QuadGuard cz Installation Manual

QuadGuard® cz

Portable, Non-Gating, RedirectivePerformance For Workzones

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Corporate Offices:35 East Wacker Dr., 11th FloorChicago, IL 60601-2076Telephone: (312) 467-6750FAX: (312) 467-1356http://www.energyabsorption.com/

Engineering and Manufacturing Facilities:Rocklin, CAPell City, AL

A Quixote CompanySaving Lives By Design

ENERGY ABSORPTIONSYSTEMS, INC.

QuadGuard® cz

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ImporImporImporImporImportant Intrtant Intrtant Intrtant Intrtant Introductoroductoroductoroductoroductory Notesy Notesy Notesy Notesy NotesProper installation of the QuadGuard cz is essential to as-sure maximum performance. Take the time to review theinstallation instructions and product limitations thoroughlybefore performing the necessary work. Do not attempt toinstall any crash cushion without the proper plans andinstallation manual from the manufacturer.

If you need additional information, or have questions aboutthe QuadGuard cz, please call Energy Absorption Systems’Customer Service Department at (888) 323-6374.

SSSSSystem Ovystem Ovystem Ovystem Ovystem OvererererervievievievieviewwwwwThe QuadGuard cz is a highly efficient, redirective, non-gating crash cushion for hazards ranging in width from610 mm to 915 mm (2' to 3'). It consists of crushable,energy-absorbing cartridges surrounded by a frameworkof Quad-BeamTM panels.

The QuadGuard cz utilizes two types of cartridges in a"staged" configuration to address both lighter cars andheavier, high center-of-gravity vehicles. Its modular de-sign allows the system length to be tailored to the designspeed of a site. Refer to the QuadGuard Product Manualto determine the appropriate length system for a givendesign speed.

Crash PCrash PCrash PCrash PCrash PerferferferferformanceormanceormanceormanceormanceThe 6 bay QuadGuard cz has successfully passed theNCHRP 350, Test Level 3 tests with both the light car andpickup truck at speeds up to 100 km/h (62 mph) at anglesup to 20 degrees.

During head-on impacts, the QuadGuard cz telescopes rear-ward and crushes to absorb the energy of impact. Whenimpacted from the side, it safely redirects the vehicle backtoward its original travel path and away from the hazard.

RETURN GOODS POLICY

Before returning any goods for credit please contactEnergy Absorption Systems Inc. Customer Service De-partment at 1-888-323-6374 or your local distributorfor proper instructions.

Table of ContentsImportant Introductory Notes ............................ 2System Overview ............................................... 2Crash Performance ............................................ 2

Installation ............................................... 3Required Tools ................................................... 3How to Determine Left/Right ............................. 5Counting the Number of Bays ............................ 5Measuring The Width ........................................ 6Site Preparation/Foundation .............................. 6QuadGuard cz Foundations ................................ 7Bidirectional Sites .............................................. 7Inspect Shipping ................................................ 8Installation Procedures ...................................... 8Transition Panel Types ....................................... 9

MP-3® Polyester Anchoring System............... 30Vertical Installations ........................................ 30Horizontal Installations .................................... 31MP-3® Installation Cautions ........................... 32QuadGuard cz MP-3® Anchoring System ....... 33

Moving the System.................................... 34QuadGuard cz (without Plate) .......................... 34QuadGuard cz (with Plate) ............................... 36QuadGuard cz (with Plate and Optional DPAAnchorage) ...................................................... 38

Maintenance and Repair ............................. 40Inspection Frequency ....................................... 40Visual Drive-By Inspection ............................... 40Walk-Up Inspection ......................................... 40Post-Impact Instructions ................................. 41Parts Ordering Procedure ................................ 44

Limitations And Warnings ........................... 45

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QuadGuard® cz

ReqReqReqReqRequired uired uired uired uired TTTTToolsoolsoolsoolsoolsDocumentation

• Manufacturer’s Installation Manual

• Manufacturer's Drawing Package

Cutting equipment

• Rebar Cutting Bit

• 22 mm (7/8") Concrete Drill Bits (*Two Fluted)

• Grinder, Hacksaw or Torch (optional)

• Drill Motor

• Drill Bits: 1/16" through 7/8"

* Energy Absorption Systems recommends using twofluted drills to achieve optimum tensile strength wheninstalling the MP-3 anchoring system.

Hammers

• Roto Hammer

• Sledgehammer

• Standard Hammer

Wrenches

• Heavy Duty Impact Wrench

• Standard adjustable wrench

• 1/2" drive sockets: 9/16", 11/16", 3/4", 15/16",1 1/8", 1 1/4"

• Deep Sockets: 5/16", 1 1/4"

• Ratchet and attachments for the above sockets

• Breaker Bar: 1/2" x 24"

• Torque Wrench: 200 ft-lbs.

• Crescent Wrench: 300 mm [12"]

• Allen Wrench: 3/8"

• Impact Wrench: 1/2"

Personal protective equipment

• Safety Glasses

• Gloves

Miscellaneous

• Traffic Control Equipment

• Lifting and Moving Equipment (A lifting deviceis preferred although a forklift can be used.) Mini-mum 5,000 lb. capacity required.

• Compressor (100 psi) and Generator (5 KW)

• Long Pry Bar

• Drift Pin 300 mm [12"]

• Center Punch

• Tape Measure 7.5 m (25')

• Chalk Line

• Concrete Marking Pencil

• Nylon bottle brush for cleaning 7/8" drilled holes

• Rags, Water, and Solvent for Touch-up

Note: The above list of tools is a general recommen-dation. The actual number of tools required willdepend on specific site conditions and the com-plexity of the installation.

InstallationInstallationInstallationInstallationInstallation

QuadGuard® cz

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Installation (cont’Installation (cont’Installation (cont’Installation (cont’Installation (cont’d.)d.)d.)d.)d.)

1 Cartridge

2 Diaphragm

3 Quad-Beam™ Fender Panel

Figure 1

4 Nose Cover

5 Monorail

6 Backup

61616161610 mm [24"]0 mm [24"]0 mm [24"]0 mm [24"]0 mm [24"]

7777760 mm [30"]60 mm [30"]60 mm [30"]60 mm [30"]60 mm [30"]

91919191915 mm [36"]5 mm [36"]5 mm [36"]5 mm [36"]5 mm [36"]

676767676740 mm [22'-1 3/8"]40 mm [22'-1 3/8"]40 mm [22'-1 3/8"]40 mm [22'-1 3/8"]40 mm [22'-1 3/8"]

Key

(Six bay systems shown)

Elevation

Plan

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QuadGuard® cz

Figure 2

HoHoHoHoHow to Determine Lefw to Determine Lefw to Determine Lefw to Determine Lefw to Determine Left/Rightt/Rightt/Rightt/Rightt/RightTo determine left from right when ordering parts, standin front of the system facing the hazard as shown in Fig-ure 2. Your left is the system's left and your right is thesystem's right.

Counting the Number of BaCounting the Number of BaCounting the Number of BaCounting the Number of BaCounting the Number of BaysysysysysOne bay consists of one cartridge, one diaphragm, andtwo fender panels. The nose section is not considered abay, though there is a cartridge in the nose of each sys-tem. Note that this means there will always be one morecartridge in the system than the number of bays in thesystem. To determine number of bays, count fender pan-els on one side, see Figure 2 (5 bay system shown).

FRONT

RIGHT

LEFT

REAR

FENDER PANELS

NOSE

System Orientation

BAY

BAY

BAY

BAY

BAY

NOSE

CARTRIDGE

DIAPHRAGM


QuadGuard® cz

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Site PSite PSite PSite PSite Preparation/Freparation/Freparation/Freparation/Freparation/Foundationoundationoundationoundationoundation

Caution: The QuadGuard cz must be correctlyanchored for proper impact performance.

Anchor the system using one of the following:

7" studs may be used to anchor the system to 28 MPa[4000 psi] min. P.C. concrete per the following mini-mums:**

a) 150 mm [6"] non-reinforced roadway

b) 200 mm [8"] reinforced portable pad per draw-ing 35-40-10

c) 180 mm [7"] deck structure

18" threaded rods may be used to install system on as-phalt.**

**Refer to the QuadGuard cz MP-3 Anchoring SystemInstallation Instructions on page 31 for specifications.

Installation cross slope shall not exceed 8% and shouldnot vary (twist) more than 2% over the length of the sys-tem; the pad surface shall have a light broom finish.

Note: Refer to pages 7 & 11 through 17 for an-choring details.

Caution: Accurate placement of all steel rebaris critical to avoid interference with the con-crete Anchor Bolts.

