CRASH TEST REPORT FOR PERIMETER BARRIERS AND GATES

CRASH TEST REPORT FOR
PERIMETER BARRIERS AND GATES
TESTED TO SD-STD-02.01, REVISION A, MARCH 2003
Anti-Ram Bollards
Prepared for:
RSA Protective Technologies, LLC
1573 Mimosa Court
Upland, CA 91784
Test Report No. TR-P25039-02-NC
KARCO Engineering, LLC
AUTOMOTIVE RESEARCH CENTER
9270 Holly Road
Adelanto, CA 92301
Tel: (760) 246-1672
Fax: (760) 246-8112
April 4, 2005
KARCO Engineering compiled this publication for information gathering only. The opinions,
findings and conclusions expressed in this publication are those of the authors and not necessarily
those of any other organization. KARCO Engineering provides test services only and is not involved
in consulting, product design or the manufacturing of any automotive products. KARCO does not
warrant, supervise or monitor compliance of products or services except as specifically agreed to in
writing. By their very nature, testing, analysis and other KARCO services are limited in scope and
subject to expected measurement variability. No activity by KARCO Engineering can release a
manufacturer from product or any other liability.
Tested By:
Mr. Matthew A. Ivory, Project Manager
Reviewed By:
Mr. Michael L. Dunlap, Quality Assurance
Approved By:
Mr. Frank D. Richardson, Program Manager
Approval Date:
______
TR-P25039-02-NC
TABLE OF CONTENTS
Section
1
2
3
Table
1
Data Sheet
1
2
3
4
5
Appendix
A
B
C
D
Introduction
Test Procedure and Instrumentation Summary
Test Results and Data Sheets
Page
1
2
5
Test Designations
Page
2
Test Vehicle Information
Test Vehicle Geometry
Evaluation of Test Results
Vehicle Accelerometer Data Summary
Camera Views and Film Speeds
Page
6
7
8
9
10
Photographs
Data Plots
Instrumentation List
Manufacturers Drawings
Page
A
B
C
D
i
TR-P25039-02-NC
LIST OF PHOTOGRAPHS
Figure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Test Article as Received
Right Front View at Test Article`
Anti-Ram Bollard 5 inch Footing
Bollard 10 inch Diameter and 1 inch Wall Thickness
Bollard Foundation Module Front View and Re-bar
Bollard Foundation Module Rear View
Excavation
Embedment Depth
Test Article Positioned in Place
Test Article During Installation
Test Article During Installation
Test Article During Installation
Test Article Left Side View
Test Article Left Front ¾ View
Test Article Front View
Test Set-Up
Test Set-Up
Test Set-Up
Test Set-Up
Test Set-Up
Test Set-Up
Test Set-Up
Test Article Orientation to Front Bumper
Test Article Orientation to Front Bumper
Test Set-Up
Ballast
Post-Test Left Side View
Post-Test Left Side view Close-Up
Post-Test Front View
Post-Test Overhead View
Post-Test Test Article Front View
Post-Test Test Article Left Side View
Post-Test Test Article Left Side View
Center Bollard Deflection
Ballast
Action Sequence 1
Action Sequence 2
Action Sequence 3
Action Sequence 4
ii
Page
A-1
A-1
A-2
A-2
A-3
A-3
A-4
A-4
A-5
A-5
A-6
A-6
A-7
A-7
A-8
A-8
A-9
A-9
A-10
A-10
A-11
A-11
A-12
A-12
A-13
A-13
A-14
A-14
A-15
A-15
A-16
A-16
A-17
A-17
A-18
A-18
A-19
A-19
A-20
TR-P25039-02-NC
TABLE OF CONTENTS...(CONTINUED)
LIST OF DATA PLOTS
Plots
B-1
Vehicle Rear Frame Rail X
Vehicle Rear Frame Rail Y
Vehicle Rear Frame Rail Z
Vehicle Rear Frame Rail Resultant
Vehicle Rear Frame Rail X Velocity
Vehicle Rear Frame Rail X Displacement
Page
B-1
B-1
B-1
B-1
B-2
B-2
Table
C-1
INSTRUMENTATION LIST
Instrument Data Channel Assignments
Page
C-1
Figure
1
MANUFACTURERS DRAWINGS
Manufacturers Test Article Layout Drawing
Page
D-1
B-2
iii
TR-P25039-02-NC
SECTION 1
INTRODUCTION
1.1
OBJECTIVES
The primary objective of this crash test was to determine if the tested vehicle impact-rated
barrier meets the minimum performance standards of the United States Department of State
Specification for Vehicle Crash Testing of Perimeter Barriers and Gates (SD-STD-02.01, Revision
A). This report presents the results of the performance and evaluation of one (1) full-scale crash test
conducted on an RSA Anti-Ram Bollard system with 5 inch footings (ID=K8B5F5T).
