Brifen TL-4 Wire Rope Safety Barrier Product and Installation Manual

Product & Install Manual : Brifen Wire Rope Safety Barrier

Brifen

TL-4 Wire Rope

Safety Barrier

Product and Installation Manual

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July 2015 / Page 1


Table of Contents

1.1

1.2

Introduction………………………………………………………………………..4

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

1.3

1.2.1 Before Installation………………………………………………………………...4

Safety Statements………………………………………………………………..5

1.3.1 General Safety…………………………………………………………………… 5

1.3.2 Brifen WRSB Safety Statements………………………………………………. 5

1.4

1.3.3 Geotechnical Warning…………………………………………………………... 5

Limited Warranty………………………………………………………………… 5

1.5

1.6

System Overview………………………………………………………………... 7

Brifen Anchor System Overview……………………………………………….. 7

1.6.1 Surface Mounted Anchors……………………………………………………… 8

1.6.3 TL-4 Terminal and Anchor System……………………………………………..9

1.7 Anchor Design…………………………………………………………………… 10

1.7.1 Anchor Foundation Shape……………………………………………………… 11

1.8

1.7.2 Anchor Foundation Sizes………………………………………………………. 11

Post Foundation Sizes………………………………………………………….. 12

1.9

1.8.1 Post Sockets………………………………………………………………………12

Important Notes and Definitions of Brifen Fences…………………………….12

1.9.1 Length of Need……………………………………………………………………12

1.9.2 Point of Need…………………………………………………………………….. 13

1.9.3 Influence of Batter Slopes……………………………………………..……….. 13

1.9.4 Influence of Fence Length and Post-Rope Interaction………………..……...13

1.9.5 Fence Length Protecting an Obstruction……………………………………… 14

1.9.6 Post spacing……………………………………………………………………… 14

1.10

1.9.7 Curvature of road alignment……………………………………………………. 14

Post Selection …………………………………………………………………….14

Design Requirements

2.1 Scope………………………………………………………………………….......15

2.2

2.1.1 Precedence………………………………………………………………………. 15

Set back…………………………………………………………………………... 15

2.3 Clearance………………………………………………………………………… 16

2.4

2.5

2.6

2.7

Limitations on Use………………………………………………………………. 17

Transitions Between Barrier Systems………………………………………… 18

Length of Fence…………………………………………………………………. 18

Design of WRSB in Medians…………………………………………………… 18

2.8 Design of Overlapping Installations…………………………………………… 19

General Installation

3.1 Mark out………………………………………………………………………….. 20

3.1.1 Allowable Deviation in Measurement…………………………………………. 20

3.1.2 Local Factors Influencing the Set out of a Fence……………………………. 20

3.2 Constructing Anchor Foundations…………………………………………….. 20

3.2.1 General Comments on Excavation for Anchor………………………………. 21

3.2.2 Concrete and Concrete Quality………………………………………………... 22

3.2.3 Finishing of Concrete Anchor………………………………………………….. 23

3.3 Constructing Post Foundations………………………………………………… 24

3.3.1 Construction of Post Foundations…………………………………………….. 24

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Assembling the Ropes

4.1 Assembling the Ropes…………………………………………………………. 27

4.1.1 Rope Supply…………………………………………………………………….. 27

4.2

4.1.2 Handling Reels………………………………………………………………….. 27

Rope Installation and Connection to Anchors……………………………….. 28

4.3

4.2.1 Connections to Anchors………………………………………………………... 28

Rope Connection……………………………………………….………………. 29

4.3.1 Installation Procedure ………………………………………………………….. 29

Annexures to Manual

Post Foundation

Site Testing Procedure ………………………………………………. ……………………….. 32

5.1

5.2

General…………………………………………………………………………… 32

Post Foundation Test…………………………………………………………… 32

…………………………………………………………………………………….. 32

Wire Rope Tensioning Procedure …………………………………………………………… 38

6.1

6.2

Initial Checks…………………………………………………………………….. 38

Determining the Tension……………………………………………………….. 39

6.3

6.2.1 Determining the AADT………………………………………………………….. 39

Tensioning the Ropes……………………………………………………………41

6.4 Notes ……………………………………………………………………………. 43

19mm Galvanised Wire Rope

Swaging Procedure …………………………………………………………………………….. 44

7.1 Personal Protection……………………………………………………………… 44

7.2

7.3

Equipment Operation…………………………………………………………….44

Site Safety………………………………………………………………………... 44

7.4 Inspections……………………………………………………………………….. 45

7.4.1 Hose Inspections………………………………………………………………… 45

7.4.3 Bleeding Air from the System ………………………………………………….. 45

7.4.4 Generator Fuel Level……………………………………………………………. 45

7.5

7.6

7.4.5 Generator Oil Level……………………………………………………………… 45

Generator Operation……………………………………………………………. 46

Swaging Unit Operation………………………………………………………….47

7.6.1 Attachment of the End Fitting ………………………………………………….. 47

7.6.2 Swaging the End Fitting………………………………………………………… 48

7.6.3 Troubleshooting…………………………………………………………………. 48

Upgrade of Existing Single & Double Terminal Ends to TL-3……………………….….. 50

7.7 Existing Single and Double Terminal End upgrade to TL-3………………… 51

7.7.1 Background………………………………………………………………………. 51

7.7.2 TL-3 Terminal End……………………………………………………………. 51

7.7.3 Installation upgrade procedure for single anchor block option………………52

7.7.4 Installation upgrade procedure for double anchor block option……………. 53

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1.1 Introduction

The Brifen Wire Rope Safety Barrier (WRSB) is a high tension cable barrier and is distinctive due to its interwoven rope construction. Brifen’s patented interweaving of the wire ropes are used to contain & redirect errant vehicles by preventing the vehicles from crossing the barrier or deflecting back into the traffic flow. Brifen WRSB is designed to absorb the energy of an impact, minimising injury to passengers and damage to vehicles. Due to the weaves interaction with the post, Brifen can achieve tighter radius than other products at the same post spacing.

The Brifen WRSB has been designed and tested to provide acceptable structural adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 for longitudinal barriers.

When impacted with a 820kg, 2000kg and 8000kg vehicle at speeds of up to 100kph and side on entry angles of up to 25 degrees, the impacting vehicle is re-directed in a safe manner.

1.2 Limitations and Warnings

Brifen WRSB has been rigorously tested and evaluated per the evaluation criteria in the

NCHRP 350 guidelines for a longitudinal barrier. The impact conditions recommended in

NCHRP 350 are intended to address typical in-service collisions.

Brifen WRSB allow an impacting vehicle to be re-directed in a safe and predictable manner under the NCHRP 350 impact conditions. It is imperative that the system is installed as per manufacturers’ specification.

Vehicle impacts that vary from the NCHRP 350 impact conditions described for longitudinal barriers may result in significantly different results than those experienced in testing. Vehicle impact characteristics different than, or in excess of, those encountered in NCHRP 350 testing (weight, speed and angle) may result in system performance that may not meet the

NCHRP 350 evaluation criteria.

1.2.1 Before Installation

Design, selection and placement of the Brifen WRSB shall be in accordance with the Road

Controlling Authority’s guidelines and the details shown in the construction drawings.

Installation shall be in accordance with the installation instructions supplied for this product.

Note: Concrete foundations will have to be designed by a local geotechnical engineer if soil conditions on site do not meet the required level described in the manual.

Depending on the application, post spacing and conditions on site, installation and assembly of the system should take a three person crew less than four hours to cast the piles, install the posts and place the cables for a 100m section.

Brifen WRSB is a highly engineered safety device made up of a relatively small number of parts. Before starting installation ensure that one is familiar with the makeup of the system.