WARNING!Location of the backup in relation to nearby objects willaffect the operation of the attenuator. Upon impact, thefender panels telescope toward and extend beyond therigid backup as much as 760 mm [30"] from their pre-impact location. Position the backup so that the rearends of the last fender panels are a minimum of 760 mm[30"] forward of objects that would otherwise interferewith movement of the panels. Failure to comply withthis requirement may result in impaired systemperformance offering motorists less protection andcause component damage.

The nominal width of a system is the width betweenside panels behind the backup (see Figure 3).

The outside width of the system is approximately150 mm [6"] to 230 mm [9"] wider than the nominalwidth. The width of the system is not the same asthe width of the backup.

BACKUP

Figure 3Width of System

Measuring Measuring Measuring Measuring Measuring The The The The The WidthWidthWidthWidthWidthThe QuadGuard cz is available in three nominal widths:

• 610 mm [24"]

• 760 mm [30"]

• 915 mm [36"]


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QuadGuard® cz

QuadGuard cz FQuadGuard cz FQuadGuard cz FQuadGuard cz FQuadGuard cz FoundationsoundationsoundationsoundationsoundationsThe QuadGuard cz may be installed on any of the followingFoundations using the specified anchorage:

Foundation A: Concrete Pad or Roadway

Foundation: 150 mm [6"] minimum depthPortland Cement Concrete (P.C.C.)

Anchorage: MP-3® with 180 mm [7"] studs140 mm [5.5"] embedment

Foundation B: Asphalt over P.C.C.

Foundation: 75 mm [3"] minimum Asphalt Concrete(A.C.) over 75 mm [3"] minimum (P.C.C.)

Anchorage: MP-3 with 460 mm [18"] studs420 mm [16.5"] embedment

Foundation C: Asphalt over Subbase

Foundation: 150 mm [6"] minimum (A.C.) over150 mm [6"] minimum Compacted Sub-base (C.S.)


Foundation D: Asphalt Only

Foundation: 200 mm [8"] minimum (A.C.)


Foundation Specifications

for Foundations A, B, C and D mentioned above

A. C. ( Asphalt Concrete )

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" 95-100

3/8" 65-80

No. 4 49-54

No. 8 36-40

No. 30 18-21

No. 200 3-8

P.C.C. ( Portland Cement Concrete )

Stone aggregate concrete mix

4000 psi minimum compressive strength

(Sampling per ASTM C31-84 or ASTM C42-84a, test-ing per ASTM C39-84)

C.S. ( Compacted Subbase )

150 mm [6"] minimum depth 95% compaction

Class 2 aggregate

Sieve Size Moving Average % Passing

3" 100

2 1/2" 90-100

No. 4 40-90

No. 200 0-25

Figure 4PCMB Anchored To Roadway

Bidirectional SitesBidirectional SitesBidirectional SitesBidirectional SitesBidirectional SitesAt bidirectional sites, the rear of the system must be eitheroffset away from the traffic approaching from rear of thesystem or be installed with a Transition Panel to preventsnagging of vehicles (see Figure 45 on page 26 for maxi-mum gap). The Transition Panels are depicted on page 9.

If attaching to portable concrete barrier (PCMB) the last sec-tion of barrier must be anchored to the roadway (see Fig-ure 4 and drawings supplied with your system). AnchorBrackets are available from Energy Absorption Systems, Inc.

Note:

Walk-up inspections are recommended at leastonce every six months for installations on asphalt.


QuadGuard® cz

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Inspect ShippingInspect ShippingInspect ShippingInspect ShippingInspect ShippingBefore installing the QuadGuard cz , check the receivedparts against the shipping list supplied with the system.Make sure all parts have been received.

Installation PInstallation PInstallation PInstallation PInstallation PrrrrroceduresoceduresoceduresoceduresoceduresNote: The drawing package supplied with theQuadGuard cz must be used with these instruc-tions for proper assembly and should take prece-dence over these general instructions.

QUAD-BEAM™ TO W-BEAMTRANSITION PANEL

Figure 5Transitioning the QuadGuard cz


1) Determine Transition TypeA transition panel or side panel will be used on eachside of the backup. A side panel is not needed when atransition panel is used. Several types of transitionsare available for use with the QuadGuard cz. Refer tofigures 5 through 10 and the drawing package to de-termine which type of panels are being installed.

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QuadGuard® cz

TTTTTransition Pransition Pransition Pransition Pransition Panel anel anel anel anel TTTTTypesypesypesypesypesNote: The proper transition or side panel must beused for optimum impact performance of the sys-tem. The correct panel to use will depend on thedirection of traffic and what type of barrier or haz-ard the QuadGuard cz is shielding. Contact theCustomer Service Department prior to installationif you have any questions.

Figure 8

Figure 9 Figure 10

Figure 7

Note: Wheel Deflectors may be required for thisapplication.

Figure 6No Transition

Quad-Beam to Thrie-Beam Transition PanelQuad-Beam to Safety Shape Barrier Transition Panel

Quad-Beam End Shoe Transition PanelQuad-Beam to W-Beam Transition Panel


QuadGuard® cz

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Bolting Monorail Segments TogetherFigure 12

MONORAIL SEGMENT

MONORAIL SEGMENT

3) Bolt together monorail segmentsAll monorail segments must be bolted together us-ing the bolts provided with the QuadGuard cz. Thenumber of monorail segments will vary by systemlength. Torque the nut until the lock washer is fullycompressed. Refer to Figure 12.

QuadGuard cz (without plate)QuadGuard cz (without plate)QuadGuard cz (without plate)QuadGuard cz (without plate)QuadGuard cz (without plate)2) Mark System Location

Locate the centerline of the system by measuring theproper offset from the hazard. Refer to the drawingpackage supplied with the system. Place chalk lineto mark the centerline of the system. Mark a con-struction line parallel to the center line and offset165 mm [6.5"] to one side as shown in Figure 11.The edge of the monorail will be placed on this line.

Note: The concrete pad should be installed per theproject plans supplied with the system.

Figure 11(Top View of Concrete Pad)Locating Construction Line

165 mm [6.5"]CENTERLINE OF SYSTEM

CONSTRUCTION LINE

WARNING!Location of system with respect to the hazard iscritical and dependent on the type of transitionpanel used. See the project plans supplied with thesystem for details.

5/8" X 3 1/2"G5 HEX BOLT

5/8" LOCK WASHER

5/8" HEX NUT


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QuadGuard® cz

4) Anchor the Backup and MonorailRefer to Figure 13 (showing backup assembly) andfigures 14 and 15 (showing monorail installation).Also refer to the drawing package.

A. Backup Installation

Locate backup and monorail on foundation with sideof monorail on the construction line (see Figure 15).Verify that any applicable transition panels fit prop-erly before anchoring backup. Drill anchor holes infoundation using the backup as template. Anchor thebackup to the foundation using the MP-3 vertical kitsprovided.

See page 12 for anchoring options and page 28 “MP-3Polyester Anchoring System".

B. Monorail installation

Locate the monorail using the monorail assemblydrawings. Orient monorail so that the monorailtongues face the backup. Drill anchor holes usingthe monorail as a template (see figure 15). Do notdrill through pad. Anchor each monorail section us-ing the MP-3 vertical kits provided. Refer to Figure 17and the MP-3 Polyester Anchoring System Instruc-tions on page 28. It is important to install each seg-ment of monorail in alignment from the back to thefront of the system (+/- 6 mm [1/4"]).

CZ BACKUP

Figure 13Anchoring cz Backup to Foundation

WARNING!Every hole and slot in backup and monorail must havean MP-3 stud anchoring it.

Figure 15Backup and Monorail Location

100 mm [4"] BACKUP MONORAIL 3/4" STUD

CENTERLINE

CONSTRUCTION LINE

CAUTION:40 mm [1.50"]

MAX. STUD HEIGHT

Figure 14

MP-3 ANCHOR

BACKUP OR MONORAIL

ROADWAY

WARNING!Improper alignment at the monorail splice joints willprevent proper system collapse during an impact.

Proper Stud Height

VERTICAL MP-3 KITWITH 3/4" X 7" STUD


QuadGuard® cz

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QuadGuard cz (without plate)QuadGuard cz (without plate)QuadGuard cz (without plate)QuadGuard cz (without plate)QuadGuard cz (without plate)Note: Cross slope shall not exceed 8% and notvary (twist) more than 2% from front to back.See Figure 16.

8% SLOPEMAX.

Figure 16Max. Allowable Cross Slope

Figure 17Anchoring the System

SOIL

3/4" DIA. MP-3THREADED ROD SYSTEM

QUADGUARD CZ SYSTEM

MIN. 483mm [19"] TYP.ROADWAY EDGE

C - ASPHALT* ROADWAY

D - NON-REINFORCED P.C. CONCRETE* ROADWAY

OR E - COMPACTED SUBBASE*

*MATERIALS:C - ASPHALTIC CONCRETE

• ASPHALT BINDER AR-4000• ASPHALT AGGREGATE 3/4

(19mm) MAX. MED A BD - 28 MPa [4000 PSI] P.C. CONCRETEE - SUBBASE PREPARED AS COMPACTED

• CLASS 2• 95% COMPACTION MIN. LAYER

Note:


Note: 18" Anchors are supplied with the QuadGuard cz.If another substrate is encountered, please call CustomerService to discuss options.