All tests were conducted in accordance with current SD-STD-02.01, Revision A,
requirements for test designation K4. Procedures for receiving, inspecting, installation, testing and
reporting of test results are described in the test procedure and are not repeated in this report. The
purpose of this test was to evaluate the crash performance of the Anti-Ram Bollards.
1.2
TEST FACILITY
All tests were conducted at KARCO Engineering’s crash test facility in Adelanto, California.
The tow road is constructed of reinforced concrete, presents a continuous level surface, and
measures 850 feet in length. The width of the tow road is twelve feet with a thickness of six inches.
A steel rail is embedded in the approach surface to provide vehicle guidance. Vehicle tow propulsion
is provided by a 1 ton truck using a 2-to-1 pulley system coupled to a fixed prime mover (an internal
combustion engine, Chevrolet V-8, 454 cubic inches displacement, with T-400 automatic
transmission) and continuous cable drive system. The test vehicle is towed to within two feet of the
barricade by a nylon rope clamped to a 3/8-inch steel cable. The clamp is released from the cable
on contact with a cable release mechanism positioned to allow the test vehicle to proceed under its
own momentum for the final two feet of travel before impacting the test array.
1.3
TEST ARTICLE
Unit consists of 5, 40 inch high, 10 inch diameter Anti-Ram Bollards. The bollards
have a 1 inch wall thickness and are filled with concrete during installation. Bollards are
equally spaced at a distance of 4 foot 6 inches center to center. The system has a 5 inch
footing that is installed 1.5 inches below the level concrete surface.
1
TR-P25039-02-NC
SECTION 2
TEST PROCEDURE AND INSTRUMENTATION SUMMARY
2.1
TEST PROCEDURE
To meet the recommended properties of SD-STD-02.01-Rev A. impact requirements, a
commercially available production model test vehicle was selected. This test was conducted using a
1987 International S1900, medium duty truck with conventional cab, front mounted diesel engine,
rear wheel drive and an automatic transmission. The vehicle was in good condition, was free of
major body damage, and was not missing any structural components. The bumpers were standard
equipment and were not modified for this test.
The materials, assembly instructions and physical configuration of the test article are specified
in the manufacturer’s documentation and are not repeated in this test report. Installation of the test
article was conducted by the manufacturer. The test article, as installed at the test facility, is illustrated
in Appendix A.
2.2
IMPACT CONDITIONS
As recommended in SD-STD-02.01-Rev A test specification, the following full-scale crash test
was conducted to evaluate the impact performance of the Anti-Ram Bollards. The primary intent of this
test is to evaluate the ability of the bollards to arrest a 15,000 pound vehicle from penetrating or vaulting
into a secured area and the extent, if any, of barrier deformation
2.2.1
Test Mass. The specific mass (gross weight) of the test vehicle as specified in the standard is
15,000 pounds (lb.) ±200 lb. The test weight, with instrumentation and ballast, was 15,142 lb.
