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Barrier Field Manual
CSP Pacific | Barrier Field Manual | December 12

Barrier Field Manual - Index
Flexrail™ W Beam Highway & Bridge Barrier Brochure 04
Installation Checklist 07
FX54 Highway Flexrail – 12G – Half Rail 08
FX55 Bridge Flexrail – 10G – Half Rail 08
FX33 Highway Flexrail – 12G – Full Rail 09
FX34 Bridge Flexrail – 10G – Full Rail 09
FX360 Standard Guardrail Assembly – 12G on Timber Posts & Blockouts 10
FX283 Standard CSP Pacific Flexrail Posts 11
FX92 Standard Flange Mounted Steel Posts 12
FX107 Standard Timber Post & Blockout 12
FX93 Standard Steel Post for Bridge Handrail 13
FX94 Standard Steel Flexrail Post 13
FX147 Standard Tested Necked Bolt 14
FX150 Standard Cast-In Brackets 14
FX91 Flexrail Steel Post Flange Mounted 15
FX253 Standard Flexrail Backing Piece 15
FX126 8 Hole Bridge Connector 16
FX146 Bullnose Terminal End – Single Piece 16
FX407 Flexrail Structure Connector 17
FX359 Buried-in-Backslope Assembly 17
Bridge Handrail
FX350-1 Flexrail Handrail – Sloping Termination 18
FX306-1 Handrail Standard Detail 19
Thriebeam™ Brochure20
FX382-1 Standard 12G Thriebeam Rail 23
FX497 W-Thrie Transition Section 23
FX408 Thriebeam Timber Post & Blockout 24
FX476 Standard Thriebeam Posts 24
FX459 Thriebeam Driven Post & Blockout 25
FX475 Thriebeam Bridge Post & Blockout 25
FX461 Thriebeam Structure Connector Assly 26
FX453 Thriebeam Structure Connector 26
FX495 Thriebeam Handrail-Sloping to Timber 27
FX495-2 Thriebeam Handrail-Sloping to Steel Base 28
FX495-1 Thriebeam Mounting Detail 29
FX553 Thriebeam Steel Post & Routered Timber Blockout 29
X-350 Tangent & Flared End Terminal Brochure30

Installation & Maintenance instructions 31
FX538 Tangential Terminal End - Timber Post-Elevation 38
FX539 Tangential Terminal End - Timber Post 39
FX540 Tangential Terminal End - Steel Posts-Elevation 40

FX541 Tangential Terminal End - Steel Posts 41
Nu-Guard 31™ Steel Guardrail System Brochure42

Installation & Maintenance instructions 43
FX514 Nu-Guard 31 System Assembly 46
FX513 Nu-Guard 31 W-Beam Post 47
FX525 Nu-Guard 31 Median System Assembly 47
FX566-1 Nu-Guard 31 Curved Terminal Installation 48
FX577 Nu-Guard 31 Transition to 27” High X-350 Timber Post Option 49
FX608 Nu-Guard 31 Transition to 31” High X-350 50
FX609 Nu-Guard 31 Transition to Standard TL4 Thriebeam 51
FX611 Nu-Guard 31 Transition to Railing End Terminal 51
Trailing End Terminal

FX335 Curved Trailing Terminal Assembly - exploded view 53
CSP PACIFIC
A | 306 Neilson St, Onehunga P | PO Box 12 949, Penrose, Auckland 1642, New Zealand W | www.csppacific.co.nz
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Barrier Field Manual - Index
FX348-2 Curved Trailing Terminal Assembly 54
FX348-4 Straight Trailing Terminal Assembly 55
NZTA Standard Details

RSB-1 Buried-in-Backslope Terminal 56
RSB-2 Curved Terminal 57
RSB-3 M23 Terminal Grading Plan 58
RSB-4 Nested Guardrail Detail 59
RSB-5 TL4 Transition Detail 59
Drawings
FX33 09
FX34 09
FX54 08
FX55 08
FX91 15
FX92 12
FX93 13
FX94 13
FX107 12
FX126 16
FX146 16
FX147 14
FX150 14
FX253 15
FX283 11
FX306-1 19
FX335 53
FX348-2 54
FX348-4 55
FX350-1 18
FX359 17
FX360 10
FX382-1 23
FX407 17
FX408 24
FX453 26
FX459 25
FX461 26
FX475 25
FX476 24
FX495 27
FX495-1 29
FX495-2 28
FX497 23
FX513 47
FX514 46
FX525 47
FX538 38
FX539 39
FX540 40
FX541 41
FX553 29
FX566 48
FX577 49
FX608 50
FX609 51
FX611 51
RSB1 56
RSB2 57
RSB3 58
RSB4 59
RSB5 59
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FlexrailTM W-Beam Highway (12g) & Bridge Barrier (10g)
Flexrail™ complies with the requirements
of AASHTO, AS/NZS 3845 : 1999 TNZ
specifications M/23 and M/17P.
CSP Pacific supplies two standard types of

