ACP MAX-Tension TL-2 Training And Product Installation Manual Download Page 2

Page: 2 / 36

July 2020 |

Page

NSW/WA/SA/ACT

02 8708 4400

VIC/TAS

03 8773 5300

QLD/NT

07 3442 6200

www.

acprod

.com.au

Product & Installation Manual: MAX-Tension

TL-2

Table of contents

Limited

Warranty

MAX-Tension

TL-2

System

Overview

Recommended

Tools

Safety

Equipment

Traffic

Control

Documentation

Installation Preparation

Preparation

Soil Conditions

Site

Grading

System Offset Requirements

Curve Installations

Panel

Lapping

Parts Identification

Bill of Materials

Installation Instructions

Step 1 - Post Assembly and Installation

Step 2 - Ground Strut and Soil Anchor Installation

Step 3 - Blockout Installation

Step 4 - Assemble Inner Side Slider (ISS) Panel on Rail 2

Step 5 - Install Rail 2

Step 6 - Assemble Traffic Side Slider (TSS) and Tooth on Rail 1

Step 7 - Install Rail 1

Step 8 - Install Impact Head

Step 9 - Install Cables

Step 10 - Turn Friction Plate

Summary of Contents for MAX-Tension TL-2

Page 1: ...TL 2 Tangent redirective non gating guardrail terminal with SabertoothTM Technology Training and Product Installation Manual Please call ACP on 1800 724 172 or visit www acprod com au for more information July 2020 ...

Page 2: ...ding System Offset Requirements Curve Installations Panel Lapping Parts Identification Bill of Materials Installation Instructions Step 1 Post Assembly and Installation Step 2 Ground Strut and Soil Anchor Installation Step 3 Blockout Installation Step 4 Assemble Inner Side Slider ISS Panel on Rail 2 Step 5 Install Rail 2 Step 6 Assemble Traffic Side Slider TSS and Tooth on Rail 1 Step 7 Install Ra...

Page 3: ...ear Side Slider RSS Plate and Tighten Tooth Step 13 Install Delineation Bracket or Yellow Plastic Housing Step 14 Install Plastic Nut Covers Inspector Checklist Maintenance Inspection Drawings Notes 23 24 25 27 28 29 31 36 ACP may make changes to this Product Manual from time to time Please check the ACP website prior to using this Product Manual to ensure that you have the latest version ...

Page 4: ...THE TERMS ORIGINALLY SHIPPED OR TO REPAIR OR TO MANUFACTURE BY ACP PRODUCTS OR PARTS NOT COMPLYING WITH ACP SPECIFICATIONS OR AT ACP S ELECTION TO THE REPAYMENT OF AN AMOUNT EQUAL TO THE PURCHASE PRICE OF SUCH PRODUCTS OR PARTS WHETHER SUCH CLAIMS ARE FOR BREACH OF WARRANTY OR NEGLIGENCE ACP SHALL NOT BE LIABLE FOR ANY INCIDENTAL CONSEQUENTIAL OR SPECIAL LOSSES DAMAGES OR EXPENSES OF ANY KIND INCL...

Page 5: ...sorbing impact head two tensioned cables a releasable Post 1 a ground anchor assembly and an energy absorbing coupler with integrated cutting tooth used in conjunction with standard W Beam guardrail panels post blockouts and hardware The MAX TL 2 is applied directly to W Beam guardrail systems at or transitioned to 787mm with panels and post spacing configured at mid span splice Transitions to str...

Page 6: ...nch 1 2 Ratchet 32mm Socket 24mm Socket 10mm Hex Socket Pipe Wrench or Large Pliers Impact Wrench Optional Safety Equipment Safety Glasses Hearing Protection Gloves Steel Toe Boots Hard Hat Safety Vest Traffic Control Traffic Control Equipment Traffic Control Plan Documentation Prior to installation and assembly of the MAX Tension TL 2 system ensure you have read and understand the installation an...

