INGAL Ezy-Guard 4 User manual

Release 07/22b
Product Manual
www.ingalcivil.com.au

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1.0 Introduction
Introducing Ezy-Guard 4, a member of
theEzy-Guardfamily,thenextgeneration
steel guardrail barrier providing superior
motorist safety and more metres of
barrier for your dollar.
Ezy-Guard 4 is crash tested to the latest
performance standard distinguishing
it from the existing Australian public
domain guardrail barrier system.
The Z-post prole shields post edges
from vulnerable road users and provides
sectional strength when driving through
dicult conditions.
An Ezy-Carriage is used to secure the
w-beam rails to the posts eliminating
the requirement for blocking pieces
and rail stiening plates. This unique
connection provides a soft ride-down
for the occupants and smooth vehicle
containment and redirection.
2.0 Specications
Ezy-Guard 4 Z-Post Length: 1,650mm
Ezy-Guard 4 Z-Post Mass: 12.5kg
Ezy-Guard 4 System Mass: 18.6kg per metre
Rail Height Above Ground: 787mm
Z-Post Height Above Ground: 777mm
Post Spacing: 2,000mm
Ezy-Guard 4 SystemWidth: 200mm
MASHTL3 CrashTest Deflection: 1.65m
Ezy-Guard 4 rails and Z-posts are manufactured from hot-rolled steel
at products in accordance with AS/NZS 1594. These items are hot dip
galvanised in accordance with AS/NZS 4680 after fabrication leaving no
surface untreated.
Australian state specic product acceptance details are available upon
request from your local Ingal representative. Acceptance conditions
should be conrmed prior to installation.

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Figure 1: Comparison of Crash Test Impact Severities
3.0 Crash Test Analysis
Crash test guidelines provide a minimum set of
requirements that a roadside barrier has to meet in order
to demonstrate its satisfactory impact performance.
Whilst crash test guidelines cannot include all possible
impact conditions that may be experienced in the real
world, the crash test matrix is selected to represent a “worst
practical condition”for a roadside barrier impact.
Ezy-Guard 4 has been fully crash tested and evaluated
according to the specications for Test Level 3 (TL3) of the
AASHTO Manual for Assessing Safety Hardware (MASH).
The system has also been crash tested in accordance
with NCHRP-350 Test Level 4, this is the containment of a
8000kg truck impacting the rail at 80km/h and 15°.
The MASH specication is an update to and supersedes
NCHRP Report 350 for the purposes of evaluating new
safety hardware devices.
The MASH TL3 crash test matrix requires the following
impacts;
•1100kg car travelling at 100km/h and 25 degrees.
•2270kg pick-up travelling at 100km/h and 25 degrees.
Crash test impact conditions are dened by the mass,
speed, and angle of the impacting vehicle. Crash test
standards and performance levels can be compared by
calculating the impact severity (IS).
IS = ½ M (V sin θ)2
Where IS is the impact severity in joules (J), M is the test
inertial mass of the vehicle in kilograms (kg), V is the
impact speed in metres/second (m/s) and θ is the impact
angle in degrees.
Impact
Severity
(kJ)
Crash Test Performance Level
Note:The MASHTL4 impact
severity is 209.3kJ

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Figure 2: Ezy-Guard 4 Considerations for
Vulnerable Road Users
4.0 Consideration for Vulnerable
Road Users
Vulnerable road users include motorcyclists, pedestrians,
cyclists and other road users. Ezy-Guard 4 has been
designed to provide consideration to vulnerable road
users as follows:
Rounded Post Corners.
The Z-post contains smooth, rounded post edges and
corners mitigating the risk and severity of fractures and/
or contusions.
Energy Absorbing, Ductile Z-Posts.
The Z-posts are designed to yield by bending near
ground level. This bending action absorbs impact energy
reducing the potential for post fracturing. A fractured
or split guardrail post presents a signicant laceration
hazard to vulnerable road users.
The Ezy-Guard 4 design does not contain any elements that
become projectiles and there are no aggressive edges.
Shielded Posts.
The revolutionary design of Ezy-Guard 4 shields the top
of the supporting Z-posts by positioning the top of the
rail above the posts. This eliminates dangerous snag
points, reducing the potential for the barrier to dismount
motorcyclists or cyclists. This is a signicant safety benet
compared to all guardrail and cable barrier designs
currently used within Australia.