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1.3 Safety Statements

1.3.1 General Safety

• All required traffic safety precautions should be complied with. All workers should wear required safety clothing. (Examples, and not limited to, include: high visibility vests, steel capped footwear, gloves etc.)

• Only authorised trained personnel should operate any machinery. Where overhead machinery is used, care must be taken to avoid any overhead hazards.

• Before drilling or excavation always ensure that the area is clear of underground services. (The appropriate service providers may need to be contacted).

1.3.2 Brifen WRSB Safety Statements

• All installers must be well clear of drilling or excavating machinery operating.

• The cable and reel are extremely heavy so it is recommended that the cable is run out from a single axis spindle. Do not place hands or fingers in or around moving parts.

• Only trained personnel can use the swaging machine. All installers must be extremely careful they are clear of moving parts when the machine is being operated.

1.3.3 Geotechnical Warning

The Brifen WRSB line post concrete foundations require sufficient strength from the supporting soil and guidelines contained within this manual on foundation sizes relate specifically to the corresponding soil strength. If it is determined that soil conditions on site do not meet or exceed these requirements, alternative size foundations must be designed by a local geotechnical engineer for use at that location.

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1.4 Limited Warranty

CSP Pacific has tested the impact performance of its barriers and crash cushion systems, and other highway safety hardware under controlled conditions, however, CSP Pacific does not represent nor warrant that the results of those controlled conditions would necessarily avoid injury to persons or property.

CSP PACIFIC 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.

CSP Pacific warrants that any product or component part manufactured by CSP Pacific will be free from defects in material or workmanship. CSP Pacific will replace free of cost any

Product or component part manufactured by CSP Pacific 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. CSP PACIFIC’S LIABILITY UNDER THIS WARRANTY IS EXPRESSLY

LIMITED TO REPLACEMENT FREE OF COST OF PARTS SUPPLIED BY CSP PACIFIC

ONLY (IN THE FORM AND UNDER THE TERMS ORIGINALLY SHIPPED), OR TO REPAIR

OR TO MANUFACTURE BY CSP PACIFIC, PRODUCTS OR PARTS NOT COMPLYING

WITH CSP PACIFIC SPECIFICATIONS, OR, AT CSP PACIFIC’S 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. CSP PACIFIC 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 CSP Pacific 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 CSP Pacific’s plant for inspection in accordance with return shipping instructions that CSP Pacific shall furnish to the

Buyer forthwith upon receipt of the Buyer’s notice of claim. If the claim is established, CSP

Pacific 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 unauthorised alterations, or that have not been installed, operated and maintained in accordance with approved procedures and (ii) any components manufactured by the Buyer.

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1.5 System Overview

The Brifen TL-4 WRSB consists of four tensioned galvanised steel wire ropes with an average height above ground level of 705mm. Galvanised or white powder coated steel posts support the wire ropes. The rope arrangement for the Brifen TL-4 WRSB has three inter woven ropes along the fence between each post and one straight rope in the notch in the top of each post. The ropes are joined and tensioned by means of rigging screws provided at intervals not exceeding 308 metres. The ends of the ropes are attached to anchors embedded in the ground. The connection between the ropes and anchors are designed to be a gating action which allows the ropes to uncouple when a vehicle impact occurs in the vicinity of the anchor. A safety check rope then restrains the movement of the ropes.

Figure 3. Brifen TL-4 Post and Rope Heights

1.6 Brifen Anchor System Overview

The Brifen TL-3 Tested Anchor is used on the TL-4 system. The Anchor consists of one large anchor block with all four ropes connecting to the anchor. The anchor can be either cast insitu or surface mounted. The connection of the ropes to the anchor is designed to uncouple when a vehicle impact occurs in the vicinity of the anchor. A ‘safety check’ rope connected to the anchor restrains the movement of the rereleased rope.

Four terminal posts are set out at 2m intervals. The first post is referred to as the deflection post and is installed at an 11 degree angle (to the vertical). The remaining posts are installed vertically. The following figures detail the anchor and also the different terminal posts for the tested system. These posts can be used for both the flared and straight terminals.

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1.6.1 Surface Mounted Anchors

Below are diagrams of the Brifen TL-3 Surface Mounted Anchor. The Surface Mounted End

Anchor is used when the regular anchor may not be suitable. For example if a concrete footing block will not fit in the area required or if underground services are present and concrete foundations already exist in the area, the concrete block may be modified by a structural engineer’s certification.

Figure 4. Surface Mounted End Anchor

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1.6.2 TL-3 Terminal and Anchor System

The TL-3 Terminal posts are detailed below.

Type of Fence

TL-4

Figure 5. Terminal Post details

Type of Anchor

TL-3 Anchor

Anchor Terminal

4 x Anchor Posts

Figure 6. TL-4 Terminal End Anchor Setup

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1.7 Anchor Design

End terminals are of cast–in or of surface mounted design, and are designed to detach the rope connectors when an errant vehicle collides with the fence upstream of the departure anchor. For contracts requiring surface mounted terminals, the terminal unit is bolted to a cast-in fixing, the fasteners are to be specified by specialist engineers using austenitic stainless steel components (refer Ramset or Hilti or a qualified Structural Engineer). When installing Catch ropes, please ensure they are tied (using cable ties) to the ropes at mid span to prevent the catch ropes becoming a hazard to pedestrian traffic.

The Brifen anchor can be installed as either a flared arrangement or the standard straight line installation. The Brifen anchor was tested on a flare of 600mm as shown in the following diagram. When constructing the anchor, if the site batter slope geometry does not permit a

600mm flare, then the minimum flare on the approach side is 300mm. It is not required that the anchor be flared on the departure side unless a vehicle can impact the anchor at an angle of 180°. The end anchor is essentially a dead-man or a laterally loaded pile. Soil conditions influence the design of the anchor system. Please refer to section 1.7.2 for standard anchor foundation size or contact CSP Pacific for advice.

Figure 7. Anchor and Post

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1.7.1 Anchor Foundation Shape

There are two shapes for the anchor foundation, block and cylindrical. The Block shape is indicated in the diagram below and is the most common form of anchor foundation. Both types of anchor foundations must have a vertical face for an even bearing capacity.

Figure 8. Anchor and Section Isomeric

1.7.2 Anchor Foundation Sizes

The standard foundation size for the anchor block is 900mm W x 900mm L x 1200mm D is for use when the soil conditions on site are compacted road base of 40-50kPa with a recommended concrete strength of 25MPa.

Anchor blocks are an essential structural component of the fence and it is important that the minimum dimensions of all anchor blocks be constructed as specified. The vertical bearing face of the anchor must be constructed vertical and square.

The Anchor Block dimensions can vary from site to site depending upon the soil type and the cross-section geometry of the carriageway (proximity to embankment, slope of embankment).

The end anchor is essentially a dead-man or a laterally loaded pile and soil conditions influence the design of the anchor system. The Anchor block shape and dimensions can vary to suit site conditions: batter slopes, ground conditions, presence of services, etc. All end anchors must be designed and checked to make sure they are constructed to suit the specific site conditions. In some cases a site specific design may be required designed by a local geotechnical/ structural engineer. CSP Pacific can be contacted for advice on site specific anchor sizes.

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1.8 Post Foundation Sizes

The size of the post foundation used is based on the soil conditions present within the project area. The standard recommended post foundation size is 250mm dia x 750mm depth for use in a compacted road base of 40-50 kPa. The concrete to be used for a post foundation must have at least 25 MPa strength.

