Steel Safety Barrier Production

Steel Safety Production

Steel Safety Barrier

Steel Safety Barriers. formerly also knows as Directional Beams are Vehicle Restrain
Systems (VRS) according to the European Norm EN 1317 ff
The PASSCO steel safety barriers comply with norms and are now produced by
various manufacturers in several countries.

Note: PASSCO steel safety barrier components are exchangeable. Distribution
throughout Europe ensures availability for repair and maintenance work.

The PASSCO steel safety barriers assemblies have been continuously developed
for over 50 years. copied several times and thereby introduced to many countries.
They have proven themselves technically and economically in Europe and meet the
requirements of EN 1317.

Procurement and Re-cycling

Appendix: Installation Procedures - Sections: C-AA-MW-02 Ordering slit strip steel
for "Steel Safety Barriers"

All remaining materials are properly disposed of i.e. recycled. attested in writing by an
appropriate organisation

Raw Material - Hot Strip Steel

All PASSCO steel safety barriers are made of hot strip steel quality S235 JRG2 (continuous cast material. fully killed aluminium - no Thomas steel) with its proven mechanical and technological properties according to EN 10025/8.4.1 (Table 4). S235JRG is fully killed aluminium steel. This material has proven itself for use in steel safety barriers and is very suitable for production without aging. The basic material must be suitable for galvanising. with max.0.033/0 Si. when P0.01% as per DIN EN 10025/7.5.4. 

Note: Killed or mild steel must be used for steel safety barriers otherwise they

degrade over years and can become brittle. As basic raw material. killed or mild steel

is approx. 10% dearer than unkilled or non-mild steel. but non-mild steel types are

absolutely unsuitable (brittal fraction) for steel barriers and endanger road safety. 

The raw materials are used in coils (hot strip steel. slit Strips) and traceable

through documentation control as per EN 10204. Chemical (with Aluminium) as well

as mechanical values must be recorded. 


Fixtures and Fittings

Fixtures and Fittings such as bolts. nuts and washers are procured by PASSCO

according to single sourcing from one specialist producer Fuchs Schraubenwerke, Siegen 

Manufacturing Process

4.0) Manufacturing Process:

The PASSCO steel safety barriers are produced to manufacturers specifications
based an German Industrial Standards and in accordance with National Standards.
These National Specifications define the type of steel safety barrier assembly and
contain drawings of the essential components as well as making references to
compliance with the Norm EN 1317.
The PASSCO manufacturing process differentiates between horizontal. vertical and
other construction parts.

4.1) Machinery

The existing plant. machinery. equipment and tools are capable of producing steel
safety barriers to national and international specifications.
- horizontal parts such as beams and box profiles are stamped or edged on a press.
Beams Profile A as well as Profile B and other open Profiles are made on semi-
automatic presses. For this process. a production line with an 800 ton press is
- vertical parts such as posts and closed profiles are shaped an profile machinery.
The posts profile Sigma and profile C are made on roll-form machinery with a 12
roller frame and various tool sets.
- other construction parts are stamped. bored and edged on various machinery.
Construction parts such as spacer bars. spacer elements. fittings. post
brackets etc. are made an different hydraulic and ex-centre presses. For these
tasks. PASSCO has a wide range of tool sets for specific requirements.
- radius profiles are bend on three-roll forming machinery.
- welding robots and diverse manual welding stations are used for welding
accessories The welding procedures Manual Electrode and Manual Protective Gas
(MIG/MAG) as well as Automatic Protective Gas are used.
Note: Welding is a specific process and therefore a Process Certification for a
welding shop is required and welders must be certified.

4.2) Personnel

Foremen and operators are trained and qualified to perform the necessary tasks.
Required Certification e.g. for welding is provided.

Surface Treatment

The PASSCO steel safety barriers are galvanised for surface protection. Two types
of galvanising are used:

  • Hot dip galvanising - piece galvanising as per EN 1461
  • Strip galvanising as per EN 10326 

5.1) Hot Dip Galvanising - Piece Galvanising

The hot dip galvanising of steel components for corrosion protection has proven itself
over many years. This also applies to steel safety barriers components which
maintain their function for decades due to this excellent surface treatment.
Hot dip galvanising. also called piece galvanising. is always applied according to DIN
EN ISO 1461.

In preparation. traverses. baskets and other supports are placed together and
loaded. Subsequently the components are wired together or fixed to hooks and/or

Note: lt is important that the individual batches are placed together correctly
according to the galvanising process. This ensures that the following steps. de-
greasing. pickling. rinsing. fluxing. drying and galvanising occur optimally and to the
quality level required for the subsequent processes as well as achieving the highest
possible throughput (highest productivity) in ton/h at the highest quality level.

As much as possible. the individual batches should contain the same or similar
products since this is the only way to ensure that the required quality levels can be

This means that all materials are placed apart so that they can be sprayed
completely in subsequent treatments and are fully exposed to the individual medians.

The individual pre-treatment steps are de-greasing. pickling. rinsing. fluxing. and
drying. The wet chemical process steps are carried out in basins.
The de-greasing basin is acidic i.e. in the pH range of 3 and 4.5. The raw materials
are procured from well-known German manufacturers. Their Base material is
phosphate acid and they have the required organic and binding materials specifically
determined for various grease materials.

Since the de-greasing basin is acidic. temperatures between 20 and 25 degrees.
produced by electrical heaters. are sufficient in the basin.

A number of pickling stations are available to ensure that the products are completely
free of rust and scales and have a smooth metal surface while in the galvanising