Flexrail™ W-beam guardrail:
» Highway Flexrail: 3810-12
» Bridge Flexrail: 4000-10
Flexrail™ is roll formed from coil steel and

sheared to length. It is then punched, slotted and
hot dip galvanised in accordance with
the appropriate standards.
Flexrail™ is generally available ex-stock in

standard net lengths of 3.81 metres and 1.905
metres for highway rail and 4.00 metres and 2.00
metres for bridge rail.
Physical Properties
Highway (12g) Bridge (10g)
Effective Cover 3810 4000
Steel Thickness (mm) 2.7 3.4
Area of Cross Section

1350 1640
(mm2)
Major 80,000 Major 103,000

Section Modulus (mm3)
Minor 22,000 Minor 29,000
Mass (kg per metre) 11.3 13.4
Profile
More information on Flexrail™ can be found at www.csppacific.co.nz or call 0800 655 200
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Flexrail™ W-Beam Highway (12g) & Bridge Barrier (10g)
Backing Piece Fish Tail Rolled End Fitting
(used on steel blockouts only)
Bullnose End Fitting Structure Connector
Post
PostBolt
Bolt
Steel Post Wooden

WoodenPost
Post
Bolt Size A mm B mm
250 25 120
350 350 80
450 450 120
Splice Bolt
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Highway Rail (2.7mm Gauge) Bridge Rail Dimensions (3.4mm Gauge)
Curved Flexrail™
Highway Rail
The standard straight section will align to give a R α C H
smooth transition on curves with a radius greater (metres) (Deg) (m) (mm)
than 45m. Pre-curved Flexrail™ is required for
3 72.7656 3.559 585
tighter radii and may be curved to traffic face
concave or convex. 4 54.5742 3.667 445
NB: Only Highway Flexrail is available pre-curved. 5 43.6594 3.719 359
6 36.3828 3.746 300
7 31.1853 3.763 258
8 27.2871 3.774 226
9 24.2552 3.782 201
10 21.8297 3.787 181
12 18.1914 3.794 151
14 15.5926 3.798 129
16 13.6436 3.801 113
20 10.9148 3.804 91
23 9.4912 3.806 79 CSP Pacific | Barrier Field Manual | December 12
29 7.5275 3.807 63
32 6.8218 3.808 57
35 6.2371 3.808 52
41 5.3243 3.809 44
46 4.7456 3.809 39
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Installation Checklist
Checklist Y N
Assembly and installtion is to be generally in accordance with TNZ
M23, AS/NZS 3845:1999 and CSP Pacific drawing FX360 and/or the
Engineers specification.
The rail height (top) is in accordance with the plans (706mm above
the edge of the shoulder or the ground line).
Correct lapping of the rail should be away from the direction of traffic
to prevent snagging.
Timber blockouts should be nailed to timber post to prevent rotation.
Installation is aligned and level.
Posts are aligned at correct spacing and backfill compacted.
Post bolts are tight and a 50 x 50 square washer is fitted to back of

post.
Steel Post Systems (Post Type FX91, FX92, FX93 & FX94)
Backing pieces to be fitted at the intermediate post only.
Post bolts are tight using a spring washer and then locked with a
lock nut.
Necked bolts are installed with washer as specified and are installed
tight.
Notes:
Location:
Installed by: Date:
Inspected by: Date:
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Bridge Handrail (Not for use on State Highways)
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Thriebeam™
Thriebeam™ has been available for more than
25 years as a natural addition to the guardrail
family of products. Thriebeam™ has an added
corrugation that gives it an advantage for use in
transitions to bridges and along high volume, high
speed roadways.
Thriebeam™ derives its name from the general

cross-sectional shape of the beam. The product is
roll formed from coil steel and sheared to length.
It is punched and slotted to suit the particular
configuration, then hot dip galvanised prior to
despatch.
Thriebeam™ complies with the requirements of

