INSTALLATION INSTRUCTIONS - Voestalpine

voestalpine Krems Finaltechnik GmbH

INSTALLATION INSTRUCTIONS

KREMSBARRIER APD P50 RL

Performance class in accordance with EN 1317-3:

Restraint category: 50 Impact severity class: B Redirection zone: Z1 Permanent lateral displacement: D1

Production and sales:voestalpine Krems Finaltechnik GmbHSchmidhüttenstraße 5, 3500 Krems, AustriaT.: +43/50304/14-670F.: +43/50304/54-628E-Mail: [email protected]

ID: TTMP50R01Status: 06/2020


TABLE OF CONTENTS

Safety information ......................................................................................................................................................................... 4

Proper use ........................................................................................................................................................................................ 4

Technical description of the vehicle restraint system ........................................................................................................... 4

Transport .......................................................................................................................................................................................... 5

Installation requirements ............................................................................................................................................................. 5

Suitable substrate .......................................................................................................................................................................... 6

Installing the crash cushion in accordance with the P50R01 data sheet, (see annex) ................................................ 7

1. Markings showing the location of the crash cushion .............................................................................................. 7

2. Creating the backup ....................................................................................................................................................... 7

2.1. Creating the pile driven backup .............................................................................................................................. 8

2.2. Creating the anchored backup ............................................................................................................................... 8

3. Installation and anchoring of “Crash Cushion C100x60 sliding rails” ................................................................ 9

4. Installation of guides on the framework .................................................................................................................. 11

5. Installing the “crash cushion frame” ......................................................................................................................... 11

6. Installing the “crash cushion rail elements” of the sled ........................................................................................ 12

7. Installing the “Crash cushion sled” ............................................................................................................................ 12

8. Installing the absorber elements ................................................................................................................................ 13

8.1. Installing the absorber elements in Segment 3 ................................................................................................. 14

8.2. Installing the absorber elements in Segment 2 ................................................................................................. 15

9. Installing the “crash cushion anchorage insulator” .............................................................................................. 16

10. Tightening the screw connections of the absorber elements ........................................................................ 17

11. Connecting the last frame with the I120 posts .................................................................................................. 17

12. Installing the “crash cushion LS.S2A end pieces” .............................................................................................. 17

13. Installing the “crash cushion LS.S2A” guide rails in Segment 3 ..................................................................... 18

14. Installing the “crash cushion LS.S2a” guide rails in segments 2 to 1 ............................................................ 19

15. Installing the “crash cushion LS.S2A heads” ....................................................................................................... 20

16. Torques of the threaded connections .................................................................................................................. 21

17. Monitoring conformity ............................................................................................................................................. 21

18. Clearing the construction site ................................................................................................................................. 21

Repairs to the vehicle restraint system ................................................................................................................................... 22


Page 3/22

Durability of the corrosion protection .................................................................................................................................... 22

Inspection and maintenance.................................................................................................................................................... 22

Recycling/Disposal ...................................................................................................................................................................... 22

Annex 1 ........................................................................................................................................................... P50R01 data sheet

Annex 2 ........................................................................................................................................................... P50R02 data sheet

Annex 3 ................................................................................................................. CC pile driven backup <> VRS data sheet

Annex 4 .................................................................................................................. CC anchored backup <> VRS data sheet

Annex 5 ............................................................................................................................................... TSM A22x155 data sheet

Annex 6 ......................................................................................................................................................... TSM 190 data sheet

Annex 7 ......................................................................................................................... KREMSBARRIER APD P50 RL parts list


Page 4/22

SAFETY INFORMATION

As performing work on vehicle restraint systems can generally be considered highly hazardous, such activitiescan only be carried out under the supervision and guidance of properly trained specialists.

These installations should only be used under the supervision and guidance of these specialists.

Personnel performing the installation must wear personal protective equipment (PPE) in accordance with89/686/EWG as well as national guidelines.

PROPER USE

Crash cushions are intended to be used to stop and redirect vehicles that have veered off the road in order tominimise the impact on the passengers.

Please note: As a rule, vehicle restraint systems should only be erected in places where veering offthe road would be worse for the vehicle and its passengers as well as other protection-worthy people or objects than driving into the restraint system would be.

TECHNICAL DESCRIPTION OF THE VEHICLE RESTRAINT SYSTEM

Performance class in accordance with ÖNORM EN 1317-3

Restraint category 50

Impact severity class B

Redirection zone Z1

Permanent lateral displacement D1

System dimensions

System width 800 mm

System length 3114 mm

System height 660 mm


Page 5/22

TRANSPORT

When transporting components of the vehicle restraint system, the following factors must be observed:

· The load must be secured properly.

· When transporting components on streets covered in salt, they can only be transported in trucks with atarpaulin enclosed bed.

· Avoid contact with other aggressive transport goods (e.g. residual chemicals on the loading platform).

· Hoists must be designed for a maximum package load of 2.5 metric tonnes.

Please note: The load must also be properly secured when transporting tools used to install vehiclerestraint systems.

