T-Lok Barrier 350

F-type profile
Portable Safety Barrier System
For Speeds Up to 100 km/h (TL-3)
T Lok 350
Product Manual
T-Lok Barrier 350
SAFEROADS P/L
PO Box 340, Drouin, VIC 3818, Australia
Email: sales@saferoads.com.au
Phone: 1800 060 672 Fax: 1800 060 673
Version 4.1.6
August 2013
This page is intentionally left blank
T-Lok Barrier 350
Table of Contents
System Overview
Introductory Notes ........................................3
System Overview ...........................................3
System Design................................................ 4
Length of Need.............................................. 8
End Treatment................................................8
Deflection ......................................................9
Installation......................................................12
Inspection.......................................................13
Limitations and Warnings.............................. 13
Site Clean up, Post Impact………………………….14
T-Lok Anchors…………………………………………….15
Important Notes regarding lifting and using
Swift Lifts provided………………………………..……16
Safe Working Method Statement ................. 18
Fence Panel Detail………………………………………20
T-Lok 350 Vs. T-Lok Mash Drawings…………...21
Saferoads T-Lok Barrier provides several
unique advantages over traditional portable
concrete barriers, or other styles of portable
safety barriers:
• Energy-absorbing
• Quick and easy deployment and retrieval
• Economical
• Variety of deployment and end terminal
options
Saferoads T-Lok Barrier is crashworthy and
has been thoroughly tested to NCHRP 350
and MASH 09 testing procedures.
Saferoads T-Lok Barrier has achieved Test
Level 3 (TL-3) as a redirecting longitudinal
safety barrier for speeds up to 100km/h.
Important Introductory Notes
Proper design, deployment and maintenance
of the Saferoads T-Lok Barrier is essential to
ensure maximum performance.
It is critical for any users of the Saferoads T-Lok
Barrier to be fully familiar with the
manufacturer’s instructions for use.
Take the time to review this manual before
performing the necessary work.
Do not attempt to install any longitudinal
barrier without the proper plans and
installation manual from the manufacturer.
If you need additional information, or have
questions about the Saferoads T-Lok Barrier,
please call:
Saferoads P/L Customer Service Department
at 1800 060 672.
Function
Saferoads T-Lok Barrier functions as a
portable longitudinal barrier to prevent
errant vehicle penetration, vaulting, or
under riding. Traffic is kept from entering the
work area or from hitting exposed objects or
excavations. Unlike cones or barricades,
Saferoads T-Lok Barrier provides positive
protection for roadside workers.
Impacting vehicles are redirected at a
shallow angle in the vicinity of the impact
area, thereby reducing the potential for
dangerous secondary impacts. Saferoads TLok Barrier absorbs impact energy and
cushions
vehicular
impacts
while
significantly reducing the risk to occupants
of the impacting vehicle.
NCHRP350 Vs MASH09
The T Lok Barrier now has 2 versions. The
existing T Lok 350 and the new T Lok Mash.
The main difference is the redesign of the T
& C connections so both versions are
operationally the same bar this change.
NCHRP350 = 2000Kg @ 100Kmh
MASH09 = 2250Kg @ 100Kmh
3
T-Lok Barrier 350
System Design
Construction
A Saferoads T-Lok Barrier is constructed from a
series of individual barrier sections. See Figure
1
The ends of each sections are constructed with
T & C Connections.
Their unique design allows for easy assemble
as well as angled adjustment to achieve up to
7 degrees radius curving for tapers and
corners. (See page 7 Figure 5)
Figure 1
Saferoads T-Lok Barrier
T&C Connections
Application
The Saferoads T-Lok Barrier can be used in
many applications.
Some examples are:
! General road maintenance performed by
road authorities, contractors, local
municipalities etc.
! Road construction
! Lane closures
! Toll plazas
! Road Resurfacing
4
!
!
!
!
Excavation or culvert protection
Detours or diversions
Bridge Repairs
Temporary or permanent
installations
! Median or verge installations
T-Lok Barrier 350
System Design (cont’d.)
In order to design the most appropriate
Saferoads T-Lok Barrier System for a given site,
this manual helps to answer the following
questions:
! Is the Saferoads T-Lok Barrier . appropriate
for my site?
