Universal Armorwire Terminal End

Product Manual

BJM(v2) 070909

ANOTHER ARMORFLEX DEVELOPMENT

Universal Armorwire Terminal End

Anchoring for 3 & 4 Cable Barriers

Proudly distributed by

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Table of Contents ____________________________

Introduction……………………………………….. . 3

System Overview…………………………………. 3

Before Installation………………………………… 3

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

Safety Statements………………………………… 4

Design Considerations…………………………… 5

Parts Identification……………………………….. 8

Installation Preparation...………………………… 9

Bill of Materials……………………………………. 10

Installation Instructions ………………………….. 11 Installation Examples…………………………….. 16

Installation Checklist……………………………… 17

Frequently Asked Questions…………………….. 18

Crash Test Results Summary…………………… 20

APPENDIX – Technical Drawings

____________________________ Universal A.T.E (4 Cable Barrier)….................... 21

Universal A.T.E (3 Cable Barrier)….................... 22

Universal A.T.E Overlap…………………………. 23

3 & 4 Cable Line Post Set Up...…….. ………….. 23

Universal A.T.E ‘Default’ Pile Option…………… 24

Universal A.T.E ‘Shallow’ Pile Option………….. 24

Universal A.T.E (4 Cable Barrier) Isometric…… 25

Universal A.T.E (3 Cable Barrier) Isometric…… 26

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Universal A.T.E Introduction Introduction The Universal Armorwire Terminal End (Universal A.T.E) is used to anchor a high tensioned 3 or 4 Cable Barrier to the ground. The Universal A.T.E has been designed and tested to meet the evaluation criteria of NCHRP 350. The Universal A.T.E has been tested to the guidelines in NCHRP 350 for a gating, re-directive cable barrier terminal end. When correctly installed, the Universal A.T.E allows a vehicle to over ride or gate through the high tensioned anchor area of the terminal end. The unique Universal A.T.E technology is based on a series of cables, special washers and a ‘Trigger’ Post. This setup offers exceptional vehicle control when the cables are impacted as they disconnect from the top of the Trigger Post and the cable barrier is de-tensioned immediately, thus eliminating any potential of the errant vehicle to vault, roll or snag.

System Overview The Universal A.T.E is designed and constructed to provide acceptable structural adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 for cable barrier terminal ends. When impacted head on with an 820 – 2000kg vehicle at speeds of up to 100kph, the impacting vehicle pushes the Anchor Cables down out of the Trigger Post. Very little energy is dissipated and due to the quick release of the cable tension, the errant vehicle remains on its wheels at all times without vaulting or rolling, which is common when the cables remain tensioned. During a re-directive or reverse angle impact the cables disconnect from the top of the Trigger Post due to its unique design. This also de-tensions the cable barrier from the anchor and allows the vehicle to continue in a safe and controlled manner. The Length of Need (LoN) of the Universal A.T.E is 8m downstream from the Trigger Post. The first 4 line posts downstream from the Trigger Post are always at 2m spacing.

Before Installation Design, selection and placement of the Universal A.T.E shall be in accordance with the local road authority guidelines and the details shown in the construction drawings. Installation shall be in accordance with the installation instructions supplied for this product. Depending on the application and circumstances at the site, installation and assembly of the system should take one person crew less than 15mins once the concrete foundation piles are poured and set. The Universal A.T.E is a highly engineered safety device made up of a relatively small number of parts. Before starting installation ensure that one is familiar with the make up of the terminal end.

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Universal A.T.E Introduction (continued)

Limitations and Warnings The Universal A.T.E has been rigorously tested and evaluated per the evaluation criteria in the NCHRP 350 guidelines for gating, re-directive cable barrier terminal end. The impact conditions recommended in NCHRP 350 are intended to address typical in-service collisions. When properly installed and maintained, the Universal A.T.E allows an impacting vehicle to remain on its wheels in a safe and predictable manner under the NCHRP 350 impact conditions. Vehicle impacts that vary from the NCHRP 350 impact conditions described for cable barrier terminal ends 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 (weight, speed and angle) may result in system performance that may not meet the NCHRP 350 evaluation criteria.

