Saferoad MEGARAIL Operating instructions

Manual for the
Installation, Maintenance & Repair of
MEGARAIL
VRS Systems
Including Steel Step Barrier
REVISION 33Oct2022

2 Revision 33October 2022
Contents
1- General
1-1 Scope
1-2 Quality Assurance
1-3 Durability
1-4 Product Design Warranty and Liability
1-5 Training
1-6 Health and Safety
2- Design Requirements
2-1 Set back
2-2 Containment level
2-3 Working Width
2-4 Vehicle intrusion
2-5 MegaRail systems information
2-6 System progression
2-7 Visibility
2-8 Sloping Ground
2-9 MEGARAIL Height
2-10 Length of MEGARAIL
2-11 Post Foundations
3- Limitations on Use
4- Installation
4-1 Setting out
4-2 Driven Posts and driven foundations
4-3 Concrete Foundations
4-4 Surface Mounted Posts
4-5 Steel Plate Foundation
5- MEGARAIL Assembly
5-1 N2, H1 & H2 systems
5-2 Connection to TCB & OBB
5-3 Mega Guard
5-4 Mega Flex
5-5 Safe End P1
5-6 Safe End P4
5-7 Connection to Other Proprietary VRS
5-8 Installation on Curves

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6- Inspection Maintenance and Repair
6-1 Inspection
6-2 Maintenance
6-3 Repair
6-4 Innovation
7 – Driven and Foundation Post Foundation Testing
7-1 Ground Conditions
7-2 Soil test criteria
7-3 Recording Foundation Test Results
8 - Post Foundation Test Procedure
8-1 Procedure
8-2 Push Test drawings
8-3 Pressure Loading Chart
9 - Company Contact Details

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1. General
1.1 Scope
This manual sets out the procedures for the installation, repair, inspection
and maintenance of all MegaRail vehicle restraint systems both new and in
service supplied by SAFEROAD (inclusive of Mega Guard, terminals,
transitions, steel step corridor & steel step barrier gates). MegaRail has
been designed and impact tested in accordance with the performance
specification laid down in EN 1317 for classes N2, H1 and H2. The product
range has been carefully selected and developed from the SAFEROAD
broader range of systems to suit the requirements of the UK highways
network and is compatible with all Non-proprietary Safety barrier Systems
(NPSBS) and all reputable EN 1317 proprietary systems.
1.2 Quality Assurance
SAFEROAD are fully compliant with BS EN ISO 9001, and have procedures
in place to ensure compliance with EN 1317. SAFEROAD are committed to
providing quality products and services which fully comply with the
specification.
1.3 Durability
SAFEROAD’s Megarail products have a minimum serviceable life of twenty
years, this covers all safety barrier, terminals, transitions and crash
cushions.
1.4 Product Design, Warranty and Liability
The product assurances given by SAFEROAD for design, warranty and
liability for the MegaRail family of products will be invalidated if it is
demonstrated that components have been used from an unapproved source
in installation, maintenance or repair and if the VRS does not comply with
SAFEROAD’s specifications. Due to Saferoad’s research and development
program, systems are evolving constantly, so before installation reference
should be made to the Saferoad website to ensure that you are working to
the latest drawings.
When connecting to another safety barrier system we recommend that the
screws in the joint or beam lap should be supplied by SAFEROAD unless
the other promoter gives express permission to use their fasteners in which
instance SAFEROAD will accept the connection as long as the system being
connected to is fully tested and approved to EN 1317 or is an NPSBS safety
barrier.
1.5 Training
SAFEROAD’s policy is that all works to install, repair, inspect and maintain
MegaRail VRS on UK roads must be undertaken by fully trained and
properly qualified personnel in accordance with the mandatory requirements
of Sector Scheme 10B and as specified in the Design Manual for Roads &
Bridges (DMRB) volume 2 section 2 part 8, CD377 Requirements for Road
Restraint systems (which has replaced TD 19/06), and the Specification for

