Metal Crash Barrier
Manufacturer in India
MORTH Clause 810 – IRC:119 – W-Beam
W-beam, thrie-beam and parking barriers manufactured to MORTH Clause 810. Hot-dip galvanised, 550 g/m². Supplied to NHAI and state highway packages, and to industrial campuses across Telangana, Andhra Pradesh and pan-India.
MORTH-Compliant Metal Crash Barriers by Sun Railings
Sun Railings manufactures metal crash barriers at our factory in Jeedimetla Industrial Estate, Hyderabad. Our barriers are manufactured to MORTH Section 800, Clause 810, read with IRC:119. Rails are cold roll formed from IS 5986 Fe 410 grade steel or equivalent and hot-dip galvanised to 550 g/m² zinc coating mass. Posts, spacers and fittings are hot-dip galvanised to IS 4759 for long-term durability in outdoor environments.
We supply W-beam crash barriers for national and state highway projects, thrie-beam systems for bridge parapets and high-containment zones, and painted MS barriers for parking structures and industrial campuses. All systems are available with custom post spacing, end terminals and transition sections.
Our team provides full documentation including material test certificates, mill certificates, and galvanising test reports. Fixed-price contracts with no surprise escalations. Also see: SS Railings | Industrial Railing
W-Beam Crash Barrier Technical Data
MATERIAL AND FINISH
| Beam Profile | W-Beam 312 × 83 mm / Thrie-Beam 507 × 83 mm, corrugated |
| Beam Thickness | 3 mm |
| Beam Length | 4.318 m total / 4.000 m effective |
| Base Metal | Cold roll formed, min. yield 2400 kg/cm²; IS 5986 Fe 410 or equivalent (IS 10748 Gr II) |
| Rail Galvanizing | Hot dip, 550 g/m² zinc coating mass |
| Post and Spacer | Channel 150 × 75 × 5 mm |
| Post Galvanizing | Hot dip to IS 4759 |
INSTALLATION AND COMPLIANCE
| Specification | MORTH Section 800, Clause 810 |
| Guidelines | IRC:119 — Traffic Safety Barriers |
| Post Spacing | 2.0 m c/c standard; 1.0 m in high-risk zones |
| Post Length / Embedment | 1.8 m overall, 1.1 m below road or ground level |
| Spacer | Channel 150 × 75 × 5 mm, 330 mm long |
| Rail Height | 700 mm ± 20 mm above road or ground level |
| Foundation | Concrete 1:2:4, 0.45 × 0.45 × 1.10 m per post |
| Fasteners | IS 1367 / IS 1364, grade 4.6, hot-dip galvanised |
| Containment / Working Width | Per approved project drawing |
| Lead Time | 2 to 4 weeks from approved drawing |
Named infrastructure references for state highway contractors, airport EPC teams and industrial developers evaluating MORTH crash barrier suppliers in Hyderabad.
Highway Crash Barrier Applications
Sun Railings fabricates W-beam and thrie-beam road safety crash barrier systems at Jeedimetla for EPC contractors, NHAI vendors and state PWD packages. As a crash barrier manufacturer in India, supply scope covers beam profiling, post fabrication, hot-dip galvanizing and BOQ-aligned dispatch — documented for consultant and PMC approval.
- National highways — NHAI median and roadside W-beam per MORTH Clause 810; kilometre-wise phased delivery to chainage programmes.
- State highways — Telangana and Andhra Pradesh PWD packages with IS 5986 Fe 410 mill certificates and galvanizing reports.
- Expressways — Higher-speed corridors where post spacing, deflection class and terminal treatments follow project drawings.
- Flyovers and bridges — Thrie-beam (three-beam) high-containment profiles on parapets, approaches and transition zones.
- Industrial roads — Plant perimeter and internal haul roads; painted MS or galvanized crash barrier where MORTH highway profile is not required.
- Ports and logistics yards — Heavy-vehicle edge protection with custom post centres and factory fabrication capability for non-standard lengths.
- Airports — Perimeter and airside road packages with submittal packs for aviation EPC teams — see infrastructure project references.