Safety Statements General Safety All required traffic safety precautions should be complied with. All workers should wear required safety clothing (high visibility vests, steel capped footwear, gloves, hard hats, safety glasses etc.). Only authorized trained personnel should operate any machinery. Where overhead machinery is used, care must be taken to avoid any overhead hazards. Before auguring, always have the area checked for underground services by the appropriate service providers. Gloves should be worn at all times. Universal A.T.E Safety Statements All installers must be well clear of machinery while the holes are augured. The components are not heavy enough to require specialized lifting equipment, but due to the dimensions and bulky nature, care should be taken when lifting the larger components into position. A maximum weight of 38kg will be encountered when installing the Ground Strut and rebar cage assembly, 2 installers should do this. Avoid placing hands or fingers in and around moving parts when components are being lifted and manoeuvred into place.

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Design Considerations

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 cable heights in relation to the ground. The ground strut is required to lay flush with the foundation piles and must not protrude more than 100mm from ground level, when measured with a straight line over a 1500mm cord.

Foundation Piles Two foundation options are available; the soil conditions that exist on site will determine which option to use. NOTE: IF THE SOIL CONDITIONS ARE UNKNOWN THE ‘DEFAULT’ OPTION MUST BE USED AT ALL TIMES. Default Option: The ground strut and rebar cage assembly must be cast into piles with the following dimensions. The augured holes for this option are 450mm diameter by 2500mm deep and required to be filled with 25mpa concrete. (shown in Figure A below)

Figure A.

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Design Considerations (continued)

Shallow Option: ONLY if the soil has been verified as a particular soil using a DCP (Dynamic Cone Penetrometer) or SV (Shear Vane) with results that match or exceed the parameters in Table 1 below can the ‘Shallow’ Pile Option be used. The dimensions of these holes are 450mm diameter by 1000mm deep and required to be filled with 25mpa concrete. (shown in Figure B below)

Figure B.

Cohesive Soils Soil Type Description Su (kpa) Foundation Pile Depth

Stiff 51 - 100 450mm ø x 1000mm

Very Stiff 101 - 125 450mm ø x 1000mm

Cohenionless Soils Soil Type Description Phi (0) Foundation Pile Depth

Very Dense > 41 450mm ø x 1000mm

Table 1.

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Design Considerations (continued)

Flared The preference is to not flare the system. If this is unavoidable then the maximum flare rate should be 30:1 over the entire length of the terminal end. Kerbs As with all road side safety hardware, the Universal A.T.E 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 kerbs or channels are not installed in front of the terminal end as they will result in altering the height of the vehicle at impact. If there is no option but to install a kerb or if it is already present, local authority guidelines re kerb height and design and barrier offset distance from it should be followed. Length of Need The Length of Need (LoN), determined from NCHRP crash tests on the Universal A.T.E, is at post #5 where post #1 is the Trigger Post. Posts #2 - #5 are always at 2m spacing, (as shown below) therefore the LoN is 8m downstream of the Trigger Post. As per the LoN design section of the local road authority guidelines, care must be taken when calculating the actual length of the barrier required versus the theoretical length of the LoN. The physical placement of the Universal A.T.E must be with post #5 positioned at or upstream from the LoN.

Line Posts The 4 line posts (posts #2 - #5 where post #1 is the Trigger Post) that make up the remainder of the Universal A.T.E terminal end are to be installed as per manufacturers’ instructions. The spacing of these posts must ALWAYS be at 2m spacing. Tension The Universal A.T.E has been designed as a terminal end to anchor 3 and 4 high tensioned Cable Barriers. The tension on the cables required will be dependant on which system is being used. Please refer to the relevant literature for the tension required for that Cable Barrier and note that tension is dependant on temperature when installing. NOTE: It is recommended that the Cable Barrier is not tensioned for at least 7 days after the Foundation Piles have been cast.

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Universal A.T.E - Parts Identification

Ground Strut Rebar Cage (1 required) (3 required plus 12x M24 (1”) nuts)

Anchor Cables Washers & Nuts (2 required) (Full set shown)

Trigger Post 3 Wire Cable Barrier 4 Wire Cable Barrier (1 required) (Fittings may vary; the 3mm (⅛”) thick polyethylene washers & 6mm

(¼”) thick, 50mm (2”) ø galvanized steel washers are always required)

All steel components used in the Universal A.T.E are hot dipped galvanized, except the Rebar Ring which are cast into the concrete piles.

