rhino-stop - safedirection.com.au · rhino-stop® may be installed as a standalone post and w-beam...

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RRHHIINNOO--SSTTOOPP®®

IInnssttaallllaattiioonn MMaannuuaall

Ref: IM 004/01


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Table of Contents

1.0 Introduction .............................................................................................................................................................. 4

2.0 Specifications ........................................................................................................................................................... 4

3.0 Bill of Materials ..................................................................................................................................................... 5

4.0 Component Identification .......................................................................................................................... 5

5.0 Tools Required ....................................................................................................................................................... 9

5.1 Recommended PPE ................................................................................................................................................. 9

6.0 Site Establishment ............................................................................................................................................. 9

6.1 Traffic Control ............................................................................................................................................................. 9

6.2 Underground Services ............................................................................................................................ 9

6.3 Overhead Obstructions .......................................................................................................................... 9

6.4 Unloading Exclusion Zone .................................................................................................................... 9

6.5 Concrete Curing ...................................................................................................................................................... 10

6.6 Concrete Substrate Thickness .......................................................................................................... 10

6.7 Bolt Edge Distance .................................................................................................................................. 10

7.0 Set-Out ......................................................................................................................................................................... 10

7.1 Cutting and Drilling ............................................................................................................................................. 10

8.0 Anchor Bolt Installation .......................................................................................................................... 11


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Table of Contents (continued)

9.0 Assembly Sequence ....................................................................................................................................... 12

9.1 RHINO-STOP® Type 1 ......................................................................................................................................... 12

9.2 RHINO-STOP® Types 2 & 3 .................................................................................................................. 13

9.3 RHINO-STOP® Type 5 ............................................................................................................................ 14

9.4 RHINO-STOP® Type 4 ............................................................................................................................ 15

9.5 RHINO-STOP® Type 6 ............................................................................................................................ 17

Installation Checklist ............................................................................................................................................. 22

List of Drawings

RHINO-STOP® Type 1 Assembly Drawing ....................................................................................... 24

RHINO-STOP® Type 2 Assembly Drawing......................................................................................... 25


RHINO-STOP® Type 4 Assembly Drawings ...................................................................................... 27


RHINO-STOP® Type 6 Assembly Drawings ...................................................................................... 30


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RRHHIINNOO--SSTTOOPP®® IInnssttaallllaattiioonn MMaannuuaall

1.0 RHINO-STOP®

Providing superior design, rapid installation and driver confidence, RHINO-STOP® is compliant to the 30kN impact force described in AS/NZS 1170.1: Structural Design Actions.

Additional crash testing achieving a 60kN impact load has also been performed demonstrating the reserve capacity and strength of the RHINO-STOP® system.

RHINO-STOP® may be installed as a standalone post and w-beam guardrail configuration or with balustrade and mesh infill attachments when fall protection for pedestrians is required. The modular design of RHINO-STOP® and its available attachments allows the system to be configured to suit site requirements using standard components.

RHINO-STOP® is an energy-absorbing, semi-rigid barrier providing reduced dynamic deflection. The energy absorbing feature reduces damage to the impacting vehicle and the barrier system. The semi-rigid feature of RHINO-STOP® reduces the space requirement between fixed object hazards and the barrier, conserving valuable floor space.

The pedestrian-friendly base plate design provides the ideal solution for installation adjacent to walkways.

2.0 Specifications

Compliance: AS/NZS 2890.1

AS/NZS 1170.1 30kN - Type F Light Traffic Areas

Post height: 625mm

Rail height: 600mm

Base plate: 110mm x 220mm

System width: 160mm

Post spacing: 2.0m centres (max.)

Anchor type*: M20 x 160mm Clawbolt

Anchors per post: 1 off

Hole diameter: 20mm

Substrate Thickness: 200mm minimum (32Mpa)

Bolt Embedment: 100mm minimum

Bolt Edge Distance: 125mm minimum

Min. number of posts: 3 off per installation

Post deflection: 90mm for 30kN impact (at the top of the post)

