valmont INGAL MashFlex MASH TL3 User manual

www.ingalcivil.com.au
Release 07/22
MashFlex is licensed to Ingal Civil Products by Blue Systems Inc. of Sweden
Product Manual
Wire Rope Safety Barrier
Wire Rope Safety Barrier
MashFlex
MASH TL3
MASH TL4

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1.0 Introduction
Introducing MashFlex, a member of the Flexfence family,
the next generation wire rope safety barrier (WRSB),
providing superior motorist safety and more metres of
barrier for your dollar.
MashFlex is crash tested to the latest performance
standard, the Manual for Assessing Safety Hardware
(MASH) Test Level 3, making it compliant to the current
AS/NZS 3845.1:2015.
The superior design and clean lines of the MashFlex
WRSB have seen it become the road safety industry’s
preferred wire rope barrier. These design characteristics
have continued in this next generation of the product,
MashFlex, with an improved design and simplied
assembly sequence.
With the introduction of the iRAP Star Rating for a
highway’s safety, critical for a 5 Star rating is the separation
of oncoming vehicles and protection from roadside
hazards, WRSB has become a key countermeasure in
these designs. Cross-median accidents are typically
violent collisions with a high probability of multiple
serious injuries and death.
The straight alignment of the ropes allows for easy
installation and tensioning. Post footings are typically
concrete with a sleeve to form a recess. Once the anchors
and footings are poured, the ropes are cut to length,
stainless steel end ttings are machine swaged and the
ropes are tensioned.
MashFlex is a 4-rope barrier assessed in accordance with
MASH Test Level 3 (TL3) and TL4.
Test Level 3 comprises two tests, the heavy vehicle impact
is performed with a 2,270kg pick-up truck travelling at
100km/h and impacting the barrier at 25°, the purpose of
this test is to verify the barrier’s performance for impacts
involving pick-up trucks and SUVs.
The small vehicle impact is performed with an 1,100kg
car travelling at 100km/h and impacting the barrier at
25˚, the purpose of the small car test is to evaluate the
risks to the vehicle occupants when impacting a safety
barrier.
TL4 requires the evaluation of the barrier when impacted
by a 10,000kg rigid truck travelling at 90km/h and
impacting the barrier at 15°, the purpose of this test is
to evaluate the capacity of the barrier to contain and
redirect the vehicle.
2.0 Specication
Material:
Steel Wire Rope: Mass – 1.21kg/m
Ultimate Tensile Strength – 165.5kN
Sigma Posts: Material to AS/NZS 1594
Anchor Bracket: Material to AS/NZS 1594
Swage Fittings: Stainless Steel, Grade 304
Plastic Parts: UV Stabilised Polypropylene
Finish:
Steel Wire Rope: Galvanised coating
Sigma Posts: Galvanised to AS/NZS 4680
Anchor Bracket: Galvanised to AS/NZS 4680
Dimensions:
Steel Wire Rope: Right Hand Lay, Ø19mm, 3 strands,
7 wires each (1 x 3.15mm + 6 x 3.0mm)
Sigma Posts: 1230mm long
Sigma Posts:
1230mm long
Figure 1: MashFlex Wire Rope Safety Barrier