For alternate soil conditions such as soft or loose soils or when rock is encountered then a larger or smaller post foundation may be required. If an alternative post foundation is required then the following processes to be followed: a) Geotechnical testing conducted to determine the existing conditions. b) A suitably qualified Engineer to design and detail the post foundations. For initial detailing, end or deflection post foundations must be designed to resist the effects of a horizontal shear of 10.26 kN, combined with a bending moment of 6.0 kN in a plane at 90 degrees to the fence line. c) Non-standard post foundations must be tested in accordance with the standard load test. This testing is detailed in the Annexes of this manual.

Note: It is the responsibility of both the Contractor and the Supervising Engineer to assess the soil conditions to access what size post foundations are used. Soil profiles are not consistent and can be subject to large variation in a short distance. A post foundation that breaks or rotates may influence the performance of the installation. If under any circumstances there is uncertainty, CSP Pacific is to be contacted for advice.

1.8.1 Post Sockets

Brifen uses plastic sockets specific for post installation. The socket is 100mm x 55mm x

425mm deep and is installed into the foundation with a supporting reinforcement ring.

1.9 Important Notes and Definitions of Brifen Fence

1.9.1 Length of Need

A fence consists of two parts, the Anchor Terminal section and the Length of Need. The

Anchor section design is gating and allows the vehicle to pass through the Anchor, with the greatest possible stability. The purpose of the length of need (the main body of the fence) is to safely restrain, contain and redirect the vehicle. The Length of Need is defined as that part of the fence between the Points of Need.

Figure 9. Length of Need

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1.9.2 Point of Need

The Point of Need is the first point of the fence that contains a vehicle upon impact. Any point of impact (upstream for approach and downstream for departure) from the Point of Need is considered gating when locating the fence and shall not be considered as protecting a hazard. The point of need for the Brifen WRSB is 9.6m from the anchor.

To define the Point of Need with respect to a Hazard, please refer to the local Road

Controlling Authority’s guidelines.

Figure 10. Point of Need for Terminal

1.9.3 Influence of Batter Slopes

NCHRP 350 recommends that the lateral extent of the soil, outside an envelope of the embedded portion of the test article, be approximately 1.3 times the embedment length.

Therefore where the post and/or anchor foundations are to be constructed within 1.5 metres of a batter slope, the foundations may be required to be deeper than the standard depth and a site specific design may be required to be designed by a local geotechnical/ structural engineer taking into consideration the site soil conditions. CSP Pacific can be contacted for advice on site specific post and anchor sizes.

1.9.4 Influence of Fence Length and Post-Rope Interaction

The combinations of the inter-woven lower ropes and the linear ‘upper’ rope delivers two energy-absorbing actions, namely:

• Linear stretching of the upper rope; and

• Mechanical action of the lower woven ropes exerting frictional force acting on the steel post and using the deformation of the posts to absorb impact energy into the fence system.

Working together in tandem, these two energy-absorbing actions result in a significant reduction in total fence deflection and fence damage during an impact. The complex interaction of rope and post ensures rapid transfer of the vehicle kinetic energy into the fence and then into the ground.

Brifen’s patented system combines the attributes of both wire rope configurations: the straight rope to provide the initial resistance to the impact; and the woven ropes to both localize and control the impact by making most efficient use of the supporting posts. The benefit of incorporating woven ropes into the fence design is best realised on longer lengths of fence.

As the fences length increases, the fence anchors have reducing influence on the fence performance therefore on short fence lengths (50 metres to 150 metres) the end anchors tend to do the bulk of the “work”.

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1.9.5 Fence Length Protecting an Obstruction

The Brifen installation is extended at full height for a minimum distance great enough to provide a clear zone behind the terminal, with redirection of the system occurring after 7.5m.

If the obstruction can be approached from two directions then the point of need on both sides will be at a distance great enough from the obstruction to create a clear zone behind the terminal end.

On embankments of 6m or more in height, the installation length should be extended beyond the 6 m high section, this will ensure that vehicles leaving the carriageway at places of lesser drop will not reach the 6 m high section. On curves, further extension may be needed to avoid the risk of vehicles passing behind the fence.

1.9.6 Post spacing

When the post spacing is reduced on a WRSB system, the deflection will decrease due to the post/rope friction increasing, Brifen WRSB’s regular post spacing is 3.2 metres. Custom post spacing may be required depending on the deflection requirements of the WRSB fence and may be subject to the local Road Controlling Authorities requirements.

1.9.7 Curvature of road alignment

If the road curvature has a horizontal radius of less than 200 metres or vertical sag of less than 3000 metres, the WRSB may not be installed unless post spacing is reduced. For further details please contact CSP Pacific for assistance. When a road heads into a sharp curve it is important to make sure the impact zone will be within the length of need and not in the terminal for maximum performance.

1.10 Post Selection

The selection of the correct posts is determined by where the WRSB fence is located. If it is located in the verge, the post cross section will be a Z shape. This is so vehicles do not impact the posts on the sharp edge. Alternatively, the median side will require S shaped posts. Also the posts must be for the correct system to be installed.

The figure below is a simple illustration to show the post shape in reference to the travelled path:

Figure 11. Post Selection Diagram

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Design Requirements

2.1 Scope

The wire rope safety fence described in this design document is anchored to the ground and is designed to resist a specified impact loading. This document sets down the essential layout requirements and limitations on the use of Brifen Wire Rope Safety Barrier TL-4.

2.1.1 Precedence

The following comments are on design and are general in nature. Each local Road

Controlling Authority has different requirements in their specifications and those specific requirements will take precedence over these general “rules” unless otherwise stated by the

Road Controlling Authorities specifications. If there is any doubt on the question of precedence contact CSP Pacific.

2.2 Set Back

Set-back is the unobstructed horizontal dimension between the traffic face of the wire rope safety fence and the edge of the: a) Paved surface adjacent to the verge; (the paved surface comprises the carriageway, hard shoulder or hard strip) b) Carriageway adjacent to the median.

Layout requirements for Setback at a verge:

The minimum setback shall normally be not less than 1.2m. It may be reduced locally to: a) 1.0 m adjacent to a hazard b) 0.6 m adjacent to a hard-strip, hard shoulder or road having a posted speed limit below 80 km/h.

Layout requirements for Setback on a Median: a) Where there are no obstructions and only one safety fence in the median between carriageways, the desirable minimum setback will be the maximum deflection of the fence calculated under the contract design conditions. b) In other situations, for example, where a dual fence line is present, the setback needs to be calculated and will depend not only on type of fence but the distance between the two adjacent fences. Suitable guidance is available from CSP Pacific.

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2.3 Clearance

Clearance is the unobstructed horizontal dimension between the rear of the wire rope safety fence and: a) The face of an obstruction; b) The top of an embankment; c) The toe of a cutting; d) The opposite carriageway on a median where there are no obstructions and there is only one safety fence between the carriageways.

The deflection of a Wire Rope Safety Barrier is dependent on a number of variables which can be project specific. The selection will take into account post spacing, anchors spacing and speed environment when determining the clearance/deflection of the system in accordance with the local Road Controlling Authority guidelines.

The deflection measurements from NCHRP compliance testing are as follows:

Test 3-10: 820kg small car, 100kph at 20 degrees (NCHRP 350 TL-3)

Post Spacing

3.2m

Dynamic Deflection

1.35m

Test 3-11: 2000kg pickup truck, 100kph at 25 degrees (NCHRP 350 TL-3)

Post Spacing

2.4m

Dynamic Deflection

1.65m

Test 4-12: 8000kg pickup truck, 80kph at 15 degrees (NCHRP 350 TL-4)

Post Spacing

3.2m

Dynamic Deflection

2.21m

Note: Deflection is influenced by cable temperature, post spacing, soil stability, barrier length and barrier curvature. Consequentially, allowance should be made for barriers to deflect more than that shown during one particular test. The deflection listed above should only be used as an indication of what deflection measurement to expect.

