VALTIR Vulcan Barrier System CEN User manual

PN 617902
REVISION B DECEMBER 2022
VulcanTM Barrier System (CEN)
ASSEMBLY AND ANCHORING MANUAL

Part No. 617902
© Valtir, LLC
www.Valtir.com 1 Revision B December 2022
Vulcan™ Barrier System (CEN)
Assembly and
Anchoring Manual
15601 Dallas Parkway
Suite 525
Addison, Texas 75001
IMPORTANT:
These instructions are to be used only in conjunction with the
assembly, maintenance, and repair of the VulcanTM
Barrier System. These
instructions are for standard assemblies
specified by the appropriate highway
authority only. In the event the specified system assembly, maintenance, or repair
requires or involves special circumstances, contact the appropriate highway authority
engineer. Valtir representatives are available for consultation with the engineer, if
needed.
This Manual must be available to the worker overseeing and/or assembling the
product at all times. For additional copies, contact Valtir at [phone] or
download from websites below.
The instructions contained in this Manual supersede all previous information and manuals. All
information, illustrations, and specifications in this Manual are based on the latest VulcanTM
Barrier System information available to Valtir at the time of printing. We reserve the right to make
changes at any time.

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Table of Contents
Customer Service Contacts ..............................................................................................3
Important Introductory Notes.............................................................................................3
System Overview ..............................................................................................................4
Recommended Safety Rules for Assembly.......................................................................4
Safety Symbols .................................................................................................................5
Warnings and Cautions.....................................................................................................5
Know your Vulcan™ Barrier System.................................................................................6
Application...................................................................................................................6
Anchoring Instructions.....................................................................................................11
Recommended Tools ................................................................................................11
Anchored VulcanTM Foundations...............................................................................11
Position the VulcanTM Barrier Sections......................................................................13
MP-3 Polyester Anchoring System .................................................................................14
Alternative Anchoring Options.........................................................................................16
Concrete:...................................................................................................................16
Asphalt: .....................................................................................................................16
Inspection Notice.......................................................................................................17
VULCAN™ 12M Drawings ..............................................................................................18
VULCAN™ 4M Drawings ................................................................................................22

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Customer Service Contacts
Valtir is committed to the highest level of customer service. Feedback regarding the
VulcanTM Barrier System, its assembly procedures, Manual content, and in-field
performance is always welcome. Our goal is to assist highway authorities in making their
highways safer. Additional information can be obtained by calling the telephone numbers
below:
Valtir:
Telephone: [phone]
Internet: http://www.Valtir.com/
Important Introductory Notes
Proper assembly of the VulcanTM Barrier System is essential for the system to perform
as tested and accepted per EN 1317. These instructions should be read in their entirety
and understood BEFORE assembling the VulcanTM Barrier. These instructions are to be
used only in conjunction with the assembly of the VulcanTM Barrier System and are for
standard assemblies only as specified by the applicable highway authority. In the event
your system assembly requires or involves special circumstances or, during the
assembly process, a question arises regarding a particular assembly step, contact the
design engineer for the highway authority before proceeding. If you proceed with an
assembly that deviates from that specified and approved by the applicable highway
authority, you negate the system’s accepted performance standards.
A set of product and project shop drawings will be supplied by Valtir. The shop drawings
will be for each section of the assembly. These drawings should be reviewed and
studied thoroughly by a qualified individual who understands their content before the
start of any deployment.

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System Overview
VulcanTM Barrier provides several unique advantages over traditional portable concrete
barriers, or other styles of portable safety barriers:
•Energy-absorbing when impacted pursuant to accepted criteria
•Quick and easy deployment and retrieval
•Lightweight
•Economical
•Easily repaired after most impacts
•Variety of deployment and end terminal options
VulcanTM Barrier and has been thoroughly tested to EN 1317 testing procedures.
VulcanTM Barrier has achieved N2 and H2 containment level acceptance as a redirecting
longitudinal safety barrier for speeds up to 100 km/h [62 mph].
Important:
Read safety instructions thoroughly and follow the suggested safe
practices before assembly, maintaining, or repairing the VulcanTM Barrier. Failure to
follow this warning can result in serious injury or death to the worker and/or
bystanders, as well as drivers who may impact a system so deployed. Please keep
these instructions for later use.
Warning:
Ensure that all of the VulcanTM Barrier Warnings, Cautions, and Important
statements within the VulcanTM Barrier manual are completely followed.
Use only
specified parts. The use of non-
specified parts is not authorized and renders the
system unacceptable to the appropriate highway authority for use on the specified
highway system. Failure to follow this warning could result in serious injury or death in
the event of a collision.
Recommended Safety Rules for Assembly
* Important Safety Instructions *
This Manual must be kept in a location where it is readily available to persons who
assemble, maintain, or repair the VulcanTM Barrier System. Additional copies of this
Manual are available from Valtir by calling [phone]. Please contact Valtir if
you have any questions concerning the information in this Manual or about the VulcanTM
Barrier System.
Always use appropriate safety precautions when operating power equipment, mixing
chemicals; and when moving heavy equipment or the VulcanTM Barrier components.
Gloves, safety goggles, and back protection should be used.
Safety measures incorporating traffic control devices must be used to provide safety for
personnel while at the assembly, maintenance, or repair site.

