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QuadGuard Installation Manual

1. 100 mm 4 TENSION STRUT BACKUP 255 mm 10 3 4 X 7 STUD CENTERLINE 3 4 X 7 STUD p CENTERLINE MONORAIL o o6 6 6 9 L E o o IN I 7 e ii l as s e e 5 o o N CONSTRUCTION LINE MONORAIL CONCRETE BACKUP CONSTRUCTION LINE Figure 51 Figure 52 Backup and Monorail Location Monorail Location for Concrete Backup for Tension Strut Backup 34 QuadGuard System Installation for Wide Hazards cont d 5 Install Side Panels and or Transition Panels to Backup Assembly a Attach hinge plate to the transition panel or side panel using 5 8 rail bolt amp 5 8 rail nut two places top amp bottom holes only b Attach transition panel or side panel assembly to side of backup using 5 8 hex bolt 5 8 lock washer amp 5 8 hex nut three places each side of backup See Figure 53 c Attach diagonal brace to fender panel and backup using 3 8 hex bolt 3 8 lock washer amp 3 8 hex nut two places per brace 4 places per side TENSION STRUT BACKUP 3 8 X 3 1 2 Be HEX BOLT gt d Secure each diagonal brace with 3 8 hex bolt 3 8 lock washer amp 3 8 hex nut two places per brace as shown in Figure 53 Note A side panel is not needed when a transition panel is used Diagonal braces not used with some transition panels See d
2. TIGHTEN NUTS TO 35 NM 25 FT LBS AFTER ALIGNING NOSE AS SHOWN Figure 85 Nose Adjustment 58 FOR SYSTEMS FITTED WITH OPTIONAL NOSE BELT Normally with a design speed impact the nose belt will not need replacement After pulling System out and replacing the nose cartridge it may be neces sary to adjust nuts attaching nose belt to diaphragm and or legs to 35 Nm 25 ft lbs Nose belt assembly is available for replacement or retrofit by calling the Customer Service Department at 1 888 32 ENERG Figure 86 Optional Nose Assembly Table C QuadGuard System Bolt Torque Specifications WARNING Anchor Studs Torqued to 165 Nm 120 ft lbs Should NOT protrude above nuts see figure 17 page 13 All Other Bolts Tightened Fender Panel Maximum gap allowed Narrow 20 mm 0 78 Wide 25 mm 1 0 13 Check the torque of all bolts on the System see Table C 14 Check to be certain that the site is free from any debris The QuadGuard System is once again ready for use QuadGuard System Maintenance and Repair Parts Ordering Procedure Make a list of all damaged parts using part descriptions shown on pages 56 and 57 Answer the following questions in the spaces provided This information is necessary to receive the proper parts DESCRIPTION What is the Width of System ref
3. Z SO THE FACE OF THE NUT TO BE FLUSH WITH HUMPS ON FENDER PANEL Figure 34 Optional Nose Belt Assembly Note Nose of System may be delineated to comply with local codes chevron reflective material signs etc supplied by others 24 Detail 34a QuadGuard System Installation for Narrow Hazards cont d 12 Checking the System Assembly At This point recheck to ensure that all fasteners are properly tightened throughout the System anchor bolts etc See warning below Check all Fender Pan els If they do not fit tightly against the underlying panel System realignment may be necessary See Figure 35 WARNING Anchor Studs Torqued to 165 Nm 120 ft Ibs Should NOT protrude above nuts see Figure 16 page 13 All Other Bolts Tightened Fender Panel Maximum gap allowed Narrow Systems 20 mm 0 78 MAXIMUM GAP 20 mm 0 78 N u N a S N p X FENDER PANEL UNDERLYING FENDER TRANSITION EXTENSION OR SIDE PANEL Figure 35 Fender Panel Gap for Narrow Systems 13 Cartridge Installation Be sure the adjustable cartridge support in the nose is installed correctly See Install Nose Assembly 10a To complete the assembly of a QuadGuard System place the appropriate Cartridge in each Bay and Nose section of the System Type Cartridges are placed toward the front Nose of the System Type II Car
4. ejt 1 d li FON L a B Y Al XE 7 2285 90 MODEL 0590__ c y h HB Jl 1 22 J Varies 6 Bay System Shown 3200 mm 126 MODEL NO QN12606 27 QuadGuard System Installation for Wide Hazards cont d Site Preparation Foundation A QuadGuard System should be installed only on an existing or freshly placed and cured concrete base 28 MPa 4000 psi minimum Location and orienta tion of the concrete base and attenuator must comply with project plans or as otherwise determined by the resident project engineer Recommended dimension and reinforcement specifica tions for new concrete pads are provided in Energy Ab sorption Systems Inc concrete pad drawings supplied with the System System may be installed on concrete roadway minimum 200 mm 8 thick Installation cross slope shall not exceed 8 and should not vary twist more than 296 over the length of the System the pad surface shall have a light broom finish Caution Accurate placement of all steel rebar is critical to avoid interference with the con crete Anchor Bolts 28 WARNING Location of the backup in relation to nearby objects will affect the operation of the attenuator Upon impact the fender panel
5. kis 3L oq 51 Ml Figure 29 Lower Cartridge Support Bracket Installation 19 QuadGuard System Installation for Narrow Hazards cont d TENSION STRUT BACKUP STEP INSTALL LOWER CARTRIDGE SUPPORT BRACKET STEP II CONCRETE BACKUP a Al FACE PLATE gt LOWER CARTRIDGE De d SUPER BR E LOWER CARTRIDGE SUPPORT BRACKET AU CARTRIDGE SUPPORT BRACKET IS WELDED TO FACE PLATE OF TENSION STRUT BACKUP CONCRETE BACKUP Figure 30 Figure 31 Lower Cartridge Support Bracket Installation Lower Cartridge Support Bracket Tension Strut Backup Concrete Backup 20 QuadGuard System Installation for Narrow Hazards cont d 11a Install Nose Assembly If your system has cartridge style A as shown in De tail 32 install cartridge support in the upper two slots Determine which style of cartridges your system has as shown If your system has cartridge style B as shown in De tail 32 install cartridge support in the lower two slots as shown CARTRIDGE STYLE A CARTRIDGE STYLE B ADJUSTABLE in _ gt lt ADJUSTABLE 1 2 2 Detail 32 Adjustable Bracket Locations 21 QuadGuard System Installation for Narrow Hazards cont d As shown in Detail 32c cartridge style A is installed with t
6. Ew m y g g E A zx wk gr gu E FRONT FACE OF BACKUP MONORAIL Figure 23 Diaphragm spacing 16 QuadGuard System Installation for Narrow Hazards cont d 8 Install Fender Panels Note Do not mix the 5 8 rail nuts large with the 5 8 hex nuts small See Figure 24 24 mm 0 94 32 mm 1 25 p P 2 ue 4 N N J N X bu P 5 8 RAIL NUT LARGE 5 8 HEX NUT SMALL Figure 24 Rail Nuts are Oversize BACKUP OR DIAPHRAGM SIDE PANEL FENDER PANEL OR a TRANSITION PANEL lt MUSHROOM WASHER 4 5 8 FLAT WASHER EM 5 8 RAIL NUT LARGE iK ss 5 8 RAIL BOLT Starting at the backup install left and right fender panels as shown in Figure 25 Detail 25a and fender panel assembly drawing Step 1 Place the fender panel so that the center of the slot of the rearward diaphragm is lined up with the ap proximate center of the slot in the fender panel Attach mushroom washer assembly as shown in Figure 25 and Detail 25a but do not torque at this time This helps to balance the fender panel Step 2 Slide the fender panel forward until the holes in the fender panel line up with the holes in the for ward diaphragm Step 3 Use a drift pin to align the center hole of the fender panel with the center hole PRIN a ofthe diaphragm 5 8 HEX NUT SMALL Ste
7. ma f JE N lt QI lt DOD GU ia E mm E oS 2285 mm 90 Qr _ 6740 mm 22 1 3 8 30 t GF T S p DE a 4 pus 3200 mm 126 lt x OG Figure 1 Plans amp Elevation Six bay Systems with Tension Strut Backups shown Key D Cartridge Nose Cover 2 Diaphragm 5 Monorail 3 Quad Beam Fender Panel 6 Backup QuadGuard System How to Determine Left Right To determine left from right when ordering parts stand in front of the System facing the hazard as shown in Fig ure 2 Your left is the System s left and your right is the System s right CARTRIDGE FENDER PANELS DIAPHRAGM Counting the Number of Bays One bay consists of one cartridge one diaphragm and two fender panels The nose section is not considered a bay though there is a cartridge in the nose of each Sys tem Note that this means there will always be one more cartridge in the System than the number of bays in the System To determine number of bays count fender pan els on one side see Figure 2 5 bay System shown Figure 2 System Orientation QuadGuard System Installation cont d Measuring The Width The QuadGuard System is available in six nominal widths 610mm 24 760 30 915 36 1755 69 2285 90 3200 mm 126 The nominal width of System with tensi
