in)

of Icily elements ........................................... Wdlh: 2808 mm (110.6 In)

TestVehldo

~ t•ttttfftt .. tt•••t•••MtoH .. eHt .. ttttltHOtttttfotl ... tf ~Qlf\MocJel DlslgM'tlOr\ ............................................... 200QP

MOdet ....................................................... 2C04 Cl'lewalet 314 Ton PidnJp Mass (Ilg)

cum .................................................... 2213 Test lneltial ........................................... 2004 Dummy(o} ............................................. NIA

GfOSS~ .......................................... 2004

Impact CGndlllOns Speeo (lq)h) ............................................. 99

Allg!e(dl!G> -··-············-·-···-· .. ··--····-·-0 ~Scwwfly(lr.I) ············-······-······ .. ••· .. 751.7

ElOt Conclldon$

Speed (lqlh) ................................................ NfA

Angle: (deg) ................................................ N.'A. Occupant Rick Valulll!:

Impact Veloeity (nv11) Xo(lil'ection ...................................... 10

~irection •.. - ......................... -· ... - 1

Ridedown Acceleratlcn (g's)

X<lireecion ....................................... 17 y<linlcticn ...................................... 3

TestAnlde Deflection (aun) Dynallic ..................................................... NIA

Petm8l"el'lt ·············"·•········••••·• .. •••··-"''''"'"DUA Volllclo cam.get

edetlor

VOS .................................................... 12~ CCC ................................................... 12FCBN't

lntettcr OCCI ·- ................................................ FSOOOOOOO

~mpact\rctltlc:ulaf Behr.llor(dof-81"> 8 ~ Nadrn&lrn Roi N1gle ............ ••••H .,. ................. ~ N<Ddmum Pitch Angle ............................. _... 22

MCDdmum Yaw.Angle ............. ·-··········--·· .. 2

t=a..ooo sec t:sAOOsec 1=.700 rec t=1.ooo sec i=1.300sec

§I I:!

~lc:aJ 9S"Tt.4 TAIJ.llR"" CC

' : •o.6 "" c:za:a ....... 1 ~:::1:::t::1 m

:di b i-l' I I i 'tf -213 . .S :.. (7UG """'~--

Genonl frrfor!TdoA

TestA;eney .................................................. SAFET&CHNOLOGl&S, IMC. Tell Designallon ............................................ NCHRP Ropon 350 3-311

TestNo ........................................................ snTm#TAR06 Dste ............................................................ 11/1Tl2010

Type ................... " .... " ...................................... CJa:Sl'i C\mt\IC11 Name ....................... •••••.•.•• ............... ............... TAIJ.llR

Dfmenslons ................... - .................................. l.engd'I: 7.4 m (24.41!)

Sim andlcir dimension and material ................. Height~ mm t33,2 ln)

cflleyelemenll ........................................... ~2808 mm (110.6 in)

TestVehldo ~ ........................................................ Producllon Model

DesionatiCn ............................................... 820C M-odd ....................................... ,. .............. 1988 Hondo~ Mas(lcg)

evm .................................................... 768 Testlnerdal ........................................... 817

Dunniy(s) ............................................. 75 Gftlls 5'lltic ...... - .................................. 892

lftlpxt Condldllns Speecl (lcpll) ............................................. 1 DO

Alltl4 (ChQ) ............................................... 0 lrf1;>act ~ "'-'> .................................... 315.0

m ~ n 0 &n c m 00 -N

a w -

Ell!t Coftdltioas

Speed (kph} ................................................ NIA Angle (Cleg} ................................................ l\S/A

Oc:cupnit Risk Values

lll'fllld Vdocity (mts)

»direction ...................................... 12 y.cfir8ction ....................................... 1

Rldedav.n Acceleradon (g's) x-diedlc!n ....................................... 17

~-··-····--···· .................... '/

Tast Alticlct Doftoc:tion (mm)

Dynamic .................................................... NIA Pennanent ................................................. NIA

Vohldo Damage ~

VOS .................................................... 12-Fl.-6 CDC ... .. .... ... ... ... ..................... ••• ...... ... 12FYE'Jl.l3

lnlerlicr OCOI ................................................... LfOOOQQOO

Pcm-hnp;act Vehlc:ular Behavior (cleg • 9'f0 8 c.g)

Maximum RGI Angla ..................................... 14 Max!ml.:m P1tdl Anste ....... ..... ••• .... ••• ......... .•. 17

MllOdrnum YawAltgle ............................ _ ••••• 162