Testing Authority National Automotive Test Tracks Test Request No.: Test Report No.: NTX/CRN/2022-2023/12 NTX/CBT/2022-2023 B11 - CRASH TEST REPORT (Standard No. EN 1317-1:2010 & EN 1317-2:2010) Name of Test Item Thrie-Beam Metal Crash Barrier Date of Test Date of Report 05/03/2023 22/03/2023Table of Contents Page No. 1 Test Laboratory 3 2 Client 4 3 Test item 5 4 ‘Test Procedure | 41 Test type 6 42 | Testarea 6 4.3 Installation and description of test item 9 44 Description of test vehicle qd 5 Results 5.1 Test condition 13 5.2 E Test item 15 5.3 Test vehicle 19 5.4 Assessment of the impact severity 2 6 General statements 26 id Approval of report 27 8 Annexes 8.A | Manufacturer Drawings & Installation Manual 8.A.1 | Manufacturer Drawings of the test item 28 8.A.2 | Installation Manual of the test item 34 8B Photographs 41 8c Video records 55Test Laboratory 11 | Name National Automotive Test Tracks (NATRAX) Madhavpur, Sagore-Manpur road, Gram oH | Panchayat - Khandawa aoe eaarees District — Dhar, Pithampur (Near Indore) Madhya Pradesh - 454774 07292-256110 1.3 | Telephone number | 97 35o soesog 1.4 | Internet address www-natrax.in 15 | Test site location | General Road near Gradient (14) Track | NABL (National Accreditation Board for | Name and address | Testing and Calibration Laboratories). Le | of bodywhich “© | accredited the test. | & laboratory NAB (National Automotive Board).3 Test Item 31 Name of test item ‘Thrie-beam Metal Crash Barrier | ] 3.2 Date of installation 03/03/2023 3.3 Date of test 05/03/2023 3.4 ‘Test number NAT/CBT/22-23/078 Additional information 3.5 For drawings of test item, see appendix 8.A.1 For Installation Manual of test item, See appendix 8.A.24 Test Procedure | 4.4 | Test type (According to EN 1317-2:2010, Table 1, page 7) 4.1.1 | Type of impact test TB11 Additional information Target impact speed (+7% ,-0%) 100 Km/h 4.1.2 Target impact angle (+1.5°, -1°) 20 deg ‘Target test weight of the vehicle (+40 kg) 900 kg 4.2 | Test Area Description of type and condition of test area 421" qhe road barrier was installed on soil at the general road near Gradient (T4)Track. | J4.2.2. Sketch of vehicle approach indicating impact point Installation Tyee Tas Direction Natfonal Automotive Test Tracks {(NATRAX), India (wrw.natrax.in)) Page 7 0f 58,Additional information Camera Positions: Where the product is a vehicle parapet, the 4.2.3 | distance between the traffic face of the parapet| Not Applicable and the bridge deck edge | ‘Type of underground 4.2.4 | Filling with murrum from 1 m to 2.5 m. Below crust there is 650mm (Sub-grade + GSB) & total crust thickness is 740 mm with following: | (Subgrade 200 mm, GSB 340 mm, murrum shoulder 200 mm) Class/Condition of underground: 4.2.8 | Type of soil: Murrum (Granular soil) of 15% CBR. Condition of the terrain:Degree of compaction 95%4.3 | Installation and detailed description of test item a Conformity between the test item drawings va : and item tested 4.3.2 | Conformity between installation manual ae and item installed 4.3.3 | Description of the Vehicle Restrain System (VRS) tested Ground fixing details 4.3.3.1 | the posts of the road safety system was driven into the murrum (granular) soil 4.9.3.9 __Total lenath of middle section in metres 80m uw" | Total length of end terminals 12m (6m+6m) | 43.3.8 | Height of the test item in the impact area | 1030 mm | Post spacing and/or unit length in metres 4.3.3.4 |" Middle Beam Section [ 2m End Beam Section I 2m | Where the product is pretensioned, the me | 4.3.3.5 | value(s) of the tension(s) shall be | Not Applicable indicated4.4.8.2 ATD mass Not Applicable 4.4.8.3 | ATD position in vehicle Not Applicable | 4.4.9 Total test mass in kilograms (kg) | 886.2 kg | 4.4.10 | Dimensions and characteristics of vehicle 4.4.10.1 | Total vehicle length 3.54 m 4.4.10.2 | Total vehicle ia (excluding side mirrors) 1.6m Hide Wheel track 1.39 m 4.4.10.4 | Number