INFORMATION HANDOUT ET Plus Replacement Options MANUFACTURER’S DRAWINGS AND SPECIFICATIONS TYPE SKT TERMINAL SYSTEM Complete Installation Manual at: http://roadsystems.com/skt.html TYPE FLEAT TERMINAL SYSTEM (Requires additional space between ETW and Hinge due to Flare) Complete Installation Manual at: http://roadsystems.com/fleat.html TYPE X-LITE and X-TENSION TERMINAL SYSTEM Complete Installation Manual at: http://www.barriersystemsinc.com/xlite-end-terminal http://www.barriersystemsinc.com/xtension-guardrail-end-treatment DISCLAIMER CONSULT MANUFACTURERS COMPLETE INSTALLATION MANUALS on their websites FOR MAINTENACE AND CONSTRUCTION INSTALLATION Compiled by TR BUCKO 12/2014 Installation Instructions for the SKT 350 ROAD SYSTEMS, INC. P. O. Box 2163 Big Spring, Texas 79721 Phone: (432) 263-2435 FAX: (432) 267-4039 Technical Support & Marketing Phone: (330) 346-0721 Technical Support & Marketing Fax: (330) 346-0722 This Installation Manual can be downloaded from RSI web site www.roadsystems.com ADDENDUM .. March 2001 This SKT installation Manual contains options for the allowable number of steel foundation tubes. See Table 1 on page 3. Either 2-tube, 4-tube, or 8?tube options are acceptable and normally, the specifying agency will indicate which option will be used. When more than 2 foundation tubes are used, tubes 3 4 or tubes 3 through 8 must be the short tube long as shown in Figure 5 on page 11. It is now permissible to eliminate the soil plates from the tubes used at posts 3 and higher provided it is approved by the specifying agency. The foundation tubes used at posts 1 2 must use the soil plate if the long tube is used. If the 6-0? long foundation tube (Figure 8, page 15) is used at posts 1 2, soil plates are not reguired. Table of Contents Page LIST OF FIGURES ................................................................................................. ii LIST OF TABLES ................................................................................................... iii Installing the SKT 350 ..................................................................................... 3 Materials ....................................................................................................... 3 Design Options .............................................................................................. 3 Site Preparation ............................................................................................. 7 Tools Required .............................................................................................. 7 Installation Procedures................................................................................... 7 Installing Posts 3 through 8 ................................................................. 7 Installing Posts 1 and 2 with Groundline Strut.................................. 13 Installing Guardrail ........................................................................... 16 Installing Cable Anchor Bracket ........................................................ 16 Installing SKT 350 Impact Head ........................................................ 18 Installing Cable Assembly ..................................................................18 SKT 350 Installation Checklist ......................................................................19 Repairing the SKT 350 .................................................................................. 20 Equipment Needed for Repair Operation...................................................... 20 General Repair Procedures ........................................................................... 20 Procedures Immediately Following an Accident (Temporary)..................... 21 NOTE: The SKT 350 has different foundation tube options available. Where reference is made to a 5'-0" long foundation tube with soil plate, a 4'-6" long foundation tube with soil plate is an acceptable alternate. See the inside cover for additional information on soil plate options. PUBLICATION ~ 020105 i 10 11 12 13 List of Figures Page Isometric View of the SK 350 (Two Foundation Tube Option) ..1 Plan Elevation View of the SK 35 0 (Two Foundation Tube Option) ..2 Optional Flared Installation "78 Section at CRT Post .. 10 Section at Posts with or Foundation Tubes with Soil Plates ..11 Proper Placement of Foundation Tubes .. 12 Above-Ground Details at Post Locations 1 and 2 .. 14 Section at Post Locations 1 and 2 .. 15 Installation of Cable Anchor Bracket Shoulder Bolts ..17 Installation of Cable Anchor Bracket .. 17 Chain Attachment to Remove Impact Head ..22 Wood Post Pulling Tool (Pipe Option) ..22 Wood Post Pulling Tool (Lag Screw Option) ..22 ii List of Tables T_ab_le_ Bags 1 SKT 350 Design Options ..3 2 SK 350 Bill of Materials - Two Foundation Tube Option ..4 3 SKT 350 Bill of Materials - Four Foundation Tube Option ..57 4 SK 350 Bill of Materials - Eight Foundation Tube Option ..6 CABLE ANCHOR BRACKET GUARD RAIL ON BACK SIDE OF RAIL SKT 350 IMPACT HEAD BREAKAWAY WOOD POSTS AT LOCATIONS 1 THROUGH 8 . GROUND STRUT a9! CABLE ASSEMBLY Figure 1. Isometric yiew of the SK 350. Cable Anchor Bracket (3 ardra?l exit start w/ Shoulder .. Quay frlom traf?c structural nuts, 6 8 Wood CRT Posts washers (Post 3 thru 8) Length of need El la, . a lil \?W?-Beam Guardrail End Section\?W?Beam Guardrail /l 50,?0? TRAFFIC 12?6? or 25? W?beam Rail Elements Standard line costs 7 6 3/8? Log Screws Wood Post Cable Ground Anchor E?l?rit ?2?S?kn??ly ELEVATION 11 3p: 3m::3 ?ll: ll]: ill? 3 :l :l Figure 2. Plan and Elevation Views of SK 350. (TWO Foundation Tube Option) Installing the SKT 350 Materials As packaged, the SK 35 0 system includes all materials needed for a complete installation except for the impact face object marker. The length of the system in this con?guration is Design Options Design options with 2, 4 or 8 foundation tubes are available as shown in Table 1. In addition for posts #1 and the optional long split foundation tubes may be substituted with solid long foundation tubes without soil plates, standard or long foundation tubes with soil plates. Table 1. SKT 350 Design Options SKT 350 *No. of Optional No. of Standard Design Split Foundation Tubes Foundation Tubes No. of CRT Total No. Options with No Soil Plate with a Soil Plate Posts of Posts 2 Foundation Tubes 2 6 8 4 Foundation Tubes 2 2 4 8 8 Foundation Tubes 2 6 8 *Note. The optional long split foundation tubes may be substituted with solid long foundation tubes without soil plates, standard or long foundation tubes with soil plates. Figure 1 shows the isometric view and Figure 2 shows the plan and elevation views of the SK 35 0 for the TWO foundation tube option. The bills of materials for the three design options are shown in Tables 2 through 4, respectively. Table 2. SK 350 Bill of Materials - TWO Foundation Tube Option Code Quantity Description S3000 7 Impact Head W?Beam Guardrail End Section, 12 Ga, 12-6" or 25'-0" 3/l W?Beam Guardrail, 12 Ga, 12'-6" or 25'-0" S730 2 Foundation Soil Tubes, 6" 8" (SEE NOTE BELOW) E740 1 Pipe Sleeve - 2" Standard Pipe 5-1/ E750 1 Bearing Plate - 8" 8? 5/8? S760 1 Cable Anchor Bracket E770 1 BCT Cable Anchor Assembly E780 1 Ground Strut P650 2 5-1/ 7-1/ 45" Wood Posts P671 6 6" 8" 6-0" Wood CRT Posts P675 6 6" 8" 14" Timber Blockouts E31 51 1 Impact Face Object Marker (Not Provided) Hardware The optional long split foundation tubes may be substituted with either solid long foundation tubes Without soil plates, standard 5'-0'l long or long foundation tubes with soil plates. B580122 16/32 5/8" Splice Bolts B580754 2 5/8" 71/2? Hex Bolts B581004 2 5/8? 10" Hex Bolts B581002 1 5/8" 10? H.G.R. Post Bolt (Post 2 Only NO BOLT USED AT POST B581802 6 5/ 18" H.G.R. Post Bolts (Posts 3 through 8) N050 27/43 5/8? H.G.R. Nuts (Splice - 16/32, Soil Tubes 4, Posts 2 to 8 7) W050 11 5/8" Flat Washers (2 each at Soil Tubes 7 Posts) N100 2 1 Anchor Cable Hex Nuts I W100 2 1? Anchor Cable Washers E350 2 3/8? 3? Lag Screws SB58A 8 Cable Anchor Bracket Shoulder Bolts N055A 8 1/2" A325 Structural Nuts W050A 16 1-1/16" OD 9/16" ID A325 Structural Washers Table 3. SKT 350 Bill of Materials - FOUR Foundation Tube Option Code Quantity Description S3000 1 Impact Head I S1 303/81305 1 A W?Beam Guardrail End Section, 12 Ga, 12'-6" or 25'-0" 3/1 W?Bearn Guardrail, 12 Ga, 12-6" or 25'?0" S730 2 Foundation Soil Tubes, 6" 8" (SEE NOTE BELOW) S735 2 Foundation Soil Tubes, 6" 8" (SEE NOTE BELOW) SP600 2 Soil Plates - 24" 18" 1/4" (SEE NOTE BELOW) E740 1 Pipe Sleeve - 2? Standard Pipe 5-1/ E750 1 Bearing Plate - 8? 8" 5/ S760 1 Cable Anchor Bracket E770 1 BCT Cable Anchor Assembly E780 1 Ground Strut P650 4 5?1/2" 7-1/2" 45" Wood Posts P671 4 6" 8" Wood CRT Posts P675 6 6" 8" 14" Timber Blackouts E3151 1 Impact Face Object Marker (Not Provided) Hardware The optional long split foundation tubes may be substituted with either solid long foundation tubes without soil plates, standard long or long foundation tubes with soil plates B5 80122 16/32 5/ 11/4" Splice Bolts B580754 6 5/8? Hex Bolts B581004 4 5/8" 10" Hex Bolts B581002 1 5/ 10? H.G.R. Post Bolt (Post 2 Only BOLT USED AT POST B581802 6 5/ 18" H.G.R. Post Bolts (Posts 3 through 8) N050 33/49 5/8" H.G.R. Nuts (Splice - 1682, Soil Tubes 10, Posts 2 to 8 7) W050 15 5/ Flat Washers (2 each at Soil Tubes 7 Posts) N1 00 2 1" Anchor Cable Hex Nuts W100 2 1? Anchor Cable Washers E350 2 3/8" 3? Lag Screws SBSSA 8 Cable Anchor Bracket Shoulder Bolts N055A 8 1/2" A325 Structural Nuts WOSOA 16 1-1/16" OD 9/16" ID A325 Structural Washers Table 4. SKT 350 Bill of Materials - EIGHT Foundation Tube Option Code Quantity Description S3 000 1 Impact Head Sl303/Sl305 1 W?Beam Guardrail End Section, 12 Ga, 12?-6" or 25'-0" 3/1 W?Beam Guardrail, 12 Ga., 12'-6" or 25'-0" S730 2 Foundation Soil Tubes, 6" 8? (SEE NOTE BELOW) S735 6 Foundation Soil Tubes, 6" 8" (SEE NOTE BELOW) SP600 6 Soil Plates - 24" 18" 1/4" (SEE NOTE BELOW) E740 1 Pipe Sleeve - 2" Standard Pipe 5-1/2? E750 Bearing Plate - 8" 8" 5/8" S760 1 Cable Anchor Bracket E770 1 BCT Cable Anchor Assembly E780 1 Ground Strut P650 8 5-1/ 7?1/2" 45" Wood Posts P675 6 6" 8" 14" Timber Blockouts E3151 1 Impact Face Object Marker (Not Provided) Hardware The optional long split foundation tubes may be substituted with either solid long foundation tubes without soil plates, standard long or long foundation tubes with soil plates. B580122 16/32 5/8? Splice Bolts B580754 14 5/8? 71/2?; Bolts B581004 8 5/8? 10" Hex Bolts B581002 1 5/ 10" H.G.R. Post Bolt (Post 2 Only NO BOLT USED AT POST B581802 6 5/8? 18" H.G.R. Post Bolts (Posts 3 through 8) N050 45/61 5/8" H.G.R. Nuts (Splice - 16/32, Soil Tubes - 22, Posts 2 to 8 - 7) W050 23 5/8" Flat Washers (2 each at Soil Tubes 7 Posts) N100 2 1 Anchor Cable Hex Nuts W100 2 1" Anchor Cable Washers E350 2 3/ 3" Lag Screws SB58A 8 Cable Anchor Bracket Shoulder Bolts I N055A 8 1/2" A325 Structural Nuts W050A 16 1-1/16" OD 9/16" ID A325 Structural Washers Site Preparation When the guardrail is installed parallel to the edge of the shoulder, a 50:1 ?are away from the roadway is recommended so the impact head will not encroach on the shoulder. However, the ?are is not required and may be decreased or eliminated for speci?c applications. When necessary, a 25:1 ?are rate can be used over a, distance of 25'-0" or .as shown in Figure 3. Minor site grading may be necessary for installations placed beyond the edge of the shoulder to prevent the foundation tubes from extending more than 4" above the ground (see Section on Installation). Tools Required The tools required for installation of the SK 350 system are those used to install standard highway guardrails (H.G.R.), including: 9/ 16", 15/ 16", and 1-1/2" sockets and wrenches, a drill with a 1/ bit, and other equipment such as augers, tampers, and post pounders commonly used in driving posts. Installation Procedures Begin installation (post location 9) to ensure that the terminal matches up with the standard section of guardrail. The major steps in the installation of the SK 350 are as follows: - Install posts 3 through 8, Install posts 1 and 2 with groundline strut, Install guardrail, - Install cable anchor bracket, - Install the SK 35 0 impact head, and - Install cable assembly. NOTE: Foundation tubes must be used at Posts #1 and Those tubes may be either 6-0? long split tubes (S730) without soil plates, long solid tubes (E731) without soil plates, long tubes (S735) with soil plates (SP600), or long tubes (E735) with soil plates (SP600). Posts 3 through 8 may be either CRT wood posts without foundation tubes or short wood posts inside a or long foundation tube with soil plates. Installing Posts 3 Through 8 For the two foundation tube option, posts 3 through 8 are 6" 8" 6-0" CRT posts (P671). When installed properly, the hole at the ground line of these CRT posts will be parallel to the roadway. For the four foundation tube option, posts 3 and 4 are inserted in foundation tubes with soil plates (SP600). - Install the 5-1/ 7-1/ 45" wood posts (P650) in the foundation tubes at the post 3 and 4 locations. Secure the post to each foundation tube with a 5/8" 10? hex head bolt (B581004) and H. GR. nut (N050) with a washer (W050) under both the bolt head and the nut, Do not over tighten and deform the tubes. Posts 5 through 8 are 6" 8" 6-0" CRT posts (P671). 