INSTALLATION REQUIREMENTS

The company performing the installation (= installation company) must be professionally competent in this areaand have the general qualifications necessary to perform such installation work.

The installation company must have the technical equipment required to perform installation workprofessionally and properly. In addition to the fleet of vehicles required for this work, this also includes piledriving devices designed for the necessary post length with driving heads and guides adapted accordingly aswell as drilling rigs, impact hammers, pilot shafts, measuring devices, etc.

The installation company must ensure that all national as well as international laws, guidelines, regulations, etc.,applicable to the installation work are adhered to and must check that the necessary permits have beenobtained in good time.

Before installation commences, the installation company must

· remove any existing installations in the anchoring area and take these installations into consideration asnecessary.

· check the suitability of the substrate (soil classification, sufficient driving depth, evenness, etc.).

· Draw the reference line guiding the installation of the vehicle restraint system.

· check deliveries of materials for accuracy and completeness and immediately inform the supplier of anydeficiencies.

· ensure that the construction site is properly secured.

When deviations are identified, the client must be immediately informed in writing and the issue must beclarified.


Page 6/22

If it is necessary to temporarily store components of a vehicle restraint system, the following storage conditionsmust be adhered to:

· The storage area must be supportive and stable and it must be possible to drive up a truck.

· Galvanised components cannot be stored in high, moist grass, in puddles or in mud.

· Packages in the supplied packing units must be stored at least 150 mm above the ground on woodenunderlays.

· Components must be stored on a surface with a slight gradient so that water can drain away.

· Puddle formation (water collection) should be avoided.

· Sheets used to prevent shifting during transport must be removed.

· The storage area cannot be treated with de-icing agents.

Components should not be stored outdoors for extended periods of time.

SUITABLE SUBSTRATE

The crash cushion can be anchored in asphalt as well as concrete.

The substrate is suitable for installation of the vehicle restraint system when the following conditions are met:

· The asphalt layers meet the requirements for street pavement.

· The total layer thickness of all incorporated asphalt layer thicknesses or the concrete thicknesses cannotbe less than 20 cm. This applies to an area corresponding to the contour of the CC according to Figure1 plus an all-round surcharge of at least 20 cm. For thinner layers, a specialised procedure must becoordinated with the manufacturer.

· The concrete strength amounts to at least C30/37.

· If the HEA 120 posts are driven into the substrate, it must be suitable for pile driving.A substrate is considered suitable for pile driving if the soil can be classified under soil classification 1,3, 4, and 5 of ÖNORM B2205, does not contain any boulders, and possesses a low stone percentageof <10 mass-% in accordance with ÖNORM EN ISO 14688-2.

· If the HEA 120 post is anchored in the concrete using a dowel, it must be reinforced to ensure it is ableto meet static demands and it must be possible to derive the characteristic forces.

· The required installation area must be designed taking into account the system conditions on a levelsurface.

· The maximum surface evenness in the anchoring area of the crash cushion should be 5 mm over a 0.50m rod metre.


Page 7/22

INSTALLING THE CRASH CUSHION IN ACCORDANCE WITH THE P50R01DATA SHEET, (SEE ANNEX)

It is not necessary to pre-assemble the components of the crash cushion in the factory.

As the vehicle barrier system is not pre-stressed, the ambient temperature at the time of installation is irrelevant.

1. Markings showing the location of the crash cushion

The middle axis of the crash cushion and the perpendicular axis of the two I120 absorbers (see Figure 1) mustbe marked on the installation surface.

The positioning of the crash cushion in the traffic zone and the continuation of any vehicle restraint systemsthat might be connected must be checked again.

2. Creating the backup

The crash cushion is generally supported by two I120 posts on the back end, the so-called “backup”.

There is generally a backup driven into the substrate. When the conditions on-site require it, the backup can beanchored with a dowel in concrete as an alternative.

Figure 1

Crashcushion –head

Crashcushion –backup

Middle axis of the crash cushion

Contour of the crash cushion


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2.1. Creating the pile driven backup

The asphalt layers and/or concrete pavement must have two core holes Ø163 mm with axes spaced 320 mmapart in accordance with Figure 2. The holes must be drilled vertical to the installation surface (see Figure 2).

A suitable piling driver should be used to drive two 2000 mm long l120 posts into the substrate vertical to theinstallation plan with axis spacing of 320 mm (160 mm to the middle axis) so far that the top edge of theabsorber is 660 ± 20 mm over the reference plan. The l120 posts must be positioned so their flanges arearranged in a line and vertical to the middle axis of the crash cushion. The holes in the l120 posts must bearranged as specified above and point toward the crash cushion (see Figures 2 to 4).

2.2. Creating the anchored backup

With this version, each of the two l120 posts is welded to a base plate via two support plates. The two I120support plate posts must be arranged as shown in Figure 5. They rest right up against each other without aspace. The support plates point away from the crash cushion.

Each base plate is anchored in the concretesubstrate using 5 TSM B16x190 concrete screwsin accordance with the TSM 190 data sheet (seeannex) and affixed using an anchor screw withone 40x18x4 washer and one M18 FK 8 nut foreach one. The drilling depth must be 130 ± 3mm.

