AU2020201185B2 - An improved wire rope barrier system - Google Patents

Abstract

21 A wire rope barrier assembly having a post with an open slot at its upper end forming a space located between two upper post portions; at least one cable or wire rope located in said space and a cap and or spacer positioned on the upper end of said post which cooperates with, or substantially surrounds or substantially envelops, said two upper post portions, said cap and or spacer including a first aperture or slot extending downwardly from its upper end, or extending inwardly from its side, to receive at least one upper wire rope or cable, said cap and or spacer including at least one second aperture or slot located intermediate upper and lower ends of said cap and or spacer, to receive at least one intermediate cable or wire rope. P5751AU02 21

Description

2020201185 19 Feb 2020

120.1 120.2 120.3 100

100 120.4 10

100 100 10

10 10 4/15 4/15

120.1

120.2,120.3,120.4 120.1

102 102

FIGURE 9

FIGURE 9 FIGURE 10

P5751AU02

1 22 Jan 2026

An Improved Wire Rope Barrier System

Field of the invention

[001] The present invention relates to roadway barriers of the cable or wire rope type. The present invention more particularly relates to improvements in wire rope post and related attachment and cable positioning systems. 2020201185

Background of the invention

[002] Wire rope and cable systems are well known and are gaining greater usage due to the advantages of such systems. Improvements in the assembly of such systems, particularly those which provide assistance to installers help to make such systems more desirable to the marketplace. In this regard Australian patent 2011305056 is directed to such improvements and specifically relates to a cap system and related improvements for such wire rope and cable systems.

[003] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention

[004] The present invention provides a wire rope barrier assembly having a post with an open slot at its upper end forming a space located between two upper post portions; at least one cable or wire rope located in said space and a cap and or spacer positioned on the upper end of said post which cooperates with said two upper post portions, said cap and or spacer including a first aperture or slot extending downwardly from its upper end, or extending inwardly from its side, to receive at least one upper wire rope or cable, said cap and or spacer including at least one second aperture or slot located intermediate upper and lower ends of said cap and or spacer, to receive at least one intermediate cable or wire rope.

[005] The cap and or spacer can include a third aperture or slot to receive the at least one cable or wire rope located at the lower end of the space or slot in the post.

[006] The one or more of the apertures or slots in the cap and or spacer can include a means to hold retain the cable in the slot, or to delay the exits of the cable or wire rope from the apertures or slots.

[007] The one or more of the apertures or slots can be sized and or shaped so as to not impede the upper wire rope from exiting the slot and or so that the cap and or spacer will resist moving off the post as the upper wire rope moves off the cap and or spacer or post.

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[008] The first aperture or slot can be able to receive at least two cables or wire ropes.

[009] The second aperture or slot can be able to receive at least two cables or wire ropes.

[010] The third aperture or slot can be able to receive at least two cables or wire ropes.

[011] The cap and or spacer and post have a matching, corresponding or complementary shape. 2020201185

[012] The cap and or spacer can include one cavity formation accessible via its base, the cavity formation being sized and shaped so as to receive therein the two upper post sections

[013] The present invention also provides cap and or spacer for a post for use in a wire rope barrier system, the cap and or spacer including a first aperture or slot in its upper region to receive at least one first wire rope, the cap and or spacer having at least one cavity to receive two upper post sections of a bifurcated post, and at least one second aperture or slot located intermediate the upper region and a lower region, to receive at least one intermediate cable or wire rope.

[014] The first and or the second aperture or slot can include a means, or is sized and shaped, so as to hold or retain a respective one of the at least one cable or wire rope in a respective slot, or to delay the exiting of a respective one of the at least one cable or wire rope from a respective aperture or slot.

[015] The first aperture or slot can be substantially in a horizontal direction when on a post in use, or is generally perpendicular to a side wall of the cap and or spacer.

[016] The first aperture or slot can have a portion which is generally perpendicular to a side wall of said cap and or spacer, and has at least one other section which is at an angle thereto.

[017] The at least one second aperture or slot can be substantially in a horizontal direction when on a post in use, or is generally perpendicular to a side wall of the cap.

[018] The at least one second aperture or slot can have a portion which is generally perpendicular to a side wall of the cap and or spacer, and at least one other section which is at an angle thereto.

[019] The at least one second aperture or slot can include a generally vertical section when on a post in use, or is generally parallel to a side wall of the cap and or spacer.

[020] The at least one second aperture or slot can be generally of an L-shaped configuration.

[021] The cap can include a slot in its lower region to receive at least one cable or wire rope.

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[022] The present invention also provides a wire rope barrier assembly having a post with an open slot at its upper end forming a space located between two upper post portions; at least one cable or wire rope located in the space and a cap to engage the upper portions of the post and a wire rope spacer positioned on the post which substantially surrounds or substantially envelops and or cooperates with the two upper post portions, the spacer including an upper aperture or slot extending downwardly from its upper end, or extending inwardly from a side, so as to receive at least one upper wire rope or cable. 2020201185

[023] The spacer can include a lower aperture or slot to receive a lower most cable of the assembly.

