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Flexfence
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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Flexfence
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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Flexfence
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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Flexfence
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
o
0.5
o
1.0
o
1.5
o
2.0
o
2.5
o
3.0
o
3.5
o
4.0
o
(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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