PRODUCT & INSTALLATION MANUAL RICOCHET SAFETY BARRIER SYSTEM TL2 MASH 1

Transcription

1 PRODUCT & INSTALLATION MANUAL RICOCHET SAFETY BARRIER SYSTEM TL2 MASH 1

2 CONTENTS INTRODUCTION... 1 PRODUCT... 2 SPECIFICATIONS... 4 PHYSICAL CHARACTERISTICS... 7 SAFETY INFORMATION INSTALLATION INSTRUCTIONS PRODUCT CARE & MAINTENCE PRODUCT PART CODE NUMBERS CERTIFICATION WARRANTY INTERIM ACCEPTANCE... 41

3 INTRODUCTION Welcome to the Ricochet Safety Barrier System (TL2 MASH 1) (AASHTO document Manual for Assessing Safety Hardware ) The greatest energy absorbing temporary barrier system Ricochet Safety Barriers bring to you the ultimate protection concept that is designed for your safety and those in associated industries. The Ricochet Safety Barrier TL2 and Terminal End TL2 have successfully undergone the stringent testing requirements and are accredited to the MASH (Manual for Assessing Safety Hardware) standards. This testing requirement is significantly more stringent then the NCHRP 350 TL-2 standards. With traffic and construction being a very important and progressive feature of everyday life the Ricochet Safety Barrier is designed to have minimal environmental exposure, very user friendly with superior quality and performance. You can be confident that your purchase or possession of this barrier product will enhance your profile and business strengths. Page 1 of 42

4 PRODUCT The Ricochet Safety Barrier TL2 and Terminal End Barrier TL2 is a rotational molded product manufactured from LHDPE (Linear High Density Polyethylene) polymer. Due to the harsh conditions these products encounter this product is superior in its ability to withstand medium speed impact 70kmh, extremes in weather conditions and every day wear and tear. The polymer used guarantees high UV stabilization, ECR Environmental Crack Resistance, very low maintenance requirements and environmentally friendly. These Barriers can be connected together by using the Ricochet galvanized pin to form a longitudinal straight or curved line for protection and traffic flow direction for all road and construction sites and situations. Barriers are designed to be filled with water in accordance with the TL2 MASH 1 standard they are certified for. The Ricochet Terminal End and Terminal End Cap are designed to connect directly to the Ricochet Safety Barrier to form Terminal Ends at each installed length of barrier which results in the certified system. When correctly installed the Ricochet Barrier and End System is certified to contain, redirect vehicles and protect all relevant personnel in accordance with the MASH 1 standard at TL2 level. Page 2 of 42

5 In respect of this barrier MASH-1 standard at TL2 is: Ability to withstand four (4) physical impact tests Vehicle masses of 1100 kg and 2270 kg Impact angle is 25 and direct end on At a speed of 70 km/hr The above determines the performance envelope for the barrier system. Impacts outside the above parameters may result in unpredictable results and subsequent adverse outcomes. In addition to the above, the minimum installed barrier units is thirty two orange (32) which ends with two yellow (2) terminal end units with one yellow (1) terminal end cap at each end. Page 3 of 42

6 SPECIFICATIONS When you are about to purchase, hire or install your Barrier Protection system, make sure what you obtain and install is as per the specifications and pictures as set out in this section. Ricochet Longitudinal Barrier Ricochet Terminal End Ricochet Terminal End Cap Male Barrier Pin Ricochet Terminal End Cap Female Page 4 of 42

7 Ricochet Longitudinal Barrier Ricochet Terminal End Page 5 of 42

8 Ricochet Terminal End Cap Male Ricochet Terminal End Cap Female Page 6 of 42

9 PHYSICAL CHARACTERISTICS Ricochet Longitudinal Barrier Ricochet Terminal End Ricochet Terminal End Cap Male Barrier Pin Ricochet Terminal End Cap Female Page 7 of 42

10 Componentry The Ricochet Barrier system is as simple a system you will ever get. When assembling the longitudinal barriers to form the determined length you will need. Ricochet Longitudinal Barrier Barrier Pin x Total Length x 1 per barrier Page 8 of 42

11 When Assembling Terminal End units you will need Ricochet Terminal End Ricochet Terminal End Cap Male x 4 x 1 Page 9 of 42

12 Ricochet Terminal End Cap Female Barrier Pin x 1 Remember x 2 All Ricochet Safety Barriers (Orange) will need to be filled with 600 litres of water after assembly. Terminal End units and Terminal End Barrier Caps (Yellow) MUST NOT contain water as they are certified not to. Page 10 of 42

