1200 New Jersey Ave., SE

 Washington, D.C. 20590

February 6, 2012

FHWA: HSST: NArtimovicht: sf: x61331:2/1/12

File: s: //directory folder/HSST/Artimovich/B-229_EZ Guard W-Beam & HD W-Beam 

MASH.docx

cc: HSST (NArtimovich; JDewar) 

In Reply Refer To:

HSST/B-229

Mr. Terry Colquhoun

Business Development Manager

Ingal Civil Products

57-65 Airds Road

Minto NSW 2566 

Australia

Dear Mr. Colquhoun:

This letter is in response to your request for the Federal Highway Administration (FHWA) to 

review a roadside safety system for eligibility for reimbursement under the Federal-aid highway 

program. 

Name of system: Ezy-Guard W-Beam & Ezy-Guard Heavy Duty (HD) W-Beam

 Longitudinal Barrier Systems

Type of system: Steel Post and W-beam roadside barrier

Test Level: AASHTO Manual for Assessing Safety Hardware (MASH)

Test Level 3 (TL3)

Testing conducted by: Holmes Solutions Ltd

Task Force 13 Designator: SGR44

Date of request: July 14, 2011

Date initially acknowledged: July 14, 2011

Date of completed package: December 15, 2011

Decision:

The following device is eligible, with details provided below:

● Ezy-Guard W-Beam & Ezy-Guard Heavy Duty (HD) W-Beam

 Longitudinal Barrier Systems

Based on a review of crash test results submitted by the manufacturer certifying the device 

described herein meets the crashworthiness criteria of the American Association of State 

Highway and Transportation Officials’ Manual for Assessing Safety Hardware (MASH), the 

device is eligible for reimbursement under the Federal-aid highway program. Eligibility for 

reimbursement under the Federal-aid highway program does not establish approval or 

endorsement by the FHWA for any particular purpose or use.
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The FHWA, the Department of Transportation, and the United States Government do not 

endorse products or services and the issuance of a reimbursement eligibility letter is not an 

endorsement of any product or service.

Requirements

Roadside safety devices should meet the guidelines contained in the MASH. 

Description

A.Ingal EZY-Guard W-beam longitudinal barrier system:

The Ingal W-beam Guardrail system consists of W-beam guardrail attached to U section

line posts via a slider bracket and attachment bolt. Line posts were driven 1170 millimeters 

into AASHTO M147-65 Standard Soil at 2000 millimeters centers. A total of 31 posts were

installed with a length of need (LON) of 60.0 meters. The finished nominal rail height of the 

system was 790 millimeters (31 inches).

The guardrail consisted of Ingal Flexbeam G4 W-beam guard rail sections with a 4.0 meters 

net laying length (NLL). Flexbeam is a standard 12ga (2.7millimeters) galvanized W-beam 

section conforming to AASHTO M-180 Class A.

The slider brackets were manufactured from ductile iron and consisted of a 110 millimeters x 

70 millimeters x 10 millimeters thick plate with a single M16 threaded hole. The slider plate 

fits down over the flanges of the line posts and is seated on the stopper plate. The threaded 

hole providing a mounting point for the guardrail via M16 post bolts.

The steel line posts were 5 lb/ft hot rolled high tensile steel fabricated in a U-section 

approximately 51 millimeters (2 inches) deep by 91 millimeters (3-1/2 inches) wide and 1980 

millimeters (78 inches) long and hot dip galvanized. Posts incorporated a 90 millimeters x 10 

millimeters x 3 millimeters mild steel stopper plate welded across the U-section 210 

millimeters (8 inches) from the top edge for seating of the slider bracket.

Guardrail sections were joined together with standard M16 x 32 galvanized mushroom head 

splice bolts and M16 oversize nuts. Guardrail sections were fixed to the slider brackets with a 

single machined steel M16 bolt with oversize head.

An ET-2000 Plus Steel Yielding Terminal Post System, tested and approved to NCHRP 350 

TL-3, was installed at each end of the barrier LON. Each terminal end consisted of an extruder 

head assembly, eight I-section line posts at 1905 millimeters centers, King Block 190 

millimeters plastic block-outs, and four lengths of Flexbeam G4 W-beam guardrail.

The terminal ends and line post for both Test 3-10 and Test 3-11 longitudinal W-beam barrier 

tests were embedded in AASHTO M 147-65 ‘Standard’ soil.

Design details are provided as enclosure to this correspondence.

B. Ingal EZY-Guard Heavy Duty W-beam longitudinal barrier system:
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This system consists of W-beam guardrail attached to EZY-Guard Heavy Duty Z-section line 

post via a guardrail carriage system and attachment bolt. The line posts were driven 1080 

millimeters (42.5 inches) into AASHTO M147-65 Standard Soil at 2.0 meters (6.6 feet) 

centers. A total of 31 posts were installed giving a test installation LON of 60.0 meters (197 

feet). The finished nominal rail height of the system was 730 millimeters (28.7 inches), with 

all steel line posts finishing below the top of the rail at a height of 720 millimeters (28.3 

inches). Each end of the length of need was terminated with an ET-2000 Plus Steel Yielding 

Terminal Post System, each with an installed length of 15.24 meters (50 feet). The overall test 

installation length was 90.8 meters (298 feet).

