Installation and Maintenance Manual. End Terminals

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1 End Terminals Rev. 01 of the 19/3/2015 1

3 1.GENERAL 1.1 Foreword. The following document represents the SMA (Safety Modular Absorber) Installation and Maintenance Manual, developed from the Company Industry A.M.S. srl, which has its seat in Marcianise (CE), ITALY. Copyright 2015, all rights reserved. 1.2 SMA End Terminals: Components. The device (as also shown in Fig. 8) is made of: - Collapsable beam; - L structure with guide; - Tie-rods welded to the collapsing beam; - Sliding bumper; - Posts for the anchoring to the soil; - Fixing bolts. 1.3 SMA End Terminal: Family and sizes. The following Installation and Maintenance Manual is worth for the devices below indicated: SMA T 2 Sizes Length: 3600 mm Speed class: 80 Km/h Height from the soil: 620 mm Width: 280 mm SMA T 4 Sizes Length: 6000 mm Speed class: 110 Km/h Height from the soil: 620 mm Width: 280 mm 1.4 Transition. Industry A.M.S. has designed and manufactured the SMA Transition which permits the connection between the End Terminal and the different barrier typologies. The SMA Transition can be: 3

4 single sided: which are used for the connection to the side barriers; double sided: which are used for the connection to the median barriers. Furthermore the Company distributes the SMA Transitions for the connection of different types of barriers. For example: Tab 1.: Transition typologies. TYPE 1 from double beam to double beam TYPE 2 from double beam to triple beam TYPe 3 connection to a new jersey In any case, the Company provides special Transitions according to the customer s requests. 1.5 Customer service. Industry A.M.S. s.r.l. commits to supply the customer service at the highest level. The Company welcomes the comments concerning the quality and the manufacturing of its products, the installation procedure and the supporting documentation. The clients are invited to contact the Company in the following ways: info@amssrl.com phone:

5 2.1 Foreword. 2. INSTALLATION PROCEDURE The End Terminal is provided already mounted in every part. For this reason, it is necessary to fix the device to the plates of the posts which are on the ground. The use of safety equipment is mandatory. Equip yourself with the traffic control equipment and with the personal security tools ( gloves, protective eyeglasses, ) mm FRONT SUBSOIL 1000 mm 1040 mm 1450 mm 840 mm Distance between the first and the last post = 3330 mm Fig.1: SMA T2 side picture mm FRONT SUBSOIL 1000 mm 840 mm 840 mm 1420 mm 1595 mm 1000 mm Fig. 2: SMA T 4 side picture. Distance between the first and the last post = 5695 mm 5

FRONT Positioning marks Fig. 3: Drilling template SMA T 2. Length: 3620 mm. Width: 150 mm. FRONT Fig. 4: Drilling template SMA T 4. Length: 5985 mm. Width: 150 mm. FRONT SOIL Fig.

6 FRONT Positioning marks Fig. 3: Drilling template SMA T 2. Length: 3620 mm. Width: 150 mm. FRONT Fig. 4: Drilling template SMA T 4. Length: 5985 mm. Width: 150 mm. FRONT SOIL Fig.5: SMA T 4 picture which shows x, y, and z axes. The axes permit to understand the End Terminal placement on the ground. 2.2 Positioning in front of the obstacle. Longitudinal placement The device has to be placed at a distance from the barrier which changes according to the type of obstacle and its height from the soil. It results mandatory for the fixing of the SMA Transition: it presents a telescopic section in the central part with 45 angle, which sets together the vertical and the horizontal extension of the device. Axial placement The End Terminal preferably has to be installed horizontally (slope = 0 ), in any case a side or longitudinal slope is permitted, as long as the correct working of the device is not altered. The maximal allowed slope is ±5 (Fig.7). 6

Carriageway Barrier Drilling template ±5 Fig.

front of a side barrier. Fig. 7: SMA T 4 front picture with maximal slope of ±5.

8b: Lateral picture of the plate welded on the post. 2.3 Installation modality.

In any case, the installation procedure is the same.

