Trinity Highway QuadGuard 2 User manual

QuadGuard® II

Product Description Manual

Revision F December 2012Part No. 611298B

Part No. 611298B

www.energyabsorption.com Revision F December 2012

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QuadGuard

Product Description Manual

2525 Stemmons Freeway

Dallas, Texas 75207

Important:

These instructions are to be used only in conjunction with the

assembly, maintenance, and repair of the specified QuadGuard

II system.

These instructions are for standard assembly specified by the appropriate

highway authority only. In the event the specified system assembly,

maintenance, or repair would require a deviation from standard assembly

parameters, contact the appropriate highway authority engineer. This system has

been accepted by the Federal Highway Administration for use on the national

highway system under strict criteria utilized by that agency. Energy Absorption

Systems representatives are available for consultation if required.

This Manual must be available to the worker overseeing and/or assembling the product

at all times. For additional copies, contact Energy Absorption Systems at (888) 323-6374

or download from websites below.

The instructions contained in this Manual supersede all previous information and Manuals. All

information, illustrations, and specifications in this Manual are based on the latest QuadGuard

II system information available to Energy Absorption Systems at the time of printing. We reserve

the right to make changes at any time. Please contact Energy Absorption Systems to confirm

that you are referring to the most current instructions.

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Table of Contents

Customer Service Contacts..........................................................................................................3

Important Introductory Notes ........................................................................................................3

Recommended Safety Rules for Assembly ..................................................................................4

Safety Symbols.............................................................................................................................5

Warning and Cautions ..................................................................................................................5

Limitations and Warnings..............................................................................................................6

System Overview..........................................................................................................................7

QuadGuard®II Deployment Criteria............................................................................................10

Transitioning ...............................................................................................................................15

Transition Panel Types...............................................................................................................16

QuadGuard®II cz Deployment Criteria.......................................................................................17

QuadGuard®II Foundation/Anchoring ........................................................................................18

Assembly ....................................................................................................................................20

Recommended Tools..................................................................................................................20

Life Expectancy...........................................................................................................................22

QuadGuard®II System w/Tension Strut Backup.........................................................................23

QuadGuard®II System w/Tension Strut Backup Wide ...............................................................24

QuadGuard®II System w/Concrete Backup ...............................................................................25

QuadGuard®II System w/Concrete Backup Wide......................................................................26

QuadGuard®II System Construction Zone System....................................................................27

QuadGuard®II System 8” Concrete Pad for Tension Strut Backup............................................28

QuadGuard®II System Backup Assembly, TS, QG....................................................................30

QuadGuard®II System Concrete Backup, QG on Grade ...........................................................31

QuadGuard®II System Concrete B-up, QG on Existing Concrete Structure..............................32

QuadGuard®II System Concrete Pad, for Concrete Backup, QG..............................................33

QuadGuard®II Backup Assembly, Concrete, QG.......................................................................34

QuadGuard®II System Concrete Pad, cz, QG ...........................................................................35

QuadGuard®II System cz Anchor/Lifting Kit, QG, (3-9 Bays).....................................................36

QuadGuard®II System Monorail Assembly, QG.........................................................................38

Diaphragm Assembly, QG..........................................................................................................41

Shim Kit, Diaphragm, Rail guide, QG II ......................................................................................42

Fender Panel Assembly, QG......................................................................................................43

Nose Assembly, QG II, Narrow...................................................................................................44

Nose Assembly, QG II, 48 ..........................................................................................................45

QuadGuard®II System Backup Assembly, TS, QG Wide...........................................................46

Backup Assembly, Concrete, QG Wide......................................................................................47

QuadGuard®System Concrete Pad & Backup, QG Wide ..........................................................48

QuadGuard®System (69”) Concrete Pad & Backup, QG Wide on Grade..................................49

Diaphragm Assembly, QG, Wide................................................................................................51

QuadGuard®Wide System Fender Panel Assembly..................................................................53

Nose Assembly, QGII, Wide.......................................................................................................54

QuadGuard®System PCMB Anchor Assembly..........................................................................55

QuadGuard®End Shoe Assembly..............................................................................................56

QuadGuard®4” Offset Transition Assembly ...............................................................................57

QuadGuard®Quad-Beam to W-Beam Transition Assembly.......................................................58

QuadGuard®Quad-Beam to Thrie-Beam Transition Assembly..................................................59

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Customer Service Contacts

Energy Absorption Systems (a Trinity Highway Products company) is committed to the highest

level of customer service. Feedback regarding the QuadGuard®II system, its assembly

procedures, supporting documentation, and performance is always welcome. Additional

information can be obtained from the contact information below:

Energy Absorption Systems:

Telephone: (888) 323-6374 (USA Only)

