Steel Wire Ropes Galvanized for Highway Median and Shoulder Construction

Galvanized steel wire ropes are used in highway construction as tension cables, guy lines and guard rails. They are made of high-strength wire and galvanized for corrosion resistance. The rope diameter can range from 6.2mm to 20mm and they powder coated in multiple colors, including green, black, brown and white.

Galvanized steel wire ropes as chief materials for cable barriers are supplied with EC-Certificate of Conformity, the testing requirements of EN 1317-1,2 for a containment level (H1) and working width of 2.0m and 1.4m dynamic deflection. End anchorages for wire rope barrier meet the testing requirements of NCHRP 350.

High Speed test conducted at minimum speed of 120 Km/h with 1500 Kg vehicle to prove performance at high speed impacts.

Wire Rope Specification
Steel wire rope for highway median and shoulder barrier

Constructed of of 3 or 4 galvanized steel wire ropes
Each rope is pre-stressed after manufacture.
Wire rope diameter 19mm nominal diameter, with 3x7 (6/1) coreless construction from 1370 N/mm2 grade tensile wire complying with EN 10264-2
Minimum breaking load of 17.7 tonnes
Minimum rope modulus of elasticity of 8,300 kg/mm2 based on an area of approximately 283mm2 after pre-stressing.

The post shall be designed to collapse on impact and shall be complete with a plastic cap to which is affixed a reflector made of Metalized Retro-Reflective Sheeting with Pressure Sensitive Adhesive. In the case of slotted concrete footings, a suitable polyethylene excluder shall be provided at foundation level to preclude the ingress of sand etc. The posts are to be made of mild steel BS EN 10025 – Grade S235 and shall be slotted at one end, through the centre of the web, prior to galvanizing to BS EN ISO 1461.1999.

Wire Rope Anchorage points shall be staggered in as regular a manner as possible.

All standard component ropes shall be joined by suitable fitted ends, assembled into rigging screws, which shall be used for tensioning. Each end rope shall be attached to the anchorage by means of a mechanical fitting. Threaded terminals shall be galvanized in accordance with BS EN ISO 1461.1999 (formerly BS 729).

Anchorages are fabricated from steel to BS EN 10025 Grade S235 and galvanized after manufacture to BS EN ISO 1461.1999.

Three Wire Rope Cable Barrier Assembly
3 galvanized wire ropes, prestressed after manufacture, having a diameter of 1.90 cm, with a nominal breaking load of 17.4 tons. These are held in posts approximately 1.8 m apart at 0.85 m above road level. Each rope "bay" of approximately 600 m is anchored at each end at ground level in concrete anchorages. The rope lengths are joined together by fitted ends, assembled into rigging screw bodies. At regular predetermined intervals, a tension indicator device is incorporated to ensure a constant predetermined tension. All the components shall be galvanized by the hot dip process in accordance with AASHTO M 111-74.

The Posts
The posts are placed in appropriate openings in concrete footings and are designed of such material that will allow easy bending movement when the vehicle enters the barrier.

The Ropes
The ropes are attached to the ground end anchorages by means of a socket. This socket is attached to the anchorage spigot and held in place by a small pin, so that should a vehicle hit this end assembly, the socket can come adrift from the main anchorage. Also attached to this socket and to another point on an anchorage, is a check wire to ensure that the socket does not fly into a vehicle.