full-scale veidcle crash test on the iowa steel …the unsatisfactory safety performance of the iowa...

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FULL-SCALE VEIDCLE CRASH TEST ON THE IOWA STEEL TEMPORARY BARRIER RAIL Dr. Edward R. Post, P.E. Professor of Civil Engineering Mr. Brian G. Pfeifer, E.I.T. Research Assistant Engineer by submitted to Mr. Ronald K. Faller, E.I.T. Research Associate Engineer Mr. James C. Holloway Research Assistant Engineer Mr. William A. Lundquist, P.E. Bridge Engineer Iowa Department of Transportation in cooperation with Federal Highway Administration - Iowa Division TRANSPORTATION RESEARCH REPORT TRP-03-20-89 Civil Engineering Department W348 Nebraska Hall University of Nebraska-Lincoln Lincoln, Nebraska 68588-0531 December, 1989

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Page 1: FULL-SCALE VEIDCLE CRASH TEST ON THE IOWA STEEL …The unsatisfactory safety performance of the Iowa Temporary Concrete Barrier Rail provoked the need for an alternative temporary

FULL-SCALE VEIDCLE CRASH TEST ON THE

IOWA STEEL TEMPORARY BARRIER RAIL

Dr. Edward R. Post, P.E. Professor of Civil Engineering

Mr. Brian G. Pfeifer, E.I.T. Research Assistant Engineer

by

submitted to

Mr. Ronald K. Faller, E.I.T. Research Associate Engineer

Mr. James C. Holloway Research Assistant Engineer

Mr. William A. Lundquist, P.E. Bridge Engineer

Iowa Department of Transportation

in cooperation with

Federal Highway Administration - Iowa Division

TRANSPORTATION RESEARCH REPORT TRP-03-20-89

Civil Engineering Department W348 Nebraska Hall

University of Nebraska-Lincoln Lincoln, Nebraska 68588-0531

December, 1989

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.I

DISCLAIMER STATEMENT

The contents of this report reflect the views of the authors who are responsible for

the facts and the accuracy of the data presented herein. The contents do not necessarily

reflect the official views or policies of the Iowa Department of Transportation or the

Federal Highway Administration. This report does not constitute a standard, specification,

or regulation.

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ABSTRACf

One full-scale vehicle crash test was conducted on the Iowa Steel Temporary Barrier

Rail. Test 15-1 was conducted with at 5,500 pound vehicle at 22.5 degrees and 60.6 mph.

The overall test length of the barrier was 200 feet. The barrier was shop fabricated

and transported to the test site in 20 foot length sections. The cross-section of the barrier

consisted of two stacked steel HP 14x73 (A36) shapes with the edges of the flanges placed

back to back and held together by welded steel straps spaced 5 feet on centers. The inside

box section between the HP shapes was filled with concrete. The height of the barrier was

29 inches. The 20 foot length sections were bolted together at the test site.

The location of the vehicle impact was 100 feet from the end of the barrier

installation. This was also the location where two sections were bolted together.

The test was evaluated according to the safety criteria in NCHRP 230 and also in the

AASHTO guide specifications, performance level 2. The safety performance of the Iowa

Steel Temporary Barrier Rail was determined to be satisfactory.

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TABLE OF CONTENTS

Page

Abstract ..................................................... .

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Ust of Tables lV

Ust of Figures v

Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

1.

2.

INTRODUCTION ........................................ .

1.1. Problem Statement ................................... .

1.2. Objective of Study ................................... .

TEST CONDITIONS ...................................... .

1

1

2

3

2.1. Test Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1.1. Test Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1.2. Vehicle Tow System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1.3. Vehicle Guidance System . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2. Barrier Design Details · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.3. Test Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4. Data Acquisition Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4.1. Accelerometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4.2. High-Speed Photography . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.4.3. Speed Trap Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.5. Test Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

11

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Page

3. PERFORMANCE EVALUATION CRITERIA . . . . . . . . . . . . . . . . . . . . 19

4. TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.1. Test No. 15-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5. CONCLUSIONS ..... : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6. RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8. APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Appendix A. Accelerometer Data Analysis . . . . . . . . . . . . . . . . . . . . . . . 37

Appendix B. Relevant Subcontractor Correspondence . . . . . . . . . . . . . . 50

lll

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1.

2.

3.

4.

5.

LIST OF TABLES

Criteria to Evaluate Crash Tests on Longitudinal Barriers ........... .

NCHRP 230 Evaluation Criteria .............................. .

AASHTO Evaluation Criteria ................................ .

NCHRP 230 Evaluation Criteria .............................. .

AASHTO Evaluation Criteria ................................ .

IV

Page

20

21

22

32

33

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LIST OF FIGURES

Page

1. Full-Scale Crash Test Facility ................................ . 4

2. Sketch of Cable Tow and Guidance Systems ..... ............. ... . 5 \

3. Photographs of Tow Vehicles and Fifth Wheel ................... . 6

4. Detail Drawing of Temporary Barrier Rail ...................... . 8

5. Photographs of Barrier Rail Installation ........................ . 9

6. Photographs of Barrier Rail Before Impact and the

Vehicle Guidance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7. Photographs of Test Vehicle Before Impact ...................... . 12

8. Vehicle Measurements ..................................... . 13

9. Flow Chart of Accelerometer Data Acquisition System .... ......... . 15

10. Data Recorder and 386/ AT Computer ......................... . 16

11. Layout of High-Speed Cameras ............................... . 17

12. Summary of Test Results 24

13. Time-Sequential Photographs, Test 15-1 . . . . . . . . . . . . . . . . . . . . . . . . . . 25

14. Photographs of Barrier Rail After Impact . . . . . . . . . . . . . . . . . . . . . . . . 27

15. Sketch of Barrier Rail Displacements . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

16. Photographs of Vehicle Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

v

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ACKNOWLEDGEMENTS

. The authors wish to express their appreciation and thanks to the following people

who made a contribution to the outcome of this research project.