AS/NZS 3845:1999 and TNZ M23.
Thriebeam™ is available ex-stock in standard net

lengths of 4 metres with post spacing at
1m centres.
Profile
DIMENSIONS & MECHANICAL PROPERTIES 2.7mm Gauge

Beam Width Minimum (mm) 508
Beam Depth Minimum (mm) 76
Cross Sectional Area (mm2) 2,013
Moment of Inertia (mm2) 1,555,000
Section Modulus (mm3) 36,400
Weight (approx) (kg/m) 16.7
More information on Thriebeam™ can be found at www.csppacific.co.nz or call 0800 655 200
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Thriebeam™
Structure connector Post options and detail
Thriebeam™ rail elevation
Transition section Backing plate
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Thriebeam™ (12g) Barrier
Checklist TL-3 Timber Post System Y N
Assembly and installation is to be generally in accordance with TNZ M23,
AS/NZS 3845:1999 and/ or Engineers specification.
The rail height (top) is in accordance with the plans (805mm above the
edge of the shoulder or the ground line).
Correct lapping of rail away from the direction of traffic to prevent snagging.
Timber blockouts nailed to timber post to prevent rotation.
Post are aligned, at correct spacing and backfill compacted.
Two post bolts per post and block.
Post bolts are tight and a 50 x 50 square washer is fitted to back of post.
Checklist TL-4 Steel Post System Y N

Assembly and installation is to be generally in accordance with TNZ M23,
AS/NZS 3845:1999, CSP Pacific drawing FX495-1 and/ or Engineers
specification.
The rail height (top) is in accordance with the plans (865mm above the
edge of the shoulder or the ground line).
Correct lapping of rail away from the direction of traffic to prevent snagging.
Modified Blockout is fixed to I-Post with 2 M16 x 50 Eng bolt and nut
diagonally.
Backing pieces at fitted at the intermediate post only.

One post bolt per post and modified blockout required only. To be installed
in the top post hole.
Post bolts are tight using a spring washer and then locked with a lock nut. CSP Pacific | Barrier Field Manual | December 12
Posts are aligned at correct spacing.

With a flange based post the necked bolts are installed with washer as
specified and are tight.
Location:
Installed by: Date:
Inspected by: Date:
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X-350 Tangent and Flared Guardrail End Terminal
Features
» Approved to NCHRP 350 TL-3
» Lower cost
» Fully re-directive
» Cost effective, life saving device
» Length of need (LoN) at post one
» Improved vehicular control
» Impact force held in tension – less chance of
kinked rail
» Little or no debris scatter
» Ease of installation and maintenance
» 3 x Standard highway rails 12 gauge
» Impact head weighs only 25 kgs
» Flared of tangent terminal end
» Designed & manufactured in NZ
» Patented technology
X-350 Tangent
Specifications: NCHRP 350 TL-3

» Speed: 100kph
» Length: 11.4m (3rails)
» Offset: 0 – 1200mm
» Post 1: Steel
» Posts 2 – 6: Breakaway timber or steel
» Run out – 22.5m x 6m
» LoN starts at Post 1
» Max grade 10:1
» All steel components hot dipped galvanised CSP Pacific | Barrier Field Manual | December 12
X-350 Flared
More information on X-350 Tangent and Flared Guardrail End Terminals

can be found at www.csppacific.co.nz or call 0800 655 200
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X-350 Tangent & Flared Installation Instructions
Step 1 - X-350 parts identification
Impact head Friction plate Soil anchor Slider panel Slider bracket + angle bar Cable bracket
(1 required) (1 required) (1 required) (1 required) (1 required roadside) (1 required)
Cable assembly Post 1 – top Post # 2 (1 required) Ground strut Standard steel line Post Post # 1 bottom
(2 required) (1 required) (roadside can be CRT timber) (1 required) (3-6) (roadside can be (1 required)
CRT timber)
Standard highway rail Shear bolts Blockout (plastic or Hardware set

(3 required roadside) (8 required) timber) (5 required)
Step 2 - Installing posts 6 - 2