2.2.2
Speed. Vehicle speed at impact with the test article shall be dependent on the condition
designation as outline in Table 1. For this test designated as K4, the velocity at impact was 32.28 mph.
Table 1. Test Designations
CONDITION DESIGNATION
IMPACT SPEED (mph)
MINIMUM
NOMINAL
MAXIMUM
K4
28.0
30.0
37.9
K8
38.0
40.0
46.9
K12
47.0
50.0
56.9
2
TR-P25039-02-NC
2.2.3
Approach Angle and Impact Point. The test vehicle is oriented such that it approaches the
test article at a critical impact angle of ninety degrees (90° ±3º), relative to the roadway, with the
centerline of the vehicle impacting the test article at the impact point designated by the DOS Technical
Representative. The actual center of the impact point must be within ± 1 foot (ft.) of the target. The
impact point designated for this test was the middle of the test article. The actual point of impact was
perpendicular to and within 2 inches of the target.
2.3
TEST INSTRUMENTATION AND DATA ACQUISITION PROCEDURES
All testing and data acquisition for this RSA Anti-Ram Bollard system with 5 inch footings
(ID=K8B5F5T) certification test was performed in accordance with the SD-STD-02.01-Revision A test
specification requirements. Appendix C contains a list of the instrumentation used in the performance of
this test.
2.3.1
On-Board Data Acquisition. MDAS is an acronym for Miniature Data Acquisition System.
The system is comprised of a 3-channel module. The module functions as a stand-alone, all-in-one
unit with integral tri-axial accelerometer, computer control, signal conditioning, A/D circuitry, memory
storage and battery pack. All functions are controlled by an off-board notebook or other PC
compatible computer. Once the off-board computer initializes the system, it is designed to collect
data with no off-board support.
2.3.2
Test Vehicle Instrumentation. Located near the vehicle rear frame rail, the test vehicle was
instrumented with a tri-axial accelerometer to measure longitudinal (x), lateral (y) and vertical (z)
acceleration. Data was recorded using the on-board MDAS three (3) channel module. Data was linked
to a personal computer and processed using the MDAS crash test software. All equipment used in this
test meets the requirements of SAE J211.
2.3.3
TDAS Software. The software utilized in this system is written in National Instruments
LabWindows/CVI (C, Visual Interface) programming language, which is a Windows based (3.1 or
Windows 95) software package with emphasis on ease of use and good engineering test practices.
2.3.4
SAE Compatibility. The software contains standard point and click processing options for
selecting Society of Automotive Engineers (SAE) class post filters and calculating the required
integrals, resultants, Head Injury Criteria (HIC), clips, and other data processing parameters that
may be required.
3
TR-P25039-02-NC
2.3.5
Photographic Documentation. Photographic documentation of this test included three (3) real-
time video cameras and (4) high-speed color digital video cameras at 1000 fps set up for an overhead
view, a driver side view perpendicular to the point of impact a driver side view with a pre-determined
angle to the point of impact and a frontal view. All high-speed cameras were activated by a pressure
sensitive tape switch, which was positioned on the test article to indicate the instant of contact (time
zero). A digital still camera was used for documenting the pre- and post-test condition of the test
vehicles and Anti Ram Bollards.
2.3.6
Test Article Instrumentation. None
4
TR-P25039-02-NC
SECTION 3
TEST RESULTS AND DATA SHEETS
3.1
TEST DESIGNATION K8
This thirty miles per hour (32.28 mph) frontal impact crash test was conducted using a
commercially available 1987 International S1900, medium duty truck to determine if the tested
vehicle impact-rated bollards meet the minimum performance standards of SD-STD-02.01-Rev. A.
The primary intent of this test was to evaluate the ability of the barrier to arrest a 15,000-pound vehicle
from penetrating or vaulting into a secured area and the extent, if any, of bollard deformation. This was
accomplished by measuring the vehicle penetration at the specified level of kinetic energy.