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5.0 Features and Benets
5.1 Fully Compliant to MASH TL3 & NCHRP-350 TL4
Ezy-Guard 4, a member of the Ezy-Guard family, is fully
compliant to MASH TL3 and NCHRP-350 TL4.
The MASH TL3 test condition represents a 13% increase
in energy when compared to NCHRP 350 Test Level 3
impacts.
The NCHRP-350 TL4 compliance demonstrates the
systems ability to contain and redirect the large 8000kg
truck, which has a higher centre of gravity compared to
the MASH TL3 pickup truck.
5.2 Rapid Installation & Repair
Ezy-Guard 4 installation can be up to twice as fast to
install than conventional guardrail barriers and unlike
cable barrier systems, no concrete is required.
The Ezy-Guard 4 design uses fewer components and
features 1,650mm Z-posts that are rapidly driven into the
ground. The Z-post embedment depth is just 873mm, a
signicant reduction when compared to other guardrail
posts. This reduces installation time providing signicant
cost savings.
Since the Z-posts are designed to yield by bending near
ground level, damaged posts can be removed easily which
reduces the time spent by work crews on the roadside.
5.3 Narrow Width
With a system width of just 200mm, Ezy-Guard 4 is
signicantly narrower than traditional guardrail barriers
that incorporate the use of blocking pieces. Ezy-Guard 4
conserves valuable formation width and allows a greater
recovery width to be provided for errant vehicles.
NCHRP-350 TL4
MASH TL3
Figure 3: Ezy-Guard 4 Width Comparison
200mm
1800mm
385mm
G4 W Beam
1800mm
440mm
Type B Guardfence
Ground
surface
Double sided W-Beam
730mm
310mm
1600mm
730mm
1650mm
787mm

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5.4 Installation in Rock, Asphalt or Concrete
Mowing Strips
The design of the Z-post diers from traditional posts in
that it relies on the yielding of the post by bending near
ground level rather than the yielding of the surrounding
soil during a vehicle impact. This makes the Z-post suitable
for installation in rock, asphalt or concrete mowing strips.
A traditional guardrail post is designed to absorb some
crash energy through post rotation in the soil prior to post
failure. Restraining these traditional posts by setting them
in narrow holes drilled into solid rock, by setting them in
thick asphalt layers or concrete, or by placing a mowing
strip around the posts can lead to a failure of the system to
safely contain and redirect the errant vehicle.
5.5 Manual Handling
Ezy-Guard 4 uses fewer components than the public
domain guardrail systems. Z-posts weighing just 12.3kg
are 50% lighter than traditional C-posts. The lightweight
Z-post reduces manual lifting by installation crews.
The rounded edges of the Z-post provides a handlelike
grip when lifting, reducing the possibility of hand
lacerations. The Z-prole allows the installer to maintain
a rm grip and facilitates correct lifting techniques.
5.6 Locally Designed & Produced
Ezy-Guard 4 is manufactured in Australia by Ingal Civil
Products using steel manufactured by BlueScope Steel.
Z-posts and rail are stamped providing traceability to
material mechanical and chemical analysis certicates.
Hot dip galvanising is performed internally by Ingal and
daily inspections ensure zinc thickness readings are in
accordance with AS/NZS standards..
5.7 Soft Ride-Down Decelerations
The Ezy-Carriage controls the release of the w beam
rail from the Z-posts. This controlled release reduces
the potential for vehicle pocketing and provides a soft
ridedown for vehicle occupants.

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Figure 4: Vehicle Trajectory
6.0 Performance
Ezy-Guard 4 provides protection from roadside hazards
located close to the edge of the travelled way. The
sectional strength of the 4 Z-post reduces lateral
deection whilst providing controlled containment and
redirection.
Crash testing guidelines provide a set of requirements
that is“worst practical conditions”in order to demonstrate
the barriers impact performance. When the combined
eects of vehicle mass, impact speed and angle of
impact are considered, the testing criteria represents the
extremes of impact conditions to be expected in real-
world situations.
6.1 Deection
The transverse deection of a barrier during a crash is
dependent upon the mass, speed, and impact angle of
the errant vehicle.
Since crash testing typically represents the extremes
of these parameters, a review of the proposed barrier
location can be undertaken to assess the following;
• Maximum attainable impact angle;
• Design speed; and
• Design vehicle.
Figure 4 illustrates the vehicle trajectory when turned
towards the barrier. The maximum attainable angle, Ø is
limited by the speed of the vehicle and the lateral oset,
x to the barrier.
The maximum attainable angle for various speeds and
osets is shown in Figure 6 and is derived using a point
mass model and assumes maximum steering and a
coecient of friction of 0.7 (dry pavement).
If the deection needs to be reduced due to the
proximity of a road side hazard, this can be achieved by
reducing the post spacing. Refer to Tables 1a and 1b for
deections with reduced post spacing. The reduced post
spacing should be initiated 8m upstream and returned
to standard spacing 8m downstream of the hazard.
If designing for a containment level of TL4, designers
should also consider the potential roll of the larger vehicle.
Guidance on the calculation of roll allowance is detailed
in the Austroads Guide to Road Design - Section 6.3.16.
Refer Table 1b for NCHRP-350 TL4 deection.
6.2 Slopes
The maximum cross fall for an installation of Ezy-Guard is
10H:1V (10%).
6.3 Batter Hinge Proximity
Installations of safety barriers in close proximity to a
batter hinge point should be considered within the
requirements of the road controlling authority Extended
Design Domain.
Ezy-Guard Smart has been successfully crash tested to
MASH TL3 with posts installed on the rounding point
of a 2H:1V batter. The batter was comprised of AASHTO
M147-65 Standard Soil.
Suitability of the ground conditions and/or erosion of the
batter should be considered by the installation designer
prior to installation of a safety barrier near a batter slope.
It is recommended the barrier be installed with the
maximum oset to hinge point possible. For NCHRP-350
TL4 containment, the oset to back of post should be
1.3m.
As the proximity of the batter slope may reduce the soil
support to the post, the designer should also consider the
use of an increased post embedment, refer section 7.5.2.
vehicle
barrier
x
v
e
hi
c
l
e
ba
rri
er
x
vehicle
p
at
h
use of an increased post embedment, refer section 7.5.2.
Figure 5: Ezy-Guard Smart on curves