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3.0 Technical Data
3.1 MashFlex Performance
Wire rope safety barriers are classied as exible barriers
and consideration must be given to the expected
movement of the barrier when impacted.
The design of a WRSB should include an assessment of
the mass of the impacting vehicle, its speed and angle
of impact. Whilst rigorous crash testing is undertaken
to evaluate the performance of roadside barriers, the
deection results obtained during testing should not be
considered an exact distance, but rather as a single point
within the range of deections that can be expected.
3.2 Working Width
The working width is the maximum width that is required
to prevent an impacting vehicle from colliding with an
object behind a road safety barrier system. This includes
the dynamic deection and the extra width due to the
roll of an impacting vehicle. The roll of a vehicle is an
important consideration in shielding a xed object hazard
such as a utility pole or bridge support. Refer to Table 2 for
tested working widths and Fig. 2 for more detail.
3.3 Dynamic Deection
The dynamic deection is dened as the largest
transverse deection of a road safety barrier system
recorded during crash testing. Refer to Table 2 for tested
deections and Fig. 2 for more detail.
If the available space between the hazard and the barrier
is not adequate, then the barrier can be stiened in
advance of, and alongside the hazard by reducing the
post spacing. Other factors that can have an inuence on
the deection of the barrier include tension in the wire
rope cables, horizontal curvature and installation length.
3.4 Footing Selection
The post footing provides lateral support to the post
during impact ensuring the post yields by bending near
ground level. The type and size of footing is dependant
upon the surrounding soil type and distance to the
embankment rounding point.
Table 1 provides guidelines for the construction of
concrete post footings for varying site conditions. If using
the Driven Sleeve footing option, please refer to drawing
WR-MF-002 and asset owner acceptance conditions
prior to installation.
prior to installation.
Figure 2: Barrier Displacement Terminology
Allowance for
system width
and/or vehicle roll
Working Width
SystemWidth
Dynamic Deection
(may be 0m with rigid barriers)
Safety
Barrier
Limit of
Dynamic
Deection
Initial position of barrier
Vehicle roll is slope line
Object
requiring
protection
from impact
Deected position of barrier
prior to installation.
prior to installation.

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Table 1: Post Footing Selection Guide
Centre of Post Footing to
Rounding Point
Standard Soil Weak Soil
Dia Depth Dia Depth
Less than 0.5m 300 600 300 750
Greater than 0.5m 300 600 300 750
The minimum concrete compressive strength at 28 days
is 30Mpa.
In the event that the soil type cannot be veried, then
a post pull-over test can be conducted to validate the
structural capacity of the footing.
A pull-over test is conducted by applying a load to the
top of the post whilst positioned in the proposed footing
design. The footing is required to remain stable until the
post yields. Once the post yields, the footing has been
subjected to its maximum potential load.
For locations where the typical 600mm deep post
foundation cannot be installed, a strip footing with post
on baseplates is an alternative option, refer drawing
WR-MF-003 for further detail.
3.5 Minimum Length
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 dierent 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 a run of MashFlex is 70m, this
includes a TL3 Terminal on both ends. These installations
should be considered within the requirements of the
road controlling authority’s Extended Design Domain.
3.6 Maximum Length
Please refer to your local road controlling authority for their
max run length recommendation.
3.7 Point-of-Need
MashFlex is designed to contain and redirect errant
vehicles away from road side hazards. The location along
the barrier system that redirection occurs is known as the
point-of-need.
The point-of need for the MashFlex system is 11.73m
from the anchor point when using the MASH TL3 End
Terminal.
barrier required to protect from this hazard.
Terminal.

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4.0 List of Components
ID COMPONENT PN
MashFlex System Components
AMashFlex Post 1230mm 10009358
BMashFlex Cap 10009397
CMashFlex Plug 10009421
DMashFlex Plastic Sleeve 10009420
EPost Ground Cover 10006740
FStainless Steel Tension Fitting 10001534
GReo Ring 10001580
Terminal Components
T1 Flexfence Post 1180mm 10001671
T2 Flexfence Short Post 700mm 10009431
T3 Flexfence Steel Spreader 4 Rope 10001570
T4 Flexfence Plastic Cap 10001563
T5 Flexfence Stainless Steel Frame 10001560
T6 TL3 Flexfence Ground Cover 10001566
T7 Flexfence Anchor Bracket 10001574
T8 Cable End Fitting 10001530
T9 M24 Stainless Steel Washer 10001531
T10 M24 Stainless Steel Nut 10001532
T11 Hook Bolt Kit 10008876
T12 M20 x 350mm Hex Bolt/Nut & Washer 10009445
T13 Flexfence Type 3 Reo SL81 Mesh (default) 10008518
T14 Flexfence Type 1 Reo SL81 Mesh (alternative) 10001581
Alternative Congurations Components
ZA MashFlex Driven Sleeve 10007593
ZB MashFlex Post on Baseplate 10009425
Table 2: Crash Test Performance
Containment Level Vehicle Weight Impact Speed Impact Angle Post Spacing Deection WorkingWidth
MASHTL3 2270 kg 100 km/h 25˚ 2.5m 2.19m 2.19m
MASHTL3 2270 kg 100 km/h 25˚ 3m 2.68m 2.73m
MASHTL4 10000 kg 90 km/h 15˚ 3m 2.8m 3.8m

