GUARD RAIL AND DELINEATORS

We supply standard guard rail and delineators for Highway Safety Barrier construction. Both standard sizes and customized sizes can be supplied and delivered.

BEAM-TYPE GUARD RAIL

Beam-type guard rail products are supplied with all component parts and materials to complete the highway road barrier works in accordance with the details requirements.

Materials and Specifications

Guardrail Posts of structural steel, meeting the requirements of AASHTO M 183.
Posts galvanized by the hotdip process in accordance with the requirements of AASHTO M 111.
Anchor bolts, nuts, and washers conform to the required sizes, galvanized in accordance with the requirements of ASTM A 153.

Guardrail Beams fabricated from sheets of open hearth, electric furnace or basic oxygen steel.

Steel sheets shaped into beams with a projected width of not less than seventyfive (75) millimetres. The sheets used shall be not less than forty-seven (47) centimetres nor more than fifty (50) centimetres in width, all tolerances included. The beams are completely formed punched with holes for mounting and splicing, and ready for assembly when delivered.

Beams are supplied of uniform section, and straight or curved as required. Beams to be erected on a radius of forty-five (45) metres or less shop-curved. Warped, kinked or bent sections not allowed.

A specimen of the beam element, when tested in tension, shall elongate not less than twelve (12) percent in a five (5) centimetre test gauge length. The tensile strength of a specimen of the full-size beam with or without a splice at the centre of the specimen, shall be not less than thirty six thousand, three hundred and fifty (36,350) kilograms. Samples for tensile strength and deflection tests shall consist of full-size beams and may be taken from stocks in the supplier's warehouse or from beams delivered to the project site when such test is ordered by the Engineer.

The galvanized beam shall be twelve (12) gauge, having a thickness of two and seventy-four hundredths (2.74) millimetres. The thickness will be determined by measurement of the galvanized sheets or coils, or of the fabricated beams. A minus variation not to exceed two hundred three thousandths (0.203) millimetres will be permitted. There is no limit on the plus variation. For fabricated beams thickness measurements will be made on tangent portions of the cross-section.

Deflections of the beam element when tested as a simple beam shall not exceed the following:

Deflection tests shall be made with the beam freely supported on a three and sixty-six hundredths (3.66) metre clear span and the load applied through a seventy-five (75) millimetre flat surface at the centre of the span. When the splice is tested, the splice shall be at the centre of the span.

Beams shall be galvanized with not less than 0.6103 kilograms of spelter per square metre of sheet, double exposed surface. Samples for determination of weight of spelter coating may be supplied from Section cut at random from sheets or coils of each heat number and coating lot designation before, reforming and punching or may, at the option of the Engineer, be obtained from beams and end sections in the supplier's warehouse or delivered to the project site, when such test is ordered by the Engineer. Samples from beams or end sections shall be twenty-five (25) millimetres by ten (10) centimetres or equivalent area, cut from the outside edge with the long dimension at right angles to the length of the beam or end section except that, at the option of the Engineer, samples may also be taken at any point over the width and length of the beam or end section. The Contractor or supplier shall provide equipment and personnel as required to obtain the samples as directed by the Engineer. At the option of the Engineer, sampling for weight of coating may be waived and the material accepted on the basis of magnetic gauge determinations.

Steel terminal, end, and buffer end sections, and cover plates for bridge anchor sections shall be formed in accordance with the shape and dimensions shown on the plans or material conforming to the requirements specified for beams. They shall be galvanized in accordance with the requirements for beams. Intermediate terminal post connectors, terminal anchor post connectors, and brackets for bridge anchor sections shall meet the requirements of AASHTO M 183, and shall be hot-dip galvanized after fabrication in accordance with the requirements of AASHTO M 111.

Splice and post bolts, nuts, and washers shall be galvanized in accordance with the requirements of ASTM A 153.

Galvanized beam elements and each bundle of galvanized end sections shall be marked at the point of fabrication with the manufacturer's name or trademark, gauge or thickness, and heat number, and with coating date or coating lot reference.

