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Energy Absorption QuadGuard cz Installation Manual Download Page 2

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Proper installation of the QuadGuard cz is essential to as-
sure maximum performance. Take the time to review the
installation instructions and product limitations thoroughly
before performing the necessary work. Do not attempt to
install any crash cushion without the proper plans and
installation manual from the manufacturer.

If you need additional information, or have questions about
the QuadGuard cz, please call Energy Absorption Systems’

Customer Service Department at (888) 323-6374.

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The QuadGuard cz is a highly efficient, redirective, non-
gating crash cushion for hazards ranging in width from
610 mm to 915 mm (2' to 3'). It consists of crushable,
energy-absorbing cartridges surrounded by a framework
of Quad-Beam

TM

 panels.

The QuadGuard cz utilizes two types of cartridges in a
"staged" configuration to address both lighter cars and
heavier, high center-of-gravity vehicles. Its modular de-
sign allows the system length to be tailored to the design
speed of a site. Refer to the QuadGuard Product Manual
to determine the appropriate length system for a given
design speed.

Crash P

Crash P

Crash P

Crash P

Crash Perf

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erformance

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ormance

The 6 bay QuadGuard cz has successfully passed the
NCHRP 350, Test Level 3 tests with both the light car and
pickup truck at speeds up to 100 km/h (62 mph) at angles
up to 20 degrees.

During head-on impacts, the QuadGuard cz telescopes rear-
ward and crushes to absorb the energy of impact. When
impacted from the side, it safely redirects the vehicle back
toward its original travel path and away from the hazard.

RETURN GOODS POLICY

Before returning any goods for credit please contact
Energy Absorption Systems Inc. Customer Service De-
partment at 1-888-323-6374 or your local distributor
for proper instructions.

Table of Contents

Important Introductory Notes ............................ 2
System Overview ............................................... 2
Crash Performance ............................................ 2

Installation ............................................... 3

Required Tools ................................................... 3
How to Determine Left/Right ............................. 5
Counting the Number of Bays ............................ 5
Measuring The Width ........................................ 6
Site Preparation/Foundation .............................. 6
QuadGuard cz Foundations ................................ 7
Bidirectional Sites .............................................. 7
Inspect Shipping ................................................ 8
Installation Procedures ...................................... 8
Transition Panel Types ....................................... 9

MP-3® Polyester Anchoring System ............... 30

Vertical Installations ........................................ 30
Horizontal Installations .................................... 31
MP-3® Installation Cautions ........................... 32
QuadGuard cz MP-3® Anchoring System ....... 33

Moving the System .................................... 34

QuadGuard cz (without Plate) .......................... 34
QuadGuard cz (with Plate) ............................... 36
QuadGuard cz (with Plate and Optional DPA
Anchorage) ...................................................... 38

Maintenance and Repair ............................. 40

Inspection Frequency ....................................... 40
Visual Drive-By Inspection ............................... 40
Walk-Up Inspection ......................................... 40
Post-Impact Instructions ................................. 41
Parts Ordering Procedure ................................ 44

Limitations And Warnings ........................... 45

Summary of Contents for QuadGuard cz

Page 1: ...n Manual Corporate Offices 35 East Wacker Dr 11th Floor Chicago IL 60601 2076 Telephone 312 467 6750 FAX 312 467 1356 http www energyabsorption com Engineering and Manufacturing Facilities Rocklin CA Pell City AL A Quixote Company Saving Lives By Design ENERGY ABSORPTION SYSTEMS INC ...

Page 2: ...d Crash P Crash P Crash P Crash P Crash Perf erf erf erf erformance ormance ormance ormance ormance The 6 bay QuadGuard cz has successfully passed the NCHRP 350 Test Level 3 tests with both the light car and pickup truck at speeds up to 100 km h 62 mph at angles up to 20 degrees During head on impacts the QuadGuard cz telescopes rear ward and crushes to absorb the energy of impact When impacted fr...

Page 3: ...16 1 1 4 Ratchet and attachments for the above sockets Breaker Bar 1 2 x 24 Torque Wrench 200 ft lbs Crescent Wrench 300 mm 12 Allen Wrench 3 8 Impact Wrench 1 2 Personal protective equipment Safety Glasses Gloves Miscellaneous Traffic Control Equipment Lifting and Moving Equipment A lifting device is preferred although a forklift can be used Mini mum 5 000 lb capacity required Compressor 100 psi ...