13 SAFETY INFORMATION It is essential that all personnel assembling the Ricochet Barrier System wear all safety clothing as recommended by the relevant employment and safety standards. This may include: - Hi Vis garments, Hard Hats, Protective Footwear, Gloves, Hearing & Eye Protection. Safety Hazards Identification and Pre Installation Identification 1) When assembling the Barrier System always have a clear working Zone of at least 2 metres on either sides of the barrier 2) Lifting Barriers must be by mechanical methods and use the lifting provision slots as provided. 3) Barriers weigh 62kg each when empty and do not attempt to lift barrier on your own. Page 11 of 42

14 4) Before filling with water make sure there is at least a safety zone area of 3 meters from any electrical point of contact. 3 m 5) Check that ground conditions are of satisfactory compactness and levelness DOES NOT exceed 10% (1v 10h) of undulation. 6) Check both drain bungs are tight before filling Page 12 of 42

15 7) Curbs and channels As with all road side safety system, the Ricochet Safety Barrier System has been designed and tested so the centre of gravity of the impacting vehicle is at a constant height with respect to the barrier. It is not recommended that the Ricochet Safety Barrier System be installed on top of or in front of any curbs or channels; as these cases conflict with the testing requirements. If there is no option but to install on top, behind or in front of a curb or channel then approval is required from the appropriate roading authority. Page 13 of 42

16 8) Allow a deflection zone area of 3.5 metres on the side opposite to traffic flow. CONSTRUCTION ZONE DEFLECTION ZONE 3.5 m TRAFFIC SIDE AND DIRECTION Page 14 of 42

17 9) Orange barriers are to be filled with water only. 10) Apply antifreeze additives in the water when using in subzero conditions. Use antifreeze ratios as per manufacturers specifications. 11) When filling barriers with water it is advisable to fill from the construction site side of the barrier. Page 15 of 42

18 INSTALLATION INSTRUCTIONS The Ricochet Safety Barrier System is a certified design and must be installed as set out in the following steps. All installers must be wearing PPE (Personal Protective Equipment). Length of Need (LoN) The barrier length requirement assures that a sufficient length of barrier is installed to prevent a vehicle leaving the road and entering the working space or protected area. Out of control vehicles typically leave the road at angles of less than 25 degrees and may travel considerable distance before impacting a hazard. The length of need is the length of approach barrier needed to shield an errant vehicle from passing behind the barrier and entering the working space or protected area. Factors influencing the length of need include: the length and width of the area personnel are occupying or the hazard to be protected the probable path and stopping distance for a vehicle leaving the roadway to avoid hitting objects in the protected area the layout of the barrier, including its lateral placement the location of the start of the flare (if any) and its flare rate, and the minimum length of barrier for the barrier to develop its ribbon strength. Page 16 of 42

19 The minimum LoN of the Ricochet Longitudinal Barriers is 32 units (52 metres). Make sure when installing the barriers there is sufficient length to accommodate this. The LoN for the Ricochet Terminal End system is 2 units + End Cap (4 metres). All orange longitudinal barriers MUST BE terminated using the yellow Ricochet terminal end system at both ends. 1) Complete a site inspection to ensure ground conditions are of satisfactory compaction and do not exceed 10% (1v 10h) undulation per barrier length. Page 17 of 42

20 2) Allow a deflection zone area of 3.5 metres on the side opposite to traffic flow. CONSTRUCTION ZONE DEFLECTION ZONE 3.5 m TRAFFIC SIDE AND DIRECTION Page 18 of 42

21 3) Allow a Gating Safety Zone as shown in the below figure. MAX SLOPE 1:10 TRAFFIC DIRECTION Notes Minimum installation length to be 61 metres inclusive of end treatments. Workers and equipment must be clear from the Gating Safety Zone and Deflection Zone. Page 19 of 42

22 4) Install each barrier individually and connect to the next interconnecting aligned barrier using the Ricochet barrier pin. Page 20 of 42

23 5) Barrier pin must be fully engaged with the plastic pin cap fully in it receptive position before proceeding. Page 21 of 42

24 6) Once the length of need (LoN) is installed then install terminal end barriers and end caps. Note: THERE MUST BE 2 YELLOW RICOCHET TERMINAL END UNITS WITH A YELLOW TERMINAL END CAP AT THE START AND FINISH OF EACH LENGTH OF ORANGE RICOCHET LONGITUDINAL BARRIERS 7) Fill all orange Ricochet barriers with water (600 litres per barrier). There is a Ø10mm level indicator hole on each orange barrier located opposite the filling hole. Page 22 of 42