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Figure 6: Maximum Attainable Angle by Speed and Oset.
1m vehicle oset to barrier
2m vehicle oset to barrier
3m vehicle oset to barrier
4m vehicle oset to barrier
5m vehicle oset to barrier
6m vehicle oset to barrier
7m vehicle oset to barrier
8m vehicle oset to barrier
Impact Angle
(degrees)
7050 60 80 90 100 110 120 130
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
7
0
50
6
0
80
90
100
11
0
1
20
130
0.0
5
.
0
10.
0
1
5.0
20.0
2
5.
0
30.0
3
5.
0
40
.
0
m
Example
Example
Speed (km/hr)
Table 1a: MASH deections for various post spacing and speeds
Containment Level
Vehicle: 2,270 kg Impact Angle: 25˚
Speed
(km/h)
Post Spacing (m)
2 1 0.5
Dynamic
Deection (m)
MASH TL3 100 1.65 1.05 0.73
MASH TL2 70 0.9 0.57 0.4
Table 1b: NCHRP-350 deections for various speeds and post spacings
Containment Level Speed
(km/h) Vehicle (kg) Post Spacing (m)
2 1
Dynamic
Deection (m)
NCHRP-350 TL4 80 8,000 1.53
NCHRP-350 TL3 100 2,000 1.46 1.04
NCHRP-350 TL2 70 2,000 0.89

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Figure 7: Clear Zone Requirement for the use of Departure Terminals
7.0 Installation
7.1 Terminals
Guardrail end terminals are designed to provide a soft
gating impact preventing the end rail from spearing
an impacting vehicle. Terminals also introduce tensile
and exural strength necessary to ensure redirection
performance of the length-of-need section.
Ezy-Guard 4 is installed at a system height of 787mm,
measured to the top of the rail. This height is compatible
with our range of proprietary and public domain
terminals, refer to installation drawings.
Departure terminals should only be installed if they are
located outside the clear zone of approaching trac. See
Figure 7. The clear zone is the horizontal width of space
available for the safe use of an errant vehicle.
The clear zone is dependant upon the speed of the vehicle.
Guidelines are contained with regulatory publications.
Terminals should be installed in accordance with the
proprietor’s drawings and specications. Z-posts are
not to be used in the terminals unless approved by the
proprietor.
The installation of terminals will typically incorporate the
use of blocking pieces positioned between the posts
and rail. This will require the supporting posts to be
oset from the set-out line used for the installation of the
Z-posts which do not require blocking pieces.
In addition, the post spacing used in the terminals and
transitions may vary from the 2m spacing used for
installation of Ezy-Guard 4. The required post spacing
for terminals and transitions will be contained in the
proprietor’s drawings.
approach terminal barrier departure terminal
A departure terminal can
only be used if located
outside the clear zone of
approac
h
termina
l
b
arrier
d
eparture termina
l
A
d
eparture termina
l
can
only be used if located
outs
i
de
t
h
e
c
l
ea
r z
o
n
e
o
f
Figure 8: ET-SS Guardrail End Terminal

