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Summary of Contents for ACP MAX-Tension TL-2
- Page 1 MAX-Tension™ TL-2 Tangent, redirective non-gating, guardrail terminal with Sabertooth Technology Training and Product Installation Manual Please call ACP on 1800 724 172 or visit www.acprod.com.au for more information July 2020...
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Page 2: Table Of Contents
Product & Installation Manual: MAX-Tension TL-2 Table of contents Limited Warranty MAX-Tension TL-2 System Overview Recommended Tools Safety Equipment Traffic Control Documentation Installation Preparation Preparation Soil Conditions Site Grading System Offset Requirements Curve Installations Panel Lapping Parts Identification Bill of Materials Installation Instructions Step 1 - Post Assembly and Installation Step 2 - Ground Strut and Soil Anchor Installation... - Page 3 Inspector Checklist Maintenance Inspection Drawings Notes ACP may make changes to this Product Manual from time to time. Please check the ACP website prior to using this Product Manual to ensure that you have the latest version. NSW/WA/SA/ACT VIC/TAS QLD/NT...
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Page 4: Limited Warranty
THE FOREGOING WARRANTY IS IN LIEU OF the Buyer forthwith upon receipt of the Buyer’s AND EXCLUDES ALL OTHER WARRANTIES notice of claim. If the claim is established, ACP will NOT EXPRESSLY SET FORTH HEREIN, reimburse that Buyer for all carriage costs incurred WHETHER EXPRESS OR IMPLIED BY hereunder. -
Page 5: System Overview
Product & Installation Manual: MAX-Tension TL-2 System Overview The MAX TL-2 is applied directly to W-Beam The MAX-Tension™ TL-2 Guardrail Terminal guardrail systems at, or transitioned to 787mm System (MAX TL-2) is a redirective, non- with panels and post spacing configured at mid- gating tension-based end terminal for span splice. -
Page 6: Recommended Tools
Product & Installation Manual: MAX-Tension TL-2 Recommended Tools Safety Equipment NOTE: The list of tools, safety equipment, and > Safety Glasses traffic control is a general recommendation and > Hearing Protection should not be considered a comprehensive list. > Gloves Depending on the specific characteristics of the job site and the complexity of the repair or >... -
Page 7: Installation Preparation
Product & Installation Manual: MAX-Tension TL-2 Preparation Soil Conditions The MAX-Tension™ TL-2 Guardrail Terminal The MAX-Tension™ TL-2 system has been System (MAX TL-2) is a redirective, non- designed to be installed in soil that meets gating tensioned-based end terminal for or exceeds the AASHTO “standard soil”... -
Page 8: Site Grading
Product & Installation Manual: MAX-Tension TL-2 Site Grading All testing was completed on a relatively flat and controlled testing environment. Ensure proper site grading prior to installation of the MAX-Tension™ TL-2 system in accordance with Federal, State and Local specifications, in addition to the AASHTO Roadside Design Guide. Source: AASHTO Roadside Design Guide, 4 Edition 2011, page 8-6 NSW/WA/SA/ACT... -
Page 9: System Offset Requirements
Product & Installation Manual: MAX-Tension TL-2 System Offset Requirements The MAX-Tension™ TL-2 system is a tangent terminal that shall be installed parallel to the edge of the roadway. The system may be installed offset away from the roadway if specified and approved by the Project Engineer. -
Page 10: Parts Identification
Parts Identification WARNING Use only ACP parts that are specified by ACP for use with the MAX-Tension™ Guardrail Terminal System. Do not use or co-mingle parts from other systems, as such configurations have not been tested nor have they been approved for use. The use of unspecified parts is prohibited and could result in severe personal injury or death. - Page 11 Product & Installation Manual: MAX-Tension TL-2 Parts Identification (Cont.) MASH W-Beam Guardrail Square Washer M16X200 Galv Hex Head M20X75 Galv Hex Head W122G, Qty. 2 FW923, Qty. 1 F123, Qty. 1 [INCL. IN MAXHDG], Qty. 4 M16X32MM Galv Splice Bolt M16X240 Galv Cup Head Guardrail Nut - 5/8 M16 Galv Round Washer...