Use MP-3 Polyester Anchoring System supplied byEnergy Absorption Systems, Inc. or approved equal.

QuadGuard czs installed on asphalt must be inspectedto ensure the anchors are still properly set followingeach impact. Re-anchor as necessary.

Use the Plate/Monorail sections as a template to drillanchor holes. Refer to figure 17 and instructions con-tained in the MP-3 Polyester Anchor box supplied withthe system for detailed anchoring instructions.

Depth Combinations

Req’d Stud LengthEDC

180 mm [7"]--150 mm [6"]--

460 mm [18"]--75 mm [3"]75 mm [3"]

--

----

150 mm [6"] 460 mm [18"]

460 mm [18"]

150 mm [6"]

200 mm [8"]


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QuadGuard® cz

PLATE/MONORAIL SEGMENT

Bolting Plate/Monorail Segments TogetherFigure 18

PLATE/MONORAIL SEGMENT

Detail 18a

3/4" X 10 UNC STUD

18A

QuadGuard cz (with plate)QuadGuard cz (with plate)QuadGuard cz (with plate)QuadGuard cz (with plate)QuadGuard cz (with plate)2) Mark System Location

Locate the centerline of the system by measuring theproper offset from the hazard. Refer to the drawing pack-age supplied with the system. Place chalk line to markthe centerline of the system. Mark a construction lineparallel to the center line and offset 534 mm [21"] toone side. The edge of the monorail plate will be placedon this line. See figure 19.

3) Bolting together of plate/monorail seg-mentsAll plate/monorail segments must be bolted togetherusing the bolts provided with the QuadGuard cz. Thenumber of monorail segments will vary by systemlength. Torque the nut until the lock washer is fullycompressed. Refer to Figure 18.

Figure 19

534 mm [21”]

CONSTRUCTION LINE

CENTERLINE

5/8" X 3 1/2" G5 HEX BOLT

5/8" LOCK WASHER

5/8" HEX NUT


QuadGuard® cz

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QuadGuard cz (with plate)QuadGuard cz (with plate)QuadGuard cz (with plate)QuadGuard cz (with plate)QuadGuard cz (with plate)4) Anchor the SystemNote: Cross slope of plate shall not exceed 8% andnot vary (twist) more than 2% from front to back.For these conditions, a leveling pad is required.See Figure 20.

8% SLOPEMAX.


Figure 21Anchoring the System

SOIL

3/4" DIA. MP-3THREADED ROD SYSTEM

QUADGUARD CZ SYSTEM

MIN. 483mm [19"] TYP.ROADWAY EDGE

C - ASPHALT*

D - REINFORCED P.C. CONCRETE*

OR E - COMPACTED SUBBASE*

*MATERIALS:C - ASPHALTIC CONCRETE

• ASPHALT BINDER AR-4000• ASPHALT AGGREGATE 3/4

(19mm) MAX. MED A BD - 28 MPa [4000 PSI] P.C. CONCRETEE - SUBBASE PREPARED AS COMPACTED

• CLASS 2• 95% COMPACTION MIN. LAYER

Depth Combinations

Note:


Note: 18" Anchors are supplied with the QuadGuard cz.If another substrate is encountered, please call CustomerService to discuss options.

Req’d Stud LengthEDC

180 mm [7"]--150 mm [6"]--

460 mm [18"]--75 mm [3"]75 mm [3"]

--

----

150 mm [6"] 460 mm [18"]

460 mm [18"]


Use MP-3 Polyester Anchoring System supplied byEnergy Absorption Systems, Inc. or approved equal.

QuadGuard czs installed on asphalt must be inspectedto ensure the anchors are still properly set followingeach impact. Re-anchor as necessary.

Use the Plate/Monorail sections as a template to drillanchor holes. Refer to figure 21 and instructions con-tained in the MP-3 Polyester Anchor box supplied withthe system for detailed anchoring instructions.

150 mm [6"]

200 mm [8"]

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QuadGuard® cz

QuadGuard cz (with plate andQuadGuard cz (with plate andQuadGuard cz (with plate andQuadGuard cz (with plate andQuadGuard cz (with plate andOptional DPOptional DPOptional DPOptional DPOptional DPA A A A A AncAncAncAncAnchorage)horage)horage)horage)horage)2) Mark System Location

Locate the centerline of the system by measuring theproper offset from the hazard. Refer to the drawing pack-age supplied with the system. Place chalk line to markthe centerline of the system. Mark a construction lineparallel to the center line and offset 534 mm [21"] toone side. The edge of the monorail plate will be placedon this line. See figure 22.

WARNING!Location of the system with respect to the hazardis critical and dependent on the type of transitionpanel used. See the project plans supplied with thesystem for details.

3a)Bolting together of plate/monorail segmentsAll plate/monorail segments must be bolted togetherusing the bolts provided with the QuadGuard cz. Thenumber of monorail segments will vary by systemlength. Torque the nut until the lock washer is fully com-pressed. Refer to Figure 18.

WARNING!All QuadGuard cz plate/monorail segments must bebolted together and torqued to fully compress the lockwasher before attempting to move or install the system.

Figure 22

534 mm [21”]

CONSTRUCTION LINE

CENTERLINE


QuadGuard® cz

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QuadGuard cz (with plate andQuadGuard cz (with plate andQuadGuard cz (with plate andQuadGuard cz (with plate andQuadGuard cz (with plate andOptional DPOptional DPOptional DPOptional DPOptional DPA A A A A AncAncAncAncAnchorage)horage)horage)horage)horage)3b) Bolting together of Wing Plates to

Monorail Plate SegmentsAfter the monorail plate segments have been boltedtogether, place the system on top of several sawhorses or other type of adequate table support. Us-ing 5/8" x 2" rail bolts and 5/8" rail nuts, attach a wingplate to the front of the first monorail plate, to therear of the backup monorail plate, and at the con-nection point for each monorail plate segment. Seefigure 23.

Figure 23Wing Plate Attachment

FIRST MONORAIL PLATE

WING PLATE

BACKUP MONORAIL PLATE

5/8” X 2" RAIL BOLT

5/8” RAIL NUT


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QuadGuard® cz

WARNING!Location of the system with respect to the hazardis critical and dependent on the type of transitionpanel used. See the project plans supplied with thesystem for details.

4) Anchor the SystemNote: The plate is not to be used on cross slopesthat exceed 8% or vary (twist) more than 2% fromfront to back. For these conditions, a leveling padis required. See Figure 24.

Use the parts supplied by Energy Absorption Systems, Inc.

QuadGuard czs installed on asphalt or soil must be in-spected to ensure the system is properly anchored fol-lowing each impact. Refurbish and re-anchor as nec-essary.

1. Lift the system into place at the marked loca-tion. If required, attach the system to the haz-ard/barrier via pin and loop connection (see Fig-ure 25) and/or transition panel(s).

8% SLOPEMAX.


Figure 25Pin and Loop Connection

2. Once system is in place, position pile drivingequipment over a square hole in the outboardwing plate as shown in Figure 26.

3. Place the 72 ¾" x 6" x 6" Drivable Post into thesquare hole in the wing plate as shown in Fig-ure 26. Use a small level to ensure the post isstraight for pile driving. Drive post into the grounduntil the post's top plate is flush with the top ofthe wing plate.

4. Use the ¾" x 2 ½" hex bolts to fasten the ¾" x 10"x 10" Post Cap to the top of the post as shown inFigure 27.

Figure 26

Figure 27

POST CAP

DRIVABLE POST

Repeat this procedure until system is completely an-chored. 3/4" X 2 1/2" G8

HEX BOLT

DRIVABLE POST

WING PLATE


QuadGuard® cz

18

5) Attach Side Panels and/or TransitionPanels to Backup AssemblyAttach the side panel or transition panel as appropri-ate to each side of backup. Refer to Figure 28 andthe drawing package for more information.

Figure 28Side Panel/Transition Panel Attachment

5/8" RAIL NUT(SEE FIGURE 32)

SIDE PANELS SHOWN.IN SOME CASES, THIS WILL

BE A TRANSITION PANEL(SEE FIGURES 7 THRU 10)

CZ BACKUP

5/8" X 2" RAIL BOLT

Installation tip:

Use drift pin to align the center hole of the panel withthe center hole of the backup before installing therail bolts.

Note: A side panel is not needed when a transitionpanel is used.


