VALTIR QuadGuard Assembly Manual Download Page 3

Page: 3 / 68

Revision D November 2022

Table of Contents

Customer Service Contacts .......................................................................................................... 3

Important Introductory Notes ........................................................................................................ 3

Safety Symbols ............................................................................................................................. 4

Safety Rules for Assembly ............................................................................................................ 4

Limitations and Warnings .............................................................................................................. 5

System Overview .......................................................................................................................... 6

Inspect Shipping...................................................................................................................... 6

System Components ............................................................................................................... 7

Foundation/Anchoring ................................................................................................................. 11

Valtir Approved Adhesive Anchoring System ............................................................................. 12

Vertical Assemblies ............................................................................................................... 12

Assembly Cautions ............................................................................................................... 13

Horizontal Assemblies ........................................................................................................... 14

Recommended Tools .................................................................................................................. 15

How to Determine Left/Right ................................................................................................. 16

System Bay Count ................................................................................................................ 16

Measuring the Width ............................................................................................................. 17

Site Preparation/Foundation ....................................................................................................... 18

Narrow System Identification ...................................................................................................... 19

Inspect Shipping.................................................................................................................... 20

Determine Backup and Transition Type ................................................................................ 20

Narrow Transitions ................................................................................................................ 21

Assembly Narrow ........................................................................................................................ 22

Monorail Alignment ............................................................................................................... 23

Attach Nose........................................................................................................................... 33

Wide System Identification .......................................................................................................... 39

Inspect Shipping.................................................................................................................... 40

Determine Backup and Transition Type ................................................................................ 40

Wide Transitions ................................................................................................................... 41

Assembly Wide ........................................................................................................................... 42

Monorail Alignment ............................................................................................................... 43

QuadGuard

Final Inspection Checklist ...................................................................................... 57

Maintenance and Repair ............................................................................................................. 58

Inspection Frequency ............................................................................................................ 58

Visual Drive-By Inspection .................................................................................................... 58

Walk-Up Inspection ............................................................................................................... 58

Post-Impact Instructions ............................................................................................................. 59

Parts Ordering Procedure ........................................................................................................... 61

Summary of Contents for QuadGuard

Page 1: ...VALTIR QuadGuard CRASH CUSHION ASSEMBLY MANUAL PN 115348 REVISION D NOVEMBER 2022...

Page 2: ...e and repair of the QuadGuard could result in serious injury or death Important These instructions are for standard assembly specified by the appropriate highway authority In the event the specified s...

Page 3: ...termine Left Right 16 System Bay Count 16 Measuring the Width 17 Site Preparation Foundation 18 Narrow System Identification 19 Inspect Shipping 20 Determine Backup and Transition Type 20 Narrow Trans...

Page 4: ...the location specified by the appropriate highway authority If there are deviations alterations or departures from the assembly instructions specified in this manual the device may not perform as tes...

Page 5: ...ling 888 323 6374 or by visiting Valtir com Contact Please contact Valtir if you have any questions concerning the information in this manual or the QuadGuard It is the responsibility of the installer...

Page 6: ...other vehicles or nearby hazards or objects by any vehicle object or person whether or not the products were assembled in consultation with Valtir or by third parties The QuadGuard is intended to be...

Page 7: ...y passed the requirements stipulated in NCHRP Report 350 Test Level 3 tests with both the light car and pickup at speeds of up to 62 mph 100 km h at angles up to 20 degrees During head on impact testi...

Page 8: ...sted nor have they been deemed eligible for use Assembly maintenance or repairs using unspecified parts or accessories is strictly prohibited Note Components are not shown to scale Narrow Diaphragm As...

Page 9: ...Grey 606027 606029 Mushroom Washer Flat Screw 5 8X8 1 2 Wide Die Spring 6 Wide 617045 116879 117458 Flat Screw 5 8X5 G8 Narrow Die Spring 1 1 2 Narrow Rail Nut Hex 5 8 116878 117458 003340 Rail Bolt 5...

Page 10: ...ort 118232 113518 605446 Washer Lock 5 8 Washer Flat 3 8 X 1 Nut Hex 3 8 X 1 118100 118036 115960 Bolt Hex 3 8 X 1 G5 Washer Fender 3 8 X 2 Bolt Hex 5 8 X 1 1 2 G5 113596 118038 113654 Bracket Pull Ou...