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MashFlex Post 1230mm
ID: A PN: 10009358
MashFlex Cap
ID: B PN: 10009397
MashFlex Plug
ID: C PN: 10009421
MashFlex Plastic Sleeve
ID: D PN: 10009420
Reo Ring
ID: G PN: 10001580
MashFlex Driven Sleeve
ID: ZA PN: 10007593
MashFlex Post on Baseplate
ID: ZB PN: 10009425
Post Ground Cover
ID: E PN: 10006740
Stainless Steel Turnbuckle
ID: F PN: 10001354
MashFlex System Components

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Flexfence Post 1180mm
ID: T1 PN: 10001671
TL3 Flexfence Ground Cover
ID: T6 PN: 10001566
Flexfence Short Post 700mm
ID: T2 PN: 10009431
Flexfence Anchor Bracket
ID: T7 PN: 10001574
Cable End Fitting
ID: T8 PN: 10001530
Flexfence Steel Spreader 4 Rope
ID: T3 PN: 10001570
M24 Stainless Steel Washer
ID: T9 PN: 10001531
Flexfence Plastic Cap
ID: T4 PN: 10001563
M24 Stainless Steel Nut
ID: T10 PN: 10001532
Hook Bolt Kit
ID: T11 PN: 10008876
M20 x 350mm Hex Bolt/Nut & Washer
ID: T12 PN: 10009445
Flexfence Stainless Steel Frame
ID: T5 PN: 10001560
Terminal Components
Flexfence Type 3 Reo SL81 Mesh
ID: T13 PN: 10008518

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5.0 End Terminals
End terminals are used to anchor the system and provide
a soft gating impact to prevent vehicles from launching
or snagging upon impact with MashFlex.
5.1 MASH TL3 Terminal
The TL3 Terminal has been crash tested to meet the
requirements of MASH TL3. It can be used on all new
installations or retrotted to existing MashFlex or
Flexfence installations.
The TL3 Terminal gradually tapers the cables from full
height to an anchor bracket located at ground level over
10m. Refer drawing WR-MF-050 general arrangement
and point of redirection.
The TL3 Terminal has demonstrated an ability to provide a
soft, gating impact without releasing the cables from the
anchor point. This non-release feature allows the system
to remain anchored following design impacts.
This important feature contrasts terminals that are
designed to release the cables for end-on impacts. Once
these terminals release the cables their ability to provide
continued containment and redirection for errant
vehicles is compromised.
5.2 Standard Terminal
The Standard Terminal is designed to provide the
necessary cable anchoring to redirect errant vehicles that
impact the wire rope barrier within the length-of-need
section. Use of this terminal is limited to locations where
geometric constraints limit the use of the TL3 Terminal
and it should only be used where it is shielded behind
another barrier and cannot be impacted.
6.0 Installation
The following written instructions should be read in
conjunction with the MashFlex drawings.
A Safe Work Method Statement is available upon request
to assist in the safe assembly of MashFlex.
The installation of MashFlex requires specic tooling for
the swaging of the end ttings onto the cables, and also
for applying the appropriate tension at the end of the
installation. This equipment is known as the FlexFence
Tension Unit and FlexFence Swaging Unit. Please contact
your nearest Ingal representative for the safe operating
instructions for this equipment.
6.1 Site Preparation
The approach terrain to the barrier should be level,
otherwise a maximum grading of 1V:10H is permitted.
Steeper slopes may result in the vehicle impacting the
barrier at other than the design height.
6.2 Horizontal and Vertical Alignment Criteria
The length and/or horizontal curvature of an installation
of wire rope barrier may increase the dynamic deection
of the barrier. In addition, horizontal curves may place
more lateral load on the post foundations. Horizontal
curve of less than 200m radius are not recommended.
To calculate the eect of a curve on the deection,
multiply the deections as detailed on the system
arrangement drawings by the curve correction factor in
Table 3, the length column is the total length of the run.
These correction factors only apply to convex curves
The minimum allowable sag vertical curve for wire rope
barriers is ≥ 30m. (K = length of VC in metres divided by
the change in grade expressed as a percentage). There is
no K value limit for crest curves.
6.3 End Anchor Site Preparation
The site should be inspected for the presence of
underground utilities prior to any excavation. The site
should be prepared free of obstructing vegetation and
other hazards that may interfere with the installation or
operational performance of the system. Some sites may
require minor grading if installed beyond the edge of the
pavement shoulder.
Table 3: Length and Curve Correction Factors
Length (m) Convex Curve Radius (m)
200-299 300-449 450-749 750+
0-100 1.4 1.3 1.1 1.0
101-200 1.6 1.4 1.2 1.0
201-300 1.6 1.5 1.3 1.1
301-500 1.7 1.5 1.3 1.2
501-1000 1.8 1.6 1.4 1.2
another barrier and cannot be impacted.
Table 3: Length and Curve Correction Factors
Figure 3: Standard Terminal

