Photos of ROSS-350 Plan sheet of ROSS-350 (Reduced Offset Slotted System) Installation instructions for ROSS-350 Installation checklist for ROSS-350 Maintenance instructions for ROSS-350 Differences between ROSS-350 and SRT-350 Installation Instructions for ROSS-350 Materials As packaged, your ROSS-350 system includes all materials needed for the installation of the 11 403 mm (37' 6) of the system. Note that no concrete footings or foundations are required. Tools Required Tools required are those ordinarily used to install standard highway guardrail (HGR). They include 9/16", 15/16", 1-1/4" and 1-1/2" sockets, wrenches, and such other equipment as augers and post pounders commonly used in driving posts. Installation The installation of the ROSS-350 is very similar to other parabolic flared terminals (ie: SRT, BCT, MELT, etc.). The same equipment and expertise is required for these systems. Anyone with experience installing flared terminals should have no difficulty installing the ROSS-350. Post Layout Start at the end of the guardrail run (connection point for the terminal). The length of the installation is 11 403 mm (37'-6"). Layout the post locations starting at location 8 which is the first post in the system. Posts 7 and 8 are in line (tangent) with the guardrail installation. Use the following table to offset posts 1 through 6: (dimensions are to the center of the traffic face of the blockouts, except measure from the face of posts 1 & 2 which have no blockouts). The offset points are measured from a tangent line of the guardrail run extending from post 9 towards post 1. Offset points are to be located by chord measurements at the back of the rail equal to the nominal post spacings. Posts are to be approximately tangent to the railing at each post location. Post Location Post Spacing Offset mm ft mm ft 9 1270 4'-2" 0 0 8 1270 4'-2" 0 0 7 1270 4'-2" 0 0 6 1270 4'-2" 20 0.1 5 1270 4'-2" 75 0.2 4 1270 4'-2" 170 0.6 3 1270 4'-2" 300 1.0 2 1270 4'-2" 565 1.9 1 1270 4'-2" 915 3.0 Installing the Posts Install the wood posts at locations 3 through 8. these posts (PC-4063B) may be driven. They may also be installed by drilling holes approximately 1120 mm (44") deep. Insert the 1830 (6'-0") wood post into these holes and backfill. Note that, in either case, the center of the upper 90 mm (3-1/2") hole in the post is at ground level and these posts are spaced at 1270 mm (4'-2") intervals. Foundation Tubes Options Option 1: 6'-0" Tube no Soil Plat No assembly required. Install the soil tube as described below. Option 2: 4'-6" Tube with Soil Plate Assemble the soil tubes and soil plates. Bolt the soil plates (PC-766G) to the foundation tubes (PC-740G) with two 16 mm x 190 mm (5/8" x 7-1/2") hex bolts (PC-3478G) and two HGR nuts (PC-3340G), no washers. DO NOT OVERTIGHTEN AND DEFORM THE TUBES. Placing Foundation Tubes Install the foundation tubes at locations 1 and 2. Note that the soil plate (if used) should be positioned on the downstream side of the post. DO NOT DRIVE TUBES WITH WOOD POST INSERTED. Installation options (best preference listed first) If the soil is permeable, so water will drain from the tubes, the tubes may be driven with an approved driving head. For non-permeable soil, drill a 305 mm (12") pilot hole approximately 1450 mm (57") deep and force the soil plate/tube assembly to the appropriate depth by impact or vibratory means with an approved driving head. Same as method 2, except the slots for the soil plates (if used) may be cut out by using a rock bar. Same as method 2, except drill three adjacent 305 mm (12") holes or one 610 mm (24") hole to accommodate the soil plate/tube assembly. Extra care must be taken to prevent settlement or lateral displacement of the tubes. Optional Installation as defined by the Governing Specifications The installer may elect (if it is an option provided by the governing specifications) to eliminate the soil plates and place the tubes in a 460 mm (18") hole, approximately 1450 mm (57") deep and backfill with concrete. Prior to installing the tubes, approximately 65 mm (2-1/2") of granular material shall be placed at the bottom of the hole to prevent the concrete from sealing the bottom of the tube and prevent it from draining. The finished guardrail height will generally be 700 mm (27-1/2") above the edge of the shoulder. Site grading may be required to prevent the tubes from projecting more than 100 mm (4") above the ground line. Installing Wood Posts Insert pipe sleeve (PC-705G) in post (PC-4147B) and install in steel tube at location 1. Install other 1145 mm (3' 9") (PC-4147B) post in steel tube at location 2. Installing the Strut Place the slotted yokes of the ground strut (PC-9852A) over the foundation tubes (PC-736G) at the base of posts 1 and 2. A 16 mm x 240 mm (5/8" x 9-1/2") hex bolt (PC-3497G), a hex nut (PC-3340G), and two round washers (PC-3300G) are used to attach the strut to the foundation tube. Note that the bolt goes through the strut, the foundation tube and the wood post. DO NOT OVERTIGHTEN AND DEFORM TUBES. Installing Wood Blockouts and Guardrail Do not bolt the guardrail panels to posts 7 and 8. At post locations 7 and 8 bolt the wood blockouts (PC-45075B) to the wood posts (PC-4063B) using a 16 mm x 460 mm (5/8" x 18") post bolt (PC-3580G), a hex nut (PC-3340G), and a round washer (PC-3300G). The washer is installed between the wood post and the nut. Install 3810 mm (12'-6") guardrail panel (PC-9G) from location 9 to location 6, splice bolted and post bolted to the standard run of guardrail with hardware provided by the standard guardrail provider. Install the next 3810 mm (12'-6") guardrail panel (PC-37G) from location 6 to location 3 with eight (8) 16 mm x 32 mm (5/8" x 1-1/4") splice bolts (PC-3360G) and hex