25 8) Once barriers are filled then position the chevrons into their appropriate positions. One chevron to be installed every fifth barrier. Example only Page 23 of 42

26 Correct Installation When installing the Ricochet Barrier System always allow for a 3.5m safe no working zone which equates to the deflection zone as tested (see page 14). Maximum longitudinal and transverse slope of 10% (1v 10h) is acceptable. Slopes greater than this will require specific design and approval from the road controlling authority. The contractor must ensure the ground is compacted and there are no humps or hollows that may significantly alter o Impacting vehicle stability o Barrier System stability o Substantially alter the barrier height in relation to the road Do not install barriers on curbs, gutters or footpaths. Barriers must be installed in front of the curbs etc. so as to retain their full height to the traffic flow (always maintain a 3.5m deflection zone between barriers and curbs, etc.). Page 24 of 42

27 When installed, THE ORANGE BARRIERS MUST BE FILLED WITH WATER TO THEIR INDICATOR LEVEL. YELLOW TERMINAL END UNITS AND TERMINAL END CAPS MUST NOT BE FILLED WITH WATER. If this is not done correctly the barrier system will be non compliant. The following must be inspected immediately after installation, every alternate working day and immediately after any involvement in a traffic crash. Alignment barrier continuity connecting systems ballast fill levels ballast leakage damage due to impacts or wear and tear condition of frangible or crushable components, and cracked barriers (these are to be replaced). Repairs and adjustments must be made to alignment faults greater than 30mm within one hour of occurrence, or within one hour of inspection, whichever allows the earliest remedial repairs to be undertaken. Other faults must be rectified within one working day. Page 25 of 42

28 PRODUCT CARE & MAINTENCE The Ricochet Barrier System is molded from Virgin Polymer that is an oil based by product. The polymer used in LHDPE (Linear High Density Polyethylene). CLEANING Dust, dirt use any detergent and a high pressure hose. Oil stains use most petroleum based products i.e.:- Thinners, Meth s, Turpentine, Petrol. DO NOT USE MEK (Methyl Ethyl Ketone) PRODUCTS Rubber marks Treat the same as oil stains Graffiti Treat the same as oil stains APPEARANCE By using a hot air gun (i.e.:- Ripack 2000 LPG Heat Shrink Gun etc.), the Barrier once cleaned can be heat treated to regain its original luster shine. When applying the hot air, hold about 200mm away from the surface face and blow the air in a left to right motion. Be careful not to blister the surface as this may interfere with the performance of the barrier. Page 26 of 42

29 REPAIR Any grazes, scratches, minor abrasions or cuts can be easily repaired. If they are less than 1mm deep they can be plastic welded or sanded out by using a 120 grit Fibre Disc. Any deeper cuts etc. may conflict with the performance of the barrier and may need to be replaced. You will need to consult the manufacturer regarding this. Barriers that have sustained impact damage may need to be replaced depending on the severity. Once again consult the manufacturer regarding this. STORAGE As the Ricochet Barrier System is UV stabilized these can be stored inside or outside. Barriers once empty of water can be stacked on top of each other. Care is needed to support the higher barriers to prevent any possibility of injury to people and damage to barriers. Page 27 of 42

30 TRANSPORTATION When transporting the Ricochet Barrier System you can use the Ricochet Barrier Cage Packs. These are a safe and efficient cage method of transporting your product; they are also very useful for storage. One cage holds 8 longitudinal barriers or 8 terminal end units. Closed Open Folded Page 28 of 42

31 PRODUCT PART CODE NUMBERS Ricochet Barrier Longitudinal Ricochet Barrier End Ricochet Terminal End Cap 1 Ricochet Terminal End Cap 2 Ricochet Barrier Pin Ricochet Barrier Pin Cap Ricochet Barrier Drain Plug Ricochet Barrier Drain Plug Tool Ricochet Barrier Flap RBLTL2 RBETL2 RTEC1TL2 RTEC2TL2 RBP RBPC RBDP RBDPT RBF Page 29 of 42

32 CERTIFICATION Ricochet Safety Barriers and End Treatments have successfully undergone the stringent testing procedures to the universally recognized MASH 1 standard at TL2 level. This supersedes the testing requirements of the NCHRP 350 TL-2 level. These procedures involved the barriers withstanding four physical vehicle impact tests at an angle of 25, and direct end on impact at speeds of 70 km/h and vehicle masses of 1100 kg and 2270 kg. Page 30 of 42