! What is the application? What warrants use
of the Saferoads T-Lok Barrier?
! How long must the barrier be? Refer to the
length of need and beginning of length of
need for Saferoads T-Lok Barrier installation
options.
! How much distance for dynamic deflection
of the barrier is available if the barrier is
impacted, and how much is required for the
correct functioning of the system?
! Are there curves, slopes or kerbs present
which may not suit the Saferoads T-Lok
Barrier?
! Is a fully tested end treatment available to
suit my particular requirement? Refer to
end terminal section of this manual.
! Do I need the higher capacity offered by the
Mash 09 version or is the T Lok 350
adequate?
The purpose of this manual is to supply some
basic application information about the
Saferoads T-Lok Barrier and to detail its
performance when tested to NCHRP 350 or
MASH 09
If you would like further assistance, please
contact:
Saferoads P/L Customer Service Department
1800 060 672.
5
T-Lok Barrier 350
System Design (cont’d.)
Figure 2
6
T-Lok Barrier 350
System Design (cont’d.)
Figure 3
7
T-Lok Barrier 350
System Design (cont’d.)
Length Of Need
Length of Need (L.O.N) is defined as the total
length of a longitudinal barrier needed to
shield an area of concern.
It is also described as that part of a
longitudinal barrier or terminal designed to
contain and redirect an errant vehicle.
The beginning of length of need (B.L.O.N)
differs depending on how the Saferoads T-Lok
Barrier is deployed.
If the Saferoads T-Lok Barrier is deployed as a
safety barrier which can be tapered through
the clear zone without the need for an
approved end terminal, the B.L.O.N. is 21
metres from the beginning of the system.
If the Saferoads T-Lok Barrier is deployed
longitudinally and incorporates the QuadGuard
cz as an end terminal, which is tethered to the
ground, then the B.L.O.N is at the very
beginning of the QuadGuard crash cushion.
km/h [62mph] redirective longitudinal
barrier, and when deployed and tapered
through the clear zone, does not require a
separate end treatment, however the use of
an approved end treatment should be
considered first.
The QuadGuard CZ end terminal or
approved equivalent is suitable for posted
speeds up to TL-3/100 km/h. As this
terminal requires tethering to the pavement,
it will offer the shortest Saferoads T-Lok
Barrier deployment.
The QuadGuard CZ is suitable for use where
the length of need occurs at or near the
beginning of the terminal. Refer to the
QuadGuard manual for specific detail.
Minimum Length
The minimum length of a T-Lok Barrier
installation should be 58m.
End Treatment
A terminal is defined by NCHRP 350 as:
“A device designed to treat the end of a
longitudinal barrier. A terminal may function
by (a) decelerating a vehicle to a safe stop
within a relatively short distance, (b)
permitting controlled penetration of a vehicle
behind the device, (c) containing and
redirecting the vehicle, or (d) a combination of
(a), (b) and (c).”
The Saferoads T-Lok Barrier has been crash
tested to NCHRP 350 as a Test Level 3 (TL3/100
8
T-Lok Barrier 350
System Design (cont’d.)
System Deflection
System deflection can be calculated by using the following formula:
Dm x Mt (vt * sin t) 2
NORMALISED DYNAMIC DEFLECTION (DN) IN M =
Mm (Vm * sin M) 2
System Deflection
Angle of Impact
5 degrees
10 degrees
15 degrees
20 degrees
25 degrees
Design Speed
(km/h)
Deflection
(m)
Deflection
(m)
Deflection
(m)
Deflection
(m)
Deflection
(m)
50 km/h
0.01
0.05
0.12
0.21
0.32
60 km/h
0.02
0.07
0.17
0.30
0.46
70 km/h
0.03
0.11
0.23
0.41
0.62
80 km/h
0.03
0.14
0.31
0.53
0.81
90 km/h
0.04
0.17
0.38
0.68
1.03
100 km/h
0.05
0.21
0.48
0.84
1.27
Angle of Impact
5 Degrees
10 degrees
15 degrees
20 degrees
25 degrees
Design Speed
(km/h)
Working
Width (m)
Working
Width (m)
Working
Width (m)
Working
Width (m)
Working
Width (m)
50 km/h
0.62
0.66
0.73
0.82
0.93
60 km/h
0.63
0.68
0.78
0.91
1.07
70 km/h
0.64
0.72
0.84
1.02
1.23
80 km/h
0.64
0.75
0.92
1.14
1.42
90 km/h
0.65
0.78
0.99
1.29
1.64
100 km/h
0.66
0.82
1.09
1.45
1.88
Working Widths
9
T-Lok Barrier 350
System Design (cont’d.)
