Summary of Contents for Barrier Systems X-TENSION XTGTSS1
- Page 1 INSTALLATION AND MAINTENANCE MANUAL X-TENSION ® NCHRP 350 TL-3 Tangent / Flared End Terminal and Median Attenuator...
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Page 2: Table Of Contents
INsTALLATIoN ANd MAINTENANCE MANUAL Table of Contents Introduction ………………………………… 3 System Overview …………………………. 3 Before Installation ………………………… 3 Limitations and Warnings ………………… 4 Safety Statements ………………………… 4 Parts Identification ………………………… 5 Preparation ………………………………… 7 Soil Conditions …………………………….. 7 Tools Required …………………………….. 7 Before Starting …………………………….. -
Page 3: Introduction
X-TENsIoN sysTEM ® X-Tension Introduction Introduction The X-Tension Guardrail End Terminal has been designed and tested to meet the evaluation criteria of NCHRP 350 Test Level 3. The system has been tested to the guidelines in NCHRP 350 for a non-gating, re-directive guard- rail end treatment. -
Page 4: Limitations And Warnings
INsTALLATIoN ANd MAINTENANCE MANUAL X-Tension Introduction (continued) Limitations and Warnings The X-Tension Guardrail End Terminal has been rigorously tested and evaluated per the recom- mendations in the NCHRP 350 guidelines for terminals and crash cushions. The impact condi- tions recommended in NCHRP 350 are intended to address typical in–service collisions. When properly installed and maintained, the system is capable of containing and re-directing im- pacting vehicles in a predictable and safe manner under the NCHRP 350 impact conditions. -
Page 5: Parts Identification
X-TENsIoN sysTEM ® X-Tension Parts Identification Impact Head Friction Plate Soil Anchor (1 Required) 1 Required) (1 Required) B061072 B061058 B061104 Slider Bracket + Angle Bar Cable Bracket Cable Assembly (1 Required Roadside – 2 Median) (1 Required) (2 Required) B061079 B061083 B061109... - Page 6 INsTALLATIoN ANd MAINTENANCE MANUAL X-Tension Parts Identification (Continued) Post # 2 (1 Req.) Standard Steel Line Post (3-6) Post #1 Bottom Roadside can be CRT Timber (CRT Timber Posts allowed roadside) (1 Required) B061100 4002338 B061098 Standard Highway Rail 12’-6” Median Radius Rail 1 (12’-6”) Median Secondary Head (3 Required Roadside –...
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Page 7: Preparation
X-TENsIoN sysTEM ® X-Tension – Preparation for all Applications Preparation Before installing an X -Tension, ensure that all materials required for an 11.4 m (38 ft) system are on site and have been identified. See bill of materials for the particular application and parts identification sheet. -
Page 8: X-Tension Tangent Installation
INsTALLATIoN ANd MAINTENANCE MANUAL X-Tension - Tangent Installation Instructions Step 1 - Set Out The tangent terminal is essentially an 11.4m (38 ft) continuation of the standard guardrail run. Pull a string line out with the desired offset (0 -450mm : 0-1.5 ft) over the length of the system, in a straight flare (Figure 1). - Page 9 X-TENsIoN sysTEM ® X-Tension - Tangent Installation Instructions Step 2 – Installing Posts 6- 2 Install posts 6 to 2 at standard highway rail spacing (1905mm: 6 ft 3 in), to the correct height. All posts should be the same height from ground level throughout the entire sys- tem.
- Page 10 INsTALLATIoN ANd MAINTENANCE MANUAL X-Tension - Tangent Installation Instructions Step 3 – Post 1, Ground Strut and Soil Anchor Place the roadside face of post 1 bottom anchor, 200mm (8 in) towards the roadway to compensate for the lack of blockout (Figure 4). Post 1 bottom, the Ground Strut and the Soil Anchor are then placed parallel to the string line at this roadside offset position.