[024] The spacer can have a tapered or stepped internal construction.

[025] There can be included at least one aperture or slot located between upper and lower ends of spacer, to receive at least one intermediate cable or wire rope.

[026] The upper aperture or slot can be able to receive at least two cables or wire ropes.

[027] The lower aperture or slot can be able to receive at least two cables or wire ropes.

[028] The aperture or slot located between upper and lower ends of spacer can be able to receive at least two cables or wire ropes.

[029] The post and the spacer can have a matching, corresponding or complementary shape.

[030] The spacer can include at least one cavity formation accessible via its base, the cavity formation being sized and shaped so as to receive therein the two upper post sections

[031] The present invention further provides a spacer for a post for use in a wire rope barrier system, the spacer including a first slot in its upper region to receive at least one first wire rope, the spacer having at least one through cavity to receive two upper post sections of a bifurcated post, and at least one second aperture or slot located between the upper and lower peripheries of the spacer, to receive at least one other cable or wire rope.

[032] The at least one second aperture or slot can be substantially in a horizontal direction when on a post in use, or is generally perpendicular to a side wall of the spacer.

[033] The at least one second aperture or slot can have a portion which is generally perpendicular to a side wall of the spacer, and at least one other section which is at an angle thereto.

[034] The at least one second aperture or slot can include a generally vertical section when on a post in use, or is generally parallel to a side wall of the spacer.

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[035] The at least one second aperture or slot can be generally of an L-shaped configuration.

[036] There can be included an aperture or slot at the spacer’s lower region or end to receive at least one cable or wire rope.

[037] The spacer can include an internal cavity which is one of: tapered or stepped or of two different wall thicknesses. 2020201185

[038] The spacer can include an externally located step, where the wall thickness of said spacer is different on either side of said step.

[039] The spacer or a cap and or spacer, or a wire rope barrier assembly having a spacer or a cap and or spacer, as described above, can be such that the spacer or the cap and or spacer can include a reinforcing collar attached to or moulded into a wall of the spacer or the cap and or spacer.

[040] According to one aspect, the present invention provides a wire rope barrier assembly having: a post with an open slot at its upper end forming a space located between two upper post portions; at least one cable or wire rope located in said space; and a cap positioned on the upper end of said post, the cap including at least one cavity to receive said two upper post portions, wherein said cap includes: a first aperture or slot at an upper region of the cap that extends inwardly from a side of the cap, for receiving at least one cable or wire rope; and a second aperture or slot that extends inwardly from a side of the cap in a region below said first aperture or slot, for receiving at least one cable or wire rope.

[041] According to one aspect, the present invention provides a cap for a post for use in a wire rope barrier system, said cap having at least one cavity for receiving two upper post portions of a bifurcated post, said cap including: a first aperture or slot at an upper region of the cap that extends inwardly from a side of the cap, for receiving at least one cable or wire rope; and a second aperture or slot that extends inwardly from a side of the cap in a region below said first aperture or slot, for receiving at least one cable or wire rope.

Brief description of the drawings

[042] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[043] Figure 1 is a perspective view of a cap and or spacer;

[044] Figure 2 is a perspective view of the cap and or spacer of Figure 1 showing hidden detail to indicate the internal shape thereof;

[045] Figure 3 is a left side view of the cap and or spacer of Figure 1;

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[046] Figure 4 is a front view of the cap and or spacer of Figure 1;

[047] Figure 5 is a right side view of the cap and or spacer of Figure 1;

[048] Figure 6 is a rear view of the cap and or spacer of Figure 1;

[049] Figure 7 is a plan view of the cap and or spacer of Figure 1;

[050] Figure 8 is an underneath view of the cap and or spacer of Figure 1; 2020201185

[051] Figure 8.1 is an upper perspective view of the upper part of a sigma post for use with the cap and or spacer of Figures 1 to 8;

[052] Figure 9 is the cap and or spacer of Figures 1 to 8 assembled into a wire rope barrier system with a post as in Figure 8.1;

[053] Figure 10 is a plan view of the assembly of Figure 9;

[054] Figure 11 is a front view of the assembly of Figure 9;

[055] Figure 12 is a left side view of the assembly of Figure 9;

[056] Figure 13 is a left side view of a cap and or spacer similar to that of Figure 1, where a second intermediate slot is provided;

[057] Figure 14 is a left side view of a cap and or spacer similar to that of Figure 1, where first and second intermediate slots, being horizontal, are provided;

[058] Figure 15 is a left side view of a cap and or spacer similar to that of Figure 24, where only a single intermediate slot, being horizontal, is provided together with an internal reinforcing sleeve;

[059] Figure 16 is a left side view of a cap and or spacer similar to that of Figure 25, where only a single intermediate slot, being horizontal, is provided.