W Beam vs Three Beam Crash Barrier
W-beam crash barrier manufacturers supply the double-corrugation profile for N2 containment on standard highway edges. Three-beam (thrie-beam) crash barrier systems add a third corrugation for H2 containment where impact severity and vehicle redirection requirements increase.
| Parameter | W-beam | Three-beam (thrie-beam) |
| Typical application | National and state highway roadside, median on lower-risk sections | Flyover parapet, bridge edge, expressway black spots, median transitions |
| Traffic conditions | Mixed highway traffic at standard design speeds per IRC alignment | Higher containment zones, steeper curvature, elevated structures |
| Impact resistance | N2 containment — standard deflection per IRC:119 | H2 containment — stiffer section, reduced dynamic deflection |
| Installation | Post spacing 2.0 m c/c, 1.0 m in high-risk zones; W-to-W splices per drawing | Heavier section; W-to-thrie transitions, overlap lengths and terminal details on shop drawings |
Galvanized Crash Barrier Specifications
Highway crash barrier steel is hot-dip galvanized after fabrication to protect against corrosion in outdoor environments. Sun Railings galvanizing is batch-tested and traceable to dispatch bundles for NHAI and state highway material approval.
| Process | Hot-dip galvanizing after beam profiling and hole punching |
| Rail coating | 550 g/m² zinc coating mass on the cold roll formed beam section |
| Post and fitting coating | Hot dip to IS 4759, unless the tender specifies an alternate class |
| Inland highways | Standard HDG schedule suitable for Telangana and AP state highway exposure |
| Coastal applications | Verify coating mass and inspection frequency on consultant schedule; SS fasteners where specified |
| Documentation | Galvanizing test reports supplied with each lot for PMC filing |
Consultant and PMC Documentation Checklist
- Drawings — Typical sections, post foundation detail, terminal and transition layouts per the approved project drawing.
- BOQ — Beam profile, metre lengths, post count, spacer blocks, bolts and terminal schedule reconciled to tender.
- Material certificates — IS 5986 Fe 410 mill test certificates with heat numbers; beam thickness and post section confirmed.
- Coating records — Rail coating mass of 550 g/m² and post galvanizing to IS 4759, with batch test reports and the field-cut repair procedure.
- Compliance statement — MORTH Section 800 Clause 810 and IRC:119 conformity.
- Inspection reports — Dimensional check sheets, galvanizing batch IDs, pre-dispatch factory inspection record and material submittal for PMC approval.
Manufacturing scope and capacity statements for EPC prequalification are available on Sun Railings fabrication capabilities. Related systems: foot over bridge fabrication · infrastructure projects portfolio.
Procurement and Tender Considerations
Crash barrier suppliers on NHAI and state highway tenders should align scope boundaries before manufacturing release so item-rate BOQs do not omit terminals, transitions or fasteners.
- Supply scope — Beams, posts, spacer blocks, bolts, terminals and transitions as per approved drawing — not beam-only unless BOQ explicitly states.
- Fabrication — Profiling, punching and bending at Jeedimetla; heat numbers traceable to mill test certificates.
- Galvanizing — Batch galvanizing after fabrication; field-cut repair method included in installation method statement.
- Dispatch — Bundles tagged by chainage or km section for phased highway programmes.
- Site delivery — Coordinated to EPC laydown and installation sequence; offloading requirements confirmed with site team.
Contact Sun Railings for BOQ review and project references on highway and airport crash barrier supply.
Pan-India Dispatch and Scope Boundary
Sun Railings manufactures metal crash barriers at Jeedimetla, Hyderabad and dispatches pan-India. Supply is manufacture-and-dispatch: barrier sections, posts, spacers, terminals and fasteners are fabricated to approved drawings and freighted to site or to the contractor stockyard. Erection is carried out by the contractor’s own team, supported by a written method statement covering post foundation, bolt torque and terminal fixing sequence per the approved drawing and MORTH Clause 810. Rates are quoted ex-works Jeedimetla as standard, with the buyer arranging transport; delivered-to-site rates are available on request.
For buyers outside Telangana and Andhra Pradesh, including Tamil Nadu and Chennai highway packages, the practical questions are inspection and documentation rather than proximity. Both are handled before the consignment leaves the works:
- Pre-dispatch inspection — Client or third-party QA can witness dimensional and coating checks at Jeedimetla on prior intimation, so material is cleared before freight rather than rejected after it.
- Material traceability — Heat numbers on supplied sections trace to mill test certificates for the IS 5986 Fe 410 feedstock.
- Coating records — Hot-dip galvanizing is batch-tested, with coating thickness records issued against the specific batch supplied.
- Consignment marking — Bundles are tagged by chainage or km section so phased programmes can be offloaded in erection sequence without re-sorting at site.
- Submittal set — Shop drawings, material submittal, galvanizing records and the method statement travel with the order, assembled for consultant review.
Scope boundaries worth fixing in the purchase order before manufacturing release: terminals and end treatments, W-to-thrie transitions, fastener schedule, whether rates are ex-works Jeedimetla or delivered to site, and which party bears offloading. Item-rate bills of quantities frequently omit terminals and transitions, which is the most common source of variation on barrier packages.
Metal Crash Barriers Hyderabad — Common Questions
Planning a Road Safety Project?
We supply to highway contractors, airport developers, parking structure builders and industrial campuses across Telangana and AP. Our engineer visits your site within 24 hours.
For highway, parking, airport or industrial barrier projects