Professional Documents
Culture Documents
Nu-Guard® 31
Roadside and Median
Guardrail System
Table of Contents
NU-GUARD® 31 Introduction……………..……..…………………….. 3
System Overview…...……………………........................... 3
Limitations and Warnings……….………........................... 4
Before Installation……….………………............................ 4
Safety Statements………………………………………....... 4
Limited Warranty………...…………..…………..…………………….... 5
Geotechnical Warning..….…………..………..………………………... 5
Design Considerations……………………………..…………………… 6
System Design……….……………………………..…………………… 7
Parts Identification………….…………………….……………………… 10
Installation Preparation...….…..……………………………………….. 12
Roadside Installation Instructions……………..……………………..... 14
Median Installation Instructions……..…………………………………. 17
Installation Examples……………………………..…………………… 20
Installation Checklist.……………………...…………………………… 21
Maintenance & Repair…..………………………....………………….. 22
Frequently Asked Questions …………………………………………. 24
Introduction
NU-GUARD® 31 roadside is a w-beam guardrail barrier comprising of unique ‘U’ shaped steel
posts. The posts are driven, which allows for quick installation, and connect to w-beam
guardrail panels on one side in the traditional manner at a height of 31” (787mm).
The barrier has been designed and tested to meet the evaluation criteria of NCHRP 350 Test
Level 4 (TL-4) & MASH (TL-3) for a longitudinal barrier.
It is recommended that the ‘roadside’ NU-GUARD® 31 barrier is anchored using a single sided
X-350 terminal end which is accepted to NCHRP 350 TL-3.
System Overview
NU-GUARD® 31 roadside barrier is designed and constructed to provide acceptable structural
adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 & MASH for
longitudinal barriers.
When impacted with an 820kg, 2270kg and 8000kg vehicle at speeds of up to 100kph and
side on entry angles up to 25 degrees, the impacting vehicle is re-directed in a safe manner.
NU-GUARD® 31 median is a w-beam guardrail barrier comprising of unique ‘U’ shaped steel
posts. The posts are driven, which allows for quick installation, and connect to w-beam
guardrail panels on both sides in the traditional manner at a height of 31” (787mm).
The barrier has been designed and tested to meet the evaluation criteria of NCHRP 350 Test
Level 4 (TL-4) & MASH (TL-3) for a longitudinal barrier.
System Overview
NU-GUARD® 31 median barrier is designed and constructed to provide acceptable structural
adequacy, minimal occupant risk and safe trajectory as set forth in NCHRP 350 & MASH for
longitudinal barriers.
When impacted with an 820kg, 2270kg and 8000kg vehicle at speeds of up to 100kph and
side on entry angles up to 25 degrees, the impacting vehicle is re-directed in a safe manner.
NU-GUARD® 31 barriers have been rigorously tested and evaluated per the evaluation criteria
in the NCHRP 350 & MASH guidelines for longitudinal barriers. The impact conditions
recommended in NCHRP 350 & MASH are intended to address typical in-service collisions.
NU-GUARD® 31 barriers allow an impacting vehicle to be re-directed in a safe and predictable
manner under the NCHRP 350 & MASH impact conditions. It is imperative that the system is
installed as per manufacturers’ specification.
Vehicle impacts that vary from the NCHRP 350 & MASH impact conditions described for
longitudinal barriers may result in significantly different results than those experienced in
testing. Vehicle impact characteristics different than, or in excess of, those encountered in
NCHRP 350 testing & MASH (weight, speed and angle) may result in system performance that
may not meet these evaluation criteria’s.
Before Installation
Design, selection and placement of NU-GUARD® 31 must be in accordance with the Road
Controlling Authority guidelines and the details shown in the construction drawings. Installation
must be in accordance with the installation instructions supplied for this product.
Note: Alternative installations techniques will need to be used if soil conditions on site do not
meet the required level described in the manual.
NU-GUARD® 31 is a highly engineered safety device made up of a small number of parts.
Before starting installation ensure that one is familiar with the make-up of the systems.
Safety Statements
General Safety
• All required traffic safety precautions should be complied with. All workers should
wear required safety clothing (Examples, and not limited to, include: high visibility
vests, steel capped footwear, gloves etc.)
• Only authorised trained personnel should operate any machinery. Where overhead
machinery is used, care must be taken to avoid any overhead hazards.