Iowa Department of Transportation

This evaluation task was administered and directed by William A Lundquis4 Bridge

Engineer for the Iowa Department of Transportation, who was assisted by lOOT engineers

Ron C. Welch and David L Uttle.

Federal Hi&hway Administration

The Iowa Division Office of the Federal Highway Administration was represented

by Bruce L Brakke, Division Bridge Engineer, and John M. Latterell, Division Safety

Engineer, who cooperated and advised during the evaluation.

University of Nebraska-Lincoln

Ron Hoffman (Electrician - Maintenance)

Michael Cacak (Manager- Automobile Support Services)

Patrick Barrett (Assistant Manager- Automobile Support Services)

James Dunlap (Manager- Photographic Productions)

Gerald Fritz (E.E. Technician)

Tom Grady (E.E. Technician)

William Kelly (Professor and Civil Engineering Chair)

Tom Hoffman (Mechanical Technician)

VI

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Syed Ataullah (C.E. PhD Student)

Virgil Oligmueller (C.E. Student)

Craig Rockwell (Work Study)

Mary Lou Tomka (C.E. Administrative Assistant)

Wilma Ennenga (C.E. Research Analyst)

Patricia Pedersen (C.E. Secretary)

Private

Larry Storjahnn (Auto Buyer)

Mike Collins (M.E. Collins Construction)

Steve Buchanan (M.E. Collins Construction)

John Magdaleno (Formerly at UNL, now at General Motors)

VII

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1. INTRODUCI'ION

1.1. Problem Statement

The Iowa Department of Transportation (lOOT) and the Federal Highway

Administration (FHWA} are concerned with the safety and structural adequacy of highway

and bridge railing systems installed on Iowa highways. The performance of certain Iowa

Railing systems, now in service, cannot be predicted nor verified by conventional analysis.

Current AASHTO Standard Specifications for Highway Bridges permits the

qualification of railing systems by full-scale vehicle crash testing. The Federal Highway

Administration has directed that bridge railing systems be successfully crash tested before

their use on Federal Aid Projects is approved.

Space limitations for work, such as repair and rehabilitation on bridge decks,

sometimes prevents the use of a full-section New Jersey barrier between the work area and

the traveled roadway. Thus, full-scale vehicle crash testing was performed to evaluate the

half-scale New Jersey barrier for the possibility of overturning, deflection, and the strength

of the connections (1). The safety performance of the Iowa Temporary Concrete Barrier

Rail Half-Section was determined to be unsatisfactory.

The unsatisfactory safety performance of the Iowa Temporary Concrete Barrier Rail

provoked the need for an alternative temporary barrier rail (1). Thus, a safety performance

evaluation was conducted for the Iowa Steel Temporary Barrier Rail.

The results of this study will be used to help guide the IDOT in the use of temporary

barriers in the work zone.

1

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1.2. Objective of Study

The objective of the research study was to evaluate the safety performance of the

Iowa Steel Temporary Barrier Rail by conducting a full-scale vehicle crash test in

accordance with the "Recommended Procedures for the Safety Performance Evaluation of

Highway Appurtenances," NCHRP 230 (2) and also in the "Guide Specifications for Bridge

Railings, 11 AASHTO (l).

2

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2. TEST CONDITIONS

2.1. Test Facility

2.1.1. Test Site

The test site facility was located at Lincoln Air-Park on the NW end of the west

apron of the lincoln Municipal Airport. The test facility, shown in Figure 1, is

approximately 5 mi. NW of the University of Nebraska-Lincoln.

An 8ft. high chain-linked security fence surrounds the test site facility to ensure that

no vandalism would occur to the test articles or test vehicles which could possibly disrupt

the results of the tests.

2.1.2. Vehicle Tow System

A reverse cable tow, with a 1:2 mechanical advantage, was used to propel the test

vehicle. The distance traveled and speed of the tow vehicle are one-half of that of the test

vehicle. A sketch of the cable tow system is shown in Figure 2. The test vehicle was

released from the tow cable approximately 18 feet before impact with the Steel Temporary

Barrier Rail. Photographs of the tow vehicle and the attached fifth-wheel are shown in

Figure 3. The fifth-wheel, built by the Nucleus Corporation, was used for accurately towing

the test vehicle at the required target speed with the aid of a digital speedometer in the tow

vehicle.

2.1.3. Vehicle Guidance System

A vehicle guidance system, developed by Hinch (~), was used to steer the test vehicle.

Photographs of the guidance s.ystem are shown in Figure 6; a sketch of the guidance system

is shown in Figure 2. The Guide flag, attached to the front left wheel and the guide cable,

3

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a FIRE STATION

CRASH· ;!..._;

FACILITY

... ~ qb•"V' JULY 1981

UAl RATE OF CHANGE fftNY 17l-35 0.2° w

S46, T RWY 17R-3

_....... S100, T200, TT..OO RWY 14-32 .l

SlOO, T170, TT280

FiGURE 1 . FULL-SCALE CRASH TEST fACILITY.

4

GENERAL AVIATION

/ PARKING

/

NEBRASKA AffMY NATIONAl GUARD •

'!,'l\. ELEV 1175

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GUIDE FLAG SHEARED orr

3/8• DIA GUIDE CABLE

STANCHIONS

PULLEY

CHUTE <TO'w' CABLE RELEASED>

~AD-END ANCHOR

TO'w' VEHICLE

5/16• DIA TO'w' CABLE

1•2 MECHANICAL

CRASH TEST VEHICLE

FIGURE 2

SKETCH OF CABLE TD'w' AND GUIDANCE SYSTEMS

5

ADVANTAGE

NO SCALE

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FIGURE 3. PHOTOGRAPHS OF TOW VEHICLE AND FIFTH WHEEL .