8. s C 5 68 HEX NUT e Using third 5 8 x 1 3 4 flat washers and third 5 8 hex nuts secure the belt clamps and nose belt three places per side f Be sure fender panel assembly is bolted to dia phragm at the hinge plate with 5 8 x 4 hex bolts 5 8 nuts and 5 8 lock washers 3 places each side Refer also to nose belt assembly drawing Note Nose alignment shown in Figure 74 not nec essary with nose belt assembly FIRST DIAPHRAGM gt C 5 8 X 1 3 4 THE FACE OF THE NUT TO FLAT WASHER BE FLUSH WITH HUMPS ON FENDER PANEL P BELT CLAMP 5 8 X 1 3 4 FLAT WASHER 5 8 HEX NUT Figure 75 T Nose Belt Assembly ps 4 Note Nose of System be delineated to comply with P local codes chevron reflective material signs etc Detail 75a 48 QuadGuard System Installation for Wide Hazards cont d 13 Checking the System Assembly At This point recheck to ensure that all fasteners are properly tightened throughout the System anchor bolts etc See warning below Check all fender pan els If they do not fit tightly against the underlying panel System realignment may be necessary See Figure 76 WARNING Anchor Studs Torqued to 165 Nm 120 ft Ibs Should NOT protrude above nuts see Figure 17 page 13 All Other Bolts Tightened Maximum gap allowed Wide Systems 25 mm 1 00 Fender Panel MAXIMUM GAP 25 mm 1 0
9. 4 Check the System to be certain that the Mush room Washer Assemblies holding the fender panels together are still intact and that the Sys tem has not been deformed in a way that would prevent pulling it back to its original position 5 Be sure that the Diaphragm support legs are all properly attached to the Monorail Caution Use safety goggles and gloves when refurbishing the mushroom spring assembly Do not place fingers underneath an assembled mushroom washer Parts may suddenly shift and fingers may be pinched If the spring is still under compression as the nut is nearing the end of the bolt to prevent injury make sure that the spring is restrained with a clamp so it does not suddenly release when nut is removed from the mushroom bolt 55 QuadGuard System Maintenance and Repair cont d 6 Attach chain to Pullout Brackets on first Dia phragm see Figure 80 Attach both ends of chain to a heavy vehicle such as a 1 ton pickup WARNING Stand clear in case chain breaks or becomes disconnected FIRST DIAPHRAGM PULLOUT BRACKETS Figure 80 Pullout Pull the QuadGuard System forward slowly un til the System reaches its original length Have someone watch the System during reposition ing to be certain previously undetected damage does not cause the diaphragms to bind or pull out improperly 7 Remove all crushed Cartridges from within the System 8 Check to see that the Diaphragms are
10. the construction line and rear edge of backup foot 4 forward of edge of pad see Figure 19 Orient monorail so that the monorail tongues face the backup see figure 18 Drill 140 mm 5 1 2 deep anchor holes using the monorail as a template Do not drill through pad WARNING Every hole and slot in backup and monorail must have WARNING Improper alignment at the monorail splice joints will prevent proper System collapse during an impact an MP 3 stud anchoring it 100 mm 4 TENSION STRUT BACKUP MONORAIL 3 4 X 7 STUD CENTERLINE B CONSTRUCTION LINE CONCRETE PAD Figure 19 Backup and Monorail Location for Tension Strut Backup o 979 s e 6 o 14 QuadGuard System Installation for Narrow Hazards cont d 5 Attach Side Panels and or Transition Panels to Backup Assembly Attach transition panel or side panel to side of backup using 5 8 rail bolt amp 5 8 rail nut two places top amp bottom holes only See Figure 20 and backup as sembly drawing Note A side panel is not needed when a transition panel is used N nare 5 8 X 2 RAIL BOLT 2 b D SIDE PANELS SHOWN IN SOME CASES THIS WILL SEE FIGURES 8 10 11 12 AND 13 27 BE TRANSITION PANEL Z lt on Installation tip Use drift pin to align the center hole of the panel with
11. See below Detail 73a install cartridge support in the upper two slots as shown If your system has cartridge style B as shown in Detail 73b install cartridge support in the lower two slots as shown CARTRIDGE STYLE A Detail 73a Adjustable Bracket Location when using Cartridge Style A CARTRIDGE STYLE B Detail 73b Adjustable Bracket Location when using Cartridge Style B 45 QuadGuard System Installation for Wide Hazards cont d As shown in Detail 73c cartridge style A is installed with the adjustable cartridge support bracket incor rectly in the lower position Detail 73c Incorrect Installation of Adjustable Cartridge Support Bracket As shown in Detail 73d cartridge style B is installed with the adjustable cartridge support bracket incor rectly in the upper position Detail 73d Incorrect Installation of Adjustable Cartridge Support Bracket Detail 73e shows the adjustable cartridge support bracket installed correctly Detail 73e Correct Installation of Adjustable Cartridge Support Bracket 46 QuadGuard System Installation for Wide Hazards cont d Step 5 Figure 73 Bolt nose to attach ment bracket with 5 8 x 2 hex bolts and bar washers 3 places each side as shown Note Nose of System may be delineated to comply with local codes chevron re flective material signs etc Step 6 Figure 74 The top and bottom holes of the nose are slotted
12. NOSE AS SHOWN Figure 33 Adjust Nose 23 QuadGuard System Installation for Narrow Hazards cont d 11b For Systems with Optional Nose Belt Assembly a Using 5 8 x 5 hex bolt two 5 8 x 1 3 4 flat washers and 5 8 hex nut attach fender panel to front diaphragm top and bottom as shown in Fig ure 34 two places per side b Using 5 8 x 5 hex bolt and 5 8 hex nut attach pullout bracket to front diaphragm and fender panel middle as shown one place per side c Thread second 5 8 nuts onto the installed bolts Be sure the face of the nuts are flush with humps on fender panels see detail 34a Slide third 38 1 3 4 flat washers onto bolts three places per side d Align holes each end of the nose belt with the installed bolts three per side and slide nose belt onto bolts BELT CLAMP 2 5 8 X 1 3 4 FLAT WASHER 5 8 HEX NUT e Align holes in belt clamps with bolts and slide belt clamps onto bolts f Using fourth 5 8 x 1 3 4 flat washer and third 5 8 hex nut secure the belt clamps and nose belt three places per side Refer also to nose belt assembly drawing Note Nose alignment shown in figure 33 not necessary with nose belt assembly 5 8 X 1 3 4 FLAT WASHER 5 8 HEX NUT EN Sa V lt 9 S Z QUADGUARD NOSE BELT 5 8 X 1 3 4 FLAT WASHER 9 8 X 5 G5 ALL THREAD HEX BOLT
13. OR BACKUP 1 1 2 DIE SPRING panels as shown in Figure 63 Attach the hinge plate 17 5 mm 11 16 at the front of the fender panels to the diaphragm in ROUND HOLE front using three 5 8 hex bolts nuts and washers LONG SLOT IN Attach mushroom washer assembly as shown in FENDER PANEL Figures Figure 63 amp Detail 63a but do not torque L at this time F2 Be sure mushroom washer lays flat against the fender MUSHROOM WASHER panel as shown in Detail 63b Standoff on washer must be seated completely through slot QUAD BEAM FENDER PANEL FENDER PANEL UU HINGE PLATE MUSHROOM WASHER PANEL ALREADY ATTACHED TO DIAPHRAGM OR BACKUP JJ Detail 63a wee Mushroom Washer Assembly CORRECT INCORRECT Detail 63b 1 1 2 DIE SPRING Mushroom Washer Orientation 5 8 RAIL NUT LARGE 25 LAST DIAPHRAGM BACKUP MUSHROOM WASHER e P d SN 5 8 X 4 G5 HEX BOLT 5 8 LOCK WASHER gt 2 5 8 HEX NUT SMALL FLATHEAD SOCKET SCREW FENDER PANEL FIGURE 63 Fender Panel Assembly 40 QuadGuard System Installation for Wide Hazards cont d Check diaphragm spacing to ensure 915 mm 36 between rear faces of consecutive diaphragms as shown in Figure 64 Once the proper spacing has been achieved torque the mushroom washer assem bly nut until it reaches the end of the threads Install the remaining diaphragms and fender panels follow ing the same procedur
14. approximately 1 3 to 1 2 full If the hole is overfilled there will not be enough grout to use all of the anchor studs kit If hole is under filled the grout may not develop the required pull out strength QuadGuard System MP 3 Polyester Anchoring System cont d 4 Add the washers and nuts Put washer and nut on stud leaving nut flush with end of stud See figure 79 5 Insert Studs into holes Push stud through part to be anchored and into hole Twist the stud in the MP 39 grout to wet the threads Note In Horizontal Applications the stud should be flush with the top of the nut See Figure 79 X a uw 4 INCORRECT Figure 79 MP 3 Horizontal Installation Caution Do not disturb or load the stud until the MP 3 material has hardened see Table B for hardening times 6 Torque the nuts Once the grout has hardened torque the nut to 165 Nm 120 ft lbs MP 3 Installation Cautions 1 Shelf life If the shelf life of the MP 3 has expired see MP 3 kit for expiration information mix a small amount of MP 3 in the proportions of one part A to two parts B by volume If the material does not set according to the instructions contact Energy Absorption Systems Inc for guidance WARNING Do not use the MP 3 if the material fails to set up Part A Resin has gelled for vertical applications or TX Resin is NOT gelled for horizontal applications 2