• Before installing the posts, always ensure that the area is clear of underground
services. (The appropriate service providers may need to be contacted)
NU-GUARD® 31 Safety Statements
• All installers must be well clear of machinery when posts are being driven.
• The posts (15kg) and fixings are easily lifted and positioned by hand. While a
highway rail panel (47kg approx.) should be moved and positioned by two
personnel and care should be taken not to have fingers near the bolt holes while
being manoeuvred.
Limited Warranty
CSP Pacific has tested the impact performance of its barriers and crash cushion systems, and other
highway safety hardware under controlled conditions. CSP PACIFIC does not represent nor warrant to
the buyer (or any other person) that the Products and Parts as tested will necessarily avoid injury to
persons or property. The use of the products and Parts is at the Buyer’s sole risk.
CSP PACIFIC EXPRESSLY DISCLAIMS ALL LIABILITY FOR CLAIMS OF ANY NATURE WHATSOEVER ARISING BY
REASON OF DEATH OR PERSONAL INJURY OR DAMAGE TO PROPERTY RESULTING FROM ANY IMPACT,
COLLISION OR HARMFUL CONTACT WITH OR USE OF THE PRODUCTS OR PARTS OR NEARBY HAZARDS OR
OBJECTS BY ANY VEHICLE, OBJECTS OR PERSONS.
CSP PACIFIC warrants solely that any product or component part manufactured by CSP PACIFIC will be
free from defects in material or workmanship.
THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER REPRESENTAIONS AND WARRANTIES
NOT EXPRESSLY SET FORTH HEREIN, WHETHER EXPRESS OR IMPLIED BY OPERATION OF LAW OR OTHERWISE,
INCLUDING BUT NOT LIMITED TO ANY IMPLIED REPRESENTATIONS OR WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE. CSP PACIFIC’S LIABILITY UNDER THE FOREGOING
WARRANTY IS EXPRESSLY LIMITED IN ALL RESPECTS AND AT AIL’S SOLE ELECTION TO:
A. THE REPLACEMENT FREE OF COST OF THE DEFECTIVE CSP PACIFIC PRODUCT OR PART
SUPPLIED BY CSP PACIFIC ONLY (IN THE FORM AND THE TERMS ORIGINALLY SHIPPED).
B. THE REPAIR OF THE DEFECTIVE CSP PACIFIC PRODUCT OR PART TO REMEDY ANY DEFECTS IN THE
MATERIAL OR WORKMANSHIP.
C. THE PAYMENT OF AN AMOUNT EQUAL TO THE ORIGINAL PURCHASE PRICE OF THE DEFECTIVE CSP
PACIFIC PRODUCT OR PART.
CSP PACIFIC SHALL NOT OTHERWISE BE LIABLE TO THE BUYER (OR ANY OTHER PARTY) FOR BREACH OF
WARRANTY, NEGLIGENCE OR ANY OTHER RESPECT WHATSOEVER. WITHOUT LIMITATION, CSP PACIFIC SHALL
NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL LOSSES, DAMAGES OR EXPENSES OF ANY
KIND, INCLUDING, WITHOUT LIMITATION, ANY SUCH LOSSES, DAMAGES OR EXPENSES ARISING DIRECTLY OR
INDIRECTLY FROM THE SALE, HANDLING OR USE OF THE PRODUCTS AND PARTS OR FROM ANY OTHER CAUSE
RELATING THERETO, OR FROM PERSONAL INJURY OR LOSS OF PROFIT SUSTAINED IN RESPECT THEREOF.
Any claim by the Buyer with reference to CSP PACIFIC Products or Parts sold hereunder for any cause shall be
deemed waived by the Buyer unless CSP PACIFIC is notified in writing, in the case of defects apparent on visual
inspection, within ninety (90) days from the delivery date, or, in the case of defects not apparent on visual inspection,
within twelve (12) months from the delivery date. CSP PACIFIC Products and Parts claimed to be defective in material
or workmanship under the foregoing warranty may be returned prepaid to CSP PACIFIC’s plant for inspection in
accordance with return shipping instructions that CSP PACIFIC shall furnish to the Buyer forthwith upon receipt of
the Buyer’s notice of claim. If the claim is established, CSP PACIFIC will reimburse that Buyer for all carriage costs
incurred hereunder.
The forgoing warranty benefits shall not apply to (i) any Products or Parts that have been subject to improper
storage, accident, misuse or unauthorised alterations, or that have not been installed, operated and maintained in
accordance with approved procedures and (ii) any Products or Parts manufactured or supplied by any party other
than CSP PACIFIC (Including the Buyer).
