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ACP X-TENSION 350, Installation Manual

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ACP X-TENSION 350 Installation Manual Download Page 7

Installation Manual : X-TENSION 350 Median

 

Ph 1800 724 172 or visit 

www.acprod.com.au

 

December 2018

 / Page 7 

X-TENSION 350 Median - Preparation for all Applications

Before installing an X-TENSION 350 Median, ensure that all materials required for an 11.43m 
system are on site and have been identified. See parts identification sheet. 

Ensure that the area where the X-TENSION 350 Median is to be installed is flat enough so that 
the soil anchor will not protrude more than 100mm from ground level, when measured with a 
straight line over a 1.5m cord. The maximum slope should not exceed 7%. Slopes above this 
may cause the terminal to behave differently in a vehicle impact to what was tested. Minor site 
grading may be required. 

Soil Conditions

 

The X-TENSION 350 Median has been designed for installation in Median locations and in soil 
that meets or exceeds the AASHTO “standard soil” specification. If rock is encountered during 
post installation, refer to local road controlling authority specifications.  

Tools Required

 

The same tools required to install standard highway guardrail will also install an X-TENSION 
350 Median. 

Specifically: 

Sockets (commonly used in Guardrail), Drill, Wrenches, Large Crow Bar, String 

line, Level, Augers, Tampers and Post Pounders commonly used in driving posts. 

Before Starting

 

For  all  applications

,  begin  the  installation  from  the  downstream  end  of  the  terminal  at  the 

point where it joins the standard guardrail (post 7). 

The median application X-TENSION 350 Median connects directly to standard steel post , W-
beam highway guardrail. 

Follow step-by-step instructions for the appropriate application. 

Important note about posts and blockouts: 

Median system: 

Posts 1 & 2 are always crimped steel 
Posts 3 – 6 are standard steel I beam posts 
Blockouts are composite plastic 

Summary of Contents for X-TENSION 350

Page 1: ...December 2018 ...

Page 2: ...Soil Conditions 7 Tools Required 7 Before Starting 7 X TENSION 350 Median Installation 8 Maintenance Traffic Face Impact 21 Head on Impacts 22 APPENDIX Drawings X350M X Tension 350 Median Composite Blockout to Steel Post 23 X350 1 X Tension 350 Median Composite Blockout to Steel Post details 24 ACP may make changes to this Product Manual from time to time Please check the ACP website prior to usin...

Page 3: ...systems Even head on high angle 15 during testing impacts on the nose resulted in the vehicle being redirected and controlled System Overview The X TENSION 350 Median Guardrail End Terminal is designed and constructed to provide acceptable structural adequacy minimal occupant risk and safe trajectory as set forth in NCHRP 350 for guardrail terminal ends When impacted head on with an 820 2 000kg ve...

Page 4: ... safety clothing high visibility vests steel capped footwear gloves hard hats safety glasses etc All underground services must be located before installation of any posts Only authorised trained personnel should operate any machinery Where overhead machinery is used care must be taken to avoid any overhead hazards Gloves should be worn at all times Particular care should be taken to avoid galvanis...

Page 5: ...ember 2018 Page 5 X TENSION 350 Median Parts Identification Impact Head Friction Plate Soil Anchor 1 required 1 required 1 required Slider Bracket Angle Bar Cable Bracket Cable Assembly 2 required 1 required 2 required Slider Panel Post 1 Top Ground Strut 2 required 1 required 1 required ...

Page 6: ... TENSION 350 Median Parts Identification continued Post 2 Standard Steel Line Post 3 6 Post 1 Bottom 1 required 1 required Standard highway rail Median Radius rail 1 Median Secondary Head 5 required 1 required shop curved 1 required Shear Bolts Plastic Blockout Hardware set 16 required 10 required Nose Cone ...

Page 7: ...allation in Median locations and in soil that meets or exceeds the AASHTO standard soil specification If rock is encountered during post installation refer to local road controlling authority specifications Tools Required The same tools required to install standard highway guardrail will also install an X TENSION 350 Median Specifically Sockets commonly used in Guardrail Drill Wrenches Large Crow ...

Page 8: ...ON 350 system is installed parallel to the standard median barrier therefore no offset is used Figure 1 Ensure that the area where the X TENSION 350 Median is to be installed is flat enough so that the soil anchor will not protrude more than 100mm preferred 75mm from ground level when measured with a straight line over a 1 5m cord Minor site grading may be required Figure 1 X TENSION 350 Median in...

Page 9: ...e out the length of the system parallel with the median barrier posts The string line should be set to follow the side of the posts on the side that it is desired to install the tangent X TENSION 350 Figure 2 Essentially a tangent system installed parallel to Figure 3 Small number of additional components Median barrier Step 2 Installing Tangent X TENSION 350 Portion For median applications follow...

Page 10: ...st may also be placed in an oversized augured hole but care must be taken to ensure the backfill is properly compacted When driving steel posts ensure that a driving cap with timber or plastic insert is used to prevent damage to the galvanising on the top of the posts Ensure that Post 2 has the post bolt holes on the side nearest the rail notches go to the backside as shown and are only used on th...

