A30032.3 Manual Bollard (Series DSC700M Counterweighted) Installation.pdf

Copyright 2007 Delta Scientific Corporation Document A30032.3 All Rights Reserved Page 1 of 9

MECHANICAL INSTALLATION INSTRUCTIONS

DELTA DSC700 SERIES MANUAL COUNTERWEIGHTED

BOLLARD SYSTEMS

ONLY QUALIFIED AND TRAINED PERSONNEL SHOULD OPERATE OR

ATTEMPT TO WORK ON THIS SYSTEM.

IF THERE ARE ANY DOUBTS OR THERE ARE ANY QUESTIONS ABOUT

OPERATING, REPAIRING OR MAINTAINING THIS UNIT, CONSULT THE

INSTRUCTIONS MANUAL OR CONTACT DELTA SCIENTIFIC CORPORATION

DIRECTLY.

Safety Precautions

At all times observe good safety practices when working on either the electrical or mechanical systems. Particular attention should be paid to the danger of working on the Bollards when the power is on, electric shock can occur. Keep body parts and hands free of the Bollard tube when operating the latch mechanism. Traffic should be controlled around the Bollards during any work so that personnel are not in danger of being struck by a vehicle while their attention is on the Bollard.

Foundation

The Bollard foundation tubes are to be cast in place. The outside of the Bollard foundation tube is the form; no additional flashing or forming should be necessary.

The excavation for the foundation tubes can be individual for each Bollard in a set or the foundation can be common for all Bollards. We recommend the common foundation as providing the strongest barrier system. See the appropriate foundation drawing in the Drawing Section of the manual. The foundations shown on Delta drawings, unless specially noted, are designed on a soil load-bearing factor of 1.5 tons/ft². Only a very boggy or migrating site would necessitate additional foundation design requirements. Care should be taken to mount the Bollards in an area that is not subject to flooding. Additionally, the roadway should be crowned in the area of the Bollards to prevent standing water from draining into the Bollard foundation tubes.

The Bollards need to be installed level or plumb to operate properly. If the roadway is not level, and can not be sloped to match the Bollard, then the Bollards may need to have special ground plates made to match the contour. The factory can work with the contractor during the procurement stage to work out any problems in this regard.

The Bollards can be secured in the foundation by leveling with concrete blocks, or held to temporary wooden frames in order to hold a group in alignment during the pour.

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Drainage

Drainage and protection against subsurface water is important. A bed of aggregate under the Bollard(s) will handle rainwater in most circumstances. Especially wet locations should have the Bollard drain line plumbed to a sump well or sewer as appropriate. Three 1 1/2" NPT (female) connections are provided on the bottom plates for drainage purposes. Perforated tail pipes of at least 12 inches [30 cm] length should extend into the aggregate for proper drainage.

While the machine is designed for harsh environments, prolonged submersion will eventually cause both appearance and operating deterioration.

Corrosion

Occasionally a site is both wet and unfriendly, i.e., either highly acidic or basic. In these cases, anodic protection is recommended. Delta will be happy to review specific job locations and make suitable recommendations where such protection is needed.

Interconnect

Provisions for the optional electric devices (limit switches and/or heaters) should be made prior to pouring the foundation of the Bollards. The limit switch and/or Bollard heater conduits are located on the front of the access box. Run rigid metallic conduit or equal. Be sure that appropriate fittings are used that will allow wire to be pulled. It is too late to correct this error after the concrete is poured! Do not run the heater wires with the limit switches. These are at different voltages and the operation of the heaters could cause false signals on the limit switch circuit.

Packaging

Before attempting to operate the Bollard for the first time, remove the retaining bolts for the counterweight sets. The counterweights serve no purpose if these bolts are in place, and approximately 750 pounds will be required to raise the Bollard to the guard position. The counterweight retaining bolts may be left in place up until the time of first operation and may be kept for future use.