19

QuadGuard® cz

6) Attach Monorail GuidesUsing 3/4" x 2" Grade 8 Hex Bolts, 3/4" Lock Washersand 3/4" Nuts, attach monorail guides to diaphragmsas shown in Figure 29.

Figure 29

DIAPHRAGM

Figure 31Diaphragm spacing

915 mm [36"] DIAPHRAGMS915 mm [36"]TYPICAL

7) Install DiaphragmsOrient a diaphragm so that the front face of theQuad-Beam shape faces toward the nose of the sys-tem as shown in Figure 30. Slide one diaphragm allthe way to the backup to ensure the system is able tocollapse properly during impact. Once this has beenverified, slide the diaphragm forward to approximately915 mm [36"] in front of the backup. Orient and slideall other diaphragms onto monorail and position eachapproximately as shown in Figure 31.

TOWARD NOSE

FRONTBACK

Figure 30Diaphragm Orientation

QUAD-BEAM

FRONT FACE OF BACKUP MONORAIL

Monorail Guide Attachment

3/4" HEX NUT

3/4" LOCK WASHER

3/4" X 2” G8 HEX BOLTMONORAIL GUIDE


QuadGuard® cz

20

8) Install Fender PanelsNote: Do not mix the 5/8" rail nuts (large) withthe 5/8" hex nuts (small). See Figure 32.

32 mm [1.25"] 24 mm [0.94"]

Figure 32Rail Nuts are Oversize

5/8" RAIL NUT (LARGE) 5/8" HEX NUT (SMALL)

Figure 33Fender Panel Assembly

DIAPHRAGM

BACKUP OR DIAPHRAGM

5/8" RAIL BOLT

5/8" FLATHEADSOCKET SCREW

MUSHROOM WASHER

FENDER PANEL

SIDE PANEL,FENDER PANEL, ORTRANSITION PANEL

KEEP CENTER HOLE EMPTYFOR NEXT PANEL

SPRING

5/8" FLAT WASHER

5/8" RAIL NUT (LARGE)5/8" RAIL BOLT

Starting at the backup, install left and right fenderpanels as shown in Figures 33, 34 and fender panelassembly drawing.

Step 1

Place the fender panel so that the center hole ofthe rearward diaphragm is lined up with the ap-proximate center of the slot in the fender panel.

Attach mushroom washer assembly as shown inFigures 33 and 34, but do not torque at this time.(This helps to balance the fender panel.)

Step 2

Slide the fender panel forward until the holes inthe fender panel line up with the holes in the for-ward diaphragm.

Step 3

Use a drift pin to align thecenter hole of the fenderpanel with the center holeof the diaphragm.

Step 4

Attach the front of thefender panels to the nextdiaphragm using two railbolts and large hex nutsper side. Use only the topand bottom holes, leavethe center hole open un-til the next fender panelis installed.

5/8" HEX NUT (SMALL)

5/8" RAIL NUT (LARGE)


21

QuadGuard® cz

Be sure mushroom washer lays flat against the fenderpanel as shown in Figure 35. Standoff on washermust be seated completely through slot.

Figure 34Mushroom Washer Attachment

Figure 35Mushroom Washer Orientation

CORRECT INCORRECT

BAY SPACING915 mm [36"]

DIAPHRAGMOR BACKUP

DIAPHRAGM

FENDER PANEL

Figure 36Proper Spacing Between Diaphragms

Check diaphragm spacing to ensure 915 mm [36"]between rear faces of consecutive diaphragms asshown in Figure 36. Once the proper spacing hasbeen achieved, torque the mushroom washer assem-bly (small hex) nuts to hold the diaphragm and fenderpanels in place during assembly of the rest of the sys-tem. Install the remaining diaphragms and fender pan-els following the same procedures.

Tighten the nut so that the spring is compressed 1mmto 3mm [1/16" to 1/8"] to complete the assembly.

FENDER PANEL (ATTACHED)

DIAPHRAGM OR BACKUP

SLOT HOLE

5/8" FLATHEADSOCKET SCREW

MUSHROOMWASHER

FENDER PANEL SPRING

5/8" FLAT WASHER

5/8" HEX NUT (SMALL)


QuadGuard® cz

22

Figure 37

MONORAIL

QuadGuard cz (without plate)QuadGuard cz (without plate)QuadGuard cz (without plate)QuadGuard cz (without plate)QuadGuard cz (without plate)9) Attach the Endcap

Using 5/8" x 3 1/2" G5 hex bolt, 5/8" hex nut and 5/8"lock washer, attach the end cap to the front of thefirst monorail segment as shown in Figure 37.

QuadGuard cz (with plate)QuadGuard cz (with plate)QuadGuard cz (with plate)QuadGuard cz (with plate)QuadGuard cz (with plate)9) Attach the Endcap

Using 5/8" x 3 1/2 hex bolt, 5/8" hex nut and 5/8" lockwasher supplied with the system, attach the endcapto the front of the first plate/monorail segment asshown in Figure 38.

FRONT OF FIRST PLATE/MONORAIL SEGMENT

Figure 38End Cap Attachment


End Cap Attachment

5/8" X 3 1/2" G5 HEX BOLT

5/8" LOCK WASHER

5/8" HEX NUTEND CAP 5/8" X 3 1/2" G5 HEX BOLT

5/8" LOCK WASHER

5/8" HEX NUT

END CAP

23

QuadGuard® cz

10) Install Cartridge Support BracketsAttach lower cartridge support bracket to all dia-phragms and backup as shown in figures 40 and 41and the diaphragm assembly drawing.

Note: 610 mm [24"] wide systems do not have sidecartridge support brackets; 762 mm [30"] and915 mm [36"] wide systems have side cartridge sup-port brackets welded to the backup and diaphragms.See Figure 39.

SIDE CARTRIDGESUPPORT BRACKETS

Figure 39Side Cartridge Support Brackets

Figure 41

LOWER CARTRIDGESUPPORT BRACKET

DIAPHRAGM

DIAPHRAGM

610 mm [24"] WIDE 762 mm [30"] AND915 mm [36"] WIDE

Figure 40Lower Cartridge Support Bracket Installation

BACKUP

STEP IIINSTALL “KEEPER"

STEP IINSTALL LOWERCARTRIDGESUPPORTBRACKET


BACKUP

Lower Cartridge Support Bracket Installation



QuadGuard® cz

24

QuadGuard cz (with Nose Belt)QuadGuard cz (with Nose Belt)QuadGuard cz (with Nose Belt)QuadGuard cz (with Nose Belt)QuadGuard cz (with Nose Belt)11a) Nose Belt Assembly

a. Using 5/8" x 5" hex bolt, two 5/8" x 1 3/4" flatwashers and 5/8" hex nut, attach fender panel tofront diaphragm top and bottom as shown in Fig-ure 42 (two places per side).

b. Using 5/8" x 5" hex bolt and 5/8" hex nut, attachpullout bracket to front diaphragm and fenderpanel middle as shown (one place per side).

d. Align holes in each end of the nose belt with theinstalled bolts (three per side) and slide NoseBelt onto bolts.

e. Align holes in belt clamps with bolts and slidebelt clamps onto bolts.

f. Using fourth 5/8" x 1 3/4" flat washer and third5/8" hex nut, secure the belt clamps and nosebelt (three places per side).

Figure 42

5/8" X 1 3/4" FLAT WASHER

BELT CLAMP

5/8" X 1 3/4" FLAT WASHER

5/8" X 5" G5 ALLTHREAD HEX BOLT

QUADGUARD NOSE BELT

5/8" HEX NUT

FRONT DIAPHRAGM

Optional Nose Belt Assembly

Detail 42a

Note: Nose of system may be delineated tocomply with local codes (chevron, reflectivematerial, signs, etc. supplied by others).

THE FACE OF THE NUT TOBE FLUSH WITH HUMPSON FENDER PANEL

5/8" X 1 3/4"FLAT WASHER

5/8" HEX NUT

c. Thread second 5/8" nut onto theinstalled bolt. Be sure the face ofthe nut is flush with humps onfender panel (see detail 42a).Slide third 5/8" x 1 3/4" flat washeronto bolt (three places per side).


25

QuadGuard® cz

Detail 43a

USE UPPER SLOTSIN ADJUSTABLECARTRIDGESUPPORT BRACKET

USE LOWER SLOTSIN ADJUSTABLECARTRIDGESUPPORT BRACKET

Detail 43b

CARTRIDGE STYLE A

CARTRIDGE STYLE B

Adjustable Bracket Locationwhen using Cartridge Style B

11b) Install Nose AssemblyDetermine which style of cartridges your system has.

If your system has cartridge style A as shown in De-tail 43a, install cartridge support in the upper twoslots as shown.

If your system has cartridge style B as shown in De-tail 43b, install cartridge support in the lower twoslots as shown.