Page 4: ...am Fender Panel Figure 1 4 Nose Cover 5 Monorail 6 Backup 61 61 61 61 610 mm 24 0 mm 24 0 mm 24 0 mm 24 0 mm 24 7 7 7 7 760 mm 30 60 mm 30 60 mm 30 60 mm 30 60 mm 30 91 91 91 91 915 mm 36 5 mm 36 5 mm 36 5 mm 36 5 mm 36 67 67 67 67 6740 mm 22 1 3 8 40 mm 22 1 3 8 40 mm 22 1 3 8 40 mm 22 1 3 8 40 mm 22 1 3 8 Key Six bay systems shown Elevation Plan ...

Page 5: ...nting the Number of Ba Counting the Number of Bays ys ys ys ys One bay consists of one cartridge one diaphragm and two fender panels The nose section is not considered a bay though there is a cartridge in the nose of each sys tem 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 pan els on one s...

Page 6: ...erence with the con crete Anchor Bolts WARNING Location of the backup in relation to nearby objects will affect the operation of the attenuator Upon impact the fender panels telescope toward and extend beyond the rigid backup as much as 760 mm 30 from their pre impact location Position the backup so that the rear ends of the last fender panels are a minimum of 760 mm 30 forward of objects that wou...

Page 7: ...Range Passing 1 100 3 4 95 100 3 8 65 80 No 4 49 54 No 8 36 40 No 30 18 21 No 200 3 8 P C C Portland Cement Concrete Stone aggregate concrete mix 4000 psi minimum compressive strength Sampling per ASTM C31 84 or ASTM C42 84a test ing per ASTM C39 84 C S Compacted Subbase 150 mm 6 minimum depth 95 compaction Class 2 aggregate Sieve Size Moving Average Passing 3 100 2 1 2 90 100 No 4 40 90 No 200 0 ...

Page 8: ...must be used with these instruc tions for proper assembly and should take prece dence over these general instructions QUAD BEAM TO W BEAM TRANSITION PANEL Figure 5 Transitioning the QuadGuard cz Installation cont Installation cont Installation cont Installation cont Installation cont d d d d d 1 Determine Transition Type A transition panel or side panel will be used on each side of the backup A si...

Page 9: ...of barrier or haz ard the QuadGuard cz is shielding Contact the Customer Service Department prior to installation if you have any questions Figure 8 Figure 9 Figure 10 Figure 7 Note Wheel Deflectors may be required for this application Figure 6 No Transition Quad Beam to Thrie Beam Transition Panel Quad Beam to Safety Shape Barrier Transition Panel Quad Beam End Shoe Transition Panel Quad Beam to ...

Page 10: ... Refer to the drawing package supplied with the system Place chalk line to mark the centerline of the system Mark a con struction line parallel to the center line and offset 165 mm 6 5 to one side as shown in Figure 11 The edge of the monorail will be placed on this line Note The concrete pad should be installed per the project plans supplied with the system Figure 11 Top View of Concrete Pad Loca...

Page 11: ...l anchor holes using the monorail as a template see figure 15 Do not drill through pad Anchor each monorail section us ing the MP 3 vertical kits provided Refer to Figure 17 and the MP 3 Polyester Anchoring System Instruc tions on page 28 It is important to install each seg ment of monorail in alignment from the back to the front of the system 6 mm 1 4 CZ BACKUP Figure 13 Anchoring cz Backup to Fo...

Page 12: ...alk up inspections are recommended at least once every six months for installations on asphalt Note 18 AnchorsaresuppliedwiththeQuadGuard cz Ifanothersubstrateisencountered pleasecallCustomer Service to discuss options Use MP 3 Polyester Anchoring System supplied by Energy Absorption Systems Inc or approved equal QuadGuardczsinstalledonasphaltmustbeinspected to ensure the anchors are still properl...

Page 13: ...ne of the system Mark a construction line parallel to the center line and offset 534 mm 21 to one side The edge of the monorail plate will be placed on this line See figure 19 3 Bolting together of plate monorail seg ments All plate monorail segments must be bolted together using the bolts provided with the QuadGuard cz The number of monorail segments will vary by system length Torque the nut unti...

Page 14: ...TION MIN LAYER Depth Combinations Note Walk up inspections are recommended at least once every six months for installations on asphalt Note 18 AnchorsaresuppliedwiththeQuadGuard cz Ifanothersubstrateisencountered pleasecallCustomer Service to discuss options Req d Stud Length E D C 180 mm 7 150 mm 6 460 mm 18 75 mm 3 75 mm 3 150 mm 6 460 mm 18 460 mm 18 Installation cont Installation cont Installa...