Heating

Cold climate installations require the use of heaters to eliminate the possibility of snow or ice blocking the Bollard mechanism. The Bollards themselves will require heaters rated at 200 watts.

The Bollard heater installation is simple, with the elements contained in an easily accessible pouch in the Bollard foundation tube.

Delta strongly recommends that the entire roadway in the immediate vicinity of the Bollards be heat traced. This is to minimize the chance that a vehicle could lose control or traction in front of the Bollards. Also, in many cases, guard and/or inspection personnel will need to work on a vehicle in front of the Bollards. The heat tracing will reduce the personnel dangers of working on snow and ice.

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Roadways containing Bollards cannot be plowed. The snow plows will shear top plate bolts and damage inspection covers. Only hand clear snow around the Bollards. Snow removing chemicals such as salt should also not be used around the Bollards as the corrosion of the steel components will be greatly accelerated.

Drainage provisions in Bollards subject to freezing will also need some consideration. Heat tracing of the drain lines and/or sump well heaters may be needed to help remove the melted snow and ice from the Bollard foundations.

Concrete Notes and Specifications (minimum requirements)

1) Contractor shall verify and be responsible for all dimensions and conditions at the job site.

2) Foundation concrete may be placed directly into neat excavations, provided the sides of the excavation are stable. Where caving occurs, provide shoring. Type and method of shoring shall be at the contractor's option.

3) The excavation shall be kept dry at all times. Groundwater, if encountered, shall be pumped from the excavation.

4) Concrete shall be laboratory designed, machine mixed, producing 3,000 psi [20,68 Mpa] at

28 days.

5) Cement shall be tested Portland cement conforming to ASTM C150, Type I or II.

6) Aggregates shall conform to ASTM C33. Maximum size of aggregate shall be 1.5 inch [38 mm].

7) Reinforcing steel shall be deformed bars conforming to ASTM A615, Grade 60 (60,000 psi

[413,7 Mpa]).

8) Hooks and bends shall conform to AIC standard 318, latest revision. Inside diameter of hooks and bends shall be at least 6 bar diameters.

9) Provide spacer bars, chairs, spreaders, blocks, etc, as required to positively hold the steel in place. All dowels shall be firmly wired in place before concrete is poured.

10) Concrete shall be conveyed from the mixer to final deposit by methods that will prevent separation or loss of materials. Troughs, buckets or the like may be used to convey concrete. In no case shall concrete be allowed to free drop more than 5 feet [1,5 M].

11) Concrete shall be thoroughly consolidated by suitable means during placement and shall be thoroughly worked around reinforcement and embedded fixtures and into corners of forms.

12) Concrete shall be maintained above 50F (10C) and in a moist condition for at least 7 days after placement. Adequate equipment shall be provided for heating concrete materials and protecting concrete during freezing or near freezing weather.

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13) Where exterior wall face requires shoring and/or forming, the forms shall be substantial and sufficiently tight to prevent leakage. Forms shall not be removed until the concrete is 7 days old.

14) Backfilling shall be done by depositing and tamping into place clean sand or pouring lean concrete. Water jetting shall not be allowed.

15) Conduits and pipes of aluminum shall not be embedded in concrete unless effectively coated or covered to prevent aluminum/concrete reaction or electrolytic action between aluminum and steel.

16) Construction joints not indicated on the drawings shall not be allowed. Where a construction joint is to be made, the surface of concrete shall be thoroughly cleaned and all laitance and standing water removed.

17) Contractor shall be responsible for the protection of all adjacent areas against damage and shall repair or patch all damaged areas to match existing improvements.

18) Contractor shall keep the construction area clean at all times and at completion of work remove all surplus materials, equipment and debris and leave the premises in a clean condition acceptable to the owner or owner's representative.

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Bollard Disassembly, Service and Assembly

ONLY QUALIFIED AND TRAINED PERSONNEL SHOULD OPERATE OR

ATTEMPT TO WORK ON THIS SYSTEM.