Available attachments: 1100mm Handrail 1300mm Sight rail Mesh infill

Finish: Hot dip galvanised

*Chemical anchor options available upon request


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3.0 Bill of Materials

Item Description SD Item Number

4m W-Beam Guardrail GR-WB-SR-4000-AG

RHINO-Post® GR-PB-IS-0625-AG

Extension Piece to suit Types 2 & 3 GR-MX-MX-0800-AG

Extension Piece to suit Types 4 & 6 GR-MX-MX-1035-AG

Extension Piece to suit Type 5 GR-MX-MX-1010-AG

Sight Rail Extension Piece to suit Type 6 GR-MX-MX-0200-AG

2400mm x 900mm Mesh Panel GR-MX-MX-2409-AG

6.5m Handrail Pipe 32NB HR-PI-32-6500-AG

32NB Straight Joiner HR-JN-32-0180-AG

32NB Pipe End Cap HR-CA-32-0000-AG

6.0m Mesh Support Angle GR-EA-30-6000-AG

Splice Bolt M16x32mm Mushroom Head GR-FS-16-0032-MG

Post Bolt M16x50mm Mushroom Head GR-FS-16-0050-MG

Bolt & Nut M16x30mm Hex. Head GR-FS-16-0030-HG

Bolt & Nut M8x20mm Mushroom Head GR-FS-08-0020-MG

Self Drilling Screw 12 gauge x 35mm GR-FS-12-0035-TG

Self Drilling Screw 14 gauge x 25mm GR-FS-14-0025-TG

Mesh Washer GR-FS-08-0000-AG

Clawbolt Stud Anchor M20x160mm GR-FS-20-0160-HG


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4.0 Component Identification

RHINO-Post

Extension Piece (Types 4 & 6)

Extension Piece (Type 5)

Extension Piece (Types 2 & 3)

M20x160mm Clawbolt Stud Anchor


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W-Beam Guardrail

Mesh Infill Panel

Mesh Support Angle

Short Bullnose

Yellow End Cap

Sight Rail Extension Piece

(Type 6)


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M16 x 32mm Splice Bolt

M16 x 50mm Post Bolt

M16 Oversize Nut

M16 x 30mm Hex Bolt/Nut

32NB Pipe Joiner

32NB Pipe

32NB Pipe End Cap

M8 x 20mm Cup Bolt/Nut

35mm Tek Screw

25mm Tek Screw

Mesh Washer


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5.0 Tools Required

Tools required for the installation of RHINO-STOP® includes;

Drill with 20mm masonry bit;

Air compressor;

Drill driver;

Hand socket;

Torque wrench;

Metal snips;

String line;

Tape measure;

Hammer;

Drop saw;

Grinder with metal cutting disk;

12mm diameter pinch bar; and

Slings or chains.

5.1 Recommended PPE

It is recommended that the following personal protective equipment (PPE) be provided;

Safety footwear;

Gloves;

Hearing protection; and

High visibility clothing.

6.0 Site Establishment

6.1 Traffic Control

Prior to the commencement of any work, the site should be evaluated for risks to workers, pedestrians and other road users. The establishment of traffic control should provide safe travel for passing vehicles and/or pedestrians and appropriately protect workers.

6.2 Underground Services

The installation of RHINO-STOP® requires holes to be drilled into a concrete substrate. Prior to drilling, investigation for potential hazards, such as electrical conduits or reinforcement is recommended.

6.3 Overhead Obstructions

The site should be evaluated for potential overhead obstructions that may present a risk during the installation process. These obstructions typically include signage or lighting.

6.4 Unloading Exclusion Zone

Only appropriate load-rated slings or chains should be used for the safe unloading of product. It is recommended that an exclusion zone be maintained around the unloading process. This provides distance between moving machinery and workers in the event that goods or the machinery move unexpectedly. Unloading and the storing of the product on a level surface is recommended. Storing product adjacent to the installation area eliminates the requirement for workers to carry items over long distances.


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6.5 Concrete Curing

If installing RHINO-STOP® on a newly poured concrete substrate, the concrete must be fully cured prior to the installation of anchor bolts. Curing time can vary from site to site and is to be advised by the site construction manager.

6.6 Concrete Substrate Thickness

The minimum concrete substrate thickness required for the use of the M20 x 160mm Clawbolt stud anchor is 200mm.

Alternate fixing methods including chemical anchor options may be available for substrates less than 200mm thick. Please contact Safe Direction for details.

6.7 Bolt Edge Distance

The minimum edge distance for the use of the M20 x 160mm Clawbolt stud anchor is 125mm.

Alternate fixing methods including chemical anchor options may be available when the edge distance is less than 125mm. Please contact Safe Direction for details.