15. assembly drawing Drill anchor holes in the concrete backup using the face plate as a template Anchor the face plate to the concrete backup using the MP 39 An choring System horizontal kit supplied with the QuadGuard System see MP 3 Polyester Anchoring page 47 FULLY CURED CONCRETE BACKUP SEE DRAWING PACKAGE HORIZONTAL MP 3 KIT WITH 3 4 X 6 1 2 STUD Figure 15 Anchoring Backup Face Plate to Concrete Backup 12 3b Anchor the Backup Tension Strut Backup installation Figure 16 Locate tension strut backup and monorail on pad with side of monorail on the construction line see Fig ure 18 Verify that any applicable transition panels fit properly before anchoring backup Drill anchor holes in pad using the backup as template Anchor the backup to the concrete pad using the 3 verti cal kits provided See MP 3 Polyester Anchoring System on page 47 TENSION STRUT BACKUP VERTICAL MP 3 KIT WITH 3 4 X 7 STUD Figure 16 Anchoring Tension Strut Backup to Foundation QuadGuard System Installation for Narrow Hazards cont d 4a Anchor the Monorail Anchor each monorail section using the MP 3 ver tical kits provided Refer to Figure 17 and the MP 3 Monorail Installation for Concrete Backup Polyester Anchoring System Instructions included Figure 18 with this manual It is important to install each seg m ment of monorail in alignment from the back to Locate monorail on pad with side of mo
16. guide up between the monorail guide brackets at the bottom of the first diaphragm align ing the two holes See Figure 55 Insert 3 4 x 4 G5 hex bolt through monorail guide bracket on diaphragm and through monorail guide oriented as shown in Figure 55 Secure with 3 4 lock washer amp 3 4 hex nut typical two places per guide See also diaphragm assembly drawing EXTRA WIDE FIRST DIAPHRAGM MONORAIL GUIDE 3 4 X 4 G5 HEX BOLT Figure 55 Monorail Guide Attachment Extra Wide First Diaphragm QuadGuard System Installation for Wide Hazards cont d 7 Install Diaphragms TOWARD NOSE Wide Systems qe Orient the widest diaphragm so that the front face of 13 PRONT the Quad Beam shape faces toward the nose of the System as shown in Figure 56 The widest diaphragm p must be installed closest to the backup with each subsequent diaphragm being progressively a QUAD BEAM rower Slide the widest diaphragm onto the monorail and all hod the way to the backup to ensure System is able to 2 collapse properly during impact Once this has been Lr verified slide the diaphragm forward to approximately E 915 mm 36 in front of the backup 561 Figure 56 Orient and slide all other diaphragms onto mono Diaphragm Orientation rail and position each approximately as shown
17. in Figure 57 _ 915 mm 361 915 mm 36 DIAPHRAGMS TYPICAL I TE TE u T ea mu amp Eum mu Due 2 FRONT FACE OF BACKUP MONORAIL Figure 57 Diaphragm spacing 37 QuadGuard System Installation for Wide Hazards cont d 7b Install Diaphragms Extra Wide Systems Quad Beam Diaphragms Orient the widest diaphragm so that the front face of the Quad Beam shape faces toward the nose of the System as shown in figure 58 The widest diaphragm must be installed closest to the backup with each subsequent diaphragm being progressively nar rower Slide the widest diaphragm all the way to the backup to ensure the System is able to collapse properly TOWARD NOSE o BACK FRONT QUAD BEAM Figure 58 Quad Beam Diaphragm Orientation Diaphragms 2 through the last 915 36 915 36 TYPICAL during impact Once this has been verified then slide the diaphragm forward to approximately 915mm 36 in front of the backup Orient and slide all other Quad Beam diaphragms onto monorail and position each approximately as shown in figure 60 Extra Wide First Diaphragm Orient the first diaphragm so the hinges are toward the rear of the system Slide the extra wide first dia phragm see figure 59 onto the monorail and posi tion approximately 915 mm 36 forward of the pre vio
18. tridges are placed toward the rear Backup of the System Refer to figures 36 and 37 WARNING Placing the wrong Cartridge in the Nose or any Bay will result in unacceptable crash performance as described in NCHRP 350 I TYPE I CARTRIDGE TYPE CARTRIDGE 11 2BAYS 1 3BAYS IIIT 4BAYS 5BAYS _ HILL II 6BAYS 7845 BBAYS QBAYS ILILILILIL IL I III 1 10BAYS III 11 5 II IE IL IL IEEE 1 1 1 1 1 12BAYS Figure 36 Cartridge Placement 25 QuadGuard System Installation for Narrow Hazards cont d Figure 37 Typical Cartridge Layout 5 Bay System Shown 26 QuadGuard System QUADGUARD SYSTEMS FOR WIDE HAZARDS 1 1 k ee ee a 1755 mm 69 MODEL 0560 _ Fi thal 061 4 On loco eH QUOI A ur jg UU S 090 J Opt OL 0 h A dk D C 3l i cl IE JN
19. 0 A Pi 74 UNDERLYING FENDER TRANSITION EXTENSION OR SIDE PANEL FENDER PANEL mmm 5 B 2 Figure 76 Fender Panel Gap for Wide Systems 14 Gartridge Installation Be sure the adjustable cartridge support in the nose is installed correctly See Install Nose Assembly 11a To complete the assembly of a QuadGuard System place the appropriate cartridge in each bay and nose section of the System Type cartridges are placed toward the front nose of the System Type II car tridges are placed toward the rear backup of the System Refer to figures 77 and 78 WARNING Placing the wrong Cartridge in the Nose or any Bay will result in unacceptable crash performance as described in NCHRP 350 I TYPE I CARTRIDGE TYPE CARTRIDGE 3BAYS 4BAYS unlit 5BAYS H 6 BAYS 7 BAYS H HII 8BAYS 9BAYS 10 11 12 Figure 77 Cartridge Placement 49 QuadGuard System Installation for Wide Hazards cont d TYPE Il Figure 78 Typical Cartridge Layout 6 Bay System Shown 50 QuadGuard System MP 3 Polyester Anchoring System The MP 3 Polyester Anchoring System is a quick and easy way to securely anchor crash cushions and other com mon highway devices MP 3 featu
20. 23 3 16 AUXILIARY VIEW N T S FRONT VIEW NOTES REMOVE ALL BURRS AND SHARP EDGES AND WELD SPATTER PART NO 6024291 0000 HOLE DIAMETERS TO BE 41 32 HOT DIP GALVANIZE AFTER FABRICATION PER ASTM A 123 S CHAFFIN 10 20 04 ENERGY ABSORPTION SYSTEMS INC WELD ITEM 3 TO ITEMS 1 amp 2 AFTER ITEM 2 HAS BEEN ENGINEERING AND RESEARCH DEPARTMENT WELDED TO ITEM 1 EE n 10 21 04 APPROVED DATE EXTENSION PANEL QB 73 G A FRANKLIN _ 10 21 04 Q C DATE S TRAGESER _ 10 21 04 CAD FILE SCALE DWG SHEET REV 6024291 0000 dwg 110 6024291 0000
21. A lifting device is preferred although a forklift can be used Mini mum 5 000 Ib capacity required Compressor 100 psi and Generator 5 KW Pry Bar e Drift Pin 300 mm 12 Center Punch Tape Measure 7 5 m 25 Chalk Line e Concrete Marking Pencil e Nylon bottle brush for cleaning 7 8 drilled holes e Rags Water and Solvent for Touch up Note The above list of tools is a general recommen dation The actual number of tools required will depend on specific site conditions and the com plexity of the installation QuadGuard System Installation cont d rib IL p fr 610 24 760 30 mr QUADGUARD SYSTEM FOR NARROW HAZARDS 915 mm 36
22. BEAM TO W BEAM TRANSITION PANEL Figure 40 Transitioning the QuadGuard System p WIDTH VARIES 1620 mm 67 FOR 1755 mm 69 WIDE SYSTEM 2100 mm 83 FOR 2285 mm 90 WIDE SYSTEM 3050 mm 120 FOR 3200 mm 126 WIDE SYSTEM Figure 38 Tension Strut Backup Pw n WIDTH VARIES 1755 mm 691 4 2285 mm 90 o EZ Figure 39 Concrete Backup 29 QuadGuard System Installation for Wide Hazards cont d Transition Panel Types Note The proper transition or side panel must be used for optimum impact performance of the Sys tem The correct panel to use will depend on the direction of traffic and what type of barrier or haz ard the QuadGuard System is shielding Contact the Customer Service Department prior to instal lation if you have any questions Figure 41 e No Transition Figure 42 Figure 43 Quad Beam 1o Safety Shape Barrier Transition Panel Quad Beam 1o Thrie Beam Transition Panel Figure 44 Figure 45 Quad Beam to W Beam Transition Panel Quad Beam End Shoe Transition Panel Note Wheel Deflectors may be required for this application 30 QuadGuard System Installation for Wide Hazards cont d 2 Mark System Location Locate the centerline of the System by measuring the proper offset from the hazard Refer to the draw ing package supplied with the System Place chalk line to mark the centerline of the System Mark a construction line parallel to the