[060] Figure 17 is a partial perspective view of a C-section post having a shaped slot that will function with the cap and or spacer of Figures 1 to 12;

[061] Figure 18 is a plan view of an RHS post with a slot that will function with the cap and or spacer of Figures 1 to 12;

[062] Figure 19 is a plan view of an C-section post with a slot that will function with the cap and or spacer of Figures 1 to 12;

[063] Figure 20 is a plan view of a cylindrical post with a slot that will function with the cap and or spacer of Figures 1 to 12;

[064] Figure 21 is a plan view of an O-post or an Ochoa post with a slot that will function with the cap and or spacer of Figures 1 to 12;

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[065] Figure 22 is a plan view of a Z-shaped post with a slot that will function with the cap and or spacer of Figures 1 to 12;

[066] Figure 23 is a plan view of an elliptical post with a slot that will function with the cap and or spacer of Figures 1 to 12;

[067] Figure 24 is a plan view of an I post or H-section post with a slot that will function with the cap and or spacer of Figures 1 to 12; 2020201185

[068] Figure 25 is a plan view of the Sigma post illustrated in Figures 9 to 12;

[069] Figure 26 is a plan view of a C-section post with a straight slot that will function with the cap and or spacer of Figures 1 to 12;

[070] Figure 27 is an upper perspective view of a modified cap and or spacer for use with the post of Figure 17;

[071] Figure 28 is an upper perspective view of the cap and or spacer;

[072] Figure 29 is a perspective view similar to that of Figure 28, with hidden detail being visible:

[073] Figure 30 Illustrates an upper perspective view of a cap and or spacer, similar to that of Figure 1, with an alternative interior construction;

[074] Figure 31 is a perspective cross section through the cap and or spacer of Figure 30;

[075] Figure 32 is a side view cross section through the cap and or spacer of Figure 30;

[076] Figure 33 is a perspective view of a combination spacer and reinforcing sleeve;

[077] Figure 34 is a perspective view of a combination spacer and reinforcing sleeve similar to that of Figure 33 showing the hidden inner detail;

[078] Figure 35 is a perspective view of a combination spacer and reinforcing sleeve similar to that of Figure 33 with an intermediate slot;

[079] Figure 36 is a perspective view of a combination spacer and reinforcing sleeve having an alternative inner construction;

[080] Figure 37 is a cross sectional view through the combination spacer and reinforcing sleeve of Figure 36;

[081] Figure 38 is a cross sectional view through the combination spacer and reinforcing sleeve, similar to that of Figure 37, but without a lower slot;

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[082] Figure 39 is a front view of a combination cap and or spacer similar to that of Figure 1, with a lower slot absent;

[083] Figure 40 is a perspective view of a wire rope barrier assembly;

[084] Figure 41 illustrates a perspective view of another cap and or spacer;

[085] Figure 42 illustrates a cross section through the cap and or spacer of figure 41; 2020201185

[086] Figure 43 illustrates a perspective view of a wire rope barrier utilising the cap and or spacer of Figure 41;

[087] Figure 44 illustrates a closer perspective view of the assembly of Figure 43; and

[088] Figure 45 illustrates a side view of the barrier of Figures 43 and 44, with some typical dimensions.

Detailed description of the embodiment or embodiments

[089] Illustrated in Figures 1 to 16 and Figures 27 to 32 and 39 and Figures 41 to 44, is a wire rope barrier post cap and wire rope spacer and or locator 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06,10.07 and 10.08 which in the instances of the cap and or spacers 10, 10.01, 10.02, 10.03, 10.04, 10.06,10.07 and 10.08 are shaped so as to be used with a sigma post such as that illustrated in Figure 8.1 or 25, whereas cap and or spacer 10.5 is shaped to be used with a post shaped similarly to that of Figures 17, 18, 19, 21, 22, 24 or 26. Whereas in Figures 33 to 38 is a wire rope barrier spacer and or locator 11, 11.01, 11.02 and 11.03 which are shaped so as to be used with a sigma post such as that illustrated in Figure 8.1 or 25. It will be readily understood that other complementary or matching shapes of cross section of spacer and or locator 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08, or spacer and or locator 11, 11.01, 11.02 and 11.03 can be used for other shaped posts, such as those in Figures 17 to 26.

[090] In general terms the combined cap and spacer or locator 10, 10.01, 10.02,10.03, 10.04, 10.05, 10.06, 10.07 and 10.08and the barrier system of Figures 9 to 12 includes a wire rope barrier assembly 100 having a post 102 (see also Figure 8.1) with slot 104 at its upper end forming a space 110 located between two upper post portions 106 and 108 (see Figure 8.1); at least one cable or wire rope 120.4 located at the lower end of the space 110 or slot 104 and a cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08positioned on the upper end of the post 102 which substantially surrounds, or substantially envelops, or cooperates with, the two upper post portions 106 and 108. The cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06 and 10.07 has a first aperture or slot 122 extending downwardly from its upper end to provide a space 124 into which is received at least one upper wire rope or cable 120.1, 120.2. Whereas in the cap and or space 10.08 has an “L” shaped upper slot 122 as illustrated in Figures 41 to 44. The cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06,

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10.07 and 10.08, also has at least one second aperture or slot 130, 130.1 located intermediate the upper and lower ends of the cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08, to receive at least one intermediate cable or wire rope 120.3.

