penswastaan penyenggaraan jalan persekutuan … guardrails.pdfmethod statement. 5. inspection and...

PENSWASTAAN PENYENGGARAAN JALAN PERSEKUTUAN

SEMENANJUNG MALAYSIA

Lokasi : …………………………………………………

CAWANGAN SENGGARA FASILITI JALAN IBU PEJABAT JKR ALAYSIA

KUALA LUMPUR

PROJECT QUALITY PLAN W-BEAM GUARDRAILS

LOGO

SYARIKAT

KONSESI

ALAMAT SYARIKAT

PROJECT QUALITY PLAN Reference No. :

WORK INSTRUCTION MANUAL Revision No. :

W-BEAM GUARDRAILS

1

1.0 OBJECTIVE

To outline the procedure by which w-beam guardrails shall be installed as per JKR

standard specifications.

2.0 SCOPE

This procedure shall be applicable for installation of w-beam guardrails. The scope of work

shall include:

a) Supply all necessary materials.

b) Install guardrail beams, posts and packer inclusive of bolts and nuts, and ancillary

works.

c) Execute the work in accordance to drawings and specifications.

3.0 DEFINITION & BRIEF DESCRIPTION

W-beam guardrails are a longitudinal traffic safety barrier (LTSB) designed primarily to

safely redirect errant vehicles away from the roadside hazards. They are classified as semi-

rigid barrier systems which can be used in areas where small to moderate deflection is

acceptable (maximum deflection of 1.2m). W-beam guardrails shall be used on both the

shoulders and the median.

Longitudinal traffic safety barriers shall be considered under the following conditions;

i. Roadways on high embankment and embankment with steep side slopes.

ii. On highways with roadside obstacles and hazards such as structures and

appurtenances.

iii. Divided highways with narrow medians, carrying large volume of traffic.

iv. Other conditions such as sharp horizontal curves, pedestrian protection and at

locations with severe accident experience.

A method to establish the length-of-need of the installation shall be based on a 100-metre

encroachment distance as shown in Fig 1: Determination of Installation Length. The length-

of-need is calculated by;



W-BEAM GUARDRAILS

2

LN = ( 1 - A/B ) x LR

where,

LN = Length of need

A = Distance of barrier from the edge of pavement

B = Distance of object from the edge pavement

LR = Runout Length

W-beam guardrails shall consist of corrugated sheet steel beam of W-shape cross-section

attached to block-outs or spacers supported on posts. Generally, spacers and post are

constructed of steel. For the safety consideration, terminal sections shall be added to both

ends to anchor the system in order that redirecting force can develop in the rail. There are

three general types of guardrail end terminal treatment;

i) Flares

ii) Ramps

iii) Straight extensions

6 Test Levels (TL) for LTSB have been established in National Cooperative Highway

Research Program (NCHRP) as shown in Table 2.1, REAM – GL 9/2006.

To ensure safety performance of the guardrail, post with height of 710mm +/- 20mm, W-

shape beam with block-out units and with 2.0m post spacing fulfilling the requirements of

Test Level 3 (TL3) shall be recommended to be installed along expressways and heavily

trafficked Federal and State major roads (R4 & U4 geometrics standard and above).

4.0 PROCEDURES

4.1 Upon receiving Work Order from the S.O., the Project Manager shall prepare and

submit Project Quality Plan (PQP) to the S.O. for approval.

4.2 Upon approval of the PQP, the Project Manager shall proceed with site

possession, mobilization of machineries, equipment and erection of the guardrail

as per requirements.



W-BEAM GUARDRAILS

3

4.3 Traffic control and safety shall be in accordance with the approved Traffic

Management Plan (TMP).

4.4 The samples submitted for approval shall be accompanied with test certificates for

the materials.

4.5 Installation and erection of guardrail shall include:

a. Setting-up and installation of guardrail post.

b. Placing of guardrail beams and delineator strip.

c. Placing of end terminal treatments.

4.6 Setting-up and installation of guardrail post

i. The alignment and finished levels of the guardrail shall be set accurately on

site.

ii. The offset from edge of traffic lane to the guardrail shall be as shown in Table

1.

iii. Recommended distance of posts from hazards shall be in accordance to

Figure 1.

iv. The post holes shall be dug either manually or mechanically to the required

level.

v. At rigid object such as bridge parapet or lateral earth clearance is less than

600mm, the holes shall be backfilled with grade 20/40 (1:2:4) concrete and

compacted in such a manner as not to displace the posts from correct

alignment. (Refer Figure 2).

vi. Posts may be installed by means of driving using suitable equipment provided

that it is capable of installing the post to the designed depth, line and level

accurately.

vii. Post shall be spaced as indicated on approved layout drawings.



W-BEAM GUARDRAILS

4

4.7 Placing of guardrail beam and delineator strip

i. The guardrail beams shall be fixed and firmly bolted and/or welded together

with the block-out / spacers on to the post to the lines and grades as shown in

the drawing.

ii. The lapping between two of guardrail beams shall be in direction of the traffic

i.e. the downstream guardrail beam shall be fixed behind the upstream

guardrail beam.

iii. Delineator strips shall be (HIP retro-reflective sheeting paste on to galvanized

steel plates) measuring 100mm x 45mm. They shall be fixed to guardrail

beams at specified spacing.

4.8 Placing of End Terminal Treatments

i. End terminal treatments shall be installed at both ends of the guardrail. The

type of end treatment unit installed shall be in accordance to approved

drawings.

