Saferoads HV2 Safety Barrier User manual

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 1
Contents
Preface .............................................................................................................................................................................. 2
Introduction ...................................................................................................................................................................... 2
Applications ....................................................................................................................................................................... 2
Limitations......................................................................................................................................................................... 3
Testing ............................................................................................................................................................................... 3
Barrier Segments ............................................................................................................................................................... 3
Minimum Deployment ...................................................................................................................................................... 6
End Treatment .................................................................................................................................................................. 6
Length of Need .................................................................................................................................................................. 6
Quadguard Crash Cushions ........................................................................................................................................... 6
SLED End Terminals ....................................................................................................................................................... 6
Deployment Options ......................................................................................................................................................... 7
System Deflection ............................................................................................................................................................. 8
Site Considerations ........................................................................................................................................................... 8
Barrier Deployment .......................................................................................................................................................... 8
Working Width .................................................................................................................................................................. 9
QuadGuard Crash Cushion Deployment ......................................................................................................................... 10
SLED Crash Cushion Deployment .................................................................................................................................... 11
Maintenance and Repair ................................................................................................................................................. 12
Safe Work Method Statement ........................................................................................................................................ 13

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 2
Preface
For optimum performance, Saferoads HV2 Safety Barrier must be designed, installed and maintained as per this
manual. Please thoroughly review and understand this manual before using HV2 Safety Barrier.
Local requirements may also impose restrictions. Please refer to local governing body for further information.
If more information is required please contact Saferoads:
Websites: www.saferoads.com.au or www.hv2barrier.com
Australia: 1800 060 672
International: [phone]
Email: [email protected]om.au
Introduction
Saferoads HV2 Safety Barrier is a free standing temporary longitudinal barrier system successfully crash tested to
MASH TL-4.
The patented hybrid technology, and unique connectors, allow Saferoads HV2 Safety Barrier to offer high containment
and low deflection, while remaining economical to transport and deploy, with no time-consuming anchoring required.
Saferoads HV2 Safety Barrier provides several unique advantages over other temporary barrier systems including:
 High containment
 Low deflection
 Safe, consistent and reliable redirection
 Fast deployment and retrieval
 No anchoring required
 No loose parts
 Economical to transport
 Maintenance free
 Durable
Applications
Saferoads HV2 Safety Barrier is tested to provide positive protection of work sites by safely redirecting errant vehicles
up to 10,000kg (22,000lbs) at 15° and 90km/h (56mph), or 2,270kg (5,000lbs) at 25° and 100km/h (62mph). This allows
HV2 Safety Barrier to be suitable for use on any roadside work zone from highways to low speed local streets. When
using HV2 Barrier with SLED end treatments, in Australia the design speed is reduced to 80km/h.
Since the HV2 Safety Barrier is free standing, it can be used on any firm surface including concrete, asphalt, spray seal,
unsealed compound pavements, and uniform natural surfaces.

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 3
Limitations
Saferoads HV2 Safety Barrier has been tested to MASH TL-4 requirements, as required by FHWA and AS3845.1.
Installations not in accordance with this manual or impacts outside of MASH TL-4 testing may result in unpredictable
performance.
Testing
Saferoads HV2 Safety Barrier has successfully passed a variety of tests to ensure compliance with MASH requirements,
including:
 MASH 4-10 (1,100C) – Test No. 690902-SFR7
 MASH 4-11 (2,270P) – Test No. 690902-SFR6
 MASH 4-12 (10,000S) – Test No. 690902-SFR8
 MASH 3-21 (2,270P) – Test No. 132266.01 Reverse Transition with Pinned Crash Cushion
 MASH 3-11 (2,270P) – Test No. 132266.3-11 BLON with SLED
 MASH 3-44M (2,270P) – Test No. 132266.3-44 CIP with SLED
Barrier Segments
A HV2 Safety Barrier installation is constructed from a series of individual barrier segments. Each segment is
constructed from steel with concrete ballast. The dimensions of each segment are:
Installed length
5,800mm (19ft)
Segment
length
5,846mm (19ft 2in)
Segment
width
450mm (18in)
Segment
height
900mm (35in)
Weight
2,088kg (4600lbs)

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 4
Barrier segments are fastened by an integrated, interlocking joiner, which simply slides together when barriers are
lowered into position.
These connectors are bidirectional, allowing barriers to be installed in either orientation.