23. Performance The 6 bay QuadGuard System has successfully passed the NCHRP 350 Test Level 3 tests with both the light car and pickup truck at speeds up to 100 km h 62 mph at angles up to 20 degrees During head on impacts the QuadGuard System tele scopes rearward and crushes to absorb the energy of im pact When impacted from the side it safely redirects the vehicle back toward its original travel path and away from the hazard QuadGuard System Installation Required Tools Documentation e Manufacturer s Installation Manual e Manufacturer s Drawing Package Cutting equipment e Rebar Cutting Bit e 22 mm 7 8 Concrete Drill Bits Two Fluted e Grinder Hacksaw or Torch optional DIil Motor e Drill Bits 1 16 through 7 8 Energy Absorption Systems recommends using two fluted drills to achieve optimum tensile strength when installing the MP 3 anchoring system Hammers Roto Hammer Sledgehammer Standard Hammer Wrenches Heavy Duty Impact Wrench e Standard adjustable wrench e 1 2 drive sockets 9 16 11 16 3 4 15 16 1 1 8 1 1 4 Deep Sockets 5 16 1 1 4 e Ratchet and attachments for the above sockets Breaker Bar 1 2 x 24 Torque Wrench 200 ft lbs Crescent Wrench 300 mm 12 Allen Wrench 3 8 Impact Wrench 1 2 Personal protective equipment e Protective Eyewear Gloves Miscellaneous Traffic Control Equipment e Lifting and Moving Equipment
24. QG211048 7 63 25 0 24 0 110 68 QG211524 QG211530 QG211536 QG211548 853 28 0 n 27 0 115 71 QG212024 QG212030 QG212036 QG212048 9 45 31 0 9 04 29 8 30 0 120 75 UNIDIRECTIONAL DER gt NOSE ASSEMBLY REFERENCES D Kohfeld 2 25 2009 _ ENERGY ABSORPTION SYSTEMS INC DIAPHRAGM ASSY 35 40 07 DESIGNED DATE ENGINEERING AND RESEARCH DEPARTMENT 9 FENDER PANEL BACKUP SERIAL NO SHIM KIT DIAPHRAGM 3540078 0000 M Buehler 12 30 2008 NOSE ASSY 3540042 0000 55552 DATE o SALES ORDER FENDER PANEL ASSY 35 40 04 3 4 2009 QUADGUARD II SYSTEM Revision Date App EH PROJECT BACKUP ASSY 35 40 03 pas WITH TENSION STRUT BACKUP MJB 3 19 2009 MONORAIL ASSY IN REFERENCES WAS 35 40 06 MONORAIL ASSY 35 40 75 CONCRETE PAD WAS 35 40 11 6 22 09 RCB NO OF UNITS REVISED DESIGN SPEED COLUMN IN TABLE 8 31 09 UPDATED SYSTEM LENGTH AND EFFECTIVE 0 23 0 LENGTH COLUMNS IN TABLE FILE CONCRETE PAD 35 40 76 QG2TSCVR U idw DRAWING NEXT ASSEMBLY QG2TSCVR U 60 24 29 SEE PARTS DRAWINGS ee PARTS LIST non Ah 6024292 0000 PANEL QB 75 W HOLES 2516531 0000 FTB ST 3 16X12X20 1 2 2508191 0000 FTB ST 1 4X1 1 2X1 2 GALV GALVANIZING 113 21 TYP WHERE ACCESSIBLE ITEM 2 TO ITEM 1 TOP VIEW TYP ITEM 3 TO ITEMS 1 AND 2 SEE NOTE 4
25. SYSTEM PRODUCT MANUAL FOR A DESCRIPTION OF ITS IMPACT PERFORMANCE CHARACTERISTICS AND DESIGN LIMITATIONS BEFORE PLACING A SYSTEM AT A GIVEN SITE INFORMATION AND COPIES OF ABOVE MANUAL ARE AVAILABLE BY CALLING CUSTOMER SERVICE DEPARTMENT AT 888 323 6374 210 8 28 816 32 14 WHERE NECESSARY THE CUSTOMER SHALL SUPPLY AN ADEQUATE TRANSITION FROM THE QUADGUARD Il SYSTEM TO THE OBJECT BEING SHIELDED UNITS OF MEASUREMENT ARE MILLIMETERS INCHES UNLESS OTHERWISE NOTED SEE NOTE 3 BACKUP MONORAIL AND NOSE ASSEMBLIES ARE NOT INCLUDED IN MODEL NUMBER ORDER SEPARATELY 915 36 02 ELEVATION LEFT SIDE THE QUADGUARD SYSTEM HAS BEEN TESTED TO NCHRP 350 1220 48 03 610 24 WIDTHI762 30 WIDTH 914 36 WIDTH 1220 48 WIDTHISYSTEM LENGTH EFFECTIVE LENGTH PAD LENGTH MAX DESIGN SPEED NO OF CARTRIDGES MODEL NO MODEL NO MODEL NO MODEL NO m ft in m ft in m ft in Km h MPH QG24024 QG24030 QG24036 QG24048 243 7 01 173 5 8 274 9 07 40 25 0 QG27024 QG27030 QG27036 QG27048 3 05 110 0 264 8 8 274 19 07 70 143 1 QG28024 QG28030 QG28036 QG28048 3 96 113 0 3 56 11 8 3 66 12 0 80 50 2 QG29024 QG29030 QG29036 QG29048 487 16 07 447 14 81 457 15 0 90 56 2 QG210036 QG210048 5 79 19 07 5 49 18 07 100 62 3 QG210536 QG210548 671 22 0 231 0 105 65 3 4 5 6 QG211024 QG211030 QG211036
26. Steel rebar If steel rebar is encountered while drilling an MP 3 anchor bolt hole apply one of the following solu tions A Using a diamond core drill or rebar drilling tool drill through the rebar only then switch back to the concrete bit and drill into the underlying con crete until the proper hole depth is reached Caution Do not drill through rebar without first obtaining permission to do so from the local project engineer B Drill a new hole down at an angle past the rebar to the proper depth Anchor the stud by com pletely filling both holes with MP 3 53 QuadGuard System Maintenance and Repair Inspection Frequency Inspections are recommended as needed based upon vol ume of traffic amp impact history Visual Drive By Inspec tions are recommended at least once a month Walk Up Inspections are recommended at least once a year for in stallations on concrete and at least once every six months for installations on asphalt Visual Drive By Inspection 1 Check to see if there is evidence of a hit If so a walk up inspection will be necessary 2 Check to see if the Cartridges appear to be off the Support Brackets Any damaged Cartridges will need to be replaced WARNING Refer to Cartridge placement on pages 23 and 45 3 Be sure the Nose cover is in place 4 Note the location and condition of the QuadGuard System and the date of visual drive by inspection 54 Walk Up Inspection 1 Clear a
27. The City of Winnipeg Bid Opportunity No 516 2014 APPENDIX C QUADGUARD PRODUCT MANUAL asss ENERGY ABSORPTION SYSTEMS INC A Quixote Company Saving Lives By Design Corporate Offices 35 East Wacker Dr 11th Floor Chicago IL 60601 2076 Telephone 312 467 6750 FAX 312 467 1356 http www energyabsorption com Engineering and Manufacturing Facilities Rocklin CA Pell City AL Eu usss e QuadGuard System Table of Contents u u TER a cn ne ERROR 2 3 Reguired TOOS ac u uuu usa 3 QuadGuard Systems for Narrow Hazards atr a nune tutu rene 7 Site Preparation Foundation a l 8 Installation u ee ee ana auqa ee 9 QuadGuard Systems for Wide Maza i uut rot tirer tegeret rotos nennt xn buena betta 27 Site Preparation Foundation I L 28 IEEE Es 29 3 Polyester Anchoring System G utente taut talea uite 51 RT 51 52 MP 3 Installation Cautions u u u uuu rds 53 M inite ane and Repair vx acetate etn mima ed rant summa mE 54 Limitat
28. age 43 QuadGuard System Installation for Wide Hazards cont d 5 X 1 1 12a Install Nose Assembly G5 HEX BOLT Install the nose assembly see Figures 70 through 74 FRONT DIAPHRAGM and the nose assembly drawing in the following order Step 1 Figure 70 Attach pullout brackets to diaphragm with 5 8 x 1 1 2 hex bolts amp 5 8 nuts 1 place each side 5 8 RAIL NUT E Pus Step 2 Figure 71 Bolt nose attachment bracket be tween hinge and fender panel with 5 8 x 1 1 2 hex bolts 5 8 nuts and 5 8 flat washers Step 3 Figure 72 Bolt fender panel assembly to dia phragm with 5 8 x 4 hex bolts 5 8 nuts and 5 8 lock washers 3 places each side Figure 70 Attach Pullout Brackets to Diaphragm RAIL BOLT 5 8 X 4 G5 HEX BOLT gt 5 8 X 1 1 2 G5 HEX BOLT 5 8 LOCK i 5 lt a 5 8 HEX NUT SMALL EN Y 5 8 RAIL NUT LARGE s S 5 8 X134 lt FLAT WASHER 5 8 HEX NUT SMALL 5 8 X 1 3 4 FLAT WASHER NOSE ATTACHMENT BRACKET Sy Figure 71 Bolt Nose Attachment Bracket j A between Hinge and Fender Panel FENDER PANEL ASSEMBLY FRONT DIAPHRAGM Figure 72 Bolt Fender Panel Assembly to Diaphragm 44 QuadGuard System Installation for Wide Hazards cont d Step 4 Determine which style of cartridges your sys If your system has cartridge style A as shown in tem has
29. ance and Repair dem 5 M3U9S IW14 X 8 9 YIHSYM WOOBHSIW N sv 9NIHdS 310 ue 08 1 2 8 8 00 LIM HOHONV 2 HLIM lm N31SAS TIVHONOMW A18IN3SSV H3HSVM WOOYHSNIN Figure 88 QuadGuard for Wide Hazards S13 2vu8 S 1 044 390iH1HV NMOHS LNYLS NOISN3L dnyova d ES gt S3dAL SNOYINNN s TANVd NOLLISNVUL 61 QuadGuard System Limitations And Warnings The 6 bay QuadGuard System has been tested and evalu ated per the recommendations of the NCHRP 350 Guide lines for Test Level 3 TL 3 terminals and crash cush ions The impact conditions recommended in this guide line are intended to encompass the majority but not all of the possible in service collisions Properly installed and maintained the QuadGuard Sys tem is capable of performing its function of stopping or containing and redirecting the test vehicles in a predictable and safe manner under the nominal NCHRP 350 TL 3 terminal and crash cushion impact conditions of Vehicles Small car and pickup Mass 820 and 2000 kg 1808 and 4409 Ib Speed 100 km h 62 mph Angle 15 degrees for small vehicle 20 degrees for pickup Impact conditions which differ from those described in NCHRP 350 test matrix for non gating redirecting crash cushions may result in different crash results than those encountered in testing Furthermor
30. center line and offset 165 mm 6 5 to one side as shown in Figure 46 The edge of the monorail will be placed on this line Note The concrete pad should be installed per the project plans supplied with the System WARNING Location of System with respect to the hazard is critical and dependent on the type of transition panel used See the project plans supplied with the System for details CENTERLINE OF SYSTEM d CONSTRUCTION LINE 77 Figure 46 Top view of Concrete Pad Locating Construction Line 31 QuadGuard System Installation for Wide Hazards cont d 3a Anchor the Backup 3b Anchor the Backup Concrete Backup Installation figure 47 Tension Strut Backup Installation figure 48 Locate tension strut backup and monorail on pad with side of monorail on the construction line see Fig ure 51 Verify that any applicable transition panels fit properly before anchoring backup Drill anchor holes in pad using the backup as template Anchor the backup to the foundation using the MP 3 vertical kits provided See MP 3 Polyester Anchoring Sys tem on page 43 Locate front face plate using the backup assembly drawing Drill anchor holes in the concrete backup using the face plate as a template Anchor the face plate to the concrete backup using the MP 39 An choring System horizontal kit supplied with the QuadGuard System see MP 3 Polyester Anchoring page 43 Caution Every hole an