Install posts 6 to 2 at standard highway rail Spacing
1905mm, to the correct height. Top of post to
be either 710mm or 805mm above ground level
depending on the guardrail system being attached to.
Posts #6 to #3 are either standard “I” beam posts
OR timber CRT posts.
Note: Only standard “I” beam posts can

Figure 1. Pull a string line with the Figure 2. Bolt the blockout prior to
be installed at the higher height of 805mm. desired offset attaching the rail
Timber posts must be 710mm above
ground level.
Post 2 is either the Special “I” beam post or a

timber CRT. For the “I” beam post at 805mm above
ground, the embedment of this post must only be
1025mm.
Posts may be directly driven, or in stiff soils a
150mm diameter hole drilled, and the post then
driven into the hole. The post may also be placed
in an oversized augured hole but care must be
taken to ensure the backfill is properly compacted.
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X-350 Tangent Installation Instructions
Step 2 - Installing posts 6 - 2
Hint: Offset Post 3 back from the string line
40-50mm to make it easier to push rail 1 and
Slider Panel over rail 2.
When driving steel posts, ensure that a driving
cap with timber or plastic insert is used to prevent
damage to the galvanising on the top of the posts.
Bolt the blockout to the post at post 3,

prior to attaching to the rail (Figure 3).
Step 3 - Post 1, ground strut & soil anchor

Place the roadside face of post 1 bottom anchor,
200mm towards the roadway to compensate for the lack
of blockout (Figure 3). Post 1 bottom the Ground Strut
and the Soil Anchor are then placed parallel to the string
line at this roadside offset position. Drive or place the
bottom of post 1 in the augured hole so that no more
than 75mm (100mm max), protrudes above ground level
(Figure 4).
Use the Ground Strut as a template to place the Soil Figure 3. Measure 20cms towards Figure 4. Drive Soil Anchor 1 into
Anchor in the correct place. The Soil Anchor can then roadway augured hole
be driven into place or placed in an augured hole and
backfilled. The Ground Strut should be level or lower at
Note: There is a choice of 2 height
the anchor end than at the post 1 bottom end (Figure 5).
Place post 1 top in the post 1 bottom anchor ensuring settings at the bottom of post #1 top.
that the post bolt notches are at the top and facing the Ensure that the correct one is selected
Soil Anchor (Figure 5). Use M16 x 200mm hex head so that centre of impact head is at the
bolt with nut and washers. correct height above ground level.
Step 4 - Hang rail 3 & cable anchor bracket CSP Pacific | Barrier Field Manual | December 12
Rail 3 is installed like standard guardrail with post 6 at

the centre of the rail and blockouts between the rail
and post.
Place the Cable Anchor Bracket on the back of the rail
at the joint between rail 3 and rail 4 (post 7).
The two “boxes” on the cable bracket should be on the
impact head side of the splice joint.
Attach rails to post with post bolt and splice rail 3 to rail Figure 5. Post 1 top in post bottom Figure 6. Splice rail 3 to rail 4 with
4 with 8 standard splice bolts (Figure 6). 8 standard splice bolts
Note: Do not over tighten bolt.
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Step 5 - Hang rail 2 and shear bolts
Before installing rail 2 double check that the blockout is
already bolted to post 3.
Bolt rail 2 to the post and blockouts at posts 4 and 5 with
the appropriate post bolt (Figure 7).
DO NOT BOLT THE RAIL TO POST 3.
Splice rail 2 to rail 3 with the 8 special shear bolts
(yellow) supplied (Figure 8). Put the washer and
nut on inside of rail.
Figure 7. Bolt rail 2 to post and Figure 8. Splice rail 2 to rail 3
blockouts with 8 special shear bolts
IMPORTANT NOTE: DO NOT USE STANDARD
SPLICE BOLTS AT POST 5 SPLICE
Step 6 - Attach slider bracket to Rail 2

Bolt the Slider Bracket to the end of rail 2 at post 3
(Figure 9). Use 4 standard splice bolts. The angle bar
end should be closest to the Impact Head end.
Remove the angle bar and 2 x M20 x 40mm bolts
(Figure 10).
Figure 9. Bolt Slider Bracket to Figure 10. Remove angle bar bolts
end of rail 2 at post 3
Step 7 - Assemble slider panel onto Rail 1