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7.2 Minimum Length Requirements
There are two geometric methods used to determine
the likely trajectory of a vehicle that leaves the road
in the vicinity of a roadside hazard and the minimum
length of barrier required to protect from this hazard.
The most common method is the run-out length
method and an alternative is a method based on angle
of departure.
Prior to design or installation, designers should consult
the relevant road controlling authority to establish the
local jurisdictional practice as the methods may result
in dierent lengths. Both methods are detailed in the
Austroads Guide to Road Design – Part 6.3.
For instances where geometric constraints limit
the installation of the recommended length under
the above design methods, the absolute minimum
length of minimum length of need for Ezy-Guard 4 is
dependent on the design containment level.
• TestLevel2containment,wherethedesignvehicleis
a 2,000kg pick-up, the minimum length of Ezy-Guard
4 between terminals is 12m.
• MASHTest Level 3 containment, where the design
vehicle is a 2,270kg pick-up, the minimum length of
Ezy-Guard 4 is 20m between terminals.
• NCHRP-350 Test Level 4 containment, where the
design vehicle is a 8,000kg truck, the minimum length
of Ezy-Guard 4 is 56m in between terminals
7.3 Sequence of Work
Where Ezy-Guard 4 is being constructed on a road open
to trac, it is recommended that the work commence
at the end closest to the approaching trac. Leading
terminals and transitions shall be commissioned at the
earliest practical time.
7.4 Modications
Ezy-Guard 4 shall be constructed in the conguration
as detailed in Ingal Civil Products’ drawings. This is the
conguration in which the system has been crash
tested. No modications shall be made to the system
unless veried by Ingal Civil Products.
Flame cutting of rails or posts is not permitted. Saw
cutting and drilling is permitted in the event that a post
is to be installed at an irregular spacing and/or rock is
encountered and the post embedment depth has been
modied in accordance with Table 4.
Any modication carried out after fabrication will require
repair to the galvanized coating. This is undertaken by
applying two coats of an organic zinc rich epoxy paint
complying with AS/NZS 3750.9. This is to be applied
to the repair areas in two coats. Each coat shall have a
minimum dry lm thickness of 50 μm
7.5 Soil Requirements & Embedment Depth
The Z-post is designed to yield by bending near ground
level during impact. Provided the post is embedded
in material that allows this failure mechanism to
be replicated, the Ezy-Guard 4 functionality will be
retained. The Z-posts will provide lateral resistance until
the impacting vehicle causes deformation of the posts.
At this point the Ezy-Carriages will provide a controlled
release of the rail from the Z-posts resulting in safe
vehicle containment and redirection.
7.5.1 Standard Soil
Ezy-Guard 4 has been evaluated for installation in
standard soil in accordance with AASHTO standard
specications for ‘Materials for Aggregate and Soil
Aggregate Subbase, Base and Surface Courses,”
designation M 147.
When installed in standard soil, the 873mm embedment
depth of the Z-post is sucient for installation up to the
rounding point on 2:1 embankment slopes.
Installations within 300mm from the hinge point should
be considered within the requirements of Section 6.3
and the road controlling authority Extended Design
Domain requirements.
7.5.2 Weak Soil
Ezy-Guard 4 has been evaluated for installation in weak
soil in accordance with AASHTO standard specication
for ‘Fine Aggregate for Hydraulic Cement Concrete,”
designation M 6.
When installed in weak soil, the 873mm embedment
depth of the Z-post is sucient for installation up to
500mm of the rounding point on 2:1 embankment
slopes. If installation is required within 500mm of the
rounding point, the post embedment depth is required
to be increased to 1,050mm. A longer Z-post is available
from Ingal for these applications. Installations in close
proximity to a batter slope should be in accordance
with Section 6.3 and the road controlling authority
extended design domain requirements..