6

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was sheared off 18 feet before impact with the Steel Temporary Barrier Rail. The 3/8 in.

diameter guide cable was tensioned to 3,000 pounds, and it was supported laterally and

vertically every 100 ft. by hinged stanchions. The hinged stanchions stood upright while

holding up the guide cable. When the vehicle passed, the guide-flag struck each stanchion

and knocked it to the ground. the vehicle guidance system was approximately 1,500 ft. in

length.

2.2. Barrier Desiam Details

The design drawing details of the Iowa steel temporary barrier rail are shown in

Figure 4, and photographs of the barrier being installed on the level concrete apron at the

test site are shown in Figure 5.

The overall test length of the barrier was 200 feet. The barrier was shop fabricated

and transported to the test site in 20 foot length sections. The cross-section of the barrier

consisted of two steel, stacked HP14x73 (A36) shapes with the edges of the flanges placed

back to back and held together by welded steel straps spaced 5 feet on centers.

In order to increase the weight and stiffness of the barrier, the inside box section

between the HP shapes was filled with concrete. The height of the barrier was 29 inches.

The 20 foot length sections were bolted together with splice plates at the test site. The fill

concrete stopped one foot short of each end of a section.

Photographs of the barrier prior to conducting the test are shown in Figure 6. The

barrier was "free-standing" with no attachments to the level concrete apron.

7

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.WI4 x 73

t'·S! ...('8) 1: 2 l 2 ': 2 2 2 1: 1

~· II I 11 -·1 riii'IC • u

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111'14 " 13

~ -~ SECTION C-C

ELEVATION VIEW - TRAFFIC SIDE ELEVATION V lEW - WORK AREA SIDE ISHCI'IINC CONNECT ION AT JOINTl

TRAFFIC L AN( I' SID(

~ L6x,xhci'·IO~

CAIN() L£..6 TO FIT COANER RADiuS Of HP1c • n.

HPic " n

ISHOWING COIH:CTION AT JOIHTI

PART PLAN ViEW A-A

NOTES FOR STEEL T(YPOAART BARR(R RA~: HP14x73 SECTIONS ARE TO BE JOIN(D 8(FO~( P.C. CONCRETE FILL IS PLACED. HP SECTIONS

WAY BE JOINED BY TIE PLATES AS DETAILED OR BY OTN(R loi(ANS APPROVED BY THE EHCINEER. HP SECTIONS SHALL BE FREE FROiol EXCESSIVE SWE(P AH() CAII8£Ra STRAIGHT[NINC WAY 8£ REOUIR(O BY THE ENG INEER IN ORDER TO PRODUCE A STABLE BARRIER.

CO<ICRETE WIX FOR !H( P.C. FILL UAY 8( ANY IOWA 0. 0. T. HIGHWAY DIVISION SPECifiCATION UIX OR WAY 8E A COUW(RCIAL READY - UIX WITH A UINIUUU F'C • ~00 P.S.I. THE P.C. FILL WAY 8£ DEPOSITED BY A UETHOO ACCEPTABLE TO THE ENCIN([R. JOINTS ARE TO BE REASONABLY WORT AR TICHY. AHO WORTAR EXTRUSIONS SH4LL BE CL[AH(O FLUSH WITH THE OUTSIDE Clf THE BARRIER. L loiiTS Of FILL SHOWN ARE APPROXIWATE AN() WAY 8£ ROUCH OR SI.I.Jioll'£0 DEPEHOINC 0H THE loi(THOO Of BUll HEAOINC.

lACl WELD ALL NUTS TO INSIDE BOlT. 6 x I I. 6 • l PlATES AN() TACK WELD INSIDE 80TT. 6 x I& 6 x l PlATES TO INSIDE Of TH£ FLANGE Of !H[ HP14x13 PilE. OH ON£ (NO Of THE PilE SECTION OHL J. TACl W£LO NUTS TO THE INSIDE W£8 Of THE TOP PILE FOR THE 6xl ANGLE CONNECTION.

~- • HOLES IN Tri( 2 INSIDE 6 x l PLAl£S. I INSIDE (, • I PLAT£, Th[ FlAHCES AN() W£8 Of TH£ PILE. ANO :· • HCII.E.S IN TH[ 17! < l OUTSIDE PLAT£. AND THE ' x I AHClE. USE j• • • 0'·2!

SECT ION B-B H. T. S. BCII.TS. PROVIDE ON£ WASHER PLACED UIIOEII THE HEAO. BOLTS SHAll BE TIGHTENED SO THAT All PlATE F4CES 8(AR AGAINST EACH OTHER.

' • ...... EICl Of P.C. CONCRETE Flll--t-1.,-,_-:-

0--1c:-•• -::

0-ot

o/" IWAX.I CWAX,I

{: ~: ~~+-~-:~-:~-:~-:~-::-:-:-:-:...;:-:-:--~:-: ~...;~ ::--::-: ~-~~-:-:-~-.1-=-r-~-1;: F :::::::::::: =: =1-" ":.i:!-:·:-~"'=~ -~="": -:P~ -:z: -ix·~:-::· //// / //,'//// ,,,,,,///////// ///////////////r/ /////;

lJP. BOTH SIO(S II SPACE o WAX. 5'·0 CTR. TO CTR. TIE !1.'S i x ll x 1'•3 II

20' WIN. LEHCTH

ELEVATION VIEW - STEEL T. B. R.

FIGURE 4. DETAIL DRAWING OF TEMPORARY BARRIER RAIL.

CRASH TEST PROJECT 8Rf·OOOSi21··38-00

TASK NO.5 APPENDIX A PROJECT SHEET I or 1

STEEL TEMPORARY BARRIER RAIL IOWA OEPA~T ioi[N T Of TRANSPORTATION - HICHW&Y 04VISION

Ot:SICoo 5><£ I HO. Ill 'llE HO. ot:SICoo HO.