The test article was positioned at an angle of ninety degrees (90°) to the direction of travel of the
impacting test vehicle, with the vehicle’s centerline impacting the middle section of the bollard system.
The vehicle was instrumented with a tri-axial accelerometer at the rear frame rail. This crash test
was documented by three (3) real-time video cameras, and four (4) high-speed digital color cameras.
Photographs of the test vehicle and the anti ram bollards are shown in Appendix A.
3.2
PRIMARY TEST RESULTS
Test K4 was conducted on April 4, 2005. The test inertial weight of the vehicle was 15,142 lb.
Test vehicle information is presented in Data Sheet No. 1 and Data Sheet No. 2. The test vehicle
impacted the center of the barrier gate at a velocity of 32.28 mph. The evaluation of the anti ram
bollard performance is presented in data Sheet No. 3. The vehicle was completely arrested by the
barrier system. Pre- and Post-test photographs of the impact vehicle as well as of the bollards are
shown Appendix A. Data plots of the event are presented in appendix B. The vehicle sustained
severe damage to the entire cab.
5
TR-P25039-02-NC
DATA SHEET NO. 1
TEST VEHICLE INFORMATION
Test Vehicle:
Test Program:
15,000 Ib. Truck
RSA Bollards with 5 in. Footing
Test No.:
Test Date:
P25039-02
4/4/05
TEST VEHICLE INFORMATION
Cylinders
6
Make
International
Model
S1900
Engine Displ. (L)
Body Style
Truck
Engine Placement
1HTLOMJP4HH518679
VIN
Longitudinal
Fuel Type
Diesel
No. of Axles
White
Color
Unknown
2
Odometer Reading
170179
Disc Brakes, Front
No
Transmission
Manual
Disc Brakes, Rear
No
Anti-lock Brakes
No
Rear
Final Drive
DATA FROM CERTIFICATION LABEL
Navistar International
Transportation Corp.
Manufactured By
Date of Manufacture
May-87
GVWR (lbs)
Unknown
GAWR Front (lbs)
Unknown
GAWR Rear (lbs)
Unknown
DATA FROM TIRE PLACARD
Measured Parameter
Front
Rear
Max. Tire Pressure (psi)
Unknown
Unknown
Cold Pressure (psi)
Unknown
Unknown
Recommend Tire Size
Unknown
Unknown
Actual Tire Size on Vehicle
Unknown
Unknown
Actual Tire Manufacturer
Unknown
Unknown
VEHICLE WEIGHTS
As Received (lbs)
As Tested (lbs)
Front
Rear
Total
Front
Rear
Total
Left
3220
2550
5770
3666
4178
7844
Right
3272
2690
5962
3228
4070
7298
Totals
6492
5240
11732
6894
8248
15142
Ratio(%)
55%
45%
100%
46%
54%
100%
6
TR-P25039-02-NC
DATA SHEET NO. 2
TEST VEHICLE GEOMETRY
Test Vehicle:
Test Program:
15,000 Ib. Truck
RSA Bollards with 5 in. Footing
Test No.:
Test Date:
P25039-02
4/4/05
TEST VEHICLE GEOMETRY (mm)
A
780
D
3503
G
650
K
2250
B
500
E
2927
I
590
L
2050
C
800
F
1878
J
1050
N
1830
7
TR-P25039-02-NC
DATA SHEET NO. 3
EVALUATION OF TEST RESULTS
Test Vehicle:
Test Program:
15,000 Ib. Truck
RSA Bollards with 5 in. Footing
CRASH TEST ASSESSMENT
Test No.:
Test Date:
PASS
Penetration of the Front Edge of the Cargo Bed Limited to
One Meter Beyond the Pre-Impact, Inside Edge of the
Barrier.
Comments:
Vehicle was completely arrested by the bollard system.