The steel line posts were manufactured from Grade 300 steel fabricated into a ‘Z’ section 

approximately 60 millimeters (2.5 inches) wide by 140 millimeters (5.5 inches) deep and 1800 

millimeters (71 inches) long. All line posts were hot dip galvanized. A series of three tabs 

were formed proud into the front face of the post. The upper two tabs formed transversely 

across the tab face were placed above the resting position of the carriage. A cavity formed in 

the carriage allowed it to pass over the tabs without fouling. The third tab was offset on the 

face of the post and made sufficiently proud so as to form a resting stop for the guardrail 

carriage. The upper tab was 7.5 millimeters (0.3 inches) in thickness and located 17.5 

millimeters (0.7 inches) from the top of the post. The middle tab had a thickness of 4 

millimeters (0.2 inches) and was located 73 millimeters (2.9 inches) from the top of the post. 

A third tab was installed 185 millimeters (7.3 inches) from the top of the post and formed the 

resting stop for the guardrail carriage. 

The guardrail consisted of Ingal Flexbeam G4 W-beam guard rail sections with a 4.0 m (13 

feet) net laying length (NLL). Flexbeam is a standard 12g galvanized Wbeam section 

conforming to AASHTO M-180 Class A.

The guardrail carriages were manufactured from ductile iron and consisted of a 85 millimeters 

x 55 millimeters x 60 millimeters (3.3 inches x 2.1 inches x 2.3 inches) thick section with a 

single M16 threaded hole. The guardrail carriages fitted over the flanges of the line posts and 

were seated on the third tab (lower tab) formed in the steel line posts. The threaded hole 

provided the mounting point for the guardrail via a proprietary M16 carriage bolt.

Guardrail sections were joined together with standard M16 x 32 Galvanized mushroom head 

splice bolts and M16 oversize nuts. Guardrail sections were fixed to posts via the guardrail 

carriages, using a single proprietary M16 bolt with an oversize domed head.

An ET-2000 Plus Steel Yielding Terminal Post System, tested and approved to NCHRP 350 

TL-3, was installed at each end of the barrier LON. Each terminal end consisted of an extruder 

head assembly, eight I-section line posts at 1905 mm centers, King Block 190 mm plastic 

block-outs, and four lengths of Flexbeam G4 W-beam guardrail. The nominal finished 

installed height of the terminal ends was 730 millimeters (28 inches), directly matching the 

installed height of the guardrail system.

The terminal ends and line post for both Test 3-10 and Test 3-11 longitudinal Wbeam barrier 

tests were embedded in AASHTO M 147-65 ‘Standard’ soil.

Design details are provided as enclosure to this correspondence.
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Findings

A. Ingal EZY-Guard W-beam longitudinal barrier system:

The 820C test vehicle (test vehicle) impacted the installation 0.95 meters (3.1 feet) 

upstream of line post 11 at an angle of 20 degrees and a velocity of 101.7 kph. The Ingal 

W-beam barrier system, consisting of fifteen 4-meter (13.1 feet) lengths of Wbeam 

guardrail supported on thirty-one 5 lb/ft U-section steel posts and slider brackets installed 

at a 2.0 meter (6.5 feet) spacing, successfully contained and redirected a 820C test 

vehicle impacting the test article at 20 degrees with a velocity of 101.7 kph. The majority 

of high tensile posts in the impact zone fractured upon collision with the vehicle. The 

larger detached post fragments were mainly scattered along the hazard side of the barrier 

installation, however a post fragment was observed on the traffic side of the barrier. This 

indicates that the trajectory of the fractured posts is uncontrolled and presents an undue 

risk to other traffic, pedestrians and work zone personnel. Minor penetration and 

deformation of the occupant compartment occurred as the result of a fractured post. 

Whilst the vehicle damage was within assessment limitations, the uncontrolled trajectory 

of the fractured posts presents an undue hazard to the vehicle occupants. The vehicle 

remained upright during and after the impact and vehicle stability was considered 

satisfactory. Occupant risk factors satisfied the test criteria and the vehicle exit trajectory 

remained within acceptable limits.

Use of the 820C test vehicle during the re-write timeframe of NCHRP Report 350 update 

(i.e., MASH) was allowed in lieu of the 1100C small car. In this particular case, Holmes 

Solutions Crash Test Report 102350.03-4 dated May 2009 used a proper 820C test 

vehicle that met the NCHRP Report 350 criteria. In addition after a full review of the test 

report, there is no reason to believe the MASH 1100C test vehicle at the higher angle 

would fail this test.