I Sfaf( I ••• ,.... ·.~ _I ---=::.· I .~ • ..,_ :o..,,..

Page 18: FULL-SCALE VEIDCLE CRASH TEST ON THE IOWA STEEL …The unsatisfactory safety performance of the Iowa Temporary Concrete Barrier Rail provoked the need for an alternative temporary

FIGURE 5. PHOTOGRAPHS OF BARRIER RAIL INSTALLATION .

9

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UNN£R~TY OF NEBRASKA TESTIS· I DATE 2 5AUG 89

IOWA 'DEPt OF TRAM VEHIClt 54005 SPEED 60 MPH ANGUZO•

FIGURE 6. PHOTOGRAPHS OF BARRIER RAIL BEFORE IMPACT AND THE VEHICLE GUIDANCE SYSTEM.

10

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2.3. Test Vehicle

The test vehicle was a 1983 3/4-ton Chevrolet (Scottsdale} pickup truck weighing

5,500 pounds. Photographs of the test vehicle are shown in Figure 7, and the physical

measurements of the test vehicle are shown in Figure 8.

Steel plates, bolted to the rear box, were used in order for the test vehicle to conform

to the weight and the center-of-mass location specifications in AASHTO (~).

Three 8-in. square, black and white checkered targets were placed on the top of the

test vehicle. The middle target was placed over the center of mass. Additional roof targets

were placed ahead of and behind the center of mass. The targets were used in the analysis

of the high speed film. In addition to the roof targets, side and rear targets were placed at

known positions to aid in the evaluation process.

Two 5B flash-bulbs were mounted on the roof of the test vehicle to record the time

of impact with the bridge rail on the high-speed film. The flash bulbs were fired by a

pressure tape switch mounted on the front face of the bumper.

The front wheels of the test vehicle were aligned to a toe-in value of zero-zero so

that the vehicle would track properly· along the guide cable.

2.4. Data Acguisition Systems

2.4.1. Accelerometers

Six Endevco triaxial piezoresistive accelerometers (Model 7264) with a range of ±

200 g's were used to measure the accelerations in the longitudinal, lateral, and vertical

directions of the test vehicle. Two accelerometers were mounted in each of the three

directions so that there would be two readings to compare. The accelerometers were rigidly

11

Page 21: FULL-SCALE VEIDCLE CRASH TEST ON THE IOWA STEEL …The unsatisfactory safety performance of the Iowa Temporary Concrete Barrier Rail provoked the need for an alternative temporary

--- . -~ ------ .......

FIGURE 7. PHOTOGRAPHS OF TEST VEHICLE BEFORE IMPACT .

12

Page 22: FULL-SCALE VEIDCLE CRASH TEST ON THE IOWA STEEL …The unsatisfactory safety performance of the Iowa Temporary Concrete Barrier Rail provoked the need for an alternative temporary

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\12 2890 2830 2830 ------- --------- -------Vtoto.l 4950 5500 5500 ------- --------- ------------

Note Qny dn"'QQ• p~or to ~--~ -------li2~------------------------------------

F'IGURE 8. VEHICLE MEASUREMENTS

13

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attached to a metal block mounted at the center-of-mass. The signals from the

accelerometers were received and conditioned by an onboard vehicle Metraplex Unit. The

multiplexed signal was then radio transmitted to the Honeywell 101 Analog Tape Recorder

in the central control van. A flow chart of the accelerometer data acquisition system is

shown in Figure 9, and photographs of the system located in the test vehicle and the

centrally controlled step van are shown in Figures 7 and 10. The latest state-of-the-art

computer software, "Computerscope and DSP'', was used to analyze and plot the

accelerometer data on a Cyclone 386/ AT, which uses a very high-speed data acquisition

board.

2.4.2. Hi2h-Speed Photo2faphy

Three high-speed 16 mm cameras were used to film the crash tests. The cameras

operated at approximately 500 frames/sec. The overhead camera was a Red Lake Locam

with a wide angle 12.5 mm lens. It was placed approximately 60 ft. above the concrete

apron. The parallel camera was a Photec IV with an 80 mm lens. It was placed 250 ft.

downstream and offset 3 ft. from a line parallel to the barrier rail. The perpendicular

camera was a Photec IV with a 55 mri1 lens. It was placed 165 ft. from the vehicle point of

impact. A schematic of the camera locations is shown in Figure 11.

A 20 ft. wide by 100 ft. long grid layout, shown in Figure 6, was painted on the

concrete slab surface parallel and perpendicular to the barrier. The white-colored grid was

incremented with 5 ft. divisions in both directions to give a visible reference system which

could be used in the analysis of the overhead high-speed film.

14

Page 24: FULL-SCALE VEIDCLE CRASH TEST ON THE IOWA STEEL …The unsatisfactory safety performance of the Iowa Temporary Concrete Barrier Rail provoked the need for an alternative temporary

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CoiiCil'bcM..rr Cards 340Q.34CI!\340d - ·· - · ·- ·· - ·· - ·· -··-

F'M Mut••XIIIO S.ctlon C7 lcalerotWwrs P•r ~ 4 Chun&tls Mu.>

Souitwrn Call' ami& Micron v• 4-ChonMl TNMW't'tH'

CO"'P6'tti• •tth C.Uulv PhOM Antnnas

SOU'thH'ft Callf'OI"'fttll Mlc:ro .. v. 4-thannel Recetwr

C.,...,.ttie With Cellular Phone Antnnu

t HoMyftU ...,., 101 14 Ch&Mel .... tic

To.pe hear.,.