of axles 1st1 4.4.10.5 | Wheel radius 0.28 m 4.4.10.6 Wheel base 2.38 m 4.4.10.7 | Height of platform, for HGVs only NR Additional information 4.4.11 | Tyres Size: 155/70 R13 79T Ground clearance of the front bumper: 0.2 m For photographs of the test vehicle, see appendix 8.B.25 Results 5.1 Test conditions Bia Actual impact speed in kilometres per hour 1008 woah (km/h) 8.1.2 % difference from nominal speed +2% 5.1.3 Actual impact angle in degrees 19 deg 8.14 Difference from nominal angle in degrees -1 deg TEST TOL TESTNO.: NATICBT/22.25/078_SPEED: 102 km/h__—_—=ANGLE: 19" —_TESTATE: 05 Mar23 Tolerance Envelop 2 as 1 ; os 2 i ot 7 aoe on 1% ™ 7% 1” * * % 03 a | | as seep5.1.5 General description of test sequence The test took place on the testing ground of NATRAX Pithampur. The system was installed on surfaced and unpaved ground. The test vehicle impacted the system on 7th Beam at 14th post at a speed of 102 km/h. The vehicle remain in contact with the barrier for 6 m. Vehicle was successfully contained by the barrier and then redirected towards road side in an acceptable manner following the Vehicles exit box criteria, 5.1.6 Air temperature 34 5.1.7 Additional information The road way was dry during the test.5.2 Test Item 8.2.1 Dynamic deflection (Dj) in metres 0.6 m 5.2.2 Normalised dynamic deflection (Dx) in metres 0.62 = 5.2.3 Working width (Wx) in metres 0.7 m 5.2.4 Normalised working width (Wx) in metres 0.72 = 0.7 m 5.2.5 Class of normalised working width w2 5.2.6 | Vehicle intrusion (for HGVs and buses only) 5.2.6.1 Measured vehicle intrusion (VIn) in metres | NR 5.2.6.2 | Normalised vehicle intrusion (Vix) in metres | NR 5.2.6.3 | Class of normalised vehicle intrusion | NR | 5.2.7 Maximum permanent deflection in metres 027m 5.2.8 Lengths of contact in meters 6m | i : on Beam No. 7 5.2.9 Actual impact point location ce Secune ia 5.2.10 | The permanent displacement of the end a anchorage caused by the impact 5.2.11 | The permanent displacement in the joints of the a main rail or in connection elementsDeformation Calculation of Restraint System CALCULATION SHEET Undeformed width of the system. Wu 0.245, Measured working width in meters Wm 0.7 Specified impact angle in degrees py 20 Measured impact angle in degrees [ xn [19 Measured maximum Dynamic deflection in meters Dm 0.6 Specified total mass in kilograms Me 900 Measured total mass in kilograms Ma 886.2 Specified velocity inm/s vi 27.8 Measured velocity in m/s [ve [283 Measute vehicle intrusion in meters L Vie NR | M, + (Ve sinX,)? Pw =Dm* lw sina)? M, + (V;# sinX,)? Wa = Wo + |Win — Wa) * bar Un ® Sin Xm)? Mz * (Ve sinX,)? Mn * Um * SIN Xp)? Vin = Vin *Description of damage to test item including foundations, | 5.2.12 ground anchorages and fixings Permanent deflection Post No. D w 10 0 0 14 0.01 0.12 | fe Az, 9.03 0.14 1D; maximum permanent deflection (in meters) 13 0.07 | 0.17 ; maximum permanent Working width (in 14 0.23 0.34 meters) 5 0.27 0.38 15 0.23 0.33 16 [oan 0.20) | a7 0.04 0.15 | 18 0.02 0.13 | 19 [009 O11 | 20 oO oO 21 oO oO 22 oO oO 23 0 0 24 o | 0 5 0 0 26 0 o | 27 0 0 28 0 0 | 23 0 oO 30 0 0 eee, o | o [ Max 0.27 | 0.38 | Deflection GraphSafety barrier including parapet contained the | 5.2.18 | vest vehicle | ar 5.2.14. | Complete breakage of any principal longitudinal i elements of the test item Details of test item parts over the mass of 2 kg 5.2.15 | ‘tally detached No 15.1 | Identification NR 5.2.15.2 | Mass in kilograms (kg) NR Final location measured perpendicular to the 5.2.15.3 | iginal traffic face of the barrier Bd Elements of the safety barrier including parapet 5.2.16 | penetrated the passenger compartment of the No vehicle 5.2.17 | Deformations of and/or intrusions into the te passenger compartment5.3 | Test vehicle | | | General description of vehicle trajectory | | The vehicle travelling at a speed of 102 km/h impacted the barrier at 19 deg on the 7th beam at 14t* post and redirected in 5.3.1. | the lane of barrier. Upon impact, the barrier began to deflect and vehicle reamin in contact with the barrier for 6 m. Vehicle was | successfully contained by the barrier and then redirected towards road side in an acceptable manner. 