3! ?z >~D1n A, at 25:1 Flore Rate mg; Lm Max Rail Offset 2' ?1 a 50,?0" at 25:1 Flore Rate or 50:1 Flore Rate Figure 3. Optional Flared Installation For the eight foundation tube option, posts 3 through 8 are inserted in foundation tubes with soil plates (SP600). Install the 5-1/ 7-1/ 45" wood posts (P650) in the foundation tubes at the post 3 through 8 locations. Secure the post to each foundation tube with a 5/8" 10" hex head bolt (B581004) and H.G.R. nut (N050) with a washer (W050) under both the bolt head and the nut. Do not over tighten and deform the tube. There are no CRT posts for this option. Figure 4 shows the section of a post. The CRT post may be driven with an approved driving head. For stiff soils, drill a 6" pilot hole and force the post to the appropriate depth by impact or vibratory means with an approved driving head. The post may also be installed by augering and back?lling if the contractor so prefers. The initial hole must be large enough to allow adequate room for proper compaction of the soil during back?ll. Care must be taken to carefully compact the baclg?ill to prevent settlement or lateral displacement of the post. Figure 5 shows the section of a post in a standard or long foundation tube with a soil plate. Fasten the soil plate to the foundation tube with two 5/8" 7-1/ hex head bolts (B5807 54) and H.G.R. nuts (N050) through the bottom holes of the foundation tubes. Do not over tighten and deform the tubes. These bolts attach the soil plate to the foundation tube and stop the post from sliding all the way into the tube during installation. Do not drive the foundation tube with wood post inserted. If the soil is penetrable so that the foundation tube does not deform, the foundation tube may be driven with an approved driving head. For non-penetrable soil, drill a 6? pilot hole and force the tube to the appropriate depth by impact or vibratory means with an approved driving head. The tube may also be installed by augering and back?lling if the contractor so prefers. The initial hole must be large enough to allow adequate room for proper compaction of the soil during back?ll. Care must be taken to carefully compact the bacljill to prevent settlement or lateral displacement of the foundation tubes. If rock is encountered during driving or excavation, refer to appropriate State speci?cations. Guidelines will vary from State to State. Figure 6 illustrates the proper placement of the foundation tubes. The top of the foundation tubes should not project more than 4? above the ground line when measured along a 5' cord, according to AASHTO speci?cations. Site grading may be required if the top of the foundation tubes project more than 4" above the ground line. The ?nished guardrail height should generally be 27-3/ above the edge of the shoulder. 3/4" Q5 Post Hole w/ 5/8? 18? Bolt W?Beom 86 Nut 6 8 1 _2 Guardrail 5/8? Timber BIackout\ under Nut only 6? 61?0)) CRT Timber Post 1?9 6 3 1/2 CD 4,63 Breakaway Holes SKT .350 LOCATION OF DESIGN OPTION CRT POSTS (2) FOUNDATION TUBES POSTS 3 THROUGH 8 (4) FOUNDATION TUBES POSTS 5 THROUGH 8 Figure 4. Section at CRT Post 10 Deep Beam Guardrail 6? 8? Timber Blackout 3/4? (D Post Hole w/ 5/8? c? 18? Bolt H.G.R. Nut 1 5/8? OD. Washer under Nut only 5.5? 7.5? 45?; Timber Post I ?5 5/8? 10? Hex 2 1/2? (2) Head Bolt HGR Breakaway I Nut Hole Washers 24? 18? 5/8 <25 7--1/2 Soil Plate Hex Bolt H.G.R. Nut gonxT?be Note that this standard foundation tube design may also be used at post locations 1 8c 2 TIMBER POST SKT 350 DESIGN OPTION LOCATION OF STANDARD FOUNDATION TUBES WITH SOIL PLATES (4) FOUNDATION TUBES POSTS 1 THROUGH 4 QB POSTS 3 AND 4 (8) FOUNDATION TUBES POSTS 1 THROUGH 8 QB POSTS 3 THROUGH 8 Figure 5. Section at Posts with or Foundation Tubes with Soil Plates 11 TOP OF RAIL 1?5? 27 3/4" SHOULDER 4 MAXIMUM Wax; I GROUND LINE . I I (VARIABLEFigure 6. Proper Placement of Foundation Tubes Based on a level line ?om the edge of the paved shoulder, the top of the foundation tube should normally be 2-1/ to 3" above the level line. The placement of the foundation tube should be an appropriate depth below the level line in order to maintain the 27?3/4" guardrail height from the edge of the shoulder. If the slope drops off some distance ?om the edge of the shoulder to the tube location, as shown in Figure 6, the depth of the foundation tube should be reduced by in order to maintain the proper guardrail height. The top of the foundation tube will project 2-1/ to above the ground. In order not to exceed the AASHTO 4" maximum projection above the ground, site grading will be necessary to assure that the dimension would not be more than 1-1/2" to 1" respectively. 12 Installing Posts 1 and 2 with Groundline Strut Figure 7 shows the above ground details and Figure 8 shows the section at post locations 1 and 2. Posts 1 and 2 may be installed with either long split foundation tubes (S730) without soil plates, solid long foundation tubes (E731) without soil plates, standard long foundation tubes (S735) with soil plates (SP600) or stande long foundation tubes (E735) with soil plates (SP600). For the long split foundation tube, fasten one 5/8" 7-1/2" hex head bolt (B580754) and H.G.R. nut (N050) through the bottom hole of the foundation tube. Do not over tighten and deform the tube. The bolt is intended to stop the post from sliding all the way into the tube during installation. Do not drive the foundation tube with wood post inserted. If the soil is penetrable so that the foundation tube does not deform, the foundation tube may be driven with an approved driving head. For non-penetrable soil, dn'll a 6" pilot hole and force the tube to the appropriate depth by impact or vibratory means with an approved driving head. The tube may also be installed by augering and back?lling if the contractor so prefers. The initial hole must be large enough to allow adequate room for proper compaction of the soil during back?ll. Care must be taken to carefully compact the baclg?ill to prevent settlement or lateral displacement of the foundation tubes. If rock is encountered during driving or excavation, refer to appropriate State speci?cations. Guidelines will vary from State to State. The top of the foundation tubes should not project more than 4" above the ground line when measured along a 5? cord, according to AASHTO speci?cations. Site grading may be required if the top of the foundation tubes project more than 4" above the ground line. The ?nished guardrail height should generally be 27?3/4" above the edge of the shoulder (see Figure 6). The installation procedure for the solid long foundation tubes without soil plates is the same as that for the split foundation tubes. The installation procedure for the standard long foundation tubes with soil plates or the long foundation tubes with soil plates is described previously under the Section on ?Installing Posts 3 through 8" and will not be repeated here. Insert the pipe sleeve (E740) into the 2-1/ diameter hole near the base of the 5-1/ 7-1/ 45" wood post (P650) and install the post in the foundation tube at post location 1. Install the second 5-1/ 7-1/ 45" wood post in the foundation tube at post location 2, and ?t the groundline strut (E780) between the two posts. Secure the post to each foundation tube with a 5/ 8" 10" hex head bolt (B581004) and H. GR. nut (N05 0) with a washer (W050) under both the bolt head and the nut. These bolts will serve to secure the posts and attach the groundline strut to the foundation tubes, as shown in Figure 8. 13 IMPACT HEAD I 5/8" CABLE ANCHOR H.G.R. Bolt BRACKET 3/8? 25 3 Lag Screws NOTE that there is I no Bolt at Post #1 RAIL TRAFFIC SIDE 14 PIPE SLEEVE BEARING PLATE CABLE ANCHOR GROUND STRUT POST #1 POST #2 LI Figure 7. Above-Ground Details at Post Locations 1 and 2. Breakaway 1? Timber Post Hex Nut 5/8" 46 10" <36 Wosher BCT Cable Lg. ng- Bolt Anchor Assy w/ H.G.R. Nut (1) Washer ?under Nut only leev P'pe GROUND LINE 7 8HX ?8?x 5/8" Beormg Plate Ground Strut 5/8" a) 10" 5/8" (a 10? Hex Head Bolt 26:1 8? 1/8? 6? H.G.R. Nut 6 w/ (2) Washers Soil Tube 5/8" 7 1/2? 4 Hex Head Bolt PARTIAL VIEW SECTION . H.G.R. Nut at Post ?1 at Post #2 Washers Note. The optional long split foundation tubes may be substituted with either solid long foundation tubes without soil plates, standard long or long foundation tubes with soil plates. Figure 8. Section at Post Locations 1 and 2. 15 Installing Guardrail Attach the standard W-beam guardrail sections, 12'-6" (G1203) or 25'-0" (G1205), beginning at post 9. Attach the W-beam guardrail end section to span from post 1 to 3 for the 12'-6" rail (S1303), or from post 1 to 5 for the 25'-0" rail (S1305). The rail is to be spliced with 5/8″ x 1-1/4″ H.G.R. bolts (B580122) and 5/8″ H.G.R. nuts (N050). For ease of installation, it is recommended to have the eight 1/2" cable anchor bracket shoulder bolts (SB58A) and the cable anchor bracket (S760) attached to the W-beam guardrail end section prior to attaching the guardrail to the posts. See Section on “Installing Cable Anchor Bracket” for details. The rails are to be attached to posts and blockouts at post locations 3 through 8 with 5/8″ x 18" H.G.R. bolts (B581802) and nuts (N050). There is no blockout on posts 1 and 2. The rail is attached to post 2 only with a 5/8″ x 10″ H.G.R. bolt (B581002). Note that no bolt is used at post #1. Be sure to place a 5/8″ flat washer (W050) on the backside of posts 2 through 8 under each nut (N050). It is recommended that the post bolt be placed through the rail at post location #5 where the rail splice occurs but it is not necessary. NOTE: After the blockout is attached, drive a galvanized steel 10d common nail through the block and into the post (toe nailed) to prevent rotation if the wood shrinks. Installing Cable Anchor Bracket For ease of installation, it is recommended to have the eight 1/2" cable anchor bracket shoulder bolts (SB58A) and the cable anchor bracket (S760) attached to the W-beam guardrail end section prior to attaching the guardrail to the posts. If this procedure is not followed, Post #2 may interfere with attaching the bracket. The eight 1/2" cable anchor bracket shoulder bolts (SB58A) are attached to the W-beam guardrail end section with two 1-1/16" OD x 9/16" ID structural washers (W050A), one on each side of the guardrail, and a 1/2" structural nut (N055A). The shoulders of the bolts should be on the backside of the guardrail, away from traffic, as shown in Figure 9. For ease of installation, attach the cable anchor bracket shoulder bolts to the rail "finger tight" only. Then align the slots on the cable anchor bracket (S760) with the shoulder bolts and tap the cable anchor bracket onto the shoulder portion of the bolts using a hammer. Tighten the bolts with a wrench when the bracket is in place. When installed properly, the welded plate on the cable anchor bracket should be toward Post #2, as shown in Figure 10. 