Page 7: ...t Before installing the MAX TL 2 system ensure that all the materials required for the system are on site and have been identified Soil Conditions The MAX Tension TL 2 system has been designed to be installed in soil that meets or exceeds the AASHTO standard soil specification If the specific site soil conditions differ from those specified in the AASHTO standard soil specification the installatio...

Page 8: ...TL 2 Site Grading All testing was completed on a relatively flat and controlled testing environment Ensure proper site grading prior to installation of the MAX Tension TL 2 system in accordance with Federal State and Local specifications in addition to the AASHTO Roadside Design Guide Source AASHTO Roadside Design Guide 4th Edition 2011 page 8 6 ...

Page 9: ...2 system SHALL NEVER be installed within a curved section of guardrail It is recommended that the guardrail be extended past the curve before the installation of the MAX Tension system The MAX Tension system should always be installed in a straight line over the length of the system Panel Lapping The MAX Tension TL 2 system is a tension based system that slides backwards upon impact For the panels...

Page 10: ...or have they been approved for use The use of unspecified parts is prohibited and could result in severe personal injury or death Soil Anchor MAXGAG Qty 1 Traffic Side Slider Panel MAXTSSG Qty 1 Friction Plate INCL IN MAXHDG Qty 1 Ground Strut MAXGSG Qty 1 Inner Side Slider Panel MAXISSG Qty 1 TL 2 Cable Assembly MAXTL2CAG Qty 2 Impact Head MAXHDG Qty 1 Tooth BSI 1610066 00 Qty 1 Line Post MAXLPG ...

Page 11: ...il W113G Qty 1 Square Washer FW923 Qty 1 M16X240 Galv Cup Head F124 Qty 4 Delineation Bracket MAXBDG Qty 1 Plastic Nut Cover X350NC Qty 17 M16X200 Galv Hex Head F123 Qty 1 M16 Galv Round Washer FW900 Qty 2 14 20 X 25mm Self Drilling F173 Qty 3 Yellow Plastic Nose Housing X350YN Qty 1 M20X75 Galv Hex Head INCL IN MAXHDG Qty 4 Guardrail Nut 5 8 4001116 Qty 1 Guardrail Washer Rect FW903 Qty 1 Highlig...

Page 12: ...ENSION CABLE FRICTION PLATE 1 10 MAXTL2CAG MAXTENSION TL2 CABLE ASSEMBLY 2 11 MAXLPG MAXTENSION LINE POST 1830MM Galv 4 12 B090534 COMPOSITE BLOCK X350 4 13 W122G 3 81M MAXTENSION W BEAM GALV 2 14 FW923 50 X 50 X 3MM GALV SQUARE Washer 1 15 F123 M16X200 GALV HEX HEAD Bolt Nut 1 16 incl in MAXHDG M20X75 GALV HEX HEAD 4 17 F1002 M16X32MM GALV SPLICE BOLT Nut GR 8 8 40 18 F124 M16X240 GALV CUP HEAD B...

Page 13: ...uardrail systems If the existing rail system is not 787mm in height ensure the guardrail end terminal is properly transitioned per Federal State and Local standards 1 1 Install posts items 11 4 in the configuration shown Ensure post height and post spacing follow the dimensions above NOTE Slot on post 1 item 4 is facing upstream NOTE The spacing between post 3 and post 4 is unique NOTE The spacing...

Page 14: ...lace prior to driving the soil anchor 2 1 Assemble the ground strut item 2 flush to the soil anchor item 1 with hardware items 15 19 in configuration shown 2 2 Tighten all hardware Item Part Description Qty 1 MAXGAG MAXTENSION GROUND ANCHOR GALV 1 2 MAXGSG MAXTENSION GROUND STRUT 1 15 F123 M16X200 GALV HEX HEAD 1 19 FW900 M16 GALV ROUND WASHER 2 SEE DETAIL GROUND STRUT GROUND STRUT DETAIL SIDE VIE...