Adjustable Bracket Locationwhen using Cartridge Style A


QuadGuard® cz

26

Detail 43c

Detail 43d

Detail 43e

As shown in Detail 43c, cartridge style A is installedwith the adjustable cartridge support bracket incor-rectly in the lower position.

As shown in Detail 43d, cartridge style B is installedwith the adjustable cartridge support bracket incor-rectly in the upper position.

Detail 43e shows the adjustable cartridge supportbracket installed correctly.

Incorrect Installation ofAdjustable Cartridge Support Bracket

Incorrect Installation ofAdjustable Cartridge Support Bracket

Correct Installation ofAdjustable Cartridge Support Bracket


27

QuadGuard® cz

QuadGuard czQuadGuard czQuadGuard czQuadGuard czQuadGuard cz(with Nose Co(with Nose Co(with Nose Co(with Nose Co(with Nose Covvvvver)er)er)er)er)11) Nose Cover Assembly

Bolt the nose directly to the front dia-phragm, as shown in Figures 44, 45 andthe nose assembly drawing, using six railbolts which also hold the front two fenderpanels to the diaphragm with bar washerunder each bolt. Place pullout bracketsunder center nuts.

The top and bottom holes of the noseare slotted to provide adjustment. Ad-just so the top edge of the nose is levelwith the top edge of the fender panels,then torque all six nuts to 35 Nm[25 ft-lbs]. See Figure 45.

Figure 44

Figure 45

PLACE A BOARD OVER THE FIRST TWO DIAPHRAGMS ASSHOWN TO FACILITATE PROPER ALIGNMENT OF NOSE

TIGHTEN NUTS TO 35 Nm [25 FT-LBS ]AFTER ALIGNING NOSE AS SHOWN

Adjust Nose

EXISTING5/8" RAIL NUT

NOSE COVER

EXISTING5/8" X 2" RAIL BOLT

1 1/4" X 2"BAR WASHER

FRONT DIAPHRAGM

Nose Assembly


QuadGuard® cz

28

12) Check the System AssemblyAt this point, recheck to ensure that all fasteners areproperly tightened throughout the system (anchorbolts, etc.). See warning below. Check all Fender Pan-els. If they do not fit tightly against the underlyingpanel, system realignment may be necessary. (SeeFigure 46).

WARNING!Anchor Studs.... Torqued to 165 Nm [120 ft-lbs]

Should NOT protrude above nuts(see Figure 16)

All Other Bolts... Tightened

Fender Panel..... Maximum gap allowed:20 mm [0.78"]

FENDER PANEL

MAXIMUM GAP = 20 mm [0.78"]

UNDERLYING FENDER,TRANSITION, EXTENSION

OR SIDE PANEL

Figure 46

WARNING!Placing the wrong Cartridge in the Nose or any Baywill result in unacceptable crash performance asdescribed in NCHRP 350.

13) Cartridge InstallationTo complete the assembly of a QuadGuard cz, placethe appropriate Cartridge in each Bay and Nose sec-tion of the system. Type I Cartridges are placed to-ward the front (Nose) of the system; Type II Car-tridges are placed toward the rear (Backup) of thesystem. Refer to figures 47 and 48.

I - TYPE I CARTRIDGEII - TYPE II CARTRIDGE

3 BAYS

4 BAYS

5 BAYS

6 BAYS

7 BAYS

8 BAYS

9 BAYS

Figure 47Cartridge Placement


Fender Panel Gap

29

QuadGuard® cz

Figure 48

REAR

TYPE II CARTRIDGES

TYPE I CARTRIDGES

FRONT

Typical Cartridge Layout5 Bay System Shown


QuadGuard® cz

30

MPMPMPMPMP-3-3-3-3-3®®®®® P P P P Polololololyyyyyester ester ester ester ester AncAncAncAncAnchoring Shoring Shoring Shoring Shoring Systemystemystemystemystem

The MP-3 Polyester Anchoring System is a quick andeasy way to securely anchor crash cushions and othercommon highway devices. MP-3 features high pulloutstrength, superior vibration resistance, and exceptionaldurability.

Each MP-3 kit contains a can of MP-3 resin, hardener, coldweather promotor, studs, washers, nuts and a completesafety sheet. The cold weather promoter shortens harden-ing time by as much as seven hours. Both vertical and hori-zontal installations are possible using the MP-3 System.

WARNING!Wear safety goggles and gloves during installation.

MP-3 Anchoring Information

WARNING!Do not allow the MP-3 Resin or Hardener to contactskin or eyes. See material safety data sheet suppliedwith the MP-3 kit for first-aid procedures. Use only inwell-ventilated area. Do not use near open flame.

VVVVVererererertical Installationstical Installationstical Installationstical Installationstical InstallationsNote: Read MP-3 Instructions before starting.

1) Prepare the concrete pad

The anchor bolts (Studs) that anchor theQuadGuard cz to the concrete pad must be thoseshipped in the kit or of high strength steel (830 MPa[120,000 psi] minimum tensile strength or equal.)These Studs must be set in minimum 28 MPa[4000 psi] concrete. Allow the concrete to cure aminimum of 7 days before installing MP-3.

2) Drill holes

Note: Energy Absorption Systems recommends us-ing two fluted drills to achieve optimum tensilestrength when installing the MP-3 anchoring system.

Use the part that is to be anchored as a drilling tem-plate. Drill the holes 3 mm [1/8"] larger than the studdiameter to the recommended depth, using a rotarypercussive drill. Full strength will not be achieved if adiamond drill is used. Refer to the MP-3 installationinstructions provided with your kit. Check to be sureall the holes are drilled to the proper depth and alignedwith the part to be anchored. Refer to Table A.

Stud size

3/4" x 6 1/2"

3/4" x 7"3/4" x 7 1/2"3/4" x 8 1/2"

3/4" x 18"

Concretebit size

22 mm[7/8"]

22 mm[7/8"]

22 mm[7/8"]

MinimumDepth

125 mm[5"]

140 mm[5 1/2"]

420 mm[16 1/2"]

RecommendedTorque

165 Nm[120 ft-lbs]

165 Nm[120 ft-lbs]

<15 Nm[<10 ft-lbs]

WARNING!Do not use Promoter when the temperature is above15 degrees Celsius (60 degrees Fahrenheit). Grout willharden too quickly.

3) Clean the holes

Blow the concrete dust from the hole, using oil-freecompressed air. Thoroughly brush it with a stiff-bristled brush, and then blow it out again. If the holeis wet, completely flush it with water while brushing.Then blow it clean, using oil-free compressed air.

4) Mix the resin and hardener

Wearing gloves and safety goggles, remove the lidsfrom the MP-3 Part A-Resin and Part B-Hardener con-tainers. Pour Part B into Part A, then mix vigorouslyfor 30 seconds to form MP-3 grout (an anchor studmay serve as a stirring rod).

5) Add cold weather promotor (in cold weather)

For faster hardening in cold weather, Promoter maybe used. Add the entire contents of the partially filledPromoter container to the MP-3 grout; then mix foran additional 30 seconds. Use immediately becausethe MP-3 grout will thicken quickly. Refer to Table Bfor hardening times.

6) Pour grout into holes

Table A

31

QuadGuard® cz

Approximate Hardening Times (hrs)

Temperature

(F)

>80

70-79

60-69

50-59

40-49

30-39

<30

NoPromoter

1/2

1

2

4

8

N/R*

N/R*

WithPromoter

N/R*

N/R*

N/R*

3/4

1

1 1/2

N/R*

(C)

>27

21-26

16-21

10-15

4-9

-1-4

<-1

Crimp the mouth of the can to form a spout, and pourthe MP-3® grout mixture down into the hole through thepart. Fill the hole 1/3 to 1/2 full.

HorizHorizHorizHorizHorizontal Installationsontal Installationsontal Installationsontal Installationsontal InstallationsThe horizontal MP-3 kit is the same as the vertical kitexcept that a cartridge for a standard caulking gun is sup-plied in the horizontal kits and the resin for the horizontalkits is a thixotropic (TX) resin. The TX-Resin is a gelledresin designed to keep the grout in place in horizontalholes during installation.

When using the horizontal MP-3 kits follow the verticalinstructions with the following exceptions:

1) Thread dispensing tip onto dispenser

Prior to mixing the grout, carefully thread the dis-pensing tip onto the dispenser.

2) Pour mixed grout into dispenser

Once the grout is mixed crimp the mouth of the canto form a spout, and pour the MP-3 grout into theopen end of the dispenser (use mixing stud to scrapeout the portion remaining in the can). You may usethe box to hold the dispenser upright. Close the boxlid and poke the dispenser tip into the top of it. Sealthe dispenser with the plunger provided.