I Me'tro.pln 1110 s..,....

rM ~ .. tor ustna ~~ 120 F'M D...acts

a GAin a# lD •

SIQMl FUH'Ing (SA£ JZUb)

Cho.~~ c~s tao t

Cyber hMU"Ch Cyctone 386/ AT CoPiputer

With Cybtrh .. o.rd\ VH'y High s.,_.c:t AID lo&rd

<12 brt r•solU'tion> CUp to 1 MHz Se.ftple Ro.t.>

Do.to. ... 1. stored 2. Derlvftt 3. Int.gro. ted 4. P\ottftt

' TEST RESUL. TS L V.Nc:te Cho.nQe-~S.,.eCII

12. Dc:cupo.nt Dlspl&c.Mnt 13. Oc:cupQnt ~ct V•t~ f4. Dccupo.nt Rldfttown

lcalerot1on

FIGURE 9 F'LD\1 CHART OF ACCELEROMETER

DATA ACQUJSlTJDN SYSTEM

15

Test V.Nc:te

Celrtrel COfttrol

Van

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FIGURE 10. DATA RECORDER AND 386/AT COMPUTER.

16

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OVERHEAD LOCAM

7

~AM£RA 60' /

1_3.3_ T- l_?O'J

I 250' r--1 ~~ - - -=-=-=---- - ---+t

I PARALLEL DOWNSTREAM

L---- PHOTEC N CAMERA

NO SCALE

PERPENDICULAR ""---- PHOTEC lY

CAMERA

5400 LB. PICKUP

FIGURE II. LAYOUT OF HIGH - SPEED CAMERAS

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The film was analyzed using the Vanguard Motion Analyzer. The camera divergence

correction factors were also taken into consideration in the analysis of the high-speed film.

2.4.3. Speed Trap Switches

Eight tape pressure switches spaced at 5 ft. intervals were used to determine the

speed of the vehicle before and after impact. Each tape switch fired a blue 5B flash-bulb

located near each switch on the concrete slab as the left front tire of the test vehicle passed

over it. The average speed of the test vehicle between the tape switches was determined

by knowing the distance between pressure switches, the calibrated camera speed, and the

number of frames from the high-speed film between flashes. In addition, the average speed

was determined from electronic timing mark data recorded on the oscilloscope software

used with the 386/AT computer as the test vehicle passed over each tape switch.

2.5. Test Parameters

Test 15-1 was conducted at a target impact speed of 60 mph with a target impact

angle of 20 degrees. A 1983 Chevrolet Scottsdale 3/ 4-ton pickup weighing 5,500 pounds was

used as the crash test vehicle. The location of impact was 100 ft. downstream from the

north end of the barrier rail, at a fieid assembly joint.

18

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3. PERFORMANCE EVALUATION CRITERIA

At the present time, there is no specific criteria for evaluating the safety performance

of temporary barrier railings to protect (a) workmen in a bridge construction zone, and (b)

the occupants in a run-off-the-road vehicle. However, there are currently two sources of

criteria for longitudinal barriers which are similar in many details to temporary barrier

railings. The two sources are:

1. NCHRP 230 (2) ... Recommended Procedures for the Safety Performance Evaluation of Highway Appurtenances (1981)

2. AASHTO (~) ...... Guide Specifications for Bridge Railings (1989)

The criteria in AASHTO has been officially adopted by the Federal Highway

Administration (FHWA), and the criteria in NCHRP 230 is currently being updated by Ross

(5.) of the Texas Transportation Institute for use in the year 1992.

The two sources of criteria to evaluate the safety performance of longitudinal barriers

are presented in Tables 1, 2, and 3. The selected vehicle impact conditions are most

representative of the actual highway conditions in which the Iowa Steel Temporary Barrier

Rail will be used. The decision to use the 5,400 pound pickup truck impacting the barrier

at 60 mph and 20 degrees was made by the Iowa DOT with approval by the FHWA.

After the test the vehicle damage was assessed by the traffic accident data scale

(TAD) (n) and the vehicle damage index (VDI) (1).

It is reasonable to assume that the update of NCHRP 230 will contain specific

criteria for construction zone barriers. The specific criteria will mostly include most of the

existing criteria with perhaps modifications on (a) the impact speed and angle, and (b) the

maximum amount of controlled lateral barrier deflection in item "A" of NCHRP 230 and

item "a" of AASHTO.

19

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N 0

Test Agency

NCHRP

230

AASHTO

(1989)

Notes:

2

TABLE 1.

CRITERIA TO EVALUATE CRASH TESTS ON LONGITUDINAL BARRIERS

Test Service Type Test Impact Conditions Criteria1

No. Level Barrier Vehicle Speed Angle Railing (lbs) (mph) (deg) Location Required Desirable

Guardrail2 4,500 Near A,D,E,

10 (Length of Need) (Sedan) 60 25 Splice H, I

5,400 Near Splice 3, a, b, 3, e, f,

PL-2 Bridge2 (Pickup) 60 20 (NCHRP 230) c,d g,h

Description of criteria in Tables 2 and 3.

Since there are no specific criteria for construction barriers, the criteria for these systems were used to evaluate this test.

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TABLE 2. NCHRP 230 EVALUATION CRITERIA

Structural A: Test article shall smoothly redirect the vehicle; the vehicle shall Adequacy not penetrate or go over the installation although controlled

lateral deflection of the test article is acceptable.

D. Detached elements, fragments or other debris from the test article shall not penetrate or show potential for penetrating the passenger compartment or present undue hazard to other traffic.

Occupant E. The vehicle shall remain upright during and after collision Risk although moderate roll, pitching, and yawing are acceptable.

Integrity of the passenger compartment must be maintained with essentially no deformation or intrusion.

Vehicle H. After collision, vehicle trajectory and final stopping position shall Trajectory intrude a minimum distance, if at all, into adjacent traffic lanes.

I. In test where the vehicle is judged to be redirected into or stopped while in adjacent traffic lanes, vehicle speed change during test article collision should be less than 15 mph and the exit angle from the test article should be less than 60 percent of test impact angle, both measured at time of vehicle loss of contact with test device.