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Universal A.T.E - Installation Preparation

Getting Started The Universal A.T.E is a tangential cable barrier terminal end designed to anchor either 3 or 4 Cable Barriers. For all installations start downstream from the terminal end at the last post of the Cable Barrier. The line posts between the end of the Cable Barrier and the Universal A.T.E trigger post must always be at 2m spacing.

Preparation Before installing a Universal A.T.E, ensure that all components required for the system are on site and have been identified. The Universal A.T.E is a highly engineered safety device made up of relatively small number of parts. Before starting installation ensure that one is familiar with the make up of the system. Refer to the ‘Bill of Materials’ and ‘Parts Identification’ sections in this manual for more information. Ensure that the area where the Universal A.T.E is to be installed is flat enough so that the Ground Strut will not protrude more than 100mm from ground level, when measured with a straight line over a 1500mm cord. Minor site grading may be required.

Soil Conditions The Universal A.T.E can be installed in median or edge of road locations. There are two foundation pile options that have been designed for a constant static load of 231kN. It is extremely important that the Universal A.T.E has the required strength to anchor the Cable Barrier. The ‘default’ foundation option is for use when the soil conditions meet or exceed AASHTO ‘weak’ soil while the ‘shallow’ foundation option, the soil conditions are required to meet or exceed AASHTO ‘standard’ soil conditions with a fully compacted sub-base. It is recommended that soil tests are carried out at the location the Universal A.T.E is to be installed. More information on the soil requirements and corresponding foundations pile options can be found under ‘Foundation Piles’ in the ‘Design Considerations’ section of this manual.

Tools Required The same tools required to install the Cable Barrier will also install an Universal A.T.E:

- Auger for drilling holes, 450mm and 300mm - 300mm Wrench - Measuring tape - String line

- Cut off saw

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Universal A.T.E - Bill of Materials

- Universal A.T.E (connected to a 4 Cable barrier)

- 1x Ground Strut

- 3x Rebar Cages (c/w 12x M24 nuts)

- 1x Trigger Post

- 2x Anchor Cables (c/w 4 x M24 nuts)

- 1x 10mm thick Rectangular Steel Washer

- 1x 6mm thick Rectangular Steel Washer

- 1x 3mm thick Rectangular Polyethylene Washer

- 4x 3mm thick Square Polyethylene Washers

- 4x 6mm thick 50mm ø Steel washers

- Universal A.T.E (connected to a 3 Cable Barrier)

- 1x Ground Strut

- 3x Rebar Cages (c/w 12x M24 nuts)

- 1x Trigger Post

- 2x Anchor Cables (c/w 4 x M24 nuts)

- 1x 10mm (thick) Rectangular Steel Washer

- 1x 6mm (thick) Rectangular Steel Washer

- 1x 3mm (thick) Rectangular Polyethylene Washer

- 3x 3mm (thick) Square Polyethylene Washer

- 3x 6mm thick 50mm ø Steel washers

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Universal A.T.E - Installation Instructions

Step 1 – Site Preparation It is preferred that the Universal A.T.E be installed on flat, level ground. The positioning of the Universal A.T.E in relation to the start position of the Cable Barrier will always be the same configuration. The Universal A.T.E is a continuation of the Cable Barrier and should be installed in a tangent position. If this is not possible, a maximum flare rate of 30:1 is preferred. The line posts between the LoN and the Universal A.T.E Trigger Post must always be at 2m spacing as shown below.

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Universal A.T.E - Installation Instructions Step 2 – Installing the Ground Strut

BEFORE DRILLING ALWAYS HAVE THE AREA CHECKED FOR UNDERGROUND SERVICES

Consult the Construction Drawings for which of the following foundation options to use. Default Foundation Pile

Using an auger, drill 3 x 450mm diameter holes 2500mm deep at 1000mm centres. Theoretical volume of concrete required for all 3 piles is 1.2m³. (Shown in Photo 1)

