Ingalls Engineering flexfence 30/11/07 User manual

Brand: Ingalls Engineering

Model: flexfence 30/11/07

Type: User manual

Ingalls Engineering flexfence 30/11/07 is a wire rope barrier system designed to safely redirect errant vehicles and prevent them from leaving the roadway. It is a versatile system that can be used in a variety of applications, including highways, bridges, and parking lots.

The flexfence system is made up of high-strength wire ropes that are supported by steel posts. The ropes are tensioned to create a strong and durable barrier that can withstand the impact of a vehicle. The posts are spaced at regular intervals to provide support for the ropes and to prevent them from sagging.

The flexfence system is designed to be easy to install and maintain. The posts can be installed in a variety of soil conditions, and the ropes can be easily tensioned using a hand-held tool. The system is also designed to be vandal-resistant, making it a good choice for use in high-traffic areas.

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4.3 END TERMINALS

End terminals are designed to provide a soft gating impact

to prevent vehicles from launching or snagging upon impact

with Flexfence WRSB.

4.3.1 TL3 Flexfence Terminal

The TL3 Flexfence Terminal has been crash tested to meet

the requirements of NCHRP 350 Test Level 3 (TL3). The

Flexfence TL3 Terminal is the only TL3 terminal proven

NOT to release the cables during approach impacts. The

non-release of cables ensures the system remains tensioned

and functional in the event of secondary impacts occurring

downstream from the end anchor.

System features;

• System Length: 12m

• Point of Need: 12.6m from anchor point

• Post Spacing: 1.0m

4.3.2 Standard Flexfence Terminal

The Standard Flexfence Terminal is designed to provide the

necessary tensile support to redirect errant vehicles that

impact the wire rope barrier near the end of the system.

Consideration has been given to preventing vehicle

launching and snagging, however this terminal has not been

subject to full scale crash testing.

System features;

• System Length: 4.2m to 1st post

• Point of Need: 2nd Post

5.0 INSTALLATION

The following written instructions should be read in

conjunction with Ingal Civil Products’ Drawings:

WR-STD-57 4 Rope TL3 Post Arrangement

WR-STD-60 3 Rope TL4 Post Arrangement

WR-STD-50 TL3 End Terminal Arrangement

WR-STD-55 Standard End Terminal Arrangement

WR-STD-51 Standard End Terminal Type 1 Anchor Block

WR-STD-28 Standard End Terminal Type 2 Anchor Block

WR-STD-52 TL3 End Terminal Type 1 Anchor Block

WR-STD-53 TL3 End Terminal Type 2 Anchor Block

WR-STD-59 Tension Panel Arrangement

5.1 Site Preparation

The approach terrain to the barrier should be level. Grading

to 1:20 is preferable and 1:10 maximum slope should be

present. Steeper slopes can result in the vehicle impacting

the barrier at other than the design height.

5.2 Horizontal and Vertical Alignment Criteria

The minimum allowable sag vertical curve is ≥ 30m. (K

= length of VC in metres divided by the change in grade

expressed as a percentage). There is no K value limit for

crest curves.

The installation of wire rope barriers on horizontal curves

may increase the expected dynamic deﬂ ection. Please refer

to Appendix A for suggested correction factors.

5.3. End Anchor Site Preparation

The site should be prepared free of obstructing vegetation

and other hazards that may interfere with the installation

or operational performance of the system. Some sites may

require minor grading if installed beyond the edge of the

pavement shoulder.

Vehicles impacting the end of the terminals will normally

continue behind and beyond the barrier and may encounter

non-traversable terrain or other roadside hazards. It is

recommended that the guidelines as stated in AS/NZS

3845:1999 for the installation of gating safety barrier end

terminals be observed.

AS/NZS 3845:1999 requires that a Hazard Free Zone

‘immediately behind the terminal... should be reasonably

traversable and free from ﬁ xed object hazards. If a clear

runout is not possible, this area should be similar in

character to adjacent unshielded roadside areas’

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5.4 Installation of Anchor Blocks

1. Excavate the anchor hole in accordance with Ingal

drawings ensuring the centre of the anchor block is in

line with the centre line of the wire rope fence.