7 Carriageway Barrier Drilling template ±5 Fig. 6: Picture from the top of the SMA T 2 drilling template which is placed in front of a side barrier. Fig. 7: SMA T 4 front picture with maximal slope of ±5. Fig. 8a:Frontal picture of the plate welded on the post. Fig. 8b: Lateral picture of the plate welded on the post. 2.3 Installation modality. SMA devices can be installed on soil and/or asphalt. In any case, the installation procedure is the same. Working space and soil conditions Before starting the installation, it is mandatory: the adequate cleaning of the ground; the fence installation along the working zone; the safety equipment; 7

8 the use of signalization tools. If rock in the subsoil is encountered during the works, please proceed as indicated from the road constructors or the road institutions. Procedure 1) Place the drilling template on the ground (Fig. 3-4). 1 It is mandatory that the long side of the drilling template is in axis with the barrier, so that there is a sort of continuity between the drilling template and the barrier (See Fig. 6). 2 2) Mark the points in the holes of the drilling template where the posts have to be installed. 3) Insert the first post into the ground through the pile driver by respecting the markings previously carried out. The insertion of the posts starting from one of the extreme sides (at the begin or the end of the device) is advised. The post must be inserted into the ground as deep as the upper plate for the anchoring is at the same level of the ground floor. 4) Proceed with the insertion of the post next to the inserted one. 5) Repeat the previous actions (number 3 and 4) for the next posts, as long as all of them are inserted. 6) Clean the plates on the ground from eventual debris and dusts. 7) Place the SMA End Terminal so that the holes on the plate of the device correspond with the anchoring holes on the plate of the posts. 8) Proceed with the anchoring to the ground, by screwing the device to the plates through M16 bolts. 9) Place the End Terminal transition in order to connect the End Terminal junction with the barrier edge. 10) Mount the transition between the End Terminal and the barrier edge through M12 bolts. In case the transition is bilateral, the same procedure must be carried out on both the sides. Tools for the installation - Drilling template; - Dynamometric wrench M12 bolts; - Dynamometric wrench M16 bolts; - Handling device. 1 The drilling template has a constriction on the front part which immediately permits the correct positioning on the soil from the installer (Fig. 3-4). This optional tool is not supplied with the End Terminal, but it is mandatory to request the specific drilling template model to the Company Industry A.M.S. during the device order. 2 The pile driver needs an optional profile which permits the correct hammering into the soil. Such tool is included into the pile driver and then screwed at the post plate. The profile has to be requested together with the End Terminal. 8

9 Fig. 9: Lateral picture of an installed SMA T 4 End Terminal. 9

10 3. INSPECTION-MAINTENANCE 3.1 Foreword. SMA End Terminals don t need maintenance under standard condition of use. If the vehicle impacts the head of the End Terminal according to the EN 1317 (frontal, or offset, or up to 15 angled impact) it can be restored by simply replacing the damaged modular stations it is also possible to recover the remaining part of the structure. The restoring doesn t need to demount the whole structure, but only the damaged parts. If the car impacts the side of the End Terminal according to the standard EN 1317 (up to 15 or 165 angled impact) it is enough to replace the damaged modular station or transition. If the impact is not compliant with the EN 1317 the parts to replace will depend on the impact scenario. Restoring time: max 1h Double side transition replacement time: 10 min. N.B. In case of impacts against heavy weight vehicles at a high speed, the L structure (see Fig. 8) of the device could be damaged in a permanent way. If the local permanent deformation to the rail results higher than 10 mm, the L structure must be replaced. 10

Head Collapsable beam Trolleys Posts L structure with rail Head SMA T 2 Exploded view

4 Side view Fig. 10: End Terminal components. 3.3 Component replacement: tools.

11 3.2 Components of the End Terminal. The End Terminal is constituted by the components below illustrated. Head Collapsable beam Trolleys Posts L structure with rail Head SMA T 2 Exploded view Collapsable beam SMA T 2 Front view Head Post Trolleys L structure with rail Backstop SMA T 4 Side view Fig. 10: End Terminal components. 3.3 Component replacement: tools. The replacement of the SMA End Terminal components requests the following tools: - Dynamometric wrench for M16 bolts; - Dynamometric wrench for M12 bolts; - Dynamometric wrench for M8 bolts. 11