16 SPECIAL SHOULDER 1/2? 1_1/4 RAIL A325 STURCTURAL BOLTS 1/2? STRUCTURAL NUTS 7 1-1/16" 0.0. 9/16" STRUCTURAL WASHERS ON BOTH SIDES OF RAIL Figure 9. Installation of Cable Anchor Bracket Shoulder BoltsFigure 10. Installation of Cable Anchor Bracket. 17 Installing the SKT 350 Impact Head The eight cable anchor bracket shoulder bolts and the cable anchor bracket should be attached to the W?beam guardrail end sectiOn prior to attaching the SK 35 0 impact head to the ?rst post with lag screws. Place the impact head (S3000) with the guide chute over the end of the W-beam guardrail. The impact head should be positioned so that the protruding tube is on the backside of the guardrail, away from traf?c as shown in Figure 2 and Figure 7. Slide the impact head forward until the post angle attachments on the impact head are aligned with the side of the ?rst post. This is the side facing post Attach the impact head to the ?rst post with two 3/ 8? 3" lag screws (E350), one each for the top and bottom post angle attachments. A 1/4" pilot hole is required to avoid breaking the lag screw. Note that an earlier design of the SK 35 0 impact head had the attachment. to post #1 with the post angle attachments of the impact head centered on the ?rst post. This design is still acceptable. Note. It is recommended that the face of the impact head be delineated with an object marker that meets State speci?cations for better night visibility. However, the impact face object marker is not included as part of the shipped materials for the SK 35 0 unless speci?cally requested in the contract plans. Installing Cable Assembly Place the cable assembly (E770) through the cable anchor bracket and through the sleeve of post 1. Place the bearing plate (E750) at the base of post 1 with 5? dimension up and 3" dimension down. Place a nail over the bearing plate to prevent the plate from rotating. Secure both ends of the cable assembly with a 1? hex nut (N100) and washer (W100). While tightening cable, use a 2-1b hammer to tap the cable anchor bracket from the end to ensure that it is securely interlocked with the bolts. Restrain the cable at the end being tightened to avoid twisting the cable. Upon completion of the installation, the cable should be taut and the cable anchor bracket should be ?illy seated on the shoulder portion of the cable anchor bolts. It is very important that the cable anchor bracket be fully seated on the shoulder portion of the cable anchor bolts. 18 SKT 350 Installation Checklist State: Date: Project Location: El The rail height is in accordance with the plans (generally 27-3/ above the edge of the shoulder). El The rail is not attached to the post at post location The foundation tubes do not protrude more than 4" above the ground line (measured by the AASHTO 5? cord method). Site grading may be necessary to meet this requirement. CI The bolts at the top of the foundation tubes are not over-tightened, deforming the walls of the tubes. The guide chute of the impact head is parallel to the top of the rail and the impact head does not encroach on the shoulder (a 50:1 taper is permitted to eliminate the potential for encroachment). CI The two lag screws holding the impact head to post 1 are snug. The 8" 8? bearing plate at post 1 is correctly positioned with the 5" dimension up the 3 dimension down. The anchor cable is taut and correctly installed. A nail has been placed over the bearing plate to prevent rotation. El The cable anchor bracket shoulder bolts are properly attached to the W?beam guardrail and the cable anchor bracket is ?illy seated on the shoulder portion of the bolts. El Posts installed in foundation tubes have the 2?1/2" breakaway hole located parallel to the roadway with the bottom of the hole at the top of the tube. El CRT posts have two 3-1/ breakaway holes (checked prior to installation) located parallel to the roadway with the center of the top hole located at the ground line. If the posts were augered, be sure the back?ll material around the posts is compacted. No washers are used on the face of the rail except at the cable anchor bracket bolts. Additional notes: Inspection performed by: l9 Repairing the SK 350 Equipment Needed for Repair Operation - Acetylene torch to cut off the damaged rail, - Heavy duty chain to remove the impact head is sometimes required (see Figure 11), - S.A.E. wrench or socket sizes 9/ 16", 15/16", and - Vice grip or channel lock pliers, - Sledge hammer, I - Post remover tool (see Figures 12 and 13), Other normal guardrail tools. General Repair Procedures After an end?on impact occurs with the SK 35 0, it will normally require replacement of the ?rst 12'- 6" or end section of rail and any other damaged rail section(s) and any broken post(s). For a traf?c face impact, the damage will be to the rail section(s) and associated posts. The general step-by-step procedure for repairing a damaged SK 35 0 terminal is as follows: (1) Check the impact head for damage. (2) Check the cable anchor bracket and cable assembly for damage. The bearing plate, nuts, washers, cable anchor bracket, and the special cable anchor bracket shoulder bolts are rarely damaged. (3) Check the number of broken posts and wood blockouts that need to be replaced, along with any damaged bolts. Inventory and pick up the reusable parts. (4) Torch off the kinked rail near the outlet of the impact head. The impact head should be able to be removed by hand at this point. Ifnot, then hook up a chain attachment through the opening behind the impact plate of the impact head, as shown in Figure 11. Pull the impact head off the rail with the chain attached to a truck frame with the W-beam guardrail still attached to the guardrail posts. 20 (5) (6) (7) Disconnect and remove the damaged rail from the posts. Remove the broken posts from the foundation tubes using one of the two post removal tools (see Figures 12 and 13) assembled from "off the shelfhardware" items. Pound the steel pipe or screw the lag screw into the top of the broken post stub and remove the remains of the broken post by pulling on the chainlever if necessary. Reinstall the system following the procedures listed in this manual. Procedures Immediately-Following an Accident (Temporary) If no repair parts are readily available immediately following an accident, the following procedure should be used to provide temporary protection of the guardrail end. It should be noted that this repair is only for temporary purposes, and the anchor cable cannot be installed to provide tension in the rail for redirectional impacts. (1) (2) (3) (4) (5) (6) Remove damaged rail and impact head from the roadway or shoulder area. Using an acetylene torch, cut the kinked rail off at the outlet of the impact head and inspect the head for any damage. Remove the impact head by hand. If this is not possible, then with a chain hook-up (see Figure 11), pull the impact head off the rail that is still attached to the posts. Locate the ?rst post of any damaged rail and cut this rail off about 9" in front of the post. Ifthe post is at a splice, simply unbolt the damaged rail. Install the irnpact head on the rail and attach it to the post with lag bolts. Warning signs should be used where appropriate. 21 FUCK 5E NOTE: WHEN THE KINKED RAIL AT THE OUTLET END OF THE IMPACT HEAD IS TORCHED OFF, CHECK TO SEE IF THE IMPACT HEAD CAN BE REMOVED BY HAND BEFORE USING THE CHAIN ATTACHMENT. Figure 11. Chain Attachment to Remove Impact Head 3/16" CHAN 3/16,, ., (12"i) STD PIPE CAP af?x" HEX BOLT (THRU 1/2" 93 HOLE) 3/8 ca 4" OR 5" LAG BOLT w/ WASHER 1?1/2" STD PIPE 6" 12"i 1?1/2" STD COUPLING WOOD POST IN TUBE 1-1/2" STD COMBINATION NIPPLE (BARBED HOSE CONNECTION) Figure 12. Wood Post Pulling Tool Figure 13. Wood Post Pulling Tool (Pipe Option) (Lag Screw Option) 22 Installation Instructions for the FLEAT 350 ROAD SYSTEMS, INC. P. O. Box 2163 Big Spring, Texas 79721 Phone: (432) 263-2435 FAX: (432) 267-4039 Technical Support & Marketing Phone: (330) 346-0721 Technical Support & Marketing Fax: (330) 346-0722 This Installation Manual can be downloaded from RSI web site www.roadsystems.com ADDENDUM June 2001 The FLEAT may now be installed with all post spacing. This approval is good for a wood post system or a steel post system. Previously, the middle 12-6" panel had post spacing. Although the post spacing is now all the FLEAT still has7 breakaway posts. This is because there is now a breakaway post at the 37'-6" location where the flare begins. ANCHOR BRACKET GROUND STRUT Table of Contents Page LIST OF FIGURES ................................................................................................ ii LIST OF TABLES .................................................................................................. iii Installing the FLEAT 350 ............................................................................... 3 Materials ....................................................................................................... 3 Design Options .............................................................................................. 3 Site Preparation ............................................................................................. 5 Tools Required .............................................................................................. 5 Installation Procedures................................................................................... 5 Installing Posts 3 through 7 ................................................................. 5 Installing Posts 1 and 2 with Groundline Strut.................................... 8 Installing Guardrail ........................................................................... 12 Installing Cable Anchor Bracket ........................................................ 12 Installing FLEAT 350 Impact Head................................................... 14 Installing Cable Assembly ..................................................................14 FLEAT 350 Installation Checklist.................................................................15 Repairing the FLEAT 350 ............................................................................ 16 Equipment Needed for Repair Operation...................................................... 16 General Repair Procedures ........................................................................... 16 Procedures Immediately Following an Accident (Temporary)..................... 17 PUBLICATION ~ 020205 i Figge 10 11 List of Figures Egg Isometric View of the FLEAT 350 ..1 Plan Elevation View of the FLEAT 350 ..2 Section at CRT Post ..6 Proper Placement of Foundation Tubes ..7 Above-Ground Details at Post Locations 1 and 2 ..9 Section at Post Locations 1 and 2 .. 10 Optional or Foundation Tubes with Soil Plates .. 11 Installation of Cable Anchor Bracket Shoulder Bolts ..13 Installation of Cable Anchor Bracket ..13 Wood Post Pulling Tool (Pipe Option) ..18 Wood Post Pulling Tool (Lag Screw Option) .. 18 Table 2 List of Tables Page FLEAT 350 Design Options ..3 FLEAT 350 Bill of Materials ..4 . 294-39" vx I. 03?: Figure 1. Isometric View of the FLEAT 350. W?Beam Guardrail End Section 3/8' 3" - Lag Screws Cable Anchor Box bolts. 