7.0 Set-Out

It is recommended that a string line be used to establish the alignment of the post locations. When establishing the post locations, take care to note the following;

1. The back of the base plate must not extend beyond the edge of the concrete slab;

2. The maximum post spacing of RHINO-STOP® is 2.0m centres;

3. The last post in the installation may be positioned at a reduced spacing (i.e. <2.0m) to cater for site dimensions

4. The w-beam guardrail panel will typically overhang the last post by 120mm;

5. A short bullnose will typically overhang the last post by 400mm;

6. A minimum of three (3) posts is required per installation;

7. Sufficient clearance behind the post to a fixed object hazard is required to allow for the deflection of the system;

7.1 Cutting & Drilling

During the assembly sequence it may be necessary to cut and drill standard length items to suit site dimensions.

Cutting of w-beam guardrails, pipe, angles and mesh is undertaken using a metal cutting disk.

Drilling of new holes can be undertaken using a step drill bit.

Any damage to the galvanised coating shall be repaired using two (2) coats of an organic zinc rich paint.

Oxy acetylene equipment is NOT to be used to cut the w-beam guardrails, mesh, pipe and mesh support angles.


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8.0 Anchor Bolt Installation

Each RHINO-STOP® post is secured to the concrete substrate with one (1) M20x160mm galvanised Clawbolt stud anchor.

The stud anchor is a pre-assembled single unit designed for solid concrete applications. Fixing is achieved by controlled torqueing of the nut which draws the tapered section up into the clip, thereby expanding it outward and forcing it against the sidewall of the pre-drilled hole.

1. Using a 20mm drill bit size, drill the hole to a depth of 105mm.

2. Blow the dust from the hole using a blowout pump or compressed air ensuring that the hole is free from loose materials.

3. Position the nut close to the tip to protect the thread from accidental damage during installation. Insert the through bolt into the hole by hammering.

4. Position the post and apply a torque of 125Nm.


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9.0 Assembly Sequence

9.1 RHINO-STOP® Type 1

Reference Drawing: SD-WB-020

RHINO-STOP® Type 1 provides vehicle barrier protection in accordance with the 30kN load (Type F) as described in AS/NZS 1170.1.

1. Install the Clawbolt stud anchor and secure the post as described in Section 8.0.

2. The w-beam guardrails are secured to the posts using a M16 x 50mm mushroom head bolt and oversize nut. The nut is tightened using a hand socket and 32mm attachment.

There is no torque requirement for the tightening of the post bolts. They should be tightened to a snug position.

3. The w-beam guardrails are spliced together using eight (8) M16 x 32mm mushroom head bolts and oversize nuts. The lap orientation of the rails should be consistent throughout the installation. The splice nuts are tightened using a pneumatic drill driver and 32mm attachment.

The use of a pinch bar will assist in aligning the splice holes as the bolts are inserted. The use of a driving pin to elongate the splice holes is NOT permitted.

There is no torque requirement for the tightening of the splice bolts. They should be tightened to a snug position.

4. In some cases the last post in the installation may be positioned at a reduced spacing (i.e. <2.0m) to cater for site dimensions.

In these instances, the last rail will be required to be cut to length.

Cutting of the rails is undertaken using a drop saw with a metal cutting disk. Drilling of new holes can be undertaken using a step drill bit.

Repair any damage to the galvanised coating using two (2) coats of an organic zinc rich paint.

5. Attach a yellow end cap or short bullnose to the end of the last guardrail to shield sharp edges from pedestrians.

The short bullnose is secured to the rail using four (4) M16 x 32mm mushroom head bolts and oversize nuts.

The yellow end cap slides over the end of the rail. An adhesive is recommended to prevent removal.


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9.2 RHINO-STOP® Types 2 & 3

Reference Drawings: SD-WB-021 & 022

RHINO-STOP® Type 2 & Type 3 provides vehicle barrier protection in accordance with the 30kN load (Type F) as described in AS/NZS 1170.1.

The handrail provides a 1.1m high grab point for pedestrians, but is NOT intended to provide fall protection where the drop to a lower level exceeds 1m. The handrail may be positioned in the nearside or offside orientation.


2. Align the bottom hole of the handrail extension with the hole in the post bracket and secure using one (1) M16 x 30mm hexagonal head bolt & nut. The nut is tightened using a hand socket and 24mm attachment.

3. The w-beam guardrails are secured to the posts using a M16 x 50mm mushroom head bolt and oversize nut. The bolt will pass through the rail, the handrail extension and the slot located in the post bracket. The nut is tightened using a hand socket and 32mm attachment.