The centres of the holes must align with thecentres of the 24 mm diameter holes in the baseplate and must run perpendicular. Using a drillstand with depth-control stop will ensure thateach hole is precise.

Figure 2 Figure 3

Figure 4

Figure 5

Middle axis of the crashcushion

Middle axis of the crashcushion


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3. Installation and anchoring of “Crash Cushion C100x60 sliding rails”

In order to determine the location of the holes used to anchor the sliding rails, the two 3000 mm long “crashcushion 100x60” sliding rails are temporarily connected using two installation aids. These set the necessarydistancing of 270 mm between sliding rails.

The sliding rails should be set out parallel to each other with the open side facing up and with flush ends, itshould be affixed in two positions (front, back) using installation aids. In order to do this, theTHB M16x30 is affixed from the inside through a side elongated hole and the 18 mm diameter holes areinserted into the legs of the installation aid and affixed with a 40x18x4 washer and M16 FK6 nut (see Figures 6and 7).

The middle of the installation aids (270/2 = 135 mm) mustthen be marked. The sliding rails attached to the installationaids with screws can now be placed in the middle over themarked middle axis of the crash cushion. The markings onthe installation aids must be located precisely over themarked middle axis of the crash cushion and the sliding railsshould be mounted on the l120 posts if possible (see Figures6 through 8).

It must be affixed in this position in order to be able to drill the anchoring holes for the sliding rails in thesubstrate with perfect accuracy.

Figure 8

Figure 6

Installation aid

Marking135 mm

Figure 7

270 mm

Assembly aid

Markings

Middle axisCrash

cushion


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Please note: The best method has been to first prepare each end of the sliding rails with two anchoring holesin accordance with Figure 9 and temporarily affix the sliding rails with four TSM A22 anchoringscrews inserted through the sliding rails and screwed halfway into the substrate.

The sliding rails can be anchored in asphalt as well as concrete.

The total layer depth of the asphalt layer thickness or concrete thickness on the surface where the installationis taking place must be at least 20 cm in order to offset the TSM A22x155 anchoring screws with a hole depthof 163 ± 3 mm.

The positions of the 6 holes with a diameter of 22 mm for each sliding rail with a hole depth of 163 ± 3 mm arevisible in Figure 9.

Once the holes have been drilled, the sliding rails and installation aids can be put to the side and the drillingresidue can be removed.

The holes must be blown off and the installation surface cleaned.

The 6 “TSM A 22x155 IM 16” asphalt screws per sliding rails are staggered in accordance with the “TSM A22x155” data sheet (see annex).

Ø ATA 2004C composite material must be used for anchoring in asphalt.

Ø CF-T410V composite material must be used for anchoring in concrete.

Make sure the asphalt screws are flush with the installation surface.

Sliding rails still attached using the installation aids must now be arranged in accordance with Figure 10 again.The 22 mm diameter holes on the bottom of the sliding rails must be located in the middle over the holes of theasphalt screws that have already been offset.

Before screwing in the sliding rails, the holes for the asphalt screws (M16 internal thread) must be cleaned!

Both sliding rails must be affixed to the asphalt anchors with 6 M16x35 FK 4.6 hexagon screws and 40x18x4washers each (see Figure 9).

The installation aids and screw connections must then be removed.

Figure 9

Middle axis of the crash cushion

22 mm diameter holes for the anchoring


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4. Installation of guides on the framework

One washer 22 (80x24x6) and three 40x18x4 washers are pushed onto each of the two THB M16x40 FK 6.8.The screws with the washer package are then inserted through the 18 mm diameter holes on the bottom of theframe and affixed with one 40x18x4 washer and M16 FK6 nut. When this is done, make sure the screw is centrallyaligned with the 80 washer.

The three 40x18x4 washers maintain the necessary distance between the frame and the 80x22x6 washer. InFigure 11, the frame puts the screws on their head for easy installation.

5. Installing the “crash cushion frame”

The three frames must be slid onto the sliding rails one after the other in such a way that the guides engagewith the sliding rails and the vertical sheets for connecting the absorbing elements point toward the head of thecrash cushion (see Figures 12 and 13).

Figure 10

Guides

Figure 11

Figure 12 Figure 13


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6. Installing the “crash cushion rail elements” of the sled

Two rail elements must be affixed to the sled at three points (seeFigure 14).

For this, six THB M16x40 FK 6.8 are inserted through the 18x30mm elongated holes in the sled, three 40x18x4 washers arepushed on, and then they are pushed through the 18 mmdiameter holes in the sled. Every screw is affixed with a 40x18x4screw and M16 FK 6 nut.

The tapers on the ends of the rail elements must point awayfrom the sled (see Figure 15).

7. Installing the “Crash cushion sled”

Slide the sled onto the sliding rails so that both rail elements engage with the sliding rails (see Figures 15 and16).

Rail elements

Sled

Figure 14

Figure 15 Figure 16


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Figure 17

8. Installing the absorber elements

The crash cushion consists of three segments (see Figure 17).