Page 11: ...inge Plate Fender Panel Bolt Hex 5 8 X 4 G5 003354 610172 113666 Parts in red are included in assemblies Panel Side QG Bracket Cartridge Support TS B U Locking Bar Cartridge Support 611898 605447 6112...

Page 12: ...ns or as otherwise determined by the project engineer or appropriate highway authority The QuadGuard may be installed on any of the following foundations using the specified anchorage Foundation A Con...

Page 13: ...ve 2 Drill Boreholes Caution It is the responsibility of the installer to consult OSHA silica respiratory standard 29 CFR 1910 134 for debris removal from borehole s and use Valtir approved adhesive t...

Page 14: ...and Wait for Adhesive to Cure Push the stud nut and washer assembly down through the part and into the borehole until the washer is seated against the part Caution Do not disturb or load the stud unt...

Page 15: ...h end of stud 3 Insert each Stud with Washer and Nut into Borehole Push stud through part to be anchored and into borehole Twist the stud in the approved adhesive to wet the threads Important The stud...

Page 16: ...er Standard hammer Wrenches Heavy Duty 1 2 drive impact wrench 1 2 drive Sockets 9 16 11 16 3 4 15 16 1 1 8 1 1 4 1 2 drive Deep Well Sockets 15 16 1 1 4 1 2 drive Ratchet and Attachments 1 2 drive Br...

Page 17: ...ired tools may vary Decisions as to what tools are needed to perform the assembly properly are the responsibility of the specifying highway authority and the authority s selected contractor performing...

Page 18: ...00 mm The nominal width of a parallel system is the width of the diaphragm Figure 4 The nominal width of a wide system is the width at the location shown in Figure 5 The outside width of the system is...

Page 19: ...shall not exceed 8 and should not twist more than 2 over the length of the system the foundation surface shall have a light broom finish Caution Accurate placement of all steel rebar is critical to a...

Page 20: ...9 Revision D November 2022 Narrow System Identification Figure 7 Narrow System s and Model Numbers 1219 mm 48 Model No QS48 _ _ 915 mm 36 Model No QS36 _ _ 760 mm 30 Model No QS30 _ _ 610 mm 24 Model...

Page 21: ...s Determine Backup and Transition Type The QuadGuard is available with a Tension Strut Backup or a Concrete Backup See Figure s 8 and 9 along with the Backup Assembly drawing to determine which type o...

Page 22: ...s to use will depend on the direction of traffic and what type of barrier or roadside obstacle the QuadGuard is shielding Contact the Customer Service Department prior to deployment if you have any qu...

Page 23: ...Figure 16 Locate Backup Face Plate using the Backup Assembly drawing Verify that any applicable Transition Panels fit properly before anchoring the Face Plate Drill anchor holes in the Concrete Backu...

Page 24: ...roved adhesive instructions included with the adhesive kit p 12 Drill 0 78 20 mm diameter by 5 3 4 145 mm boreholes using the Monorail as a template Do not drill through foundation Figure 16 Anchoring...

Page 25: ...must be anchored by a stud using an approved adhesive Anchor each Monorail section using the approved adhesive kits provided Reference the adhesive manufacturer s instructions included with kit It is...

Page 26: ...on Warning Every borehole and slot in Backup and Monorail must be anchored by a stud using an approved adhesive Anchor each Monorail section using the approved adhesive kits provided Reference the adh...

Page 27: ...rail bolt and 5 8 rail nut two places top and bottom holes only See Figure 22 and Backup Assembly drawing Note A Side Panel is not needed when a Transition Panel is used Assembly tip Use drift pin to...

Page 28: ...ch Diaphragms Orient a Diaphragm so that the front face of the Diaphragm shape faces toward the Nose of the system as shown in Figure 24 Slide one Diaphragm all the way to the Backup to ensure the sys...

Page 29: ...Washer Assembly as shown in Figure 27 and Detail 27a and Detail 27b 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...

Page 30: ...e Mushroom Washer lays flat against the Fender Panel as shown in Figure 27b Standoff on Mushroom Washer must be seated completely through slot Figure 27 Fender Panel Assembly Detail 27b Mushroom Washe...