[091] The cap and or spacer 10, 10.01, 10.02, 10.03, 10.04,10.05 and 10.06 also includes a third or lower aperture or slot 132 to receive at least one cable or wire rope 120.4 located at the lower end of the space 110. Whereas it will be noted that the cap and or spacers 2020201185

10.07 of Figure 39 and 10.08 of Figures 41 to 44, differ from the cap and or spacers 10, 10.01, 10.02, 10.03, 10.04,10.05 and 10.06 in that they do not include a lower slot 132. These cap and or spacers 10.07 and 10.08 are designed to rest on the upper perpheriy of the lower cable 120.4 as in the case of cap and or spacer 10.07, or be spaced therefrom as is the case of cap and or spacer 10.08. It is expected that the cap and or spacers 10, 10.01, 10.02, 10.03, 10.04, 10.05 and 10.06 may be stronger than the cap and or spacer 10.07 or 10.08 by virtue of their lower end 133 being below the lowest point of the post slot 104.

[092] The one or more of the apertures or slots 122,130, 130.1 and 132 in the cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08 can be shaped and sized or include other securement means to hold or retain a cable in a respective slot, or to delay the exit of such a cable or wire rope a respective aperture or slot, in much the same way as indicated in Australian patent 2011305056. However, it is preferred that the one or more of the apertures or slots 122,130, 130.1 and 132 are sized and or shaped so as to not impede the upper wire rope or ropes 120.1, 120.2 from exiting the slot 122 and or so that the cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08will not move off the post 102 as the upper wire rope or ropes 120.1 120.2 move off the cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06 and 10.07 or post 102.

[093] The first aperture or slot 122 preferably receives, as is illustrated in Figures 9 to 12, and Figures 43 and 44 at least two cables or wire ropes 120.1 and 120.2.

[094] The second or intermediate aperture or slot 130, 130.1, when of an L-shaped configuration, are each able to receive at least two cables or wire ropes like cable 120.3, but only one is shown as this is the currently preferred number of cables to be located therein. Where a slot 130 or 130.1, as in Figures 14 to 16, and Figures 41 to 44 have only a horizontal slot section, then the preferred number of cables is one, but if the slot is wide enough, as in the post 102.1 of Figure 17, the two cables or wire ropes can be received therein.

[095] The third or lower aperture or slot 132 preferably receives only one cable or wire rope 120.4, but can be sized and shaped so as to receive at least two cables or wire ropes. As is described further below if more than one cable is received into the lower slot 132, it is preferable

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that the lower most rim of the cap and or spacer be below the lower most periphery of the slot 104 in the post 102.

[096] The cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08 and post 102 have a matching or complementary shape. That is the internal space 140, which is technically of an obround cross-section, as best seen in Figure 8, is within the confines of the cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08 and is 2020201185

accessible from the underneath of the cap and or spacer by the post 102. The space or cavity 140 is shaped so as to receive the respective sides 106 and 108 of the upper end of the post 102. The same relationship is present in the cap and or spacer 10.5 of Figures 27 to 29 and the respective post or posts 102.1 to 102.8 of Figures 17 to 26. In this respect for the cap and or spacers 10 to 10.08, the slot 122 is only marginally wider than the slot 104 in the post 102. Whereas with the cap or spacer 10.05 of Figures 27 to 29, the width of the slot 104.1 will be approximately equal to the widest width of the converging diverging slot 104.1 in the post 102.1. This will allow the post 102.1 having such a converging diverging slot configuration to continue to function as intended by that design of post.

[097] The cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08 as described above while having a single, non-separated cavity 140 to receive the two upper post sections 106 and 108, could instead be provided with two separate cavity or pocket formations (not illustrated) which are both accessible via its base and would be sized and or shaped so as to receive therein the two upper post sections 106 and 108. The simplest and cheapest way to manufacture a functional cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08 is to provide a non- segmented internal space 140.

[098] In a general sense, as illustrated in Figures 9 to12, Figures 40, 43 and 44, there is also provided a cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08 for a post 102 for use in a wire rope barrier system 100, with the cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08 including a first slot 120 in its upper region to receive at least one first wire rope 120.1, 120.2, with the at least one first wire rope 120.1, 120.2 being able to exit the cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06 and 10.07 in the event of a collision while the cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06 and 10.07 remains on the post 102. Whereas in the case of the cap and or spacer 10.08, the first and second wire ropes 120.1 and 120.2 do not exit the cap and or spacer 10.08 in the event of a collision until the cap and or spacer 10.08 loses contact with the post 102. The cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08have at least one cavity 140 to receive two upper post sections 106 and 108 of a bifurcated post 102. The cap and or spacer can have at least one second or intermediate aperture or slot 130, 130.1 being located intermediate

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the upper region and a lower region of the cap and or spacer, to receive at least one intermediate cable or wire rope 120.3.

[099] The cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08can be constructed so that first and or the second aperture or slot 122 and 130, 130.1 can have a means, shape or formations so as to hold or retain a respective one of the at least one cable or wire rope 120.1, 120.2, 120.3 in a respective slot 122, 130, 130.1, or to delay the exiting 2020201185

of a respective one of the at least one cable or wire rope 120.1, 120.2, 120.3 from a respective aperture or slot 122, 130, 130.1. The most preferred construction is to have no such means to hold, retain or delay the cables from exiting a respective slot.