Start by sitting rail 1 on a blockout or post so that it
is raised off the ground as shown (Figure 11). Slide
the Slider Panel onto the downstream end of rail at
post 3 location (Figure 12) and bolt into place using 4
standard splice bolts, pushing the bolt through from the
inside of the slider to the outside so that the nut is on
the traffic face.
The curved and reinforced (post breaker) end of Slider
Panel sits at the rail end. Use guardrail pin bar or crow Figure 11. Sit rail 1 so it is raised Figure 12. Slide the Slider Panel
bar to assist with lining up splice holes. off the ground onto downstream end
Step 8 - Hang rail 1

Lift rail 1 with Slider Panel attached and push the slider
end over rail 2 (Figure 13). Overlap the rails as per a
standard splice joint overlap.
Bolt rail 1 and blockout to post 2 using a standard post
bolt that is supplied (Figure 14).
Re-attach the angle bar to the slider bracket on the
backside of the rail (Figure 15).
Figure 13. Push Slider Panel over Figure 14. Bolt rail 1 and blockout
rail 2 to post 2
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Step 9 - Attach Impact Head
Place Impact Head on upstream end of rail 1 and attach
using 8 standard splice bolts with nuts on traffic face
(Figure 16).
Hint: Place bottom two bolts first then use guardrail pin
bar to lever head up snug onto rail.
Bolt head and rail 1 to post 1 using the supplied
M16 x 50mm guardrail post bolt.
Use a 50mm x 50mm washer under the nut on the
Figure 16. Attach Impact Head to Figure 17. Bolt head and rail 1 to
inside of post 1 (Figure 17). rail 1 post 1 with washer
Step 10 - Place the Cables

Push the cables under the steel strap on the Ground
Strut (Figure 18) and forward through the holes at the
top of the anchor. Lay the cables out parallel to the
guardrail, downstream from the anchor.
Ensure that bottom cable (closest to road) has half the
thread protruding through the anchor, as shown. Ensure
the top cable has the nut wound on a least two turns
past the end of the thread (Figure 19).
Figure 18. Push cables under Figure 19. Thread the nuts as
steel strap on Ground Strut shown
Step 11 - Installing the Cables

Install the Friction Plate in the top of the Impact Head,
adjustment hole up. Take the cable closest to the
road, pick up the downstream cable fitting and walk to
the head, passing the cable through the bottom hole,
through the Friction Plate (Figure 20) and out the
backside of the Impact Head.
Now thread the cable down the backside of the rail
following the bottom trough of the W-beam and attach
to the bottom “box” on the Cable Bracket at post 7. Figure 20. Pass the cable through Figure 21. Place the nuts and
Repeat this process with the other cable but push it the bottom hole washer on the cables at the Cable
through the top hole and thread it along the top trough Bracket end but only turn them a
of the W-beam. few turns
Place the nuts and washer on the cables at the Cable

Bracket end but only run them a few turns (Figure 21).
Do not tighten cables at this stage

(or the Friction Plate will not turn)
Figure 15. Reattach the angle bar
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Step 12 - Turning the Friction Plate
Put a crow bar through the hole at the top of the friction
plate (Figure 22) and turn it in slot as far as it will go.
Using a socket spanner tighten the 4 - M20 x 75mm
bolts on the side of the impact head to lock the bar in
the turned position (Figure 23).
Figure 22. Use crow bar to turn Figure 23. Use socket to lock bar
Friction Plate in the turned position
Step 13 - Tightening the Cables

Only tighten the cables using the nuts at the Cable
Bracket end (post 7) (Figure 24). Do not tighten the
cable nuts at front of the Ground Anchor.
Tighten the cables until they are taut, i.e. they rest in the
backside of the W-beam and do not visibly sag between
posts (Figure 25). There is no torque requirement for
the cables.
Figure 24. Tighten cables at Cable Figure 25. Tighten cables until
Bracket end (post 7) they are taut
Step 14 - Attach Nosing and Nut Protectors

Push nosing into place on the front of the impact head.
Attach using the supplied nylon push rivets (Figure
26). Delineation to be attached to nosing as per Local
Authority requirements.
The X-350 Plastic Nut Protectors are available for all
X-350 Terminal Ends. They protect pedestrians and
cyclists from exposed splice bolt nuts and threads. Fit 8
Nut Protectors on the Impact Head (Figure 27) and 4
on Slider Panel (Figure 28).
Figure 26. Attach nose using nylon Figure 27. Nut Protectors fitted on
push rivets Impact Head
Figure 28. Nut Protectors fitted to