Page 15: ...item 12 in the configuration shown 3 2 Secure blockout item 12 on post 6 with hardware item 18 as shown 3 3 Tighten all hardware NOTE The blockout must be secured to post 4 before hanging the rail using hardware items 18 and 20 as listed in the table above Item Part Description Qty 12 B090534 COMPOSITE BLOCK X350 4 18 F124 M16X240 GALV CUP HEAD 1 POST 4 ONLY SEE POST 4 BLOCKOUT DETAIL POST 4 BLOCK...

Page 16: ...r ISS panel item 6 on upstream end of rail 2 item 13 using the supplied hardware item 17 NOTE Secure ISS on the non traffic side of the rail DANGER BOLTS SHALL BE INSTALLED WITH THE BOLT HEADS ON THE TRAFFIC SIDE AND NUTS ON THE NON TRAFFIC SIDE 5 2 Tighten all hardware Item Part Description Qty 6 MAXISSG MAXTENSION INSIDE SLIDER GALV 1 13 W122G 3 81M MAXTENSION W BEAM GALV 1 17 F1002 M16X32MM GAL...

Page 17: ...t supplied with the system This hardware shall be supplied by the end user NOTE Bolts shall be installed with the bolt heads on the traffic side and nuts on the non traffic side NOTE Do not install any type of washer e g rectangular washer or delineator between the post bolt head and the guardrail NOTE Rail 2 is not bolted at post 4 Ensure that the blockout on post 4 has already been secured with ...

Page 18: ...SHALL BE INSTALLED WITH THE BOLT HEADS ON THE NONTRAFFIC SIDE AND NUTS ON THE TRAFFIC SIDE 6 3 Secure the tooth item 7 using nut item 20 Only hand tighten at this time The RSS engagement hook on the tooth shall point toward the front of the system 6 4 Tighten all hardware except the nut item 20 on the tooth item 7 The nut will be tightened during Step 12 Item Part Description Qty 5 MAXTSSG MAXTENS...

Page 19: ...the tooth goes through elongated slot on rail 2 7 1 Install the preassembled rail 1 with attached traffic side slider TSS panel and tooth in configuration shown ensuring the tooth goes through the slot on rail 2 7 2 Secure rail 1 to post 2 and post 3 using hardware item 18 NOTE Do not install any type of washer e g rectangular washer or delineator between the post bolt head and the guardrail 7 3 T...

Page 20: ...raffic side 8 3 Secure the impact head item 3 and rail 1 to post 1 in the configuration shown 8 4 Ensure that the rectangular washer item 24 is placed between the post bolt head item 21 and the impact head item 3 and that the square washer item 14 is used on the backside between post 1 and the nut item 21 8 5 Tighten all hardware Item Part Description Qty 3 MAXHDG MAXTENSION IMPACT HEAD GALV 1 14 ...

Page 21: ...de of the system must pass through the bottom hole of the impact head The second cable must pass through the top hole 9 3 Ensure that the friction plate item 9 is inserted through the top of the impact head 3 while passing the cables item 10 through the impact head item 3 9 4 Pass the cables item 10 along the backside of rail 1 until reaching the ISS panel Ensure that the threads on the cable pass...

Page 22: ...ide of the impact head item 3 and turn the friction plate simultaneously until the friction plate reaches its engaged position and the bolts are completely tightened WARNING Once the friction plate has been turned the cables cannot be reused CAUTION A minimum of two people should be used to turn the friction plate Item Part Description Qty 16 INCL IN MAXHDG M20X75 GALV HEX HEAD 4 FRICTION PLATE NE...

Page 23: ... rear in configuration shown 11 2 While tightening the cables ensure that the cable does not spin by holding the swage with large pliers or pipe wrench 11 3 Tighten until there is no visible sag in the cables HOLD SWAGE HOLD CABLE SWAGE TRAFFIC FLOW CABLE HOLD CABLE CABLE SWAGE CABLE CABLE POST 4 ISS PANEL DETAIL ISS PANEL SEE DETAIL ISS PANEL REAR VIEW REAR VIEW TIGHTEN NUT TIGHTEN NUT TIGHTEN NU...

