Steel Safety Barrier Installation

Steel Safety Production

The Steel Safety Barrier system is only functional when installed on the roadway
and/0r on a civil structure.
Note: Due to product liability. steel safety barrier installations should only be carried
out by competent companies.
PASSCO has its own installation crews and work together with Installation partners
in many countries. This enables fast and flexible installations. If required locally.
installation crews can be strengthened or capacity increased quickly.
The PASSCO steel safety barrier systems are basically tested according to EN
Note: According to the Norm. EN 1317. tested assemblies must be installed as they
were tested. This requires competent personnel.
Steel safety barrier assemblies are a safety installation to improve road safety and
should only be installed by competent personnel.

Planning and Installation Regulations for Steel Safety Barriers

These National Regulations contain planning and installation regulations. basic
requirements for the application of steel safety barrier and controls for application
criteria in Planning and Procedures.

PASSCO has applied these National Regulations as internal Installation procedures
and also works to customer specifications.

The safety aims for German roadways are specified by the Federal Ministry for
Transport and the Federal Agency for Traffic in their Guidelines for Passive Safety
Constructions (RPS) and adapted to comply with the European Requirements
EN 1317.

European expectations for Passive Safety Constructions are to minimise the effects
of accidents and should be used to protect:

  • innocent bystanders or valuable property along the roadway, oncoming traffic on bi-directional roads or following vehicles
  • road users from excessive consequences due to their own errors e.g. veering off the road or impacting other vehicles or hazards along the verge.

The installation of steel safety barrier depends on the road type. the type of hazard
and the design speed. A guideline table is available to assist the decision process.


When choosing the Containment Level, the desicion is basically whether to protect a third party e.g. diverging throght the median, or the safety of passenger in the vehicle.

Containment level is N2 is generally used for passenger protection in errant vehicles impacting a hazard or divering off the road. If the distance from the edge of the road to the hazard is less than 2,5m, the EDS-2,0 (H1) system can be deployed. For a distance over 2,5 m the ES-4,0 (N2) system will suffice.

Note: If posts have to be driven near embankments, longer posts have to be used. It may also be necessary to incrase the post spacing. Required measures bit contained in the Specifiction must be considered as departures

Note: For radii lower than 30m, only beams bend by the manufacture may be used.

Central Reserves

If systems with a Containment Level of H2 are required for medians. the tested
systems DDS-2.0m and 2 x EDS-2.0m can be deployed.

The double sided DDS-2.0 m system should only be used in medians with a width of
3.5 m. This limitation still allows it to be used for the standard 3.5m wide median.

If there are height differences or obstacies in the median.then such a particular
situation must be treated individually and protected with the EDS-2.0m system.

For crossovers in central reserves and sections with socket posts. height variations
may not be compensated using spacer sockets.

Socket posts and tube bushings must fit the local ground conditions with regard to
height and cross section. To stop the tubes from deviating or sinking. concrete B15
may be used.

In central reserves crossovers. tubes with foundations must be placed even in softer
ground at the transition.

Note: When installing a double sided system DDS-2.0m. the bracket clamps may not
be connected to the driven posts.

Bridges and Civil Structures

On bridges. the Containment Level H2 should be used as a rule. The EDS-1.33
system with base-plated posts and hand rail can be used on the verge as well as in
the median to protect from falling off.

Note: In order to protect third parties underneath a bridge and/or civil structure.
systems with a higher Containment Level e.g. H4b. Super Rail Plus must be used.

Relevant manufacturers drawings appiy for post and base-plate anchoring systems:

  • single spacer-barriers on concrete. single safety barriers on concrete
  • double spacer-barriers on concrete
  • single spacer-barriers on steel
  • double spacer-barriers on steel

Note: Toggle bolts may not protrude more than 15 mm above the nut.

When fitting on concrete. the compensating layer made of water resistant rubber
should not be more than 5mm thick. The use of plastic mats. which are capable of
reducing condensation in temperatures below 5C and relevant humidity. as well as
balancing off uneven surfaces. are only permitted on the instructions of the main

The long slits in the mats must be filled carefully with plastic material or covered.