- Page 11 X-TENsIoN sysTEM ® X-Tension - Tangent Installation Instructions Step 5 – Hang Rail 2 and Shear Bolts Before installing rail 2, double check that the blockout is already bolted to post 3. Bolt rail 2 to the post and blockouts at posts 4 and 5 with the appropriate post bolt (Figure 8). DO NOT BOLT THE RAIL TO POST 3.
- Page 12 INsTALLATIoN ANd MAINTENANCE MANUAL X-Tension - Tangent Installation Instructions Step 7 – Assemble Slider Panel onto Rail 1 Start by sitting rail 1 on a blockout or post so that it is raised off the ground as shown (Figure 12). Slide the Slider Panel onto the downstream end of rail at post 3 location (Figure 13) and bolt into place using 4 standard splice bolts, pushing the bolt through from the inside of the slider to the outside so that the nut is on the traffic face.
- Page 13 X-TENsIoN sysTEM ® Step 9 – Attach Impact Head Place Impact Head on upstream end of rail 1 and attach using 8 standard splice bolts with nuts on traffic face (Figure 17). Hint: Place bottom two bolts first then use guardrail pin bar to lever head up snug onto rail.
- Page 14 INsTALLATIoN ANd MAINTENANCE MANUAL Step 11 – Installing the Cables Install the Friction Plate in the top of the Impact Head, adjustment hole up. Take the cable closest to the road, pick up the downstream cable fitting and walk to the head, passing the cable through the bottom hole, through the Friction Plate (Figure 21) and out the backside of the Impact Head.
- Page 15 X-TENsIoN sysTEM ® Step 13 – Tightening the Cables Only tighten the cables using the nuts at the Cable Bracket end (post 7) (Figure 25). Do not tighten the cable nuts at front of the Ground Anchor. Tighten the cables until they are taut, i.e. they rest in the backside of the W-beam and do not visibly sag between posts (Figure 26).
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Page 16: X-Tension Flared Installation
INsTALLATIoN ANd MAINTENANCE MANUAL X-Tension - Flared Installation Instructions This section deals with installation of a Flared X-Tension system in a roadside guardrail terminal end application. Apart from the initial set out, the flared X-Tension and installation procedure is identical to the Tangent system, the only difference being the amount of offset used. - Page 17 X-TENsIoN sysTEM ® X-Tension - Flared Installation Instructions Step 1 - Set Out Pull a string line out with the desired offset (0 -1.2m; 0-4 ft) Note that the flare is a straight flare, over the length of the system (11.4m; 38 ft) The string line should be set to follow the roadside edge of the posts (Figure 29).
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Page 18: X-Tension Median Installation
INsTALLATIoN ANd MAINTENANCE MANUAL X-Tension - Median Installation Instructions This section deals with installation of a Median X-Tension system as a Median guardrail terminal end application. Site preparation The Median X-Tension system is installed parallel to the standard median barrier, therefore no offset is used (Figure 32). - Page 19 X-TENsIoN sysTEM ® X-Tension - Median Installation Instructions Step 1 - Set Out The Median X -Tension is essentially one Tangent X-Tension installed parallel to one side of the median barrier (Figure 33), with a small number of additional components and rail attached parallel with the other side of the barrier (Figure 34).
- Page 20 INsTALLATIoN ANd MAINTENANCE MANUAL X-Tension - Median Installation Instructions Step 3 – Attach Secondary Impact Head Fit secondary head to main head by pushing sideways onto the main head as shown below (Figure 35), until the holes in the gussets line up. Fix into place with either the 25mm (1 in) pin and pin lynch, or 2 M24 x 50mm (1 in X 2 in) bolts as shown (Figure 36).
- Page 21 X-TENsIoN sysTEM ® X-Tension - Median Installation Instructions Step 5 – Attach Slider Bracket to Backside Rail 2 Bolt the Slider Bracket to the upstream end of rail 2 (at post 3) using 4 standard splice bolts (Figure 39). The angle bar end should be closest to the Impact Head end (Figure 40). Remove the angle bar and 2 M20 X 25mm (3/4 in x 1 in) bolts.