Page 11: ...ttom end Figure 8 Place post 1 top in the post 1 bottom anchor ensuring that the post bolt notches are at the top and facing the Soil Anchor Figure 9 Use M16 x 200mm hex head bolt with nut and washers Do not over tighten bolt Figure 7 Measure 200mm towards roadway Figure 8 Drive soil anchor into augured hole Figure 9 Post 1 top in post bottom Step 4 Hang Rail 3 and Cable Anchor Bracket Rail 3 is i...

Page 12: ...ecial shear bolts yellow supplied Figure 12 Put the washer and nut on inside of rail IMPORTANT NOTE DO NOT USE STANDARD SPLICE BOLTS AT POST 5 SPLICE Figure 11 Bolt rail 2 to post and blockout Figure 12 Splice rail 2 to rail 3 with 8 special shear bolts Step 6 Attach Slider Bracket to Rail 2 Bolt the Slider Bracket to the end of rail 2 at post 3 Figure 13 Use 4 standard splice bolts The angle bar ...

Page 13: ...ed and reinforced post breaker end of Slider Panel sits at the rail end Use guardrail pin bar or crow bar to assist with lining up splice holes Figure 15 Sit rail 1 so it is raised off the ground Figure 16 Slide the Slider Panel onto downstream end Step 8 Hang Rail 1 Lift rail 1 with Slider Panel attached and push the slider end over rail 2 Figure 17 Overlap the rails as per a standard splice join...

Page 14: ...der the M16 small nut on the inside of post 1 Figure 21 Figure 20 Attach Impact Head to rail 1 Figure 21 Bolt head and rail 1 to post 1 with washer Step 10 Place the Cables Push the cables under the steel strap on the Ground Strut Figure 22 and forward through the holes at the top of the anchor Lay the cables out parallel to the guardrail downstream from the anchor Ensure that bottom cable closest...

Page 15: ...7 Repeat this process with the other cable but push it through the top hole and thread it along the top trough of the W beam Place the nuts and washer on the cables at the Cable Bracket end but only run them a few turns Figure 25 Do not tighten cables at this stage or the Friction Plate will not turn Figure 24 Pass the cable through the bottom hole Figure 25 Do not tighten nuts at this time Step 1...

Page 16: ...the W beam and do not visibly sag between posts Figure 29 There is no torque requirement for the cables Figure 28 Tighten cables at Cable Bracket end post 7 Figure 29 Tighten cables until they are taut Step 14 Attach Secondary Impact Head Fit secondary head to main head by pushing sideways onto the main head as shown below Figure 30 until the holes in the gussets line up Fix into place with either...

Page 17: ...ap rail in the direction of traffic as per standard Median barrier Ensure that rail 2 is spliced to rail 3 using the special shear bolts yellow head supplied DO NOT use standard splice bolts at this joint Figure 33 Be sure rail 2 is lapped outside rail 3 in both directions Figure 32 Rails installed with blockouts Figure 33 Splice rail 2 to rail 3 with 8 special shear bolts Step 16 Attach Slider Br...

Page 18: ...on and fit the Slider Panel onto the downstream straight end of rail Figure 34 Bolt into place using 4 standard splice bolts pushing the bolt through from the inside of the slider to the outside so the nut is on the traffic face The curved and reinforced post breaker end of Slider Panel sits at the rail end Use guardrail pin bar or crow bar to assist with lining up splice holes Figure 34 Fit the S...

Page 19: ...ng supplied standard post bolt and 50x50mm washer on inside of post bolt notch on the backside of post 2 Figure 35 Re attach the angle bar to the Slider Bracket Figure 36 on the backside of the rail at post 3 Figure 35 Bolt rail 1 and blockout to post 2 using the Figure 36 Re attach the angle bar to the Slider Bracket square washer Splice the rail to the secondary impact head using 8 standard spli...

Page 20: ...rivets Figure 38 Delineation to be attached to nosing as per local roading authority requirements The X TENSION 350 Median Plastic Nut Protectors are available for all X TENSION 350 Median Terminal Ends They protect pedestrians and cyclists from exposed splice bolt nuts and threads Fit 8 Nut Protectors on the Impact Head Figure 39 and 4 on Slider Panel Figure 38 Attach nose cone using cable nuts F...

Page 21: ...ating the cables as you pull them will help Undo nuts at ground anchor end and remove cables Step 2 Remove Rails Unbolt the splice bolts first Then unbolt the post bolts and lower rails to ground Step 3 Remove X TENSION 350 Median Components All the X TENSION 350 Median components are attached to the rails with standard splice bolts Unbolt and remove the components Step 4 Remove Posts Undo the bol...

Page 22: ...as you pull them will help Undo nuts at ground anchor end last and remove cables Step 2 Pull Rails Back Out Attach a chain or two ton strap to the front of the impact head and pull upstream to its original position with a light truck or utility vehicle The components are easier to unbolt when the rails are separated Step 3 Remove X TENSION 350 Median Components All components are attached to the r...

Page 23: ...Installation Manual X TENSION 350 Median Ph 1800 724 172 or visit www acprod com au December 2018 Page 23 ...

Page 24: ...Installation Manual X TENSION 350 Median Ph 1800 724 172 or visit www acprod com au December 2018 Page 24 ...

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