6" 8" Wood CRT Poets 3 th 7 structum' ""ta'waahem Length of need (Pas End payment for Installation (em) begin in payment for standard metal w_Beam Guardrail W-Beom Guardrali beam guard fence I: a: Roll exit on a to traf?c elde PE :2 I 37'-6' FLARE PLAN OPTIONAL ALL POST SPACING IS ALLOWABLE Standard 12-6 beam Rail Elements na posts 0 6?3" 6 C7) m3" a i: Wood Post Hill. 5' II I :ii? I'l I GROUND LINE A I II I Cable Anchor Box Assembly I II?ll-ii- :II-il?ll? Ground Line II tt of ?21 35 ?m NOTE: THE FLEAT MAY BE INSTALLED AN OFFSET NOTE: Posts 1 and 3 that are not bolted through the rail should ANYWHERE BETWEEN 2 '6 AND 4 '0 REFER To be driven with sufficient accuracy that the slot in the rail is aligned THE CONTRACT PLANS FOR THE REQUIRED A with the post bolt hole after installation. LEVATI Figure 2. Plan and Elevation Views of FLEAT 350. Installing the FLEAT 350 Materials As packaged, the FLEAT 350 system includes all materials needed for a complete installation except for the impact face object marker. The length of the system in this con?guration is Design Options There are four foundation tube options as shown in Table 1 below. Table 1. FLEAT 350 Design Options FL A 3 50 Total Number of Number of Total Design Foundation Standard BCT CRT Number of Options Tubes Posts Posts Posts split 2 2 5 7 Foundation Tube solid 2 2 5 7 Foundation Tube 41-6" Foundation Tubes 2 2 5 7 with soil plate Figure 6 shows a section with the 6-0" foundation tubes. Figure 7 shows a section with the or foundation tubes with soil plates. Table 2. FLEAT 350 Bill of Materials Code Quantity Description F3000 1 Impact Head F1303 1 W?Beam Guardrail End Section, 12 Ga., 12?6" F1304 1 W-Beam Guardrail, Center Section spacing) 12 Ga., 12'-6" G1203 1 W-Bearn Guardrail, spacing) 12 Ga, 12'-6" S730 2 Foundation Soil Tubes, 6" 8" 6-0" (SEE NOTE BELOW) E740 1 Pipe Sleeve 2? Standard Pipe 5-1/ E750 1 Bearing Plate - 8" 8" 5/ S760 1 Cable Anchor Bracket E770 1 BCT Cable Anchor Assembly E780 1 Ground Strut P650 2 5?1/2" 7-1/2? 45" Wood Posts P671 5 6" 8" 6-0" Wood CRT Posts P675 5 6" 8" 14" Timber Blockouts Hardware The optional long split foundation tubes may be substituted with either solid long foundation tubes without soil plates or standard 5'41" long or long foundation tubes with soil plates. B5 80122 24 5/8" Splice Bolts 13580754 2 5/ 71/2" Hex Bolts B581004 2 5/8" 10" Hex Bolts B581002 1 5/8? 10? H.G.R. Post Bolt (Post 2 Only NO BOLT USED AT POST B581802 5 5/ 18" H.G.R. Post Bolts (Posts 3 through 7) N050 34 5/8" H.G.R. Nuts (Splice - 24, Soil Tubes - 4, Posts 2 to 7 - 6) W050 10 5/8? Flat Washers (2 each at Soil Tubes 6 Posts) N100 2 1" Anchor Cable Hex Nuts W100 2 1" Anchor Cable Washers E350 2 3/8" 3" Lag Screws SBSSA 8 Cable Anchor Bracket Shoulder Bolts N055A 8 1/2" A325 Structural Nuts W050A 16 1-1/16" OD 9/16" 11) A325 Structural Washers 55?112.. .9. 11.1,. Korma walk :5 3.: r? Site Preparation The FLEAT 350 is installed with a straight ?are offset anywhere between and Refer to the contract plans for the required offset. Simply measure the o?'set distance over the 37'-6" length with a straight string line. This offset becomes the location of post A parabolic curve is not required. Minor site grading may be necessary to prevent the foundation tubes from extending more than 4" above the ground (see Section on Installation). Tools Required The tools required for installation of the FLEAT 350 system are those used to install standard highway guardrails (H.G.R.), including: 9/ 16", 15/ 16", and 1-1/2" sockets and wrenches, a drill with a 1/ bit, and other equipment such as augers, tampers, and post pounders commonly used in driving posts. Installation Procedures Begin installation at the end of the FLEAT 350 (post location 8) to ensure that the terminal matches up with the standard section of guardrail. The major steps in the installation of the FLEAT 350 are as follows: - Install posts 3 through 7, - Install posts 1 and 2 with groundline strut, - Install guardrail, - Install cable anchor bracket, - Install the FLEAT 350 impact head, and - Install cable assembly. NOTE: The impact head must be placed over the rail prior to tightening the rail to post 2. Installing Posts 3 Through 7 Posts 3 through 7 are 6" 8" CRT posts (P671). When installed properly, the hole at the ground line of these CRT posts will be parallel to the roadway. Figure 3 shows the section of a CRT post. The CRT post may be driven with an approved driving head. For stiff soils, drill a 6? pilot hole and force the post to the appropriate depth by impact or vibratory means with an approved driving head. The post may also be installed by augering and back?lling if the contractor so prefers. The initial hole must be large enough to allow adequate room for proper compaction of the soil during back?ll. Care must be taken to carefully compact the back?ll to prevent settlement or lateral displacement of the post. If rock is encountered during driving or excavation, refer to appropriate State speci?cations. Guidelines will vary from State to State. FWJE- - 3/4" (25 Post Hole w/ 5/8" (D 18" Bolt W_Beam H.G.R. Nut 6? 8" . . Guardrall 1 5/8 OD. Washer Timber Blackout under NUJC only r7130" 6? 8? 63?0? CRT Timber Post 1? 21 31/2" co 4 Breakaway Holes NOTE: THE RAIL IS NOT BOLTED TO POST 3 SECTION TYPICAL AT POSTS 3 - 7 Figure 3. Section at CRT Post TOP OF RAIL EDGE OF PAVED TOP OF TUBE I, 2 To 3.. SHOULDER MAXIMUM LINE GROUND LINE (VARIABLE) XII Figure 4. Proper Placement of Foundation Tubes Figure 4 illustrates the proper placement of the foundation tubes. The top of the foundation tubes should not project more than 4" above the ground line when measured along a 5' cord, according to AASHTO speci?cations. Site grading may be required if the top of the foundation tubes project more than 4? above the ground line. The ?nished guardrail height should generally be 27~3/ above the edge of the shoulder. Based on a level line from the edge of the paved shoulder, the top of the foundation tube should normally be 2-1/2" to 3" above the level line. The placement of the foundation tube should be an appropriate depth below the level line in order to maintain the 27-3/4" guardrail height from the edge of the shoulder. If the slope drops off some distance (X ?om the edge of the shoulder to the tube location, as shown in Figure 4, the depth of the foundation tube should be reduced be in order to maintain the proper guardrail height. The top of the foundation tube will project (X 2 to above the ground. In order not to exceed the AASHTO 4" maximum projection above the ground, site grading will be necessary to assure that the dimension would not be more than 1 1/2" to 1" respectively. Installing Posts 1 and 2 with Groundline Strut Figure 5 shows the above ground details and Figure 6 shows the section at post locations 1 and 2. Posts 1 and 2 may be installed with either long split foundation tubes (S730) without soil plates, solid long foundation tubes (E731) without soil plates, standard long foundation tubes (S735) with soil plates (SP600) or long foundation tubes (E735) with soil plates (SP600). Figure 7 shows the optional or foundation tubes with soil plates. For the long split foundation tube, fasten one 5/8? 7-1/2" hex head bolt (B580754) and H.G.R. nut (N050) through the bottom hole of the foundation tube. Do not over tighten and deform the tube. The belt is intended to stop the post from sliding all the way into the tube during installation. Do not drive the foundation tube with wood post inserted. If the soil is penetrable so that the foundation tube does not deform, the foundation tube may be driven with an approved driving head. For non-penetrable soil, drill a 6? pilot hole and force the tube to the appropriate depth by impact or vibratory means with an approved driving head. The tube may also be installed by augering and back?lling if the contractor so prefers. The initial hole must be large enough to allow adequate room for proper compaction of the soil during back?ll. Care must be taken to carefully compact the bach?ll to prevent settlement or lateral displacement of the foundation tubes. If rock is encountered, refer to appropriate State speci?cations. Guidelines will vary from State to State. The top of the foundation tubes should not project more than 4? above the ground line when measured along a 5? cord, according to AASHTO speci?cations (see Figure 4). The installation procedure for the solid long foundation tubes without soil plates is the same as that for the split foundation tubes. The installation for the standard long foundation tubes with soil plates or the standard long foundation tubes with soil plates is shown in Figure 7. Fasten the soil plate to the foundation tube with two 5/8? 7-1/2" hex head bolts (B580754) and H.G.R. nuts (N050) through the bottom holes of the foundation tubes. Do not over tighten and deform the tubes. These bolts attach the soil plate to the foundation tube and stop the post from sliding all the way into the tube during installation. Insert the pipe sleeve (E740) into the 2 1/2" diameter hole near the base of the 5-1/2" 7-1/2" 45? wood post (P650) and install the post in the foundation tube at post location 1. Install the second 5-1/2" 7-1/2" 45" wood post in the foundation tube at post location 2, and ?t the groundline strut (E780) between the two posts. Secure the post to each foundation tube with a 5/8? 10" hex head bolt (B581004) and H.G.R. nut (N 050) with a washer (W 050) under both the bolt head and the nut. These bolts will serve to secure the posts and attach the groundline strut to the foundation tubes, as shown in Figure 6. NOTE that there is no Bolt at Post#1 Cable Anchor Box w/shoulder bolts, structural nuts, washers 5/8" 95 x10" H.G.R. Bolt Ra? exH on traffic side Bearing Plat Pipe Sleev . Ground Line Cable Strut Anchor Box Assembly Figure 5. Above-Ground Details at Post Locations 1 and 2. Breakaway 1" Timber Post Hex Nut 5/8" it 10" 86 Washer BCT Cable Lg- ng. Bolt Anchor Assy l__7_50" w/ H.G.R. Nut 8: (1) Washer under Nut only Pipe Sleeve GROUND LINE 8 {3 5/8 Bearmg Plate Ground Strut ll 3, 10? 5/8 a 10 Hex Head Bolt Hex Head Bolt Nut \6n 8? 1/8" 6: 8C Nut (2) Washers Soil Tube 5/8" 7 1/2" Hex Head Bolt PARTIAL VIEW SECTION H.G.R. Nut at Post #1 at Post #2 Note. The optional long split foundation tubes may be substituted with either solid long foundation tubes without soil plates or stande or long foundation tubes with soil plates. Figure 6. Section at Post Locations 1 and 2. 10 . yew, unwr' E3 - urn A Deep Beam Guardrail 3/4" 9) Post Hale w/ 5/18" 9) 10," Bolt H.G.R. Nu?t w/ 1 5/8" OD. Washer under Nut only 5.5" 7.5" 45" Timber Post I 27?5 5/8? 10" Hex - Head Bolt 8: HGR 2 1/2" as Breakaway Nut Hole Washers .. .. 24" 18? 5/8 9? 7-1/2 Soil Plate Hex Bolt 8c 5 HGR 6" 8" Sail Tube TIMBER POST Figure 7. Optional or Foundation Tubes with Soil Plates 11 Installing Guardrail The required offset is achieved by ?rst splicing the guardrail panels together and then manually pushing the rails back. Shop curving or bending is not required. Attach the standard 12'-6" W?beam guardrail section with 6-3" post spacing (G1203) beginning at post 8 and spanning to post 6. Then attach the standard 12'-6" W?beam guardrail section with post spacing (F 1304) which will span from post 6 to post 3. Note that the rail is not bolted to post Attach the 12'-6" W?beam guardrail end section (F 1303) to span from post 3 to 1. Note that the impact head must be placed over the rail prior to tightening the rail to post 2. The rail is to be spliced with 5/8? 1-1/ H.G.R. bolts (B580122) and 5/8? H.G.R. nuts (N050). For ease of installation, it is recommended to have the eight 1/2" cable anchor bracket shoulder bolts (SB58A) and the cable anchor bracket (S760) attached to the W-beam guardrail end section prior to attaching the guardrail to the posts. See Section on ?Installing Cable Anchor Bracket? for details. The rails are to be attached to posts and blockouts at post locations 4 through 7 with 5/8" 18" H.G.R. bolts (B581802) and nuts (N050). At post location 3. the raiLiinot bolted to the post. The bolt only holds the blockout to the post. There is no blockout on posts 1 and 2, and the rail is attached to post 2 only with a 5/8" 10" H.G.R. bolt (B581002). Note that no bolt is used at post Be sure to place a 5/8" ?at washer (W050) on the backside of posts 2 through 7 under each nut (N050). NOTE: After the blockout is attached, drive a galvanized steel 10d common nail through the block and into the post (toe nailed) to prevent rotation if the wood shrinks. Installing Cable Anchor Bracket For ease of installation, it is recommended to have the eight 1/2" cable anchor bracket shoulder bolts (SBS 8A) and the cable anchor bracket (S760) attached to the W-beam guardrail end section prior to attaching the guardrail to the posts. If this procedure is not followed, Post #2 may interfere with attaching the bracket. The eight 1/ cable anchor bracket shoulder bolts (SB58A) are attached to the W?beam guardrail end section with two 1-1/ 16" 0D 9/ 16" ID structural washers (W05 0A), one on each side of the guardrail, and a 1/ structural nut (N055A). The shoulders of the bolts should be on the backside of the guardrail, away from tra?ic, as shown in Figure 8. A For ease of installation, attach the cable anchor bracket shoulder bolts to the rail "?nger tight" only. Then align the slots on the cable anchor bracket (S760) with the shoulder bolts and tap the cable anchor bracket onto the shoulder portion of the bolts using a hammer. Tighten the bolts with a wrench when the bracket is in place. When installed properly, the welded plate on the cable anchor bracket should be toward Post as shown in Figure 9. 