IF THERE ARE ANY DOUBTS OR THERE ARE ANY QUESTIONS ABOUT

OPERATING, REPAIRING OR MAINTAINING THIS UNIT, CONSULT THE

INSTRUCTIONS MANUAL OR CONTACT DELTA SCIENTIFIC CORPORATION

DIRECTLY.

The Bollard assembly is designed to facilitate easy repair and maintenance. Depending on the environmental conditions, we recommend at least a one-month interval of inspection to confirm that no debris, sand or dirt is accumulated inside the Bollard that would interfere with its operation. This can be accomplished by removing the access box cover plates and checking in the counterweight tubes and around the Bollard tube. During the inspection, also examine the Bollard parts for any corrosion damage that might interfere with good operation of the unit.

If it is discovered during this inspection period that there appears to be excessive buildup of dirt and debris within the ground tubes, then it is recommended that the following procedure for removing the Bollard and/or counterweights be followed:

1) The DSC700 Series Counterweighted Bollards have two counterweight tubes and two access boxes. Remove the access box cover plates.

2) Verify that the locking pin is forward and engaged with the Bollard tube so that the tube may not rise as weight is removed from it. The counterweights have slightly less mass than the fully assembled Bollard tube so that it will tend to sink rather than rise.

However, as the Bollard lid and optional casting are removed, the counterweights become slightly more massive than the Bollard and tend to pull it upward.

3) Remove the cable guards from the top of the sheave assemblies by removing the two screws (2) on the side of each of the brackets.

4) Remove the Bollard cap. The optional aluminum casting cap weighs approximately 14 pounds and the steel lid weighs approximately 31 pounds. Removing the cap will significantly reduce the weight of the Bollard tube, and it may begin to rise as the cap is lifted off if the lock pin is not engaged.

5) Reach inside the Bollard tube and remove the ½”-13NC nut holding the stop plate to the stop rod. Carefully remove the nut and stop plate from within the Bollard and set aside.

6) Insert two ½”-13NC eyebolts in two of the angle brackets at the top of the Bollard to attach a sling for removing the Bollard. Choose two angle brackets located directly across from each other rather than two that are adjacent to each other.

7) Place a sling, or hooks attached to a sling, in the eyebolts and prepare to remove the

Bollard.

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8) Disengage the locking pin from the Bollard tube so that it cannot interfere with the removal of the Bollard assembly. Lift the Bollard tube straight up. The DSC700 series Bollard assembly weighs approximately 655 pounds. The optional aluminum casting adds approximately 62 pounds to this. The Bollard may move upward without assistance, but its movement must be controlled since the stop plate has been removed.

9) When the Bollard tube has reached approximately the normal raised position, carefully raise the tube to add slack to the 1/4" cables.

10) Remove the mounting bolts from the sheave/latch assemblies and move them away from the Bollard tube.

11) The clevis ends that connect the cables to the Bollard tube should now be visible through the access hole in the side of the ground tube.

12) Carefully disconnect the counterweight cables from the Bollard tube.

13) Continue to lift the Bollard out of the ground tube but do not attempt to fully remove the

Bollard tube until the counterweight cables have been disconnected. Set the Bollard tube aside. The optional aluminum casting may now be removed.

14) Remove the sheave/latch assemblies from the access boxes. Remove the padlock hasp from the side of the access box. This tab must be removed before attempting to lift the counterweights from their tube.

15) Using the ¼” cables, lift the counterweights from within their guide tubes, and set aside.

DSC700 series counterweights weigh approximately 353 pounds each. If necessary, a backup hooking location has been added to the top of the counterweights so they may be lifted without using the ¼” cable.

16) Reach inside foundation tube and lift out the basket assembly.

17) The foundation tubes can now be inspected and vacuumed of debris and the drains can be cleaned as required.

18) Inspect the stainless steel cables for kinks, fraying, or other signs of weakness. Replace the cables if any of these conditions exist.