OR

Shallow Foundation Pile

Using an auger, drill 3 x 450mm diameter holes 1000mm deep at 1000mm centres. Theoretical volume of concrete required for all 3 piles is 0.48m³. (Shown in Photo 1) Ground Strut and Rebar Cage Assembly Attach the Rebar Cages to the ground strut as shown using M24 nuts, one below and one above the Ground Strut. At least 15mm of thread above the top nut must be showing on ALL threads. (Shown in Photo 2) Construction Fill the holes to the top with 25mpa concrete, place the Rebar Cages connected to the Ground Strut into the foundation piles with the middle Rebar Cage centred into the centre pile. The end Rebar Cages will then both fit off-centre in their respective piles as per the Universal A.T.E design. The hollow RHS end of the Ground Strut is at the upstream end. Be careful that this end doesn’t sink while the concrete is curing because there needs to be sufficient room to install the 10mm (thick) washer and anchor cables. (Shown in Photo 3 below)

N.B. Due to the drilling and removing spoil the actual amount of concrete required is likely to be larger than the theoretical volume.

PHOTO 1 PHOTO 2 PHOTO 3

Upstream End

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Universal A.T.E - Installation Instructions Step 3 – Installing the Anchor Cables Once the concrete has had sufficient time to harden, the cables can be connected to the Ground Strut. Holding both cables at once, slot one end down through the RHS end of the Ground Strut. The large 10mm (thick) washer is positioned onto the threads at the upstream end of the Ground Strut and the nuts attached as shown.

At the other end of the cables the 3mm (thick) polyethylene washer is positioned onto the threads first, followed by the 6mm (thick) steel washer. The nuts are wound onto the threads with 2 threads showing through as shown.

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Step 4 – Connecting the Trigger Post

To connect the Trigger Post, remove the two M24 nuts on the top side of the downstream end of the Ground Strut. The Trigger Post then drops over the exposed threads and the nuts re-attached and tightened with a wrench (Trigger Post is angled towards the Ground Strut). Note: At least one thread must be wound through the nuts when re-attached.

Step 5 – Connecting the Anchor Cables to the Trigger Post

The cables with washers are positioned onto the triangular wedges on the Trigger Post. The anchor cables are then tightened using a wrench on the nuts at the upstream end of the Ground Strut until the Anchor Cables are taut.

MAKE SURE THE CABLES REMAIN FULLY INSIDE THE TRIGGER POST

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Step 6 – Connecting to a 3 Cable Barrier The top cable from the cable barrier is placed in the top slot of the Trigger Post while the bottom two cables are placed in either side of the Trigger Post in the bottom slots. (either cable to either side) Make sure that the 3mm (thick) polyethylene washer is positioned between the 6mm (thick) 50mm ø steel washer and the Trigger Post on each cable.

OR

Step 6 – Connecting to a 4 Cable Barrier The top two cables from the Cable Barrier are placed on either side of the Trigger Post in the top slots (either cable to either side) while the bottom two cables are placed in either side of the Trigger Post in the bottom slots (either cable to either side). Make sure that the 3mm (thick) polyethylene washer is positioned between the 6mm (thick) 50mm ø steel washer and the Trigger Post on each cable.

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Universal A.T.E – Installation Examples

Installed Universal A.T.E anchor assembly connected to a 3 Cable Barrier

Installed Universal A.T.E anchor assembly

connected to a 4 Cable Barrier

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INSTALLATION CHECKLIST FOR THE

Universal A.T.E

Location Installed By Date

Inspected By Date

Y/N N/A General

• Ground is level for a 1500mm cord around Ground Strut.

• The M24 nuts holding the Ground Strut to the foundation are spanner tight.

• The 10mm (thick) steel washer has been used to fix the anchor cables to the upstream end of the Ground Strut.

• The 3mm (thick) polyethylene washer and 6mm (thick) steel washer have been used to fix the anchor cables to the Trigger Post (see diagram below for orientation).

• The Anchor Cables are firmly held in the body of the triangular wedges on the Trigger Post and the M24 nuts at the upstream end of the Ground Strut are spanner tight.

Connected to a 3 Cable Barrier

• The top cable of the Cable Barrier is positioned in the top slot on the Trigger Post.

• The two bottom cables are positioned on either side of the Trigger Post in the bottom slots.

• The 3mm (thick) square polyethylene washer is between the 6mm round steel washers and the Trigger Post for all three cables. (see diagram below)

Connected to a 4 Cable Barrier

• The two top cables of the Cable Barrier are positioned on either side of the Trigger Post in the top slots.