[0100] As seen in the Figures, the at least one second or intermediate aperture or slot 130, 130.1 is solely, or includes a portion, which is substantially in a horizontal direction when on a post 102 in use, or which can be described as being generally perpendicular to a side wall 150 or 153 of the cap or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08.

[0101] Whereas in respect of Figures 1 to 13 and Figures 27 to 32 and 39, the at least one second or intermediate aperture or slot 130, 103.1 has a portion which is generally perpendicular to a side wall 150, 152 of the cap and or spacer 10, 10.01, 10.05, 10.06 and 10.07, and at least one other section 130.2 which is at an angle thereto, which in the case of the ones illustrated is at 90 degrees forming an L-shaped slot to receive a wire rope. The other section 130.2 is a generally vertical section when on a post 102 in use, or is generally parallel to a side wall 150, 152 of the cap and or spacer 10, 10.01, 10.05, 10.06 and 10.07, and is located so as to have its central axis aligned to the axis of the post slot 104.

[0102] The cap or spacers 10, 10.01, 10.02, 10.03, 10.04, 10.05 and 10.06 also includes a third or lower slot 132 in its lower end 133 to receive at least one cable or wire rope such as rope 120.4. Whereas the cap and or spacer 10.07 does not include such a lower slot.

[0103] As best illustrated in Figure 12, the overall length of the cap or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, and 10.06 is such that when the under surface 125.2 (see Figures 31 and 32) of the upper section of the cap or spacer has engaged the top of sections 106 and 108 of the post 102, the lower most skirt or rim or end 133 of the cap extends past the lowest end of the post slot 104, by a distance 133.1 of approximately 2 cable or wire rope diameters. This will assist in the cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05 and 10.06 to act as an additional reinforcement to assist the post to keep the portions 106 and 108 in their spaced aligned relationship for as long as possible during a collision.

[0104] On either side of the slots 122 or spaces 124 at the upper end of the cap or spacer 10, 10.01, 10.02, 10.03, 10.04,10.05 , 10.06 and 10.07 is a pair of closed off or capped sections 125, the undersides 125.2 (see Figures 31 and 32) of which will engage, bear against or

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cooperate with the upper ends of the sections 106 and 108, to prevent the cap or spacer 10, 10.01, 10.02, 10.03, 10.04,10.05 , 10.06 and 10.07 from descending further down the post. Once these sections are engaged, the cap or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06 and 10.07, by virtue of the positioning of the slots 122, 130, 130.1 and 132 thus automatically locates and or positions the location of the respective cables or wire ropes.

[0105] Whereas in respect of the cap and or spacer 10.08 of Figures 41 to 44, the upper 2020201185

end of the cap and or spacer 10.08 has a single closed off or capped section 125, the underside 125.2 (see Figure 42) will engage, bear against or cooperate with the upper ends of the sections 106 and 108, to prevent the cap or spacer 10.08 from descending further down the post 102. Once the capped section 125 is engaged, the cap and or spacer 10.08, by virtue of the positioning of the slots 122, 130, thus automatically locates and or positions the location of the respective cables or wire ropes 120.1, 120.2 and 120.3 with respect to the upper edge of the post 102. Whereas the lower periphery of the slot 104 locates the wire rope 120.4 relative to the upper edge of the post 102.

[0106] It will be noted that around the closed off or capped section or sections 125, is a curved, chamfered or bevelled edge 125.1. In the case of the cap and or spacers 10 to 10.07, is also in the region adjacent the upper rim of the space 124 or slot 122, provides a diverging lead- in for the assembly of the cable or wire ropes. On the outboard sides of the cap and or spacers, the chamfered or bevelled edges 125.1 assist in not presenting a sharp edge which is advantageous to motor cycle and or bicycle riders.

[0107] The cap or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08can be manufactured from any appropriate material, such as steel, aluminium, and polymeric materials. The currently preferred material is glass or fibre reinforced nylon, which will give an acceptable weight to strength capability for the cap or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08to act as temporary reinforcing for the post structure, to assist it to stay together, even if temporarily during a collision.

[0108] Illustrated in Figure 13 is a cap and or spacer 10.01 which is similar to the cap or spacer 10 of figures 1 to 12, except that a second intermediate slot 130.1 is provided. Like the slot 130, the vertical section 130.2 of the slot is capable of receiving two cables or wire ropes therein, if desired, although the preference would be for a single such cable to be assembled therein.

[0109] Illustrated in Figure 14 is a cap or spacer 10.02 which is similar to that of Figure 13, except that the two intermediate slots 130 and 130.1 do not include a vertical section 130.2, that is, only a horizontal section is provided, each of which is of an extent to hold and vertically space a cable or wire rope relative to the upper end of the post.

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[0110] Figure 15 illustrates a cap or spacer 10.03 which is similar to that of Figure 1 except that the slot 130 has only a horizontal section. The cap or spacer 10.03 differs from earlier described caps or spacers in that it includes a captured reinforcing steel band or ring 130.5, which is embedded in the moulded fibre reinforced nylon during the moulding process. This will assist to provide a captured reinforcement.

