Mr. Barry D. Stephens, P.E. 

 Sr. Vice President Engineering 

 Energy Absorption Systems, Inc. 

 3617 Cincinnati Avenue 

 Rocklin, California 95678 

Dear Mr. Stephens: 

Recently, Mr. Douglas Bernard delivered your letter dated January 7, 2005, to Mr. Richard 

Powers of my staff. In this letter, you requested formal Federal Highway Administration 

(FHWA) review and acceptance of a temporary longitudinal barrier called the Vulcantm Barrier 

(Vulcan). To support your request, you supplied a summary report and video prepared by 

E-Tech Testing Services that describes the Vulcan Barrier as well as the three full-scale crash 

tests you conducted. 

The Vulcan is a longitudinal barrier fabricated from hot-dipped galvanized steel and is 

intended for use as a portable longitudinal barrier in work zones. Each segment has a nominal 

length of 4115 mm, a height of 813 mm and a width of 546 mm. The mass of each segment is 

approximately 395 kg. The upper portion incorporates standard Thrie-beam guardrail panels 

and the bottom incorporates sheet metal rub rails. Five steel bulkheads tie the sides of the 

Vulcan together. The end bulkheads incorporate vertically aligned holes to facilitate pinning 

Vulcan segments together. The center bulkhead incorporates a lifting tab for assembly and 

transport. A stiffener plate also runs the length of each segment. Vulcan sections are pinned 

together using 48 mm diameter steel connecting pins. When installed in straight 

configurations, an optional steel spacer can be installed in the connecting joint to reduce lateral 

deflection. This spacer was used in the three tests submitted for review. The Vulcan’s end 

bulkheads can also be used to connect an appropriate crash cushion to a Vulcan installation. 

Enclosure 1 is a schematic drawing of a Vulcan segment. 

The Vulcan Barrier was crash tested in two configurations. Two tests were conducted 

following the guidelines in the National Cooperative Highway Research Program (NCHRP) 

Report 350 for tests 3-10 and 3-11 with the Vulcan freestanding and unanchored on an asphalt 

surface. For these two tests, eighteen (18) freestanding Vulcan segments were pinned together 

and the ends were ballasted with four unanchored 3.0 m long PCMB segments to simulate 

400 Seventh St., S.W. 

Washington, D.C. 20590

In Reply Refer To: HSA-10/B-134 

February 14, 2005 
2

longer lengths of upstream and downstream Vulcan Barrier. These concrete segments weighed 

8880 kg, which is equal to 23 segments of Vulcan. Consequently, when installed freestanding, 

the same weight of PCMB segments or a minimum of 23 Vulcan segments (92 m = 302 ft) 

must be attached to each end of unanchored Vulcan barriers to establish a “beginning of length 

of need” (BLON) point and to limit the barrier’s dynamic deflection within the length of need 

to that noted in the crash test. The impact point for these tests was at a point 16.5 m from the 

connection to the PCMB or the BLON point. The vehicles were smoothly redirected and 

occupant risk values were acceptable. The lateral dynamic deflection for the 820c test was 

1.6 m and for the 2000p test was 4.0 m. Impacts nearer to either end of an unanchored 

installation may result in significantly greater deflections. Impacts immediately adjacent to 

either unanchored end may not redirect an impacting vehicle and are likely to result in 

pocketing or penetration into the area behind the barrier. 

A second Vulcan Barrier configuration was also tested per the NCHRP Report 350 Test 3-11 

and submitted for evaluation. In this configuration both ends of fourteen (14) Vulcan segments 

were restrained from moving by connecting the barrier to a QuadGuard CZ crash cushion 

anchored with DPA anchors (reference the FHWA acceptance letter HSA-10/CC-35G) on the 

approach end and the QuadGuard base platform on the departure end. The impact point was 

into the third Vulcan segment at a point 1.2 m downstream from the connection between the 

second and third segments. The 2000p vehicle was smoothly redirected and the reported 

occupant risk values were acceptable. The maximum lateral dynamic deflection was reported 

as 2.1 m. As expected, dynamic deflection was significantly reduced when the Vulcan 

installation was anchored at both ends and this treatment is acceptable for use in uni-directional 

applications or where opposite direction impacts immediately adjacent to the QuadGuard are 

deemed to be unlikely. Since you are connecting a flexible barrier system directly to a rigid 

crash cushion, further evaluation or a crash test will be required to validate use of QuadGuard 

systems on both ends in bidirectional traffic applications to make sure there is no snag point 

when this transition is impacted from the opposing traffic direction. Enclosure 2 includes 

summary test sheets for the three tests you reported. 