31. d Installation Procedures Note The drawing package supplied with the QuadGuard System must be used with these in structions for proper assembly and should take precedence over these general instructions 1 Determine Backup and Transition Type The System is available with a tension strut backup or a concrete backup Refer to figures 6 and 7 along with the backup assembly drawing to determine which type of backup is being installed A transition panel or side panel will be used on each side of the backup A side panel is not needed when a transition panel is used Several types of transitions are available for use with the QuadGuard System Re fer to figures 8 through 13 and the drawing package to determine which type of panels are being installed QUAD BEAM TO W BEAM TRANSITION PANEL Figure 8 Transitioning the QuadGuard System WIDTH 77 VARIES 610 mm 24 760 mm 30 915 mm 36 Figure 6 Tension Strut Backup M 610 mm 24 ow 760 mm 30 o ces 915 mm 136 6 WIDTH 7 _ gt VARIES 75 li d Figure 7 Concrete Backup QuadGuard System Installation for Narrow Hazards cont d Transition Panel Types Note The proper transition or side panel must be used for optimum impact performance of the Sys tem The correct panel to use will depend on the direction of traffic and what type of barrier or haz ard the QuadGuard System is shielding Contact the Custo
32. d slot in backup and Caution Every hole and slot in backup and monorail must have an MP 3 bolt anchoring it monorail must have an MP 3 bolt anchoring it FULLY CURED CONCRETE BACKUP SEE DRAWING PACKAGE Pub TENSION STRUT BACKUP BACKUP FACE PLATE A 4 VERTICAL MP 3 KIT WITH 3 4 X 7 STUD OC HORIZONTAL MP 3 KIT Y WITH 3 4 X 6 1 2 STUD Figure 47 Figure 48 Anchoring Backup Face Plate to Concrete Backup Anchoring Tension Strut Backup to Foundation 32 QuadGuard System Installation for Wide Hazards cont d 3c Anchor the Backup Secure the backup sections to each other using Extra Wide Tension Strut Backup Installation figure 49 Locate the extra wide tension strut backup center section and monorail on pad with side of monorail on the construction line see Figure 51 Locate the extra wide tension strut backup left sec tion on the left side of the center section aligning the three holes in the side plates 5 8 x 2 hex bolt 5 8 x 1 3 4 flat washer 2 5 8 lock washer amp 5 8 hex nut 6 places as shown in Figure 49 amp Detail 49a Verify that any applicable transition panels fit prop erly before anchoring backup Drill anchor holes in pad using the backup as template Anchor the backup to the foundation using the MP 3 vertical kits pro vided See MP 3 Polyester Anchoring System on page 43 Locate the extra wide tension strut backup right sec tion on the
33. e impacts in excess of TL 3 impact severity or the existence at the site of the installation of curbs or cross slopes in excess of 8 may yield crash performance which does not meet NCHRP 350 evaluation criteria relative to structural ad equacy occupant risk and vehicle trajectory factors Copy may be obtained from Transportation Research Board National Research Council 2101 Constitution Avenue N W Washington D C 20418 62 QuadGuard System Notes 35 East Wacker Dr 11th Floor Chicago IL 60601 2076 Engineering and Manufacturing Facilities Rocklin California and Pell City Alabama s ENERGY ABSORPTION SYSTEMS INC A Quixote Company Saving Lives By Design Part No 2750871 0000 Rev 12 6 07 http www energyabsorption com 2007 Energy Absorption Systems Inc SEE NOTE 5 1220 48 03 lt TRAFFIC 102 4 00 EFFECTIVE LENGTH SYSTEM LENGTH PAD LENGTH NOTES 1 IN COMPLIANCE WITH THE AASHTO 2002 ROADSIDE DESIGN GUIDE MANUFACTURER RECOMMENDS REMOVAL OF ALL CURBS AND ISLANDS TO ENSURE PROPER IMPACT PLAN PERFORMANCE PROVISION SHALL BE MADE FOR REAR FENDER PANELS TO SLIDE REARWARD UPON IMPACT 762 30 00 MIN 150 6 00 MIN REINFORCED 28 MPa 4000 PSI P C CONCRETE PAD OR 200 8 00 MIN NON REINFORCED 28MPa 4000 PSI CONCRETE ROADWAY MEASURING AT LEAST 3 66 m 12 0 WIDE BY 15 24 m 50 0 LONG SEE THE QUADGUARD Il
34. er to Measuring the Width page 6 Table D QuadGuard System Ordering Information Chart CHOICES 610 mm 24 760 mm 30 915 mm 36 1755 mm 69 2285 mm 90 Extra Wide specify width FILL IN THIS SECTION What is the Number of Bays refer to Counting The Number of Bays page 5 Narrow Hazards 1 through 12 Wide Hazards 3 through 12 What Type of Backup Does the System Have Concrete Tension Strut What Type of Transition Panel Refer to Side Panel amp Transition Panel Types page 10 Be sure to note right side left side both sides refer to How to Determine Left Right page 5 or no transitions Quad to W Quad to Thrie Quad to Safety Shape Barrier Quad to End Shoe 4 Offset Panel 59 QuadGuard System Maintenance and Repair EN M39U9S LV14 6 X 8 9 M18IN3SSV H3A02 JSON ATTE anis Z X gt f HOHONV dIN 1V21 183A E J x EM i 9NIudS ra n Z m d InN pa HOHONV diN Pi lt lt IN31SAS d3dNf TIVHONOM ET u3HSVM wid s lt b g L X 8 9 19814 KSA a S A18NN3SSV H3HSVM WOOHHSNW 1 5 EITAS NMOHS 11819 NOISN31 dnyova S3dAL SNOYAINNN TANWd NOLLISNVHL Figure 87 QuadGuard for Narrow Hazards 60 QuadGuard System Mainten
35. ergy Absorption Systems Inc s Customer Service Department for more information 52 Horizontal Installations The horizontal MP 3 kit is the same as the vertical kit except that a cartridge for a standard caulking gun is sup plied in the horizontal kits and the resin for the horizontal kits is a thixotropic TX resin The TX Resin is a gelled resin designed to keep the grout in place in horizontal holes during installation When using the horizontal MP 3 kits follow the vertical instructions with the following exceptions 1 Thread dispensing tip onto dispenser Prior to mixing the grout carefully thread the dis pensing tip onto the dispenser 2 Pour mixed grout into dispenser Once the grout is mixed crimp the mouth of the can to form a spout and pour the MP 3 grout into the open end of the dispenser use mixing stud to scrape out the portion remaining in the can You may use the box to hold the dispenser upright Close the box lid and poke the dispenser tip into the top of it Seal the dispenser with the plunger provided 3 Place dispenser in caulking gun and dispense grout Cut off the small end of the dispenser tip Place the dispenser into a caulking gun and dispense until MP 3 TX grout reaches the tip of the dispenser then re lease pressure Push the dispenser tip through the part to the bottom of the hole and dispense while slowly withdrawing the tip Caution Do not overfill or underfill the hole Fill hole
36. es DIAPHRAGM OR BACKUP BAY SPACING 915 mm 36 FENDER PANEL Figure 64 Proper Spacing Between Diaphragms 10 Install End Cap Using 5 8 x 3 1 2 G5 hex bolt 5 8 hex nut and 5 8 lock washer attach the end cap to the front of the first monorail segment as shown in Figure 65 55 2 MONORAIL 9 8 HEX NUT END CAP Figure 65 Monorail End Cap Installation 41 QuadGuard System Installation for Wide Hazards cont d 11 Install Cartridge Support Brackets Attach cartridge support bracket to all diaphragms and backup as shown in Figures 66 67 68 69 the backup assembly drawing and the diaphragm assem bly drawing A STEP A INSTALL LOWER CARTRIDGE SUPPORT BRACKET d CARTRIDGE SUPPORT BRACKET IS WELDED TO FACE PLATE CARTRIDGE SUPPORT BRACKET Figure 67 Concrete Backup with Cartridge Support Bracket Figure 66 Tension Strut Backup with Cartridge Support Bracket 42 QuadGuard System Installation for Wide Hazards cont d DIAPHRAGM DIAPHRAGM ae C CARTRIDGE SUPPORT BRACKET CARTRIDGE SUPPORT BRACKET A N Figure 68 Diaphragm with Cartridge Support Bracket EXTRA WIDE FIRST DIAPHRAGM T CARTRIDGE SUPPORT BRACKET CARTRIDGE SUPPORT BRACKET Figure 69 Extra Wide First Diaphragm with Cartridge Support Bracket See Drawing Pack