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Highway works Volume 1 clause 104. Sector Scheme 10B training is
available from SAFEROAD’s Lantra Awards approved training centre.
SAFEROAD’s training policy extends to anyone installing MegaRail from
outside of the UK who already has MegaRail training and therefore these
erectors must also have the LANTRA basic training for safety barriers and
hold a Blue, Gold or Black CSCS / FISS card. For details of available
training contact SAFEROAD. (Company contact details on page 28)
1.6Health and Safety
It is the installer’s responsibility to ensure that all necessary safety
procedures are in place and implemented at all times. The site specific
conditions and restrictions should be assessed and a risk assessment,
method statement and lift plan produced by the installation company for the
specific site. All endeavours must be used to ensure that no one is injured or
put at risk during the installation, repair, inspection or maintenance of the
MegaRail VRS systems.
2. Design Requirements
The installation, inspection and repair of the MegaRail family of products
must comply with the requirements of The Specification for Highways Works
series 400, CD377 Requirements for Road Restraint systems, CD127, EN
1317 and SAFEROAD product specifications. It is important to note that
whilst product specification is constant, the requirements of Highways
Authorities across Europe will have differing constraints. This manual only
takes cognisance of the requirements in the UK.
2.1 Set Back
Set Back should normally be as described in the table below, but the
Design Organisation may use further relaxations in accordance with the
notes on the table which is taken from CD127 2.24
If both set back and working width cannot be achieved, we recommend that
set back should be reduced and working width maintained.
(i)
(ii)
(iii)
Relaxation to 1000mm at existing roads with physical restraints (e.g. a structure)
where it would be difficult to provide the desirable value.
Relaxation to 450mm will be permitted where it is considered necessary to position
the VRS away from the edge of an existing embankment in order to provide support
to the foundation.
Available relaxations at sites
described in footnotes
1200
600
1200
Note (i), (ii)
Note (iii)
Note (i), (ii)
In verges with no adjacent hard
shoulder or hard strip
In verges with an adjacent hard
shoulder or hard strip
Central reserves
Desirable minimum
setback value (mm)
Location
Design Organisations may, where justified, consider Relaxations to set-back as follows:
Relaxation to 600mm for roads of speed limit 50mph or less (including temporary
mandatory speed limits).

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In central reserves where there are two single sided safety barriers it must
be ensured that the working width is maintained between the two.
Note: For either of the above situations, a departure from standard must be
obtained from the overseeing authority.
2.2 Containment level
This is the type of vehicle the system is designed to retain at a given speed
and angle of impact, see table below for the test criteria.
The system identification is made up of the containment level and the
working width for example N2 W2 for details of the available systems and
the post centres please see the table on page 8 and the working width table
below.
2.3 Working Width
The working width is the distance between the traffic face of the VRS and
the furthest point of deflection and therefore a safety barrier should be
selected to suit the location, see table below for working width classes
KPH MPH
N2 1500kg Car 110 68 20 degrees
900kg Car 100 62 20 degrees
H1 10000kg Rigid HGV 70 44 15 degrees
900kg Car 100 62 20 degrees
H2 13000kg Bus 70 44 20 degrees
900kg Car 100 62 20 degrees
Containment
level
Test Vehicle
Test speed
Impact
angle

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2.4 Vehicle intrusion
Consideration must be given to the available space behind the VRS
system to ensure that the errant vehicle does not strike the obstruction
when the system is impacted. Although a system may have a working
width of W2 ≥800mm its class of normalised vehicle intrusion (VI)
rating may be VI4 ≥1300mm.
See sketch below.

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2.5 MegaRail systems Information

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2.6 System progression

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2.7 Visibility
The design layout of the MegaRail shall comply with the sight distance
requirements set out in CD109 (section 3) which has replaced TD 9.
2.8Sloping Ground
The ground below the MegaRail shall be near level within the set back and
working width as shown in CD377 figures 3.28 & 3.29.
2.9MegaRail height
The MegaRail systems should be set to the heights shown on the drawings
with a tolerance of plus or minus 50mm for all systems. Where the kerb
height is less than 100mm and the distance between the face of the beam
and the edge of the adjacent paved area is less than 1.5m the height should
be measured from the edge of the paved area.
Where the kerb height is less than 100mm and the distance between the
face of the beam and the edge of the adjacent paved area is greater than
1.5m the height should be measured from the ground beneath the beam.
See drawing MR-GA-001
On certain systems where the kerb height is more than 100mm and the
distance between the face of the beam and the edge of the adjacent paved
area is less than 250mm the height should be measured from the edge of
the paved area.
Where the kerb height is more than 100mm and the distance between the
face of the beam and the edge of the adjacent paved area is greater than
250mm the height should be measured from the top of the kerb or adjacent
ground level.
See drawing MR-GA-003
See notes on system drawings to determine which method to use.
MegaRail installation and maintenance tolerances
Maintenance
tolerance
+/- 50mm
+/- 75mm
+/- 30mm
+/- 30mm
+/- 100mm
+/- 100mm
The maintenance tolerance can be used during
installation when the safety barrier height reference
is changing from carriageway to verge level or when
connecting to an existing VRS.
Post centres
Alignment
Height
Installation
tolerance