Work Area Protection SMART CUSHION INNOVATIONS SCI70GM User manual

The World’s Only
Speed-Dependent
Crash Attenuator
Corporate Office:
2500 Production Drive •St. Charles, Il 60174
Telephone: [phone]
workareaprotection.com
SMART CUSHION INNOVATIONS
®
NCHRP 350 Approved
WORK AREA PROTECTION
SCI70GM AND SCI100GM
DESIGN & INSTALLATION MANUAL
MASH and

TABLE OF CONTENTS
OVERVIEW ...........................................................................1
Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance ........................................................................................1
Crash Performance ....................................................................................1
SPECIFICATIONS ......................................................................2
Description ..........................................................................................2
System Dimensions & Weight ...........................................................................2
DESIGN CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General.............................................................................................2
Foundations .........................................................................................2
Support Structure .....................................................................................3
Location ............................................................................................3
Transition Design .....................................................................................4
Drawing List .........................................................................................5
INSTALLATION......................................................................6-9
Installation & Performance Statements ....................................................................6
Safety ..............................................................................................6
Equipment List ...............................................................................Appendix B
Site Preparation ......................................................................................6
Foundations .........................................................................................6
Placement of Crash Cushion.............................................................................7
Anchor Installation ....................................................................................7
Delineator Panel Attachment ............................................................................8
Transition Installation..................................................................................8
Final Inspection ......................................................................................9
RESETTING CRASH CUSHION AFTER IMPACT ..........................................9-13
Site Preparation ......................................................................................9
Re-Extension & Inspection After Frontal Impact............................................................9-10
Side Impact Inspection & Repair ........................................................................11
Cable Inspection Procedure ............................................................................11
Cylinder Inspection...................................................................................12
Anchor Bolt Inspection ................................................................................12
Side Panel Inspection .................................................................................12
Side Guide Inspection.................................................................................12
Final Inspection .....................................................................................13
Non-Repairable Impacts...............................................................................13
Periodic Maintenance.................................................................................13

APPENDICES
SCI ATTENUATOR PARTS LIST ......................................................... A
EQUIPMENT LIST..................................................................... B
ATTENUATORS
SMART CUSHION®, TEST LEVEL 2 ........................................................................C
SMART CUSHION®, TEST LEVEL 3. .......................................................................D
FOUNDATIONS
Test Level 2 Foundation ...............................................................................E1
Test Level 3 Foundation ...............................................................................E2
LAYOUTS
Gore Assembly .......................................................................................F
Gore Assembly Calculations ...........................................................................F3
TRANSITIONS
Jersey/F Shape Barrier.................................................................................G
Concrete Block, 24 Inch (610 mm) ........................................................................H
Concrete Block, 30 Inch (762 mm) .........................................................................I
Concrete Block, 36 Inch (915 mm) ........................................................................J
Concrete Block, 30 Inch (762 mm), Flared ..................................................................K
Concrete Block, 36 Inch (915 mm), Flared................................................................... L
Thrie-Beam (Bidirectional Traffic Design) .................................................................. M
W-Beam (Bidirectional Traffic Design) .....................................................................N
Jersey/F Shape, 30-38 Inch (762-965 mm), Variable Width Base.................................................O
Median Barrier, Single Slope 24-26.75 Inch Base (610-679 mm) ................................................P
W-Beam 28 Inch Tall (unidirectional traffic design) ...........................................................Q
W-Beam 32 Inch Tall (unidirectional traffic design) ...........................................................R
Wide Block Spanner ...................................................................................S
Offset Wide Concrete Block ............................................................................T
Concrete Block, 36-44 Inch (914-1118 mm), Flush Mount .....................................................U
Concrete Block, 46-48 Inch (1168-1219 mm), Flush Mount ....................................................V
Concrete Block, 50+ Inch, Flush Mount Reverse Direction Side ................................................ W

1
OVERVIEW
Product
The SMART CUSHION®impact attenuators are manufactured by SCI Products, Inc./Work Area Protection Corp. They are NCHRP
Report 350, Test Levels 2 and 3 (TL2 and TL3) compliant (Models SCI 70 GM and SCI 100 GM, respectively) and are fully redirec-
tive, non-gating, and bi-directional. SMART CUSHION®impact attenuators are used to help protect motorists from hazards in both
permanent and work zone locations. They can be attached to most types of median and roadside barriers.
The SMART CUSHION®attenuators use a patented system for stopping vehicles. The system is speed dependent and stops small
and large vehicles by automatically regulating the stopping force exerted on a vehicle. Essentially, the system provides the neces-
sary forces based on the speed of the vehicle automatically compensating for the mass of the vehicle.
The SMART CUSHION®attenuators are slightly tapered from front to rear. This allows the side panel sections to collapse over the
next section without stress or damage. During collapse, the parts move freely past each other and do not become wedged during
the impact.
Wide temperature variations and temperature extremes do not affect the performance of SMART CUSHION®impact attenuators.
Temperature driven changes in viscosity of the fluid in the shock-arresting cylinder does not affect performance.
Maintenance
SMART CUSHION®impact attenuators are low-maintenance units. In a two-year in-service evaluation report submitted to the
Federal Highway Administration, the average cost of parts to repair the SMART CUSHION®impact attenuator was $39, excluding
two catastrophic impacts. More than four out of five of the reported repairs only required two shear bolts costing under $2. A
trained, two-person maintenance crew can return most impacted SMART CUSHION®attenuators to full service within 30 minutes.
This short repair time reduces the maintenance workers’ exposure to traffic and minimizes motorist inconvenience. Side impacts
rarely require a repair which eliminates exposure by 40%.
Crash Performance
The SMART CUSHION®broke new ground during NCHRP Report 350 crash testing. In the high-speed test, 100 kilometers per hour
(63 miles per hour), the small vehicle’s deceleration rate was significantly lower than any previously recorded value (-9.8 G’s as
compared to previous low of –13.4 G’s). This means less impact forces on the vehicle’s occupants and a reduced risk of injury and
severity.
All the tests were conducted on the same SMART CUSHION®unit over four consecutive days with no damage to non-expendable
parts. The only parts replaced after each crash test were the two shear bolts, costing less than $2 for each reset.