Only segments 2 and 3 are equipped with absorber components.


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8.1. Installing the absorber elements in Segment 3

Prior to installation, six absorption half-shells are screwed together loosely to form an “absorber package” asshown in Figure 18.

In order to accomplish this, two absorber half-shells are positioned as mirror images and attached on bothsides with another pair of absorber half-shells, each connected with two Hex bolt M16x50 FK 8.8 with a 40x18x4washer already pushed on as shown in Figure 19 and each affixed with one 40x18x4 washer and M16 FK 8hexagonal nut.

Two of these loosely attached “absorber packages” are required for Segment 3.

Two “absorber packages” are arranged symmetrically next to each other for each segment, installed betweenthe respective frame (see Figure 19).

In order to accomplish this, a40x18x4 washer is pushed onto theHex bolt M16x50 FK 8.8 and thenpushed through the empty 18 mmdiameter holes for the last absorberhalf-shell pair, through the 30x18mm elongated hole in the web plateof the frame, as well as through the18 mm diameter holes of the firstabsorber half-shell set in Segment 2and affixed with one 40x18x4 washerand one hexagonal M16 FK 8 nut.

Figure 18

Figure 19


Page 15/22

The back absorber half-shell sets are screwed directly into the frame in front of the backup. In order toaccomplish this, a 40x18x4 washer is pushed onto the Hex bolt M16x50 FK 8.8 and it is pushed through the30x18 mm elongated hole in the web plate of the frame, as well as through the 18 mm diameter holes of thefirst absorber half-shell set in the next segment and affixed with one 40x18x4 washer and one hexagonal M16FK 8 nut.

8.2. Installing the absorber elements in Segment 2

Installation of the absorber package for the second segment of the crash cushion, which consists of eightsymmetrically arranged absorber half-shells and four connections, must be performed in accordance with

Figure 20.

Two absorber half-shell pairs arranged next to each other are affixed one after the other to two individualabsorber half-shells with the convex side facing outward. The spacing of the absorber half-shells is defined by

the “DHS connections” that alsohave to be fastened between theabsorber half-shells.

In order to accomplish this, a40x18x4 washer is pushed ontoeach of the four Hex bolt M16x50FK 8.8 and then pushed throughthe 18 mm diameter absorber half-shell hole(s), the 20 mm diameterhole for the connection, and againthrough the 18 mm diameterabsorber half-shell hole, and eachis affixed with a washer 40x18x4and a hexagonal M16 FK 8hexagonal nut.

FRONT

BACK

Connection DHS

Figure 20

Figure 21


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The pre-assembled absorber package from Segment 2 is similarly screwed together with the absorber packagefrom Segment 3 as like Segment 3 was attached with the others (see Figure 21).

In order to screw the absorber package onto the web plate, 40x18x4 washers are placed on the four Hex boltM16x50 FK 8.8, which are then inserted through the 18 mm diameter holes of the absorber half-shells and theelongated 30x18 hole in the web plate of the frame and affixed with a 40x18x4 washer and M16 FK 8hexagonal nut.

9. Installing the “crash cushion anchorage insulator”

The precise location of the three frames between segments 2 and 3 is set by two anchorage insulators on eachside of the middle frame.

The top end of the anchorage insulator is affixed to the bottom of the frame and the bottom end is attachedto the outside of the sliding rail.In order to accomplish this, an THB M10x25 FK4.6 is inserted through the 12x30 elongated hole of theanchorage insulator and the 18 mm diameter hole on the inside of the frame and affixed with an 11 washerand M10 FK 4 hexagonal nut. AnTHB M16x30 FK 6.8 is inserted from the inside through the 36x18 mm outside oblong hole in the sliding railingand the 18 mm diameter hole in the anchorage insulator and affixed with a 40x18x4 washer and M16 FK6 nut(see Figures 22 and 23).

Make sure the locking device on the screw heads is correctly positioned in the elongated holes when tighteningthe screws on the anchorage insulator.

Please note: If the hole patterns used to screw on the anchorage insulator do not exactly align with the slidingrails due to assembly tolerances, the frame in question must be correctly positioned. It may alsobe helpful to further loosen the screw connections in the absorber elements.

Figure 22 Figure 23


Page 17/22

10.Tightening the screw connections of the absorber elements

Once the frame’s position has been fixed by tightening the screws on the anchorage insulator, all screws on theabsorber elements in segments 2 and 3 must be tightened.

11.Connecting the last frame with the I120 posts

The back frame is connected to each I120-post with two Hex boltsM16x160 FK8.8.

In order to achieve this, 40x18x4 washers are pushed onto the fourHex bolts and the screws are inserted through the 18x30 mm holes onthe top and bottom end of the two web plates of the frame andinserted into the I120 posts through the 24x36 elongated holesbehind and affixed with a washer 40x18x4 and M16 FK8 hexagonalnut (see Figure 24).

Please note: The frame can only be tightened onto the I post withenough tension that the vertical sheets of the frameare not bent and it can no longer be loosened byhand.

