MASH _SBT_testing_draft SOW_8-20-26_SSN.pdf

1 BACKGROUND

The FHWA is seeking a qualified Contractor that demonstrates the capabilities, experience, and resources required to perform crash testing on safety hardware devices. FHWA is transitioning to the latest crash test criteria for road safety hardware. This means transitioning from the National Cooperative Highway Research Program (NCHRP) Report 350 Recommended Procedures for the Safety Performance Evaluation of Highway Features to the American Association of State Highway Transportation Officials (AASHTO) Manual for Assessing Safety Hardware (MASH) methods. The goal of this effort is to make off- National Highway System (NHS) roads and highways as safe as possible, in part by accelerating the move to newer crash test criteria for Steel- Backed Timber roadway safety hardware devices.

In 2018, 36,560 people died on our nation’s highways. Of those, an estimated 55-60% died on off- NHS roadways. More than 70% of the vehicles involved in these off-NHS fatal crashes were driving on rural, two-lane highways with posted speeds of 55 mph or less. A high percentage of these crashes are attributable to run off the road departures. Local governments, tribes and Federal Land Management Agencies (FLMA), the primary off-NHS owners, use combinations of road safety devices to prevent vehicles from colliding with dangerous obstacles such as trees, mountain sides, or traversing steep (non- recoverable) slopes or entering deep water.

The impact conditions of roadside safety hardware vary as a function of site and traffic characteristics. Local agencies, tribes and FLMAs are often faced with constrained right of way, the need for aesthetic design and limited view shed obstructions, difficult geometry, frequent access points, compatibility with non-motorized users and low maintenance budgets. The same vehicles that increased in size and bumper height on the NHS also use this system. Therefore, hardware crashworthiness is of upmost concern considering the high number of run off the road fatalities off the NHS and necessitates the need for MASH testing for hardware not typically used on the NHS.

MASH is an update to and supersedes NCHRP Report 350 for the purposes of evaluating new safety hardware devices. An implementation plan for MASH that was adopted jointly by AASHTO and FHWA states that highway safety hardware accepted prior to the adoption of MASH – using criteria contained in NCHRP Report 350 – may remain in place. However, on the NHS, only safety hardware evaluated using MASH will be allowed for new installations.

This project proposes to follow AASHTO 2016 MASH to crash test and document a Steel-Backed Timber roadway barrier, transition, and terminal common to the off- NHS system. This MASH testing will provide additional crashworthy alternative systems for local, federal, and tribal agencies and decrease occupant risk if they impact a device that meets current crash test standards.

Upon completion of successful crash testing of the three safety hardware devices the FHWA will share the MASH test results and the standard details with the transportation community.

2 OBJECTIVE

The goal of this project is to crash test and evaluate the impact performance of safety hardware devices used, or that will be used, off the NHS by Federal Land Management Agencies, counties and cities, and Tribal Nations when cost, maintenance and compatibility with the local setting is important. These tests are to determine that these safety hardware devices meet safety performance criteria set forth under MASH Test Level criteria.

3 SCOPE

The Contractor shall furnish all necessary labor, materials, facilities, and supervision to perform all technical, non-personal services necessary.

For each of the safety hardware devices identified in Table 1, the Contractor shall coordinate with an approved testing facility to at least fabricate the test safety hardware devices, procure test vehicle(s), conduct physical crash testing, and return the crash site to an acceptable condition to the testing facility.

The crash testing will be conducted following criteria from the AASHTO 2016 MASH. Upon completion of successful crash testing of each safety hardware device identified in Table 1, the Contractor will analyze results, and submit the findings to the Contracting Officer Representative

(COR).

The parameters of the tests must be provided in specific detail, such that the tests performed can be replicated, and the results of the crash tests will be accurate and reliable.

Standard Details are available at: https://flh.fhwa.dot.gov/resources/standard/.

https://flh.fhwa.dot.gov/resources/standard/

TABLE 1 – STEEL-BACKED TIMBER SYSTEM (SBT) TO BE EVALUATED

Device

Safety Hardware Device Description Standard

Detail Designation

MASH Crash Testing Needs

SBT

Guardrail

Steel-Backed Timber Guardrail Type A & Type B.

https://highways.dot.gov/federal-lands/std-drawings/Std617-60.pdf

The Type A configuration is to be tested.