The 2270P test vehicle (test vehicle) impacted the Critical Impact Point (CIP) 1.48 meters 

(4.85 feet) upstream of line post 11 at a velocity of 99.7 kph and an angle of 25 degrees 

before impacting on post 11 with the left front wheel causing the post to fracture at 

ground level. The Ingal W-beam barrier system, consisting of fifteen 4-metre lengths of 

Wbeam guardrail supported on thirty-one 5 lb/ft U-section steel posts and slider brackets 

installed at 2.0 spacing, successfully contained and redirected a 2270P test vehicle 

impacting the test article at 25 degrees with a velocity of 99.7 kph. The majority of high 

tensile posts in the impact zone fractured upon collision with the vehicle. The detached 

post fragments were scattered along the hazard side and traffic side of the barrier 

installation. This indicates that the trajectory of the fractured posts is uncontrolled and 

presents an undue risk to other traffic, pedestrians and work zone personnel. There were 

no deformations recorded in the occupant compartment and the vehicle remained upright 

during and after the impact. The vehicle trajectory behind the test article remained 

straight and stable. 

Testing Summary sheets are provided as enclosures to this correspondence.

B. Ingal EZY-Guard Heavy Duty W-beam longitudinal barrier system:

The Ingal EZY-Guard Heavy Duty W-beam barrier system when installed at a nominal 

height of 730 millimeters (28 inches), successfully contained and redirected a 1100C test 
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vehicle impacting the test article at 24.9 degrees with a velocity of 101.8 kph. No debris 

or detached elements penetrated or showed potential to penetrate the occupant 

compartment. No fragments were distributed outside of the vehicle trajectory and 

therefore did not present any undue hazard to other traffic, pedestrians or work zone 

personnel. The vehicle remained upright during and after the impact and vehicle stability 

was considered satisfactory. Occupant risk factors satisfied the test criteria and the 

vehicle exit trajectory remained within acceptable limits.

The Ingal EZY-Guard Heavy Duty W-beam barrier system when installed at a nominal 

height of 730 millimeters (28 inches) successfully contained and redirected a 2270P test 

vehicle impacting the test article at 25 degrees with a velocity of 99.0 kph. No debris or 

detached elements penetrated or showed potential to penetrate the occupant compartment. 

No fragments were distributed outside of the vehicle trajectory and therefore did not 

present any undue hazard to other traffic, pedestrians or work zone personnel. The 

vehicle remained upright during and after the impact and vehicle stability was considered 

satisfactory. Occupant risk factors satisfied the test criteria and the vehicle exit trajectory 

remained within acceptable limits. 

Testing Summary sheets are provided as enclosures to this correspondence.

Therefore, the systems described and detailed in this correspondence and the crash test 

reports are eligible for reimbursement and may be installed under the range of conditions 

tested.

Please note the following standard provisions that apply to FHWA eligibility letters:

• This letter provides a AASHTO/ARTBA/AGC Task Force 13 designator that should be 

used for the purpose of the creation of a new and/or the update of existing Task Force 13 

drawing for posting on the on-line ‘Guide to Standardized Highway Barrier Hardware’ 

currently referenced in AASHTO Roadside Design Guide.

• This finding of eligibility is limited to the crashworthiness characteristics of the systems 

and does not cover their structural features, nor conformity with the Manual on Uniform 

Traffic Control Devices.

• Any changes that may influence the crashworthiness of the system will require a new 

reimbursement eligibility letter.

• Should the FHWA discover that the qualification testing was flawed, that in-service 

performance reveals safety problems, or that the system is significantly different from the 

version that was crash tested, we reserve the right to modify or revoke this letter.

• You will be expected to supply potential users with sufficient information on design and 

installation requirements to ensure proper performance.

• You will be expected to certify to potential users that the hardware furnished has the same 

chemistry, mechanical properties, and geometry as that submitted for review, and that it 

will meet the crashworthiness requirements of the Manual for Assessing Safety Hardware. 

• To prevent misunderstanding by others, this letter of eligibility is designated as number B229 and shall not be reproduced except in full. This letter and the test documentation 

upon which it is based are public information. All such letters and documentation may be 

reviewed at our office upon request. 
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• This letter shall not be construed as authorization or consent by the FHWA to use, 

manufacture, or sell any patented system for which the applicant is not the patent holder. 

The finding of eligibility is limited to the crashworthiness characteristics of the candidate 

system, and the FHWA is neither prepared nor required to become involved in issues 

concerning patent law. Patent issues, if any, are to be resolved by the applicant.

• The Ezy-Guard W-Beam & Ezy-Guard Heavy Duty (HD) W-Beam Longitudinal Barrier 

Systems are patented products and considered proprietary. If proprietary systems are 

specified by a highway agency for use on Federal-aid projects: (a) they must be supplied 

through competitive bidding with equally suitable unpatented items; (b) the highway 

agency must certify that they are essential for synchronization with the existing highway 

facilities or that no equally suitable alternative exists; or (c) they must be used for research 

or for a distinctive type of construction on relatively short sections of road for 

experimental purposes. Our regulations concerning proprietary products are contained in 

Title 23, Code of Federal Regulations, Section 635.411. 

Sincerely yours,

Michael S. Griffith 

Director, Office of Safety Technologies

Office of Safety

Enclosures