Other Considerations
Certain conditions may effect the performance of the Saferoads T-Lok Barrier. Since every job site
is unique, the designer needs to consider the following conditions when incorporating the
Saferoads T-Lok Barrier in the design.
Curves
The ends of each section are constructed with unique T&C Connection design that interlocks all
the segments together.
The sections can swivel up to 7 degrees at the connection for easy positioning around work areas
or following road contours. See Figure 5. Refer to Page 24 for detail on T-Lok 350 Vs. T-Lok Mash
Figure 5
Slopes
Cross slopes
The Saferoads T-Lok Barrier can be placed on
cross slopes up to 5% (3o). (Figure 6).
Longitudinal slopes
The Saferoads T-Lok Barrier may be placed on
longitudinal slopes up to 5%(3 deg.) (Figure 7).
Figure 6
Cross Slopes
Figure 7
Longitudinal Slopes
10
T-Lok Barrier 350
System Design (cont’d.)
Crest
The Saferoads T-Lok Barrier has the ability to
conform to a crest up to 20:1 (See Figure 8).
Please note the maximum longitudinal slope
in Figure 7. Refer to Page 23 for detail on TLok 350 Vs. T-Lok Mash
Ditch
Figure 8
The Saferoads T-Lok Barrier has the ability to
conform to a ditch up to 20:1 (See Figure 9).
Please note the maximum longitudinal slope
in Figure 7. Refer to Page 23 for detail on TLok 350 Vs. T-Lok Mash
Kerbs
Figure 9
The Saferoads T-Lok Barrier should NOT be
placed directly against a kerb that can
prevent it’s lateral movement (See Figure
10a). The Saferoads T-Lok barrier should not
be placed on top of a kerb or placed within
the expected deflection zone of the kerb (See
Figure 10b).
Figure 10a
Trenches
The Saferoads T-Lok Barrier should NOT be
placed directly up to the trenches or
excavations where the necessary deflection
of the system in the event of an impact may
result in barrier failure.
Reference to safe working widths is detailed
in the deflection summary.
11
Figure 10b
T-Lok Barrier 350
Installation
Preparation
Required Tools
Begin preparing for the installation by
thoroughly reviewing the specified barrier
location, layout and orientation as per the
approved traffic management plan.
For a typical installation, the recommended
tools and equipment are:
Barriers should be placed on a flat, stable and
compacted surface capable of being trafficked
by road vehicles for short periods. The crossfall
should not exceed 6%. Unstable surfaces such
as deep mud, uncompacted sand or excessively
wet surfaces are considered inappropriate.
Ideally the surface should be paved and free of
swales, ditches or other irregularities. The
minimum width of stable ground behind the
barriers should not be less than the expected
deflection of the barrier system.
Determine the number of segments required
for the installation. The installed length of each
Saferoads T-Lok Barrier segment is 5.4 or 3.6
metres. Consideration must be given to
determine if an end treatment is required and
allow for the length of the treatment in
determining segments required. A visual
inspection should be carried out to confirm the
suitability of all segments. Should visible
damage be evident in any segments, they
should be sent for inspection and refurbishment
prior to use.
Caution: Refer to the minimum installed
lengths as illustrated in this manual to ensure
compliance to NCHRP 350.
WARNING!
1. Saferoads T-Lok Barrier Installation Manual.
2. Traffic control plan and approval (as
required).
3. Traffic control equipment (as required).
4. A truck mounted crane or forklift suited to a
minimum 4000kg lift and appropriate
slinging gear.
Deployment
Only begin deployment at the upstream traffic
end of the site and work downstream. Work
from the non-traffic side of the installation
whenever possible.
Unloading proceeds much faster if one person
remains on truck and two people work on the
ground. If site conditions permit, a fourth
person can drive the truck so that segments
can be unloaded continuously as the
installation is progressing.
Align the segments according to the specified
configuration and layout in the traffic control
plan.