6. Position the 32NB pipe (supplied in 6.5m sections) within the saddle of the handrail extensions and secure using four (4) 14 gauge x 25mm long self -drilling screws.

7. Pipe sections are joined using sleeve joiners. Welding is NOT required.

8. Each pipe section shall be supported by a minimum two (2) handrail extensions.


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9. At the end of the installation, the pipe will be required to be cut to length. The overhang of the pipe from the last post should be vertically aligned with the overhang of the guardrail.

Cutting of the pipe is undertaken using a drop saw with a metal cutting disk.


10. Attach a yellow end cap or short bullnose to the end of the last guardrail to shield sharp edges from pedestrians.

The short bullnose is secured to the rail using eight (4) M16 x 32mm mushroom head bolts and oversize nuts.

The yellow end cap slides over the end of the rail. An adhesive is recommended to prevent removal.

11. Attach pipe end caps to the ends of the handrail system.




The 1.3m high sight rail allows drivers of cars backing into the parking space to see the barrier above the rear of the car.

The assembly sequence of Type 5 follows that of Type 2 & Type 3 assemblies. A longer extension piece is used for Type 5 to position the sight rail 1.3m above floor level.


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The mesh infill and handrail combination provides a BCA compliant barrier (balustrade) providing anti-climb and fall protection for pedestrians.


2. Align the bottom slot of the double-cranked handrail extension with the hole in the post bracket and secure using one (1) M16 x 30mm hexagonal head bolt & nut. The nut is only hand tightened at this stage.

3. Position the 32NB pipe (supplied in 6.5m sections) within the saddle of the handrail extensions and secure using four (4) 14 gauge x 25mm long self -drilling screws.


5. Each pipe section shall be supported by a minimum two (2) handrail extensions.

6. Approaching the end of the installation, it may be necessary to cut the last pipe to length.



7. Adjust the height of the handrail extension pieces to ensure the 32NB handrail is level before fully tightening the M16 x 30mm bolt & nut using a hand socket and 24mm attachment.

8. Position the mesh support angles (supplied in 6m lengths) across the top and bottom of the handrail extensions.

The top and bottom of each handrail extension is manufactured with two (2) 10mm wide x 40mm long slots for attachment of the angles.

The angle is only required to be attached through one slot only. The provision of two slots caters for joins in the angle which must be located at a handrail extension.

When positioning the angle, allow for sufficient overhang from the first post to ensure there will be no gaps in the system greater than 120mm.

9. Predrill a 10mm hole in the angle to align with the location of one of the slots.

10. Secure the angle to each extension with one (1) M8 x 20mm cup head bolt & nut. It is recommended that the bottom angles be positioned at the highest point within the slot. The top angles should be positioned at the bottom of each slot.

11. Each angle section shall be supported by a minimum two (2) handrail extensions.

12. Approaching the end of the installation, it may be necessary to cut the last angles to length. When cutting the angle, allow for sufficient overhang from the last post to ensure there will be no gaps in the system greater than 120mm.

Cutting of the angle is undertaken using a drop saw with a metal cutting disk.


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13. The w-beam guardrails are secured to the posts using a M16 x 50mm mushroom head bolt and oversize nut. The bolt will pass through the rail, the handrail extension and the slot located in the post bracket. The nut is tightened using a hand socket and 32mm attachment.









16. The mesh panels (2400mm wide x 900mm high) are positioned within the frame formed by the top and bottom angles. It may be necessary to adjust the top angle to ensure a snug fit around the mesh panels.

17. The mesh panels are secured to the top angle with one (1) M8 x 20mm cup head bolt & nut at 500mm centres. Predrill a 10mm hole in the angle for each fixing location.

18. The mesh panels are secured to the top corrugation of the w-beam guardrail and the bottom angles at 500mm centres with one (1) 12 gauge x 35mm long self -drilling screw and one (1) mesh washer. Take care to vertically align the fixing points of the mesh panels.

Do not over-tighten the self -drilling screws.

19. Subsequent mesh panels are placed side-by-side. There is no overlapping of mesh panels.

20. Approaching the end of the installation, it may be necessary to cut the last mesh panel to length. The overhang of the mesh panel from the last post should be vertically aligned with the support angles.

Cutting of the mesh is undertaken using an angle grinder.


21. An offcut piece of angle can be attached to the outer edge of the mesh panel to form a fully enclosed frame.



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The mesh infill and handrail combination provides a BCA compliant barrier (balustrade) providing anti-climb and fall protection for pedestrians.

