Highway Care BarrierGuard 800 User manual

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Product and Installation Manual
BarrierGuard 800 Gate
NCHRP 350 TL-3
Australia & New Zealand

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Revision History
Revision
Date
Prepared by
Approved by
Reason for change
A
June 2017
O. Pulling
W. Duckworth
New branding - first issue.
Contents
Introduction ........................................................3
Testing & Acceptance .....................................3
Characteristics.................................................3
Design Considerations.......................................4
Median and Roadside Applications ..............4
Connection.......................................................4
Environment....................................................4
Gate Length .....................................................4
Anchoring Options..........................................5
Deflections.......................................................5
Standard Opening Options ...............................6
Component Identification .................................7
Safety Statements ..............................................8
Installation Instructions ....................................9
Preparation......................................................9
Tools & Equipment..........................................9
Installation.........................................................10
Step 01 –Measuring .....................................10
Step 02 –Assembly .......................................10
Step 03 –Position...........................................11
Step 04 –Connection....................................11
Step 05 –T-Top ..............................................11
Step 06 –Anchor ...........................................12
Step 07 –System Check................................12
Operation ..........................................................13
Maintenance & Repair .....................................14
Photo Examples ................................................15
Frequently Asked Questions...........................16
Appendix............................................................18
Foundation Details .......................................18
Anchor Installation Detail............................20
Resin Anchor Studding .............................20
Mechanical Anchor Bolt ...........................20
Installation Checklist Example....................21
Approvals...........................................................22
Contact Details..................................................23

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Introduction
The BarrierGuard 800 Gate is a modular system
that is made up from special sections of
BarrierGuard 800, these are listed below;
•Gate post sections
•Gate hinge sections
•Gate sections
The BarrierGuard 800 Gate can be utilised as a
permanent or temporary application and
installed directly into a run of BarrierGuard 800
or by utilising one of the connection pieces can
be used as a stand-alone system attached to
various safety barriers & fences including, but
not limited to; concrete and thrie beam to w-
beam.
Testing & Acceptance
The BarrierGuard 800 Gate system has been
designed and tested to meet the evaluation
criteria of NCHRP 350 Test Level 3 (TL-3) and has
been given eligibility by the Federal Highways
Administration (FHWA). It is approved for use in
USA, Australia and many more countries.
BarrierGuard 800 Gate smoothly redirects a
vehicle during an impact that meets the test
parameters of NCHRP 350.
Characteristics
BarrierGuard 800 Gate has been designed for
both permanent or temporary applications and
acts as a longitudinal barrier when closed.
Common uses include;
•Emergency vehicle access
•Work zone access
•Contraflow opportunities
•Controlled access point
Note: This manual is designed to complement the
gate drawing package provided. Where Highway
Care bespoke gates are designed the project
drawings take priority over this manual.

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Design Considerations
Median and Roadside
Applications
The BarrierGuard 800 Gate can be impacted
from either side of the barrier with no difference
in performance levels. Therefore, the barrier
can be used in both median and road side
situations in either orientation; as long as the
site condition has sufficient space and suitable
ground conditions.
Connection
Connections from the BarrierGuard 800 Gate to
other types of barriers are possible (thrie beam,
w-beam, concrete and BarrierGuard 800).
Examples are below. Additional connections are
available; please contact Highway Care for
further details.
Connection to precast or slip form concrete
Connection to BarrierGuard 800
As the gate is anchored at the full height
terminal/gate post no strength is required from
adjoining barrier for the system performance.
Environment
BarrierGuard 800 Gate should not be installed
where there are ditches or kerbs that may affect
operation of the gate. It is recommended that
the gate is installed on straight sections but
slight curves can be accommodated.
The BarrierGuard 800 Gate works on slopes, but
it is recommended that the cross fall does not
exceed 5% to allow controlled manual
operation.
Note: Care must be taken when opening the gate
on a slope as the gate can move by itself when
detached from both hinges with the wheels down.
Gate Length
Standard gate lengths are 6m, 12m, 18m, 24m,
30m and 36m. These gate sizes provide
openings of 4.67m, 10.67m, 16.67m, 22.67m,
28.67m and 34.67m respectively.
Please contact Highway Care for bespoke sizing
options.