Install approved Delineators as required by
relevant State Road Authority Specifications.
Caution: The existence of any cross slopes in
excess of 5% (3o) or kerbs may create a
vaulting effect on the impacting vehicle.
The correct safety equipment and approved
traffic management must be used as
required for any installation using the
Saferoads T-Lok Barrier.
12
T-Lok Barrier 350
Installation (cont’d.)
Limitations and Warnings
Caution: When deploying the Saferoads T-Lok
Barrier, care must be taken not to exceed the
maximum recommended taper angle as
detailed in this manual.
The Saferoads T-Lok Barrier has been fully
tested
and evaluated
as per the
recommendations of NCHRP 350.
If an end treatment is specified for the layout,
follow the instructions provided by the
manufacturer and install it at this time.
The Saferoads T-Lok Barrier is capable of
decelerating and redirecting an errant vehicle
(820kg and 2000kg) at speeds up to 100 km/h
(Test Level 3).
Caution: A crashworthy end treatment must be
supplied where warranted to ensure proper
crash performance.
Deployment is now complete. Take the time to
double check the integrity of the system as to
confirm functionality.
Retrieval
Retrieval is a reverse of the instructions for
deployment.
Inspection
A visual inspection of each barrier segment is
required prior to shipping.
Barrier segments which show evidence of prior
impact should be thoroughly inspected for any
sign of distortion or disfigurement.
Under normal operating conditions, T-Lok
barriers require no maintenance other than
regular inspections for damage, removal of litter
and debris.
IMPORTANT!
If cracks in the T-Lok barrier are detected,
the barrier should be removed from service
immediately. Any cracking will compromise
the structural integrity of the T-Lok barrier.
13
To ensure adequate performance in the event
of an impact, the Saferoads T-Lok Barrier must
be deployed and maintained in accordance
with the manufacturer’s instructions, NCHRP
350, and local authority guidelines.
Impacts that exceed the design capabilities
described in this manual (vehicle weight,
speed and impact angle) may not result in
acceptable crash performance as described in
NCHRP 350 relative to structural adequacy,
occupant risk and vehicle trajectory factors.
Higher than reported deflections can be
expected in the B.L.O.N section.
Post impact the barrier should be inspected to
ensure their structural integrity is maintained.
If lifters show signs of fatigue, corrosion or
excessive cracks in the vicinity of the lift,
advice on safe handling should be sought from
Saferoads or follow the Lifting procedures
detailed on page 16.
*Do not affix anything to the T-Lok Barrier
without first confirming suitability with the
manufacturer.
T-Lok Barrier 350
Site clean up after impact
Saferoads recommend the following
guidelines be considered should a T-Lok
Barrier system be impacted in the field.
As the T-Lok is a concrete element, in doing
it’s job it can often be damaged beyond
repair. Sometimes the barrier will break apart
into smaller rubble depending on the severity
of the impact and the mass of the impacting
vehicle.
Saferoads recognize this is a consequence of
using concrete barriers and recommend users
of T-Lok have in place a Post Impact
Procedure as part of their Traffic
Management Plans.
The Plan should consider the following in
relation to site clean up. These relate to the
system directly and do not cover all OH&S
issues regards worker injury, driver injury, 3rd
party damage etc etc. These are the
responsibility of the barrier user, not the
barrier manufacturer.
•Control of traffic after impact
•Assessment of damage to site
•Assessment of damage to T-Lok
•Method to remove T-Lok rubble from
roadway and worksite and reopen road as
soon as practicable
•Method to remove compromised T-Lok
units from barrier run and ensure compliant
reconnection
•Procedure to reopen roadway and ensure
site is again compliant with the relevant
State approvals
Saferoads recommend that
suitable
machinery for site remediation always be
available to address post impact issues. These
could
include
Skid
Steer
Loaders,
Telehandlers, Front End Loader, Street
Sweepers, Truck for removal of debris, Traffic
Control equipment.
14
The most common type of Impact experienced in
worksites using Temporary Barriers are glancing
blows at shallow angles. Typically these type of
impacts do not compromise the integrity of the
system and show minimum deflection. Often the
run of Barriers can be simply pushed back into line
using a Skid steer or similar taking care not to
overload the connections.