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Page 12: Bill Of Materials
Product & Installation Manual: MAX-Tension TL-2 Bill of Materials Item # Part # Description Description 2 Quantity MAXGAG MAXTENSION GROUND ANCHOR GALV MAXGSG MAXTENSION GROUND STRUT MAXHDG MAXTENSION IMPACT HEAD GALV MAXP1G MAXTENSION POST 1 1830MM GALV MAXTSSG MAXTENSION TS SLIDER GALV Traffic Side Slider Panel MAXISSG MAXTENSION INSIDE SLIDER GALV... -
Page 13: Installation Instructions
Product & Installation Manual: MAX-Tension TL-2 Step 1 - Post Assembly and Installation Item # Part # Description MAXP1G MAXTENSION POST 1 1830MM GALV MAXLPG MAXTENSION LINE POST 1830MM The MAX-Tension™ TL-2 guardrail end terminal is designed to attach to 787mm W-beam guardrail systems. -
Page 14: Step 2 - Ground Strut And Soil Anchor Installation
Product & Installation Manual: MAX-Tension TL-2 Step 2 - Ground Strut and Soil Anchor Installation POST 1 70mm FINISHED GRADE LINE GROUND STRUT DETAIL FINISHED GRADE LINE GROUND STRUT DETAIL SIDE VIEW DETAIL Item # Part # Description MAXGAG MAXTENSION GROUND ANCHOR GALV MAXGSG MAXTENSION GROUND STRUT F123... -
Page 15: Step 3 - Blockout Installation
Product & Installation Manual: MAX-Tension TL-2 Step 3 - Blockout Installation SEE POST 4 BLOCKOUT DETAIL POST 5 NOTICE POST 4 POST 3 POST 2 POST 1 POST 4 (ONLY) POST 4 BLOCKOUT DETAIL Item # Part # Description B090534 COMPOSITE BLOCK - X350 F124 M16X240 GALV CUP HEAD... -
Page 16: Step 4 - Assemble Inner Side Slider (Iss) Panel On Rail 2
Product & Installation Manual: MAX-Tension TL-2 Step 4 - Assemble Inner Side Slider (ISS) Panel on Rail 2 NOTICE NOTICE Item # Part # Description MAXISSG MAXTENSION INSIDE SLIDER GALV W122G 3.81M MAXTENSION W-BEAM GALV F1002 M16X32MM GALV SPLICE BOLT 4.1 Prior to installing rail 2 (item 13), secure the inner side slider (ISS) panel (item 6) on upstream end of rail 2 (item 13) using the supplied hardware (item 17). -
Page 17: Step 5 - Install Rail 2
Product & Installation Manual: MAX-Tension TL-2 Step 5 - Install Rail 2 POST 6 SPLICE BOLTS & NUTS UPSTREAM NOT SUPPLIED POST 5 POST 4 NOTICE (DO NOT BOLT RAIL TO POST 4) (NO WASHERS) Item # Part # Description F124 M16X240 GALV CUP HEAD DANGER... -
Page 18: Step 6 - Assemble Traffic Side Slider (Tss) And Tooth On Rail 1
Product & Installation Manual: MAX-Tension TL-2 Step 6 - Assemble Traffic Side Slider (TSS) and Tooth on Rail 1 (BOLTS IN) ARROW DETAIL TOOTH NOTICE CUTTING EDGE RSS ENGAGEMENT HOOK TOWARD FRONT OF SYSTEM HAND (NUTS OUT) NOTICE TIGHTEN ONLY Item # Part # Description... -
Page 19: Step 7 - Install Rail 1
Product & Installation Manual: MAX-Tension TL-2 Step 7 - Install Rail 1 SLOT POST 3 POST 2 POST 1 (NO WASHERS) Item # Part # Description F124 M16X240 GALV CUP HEAD DANGER RAIL 1 IS LAPPED OVER TOP OF RAIL 2. THIS IS DONE REGARDLESS OF AN UPSTREAM OR DOWNSTREAM END SYSTEM POSITION. -
Page 20: Step 8 - Install Impact Head
Product & Installation Manual: MAX-Tension TL-2 Step 8 - Install Impact Head POST 2 POST 1 (BOLTS IN) DANGER (NUTS OUT) DANGER Item # Part # Description MAXHDG MAXTENSION IMPACT HEAD GALV FW923 50 X 50 X 3MM GALV SQUARE F1002 M16X32MM GALV SPLICE BOLT F1012... -
Page 21: Step 9 - Install Cables
Product & Installation Manual: MAX-Tension TL-2 Step 9 - Install Cables POST 4 SEE DETAIL ISS PANEL (REAR VIEW) POST 2 SLEEVE END TSS PANEL ISS PANEL TOOTH WASHER DETAIL ISS PANEL (REAR VIEW) Item # Part # Description [INCL. IN MAXHDG] MAXTENSION CABLE FRICTION PLATE MAXTL2CAG MAXTENSION TL2 CABLE ASSEMBNLY... -
Page 22: Step 10 - Turn Friction Plate
Product & Installation Manual: MAX-Tension TL-2 Step 10 - Turn Friction Plate FRICTION PLATE ENGAGED POSITION FRICTION 1.8m PRY BAR PLATE (NOT SUPPLIED) NEUTRAL POSITION TOP VIEW FRICTION PLATE ENGAGED POSITION FRICTION PLATE NEUTRAL POSITION Item # Part # Description [INCL. -