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Anchoring Options
The BarrierGuard 800 Gate requires anchoring
with sufficient strength from the supporting
ground conditions, to allow the gate to perform
as tested. The appendix contains further details
for foundation options.
Deflections
Deflection measurements from actual crash
testing provides a setting that can be useful
when assessing a products suitability to
perform at a given location.
Tested Parameters
Test
Standard
Performance
Level
Test
Reference
Vehicle
Type
Impact
Speed
(km/h)
Impact
Angle
(˚)
Vehicle
Mass
(kg)
NCHRP 350
TL-3
3-21
Pickup
100
25
2000
Test Result
Dynamic Deflection
1.16m

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Standard Opening Options

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Component Identification
Fixed Gate Post
Mobile Hinge
Gate Section
T-Top
T-Top Transition
Weather Cover
Removable T-Top Section &
Fittings
Gate Pin

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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 and gloves).
•Only authorised trained personnel should
operate any machinery. Where overhead
machinery is used, care must be taken to
avoid any overhead hazards.
•Before drilling or excavation, always ensure
that the area is clear of underground
services. (The appropriate service providers
may need to be contacted).
•Avoid placing hands or fingers in and around
moving machine parts when components
are being lifted and manoeuvred into place.
System Safety Statements
•Take care when unloading the BarrierGuard
800 Gate components, as often there will be
limited space to work with. Never go
underneath a load that is being lifted.
•All installers must be careful when fitting
gates, especially with the risk of a trapping
injury occurring.

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Installation Instructions
Preparation
The gate needs to be installed on a smooth and
level surface that will allow the system to be
opened and closed.
When installing the gate, it is good practise to
start from one end and work towards the other,
but always check total length measurements
before anchoring. It is good practice to fully
install the gate before anchoring to ensure
correct fit and alignment.
To speed up installation time, it is
recommended that as many BarrierGuard 800
Gate sections as possible, are pre-assembled
before delivery to site. The quantity that can be
pre-assembled is usually determined by the size
of the vehicle used to deliver to site.
Before installing a BarrierGuard 800 Gate,
ensure that all components required for the
system are readily available and have been
identified. BarrierGuard 800 Gate is a highly
engineered safety device made up of relatively
small number of parts. Before starting
installation ensure that you are familiar with the
design of the system.
The BarrierGuard 800 Gate ground conditions
must meet or exceed the design specification.
Ensure that the area where the BarrierGuard
800 Gate is to be installed has enough space to
work in and is flat enough so that the ground
conditions will not impede installation. Minor
site grading may be required.
Tools & Equipment
The tools required to install the BarrierGuard
800 Gate are:
•Suitable drilling equipment.
•Airline blower (for cleaning out anchor holes
for resin fixings).
•Measuring tape and road marking
equipment.
•Lifting chains –recommended 3m leg
lengths, rated at 2 ton per leg with 1 one
choke (not required if a forklift is used).
•Lifting equipment capable of lifting the
BarrierGuard 800 Gate units. E.g. fork lift,
crane, wheeled excavator, etc.
•¾ inch drive socket suitable for the anchors
–M24 Galvanised stud, washer & nut.
•¾ inch drive ratchet
•½ inch drive ratchet, ½ inch 24mm socket, ½
inch drive 4 inch extension bar; used to
raise/lower gate wheels.
•½ inch drive impact gun, ½ inch drive 24mm
double depth impact socket, compressor
and pipe. Note: Not critical items but speeds
up installation time.
•Spanner/Socket to remove inspection
hatches (16mm & 17mm).
•½ inch torque wrench with 24mm socket (90-
110Nm); for tightening M16 x 45 barrier
bolts.
•¾ inch torque wrench with 36mm socket
(150Nm); for tightening M24 anchor
studding if used.
•2 off 50mm spacers; for setting hinge gaps.
•Large and small podger/pry bars.
•6ft crow bar; useful for slight adjustments
when lining up the barrier.

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Installation
There are many variations of gate installations,
depending on the BarrierGuard 800 Gate
components used. The following installation
shows the basic principles which vary little from
the numerous models of gates designed to
meet specific site requirements.
General drawing packs and/or project specific
drawings give further information regarding
exact gate design.
Note: Further installation advice can be sought
from Highway Care International.
Step 01 –Measuring
Measure the space where the gate will be
installed and mark the start and end point. Start
the installation from one end of the gate
assembly.
Step 02 –Assembly
Assemble the gate to the desired length
according to the installation drawings. Ensure
any wheels and anchor points are assembled in
there correct positions.