Occasionally the Barrier system may experience a
capacity Impact which will destroy several T-Lok
segments. The following procedure is
recommended so as to ensure the reinstated
system is again crashworthy.
Using suitable Traffic Control and lifting machinery
remove the damaged T-Loks from the run and
clean up site debris.
It is not always suitable to simply insert new T-Loks
into the space left by the removal of the damaged
units due to possible misalignment.
Saferoads recommend working away from the
normal Traffic flow in this instance.
Using a Crane or similar suitable lifting device
remove the first undamaged T-Lok Barrier
downstream from the Impact point and shift it
forward towards the normal flow of traffic, then
interlock this unit with the end of the first T-Lok in
the gap. Repeat this until all T-Loks have been
reconnected correctly then add the replacement TLoks Barriers (for the damaged units) to the tail of
the system.
This method will ensure that the user correctly
interlocks the C & T ends to ensure
crashworthiness when reopened to Traffic. This
method also allows the system to be straightened
up as it is repaired and ensure the correct T-Lok
deflection clearance is achieved.
T-Lok Barrier 350
Anchoring procedure for T-Lok Barrier
15
T-Lok Barrier 350
Important Notes Regarding Lifting and Using
Swift Lifts Provided
Each T-Lok Barrier segment is fitted with 2x
5000kg rated Swift Lifts placed at either end of
each module. When slinging it is of great
importance to adhere to the following points so
at to avoid lifting lug failure.
Prior to attempting any lift, inspect barrier for
any signs of cracking in concrete or corrosion
or fatigue in Swift Lift fitting.
DO NOT LIFT BARRIER WITH SWIFT LIFTS if any
evidence of fatigue, corrosion or cracking is
found follow the procedure detailed on page
16.
Barrier must then be lifted from beneath.
Lifting Procedure with Swift Lifts .
! Lift one T-Lok segment only at a time.
! If binding of the connection occurs, stop lift
and readjust sling gear.
! Sling angle 60° maximum.
! Chain/sling length SL= 3.5m (2 off tied to one
ring). Shorter slings than recommended will
overload lifting lugs.
! Lifting to be vertical only.
If these conditions cannot be met we
recommend the use of an approved spreader
bar see Figures 11a and b, or T-Lok Lifting
Cradle, Figures 11c, d and e.
Figure 11a
Figure 11
Figure 11b
16
T-Lok Barrier 350
Important Notes Regarding Use of the Spreader
Bar and Lifting Cradle
When using the Spreader Bar method (see Figure
11a) care should be taken to ensure Spreader Bar
manufacturers guidelines are clearly understood
and followed.
When using the Saferoads tested Lifting cradle,
the following steps should be understood and
applied:
Lifting Procedure with Saferoads
Tested Lifting Cradle
! ensure all relevant safety regulations are met.
! attach the lifting cradle to crane using suitable
slinging equipment with S.W.L rating to
5000Kg
! lower lifting cradle over barrier ensuring
bottom plate is maneuvered into lower
drainage port (i.e. bottom edge of the barrier)
! ensure the upper portion of the lifting cradle
is positioned fully over the barrier top
! begin lifting.
WARNING!
The fully tested Saferoads Lifting Cradle is
solely designed and manufactured for
exclusive use with the Saferoads T-Lok
barrier only and should not be used for any
other purpose.
17
T-Lok Barrier 350
Safe Working Method Statement
Hazard Rating Assessment H - High Risk M - Medium Risk L - Low Risk
18
T-Lok Barrier 350
Hazard Rating Assessment H - High Risk M - Medium Risk L - Low Risk
19
T-Lok Barrier 350
Saferoads T-Lok anti debris/gawk screen
Use only Panels
supplied by Saferoads
on T-Lok Barrier
20
T-Lok Barrier 350
21
T-Lok Barrier 350
22
T-Lok Barrier 350
23
T-Lok Barrier 350
24
T-Lok Barrier 350
25
T-Lok Barrier 350
Notes
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T-Lok Barrier 350
Notes
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SAFEROADS P/L
PO Box 340, Drouin, VIC 3818, Australia
Email: sales@saferoads.com.au
Phone: 1800 060 672 Fax: 1800 060 673
http://www.saferoads.com.au Rev. August 2013 2010 Saferoads P/L