Page 24: ...late 8 in configuration shown using the supplied hardware item 17 NOTE Bolts shall be installed with the bolt heads on the traffic side and nuts on the non traffic side 12 2 Tighten the nut securing the tooth that was hand tightened in Step 7 12 3 Tighten all remaining hardware Item Part Description Qty 8 MAXRSSG MAXTENSION REAR SIDE SLIDER 1 17 F1002 M16X32MM GALV SPLICE BOLT 8 POST 3 8x TIGHTEN ...

Page 25: ...nstall delineation bracket item 22 in configuration shown using screws item 23 If installing the yellow plastic housing go to the next step 13 3 Follow the following instructions to install the Yellow Nose Motorcyclist Delineation Cover on the MAX Tension Terminal TL 2 TL 3 Models Item Part Description Qty 22 MAXBDG MAX BRACKET DELINEATION 1 23 F173 14 20 X 25MM SELF DRILLING 3 27 X350YN YELLOW PL...

Page 26: ...wo cables slots over the threaded rods ensuring the nuts and washers are on the outside as shown below Retighten the cable assembly nuts 13 6 Fix two self drilling hex head screws supplied with kit hardware through the yellow nose cover and into the predrilled holes of the impact head on the traffic side only as shown below 13 7 Lastly if not already done place the appropriate delineation chevron ...

Page 27: ... 8773 5300 QLD NT 07 3442 6200 www acprod com au Product Installation Manual MAX TensionTM TL 2 Step 14 Install Plastic Nut Covers 14 1 Apply plastic nut covers to all nuts exposed on the traffic side Item Part Description Qty 26 X350NC PASTIC NUT COVER 17 ...

Page 28: ...de Pg 16 Step 4 Slider Joint rear side slider RSS should be attached with the nuts on the non traffic side and arrow pointing toward the front of the system Pg 24 Step 12 8 bolts should connect the TSS to the RSS Bolts should pass from the TSS to the RSS Pg 24 Step 12 Tooth is installed and engaged in the slot at the slider joint Pg 18 Step 6 TSS and RSS arrows should be aligned so as to see throu...

Page 29: ...t drawings Visual Drive By Inspections Recommended Frequency Monthly Check for Damage caused by vehicle impacts Minor damage cause by impacts from roadside maintenance equipment Misalignment Missing components Damage from vandalism Loose hardware Walk Up Inspections Recommended Frequency Twice a Year Before performing walk up inspections ensure traffic control is deployed in accordance with Local ...

Page 30: ...is in and around the system Cutting tooth is in correct position Disengaged friction plate Frayed cable Grading around system Loose hardware The cable sleeves shall rest a minimum of 150mm below the impact head Inspector signature Date Print Name Location If any of the above items are identified during the walk up inspection swift action should be taken to repair and return the MAX Tension TL 2 Gu...

Page 31: ...July 2020 Page 31 NSW WA SA ACT 02 8708 4400 VIC TAS 03 8773 5300 QLD NT 07 3442 6200 www acprod com au APPENDIX Drawings ...

Page 32: ......

Page 33: ......

Page 34: ...GA TR09 AUSTRALIAN CONSTRUCTION PRODUCTS ACP ...

Page 35: ...GA TR12 AUSTRALIAN CONSTRUCTION PRODUCTS ACP ...

Page 36: ...open to the environment Provide adequate ventilation between stacked pieces Elevate and separate articles stacked outdoors with spacers poplar ash spruce Incline parts to allow for Maximum Drainage Avoid stacking material directly on soil or decaying vegetation For crated items remove the lids to provide better ventilation and drying of the galvanized parts Customers will need to remove kits packe...

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