12.Installing the “crash cushion LS.S2A end pieces”

Two LS.S2A end pieces are screwed onto the backframe, which is already connected to the I120 absorber,on both sides.

To this end, one THB M16x35 FK4.6 is pushed througheach 20 mm diameter hole in the middle axis of the endpieces, such that the screw head fits closely to the axleradius. Two 40x18x4 washers must also be pushed ontoeach of the screws. Only then will the screws be insertedinto the 18 mm diameter holes positioned on the side ofthe frame and affixed on the inside with one 40x18x4washer and one M16 FK6 hexagonal nut each.

The middle axis of the end pieces must be horizontaland the 18 mm diameter holes must be located on theedge of the end pieces (see Figure 25).

Please note: If another vehicle restraint system is attached to the crash cushion, therespective “vehicle restraint system end piece” must be replaced by a “crash cushion LS.S2A”guide rail in accordance with the “CC<>VRS” data sheet.

Figure 24

Figure 25 Figure 26


Page 18/22

13.Installing the “crash cushion LS.S2A” guide rails in Segment 3

Two LS.S2A should be positioned on each side, such that the 20 mm diameter hole in the middle axis of theLS.S2A is covered by the 18 mm diameter hole on the side of the frame and the elongated holes are positionedover the 18 mm diameter holes in the edge of the end pieces (see Figures 26 to 28).

To this end, one THB M16x35 FK4.6 is pushed through each 20 mm diameter hole in the middle axis, such thatthe screw head fits closely to the axle radius. Two 40x18x4 washers must also be pushed on. Only then will thescrews be inserted into the 18 mm diameter holes positioned on the side of the frame and affixed on the insidewith one 40x18x4 washer and one M16 FK6 hexagonal nut each.

The back end of the LS.S2A is affixed to the end pieces with two THB M16x35 FK4.6.

Before this is done, a 20 washer (60x22x4) is pushed onto each of the THB M16x35 FK4.6 and an 11 mm spaceris pushed on. The screw is then inserted into the end pieces through the elongated hole of the LS.S2A and the18 mm diameter hole and affixed with a 40x18x4 washer and M16 FK6 hexagonal screw (see Figures 26 to 31).The jacket rests in the elongated hole.

Figure 27 Figure 28

Figure 29 Figure 30 Figure 31


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14.Installing the “crash cushion LS.S2a” guide rails in segments 2 to 1

When installing from back to front, the screws of the LS.S2A shouldbe fastened in a configuration analogous to Segment 3 (seeFigures 27 to 35).

The only difference is that in segments 2 to 1, the elongated holesin the guide rail edges do not rest on the end pieces, but rathermust be be covered by the 18 mm diameter holes in the edges ofthe installed LS.S2A (see Figure 32).

Please note: It is important to make sure that the 11 mmspacer is positioned in the elongated hole of theguide rail and is not pinched (see Figure 34).

The four LS.S2A in the first segment must be screwed onto the sledtogether with the head pieces. Figure 32

Figure 33 Figure 34


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15.Installing the “crash cushion LS.S2A heads”

The two head pieces form the front cap of the overlapping guide rail strips. Here it is important that theelongated LS.S2A properly overlaps. The guide rail ends of the head pieces must always be on the outside.

Every head piece is screwed onto the sled in the middle axis with four THB M16x55 FK4.6 (see Figures 36 and37).

To this end, the back THB M16x55 FK4.6 is inserted through the 20x26 mm elongated hole on the end of thehead pieces, the 20 mm diameter holes in the respective LS.S2A, and 18 mm diameter holes on the side of thesled and affixed on the inside with a 40x18x4 washer and M16 FK6 hexagonal nut.

Figure 35

Figure 36 Figure 37


Page 21/22

The front THB M16x55 FK4.6 are first inserted through the 20x26 mm elongated hole at the bend in the headpieces as well as the 18 mm diameter holes in the sled and affixed on the inside with a 40x18x4 washer andM16 FK6 hexagonal nut.

Please note: It is important to ensure that the head pieces screwed onto the sled are centred andsymmetrical (see Fig. 37).

16.Torques of the threaded connections

Please note: When tightening the screw connections that are not pretensioned in accordance withthe plan in the range of the torques given above, make sure that everything is even in thetightening zone.

17.Monitoring conformity

The following checks must be performed continuously during installation and at final inspection:

· Proper arrangement and bolting of the components

· Proper positioning of the spacer to avoid clamping the guide rails.

· Proper component overlap

· Symmetrical arrangement of the components

When deviations are seen outside of the permissible tolerances, corrective action must be taken accordingly.

Once installation work is completed, an inspection must be performed to ensure proper installation in keepingwith the installation instructions and approval must be issued and documented in the acceptance protocol.

18.Clearing the construction site

All left over materials (even fasteners), packaging materials and wooden underlays, screw storage bins, sheets,packaging straps, etc., as well as any other waste, must be removed.

The construction site must be left well-swept.

Thread / Strength class Torques

min. max.