(Refer to Figures 3, 4, and 5).

ii. For terminal sections, flared terminal treatment shall be used. In case where

space is not available, ramped terminal shall be used. Straight extension

terminal shall be used only where terminal is pointing away from one

directional traffic flow. Return section terminal shall be used at narrow median

installation.

iii. For terminal treatment ends, the drum-end is recommended at all upstream

end and at down stream end if the road is a single two way traffic carriageway.

Plain end (fish tail) terminal is only recommended at downstream dual

carriageway. (Refer to Figure 6).

iv. On approaches to structures, the guardrail shall be securely attached to the

structure.

v. For night visibility, HIP retro-reflective strip shall be paste on to the End

Terminal.

4.9 Upon completion of work, final inspection/ measurement shall be carried out jointly

with S.O. representatives.



W-BEAM GUARDRAILS

5

4.10 Refer to Flow Chart on page 12.

5.0 PLANT AND EQUIPMENT

i. Auger machine

ii. Plumbob

iii. Driving machine

iv. Backhoe

v. Welding set

vi. Measuring tape

6.0 REFERENCES

i. Standard Specification for Road Works (JKR/SPJ/1988), Section 6 – Guardrail.

ii. Arahan Teknik (Jalan) 2C/85 - Manual on Traffic Control Devices: Temporary Sign

and Work Zones Control.

iii. Arahan Teknik (Jalan) 1/85 - Manual on Design Guidelines Of Longitudinal Traffic

Barrier.

iv. REAM (GL 9/2006) - Guidelines on Design and Selection of Longitudinal Traffic

Safety Barrier.

2

1



W-BEAM GUARDRAILS

6

Table 1 : Recommended Shy Line Offsets

Design or 85th

Percentile Speed (km/h)

Shy Line Offset – Ls (m)

Nearside (Left) Offside (Right)

< 70 1.5 1.0

80 2.0 1.0

90 2.5 1.5

>100 3 2.0

Fig. 1: Determination of Installation Length



W-BEAM GUARDRAILS

7

Fig. 2: Minimum Clearance Required Behind Guardrail Beam (REAM GL – 9/2006)



W-BEAM GUARDRAILS

8

Fig. 3: Flared Terminal Treatment



W-BEAM GUARDRAILS

9

Fig. 4 : Ramped Terminal Treatment



W-BEAM GUARDRAILS

10

Fig. 5: Straight Extension Terminal Treatment



W-BEAM GUARDRAILS

11

Fig. 6: Terminal Treatment Ends

RESPONSIBILITYACTIVITY REFERENCE

A)

Work Order

Pre-Construction

Project Manager

Project Manager Project Quality Plan

Revision No. :

PROJECT QUALITY PLAN

WORK INSTRUCTION MANUAL

W-BEAM GUARDRAILS

Reference No. :

Prepare PQP and submit to S.O. for approval

which consist of :-

1. Traffic Management Plan.

2. Guardrail Layout Plan & Design.

3. Certificate of Material Conformance.

4. Method Statement.

5. Inspection and Test Plan.

6. Bills of Quantities.

Start

Receive Work Order from S.O.

YES

S.O.

S.O.

NO

B) Construction

Inspection and Test Plan

YES

Project Manager

Project Manager S.O.

NO

Inspection and testing

Approved

by S.O.

Installation of W-Beam Guardrail

Approved

by S.O.

End

12

W WITNESSED

A APPROVED

C CONFIRMED

V VERIFIED

P PREPARED

DESCRIPTION REQUIREMENT / STANDARD INSPECTIONFREQUENCY OF

TEST

LAB TECHNICIAN

/ SUPERVISOR

TECHNICAL

EXECUTIVE /

ENGINEER

PROJECT

MANAGERS.O.

Arahan Teknik (Jalan) 2C/85

LEGEND

Demarcation

PROJECT QUALITY PLAN

ITEM

1.0

COMPLIANCE / CRITERIA

1.1

TEST

Traffic Management

Visual Approved TMP WV CTraffic control at worksite

INSPECTION AND TEST PLAN

Revision No. :

2.0

P

W-BEAM GUARDRAILS

Reference No. :

Setting out and demarcation Visual P V C W

Material JKR/SPJ/1988 Sub-Section 6.1.2

Beam Element

(Galvanized Steel)AASHTO Specification - M180

Material properties,

dimension

Steel Post and Packer

(Galvanized Steel)BS 449 Part 1 Grade 43

Material properties,

dimension

Bolts & Nuts REAM - GL 9/2006Material properties,

dimension

Delineator Strip REAM GL 8/2004Dimension, retro-

reflectivity, spacing

Installation JKR/SPJ/1988 Sub-Section 6.1.3

Posts

Alignment and Level

Beams

Alignment and Level

Lapping arrangement

End Terminal Unit

Type

All end terminals

Visual

Once every 200

units

JKR/SPJ/1988 Sub-Section 6.1.3.3,

REAM - GL9/2006

JKR/SPJ/1988 Sub-Section 6.1.3.2

Visual


REAM - GL9/2006

JKR/SPJ/1988 Sub-Section 6.1.3.2


REAM - GL9/2006

As per Project Quality Plan Section 4.7

(ii)

Visual

Manufacturer's Test Certificate

P V C


4.0

Aprroved Layout Plan

3.4

2.1

3.0

4.1

4.2

4.3

3.1

3.3

3.2

W

P V C W


100mm x 45mm &



REAM - GL9/2006

Delineator Strip Dimension4.5 Approved Layout Plan

13

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