21

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TABLE 3. AASHTO EVALUATION CRITERIA

a. The test article shall contain the vehicle; neither the vehicle nor its cargo shall penetrate or go over the installation. Controlled lateral deflection of the test article is acceptable.

b. Detached elements, fragments, or other debris from the test article shall not penetrate or show potential for penetrating the passenger compartment or present undue hazard to other traffic.

c. Integrity of the passenger compartment must be maintained with no intrusion and essentially no deformation.

d. The vehicle shall remain upright during and after collision.

e. The test article shall smoothly redirect the vehicle. A redirection is deemed smooth if the rear of the vehicle does not yaw more than 5 degrees away from the railing from time of impact until the vehicle separates from the railing.

f. The smoothness of the vehicle-railing interaction is further assessed by the effective coefficient of friction #J., where #J. = (cose - VP/V)/sine.

u Assessment 0.0 - 0.25 Good 0.26- 0.35 Fair

>0.35 Marginal

g. The impact velocity of a hypothetical front-seat passenger against the vehicle interior, calculated from vehicle accelerations and 2.0 ft. longitudinal and 1.0 ft. lateral displacements, shall be less than:

Occupant Impact Velocity- fps Lon~itudinal Lateral

30 25

and for the vehicle highest 10-ms average accelerations subsequent to the instant of hypothetical passenger impact should be less than:

Occupant Ridedown Accelerations - &'s Lon~itudinal Lateral

15 15

h. Vehicle exit angle from the barrier shall not be more than 12 degrees. Within 100 ft. plus the length of the test vehicle from the point of initial impact with the railing, the railing side of the vehicle shall move no more than 20 ft. from the line of the traffic face of the railing.

22

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4. TEST RESULTS

4.1. Test No. 15-1

A summary of the test results are shown in Figure 12. The test vehicle impacted the

barrier at the midspan bolted connection (Joint #5) at a speed of 60.6 mph and an angle

of 22.5 degrees. The sequential photographs are shown in Figure 13.

The barrier began to deflect and slide on the concrete apron at a time of 44 msec

after impact. At a time of 223 msec., the test vehicle speed decreased to 50.2 mph as it

became parallel to the undeformed centerline of the barrier. The test vehicle exited the

barrier at a speed of 49.4 mph and at a flat angle of 1.5 degrees.

At a distance of 65 feet from the point of impact, the impact side of the test vehicle

reached a maximum rebound distance of 2.0 feet from the traffic face of the barrier. The

test vehicle then began to turn rapidly back toward the barrier and crossed over the

extended centerline of the barrier at a distance of approximately 122 feet from the point of

impact and 22 feet beyond the end of the barrier.

Photographs of the barrier after impact are shown in Figure 14 and a sketch of the

displacements of the barrier bolted connections is shown in Figure 15. The maximum

displacement of 17 9/16-inches occurred at the point of vehicle impact and connection Joint

No. 5. Member 5-6, the first member downstream from the point of impact, was the only

member to experience a permanent deformation. This deformation is 1 /8-inch.