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Figure 10: Z-Post on Base Plate
7.6 Post Pullover Test
In the event that the soil type cannot be veried, the
suitability of the post foundation can be established
through a post pullover test.
This is undertaken by applying a 1kN load to the post,
550mm above ground level. The load is applied prior to
the attachment of the rail. Displacement at the base of
the post shall not exceed 1mm whilst the load is applied.
An alternative post pull over test can be achieved via a
more destructive means, whereby a load of 1.2 tonnes is
applied to the test post at a height of 700mm.This loading
approximates the probable capacity of the post and
should be able to be maintained with minimal rotation
of the post in the soil. At the completion of the testing
the post should be removed from the test location and
should not be used in the installation.
7.7 Posts on Base Plates
In the event that the Z-post cannot be installed to
the required in-ground depth, the use of a base plate
mounted on a suitable foundation can be adopted. Posts
on base plates are typically used at culvert locations, and
in areas where underground services restrict posts from
being driven into the ground. Refer to Ingal Civil Products
drawings for the installation of posts on base plates.
7.8 Z-Posts in Rock
Traditional guardrail posts are designed to yield in the
surrounding soil and their placement in rock or concrete
is problematic. Restraining the traditional posts by setting
them in narrow holes drilled into rock, setting them in
concrete or placing a mowing strip around the posts
can lead to a failure of the system to safely contain and
redirect the errant vehicle.
The specially engineered Z-post dissipates energy by
yielding through bending near ground level. This means
that typical recommendations for the installation of a
traditional guardrail post in rock are not applicable to
the Z-post. When rock is encountered, the installation
guidelines as detailed in Table 4 are applied. If required
the post may be cut onsite by a disc grinder or equivalent
steel cutting tool. A corrosion resistant treatment
will need to be applied to the freshly cut surface, ICP
recommend a Zinc metal spray in accordance with ISO
2063 or AS/NZS 2312.
7.9 Non-Standard Post Spacing
Occasionally, a roadside hazard may prevent a post from
being installed at the recommended spacing. In these
instances it may be possible to stien the barrier with
reduced post spacing on the approach and trailing side
of the hazard, we would recommend you discuss these
options with your local Ingal Civil Products representative.
Approval may be required from the relevant road authority.
7.10 Delineation
A specially designed delineator may be attached to the
Z-post. Typically, delineation is arranged so that drivers
approaching from either direction will see only;
•Red retro-reectors on their left;
•White retro-reectors on their right
on two-way carriageways; and
•Yellow retro-reectors on their
right on one-way carriageways
and medians separating trac in
opposing directions
The spacing of delineators is
dependant upon driver line of sight.
As a general rule delineators are
provided for installation every 20m on
straight alignments and may be closer
on curves, depending on the radius.
Refer Road Authority specs.
should not be used in the installation.
7.7
Posts on Base Plates
Figure 9: Z-Post Pullover Test
1kN Force
700mm
Embedded Z-Post
Ground Level
Displacement
less than 1mm
1
kN F
o
r
ce
550
mm
E
m
bedded
Z-P
ost
G
round Leve
l
Disp
l
acemen
t
l
ess
t
h
a
n 1mm

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Table 4: Installation of Ezy-Guard 4 Z-Posts in Rock
Site Condition Installation Requirements
Rock is
encountered at
the surface.
Drill a 110-300mm diameter
hole to a depth of 450mm,
install the post in the hole
and backll.
Rock is
encountered
within 450mm
of the surface.
Drill a 110-300mm diameter
hole 450mm into the rock
or to a minimum total post
embedment depth of
650mm, whichever comes
rst, install the post and
backll.
450
650 min.
0-450
rock
soil
450
rock

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Site Condition Installation Requirements
Rock is
encountered
450mm to
600mm below
ground.
Drill a 110-300mm diameter
hole 200mm into the rock
or to a minimum total post
embedment depth of
650mm, whichever comes
rst, install the post and
backll.
Rock is
encountered
600mm to
800mm below
ground.
Drill a 110-300mm diameter
hole 50mm into the rock
or to a minimum total post
embedment depth of
800mm, whichever comes
rst, and install the post and
backll.
200
650 min.
450-600
rock
soil
50
800 min.
600 – 800
rock
soil

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Figure 11:
Figure 12:
Figure 12:
Figure 11: Curvature Measurements
Figure 12: Curvature Orientation
7.11 Curving of Rails
Guardrail used for the assembly of Ezy-Guard 4 may be
shop curved to t any radius from 2.4m to 45m Convex.
Ezy-Guard 4 for Concave Curves can be used from 2.4m to
45m. Curves in excess of 45m do not require shop curving
as the rail can be eld installed to suit. Guardrail may be
curved either concave or convex to the trac face and can
be part-curved along its length to suit site requirements.
7.11.1 Measuring Curvature
1. Mark along the arc of the curve at 4m intervals.
2. Measure the corresponding chord length (C) - refer
to Figure 11.
3. Measure the corresponding centre oset (H) - refer
to Figure 11.
4. Use the values for C & H to select the radius from
Table 5.
5. Determine the curvature orientation from Figure 12.
7.11.2 Identication of Curved Rails
Where a rail has been factory curved by Ingal, the radius
of curvature is marked on the rear face of the rail.
Table 5: Rail Curvature Values
Radius (m) Ø Degrees C (mm) H (mm)
2.4 95 3553 786
3 76 3710 642
4 57 3835 490
5 45 3894 395
6 28 3926 330
7 33 3946 284
8 29 3958 249
9 26 3967 221
10 23 3973 199
12 19 3982 166
14 16 3986 143
16 15 3990 125
20 12 3993 100
24 10 3995 83
28 8 3997 71
32 7 3997 62
35 73998 57
40 5 3998 50
45 5 3999 44