M10 / 4.6 10 Nm 17 Nm

M16 / 4.6 35 Nm 70 Nm

M16 / 6.8 35 Nm 150 Nm

M16 / 8.8 35 Nm 210 Nm

M18 / 8.8 80 Nm 330 Nm


Page 22/22

REPAIRS TO THE VEHICLE RESTRAINT SYSTEM

All components showing mechanical damage or deformation following an accident must be replaced with newcomponents. These components must be installed in accordance with the installation instructions.

New fasteners generally must be used when repairing a vehicle restraint system.

DURABILITY OF THE CORROSION PROTECTION

In order to achieve a durability / protection period in accordance with EN ISO 1461, components in the vehiclerestraint system are galvanised.

The protection period for zinc coatings is defined in EN ISO 14713 and primarily depends on the thickness ofthe coating. It can generally be assumed that the zinc wears off in layers. Due to the macroclimatic corrosionload falling in Corrosion Category C4 known to exist on roads, it can be expected that the zinc will wear off ata rate of 2.1 to 4.2 µm per year. Based on these numbers, a medium zinc coating thickness of at least 70 µm inkeeping with EN ISO 1461 will provide protection for at least 15 years.

Please note: The protection period calculated using the above method is only valid for corrosionloads under macroclimatic conditions. Microclimatic peculiarities may decrease theprotection period.

INSPECTION AND MAINTENANCE

Voestalpine Krems Finaltechnik GmbH vehicle restraint systems generally do not require maintenance.

A visual inspection of the vehicle restraint system should be performed during the regular inspection drives ofthe entity maintaining the road, but should be performed at least once each year and preferably after winterhas ended. During these inspections, personnel should look for deformed components and check that thefasteners are screwed in properly. The rail system must be kept free of dirt and soiling that could negativelyimpact the proper function of the system.

RECYCLING/DISPOSAL

Dismantled vehicle restraint systems or components replaced when repairs are made should be disposed of inaccordance with legal requirements and recycled. The components of voestalpine Krems Finaltechnik GmbHvehicle restraint systems are 100% recyclable.

Packing materials and other waste must be recycled or disposed of in accordance with legal requirements.

Toxic or hazardous materials are not used in voestalpine Krems Finaltechnik GmbH vehicle restraint systems.

756±10 756±10 756±10570±5

600±5

66

0±2

0

700±5 700±5 700±5350±565±5

135±5

647±5 756±10 756±10 756±10

27

0±

4

32

0±2

0

60

0±2

0

~8

00

±2

0

3114±80

A

A

77

4±5

600±5

66

0±2

0

65

2±

203

42±

10

370±5

800±20


voestalpineONE STEP AHEAD.06/2020

Section: A-A

Side View

Ground ViewAbsorber half shell.S130-001.1360D

30-100.2727DIBL120-post 2,00m

CC rail elements30-400.3020D

CC LS.S2A30-400.4010

CC LS.S2A30-400.4010D

30-400.4010DCC LS.S2SA

CC LS.S2A head30-400.4020D

CC C100x60x3000 rail30-400.2030C

CC sled30-400.3010B

CC frame30-400.3030B

CC frame30-400.3030

CC anchorade insulator30-400.3040D

Anchor TSM A22x155 IM16

Absorber half shell.S130.001.1360D

30-400.3030BCC frame

THB M16X35-4.6 +nut30-005.0991E

THB M16x40-6.8 with nose +nut30-001.0990E


THB M10x25-4.6 +nutDIN603

THB M16X55-4.6 +nut30-005.0991E

Washer 40x18x430-101.0995E

Washer 11ISO 7091

3 piece Washer 40x18x430-101.0995E

Washer 40x18x430-101.0995E

Spacer 11mm30-001.4088Washer 40x18x430-101.0995E

Washer 80x24x6

4 pieces Washer 40x18x430-101.0995E

Washer 60x22x4

2 pieces / frame

1 piece / C100x60x3000 rail

8 pieces / sled

4 pieces / frame

2 pieces / stack

TOGEHex bolt M16x35-4.6 +Mu

ISO 4018Washer 40x18x4

30-101.0995E

CC LS.S2A end piece30-400.4030D

CC Connection AHS30-400.1360D

Hex bolt M16x50-8.8 +nutISO 40182 piece Washer 40x18x430-101.0995E2 pieces / Connection absorber2 pieces / Connection frame


Hex bolt M16x160-8.8 +nut

Hex bolt M16x160-8.8 +nutISO 40142 pieces Washer 40x18x430-101.0995E2 pieces / IBL120-post

If additional VRS are connected to the CC, the respective “CC end piece” must be replaced bya “CC LS.S2A” guardrail in accordance with data sheet “CC <> VRS”.