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Vehicles impacting the end of the terminals will normally
continue behind and beyond the barrier and may
encounter non-traversable terrain or other roadside
hazards. It is recommended that the guidelines as stated
in AS/NZS 3845 for the installation of gating safety barrier
end terminals be observed.
AS/NZS3845 requires that a Hazard Free Zone
‘immediately behind the terminal… should be
reasonably traversable and free from xed object hazards.
If a clear runout is not possible, this area should be similar
in character to adjacent unshielded roadside areas.’
6.4 Construction of Anchor Blocks
MashFlex is available with a variety of anchor block
designs. These include;
1. Default block - Type 3 - WR-STD-64
2. Poor soil conditions - Type 1 - WR-STD-62
3. Spacial limitations - Pier - WR-STD-82
The selection of a suitable design will depend upon soil
type, refer anchor drawings for minimum conditions.
Typically, the alignment of the anchor block will follow
the same alignment as the length of need section. If site
conditions require the anchor block to be oset to the
length of need section, a 200m radius can be introduced
upstream from the end anchor until the desired oset
angle is achieved. The fence can then be tapered at a
constant rate to achieve the required oset distance.
The construction sequence is as follows;
1. Excavate the anchor hole in accordance with the
chosen anchor block drawing.
2. If installing the rectangular anchor block, clip out several
grids of the reomesh square to t over the anchor
bracket as shown in Ingal drawing WR-STD-62.
Figure 4: Clipping of Reomesh
3. Attach 3 o M20 x 550mm hook bolts to the base of
the anchor bracket using 2 o M20 nuts per hook bolt.
One M20 nut is used either side of the anchor bracket
to secure each hook bolt.
4. Using formwork, suspend the anchor bracket and
reomesh, ensuring the anchor bracket levelling plate
is at the same longitudinal grade as the roadway. The
position of the anchor bracket is to be in accordance
with the anchor block drawing.
with the anchor block drawing.
Figure 5: Placement of Anchor Bracket
5. To prevent otation or dislodgement during the
concrete pour, drive a shortened star picket into the
base or side of the excavation and use tie wire to
secure the bracket.
6. Pour concrete into the excavation and vibrate. Ensure
that the anchor bracket has remained secure.
7. Trowel the surface of the anchor block and shape to
provide fall way from the anchor bracket.
provide fall way from the anchor bracket.
Figure 6: Trowelling of the Anchor Block
6.5 Construction of Concrete Post Footings
1. Establish post spacing in accordance with expected
dynamic deections and excavate postholes to the
dimensions in accordance with Table 1. Note that the
height of the footing must be within 20mm of the
design reference height.
If the sides of the postholes are seen to fall away into
the hole upon coring/excavation, creating a ‘coning’
or tapering of the hole, the hole depth should be
increased to 750mm.
2. Pour concrete into each hole.