Page 15: ...l be placed on this line See figure 22 WARNING Location of the system with respect to the hazard is critical and dependent on the type of transition panel used See the project plans supplied with the system for details 3a Bolting together of plate monorail segments All plate monorail segments must be bolted together using the bolts provided with the QuadGuard cz The number of monorail segments wil...

Page 16: ...late segments have been bolted together place the system on top of several saw horses or other type of adequate table support Us ing 5 8 x 2 rail bolts and 5 8 rail nuts attach a wing plate to the front of the first monorail plate to the rear of the backup monorail plate and at the con nection point for each monorail plate segment See figure 23 Figure 23 Wing Plate Attachment FIRST MONORAIL PLATE ...

Page 17: ...d barrier via pin and loop connection see Fig ure 25 and or transition panel s 8 SLOPE MAX Figure 24 Max Allowable Cross Slope Figure 25 Pin and Loop Connection 2 Once system is in place position pile driving equipment over a square hole in the outboard wing plate as shown in Figure 26 3 Place the 72 x 6 x 6 Drivable Post into the square hole in the wing plate as shown in Fig ure 26 Use a small le...

Page 18: ... Panel Attachment 5 8 RAIL NUT SEE FIGURE 32 SIDE PANELS SHOWN IN SOME CASES THIS WILL BE A TRANSITION PANEL SEE FIGURES 7 THRU 10 CZ BACKUP 5 8 X 2 RAIL BOLT Installation tip Use drift pin to align the center hole of the panel with the center hole of the backup before installing the rail bolts Note A side panel is not needed when a transition panel is used Installation cont Installation cont Inst...

Page 19: ... one diaphragm all the way to the backup to ensure the system is able to collapse properly during impact Once this has been verified slide the diaphragm forward to approximately 915 mm 36 in front of the backup Orient and slide all other diaphragms onto monorail and position each approximately as shown in Figure 31 TOWARD NOSE FRONT BACK Figure 30 Diaphragm Orientation QUAD BEAM FRONT FACE OF BACK...

Page 20: ... that the center hole of the rearward diaphragm is lined up with the ap proximate center of the slot in the fender panel Attach mushroom washer assembly as shown in Figures 33 and 34 but do not torque at this time This helps to balance the fender panel Step 2 Slide the fender panel forward until the holes in the fender panel line up with the holes in the for ward diaphragm Step 3 Use a drift pin t...

Page 21: ...hragms as shown in Figure 36 Once the proper spacing has been achieved torque the mushroom washer assem bly small hex nuts to hold the diaphragm and fender panels in place during assembly of the rest of the sys tem Install the remaining diaphragms and fender pan els following the same procedures Tighten the nut so that the spring is compressed 1mm to 3mm 1 16 to 1 8 to complete the assembly FENDER...

Page 22: ...h plate QuadGuard cz with plate QuadGuard cz with plate QuadGuard cz with plate 9 Attach the Endcap Using 5 8 x 3 1 2 hex bolt 5 8 hex nut and 5 8 lock washer supplied with the system attach the endcap to the front of the first plate monorail segment as shown in Figure 38 FRONT OF FIRST PLATE MONORAIL SEGMENT Figure 38 End Cap Attachment Installation cont Installation cont Installation cont Instal...

Page 23: ... and diaphragms See Figure 39 SIDE CARTRIDGE SUPPORT BRACKETS Figure 39 Side Cartridge Support Brackets Figure 41 LOWER CARTRIDGE SUPPORT BRACKET DIAPHRAGM DIAPHRAGM 610 mm 24 WIDE 762 mm 30 AND 915 mm 36 WIDE Figure 40 Lower Cartridge Support Bracket Installation BACKUP STEP II INSTALL KEEPER STEP I INSTALL LOWER CARTRIDGE SUPPORT BRACKET LOWER CARTRIDGE SUPPORT BRACKET BACKUP Lower Cartridge Sup...

Page 24: ...de belt clamps onto bolts f Using fourth 5 8 x 1 3 4 flat washer and third 5 8 hex nut secure the belt clamps and nose belt three places per side Figure 42 5 8 X 1 3 4 FLAT WASHER BELT CLAMP 5 8 X 1 3 4 FLAT WASHER 5 8 X 5 G5 ALL THREAD HEX BOLT QUADGUARD NOSE BELT 5 8 HEX NUT FRONT DIAPHRAGM Optional Nose Belt Assembly Detail 42a Note Nose of system may be delineated to comply with local codes ch...

