New safety barrier solutions protect road users

Novel safety barrier solutions are coming to market, writes Mike Woof

The safety barrier market is a focus for innovative products designed to meet a range of different applications. The diverse range of vehicle types on the road poses numerous technical challenges to barrier manufacturers. At the same time, different applications such as motorcycle safety, end treatments, bridge barriers and roadside obstacle protection require novel solutions.

Although motorcycles account for only a small proportion of vehicles on the roads, they feature a high risk factor for riders. Accident data in Europe shows that most motorcycle accidents are not the fault of the rider, with other road users being the highest cause of accidents. However motorcyclists also suffer injuries and fatalities from roads that have been designed around road users in passenger cars, buses or trucks. A notable issue is with many conventional safety barriers as these are designed to protect road users sitting inside a vehicle. Work is being carried out on tackling this problem, but progress is only being made slowly at a pan-European level.

The French test laboratory 2905 LIER is now developing novel solutions for analysing the results of crash testing. One of the key projects being worked on is a new testing procedure that will become part of a new European standard for motorcyclist protection. This will offer a comprehensive solution for system testing once the new standard is added to the existing EN1317 requirement. The new safety specification is intended to protect fallen motorcyclists from striking the support posts of conventional steel barriers, which can result in major injuries or death.

However delays to the introduction of this new specification have arisen from extended discussions over technical parameters. The Federation of European Motorcycle Associations (2906 Fema) has even accused some parties of introducing delaying tactics. In the mean time only Spain has a written specification for protecting motorcyclists, with the result that many riders are still being needlessly killed or seriously injured in barrier impact accidents across Europe.

Ironically, much of the technology needed already exists. Because of the more far-sighted approach to safety by the Spanish authorities, a range of systems have already been developed to help protect motorcyclists with new products also coming to market. One of the latest is a new steel motorcycle safe barrier product from 272 Marcegaglia that is made of galvanised steel and offers the benefits of durability, longevity and versatility. The system is universal and export area manager, Stefano Caviglioli said, "It can be fitted to almost any steel guard rail barrier as long as there is no more than 4m between the posts as the rail sections are 4m long." He added, "It is very easy to install." This system has been developed primarily for the Spanish market although the firm says it also hopes to market the units in other parts of Europe, particularly Belgium and Italy where there is already a recognised need for such products.

Other firms with existing products intended to boost barrier safety for motorcycle riders include 238 Industrias Duero and 333 Snoline and these units have been installed on an array of Spanish roads, as well as other European roads.

Safety technology is at a much greater state of development for more conventional vehicle occupant protection measures, with some truly innovative designs having been produced. One of the most original concepts comes from South Korean supplier 223 GSI, which is looking to expand its market for its innovative roller safety barriers. The firm is looking to gain European approval for the highly durable and effective patented roller barrier system and is in discussion with two key European testing and approval agencies at present. The firm intends to award a contract for barrier testing to the winning bidder so that it can then gain the necessary EN1317 rating. The GSI barriers feature plastic rollers made from a patented material grade that is precisely specified to be shock absorbing and durable. These also feature high visibility reflective material for conspicuity, while the roller barrier itself is patented.

Modular design can help reduce costs to the install in conventional roadside barriers and this is a feature 2848 Fracasso has worked on with its versatile new range. Called the 4safe system, this is based on a common architecture approach and offers easy assembly and installation, helping to cut costs for the client. Common components are used for all barrier configurations, reducing storage needs and cutting confusion during installation. Area export manager Elvis Dobro said, "The components are the same and the impact rating depends on the distance between the poles." Tested to the EN1317 requirements, the 4safe systems can be suited to an array of installations, depending on the requirements needed and by using the components appropriately to the conditions. According to the firm this long-life, galvanised system also offers good shock absorbing capabilities and is also highly versatile as it can be configured to suit an array of installation requirements.

In the end treatment sector, 165 Barrier Systems and Snoline are developing a combined safety barrier range, now that they are both owned by US firm 2438 Lindsay Manufacturing. Based on their joint product and marketing partnership, Snoline plans to launch a new barrier end treatment for the European market that has been developed from the proven Barrier Systems product for the US.