Slider Panel
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X-350 Flared Installation Instructions
X-350 - Flared Installation Instructions
This section deals with installation of a Flared X-350 0 - 1.2m
system in a roadside guardrail terminal
end application.
Apart from the initial set out, the flared X-350 and
installation procedure is identical to the Tangent
system, the only difference being the amount of offset
used.
Site preparation
The Flared terminal may be installed either parallel to
the edge of the roadway (tangent) or with the impact
head end of the rail offset by up to 1.2m away from the
road (Figure 29) in a straight flare, over the length of
the system. No parabolic curve is required.
Ensure that the area where the X-350 is to be installed
is flat enough so that the anchor will not protrude more
than 75 mm (100 mm max) above ground level, when Figure 29. Pull string line to follow roadside
measured with a straight line over a 1.5m cord. Minor edge of post. Maximum offset is 1.2m
site grading may be required.
Step 1 - Set Out

Pull a string line out with the desired offset 0 -1.2m. Note
that the flare is a straight flare, over the length of the
system (11.4m).
The string line should be set to follow the roadside edge
of the posts (Figure 29).
All the posts except post 1 have a blockout so take care
to place the roadside face of post 1, 200mm towards the
roadway (Figure 30).
Figure 30. Place roadside face of Figure 31. Place ground strut
Post 1 bottom; the Ground Strut and the Soil Anchor are post 1 towards roadway parallel to string line
then placed parallel to the string line on the roadside of
it (Figure 31).
Now follow steps 2 – 14 in the Tangent

installation instructions.
Note: The “kink” in the line of rail between rail

3 and rail 4 (at post #7) is formed by simply
pushing the rails around to follow the flared
line of posts. This is not factory bent.
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X-350 Installation Instructions
Checklist Y N
Ground strut is flush to ground surface
No more than 100mm to protrude above ground surface
Bolted to post # 1 at base of post
Impact head has rail bolted with all 8 nuts on the face of the rail
Locking bar is turned fully in slot and secured with 4 x 8.8HT
bolts only
Post # 2 is a steel I beam breakaway (weakened) or timber CRT
post with blockout
Post # 3 is not bolted to rail
Post # 3 to 6 are steel I beam line posts (not weakened) or
timber CRT posts with blockouts
Slider panel is attached to rail # 1 with all four nuts on the face of rail
Slider bracket is attached to rail # 2 with all four nuts inside the
rail
Angle bar is bolted to the slider bracket with the flat section
facing post # 3 at the impact head side
Cables are tensioned up “taut” with no visible sag over the 11.4m
span
8 x yellow shear bolts are bolted at rail # 2 and # 3 with the spacers
washers between the nut and rail depending on guardrail system.
Note that steel posts must be used if at 635mm high.
Guardrail height is 550mm or 635mm from the finished road surface
to the centre of the rail depending on guardrail system. Note that
steel posts must be used if at 635mm high.
Flare rate 0 - 1200mm from the tangent 11.43m
Location:
Installed by: Date:
Inspected by: Date:
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Nu-Guard 31™ Steel Guardrail System
A smaller footprint, lighter weight and no Features
requirement for a blockout means the » System has a smaller footprint and no blockout
Nu-Guard 31™ steel post guardrail system » NUCOR™ steel posts, with no blockout, enables
is comparable in cost to wooden post faster installation
systems and is simpler and quicker » It is possible for one post to be installed per
to install. minute using a post rammer
» NUCOR™ steel posts are lighter and smaller in
area than traditional posts
» High tensile galvanised NUCOR™ steel post is
designed for easy after-impact repair of system
» Environmentally friendly - manufactured using
recycled steel
» Uses standard highway rail and fixings
» A median or roadside barrier
» NUCOR™ steel posts will split on impact to avoid
guardrail tearing, reducing the incidence of wheel
snagging
» Only NCHRP350 TL-4 tested and approved
system using standard highway rail
Specifications
» Tested and approved to MASH-1 TL-3
and NCHRP 350 TL-4
» Post weight: 14.78 kg
» Post length: 1980mm
» Height to centre of rail: 635mm
» Post footprint: 0.0375m2
» Maximum system deflection is 1200mm for CSP Pacific | Barrier Field Manual | December 12
roadside applications
» No blockouts required
» Standard highway rail and fixings
» All components hot dip galvanised
» Posts are manufactured from high tensile steel
More information on Nu-Guard 31™ can be found at www.csppacific.co.nz or call 0800 655 200
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Nu-Guard 31™ Installation Instructions
Install Posts
Use standard guardrail procedures to mark out and
align the posts. Post spacing is the same as standard
rail at 1905mm.
The Nu-Guard 31™ posts are 1980mm long with a slot
at the top.
For roadside installations, ensure that the flanges are
facing to the side the rail will be installed on and that
they are parallel to the line of the rail.
For median installations ensure the posts are
alternated between flanges forward and then flanges
back.
When driving steel posts, ensure that a driving
cap with timber or plastic insert is used to prevent
damage to the galvanising on the top of the posts.
The top of the post should be 812mm above the
nominal ground line. This places the centre of the rail at
approximately 635mm from the nominal ground line.
Posts may be driven or in stiff soils a 100 dia. hole
drilled and the post then rammed into the hole. The
post may also be placed in an oversized augured hole
but care must be taken to ensure the backfill is properly
compacted.
Install Rail
The rail is installed the same as standard guardrail with
a splice join being at a post.
It is generally easiest to lift one rail at a time and while
it’s held in place, fit the post bolt in the centre of the rail
to hold the rail in place.
Use the M16 x 90mm coach bolt to fix rail to post,
ensuring that the 90mm diameter washer is fitted
between the rail and post as detailed below.
Secure on back of post with a standard splice nut (no