3) Place dispenser in caulking gun and dispense grout

Cut off the small end of the dispenser tip. Place thedispenser into a caulking gun and dispense until MP-3TX grout reaches the tip of the dispenser, then re-lease pressure. Push the dispenser tip through thepart to the bottom of the hole and dispense whileslowly withdrawing the tip.

Caution: Do not overfill or underfill the hole.Fill hole approximately 1/3 to 1/2 full. If thehole is overfilled, there will not be enoughgrout to use all of the anchor studs/kit. If holeis under-filled the grout may not develop therequired pull out strength.

* Not recommended. Contact Energy Absorption SystemsInc.’s Customer Service Department for more information.

Caution: Do not overfill or underfill the hole. Ifthe hole is overfilled, there will not be enoughgrout to use all of the anchor studs/kit. If holeis under-filled the grout may not develop therequired pull out strength.

7) Add the washers and nuts

Place a flat washer onto the stud; then thread a nuton until 1 or 2 threads of the NUT are left exposed.

8) Insert Studs in holes and wait for grout to harden

Push the stud down through the part to be anchoredand into the hole. Give the stud several twists in theMP-3 to wet the threads.

Caution: Do not disturb or load the stud untilthe MP-3 material has hardened (see Table Bfor hardening times).9) Torque the nuts

Once the grout has hardened, torque the nut to therecommended values. (See Table A.) Now no threadsof the nut should be exposed.

Table B

MPMPMPMPMP-3-3-3-3-3®®®®® P P P P Polololololyyyyyester ester ester ester ester AncAncAncAncAnchoring Shoring Shoring Shoring Shoring System (cont’ystem (cont’ystem (cont’ystem (cont’ystem (cont’d.)d.)d.)d.)d.)

QuadGuard® cz

32


CORRECT

INCORRECT

MP-3MP-3MP-3MP-3MP-3®®®®® Installation Cautions Installation Cautions Installation Cautions Installation Cautions Installation Cautions1) Shelf life

If the shelf life of the MP-3 has expired (see MP-3 kitfor expiration information), mix a small amount ofMP-3 in the proportions of one part A to two parts Bby volume. If the material does not set according tothe instructions, contact Energy Absorption Systems,Inc. for guidance.

Figure 49

WARNING!Do not use the MP-3 if the material fails to set up, PartA-Resin has gelled (for vertical applications), or TX-Resin is NOT gelled (for horizontal applications).

2) Steel rebar

If steel rebar is encountered while drilling an MP-3 an-chor bolt hole, apply one of the following solutions:

A. Using a diamond core drill or rebar drilling tool,drill through the rebar only, then switch back tothe concrete bit and drill into the underlying con-crete until the proper hole depth is reached.

Caution: Do not drill through rebar without firstobtaining permission to do so from the localproject engineer.

B. Drill a new hole down at an angle past the rebarto the proper depth. Anchor the stud by com-pletely filling both holes with MP-3.

MP-3 Horizontal Installation

Caution: Do not disturb or load the stud untilthe MP-3 material has hardened (see Table Bfor hardening times).

6) Torque the nuts

Once the grout has hardened, torque the nut to165 Nm [120 ft-lbs.]. Now no threads of the nutshould be exposed.

4) Add the washers and nuts

Put washer and nut on stud leaving nut flush withend of stud. See figure 49.

5) Insert Studs into holes

Push stud through part to be anchored and into hole.Twist the stud in the MP-3® grout to wet the threads.

Note: In Horizontal Applications the stud shouldbe flush with the top of the nut. See Figure 49.

33

QuadGuard® cz

QuadGuard czQuadGuard czQuadGuard czQuadGuard czQuadGuard czMPMPMPMPMP-3-3-3-3-3®®®®® AncAncAncAncAnchoring Shoring Shoring Shoring Shoring SystemystemystemystemystemThe QuadGuard cz MP-3 Anchoring System is the recom-mended anchoring system for the QuadGuard cz. It canbe used on Portland Cement Concrete (P.C.C.), on As-phalt Concrete (A.C.) over P.C.C., on A.C. over CompactedSubbase (C. S.), and on A. C. alone. The foundations meet-ing the specifications are listed on pages 12 & 14.

The QuadGuard cz MP-3 Anchoring System consists ofstuds, anchor rods, and contents for mixing MP-3 grout.The components of this anchoring system are used invarying ways, depending on the type of foundation.

Foundation A (from page 7)

The 180 mm [7"] studs are only used in Foundation A,and are embedded to a depth of 140 mm [5.5"].

Foundation B, C, or D (from page 7)

The 460 mm [18"] long studs are used in Founda-tions B, C or D, and are embedded to a depth of420 mm [16.5"].

Note: Contact Energy Absorption Systems, Inc. be-fore using supplied anchoring system to anchorin materials outside of these guidelines.

1. Drill holesPosition the QuadGuard cz Backup and Monorail as-sembly according to the plans supplied with the sys-tem. Use the QuadGuard cz Backup and Monorailassembly as a template for drilling the anchor holes.Use the recommended embedment depths stated onpage 12 & 14 and drawing package. Drill 22 mm[7/8"] diameter holes using a rotary percussive drill.

2. Clean the holesBrush each hole with a stiff bristled brush and cleanwith oil-free compressed air to remove the dust. If thehole is wet, completely flush it with water while brush-ing then blow it clean using oil-free compressed air.

3. Mix and pour grout into holesFollow instructions for vertical installations describedon page 28 noting the following:

When using the 180 mm [7"] studs fill the hole ap-proximately 1/3 full.

When using the 460 mm [18"] studs fill the hole com-pletely (approximately 1/4 of the contents of the can).Do not underfill the hole.

When using the 460 mm [18"] long studs it may benecessary to drive the stud down with a hammer sothat the washer and nut come in contact with theplatform.

4. Torque the nutsOnce the grout has hardened (see Table B onpage 29), torque the nuts on the 180 mm [7"] longstuds to 165 Nm [120 ft-lbs]. The nuts on the 460 mm[18"] long studs are tightened until they are just snugagainst the QuadGuard cz platform (less than 15 Nm[10 ft-lbs]).

WARNING!Do not allow the MP-3 Resin or Hardener to contactskin or eyes. See material safety data sheet suppliedwith the MP-3 kit for first-aid procedures. Use only inwell-ventilated area. Do not use near open flame.

WARNING!Wear safety goggles and gloves during installation.

Note:



QuadGuard® cz

34

MoMoMoMoMoving the Sving the Sving the Sving the Sving the Systemystemystemystemystem

Figure 51Lifting the System

(6 Bay System Shown)

90 DEG. MAX.123456

QuadGuard cz (without Plate)QuadGuard cz (without Plate)QuadGuard cz (without Plate)QuadGuard cz (without Plate)QuadGuard cz (without Plate)1) Installing Lifting Brackets

Lifting Brackets may be installed on theQuadGuard cz. The location of the lifting brackets willvary by system length and are attached to the appro-priate diaphragms using the top rail bolts. Dia-phragms are numbered starting from the nose of thesystem. Refer to Table C for lifting bracket locations.

LIFTING BRACKET LOCATION CHART

NO. OF BAYS(DIAPHRAGMS)

ASSEMBLYNUMBER

ATTACH TODIAPHRAGM NO.

3

4

5

6

7

8

9

3540243-0000

3540244-0000

3540245-0000

3540246-0000

3540247-0000

3540248-0000

3540249-0000

2 & 3

2 & 4

2 & 4

3 & 5

3 & 6

3 & 6

4 & 7

Table C

Figure 50Lifting Brackets

LIFTING BRACKET

Count the diaphragms starting from the nose sec-tion to determine lifting bracket location. Attache lift-ing brackets to the QuadGuard cz using top rail bolts.Refer to Figures 50 & 51.

5/8" RAIL BOLT

5/8" RAIL NUT (LARGE)

35

QuadGuard® cz

2) To Move the System:1. Verify monorail sections are bolted together.

2. Attach two lifting brackets each on diaphragmslisted (four brackets total). See Figure 50.

3. Minimum sling length 3 meters (9 ft). Use fixedequal length slings.

4. Free the system from anchor bolts & grout priorto lifting the system. To accomplish this, start atthe nose of the system and use pry bars to gradu-ally raise the system off of the studs. Place blockssuch as 2X4's under the monorail and work downthe length of the system until the system is com-pletely free of the studs.

5. Lift the system to new location.

6. Replace all damaged parts.

7. Re-anchor system.

ANCHOR SYSTEM FOR PROPER IMPACT PER-FORMANCE. Use MP-3 polyester anchor system,supplied by Energy Absorption Systems, or ap-proved equal. The QuadGuard cz installed on as-phalt must be inspected to ensure the anchorsare still properly set following each impact. Re-anchor as necessary. See drawing 35-40-06.