12 ?llE?i?L u' "in u- SPECIAL SHOULDER 1/2? 1-1/4? W-BEAM RAIL A325 STURCTURAL BOLTS 1/2? STRUCTURAL <22> NUTS 1*1/16" 9/16" TD. STRUCTURAL WASHERS ON BOTH SDES OF Wfi?f? Figure 9. Installation of Cable Anchor Bracket. 13 Installing the FLEAT 350 Impact Head The eight cable anchor bracket shoulder bolts and the cable anchor bracket should be attached to the W?beam guardrail end section prior to attaching the FLEAT 350 impact head to the ?rst post with lag screws. Prior to tightening the rail to post 2, place the impact head (F3000) with the guide chute over the end of the W?beam guardrail. The exit slot will be toward the traf?c side. The impact head should be positioned so that the protruding tube is on the backside of the guardrail, away from traffic as shown in Figure 2 and Figure 5. Slide the impact head forward until the post angle attachments on the impact head are aligned with the side of the ?rst post. This is the side facing post Attach the impact head to the ?rst post with two 3/8" 3" lag screws (E350), one each for the top and bottom post angle attachments. A 1/4" pilot hole is required to avoid breaking the lag screw. Note. It is recommended that the face of the impact head be delineated with an object marker that meets State speci?cations for better night visibility. However, the impact face object marker is not included as part of the shipped materials for the FLEAT 350 unless speci?cally requested in the contract plans. Installing Cable Assembly Place the cable assembly (E770) through the cable anchor bracket and through the sleeve of post 1. Place the bearing plate (E750) at the base of post 1 with 5" dimension up and 3" dimension down. Place a nail over the bearing plate to prevent the plate from rotating. Secure both ends of the cable assembly with a 1" hex nut (N100) and washer (W100). While tightening cable, use a 2-lb hammer to tap the cable anchor bracket from the end to ensure that it is securely interlocked with the bolts. Restrain the cable at the end being tightened to avoid twisting the cable. Upon completion of the installation, the cable should be taut and the cable anchor bracket should be fully seated on the shoulder portion of the cable anchor bolts. It is very important that the cable anchor bracket be fully seated on the shoulder portion of the cable anchor bolts. 14 FLEAT 350 Installation Checklist State: Date: Project Location: El El El El The rail height is in accordance with the plans (generally 27-3/ above the edge of the shoulder). The rail at post #1 is placed at a straight ?are (offset between 2-6" over the 37 terminal length. The rail is not attached to the post at post location #3 or post location The foundation tubes do not protrude more than 4? above the ground line (measured by the AASHTO 5? cord method). Site grading may be necessary to meet this requirement. The bolts at the top of the foundation tubes are not over-tightened, deforming the walls of the tubes. The guide chute of the impact head is parallel to the top of the rail and the exit slot of the impact head is facing traf?c. The two lag screws holding the impact head to post 1 are snug. The 8? 8? bearing plate at post 1 is correctly positioned with the 5" dimension up the 3" dimension down. The anchor cable is taut and correctly installed. A nail has been placed over the bearing plate to prevent rotation. The cable anchor bracket shoulder bolts are properly attached to the W?beam guardrail and the cable anchor bracket is ?Jlly seated on the shoulder portion of the bolts. Posts #1 and #2 are installed in foundation tubes and have the 2-1/2" breakaway hole located parallel to the roadway with the bottom of the hole at the top of the tube. CRT posts at locations 3 through 7 have two 3-1/2" breakaway holes (checked prior to installation) located parallel to the roadway with the center of the top hole located at the ground line. If the posts were augered, be sure the back?ll material around the posts is compacted. No washers are used on the face of the rail except at the cable anchor bracket bolts. Additional notes: Inspection performed by: 15 Repairing the FLEAT 350 Eguipment Needed for Repair Operation Acetylene torch to cut the damaged rail, S.A.E. wrench or socket sizes 9/16", 15/16", and 1?1/ Vice grip or channel lock pliers, Sledge hammer, Post remover tool (see Figures 10 and 11), Other normal guardrail tools. General Repair Procedures After an end-on impact occurs with the FLEAT 350, it will normally require replacement of the 12'-6? end section of rail and any other damaged rail section(s), any broken post(s) and potentially the impact head. For a traf?c face impact, the damage will be to the rail section(s) and associated posts. The general step-by?step procedure for repairing a damaged FLEAT 350 terminal is as follows: (1) (2) (3) (4) (5) (6) (7) Check the impact head for damage. Check the cable anchor bracket and cable assembly for damage. The bearing plate, nuts, washers, cable anchor bracket, and the special cable anchor bracket shoulder bolts are rarely damaged. Check the number of broken posts and wood blockouts that need to be replaced, along with any damaged bolts. Inventory and pick up the reusable parts. Torch 01f the kinked rail near the outlet of the impact head. The impact head should be able to be removed by hand at this point. If not, the impact head is probably not reusable. Disconnect and remove the damaged rail ?'om the posts. Remove the broken posts from the foundation tubes using one of the two post removal tools (see Figures 10 and 11) assembled ?om "off the shelfhardware" items. Pound the steel pipe or screw the lag screw into the top of the broken post stub and remove the remains of the broken post by pulling on the chainlever if necessary. Reinstall the system following the procedures listed in this manual. 16 Procedures Immediately Following an Accident (Temporary) If no repair parts are readily available immediately following an accident, the following procedure should be used to provide temporary protection of the guardrail end. It should be noted that this repair is only for temporary purposes, and the anchor cable cannot be installed to provide tension in the rail for redirectional impacts. (1) (2) (3) (4) (5) (6) Remove damaged rail and impact head from the roadway or shoulder area. Using an acetylene torch, cut the kinked rail off at the outlet of the impact head and inspect the head for any damage. Remove the impact head by hand. I Locate the first post of any damaged rail and cut this rail off about 9" in front of the post. If the post is at a splice, simply unbolt the damaged rail. Install the impact head on the rail and attach it to the post with lag bolts. Warning signs should be used where appropriate. 17 3/16' CHAN (121) 3/5' 2-1/2' HEX BOLT NUT (THRU 1/2" a HOLE) 1-1/2" STD PIPE CAP 1?1/2" STD PIPE 6" 12":l: 1?1/2" STD COUPLING 1-1/2' STD COMBINATION NIPPLE (BARBED HOSE CONNECTION) Figure 10. Wood Post Pulling Tool (Pipe Option) 3/16? CHAIN 3/8 ?9 4" 0R 5' LAG BOLT w/ WASHER WOOD POST IN TUBE Figure 11. Wood Post Pulling Tool (Lag Screw Option) 18 INSTALLATION MANUAL TANGENT NCH RP 350 TL-3 Redirective, Gating, End Terminal BARRIER BY LINDSAY TABLE OF CONTENTS Installation Manual X-LITE TANGENT END TERMINAL Preface -------------------------------------------------------------------------------------------- 3 System Overview -------------------------------------------------------------------------------- 3 Before Installation -------------------------------------------------------------------------------- 3 Limitations and Warnings ----------------------------------------------------------------------- 3 Preparation -------------------------------------------------------------------------------------- 4 Soil Conditions ---------------------------------------------------------------------------------- 4 Before Starting ----------------------------------------------------------------------------------- 4 Required Tools -------- --------------------------------------------------------------------------- 4 Limited Warranty -------------------------------------------------------------------------------- 5 Parts Identification ------------------------------------------------------------------------------- 6 Step 1 - Assembling Components -------------------------------------------------------------- 8 Step 2 - Post and Blockout Installation -------------------------------------------------------- 10 Step 3 - Install Ground Strut Assembly -------------------------------------------------------- 13 Step 4 - Hang Rails ------------------------------------------------------------------------------- 14 Step 5 - Install Impact Head --------------------------------------------------------------------- 17 Final Inspection Checklist ----------------------------------------------------------------------- 20 APPENDICES Appendix A - System Configuration Drawings ------------------------------------------------- 21 2 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 X-LITE­® TANGENT END TERMINAL Preface The X-Lite Guardrail End Terminal Tangent System incorporates the latest roadside safety technologies and engineering processes. As with any roadside safety device, the X-Lite System must be installed in accordance with the manufacturer’s specifications to ensure proper performance. Thoroughly review and fully understand the installation instructions and product limitations before starting the installation. Do not start the installation without the proper plans and tools required. System Overview The X-Lite System is a re-directive, gating end terminal designed for shielding the ends of guardrail systems. The system offers exceptional vehicle control, energy absorbing capabilities in head on impacts, and is re-directive starting at post 3. The X-Lite is comprised of a head unit, specially designed crimped posts, tension rods, cable assembly, slider assembly, and other standard guardrail components. Before Installation Placement and use of the X-Lite System should be done in accordance with the guidelines and recommendations set forth in the “AASHTO Roadside Design Guide,” FHWA memoranda, and other state and local standards. Limitations and Warnings The X-Lite System has been rigorously tested and evaluated per the recommendations in the National Cooperative Highway Research Program Report 350 (NCHRP Report 350) guidelines for end terminals and crash cushions. The impact conditions recommended in NCHRP Report 350 are intended to address inservice collisions. When properly installed and maintained, the system is capable of stopping, containing, and re-directing impacting vehicles in a predictable and safe manner under NCHRP Report 350 impact conditions. Vehicle impacts that vary from the NCHRP Report 350 impact conditions for gating, re-directive end terminals may result significantly different than those experienced in testing. Vehicle impact characteristics different than or in excess of those encountered in NCHRP Report 350 testing (speed and angle) may result in system performance that may not meet NCHRP Report 350 evaluation criteria. If you need additional information, or have questions about the X-Lite System, please call the Lindsay Transportation Solutions Customer Service Department at (888) 800-3691 (U.S. toll free) or (707) 374-6800. Depending on the application and the circumstances at the site, installation should take an experienced two person crew with proper tools approximately two hours to complete. The X-Lite System is a highly engineered safety device made up of a relatively small number of parts. It is available in both tangent and flared versions. Before starting installation ensure that one is familiar with the make up of the system that is being installed. Prior to installation, ensure that proper manuals and components are on site. Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 3 INSTALLATION MANUAL Preparation Before installing the X-Lite System, ensure that all materials required for the system are on site and have been identified. Soil Conditions The X-Lite has been designed to be installed in soil that meets or exceeds the AASHTO “standard soil” specification. If rock or stiff soil is encountered, the posts may be installed by augering and backfilling the hole. Extra care must be taken to prevent settlement or lateral displacement of the post. Backfill material shall be compacted to optimum compaction. Before Starting For all applications, begin the installation from the trailing / back end of the system where it joins the standard guardrail system at post 7. TRAILING / BACK APPROACH / FRONT The picture of the X-Lite System above illustrates how the System is referred to throughout this manual. Required Tools The system uses standard tools required to install typical guardrail; the list below is a general recommendation. • • • • • • • • • • • • • • • Post driver Tape measure String line Hammer Stakes Pry Bar Crescent Wrench Vice Grips or Clamps 1-5/8” [42 mm] Wrench ½” Ratchet 1-1/4” [32 mm] Socket Air Impact Wrench (Optional) Pick Axe Pipe Wrench or Large Pliers Torque wrench (capable of applying 60 ft. lbs. torque) Required Tools Note: The tools list is a general recommendation. Depending on the specific characteristics of the job site, more or less tools may be necessary. The tools listed are for US/Imperial fasteners. If metric hardware is used, use metric equivalents for the hardware as required. 4 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 X-LITE­® TANGENT END TERMINAL STANDARD LIMITED WARRANTY Lindsay Transportation Solutions, Inc. “LTS” ( formerly Barrier Systems ) has tested the impact performance of its barriers and crash cushion systems, and other highway safety hardware under controlled conditions, however, LTS does not represent nor warrant that the results of those controlled conditions would necessarily avoid injury to persons or property. LTS EXPRESSLY DISCLAIMS ANY WARRANTY OR LIABILITY FOR CLAIMS ARISING BY REASONS OF DEATH OR PERSONAL INJURY OR DAMAGE TO PROPERTY RESULTING FROM ANY IMPACT, COLLISION OR HARMFUL CONTACT WITH THE PRODUCTS OR NEARBY HAZARDS OR OBJECTS BY ANY VEHICLE, OBJECTS OR PERSONS. LTS warrants that any product or component part manufactured by LTS will be free from defects in material or workmanship. LTS will replace free of cost any Product or component part manufactured by LTS that contains such a defect. THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES NOT EXPRESSLY SET FORTH HEREIN, WHETHER EXPRESS OR IMPLIED BY OPERATION OF LAW OR OTHERWISE, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. LTS’ LIABILITY UNDER THIS WARRANTY IS EXPRESSLY LIMITED TO REPLACEMENT FREE OF COST (IN THE FORM AND UNDER THE TERMS ORIGINALLY SHIPPED), OR TO REPAIR OR TO MANUFACTURE BY LTS, PRODUCTS OR PARTS NOT COMPLYING WITH LTS SPECIFICATIONS, OR, AT LTS’ ELECTION, TO THE REPAYMENT OF AN AMOUNT EQUAL TO THE PURCHASE PRICE OF SUCH PRODUCTS OR PARTS, WHETHER SUCH CLAIMS ARE FOR BREACH OF WARRANTY OR NEGLIGENCE. LTS SHALL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL LOSSES, DAMAGES OR EXPENSES OF ANY KIND, INCLUDING, WITHOUT LIMITATION, ANY SUCH LOSSES, DAMAGES OR EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM THE SALE, HANDLING OR USE OF THE PRODUCTS FROM ANY OTHER CAUSE RELATING THERETO, OR FROM PERSONAL INJURY OR LOSS OF PROFIT. Any claim by the Buyer with reference to Products sold hereunder for any cause shall be deemed waived by the Buyer unless LTS is notified in writing, in the case of defects apparent on visual inspection, within ninety (90) days from the delivery date, or, in the case of defects not apparent on visual inspection, within twelve (12) months from the said delivery date. Products claimed to be defective may be returned prepaid to LTS’ plant for inspection in accordance with return shipping instructions that LTS shall furnish to the Buyer forthwith upon receipt of the Buyer’s notice of claim. If the claim is established, LTS will reimburse that Buyer for all carriage costs incurred hereunder. The forgoing warranty benefits shall not apply to (i) any Products that have been subject to improper storage, accident, misuse or unauthorized alterations, or that have not been installed, operated and maintained in accordance with approved procedures and (ii) any components manufactured by the Buyer. W030587 Rev. 8 revised February 4, 2013 180 River Road • Rio Vista, CA 94571 • Tel. +1 (707) 374-6800 • Fax. +1 (707) 374-6801 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 5 INSTALLATION MANUAL Parts Identification A Complete Bill of Materials for Systems and Kits Can be Found in Appendix A Crimp Post #1 (QTY. 1) BSI-1310024-00 Crimp Post # 3 (QTY. 1) BSI-1310027-00 Post II BSI-1012086-00 Line Post (QTY. 3)* BSI-1012078-00 Impact Head BSI-1012103-00 Slider Panel (Front) BSI-1012093-00 Slider Panel (Back) BSI-1012096-00 Slider Bracket BSI-1012090-00 Ground Strut BSI-1012097-00 (QTY. 2), Nut 4001116 (QTY. 4), Angle BSI-1012098-00 (QTY. 1) Cable Anchor Assembly BSI-1012104-00 Shear Bolt Kits (8 Yellow Bolts per Kit) K080123 Square Washer (Used on Post 1) BSI-1102027-00 * Denotes Shipped With Full System Only 6 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 X-LITE­® TANGENT END TERMINAL Parts Identification A Complete Bill of Materials for Systems and Kits Can be Found in Appendix A Blockouts (QTY. 4)* B090534 Guardrail Bolts (QTY. 16)* 4001115 5/8” x 2” Guardrail Bolt (For Post 1 & 2) (QTY. 2)* 2001758 5/8” x 10” Guardrail Bolt (QTY. 4)* 2001840 Guardrail Nut (QTY. 22)* 4001116 1” Washer (For Slider Panel-Back & Cable Assy.)* (QTY. 2) 2001580 W-Beam Guardrail (QTY. 3)* 4000443 Soil Plate BSI-1312100-00 5/8” x 3 ½” Bolt (Used on Soil Plate) (QTY. 2) 2000220 5/8” Washer (Used on Soil Plate) (QTY. 4) 2001636 5/8” Nut (Used on Soil Plate) (QTY. 2) 2000312 L-Bracket (used on cable at Post 2) BSI-1303005-00 * Denotes Shipped With Full System Only Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 7 INSTALLATION MANUAL Step 1 – Assembling Components Notes: Components required: • (1) Post II – BSI-1012086-00 • (1) Soil Plate – BSI-1312100-00 • (2) W-Beam – 4000443 • (1) Slider Panel (Front)– BSI-1012093-00 • (1) Slider Bracket – BSI-1012090-00 Hardware Required: • (2) 5/8” x 3 ½” Bolt - 2000220 • (8) 5/8” x 1 ¼” Guardrail Bolt - 4001115 • (4) 5/8” Washer - 2001636 • (2) 5/8” Nut - 2000312 • (8) 5/8” Guardrail Nut - 4001116 Some components require assembly and it is recommended that this step be completed prior to the start of the system assembly. Open Slots Post II Assembly: 1. Attach the soil plate to the trailing / back side of Post II using two (2) 5/8” x 3 ½” bolts, washers (4), and nuts (2). The trailing / back end of the post is identified by the open slots on the top of the post. The bolts should be installed from back to front so that the head of the bolts rests on the soil plate. Depending on your post driver equipment, Post 2 may need to be partially driven before this step can be accomplished. 8 Trailing / Back Attach Soil Plate to Post II Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 X-LITE­® TANGENT END TERMINAL Slider Bracket and Panel Assembly: 2. Attach the slider bracket to the inside of the approach / front end of rail 2 using four (4) 5/8” x 1 ¼” guardrail bolts. Bolts should be installed with the bolt head on the outside and the nuts the inside. Note: When properly installed, a portion of the bracket will stick out of the rail. Attach Slider Bracket to Rail 2. 3. Attach the Slider Panel (Front) to the outside of the trailing / back end of rail 1 using four (4) 5/8” x 1 ¼” guardrail bolts. Bolts should be installed with the bolt head on the inside and the nuts on the outside. The angled portion of the Slider Panel should extend beyond the end of the rail and should face the trailing / back of the system when assembled in step 18. Attach Slider Panel (Front) to Rail 1. Angled Portion Extends Beyond the End of the Rail. Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 9 INSTALLATION MANUAL Step 2 – Post and Blockout Installation Components required: • (1) Crimp Post w/ Slots (Post 1) - BSI-1310024-00 • (1) Crimp Post w/ Holes (Post 3) - BSI-1310027-00 • (1) Post II Assembly with Soil Plate • (3) Line Post – BSI-1012078-00 • (4) Blockout – B090534 • (1) Slider Panel (Back) – BSI-1012096-00 Notes: 4 POST 7 D 2 POST 6 POST 5 POST 6 POST 5 POST 4 194 7 5/8" POST POST 3 POST 2 POST 1 POST 1 AND 2 NO BLOCKOUT Post Identification POST 7 Always start the installation at the existing w – beam barrier and assemble the system toward the impact head. POST 6 POST 5 POST 4 POST 3 POST 2 POST 1 RAIL DOES NOT ATTACH TO POSTS 3 OR 5 REFERENCE�DIMEN RAIL�HEI A B HEAD�HE C POST�HE A 4. Begin by running a string line from the existing posts in a tangent position. SIZE B SCALE Doc. B100108 4 3 Existing Trailing / Back Guardrail Note: The X-LITE can be installed with an offset of 0 - 24” (0 - 600 mm) over the length of the system. Note: The front of posts 3-6 will be 7 5/8” (195mm) from the backside of rails 2 and 3 as blockouts are used. Posts 1 and 2 do not require blockouts and will align with the backside of rail 1. Post 3 requires up to an additional 2” (50mm) offset away from the rail to allow space for the slider assembly. (See Step 5.) Post Layout 10 POST 3 C B When driving the posts into stiff/rocky soil, place close attention not to bend the posts. If rock or stiff soil is encountered, the posts may be installed by augering and backfilling the holes. Extra care must be taken to prevent settlement or lateral displacement of the post. Backfill material shall be compacted to optimum compaction. POST 4 GROUND STRUT ASSEMBLY BETWEEN PSOTS 1 A POST 7 Hardware Required: • (2) 5/8” x 10” Guardrail Bolt - 2001840 • (2) 5/8” Guardrail Nut - 4001116 • (1) 1” Washer - 2001580 3 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 2 DWG NO. 1:50 B X-LITE­® TANGENT END TERMINAL 5. Begin installing the posts at standard highway post spacing, 75” (1905mm) and post height, 28 1/4” (720mm) or 31 3/4” (805mm).. Post spacing and post height are found on drawing BSI-1012105-00 in Appendix A. Post 4-6: Line Posts Note: if you are installing a 50 FT. system, the systems will have an additional 2 posts and an additional section of guardrail. Please reference Appendix A for detail of a 50 FT. system. Post 3: Crimped Post Offset Post 3, up to 2” (50mm) back from the string line to allow sufficient space for the slider bracket assembly. Post 3 is identified by the post having a crimp and holes on one side of the post only. These holes are used to mount the blockout and slider panel (back) on a later step. In addition, Post 3 can be easily identified by having black paint near the bottom. Post 2: Post II Assembly with Soil Plate Soil Plate should be on the trailing / back side of the system. Post 3 Offset Post 2 does not require a blockout, therefore, align the post with the backside of the rail. Position the outside edge of the post roughly 8” (200mm) from the string line on the rail side of the string. Depending on your post driver equipment, it may be necessary to partially drive Post 2 prior to attaching the Soil Plate. Begin to drive Post 2 approximately 18” (450mm), more if necessary. If the post is driven more than 18” (450mm) it will be necessary to use a pick ax or other digging tool to remove some of the soil in order to install the soil plate. Once the soil plate is installed, continue driving the post to the desired height. Trailing / Back It may be necessary to remove / dig out some soil in order to install the Soil Plate Drive Post 2 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 11 INSTALLATION MANUAL Open Slots Post 1: Crimped Post Post 1 does not require a blockout, therefore, align the post with the backside of the rail. Position post roughly 2” (50mm) from the string line on the rail side of the string. Post 1 is identified by the post having a crimp and slots instead of holes. These slots are used to bolt the guardrail on a later step. In addition, Post 1 can be easily identified by having yellow paint near the bottom. 