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7.12 Installation Sequence
The following written instructions should be read in
conjunction with Ingal Civil Products’ drawings.
A generic SafeWork Method Statement is available from
Ingal Civil Products to assist in the safe installation of
Ezy-Guard 4. Suitable trac control should be in place
before any works.
Only items purchased from Ingal Civil Products shall be
used for the construction of Ezy-Guard 4.
1. Ensure the area has been inspected for underground
hazards and where a service clash has been
identied, the barrier should be adjusted
longitudinally if possible.
2. Post locations are marked ensuring any xed object
hazard is located outside the expected dynamic
deection of the barrier.
3. The post lugs are to be at the top of the post and
facing the trac as per Figure 13 and 14.
4. Posts are driven directly into the ground and should
be vertical. The post installation process shall not
cause damage to the post, such that it reduces the
eective operation of the safety barrier or its design
life, or introduces sharp tearing edges, nor shall it
cause damage to pavement. If the Ezy-Carriage
cannot freely move as it is attached to the post as a
result of deformation of the post during installation,
then the post shall be replaced.
The use of a vibrating post hammer will reduce
deformation to the top of the post and install the
post at a controlled rate.
5. Alternate to driving the posts, a minimum 110-
300mm hole can be augured and the post placed
in the hole. The posthole is then backlled with the
material that was excavated. If installing in soil, the
material should be placed in layers of 150mm and
suitably compacted to not less than the density of
the surrounding layers.
6. Posts are spaced at 2m – Lesser spacings are required
on transitions to Thriebeam, and where requested
by an engineer.
7. The height of the Z-post above ground level is
777mm.
8. The Ezy-Carriage is attached to the face of the post.
The Ezy-Carriage will come to rest on the positioning
lug fabricated on the Z-post.
facing the trac as per Figure 13 and 14.
4.
Posts are driven directly into the ground and should
Figure 13: Z-Post Orientation
FACING TRAFFIC
F
A
C
ING TRAFFI
C
Figure 14: Ezy-Carriage Orientation
Figure 15: Attachment of Carriage to Z-Post
Carriage resting
on lugs

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16
Release 07/22b
9. Rails are attached to the Ezy-Carriage using the
M16x30mm post bolts.The post bolts are identied
by the socket recess located in the head of the
bolt. The bolts are tightened to snug tight using a
10mm hex. key.
10. Rails are spliced together at every second post
using M16x32mm mushroom head bolts and
oversized nuts. There are 8 bolts required per splice
connection. A pinch bar may be used to assist in
the alignment of splice holes. The use of a driving
pin to elongate the slots is NOT to be used since
this may cause tearing of the rail at the slot location.
The bolts are tightened to snug tight.
11. Rails are orientated so that no leading edge is
presented to the trac face as shown in Figure 18.
12. It is recommended that posts be installed only a
few metres ahead of rail assembly to ensure correct
post spacing and alignment. On curves, the rails
can be used as a template and laid on the ground
to determine post locations.
13. Where possible, the barrier should form a smooth
line vertically and horizontally when viewed along
the line of the system, free from humps, sags or
other irregularities..
14. The Ezy-Guard 4 components are to be free from
splits, burrs or sharp edges after installation. Any
minor damage to the galvanise coating is to be
repaired by applying two coats of an organic zinc
rich paint.
15. Any disturbed pavement or material around a
post shall be left dense, tight, and smooth so that
resistance to water penetration is similar to that of
the adjacent surface.
7.13 Back to Back W-Beam Installation
The Ezy-Guard 4 system can also be used in median
applications where the W-Beam is installed on both sides
of the post. This conguration requires a special post with
resistance tabs on both sides of the post. The installation
procedure is the same as for a single sided installation with
steps 8 thru 15 repeated on the opposite side of the post.
Refer drawing Ezy-SM-035 for further assembly detail.
7.14 Installation Tolerances
• The tolerance on height of the barrier shall be
+25mm/-0mm.
• The tolerance for the line of the barrier shall be plus or
minus 20mm in plan view.
• The tolerance for departure from the upright axis shall
be plus or minus 15mm at the top of the barrier.
• The tolerance on post spacing shall be plus or minus
25mm.
8.0 Maintenance
8.1 Preventative Maintenance
It is recommended that annual inspections be performed
to ensure the following;
• The system is appropriately delineated;
• Debris has not accumulated around the system that
may impede the performance of the barrier or the
trajectory of an impacting vehicle;
• The system is suitably anchored with appropriate
terminals and/or transitions. If the system is anchored
with terminals, the cable assembly shall be taut and
tensioned to its recommended value; and
• All splice bolts and post bolts are snug tight.
10mm hex. key.
Rails are spliced together at every second post
Figure 16: Post Bolt
The bolts are tightened to snug tight.
11.
Rails are orientated so that no leading edge is
Figure 17: Splice Bolt & Nut
presented to the trac face as shown in Figure 18.
Figure 18: Orientation of Rail Lap
TRAFFIC
DIRECTION
TRAFFI
C
DIRE
C
TI
O
N