MoMoMoMoMoving the Sving the Sving the Sving the Sving the System (cont'd.)ystem (cont'd.)ystem (cont'd.)ystem (cont'd.)ystem (cont'd.)

QuadGuard® cz

36

Figure 53Lifting 6-Bay System in 3-Bay Sections

90 DEG. MAX. 90 DEG. MAX.

QuadGuard cz (with Plate)QuadGuard cz (with Plate)QuadGuard cz (with Plate)QuadGuard cz (with Plate)QuadGuard cz (with Plate)1a) Moving the System in 3-Bay Sections

1. Remove cartridges from bays that have a mono-rail bolt connecting sections together below them.

2. Remove mushroom bolts for the bay that hashad the cartridge removed. This will become thebreak point for the QuadGuard cz.

3. Remove all anchor nuts and bolts.

4. Remove monorail bolts that connect sectionstogether.

5. Lift only one 3 bay section at a time. Start withthe nose section.

6. Place the sling through the lifting loops on eachcorner of the plate. The sling needs to be a mini-mum of 9 feet long out to each lifting loop. Makesure that the sling is long enough that the angleis less than 90 deg. as shown.

7. Free the system from anchor bolts and grout priorto lifting. To accomplish this, start at the nose ofthe system and use pry bars to gradually raisethe system off of the studs. Place blocks such as2x4's under the anchor plates and work downthe length of the system until the system is com-pletely free of the studs.

8. Install the End Plate (Figure 52) and/or Endcap(Figure 38) on the 3 bay section of the monorailto be moved. The end plate is not needed for thebackup section. If the total system has 7 or morebays, both the endcap and end plate will need tobe moved to the middle section that is being liftedto prevent the diaphragms from sliding off themonorail.

9. Lift the system to new location, remove end plateand re-install end cap at the front of the system.


11. Re-install system.


5/8" X 3 1/2"G5 HEX BOLT

5/8" HEX NUT

5/8" LOCK WASHER

END CAP


37

QuadGuard® cz

1b) To Move 6 through 9-BaySystem Assembled1. Remove all anchor nuts and bolts.

2. Attach a four point sling to each plate. Place slingthrough the lifting loops located on each cornerof the plates, see Figure 54.

3. Free the system from anchor bolts and grout priorto lifting. To accomplish this, start at the nose ofthe system and use pry bars to gradually raisethe system off of the studs. Place blocks suchas 2x4's under the anchor plates and work downthe length of the system until the system is com-pletely free of the studs.

4. Attach slings to a multiple spread lifting bar/beamand adjust sling positions as needed in order tobalance the system.




Figure 54Lifting the System in 6 through 9-Bay Assembled Sections



QuadGuard® cz

38

Figure 56Lifting 6-Bay System in 3-Bay Sections


QuadGuard cz (with Plate andQuadGuard cz (with Plate andQuadGuard cz (with Plate andQuadGuard cz (with Plate andQuadGuard cz (with Plate andOptional DPOptional DPOptional DPOptional DPOptional DPA A A A A AncAncAncAncAnchorage)horage)horage)horage)horage)1a) Moving the System in 3-Bay Sections

1. Remove cartridges from bays that have a mono-rail bolt connecting sections together below them.

2. Remove mushroom bolts for the bay that hashad the cartridge removed. This will become thebreak point for the QuadGuard cz.

3. Unfasten all post caps, inspect for damage andset aside for next installation.

4. Remove monorail bolts that connect sectionstogether.

5. Lift only one 3 bay section at a time. Start withthe nose section.

6. Place the sling through the lifting loops on eachcorner of the plate. The sling needs to be a mini-mum of 9 feet long out to each lifting loop. Makesure that the sling is long enough that the angleis less than 90 deg. as shown.

7. Free the system from anchor posts prior to lift-ing. To accomplish this, start at the nose of thesystem and use pry bars to gradually raise thesystem off of the posts. Place blocks such as2x4's under the anchor plates and work downthe length of the system until the system is com-pletely free of the studs.

8. Install the End Plate (Figure 55) and/or Endcap(Figure 38) on the 3 bay section of the monorailto be moved. The end plate is not needed for thebackup section. If the total system has 7 or morebays, both the endcap and end plate will need tobe moved to the middle section that is being liftedto prevent the diaphragms from sliding off themonorail.

9. Lift the system to new location, remove end plateand re-install end cap at the front of the system.

10. Extract the Drivable Pile Anchors (see Steps 2 & 3).




5/8" X 3 1/2"G5 HEX BOLT

5/8" HEX NUT

5/8" LOCK WASHER

END CAP


39

QuadGuard® cz

1b) To Move 6 through 9-BaySystem Assembled1. Unfasten all post caps, inspect for damage and

set aside for next installation.

2. Attach a four point sling to each plate. Place slingthrough the lifting loops located on each cornerof the plates, see Figure 57.

3. Free the system from anchor posts prior to lift-ing. To accomplish this, start at the nose of thesystem and use pry bars to gradually raise thesystem off of the studs. Place blocks such as2x4's under the anchor plates and work downthe length of the system until the system is com-pletely free.

4. Attach slings to a multiple spread lifting bar/beamand adjust sling positions as needed in order tobalance the system.


6. Extract the Drivable Pile Anchors (see next steps).



Figure 57Lifting the System in 6 through 9-Bay Assembled Sections


2) Extracting Drivable Pile Anchors1. Fasten a ¾" threaded lifting ring or eye into a

hole at the top of the post.

2. Attach a hoist or crane to the ring and pull thepost from the ground.

3. Remove posts as necessary and backfill holescreated by the extraction.

WARNING!The posts will be filled with soil and extremelyheavy. Handle with caution.

3) DPA RefurbishmentRemove all soil and other material from inside of thepost being careful not to damage the side walls ofthe tubing. The bottoms of the posts may be dam-aged from initial pile driving. Cut the damaged por-tion of tubing from the post so that side walls arestraight for the next installation. If the side walls ofthe post are damaged at more than 12" from the bot-tom of the post, scrap the post and replace it with anew one.


QuadGuard® cz

40

Inspection FInspection FInspection FInspection FInspection FreqreqreqreqrequencuencuencuencuencyyyyyInspections are recommended as needed based upon vol-ume of traffic & impact history. Visual Drive-By Inspec-tions are recommended at least once a month. Walk-UpInspections are recommended at least once every sixmonths for temporary installations.

VVVVVisual Drivisual Drivisual Drivisual Drivisual Drive-By Inspectione-By Inspectione-By Inspectione-By Inspectione-By Inspection1) Check to see if there is evidence of a hit. If so a

walk-up inspection will be necessary.

2) Check to see if the Cartridges appear to be offthe Support Brackets. Any damaged Cartridgeswill need to be replaced.

WWWWWalk-Up Inspectionalk-Up Inspectionalk-Up Inspectionalk-Up Inspectionalk-Up Inspection1) Clear and dispose of any debris on the site.

2) Be sure all bolts are tight.

3) Be sure concrete anchor bolts are securely an-chored.

4) Be sure diaphragm legs are straight.

5) Be sure all Mushroom Washer assemblies areproperly aligned and positioned.

6) Fender Panels and Transition Panels should nesttightly against the system. (See figure 46 onpage 28.)

3) Be sure the Nose cover is in place.

4) Note the location and condition of the Quad-Guard cz and the date of visual drive-by in-spection.

WARNING!Refer to Cartridge placement on pages 28 and 29.

WARNING!Refer to Cartridge placement on pages 28 and 29.

8) Make all necessary repairs as described above.Refer to Post-Impact Instructions, next page, formore information.

9) Note the location and condition of theQuadGuard cz and any work done in the ImpactAttenuator Inspection Logbook under the dateof this inspection. If further repair is necessary,note repair request date in logbook. Refer to Post-Impact Instructions, next page, and installationsection of this manual for more information.

Maintenance and RepairMaintenance and RepairMaintenance and RepairMaintenance and RepairMaintenance and Repair

WARNING!Fender Panel..... Maximum gap allowed:

20 mm [0.78"]

7) Be sure Cartridges have not been damaged andare properly positioned on their Support Brack-ets. Replace crushed or sagging Cartridges. Toensure 100% of the full design speed character-istics, partially crushed Cartridges (due to slowspeed impacts) should be replaced.

41

QuadGuard® cz

Figure 58

FIRST DIAPHRAGM

PULLOUT BRACKETS

Pull the QuadGuard cz forward slowly until the sys-tem reaches its original length. Have someonewatch the system during repositioning to be cer-tain previously undetected damage does not causethe diaphragms to bind or pull out improperly.

7. Remove all crushed Cartridges from within thesystem.

8. Check to see that the Diaphragms are in usablecondition. Diaphragms which are bowed or havebent legs must be replaced.