All galvanized materials for guard rail shall be handled in a manner to avoid damage to the surfaces. Any galvanized material on which the spelter coating has been bruised or broken will be rejected or may, with the approval of the Engineer, be repaired by an approved method.

The entire length of the guard rail shall be furnished with two-faced white and red reflectors fixed at each post location.

The reflectors shall not be smaller than 50 cm2 and shall be prismatic type only.

Guard Rail Beams Construction

Guard rail shall be placed at the locations shown on the plans or designated by the Engineer, and shall be erected as shown on the plans. Holes for guard rail posts shall be of the depth and size shown on the plans. Posts shall be spaced as shown on the plans and shall be set plumb and to the established line and grades. Posts shall be encased in an approved concrete Class "C" unless otherwise shown on the plans.

Beam posts, and appurtenances for guard rail shall not be field punched, reamed, or drilled except as may be approved by the Engineer to provide for lapped beams, or for changes in location of splices necessitated by field clearances. The beams shall be spliced by lapping in the direction of traffic. The use of seven and six-tenth (7.6) metre section of beam rails may, on approval of the Engineer be used for terminal sections and bridge anchor sections, and elsewhere where true line and grade may be maintained. Beams for terminal sections may be either shop or field twisted and bent. Deformation shall be such that the beam will retain the required shape in a relaxed condition. Galvanized material shall be handled in a manner to avoid damage to the surfaces. Any galvanized material on which the spelter coating has been bruised or broken will be rejected or may, with approval of the Engineer, be repaired by an approved method.

GUARD POST-TYPE DELINEATORS

The delineators have a minimum design life of 20 years and shall be designed to withstand a number of vehicle impacts without loss of its effectiveness. Reflective units shall be capable of reflecting light clearly visible, under normal atmospheric conditions from a distance of 350 metres when illuminated by the upper beam of standard automobile headlamps. To demonstrate the ability of the product to meet its intended use, it shall satisfactorily meet and pass all of the following specifications.

Materials and Physical Description

The delineators shall be manufactured from a glass reinforced thermosetting resin, CURV-FLEX or equal which will satisfactorily meet all of the requirements of this specification.

The color or the delineator shall be opaque white.

The width of the delineator shall be 10.16 ± 0.64 cm.

The overall length of the delineator shall be 198.12 ± 2.54cm.

Both the front and back surfaces of the top 45.72cm of the delineator shall be smooth surfaces capable of accepting 7.62cm wide reflective sheeting. The surface facing the oncoming traffic shall be formed in such a manner as to offer physical protection to the reflective sheeting.

Reflective sheeting shall be 7.62cm wide and 30.48cm long. Colour shall be red facing the oncoming traffic and white on the back.

Field Tests

To demonstrate the ability of the delineator to withstand repeated vehicle impacts, the following tests shall be conducted.

Install 3 delineators on a common centreline separated by approximately 9.13m.

Install the first delineator normal to the direction of travel of the test vehicle. Install the second delineator rotated 15o clockwise from the normal, and the third 15o counter clockwise from the normal.

The dimension from the top of the delineator to ground level shall be 121.92 ± 2.54cm.

The delineator shall have one piece of reflective material of the type and color specified applied to the face directed toward the test vehicle.
The test vehicle shall be standard sedan, or equal, and shall have no unusually sharp hood ornaments or other appurtenances.

The following tests shall be conducted.

At 60 Kph impact all three delineators with the centreline of the test vehicle approximately coincident with the centreline of the delineators. Repeat this test for a total of 5 impacts.

With the centreline of the left wheels of the test vehicle coincide with the centreline of the delineators, roll the wheels of the vehicle over the delineator at approximately 20 Kph. Repeat this test for a total of 2 wheel impacts.

At the conclusion of the tests specified above, all delineators shall have regained a vertical attitude, ±10o from their original attitude, and shall have a minimum of 50% of the reflective material in place and suitable for the use intended.

Erection of Delineators

Delineators posts shall be erected at locations and elevation shown on the plans. Installation shall be by a tool purposely made and supplied by the Guard Post Manufacturer.

Supplied with installation tools and removal tool.

ROAD STUDS

The Roadstud 100 x 100 x required height or 150 x 150 x required height when seated on the Road surface.