Geotechnical Warning
NU-GUARD® 31 posts require sufficient strength from the supporting soil to function as
required and remain at the correct height.
If it is determined that soil conditions on site do not meet these requirements, alternative
installation options will need to considered. For further details contact CSP Pacific.
Design Considerations
Curves
NU-GUARD® 31 can accommodate curved w-beam guardrails panels like other guardrails
systems if conditions on site require.
For radii below 25m the Nu-Guard® 31 must be anchored at the start and the end of the curve
by using an intermediate anchor and/or a trailing terminal end. There should be no bolts
holding the rail at the apex of the curve with the rail instead sitting on a shelf angle. For further
details refer to drawings FX566-1 and FX636 in the appendix of this manual.
Slopes
Curbs
As with all road side safety hardware, NU-GUARD® 31 has been designed and tested so that
the centre of gravity of the impacting vehicle is at a constant height in relation to the barrier.
For this reason, it is preferred that curbs or channels are not installed in front of the barrier as
they will result in altering the height of the vehicle at impact. If there is no option but to install a
curb or if it is already present consult Road Controlling Authority guidelines re curb height and
design, and barrier offset distance.
Site specific grading may be necessary to ensure that there are no ‘humps’ or ‘hollows’ that
may significantly alter the impacting vehicles stability or substantially alter the barrier height in
relation to the ground.
Ditches
If the slope of the ditch is greater than 10:1 then follow the Road Controlling Authority’s
guidelines.
System Design
Roadside and Median Applications
NU-GUARD® 31 can be used in both roadside and median applications. The single sided
system is to be used on the edge of road, while the ‘back to back system, is required in a
median situation.
Transitions
To connect NU-GUARD® 31 systems to other types of barriers or terminal ends consult the
transition drawings contained in the Technical Drawing Appendix of this manual. If the situation
is not covered in these drawings contact CSP Pacific for advice.
The Length of Need (LoN) of NU-GUARD® 31 system is dependent on the terminal end used
to anchor the barrier as all LoN’s are contained within the terminal end itself.
Note: As per the LoN design section of the Road Controlling Authority’s guidelines, care must
be taken when calculating the actual length of barrier versus the theoretical length of the LoN.
NU-GUARD® 31 when connected at either end to an X-350 end terminal creates a fully re-
directive barrier, and therefore the actual length of the barrier is the same as the theoretical
length of the LoN. The use of ‘other’ terminal ends may require addition length of barrier
‘upstream’ and ‘downstream’ of the LoN to achieve the same protection.
Deflections
Deflection measurements from actual crash testing can be useful when assessing a products
suitability to perform as required at a given location. The below distance measurements are
from NCHRP 350 and MASH compliance testing on the ‘roadside’ and ‘median’ systems
respectively.
Note: The MASH pickup truck has the highest impact severity of all the tests results below.
Test 3-11: 2270kg pickup truck, 25 degree angle at 100kph (MASH TL-3)
Test 4-12: 8000kg truck, 15 degree angle at 80kph (NCHRP 350 TL-4)
Note: If tests 3-11 and 4-12 were run on the back to back NU-GUARD® 31 ‘median’ system,
the deflection results would be expected to be lower than those listed above.
Figure A Figure B
If the soil conditions do not meet these specifications CSP Pacific recommends either a
minimum of 600mm between the post and the hinge batter point (shown in Figure B) or an
alternate installation method is used. For further information contact CSP Pacific.
A site specific project approval must be granted by NZ Transport Agency National Office to
have NU-GUARD® 31 located less than 600mm to the batter hinge point.
Soil Conditions
For NU-GUARD® 31 to perform as intended and remain at the correct height it must be
installed in soil conditions that have sufficient strength to support the posts as required. A
push/pull test to check the post installation strength should be done at 12kN applied at a height
of 635 mm. The yield displacement should not exceed 140mm for a BHP at 200 mm, 100mm
for a BHP at 400 mm, and 75 mm for a BHP at 600 mm. These results are not to be used
as substitutes for the necessary soil testing (classification and compaction). Soil
conditions should meet the requirements of AS/NZS 3845.1:2015, Specification TNZ B/2 -
Construction of unbound granular pavement layers and TNZ M/4 - Basecourse aggregate.