8
P25039-02
4/4/05
FAIL
x
TR-P25039-02-NC
DATA SHEET NO. 4 - VEHICLE ACCELEROMETER DATA SUMMARY
Test Vehicle:
15,000 lb Truck
Project No.: P25039-02
Test Program:
RSA Bollards with 5 in. Footing
Test Date:
4/4/05
VEHICLE ACCELEROMETER PEAK DATA
Vehicle
Location
Axis
Units
Max
Time
Min
Time
Vehicle Rear Frame Rail X
X
G's
19.4
43.4
-33.5
54.6
Vehicle Rear Frame Rail Y
Y
G's
37.1
65.4
-35.3
73.2
Vehicle Rear Frame Rail Z
Z
G's
27.6
99.2
-21.9
93.1
Vehicle Rear Frame Res.
N/A
G's
41.5
72.9
9
TR-P25039-02-NC
DATA SHEET NO. 5
CAMERA VIEWS & FILM SPEEDS
Test Vehicle:
Test Program:
No.
15,000 Ib. Truck
RSA Bollards with 5 in. Footing
Test No.:
Test Date:
Location (mm)
Camera View
X
Y
Z
1
Real Time (Panning)
10288 -20422 -2438
2
Real Time (Driver's Side) -305
3
Real Time (Left Front 3/4 18288 -3658
-20422 -2438
-914
Angle
(Deg.)
Film
Plane to
Head
Lens
(mm)
Speed
(fps)
-4
N/A
N/A
30
-4
N/A
N/A
30
0
N/A
N/A
30
High Speed Digital Color
0
-12802 -914
0
(Driver's Side)
High Speed Digital Color
5
-152
152
-5791
-90
(Overhead)
High Speed Digital Color
6
-14935 -14935 -1524
-10
(Left Front 3/4)
High Speed Digital Color
7
-57912
0
-2438
-10
(Front)
All camera measurements were made relative to the point of impact.
4
10
P25039-02
4/4/05
N/A
50 mm 1000
N/A
24 mm 1000
N/A
85 mm 1000
N/A
17-102 1000
TR-P25039-02-NC
APPENDIX A
PHOTOGRAPHS
A
TR-P25039-02-NC
FIGURE 1. Test Article as Received
FIGURE 2. Right Front View at Test Article
A-1
TR-P25039-02-NC
FIGURE 3. Anti-Ram Bollard 5 Inch Footing
FIGURE 4. Bollard 10 Inch Diameter and 1 inch Wall Thickness
A-2
TR-P25039-02-NC
FIGURE 5. Bollard Foundation Module Front View and Re-bar
FIGURE 6. Bollard Foundation Module Rear View
A-3
TR-P25039-02-NC
FIGURE 7. Excavation
FIGURE 8. Embedment Depth
A-4
TR-P25039-02-NC
FIGURE 9. Test Article Positioned in Place
FIGURE 10. Test Article During Installation
A-5
TR-P25039-02-NC
FIGURE 11. Test Article During Installation
FIGURE 12. Test Article During Installation
A-6
TR-P25039-02-NC
FIGURE 13. Test Article Left Side View
FIGURE 14. Test Article Left Front ¾ View
A-7
TR-P25039-02-NC
FIGURE 15. Test Article Front View
FIGURE 16. Test Set-Up
A-8
TR-P25039-02-NC
FIGURE 17. Test Set-Up
FIGURE 18. Test Set-Up
A-9
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FIGURE 19. Test Set-Up
FIGURE 20. Test Set-Up
A-10
TR-P25039-02-NC
FIGURE 21. Test Set-Up
FIGURE 22. Test Set-Up
A-11
TR-P25039-02-NC
FIGURE 23. Test Article Orientation to Front Bumper
FIGURE 24. Test Article Orientation to Front Bumper
A-12
TR-P25039-02-NC
FIGURE 25. Test Set-Up
FIGURE 26. Ballast
A-13
TR-P25039-02-NC
FIGURE 27. Post-Test Left Side View
FIGURE 28. Post-Test Left Side View Close-Up
A-14