37. he adjustable cartridge support bracket incor rectly in the lower position Detail 32c Incorrect Installation of Adjustable Cartridge Support Bracket As shown in Detail 32d cartridge style B is installed with the adjustable cartridge support bracket incor rectly in the upper position Detail 32d Incorrect Installation of Adjustable Cartridge Support Bracket Detail 32e shows the adjustable cartridge support bracket installed correctly Detail 32e Correct Installation of Adjustable Cartridge Support Bracket 22 QuadGuard System Installation for Narrow Hazards cont d Bolt the nose directly to the front diaphragm EXISTING as shown in figures 32 33andthenoseas 5 8 RAIL _ sembly drawing using six rail bolts which 27 also hold the front two fender panels to the diaphragm with bar washer under each bolt Place pullout brackets under center nuts The top and bottom holes of the nose are slotted to provide adjustment Adjust so the top edge of the nose is level with the top edge of the fender panels then torque all six nuts to 35 Nm 25 ft lbs EXISTING gt 5 8 X 2 RAILBOLT YT j 1 1 4 X 2 BAR WASHER Figure 32 Nose Assembly PLACE A BOARD OVER THE FIRST TWO DIAPHRAGMS AS SHOWN TO FACILITATE PROPER ALIGNMENT OF NOSE J 2 TIGHTEN NUTS TO 35 mm 25 FT LBS ci px gt m AFTER ALIGNING
38. heck to see that all Anchor Bolts have remained firmly anchored in the roadway surface Failed anchor bolts are those found to be loose bro ken or showing signs of pull out and are to be replaced If the System is anchored to asphalt up to 20 of the total anchors may be replaced if damaged If more than 20 of the anchors are damaged the system should be relocated to fresh undis turbed asphalt and reinstalled using the 460 mm 18 threaded rods The proper performance of the System during an angle impact depends on the monorail an chors being properly anchored Clear and dispose of any debris on the site Check the System to be certain that the Mush room Washer Assemblies holding the fender panels together are still intact and that the Sys tem has not been deformed in a way that would prevent pulling it back to its original position Be sure that the Diaphragm Support Legs are all properly attached to the Monorail Post Impact Instructions Wide Hazards 1 Deploy the appropriate traffic control devices to protect your crew 2 Check to see that all Anchor Bolts have remained firmly anchored in the roadway surface Replace any that are loose broken or pulled out The proper performance of the System during an angle impact depends on the Monorail An chors being properly anchored Note QuadGuard Systems for Wide Hazards should never be anchored to asphalt 3 Clear and dispose of any debris on the site
39. hieved if a diamond drill is used Refer to the MP 3 installation instructions provided with your kit Check to be sure all the holes are drilled to the proper depth and aligned with the part to be anchored Refer to Table A Table A MP 3 Anchoring Information Stud size Concrete Minimum Recommended bit size Depth Torque 3 4 x 6 1 2 22mm 125 mm 165 Nm 7 8 5 120 ft Ibs 3 4 x 7 22 mm 140 mm 165 Nm 3 4 x 71 2 7 8 5 1 2 120 ft lbs 3 4 x 8 1 2 18 22mm 420 mm lt 15 Nm 7 8 16 1 2 lt 10 ft Ibs 3 Clean the holes Blow the concrete dust from the hole using oil free compressed air Thoroughly brush it with a stiff bristled brush and then blow it out again If the hole is wet completely flush it with water while brushing Then blow it clean using oil free compressed air 4 Mix the resin and hardener Wearing gloves and safety goggles remove the lids from the MP 3 Part A Resin and Part B Hardener con tainers Pour Part B into Part A then mix vigorously for 30 seconds to form MP 3 grout an anchor stud may serve as a Stirring rod 5 Add cold weather promotor in cold weather For faster hardening in cold weather Promoter may be used Add the entire contents of the partially filled Promoter container to the MP 3 grout then mix for an additional 30 seconds Use immediately because the MP 3 grout will thicken quickly Refer to Table B for hardening times 6 Pour grout into
40. holes WARNING Do not use Promoter when the temperature is above 15 degrees Celsius 60 degrees Fahrenheit Grout will harden too quickly 51 QuadGuard System MP 3 Polyester Anchoring System cont d Crimp the mouth of the can to form a spout and pour the MP 3 grout mixture down into the hole through the part Fill the hole 1 3 to 1 2 full Caution Do not overfill or underfill the hole If the hole is overfilled there will not be enough grout to use all of the anchor studs kit If hole is under filled the grout may not develop the required pull out strength 7 Add the washers and nuts Place a flat washer onto the stud then thread a nut on until 1 or 2 threads of the NUT are left exposed 8 Insert Studs in holes and wait for grout to harden Push the stud down through the part to be anchored and into the hole Give the stud several twists in the MP 3 to wet the threads Caution Do not disturb or load the stud until the MP 3 material has hardened see Table B for hardening times 9 Torque the nuts Once the grout has hardened torque the nut to the recommended values See Table A Now no threads of the nut should be exposed Table B Approximate Hardening Times hrs Temperature No With C F Promoter Promoter gt 26 gt 80 1 2 N R 22 26 70 79 1 N R 16 21 60 69 2 N R 10 15 50 59 4 3 4 4 9 40 49 8 1 1 3 30 39 N R 1 1 2 lt 1 lt 30 N R N R Not recommended Contact En
41. in usable condition Diaphragms which are bowed or have bent legs must be replaced 9 Check that the Fender Panels are properly at tached with the Mushroom Washer Assemblies Damaged Fender Panels and Transition Panels 56 must be replaced Often Cartridge Support Brack ets with minor damage can be straightened and reused by doing the following A Remove damaged Cartridge Support Bracket from diaphragm B Clamp Cartridge Support Bracket to backup and begin bending using pipe wrench as shown in Figure 81 BACKUP CLAMP PIPE WRENCH CARTRIDGE SUPPORT BRACKET Figure 81 Straighten Cartridge Support Bracket C Then using a sledge hammer and Quad Beam shape on backup as an anvil form Cartridge Support Bracket back into 90 shape see Figure 82 CARTRIDGE SUPPORT BRACKET SLEDGE HAMMER Figure 82 Form Cartridge Support Bracket QuadGuard System Maintenance and Repair WARNING Fender Panel Maximum gap allowed Narrow Systems 20 mm 0 78 Wide Systems 25 mm 1 00 Narrow Hazards 10 Check gaps between Fender Panels The maxi mum gap allowed for these overlapping parts in cluding Fender Panels overlapping panels behind the System is 20 mm 78 see figure 83 MAXIMUM GAP 20 mm 0 78 i UNDERLYING FENDER FENDER PANEL TRANSITION EXTENSION OR SIDE PANEL Figure 83 Fender Panel Gap for Narrow Ha
42. ion and reinforcement specifica tions for new concrete pads are provided in Energy Ab sorption Systems Inc concrete pad drawings supplied with the System System may be installed on concrete roadway minimum 200 mm 8 thick Installation cross slope shall not exceed 8 see figure 5 and should not vary twist more than 2 over the length of the System the pad surface shall have a light broom finish Caution Accurate placement of all steel re bar is critical to avoid interference with the concrete Anchor Bolts S C B 59 12 1 MAXIMUM LEVELING PAD SHOWN EXAGGERATED FOR CLARITY Figure 5 Cross Slope WARNING Location of the backup in relation to nearby objects will affect the operation of the attenuator Upon impact the fender panels telescope toward and extend beyond the rigid backup as much as 760 mm 30 from their pre impact location Position the backup so that the rear ends of the last fender panels are a minimum of 760 mm 30 forward of objects that would otherwise interfere with movement of the panels Failure to comply with this requirement may result in impaired System performance offering motorists less protection and cause component damage QuadGuard System Installation for Narrow Hazards cont d Inspect Shipping Before installing the QuadGuard System check the re ceived parts against the shipping list supplied with Sys tem Make sure all parts have been receive
43. ions And Warnings 2 Fein anu eios 62 Important Introductory Notes System Overview Proper installation of the QuadGuard System is essential to assure maximum performance Take the time to re The QuadGuard System is a highly efficient redirective non gating crash cushion for hazards ranging in width view the installation instructions and product limitations thoroughly before performing the necessary work Do not attempt to install any crash cushion without the proper plans and installation manual from the manufacturer If you need additional information or have questions about the QuadGuard System please call Energy Absorp tion Systems Customer Service Department at 888 323 6374 RETURN GOODS POLICY Before returning any goods for credit please contact Energy Absorption Systems Inc Customer Service De partment at 1 888 323 6374 or your local distributor for proper instructions from 610 mm to 3200 mm 2 to 10 5 It consists of crushable energy absorbing cartridges surrounded by a framework of Quad Beam panels The QuadGuard System utilizes two types of cartridges in a staged configuration to address both lighter cars and heavier high center of gravity vehicles Its modular de sign allows the System length to be tailored to the design speed of a site Refer to the QuadGuard Product Manual to determine the appropriate length System for a given design speed Crash