• The two bottom cables are positioned on either side of the Trigger Post in the bottom slots.

• The 3mm (thick) square polyethylene washer is between the 6mm round steel washer and the Trigger Post for all four cables. (see diagram below)

Comments:

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Universal A.T.E – Frequently Asked Questions

1) What type of equipment is required to install the Universal A.T.E? Standard tools required include a wrench, measuring tape and a string line. Machinery includes an Auger for drilling holes, 450mm and 300mm in diameter and up to a depth of 2500mm. A cut off saw is required to cut the cables. 2) How much concrete is required to install the footings on a

Universal A.T.E and what strength does it need to be? The volume can vary because the depth of the footings beneath the ground strut is dependant on the soil conditions that exist. When 2500mm footings are used the total theoretical volume is 1.2m³. When the smaller 1000mm footings can be used the total theoretical volume is 0.48m³. (Due to the drilling and removing spoil the actual amount may be larger than this for each option) (This does not allow for the 4 line post footings required downstream from the Trigger Post to the LoN, they require approx 0.05m³ each) The concrete must be 25mpa. 3) Is there a curing period for the concrete before the Cable Barrier

can be tensioned? Yes, it is recommended that the system is not tensioned until 7 days after the concrete footings have been poured. 4) Does your company provide spare parts? What is the lead-time for

supply? It is important to fix a damaged Cable Barrier as soon a possible because it most probably won’t perform as required when damaged. For this reason it is recommended that spares are held by Maintenance Contractors. (the concrete footings and Ground Strut Assembly are very unlikely to be damaged) 5) On average, how long does it take to install a Universal A.T.E? Depending on the application and circumstances at the site, installation and assembly of the system should take one person crew less than 15mins once the concrete piles are poured and set. 6) What about vandalism, can the Universal A.T.E be easily damaged? No, once the system has been tensioned it is an extremely rigid system and tampering without the use of heavy duty tools or machinery is very unlikely to damage or affect the performance of the system.

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FAQ’s (continued)

7) How easily can the Universal A.T.E be restored after impact? The system is easily repaired after impact as the foundations and ground strut should not be damaged in anyway. The damaged posts can be removed using a crow bar and new ones positioned in the sockets. If the system has been de-tensioned or Trigger Post damaged, a hydraulic Tension Machine and trained personnel will be required to re-tension the system. 8) What maintenance does the Universal A.T.E require? The Universal A.T.E terminal end is maintenance free as the anchor cables used are pre-stretched. Refer to the relevant Product Manual for manufacturer’s recommendations on maintenance for the Cable Barrier itself which may include routine inspections and/or cable tension checking. 9) Apart from the configuration of the cables from the Cable Barrier

onto the Trigger Post, are there any other differences between installing a 3 or 4 Cable Barrier to a Universal A.T.E?

No, the setup of the Universal A.T.E apart from how the cables connect to the Trigger Posts is always the same. (The only variance that can happen, and not related to whether it is a 3 or 4 Cable Barrier, is the depth of the footings may change due to the soil conditions that exist at that location)

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Universal A.T.E – Crash Test Results Summary

820kg Vehicle, 100kph, 20º Reverse Direction Impact on the Universal A.T.E

The Results: The vehicle passed through the Universal A.T.E safely and remained on all 4 wheels through to its final resting point. (At impact the cables disconnect from the top of the trigger post resulting in immediate loss of tension which allows a vehicle to over ride and gate through the high tensioned anchor area of the terminal end)

The vehicle passes through the terminal end with very little change to its direction of travel.

450mm Exterior Deformation to the LH Corner. 0.0mm Interior Deformation

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APPENDIX – Technical Drawings

Universal A.T.E – Connecting to a 4 Cable Barrier

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APPENDIX – Technical Drawings (continued)

Universal A.T.E – Connecting to a 3 Cable Barrier

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Universal A.T.E – Overlap

3 Cables Line Post Set Up 4 Cables Line Post Set Up

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Universal A.T.E – Set-up, 2500mm ‘Default’ Pile Option

Universal A.T.E – 1000mm ‘Standard’ Pile Option

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Universal A.T.E – Connecting to a 4 Cable Barrier (isometric)

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Universal A.T.E – Connecting to a 3 Cable Barrier (isometric)

Documents

Universal Armorwire Terminal End