(214) 589-8140 (USA or International)

E-mail: [email protected]

Internet: Energy Absorption Systems

Trinity Highway Products, LLC http://www.energyabsorption.com

http://www.highwayguardrail.com

Important Introductory Notes

Proper assembly of the QuadGuard®II is essential to achieve performance of the system under

appropriate federal and state criteria. These instructions should be read in their entirety and

understood before assembling the QuadGuard®II. These instructions are to be used only in

conjunction with the assembly of the QuadGuard®II and are for standard assemblies only as

specified by the applicable highway authority. In the event your system assembly requires or

involves deviation from standard parameters or, during the assembly process a question arises,

please contact the appropriate highway authority that specified this system at this particular

location for guidance. Energy Absorption Systems is available for consultation with that agency.

These instructions are intended for an individual who is qualified to both read and accurately

interpret them as written. They are intended for the individual who is experienced and skilled in

the assembly of highway products which are specified and selected by the highway authority.

A set of product and project shop drawings will be supplied by Energy Absorption Systems. The

shop drawings will be for each section of the assembly. These drawings should be reviewed

and studied thoroughly by a qualified individual who is skilled in interpreting them before the

start of any assembly.

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Important: Read safety instructions thoroughly and follow the assembly

directions and suggested safe practices before assembling, maintaining, or

repairing QuadGuard®II system. Failure to follow this warning can result in

serious injury or death to workers and/or bystanders. It further compromises the

acceptance of this system by the FHWA. Please keep these instructions for later

use.

Warning: Ensure that all of the QuadGuard®II system Warnings, Cautions, and

Important Statements within the QuadGuard®II Manual are completely followed.

Failure to follow this warning could result in serious injury or death in the event of

a collision.

Recommended Safety Rules for Assembly

* Important Safety Instructions *

This Manual must be kept in a location where it is readily available to persons who assemble,

maintain, or repair the QuadGuard®II system. Additional copies of this Manual are immediately

available from Energy Absorption Systems by calling (888) 323-6374. Please contact Energy

Absorption Systems if you have any questions concerning the information in this Manual or

about the QuadGuard®II system. This Manual may also be downloaded directly from the

websites indicated below.

Always use appropriate safety precautions when operating power equipment, mixing chemicals,

moving heavy equipment or QuadGuard®II components. Gloves, safety goggles, steel toe

boots, and back protection should be used.

Safety measures incorporating traffic control devices specified by the highway authority must be

used to provide safety for personnel while at the assembly, maintenance, or repair site.

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Safety Symbols

This section describes the safety symbols that appear in this QuadGuard®II Manual. Read the

Manual for complete safety, assembly, operating, maintenance, repair, and service information.

Symbol Meaning

Safety Alert Symbol: Indicates Danger, Warning, or Caution. Failure to read

and follow the Danger, Warning, Safety, or Caution indicators could result in

serious injury or death to the workers and/or bystanders.

Warning and Cautions

Read all instructions before assembling, maintaining, or repairing the QuadGuard®II system.

Warning: Do not assemble, maintain, or repair the QuadGuard®II system until

you have read this Manual thoroughly and completely understand it. Ensure that

all Warnings, Cautions and Important statements within the Manual are

completely followed. Please call Energy Absorption Systems at (888) 323-6374 if

you do not understand these instructions. Failure to follow this warning could

result in serious injury or death in the event of a collision.

Warning: Safety measures incorporating appropriate traffic control devices

specified by the highway authority must be used to protect all personnel while at

the assembly, maintenance or repair site. Failure to follow this warning could

result in serious injury or death in the event of a collision.

Warning: Use only Energy Absorption Systems parts that are specified herein

for the QuadGuard®II for assembling, maintaining or repairing QuadGuard®II

system. Do not utilize or otherwise comingle parts from other systems, even if

those systems are other Energy Absorption Systems or Trinity Highway Products

systems. Such configurations have not been tested nor have they been accepted

for use. Assembly, maintenance or repairs using unspecified parts or accessories

is strictly prohibited. Failure to follow this warning could result in serious injury or

death in the event of a vehicle impact with an UNACCEPTED system.

Warning: Do NOT modify the QuadGuard®II system in any way. Failure to

follow this warning could result in serious injury or death in the event of a

collision.

Warning: Ensure that the QuadGuard®II system and delineation used meet all

federal, state, specifying agency, and local specifications. Failure to follow this

warning could result in serious injury or death in the event of a collision.

Warning: Ensure that your assembly meets all appropriate Manual on Uniform

Traffic Control Devices (MUTCD) and local standards. Failure to follow this

warning could result in serious injury or death in the event of a collision.