The 1.3m high sight rail allows drivers of cars backing into the parking space to see the barrier above the rear of the car.

Fully assemble the barrier as described in Section 9.4 for Type 4. Once complete, undertake the following;

1. A sight rail extension piece is positioned directly above each handrail extension and secured to the 32NB handrail using four (4) 14 gauge x 25mm long self -drilling screws.

2. A sight rail extension piece is positioned directly above each handrail extension and secured to the 32NB handrail using four (4) 14 gauge x 25mm long self -drilling screws.

3. Position an additional 32NB pipe (supplied in 6.5m sections) within the saddle of the sight rail extensions and secure using four (4) 14 gauge x 25mm long self -drilling screws.


5. Each pipe section shall be supported by a minimum two (2) sight rail extensions.

6. Approaching the end of the installation, it may be necessary to cut the last pipe to length.





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RRHHIINNOO--SSTTOOPP®® IInnssttaallllaattiioonn CChheecckklliisstt ((PPaaggee 11 ooff 22))

Customer:

Location:

Checked By:

Signed:

Date:

Applies to the use of the M20x160mm Clawbolt Stud Anchor

The minimum substrate thickness is 200mm.

The minimum anchor bolt edge distance is 125mm.

Fresh concrete has appropriately cured as advised by the site construction manager.

Anchor holes have been drilled to a depth of 105mm ± 5mm using a 20mm drill bit.

Anchor holes have been thoroughly cleaned of debris.

Each anchor has been torqued to 125Nm.

Applies to all RHINO-STOP® Configurations

Post spacing does not exceed 2m.

Each installation is supported by a minimum three (3) posts.

The w-beam guardrail is secured to each post using one (1) M16 x 50mm mushroom head bolt & nut.

The w-beam is spliced together using eight (8) M16 x 32mm mushroom head bolt & nuts.

All fasteners are tightened.

Any damage to the galvanised coating has been repaired using two (2) coats of a zinc rich paint.

The area around the system is clean and free from debris.

On exposed edges, a short bullnose or yellow end cap has been attached to the w-beam guardrail.

Applies to RHINO-STOP® Types 2, 3, 4, 5 and 6

The handrail extension is secured to each post using one (1) M16 x 30mm bolt & nut.

The 32NB pipe handrail is secured to each handrail extension with four (4) self-drilling screws (14 gauge x 25mm).

Joiners have been used to connect pipe sections.

Each pipe section is supported by a minimum two (2) handrail extensions.

Caps are attached to the ends of the pipe sections.


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RRHHIINNOO--SSTTOOPP®® IInnssttaallllaattiioonn CChheecckklliisstt ((PPaaggee 22 ooff 22))

Customer:

Location:

Checked By:

Signed:

Date:

Applies to RHINO-STOP® Types 4 and 6

The upper mesh support angle is secured to the handrail extension with one (1) M8 x 20mm cup bolt & nut

The lower mesh support angle is secured to the handrail extension with one (1) M8 x 20mm cup bolt & nut

Joins in the mesh support angle are positioned at a handrail extension.

Each mesh support angle section is supported by a minimum two (2) handrail extensions.

The mesh panel is secured to the upper support angle using one (1) M8 x 20mm cup bolt & nut at 500mm centres.

The mesh panel is secured to the lower mesh support angle using one (1) mesh washer and self-drilling screw (14 gauge x 35mm) at 500mm centres.

The mesh panel is secured to the corrugation of the w-beam using a mesh washer and self-drilling screw (14 gauge x 35mm) at 500mm centres.

The 14 gauge x 35mm self-drilling screws are not over-tightened.

There are no gaps in the system greater than 120mm.

Applies to RHINO-STOP® Type 6

The sight rail extensions are positioned directly above the handrail extensions.

The sight rail extensions are secured to the 32NB handrail pipe with four (4) tek screws (14 gauge x 25mm).

The 32NB pipe sight rail is secured to each sight rail extension with four (4) tek screws (14 gauge x 25mm)

Joiners have been used to connect pipe sections.

Each pipe section is supported by a minimum two (2) sight rail extensions.

Caps are attached to the ends of the pipe sections.


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Safe Direction Pty Ltd Ph: 1300 063 220

E: [email protected] safedirection.com.au

ABN 53 156 459 684

rhino-stop - safedirection.com.au · rhino-stop® may be installed as a standalone post and w-beam...

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