Page 23: Step 11 - Tighten Cables
Product & Installation Manual: MAX-Tension TL-2 Step 11 - Tighten Cables ISS PANEL TIGHTEN HOLD CABLE SWAGE POST 4 SEE DETAIL ISS PANEL (REAR VIEW) CABLE HOLD CABLE TIGHTEN SWAGE DETAIL ISS PANEL (REAR VIEW) CABLE CABLE HOLD SWAGE TIGHTEN CABLE TIGHTEN 11.1 Tighten cable nuts both front and rear in configuration shown. -
Page 24: Step 12 - Install Rear Side Slider (Rss) Plate And Tighten Tooth
Product & Installation Manual: MAX-Tension TL-2 Step 12 - Install Rear Side Slider (RSS) Plate and Tighten Tooth POST 4 POST 3 TIGHTEN POST 2 NOTICE Item # Part # Description MAXRSSG MAXTENSION REAR SIDE SLIDER F1002 M16X32MM GALV SPLICE BOLT 12.1 Install rear side slider (RSS) plate (8) in configuration shown using the supplied hardware (item 17). -
Page 25: Step 13 - Install Delineation Bracket Or Yellow Plastic Housing
Product & Installation Manual: MAX-Tension TL-2 Step 13 - Install Delineation Bracket or Yellow Plastic Housing 355mm 558mm AVAILABLE DELINEATION SPACE DECAL Item # Part # Description MAXBDG MAX BRACKET DELINEATION F173 14-20 X 25MM SELF DRILLING X350YN YELLOW PLASTIC NOSE HOUSING 13.1 Apply delineation decal per Federal, State, and Local Standards. - Page 26 Product & Installation Manual: MAX-Tension TL-2 13.4 Loosen (if not already loosened) the front 13.6 Fix two self-drilling hex head screws cable assembly nuts at the foot of the ground (supplied with kit hardware) through the yellow nose cover and into the predrilled holes of the strut as shown below.
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Page 27: Step 14 - Install Plastic Nut Covers
Product & Installation Manual: MAX-Tension TL-2 Step 14 - Install Plastic Nut Covers Item # Part # Description X350NC PASTIC NUT COVER 14.1 Apply plastic nut covers to all nuts exposed on the traffic side. NSW/WA/SA/ACT VIC/TAS QLD/NT July 2020 | Page 02 8708 4400 03 8773 5300 07 3442 6200... -
Page 28: Inspector Checklist
Product & Installation Manual: MAX-Tension TL-2 Inspector Checklist Confirm all items in checklist have been properly completed and hardware is tightened. Date Item Cable closest to the traffic side of the system passes through bottom hole on impact head. (Pg. 21, Step 9) Cable sleeves are at the front of the system. -
Page 29: Maintenance Inspection
> Missing components inspected for damage after every impact. > Damage from vandalism Repairs shall be made accordingly using ACP components as specified in the product > Sagging cables drawings. > Clear and dispose of any debris in and around the system Visual Drive-By Inspections ....... - Page 30 Product & Installation Manual: MAX-Tension TL-2 Walk-Up Inspection Item Comment Damage caused by vehicle impacts Minor damage caused by impacts from roadside maintenance equipment Misalignment Missing components Damage from vandalism Sagging cables Clear and dispose of any debris in and around the system Cutting tooth is in correct position Disengaged friction plate...
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Page 31: Drawings
APPENDIX Drawings NSW/WA/SA/ACT VIC/TAS QLD/NT July 2020 | Page 02 8708 4400 03 8773 5300 07 3442 6200 www.acprod.com.au... -
Page 36: Notes
Product & Installation Manual: MAX-Tension TL-2 Notes Long-Term Storage Store materials under cover in dry, well-ventilated conditions, away from doorways open to the environment. Provide adequate ventilation between stacked pieces. Elevate and separate articles stacked outdoors with spacers (poplar, ash, spruce). Incline parts to allow for Maximum Drainage.
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