12 3.4 Component replacement: procedure. Each component is associated to a different reference code (Rif.) which helps to individuate the damaged part to replace. They can be consulted in the sheets at the Chapter 5: SPARE PARTS. Head (Rif. S) 1) Unscrew the M8 bolts on the Head rear side (Fig. 10) - which connect the head to the collapsable beam, by inserting the wrench into the 4 lateral openings (2 per side) on the head. 2) Slide the head forward along the rail through a handling device and pull the component out. 3) Replace the damaged component with the new one, by taking care of inserting the rail into the T opening at the lower part of the Head, and slide the new Head along the rail so that it comes in contact with the collapsible beam. 4) Avvitare i bulloni M8. Modular Station (Rif. M) Although the specific difference for each single modular station, the replacement procedure is the same. Anyway, the more is the distance of the damaged station to replace from the head, the higher is the number of (recurring) steps to carry out and the longer is the time needed for the component replacement. 1) Unscrew the 4 M8 bolts on the rear face of the head (Fig. 10) - which connect the head to the beam, by inserting the dynamometric wrench into the 4 lateral openings (2 per side) on the head. 2) Slide the head forward along the rail with a handling machine, then pull it out. 3) Unscrew the M8 bolts which connect the rear part of the modular station with the front part of the next station or with the L structure. 4) Slide the modular station forward along the rail with a handling machine, then pull it out. 5) Replace the damaged modular station with the new one, by taking care to insert the rail into the T shape opening (Fig. 10) between the trolleys in the lower part of the station -, then take it to the original position by sliding the component up the contact with the next modular station or the backstop. 6) Screw the bolts. Transition Although the specific difference for each transition typology, the replacement procedure is the same. The replacement procedure for a double side transition is the same of the single side transition. It only needs to be replicated for both the sides. 1) Unscrew the M12 bolts (the number of bolts is different according to the transition typology) on the End Terminal junction and on the barrier; 2) Pull the damaged transition out. 3) Place the new transition. 12

13 4) Screw the bolts. Openings Bolt holes T shape opening Fig.10: Head rear face with indications of the holes and the openings for the screwing/unscrewing and the handling. 13

During the assembly it is needed to take care of each type and dimension of the modular station.

14 4. PLAN OF THE COLLAPSABLE BEAM The Company can supply the End Terminal with the collapsable beam splitted in modular stations. In case the beam components are replaced, they must be assembled according to the plaque indications on the End Terminal backstop. During the assembly it is needed to take care of each type and dimension of the modular station. Each station type is different from the others in terms of length and number and position of the trolleys on the lower part. 4.1 Modular station details. The positioning of the modular stations in each single device is shown below. The modular stations are connected through 4 bolts that fasten 2 joint-cover profiles in order to ensure the stability. TYPE 1 TYPE 2 Fig.11: SMA T 2 collapsable beam sections. TYPE 3 TYPE 4 TYPE 5 Fig.12: SMA T 4 collapsable beam sections. Tab 2.: Modular stations typology. Modular station Length Number of trolleys Type mm 2 in the rear part Type mm 2 in the front part Type mm 3 Type mm 4 14

15 Tipo mm 2 5. SPARE PARTS Rif. Component Name of component Q.ty SMA T 2 S Head 1 M 1 Modular station (TYPE 1) 1 M 2 Modular station (TYPE 2) 1 P Post 4 Rif. Component Name of component Q.ty SMA T 4 S Head 1 M 3 Modular station (TYPE 3) 1 M 4 Modular station (TYPE 4) 1 M 5 Modular station (TYPE 5) 1 P Post 4 15

16 6. DURABILITY The structure and main parts are treated with hot-dip galvanized process according to UNI 1461 and galvanized according to ISO The absorbing panels are treated with cataphoresis treatment under the law n FIAT , 20/12/2001. The SMA devices are guaranteed for 10 years against the corrosion. 7. STORAGE The SMA End terminals can be placed in groups of 3x3 or 3x4 in order to facilitate the loading in a standard box. 8. TECHNICAL REFERALS AND NORMATIVES UNI EN 1317 /2010 End Terminals UNI EN 22768: 1996 Tolerance UNI 1461 Hot-dip galvanized process Norma FIAT n del 20/12/2001 Cataphoresis 16

17 9. APPENDIX Attached A Check of right installation Match with a X the work-flow steps. # Step Done Indication of the distance of the end terminal from the barrier (for transition 1 installation) 2 The drilling template is placed and the points for each post are marked 3a First post inserted into the soil through the handling machine 3b Next posts inserted into the soil 4 SMA End Terminal is fixed on the posts through M16 bolts. 5 SMA End Terminal is connected to the barriere and fastened with M12 bolts 17

18 Industry A.M.S. s.r.l. Via Dante Giacosa snc zona ASI sud Marcianise (CE) Italy Phone:

End Terminals Installation and Repair Manual SMAT2 SMAT4

End Terminals Installation and Repair Manual SMAT2 SMAT4 Industry A.M.S. s.r.l. Via Dante Giacosa snc zona ASI sud 81025 Marcianise (CE) Italy Phone: +39 0823 821 560 info@amssrl.com Rev. 04/08/2016 INDEX