Accessories
Bill of Materials
‘Roadside’ Barrier
For every linear 3.81m of barrier the following components are required:
‘Median’ Barrier
For every linear 3.81m of barrier the following components are required:
NB: Above descriptions are only for calculating total amount of components required.
Installation Preparation
Getting Started
NU-GUARD® 31 barriers have virtually the same components and barrier setup for the
‘roadside’ or ‘median’ systems. For all installations, whether edge of road or median locations,
start from the last post of the adjacent system. NU-GUARD® 31 post spacing between the
systems for a standard installation is 1.905m.
Preparation
Before installing NU-GUARD® 31, ensure that all components required for the system are on
site and have been identified. NU-GUARD® 31 is a highly engineered safety device made up
of small number of parts. Before starting installation ensure that one is familiar with the make
up of the system. Refer to the Parts Identification and Bill of Materials section in this manual
for more information.
Ensure that the area where NU-GUARD® 31 is to be installed is flat enough so that the ground
conditions will not significantly alter the height of the vehicle in relation to the height of the w-
beam guardrail panels.
Soil Conditions
NU-GUARD® 31 can be installed in ‘Roadside’ and ‘Median’ locations where soil conditions
that exist are essentially a fully compacted sub-base. Refer to the Soil Conditions section in
this manual for more information.
It is recommended that soil tests are carried out at the location the NU-GUARD® 31 is to be
installed.
IF SOIL CONDITIONS ON SITE DO NOT MEET OR EXCEED THE REQUIRED STRENGTH
DETAILED IN THIS MANUAL DO NOT INSTALL THE SYSTEM. CONTACT CSP PACIFIC FOR
FURTHER ADVICE.
Tools Required
The top of the hole can also be filled with a topping asphalt with a maximum depth of 75mm. If
the depth of the hole is greater than 75mm then a suitable compacted fill such as GAP20
should be used to bring the surface to the correct height before applying the asphalt. The
same applies for a median installation except the NU-GUARD® 31 post is placed centrally in
the 450mm x 450mm hole in the hard surface.
Installation Instructions
‘Roadside’ Application
It is preferred that NU-GUARD® 31 is installed on flat, level ground with sufficient distance
behind the posts as described in the Batter Hinge Point section. The barrier itself must be
connected (anchored) at either end to either an approved terminal end, transition section or w-
beam guardrail in order to perform as designed and tested.
Post spacing is 1.905m, further details will be shown in the construction drawings on how to
mark the appropriate locations at which the posts are to be installed.
Before driving posts, always ensure that the posts are clear of underground services.
Note: During the construction period NU-GUARD® 31 should be installed in a way so that the
exposed end of the w-beam guardrail is located at the ‘downstream’ end, and not dangerous to
other road users. Protective techniques commonly used when installing ‘other’ types of w-
beam guardrail can also be used for NU-GUARD® 31.
Note: If the conditions on site don’t allow for the posts to be driven, contact CSP Pacific for
alternative accepted installation methods.
Step 3 – Joining the W-Beam Guardrail Panels
The centre of the guardrail is 635mm above the nominal ground line. Lap the w-beam
guardrail panels on the side of the posts with the direction of the laps the same as the
direction of the traffic flow. (shown in Figures 4 & 5)
Each ‘splice joint’ requires the w-beam guardrail panels to be joined using 8 splice bolts and
tightened with a wrench or socket. (An impact wrench is optional)
Figure 4 Figure 5
Once the w-beam guardrail panels have been joined together on the traffic side of the posts
they can be attached to the post.
Insert the 90mm M16 coach bolt through from the face of the guardrail with the 90mm
diameter round washer positioned between the back of the rail and the ‘flanges’ on the
post. (shown in Figure 6)
The bolt can then be secured at the back of the post with the splice bolt nut and
tightened with a spanner ONLY.
The post bolt position in the vertical slot in the post may vary and will not be at the bottom of
the slot. Ensure the top of the post is at 780mm and the centre of the w-beam guardrail panel
is at 635mm relative to the ground. (shown in Figure 7)
Figure 6 Figure 7
Repeat these steps until the barrier is the required length and joined to a terminal end,
transition section or w-beam guardrail at the other end.
During construction of NU-GUARD® 31 ensure that the exposed end of the w-beam
guardrail is ALWAYS at the ‘downstream’ end of the installation and/or protected using
a suitable technique if road users are present.
Step 6 – Delineation.
For further details including type, location and placement contact the Road Controlling
Authority.