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 5
Barrier segments feature three integrated lifting points. Barriers can be safely lifted from the centre lifting point, or
the outer two lifting points.
Barrier segments can be stacked for storage or transport, but appropriate bearers should be used between layers.

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 6
Minimum Deployment
HV2 Safety Barrier installations require a minimum deployment length of 98.6m (17no. HV2 Barriers) plus the required
end treatments, to safely contain and redirect at MASH TL3.
For MASH TL-4 the minimum Deployment is 278m (48no. HV2 Barriers) plus the required end treatments.
End Treatment
HV2 Safety Barrier installations require appropriate end treatments to ensure occupant safety in the event of an
impact to the end of the system.
The QuadGuard Crash Cushion has been successfully tested with the HV2 Safety Barrier using a HV2 transition. This
configuration requires anchoring of the end terminal and transition to the ground. Refer to page 10 for deployment
details.
The SLED Water Filled Crash Cushion with Transition Kit has been successfully tested with the HV2 Safety Barrier. This
configuration does not require any anchoring to the ground and is completely freestanding. Refer to page 11 for
deployment details.
Length of Need
Quadguard Crash Cushions
When using QuadGuard Crash Cushions to protect the ends of the system, the length of need begins and ends at the
first fender panel of the QuadGuard next to the Yellow Nose for MASH TL-3 Deployments. Refer to the QuadGuard
product manual for further information.
For MASH TL-4 Deployments the length of need begins and ends 138m in from the join between the HV2 Barrier and
Quadguard.
SLED End Terminals
When using SLED crash cushions to protect the ends of the system, the length of need begins and ends midway along
the 3rd HV2 Safety Barrier segment, 22.5m (73.8ft) from the beginning or end of the system for MASH TL-3 Deployment.
Note a SLED to HV2 Transition Kit is required, see pages 11 and 12 for detail.
For MASH TL-4 Deployments the length of need begins and ends 138m in from the join between the HV2 Barrier and
the SLED End Terminal.

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 7
Deployment Options
100km/h when using Quadguard Crash Cushions, limited to 80km/h when using SLED end Treatments.
SLED QUADGUARD

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 8
System Deflection
A sufficient clear zone must be allocated between the HV2 Safety Barrier and the work zone to allow for deflection of
the barrier during an impact. The tested deflections are shown in the below table.
Test Level Vehicle Speed Angle Deflection
TL3 2,270kg (5,000lbs) 100km/h (62mph) 25° 1.47m (4ft 10in)
TL4 10,000kg
(22,000lbs) 90km/h (56mph)
15° 2.37m (7ft 10in)
Site Considerations
While Saferoads HV2 Safety Barrier can be installed on most worksites, some obstacles must be avoided. HV2 Safety
Barrier should not be installed if there is:
 Curvature tighter than 80m radius
 Cross slope steeper than 5%
 Longitudinal slope steeper than 5%
 Crest sharper than 5%
 Ditch sharper than 5%
 Kerbs or similar obstacles restricting deflection
For more information please contact Saferoads or the relevant road authority.
Barrier Deployment
Before beginning deployment, ensure there is adequate traffic management, and whenever possible personnel should
remain on the non-traffic side of the installation. Also ensure appropriate lifting equipment is used and operated by
competent personnel.
1. Beginning at the upstream end of the installation, unload the first barrier segment and place in the correct
position. Orientation is not important as segments are bidirectional.
2. Working downstream of the first barrier segment, unload the second barrier segment and align the connectors
while lowering the segment into position. The connection is made in the top 200mm of the barriers. Remain
cautious of potential pinch and crush points when lowering and connecting barriers.
3. Repeat until all barrier segments are placed into the correct position and joined to adjacent barrier segments.
4. For installing an end terminal refer to the relevant deployment section below.

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 9
Working Width
The Working Width is the distance between the traffic face of the barrier before impact and the maximum lateral
position of any major part of the barrier or vehicle after impact.
MASH TL-3 – 2,270kg Pickup
The TL-3 Working Width is a constant 1.81m as the vehicle does not roll over the top of the barrier.
MASH TL-4 – 10,000kg Truck
The below image shows the working width of the TL-4 Truck at 1m intervals above the ground. The working width
varies depending on the height of the work-zone that requires protection.