Standard (Std) 617- 60

FEM, FEA, and Crash Testing Completed in Phase 1

Technical Evaluation for installation of Type B Phase 2

Terminal

TL-2 End Terminal for Steel-Backed Timber Guardrail.

https://highways.dot.gov/federal-lands/std-drawings/Std617-69.pdf

Std 617- 69

FEM and FEA were performed in Phase 1

FEM, FEA, and Crash Testing to be performed in Phase 2.

Transition

Steel-Backed Timber Guardrail TL-3 Transition to Straight or Curved-End Structure.

https://highways.dot.gov/federal-lands/std-drawings/Std617-67.pdf

Std 617-67

FEM, and FEA were completed in Phase 1

Crash Testing needs to be performed and completed in Phase 2

NOTE: The hyperlinks above in Table 1 include the detailed construction and installation drawings for each of the systems that are required to be investigated and design to be tested to meet MASH.

4 PERIOD OF PERFORMANCE –

Shall be thirty (30) months from the effective date.

5 DETAILED REQUIREMENTS

TASKS

Task 1 – Project Kick-off and Finalize the Testing Plans

Within five (5) days after award, the Contractor shall organize and host a virtual Project Kick-off meeting to introduce the Contractor’s team. The Contractor key personnel shall attend the meeting.

The contractor shall present a proposed plan for conducting this research effort. The FHWA Contracting Officer’s Representative (COR) and other FHWA technical staff will attend.

https://highways.dot.gov/federal-lands/std-drawings/Std617-60.pdf https://highways.dot.gov/federal-lands/std-drawings/Std617-60.pdf https://highways.dot.gov/federal-lands/std-drawings/Std617-69.pdf https://highways.dot.gov/federal-lands/std-drawings/Std617-69.pdf https://highways.dot.gov/federal-lands/std-drawings/Std617-67.pdf https://highways.dot.gov/federal-lands/std-drawings/Std617-67.pdf

Within 20 days after award, and no later than the Project Kick-off meeting, the Contractor shall provide the names and contact information for at least two (2) Points of Contact (POCs). One POC shall be designated as the Primary Project Manager with authority to make project decisions, and the second shall serve as an alternate or Technical Lead to ensure continuity of communication throughout the period of performance.

At the meeting, the Contractor shall discuss its proposed Plan(s) and steps shown for the systematic analysis and testing of the three safety hardware devices shown in Schedule A in Table 1. The FHWA team will provide comments on each Plan and the testing schedules. Within 10 days after the Kick-off meeting, the Contractor shall submit a final Plan that addresses FHWA’s comments and include a milestone schedule with deliverable dates. This final Testing Plan shall be included in the Final Report.

Task 2 – Conduct the Testing Plan

The Contractor shall follow the steps and schedule as shown in the final Testing Plan. The Contractor shall deliver and discuss the pre-testing analysis and crash test matrix. Once testing is initiated, the Contractor shall provide a short email to the COR after each test stating the test was conducted and an estimate of whether the device passed the appropriate criteria.

The Contractor shall develop or use existing (attached) finite element models (FEM) for each of the safety hardware devices shown in the Table 1 and perform finite element analyses (FEA) for each device to determine and predict the MASH impact performance.

NOTE TO CONTRACTOR: As an alternative to FEM and FEA, or used in combination with FEM and FEA, the Contractor shall document other data, information, or crash tests for similar devices such as the Merritt Parkway SBT Barrier on which professional judgement decisions were or can be based.

Items to consider shall include:

a. Height of devices: Would the three devices be likely to pass at the designed height of 27 inches (preferred by FHWA partners), or should height be increased, such as 31 inches?

b. For the transition:

• Rub rail (Already determined is needed in Phase 1)

• Curb

• Parapet height Min 24” max 40”

The Contractor shall provide recommendations and rationale for design modifications that would increase their likelihood to pass and develop a recommended critical testing matrix for each of the three devices. The critical matrix shall provide recommendations for each test on whether to proceed with its full-scale test, or to not conduct the test based on data and information that indicate a particular test is not applicable or necessary.