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2.4 Limitations on Use

2.4.1 Limitation for Minimum Length

In terms of overall length of the barrier, the minimum length of the TL-4 system is 78m.

2.4.2 Horizontal Curves

The Brifen system can be used on horizontal curves of less than 200m. This is due to the woven rope system which makes it suitable for use on curves down to 60m radius. Prior to proceeding with a design/installation of <200m radius, please contact CSP Pacific to ensure suitability and advise on minimum radius so that post pitch, anchor spacing etc. can be calculated.

2.4.3 Sag Vertical Curves

Vertical sag curves of less than a 3000m radius are not recommended for WRSB. However for the right site conditions Brifen can be installed at less using careful design and specially designed hold down posts, for designs requiring this application please contact CSP Pacific for assistance.

2.4.4 Height of Ropes

Where the horizontal distance from the traffic face of the fence to the edge of the adjacent paved surface is less than 1.5m, the heights of the ropes shall be measured from the level of the paved surface adjacent. Elsewhere, the heights of the ropes will be measured from the general ground level below the fence.

2.4.4.1 Rope Height Tolerance

A tolerance of ±30mm shall apply to the specified rope heights at any point in the system.

2.4.5 Kerb in front of Brifen WRSB

While it is desirable to have a level transverse region before and after the WRSB, it is not always possible. The kerb before the fence line can depress the vehicle suspension causing a ramping of the vehicle. For this reason the following general guidelines should be followed: a) If the kerb height is no greater than 100mm, locate the WRSB immediately behind the kerb. b) If the kerb height is greater than 100mm, locate the WRSB at an alignment 1500mm or greater from the face of the kerb. c) If the kerb height is greater than 100mm and the WRSB cannot be relocated contact

CSP Pacific.

2.4.5 Kerb behind Brifen WRSB

It is not uncommon to locate a kerb behind the WRSB on highways for surface water diversion. When these drains are located in the deflection area by WRSB they can influence the passage of the vehicle. It is desirable that the kerb face is either sloped at an angle of 45° or flatter, or, that the kerb be less than 100mm high. Contact CSP Pacific for assistance if required.

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2.5 Transitions Between Barrier Systems

Transitions from Brifen WRSB to other types of barriers are possible and details are available on request. Please contact CSP Pacific.

2.6 Length of Fence

Where Brifen WRSB is protecting an obstruction, the leading Point of Need will be located not less than the distance required for the creation of a clear zone after the terminal and as per the local Road Controlling Authority guidelines. If the obstruction can be approached from both sides then both sides will be treated as a leading Points of Need, and must include provision of a clear zone at the terminal. The system is redirecting after 7.5m.

2.7 Design of WRSB in Medians

Brifen use S Shaped posts for median applications where in the event of a vehicle impact, the vehicle shall make contact with the post on the rounded edge and not the sharp edge.

If the median has a batter to the centre line and the median is less than 10 metres in width, the WRSB should be located in the centre of the median.

Figure 12. Median impact for medians of 10 metres or less

If the median has a batter to the centre line and the median is greater than 10 metres in width, the WRSB can either be installed in the centre of the median or adjacent to the traffic lane.

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Figure 13. Median impact for medians greater than 10 metres

2.8 Design of Overlapping Installations

The desirable minimal distance between the fence lines (denoted “D”) is 2000mm but this is not always achievable due to the width of median or steepness of batter slope. The minimum separation distance between the fences (denoted “D”) is 200mm however every attempt should be made to maximize the separation. A separation distance of D>2000mm is considered ideal for NCHRP350 TL-3 impact conditions.

Figure 14. Overlapping of WRSB fence (Points of Need are adjacent)

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General Installation

3.1 Mark Out

a) Establish location of the datum, this may be the point of need or the centre of the outermost anchor block. b) Establish location of the end anchor blocks. c) Establish the fence alignment. d) Mark out the anchor locations at the required offsets.

3.1.1 Allowable Deviation in Measurement

a) The post spacing should not deviate more than ±50mm in location as measured from the starting anchor face. b) The post location must not deviate more than ±20mm from the fence alignment.

3.1.2 Local Factors Influencing the Set out of a Fence

The nominal post spacing may need to be varied slightly during construction. Typical variations include underground services or drainage pipes. The deflection performance of the

Brifen WRSB is tolerant of the variation of a single post spacing.

All variations must be referred to the Road Controlling Authority for advice before proceeding with installation of the Brifen WRSB.

3.2 Constructing Anchor Foundations

Before any construction commences, be clear what anchor foundations are required.

Specifically it must be known (a) the dimensions of the anchor foundation (b) the type of anchor to be used and (c) they are suitable for the site soil conditions.

The standard dimension for the concrete anchor foundation for the TL-3 tested 4 rope terminal is 900mm W x 900mm L x 1200mm D. This foundation size is designed for compacted road base, if other soil conditions exist, please consult section 1.7.2 of this manual.

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3.2.1 General Comments on Excavation for Anchor

a) All excavations for concrete post foundations and anchor blocks shall have vertical sides and shall be formed to the line and level detailed in the design plans. b) Where the vertical faces cannot be kept vertical, temporary formwork shall be provided. c) The minimum dimensions of the excavation shall be at least as large as those specified in the standard drawings. d) All spoil should be removed from any hole. Where this cannot be achieved, ensure that the minimum depth is achieved and that the spoil at the bottom of the hole is tamped and compacted as tightly as possible. e) Where the specified minimum depth cannot be attained due to the presence of rock the supervising engineer and CSP Pacific must be consulted. f) Where the specified minimum depth cannot be attained due to the presence of services the supervising engineer and CSP Pacific must be consulted. g) Where the fence line requires that the anchor and/or post foundations are located in fill batters the supervising engineer and CSP Pacific must be consulted. h) Where the fence line requires that the anchor and/or post foundations are located in very hard deep pavement the supervising engineer and CSP Pacific must be consulted to revise the minimum excavation depths. i) Some excavation may require a rock breaker to assist the auguring process. j) In general, there will not be any variation in the minimum dimensions of the anchor block after work on the project has commenced.

Figure 1. Excavation for Brifen Anchor Block

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3.2.2 Concrete and Concrete Quality

a) All concrete shall be minimum 25MPa. b) No additional reinforcement is required unless it is a requirement of a site specific design due to soil conditions. c) All anchor frames shall be secured against displacement during placing of the concrete. d) Concrete shall be poured from an appropriate height to prevent segregation of aggregates. e) All concrete shall be adequately vibrated to produce a dense mass substantially free from voids. f) All surfaces shall be free from voids, honeycombing or other defects. Small blemishes caused by entrapped air or water are acceptable. g) Exposed concrete surfaces shall be hand toweled. h) Adjacent ground shall be shaped to prevent ponding of surface water, which may later saturate and weaken the soil profiles. i) Concrete shall be left to cure for a minimum of seven (7) days.

Figure 2. Vibrating the concrete when pouring

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Figure 3. Adjusting the slope of the anchor face

3.2.3 Finishing of Concrete Anchor

When finishing the Brifen concrete end anchor ensure the following:

• The recess at the rear of the anchor has a one-way fall away from the centre of the fence.

• The recess facilitates the entry of the wire ropes into the anchor.

• The fall ensures water is dissipated away from the bearing place.

• So that water does not pool at the anchor face, ensure the surface of the concrete falls away from the exposed anchor face.

• The concrete should be kept clear of the anchor frame face.

Figure 4. Finished anchor frame and A Post (at 11 degree slope)

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3.3 Constructing Post Foundations

Before any construction commences, be clear what post foundations are required.