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Figure 7: Trowelling of the Post Footing
3. Insert the post footing reinforcement ring to a depth
providing 50mm of cover.
4. Insert the MashFlex post into the plastic HDPE sleeve
and push the plastic sleeve into the wet concrete so
that the top of the plastic sleeve is at ground level.
The posts are orientated so that the smooth face is
towards the trac face.
5. Trowel the surface of the post footings and shape to
provide a slight fall away from the post sleeve. Any
doming should not exceed 20mm in height.
6.6 Driven Sleeve Post Footings
The Driven Sleeve Footings are driven directly into
the ground and should be vertical. Refer drawing
WR-MF-002 for minimum ground conditions, where
these conditions cannot be veried, a post pull-over
test can be conducted to verify suitability.
The sleeve installation process shall not cause damage
to the sleeve, such that it reduces the design life, or
introduces sharp edges.
Ensure the area has been inspected for underground
hazards and services prior to installation. Sleeves
should be driven to a depth appropriate for the
nished cable heights, as per drawing WR-MF-002.
6.7 Post on Baseplate Installation
Recommended ground beam dimensions and
reinforcement specications for new concrete
foundations are provided in ICP drawing WR-MF-083,
available from your local Ingal Civil representative.
Two reinforcement options are given on this drawing
for convenience of install. Minimum 28-day strength
of concrete shall be 30MPa. Posts should be anchored
to a suitable concrete foundation via four M20 G5.8
studs, chemically anchored using Hilti HY-200R, refer
drawing WR-MF-003. Anchor studs shall be installed
in accordance with the manufacturer’s instructions..
6.8 Post Assembly Sequence
1. Slide the ground covers over each terminal and
longitudinal barrier post (gure 10).
2. Starting at the leading or high end of the fence,
connect the bottom cable to the anchor using a
temporary anchor connection and run out the cable
through the post slots to the far anchor and cut the
rope to length. Bottom cable should be inserted into
anchor bracket slot nearest the trac.When a reel is
depleted, attach the end to the next reel via a tension
bay, refer section 6.9.
3. Insert steel cable spreader into terminal posts 1 and 2.
4. Assemble MashFlex cap onto longitudinal barrier
posts with particular attention to orientation of cap,
refer embossed post prole on top of cap (gure 8).
5. Starting at the leading end of the fence, connect the
second wire rope to the anchor bracket, with second
cable in second anchor bracket slot from trac, and
run out the wire through the post slots up to the rst
MashFlex post.
MashFlex post.
Figure 8: Cap orientation embossed on cap
6. Lift MashFlex cap halfway and insert cable into second
slot until the cable can slide down post centre slot.
Repeat to end of run (gures 10 and 11).
7. Repeat these steps for cables 3 and 4 with both cables
inserted in top slot of MashFlex cap, in accordance
with drawing WR-MF-001 and gures 12 through 14.
Prior to installing the top cable, ensure the stainless
steel collar is installed between the top two cables of
the terminal posts only.
8. When all cables have been installed, t the plastic cap
to the two terminal posts.
to the two terminal posts.
Figure 9: Driven Sleeve Installation

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Figure 10 Figure 11
Figure 12 Figure 13

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Figure 14 Figure 15
Figure 16 Figure 17