23

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~

IMpo.ct 45 Msec 161 Msec 223 Msec 314 Msec

9 8 7 6 5 4 3 2 1 1'-1 5/8 -I r-

• • p~$· IMpo.ct

• • J- 20' -1 • zol1:ed1

1 1/2 -II-- -II-- 1/2

~~~ "' 1£ "' 2'- 5

200'

Test No . .. . . . .... !5-1 Do.te . . . . . . . . •• • 8/25/89

Test Vehicle Model ... . . ... 1983 Chev. Prckup 'w'erght

Test Inertia. . 51500 llos. Gross Sto. tic . 51500 Uos.

IMpo.ct Conolltlons Speed . . . . . . . 60.6 Mph Angle . . • • 22.5 deg .

Exrt Conditions Speed . . .. . 49.4 Mph Angle . . . . . . 1.5 deg. Reloound (Mo.x ). . . 2.0 ft @ 65 ft

Connec Ions ~....-.... u "'

Bo.rrrer Do.Mo.ge (deflections) Connection <no. 5). . . . . . . . 17 9/16 rn. PerMo.nent Set <MeMioer 5-6). 1/8 ln.

Vehicle Do.Mo.ge TAD .. .... . .... . VDI ...... . . . . . . . ..

Occupo.nt !Mpo.ct Velocity Longltudlno.l . . .... . Lo.tero.l .. .. .... . .....

Occupo.nt Rldedown Decelero. tlons

1-RFQ-4 01RYEN2

13.5 fps 19.6 f'ps

1-4 X 73

Longltudlno.l . . . . . . . . . . . . +4.7 g's/ -6.7 g's La. tero.l . . . . . . . . . . . . . . 12.8 g' s

FIGURE 12. SUMMARY OF TEST RESULTS

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-100 msec -102 msec

Impact -53 msec

24 msec Impact

138 msec 44 msec

225 msec 100 msec

316 msec 161 msec

FIGURE 13 . TIME-SEQUENTIAL PHOTOGRAPHS, TEST IS-1.

25

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440 msec 223 msec.

586 msec 314 msec

855 msec

1083 msec

1389 msec

1739 msec

FIGURE 13. TIME-SEQUENTIAL PHOTOGRAPHS, TEST I5-1 (cont'd).

26

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FIGURE 14. PHOTOGRAPHS OF BARRIER RAIL AFTER IMPACT.

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BARRIER LENGTH (ft)

FIGURE 15. SKETCH OF BARRIER RAIL DISPLACEMENTS.

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Photographs of the damage to the test vehicle are shown in Figure 16. It is estimated

that the test vehicle was traveling at a speed of less than 5 mph when it impacted head-on

the previously tested retrofitted concrete barrier that was 200 feet downstream and 24 feet

to the right of the steel temporary barrier rail. The inside occupant compartment cab area

was intact with no barrier intrusions and essentially no deformation. It appears that the

right rear tire and rim were badly damaged due to snagging on several of the 3 /8-inch thick

welded tie plate straps.

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FIGURE 16. PHOTOGRAPHS OF VEHICLE DAMAGE.

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S. CONCLUSIONS

One full-scale vehicle crash test was conducted to evaluate the safety performance

of the Iowa Steel Temporary Barrier Rail.

Test 15-1 was evaluated according to the safety performance criteria given in NCHRP

230 (2) and AASHTO (l). The safety evaluation summaries using both sets of criteria are

presented in Tables 4 and 5.

The analysis of the crash test revealed the following:

1. The temporary barrier smoothly redirected the test vehicle.

2. The test vehicle did not penetrate or ride over the installation.

3. The controlled lateral deflection of the test article was acceptable.

4. There were no detached elements or fragments from the test article which

showed potential for undue hazard to other traffic.

5. The integrity of the passenger compartment was maintained.

6. The test vehicle remained upright during and after the collision.

7. The occupant risk values for impact velocity and ridedown decelerations were

acceptable during impact.

8. The test vehicle's change in speed was satisfactory (11.20 mph < 15 mph).

9. The test vehicle's trajectory was satisfactory.

Based upon the above listed items, the results of Test 15-1 are acceptable according

to the NCHRP 230 (2) and AASHTO (J) guidelines.

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TABLE 4. NCHRP 230 EVALUATION CRITERIA

Structural Adequacy

Occupant Risk

Vehicle Trajectory

S - Satisfactory M- Marginal

A:

D.

E.

H.

I.

U - Unsatisfactory

Test article shall smoothly redirect the vehicle; the vehicle shall not penetrate or go over the installation although controlled lateral deflection of the test article is acceptable.

Detached elements, fragments or other debris from the test article shall not penetrate or show potential for penetrating the passenger compartment or present undue hazard to other traffic.

The vehicle shall remain upright during and after collision although moderate roll, pitching, and yawing are acceptable. Integrity of the passenger compartment must be maintained with essentially no deformation or intrusion.

After collision, vehicle trajectory and final stopping position shall intrude a minimum distance, if at all, into adjacent traffic lanes. .

In test where the vehicle is judged to be redirected into or stopped while in adjacent traffic lanes, vehicle speed change during test article collision should be less than 15 mph and the exit angle from the test article should be less than 60 percent of test impact angle, both measured at time of vehicle loss of contact with test device.

32

s

s

s

s

s

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TABLE 5. AASHTO EVALUATION CRITERIA

AREA

a. The test article shall contain the vehicle; neither the vehicle nor its cargo shall penetrate or go over the installation. Controlled lateral deflection of the test article is acceptable.

b. Detached elements, fragments, or other debris from the test article shall not penetrate or show potential for penetrating the passenger compartment or present undue hazard to other traffic.

c. Integrity of the passenger compartment must be maintained with no intrusion and essentially no deformation.

d. The vehicle shall remain upright during and after collision.

c. The test article shall smoothly redirect the vehicle. A redirection is deemed smooth if the rear of the vehicle does not yaw more than 5 degrees away from the railing from time of impact until the vehicle separates from the railing.

f. The smoothness of the vehicle-railing interaction is further assessed by the effective coefficient of friction ll, where ll = (cos9 - Vp/V)/sin9.

u Assessment 0.0- 0.25 Good

0.26- 0.35 Fair > 035 Marginal

g. The impact velocity of a hypothetical front-seat passenger against the vehicle interior, calculated from vehicle accelerations and 2.0 ft. longitudinal and 1.0 ft. lateral displacements, shall be less than:

Occupant Impact Velocity- fps Lon~tudinal l&1llil

30 25

and for the vehicle highest 10-ms average accelerations subsequent to the instant of hypothetical passenger impact should be less than:

Q~UPilnt Ri!.J~!.JQwn A!;;~l~rlltiQn:i - ~·:i Lon~tudinal !&1sa:ill

15 15

h. Vehicle exit angle from the barrier shall not be more than 12 degrees. Within 100 ft. plus the length of the test vehicle from the point of initial impact with the railing, the railing side of the vehicle shall move no more than 20 ft. from the line of the traffic face of the railing.

S - Satisfactory M - Marginal U - Unsatisfactory

33

Required

s

s

s

s

Desirable

s

Good (0.25)

s

s

s

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6. RECOMMENDATIONS

Currently, there is no specific vehicle crash test matrix that addresses temporary