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Step 03 –Position
Position the gate components in place (gate,
hinge, gate posts). Ensure spacer and pins are in
place. Lower the gate wheels when satisfied and
make final adjustments.
Note: Ensure the gate post and hinge edges are
aligned smoothly.
Step 04 –Connection
Depending on the connection used, ensure this
lines up with the barrier being attached. Adjust
the gate/gate post position to best match the
connection section. This can be done with a
large pry bar or lifting equipment.
Step 05 –T-Top
If T-top is part of your gate design then install it
aligned with the barrier away from where the
gate post and hinge spacer gap is. Splice plates
can be used to join T-top sections.
Note: It is recommended to leave the fixings loose
in the T-top until after anchoring to the removable
sections.

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Install the removable T-top section, pins and
turnbuckle. Do not tighten these components
until ground anchoring is complete.
Step 06 –Anchor
Ensure the gate is aligned with connections
correctly and then drill and fit any ground
anchors. The type will depend on the application
and ground conditions of the gate.
Note: If an internal anchor shoe is utilised it will be
necessary to remove the barrier to allow the
anchor to be drilled. Mark the anchor shoe position
before removing the barrier.
Step 07 –System Check
Perform an operation check of the system to
ensure usability.

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Operation
Ensure appropriate Traffic Management is in
place before operating the gate.
Remove weather cover if fitted.
Loosen the T-Top turn buckle on the hinge unit
and remove. The spanner should be stored with
the turn buckle.
Loosen the 4 off T-Top pins and fully remove;
refit the nuts and washers to the pins to stop
them getting lost.
Store the pins, turn-buckle and removable T-top
panel inside the T-top of the gate post, so that it
is ready for use when the gate is closed.
Now the gate post T-top section highlighted can
be removed.
Repeat these operations for the other end of the
gate post.
Use the correct socket for your gate (normally
24mm), a short extension (approximately
150mm is recommended) and a ratchet/ T bar
or similar to lower all the wheel sets on the gate.
Turn the socket anti-clockwise.

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Lift and remove all 4 gate pins to fully disconnect
the BarrierGuard 800 Gate. To hinge the gate,
leave 1 pin inserted.
CAUTION: Once these pins are
removed the gate is free to move.
Once the gate has been opened to the required
position; use the socket, extension bar and
ratchet to raise the wheels and lower the
barrier.
Reverse these steps to close the gate.
Maintenance & Repair
Maintenance
Highway Care International recommends that
the BarrierGuard 800 Gates are opened at least
once a year during routine maintenance
programs. This provides the opportunity to
grease/check the lifting jacks and jockey wheels
operate correctly.
Repair
The BarrierGuard 800 Gate is a low maintenance
system that is unlikely to be damaged after
typical impacts, with just minor cosmetic
damage the most common occurrence.
After more substantial impacts where a vehicle
has significantly damaged the gate, it will be
necessary to fully test the gates operation and
also seek advice from Highway Care
International regarding replacement gate
components.
Ensure the galvanised coating is repaired if
damaged.
Note: Further advice is available from Highway
Care International where required.

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Photo Examples
Thrie Beam Connection
T-Top Transition
Hinge Pin Being Removed
Wheel Set
Vehicle Passing Through Open Gate
Hinge Joint

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Frequently Asked Questions
1) What type of equipment is required to install BarrierGuard 800 Gate?
Suitable lifting equipment such as a hiab crane with hook lifting chains, marking and drilling equipment
(e.g. Hilti or compressed air rock drill), various sockets and spanners up to 36mm, 6mm Allen key. Please
refer to the Tools and Equipment section in this manual.
2) What ground conditions are required to install BarrierGuard 800 Gate?
Typical foundations are concrete and asphalt. Gradients need to be considered. The condition around
the gate should be smooth paved and flat; free from debris to allow operation of the gate. Please refer
to the Design Consideration section in this manual. Contact Highway Care International for further
assistance.
3) What can the gate attach to?
There are connections to concrete, thrie beam, w-beam and BarrierGuard 800. Contact Highway Care
International for further assistance.
4) Does the gate require anchoring when in a run of BarrierGuard 800?
It is recommended that the gate posts are anchored to ensure that when the gate is opened the
BarrierGuard 800 upstream and downstream of the opening gap will still perform as tested.
5) On average, how long does it take to install BarrierGuard 800 Gate?
Depending on the application and circumstances at the site, experience of the workforce, equipment
available, pre assemble taken place, once the ground conditions are suitable, installation and assembly
on site should take approximately 2hrs.
6) What testing has BarrierGuard 800 Gate been approved to?
BarrierGuard 800 Gate has been tested and accepted to NCHRP 350 test level 3.
7) Can the gate be installed in any temperature/humidity environment?
BarrierGuard 800 Gate can be installed in the majority of environments, in some extreme environments
enhanced components may be required. Contact Highway Care International for further assistance.
8) What maintenance does the BarrierGuard 800 Gate require?
BarrierGuard 800 Gate is a low maintenance gate that requires minimal upkeep. It is recommended
that gate is opened and closed annually to ensure functioning operation.
Whilst BarrierGuard 800 Gate can be opened after a ‘design’ impact, it is recommended that any
damaged components are replaced once opened.
9) What is the expected lifespan of BarrierGuard 800 Gate?
The gate has an expected lifespan of over 25 years. This is dependent on maintenance regime and site
specific environment.