Page 25: ...se Assembly Determine which style of cartridges your system has If your system has cartridge style A as shown in De tail 43a install cartridge support in the upper two slots as shown If your system has cartridge style B as shown in De tail 43b install cartridge support in the lower two slots as shown Adjustable Bracket Location when using Cartridge Style A Installation cont Installation cont Insta...

Page 26: ...h the adjustable cartridge support bracket incor rectly in the upper position Detail 43e shows the adjustable cartridge support bracket installed correctly Incorrect Installation of Adjustable Cartridge Support Bracket Incorrect Installation of Adjustable Cartridge Support Bracket Correct Installation of Adjustable Cartridge Support Bracket Installation cont Installation cont Installation cont Ins...

Page 27: ...ets under center nuts The top and bottom holes of the nose are slotted to provide adjustment Ad just so the top edge of the nose is level with the top edge of the fender panels then torque all six nuts to 35 Nm 25 ft lbs See Figure 45 Figure 44 Figure 45 PLACE A BOARD OVER THE FIRST TWO DIAPHRAGMS AS SHOWN TO FACILITATE PROPER ALIGNMENT OF NOSE TIGHTEN NUTS TO 35 Nm 25 FT LBS AFTER ALIGNING NOSE A...

Page 28: ...NDER TRANSITION EXTENSION OR SIDE PANEL Figure 46 WARNING Placing the wrong Cartridge in the Nose or any Bay will result in unacceptable crash performance as described in NCHRP 350 13 Cartridge Installation To complete the assembly of a QuadGuard cz place the appropriate Cartridge in each Bay and Nose sec tion of the system Type I Cartridges are placed to ward the front Nose of the system Type II ...

Page 29: ...uard cz Figure 48 REAR TYPE II CARTRIDGES TYPE I CARTRIDGES FRONT Typical Cartridge Layout 5 Bay System Shown Installation cont Installation cont Installation cont Installation cont Installation cont d d d d d ...

Page 30: ...ing two fluted drills to achieve optimum tensile strengthwheninstallingtheMP 3anchoringsystem Use the part that is to be anchored as a drilling tem plate Drill the holes 3 mm 1 8 larger than the stud diameter to the recommended depth using a rotary percussive drill Full strength will not be achieved if a diamond drill is used Refer to the MP 3 installation instructions provided with your kit Check...

Page 31: ...off the small end of the dispenser tip Place the dispenser into a caulking gun and dispense until MP 3 TX grout reaches the tip of the dispenser then re lease pressure Push the dispenser tip through the part to the bottom of the hole and dispense while slowly withdrawing the tip Caution Do not overfill or underfill the hole Fill hole approximately 1 3 to 1 2 full If the hole is overfilled there wi...

Page 32: ...rilling an MP 3 an chor bolt hole apply one of the following solutions A Using a diamond core drill or rebar drilling tool drill through the rebar only then switch back to the concrete bit and drill into the underlying con crete until the proper hole depth is reached Caution Do not drill through rebar without first obtaining permission to do so from the local project engineer B Drill a new hole do...

Page 33: ...er holes using a rotary percussive drill 2 Clean the holes Brush each hole with a stiff bristled brush and clean with oil free compressed air to remove the dust If the hole is wet completely flush it with water while brush ing then blow it clean using oil free compressed air 3 Mix and pour grout into holes Follow instructions for vertical installations described on page 28 noting the following Whe...

Page 34: ...nd are attached to the appro priate diaphragms using the top rail bolts Dia phragms are numbered starting from the nose of the system Refer to Table C for lifting bracket locations LIFTING BRACKET LOCATION CHART NO OF BAYS DIAPHRAGMS ASSEMBLY NUMBER ATTACH TO DIAPHRAGM NO 3 4 5 6 7 8 9 3540243 0000 3540244 0000 3540245 0000 3540246 0000 3540247 0000 3540248 0000 3540249 0000 2 3 2 4 2 4 3 5 3 6 3 ...

Page 35: ...s such as 2X4 s under the monorail and work down the length of the system until the system is com pletely free of the studs 5 Lift the system to new location 6 Replace all damaged parts 7 Re anchor system ANCHOR SYSTEM FOR PROPER IMPACT PER FORMANCE Use MP 3 polyester anchor system supplied by Energy Absorption Systems or ap proved equal The QuadGuard cz installed on as phalt must be inspected to ...

Page 36: ...as shown 7 Free the system from anchor bolts and grout prior to lifting To accomplish this start at the nose of the system and use pry bars to gradually raise the system off of the studs Place blocks such as 2x4 s under the anchor plates and work down the length of the system until the system is com pletely free of the studs 8 Install the End Plate Figure 52 and or Endcap Figure 38 on the 3 bay se...