‘Median’ Application
Step 1 – Site Preparation & General Information
Before driving posts, always ensure that the posts are clear of underground services.
Note: If the conditions on site don’t allow for the posts to be driven, contact CSP Pacific for
alternative accepted installation methods.
Step 3 – Joining the W-beam Guardrail Panels Together
The centre of the guardrail is 635mm above the nominal ground line. Lap the w-beam
guardrail panels on each side of the posts with the direction of the laps the same as the
direction of the traffic flow. (shown in Figures 11, 12 & 13)
Each ‘splice joint’ requires the w-beam guardrail panels to be joined using 8 splice bolts and
tightened with a wrench or socket. There is limited access when connecting the second side of
w-beam guardrail and a small specialised socket wrench is required.
Once the w-beam guardrail panels have been joined together on either side of the posts they
can be attached to the posts.
Insert the 100mm M16 Coach Bolt through from the face of the rail with a 90mm
diameter round washer positioned between the back of the w-beam guardrail panel and
post on each side. (shown in Figure 14)
Bolt orientation is consistent with post. Consult the drawing in the Appendix for further detail.
The bolt can then be secured on the face of the guardrail with a small round washer
under the M16 nut and tightened with a wrench or socket ONLY. (shown in Figure 15)
The post bolt position in the vertical slot in the post may vary and may not be at the bottom of
the slot. Ensure the top of the post is at 780mm and the centre of the W-beam guardrail panel
is at 635mm relative to the ground. (shown in Figure 16)
Repeat these steps until the barrier is the required length and joined to a terminal end,
transition section or w-beam guardrail at the other end.
During construction of Nu-Guard® 31 ensure that the exposed end of the w-beam
guardrail is ALWAYS at the ‘downstream’ end of the installation and/or protected using
a suitable technique if road users are present.
Step 6 – Delineation.
For further details including type, location and placement contact the Road Controlling
Authority.
Top of post is just below the top edge of the rail, it does not protrude above the
rail.
There is no blockout.
When driving post, use a driving cap with timber or plastic insert to avoid damage
to the post.
Post is aligned with flanges rail (for road side applications) and alternating
between flanges forward and back for median applications.
There is a 90mm dia. washer between rail and post.
Position of M16 x 90mm post bolt in post slot may vary. It is not located in the
bottom of the slot.
Project/Job number:
Location:
Client/Asset Owner:
Principal Contractor:
Installer:
Installed by: Date:
Inspected by: Date:
Installations of NU-Guard® 31 installed prior to November 2017 will have the post height
812mm above nominal ground level and 20mm above the top of the guardrail. To update NU-
Guard® 31 installations with the post height reduced to 780mm above nominal ground level
the following method is to be used:
Loosen the M16 x 90mm coach bolt so there the guardrail is not tight against the post.
Drive the post down by 32mm using suitable machinery. Check the post height is now 780mm.
Ensure the centre of guardrail is still 635mm above nominal ground line.
Secure the M16 x 90mm coach bolt at the back of the post with the splice bolt nut with a
spanner only.
Note: The bolt will not sit in the bottom of the post slot.
Repeat the above steps until all NU-GUARD® 31 posts are at 780mm height above the
nominal ground level.
Repair
Recommended tools:
• Wrenches and 32mm sockets
• Podger bars
• Vertical Plate lifting clamp
• Machinery to remove the damaged posts and install new ones
Key Steps:
• Separate the components by undoing the splice bolts and post bolts
• Remove any damaged posts (machinery may be required as detailed above)
• Assess which components are damaged and replace with new parts accordingly
• Drive new posts and install new guardrail as per the Installation Instructions in this
manual for the type of barrier system being repaired.
3) When driving the posts what can be used to prevent damage to the galvanising
on the top of the posts?
It is recommended that a timber, plastic or brass insert is fitted to the device being
used to drive the posts. (Experience has shown that a brass insert will last the longest)
5) Does your company provide spare parts? What is the lead-time for supply?
It is important to fix a damaged barrier as soon as possible because it may not perform
as required when damaged. For this reason it is recommended that spare
NU-GUARD® 31 key components are held by maintenance contractors along with the
standard w-beam guardrail hardware.
7) Are the same posts used for both the TL-3 and TL-4 Barriers?
Yes, there are no differences in any components or installation characteristics
between the systems. In summary, the same barrier has passed the test criteria for
both MASH TL-3 and NCHRP350 TL-4.