construction zone barriers. The 5,400 pound vehicle within the PL-2 performance level of

AASHTO (J.) has been inherently chosen to be an adequate indicator for safety

performance evaluation. This is comparable to the 4,500 pound vehicle within test

designation No. 10 of NCHRP 230 (2).

The Iowa steel temporary barrier rail has met the required performance evaluation

criteria set forth by NCHRP 230 (!) and AASHTO (2). Thus, it is our recommendation

that the Federal Highway Administration approve this installation for use on Federal Aid

Projects.

The Iowa Steel Temporary Barrier Rail performed very well. The amount of work

required to assemble and disassemble the barrier rail was found to be very time consuming,

as stated in Appendix B. This does not promote the design concept of being portable or

temporary. When the connection holes were match drilled and oversize drilled (varying

between 1/16" and 3/16"), the barrier rail was still time consuming to install on the level

concrete apron surface.

After the vehicle had impacted and displaced the barrier rail, removal of the

connection bolts was found to be both time consuming and difficult. The time required to

assemble and disassemble the barrier rail installation could be reduced if the bolted

connections were redetailed.

34

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7. REFERENCES

1. Faller, R.K., Magdaleno, J.A, and Post, E.R. "Full-Scale Vehicle Crash Test on the Iowa Temporary Concrete Barrier Rail Half-Section," Final Report to Iowa Department of Transportation, Report No. TRP-03-014-88, Civil Engineering Department, University of Nebraska-lincoln, December, 1988.

2. "Recommended Procedures for the Safety Performance Evaluation of Highway Appurtenances," National Cooperative Highway Research Program Report 230, Transportation Research Board, Washington, D.C., March, 1981.

3. "Guide Specifications for Bridge Railings," American Association of State Highways and Transportation Officials, Washington, D.C., 1989.

4. Hinch, J., Yang, T-~ and Owings, R., "Guidance Systems for Vehicle Testing," ENSCO, Inc., Springfield, VA, 1986.

5. Ross, H.E., Jr., "Update of Recommended Procedures for the Safety Performance Evaluation of Highway Appurtenances," National Cooperative Highway Research Program Project No. 22-7, Texas Transportation Institute, Texas A&M University, Proposed 1991.

6. "Vehicle Damage Scale for Traffic Accident Investigators," Traffic Accident Data Project Technical Bulletin No. 1, National Safety Council, Chicago, II..., 1971.

7. "Collision Deformation Classification, Recommended Practice J224 Mar 80, "SAE Handbook Vol. 4, Society of Automotive Engineers, Warrendale, Penn., 1985.

35

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8. APPENDICES

36

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A-1

A-2

A-3

A-4

A-5

A-6

A-7

A-8

A-9

APPENDIX A.

ACCELEROMETER DATA ANALYSIS

Graph of Longitudinal Deceleration, Test 15-1

Graph of Longitudinal Deceleration, Test 15-1

Graph of Vehicle Change in Speed, Test 15-1

Graph of Vehicle Change in Speed, Test 15-1

Graph of Longitudinal Occupant Displacement, Test 15-1

Graph of Longitudinal Occupant Displacement, Test 15-1 ........... .

Graph of Lateral Deceleration, Test 15-1 ....................... .

Graph of Lateral Deceleration, Test 15-1 ....................... .

Graph of Lateral Occupant Impact Velocity, Test 15-1 .............. .

A-10 Graph of Lateral Occupant Impact Velocity, Test 15-1

A-11 Graph of Lateral Occupant Displacement, Test 15-1

A-12 Graph of Lateral Occupant Displacement, Test 15-1

37

Page

38

39

40

41

42

43

44

45

46

47

48

49

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,......, (I)

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~IGURE A-1 . GRAPH OF LONGITUDINAL DECELERATION , TEST IS-1.

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FIGURE A-6. GRAPH OF LONGITUDINAL OCCUPANT DISPLACEMENT, TEST I5-1 .

Page 53: FULL-SCALE VEIDCLE CRASH TEST ON THE IOWA STEEL …The unsatisfactory safety performance of the Iowa Temporary Concrete Barrier Rail provoked the need for an alternative temporary

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FIGURE A-8. GRAPH OF LATERAL DECELERATION, TEST IS-1.

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FI GURE A-9. GRAPH OF LATERAL OCCUPANT I MPACT VELOCITY, TEST I S- 1.

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Fir.URE A-10. GRAPH OF LATERAL OCCUPANT IMPACT VELOCITY, TEST IS-1.

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Page 58: FULL-SCALE VEIDCLE CRASH TEST ON THE IOWA STEEL …The unsatisfactory safety performance of the Iowa Temporary Concrete Barrier Rail provoked the need for an alternative temporary

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FIGURE A-12. GRAPH OF LATERAL OCCUPANT DISPLACEMENT, TEST 15-1.

Page 59: FULL-SCALE VEIDCLE CRASH TEST ON THE IOWA STEEL …The unsatisfactory safety performance of the Iowa Temporary Concrete Barrier Rail provoked the need for an alternative temporary

APPENDIX B.

RELEVANT SUBCONTRACI'OR CORRESPONDENCE

50

Page 60: FULL-SCALE VEIDCLE CRASH TEST ON THE IOWA STEEL …The unsatisfactory safety performance of the Iowa Temporary Concrete Barrier Rail provoked the need for an alternative temporary

M. E. Collins Contracting Co. , Inc.

To: Dr. Ed Post Civil Engr. Dept. Univ. of Nebraska

P.O. Box 83 Wahoo, NE 68066

(402) 443-3663 Dec. 18, 1989

W 348 Nebraska Hall Lincoln, NE 68588-0531

Re: Steel Temporary Barrier Rail Crash Test for Iowa D.O.T.

Deur D.r. Pos L,

As per your request. I have addressed in this letter the difficulties which M. E. Collins Contracting Co., lnc. encountered while dismantling the railing on the above mentioned project.

Dismantling of the rail began at the Joint at which impact occurred. The bolts were initially attempLcd to bo removed by the use of a breaker bar and socket. This proved to be unsuccessful. A one inch air impact drill was then used and it did remove all of the bolts except for one. The bolts which the air impact drill did remove, dam~gcd the threads beyond reuse. The remaining bolt required the use of a torch to cut off the bolt head.

The remainder of the steel rail was dismantled at every other joint. The one inch air impact drill was used on all of these bolts with four. or five bolts requiring the use of a torch. The maJority of the bolts removed where not rf"!usa b le because of damage to the threads.

In my opinion, the work required to assemble and disassemble this rail system does not lend itself well to a multiple use barrier rail system. Mobilizing and sBtting the rails in place was not difficult, but assembling the rail was very time consuming even though the holes in the plates and rails were match drilled. The force required to remove the bolts also stripped the maJority of the bolts. I also believe that any attempt to assemble this rail system on an unlevel surface would be vory difficult.

1 hope t,hat this let.ter has answered your questions adequately, and if I can be of any further help please let me know.

Respectfully,

foa~~~ Stave A. Buchanan

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