Page 31: ...e Diaphragms as shown in Figure 28 and Fender Panel Assembly drawing Step 7 Once proper spacing has been achieved torque the Mushroom Washer Assembly small hex nut until it reaches the end of the thre...

Page 32: ...s Attach lower Cartridge Support Bracket to front and back of all Diaphragms and front of Backup as shown in Figures 31 to 33 the Diaphragm Assembly drawings and the Backup Assembly drawings p 35 Note...

Page 33: ...ket Concrete Backup STEP II INSERT KEEPER STEP I INSERT LOWER CARTRIDGE SUPPORT BRACKET Figure 31 Lower Cartridge Support Bracket Assembly TENSION STRUT BACKUP CONCRETE BACKUP FACE PLATE LOWER CARTRID...

Page 34: ...le of Cartridges your system has If your system has Cartridge style A as shown in Figure 34 attach Cartridge Support in the upper two slots as shown If your system has Cartridge style B as shown in Fi...

Page 35: ...e Style B is attached with the Adjustable Cartridge Support Bracket incorrectly in the upper position Detail 34c shows the Adjustable Cartridge Support Bracket attached correctly Detail 34a Incorrect...

Page 36: ...the front two Fender Panels to the Diaphragm with Bar Washer under each bolt Place Pullout Brackets under center nuts The top and bottom holes of the Nose are slotted to provide adjustment Adjust so t...

Page 37: ...h end of the Nose Belt with the attached bolts three per side and slide Nose Belt onto bolts e Align holes in Belt Clamps with bolts and slide Belt Clamps onto bolts f Using fourth 5 8 x 1 3 4 flat wa...

Page 38: ...sembly Be sure the Adjustable Cartridge Support in the Nose is attached correctly See Attach Nose Assembly in Step 11 on page 33 The top surface of the Nose Cartridge should be horizontal It is the re...

Page 39: ...Valtir com 38 Revision D November 2022 Figure 38 5 Bay Cartridge Placement Shown Figure 37 Cartridge Placement 1 BAY 2 BAYS 3 BAYS 4 BAYS 5 BAYS 6 BAYS I TYPE I CARTRIDGE II TYPE II CARTRIDGE...

Page 40: ...Valtir com 39 Revision D November 2022 Wide System Identification Figure 39 Wide Systems and Model Numbers...

Page 41: ...ckup and Transition Type The QuadGuard is available with a Tension Strut Backup or a Concrete Backup See Figures 40 and 41 along with the Backup assembly drawing to determine which type of Backup is b...

Page 42: ...of traffic and what type of barrier or roadside feature the QuadGuard is shielding Contact the Customer Service Department prior to deployment if you have any questions Figure 42 No Transition Figure...

Page 43: ...ndent on the type of Transition Panel used See the Project Plans supplied with the system for details 2 Anchor the Backup A Concrete Backup Construction Figure 48 Locate Backup Face Plate using the Ba...

Page 44: ...il must be anchored by a stud using an approved adhesive Monorail Alignment It is important to align each segment of Monorail from the back to the front of the system 1 4 6 mm Anchor each Monorail sec...

Page 45: ...5 8 x 1 3 4 flat washer 2 5 8 lock washer and 5 8 hex nut 6 places as shown in Figure 51 and Detail 51A Verify that any applicable Transition Panels fit properly before anchoring Backup Drill anchor h...

Page 46: ...arning Every borehole and slot in Backup and Monorail must be anchored by a stud using an approved adhesive Anchor each Monorail section using the approved adhesive kits provided See Figure 51 and the...

Page 47: ...r Transition Panels to Backup Assembly Figure 55 a Attach Hinge Plate to the Transition Panel or Side Panel using 5 8 rail bolt and 5 8 rail nut two places top and bottom holes only b Attach Transitio...

Page 48: ...le of the Panel with the center hole of the Backup before attaching the rail bolts Figure 55 Side Panel Transition Panel Attachment TENSION STRUT BACKUP 3 8 X 3 1 2 HEX BOLT 3 8 LOCK WASHER CONCRETE B...