The stud is manufactured by using chill cast permanent mould casting techniques.

The slope of the reflecting face shall be 20 degree.

The enveloping profile of the head of the road studs shall be smooth and the studs shall not present any sharp edges to traffic.

The Shaft "Anti - Twist / Hold - Tite" x 76 mm Long.

The anchorage part of the stud shall consist of a circumferential ribbed shank with parallel flats, the flats on alternate ribs being at 90 degrees to each other to prevent rotation of the stud when located in the road surface.

The Studs shall be constructed in aluminium alloy to BS 1490 LM6-M.

GUARD POSTS AND DELINEATORS - Performance / Quality Tests

Guard Posts and Delineators shall be performed in accordance with following tests standards.

BEAM GUARD RAIL

In addition to what is stated in the General Specification, the beam type guard rail system complies to the test requirements of NCHRP Report 350 evaluation criteria for TL-4 or EN 1317-2 for a containment level (H2).

HEAVY DUTY CAT'S EYES / REFLECTORS

We supply contractor and supplier with the cats' eyes / reflectors with durability and efficiency of the materials for a period of 5 years.

The reflectors are disc reflector 16mm dia and each reflector shall contain seven reflective elements.

Colorimetric Requirement for Retroreflectors
The colour limits of the retroreflector(s) when illuminated by CIE standard illuminant A (as defined in the proceedings of the 1951 meeting of the International Commission on illumination (CIE), publication No. 15), with an entrance angle V(vertical)=0 degree, H(horizontal)=5 degree, L(left)or R(right) and an observation angle of 0.3 degree shall comply with the requirements given below.

Compliance with the colorimetric requirements shall normally be verified by means of a visual comparison test. If the Engineer is not satisfied after this test, compliance shall be verified by the determination of the chromaticity co-ordinates.

White (uncoloured) reflectors shall have chromaticity co-ordinates which lie within the area formed by the straight lines joining the corner co-ordinates having X and Y values following:

Red reflectors shall have chromatically co-ordinates which lie within the area formed by the straight lines joining the corner co-ordinates having X and Y values following:

Amber reflectors shall have chromatically co-ordinates which lie within the area formed by the straight lines joining the corner co-ordinates having X and Y values following:

Green reflectors shall have chromatically co-ordinates which lie within the area formed by the straight lines joining the corner co-ordinates having X and Y values following:

S5.1.3.4 Photometric Requirements for Retroreflectors
The retroreflectors of each face of the stud have a coefficient of luminous intensity R, not less than the values given in BS 873 and as follows:-

CRASH CUSHION- Requirements References

Fully re-directive and non-gating crash cushions.

The crash cushion shall be able to withstand head-on, side-angle and reverse-angle impacts at the design speed specified for the site. Additionally, the crash cushion shall be able to satisfy all of the following performance characteristics: Non-Gating, Re-directive, Non- Snagging, Anti- Climb Characteristics, Low profile, Low Maintenance, Energy Dissipating, Free of Debris during impacts, Climatic Compatibility, and has Design Adaptability to the hazard. All concrete foundation and backup related to crash cushion to be class 30/20.

The crash cushion shall have been successfully tested following the procedures and criteria set forth in the NCHRP Report 350 TL-3 for non-gating, re-directive terminals and crash cushions (or its equivalent EN 1317). Accordingly, the proposed crash cushion must have completed and passed NCHRP 350 Tests at a nominal speed 100 kph (Test Level 3) and passed the NCHRP 350 Tests at a speed of not less than 120 kph.

Certified proof of successful performance in these Tests at 120 kph or higher must be submitted.

END TERMINALS
This specification provides the minimum requirements for all End Terminals (ET) used and placed into operation on the roadways to provide protection at guardrail and concrete barrier terminals.

The ET shall control the deceleration of an impacting vehicle and dissipation of the vehicle's kinetic energy. When struck the unit shall bring the errant vehicle to a safe and controlled stop.

Testing Criteria
The ET shall be tested and meet the criteria's of NCHRP 350, TL-3 or EN 1317-4, class P4.