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Release 07/22b
8.2 Ezy-Lift for Maintenance Overlays
For existing Ezy-Guard installations where the road
surface has been overlayed or resurfaced, resulting
in the barrier height being outside of the installation
tolerance, the Ezy-Lift carriage is available to bring the
W-Beam back to the appropriate height. The carriage
gives the option to lift the W-Beam by +50, +100, +150
and +180mm. Refer assembly drawing EZY-SM-137 for
further detail.
Installation sequence:
1. Unbolt M16x32 Splice Bolts at splice joint at either
end of W-Beam rail.
2. Unbolt each carriage bolt on W-Beam rail. Exercise
caution on removal of carriage bolts as rail will be
unsupported after removal and may fall to the ground.
3. Lay W-Beam on ground adjacent to original position.
4. Remove carriage from post and replace with Ezy-
Lift Carriage.
5. Reinstall carriage bolt and M16 washer into lowest
hole in carriage and tighten to snug tight using a
10mm hex key. Refer to Detail A on drawing.
6. Repeat steps 1 through 5 until required W-Beam rail
has been disassembled.
7. Determine the required lift by measuring the height
of overlay.The nominalW-Beam height of Ezy-Guard
Smart is 730mm.
8. Rails are to be re-attached to the Ezy-Lift carriage
using a M16x30mm post bolts and 75x45mm
rectangular washer at each post.
9. Rails are overlapped so that no leading edge is
presented to the trac face as shown in Figure 18.
10. Rails are spliced together at every second post using
M16x32mm splice bolts and oversized nuts. There
are 8 bolts required per splice connection. A pinch
bar may be used to assist in the alignment of splice
holes. The use of a driving pin to elongate the slots
is NOT to be used since this may cause tearing of
the rail at the slot location. The bolts are tightened
to snug tight.
9.0 Product Storage
All posts and rails are hot dip galvanized in accordance
with AS/NZS 4680. It is important that stored galvanized
work is stacked so that each item is well ventilated and
can adequately drain rainwater from its surfaces.
Poor storage can give rise to wet storage stain (white
rust) which is caused by water (rain or condensation) in
badly drained or ventilated conditions. This can occur
very quickly, particularly in warm, humid conditions.

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Release 07/22b
Figure 19: Ezy-Guard 4 Installation Tolerances
± 20mm lateral tolerance
from design position of rail
± 25mm post spacing
tolerance measured
at top of post
rail
rail
Plan View Side View
Height ± 20mm
± 15mm
Front View
± 15mm
± 2
0
mm l
ate
r
a
l
to
l
e
r
a
n
ce
from desi
g
n position of rai
l
±
25mm post spacin
g
tole
r
a
n
ce
m
easu
r
ed
a
t to
p
of
p
os
t
r
a
il
r
a
i
l
P
l
an Vie
w
S
i
de
Vi
ew
Height ± 20mm
±
1
5
mm
Fr
o
n
t
Vi
ew
±
15mm
+25/-0mm

Roadside Safety Barrier
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Release 07/22b
Ezy-Guard 4 Installation Checklist
Ezy-Guard 4 Installation Checklist
Customer:
Project:
Barrier ID:
Barrier Length:
Checked By:
Signed:
Date
Have the Z-posts been positioned every 2m Yes No
Have the Z-posts been correctly orientated in relation to the direction of trac Yes No
Carriages are positioned on the posts between the retaining lugs and the resistance tabs Yes No
Posts are installed to the correct height (777mm) and within the tolerances of section 7.14 Yes No
Have the Ezy-Carriages been correctly orientated Yes No
Have the rails been attached to the Ezy-Carriages using the post bolts with the socket recess Yes No
Have the rails been spliced observing the correct lap Yes No
Have the rails been spliced with M16x32mm mushroom head bolts Yes No
Are all splice bolts and post bolts snug tight Yes No
Is Ezy-Guard 4 appropriately delineated Yes No
Is Ezy-Guard 4 suitably anchored with approved terminals Yes No
Are the cables in the terminals tensioned to their nominated torque Yes No
Has any minor damage been repaired using two coats of an organic zinc rich paint Yes No
Is the barrier system free from humps, sags or other irregularities Yes No
Has the ground or pavement around the post been left dense, tight and smooth Yes No
Are the barrier components free from splits, burrs or sharp edges after installation Yes No
Has the top of the post been cut or otherwise altered? Yes No
Disclaimer:
Important Note: The conformity of the installation is the responsibility of the installation contractor, and Ingal Civil Products accepts no liability for or
in connection with any installation that is outside of the specications of this manual or the Road Controlling Authority. For more information, please
refer to our Standard Terms and Conditions of Sale available on our website: www.ingalcivil.com.au.