44. mer Service Department prior to instal lation if you have any questions Figure 9 No Transition Figure 10 Figure 11 Quad Beam 1o Safety Shape Barrier Transition Panel Quad Beam 1o Thrie Beam Transition Panel Figure 12 Figure 13 Quad Beam to W Beam Transition Panel Quad Beam End Shoe Transition Panel Note Wheel Deflectors may be required for this application 10 QuadGuard System Installation for Narrow Hazards cont d 2 Mark System Location Locate the centerline of the System by measuring the proper offset from the hazard Refer to the draw ing package supplied with the System Place chalk line to mark the centerline of the System Mark a construction line parallel to the center line and offset 165 mm 6 5 to one side as shown in Figure 14 The edge of the monorail will be placed on this line Note The concrete pad should be installed per the project plans supplied with the System WARNING Location of System with respect to the hazard is critical and dependent on the type of transition panel used See the project plans supplied with the System for details CENTERLINE OF SYSTEM CONSTRUCTION LINE 165 mm 6 5 l Figure 14 Top view of concrete pad Locating Construction Line 11 QuadGuard System Installation for Narrow Hazards cont d 3a Anchor the Backup Concrete Backup Installation Figure 15 Locate front face plate using the backup
45. ms and fender panels fol lowing the same procedures Tighten the nut so that the spring is compressed 1mm to 3mm 1 16 to 1 8 to complete the assembly BAY SPACING 915 mm 36 DIAPHRAGM DIAPHRAGM OR BACKUP FENDER PANEL Figure 26 Proper Spacing Between Diaphragms QuadGuard System Installation for Narrow Hazards cont d 9 Install End Cap Using 5 8 x 3 1 2 G5 hex bolt 5 8 hex nut and 5 8 lock washer attach the end cap to the front of the first monorail segment as shown in Figure 27 and monorail assembly drawing 5 X312 65 HEXBOLT END CAP Figure 27 Monorail End Cap Installation DIAPHRAGM LOWER CARTRIDGE SUPPORT BRACKET 5 8 HEX NUT 10 Install Cartridge Support Brackets Attach lower cartridge support bracket to front and back of all diaphragms and front of backup as shown in fig ures 29 30 diaphragm assembly drawing amp backup assembly drawing Note 610 mm 24 wide Systems do not have side cartridge support brackets 762 mm 30 and 914 mm 36 wide Systems have side cartridge sup port brackets welded to the backup and diaphragms 610 mm 24 WIDE 762 mm 30 AND X N 915 36 WIDE Pa S SIDE CARTRIDGE SUPPORT BRACKETS Figure 28 Side Cartridge Support Brackets DIAPHRAGM LOWER CARTRIDGE 0 SUPPORT BRACKET p 4571 J fee US i
46. nd dispose of any debris on the site 2 Be sure all bolts are tight 3 Be sure concrete anchor bolts are securely an chored 4 Be sure diaphragm legs are straight 5 Be sure all Mushroom Washer assemblies are properly aligned and positioned 6 Fender Panels and Transition Panels should nest tightly against the System WARNING Fender Panel Maximum gap allowed Narrow Systems 20 mm 0 78 Wide Systems 25 mm 1 00 See figures 83 and 84 on page 53 7 Be sure Cartridges have not been damaged and are properly positioned on their Support Brack ets Replace crushed or sagging Cartridges To ensure 100 of the full design speed character istics partially crushed Cartridges due to slow speed impacts should be replaced WARNING Refer to Cartridge placement on pages 23 and 45 8 Make all necessary repairs as described above Refer to Post Impact Instructions page 48 for more information 9 Note the location and condition of the Quad Guard System and any work done in the Impact Attenu ator Inspection Logbook under the date of this inspection If further repair is necessary note re pair request date in logbook Refer to Post Im pact Instructions next page and installation sec tion of this manual for more information QuadGuard System Maintenance and Repair cont d Post Impact Instructions Narrow Hazards 1 Deploy the appropriate traffic control devices to protect your crew C
47. norail on the front of the System 6 mm 1 4 the construction line and rear edge of monorail foot 10 forward of front face of concrete backup see Figure 18 Orient monorail so that the monorail tongues face the backup see figure 18 Drill 140 mm 5 1 2 deep anchor holes using the monorail as a template Do not drill through pad WARNING Improper alignment at the monorail splice joints will prevent proper System collapse during an impact WARNING CAUTION Every hole and slot in backup and monorail must have MP 3 ANCHOR 40 mm 1 50 an MP 3 stud anchoring it MAX STUD HEIGHT 3 ROADWAY BACKUP OR MONORAIL Figure 17 Proper Stud Height 255 mm 10 CONCRETE BACKUP MONORAIL 3 4 X 7 STUD AN eaea 8 4 sj CENTERLINE CONSTRUCTION LINE MONORAIL TONGUE Figure 18 Monorail Location for Concrete Backup 13 QuadGuard System Installation for Narrow Hazards cont d 4b Anchor the Monorail Anchor each monorail section using the MP 3 ver tical kits provided Refer to Figure 17 and the MP 3 Monorail Installation for Tension Strut Backup Polyester Anchoring System Instructions included Figure 19 with this manual It is important to install each seg ment of monorail in alignment from the back to Locate monorail on pad with side of monorail on the front of the System 6 mm 1 4
48. on strut backup is the width between side panels behind the backup see Figure 3 The nominal width of a System with concrete backup is the width of the concrete backup at location shown in Figure 4 The outside width of the System is approximately 150 mm 67 to 230 mm 9 wider than the nominal width The width of the System is not the same as the width of the backup Figure 3 Width of System with Tension Strut Backup Figure 4 Width of System with Concrete Backup QuadGuard System QUADGUARD SYSTEMS FOR NARROW HAZARDS E 610 mm 2471 MODEL NO 0524 _ dedisse _ 762 mm 30 MODEL QS30_ s JE JE 914 36 MODEL NO 05836 _ QuadGuard System Installation for Narrow Hazards cont d Site Preparation Foundation A QuadGuard System should be installed only on an ex isting or freshly placed and cured concrete base 28 MPa 4000 psi minimum Location and orientation of the concrete base and attenuator must comply with project plans or as otherwise determined by the resident project engineer Recommended dimens
49. p 4 Attach the front of the fender panels to the next diaphragm using two rail bolts and large hex nuts per side Use only the top and bottom holes leave the center hole open un til the next fender panel is installed DIAPHRAGM A x 5 8 FLATHEAD 7 4 5 8 RAIL NUT LARGE SOCKET SCREW FENDER PANEL F N d 5 8 RAIL BOLT Figure 25 Fender Panel Assembly KEEP CENTER HOLE EMPTY FOR NEXT PANEL 17 QuadGuard System Installation for Narrow Hazards cont d FENDER PANEL one MUSHROOM amp _ WASHER 7 5 5 8 FLAT WASHER TEE 5 8 FLATHEAD SOCKET SCREW FENDER PANEL ATTACHED DIAPHRAGM OR BACKUP Z ____ Detail 25a Mushroom Washer Attachment Be sure mushroom washer lays flat against the fender panel as shown in Figure 27 Standoff on washer must be seated completely through slot FENDER PANEL MUSHROOM BEA WASHER CORRECT INCORRECT Detail 25b Mushroom Washer Orientation 18 Check diaphragm spacing to ensure 915 mm 36 be tween rear faces of consecutive diaphragms as shown in Figure 26 and fender panel assembly drawing Once the proper spacing has been achieved torque the mushroom washer assembly small hex nuts to hold the diaphragm and fender panels in place during assembly of the rest of the System Install the remaining diaphrag
50. rawing package Installation tip Use drift pin to align the center hole of the panel with the center hole of the backup before installing the rail bolts CONCRETE BACKUP MO 2 5 5 8 HEX NUT SMALL 9 8 LOCK WASHER 5 8 RAIL NUT LARGE SEE FIGURE 61 WIDE SIDE PANEL 3 8 LOCK WASHER 3 8 HEX NUT VIE X PLATE 5 8 RAIL BOLT Figure 53 Side Panel Transition Panel Attachment 35 QuadGuard System Installation for Wide Hazards cont d 6a Install Monorail Guides Wide Systems 6b Install Monorail Guides Extra Wide Systems Attach monorail guides to diaphragm as follows Insert 3 4 x 2 G8 hex bolt through monorail guide and diaphragm oriented as shown in Figure 54 Se cure with 3 4 lock washer amp 3 4 hex nut typical two places per guide See also diaphragm assembly drawing Repeat for each diaphragm i i lt DIAPHRAGM 24 3 4 NUT GR DH 7 P di 3 4 LOCK WASHER MONORAIL GUIDE Figure 54 Monorail Guide Attachment 36 Attach monorail guides to diaphragms as follows Second through Last Diaphragms Insert 3 4 x 2 G8 hex bolt through monorail guide and diaphragm oriented as shown in Figure 54 Se cure with 3 4 lock washer amp 3 4 hex nut typical two places per guide Repeat for all diaphragms except the first First Diaphragm Slide monorail