Specifically the dimensions of the post foundation. The standard dimension for the concrete post foundation is 250mm dia. x 750mm deep. Variations in dimensions are allowed, refer to section 1.8 of this manual.

Figure 5. Excavator with augur attachment to drill post foundations

3.31 Construction of Post Foundations

a) Establish post center referenced from the datum and excavate foundation, ensuring requirements in terms of foundation size and depth and socket length are as specified.

(The post/socket position to be central within the foundation). b) Where the sides of excavations cannot be maintained vertical until concrete is placed, suitable permanent or temporary casings shall be used. The casings shall be installed immediately after excavation and any lateral over break of the excavation shall be filled with concrete. c) Place concrete as a monolithic mass and vibrate for compaction. Specified concrete grade is a minimum of 25MPa. The curing period must not be less than four days. d) Ensure that the post is of the correct type. e) Set post and/or socket and reinforcing ring in wet concrete to the specified height, setback and post spacing, ensuring that post and/or socket and reinforcing ring remain in the correct position. It is best practice to place the reinforcement ring into concrete when the level is about 60mm below the ground level and then complete the pour prior to the insertion of the plastic socket.

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Figure 6. Post and foundation arrangement with Reinforcing ring location

f) Re-compact concrete. Slope concrete away from post/socket to prevent formation of corrosion pockets. Finish to level and cure. A 20mm ‘crown’ or ‘dome’ should be formed on the top surface to encourage water dissipation.

Figure 7: Use of finishing tool to create dome (Left) Finished post foundation (Right)

g) Install post in socket and fill void with safety non-setting passive filler to a level slightly above the top of the socket, ensuring that the radius edge of the post faces oncoming traffic.

Important

• Positioning of the posts is critical.

• Measure each post center and relevant distance from the point of setback.

• Double check all dimensions before setting posts and sockets in concrete.

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Do Not:

• Cast footing in two separate pours.

• Ram a post into the socket to push it into position in the concrete, since this could push the bottom out of the plastic socket.

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Figure 8. Vibrating concrete in posthole

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Assembling the Ropes

4.1 Assembling the Ropes

The installation of the ropes is to be conducted in accordance with the following guidelines to ensure that the correct weave pattern will be installed along the length of the barrier.

4.1.1 Rope Supply

Ropes are supplied as one continuous length on reels without any fittings attached. It is recommended to swage one fitting so that attachment to one of the anchors is possible. Run out the wire in its final position under as much tension as possible. Over-cut the length at the other anchor, and repeat for the other four (4) ropes.

4.1.2 Handling Reels

The reel should be mounted on a reel stand on the back of a truck or trailer. The reel stand should not have bearings so that the rope remains reasonably taut while it is being run off.

Figure 9. Rope being run off from reel

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4.2 Rope Installation and Connection to Anchors

4.2.1 Connections to Anchors

The connection consists of a swage fitting and M16 threaded rod being coupled together by means of a fuse coupling fitting. The M16 threaded bar is then fixed to the anchor. The order of item connection to the anchor is as follows:

60 x 60 Nylon washer, 60 x 60 Steel washer, Tapered washer, M16 galvanised washer and 2 x M16 galvanised Nuts.

Figure 10. Fuse coupling/threaded bar connection

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4.3 Rope Connection

4.3.1 Installation Procedure

The following procedure outlines the steps required to install the ropes along the entire length of the fence: a) Support reel of rope on a suitable reel carrier. As a minimum arrangement the reel should be mounted on a reel stand on the back of a truck or trailer. The reel stand should not have bearings so that the rope remains reasonably taut while it is being run off. b) Starting with the rope end terminal in the anchor frame slot, using a washer, nut and locknut, connecting the safety check rope to the terminal and the anchor frame. c) Move reel carrier down fence line, paying out the rope from the reel and weaving the rope around the posts, locating the rope on the locating pegs until the point where a rigging screw connection is required. d) Connect the paid out length of rope to the next length of rope on the reel, using a rigging screw. A length of not less than 30mm of each terminal end should be inserted in end of the rigging screw. e) Continue down the fence line connecting all the ropes in a similar manner until the next anchor block. f) Attach a safety check rope to the rope and the rope end to the anchor frame using a washer and two nuts or a mechanical fitting. Connect the safety check rope to the anchor frame. g) Repeat (a) to (g) for remaining ropes. h) Place caps on tops of posts. i) Remove slack in the safety check rope by clipping it to the end of the rope using suitable plastic clips or ties. The removal of slack avoids the safety check rope causing a tripping hazard. j) Ensure that rigging screws/threaded terminals are no closer than 100mm to any post after tensioning.

To ensure that the ropes are within the correct position in the fence line, the following steps detail the connection procedure.

Step 1 – Rope Identification

Standing at the anchor block facing the terminal posts and along the length of need, the rope on the far left hand is rope number 1 and the rope on your far right is rope number 4. (See

Fig 11).

Figure 11. Rope Identification

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Step 2 – Starting the Weave of the Rope

For the below details, refer to Fig 12 for visual locations.

Rope 1 is to extend to the middle hook on the LHS of the first post.

Rope 2 is to extend to the top hook on the LHS of the first post.

Rope 3 is to extend to the bottom hook on the RHS of the first post.

Rope 4 is to extend to the middle hook on the RHS of the first post.

Step 3 – Weaving after the First Rope

TL-4 Weave Pattern

Figure 12. Rope Locations

Rope 1 continues to weave along the second from the top location to the far end of the fence.

Rope 2 weaves along the upper level until at post 4 of the terminal it sits in to the slot at the top of the post and continues straight to the end terminal.

Rope 3 continues to weave along the bottom location to the far end of the fence.

Rope 4 continues to weave along the second from the bottom location to the far end of the fence.

Figure 13. Rope Locations

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Step 4 – Ending the Weave

The weave pattern continues along the entire length of need and through the far terminal in the same manner as the start of the weave.

Stand at the far anchor block looking back along the woven fence.

The ropes come back in to the anchor in exactly the same manner as the ropes went from the first anchor. (See Fig 14 below).

Figure 14. Rope Locations for End Treatment

Note: Figure 14 above is a representation of both the approach and trailing end treatment.

The weave pattern is the same for both. Also, for a median installation, the longitudinal reverse is to take place to ensure that rope #4 is still closest to the roadway.

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Annexures to Manual

Post Foundation Site Testing Procedure

5.1 General

To enable Brifen WRSB to perform as designed it is imperative that the post can yield.

Concrete foundations can have two functions, the first being ground strengthening (these foundations have an allowable amount of movement) and the second is to enable repair of the Brifen WRSB after a vehicle impact without having to repair the ground. It is recommended that before installation begins posts should be installed in sockets and the destructive test carried out to ensure the post yields before the foundation moves.

5.2 Post Foundation Test

The concrete foundation should require no maintenance for the life of the Brifen WRSB. The post may be damaged and may be replaced several times, but the foundation should be stable and incur no maintenance cost.

Prior to starting construction a series of load tests can be undertaken to minimise the size of the post foundation. Typically post foundations are constructed at depths of 600mm (in very hard ground), 750mm (in compact ground), and 950mm (loose sands). These load tests can be carried out on a variety of post foundation sizes to see which size will perform best in the site soil conditions.

A load test is usually required when:

1. Stipulated in the Contract.

2. When non-standard foundation sizes are used (the standard foundation size for compacted road base is 250mm dia x 750mm depth).

3. When the Supervising Engineer has identified soft clay or medium to loose sand profiles, and suspects that the standard foundation dimensions will be insufficient.

4. When the Supervising Engineer has identified hard strata and wants to investigate whether the foundation depth can be reduced.