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9. Ensure MashFlex cap is fully pushed down on post
and insert MashFlex Plug into hole on side of cap, the
plug is an interference t and may require some light
force from a rubber mallet. Before inserting plug,
ensure the cable order is consistent and there are no
twists in the pattern, i.e. the third cable is consistently
in the third position for the entirety of the run. to the
two terminal posts (gures 15 and 16).
10. Insert the locking bolt into the cable anchor bracket,
refer gure 18.
6.9 Installation of Tension Bays
Tension bays are located at 300m centres and not more
than 150m from either anchor point. This section is to be
read in conjunction with drawing WR-MF-059.
For fences less than 600m:
1. Swage the stainless steel end ttings onto all
the cables and attach to the anchor bracket. The
procedure for swaging is contained in the FlexFence
Swaging Unit Safe Operating Procedure Manual.
Thebottomropeislocatednearesttotheapproaching
trac face. Each end tting is secured at the anchor
with one washer and two nuts. If using the standard
terminal, ensure safety check ropes are attached
before swaging.
Note: An inspection hole is drilled into each stainless steel
end tting to ensure the wire rope cables are properly
inserted into the end ttings before swaging.
2. Pull the slack out of the wire ropes toward the other
anchor. This can be achieved by hand or by using a
sling equipped with a lever claw clamp.
3. At locations where the wire rope reels have been
temporarily joined, swage the end ttings onto
the cables and install a tension tting. End ttings
should be positioned so that the end of the tting is
a minimum distance of 100mm from the post.
4. After the slack has been removed from the fence,
attach the check ropes (if required), machine swage
the end ttings and attach to the trailing or low-end
anchor.
5. Identify the tension bay location(s).
6. Mark and cut out an 800mm section from bottom,
second from bottom and top cables. Move past the
adjacent post and cut the 800mm section from the
third from bottom cable. This osetting of the tension
bay for this cable will help expedite the tensioning
process. It may be necessary to attach temporary
clamps one post back from the tension bay location
prior to cutting in order to prevent the cables from
retracting. End ttings should be positioned so
that the end of the tting is a minimum distance of
100mm from the post. Refer drawing WR-MF-059
and gure 19.
7. Swage the end ttings to each cable and attach
the tension ttings. The procedure for swaging
is contained in the FlexFence Swaging Unit Safe
Operating Procedure Manual.
8. Attach the tensioning rig to the bottom cable and
tension from the bottom up. The procedure for
Tensioning is contained in the FlexFence Tension
Unit Safe Operating Procedure Manual. Each rope is
tensioned in accordance with Table 5.
For fences greater than 600m:
1. Attach the safety check ropes (if required) and
machine swage the cables at the leading or high-
end anchor tand attach to the anchor bracket.
2. Pull the slack out of the wire ropes towards the 1st
tension bay location. This can be achieved by hand or
by using a sling equipped with a lever claw clamp.
3. At the 1st tension bay location clamp the wire
rope cable to a post. Repeat process for each cable,
clamping each cable to a dierent post.
4. Cut the cables on the un-tensioned side of clamps
and machine swage ttings. Assemble the tension
ttings.
5. Relocate to the 2nd tension bay and repeat the
above process. Continue until all the tension bays are
completed.
6. Once the slack has been removed from the fence,
attach the check ropes (if required), swage the end
ttings and attach to the trailing or low-end anchor.
7. Once the cables are attached at the anchor bracket,
relocate to the centre tension bay.
8. Attach the tensioning rig and tension in accordance
with Table 5 from the bottom up.
9. Relocate from the centre bay outwards repeating the
tension process.
10. Once complete, relocate to the centre bay and repeat
tensioning in this bay only.
Note: Upon completion, the tension bays shall not be
more than 90% (40mm gap) of their full extent so as to
allow for further adjustment. There should also be a min
40mm exposed thread beyond each nut.
Itisrecommendedthatconcreteusedfortheconstruction
of anchor blocks and post footings be cured for a period
of 7 days prior to tensioning.

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Table 4: Construction Tolerances
Description RecommendedTolerance
Rope Height -10mm /+30 mm
Post Spacing ± 30mm
Post Footing Dimensions - 10mm
Anchor Block Dimensions - 20mm
CableTension - 1kN / +2kN
Table 5: Tension Unit Pressure Requirements
AmbientTemperature ºC CableTension (Tension Unit Bar)
- 5 36kN (386)
034kN (363)
532kN (340)
10 29kN (316)
15 27kN (293)
20 25kN (270)
25 23kN (247)
30 21kN (224)
35 19kN (201)
40 17kN (177)
6.10 Clean-up and Waste Materials
Recycle, reuse or dispose of all surplus material, rubbish
and other debris in accordance with the requirements
of the local state based environmental protection
specication. Generally all components can be recycled.
Posts and cables are made from a galvanised steel. Post
caps are Nylon.
Table 4: Construction Tolerances
Table 5: Tension Unit Pressure Requirements
Figure 19: MashFlex Tension Bay
Figure 18: Anchor bracket with locking bolt

