Water-Ballasted Plastic Barrier with Embedded Cable
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Solution Overview
Problem
Existing water ballasted vehicle traffic protection barriers fail to meet the stringent impact test standards of NCHRP 350, particularly Test Levels 1, 2, and 3, due to durability issues and inability to prevent vehicle penetration and rollover.
Innovation Solution
A modular, hollow plastic barrier segment filled with water and reinforced with a metallic cable system, featuring interlocking lugs and a concave redirective design, along with a wire rope cable assembly for enhanced strength and impact absorption, and a unique drain aperture closure mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If water ballasted barriers are made from molded lightweight plastic and filled with water, then they are easy to transport and install, but they cannot meet the NCHRP 350 impact test standards and fail durability requirements
Solution Approach 1:
The barrier combines lightweight molded plastic with a metallic cable reinforcement system. The plastic container provides the ballasted barrier structure for easy transport, while the embedded metallic cable (preferred stainless steel wire rope or galvanized steel stranded wire) provides the structural strength to meet NCHRP 350 impact test standards. This composite construction resolves the contradiction between ease of operation and reliability.
2Ease of operation
If the barrier is made hollow and filled with water, then it can be transported and installed easily, but it lacks the structural strength to prevent vehicle penetration at high impact velocities
Solution Approach 1:
The hollow plastic container filled with water provides portability, while the integrated metallic cable reinforcement system provides the necessary strength to resist vehicle impact. The cable is molded within the container so most of its length is entirely disposed within the interior volume, creating a composite structure that combines the advantages of both materials.
Solution Approach 2:
The barrier features a concave redirective design with curved surfaces that redirective of impact forces. The concave shape helps distribute impact loads and redirect vehicles away from the barrier, enhancing the structural resistance to penetration while maintaining the hollow water-filled design for easy transport.
3Ease of manufacture
If the barrier uses simple plastic construction, then manufacturing is simple and cost-effective, but it cannot prevent vehicle rollover and exceeds occupant velocity limits
Solution Approach 1:
The barrier maintains simple plastic manufacturing processes while incorporating a metallic cable reinforcement system. The cable is molded within the plastic container during fabrication, integrating the reinforcement into the manufacturing process rather than requiring separate assembly steps. This composite approach enables the barrier to prevent rollover and control occupant velocity while maintaining manufacturing efficiency.
Solution Approach 2:
The concave redirective design with curved surfaces helps control vehicle impact dynamics by redirecting forces and reducing the likelihood of rollover. The curved geometry works in conjunction with the reinforced structure to maintain occupant velocity within safe limits while preserving manufacturing simplicity.
4Adaptability or versatility
If the barrier is designed as sectional and modular, then it can be assembled to any desired length, but the connection points become weak points that reduce overall structural integrity
Solution Approach 1:
The barrier is designed as sectional and modular with connecting lugs disposed on each end, allowing assembly to any desired length. Each module maintains its internal cable reinforcement, ensuring that connection points between segments are as strong as the segments themselves.
Solution Approach 2:
The metallic cable reinforcement extends through the connection lugs and joining mechanisms, creating a continuous load path that maintains structural integrity across module boundaries. The composite construction ensures that connection points do not become weak links in the barrier system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively meets all NCHRP 350 test standards by distributing impact forces, preventing vehicle penetration, and reducing the risk of rollover, while maintaining structural integrity during high-velocity impacts.
Implementation Method 1
A length of metallic cable, preferably stainless steel wire rope cable or galvanized steel and stranded wire for corrosion resistance, comprising a plurality of 3/8 inch 7 x19 strands, is molded within the molded plastic container
Implementation Method 2
Water ballasted vehicle traffic protection barriers are comprised of molded, lightweight plastic, and are hollow, having a fill port for filling them with water to ballast them in place
Implementation Method 3
a wire rope cable assembly for enhanced strength and impact absorption, and a unique drain aperture closure mechanism
Data Source
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Figure 12~17
AI summary
A water-ballasted molded plastic barrier system incorporates barrier segments wherein each segment employs a sawtooth reflective design, designed to prevent the tire of a vehicle, impacting the barrier, from climbing up the side of the barrier segment. Adjacent barrier segments are attached together using an interlocking knuckle design, having a lug pin connection system. Wire rope cable assemblies are internally molded into each barrier segment to create an impenetrable cable fence. The wire rope cable assemblies include steel bushings which are molded into the interlocking knuckles to further strengthen the barrier system.