5. When the post foundations are constructed on a batter and the Supervising Engineer suspects that the standard foundation dimensions will be insufficient.

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Methodology

a) Ensure that the concrete has partially cured for at least 4 days and that the concrete strength is at least 18MPa prior to conducting the load test. b) Place a post into the plastic socket of the concrete foundation. c) Attach a sling (synthetic is preferred to avoid post damage) to the post 600mm above ground level and a load cell to this sling. d) Rig a lever hoist or equivalent to the load cell and anchor the apparatus to a truck parked alongside. e) Using the lever hoist, generate a force of 10kN as read off the calibrated load cell. f) This method applies a bending moment of 6kN. If the foundations can withstand this bending moment with minimal horizontal movement (3mm) at ground level, then the foundation it is proven to be acceptable. g) Note: If the concrete foundations are to the full depth of 750mm it is usually unnecessary to perform such a test unless the ground conditions are unusually soft or the soil is cohesion less. h) A typical arrangement for the load test is shown in the following picture. The equipment is simply a mechanical or digital load gauge in line with mechanical or hydraulic tensioning device coupled to a solid object one end and to an assembly (in this case a chain sling) to load the post 600mm above ground level.

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A photo-sequence of the test follows:

Prepare post load assembly

In this case a digital load gauge is shackled to the post and to a chain block. A concreter’s truck provides the resistance.

Prepare the reference point

In this case a string line is set across the post foundation at a known distance from the edge of the plastic socket insert into the post foundation.

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Check all measurements

In this case a certified testing facility was engaged for an independent assessment of the post foundation capacity to resist the load imposed by the post.

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Load the post

Once all the measurements are checked apply a load of 10 kN.

Determine the result

Once the load of 10 kN has been applied at

600mm above ground level, then measure the deflection.

A result of 0-3mm is deemed acceptable.

Movement of >3mm must be assessed in relation to further load tests on adjacent posts.

Records and Results

The result of all tests should be recorded by location with photographs and the attached test report sheets.

If a single result is greater is >3mm then load test the adjacent post foundations to determine if it is a unique result or not.

If the fence is in a high impact zone (middle of a highway) that is expensive to affect lane closure then the contract may require ALL test results to be >3mm (to ensure minimal maintenance in the future).

If the fence is on a bend in a country road with low traffic volume and the result was 10 tests with seven passes and three readings in the range 3mm-6mm then the Supervisor may deem a satisfactory result.

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Wire Rope Tensioning Procedure

6.1 Initial Checks

Before continuing to tension the ropes you must perform the following checks:

• Ensure that the threaded terminal ends are securely placed in the anchor blocks and threaded terminals fitted with nut and locking nut. There should be at least three threads showing on the outside of the locking nut.

(Temporary locking wire passed through the holes provided in the anchor plate will ensure ropes are not dislodged during tensioning).

• Ensure that all rigging screw threads are lubricated before assembly to facilitate adjustment and/or removal during maintenance or repair of the Brifen WRSB and have a minimum thread engagement of 30 mm before tensioning.

• Ensure that all ropes are correctly located and are placed on the appropriate terminal posts.

• Ensure that the upper rope(s) are in the slots of the posts and are led to the anchor frame from the correct slot in the terminal post.

• Safely remove initial installation slack by tensioning each of the fence ropes from one end anchorage by means of a three tonne rated rope grip and 1.5 tonne rated strop.

Tighten nuts and lock nuts on threaded terminals to remove slack from system.

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6.2 Determining the Tension

To determine the correct rope tension, first a Tension Vs Temperature chart is needed for the region the fence is being built in. The correct tension for the Average Annual Daily

Temperature (AADT) is 22.25kN. The following table shows the tension variation with 5°C increments in temperature.

Determine the difference for the site temperature at time of tensioning to the AADT and then work out the required tension and allowable tension range from this table.

Site Temperature

Standard

Tension (kN) for

AADT

Allowable

Minimum

Tension (kN)

Allowable

Maximum

Tension (kN)

-20°C

-15°C

-10°C

-5°C

AADT

+5°C

+10°C

+15°C

33.25

30.50

27.75

25.00

33.25

30.50

27.75

25.00

22.25

19.50

16.75

22.25

19.50

16.75

14.00 14.00

Table 1. Tension of WRSB determined by Average Annual Daily Temperature

41.60

38.10

34.70

31.20

27.90

24.40

17.50

16.80

6.2.1 Determining the AADT

Average annual daily temperatures range from 9°C in the south to 16°C in the north of New

Zealand. The coldest month is usually July and the warmest month is usually January or

February. There are relatively small variations between summer and winter temperatures, although inland and to the east of the ranges the variation is greater (up to 14°C).

Temperatures also drop about 0.7°C for every 100 m of altitude.

The AADT for New Zealand is found from the National Institute of Water and Atmospheric

Research (NIWA) web site www.niwa.co.nz

The table below gives the AADT for most New Zealand locations and was correct at the release date of this manual.

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LOCATION

Average Annual Daily

Temperature °C

Highest Daily

Temperature °C

KAITAIA

WHANGAREI

AUCKLAND

TAURANGA

HAMILTON

ROTORUA

GISBORNE

TAUPO

NEW PLYMOUTH

NAPIER

WANGANUI

PALMERSTON NORTH

MASTERTON,

WELLINGTON

NELSON

BLENHEIM

WESTPORT

KAIKOURA

HOKITIKA

CHRISTCHURCH

MT COOK

LAKE TEKAPO

TIMARU

MILFORD SOUND

QUEENSTOWN

ALEXANDRA

MANAPOURI

DUNEDIN

INVERCARGILL

12.9

12.6

12.4

11.7

12.1

8.8

8.8

11.2

10.3

10.7

11.9

13.7

14.5

14.0

13.3

12.7

12.8

12.6

15.7

15.5

15.1

14.5

13.7

12.8

14.3

10.8

9.3

11.0

37.2

32.0

35.7

9.9

32.2

Table 2. Average Annual Temperatures for New Zealand locations

36.0

28.6

33.3

30.0

41.6

32.4

33.3

37.2

28.3

34.1

33.0

30.3

35.8

32.3

33.0

35.2

31.1

36.3

30.2

30.8

30.5

33.7

34.7

31.5

38.1

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Lowest Daily

Temperature °C

-6.8

-5.0

-8.4

-11.7

-8.1

-8.0

-9.0

-8.8

-3.5

-0.6

-3.4

-7.1

-12.8

-15.6

-6.0

-6.9

-1.9

-6.6

-6.3

-2.4

-3.9

-2.3

0.9

-0.1

-2.5

-5.3

-9.9

-5.2

-5.3

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6.3 Tensioning the Ropes

The following steps will outline the process involved in tensioning the ropes to the correct tension required:

Step 1

Starting at one end of the fence in the vicinity of the first rigging screw, turn the meter on by pressing the on-off button and pulling out the pin. Open the lever arm and hang the metre on one of the ropes (See Fig 2 below). Ensure that all three rollers are riding on the rope, then close the lever arm and lock it in position. The centre roller will deflect the rope. Read the rope tension in the display. Record the tension in the tension log provided.

Figure 1. Left: Tension meter in box Figure 2. Right: Tension Meter attached to Brifen Rope

Step 2

Check the air temperature and determine the tension range required for that time of day.

Refer to Section 4.2 for details on the determination of the Average Annual Daily

Temperature and how this effects the tension of the system.

Step 3

Commence tensioning: Ideally in early morning, at the rigging screws nearest to one end anchor.