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7.0 MashFlex Maintenance
MashFlex is a low maintenance roadside safety barrier.
Except for repairs due to impacts, there is virtually no
maintenance required for the system. It is recommended
that regular drive-by inspections be performed to ensure
the following;
1. Post caps have not dislodged from terminal posts.
Delineation stickers are attached to the post caps
and a loss of numerous caps could result in poor
delineation.
2. Debris has not accumulated around the system. A
clear zone, free of hazards should exist immediately
behind the fence to accommodate for the expected
dynamic deection.
3. Safety check ropes should be secured to the anchor -
Standard Terminal only. Refer WR-MF-55.
4. Ropes have not dislodged from the posts as a result of
minor impacts.
7.1 Cable Tension
MashFlex is supplied with pre-stretched wire rope. The
pre-stretchingprocessremovestheconstructionalstretch
in the wires as they‘bed-down’. Wire rope is essentially an
elastic member and will not require retensioning after
most impacts. For fences subjected to regular vehicle
impacts or large seasonal temperature variations, it may
be necessary to evaluate the rope tension annually. This
can be undertaken using the FlexFence Tension Unit.
7.2 Bush Fire Damage 1
The performance of galvanized coatings when subjected
to bushre depends on a number of factors, such as ame
duration, intensity and the characteristics of the galvanized
coating and the technology with which it is applied.
Typical bushre conditions may expose steel structures to
air temperature of 800°C for periods of up to 120 seconds,
however zinc coatings are generally reective 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 temperatures may not exceed 350°C.
Typically, the bushre ame duration and intensity are
not high enough to compromise the structural strength
of the steel. The hot dip galvanized coating will thus
remain largely unaected through a bushre event. If the
bushre causes damage to the galvanized surface, then
the item(s) shall be replaced.
7.3 Damage Assessment
In the event of a vehicle impact, damage to the barrier is
to be assessed in accordance with Table 6. In the event
that the ropes are to be cut, they are NOT to be cut under
tension.
A Safe Work Method Statement is available upon request
to assist in the safe repair of MashFlex.
1Information based upon testing conducted on behalfof BlueScope
Steel by the CSIRO Manufacturing and Infrastructure Technology
Bushre CRC in 2005.