ISO4014

Data Sheet P50R01

CC pile driven Backup

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756±10 756±10 756±10570±5

600±5

66

0±2

0

700±5 700±5 700±5350±565±5

647±5 756±10 756±10 756±10

27

0±4

3500±80

A

A

77

4±5

32

0±2

0

64

0±2

0

~8

00±

20

325±5 260±5

210±5

600±5

66

0±2

0

65

2±

203

42±

10

370±5

800±20



Section: A-A

Side View

Ground ViewAbsorber half shell.S130-001.1360D

30-400.2727CCC anchored Backup

CC rail elements30-400.3020D

CC LS.S2A30-400.4010

CC LS.S2A30-400.4010D

30-400.4010DCC LS.S2SA

CC LS.S2A head30-400.4020D

CC C100x60x3000 rail30-400.2030C

CC sled30-400.3010B

CC frame30-400.3030B

CC frame30-400.3030

CC anchorage insulator30-400.3040D

Anchor TSM A22x155 IM16

Absorber half shell.S130.001.1360D

30-400.3030BCC frame

THB M16X35-4.6 +nut30-005.0991E



THB M10x25-4.6 +nutDIN603

THB M16X55-4.6 +nut30-005.0991E

Washer 40x18x430-101.0995E

Washer 11ISO 7091

3 piece Washer 40x18x430-101.0995E

Washer 40x18x430-101.0995E

Spacer 11mm30-001.4088Washer 40x18x430-101.0995E

Washer 80x24x6

4 pieces Washer 40x18x430-101.0995E

Washer 60x22x4

2 pieces / frame

1 piece / C100x60x3000 rail

8 pieces / sled

4 pieces / frame

2 pieces / stack

TOGEHex bolt M16x35-4.6 +Mu

ISO 4018Washer 40x18x4

30-101.0995E

CC LS.S2A end piece30-400.4030D

CC connection AHS30-400.1360D

Hex bolt M16x50-8.8 +nutISO 40182 piece Washer 40x18x430-101.0995E2 pieces / connection absorber2 pieces / connection frame


ISO 4014Hex bolt M16x160-8.8 +nut

Hex bolt M16x160-8.8 +nutISO 40142 pieces Washer 40x18x430-101.0995E2 pieces / CC anchored Backup

Data Sheet P50R01

If additional VRS are connected to the CC, the respective “CC end piece” must be replaced bya “CC LS.S2A” guardrail in accordance with data sheet “CC <> VRS”.

CC Anchored Backup

Anchor TSM A22x155 IM16TOGEhex nut M18-8ISO 4032Washer 40x18x430-001.0995E5 pieces / CC anchored Backup

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1266

Crash Cushion

1266

Crash Cushion

ma

x. 4

50

Connection VRS < > CC ~2263 Continuing system

Connection VRS < > CC ~2263 Continuing system ma

x. 4

50m

ax.

450


KREMSBARRIER APD P50, 80, 100 RLConnection of Vehicle Restraint Systems to

Data Sheet CC pile driven Backup <> VRS

30-100.2727DIBL120-posts 2,00m

30-400.4040DConnector VRS CC

30-105.4240DLS.S2A < concrete 1,90m OT

30-001.0995EWasher 40x18x4

ISO 4018Hex bolt M16x45-8.8+Mu

12 pieces / Connector VRS CC


30-001.0995EWasher 40x18x4

ISO 4018Hex bolt M16x45-8.8+nut



Hex bolt M16x160-8.8 +nutISO 40141 piece / Connector VRS CC


30-001.0995EWasher 40x18x4





30-001.0995EWasher 40x18x4





30-105.2715DC100x60-post 1,70m

30-105.1350Dretaining bracket S2A

30-400.4010DCC LS.S2A

Connection to Vehicle Restraint System one-sided and double-sided

Instead of the respectiveCC LS.S2A end piece an CC LS.S2A

is to be screwed to the CC

Presentation one-sided

THB M16x40-6.8 with nose +nut30-001.0990EWasher 40x18x430-101.0995EWasher 60x22x42 pieces / CC LS.S2Amake the 2 holes Ø18 on site

Presentation double-sided


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1266

1266

ma

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Connection VRS ~1878 Continuing VRSCrash Cushion

Connection VRS ~1878 Continuing VRS

Crash Cushion

ma

x. 4

50m

ax.

450


KREMSBARRIER APD P50, 80, 100 RLConnection of Vehicle Restraint System to

Data Sheet CC anchored Backup <> VRS

KREMSBARRIER APD P50, 80, 100 RL

Connection to Vehicle Restraint System one-sided and double-sided

Presentation one-sided

Presentation double-sided

30-400.2727DCC anchored Backup



30-001.0995EWasher 40x18x4




30-001.0995EWasher 40x18x4






30-001.0995EWasher 40x18x4





30-001.0995EWasher 40x18x4





30-105.2715DC100x60-post 1,70m

30-400.4010DCC LS.S2A

Instead of the respectiveCC LS.S2A end piece an CC LS.S2A

is to be screwed to the CCTHB M16x40-6.8 with nose +nut30-001.0990EWasher 40x18x430-101.0995EWasher 60x22x42 pieces / CC LS.S2Amake the 2 holes Ø18 on site


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Data Sheet TSM A22x155

ASPHALT ANCHOR TSM A22 x 155

1.Drilling bore holeThe holes are normal to the mounting surface.