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 10
QuadGuard Crash Cushion Deployment
When deploying the system with a QuadGuard Crash Cushion, a HV2 Transition must be used between the QuadGuard
and the end HV2 Barrier segment. A 610mm (24in) QuadGuard, model number QS2406Y with Tension Strut Backup
should be used for a 100km/h system.
1. Replace the side panels (part number 2760141-0000) between the rearmost fender panels and the tension
strut backup of the QuadGuard with the HV2 Transition. This transition can remain attached to the
QuadGuard, including during transport.
QuadGuard parts excluded for clarity
2. Align the connectors of the HV2 Transition with the connectors of the end HV2 Barrier segment while lowering
the QuadGuard and HV2 Transition assembly into position.
3. Anchor both the HV2 Transition and the QuadGuard. The HV2 Transition should be anchored using Hilti HIT-
RE 500 V3 epoxy or equivalent. QuadGuard should be anchored according to the QuadGuard product manual.
Surface Minimum Foundation Depth Anchor
Concrete 150mm (6in) Concrete 180mm (7in) Stud
140mm (5.5in) Embedment
Asphalt Over
PCC
76mm (3in) Asphalt
76mm (3in) Concrete
460mm (18in) Stud
420mm (16.5in) Embedment
Asphalt Over
Subbase
150mm (6in) Asphalt
150mm (6in) Compacted Subbase
460mm (18in) Stud
420mm (16.5in) Embedment
Asphalt 200mm (8in) Asphalt 460mm (18in) Stud
420mm (16.5in) Embedment

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 11
SLED Crash Cushion Deployment
Note: When using HV2 Barrier with SLED end treatments, in Australia the design speed is reduced to 80km/h.
When deploying the system with a SLED Crash Cushion, the generic SLED Transition must be used to connect the SLED
to the end HV2 Barrier segment. A SLED to HV2 Transition kit is also required that includes 2no. 3.6m (11.8 feet)
Stiffening beams for the first 2 HV2 Barrier joints adjacent to the SLED.
1. Assemble the SLED transition according to the SLED product manual, and position at the end of the system.
2. Clamp the transition panels to the end HV2 Barrier segment and using the transition panels as a template, drill
four 22mm (7/8”) holes through both sides of the HV2 Barrier. The below diagram shows the recommended
hole pattern. A 100mm (4”) access hole should also be cut through one side of the barrier in the approximate
position shown. This hole should be on the work zone side of the barrier where possible.
3. Attach the transition panels to the HV2 Barrier using eight M20 x 75mm hex head bolts and nuts. The hex
heads are to be on the outside face of the transition plates.
4. Deploy the remaining SLED components according to the SLED product manual.

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 12
5. The SLED Transition Kit includes 2 stiffening beams, the 3.6m long U-shaped beams shall be installed at the
first 2 HV2 Barrier joints adjacent to the SLED Crash Cushions. A single M20 x 280mm hex head Bolt secures
each Beam in place, installed in the centre of the beam under the HV2 Connectors through the gap between
the Barriers. Washers are to be installed each end and a Nyloc Nut is to be used.
Maintenance and Repair
No ongoing maintenance is required for the Saferoads HV2 Safety Barrier. Barriers should be inspected regularly and
any segments with cracking, tearing, bending or perforation of steel components should be disposed of. Damaged
barrier segments can be removed and replaced from between undamaged segments. Repair of barriers is not
recommended.

W www.saferoads.com.au
T [phone]
E [email protected]m.au
Australian Version 1.
4
April 2019
Page 13
Safe Work Method Statement
Sign
Off
Residual
Risk
L L L L L L L L
Person
Responsible
Risk Before
Controls
M
H
M M
L L
M M
Controls Required
Ensure machinery and operators are
appropriately certified. Ensure all
equipment is in good, working and
tagged condition.
Ensure there are no hazards above the
area. If unsure arrange a spotter.
Ensure hazards are cleared from area,
and do not use lifting equipment in
adverse weather.
Where possible personnel should be
away from area. If personnel are
required body parts should be clear
when lowering and joining barrier
segments. Appropriate PPE should also
be worn.
Abide by worksite speed limits and
transport routes. Ensure nearby
personnel are wearing high-vis clothing.
Personnel should wear appropriate
clothing and foot wear for
environmental conditions.
Where required personnel should wear
appropriate hearing protection.
Where required personnel should wear
appropriate protective gear such as
helmets, boots and eye protection.
Hazard Identified
Lifting equipment failure
Contact with overhead
services
Contact with people or
property
Crushing under or
between segments
Collision with people or
property
Environmental hazards
Excess noise
Falling items or debris
Activity
Lifting HV2
Segments
Placing HV2
Segments
Arriving or
departing
worksite
Attending
worksite