washer).
Lap rails in direction of traffic.
The top of the post must be a minimum of 20mm above
the top of the guardrail.
Therefore the position of the M16 x 90mm post bolt in
the slot may vary slightly.
M16 x 90mm coach bolt c/w splice nut
90mm Dia. washer between rail and post flanges
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Nu-Guard 31™ Installation Instructions
Assemble Rails
Splice the rails together in the standard manner,
ensuring that all eight splice bolts are used and
fully tightened at every joint.
For Median Installations Only

It may be easier to hang the rails on one side, two
or three panels ahead of the other, holding them
temporarily in place with the centre post bolts.
Then as the panels on the other side are placed, secure
them into place bolting both sides of rail with one bolt at
the splice joins.
The temporarily placed centre bolts can then be
removed and pushed through both sides of rail as well.
Washers are placed between the post rail on both sides
of the post in median situations.
In median installations, if more than 20mm of bolt
protrudes past nut on backside, cut off
and treat with cold galvanising paint.
System Maintenance
Nu-Guard 31TM is maintained exactly the same as
standard timber post and block-out guardrail.
If the rail and/ or the post is damaged and/or bent then
it must be replaced.
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Nu-Guard 31™ Steel Guardrail System
Checklist Y N
Height to centre of rail is 635mm
There is no blockout
When driving post, use a driving cap with timber or plastic insert
to avoid damage to the post
Top of post should be a minimum of 20mm above top of guardrail
Post is aligned with flanges rail (for road side applications)

and alternating between flanges forward and back for median
applications
There is a 90mm dia. Washer between rail and post
Rail is lapped in the direction of traffic
All bolts are fully tightened
Nut on backside of post is a splice nut
If a median installation-excessive bolt length is cut off on backside
That transition details to existing guardrail or terminations

are correct
Notes:
Location:
Installed by: Date:
Inspected by: Date:
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Trailing End Terminal
Checklist Y N
Assembly and installation is to be generally in accordance
with AS/NZS 3845:1999, TNZ M23 and CSP Pacific drawing
FX348-2
The rail height (top) is in accordance with the plans

(706mm above the edge of the shoulder or the ground line)
The steel tubes/posts do not protrude more than 100mm above

the ground line (measured by the AASHTO 1.5m cord method, site
grading may be necessary to meet this requirement
The bolts at the top of the steel tubes are not over tightened
and the walls of the steel tubes are not collapsed/distorted.
The 200mm x 200mm bearing plate at post 1 is correctly