[0111] If desired, the cap or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 2020201185

and 10.08 can include one or more captured reinforcing steel bands or rings, similar in nature to 130.5, located at one or more locations through or along the height of the cap and or spacer 10, 10.01, 10.02, 10.03, 10.04, 10.05, 10.06, 10.07 and 10.08, or at perceived locations of weakness, to assist in maintaining the integrity of the cap and or spacer, and or the post, during a collision.

[0112] As briefly mentioned above the post sections 102.1,102.2, 102.3,102.5, 102.6, 102.8, 102.9 of Figures 17 to 19, 21 and 22, 24 and 26, will all generally work with a cap and or spacer cross section similar to that of Figures 27 to 29, being of a generally square or rectangular cross section. The width of the slot 122 in the cap or spacer however, will be selected to match the width of the slot 104 or 104.1 provided in a respective post. Whereas for the cylindrical post 102.4 of Figure 20 and elliptical cross section post 102.6 of figures 20 and 23, a cap and or spacer of matching or corresponding shape will be preferred.

[0113] Illustrated in Figures 30 to 32 is another embodiment of a cap and or spacer 10.06. The cap and or spacers 10 to 10.05 and 10.07 are each of a generally constant cross sectional shape, in this case obround to suit the sigma post of Figures 8.1 and 26. This constant cross sectional shape also envisages that the wall thickness will be substantially constant, and when made from a fibre reinforced nylon material will be approx. 5mm in thickness. However, cap and or spacer 10.06 has a stepped internal construction, that is the thickness of the lower wall section is approximately 5 mmm which is thinner than the upper wall section which is approx. 6mm thick as illustrated in Figures 30 to 32. This provides the cap and or spacer 10.06 with the added advantage that the lower section will go onto the post 104 relatively easily, and the upper edges of the portions 106 and 108, will engage the step 135, and will have the relative motion stopped, so that the aperture or slot 130 will be above the portions 106 and 108. This will allow the ready insertion of the one or more wire rope or cable(s) 120.3 into the slot 130. Once in the slot 130, the cap and or spacer 10.06 can be pushed into its final position, so that the slot 122 can then receive the one or more upper wire rope or cable 120.1 and 120.2.

[0114] The cap and or spacers 10 to 10.05 and 10.07 have a single constant cross section cavity formation through it, which is accessible via its base. The cavity formation in the base of the cap and or spacers 10 to 10.05 and 10.07 are sized and shaped so as to receive therein the two upper post sections 106 and 108. Whereas the cap and or spacer 10.06 has two different size cavity formations which open into each other to produce the step135.

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[0115] If desired the step 135 and the two different dimensioned cavities which form the hollow of the cap and or spacer 10.06 can be replaced by a tapered internal cavity, wherein the taper converges from the lower end 133 of the spacer to the upper end. This taper will be sized so that the motion of the cap and or spacer 10.06 onto the post will be stopped at an appropriate location thus allowing access to an intermediate slot or aperture 130.

[0116] In respect of the cap and or spacer 10.08 of Figures 41 and 42, a step 135 is 2020201185

located externally of the cap and or spacer 10.08. The section of the cap and or spacer 10.08 above the step 135 has a wall thickness of approx 7mm, while the lower section has a wall thickness of approx 5mm.

[0117] It will be noted from Figures 41 and 44, that the upper surface of cap section 125 includes an embossed or debossed image of the post 102 cross section, so as to indicate to the installer the correct assembly orientation, as the cap and or spacer 10.08 includes an aperture 125.7 which will align with a corresponding aperture or hole 125.71 (see Figure 8.1) near the upper edge of the post 102, which is used to suspend the post 102 during the galvanizing process. When the respective holes are aligned during assembly of the barrier 100, a plastic pin or a threaded bolt 125.8 (as illustrated in Figures 34 and 44) or such like, can be inserted to lock the cap and or spacer 10.08 to the post 102. Another advantage of the cap and or spacer 10.08 is that there is a region or surface above the upper rope 120.1 which can receive an adhesive reflector 125.9.

[0118] Additionally it will be noted from Figure 45, that the lower rim 133 of the cap and or spacer 10.08 is spaced, by a distance 133.2 of approx. 10mm, away from the upper periphery of the lower most wire rope 120.4, so that in the event of a collision there will be a delay before the lower rope 120.4 will push against the rim 133. In Figure 45 are some typical dimension of the wire rope barrier assembly 100 showing the post 102 above ground level. The full length of the post being some 1220mm, thus approx. 350mm is inserted below ground level, by any known means, such as forming foundations, using a foundation sleeve or direct driven into the ground.