Roadside Safety Barrier
20
Release 07/22b
Table 6: Damage Assessment of Ezy-Guard 4
Type of Defect Description of the Defect Action to be Taken
Galvanizing damage on
Z-Posts.
The sum total of the damaged area does not exceed 35cm2(0.5% of the
total surface area).
The sum total of the damaged area exceeds 35cm2
An organic zinc rich epoxy paint is to be applied to the repair area in
two coats.
The Z-post is to be replaced.
Galvanizing damage
on rails.
The sum total of the damaged area does not exceed 200cm2(0.5% of
the total surface area) and no individual damaged area does not exceed
40cm2.
The sum total of the damaged area exceeds 200cm2(0.5% of the total
surface area) and/or an individual damaged area exceeds 40cm2.
An organic zinc rich epoxy paint is to be applied to the repair area in
two coats.
The rail is to be replaced.
Mechanical damage on
Ezy-Carriages.
The Ezy-Carriage has chips or cracks. The Ezy-Carriage is to be replaced.
Mechanical damage on
Z-Posts.
The post is bent.
The Ezy-Carriage cannot travel freely along the post due to distortion.
The post is to be replaced.
The post is to be replaced.
Mechanical damage
on rail.
The rail is dented, twisted or flattened.
There are tears in any part of the rail.
The slots in the rail are distorted.
The rail is to be replaced.
The rail is to be replaced.
The rail is to be replaced.
Mechanical damage
on bolts.
The body of the bolt is distorted.
The thread of the bolt is damaged.
The bolt is to be replaced.
The bolt is to be replaced.
Disturbance of material
around posts
The material around the post is loose or uncompacted. Any disturbed pavement or material around a post shall be left dense,
tight and smooth so that resistance to water penetration is similar to
that of the adjacent surface.
10.0 Repair
10.1 Damage Assessment
In the event of a vehicle impact, damage to the barrier is
to be assessed in accordance with Table 6.
A Safe Work Method Statement is available from Ingal
Civil Products upon request to assist in the safe repair of
Ezy-Guard 4.
Any item that is replaced is to be reinstated observing
the installation tolerances nominated in Section 7.14.
Only items purchased from Ingal Civil Products shall be
used for the repair of Ezy-Guard 4.
10.2 Dismantling Sequence
Prior to undertaking dismantling due to a vehicle impact,
the area should be assessed for hazards. These include
trip hazards, sharp edges and snag points.
During a vehicle impact, the rail will disengage from the
posts as they yield by bending at ground level.
The recommended dismantling sequence is as follows;
1. Dismantle the railsplice by removing the M16x32mm
mushroom head bolts and nuts. There are 8 bolts
located at each splice location.
2. Rails that are still attached to posts outside the
impact area are disconnected by removing the
M16x30mm post bolts. A 10mm hex key is required.
3. Once the area is clear of damaged rail, the posts can
be removed. Since the posts yield by bending near
ground level, a sling or chain can be attached below
the bent section.
4. The damaged post can be lifted using a backhoe or
post extractor attachment.
5. Any disturbed pavement material shall be left
dense, tight, and smooth prior to the installation of
replacement posts.
10.3 Bush Fire Damage
Ezy-Guard 4 does not contain any plastic, timber or
rubber components that will burn.
The performance of galvanised coatings when subjected
to res depends upon a number of factors, such as
ame duration, intensity and the characteristics of the
galvanised coating.
Typical bushre conditions may expose steel structures to
an air temperature of 800°C for periods of up to 120 seconds,
however zinc coatings are generally reective and will not
absorb heat at the same rate as an uncoated steel surface.
Depending on the section thickness of the steel, the actual
steel surface temperature may not exceed 350°C.
Typically, the bushre ame duration and intensity are
not high enough to compromise the structural strength
of the steel. The hot dip galvanized coating will also
typically remain unaected through a bushre event. If
the bushre causes damage to the galvanized surface,
then the item(s)shall be replaced.