2
SPECIFICATIONS
Description
The SMART CUSHION®is a re-directive, non-gating crash attenuator that consists of a base, supporting frames, a sled, side
panels, a wire rope cable, sheaves, and a shock-arresting cylinder. The base is anchored to the mounting surface and provides
support for the frames that are mounted on it. The support frames hold the side panels that provide a flat outer redirective surface
for side impacts. The sled provides redirective support for side impacts and deceleration force for frontal impacts. The SMART
CUSHION®telescopes rearward upon frontal impact and can be reset with minimal repair parts. It is NCHRP 350 approved at Test
Levels 2 and 3.
System Dimensions & Weight
SCI 70 GM SCI 100 GM
Width 24 inch (610 mm) 24 inch (610 mm)
Length 13 ½ feet (4115 mm) 21 ½ feet (6550 mm)
Height 33 inch (840 mm) 33 inch (840 mm)
Weight 2465 lbs. (1120 kg) 3450 lbs. (1570 kg)
NCHRP 350, Test Level 2 3
DESIGN CRITERIA
General
SMART CUSHION®impact attenuators comply with NCHRP Report 350, TL2 and TL3, and are designed for work zone and perma-
nent applications.
Foundations
Foundations must be a flat surface with longitudinal and cross slopes of 10:1 (horizontal: vertical) or less. SMART CUSHION®
impact attenuators should not be located over drainage basins or expansion joints. Portland cement concrete foundation pads are
preferred for permanent installations; asphaltic concrete foundation pads are appropriate for work zone installations.
The following table describes the foundations that may be used. See Appendices for drawings.
Foundations
Pad Material and Thickness Anchor Embedment
6 inch (150 mm) reinforced PCC 15 ½ inch (140 mm)
8 inch (205 mm) non-reinforced PCC 5 ½ inch (140 mm)
3 inch (75 mm) AC 2,3 over 3 inch (75 mm) non-reinforced PCC 16 ½ inch (420 mm)
6 inch (150 mm) AC over compacted subgrade 316 ½ inch (420 mm)
8 inch (205 mm) AC 316 ½ inch (420 mm)
Notes: 1. Portland cement concrete 2. Asphaltic concrete 3. Minimum compaction: 95% of optimal

3
Concrete compressive strength shall be 4000 psi (28 MPa) at 28 days.
Foundation lengths may vary when using wide transitions.
Support Structure
SMART CUSHION®impact attenuators are self-supporting and do not require an additional support structure.
Location
The SMART CUSHION®impact attenuator’s location determines its position and transition requirements.
1. Approach Zone – SMART CUSHION®impact attenuators should not be placed directly behind raised curbs that exceed
4 inches in height. The longitudinal and cross slopes in front of the device should not exceed 10:1 (horizontal: vertical).
2. Barrier Width – SMART CUSHION®impact attenuators are 24 inch (610 mm) wide at the rear. Barriers
24 inch (610 mm) wide, or less, can be shielded without using a transition if there is no reverse direction traffic. Barriers
that are wider than 24 inch (610 mm) and/or have reverse direction traffic require a transition, available from
Work Area Protection Corp.
3. Barrier Height – SMART CUSHION®impact attenuators are approximately 33 3/8 inch (848 mm) high.
4. Barrier Shape – SMART CUSHION®transitions allow for connection to many barrier shapes.
Transition Design
SMART CUSHION®impact attenuators can be attached to many different barrier shapes. The attenuators are designed for direct
attachment to 24 in wide barriers and Jersey/F-Shape barriers. The SMART CUSHION®side panels move rearward beyond
the end of the attenuator up to 30 inch (760 mm) upon impact. This area is known as the travel zone. SMART CUSHION®
transitions provide this travel zone in front of wider barriers and obstacles.
See appendices for SMART CUSHION®transition drawings. Work Area Protection Corp. can design transitions for other frequently
used applications. Contact us for details.