2. If installing the rectangular anchor block, clip out several

grids of the reomesh square to ﬁ t over the anchor

bracket.

3. Attach 3 off M20 x 550mm hook bolts to the base of

the anchor bracket using 2 off M20 nuts per hook bolt.

One M20 nut is used either side of the anchor bracket to

secure each hook bolt

4. Using formwork, suspend the anchor bracket and

reomesh (if required), ensuring the anchor bracket

leveling plate is at the same longitudinal grade as the

roadway. The position of the anchor bracket is to be in

accordance with Ingal drawings.

5. To prevent ﬂ oatation or dislodgement during the concrete

pour, drive a shortened star picket into the base of the

excavation and use tie wire to secure the bracket.

6. Pour concrete into excavation and vibrate. Ensure that

anchor bracket has remained secure.

7. Trowel surface of the anchor block and shape in

accordance with Ingal drawings.

8. If installing the Type 2 anchor block, back ﬁ ll material

should satisfy the requirements as per Ingal drawings.

5.5 Construction of Post Footings

1. Establish post spacing in accordance with expected

dynamic deﬂ ections and excavate postholes. Typically

the footings are 300mm diameter x 600mm deep using

32Mpa concrete.

2. Pour concrete into each hole.

3. Insert sigma post into plastic HDPE sleeve.

4. Push the sigma post and plastic HDPE sleeve into

the wet concrete so that the top of the plastic sleeve is

at pavement level. Ensure the sigma post is vertical

and 780 ± 25mm above ground level. The posts are

orientated so that the smooth face is towards the trafﬁ c

face.

5. Insert post footing reinforcement to a depth of 50mm and

shape top of footing to shed rainwater

5.6 Assembly Sequence – 4 Rope TL3

1. Slide ground covers over each post.

2. Starting at the leading or high end of the fence, connect

the bottom wire rope to the anchor using a temporary

anchor connection and run out the wire through the post

slots to the far anchor and cut the rope to length. When

a reel is depleted, attach the end to the next reel by tying

the cables together and continue to run out the cable.

3. Insert the plastic spreaders into the post slots.

4. Repeat these procedures with subsequent wire ropes.

Ensure stainless frames are inserted between top two

ropes.

5. When all ropes have been installed, ﬁ t the plastic caps

to the posts. Post grommets can be inserted into the

pre-punched hole located in the top of the post prior to

the placement of the cap to provide extra resistance to

vehicle updraft and wind.

5.7 Assembly Sequence – 3 Rope TL4

1. A reinforcement sleeve is inserted into each post. The

post reinforcement will come to rest within the post

sleeve at the correct position.

2. Starting at the leading or high end of the fence, connect

the bottom wire rope to the anchor using a temporary

anchor connection and run out the wire through the post

slots to the far anchor and cut the rope to length. When

a reel is depleted, attach the end to the next reel by tying

the cables together and continue to run out the cable.

3. Insert the plastic spreaders into the post slots.

4. Repeat these procedures with subsequent wire ropes.

Ensure stainless frames are inserted between top two

ropes.

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5. When all ropes have been installed, ﬁ t the rope hook

through the pre-punched holes in the posts.

6. Fit the plastic caps to the posts. The rope hook will

provide extra resistance to vehicle updraft and wind.

5.8 Installation of Tension Bays – All systems

Tension bays are located at 300m centres and not more

than 150m from either anchor point.

For fences less than 600m;

1. Attach safety check ropes to the wire ropes at the leading

or high-end anchor. Swage end ﬁ ttings onto all cables

and attach to the anchor bracket. The bottom rope is

located nearest to the trafﬁ c face. Each end ﬁ tting is

secured at the anchor with one washer and two nuts.

2. Pull the slack out of the wire ropes toward the other

anchor. This can be achieved by hand or by using a

vehicle and sling equipped with a lever claw clamp.

3. At locations where wire rope reels have been temporarily

joined, swage end ﬁ ttings onto cables and install tension

ﬁ tting.