nuts (PC-3340G). At posts 4, 5 and 6, bolt the rail to the post and block with a 16 mm x 460 mm (5/8" x 18") post bolt (PC-3580G), a hex nut (PC-3340G) and a round washer (PC-3300G). NOTE: Slot orientation. Guardrail panel PC-37G has three (3) sets of slots. Guardrail panel PC-34G has two (2) sets of slots and holes for the cable anchor bracket. Both guardrail panels should be installed so that the slot guard attachment holes are at the end of the slots away from the end of the terminal. The cable anchor bracket holes on PC-34G will be between post 1 and post 2. Set the last guardrail panel (PC-34G) into place. Connect the two guardrail panels together at the splice with eight (8) 16 mm x 32 mm (5/8" x 1-1/4") splice bolts (PC-3360G) and hex nuts (PC-3340G). Bolt the rail to the posts at locations 1 and 2 by using a 16 mm x 255 mm (5/8" x 10") post bolt (PC-3500G), a hex nut (PC-3340G), and a round washer (PC-3300G). The round washer is installed between the wood post and the nut. Installing Slot Guards Install the slot guards (PC-9959G) at the locations shown on the drawings. Slot guards are installed on the downstream end of the slots (the deflector angle should be closest to the elongated slots). Each slot guard is bolted to the backside of the guardrail panels with six (6) 16 mm x 32 mm (5/8" x 1-1/4") splice bolts (PC-3360G) and hex nuts (PC-3340G). Installing the Cable Anchor Assembly The cable anchor bracket (PC-700A) is bolted to the backside of the guardrail panel (PC-34G) using eight (8) 16 mm x 38 mm (5/8" x 1-1/2") hex bolts (PC-3380G), eight (8) hex nuts (PC-3340G), and eight (8) round washers (PC-3300G). The round washers are installed between the bolt head and the guardrail on the face (traffic) side. Slide one end of the cable (PC-3000G) into the cable anchor bracket (PC-700A) and the other end through the sleeve (PC-705G) in post 1. Place the bearing plate (PC-775G) with the open side of the V-notch pointing upward and connect it to post 1 by driving two (2) nails (PC-5968G), through the holes provided, bending the nails to attach the bearing plate. Place the plate washer (PC-9961G) on the end of the cable. Secure both ends of the cable assembly with 25 mm (1") hex nuts (PC-3910G) and tighten. Restrain cable with vise grips at the end being tightened to avoid twisting the cable. Make sure the nuts are tight and the cable is taut. Installing the End Section Install the end section (PC-907G) by connecting it to the end of the guardrail panel with four (4) 16 mm x 32 mm (5/8" x 1-1/4") splice bolts (PC-3360G) and hex nuts (PC-3340G). Installation Checklist for ROSS-350 The rail height is in accordance with the plans (generally 706 mm [27-3/4"] above the edge of the shoulder). The steel tubes do not protrude more than 100 mm (4") above the ground line. The bolts at the top of the steel tubes are not overtightened and collapsing the walls of the steel tubes. The 150 mm x 200 mm (6" x 8") bearing plate at post 1 is correctly positioned and the anchor cable is taut and correctly installed (it should be re-checked after installation to make sure it hasn't slackened). The guardrail is not attached to the posts at locations 7 and 8. No rectangular washers are used on the face of the rail. Slot guards are in place and oriented correctly. Guardrail panels are oriented correctly. Maintenance Instructions for ROSS-350 Maintenance of the ROSS can be categorized as routine or repair. Routine maintenance consists of periodically checking the system to see that the cable is taut, the nuts have not been removed from the cable, and the blockouts have not rotated. Repair maintenance deals with the system after it has been hit. Most hits on the ROSS will require the replacement of 3/81 M (12' 6") to 11.43 M (25' 0") of rail and broken posts, depending on the severity of the hit. The following steps should be taken in making the repairs: Check the anchor cable and bracket for damage. The bearing plate, nuts, washers and anchor bracket are rarely damaged. Make note of the number of broken posts and wood blockouts that need to be replaced, along with any damaged bolts. Inventory and pick up the reusable parts. Bring necessary replacement parts from the maintenance yard. The two new slotted pieces (PC-34G; and PC-37G) brought to the repair site should have the slot guards (PC-9959G) already bolted to them to minimize work zone repair time. The slot guards on the damaged rail can be removed back at the maintenance yard. Disconnect and remove the damaged rail from the posts. Remove the broken posts in the steel tubes using one of the two post removal tools recommended that can be assembled from "off the shelf hardware" items. Pound the steel pipe assembly or screw the lag screws into the top of the broken post and remove the remains of the broken post by pulling on the chain. If necessary, place a steel rock bar in the loop of the chain and use it as a lever arm to remove the post. Remove broken posts not installed in steel tubes. After the site has been cleared of damaged debris, the system can be reconstructed following the construction installation instructions, at the front of this manual. Differences between ROSS-350 and SRT-350 (9-Post)   ROSS-350 SRT-350 Offset 3'-0" (0.9 m) 4'-0" (1.2 m) Length of flare 29'-3" (8.9 m) 37'-6" (11.4 m) Length of system 37'-6" (11.4 m) 37'-6" (11.4 m) Number of posts 8 9 Number of sets of slots 5 4 Not bolted at posts 7,8 2,3,4,6,7,8,&9 Back up plates 0 5 or 6* Slot guards New (5) Old (4) Soil tube 6'-0" (1.8 m) 5'-0" (1.5 m) Soil plate No** Yes End section Small buffer One piece wrap around * Depending on 25'-0" or 12'-6" option ** Option for 4'-6" tubes with soil plates The documents are provided in Acrobat Reader format. Free Acrobat Reader download