You also submitted a drawing (Enclosure 3) depicting Vulcan Barrier ends shielded by your 

TRITON CET crash cushion (reference the FHWA acceptance letter dated February 6, 2004, 

HSA-10/CC-47B). I agree that this is an acceptable means of shielding the exposed ends of 

Vulcan Barrier, but users must be cautioned that impacts into the TRITON CET will likely 

result in pocketing or penetration into the area beyond the terminal and impacts immediately 

downstream from this crash cushion will result in greater deflection of the barrier into the work 

area. 

Based upon review of the data you submitted, I agree that the Vulcan Barrier, as tested, meets 

the NCHRP Report 350 evaluation criteria and may be used on the National Highway System 

(NHS) as a test level 3 temporary barrier. In its unanchored configuration, at least 8880 kg of 

mass (23 segments of Vulcan or equivalent weight) must be attached to the ends in advance of 

the barrier length of need. The freestanding, unshielded end of this design is not crashworthy 

and requires either shielding with a suitable anchored impact attenuator for uni-directional 

applications) or introduction outside the appropriate clear zone. I also agree that the ends of 

the Vulcan can be attached to and shielded by your unanchored TRITON CET crash cushion. 
3

Anticipated lateral deflection of the Vulcan for anchored and unanchored configurations must 

be communicated to end users so effective field installations can be designed. 

Please note also that the following provisions apply to the FHWA letters of acceptance: 

• This acceptance is limited to the crashworthiness characteristics of the device and does 

not cover its structural features or its conformity with the Manual on Uniform Traffic 

Control Devices. 

• Any design changes that may adversely influence the crashworthiness of the device will 

require a new acceptance letter. 

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

performance reveals unacceptable safety problems, or that the device being marketed is 

significantly different from the version that was crash test, it reserves the right to modify 

or revoke it acceptance. 

• 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 

essentially the same chemistry, mechanical properties, and geometry as that submitted for 

acceptance, and that it will meet the crashworthiness requirements of the NCHRP Report 

350. 

• To prevent misunderstanding by others, this letter of acceptance, designated as number 

B-134, shall not be reproduced except in full. This letter, and test documentation upon 

which this letter is based, is public information. All such letters and documentation may 

be reviewed at our office upon request. 

• The Vulcan Barrier is a patented product and is considered proprietary. If proprietary 

devices are specified by a highway agency for use on a Federal-aid projects, except 

exempt, non-NHS projects, they: (a) 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, 

 

 /Original Signed by Harry W. Taylor/ 

 ~for~ 

John R. Baxter, P.E. 

 Director, Office of Safety Design 

 Office of Safety 

3 Enclosures 
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D. Hayes Jr.

D. Wilkinson

J. EspinozaJ. M. Thompson3596000-0000.idw

3/3/2004

10/28/2003

3/5/2004

3/5/2004

Revision Date Rev By Chk. App.

ASSIGNED P/N'S 10/6/04 - DPH JME KWL

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NOTE: INSERT PIN AND SPACER (ITEM 5 & 6) TO JOIN LEFT AND RIGHT ENDS OF ADJACENT BARRIER SEGMENTS DURING INSTALLATION.

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D. Wilkinson

J. EspinozaJ. M. Thompson3596000-0000.idw

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10/28/2003

3/5/2004

3/5/2004

Revision Date Rev By Chk. App.

ASSIGNED P/N'S 10/6/04 - DPH JME KWL

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D. Hayes Jr.

D. Wilkinson

J. EspinozaJ. M. Thompson3596000-0000.idw

3/3/2004

10/28/2003

3/5/2004

3/5/2004

Revision Date Rev By Chk. App.

ASSIGNED P/N'S 10/6/04 - DPH JME KWL

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DRAWN:

DESIGNED:

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NEXT ASSEMBLY:

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APPROVED: DATE:

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D. Hayes Jr.

