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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;
PROJECT QUALITY PLAN Reference No. :
WORK INSTRUCTION MANUAL Revision No. :
W-BEAM GUARDRAILS
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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.
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W-BEAM GUARDRAILS
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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.
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W-BEAM GUARDRAILS
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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.
PROJECT QUALITY PLAN Reference No. :
WORK INSTRUCTION MANUAL Revision No. :
W-BEAM GUARDRAILS
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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
PROJECT QUALITY PLAN Reference No. :
WORK INSTRUCTION MANUAL Revision No. :
W-BEAM GUARDRAILS
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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
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Fig. 2: Minimum Clearance Required Behind Guardrail Beam (REAM GL – 9/2006)
PROJECT QUALITY PLAN Reference No. :
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Fig. 3: Flared Terminal Treatment
PROJECT QUALITY PLAN Reference No. :
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W-BEAM GUARDRAILS
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Fig. 4 : Ramped Terminal Treatment
PROJECT QUALITY PLAN Reference No. :
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W-BEAM GUARDRAILS
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Fig. 5: Straight Extension Terminal Treatment
PROJECT QUALITY PLAN Reference No. :
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W-BEAM GUARDRAILS
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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
JKR/SPJ/1988 Sub-Section 6.1.3.1,
REAM - GL9/2006
JKR/SPJ/1988 Sub-Section 6.1.3.2
JKR/SPJ/1988 Sub-Section 6.1.3.3,
REAM - GL9/2006
As per Project Quality Plan Section 4.7
(ii)
Visual
Manufacturer's Test Certificate
P V C
Manufacturer's Test Certificate
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
Manufacturer's Test Certificate
100mm x 45mm &
Manufacturer's Test Certificate
JKR/SPJ/1988 Sub-Section 6.1.3.1,
REAM - GL9/2006
Delineator Strip Dimension4.5 Approved Layout Plan
13