6. Install blockouts on posts 3-6. Blockouts at posts 3 and 5 must be bolted on before hanging the rails. 4 3 POST 7 2 POST 6 POST 5 POST 4 POST 3 Installed Posts POST 2 7. At post 5, attach the blockout using the 5/8” x 10” bolt. Secure blockout using the approach / front hole on the post. The rail does not attach at post 5. D 1 POST 1 D GROUND STRUT ASSEMBLY BETWEEN PSOTS 1 AND 2 POST 7 POST 6 POST 5 POST 4 POST 3 POST 2 POST 1 C C See diagram below for post identification. 194 7 5/8" POST 7 POST 6 POST 1 AND 2 NO BLOCKOUT POST 5 POST 4 POST 3 B POST 2 POST 1 B RAIL DOES NOT ATTACH TO POSTS 3 OR 5 SYSTEM�HEIGHT�DIMENSIONS REFERENCE�DIMENSIONS INCHES MM INCHES RAIL�HEIGHT 27�5/8 700 A 31 OR B HEAD�HEIGHT 33�3/8 850 36�7/8 C POST�HEIGHT 28�1/4 720 31�3/4 A SIZE B SCALE Doc. B100108 4 3 2 8. At post 3, attach blockout and slider panel (back) using the 5/8” x 10” bolt and 1” washer. The slot on the slider panel should point toward the front of the system. Secure blockout using the approach / front hole on the post. DWG NO. 1:50 Approach / Front Install Blockout at Post 5 BSI-1012105-00 B MM 790 935 805 A REV. SHEET 1 2 OF 2 Arrow should point to front of system. Blockouts at posts 4 and 6 are secured when the rail is bolted to the posts. Approach / Front Ensure the 1” washer is used here. Slider Panel (Back) and Blockout on Post 3 12 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 X-LITE­® TANGENT END TERMINAL Step 3 – Install Ground Strut Assembly Components required: • (2) Ground Strut Tension Rods – BSI-1012097-00 • (1) Ground Strut Angle – BSI-1012098-00 Hardware Required: • (4) 5/8” Guardrail Nut - 4001116 9. Install ground strut tension rods between posts 1 and 2 by sliding the rods through the openings on the bottom of post 2. 3 POST 7 2 POST 6 POST 5 POST 4 1 POST 3 POST 2 POST 1 D Ground Strut Tension Rods Installed at Post 2 GROUND STRUT ASSEMBLY BETWEEN PSOTS 1 AND 2 T6 POST 5 194 7 5/8" POST 6 POST 4 POST 3 POST 2 POST 1 C 10. Secure the rods at post 1 by passing the rods through the small piece of angle with the angle sitting flush on the ground, just above the crimp on the post. POST 1 AND 2 NO BLOCKOUT POST 5 POST 4 POST 3 POST 2 POST 1 B The small piece of angle will sit flush with the ground on 28” systems only. On 31” height systems, the small piece of angle will sit approximately 3” (75mm) off the ground. RAIL DOES NOT ATTACH TO POSTS 3 OR 5 SYSTEM�HEIGHT�DIMENSIONS REFERENCE�DIMENSIONS INCHES MM INCHES RAIL�HEIGHT 27�5/8 700 A 31 OR B HEAD�HEIGHT 33�3/8 850 36�7/8 C POST�HEIGHT 28�1/4 720 31�3/4 SIZE B SCALE 3 2 DWG NO. BSI-1012105-00 SHEET 1:50 1 MM 790 935 805 A REV. 2 OF 2 B Ground Strut Tension Rods Attached at Post 1 11. Tighten the rods so that there are equal amount of threads exposed at both ends of the rods. Nuts Tightened on Ground Strut Tension Rods Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 13 INSTALLATION MANUAL Step 4 – Hang Rails Notes: Components required: • (3) W-Beam Guardrail - 4000443** 4 Hardware Required: • (2) 5/8” x 10” Guardrail Bolt -2001840 • (4) 5/8” x 1 ¼” Guardrail Bolt - 4001115 • (2) 5/8” x 2” Guardrail Bolt - 2001758 • (16) Shear Bolts – K080123 (Kit of 8; 2 Required) • (5) 5/8” Guardrail Nut - 4001116 • (1) 5/8” Nut - 2000468 • (1) Square Washer – BSI-1102027-00 3 2 D C POST 7 POST 6 Rail 3 POST 5 POST 4 POST 3 Rail 2 POST 2 POST 1 Rail 1 Post Identification If installing a 50 ft system, the system uses 4 sections of rail in stead of 3. B If you are attaching to an MGS rail system, a transition guardrail panel is necessary. A Please reference Appendix A for 50 ft. or MGS system details. Doc. B100108 Note: For the system to telescope properly, the forward most guardrail panel should always be on the outside. 12. Before installing rail 3 ensure that the blockout at post 5 has already been bolted on. Attach rail 3 using the 5/8” x 10” bolt at post 6, pass bolt through the approach / front hole of post. SIZE B SCALE 4 3 2 Approach / Front Attach Rails to Posts Note: Rail 3 is not attached to Post 5 13. Splice rail 3 with the existing rail using the special yellow shear bolts. DO NOT USE AN AIR IMPACT WRENCH TO TIGHTEN SHEAR BOLTS. Ensure that the 10” bolt used secure the rail and blockout passes through both sections of guardrail, blockout and post. Shear Bolts at Rail 3 and 4 Connection 14 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 DWG NO. 1:50 BS X-LITE­® TANGENT END TERMINAL 14. Before installing rail 2 ensure that the blockout and slider panel (back) at post 3 has already been bolted on. Attach rail 2 using the 5/8” x 10” bolt at post 4, pass bolt through the approach / front hole of post. Approach / Front Attach Rail 2 at Post 4 15. Splice rail 2 with rail 3 using the special yellow shear bolts. The rails do not attach to post 5. DO NOT USE AND AIR IMPACT WRENCH TO TIGHTEN SHEAR BOLTS. Shear Bolts at Rail 2 and Connection 16. Attach rail 1 using the 5/8” x 2” guardrail bolt at post 2, pass bolt through the trailing / back slot of post. 17. Connect rails 1 and 2 using 5/8” x 1 ¼” guardrail bolts by connecting the slider panel assembly (front and back parts together). Ensure that the angled portion of the Slider Panel points toward the trailing / back end of the system. Connect Rails 1 and 2 at Slider Assembly Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 15 INSTALLATION MANUAL 18. Install the bolts from back to front with the nuts on the front side. Arrow should point to front of system. Angled portion to point trailing / back Slider Panel Assembly Installed 19. Attach rail 1 to post 1 using the 5/8” x 2” bolt and square washer, pass bolt through the approach / front slot of post. Use square washer here. Attach Rail 1 at Post 1 All Rails Installed 16 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 X-LITE­® TANGENT END TERMINAL Step 5 – Install Impact Head Notes: Components required: • (1) Impact Head – BSI-1012103-00 Hardware Required: • (4) 5/8” x 1 ¼” Guardrail Bolt - 4001115 • (4) 5/8” Guardrail Nut - 4001116 20. Install Impact Head to the approach / front end of rail 1 using 5/8” x 1 ¼” guardrail bolts. Place Impact Head on the outside of the rail. Install Impact Head at the End of Rail 1 21. Install bolts from outside in with nuts on the inside. Impact Head Installed Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 17 INSTALLATION MANUAL Step 6 – Install Cable Notes: Components required: • (1) Cable – BSI-1012104-00 • (1) 1” Washer - 2001580 • (1) L-Bracket - BSI-1301005-00 The cable is attached to the bottom of post 2 and at the slider bracket at post 3. 22. Begin to install the cable by passing the threaded end through the slot at the bottom of post 2. Install L-Bracket Install Cable at Post 2 23. Thread the nut so that 1” of the threads are protruding. Ensure to install the small L-Shaped bracket and round washer included with the cable. This bracket and washer are critical components and help keep the cable engaged in the slot. Install L-Bracket and round washer here Proceed to thread the nut while not exposing any threads. This will ensure you can achieve the required to torque for the cable nut in a subsequent step. L-Bracket installed at Post 2 Prior to Tightening 18 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 X-LITE­® TANGENT END TERMINAL 24. Pass the other end of the cable through the slider bracket at post 3. Install the nut. Tightening of the cable should be done at the bottom of Post 2 in the following step. Install Trailing / Back End of Cable Through Bracket at Post 3 25. Tighten the cable nut at Post 2. It will be necessary to use a pipe wrench or large pliers on the backside of the cable to hold it in place while tightening. If the cable is not held in place with a pipe wrench or large pliers, it will spin while you attempt to tighten the cable and you will not be able to tighten it. Apply approximately 60 FT-Lb torque. Continue to tighten the cable nut until the cable is tight and the approximate torque is achieved. When tightening, ensure that the L-Bracket does not shift, turn and move out of position. Note: Standard BCT cables used on other systems may not require a specific torque on the cable nuts. The X-LITE® Tangent system requires a tensioned cable to maintain engagement in the slot on Post 2. Torque cable nut to 60 ft.-lb. at Post 2 If a torque wrench is not available, use the following method to ensure cable is adequately tensioned: Tighten cable nut until a maximum 1/2” cable deflection is measured at the midpoint when pressure is applied by hand. Cable Installed Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 19 INSTALLATION MANUAL Final Inspection Checklist Inspection Date Inspection By: Item Post 1 uses slotted holes Post 3, uses standard post holes Rail bolted at posts 1, 2, 4 and 6 only (7, 8 for 50 ft. system) Rails not bolted to posts at Posts 3 and 5 Square washer used at Post 1 Post 2, rail bolted using trailing / back slot on post Posts 1, 4, 6, rails bolted using approach / front hole on posts Rails 3 and 4 spliced using special yellow shear bolts Rails 2 and 3 spliced using special yellow shear bolts At Post 7, 10" bolt passes through both guardrail sections, blockout and post. Slider assembly properly assembled with bolts from back to front with nuts on the outside Angled position of Slider panel points toward the trailing / back end of the system. Arrows on slider should point toward the front of the system Cable bracket and washer installed on cable at Post 2 Approximately 60 ft.-lb. torque applied to cable nut at Post 2 No blockout on Post 1 or Post 2 Tangent installation or with allowable offset from 0 - 24” (0 600mm) over length of the system 20 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 22 A B C D 3X 3 IF ROCK IS ENCOUNTERED, THE SOIL PLATE MAY BE MODIFIED IF APPROVED BY THE PROJECT ENGINEER. 5. 4 IF ROCK OR STIFF SOIL IS ENCOUNTERED, THE POST AND SOIL PLATE MAY BE INSTALLED BY AUGERING AND BACKFILLING THE HOLE. EXTRA CARE MUST BE TAKEN TO PREVENT SETTLEMENT OR LATERAL DISPLACEMENT OF THE POST. BACKFILL MATERIAL SHALL BE COMPACTED TO OPTIMUM COMPACTION. 4. Doc. B100108 AFTER STEPS 1 & 2 SECURE FIRST AND SECOND W-BEAM GUARDRAIL PANEL USING ITEMS 7, 13 & 16. HEX NUTS TO BE ON TRAFFIC SIDE. 3. 5 16 13 4X 16 13 4X 37 PA NE L2 12 INSTALL SLIDER BRACKET (ITEM 6) TO SECOND W-BEAM GUARDRAIL PANEL USING ITEMS 13 & 16. 16 15 3 3 4 16 14 12 5 DRAWN DATE: APPR'D DATE: APPR'D BY: 2 4X 16 13 4X 32 2X 12 DECIMAL .XX = .03 .XXX = .010 ANGLES 1/2 F E REV 2/25/11 G ECN# 2162 2165 2220 2444 2253 I 2510 J H 2540 K 2 D 16 13 4X JMT DO NOT SCALE DRAWING THIRD ANGLE PROJECTION INTERPRET DIMENSIONS AND TOLERANCES PER ASME Y14.5-1994 FRACTIONS 1/16 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES. TOLERANCES ARE: 17 31 9 7 PA NE L1 34 2 1 DATE 10/28/13 11/13/13 01/24/14 03/25/14 10/03/14 11/12/14 SCALE SIZE 8 36 2X 1:30 DWG NO. B 33 B TITLE 4 A C 15 16 NOT SHOWN 12/15/14 DETAIL D SCALE 1 : 20 USE BOLT/NUT/WASHER (ITEMS 15/16/34) TO INSTALL SLIDER PANEL, BACK (ITEM 7), USE UPSTREAM BLOCKOUT (ITEM 12) TO CRIMPED HOLE POST (ITEM 1), DO NOT PASS BOLT THROUGH W-BEAM GUARDRAIL PANELS. 