Installation Method

Most mistakes which can affect a road user are actually made when safety barriers

are installed and for this reason the installation company must have credentials and

references. Proper installation is a prerequisite for optimal functioning of the safety barrier system in location.


Note: Since Vehicle Restrain Systems are safety constructions. only competent

companies with trained personnel should be employed for installation.

Steel safety barrier installation consists basically of post driving or bolting to



Note: Concreting in safety barrier posts is absolutely not permitted.

Overlapping safety barrier beams at the joints should be in the traffic direction.

General Assembly Guidelines are contained in the manufacturers instructions and

the Additional Technical Installation Regulations for Passive Safety Constructions



Prior to commencing work. the installation company must check the position and

direction of cables. pipes. ducts etc. Posts should not be driven In areas with

underground ducts. The directions of the owner of the cables. pipes and ducts must

be followed.


To optimise safety barrier installation and avoid obstructions on site. only the barrier

material required on the day should be delivered.


If there is live traffic on the road. the sections of safety barrier installed should be

aligned on the same day and fully bolted.


Site management is responsible for material disposition and installation and therefore

responsible for daily delivery and work assignment. This presumes that the main

contractor has given the installation company the required authority.


The crew distributes the safety barrier parts along the installation section and

assembles the safety barrier beams according to specifications i.e. drawings. The

crew writes daily reports on completed work and documents progress. 


The installation crew is equipped with a 7.5 to 10 to truck. compressor. pneumatic
rammer and pneumatic hand tools.

Hydraulic equipment is used for drilling (rock. concrete. asphalt) or ramming in heavy
ground conditions.


The installation crew consists of 3 to 5 workers (depending an construction type). The

installation crew has one foreman working the rammer and assembly workers.

The foremen are trained for Safety at Work. First Aide in case of accidents and

Environmental Safety.


The installation work is managed by trained supervisors. Supervisors have to attend

training courses and complete examinations. On attaining the examinations. the

supervisor receives the title Certified Installation Specialist for Steel Safety Barriers


Note: Installation Specialist Certification from the Steel Safety Barrier Association.

Installation Instruction

The PASSCO Installation Instructions for each steel safety barrier assembly.
dilatation and approach and departure terminals are contained in the appendix.

Note: Manufacturers Installation Instructions are a requirement of EN 1317-5

Guidelines for Repair and Maintenance

Steel Safety Barriers are repair friendly and can be correctly fixed by replacing
individual components. The PASSCO steel safety barriers components comply with
norms and are thereby exchangeable.

If possible. maintenance and repair work should be undertaken without cut parts
even if this means additional work in dismantling and re-fitting undamaged parts in
the transition section.

Construction parts may only be drilled and cut with proper equipment. Welding and
cutting equipment as well as punches and bending equipment may not be used on
safety barrier material.

Basically all parts showing permanent deformation must be replaced. If components
of an installation displaced by less than 30 cm are not deformed. the displaced
section can be re-aligned. Any widened post holes must be filled and sufficiently
compacted. Damage to the zinc surface should be avoided when re-setting the
barrier line. Small faults on the zinc layer can be carefully repaired with zinc spray as
per DIN 50976

Note: When undertaking repairs. the complete deformed beam should be replaced.
Re-use of old parts is not permitted.

Safety and work

Foremen and workers are required to observe Safety at Work regulations and
conduct themselves with due rare.

PASSCO adherence to Safety at Work regulations is regularly checked by several
institutions. The results of these checks are documented and available any time.

Prior to starting a new installation scheme. the Crew members are instructed on the
Main Contractors requirements.

Environmental Protection and Recycling

Foremen and workers are required to observe regulations concerning Environmental

PASSCO adherence to Environmental Protection regulations is regularly checked
by several institutions. The results of these checks are documented and available
any time.

Residual materials are transported to suitable locations for correct disposal or

Construction parts which cannot be utilised again are made useless by cutting or