INGAL Ezy-Guard Smart, Product Manual

Page: 20 / 32

20
Release 07/22
Roadside Safety Barrier
Table 6: Damage Assessment of Ezy-Guard Smart
Type of Defect Description of the Defect Action to be Taken
Galvanizing damage on
Z-Posts.
The sum total of the damaged area does not exceed 35cm
2
(0.5% of the total
surface area).
The sum total of the damaged area exceeds 35cm
2
An organic zinc rich epoxy paint is to be applied to the repair area
in two coats.
The Z-post is to be replaced.
Galvanizing damage
on rails.
The sum total of the damaged area does not exceed 200cm
2
(0.5% of the
total surface area) and no individual damaged area does not exceed 40cm
2
.
The sum total of the damaged area exceeds 200cm 2 (0.5% of the total
surface area) and/or an individual damaged area exceeds 40cm 2 .
An organic zinc rich epoxy paint is to be applied to the repair area
in two coats.
The rail is to be replaced.
Mechanical damage on
Ezy-Carriages.
The Ezy-Carriage has chips or cracks. The Ezy-Carriage is to be replaced.
Mechanical damage on
Z-Posts.
The post is bent.
The Ezy-Carriage cannot travel freely along the post due to distortion. The post is to be replaced.
The post is to be replaced.
Mechanical damage
on rail.
The rail is dented, twisted or flattened.
There are tears in any part of the rail.
The slots in the rail are distorted. The rail is to be replaced.
The rail is to be replaced.
The rail is to be replaced.
Mechanical damage
on bolts.
The body of the bolt is distorted.
The thread of the bolt is damaged. The bolt is to be replaced.
The bolt is to be replaced.
Disturbance of material
around posts
The material around the post is loose or uncompacted. Any disturbed pavement or material around a post shall be left
dense, tight and smooth so that resistance to water penetration is
similar to that of the adjacent surface.
10.0 Repair
10.1 Bush Fire Damage
Ezy-Guard Smart does not contain any plastic, timber or
rubber components that will burn.
The performance of galvanised coatings when subjected
to fires depends upon a number of factors, such as flame
duration, intensity and the characteristics of the galvanised
coating.
Typical bushfire conditions may expose steel structures to
an air temperature of 800°C for periods of up to 120 seconds,
however zinc coatings are generally reflective and will not
absorb heat at the same rate as an uncoated steel surface.
Depending on the section thickness of the steel, the actual
steel surface temperature may not exceed 350°C.
Typically, the bushfire flame duration and intensity are not
high enough to compromise the structural strength of
the steel. The hot dip galvanized coating will also typically
remain unaffected through a bushfire event. If the bushfire
causes damage to the galvanized surface, then the item(s)
shall be replaced.
10.2 Damage Assessment
In the event of a vehicle impact, damage to the barrier is
to be assessed in accordance with Table 6.
A Safe Work Method Statement is available from Ingal
Civil Products upon request to assist in the safe repair of
Ezy-Guard Smart.
Any item that is replaced is to be reinstated observing
the installation tolerances nominated in Section 7.13.
Only items purchased from Ingal Civil Products shall be
used for the repair of Ezy-Guard Smart.
10.3 Dismantling Sequence
Prior to undertaking dismantling due to a vehicle impact,
the area should be assessed for hazards. These include
trip hazards, sharp edges and snag points.
During a vehicle impact, the rail will disengage from
the posts as they yield by bending at ground level. The
recommended dismantling sequence is as follows;
1. Dismantle the rail splice by removing the M16x32mm
mushroom head bolts and nuts. There are 8 bolts
located at each splice location.
2. Rails that are still attached to posts outside the
impact area are disconnected by removing the
M16x30mm post bolts. A 10mm hex key is required.
3. Once the area is clear of damaged rail, the posts can
be removed. Since the posts yield by bending near
ground level, a sling or chain can be attached below
the bent section.
4. The damaged post can be lifted using a backhoe or
post extractor attachment.
5. Any disturbed pavement material shall be left
dense, tight, and smooth prior to the installation of
replacement posts.