- Page 22 INsTALLATIoN ANd MAINTENANCE MANUAL X-Tension - Median Installation Instructions Step 7 – Hang Curved Backside Rail #1 Lift rail 1 with Slider Panel attached and push the slider end over rail 2. Bolt rail 1 and blockout to post 2 using supplied standard post bolt and 50x50mm (2 in x 2 in) washer on inside of post bolt notch on the backside of post 2 (Figure 43).
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Page 23: Optional Nose Cover
X-TENsIoN sysTEM ® X-Tension - Median Installation Instructions Step 8 – Attach Nosing Push nosing into place on the front of the impact head. Attach using the supplied nylon push rivets (Figure 47). Delineation to be attached to nosing, as per Local Authorities requirements. Figure 47. -
Page 24: Installation Checklist
INsTALLATIoN ANd MAINTENANCE MANUAL INSTALLATION CHECKLIST FOR X-Tension Systems Location Installed By Date Inspected By Date X-Tension Tangent and Flared Systems [System Length 11.4m (38ft)] Y/N NA • Rail is bolted at all posts except post 3. • Post 1, post bolt notches face impact head. Bolted to ground strut. •... -
Page 25: Traffic Face Impacts
X-TENsIoN sysTEM ® X-Tension Maintenance (Traffic Face Impacts) Types of repair are divided into two categories: Traffic Face Impacts and Head on Impacts (Next Page) Traffic Face Impacts Key Repair Steps: 1. Remove cables 2. Remove damaged rail 3. Remove components from rails 4. -
Page 26: Head On Impacts
INsTALLATIoN ANd MAINTENANCE MANUAL X-Tension Maintenance (Head on Impacts) Head on Impacts Key Repair Steps: 1. Remove the cables 2. Pull the rails back 3. Remove components from rails 4. Remove damaged posts 5. Assess damage 6. Reassemble Step 1: Remove Cables After a head on impact the cables may appear to be slack but may in fact still retain some tension from the impact. -
Page 27: Roadside / Imperial Wood Blockout - Wood Post
X-TENsIoN sysTEM ® Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800... -
Page 28: Roadside / Imperial Wood Blockout - Steel Post
INsTALLATIoN ANd MAINTENANCE MANUAL Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800... -
Page 29: Roadside / Imperial Composite Blockout - Steel Post
X-TENsIoN sysTEM ® Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800... -
Page 30: Median / Imperial Wood Blockout - Steel Post
INsTALLATIoN ANd MAINTENANCE MANUAL Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800... -
Page 31: Median / Imperial Composite Blockout - Steel Post
X-TENsIoN sysTEM ® Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800... -
Page 32: Roadside / Metric Wood Blockout - Wood Post
INsTALLATIoN ANd MAINTENANCE MANUAL Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800... -
Page 33: Roadside / Metric Wood Blockout - Steel Post
X-TENsIoN sysTEM ® Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800... -
Page 34: Roadside / Metric Composite Blockout - Steel Post
INsTALLATIoN ANd MAINTENANCE MANUAL Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800... -
Page 35: Wood Blockout - Steel Post
X-TENsIoN sysTEM ® Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800... -
Page 36: Composite Blockout - Steel Post
INsTALLATIoN ANd MAINTENANCE MANUAL Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800... - Page 37 Page Left Intentionally Blank Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800...
- Page 38 Page Left Intentionally Blank Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800...
- Page 39 Page Left Intentionally Blank Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800...
- Page 40 180 River Road • Rio Vista, CA 94571 • +1 707.374.6800 U.s. Toll Free: 888.800.3691 • www.barrriersystemsinc.com Installation manual details for the X-Tension System are subject to change without notice to reflect improvements and upgrades. Additional information is available from Barrier systems sales and service © Lindsay Transportation solutions XT06 041112...
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