5.3.2 Vehicle Cockpit Deformation Index (VCD1), fancuernt required for cars ST) Fy CED LN CiepLze)) a Vehicle Cockpit Measurements Parameters Before Crash I After Crash % Deformation a [1682 1659 02 b 1263 1263 00 c 1410 1408 O14 d 314 317 [ -1.0 e 3319 1323 03 | f 1244 1248 0.3 @ 1224 1225 “04 Description of the damage and deformation to the test vehicle eas * Deformed front left vehicle structure. 3. * Front Left Door deformed and stucked. | + Front Left suspention assembly ditached. + Front left wheel rim defromed. T 5.3.4 Description of any contact of the dummy head | " with part of the barrier | Not ApplicableImpact test acceptance criteria Actual impact speed and angle within tolerance Beso. limits? (Refer Clause 5.1) Yes Actual impact speed and angle combination within 53.6 the tolerance envelope. (Refer Clause 5.1) Yes During and after the impact, no more than one 5.3.7 wheel of the vehicle passes over the rearmost part Yes of the deformed system? 5.3.8 Vehicle rolls over during the test? No For tests with HGVs, more than 5 % of the mass of 5.3.9 the ballast becomes detached or spilt during the NR test up to the time when the vehicle comes to rest? 5.3.10 Vehicle within “exit box"? Yes | S = A+ Width of vehicle + 16% of Length of vehicle where A = 2.2 m S$-4.4m B= 10m For vehicle restraint systems to be mounted on bridges, retaining walls, or on other structures: Vehicle or tested item supported by any structure beyond the bridge deck edge? 5.3.11 Not Applicable5.4 | Assessment Of Impact Severity 5.4.1 | Graphs of linear accelerations and angular velocities: X Acceleration at CO Y Acceleration at CG |---~! Testiumber NaTicaTi92 cours + Test Atte THRIE BEAK ‘Tesi Vericle HYUNDAITTC | | rer Rass: 26829 Grose Maes 885 219 Inpaet Space 102 9 Impeet Angie 19 degrees Transverse Acceleration (g's) Timo (sec) SAE Class eo Fite |Z Acceleration at CG Test Nureer, NATICET =e 22078 ‘Testhrtoe THRIE Beat ‘Testvetice HYUNDAIIT0 ~ ert tans 8862 (Goss isso eee 1 : : raat Sees 102 in Impact Angie 19 aegroes “ay ara 33 eas oe a7 3 OF 70 ‘Time (see) — SAE Clase 60 Fiter Roll, Pitch and Yaw Rates Teot Nurber NATIOBTI22 28 Teste THAIS BEaNt Test Veticie BYUNDAIITO Inert Mase 235.19 Grose Woes 388215 Impact Speed 102 awh InoaetAnie: 1 dears Rates (degrees'sec) ‘Tme (sec) [=a = pick — You |Acceleration Severity Index, ASI (rounded to one 5.4.2 decimal place) 0.68 = 0.7 5.4.2.1 | Impact Severity Level (As per Table 3 of EN1317-2) A 5.4.2.2 | Graph of ASI versus time ASI urbe NATICBTI2- 25078 | TestVenle HYUNDAI /-}------4 Ines Ute E26 21g i (Sse mars aa6 2g) + act speea 302. -f----- neat Aree: 1 coprece Asi ‘Time (sec) ASL5.4.3 5.4.3.1 | Theoretical head impact velocity, THIV | ‘Time of flight of the theoretical head in milliseconds (ms) Figure A The notional impact surfaces inside the vehicle are assumed to be flat and perpendicular to the vehicle x and y axes (sce Figure A). The distances of such surfaces from the original head position (fail distances} shall be Dx and forward and Dy laterally on both sides. Ds= 0.6 m Dy=0.3m Dx Dy Figure - B From Figure B 123 ms2 + Dy? X = Dx? + Dy? X= VOGT +03 X= 0.67082 Approximate 0.7 m THIV= 20.4 Km/h = 5.7 m/s THIV- X/t where t, is time of flight t=X/THIV | t=0.7/5.7 123 ms | 5.4.3.2. | THIV in kilometres per hour (km/h) 206 General Statements 6.1 The test results in this report relate only to the VRS tested. G2! ‘This report may not be reproduced other than in full, except with : the prior written approval of the issuing laboratory.7 Approval of Report ma Signatures : ct Ge cof 72 (Joyanta Chakrabarty) Test Engineer - Incharge Technical Advisor 7.38 Annexes 8.4.2. | Installation Manual of the test item | ‘Methodology of installation of “Thrie” Metal Beam crash Barriers 1, Ensure the area has been inspected for underground hazards and ‘that suitable traffic control isin place. 