- drill diameter 22mm- drill depth 163 ± 3mm- controlling the drilling depth- to clean the bore hole

Details: The use of a drill rig with a depth stop ensuresaccurate production drilling

2. Placing the anchorInject composite adhesive compound

- ATA 2004C for anchoring in asphalt- CFT 410V for anchoring in concrete

screw in the concrete screw up to the collar.Remove redundant compound mass.One cartridge lasts for about 33 pc. asphalt anchors.It is mandatory to follow the guidelines stated on the cartridge.

Details: Contribute to the mass of the composite is a specialrequired to press the cartridge matched.

drill diameter 22mm

dril

l de

pth

163

±3

mm

hexagon socket 12mm

anc

hor

len

ght

155

mm

drilling bore hole inject the compundmass

screw the asphaltanchor

composite adhesive compound

Installation Instruction


01/2015

product specification sheet TSM 190

CONCRETE ANCHOR TSM B16 x 190

1. Drilling bore holeThe holes are normal to the mounting surface.

- drill diameter 16mm- drill depth 130 ± 3mm- controlling the drilling depth- to clean the drill hole

Details: The use of a drill rig with a depth stop ensuresaccurate production drilling.

2. Placing the anchorInject composite adhesive compound (Chemofast) into the drill hole. Turn in screw to a depth of 130 mm, using animpact driver until the compound mass oozes out of the drill hole.Remove redundant compound massOne cartridge lasts for about 33 pc. concrete anchors.

It is mandatory to follow the guidelines stated on the cartridge.

Details: Contribute to the mass of the composite is a specialrequired to press the cartridge matched.

concrete anchorTSM B16 x 190

drill diameter 16mm

dril

ling

dep

th1

30

±3

mm

SW 13mm

anc

hor

leng

th 1

90

mm

drilling bore hole inject thecompound mass

screw the concreteanchor

composite adhesivecompound

Installation instruction


Parts List Page 1 / 2


Performance class 50 crash cushion

anchoring in asphalt and concrete

Need for crash cushion KB APD P50 RL

Piece Component designation Weight [kg]Designation

numberMaterial /

QualityCorrosion protection

2 CC rail elements 3,11 30-400.3020D S355JO

12 CC LS.S2A 9,82 30-400.4010D S355JO

2 CC LS.S2A head 24,32 30-400.4020D S355JO

2 CC C100x60x3000 rail 23,20 30-400.2030C S355JO

1 CC sled 38,20 30-400.3010B S355JO

3 CC frame 15,40 30-400.3030B S355JO

2 CC anchorage insulator 1,15 30-400.3040D S355JO

20 Absorber half shell.S1 3,51 30-001.1360D S355JO

2 CC installation aid 0,72 30-400.2020D S355JO

4 CC LS.S2A end piece 1,57 30-400.4030D S355JO

4 CC connection AHS 0,75 30-400.1360D S355JO

2 IBL120 post 2.00 m BE 41,39 30-100.2727D S235JR

Connector

6 THB M16x30-6.8 with nose +nut 0,11 30-100.0990E 6.8

36 THB M16x40-6.8 with nose +nut 0,13 30-100.0990E 6.8

198 Washer 40x18x4 0,03 30-001.0995E 100HV

24 Spacer 11 mm 0,02 30-001.4088E S235JR

16 THB M16X35-4.6 +nut 0,14 30-005.0991E 4.6

8 THB M16X55-4.6 +nut 0,17 30-005.0991E 4.6

2 THB M10x25-4.6 +nut 0,04 DIN 603 4.6

2 Washer 11 0,00 ISO 7091 100HV

28 Hex bolt M16x50-8.8 +nut 0,14 ISO 4018 8.8

4 Hex bolt M16x160-8.8 +nut 0,28 ISO 4014 8.8

6 Washer 22 (80x24x6) 0,22 ISO 7094 100HV

24 Washer 20 (60x22x4) 0,08 ISO 7093-2 100HV06/2020

in a

cco

rda

nce

wit

h EN

ISO

14

61

in a

cco

rda

nce

wit

h EN

ISO

10

68

4


Parts List Page 2 / 2


Performance class 50 crash cushion

anchoring in asphalt and concrete

Anchoring system I+II

12 Anchor TSM A22x155 IM16 0,35 TOGE 8.8 TOGE-KORR

12 Washer 40x18x4 0,03 30-001.0995E 100HV

12 Hex bolt M16x35-4.6 +Mu 0,12 ISO 4018 4.6

Anchoring system III

12 Anchor TSM A22x155 IM16 0,35 TOGE 8.8 TOGE-KORR

12 Washer 40x18x4 0,03 30-001.0995E 100HV

12 Hex bolt M16x35-4.6 +Mu 0,12 ISO 4018 4.6

10 Anchor TSM B16 M18x190 0,27 TOGE 10.9 TOGE-KORR

10 hex nut M18-8 0,04 ISO 4032 8.8

10 Washer 40x18x4 0,03 30-001.0995E 100HV06/2020

in accordance with EN ISO 10684



INSTALLATION INSTRUCTIONS - Voestalpine

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