CE Marking
If the end terminal is tested to EN 1317 it shall also be CE Certified.

General Characteristics

a. Safety
Impact Severity Class A (with an ASI <1,0) is preferred when other parameters are the same.

b. Side Impacts
The ET shall be designed to minimize the risk of penetration of a vehicle impacting with its side (yawing).

c. Installation
The ET shall be installed in accordance to the Manufacturer's instructions.

d. Reusability
At least 50% of the monetary value of the end terminal shall be reusable after a full design impact.

e. Lifetime
The ET shall be designed for a functional lifetime of 15-25 years without any major maintenance.

All parts involved in the energy absorbing process shall be of hot-dip galvanized steel in order to guarantee the functional lifetime of the ET.

All components and material of the system shall be suitable for use in the actual climate conditions and shall not be liable to damage or deterioration in various temperatures or by exposure to direct sunlight.

HEIGHT WARNING SYSTEM

Furnishing and erecting height warning systems at locations within the project as directed by the Department.

Each Height Warning System shall consist of a photocell mounted on poles, visual warning signs, rotating beacons, and audible alarms and all the relevant electrical connections.

The visual warning sign boards shall be furnished with rotating beacons fitted with 250 watt halogen lamps, and the audible alarm shall have high sound pressure in a lower frequency range (approx. 500 to 700 Hz).

Features and Characteristics

1. Modulated invisible beam photoswitch with extremely long life. Non responsive to high ambient light.
2. Operation range of photocell system up to 274 Meters.
3. Photocell has high penetration capability for dust, dirt smoke etc.
4. Rugged corrosion resistant NORYL enclosure, rated NEMA 3,4,5 12 and 13.
5. Timer controlled system. Audio Visual Warning time can be adjusted from One second to One Hrs.
6. System self adjusts and automatically recalibrates after each and every warning operation. No need for any manual adjustment.
7. In the event of a malfunction, a new improved Control Circuity will automatically engage the visual alarm system (only) until proper repairs are carried out. The new improved circuit will now disengage the Audio Alarm in case of a system failure and protect the sirens from damage by continuous operation.
8. Control panel incorporates several switches to the test the operation of system components during routine maintenance.
9. Flashing lights system are Traffic Signal Heads made from die cast aluminium body with high intensity lenses. The flash light system is operated through a solid safe adjustable flasher.
10. High performance Siren, Range for 127 dB.
11. All junction boxes resistant, fully sealed and weather proof.

System Components and Equipments

1. Infrared Photocell set
The infrared Photocell set (Transmitter and Receiver) shall be single path infra-red light switch, 900 feet operating range, Shock resistant housing. IP66 protection Minimum input use duration 250 Second (Antennas higher than trucks WILL NOT BREAK the infrared light).

2. The 200mm Signal Light Heads
The warning Light will be High Intensity Flashing Signal Heads with 200mm dia. Polycarbonate lenses, manufactured from pressure cast aluminum. The signal heads are heavy duty and weather resistant with 8000 hour's lamp duration. Light flashers are controlled by very reliable solid sate unit with adjustable flashing rate.

3. The rotating (Flash Beacons)
The materials shall be light weight and made on non-corroded materials with wide operating temperatures 30oC - 50oC. It shall produce a highly effective warning signal.

4. The Warning Sirens
High performance Sirens shall be model recommended for Height Warning System is the ‗Super M'. The ‗Super M' is rated at 127 dB and it has provided to an impressive performer for outdoor applications.

5. Control Circuity
Control Circuit components i.e. Time Delay Relays, MCB, Test switch, Magnetic Contactors etc. are all supplied by reputable manufactures.

6. The Control Cabinet
The Control cabinet shall be weather resistant, metal lockable control cabinet with weather proof IP55 and polyester epoxy resin grey paint to RAL7032 texturized.

KERBS AND CONCRETE BARRIER

Kerbs, spillways and Concrete Barriers

Concrete for bedding to be class 20/20.