2. Post locations ere marked ensuring any fixed object hazard to be protected is located outside the expected dynamic deflection of the barrier. 3. ‘The post in relation to the direction of trafficis orientated (Figure A). 4, Posts are driven directly into the ground and should be vertical. The post installation process shall not cause damage to the post, such that itreduces the effective operation of the safety barrier or its design life, of introduces sharp tearing edges, nor shall it cause damage to pavement. If the Ezy-HC-Carriage cannot freely move as it is attached to the post because of deformation of the post during installation, then ‘the post shall be replaced. The use of a vibrating post hammer will reduce deformation to the top of the post and install the post at @ controlled rate. 5. Posts are spaced at 2m from center to centei 6. The height of the Z-post above ground level is 1020mm. 7. The Ezy-HC-Carriage is attached to the face of the post. The Ezy-HC- Carriage will come to rest on the posit lug fabricated on the 2- post (Figure 8 and Figure C). 8. Rails are attached to the Ezy-HC-Carriage using the 16x30mm carriage bolts. The post bolts are identified by the socket recess located in the head of the bolt. The bolts are tightened to snug tight using a 10mm hex. key. 9. Rails are spliced together at every second post using M16x32mm mushroom head bolts and oversized nuts. There are 12 bolts required er splice connection. A pinch bar may be used to assist in the alignment of splice holes. The use of a driving pin to elongate the slots is NOT to be used since this may cause tearing of the rail at the slot location. The bolts are tightened to snug tight.Installation guidelines as shown in the attached sheets for installation of “Thrie” Metal Beam Crash Barriers in various site conditions are applied. However, it may change to suit actual site conditions. Stages of Work Marking the Run: Step-1 Unloading the Steel: Step-2 National Automotive Test Tracks (NATAAN), India (wow-natrax.in) Page 37 0f 56)7 | 8.B Photographs 8.B.1 | Photographs of the test item to be tested before the test National Automotive Test Tracks (NATRAX), India) (wwenatrax.in) Page 41 of 56)National|Automotive Test Tracks (NATRAX), India (wiv natran.in) Powe 45 of 56ATR 8. B.2 Photographs of the test vehicle before the test.8. B.4 Photographs of the test vehicle after the test. Sos Oy National Automotive Test Tracks (NATRAX)) India’ ay (war nateak.in) Page 510756QUATRE) 8. B.5 Sequences and additional photographsVideo records See the enclosed CDDISCLAIMER NATRAX issues Test Reports) Extension Reports/ Developmental Test Reports for vehicles/ engines/ gensets/ components/ parts) assemblies! Vehicle Restraint System etc. based on the documents produced and/or prototype / vehicle(s) or sample(s) submitted by the applicant end testing thereof NATRAX issues Test Reports/ Extension Reports! Developmental Test Reports in compliance to Motor Vehicle Act Central Motor Vehicle Rules/ Central Pollution Control Board rules and their 2 provisions as amended from time to time or any other statutory orders under which NATRAX is authorized, Other Rules/Acts are outside the purview/scope of the Test Reports/Extension Reports! Developmental Test Reports, Test(s) on prototype/ vehicle(s}/ sample(s) is/are carried out on the basis of standard procedures 3 a8 Notified under specific rules! requested by the applicant, Results of such tests are property of bearer of Test Reports/ Extension Reports / Developmental Test Reports, These results cannot be disclosed unless specifically ordered so by Government, Court, ete. 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