03/19/13 AEM APPROVALS © 2010 BARRIER SYSTEMS INC. THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF BARRIER SYSTEMS INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT THE WRITTEN PERMISSION OF BARRIER SYSTEMS INC. IS PROHIBITED. 16 15 DRAWN BY: 6 3 USE BOLT/NUT (ITEMS 15/16) TO INSTALL BLOCKOUT (ITEM 12) TO LINE POST (ITEM 3), DO NOT PASS BOLT THROUGH W-BEAM GUARDRAIL PANELS. 2. 3 INSTALL SLIDER PANEL, FRONT (ITEM 5) TO FIRST W-BEAM GUARDRAIL PANEL USING ITEMS 13 & 16. HEX NUTS TO BE ON TRAFFIC SIDE. 37 12 1. DETAIL A SCALE 1 : 8 [ 9 ] 35 34 PA NE L3 SHEAR BOLTS (ITEM 10) HEADS OF SHEAR BOLTS ON TRAFFIC SIDE. 16 15 18 4 11 1 XLTSUS SHEET C D DETAIL B SCALE 1 : 20 1 OF 2 REV. K A USE UPSTREAM B SLOT BARRIER SYSTEMS 180 River Road Rio Vista, CA 94571 Tel: 888-800-3691 www.barriersystemsinc.com DETAIL C SCALE 1 : 20 X-LITE SYSTEM ASSEMBLY TANGENT 19 14 16 USE DOWNSTREAM SLOT 1 INSTALLATION MANUAL Appendix A - System Configuration, 37’ 6” Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 A B C D Doc. B100108 DIM. 'A' RAIL HEIGHT 2 BEGIN STANDARD HIGHWAY W-BEAM GUARDRAIL 4 POST 7 DETAIL E (SCALE 1:20) 1 1905 75" 1905 75" E POST 4 DETAIL G (SCALE 1:20) 194 7 5/8" 1905 75" F POST 3 3 11430 37'-6" 1905 75" G POST 2 1905 75" 0" 75"+2" - 268 10 9/16" 2 0 1905-51 POST 1 AND 2 NO BLOCKOUT POST 2 1 POST 1 SCALE B SIZE 1:50 DWG NO. GROUND LINE DIM. 'B' HEAD HEIGHT 1 XLTSUS 552 21 3/4" SHEET POST 1 2 OF 2 DIM. 'C' POST HEIGHT POSTS 4, 5 AND 6 ARE IN LINE. OFFSET POST 3 FROM POST 4 PER DIMENSION SHOWN. OFFSET POSTS 2 AND 1 FROM POST 4 PER DIMENSION SHOWN. ALL DIMENSIONS ARE TO THE OUTSIDE FLANGE OF THE POSTS. POST 3 2 POST AND BLOCKOUT NOT CONNECTED TO W-BEAM GUARDRAIL PANEL 41 1 5/8" USE DOWNSTREAM SLOT TO SECURE RAIL TO POST 2 POST AND BLOCKOUT NOT CONNECTED TO W-BEAM GUARDRAIL PANEL 3 USE SHEAR BOLT KIT (ITEM 10) AT POST 5 POST 5 USE SHEAR BOLT KIT (ITEM 10) WHEN INSTALLING TO EXISTING W-BEAM GUARDRAIL AT POST 7 POST AND BLOCKOUT PROVIDED BY OTHERS POST 6 DETAIL F (SCALE 1:20) USE UPSTREAM HOLE TO SECURE BLOCKOUT TO POST 3 A MINIMUM OF 25 FT OF STANDARD W-BEAM GUARDRAIL IS REQUIRED DOWNSTREAM OF POST 7 PRIOR TO ANY TRANSITION OR ATTACHMENT TO RIGID BARRIER. 2. USE UPSTREAM HOLE TO SECURE BLOCKOUT TO POST 4, 5, 6 ENSURE GUARDRAIL BOLT IS BOLTED THROUGH BOTH GUARDRAIL PANELS, BLOCKOUT AND POST AT POST 7. 1. 4 K REV. A B C D X-LITE­® TANGENT END TERMINAL Appendix A - System Configuration, 37’ 6” Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 23 Lindsay Transportation Solutions Sales and Services, Inc. 180 River Road • Rio Vista, CA 94571 • +1 707.374.6800 U.S. Toll Free: 888.800.3691 • www.barrriersystemsinc.com Installation manual for the X-LITE Tangent System are subject to change without notice to reflect improvements and upgrades. Additional information is available from Lindsay Transportation Solutions Sales and Services, Inc. © Lindsay Transportation Solutions, Inc. X-LITE TANGENT INSTALLATION 01202015 v11 X-Tension ™ Redirective, Non-Gating Guardrail End Terminal • Contractor Friendly • Simple Installation • Meets NCHRP 350 TL-3 X-Tension™ Redirective, Non- Gating Terminal 1 2 3 4. 5. 6. 3 2 5 4 IMPACT HEAD SOIL ANCHOR CABLES X-TENSION POSTS STANDARD POSTS STANDARD GUARDRAIL 1 6 NCHRP 350 TL-3 Redirective, Non-Gating Guardrail end terminal The X-Tension Redirective, Non-Gating Terminal is the only Redirective, Non-Gating guardrail terminal in the market. The X-Tension Terminal has been engineered to X - T E N U A T O R beS used Y S Tinterchangeably E M S P E C for I Fflared I C Aand T Itangent O N S roadside applications. This results in significant savings in inventory, repair and maintenance costs. The X-Tension Terminal uses standard guardrail components and is available with either wood or steel posts and with either wood or composite blockouts. FEATURES • • • • • Only NCHRP 350 tested Redirective Non-Gating Guardrail Terminal available Available in 727 or 787mm [28.5 or 31”] heights Uses same components for tangent or flared applications Easy to install Utilizes many standard guardrail components PHYSICAL SPECIFICATIONS Length Width Height Weight Test Level 12 m [40’] 572 mm [22.5”] 727 / 787mm [28.5/31”] 534 kg [1179 lb] NCHRP 350 TL-3 WHERE TO USE Side of road where limited clear zone or excessive slope restricts the use of Redirective Gating terminals. REDIRECTIVE NON-GATING Frequently Asked Questions What makes the X-Tension Terminal different from the other end tERMINALs on the market? The X-Tension Terminal is tested to NCHRP 350 as a Redirective NonGating System. All other terminals are tested as Redirective Gating Systems, meaning they will only start to redirect at the third post. CAN the X-Tension Terminal BE ATTACHED TO CONCRETE BARRIER? The X-Tension Terminal can be attached to concrete barrier with the addition of standard transitions. IS A TRANSITION NEEDED TO ATTACH TO STANDARD GUARDRAIL? can the x-Tension Terminal be installed using composite The X-Tension Terminal is designed to attach directly to guardrail with blockouts? The x-Tension Terminal can be ordered with either wood or composite no transition required. blockouts. D I S T R I B U T E D B Y: The X-Tension Terminal can be installed either flared or tangent. General details for the X-Tension Terminal are subject to change without notice to reflect improvements and upgrades. Additional information is available from Barrier Systems, Inc. PT # PTXT03-100111 © Barrier Systems, Inc. 3333 VACAVALLEY PKWY, VACAVILLE, CA 95688 TEL. +1 707.374.6800 U.S. TOLL FREE 888.800.3691 W W W. B A R R I E R S Y S T E M S I N C . C O M X-Tension Guardrail Terminal End General Specifications I. Description The X-Tension guardrail terminal end is designed, manufacture and supplied by Barrier Systems Sales and Service LLC. The X-Tension is a Tangent, Flared, Median, fully redirective, non-gating terminal end which is energy absorbing. The X-Tension substantially consists of an impact head with a brake bar inside, a slider assembly and slider bracket, a cable anchor bracket, a foundation anchor assembly, ground strut, steel breakaway posts and three standard 12 gauge highway W-beam rails. The total length of the system is 11.4 meters and may be flared at the head end over the 11.4 meters, 0 - 1219mm / 0 – 4’ to the face of the rail. II. Performance A. The X-Tension is capable of redirecting vehicles of 820 to 2000Kg’s impacting the side of the system at an angle of up to 20 degrees and 100 KPH when impacting from the length of need. The length of need starts at post #1. B. When impacted end on with the 820 to 2000Kg vehicle at speeds of up to 100 KPH, the system is brought to a controlled stop or allowed to penetrate to the back side, depending on the impact conditions. C. In all end on impacts, varying amounts of energy are dissipated depending on the length of time the vehicle remains in contact with the impact head. D. During end on impacts the head, rail one and the slider, telescope over rail two until rail two comes to rest in the back of the impact head. At this point, the V notch bolts joining rail one and two are sheared allowing the entire rail one, head, slider and rail two assembly to slide over rail three. E. As the head is pushed down the two cables, the cables are pulled through the brake bar in a torturous path, which dissipates energy. III. Materials A. Impact Head The impact head shall be fabricated from hot rolled steel that is galvanized after fabrication in accordance with AS/NZS 4680. The hot rolled steel specification – ASM A36 , AS 3678-250, JISG3101 – SS400, BS4360 -43A. The impact head shall be attached to the end of rail one with 8 standard splice bolts reversed so that the nut is on the traffic face. The head contains the brake bar through which the cables are threaded before tightening the brake bar. B. Steel Line Posts These posts are fabricated from W6 x 13.5 standard I beam section. Standard specification for this section is AASHTO M270M (ASTM A 709M) grade 250steel. Posts #1 and #2 are crimped. Posts 3 – 6 are standard guardrail posts as per AASHTO PWE01, Wide Flange Post. C. Timber Block Outs Standard routed block outs H4 treated, Number one rough sawn pine. 5 block outs are required; Post #1 does not have a block out. D. Slider and Slider Bracket Shall be constructed from standard, 350 grade, guardrail and hot rolled steel of the same specification as the impact head. The slider is bolted to the downstream end of rail one with 4 standard splice bolts reversed so that the nuts are on the outside. The slider bracket is bolted with 4 splice bolts to the end of rail two in the usual manner. Once rail one is slid over rail two into its final position, the locking angle is bolted to the slider bracket. The combination of these two devices allows the rails to telescope when impacted end on and yet still maintain full ribbon strength in the rail during a redirect impact. Both components are to be hot dipped galvanized after fabrication. E. Cable Anchor Bracket The cable bracket is fabricated from hot rolled mild steel, 5mm thick, and attached to the back of the rail at the junction between rails 3 and 4. (Post 7). The bracket is attached using four centre splice bolts that are joining the rails. Bracket is also hot dip galvanized after fabrication. F. Cables Two cables are constructed using 19mm 3x7 strand galvanised cable complete with an M24 threaded rod swaged onto each end. The cables are attached to the ground anchor point, threaded through the impact head and brake bar, down the back of the W beam in the “hollows” and attached to the cable anchor bracket at the downstream end. The brake bar is then turned and locked into place before the cables are tightened. Cable specification, DSR Galvanized 320 / ASTM A-603 G. Foundation Anchor Foundation anchor consists of one C section anchor fabricated from mild steel channel and one I section anchor fabricated from the same section and specification as the Line Posts. The C section anchor shall be constructed from mild steel conforming to the following specifications ASM A36, AS 3678-300, JISG3101 – SS400, BS4360 43A. H. Ground Strut Ground strut is fabricated from C section mild steel made to the same standard as the foundation anchor specifications. The ground strut shall join the C section anchor point and the, I section, anchor point which is also the bottom half of post one. I. Post One and Two Fabricated from the same section and specification as the line posts. Post #1 is a short post and bolts into the top of the, I section, anchor point. Both Post #1 and #2 are crimped near the ground level. The impact head is bolted to post one with a standard 50mm long splice bolt. J. Bull nose Fabricated from a, 3mm thick, polyethylene plastic sheeting. This bull nose is “bent” into position on site. K. Rail Elements Standard 12 gauge, 2.7mm BMT, 350 grade galvanised W beam. As per AASHTO M180 Class A rail. Three standard sections are required. L. Fasteners All fasteners shall be Class 4.6 (Grade2) or greater and galvanized in accordance with ASTM 153. Washers shall be hardened and galvanized. IV. Construction Design, selection and placement of the X-Tension terminal end shall be in accordance with the AASHTO Roadside Design Guide and the details shown in the construction drawings. Installation shall be in accordance with the installation instructions supplied by Barrier Systems. Damaged systems shall be repaired or replaced immediately at the expense of the owner of the installed system. V. Performance Specification All leading Guardrail Terminal Ends must be fully re-directive and non-gating, capable of redirecting an errant vehicle from post one in side on impacts. (up to 2000P at 20 Degrees and 100 kph). The terminal end must be telescoping and energy absorbing in end on impacts with the impacting force held in tension rather than compression. No debris shall be expelled from the system.