4. Once slack has been removed from cable, attach check

ropes, machine swage end ﬁ ttings and attach to anchor.

Figure 3: End Fitting Attachment

5. Identify tension bay location(s) and if necessary attach

temporary clamps one post back from the tension bay.

6. Mark and cut out 800mm section of cable from each

strand.

7. Machine swage end ﬁ ttings to each cable and attach the

turnbuckle.

8. Attach the tensioning rig to the bottom cable and

tension from the bottom up. Each rope is tensioned in

accordance with Table 2.

Figure 4: Tension Bay Arrangement

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Figure 2: 3 Rope TL4 Post Arrangement

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For fences greater than 600m

1. Attach safety check ropes and machine swage cables at

leading or high-end anchor and attach to anchor bracket.

2. At 1st tension bay, install the hydraulic tensioning unit

between a clamp on the 1st cable and the bottom of a

post located 5m away. Pretension the cable to 800kg

and clamp off to a post.

3. Repeat process for each cable. Clamp off each cable to a

different post.

4. Cut cables on un-tensioned side of clamps and machine

swage ﬁ ttings. Assemble tension ﬁ ttings.

5. Relocate to 2nd tension bay and repeat above process.

Continue until all tension bays are completed.

6. At other anchor, pretension cables, clamp off to a post,

attach safety check ropes and machine swage ﬁ ttings.

7. Once cables are attached at anchor bracket, relocate to

the centre tension bay.

8. Attach the tensioning rig and tension in accordance with

Table 2 from the bottom up.

9. Relocate from the centre bay outwards repeating tension

process.

10. Once complete, relocate to centre bay and repeat

tensioning in this bay only.

Table 2:Tension Requirements

Ambient Temperature Tension Force Required Hydrapac Gauge

(Degrees C) (kg) (Bar)

-10 2600 265

-5 2450 250

0 2300 235

+5 2150 220

+10 2000 205

+15 1850 190

+20 1700 175

+25 1550 160

+30 1400 145

+35 1250 130

+40 1100 115

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5.9 Installation Checklist

To ensure the correct installation of Flexfence WRSB, you must have answered yes for each question.

End Anchors

Is the anchor block dimensions in accordance with Ingal drawings Yes No

Is the centerline of the anchor block aligned with the centerline of the posts

Yes No

Has the anchor bracket been installed with the leveling plate at the same

longitudinal grade as the roadway

Yes No

Have safety check ropes been attached to each cable

Yes No

Have the safety check ropes been secured to the anchor bracket

Yes No

Has each end ﬁ tting been secured with one washer and two nuts

Yes No

Posts and Fittings – All systems

Have the posts been installed at the correct spacing ensuring sufﬁ cient

clearance to hazards

Yes No

Have the posts been installed with the correct orientation

Yes No

Have ground covers been attached to the posts

Yes No

Have plastic spacers been inserted between each cable

Yes No

Has the stainless frame been inserted between the top and second cable

Yes No

Have post caps been attached to the posts

Yes No

Has delineation been attached to the post caps

Yes No

Posts Fittings – 3 Rope TL4

Has the post reinforcement sleeve been installed at each post location

along the length of need section

Yes No

Have the rope hooks been attached to each post along the length of need section

Yes No

Tension Bays

Have tension bays been installed at not more than 150m from the end anchors Yes No

Have tension bays been installed at not more than 300m apart

Yes No

Has each cable been tensioned in accordance with Table 3

Yes No

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6.0 FLEXFENCE WRSB MAINTENANCE

Flexfence WRSB is a very low maintenance roadside safety

barrier. Except for repairs due to impacts, there is virtually

no maintenance required for the system. It is recommended

that regular drive-by inspections be performed to ensure the

following;

1. Post caps have not dislodged. Delineation stickers are

attached to the post caps as a loss of numerous caps

could result in poor delineation.

2. Debris has not accumulated around the system. A clear

zone, free of hazards should exist immediately behind

the fence to accommodate for the expected dynamic

deﬂ ection.