Pre-cast Concrete Kerbs
In addition to what is stated in the Standard Specification, Precast Concrete Kerb shall be measured by linear meter and the rate shall be considered as full compensation for providing all labours, materials, tools, equipment and incidental items for excavation preparation, mortar, precast concrete kerb, installation of cast-in-situ foundation, haunching, painting and all other work required for the furnishing and installing of kerb as shown on the drawing and shall be paid under the following items:

ITEM 5.3.1 Precast Upstand Kerb Type A (35 x 15 cm) m
ITEM 5.3.2 Precast Upstand Kerb Type C (40 x 20 cm) m
ITEM 5.3.3 Precast Mountable Kerb Type C (40 x 20 cm) m
ITEM 5.3.4 Precast Flush Kerb m

CONCRETE BARRIERS
Cast In Situ Concrete Barriers of any Length / Varying Heights.

CONCRETE DWARF RETAINING WALL

All concrete and reinforcement steel shall comply with the requirements under Section IV, Concrete Works of the General Specifications.

Construction.

Forms shall be smooth and tight fitting which can be held rigidly to line and grade during placing of concrete and which can be readily removed without injuring the green concrete. All form detail work shall comply with the requirements as specified in all applicable Sections under Section IV, Concrete Works of the Standard Specifications.

The method of casting, handling and placing dwarf wall sections shall be as approved and directed by the Engineer. Shop drawings complete with details of any reinforcement required in precast dwarf wall to facilitate handling shall be prepared by the Contractor and submitted to the Engineer for approval.

Contraction joints, shall be placed at intervals not to exceed 2.0 meters, except as directed by the Engineer. Preformed joint filler and sealer shall comply with the requirements for expansion joints as specified herein, and styrofoam backup rods shall be as detailed for precast dwarf joints.

RUMBLE STRIPS

Rumble Strips shall be constructed of the following type of material, all as shown on the Drawings or as directed by the Engineer in consultation with the Traffic Police.

Thermoplastic Rumble Strips shall consist of Thermoplastic Traffic Marking Material conforming to the requirements in Section 5.4 of the General Specifications and the following:

• • The thermoplastic material shall contain 20% by weight of calcined bauxite whose grading shall be between the 1.70 and 1.18mm test sieves to BS 410.
• • Ballotini shall not be applied to the surface of the strips.
• • The height of the strips shall not be less than 5mm nor more than 6mm above the road surface immediately adjacent to the strips.
• • The skid resistance of the material when laid shall meet the minimum skid resistance requirements for Category A in Table 1 of Road Note 27 issued by the Transport & Road Research Laboratory (UK).
• • Special Rumble Strips shall consist of manufactured or fabricated items of the types shown on the Drawings and in the Specification and in the Bill of Quantities.

Construction Requirements

Thermoplastic Rumble Strips: The existing road surface shall be thoroughly cleaned and the thermoplastic material laid to the form and to the lines and grades shown on the Drawings, all in accordance with Section 5.4 "Pavement Markings" and all to the approval of the Engineer.

Special Rumble Strips shall be installed in accordance with the manufacturer's instructions and the Specifications, all to the Engineers approval.

ROAD SIGNING - Construction and Finishes Requirements

Road Signing shall be done according to General Specifications.

The approximate position and mounting height of each road sign is indicated on the Drawing(s); the exact sign position and mounting height shall be determined on site and marked on the ground by numbered pegs or painted marks. The Contractor shall make arrangements with the Engineer in order to agree the exact positions and mounting heights prior to starting the sign foundations.

In order to avoid reflections from the sign plates, signs which are approached along a straight length of road shall be set generally at an angle of 85 measured clockwise or 95 measured anticlockwise from the nearside edge of the carriageway. Signs sited on left hand bends shall be set at 90 to the tangent at that point.

The supports for overhead and ground mounted signs shall be designed in accordance with AASHTO's publication ―Standard Specification for Structural Supports for Highway Signs‖ to withstand a wind speed of 160kph with a gust factor of 1.3.

All foundations, framing and fixings for Information Signs shall be suitable for local conditions. Calculations and drawings showing the design shall be submitted to the Engineer for approval.

There shall be full adhesion of all sheeting materials including letters, symbols and borders and there shall be no air-bubbles, creases or other blemishes.