4
Transitions
Necessary Locations (see Figure 1 – Necessary Locations):
• There is reverse direction traffic within the clear zone.
• The barrier intrudes into the side panels’ travel zone.
Figure 1 – Necessary Locations
Examples are median applications with bidirectional traffic, two lane roads with crossover potential, etc.
Unnecessary Locations (see Figure 2 – Unnecessary Locations):
• No reverse direction traffic within the clear zone.
• The barrier does not intrude into the side panels’ travel zone.
Figure 2 – Unnecessary Locations
Examples are traffic splits, shoulder applications with no crossover potential, one-way roads, etc.
Determining Side of Transition
The transition’s side is determined by standing at the front of the attenuator looking rearward toward the barrier to choose be-
tween left and right.
MedianSCI ATTENUATOR
Transition required on this side
BarrierSMART CUSHION

5
Drawings
The following SMART CUSHION®transitions and layouts are available from Work Area Protection Corporation. Diagrams are
shown in the Appendices as follows:
• Layout – Gore Assembly, Appendix F & F2 - Rigid design for wide obstacles
• Layout – Gore Assembly Calculations, Appendix F3 - Used to calculate longitudinal distances and parts requirements
• Transition - Jersey/F Shape, Appendix G - Used on standard Jersey/F shaped barriers with a 24 inch Base
• Transition - Concrete Block, 24 Inch, Appendix H - Used on 24 inch Concrete Block that must be 30 inch longitudinal
length for our travel zone
• Transition - Concrete Block, 30 Inch, Appendix I - Used on 30 inch Concrete Block and will extend our installation
length 38 inches
• Transition - Concrete Block, 36 Inch, Appendix J - Used on 36 inch Concrete Block and will extend our installation
length 52 inches
• Transition - Concrete Block, 30 Inch, Flared, Appendix K - Used on 30 inch Concrete Block/Pillars and will extend our
installation length 52 inches
• Transition - Concrete Block, 36 Inch, Flared, Appendix L - Used on 36 inch Concrete Block/Pillars and will extend our
installation length 71 inches
• Transition – Thrie-Beam Rigid Assembly, Appendix M - Rigid design for possible reverse direction impacts
• Transition – W-Beam Rigid Assembly, Appendix N - Rigid design for possible reverse direction impacts
• Transition – Jersey, Median Barrier Variable Width, Appendix O - Used on Jersey Shape barrier with base widths of
30 - 38 inches wide.
• Transition – Single Slope Barrier, Appendix -P - Used on 42 inch and 48 inch Single Slope barrier up to 26 inches
wide at the base
• Transition – W-Beam 28 Inch High, Appendix Q – Connection to 28 inch high W-Beam Guardrail with no reverse
direction traffic
• Transition – W-Beam 32 Inch High, Appendix R – Connection to 32 inch high W-Beam Guardrail with no reverse
direction traffic
• Transition – Wide Block Spanner, Appendix S – Connection to a wide Concrete Block for one sided protection
• Transition – Wide Block Offset, Appendix T – Connection where rear oncoming contact with the back side is not possible
• Transition – 36-44 Inch Flush Mount, Appendix U – Incremental widths for Bi-directional traffic.
• Transition – 46-48 Inch Flush Mount, Appendix V – Incremental widths for Bi-directional traffic.
• Transition – 50+ Inch Gore Reverse Direction Flush Mount, Appendix W – Incremental widths for Bi-directional traffic.

6
INSTALLATION
Installation and Performance Statements
Proper performance within these limits depends on correct installation of the SMART CUSHION®on an approved foundation.
Any SMART CUSHION®not installed according to the drawings and the requirements of this installation manual may present an
unsafe condition and should be reinstalled accordingly.
Impacts with vehicles whose size or mass are outside of those tested according to NCHRP 350 or with vehicles traveling at
speeds greater than those tested according to NCHRP 350 will not necessarily produce results within the test criteria. The crash
cushion is in conformance with all requirements of NCHRP 350 Levels 2 & 3 but is not guaranteed to safely stop a vehicle in a
situation not encompassed by the test conditions.
Safety
All work during installation, repair and inspection of the SMART CUSHION®should be performed according to feder-
al, state and local laws.
Equipment List
See Appendix B
Site Preparation
Check to make sure there are no drains, expansion joints, or buried conduit, cables or utility lines in the footprint space where the
attenuator will be placed. Remove any curbs >4 inch or obstacles in front of or beside where attenuator will be installed for a min-
imum distance of 12 feet from any edge of the attenuator. Be sure to set up proper traffic control before beginning any installation
or repair work at the site.
Foundations – (reference Appendices E1 and E2)
New foundations should be installed according to Appendix E – Foundation Drawing. Concrete should reach full cure strength
before use. The surface of the foundation must be cleaned of all debris, dirt, mud, sand, etc., as the crash cushion must sit on a
level plane, although longitudinal and/or cross slope of up to 10:1 (horizontal:vertical) is allowed.
Any of the following foundations will meet the minimum requirements:
• 6 inch reinforced concrete pad
• 8 inch non-reinforced concrete pad
• 3 inch asphalt over 3 inch of concrete
• 6 inch asphalt over 6 inch of compacted sub base
• 8 inch asphalt
Note: Concrete should be 28 MPa or 4000 psi minimum at full cure. The slope should not exceed 10:1.