3. Safety check ropes should be secured to the anchor

bracket.

4. Ropes have not dislodged from the posts as a result of

minor impacts.

7.0 FLEXFENCE WRSB REPAIR

In the event of an impact, the following procedures should

be carried out;

1. At the location of the damaged posts, the ropes will be

required to be lifted. This can be done by hand without

machinery or tools. Damaged posts are removed from

the footings.

2. Replacement posts are reinserted into the concrete

footings and ground covers are attached.

3. Ropes are lowered back into position ensuring that

spacers and caps are ﬁ tted correctly.

4. Concrete footings should be inspected to ensure they

are intact and cables inspected for signs of structural

damage.

5. The fence should be thoroughly inspected using the

Installation Checklist as a guide.

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APPENDIX A: RECOMMENDED DYNAMIC

DEFLECTION DESIGN

MULTIPLYING FACTORS FOR

WIRE ROPE BARRIERS

Table 3: Curve and length factors for cable barriers

Barrier

Degree of Curvature (Degrees)

Length 0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

(metres) 3,500m 1,750m 1,164m 874m 700m 582m 500m 437m

radius radius radius radius radius radius radius radius

30 0.85 0.88 0.89 0.91 0.91 0.93 0.95 0.97 0.99

60 0.96 0.98 1.01 1.05 1.08 1.12 1.17 1.21 1.26

90 1.00 1.06 1.11 1.14 1.17 1.23 1.28 1.33 1.39

120 1.08 1.11 1.17 1.21 1.29 1.32 1.35 1.48 1.55

150 1.11 1.16 1.20 1.25 1.34 1.38 1.49 1.56 1.68

180 1.14 1.19 1.25 1.30 1.38 1.49 1.57 1.69 1.77

210 1.17 1.20 1.28 1.38 1.46 1.53 1.66 1.74 1.84

240 1.18 1.21 1.35 1.42 1.50 1.57 1.70 1.80 1.91

270 1.18 1.28 1.35 1.43 1.51 1.62 1.75 1.84 1.98

300 1.18 1.29 1.37 1.45 1.57 1.67 1.77 1.88 2.12

330 1.18 1.30 1.37 1.46 1.59 1.71 1.81 1.95 2.18

360 1.19 1.30 1.39 1.48 1.62 1.74 1.86 2.01 2.24

390 1.19 1.30 1.39 1.49 1.64 1.76 1.90 2.07 2.42

420 1.19 1.30 1.41 1.50 1.66 1.80 1.95 2.23 2.50

450 1.19 1.30 1.43 1.50 1.69 1.83 2.00 2.26 2.54

The factors presented in Table 3 show the diminishing increase in barrier deﬂ ection as barrier length increases. The extent of the

increased deﬂ ection presented is signiﬁ cant and must be taken into account when selecting and locating a cable barrier system.

The factors have been adopted from a paper written by Alberson, Bligh, Buth and Bullard (January 2003) presented to the

Transportation Research Board in Washington D.C.

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Ingal Civil Products

A Division of Industrial Galvanizers Corporation Pty.Ltd.

www.ingalcivil.

com.au

or contact us on the web

information

for more

NEW SOUTH WALES

Sydney (Head Ofﬁ ce)

57-65 Airds Road,

Minto, NSW 2566

Ph: +61 2 9827 3333

Fax: +61 2 9827 3300

QUEENSLAND

Brisbane

90 Mica Street

Carole Park QLD 4300

Ph: (07) 3271 3369

Fax: (07) 3271 3299

VICTORIA

Melbourne

28-38 Albert Street

Preston VIC 3072

Ph: (03) 8470 0082

Fax: (03) 9480 1834

WESTERN AUSTRALIA

Perth

9 Millrose Drive

Malaga WA 6090

Ph: (08) 9249 3155

Fax: (08) 9249 3166

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Ingalls Engineering flexfence 30/11/07 User manual

Brand: Ingalls Engineering

Model: flexfence 30/11/07

Type: User manual

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Ingalls Engineering flexfence 30/11/07 User manual

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