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Safety Symbols
This section describes safety symbols that may appear in the VulcanTM Barrier System
Manual. Read the Manual for complete safety, assembly, operating, maintenance,
repair, and service information.
Symbol
Meaning
Safety Alert Symbol:
Indicates Danger, Warning, or Caution; failure to read and follow the Danger,
Warning, Safety, or Caution notices could result in serious injury or death to the
workers and/or bystanders.
Warnings and Cautions
Read all instructions before assembling, maintaining, or repairing the VulcanTM Barrier
System.
Warning:
Read the instructions carefully. Be familiar with the complete instructions
for the VulcanTM Barrier before assembling, maintaining, or repairing the VulcanTM
Barrier. Failure to follow this warning could result in serious injury or death in the event
of a collision.
Warning:
Ensure that all Warnings, Cautions and Important statements within the
VulcanTM Barrier manual are completely followed. Failure to follow this warning could
result in serious injury or death in the event of a collision.
Warning:
Be sure adequate time is available for complete assembly, maintenance,
or repair before beginning the assembly, maintenance, or repair process. Failure to
follow this warning could result in serious injury or death in the event of a collision.
Warning:
Do not assemble, maintain, or repair the VulcanTM Barrier until you have
read this Manual thoroughly and completely understand it. Please call Valtir at +1
[phone] if you do not understand the assembly instructions. Failure to follow
this warning could result in serious injury or death in the event of a collision.
Warning:
Use only Valtir parts for assembling
, maintaining, or repairing the
VulcanTM Barrier. Assembly, maintenance, or repairs using unaccepted accessories is
strictly prohibited. Failure to follow this warning could result in serious injury or death
in the event of a vehicle impact with an UNACCEPTED system.
Warning: DO NOT modify the VulcanTM Barrier in any way. Failure to follow this
warning could result in serious injury or death in the event of a collision.
Warning:
Ensure that the VulcanTM Barrier and delineation used meet all specifying
agency and local specifications. Failure to follow this warning could result in serious
injury or death in the event of a collision.
Warning:Ensure that your assembly meets all appropriate local standards. Failure
to follow this warning could result in serious injury or death in the event of a collision.
Warning:
Ensure that there is proper site grading for VulcanTM Barrier placement
as dictated by the specifying agency. Failure to follow this warning could result in
serious injury or death in the event of a collision.

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Know your Vulcan™ Barrier System
Application
The VulcanTM Barrier can be used in many applications specified by the appropriate
highway authority such as:
•General road maintenance performed by road authorities, contractors, local
municipalities, etc.
•Road construction
•Lane closures
•Toll plazas
•Road Resurfacing
•Excavation or culvert protection
•Detours or diversions
•Bridge repairs
•Temporary or permanent assemblies
•Median or verge assemblies
•A variety of approved end terminals available or option to "Taper Through Clear
Zone"
In order to select the most appropriate VulcanTM Barrier System for a given site, this
manual helps the appropriate highway authority answer the following questions:
•Is the VulcanTM Barrier appropriate for my site?
•What is the application? What indicates the use of the VulcanTM Barrier?
•How long must the barrier be? Refer to the length of need and beginning of length
of need for VulcanTM Barrier assembly options.
•How much clear zone is available, and how much is required for the correct
functioning of the System?
•Are there curves, slopes or curbs present which may not suit the VulcanTM Barrier?
•Is an end treatment, which has been accepted by the appropriate highway
authority, available to suit my particular requirement? Refer to end terminal section
of this manual.
The purpose of this manual is to supply some basic application information about the
VulcanTM Barrier and to detail its performance when tested to EN 1317 criteria.
If you would like further assistance, please contact Valtir Customer Service Department
at [phone].

www.Valtir.com 7 Revision B December 2022
Figure 1 - Freestanding Configuration
(Not H2)

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Figure 2 - Anchored Configuration

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Figure 3 - Anchored Configuration

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Figure 4 - Freestanding End Treatment