Remove the rope tension indicator and adjust the rigging screw to achieve desired rope tension. The rope tension indicator should be removed from the rope between each reading; if this is not done an inaccurate reading will be produced because the deflection in the rope caused by the metre will not be removed by the increased or decreased tension. The two terminal ends should be held steady with wrenches whilst the rigging screw is rotated.

Protect the galvanised finish with leather or heavy cloth strips under the wrench jaws. See

Fig 3 below for visual indication of the setup. After tensioning, re-attach rope tension indicator and check tension.

Figure 3. Tension Setup

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Step 4

Repeat Step 3 for each rope until the tensile force, as measured by the tension indicator, is at the required reading. Recheck that rigging screw/terminal ends have a minimum thread engagement of 30mm.

Note: The ambient air temperature must be checked on a regular basis and the appropriate tension used.

Proceed along the fence to each group of rigging screws and repeat the above procedure.

Upon completion of tensioning the following checks must be conducted:

• Check for any movement in the anchor blocks and deflection posts. If any movement is observed in any of the foundations, larger blocks are required.

• Ensure that no part of the threaded terminal is closer than 100mm to a post.

The Tension Log Is provided to record all information throughout the tensioning process to ensure uniformity throughout the system.

Date

Region AADT

Current Temp

Time

Tension (kN)

Rigging Sc

A

B

C

D

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Tension Log

Table 3. Tension Log Table

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6.4 Notes

• Appropriate tension settings must be determined using the rope tension table.

• The rigging screws should be lubricated before assembly to facilitate adjustment and/or removal during maintenance or repair of the safety fence. If lubricant is needed, a copper anti-seize lubricant is recommended.

• Care should be taken to ensure that tension is consistent throughout the system. It has been found that the appropriate tension may be obtained by applying an initial force of approximately 120% of that required and vibrating the ropes by rapping the line posts with a rubber mallet of by use of a mechanical vibrator. This accelerates the creep and redistribution of the tensile force by reducing the friction between the posts and the interwoven ropes.

• When a tensile force of +/-20% of the Rope Tension Table value is recorded along the length of the rope, the procedure is complete.

• Due to the natural settling and redistribution of tension in the ropes, a second tensioning is recommended after approximately a two to three week period. Use the tensions listing on the rope tension table for the rope temperature, and record findings in the tension log.

• Future checks of tension should be within approximately +/-20% of these values.

• Future tension checks at varying locations after installation can have significant variation from the Tension Table values but this is normal and expected. As long as the ropes are tight enough to prevent droop in the ropes between posts, the system will operate as designed. In coastal locations it is recommended that tape be used to ensure the threads are maintained in good condition.

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19mm Galvanised Wire Rope – On Site Swaging Procedure

7.1 Personal Protection

Before operating the swaging and tensioning equipment read all instructions and follow the safe operating procedures. While operating this equipment it is recommended that the following personal protective equipment be worn:

• Long sleeve shirt and trousers or overalls.

• High visibility vest or high visibility component included in clothing.

• Gloves.

• Safety glasses/ face shield or other appropriate eye protection.

• Steel capped protective footwear.

To avoid personal injury keep hands and feet away from moving components during operation. Always keep your body to the side of the swaging operation, and ensure guards are in place during operation. Be sure there is adequate ventilation when the generator is in use.

Running the generator will cause the engine and exhaust to become hot. Keep body parts clear until components have cooled.

Ensure that the equipment is in proper working order and the guards are all in place; cycle the equipment at least once without a swage fitting in the dies before commencing the job.

Read all instructions, warnings and cautions carefully. Follow all safety precautions to avoid personal injury or property damage during system operation.

CSP Pacific cannot be held responsible for damage or injury resulting from unsafe product use or incorrect product and/or system operation. Contact CSP Pacific when in doubt regarding safety precautions and operations.

7.2 Equipment Operation

The CSP Pacific swaging unit is designed for the swaging of CSP supplied swage fittings, keep free of kinks and keep away from fire. All other use is prohibited. Avoid kinking or twisting the hoses and avoid contact with fire.

7.3 Site Safety

Identify the area where work is to be completed and clear area of debris so there are no trip hazards or other obstructions which may prevent the work being conducted in a safe manner and ensure suitable traffic control is in place.

Select a safe area where the swaging and tensioning unit will sit during the duration of the process. Make sure the area complies with the site safe working conditions.

Observe weather conditions and operate the equipment out of the rain, or cover if using in the rain to protect the equipment. Keep the swaging area clean and clear of debris.

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7.4 Inspections

7.4.1 Hose Inspections

Before operating the swaging unit, check that all hose connections are tight with the proper tools. If loose, tighten using proper tools. Do not over tighten. Connections need only be tightened securely and leak free.

The hydraulic hoses are fitted with protective sheathing to prevent escaping hydraulic fluid from causing injury. Do not operate the swaging tool if the sheathing is damaged or missing.

7.4.2 Hydraulic Fluid Level

Check the fluid level in the hydraulic reservoir through the oil level gauge. The power supply is to be disconnected when adding fluid to the reservoir. Only use approved Enerpac hydraulic fluid to fill the reservoir.

7.4.3 Bleeding Air from the System

Air can accumulate in the hydraulic system during the initial set-up or after prolonged use, causing the cylinder to respond slowly or in an unstable manner.

To remove the air:

1. Loosen a fitting that is situated higher than the rest of the fittings in the system.

2. Run the pump until the oil is flowing freely.

3. Tighten the fitting.

7.4.4 Generator Fuel Level

The Honda engine is designed to run on unleaded fuel. Check the fuel level before starting the generator. If refuelling is required, refuel when the engine is not running. Do not over fill, and wipe away any spilled fuel. Avoid getting water or dirt in the fuel tank. Ensure fuel is stored in an approved container.

7.4.5 Generator Oil Level

Oil is a major factor affecting performance and service life. Check the engine oil level with the engine stopped and in a level position. Use Honda 10W-30 or equivalent.

1. Remove the oil filler cap/dipstick and wipe it clean.

2. Insert the oil filler cap/dipstick into the oil filler neck, but do not screw it in, then remove it to check the oil level.

3. If the oil level is near or below the lower limit mark on the dipstick, fill to the upper limit mark. Do not overfill.

4. Reinstall the oil filler cap/dipstick.

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7.5 Generator Operation

A generator is used as the power source to the hydraulic pump.

To operate the generator:

1. Turn the fuel valve ON and turn the key to the on position.

2. Move the throttle lever to the MAX position.

3. Using the pull cord, pull the cord and start the engine

4. Move the throttle lever away from the MAX position, about 2/3 of the way toward the MIN position.

5. Turn pendant switch to the swaging position, far right as indicated.

6. Position the throttle lever for the desired engine speed.

To stop the generator in an emergency, simply push the emergency stop button (red button).

When transporting the generator, ensure the fuel lever valve isswitched OFF. If left ON, fuel may gather in the engine crankcase and dilute the engine oil.

This will reduce the lubrication properties of the oil and can cause severe engine damage.

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7.6 Swaging Unit Operation

7.6.1 Attachment of the End Fitting

Only end fittings supplied by CSP Pacific are to be used.

1. Identify the location where the end fitting is to be attached to the wire rope.

2. Cut the wire rope at the required location. This can be achieved by using a wire cutter or a disk grinder. If using a disk grinder the following is to be observed; i. The operator is to be fitted with a full face shield and PPE as noted under Personal

Protection at the beginning of this section. ii. The wire rope is to be appropriately clamped or secured. The wire rope should NOT be held by hand when cutting. iii. Care is to be taken not to contact the wire rope downstream of the cutting location.

3. When the wire rope is cut to its correct length, remove any burrs with a file and ensure the rope is correctly twisted.