Page 49: ...d as shown in Figure 56 Secure with 3 4 lock washer and 3 4 hex nut typical two places per guide See also Diaphragm assembly drawing Shims are sandwiched between Monorail guides and Diaphragm Repeat p...

Page 50: ...he widest Diaphragm onto the Monorail and all the way to the Backup to ensure system is able to collapse properly during impact Once this has been verified slide the Diaphragm forward to approximately...

Page 51: ...g the center hole open as shown in Figure 60 9 Attach Fender Panels Starting at the Backup attach left and right Fender Panels as shown in Figure 61 and Fender Panel Assembly drawing Step 1 Place the...

Page 52: ...center hole of the Diaphragm Step 4 Attach the front of the Fender Panels to the next Diaphragm using two 2 rail bolts and large hex nuts per side Use only the top and bottom holes leave the center h...

Page 53: ...Washer Orientation Detail 61B Mushroom Washer Attachment DIAPHRAGM OR BACKUP 11 16 18 mm ROUND HOLE LONG SLOT IN FENDER PANEL MUSHROOM WASHER QUAD BEAM FENDER PANEL HINGE PLATE PANEL ALREADY ATTACHED...

Page 54: ...ly small hex nut until it reaches the end of the threads Assemble the remaining Diaphragms and Fender Panels following the same procedures 10 Attach End Cap Using 5 8 x 3 1 2 G5 hex bolt 5 8 hex nut a...

Page 55: ...Figures 64 67 the Backup Assembly drawing and the Diaphragm Assembly drawing Figure 65 Cartridge Support Bracket Tension Strut Backup Figure 66 Cartridge Support Bracket Concrete Backup Figure 64 Dia...

Page 56: ...em anchor bolts etc See warning below Check all Fender Panels If they do not fit tightly against the underlying Fender Panels system realignment may be necessary Figure 68 Warning Bolt Torque Requirem...

Page 57: ...d Type I Cartridges are placed toward the front and Nose of the system Type II Cartridges are placed toward the rear of the system Figure 69 Warning Placing the wrong Cartridge in the Nose or any Bay...

Page 58: ...attached to the Diaphragms with shims p 27 47 Mushroom Washer tabs lay flat within fender panel slots p 29 51 Fender Panel nuts are bottomed out on Mushroom Washer bolt p 29 52 Monorail End Cap Assemb...

Page 59: ...date of visual drive by inspection Walk Up Inspection Clear and dispose of any debris on the site Clear and remove excessive dirt from around the Monorail and Diaphragm feet Bolts are tight and rust f...

Page 60: ...at the system has not been deformed in a way that would prevent pulling it back to its original position 5 Be sure that the Diaphragm Support Legs are all properly attached to the Monorail Caution Use...

Page 61: ...ng Fender Panel Maximum gap allowed Narrow Systems 0 78 20 mm Wide Systems 1 00 25 mm 10 Replace all crushed Cartridges p 38 56 11 Remove damaged Nose Assembly Attach the new Nose to the first Diaphra...

Page 62: ...tion Chart Description Choices Fill in this section What is the system width p 17 24 610 mm 30 760 mm 36 915 mm 48 1219 mm 69 1755 mm 90 2285 mm 126 3200 mm How many Bays p 16 Narrow systems 1 through...

Page 63: ...E WITH 3 4 X 7 STUD 5 8 HEX NUT DIAPHRAGM TRANSITION PANEL P 24 DIAPHRAGM MONORAIL UNDER SYSTEM ANCHORED WITH APPROVED ADHESIVE TYPE I CARTRIDGES MUSHROOM WASHER ASSEMBLY NOSE COVER ASSEMBLY BACKUP TE...

Page 64: ...L UNDER SYSTEM ANCHORED WITH APPROVED ADHESIVE MUSHROOM WASHER 5 8 X 5 FLAT SCREW MONORAIL SECTION VERTICAL APPROVED ADHESIVE WITH 3 4 X 7 STUD NOSE COVER ASSEMBLY FIRST DIAPHRAGM TYPE I CARTRIDGE MON...

Page 65: ...Valtir com 64 Revision D November 2022 Notes...

Page 66: ...Valtir com 65 Revision D November 2022 Notes...

Page 67: ...Valtir com 66 Revision D November 2022 Notes...

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