D. Wilkinson

J. EspinozaJ. M. Thompson3596000-0000.idw

3/3/2004

10/28/2003

3/5/2004

3/5/2004

Revision Date Rev By Chk. App.

ASSIGNED P/N'S 10/6/04 - DPH JME KWL

14 13

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8
Vulcan Barrier Crash Test Results - 9 of 58

E-TECH Testing Services, Inc. 162"

32"

21 1/2"

A W

Vulcan Barrier

Segment

Exit conditions

Speed (km/h) ........................................................... 84.0Angle (deg - veh. c.g.) ............................................. 7

Occupant Risk Values

Impact Velocity (m/s)

x-direction ....................................................... 3.8y-direction ....................................................... -5.4

Ridedown Acceleration (g's)

x-direction ....................................................... -5.3y-direction ....................................................... -4.8

European Committee for Normalization (CEN) Values

THIV (km/h) ............................................................ 22.8PHD (g's) ................................................................. 9.2ASI .......................................................................... 0.9

Test Article Deflections (m)

Dynamic .................................................................. 1.6Permanent ............................................................... 1.4

Vehicle Damage (Primary Impact)

Exterior

VDS .................................................................. RFQ-2CDC ................................................................. 01RFWE1

Interior

VCDI ................................................................ AS0000000Maximum Deformation (mm) ........................ Negligible

Post-Impact Vehicular Behavior (deg - rate gyro)

Maximum Roll Angle ............................................ 6.3Maximum Pitch Angle ........................................... 1.7Maximum Yaw Angle ............................................ -27.4

Figure 1. Summary of Results - Vulcan Barrier NCHRP 350 Test 3-10

t = 0.096 sec t = 0.192 sec t = 0.288 sec t = 0.384 sec t = final

General Information

Test Agency ............................................................. E-TECH Testing Services, Inc.Test Designation .................................................... NCHRP 350 Test 3-10Test No. ................................................................... 01-8430-002Date .......................................................................... 2/10/04

Test Article

Type ......................................................................... VulcanTM Barrier

.......................................................................... Segment 4115 mm x 813 mm x.......................................................................... 546 mm (L x H x W).......................................................................... 395 kg mass

Installation Length ................................................ (18) segments 74.1 m overall

.......................................................................... length w/o (4) 3.0 m concrete.......................................................................... barrier end ballast

Material and key elements ................................... AASHTO M180 galvanized steel

.......................................................................... panels, ASTM A53 Pins, and A36.......................................................................... other

Foundation Type and Condition .................................. Chip-seal asphalt, dryTest Vehicle

Type ......................................................................... Production ModelDesignation ............................................................. 820CModel ....................................................................... 1987 Ford FestivaMass (kg)

Curb ................................................................. 823Test inertial .................................................... 828Dummy ............................................................ 75Gross ................................................................ 903

Impact Conditions

Speed (km/h) ........................................................... 103.2Angle (deg) .............................................................. 20Impact Severity (kJ) ............................................... 39.8

t = 0.000 sec
Vulcan Barrier Crash Test Results - 15 of 58

E-TECH Testing Services, Inc. 162"

32"

21 1/2"

A W

Vulcan Barrier

Segment

Exit conditions

Speed (km/h) ........................................................... 80.0Angle (deg - veh. c.g.) ............................................. 10

Occupant Risk Values

Impact Velocity (m/s)

x-direction ....................................................... 3.8y-direction ....................................................... -4.3

Ridedown Acceleration (g's)

x-direction ....................................................... -3.7y-direction ....................................................... -5.5

European Committee for Normalization (CEN) Values

THIV (km/h) ............................................................ 19.9PHD (g's) ................................................................. 5.5ASI .......................................................................... 0.6

Test Article Deflections (m)

Dynamic .................................................................. 4.0Permanent ............................................................... 3.5

Vehicle Damage (Primary Impact)

Exterior

VDS .................................................................. RFQ-3CDC ................................................................. 01RFWE1

Interior

VCDI ................................................................ AS0000000Maximum Deformation (mm) ........................ Negligible

Post-Impact Vehicular Behavior (deg - rate gyro)

Maximum Roll Angle ............................................ -8.0Maximum Pitch Angle ........................................... -6.5Maximum Yaw Angle ............................................ -42.2