[0119] In respect of the spacer or locator 11, 11.01, 11.02 and 11.03 and a wire rope barrier assembly utilising this, it can be generally the that the barrier assembly has a post 102 with an open slot 104 at its upper end forming a space 124 located between the two upper post portions 106 and 108. The assembly 100.1 has an upper cap 100.2, and this cap 100.2 can be the same as that described in Australian patent 2011305056, and where at least one cable or wire rope located in the space via the cap which engages the upper portions 106 and 108 of the post 104. The assembly 100.1 also includes a wire rope spacer 11, 11.01, 11.02, 11.03 positioned on the post 104 which substantially surrounds or substantially envelops and or cooperates with the two upper post portions 106 and 108. The spacer 11, 11.01, 11.02, 11.03 also includes an

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upper aperture or slot 122.1 extending downwardly from its upper end to receive at least one wire rope or cable 120.3 as illustrated in Figure 40.

[0120] The spacer 11, 11.01, 11.02, 11.03 includes a lower aperture or slot 132 to receive at least one lower most cable 120.4 of the assembly 100.1.

[0121] The spacer 11 has a generally constant cross sectional shape, in this case obround to suit the sigma post of Figures 8.1 and 26. The constant cross sectional shape also 2020201185

envisages that the wall thickness will be substantially constant, and when made from a fibre reinforced nylon material will be approx. 5mm in thickness. However, the spacers 11.02, and 11.03 of Figures 36 to 38 have a stepped internal construction, that is, the thickness of the lower wall section being of approx. 5mm in thickness, is thinner than the upper wall section being of approx. 6mm in thickness. This provides the spacer 11.02 and 11.03 with the added advantage that the lower section will go onto the post 104 relatively easily, and the upper edges of the portions 106 and 108, will engage the step 135, and will have the motion stopped, so that the aperture or slot 130 will be above the portions 106 and 108, as this will allow the ready insertion of the wire rope or cable 120.3 into the slot 130. Once in the slot 130, the sleeve 11.02 and 11.03 can be pushed into position, so that the slot 122.1 can then receive another intermediate wire rope or cable. Such a step 135 is not of assistance for the spacer 11, as there are no intermediate slots or apertures

[0122] While the embodiments of Figures 35 to 38 show only one aperture or slot located between upper and lower ends of spacer, it will be understood that there can be more than one allowing each allowing one or more than one intermediate wire rope to be assembled.

[0123] Like the cap and or spacers described above the slots and or apertures 122.1, 130, 132 can each be sized so as to hold more than one wire rope.

[0124] The post 104 and the spacers 11, 11.01, 11.02, 11.03 preferably have a matching, corresponding or complementary shape to each other, but it would be understood that this does not have to be so.

[0125] The spacers 11, 11.01 each have a single constant cross section cavity formation through it, which is accessible via its base or its upper end. In fact the spacer 11 can be used in either direction. The cavity formation through the spacer is sized and shaped so as to receive therein the two upper post sections 106 and 108. Whereas the spacers 11.02 and 11.03 have two different size cavity formation which open into each other to produce the step135.

[0126] If desired the step 135 and the two different dimensioned cavities which form the hollow of the spacer can be replaced by a tapered internal cavity, where in the taper converges from the lower end 133 of the spacer to the upper end. This taper will be sized so that the motion

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of the spacer onto the post will be stopped allowing access to an intermediate slot or aperture 130.

[0127] In a like fashion to the above described cap and or spacer, the spacer 11, 11.01, 11.02 or 11.03 can include a reinforcing collar attached to or moulded into the internal wall of the spacer 11, 11.01, 11.02 or 11.03.

[0128] The spacer 11.03 of Figure 38 differs from the other spacers 11, 11.01 and 11.02 2020201185

in that it does not include a lower slot 132. This embodiment is designed to rest on the upper end of the lower cable 120.4. It is expected that the spacers 11 to 11.02 will be stronger than the spacer 11.03 by virtue of their lower end 133 being below the lowest point of the post slot 104.

[0129] While the above description details that the slots 122, 130, 130.1 and 132 are generally aligned with the axis of the post, it will be readily understood that a different angular relationship can be utilised or selected, without departing from the scope of this invention.

[0130] A particular advantage of the present invention over the prior art is that it simplifies assembly of a wire rope barrier 100, 100.1 in that considerably less inventory is required.

[0131] The assembly procedure of a wire rope barrier 100 and 100.1, will be slightly different compared to existing wire rope barriers as there are less components, however, the remainder of the safety barrier assembly is unchanged. The following wire rope post assembly process is described with respect of the cap and or spacers 10 to 10.07. The assembly process for the spacers 11 to 11.03 will be different, but will be readily understood to be comparable to the following process for cap and or spacers 10 to 10.07.