33 Impact testing results information Test 1. Longitudinal Barrier System 0.0 sec 0.06 sec 0.12 sec 0.18 sec 0.24 sec Vehicle Rest at 21/ m Vehicle Impact at 16 Test Article Total Length Key Elements Barrier Description. Length. Barrier Height... Barrier filled weight.. Longitudinal barrier system constructed from water filled plastic barrier segments 61.0 m Plastic longitudinal barrier system 61.0 m LON 1020 mm 600 kg of water ballast per unit Report A (v1.1) V1.1 MASH TL2 COMPLIANCE TESTING OF July 2012 RICOCHET TEMPORARY LONGITUDINAL BARRIER SYSTEM Page 31 of 42

34 Longitudinal Barrier System Test 1 Longitudinal Barrier System Test Vehicle Curb Wt.. Test Inertial Wt. Gross Static Wt. Impact Conditions kg kg kg Speed Angle 25 Impact Point. 1.0 meter upstream of barrier junction 16/17 Exit Conditions Exit Speed. - Exit Angle.. - Post Impact Vehicle Behaviour Vehicle Stability Stopping Distance Vehicle Snagging... Vehicle Pocketing... Occupant Impact Velocity Longitudinal. Lateral (optional). Occupant Ridedown Deceleration x-direction. y-direction. THIV (optional).. PHD (optional)... Test Article Damage... Test Article Deflections Dynamic. Permanent. Working Width. Vehicle Damage - Exterior VDS. CDC. Max. Deformation... good 10.2 meters from CIP None None RHS of interior 7.2 m/s 3.6 m/s -6.9 m/s -2.6 m/s 7.7 m/s 7.0 g Moderate 2.50 m 2.45 m 2.50 m 11FL-3 11LFEE3 180 mm Report A (v1.1) V1.1 MASH TL2 COMPLIANCE TESTING OF July 2012 RICOCHET TEMPORARY LONGITUDINAL BARRIER SYSTEM Page 32 of 42

35 Longitudinal Barrier System Test 1 Longitudinal Barrier System 0.00 sec 0.06 sec 0.12 sec 0.18 sec 0.24 sec Vehicle Rest at 20/ m Vehicle Impact at 16 Report A (v1.1) V1.1 MASH TL2 COMPLIANCE TESTING OF July 2012 RICOCHET TEMPORARY LONGITUDINAL BARRIER SYSTEM Page 33 of 42

36 Longitudinal Barrier System Test 1 Longitudinal Barrier System Test Article Total Length Key Elements Barrier Description. Length. Barrier Height... Barrier filled weight.. Test Vehicle Longitudinal barrier system constructed from water filled plastic barrier segments 61.0 m Plastic longitudinal barrier system 61.0 m LON 1020 mm 600 kg of water ballast per unit Designation 2270P Make/Model Dodge Ram 1500 Quad Cab Dimensions (lwh) x 2000 x 1900 mm Curb Weight kg Test Inertial weight kg Gross Static weight kg Impact Conditions Speed kph Angle 25º Impact Point. 1.0 m upstream of line post 11 Exit Conditions Exit Speed. - Exit Angle.. - Post Impact Vehicle Behaviour Vehicle Stability Good Stopping Distance 10.2 m Vehicle Snagging... Minor Vehicle Pocketing... minor Occupant Impact Velocity Right side of interior Longitudinal. 4.0 ms Lateral (optional). 2.9 ms Occupant Ridedown Deceleration x-direction. y-direction. THIV (optional).. PHD (optional) g -4.0 g 4.9 m/s 8.0 g Report A (v1.1) V1.1 MASH TL2 COMPLIANCE TESTING OF July 2012 RICOCHET TEMPORARY LONGITUDINAL BARRIER SYSTEM Page 34 of 42

37 Longitudinal Barrier System Test 1 Longitudinal Barrier System Vehicle Damage - Exterior VDS. CDC. Max. Deformation LFQ-3 11FLEE2 110 mm Report A (v1.1) V1.1 MASH TL2 COMPLIANCE TESTING OF July 2012 RICOCHET TEMPORARY LONGITUDINAL BARRIER SYSTEM Page 35 of 42