The Contractor shall deliver to the COR an interim report(s) summarizing the FEA and/or professional judgement results. The report shall summarize each device analyses and suggested design modifications to increase likelihood of meeting MASH criteria. The recommended critical matrix will be included in this report(s).

For each of the safety hardware devices identified in Table 1, the Contractor shall coordinate with an approved testing facility to at least fabricate the test safety hardware devices, procure test vehicle(s), conduct physical crash testing, and return the crash site to an acceptable condition to the testing facility.

The Contractor shall construct the safety hardware devices for each test. The Contractor shall crash test the safety hardware devices in accordance with the agreed-upon critical testing matrix. The Contractor shall provide a short email after each test stating the test was conducted and an estimate of whether the device passed the appropriate criteria.

Provide final design CADD drawings in MicroStation and PDF format for railing, transition and terminal listed in Table 1. The details provided on these plans should be adequate so that they can be used as standard sheets. Structure the documents to be in TF13 format (TF13.org). Submit digital copies to the COR.

NOTE: Should a test fail, the Contractor shall suspend further testing and submit a revised testing plan, in coordination with the COR, to show modified safety hardware that would be likely to successfully pass the MASH testing. For each unsuccessful crash test, the Contractor shall prepare a summary of the test along with an evaluation of failure mechanisms along with recommendations for changes which could be made to the safety hardware devices to increase the likelihood of a successful crash test.

Optional Tasks:

Option Task 2B: If it is determined that additional simulation and crash testing is needed for the SBT Terminal System, it will be covered under Option Task 2B. All requirements under task 2 Task 2 – Conduct the Testing Plan are applicable. At a minimum it will include FEM, and FEA evaluation and the following crash test (2-30, 2-31).

Option Task 2C: If it is determined that additional simulation and crash testing is needed for the SBT Transition Systems, it will be covered under Option Task 2C. All requirements under task 2 Task 2 – Conduct the Testing Plan are applicable. At a minimum it will include FEM, and FEA evaluation and the following crash test (3-20).

Task 3 – Presentation

Task 3.a Draft Presentation The Contractor shall prepare and present, via webinar, a PowerPoint Presentation with talking note materials, including crash test videos, graphical results, conclusions, and recommendations. A draft PowerPoint Presentation shall be submitted 60 days or earlier prior to the end date of the contract. The FHWA will review and provide comments and feedback within 15 days of receipt of the PowerPoint Presentation.

Task 3.b Final Presentation The Contractor shall address FHWA’s comments on the draft presentation and submit a final revision of the Power Point Presentation within 30 days to address comments, make revisions, and conduct the presentation in a webinar at the last Quarterly Interim Meeting.

Task 4 – Final Report The Contractor shall submit a final report, inclusive of all crash test videos. The final report shall include an evaluation of whether the safety hardware devices met all MASH criteria. The Contractor shall also deliver a DVD or electronic link to the FHWA of each crash test video, CADD Drawing, and if used, the FEM file.

If the testing was unsuccessful for any device, the Contractor shall prepare a final report on all aspects of the testing with an analysis of design problems and recommendation on how to overcome these issues.

Task 4.a Draft Final Report The Contractor shall submit a draft Final Report, in electronic format, summarizing the results and recommendations. The draft final report shall be submitted 45 days or earlier prior to the end date of the contract. The FHWA will review and provide comments and feedback within 15 days of receipt of the draft final report.

Task 4.b Task Final Report The Contractor shall submit the Final Report within 30 days to address the comments, questions, make revisions, and present it at the Closeout Meeting.

6 GENERAL REQUIREMENTS

6.1 FACILITY REQUIREMENT

Due to the nature of this study, all laboratories that perform crash testing for acceptance of roadside safety hardware shall be accredited under ISO/IEC 17025:2005 General Requirements for the Competence of Testing and Calibration Laboratories. Additionally, as required under ISO/IEC17025:2005, laboratories must show past experience in MASH09 or MASH16 crash testing. Laboratories must also show past experience with detailed finite element analysis for guardrails, end terminals, and transitions.

NOTE: The Contractor team must include at least one individual who is knowledgeable and experienced in performing current MASH testing. The proposal must demonstrate this requirement is met.