Figure 6. Summary of Results - Vulcan Barrier NCHRP 350 Test 3-11

t = 0.120 sec t = 0.240 sec t = 0.360 sec t = 0.480 sec t = 0.600

General Information

Test Agency ............................................................. E-TECH Testing Services, Inc.Test Designation .................................................... NCHRP 350 Test 3-11Test No. ................................................................... 01-8430-001Date .......................................................................... 1/21/04

Test Article

Type ......................................................................... VulcanTM Barrier

.......................................................................... Segment 4115 mm x 813 mm x.......................................................................... 546 mm (L x H x W).......................................................................... 395 kg mass

Installation Length ................................................ (18) segments 74.1 m overall

.......................................................................... length w/o (4) 3.0 m concrete.......................................................................... barrier end ballast

Material and key elements ........................... AASHTO M180 galvanized steel

.......................................................................... panels, ASTM A53 Pins, and A36.......................................................................... other

Foundation Type and Condition .................................. Chip-seal asphalt, dryTest Vehicle

Type ......................................................................... Production ModelDesignation ............................................................. 2000PModel....................................................................... 1989 Chevrolet C-2500Mass (kg)

Curb ................................................................. 1879Test inertial .................................................... 2008Dummy ............................................................. N/AGross ................................................................ 2008

Impact Conditions

Speed (km/h) ........................................................... 102.5Angle (deg).............................................................. 25Impact Severity (kJ) ............................................... 145.3

t = 0.000 sec
Vulcan Barrier Crash Test Results - 21 of 58

E-TECH Testing Services, Inc.

Vulcan Barrier

Segment

Exit conditions

Speed (km/h) .................................................... 30Angle (deg - veh. c.g.) ....................................... N/A

Occupant Risk Values

Impact Velocity (m/s)

x-direction ................................................. 3.2y-direction ................................................. -3.8

Ridedown Acceleration (g's)

x-direction ................................................. 4.6y-direction ................................................. -9.1

European Committee for Normalization (CEN) Values

THIV (km/h) ..................................................... 18.1PHD (g's).......................................................... 9.1ASI ................................................................... 0.7

Test Article Deflections (m)

Dynamic ........................................................... 2.1Permanent ........................................................ 2.1

Vehicle Damage (Primary Impact)

Exterior

VDS ........................................................... RFQ-2CDC........................................................... 01RFWE1

Interior

VCDI ......................................................... AS0000000Maximum Deformation (mm) .................... Negligible

Post-Impact Vehicular Behavior (deg - rate gyro)

Maximum Roll Angle ....................................... -10.8Maximum Pitch Angle ..................................... -4.6Maximum Yaw Angle ....................................... -36.2

t = 0.120 sec t = 0.240 sec t = 0.360 sec t = 0.480 sec

General Information

Test Agency ..................................................... E-TECH Testing Services, Inc.

Test Designation .............................................. NCHRP 350 Test 3-11Test No. ............................................................ 55-8430-003

Date .................................................................. 10/13/04

Test Article

Type .................................................................. VulcanTM Barrier

................................................................... Segment 4115 mm x 813 mm x................................................................... 546 mm (L x H x W) 395 kg mass................................................................... with QuadGuard QZ2406PY................................................................... end anchorage

Installation Length .................................................. (14) segments 57.6 m length

................................................................... 67.9 m overall length................................................................... with QuadGuard Drivable Pile end................................................................... anchorage (6) upstream and (4)................................................................... downstream

Material and key elements ...................................... AASHTO M180 galvanized steel

................................................................... panels, ASTM A53 Pins, and A36................................................................... other

Foundation Type and Condition ............................... Chip-seal asphalt over dry soilTest Vehicle

Type .................................................................. Production ModelDesignation ...................................................... 2000PModel ................................................................ 1995 Chevrolet C-2500Mass (kg)

Curb .......................................................... 1858Test inertial .............................................. 2012Dummy ...................................................... N/AGross......................................................... 2012

Impact Conditions

Speed (km/h) .................................................... 100.4Angle (deg) ....................................................... 25Impact Severity (kJ) ......................................... 139.6

 Figure 11. Summary of Results - Vulcan Barrier NCHRP 350 Test 3-11

t = 0.000 sec Final
DETAIL A

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klooney

klooney

1/6/2005

Trition VET 

A

Triton CET

Vulcan Barrier