38 Impact testing results information Test 2. Terminal End Barrier 0.0 sec 0.17 sec 0.34 sec 0.50 sec Test Article Total Length Key Elements Barrier Description. Length. Barrier Height. Unit Lengths Test Vehicle Designation Make/Model.. Ricochet Temporary Longitudinal Barrier Systems Terminal End 38 metres Water filled plastic barriers and hollow plastic terminal end sections 38 m 1020 mm 1.67 metres nominal 1100C Kia Rio Liftback LS Dimensions (lwh) L x 1675 W x 1435 Curb Wt kg Test Inertial Wt kg Gross Static Wt kg Impact Conditions Speed Angle 0 Impact Point. End of unit, offset by a quarter of vehicle width Exit Conditions Exit Speed. 12 kph Exit Angle.. 5 Report B (v1.0) - TERMINAL END V1.0 MASH TL2 COMPLIANCE TESTING OF SEPTEMBER RICOCHET TEMPORARY LONGITUDINAL 2012 BARRIER SYSTEMS TERMINAL END Page 36 of 42

39 Impact testing results information Test 2. Terminal End Barrier Post Impact Vehicle Behaviour Vehicle Stability Stopping Distance Vehicle Snagging... Vehicle Pocketing... Occupant Impact Velocity Longitudinal. Lateral (optional). Occupant Ridedown Deceleration x-direction. y-direction. THIV (optional).. PHD (optional)... Test Article Damage... Test Article Deflections Dynamic. Permanent. Working Width. Vehicle Damage - Exterior VDS. CDC. Max. Deformation... good 16.5 meters from point of impact None Minor RHS of interior 3.0 m/s at s 0.1 m/s at s 6.3 m/s at s 3.4 m/s at s 3.1 m/s at s 6.7 g at s Moderate 0.98 m longitudinal and 4.1m lateral 0.98 m longitudinal and 4.1m lateral 12FR3 12FRME2 185 mm Report B (v1.0) - TERMINAL END V1.0 MASH TL2 COMPLIANCE TESTING OF SEPTEMBER RICOCHET TEMPORARY LONGITUDINAL 2012 BARRIER SYSTEMS TERMINAL END Page 37 of 42

40 Impact testing results information Test 2. Terminal End Barrier 0.00 sec 0.13sec 0.26 sec 0.39 sec 0.52 sec Test Article Total Length Key Elements Barrier Description. Length. Barrier Height. Unit Lengths Test Vehicle Designation Make/Model.. Dimensions (lwh). Curb Weight.... Test Inertial weight. Gross Static weight... Ricochet Temporary Longitudinal Barrier Systems Terminal End 38 metres Water filled plastic barriers and hollow plastic terminal end sections 38 m 1020 mm 1.67 metres nominal 2270P 2003 Dodge Ram 1500 Quad Cab 5660 x 2000 x 1900 mm 2265 kg 2270 kg 2270 kg Report B (v1.0) - TERMINAL END V1.0 MASH TL2 COMPLIANCE TESTING OF SEPTEMBER RICOCHET TEMPORARY LONGITUDINAL 2012 BARRIER SYSTEMS TERMINAL END Page 38 of 42

41 Impact testing results information Test 2. Terminal End Barrier Impact Conditions Speed kph Angle 0º Impact Point. End of terminal section Post Impact Vehicle Behaviour Vehicle Stability Good Stopping Distance 8.15 metres Vehicle Snagging... None Vehicle Pocketing... None Occupant Impact Velocity Right side of interior Longitudinal. 3.1 ms at sec Lateral (optional). 0.3 ms at sec Occupant Ridedown Deceleration x-direction g at g y-direction g at g THIV (optional) m/s at s PHD (optional) g at g Test Article Damage... Mild Test Article Deflections Dynamic m longitudinal embedment Permanent m longitudinal embedment Working Width. Vehicle Damage - Exterior VDS. 12FC5 CDC. 12FCMV2 Max. Deformation mm Report B (v1.0) - TERMINAL END V1.0 MASH TL2 COMPLIANCE TESTING OF SEPTEMBER RICOCHET TEMPORARY LONGITUDINAL 2012 BARRIER SYSTEMS TERMINAL END Page 39 of 42

42 WARRANTY The Ricochet Road Barrier System is covered by a 3 year warranty which covers the general wear & tear and performance of the product and associated componentry. Any damage or malfunction of the product must be reported to the seller within 3 days of occurrence. Replacement of faulty product is the responsibility of the manufacturer. The following actions will void the Ricochet Road Barrier System warranty. Use of non-genuine Ricochet Products as part of the Ricochet Barrier System. Incorrect installation. Incorrect installation processes being used. Use of damaged product that conflicts with the TL2 MASH 1 regulations in the determined barrier lengths. Product failure resulting from impacting of construction equipment i.e. excavators, loaders, rollers, trucks, graders, cranes etc. Insufficient water levels when installed. Insecure restraint systems when transporting product. Page 40 of 42

43 INTERIM ACCEPTANCE Page 41 of 42

44 Page 42 of 42