51. res high pullout strength superior vibration resistance and exceptional durability Each MP 3 kit contains a can of MP 3 resin hardener cold weather promotor studs washers and a complete safety sheet The cold weather promoter shortens hardening time by as much as seven hours Both vertical and horizontal installations are possible using the MP 3 System Vertical Installations Note Read MP 3 Instructions before starting 1 Prepare the concrete pad WARNING Do not allow the MP 3 Resin or Hardener to contact skin or eyes See material safety data sheet supplied with the MP 3 kit for first aid procedures Use only in well ventilated area Do not use near open flame WARNING Wear safety goggles and gloves during installation The anchor bolts Studs that anchor the QuadGuard System to the concrete pad must be those shipped in the kit or of high strength steel 830 MPa 120 000 psi minimum tensile strength or equal These Studs must be set in minimum 28 MPa 4000 psi concrete Allow the concrete to cure a minimum of 7 days before installing MP 3 2 Drill holes Note Energy Absorption Systems recommends us ing two fluted drills to achieve optimum tensile strength when installing the MP 3 anchoring system Use the part that is to be anchored as a drilling tem plate Drill the holes 3 mm 1 8 larger than the stud diameter to the recommended depth using a rotary percussive drill Full strength will not be ac
52. right side of the center section aligning the three holes in the side plates Caution Every hole and slot in backup and monorail must have an MP 3 bolt anchoring it EXTRA WIDE TENSION STRUT BACKUP RIGHT SECTION EXTRA WIDE TENSION STRUT BACKUP PNR SELLON VERTICAL MP 3 KIT WITH 3 4 X 7 STUD SEE DETAIL 50a EXTRA WIDE TENSION STRUT BACKUP LEFT SECTION 209 Detail 49a Figure 49 Anchoring Extra Wide Tension Strut Backup to Foundation See Drawing Package 33 QuadGuard System Installation for Wide Hazards cont d 4 Install Monorail WARNING Locate the monorail using the monorail assembly Every hole and slot in backup and monorail must have drawings an MP 3 stud anchoring it Drill 140 mm 5 1 2 deep anchor holes using the monorail as a template see figures 51 and 52 Do not drill through pad Anchor each monorail section using the MP 3 verti BACKUP OR MONORAIL cal kits provided Refer to Figure 50 and the MP 3 MP 3 ANCHOR Polyester Anchoring System Instructions included with this manual CAUTION It is important to install each segment of monorail in 40 mm 1 50 alignment from the back to the front of the System L 6 mm 1 47 T WARNING ROADWAY Improper alignment at the monorail splice joints will Figure 50 prevent proper System collapse during an impact Proper Stud Height
53. s telescope toward and extend beyond the rigid backup as much as 760 mm 30 from their pre impact location Position the backup so that the rear ends of the last fender panels are a minimum of 760 mm 30 forward of objects that would otherwise interfere with movement of the panels Failure to comply with this requirement will result in impaired System performance offering motorists less protection and cause component damage QuadGuard System Installation for Wide Hazards cont d Inspect Shipping Before installing the QuadGuard System check the re ceived parts against the shipping list supplied with Sys tem Make sure all parts have been received Installation Procedures Note The Drawing Package supplied with the QuadGuard System must be used with these in structions for proper assembly and should take pre cedence over these general instructions 1 Determine Backup and Transition Type The System is available with a tension strut backup or a concrete backup Refer to Figures 38 and 39 along with the backup assembly drawing to deter mine which type of backup is being installed A transition panel or side panel will be used on each side of the backup A side panel is not needed when a transition panel is used Several types of transi tions are available for use with the QuadGuard Sys tem Refer to Figures 40 through 45 and the drawing package to determine which type of panels are being installed QUAD
54. the center hole of the backup before installing the rail bolts CONCRETE BACKUP 5 8 RAIL NUT 2 SEE FIGURE 24 Figure 20 Side Panel Transition Panel Attachment 15 QuadGuard System Installation for Narrow Hazards cont d 6 Attach Monorail Guides Attach monorail guides to diaphragm as follows Insert 3 4 x 2 G8 hex bolt through monorail guide and diaphragm oriented as shown in Figure 21 Secure with 3 4 lock washer amp 3 4 hex nut typical 4 places See also diaphragm assembly drawing Repeat for each diaphragm DIAPHRAGM m d o 3 4 LOCK WASHER 77 f HEX NUT Ke 3 4 X 2 68 HEX BOLT MONORAIL GUIDE Figure 21 Monorail Guide Attachment 7 Install Diaphragms Orient a diaphragm so that the front face of the Quad Beam shape faces toward the nose of the System as shown in Figure 22 Slide one dia phragm all the way to the backup to ensure the System is able to collapse properly during impact Once this has been verified slide the diaphragm forward to approximately 915 mm 36 in front of the backup Orient and slide all other diaphragms onto monorail and position each approximately as shown in Figure 23 TOWARD NOSE 74 4 BACK Th 2 S QUAD BEAM Figure 22 Diaphragm Orientation _ 915mm 36 915 367 DIAPHRAGMS TYPICAL 0
55. to pro vide adjustment Adjust so the top edge of the nose is level with the top edge of the fender panels Torque all six nuts to 35 Nm 25 ft Ibs FIRST DIAPHRAGM NOSE ATTACHMENT BRACKET t 5 8 X 2 HEX BOLT mM BAR WASHER 1 8 X 1 1 4 X 2 Figure 73 Attach Nose to Attachment Bracket PLACE A BOARD OVER THE FIRST TWO DIAPHRAGMS AS SHOWN TO FACILI TATE PROPER ALIGNMENT OF NOSE TIGHTEN NUTS TO 35 mm 25 FT LBS 7215 AFTER ALIGNING NOSE AS SHOWN Figure 74 Adjust Nose 47 QuadGuard System Installation for Wide Hazards cont d 12b For Wide Systems with Optional Nose Belt Assembly a Using 5 8 x 5 hex bolts 5 8 x 1 3 4 flat wash ers and 5 8 hex nuts attach hinge plate to fender panel as shown in Figure 75 three places per side b Thread second 5 8 nuts onto the installed bolts Be sure the face of the nuts are flush with humps on fender panels see detail 75a Slide second 5 8 x 1 3 4 flat washers onto bolts three places per side c Align holes in each end of the nose belt with the installed bolts three per side and slide nose belt onto bolts d Align holes in belt clamps with bolts and slide belt clamps onto bolts 5 8 X HINGE PLATE X13 FENDER PANEL JASPER QUADGUARD NOSE BELT D Em FENDER PANEL THREADHEXBOLT
56. us diaphragm as shown in Figure 60 TOWARD NOSE p BACK FRONT HINGES uU Figure 59 Extra Wide Diaphragm Diaphragm 1 EXTRA WIDE QUAD BEAM DIAPHRAGMS FIRST DIAPHRAGM Figure 60 Diaphragm spacing 38 QuadGuard System Installation for Wide Hazards cont d 8 Install Hinge Plates onto Fender Panels Note Do not mix the 5 8 rail nuts large with the 5 8 hex nuts small See Figure 61 24 mm 0 94 32 mm 1 25 VN A f 27 VN ES N N CNET 5 N ie I Bond So 088 5 8 RAIL NUT LARGE 5 8 HEX NUT SMALL Figure 61 Rail Nuts are Oversize Note For proper impact performance Systems for wide hazards must have hinge plates Install a hinge plate on each fender panel using two 5 8 rail bolts amp two 5 8 rail nuts using top and bottom holes only leaving the center hole open as shown in Figure 62 FENDER PANEL 5 8 RAIL NUT LARGE HINGE PLATE 5 8 RAIL BOLTS Figure 62 Hinge Plate Assembly 39 QuadGuard System Installation for Wide Hazards cont d 9 Install Fender Panels 5 8 RAIL NUT LARGE DIAPHRAGM Starting at the last bay install left and right fender
57. zards Be sure the Mushroom Washer Assemblies are torqued so that the spring is compressed If the gaps between the Fender Panels are still too large it may be necessary to replace bent parts Wide Hazards 10 Check gaps between Fender Panels The maxi mum gap allowed for these overlapping parts in cluding Fender Panels overlapping panels behind the System is 25 mm 1 00 see figure 84 MAXIMUM GAP 25 mm 1 00 NS UNDERLYING FENDER E TRANSITION EXTENSION ORSIDEPANEL FENDER PANEL Ay Figure 84 Fender Panel Gap for Wide Hazards Be sure the Mushroom Washer Assemblies are torqued to 80 Nm 60 ft lbs If the gaps between the Fender Panels are still too large it may be necessary to replace bent parts 57 QuadGuard System Maintenance and Repair 11 Replace all crushed Cartridges Refer to Car tridge Placement on pages 25 amp 49 12 Remove damaged plastic Nose Cover Attach the new nose cover to the first diaphragm using the six rail bolts rail nuts and bar washers that hold the front fender panels to the first diaphragm The top and bottom holes of the nose cover are slotted to provide adjustment Adjust nose to align with fender panels then torque all six nuts to 35 Nm 25 ft lbs See Figure 85 Nose Ad justment PLACE A BOARD OVER THE FIRST TWO DIAPHRAGMS AS SHOWN TO FACILITATE PROPER ALIGNMENT OF NOSE

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