On the US market version, the cables help redirect the vehicle but on the new European model developed by Snoline, the cables are used to absorb the impact forces. With the US vehicle fleet including a much higher proportion of SUVs that are heavier and have a higher centre of gravity than the smaller, lower and lighter passenger cars that predominate on European roads, barrier designs and specifications have been tuned to meet vehicle trends. Chiara Luini, director of marketing at Snoline explained that to meet the European requirements the unit now has an additional cable retention feature. Steel guides are used to hold the cables in place and she added, "Redirection is made by the lateral barrier." She said that while the concept of this barrier is comparatively simple it offers an effective safety solution. "We are going to test it in the next few months but we've already carried out computer simulations and the results are good," she said, adding that full European approval is expected in the next few months.

Other new end treatments are also being introduced by rival firms. 315 Energy Absorption has developed the Terminus CEN end terminal unit, which meets the European ENV 1317-4 specification as a P4 terminal for 110km/h impacts and is designed for use with W-beam safety barriers. This unit features innovative steel breakaway posts. The lower posts have U-sections and are driven into the ground while the upper posts also have U-sections. This design allows the upper posts to slide into the lower units and the assembly can then be secured in place. Clamping forces between the rails and deformation of the rail sections provide the necessary energy absorption in the event of an impact. Easy to transport, this end terminal weighs just 400kg and can be carried to site on a standard pallet using a small utility machine. Installation takes just two hours using a crew of three equipped with standard tools.

And Marcegaglia has developed the improved P4 improved energy absorbing terminal and this has been designed for easy installation. This is available in H2, H3 or H4 ratings and is based on a modular design approach using common components but different posts depending on the impact rating required.


Bridge barriers offer further challenges and a high performance system is now coming to market from Spanish specialist Industrias Duero. The H3 rated bridge parapet structure has been designed to cope with impacts from large trucks and coaches as well as passenger cars and meets the relevant EN1317 specification in this category. Twin innovations allow the novel two part barrier to be used to boost safety in an array of bridge applications and installations.

Area manager Zoubeida Foughali explained that one development is the use of bolts designed to absorb some of the forces when a large vehicle impacts with the structure and to then shear off, without damaging the bridge. She said, "The forces are not transferred to the concrete structure. The bridge has reduced maintenance needs in case of an accident as you only need to change the bolts and the two part barrier." According to international manager for the firm Fernando Montesinos this specification is of particular importance for the Spanish, Portuguese and French markets where there is a requirement to minimise damage to a bridge structure in the event of an impact. He explained that where repairs are carried, they will never be as strong as the original structure so these countries have established a specification intended to minimise damage and prevent any weakening.

While able to withstand impacts from large vehicles such as trucks and coaches, this two part barrier also features a lower rail designed for passenger vehicle retention. The lower rail projects forward slightly from the two upper rails and features a spacer designed to absorb the impact from lighter passenger cars, while the two upper rails are set back and retain heavy vehicles.

Temporary barriers have to be used on some sections of road, whether to delineate workzone areas, road closures or special events for example. A novel temporary barrier system has been developed by Spanish firm 2909 Cegasa. This stackable plastic barrier system is lightweight and durable and can be used in an array of roadside applications such as workzones, parking areas or temporary works for example for delineation purposes. Luis Moreno, international commercial director at Cegasa said, "You can carry 3km worth on one truck," and he explained that this significantly cuts transport costs for the user.

The units are hinged and can be folded open for stacking or closed and locked in place for use at the roadside. Once in place the sections can be filled with either sand or water to make them more stable. The barrier units are offered in red or white plastic as standard although other colours are available on request.

Border Barrier Systems is continuing to develop the market for its Rhino water-filled barrier units, with the standard products tested to vehicle impacts of 50km/h and the high specification units tested to 80km/h. All of the Border Barrier Systems units are made from plastic, making them lighter and easier to transport than conventional steel or concrete units, as well as increasing safety in a range of applications. The company also points out that its various units can also be interlinked where necessary between different model types. Meanwhile the new Klik Panel sections can be fitted on top of the new self-weighted units as well as the proven Rhino barriers. The Klik Panel units can be used to screen off construction sites and are lighter and more resistant to damage than conventional steel sheets. Because the Rhino barriers are so much lighter than conventional products, this reduces transport and handling costs considerably and also increases safety when handling on-site.

Meanwhile Snoline now offers a temporary roundabout called the Giro, which comes in polyurethane sections and is suitable for use in roadworks or diversions. And Snoline also has a novel crash cushion product made from plastic that can be placed around roadside obstacles such as trees in noted danger spots, reducing impact forces in the event of an accident.