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Limitations and Warnings

Energy Absorption Systems, in compliance with the National Cooperative Research Highway

Program 350 (NCHRP Report 350) “Recommended Procedures for the Safety Performance of

Highway Safety Features”, contracts with FHWA approved testing facilities to perform crash

tests, evaluation of tests, and submittal of results to the Federal Highway Administration for

review.

The QuadGuard®II system has been approved by FHWA as meeting the requirements and

guidelines of NCHRP Report 350* TL-1 (2 Bay system), TL-2 (2 Bay system) and TL-3 (5 Bay

system). These tests, typically evaluate product performance by closely simulating actual

impacts involving a typical range of vehicles on our roadways, from lightweight cars (approx.

820kg [1800 lb.]) to full size pickup trucks (approx. 2000 kg [4400 lb.]) as specified by the

FHWA. A product can be certified for multiple Test Levels. The QuadGuard®II is certified to the

Test Level(s) as shown below:

Test Level 1: 50 km/h [31 mph]

Test Level 2: 70 km/h [44 mph]

Test Level 3: 100 km/h [62 mph]

These FHWA directed tests are not intended to represent the performance of systems

when impacted by every vehicle type or every impact condition existing on the roadway.

This system is tested only to the test matrix criteria of NCHRP 350 as approved by

FHWA.

These tests are not intended to represent the performance of products when impacted by every

vehicle type or every impact condition.

Energy Absorption Systems does not represent nor warrant that the results of these controlled

tests show that vehicle impacts with the products in other conditions would necessarily avoid

injury to person(s) or property. Impacts that exceed criteria capabilities of the product may not

result in acceptable impact performance as outlined in NCHRP Report 350, relative to structural

adequacy, occupant risk, and vehicle trajectory. Energy Absorption Systems expressly

disclaims any warranty or liability for injury or damage to persons or property resulting from any

impact, collision, or harmful contact with products, other vehicles, or nearby hazards or objects

by any vehicle, object or person, whether or not the products were assembled by or in the

presence of Energy Absorption Systems representatives or by third parties.

The QuadGuard®II system is intended to be assembled, delineated, and maintained in

accordance with specific state and federal guidelines. It is important to select the most

appropriate product configuration for a site. The customer should be careful to properly select,

assemble and maintain the product. Careful evaluation of the site geometry, vehicle population

type, speed, traffic direction and visibility are some of the elements that require evaluation in the

proper selection of a safety appurtenance. For example, curbs could cause an untested effect

on an impacting vehicle.

After an impact occurs, the product should be restored to its original condition as soon as

possible. When a potentially reusable safety product is impacted, it is still necessary to restore

the product to its original length and inspect all the components as necessary.

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System Overview

The QuadGuard®II is a potentially reusable, redirective, non-gating crash cushion for hazards

ranging in width from 610 mm to 2285 mm (24" to 120"). It consists of energy-absorbing

Cartridges surrounded by a framework of Quad-BeamTM panels.

The QuadGuard®II system utilizes two types of Cartridges in a “staged” configuration to

address both lighter cars and heavier, high center-of-gravity vehicles. Its modular design allows

the system length to be tailored to the design speed of a site.

Impact Performance

The 5 Bay QuadGuard®II systems have successfully passed the requirements stipulated in

NCHRP Report 350, Test Level 3 tests with both the light car and pickup at speeds of up to 100

km/h [62 mph] at angles up to 20 degrees.

During head-on impacts within NCHRP Report 350 criteria, the QuadGuard®II telescopes

rearward and crushes the Cartridges to absorb the energy of impact. When impacted from the

side, under those same 350 criteria, crash testing showed that it safely redirects the vehicle

back toward its original travel path and away from the hazard.

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How to Determine Left/Right

To determine left from right when ordering parts, stand in front of the system facing the hazard.

Your left is the system’s left and your right is the system’s right.

Counting the Number of Bays

One Bay consists of one Cartridge, one Diaphragm, two Fender Panels, etc. The Nose section

is not considered a Bay, though there is a Cartridge in the Nose of each system. 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 Panels on one side (See Figure 1). Five

Bay system shown.

Figure 1

System Orientation

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Measuring the Width

The QuadGuard

II system is available in seven nominal widths:

610 mm [24”]

760 mm [30”]

915 mm [36”]

1219 mm [48”]

1755 mm [69”]

2285 mm [90”]

3200 mm [126”]

The nominal width of a system with Tension Strut Backup is the width between Side Panels

behind the Backup (See Figure 2).

The nominal width of a system with Concrete Backup is the width of the Concrete Backup at

location shown in Figure 3.

The outside width of the system is approximately 150 mm [6”] 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 2

Width of system with Tension Strut Backup

(Minimum 3 Bays Required)

(Minimum 6 Bays Required)

Figure 3

Width of system with Concrete Backup

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