16
Release 07/22
MashFlex Wire Rope Safety Barrier
Wire Rope Safety Barrier Wire Rope Safety Barrier
ASH LE
INGAL CIVIL PRODUCTS
ASH LE
INGAL CIVIL PRODUCTS
7.4 Emergency Dismantling
Due to the dynamic nature of a trac accident, safety
barriers may inhibit access of rescue personnel to the
vehicle, or crash site, and may need to be moved.
Interfering with the WRSB at a crash site may be
hazardous due to the potential latent tension in the
cables and all de-tensioning should be conducted by
trained personnel at the tension bays.
In an emergency situation, where waiting for a trained
WRSB install crew is not viable, cutting the cables may
be deemed absolutely necessary. Please note, this can
be a very dangerous task and a thorough risk assessment
should be conducted before the cutting commences.
If the cables are under tension, any interference may
cause them to release.
There are two options to cut the cable, the
preferred option is to cut the turnbuckle on each
cable. Turnbuckles should be located every 300m
approximately. Alternatively, the cables can be cut with
a disc grinder.
Before commencing any cutting:
• Ensure all personnel are in a safe location.
• Do not stand on the concave side of restrained cables.
• Do no cut in close proximity to the crash scene.
A video demonstration of how to work
with, and around, high tension WRSB
can be viewed at:
https://www.ingalcivil.com.au/wrsb-
emergency-cut.
8.0 Product Storage
Most components of the MashFlex system are galvanized
steel. 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 of galvanized product can give rise to wet
storage staining (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.
Table 6: Damage Assessment
Type of Defect Description of the Defect Action to be Taken
Galvanizing damage
on Posts.
The sum total of the damaged or uncoated areas does not exceed
10cm2(0.5% of the total surface area).
The sum total of the damaged or uncoated areas exceeds 10cm2(0.5%
of the total surface area).
An organic zinc rich epoxy paint, complying with AS/NZS 3750.9, is to be
applied to the repair areas in two coats.
The post is to be replaced.
Galvanizing Damage
onWire Rope Cable
The wire rope is nicked or gouged to less than 10% depth.
The wire rope is nicked or gouged greater than 10% depth.
An organic zinc rich epoxy paint, complying with AS/NZS 3750.9, is to be
applied to the repair areas in two coats.
The wire rope section is to be replaced.
Mechanical Damage
onWire Rope Cable
(Refer drawing
WR-STD-59)
Any rope length containing more than 1 broken wire.
Any rope where the diameter is reduced by more than 10% by abrasion.
Any rope which has been crushed or flattened by more than 10% of its
nominal diameter.
The rope section is to be replaced.
The rope section is to be replaced
The rope section is to be replaced.
Mechanical damage
on Posts.
The post is distorted. The post is to be replaced.
Damaged End Fitting There is damage to the thread of the fitting, however tension can be
maintained in the wire rope system without relying on the fitting.
There is damage to the thread of the fitting and tension cannot be
maintained in the wire rope system without relying on the fitting.
The fitting is cracked.
The body of the fitting is distorted.
There is no requirement for immediate replacement.The location of the
fitting should be noted and scheduled for replacement during routine
maintenance.
The fitting is to be replaced.
The fitting is to be replaced.
The fitting is to be replaced.
DamagedTension
Fitting
The fitting is cracked.
The body of the fitting is distorted.
The fitting is to be replaced.
The fitting is to be replaced.
Damaged Driven
Sleeve
Sleeve opening is significantly distorted from yielding post.
Sleeve is dislocated causing new post to be out of alignment.
Install a new sleeve 200mm upstream or downstream of damaged sleeve.
Install a new sleeve 200mm upstream or downstream of damaged sleeve.
Damaged Post
Footing
Footing cracked causing replaced post to be out of alignment.
Footing is dislocated causing replaced post to be out of alignment.
Install a new footing 200mm upstream or downstream of damaged footing.
Install a new footing 200mm upstream or downstream of damaged footing.

Wire Rope Safety Barrier Wire Rope Safety Barrier
ASH LE
INGAL CIVIL PRODUCTS
ASH LE
INGAL CIVIL PRODUCTS
17
Release 07/22
MashFlex Wire Rope Safety Barrier
MashFlex Tensioning Report And Checklist
Customer:
Project:
Fence ID:
Fence Length:
Ambient Temperature:
Tensioning Force:
Checked By:
Signed:
Date
End Terminals
Is the anchor block dimensions in accordance with the chosen anchor block drawing Yes No
Has the anchor bracket been installed with the levelling plate at the same
longitudinal grade as the roadway Yes No
Have check ropes been attached to the cables and anchor bracket (drawing WR-MF-55 only) Yes No
Have steel cable spreaders been used in both terminal posts Yes No
Has each end tting been secured with one washer and two nuts Yes No
Has the stainless frame been inserted between the top and second from top cable Yes No
Have post caps been attached to the posts Yes No
Has the anchor cable locking bolt been installed with nuts tightened to snug Yes No
Longitudinal Barrier Posts
Have the posts been installed at the correct spacing Yes No
Have the posts been installed with the correct orientation towards approaching trac Yes No
Have ground covers been installed on each post Yes No
Has delineation been attached to the post caps Yes No
Is the cable order consistent throughout the run Yes No
Has a MashFlex plug been inserted into each cap Yes No
Has any minor damage been repaired using two coats of an organic zinc rich paint Yes No
Tension Bays
Have tension bays been installed at not more than 150m from the end anchors Yes No
Have tension Bays been installed at not more than 300m apart Yes No

18
Release 07/22
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