positioned and the anchor cable is taut and correctly installed
(it should be rechecked after installation to be sure it hasn’t
relaxed)
Blockouts have been toe nailed to the posts
The backfill material around the posts is properly compacted
The rail panel is not attached to the post at post No. 2 the rail sits
on the shelf angle only
Notes:
Location:
Installed by: Date:
Inspected by: Date:
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NZTA Standard Details
The following drawings are the property of the New Zealand Transport Agency and are subject to amendment.
The latest version is available on www.nzta.govt.nz
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Copyright and Limited Reproduction:
The design of and all content appearing in this brochure are the copyright of CSP Pacific. No part of this brochure may be:
» distributed or copied for any commercial purpose, nor incorporated in any other work or publication (whether in hard
copy, electronic or any other form); or
» resold, published, copied, reproduced, transmitted or stored (including in any other brochures or other electronic form)
except that you may print, or copy only for your own use (or for use in any document, proposal or presentation for the
purpose of specifying products manufactured or supplied by CSP Pacific), without the express permission of CSP
Pacific.
Disclaimer:
This Brochure contains files which were current at the time of printing. Latest drawings and informations are available in
PDF format from our web site www.csppacific.co.nz
Issue: Barrier Field Manual V8 December 2012
CSP Pacific – A member of the Fletcher Building Group

306 Neilson Street, Onehunga, Auckland 1061
PO Box 12 949, Penrose, Auckland 1642
Ph: 0800 655 200 or 09 634 1239 Fax: 09 634 4525
www.csppacific.co.nz

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Barrier Field Manual

CSP Pacific | Barrier Field Manual | December 12

X-350 Tangent & Flared End Terminal Brochure30

FX540 Tangential Terminal End - Steel Posts-Elevation 40

Nu-Guard 31™ Steel Guardrail System Brochure42

Trailing End Terminal

NZTA Standard Details

CSP Pacific supplies two standard types of

Flexrail™ is roll formed from coil steel and

Flexrail™ is generally available ex-stock in

Effective Cover 3810 4000

Steel Thickness (mm) 2.7 3.4

Area of Cross Section

Major 80,000 Major 103,000

Mass (kg per metre) 11.3 13.4

CSP Pacific | Barrier Field Manual | December 12

Bullnose End Fitting Structure Connector

Steel Post Wooden

Timber blockouts should be nailed to timber post to prevent rotation.

Installation is aligned and level.

Posts are aligned at correct spacing and backfill compacted.

Post bolts are tight and a 50 x 50 square washer is fitted to back of

Backing pieces to be fitted at the intermediate post only.

CSP Pacific | Barrier Field Manual | December 12

Installed by: Date:

Inspected by: Date:

CSP Pacific | Barrier Field Manual | December 12

Thriebeam™ derives its name from the general

Thriebeam™ complies with the requirements of

Thriebeam™ is available ex-stock in standard net

CSP Pacific | Barrier Field Manual | December 12

DIMENSIONS & MECHANICAL PROPERTIES 2.7mm Gauge

Thriebeam™ rail elevation

Transition section Backing plate

CSP Pacific | Barrier Field Manual | December 12

Timber blockouts nailed to timber post to prevent rotation.

Installation is aligned and level.

Post are aligned, at correct spacing and backfill compacted.

Two post bolts per post and block.

Checklist TL-4 Steel Post System Y N

Installation is aligned and level.

Posts are aligned at correct spacing.

Inspected by: Date:

Specifications: NCHRP 350 TL-3

More information on X-350 Tangent and Flared Guardrail End Terminals

Standard highway rail Shear bolts Blockout (plastic or Hardware set

Step 2 - Installing posts 6 - 2

Note: Only standard “I” beam posts can

Post 2 is either the Special “I” beam post or a

Bolt the blockout to the post at post 3,

Step 3 - Post 1, ground strut & soil anchor

Rail 3 is installed like standard guardrail with post 6 at

Note: Do not over tighten bolt.

Step 6 - Attach slider bracket to Rail 2

Step 7 - Assemble slider panel onto Rail 1

Step 8 - Hang rail 1

Step 10 - Place the Cables

Step 11 - Installing the Cables

Place the nuts and washer on the cables at the Cable

Do not tighten cables at this stage

Figure 15. Reattach the angle bar

Step 13 - Tightening the Cables

Step 14 - Attach Nosing and Nut Protectors

push rivets Impact Head

X-350 Tangent & Flared End Terminal Brochure30

FX540 Tangential Terminal End - Steel Posts-Elevation 40

Nu-Guard 31™ Steel Guardrail System Brochure42