4. Insert the wire rope into the end fitting. Making sure the wire rope is driven hard into the back of the fitting.

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7.6.2 Swaging the End Fitting

1. Turn the generator on in accordance with Section 4.0.

2. Remove the nut from the end fitting.

3. Feed the end fitting through the roller die area so that the threaded section of the end fitting passes through the cross bar.

4. Reattach the end-fitting nut so that the thread of the end fitting is flush with the back of the nut. Refer above.

5. Gripping the end fitting, pull back to ensure a tight connection with the cross.

6. Close the roller heads against the end fitting so they rest onthis and insert the safety key to begin the swaging operation.

7. Operate the hydraulic ram by pressing the button on the pendant control.

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July 2015 / Page 48


8. Pressure around the end fitting will increase as the hydraulic ram moves and the roller dies rotate. The end fitting will pull through the roller dies.

9. Once the swage is complete, rotate the roller dies to the front of the swaging unit.

10. Remove the end fitting from the cross bar by releasing the nut.

11. Return the nut to the end fitting.

To stop the hydraulic pump in an emergency press the emergency stop buttons located on the unit. Under normal conditions turn the main switch on the control box to the OFF position.

Completed process - Swaged wire

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7.6.3 Troubleshooting

Repairs must be performed in a dirt-free environment by qualified personnel, familiar with this equipment.

Problem

Generator will not start

Generator lacks power

Pump does not operate

Pump is not delivering oil or delivers only enough oil to advance hydraulic ram partially or erratically

Swaging Dies do not turn

Tensioning Unit does not extend or contract

Cause

1. Fuel valve OFF

2. Choke OPEN

3. Engine switch OFF

4. Out of fuel

5. Spark plug faulty

6. Flooded engine

7. Fuel filter restricted

8. Carburettor malfunction

9. Ignition malfunction

1. Filter element(s) restricted

2. Wrong fuel

3. Fuel filter restricted

4. Carburettor malfunction

5. Ignition malfunction

1. Main isolator switch OFF

2. Unit is not plugged in

3. Emergency stop button has not been reset

4. Swaging guard open

1. Low fluid level reservoir

2. Air trapped in system

3. Loose coupler

4. Contaminated oil

5. Relief valve or low pressure valve out of adjustment

1. Low fluid level

2. Directional Valve Spool is sticking

3. Oil leakage through hose of fitting

4. Selector Switch is in wrong position

5. Valve spool is sticking

1. Selector switch on pendant in wrong position

2. Low hydraulic fluid level

3. Oil leakage coming from hose or fitting

4. Blocked hose, fitting or valve

5. Valve spool is sticking

Solution

Move lever to ON position

Move lever to CLOSED position unless warm

Turn switch to ON position

Refuel

Replace spark plug

Dry and reinstall spark plug. Start engine with throttle lever in MAX position

Repair by authorised service dealer



Clean or replace filter element(s)

Drain fuel tank and carburettor and refuel




Switch main isolator ON

Plug unit in

Reset emergency stop buttons and press reset button on the control box

Close the swaging guard

Check fluid level and refill if necessary

Remove air from system

Check all couplers




Repair by authorised service provider

Tighten fittings or replace hoses and refill tank with hydraulic oil

Move selector switch on pendant to swage position


Move selector switch on pendant to the tensioning position.


Tighten fittings or replace hoses and refill tank with hydraulic oil



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July 2015 / Page 50


Upgrade of Pre 2014 Single & Double Terminal Ends to TL-3

7.7 Upgrade Procedure

7.7.1 Background

There are multiple existing Brifen Terminal end installations within New Zealand that have been installed using single or double anchor blocks, pre 2014. These terminal ends are required to be upgraded to the tested TL-3 specification if they are impacted or the installation is being upgraded or modified.

Below is the maintenance procedure when these older terminal ends are impacted and require repair.

7.7.2 TL-3 Terminal End

The TL-3 tested approved terminal end is identified on drawing WR3045.

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7.7.3 Installation upgrade procedure for single anchor block option

• Remove all A & B Posts (flat top and 125mm wide).

• Remove existing concrete foundations for Anchor Block and A & B Posts.

• Install new terminal foundations with sockets according to current installation manual and drawing WR3045.

• Remove 15 Length of Need Posts (flat top and 100mm wide).

• Measure the socket depth, if 400mm deep continue installing new Length of Need posts as per drawing WR1066.

• If sockets are 300mm deep then shorten the new Length of Need posts by 100mm and treat the cut section of the post with a zinc rich cold galvanising paint.

• New foundations will be required where the existing are damaged. These new foundations are to be constructed as per current installation manual and drawing

WR3045.

• Rope heights need to be within ±50mm of those dimension shown on drawing

WR1066. If they are not contact CSP Pacific for advice.

• Please note that post 4 of the new terminal end could be 100mm higher than the heights given in drawing WR1066. This means the wire rope cables will taper in height from terminal end to Length of Need posts. This height variation is only acceptable in the instance of a terminal end upgrade. It is not accepted when installing a new TL-3

Terminal End on to the TL-4 system.

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7.7.4 Installation upgrade procedure for double anchor block option

• Remove Deflection Posts (100mm wide with welded metal hooks).

• Remove existing concrete foundations for Anchor Block and Deflection Posts.

• Install new terminal foundations with sockets according to current installation manual and drawing WR3045.

• Rope heights need to be within ±50mm of those dimension shown on drawing

WR1066. If they are not contact CSP Pacific for advice.

• Please note that post 4 of the new terminal end could be 100mm higher than the heights given in drawing WR1066. This means the wire rope cables will taper in height from terminal end to Length of Need posts. This height variation is only acceptable in the instance of a terminal end upgrade. It is not accepted when installing a new TL-3

Terminal End on to the TL-4 system.

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July 2015 / Page 53

Brifen TL-4 Wire Rope Safety Barrier Product and Installation Manual

Assistant Bot

Brifen

TL-4 Wire Rope

Safety Barrier

Product and Installation Manual

1.1 Introduction

1.2 Limitations and Warnings

1.3 Safety Statements

1.4 Limited Warranty

1.5 System Overview

1.6 Brifen Anchor System Overview

1.7 Anchor Design

1.8 Post Foundation Sizes

1.9 Important Notes and Definitions of Brifen Fence

1.10 Post Selection

Design Requirements

2.1 Scope

2.2 Set Back

2.3 Clearance

2.4 Limitations on Use

2.5 Transitions Between Barrier Systems

2.6 Length of Fence

2.7 Design of WRSB in Medians

2.8 Design of Overlapping Installations

General Installation

3.1 Mark Out

3.2 Constructing Anchor Foundations

3.3 Constructing Post Foundations

Assembling the Ropes

4.1 Assembling the Ropes

4.2 Rope Installation and Connection to Anchors

4.3 Rope Connection

Annexures to Manual

Post Foundation Site Testing Procedure

5.1 General

5.2 Post Foundation Test

Wire Rope Tensioning Procedure

6.1 Initial Checks

6.2 Determining the Tension

6.3 Tensioning the Ropes

6.4 Notes

19mm Galvanised Wire Rope – On Site Swaging Procedure

7.1 Personal Protection

7.2 Equipment Operation

7.3 Site Safety

7.4 Inspections

7.5 Generator Operation

7.6 Swaging Unit Operation

Upgrade of Pre 2014 Single & Double Terminal Ends to TL-3

7.7 Upgrade Procedure

Key Features

Frequently Answers and Questions

What is the purpose of the Brifen TL-4 Wire Rope Safety Barrier?

What is the minimum length of the TL-4 system?

What is the standard dimension for the concrete anchor foundation for the TL-3 tested 4 rope terminal?

What are the typical variations in post spacing?

What is the minimum concrete strength required for the anchor and post foundations?

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