[0132] The post assembly 100 will include the following steps: a) a post 102 or series of posts 102 is or are inserted into, or otherwise secured to, the post foundation or a ground location; b) a bottom cable 120.4 is placed in the base of the post slot 104; c) a cap and or spacer 10 to 10.08 is lowered onto the post 102 to 102.8 with the top of the post 102 to 102.8 inserting to approximately the location of the only intermediate slot 130 or first intermediate slot 130.1 which if only one intermediate slot would be approximately half way between the bottom vertical slot and the horizontal slot, and in this position it is held by the installer’s hand; d) then second cable 120.3 (or first intermediate cable) is then fully inserted to the end of the intermediate slot 130 or first intermediate slot 130.1. e) step c) and d) are repeated if a second or third intermediate cable is present; f) once the intermediate cables are in position, the cap and or spacer 10 to 10.07 is then pushed down on the post 102 to 102.8 to the point of full penetration of the post 102 to 102.8 into the cap and or spacer 10 to 10.07; or in the case of cap and or spacer 10.08 the upper slot 122 is

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held adjacent the post 102 upper end, to receive the ropes 120.2 and then lastly 120.1; g) in the case of cap and or spacer 10 to 10.07, the third from bottom cable, or lower upper most cable 120.2 is then inserted into the vertical slot 122 at the top of the post 102 to 102.8, followed by the fourth cable or upper uppermost cable 120.1.

[0133] Typically, in a crash repair situation, one or more posts 102 to 102.8 would first have to be replaced and the above procedure is then employed. 2020201185

[0134] Some prior art wire rope barriers, which employ four cables have three spacers, a cap, a stiffening collar and a retaining pin to hook together the upper bifurcated end of the post. The above described embodiments combine a multiplicity of components into a single combination cap and or spacer 10 to 10.08, or spacer 11 to 11.03, each of which will speed up installation, and can make a wire rope barrier intrinsically safer in that there are less individual parts which may separate in the event of a collision.

[0135] Where ever it is used, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.

[0136] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[0137] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.

Claims (20)

P5751AU02 17 22 Jan 2026 Claims

1. A wire rope barrier assembly having: a post with an open slot at its upper end forming a space located between two upper post portions; at least one cable or wire rope located in said space; and a cap positioned on the upper end of said post, the cap including at least one cavity 2020201185

to receive said two upper post portions, wherein said cap includes: a first aperture or slot at an upper region of the cap that extends inwardly from a side of the cap, for receiving at least one cable or wire rope; and a second aperture or slot that extends inwardly from a side of the cap in a region below said first aperture or slot, for receiving at least one cable or wire rope.

2. A wire rope barrier assembly according to claim 1, wherein the cap includes a top section to abut the upper end of said post and limit movement of the cap down the post.

3. A wire rope barrier assembly as claimed in claim 2, wherein said top section includes a single wall having an underside to abut both of said two upper post portions.

4. A wire rope barrier assembly as claimed in any one of the preceding claims, wherein said first aperture or slot is able to receive at least two cables or wire ropes.

5. A wire rope barrier assembly as claimed in any one of the preceding claims, wherein said second aperture or slot is able to receive at least two cables or wire ropes.

6. A wire rope barrier assembly as claimed in any one of the preceding claims, wherein said cap includes a single cavity accessible via its base, said single cavity being sized and shaped so as to fit said two upper post portions.

7. A wire rope barrier assembly as claimed in any one of the preceding claims, wherein at least one of the apertures or slots is generally of an L-shaped configuration.

8. A wire rope barrier assembly as claimed in any one of the preceding claims, wherein said first aperture or slot has a portion which is generally perpendicular to a side wall of said cap, and has at least one other section which is at an angle thereto.

9. A wire rope barrier assembly as claimed in any one of the preceding claims, wherein said second aperture or slot is substantially in a horizontal direction when on a post in use, or is generally perpendicular to a side wall of said cap.

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10. A wire rope barrier assembly as claimed in any one of the preceding claims, wherein the first and second apertures or slots extend inwardly from opposing sides of the cap.

11. A cap for a post for use in a wire rope barrier system, said cap having at least one cavity for receiving two upper post portions of a bifurcated post, said cap including: a first aperture or slot at an upper region of the cap that extends inwardly from a side of the cap, for receiving at least one cable or wire rope; and 2020201185

a second aperture or slot that extends inwardly from a side of the cap in a region below said first aperture or slot, for receiving at least one cable or wire rope.

12. A cap as claimed in claim 11, wherein the cap includes a top section to abut an upper end of said post and limit movement of the cap down the post.

13. A cap as claimed in claim 12, wherein said top section includes a single wall having an underside to abut both of said two upper post portions.

14. A cap as claimed in any one of claims 11 to 13, wherein said first aperture or slot is able to receive at least two cables or wire ropes.

15. A cap as claimed in any one of claims 11 to 14, wherein said second aperture or slot is able to receive at least two cables or wire ropes.

16. A cap as claimed in any one of claims 11 to 15, wherein said cap includes a single cavity accessible via its base, said single cavity being sized and shaped so as to fit said two upper post portions.

17. A cap as claimed in any one of claims 11 to 16, wherein at least one of the apertures or slots is generally of an L-shaped configuration.

18. A cap as claimed in any one of claims 11 to 17, wherein said first aperture or slot has a portion which is generally perpendicular to a side wall of said cap, and has at least one other section which is at an angle thereto.

19. A cap as claimed in any one of claims 11 to 18, wherein said second aperture or slot is substantially in a horizontal direction when on a post in use, or is generally perpendicular to a side wall of said cap.

20. A cap as claimed in any one of claims 11 to 19, wherein the first and second apertures or slots extend inwardly from opposing sides of the cap.