NOTE: Contractor must include a Testing Plan that outlines the minimum required testing per MASH the steps shown below for the systematic testing of the safety hardware devices.

Use the basic MASH Test Level criteria.

The Federal Register 72 FR 54210 Crash Test Laboratory Requirements for FHWA Roadside Safety Hardware Acceptance https://www.federalregister.gov/documents/2007/09/24/E7- 18725/crash-test-laboratory- requirements-for-fhwa-roadside-safety-hardware-acceptance amended 23 CFR 637.209 Laboratory and Sampling and Testing Personnel Qualifications to add 23 CFR 637.209(a)(5).

6.2 DATA OWNERSHIP

The FHWA secures full rights to the crash testing data. Contractor shall give the FHWA copies of all the data. All data provided by the Contractor shall be available for full use by the FHWA.

The Contractor shall request prior approval from the COR before sharing the results of these tests with any other entity other than FHWA. The FHWA may share this data without restriction with external partners such as other Federal Land Management Agencies, Tribal Nations, state and local agencies, metropolitan planning organizations, universities, and consultants.

6.3 TECHNICAL REPORTS

All non-standard fonts used in documents must be supplied on a disk so the document will print as it appeared on the offeror’s equipment. Files must be included in the programs of origin, such as MS Word, PowerPoint, Excel, etc., so these files can be modified or corrected and re-imported into the full text document. Graphics should be created as separate elements and imported into the text file. An electronic file of each imported graphic shall be delivered. Graphics must be produced in a program that can export an interchange file format that can be imported into the full text.

Photos must be in TIF or EPS (GIF and JPEG are acceptable for electronic publishing) with on-screen preview and with line screen appropriate for printing. Files should be provided in a recommended manageable size of 10 Mb or less.

Except as specified in this section for contract level reports, all reports and other data items required for each individual task will be defined at the task level. Contract level reports incorporate all issued tasks, performance and problems, and are required in accordance with the requirements specified herein.

All deliverables for posting on the World Wide Web must conform with the Minimum Requirements for FHWA Web Pages (http://www.fhwa.dot.gov/wpcz/minimum.htm).

Deliverables will be evaluated for Section 508 compliance. Non-conforming deliverables will be returned to the Contractor to be brought into conformance at the Contractor’s expense. The Contractor shall provide a report displaying the test results for the Minimum Requirements for FHWA Web Pages and this includes the Section 508 compliance testing of the deliverables.

6.4 PROGRESS REPORTS

The Contractor shall submit an electronic (2016 or higher Microsoft (MS) Office or PDF) progress reports to the COR and the Contract Specialist (CS). These reports shall be prepared every 2 months and submitted by the 10th of the month following the reporting period. The reports shall be in format as directed by the COR and, at a minimum, include the following items:

https://www.federalregister.gov/documents/2007/09/24/E7-18725/crash-test-laboratory-requirements-for-fhwa-roadside-safety-hardware-acceptance https://www.federalregister.gov/documents/2007/09/24/E7-18725/crash-test-laboratory-requirements-for-fhwa-roadside-safety-hardware-acceptance https://www.federalregister.gov/documents/2007/09/24/E7-18725/crash-test-laboratory-requirements-for-fhwa-roadside-safety-hardware-acceptance https://www.federalregister.gov/documents/2007/09/24/E7-18725/crash-test-laboratory-requirements-for-fhwa-roadside-safety-hardware-acceptance

(a) A clear account of the work performed under each task during the reporting period.

• Task 1

• Task 2 Conduct Testing Plan

• Task 2.a SBT Type B Guardrail Professional Opinion

• Task 2.b SBT Terminal

• Task 2.c SBT Transition

• Task 3 Presentation

• Task 4 Final Report

(b) An outline of the work to be accomplished during the next reporting period.

(c) Project schedule status based on opinion of the PM, shown as red (major delays and significant impact overall), yellow (slight delay to schedule but minimum impact overall), and green (on schedule).

(d) A description of any problem encountered or anticipated that will affect the completion of any work within the timeframe set, together with recommended solutions to such problems;

or, a statement that no problems were encountered. Also, a description of any identified risks and plan to mitigate risk