9. Check that the Fender Panels are properly at-tached with the Mushroom Washer Assemblies.Damaged Fender Panels and Transition Panelsmust be replaced. Often, Cartridge Support Brack-

WARNING!Stand clear in case chain breaks or becomesdisconnected.

6. Attach chain to Pullout Brackets on first Dia-phragm (see Figure 58). Attach both ends of chainto a heavy vehicle (such as a 1 ton pickup).

PPPPPost-Impact Instructionsost-Impact Instructionsost-Impact Instructionsost-Impact Instructionsost-Impact Instructions1. Deploy the appropriate traffic-control devices to

protect your crew.

2. Check to see that all Anchor Bolts have remainedfirmly anchored in the roadway surface. Failedanchor bolts are those found to be loose, bro-ken, or showing signs of pull out and are to bereplaced.

If the system is anchored to asphalt, up to 20%of the total anchors may be replaced if damaged.If more than 20% of the anchors are damaged,the system should be relocated to fresh, undis-turbed asphalt and reinstalled using the 460 mm[18"] threaded rods.

The proper performance of the system duringan angle impact depends on the Monorail An-chors being properly anchored.

3. Clear and dispose of any debris on the site.

4. Check the system to be certain that the MushroomWasher Assemblies holding the fender panels to-gether are still intact and that the system has notbeen deformed in a fashion that would prevent pull-ing it back to its original position.

5. Be sure that the Diaphragm support legs are allproperly attached to the Monorail.

System Pullout

Maintenance and Repair (cont’Maintenance and Repair (cont’Maintenance and Repair (cont’Maintenance and Repair (cont’Maintenance and Repair (cont’d.)d.)d.)d.)d.)

QuadGuard® cz

42


CLAMP

PIPE WRENCH

BACKUP

Figure 59

CARTRIDGE SUPPORT BRACKET

ets with minor damage can be straightened andreused by doing the following:

A. Remove damaged Cartridge Support Bracketfrom diaphragm.

B. Clamp Cartridge Support Bracket to backupand begin bending using pipe wrench asshown in Figure 59.

C. Then, using a sledge hammer and

Figure 60

BACKUP

SLEDGE HAMMERCARTRIDGE SUPPORT BRACKET

Quad-BeamTM shape on backup as an anvil,form Cartridge Support Bracket back into 90°shape (see Figure 60).

10. Check gaps between Fender Panels. The maxi-mum gap allowed for these overlapping parts (in-cluding Fender Panels overlapping panels behindthe system) is 20 mm [.78"] (see figure 61).

WARNING!Fender Panel..... Maximum gap allowed:

20 mm [0.78"]

Figure 61

FENDER PANEL

MAXIMUM GAP = 20 mm [0.78"]

UNDERLYING FENDER,TRANSITION, EXTENSION

OR SIDE PANEL

Be sure the Mushroom Washer Assemblies aretorqued so that the spring is compressed. If thegaps between the Fender Panels are still too largeit may be necessary to replace bent parts.

11. Replace all crushed Cartridges. Refer to Car-tridge Placement on pages 28 & 29.

Form Cartridge Support Bracket

Fender Panel Gap

Straighten Cartridge Support Bracket

43

QuadGuard® cz

WARNING!Anchor Studs.... Torqued to 165 Nm [120 ft-lbs]

Should NOT protrude above nuts(see figure 14)

All Other Bolts... Tightened

Fender Panel..... Maximum gap allowed:20 mm [0.78"] (See figure 60)

12a. Nose Belt

Normally, with a design speed impact, the nosebelt will not need replacement. After pulling sys-tem out and replacing the nose cartridge, it maybe necessary to adjust nuts attaching nose beltto diaphragm and/or legs to 35 Nm [25 ft-lbs].Nose belt assembly is available for replacementby calling the Customer Service Department at1-888-32-ENERG.

13. Check the torque of all bolts on the system (seeTable A).

14. Check to be certain that the site is free from anydebris. The QuadGuard cz is once again readyfor use.

Table A

Figure 62Nose Belt

QuadGuard cz Bolt Torque Specifications

12b. Nose Cover

Remove damaged plastic Nose Cover. Attach thenew Nose Cover to the First Diaphragm, usingthe six Rail Bolts, Rail Nuts, and Bar Washersthat hold the front Fender Panels to the First Dia-phragm. The top and bottom holes of the Nosecover are slotted to provide adjustment. Adjustnose to align with Fender Panels, then torque allsix nuts to 35 Nm [25 ft-lbs]. See Figure 63, NoseAdjustment.

Figure 63

PLACE A BOARD OVER THE FIRST TWO DIAPHRAGMS ASSHOWN TO FACILITATE PROPER ALIGNMENT OF NOSE

TIGHTEN NUTS TO 35 NM [25 FT-LBS]AFTER ALIGNING NOSE AS SHOWN

Nose Cover Adjustment


QuadGuard® cz

44


DESCRIPTION

What is the Width of System?(refer to "Measuring theWidth" page 6)

What is the Number of Bays?(refer to "Counting TheNumber of Bays" page 5)

Table D

PPPPParararararts Ordering Pts Ordering Pts Ordering Pts Ordering Pts Ordering PrrrrrocedureocedureocedureocedureocedureMake a list of all damaged parts using part descriptions shown in Figure 64. Answer the following questions in thespaces provided. This information is necessary to receive the proper parts.

What Type of Transition Panel?Be sure to note right side, leftside, both sides or no transi-tions (refer to "Side Panel &Transition Panel Types" page 9)

QuadGuard cz Ordering Information Chart

• Quad to W• Quad to Thrie• Quad to End Shoe• Quad to Safety

Shape Barrier• 4" Offset Panel

3 through 9

610 mm [24"]760 mm [30"]915 mm [36"]

TRANSITION PANEL(NUMEROUS TYPES)

BACKUPTYPE IICARTRIDGES

TYPE I CARTRIDGES

FIRST DIAPHRAGM

NOSE COVERASSEMBLY

QUAD-BEAMFENDER PANEL

MONORAIL (UNDER SYSTEM)ANCHORED WITH MP-3ANCHOR KIT

5/8" X 1 3/4" FLAT WASHER5/8" HEX NUT

SPRING

5/8" X 5" FLAT SCREW

MUSHROOM WASHER

DIAPHRAGM


MONORAIL GUIDE

MONORAIL SECTION

DIAPHRAGMASSEMBLY

Figure 64QuadGuard cz

VERTICAL MP-3 ANCHOR KITWITH 3/4" X 7" STUDS

FILL IN THIS SECTIONCHOICES

45

QuadGuard® cz

Limitations Limitations Limitations Limitations Limitations And And And And And WWWWWarningsarningsarningsarningsarnings

The 6 bay QuadGuard® cz has been tested and evaluatedper the recommendations of the NCHRP 350 Guidelines*for Test Level 3 (TL-3) terminals and crash cushions. Theimpact conditions recommended in this guideline are in-tended to encompass the majority but not all, of the pos-sible in-service collisions.

Properly installed and maintained, the QuadGuard cz iscapable of performing its function of stopping or con-taining and redirecting the test vehicles in a predictableand safe manner under the nominal NCHRP 350 TL-3terminal and crash cushion impact conditions of:

Vehicles: Small car and pickup

Mass: 820 and 2000 kg [1808 and 4409 lb.]

Speed: 100 km/h [62 mph]

Angle: 15 degrees for small vehicle20 degrees for pickup

Impact conditions which differ from those described inNCHRP 350 test matrix for non-gating, redirecting crashcushions may result in different crash results than thoseencountered in testing. Furthermore, impacts in excessof TL-3 impact severity, or the existence (at the site ofthe installation) of curbs or cross slopes in excess of 8%may yield crash performance which does not meetNCHRP 350 evaluation criteria relative to structural ad-equacy, occupant risk and vehicle trajectory factors.

* Copy may be obtained from:

Transportation Research BoardNational Research Council2101 Constitution Avenue, N.W.Washington, D.C. 20418

QuadGuard® cz

46

NotesNotesNotesNotesNotes

47

QuadGuard® cz

NotesNotesNotesNotesNotes

Customer Service Department

USAPhone 1-888-323-6374 Fax 1-312-467-1356

Asia PacificPhone +65 6276 3398 Fax +65 6276 6218

EuropePhone +44-1473-221-105 Fax +44-1473-221-106

35 East Wacker Dr., 11th FloorChicago, IL 60601-2076Engineering and Manufacturing Facilities:Rocklin, California and Pell City, Alabama

A Quixote CompanySaving Lives By Design

ENERGY ABSORPTIONSYSTEMS, INC.

http://www.energyabsorption.com/Part No. 2735992-0000

©2007 Energy Absorption Systems, Inc.Rev. 04/18/07

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QuadGuard cz Installation Manual