TR-P25039-02-NC
FIGURE 29. Post-Test Front View
FIGURE 30. Post-Test Overhead View
A-15
TR-P25039-02-NC
FIGURE 31. Post-Test Test Article Front View
FIGURE 32. Post-Test Test Article Left Side View
A-16
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FIGURE 33. Post-Test Test Article Left Side View
FIGURE 34. Center Bollard Deflection
A-17
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FIGURE 35. Ballast
FIGURE 36. Action Sequence 1
A-18
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FIGURE 37. Action Sequence 2
FIGURE 38. Action Sequence 3
A-19
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FIGURE 39. Action Sequence 4
A-20
TR-P25039-02-NC
APPENDIX B
DATA PLOTS
B
TR-P25039-02-NC
Test Vehicle:
15,000 lb Truck
Test Date:
Test Program:
RSA Bollards with 5 in. Footing
Project No.:
4/4/05
P25039-02
20
10
G's
0
-10
-20
-30
-40
-100
0
100
200
300
400
Curve Description
Vehicle Rear Frame Rail X
CURNO
Type
SAE Class
001
FIL
60
Max
Time
Min
19.4
43.4
-33.5
Units
G's
Time
54.6
Curve Description
Vehicle Rear Frame Rail Y
CURNO
Type
SAE Class
002
FIL
60
Max
Time
Min
37.1
65.4
-35.3
Units
G's
Time
73.2
Curve Description
Vehicle Rear Frame Rail Z
CURNO
Type
SAE Class
003
FIL
60
Max
Time
Min
27.6
99.2
-21.9
Units
G's
Time
93.1
Curve Description
Vehicle Rear Frame Rail Resultant
CURNO
Type
SAE Class
001
RES
60
Max
Time
Min
41.5
72.9
0.2
Units
G's
Time
459.1
500
Time - Milliseconds
40
G's
20
0
-20
-40
-100
0
100
200
300
400
500
Time - Milliseconds
30
20
G's
10
0
-10
-20
-30
-100
0
100
200
300
400
500
Time - Milliseconds
50
40
G's
30
20
10
0
-10
-100
0
100
200
300
400
500
Time - Milliseconds
B-1
TR-P25039-02-NC
Test Vehicle:
15,000 lb Truck
Test Date:
Test Program:
RSA Bollards with 5 in. Footing
Project No.:
4/4/05
P25039-02
40
30
Curve Description
Vehicle Rear Frame Rail X Velocity
CURNO
Type
SAE Class
001
IN1
180
Max
Time
Min
32.3
2.5
-1.4
MPH
20
10
0
-10
-100
0
100
200
300
400
Units
MPH
Time
438.8
500
Time - Milliseconds
75
Inches
50
Curve Description
Vehicle Rear Frame Rail X Displacement
CURNO
Type
SAE Class
Units
001
IN2
180
Inches
Max
Time
Min
Time
61.5
245.6
0.0
0.0
25
0
-25
-50
-100
0
100
200
300
400
500
Time - Milliseconds
B-2
TR-P25039-02-NC
APPENDIX C
INSTRUMENTATION LIST
C
TR-P25039-02-NC
RSA Bollards with 5 in. Footing
Instrumentation Data Channel Assignments
4/4/05
15,000 lb Truck
CH.
LOCATION
AXIS
IDENT. NO.
DESCRIPTION
MFR
MODEL
UNITS
1
Rear Frame Rail
X
MDASX
Accel., Vehicle block
I.C.Sensor
3031-100
G
2
Rear Frame Rail
Y
MDASY
Accel., Vehicle block
I.C. Sensor
3031-100
G
3
Rear Frame Rail
Z
MDASZ
Accel., Vehicle block
I.C. Sensor
3031-100
G
C-1
TR-P25039-02-NC
APPENDIX D
MANUFACTURERS DRAWINGS
D
TR-P25039-02-NC