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10) What is the smallest gate and largest gate available?
Standard metric gate lengths are 6m, 12m, 18m, 24m, 30m and 36m. These gate sizes provide openings
of 4.67m, 10.67m, 16.67m, 22.67m, 28.67m and 34.67m respectively.
Bespoke opening sizes are available subject to application. Contact Highway Care International for
further details.
11) How many people and how long does it take to open a gate?
A gate can be opened by two operatives in under 2mins.
12) Does the deflection change with different gate sizes?
The gate was tested as part of the BarrierGuard 800 family with a large anchor spacing. It is reasonable
to expect based on standard BarrierGuard 800 testing that when the anchor spacing is reduced the
tested deflection figure will also be lowered.
13) What opening angle can the gate achieved when hinged from one end?
A gate can be opened to in excess of 90 degrees when hinged from the rear pin on the gate post.

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Appendix
Foundation Details
BarrierGuard 800 Gate can be installed in a range of pavement conditions and a variety of anchors
are available to suit the pavement type.
Typical Pavement Material Specification
Typical Pavement Construction Specifications

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Typical Optional Foundation Pad Specification
Foundation Pad Notes:
1) One layer of steel mesh A252 (BS 4483) or equivalent. Minimum Lap –400mm. Minimum cover
50mm unless otherwise stated.
2) Mesh should be positioned so as not to conflict with anchor locations.
3) Minimum concrete grade strength at time of fixing C30. Poker vibration, surface finish –U2.
4) Slab surface to be level with surrounding surface levels.
5) Maximum recommended cross slope 2.5%. Back to front not to vary more than 2%.
6) All edges must be backfilled with aggregate sub base material (maximum size 20mm) and fully
compacted.
7) Slab surface to be level with surrounding surface levels.
8) Minimum depth of slab –350mm.
9) The area between the anchor pads and the swept arc of the gate movement should be smooth
paved and flat to allow operation of gates. Also, consideration should be given to location of any
road studs, drainage covers and access hatches.
10) The ground bearing resistance to be no less than 50kN / sq.m.

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Anchor Installation Detail
Resin Anchor Studding
The steps below detail a typical resin anchor
studding installation.
Note: Always follow the installation instructions
supplied by the fixing manufacturer. These may
differ to the guidelines below.
FATB-24-250-GLV
Note: this part No. does not include the resin
1. Drill a hole with a diameter of 28mm and a
depth of 250mm.
2. Clean the hole using an air line and blow
pipe or similar.
3. Mix the resin as specified by the
manufactures specification.
4. Pour the required volume of resin into the
hole; leave approximately 100mm without
resin at the top of the hole as this may need
to be increased or decreased to suit each
application.
5. Position the anchor plate.
6. Fit the nut and washer to the anchor
studding; leave approximately 2 full threads
showing at the top of the studding.
7. Push the anchor stud into the hole to the
required depth, the resin should reach the
top of the hole, if not increase the quantity
of resin.
8. Wait for the resin to cure as per
manufacturers specifications.
9. Tighten the anchor nuts to the
manufacturer’s specification.
Mechanical Anchor Bolt
The steps below detail a typical mechanical
anchor bolt fixing installation.
Note: Always follow the installation instructions
supplied by the fixing manufacturer. These may
differ to the guidelines below.
FMA-24-185-YZ
1. Drill a hole with a diameter of 30mm and a
depth of 250mm.
2. Clean out the hole using an air line and blow
pipe or similar.
3. Insert the complete mechanical anchor into
the hole.
4. Tighten the anchor to the manufacturer’s
specification.