Page 37: ...em off of the studs Place blocks such as 2x4 s under the anchor plates and work down the length of the system until the system is com pletely free of the studs 4 Attach slings to a multiple spread lifting bar beam and adjust sling positions as needed in order to balance the system 5 Lift the system to new location 6 Replace all damaged parts 7 Re install system Figure 54 Lifting the System in 6 th...

Page 38: ...ke sure that the sling is long enough that the angle is less than 90 deg as shown 7 Free the system from anchor posts prior to lift ing To accomplish this start at the nose of the system and use pry bars to gradually raise the system off of the posts Place blocks such as 2x4 s under the anchor plates and work down the length of the system until the system is com pletely free of the studs 8 Install...

Page 39: ...all system Figure 57 Lifting the System in 6 through 9 Bay Assembled Sections 90 DEG MAX 90 DEG MAX 2 Extracting Drivable Pile Anchors 1 Fasten a threaded lifting ring or eye into a hole at the top of the post 2 Attach a hoist or crane to the ring and pull the post from the ground 3 Remove posts as necessary and backfill holes created by the extraction WARNING The posts will be filled with soil an...

Page 40: ...operly aligned and positioned 6 Fender Panels and Transition Panels should nest tightly against the system See figure 46 on page 28 3 Be sure the Nose cover is in place 4 Note the location and condition of the Quad Guard cz and the date of visual drive by in spection WARNING Refer to Cartridge placement on pages 28 and 29 WARNING Refer to Cartridge placement on pages 28 and 29 8 Make all necessary...

Page 41: ...t Instructions 1 Deploy the appropriate traffic control devices to protect your crew 2 Check to see that all Anchor Bolts have remained firmly anchored in the roadway surface Failed anchor bolts are those found to be loose bro ken or showing signs of pull out and are to be replaced If the system is anchored to asphalt up to 20 of the total anchors may be replaced if damaged If more than 20 of the ...

Page 42: ...shape on backup as an anvil form Cartridge Support Bracket back into 90 shape see Figure 60 10 Check gaps between Fender Panels The maxi mum gap allowed for these overlapping parts in cluding Fender Panels overlapping panels behind the system is 20 mm 78 see figure 61 WARNING Fender Panel Maximum gap allowed 20 mm 0 78 Figure 61 FENDER PANEL MAXIMUM GAP 20 mm 0 78 UNDERLYING FENDER TRANSITION EXTE...

Page 43: ...om any debris The QuadGuard cz is once again ready for use Table A Figure 62 Nose Belt QuadGuard cz Bolt Torque Specifications 12b Nose Cover Remove damaged plastic Nose Cover Attach the new Nose Cover to the First Diaphragm using the six Rail Bolts Rail Nuts and Bar Washers that hold the front Fender Panels to the First Dia phragm The top and bottom holes of the Nose cover are slotted to provide ...

Page 44: ... is necessary to receive the proper parts What Type of Transition Panel Be sure to note right side left side both sides or no transi tions refer to Side Panel Transition Panel Types page 9 QuadGuard cz Ordering Information Chart Quad to W Quad to Thrie Quad to End Shoe Quad to Safety Shape Barrier 4 Offset Panel 3 through 9 610 mm 24 760 mm 30 915 mm 36 TRANSITION PANEL NUMEROUS TYPES BACKUP TYPE ...

Page 45: ...nominal NCHRP 350 TL 3 terminal and crash cushion impact conditions of Vehicles Small car and pickup Mass 820 and 2000 kg 1808 and 4409 lb Speed 100 km h 62 mph Angle 15 degrees for small vehicle 20 degrees for pickup Impact conditions which differ from those described in NCHRP 350 test matrix for non gating redirecting crash cushions may result in different crash results than those encountered in...

Page 46: ...QuadGuard cz 46 Notes Notes Notes Notes Notes ...

Page 47: ...47 QuadGuard cz Notes Notes Notes Notes Notes ...

Page 48: ...4 1473 221 105 Fax 44 1473 221 106 35 East Wacker Dr 11th Floor Chicago IL 60601 2076 Engineering and Manufacturing Facilities Rocklin California and Pell City Alabama A Quixote Company Saving Lives By Design ENERGY ABSORPTION SYSTEMS INC http www energyabsorption com Part No 2735992 0000 2007 Energy Absorption Systems Inc Rev 04 18 07 ...

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