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Anchoring Instructions
Recommended Tools
1. VulcanTM Barrier Product Description / Instructional Manual
2. Traffic Control Plan and Approval (as required)
3. Traffic Control Equipment (as required)
4. Rebar Cutting Bit
5. 22 mm (7/8") Concrete Drill Bit (Two-Fluted*)
* Valtir recommends using two-fluted drills to achieve optimum tensile strength when
applying the MP-3®anchoring system.
6. Grinder, Hacksaw or Torch (optional)
7. Drill Motor
8. 1/2" Drive Sockets: 1 1/8", 1 1/4"
9. Ratchet for the Above Sockets
10. Torque Wrench: 200 ft-lbs.
11. Safety Glasses
12. Gloves
13. Nylon Bottle Brush For Cleaning 7/8" Drilled Holes
14. Rags, Water, and Solvent for Touch-Up
Note: The above list of tools is a general recommendation. Depending on specific
site conditions and the complexity of the assembly specified by the appropriate
highway authority, additional or fewer tools may be required. Decisions as to what
tools are needed to perform the job are entirely within the discretion of the
specifying highway authority and the authority’s selected contractor performing
the assembly of the system at the authority’s specified assembly site.
Anchored VulcanTM Foundations
The VulcanTM Barrier may be assembled on any of the following foundations using the
specified anchorage:
Note: MP-3 is Valtir available anchoring system. Other options are acceptable if they
provide identical (or better) anchoring properties.
Foundation A: Concrete Pad or Roadway
Foundation: 150 mm [6"] minimum depth
Portland Cement Concrete (P.C.C.)
Anchorage: MP-3®with 180 mm [7"] studs
140 mm [5.5"] embedment
Foundation B: Asphalt over Portland Cement Concrete
Foundation: Minimum anchor embedment depth is 140 mm [5.5"]
Anchorage: Length of anchor required is 180 mm [7"] stud + asphalt thickness.
Foundation C: Asphalt over Sub-base
Foundation: 150 mm [6"] minimum (A.C.) over
150 mm [6"] minimum Compacted Sub-base (C.S.)
Anchorage: MP-3®with 460 mm [18"] studs
420 mm [16.5"] embedment

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Foundation D: Asphalt Only
Foundation: 200 mm [8"] minimum Asphalt Concrete (A.C.)
Anchorage: MP-3®with 460 mm [18"] studs – 420 mm [16.5"] embedment
Foundation Specifications for Foundations A, B, C and D
Note: Walk-up inspections are recommended at least once every six months for
assemblies on asphalt.
Asphalt Concrete (A. C.)
AR-4000 A.C. (per ASTM D3381 '83) .75" Maximum, Medium (Type A or B) aggregate
Sieve Size
Operating Range
(%) Passing
1"
100
3/4"
95 to 100
3/8"
65 to 80
No. 4
49 to 54
No. 8
36 to 40
No. 30
18 to 21
No. 200
3 to 8
Portland Cement Concrete (P.C.C.)
Stone aggregate concrete mix
4000 psi [28MPa] minimum compressive strength
(Sampling per ASTM C31-84 or ASTM C42-84a, testing per ASTM C39-84)
Compacted Sub-base (C.S.)
150 mm [6"] minimum depth 95% compaction
Class 2 aggregate
VulcanTM Barrier Sections assembled on asphalt must be inspected by the appropriate
authority to ensure the anchors are still properly set following each impact. Re-anchor as
necessary.
Sieve Size
Moving Average
% Passing
3"
100
2 1/2"
90 to 100
No. 4
40 to 90
No. 200
0 to 25

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Position the VulcanTM Barrier Sections
Locate anchor straps at panel connection points as shown in Figure 5 when anchoring
each barrier section.
Use the Anchor Straps as templates to drill anchor holes. Refer to Figure 6 and
instructions contained in the MP-3®Polyester Anchor box supplied with the system (or
equivalent anchoring options) for detailed anchoring instructions.
Figure 5 - Anchor Strap Locations
Figure 6 - Anchoring the System
ANCHOR

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MP-3 Polyester Anchoring System
Assembly and Safety Instructions
Important: Read all
instructions and materials thoroughly before
proceeding.
1. Do not allow contact with skin
or eyes. Use only in a well-
ventilated area. Do not use near
open flame.
2.
Wear safety goggles. If
possible, use the part to be
anchored as a drilling template.
Drill the holes 1/8" larger than
the stud diameter to the
reco
mmended depth, using a
two fluted rotary percussive drill.
Full strength will not be achieved
if a diamond drill is used. Check
to be sure all holes are drilled to
the proper depth and aligned
with the part to be anchored.
3. While wearing safety glasses,
blow the concrete dust from the
hole, using oil-
free compressed
air. Thoroughly clean the hole
with a stiff-
bristled brush, and
then blow it out again. If the hole
is wet, completely flush it with
water while brushing. Then blow
it clean using oil-free
compressed air.
4.
While wearing gloves and
safety goggles, remove the lids
from the MP-3 Part A-Resin and
Part B-
Hardener containers.
Pour Part B into Part A and mix
vigorously for 30 seconds to
form MP-
3 grout. (An anchor
stud may serve as a stirring rod.)
5.
For faster hardening in cold
weather, Promoter may be used.
Do not use Promoter when the
temperature is above 60°F.
Add the entire contents of the
Promoter container to the MP-3
grout and mix for an additional
30 seconds. Use immediately,
the MP-
3 grout will thicken
quickly.
6.
Position the part to be
anchored over the clean holes.
Crimp the mouth of the can to
form a spout and pour the MP-3
grout mixture down into the hole
through the part. Fill 1/3 of the
hole. Do not over- or under-fill
the hole.