19) Inspect the sheaves for freedom of operation. The bearings are sealed and should not require any lubrication. However, clean around the bearings and shafts and spray with a good silicone lubricant. This will help repel water and maintain free operation. If the sheaves do not operate freely, replacements may be obtained from Delta Scientific Corp.

20) Before reassembly, any rust or other corrosion should be removed and the area coated with sealer or rust inhibiting paint.

21) When all is well, replace parts in reverse order. Keep the lock pin mechanism well lubricated.

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Manual Bollard Operation

It is assumed that the Bollards will remain fully raised and locked at all times and will be unlocked and lowered on occasion to permit the passage of vehicles. After the vehicle(s) are clear, the Bollard will again be raised to the guard position, the Bollard locked and the access cover replaced to prevent unauthorized entry. To operate (from raised and locked position):

LOWERING

1) Remove the access box cover plate containing the latch and remove the padlock from the locking pin.

2) Pull back the locking pin. The Bollard may need to be moved slightly and held if it is resting on or otherwise preventing movement of the locking pin.

3) The Bollard is counterweighted and by design is slightly heavier than the attached weights.

Therefore, the Bollard may have a tendency to begin moving when released. Care should be taken to keep hands and feet clear of any of the moving parts to prevent injury.

4) The Bollard can now be pushed down until it comes to rest in the bottom of the foundation tube.

5) Push the locking pin forward into its locking hole in the Bollard and reinstall the padlock.

Secure the access box cover plate to prevent any unauthorized operation of the Bollard.

RAISING

1) Remove the access box cover plate containing the latch and remove the padlock from the locking pin.

2) Pull back the locking pin. The Bollard may need to be moved slightly and held if it is resting on or otherwise preventing movement of the locking pin.

3) The Bollard is heavier, by design, than the counterweights and should not move. However, use caution and keep hands and feet clear of any of the moving parts to prevent injury.

4) Using the lifting handle in the Bollard cap, begin to pull up on the Bollard. Pull upward until the Bollard is in the full up position. The Bollard will tend to stay in any position in which it is placed. However, because the Bollard is designed to be slightly heavier than the weights, it may have a tendency to drift downward. It is important to keep hands, feet and body parts away from the path of the Bollard. If the Bollard were to move upward or downward when you are not prepared, an injury could occur.

5) Push the locking pin forward to lock the Bollard in the up position. Replace the padlock and the access cover to again secure the entrance.

(Should the locking pin not move easily into position at either the full up or down position, clean the pin mechanism and lubricate with a good general purpose grease.)

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MAINTENANCE SCHEDULE

FIRST WEEK

Check operation of the Bollards at least once daily. Have the guards or operators report if Bollards fail to operate, or operate with a jerky motion. It is recommended that someone be on call who can explain the operation of the Bollard system to each new guard or operator.

Daily Check

1) Check operation for smooth raising and lowering and that no excessive force is required while moving the Bollards.

2) Check that the Bollards do not drag on the frame or top plates and that the finish is not being scrapped.

3) Check that all fasteners are secure. Tighten where necessary.

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MAINTENANCE SCHEDULE

MONTHLY

Check and service the following at monthly service intervals:

Note: Block traffic during maintenance to prevent accidents. See Bollard disassembly instructions should anything need repair.

1) Check operation for smooth raising and lowering and that no excessive force is required while moving the Bollards.

2) Check that the Bollards do not drag on the frame or top plates and that the finish is not being scrapped.

3) Remove Bollard top cover plate and check that water has not and is not accumulating in the foundation tubes. Clear drain if necessary.

4) Clear debris and silt from the foundation tubes. A wet/dry shop vacuum with a rigid extension wands at least 60 inches [1.5 M] long is useful for this task.

5) Check the Bollard finish. Any rusting or other corrosion should be attended to immediately.

6) Check that all fasteners are secure. Tighten where necessary.