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7. Push the stud down through
the part to be anchored and into
the hole. Leave enough of the
stud exposed to attach the nut
and washer. Twist the stud
several turns in the grout to wet
the threads.
8. Place a flat washer onto the
stud and thread a nut on until it
is flush with the top of the stud or
seated against the part. Do not
disturb or load the stud until the
material has hardened.
9. Once the grout has hardened,
torque the nut to recommended
values.
In compliance with the US Department of Labor Hazard Communication 1910.1200,
Material Safety Data Sheets are available upon request.
Valtir expressly disclaims any express or implied warranty of any kind in connection with
the use of the MP-3 Polyester Anchoring System.
Valtir expressly disclaims liability for injury to persons or damage to property resulting
from failure to follow instructions or improper application of the MP-3 Polyester
Anchoring System.
Valtir is committed to meeting our customer’s requirements and to supplying high quality,
safe products to the requesting highway authority for use on the nation’s highways. If
you have any questions, please contact our Customer Service Department at +1 (214)
589-8140.
Document No. 2735041-0000, Sheet 1/2 Revision B

www.Valtir.com 16 Revision B December 2022
Alternative Anchoring Options
There are numerous manufacturers of anchors that provide a product that will
successfully anchor the Vulcan™ Barrier CEN System to the foundation. Valtir has
performed anchor performance tests on several of these alternative anchors. The
following list states which anchors have satisfactorily passed our minimum requirements
(i.e. min. pull out strength of 82.3kN [18,500lbs] and min. shear strength of 109kN
[24,500lbs]. Valtir makes no representations as to the performance of anchors that it has
not tested and is not listed herein.
Caution:
All anchors must be assembled strictly according to
each anchor
manufacturer’s specific requirements. It is recommended that the anchor
manufacturer be consulted to discuss your specific assembly site conditions prior to
finalizing your anchor selection.
Concrete:
http://www.hilti.com
Models [Epoxy-based anchoring systems]:
HVU M20 x 170
HY 150
RE 500
Asphalt:
http://www.kelken.com
Model [Epoxy-based anchoring system]:
N/A Kelken "Lefty" anchor coated with Kelislip bond release agent and anchored with
Keligrout epoxy
•Kelken “Lefty” anchors (3/4 inch diameter x 18 inch long)
•3/4-10 threads at top 2 inches of anchor, 3/4 inch “Lefty” removable thread
for remaining anchor length (~16 inches)
•Material per ASTM A449 Type 1 or ASTM A193 Grade B7 or SAE J429
Grade 5
•Galvanized for corrosion resistance
•Includes 3/4 inch galvanized washers and 3/4-10 galvanized nuts
•1KS12Q (Kelislip bond release agent)
•1KG101T (Keligrout epoxy)

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http://www.simpsonanchors.com
Model [Mechanical anchoring systems]:
THD75812HMG (3/4 inch diameter x 8.5 inches long; mechanically galvanized)
THD75100HMG (3/4 inch diameter x 10 inches long; mechanically galvanized)
http://toge-road.de
Model [Epoxy-based anchoring system]:
TSM B 22 X 155 IM 16 ASPHALT
Inspection Notice
For permanent applications on asphalt, using alternative anchor options (like Toge);
Valtir recommends that the system be inspected by qualified personnel according to the
guidelines set forth in the Maintenance and Repair section in the Product Manual, with
the following additions:
1. Increase the frequency of Walk-Up Inspections to once every six months (instead
of once every 12 months for concrete applications).
2. After each impact, check to see that all Anchor Bolts are not damaged and have
remained firmly anchored in the roadway surface. Damaged anchor bolts are
those found to be loose, broken, or showing signs of pull out and are to be
replaced. If the system is anchored to asphalt, then up to 20% of the total anchors
may be replaced if damaged. If more than 20% of the anchors are damaged, then
the system shall be relocated and reassembled onto new and undisturbed asphalt.

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Assembly Drawing 616960 (Sheet 1) Vulcan 12m
VULCAN™ 12M Drawings

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Assembly Drawing 616960 (Sheet 2) Vulcan 12m