“Crash barrier ratings” sounds technical and is another thing that brings documentation and paperwork into your project. But it’s not a headache if you know what crash ratings are and where to get certified and rated crash barriers.
This short article will walk you through what crash barrier ratings are and how to match the rating to your speed zone, traffic load, and risk level so you can get the right barrier for the safety you require.
What are crash barrier ratings?
Crash ratings or crash barrier ratings are a method to evaluate and rank the performance of a crash barrier. The roadside barriers, either temporary or permanent, and crash cushions undergo rigorous crash tests in a controlled environment to evaluate the impact resistance of a barrier.
Engineers test the crash barrier using different vehicles at varying speeds and assess each crash across multiple parameters to measure the barrier’s impact resistance.
Crash rating system in Australia: MASH
In Australia, the crash rating system followed and accepted is called MASH. It stands for Manual for Assessing Safety Hardware. The American Association of State Highway and Transportation Officials (AASHTO) developed MASH.
The Austroads Safety Barrier Assessment Panel (ASBAP), Australia’s regulatory body, requires manufacturers to test all barriers under MASH and certify them according to the AS 3845.1 standard.
MASH tests assess the performance of crash barriers, crash cushions and guardrails and rate them based on their ability to safely stop or redirect the vehicle in case of a crash.
Before MASH, NCHRP Report 350 was the official crash testing system in Australia. Authorities adopted MASH because it tests barriers using heavier vehicles, higher speeds, and steeper angles, offering better protection in real-world crashes.
The 6 levels of MASH crash ratings
There are six levels of MASH ratings, ranging from TL-1 to TL-6. The higher the rating, the heavier and faster the vehicles the barrier can safely stop or redirect.
MASH tests evaluate multiple parameters during a crash test, including dynamic deflection of the barrier and impact severity to rate a barrier. However, the barrier design should accommodate the following three aspects to pass the MASH test.
- There should be no vehicle rollover
- The vehicle can’t go over the barrier or tilt more than 75 degrees
- The passenger compartment should remain intact, with no penetration or crushing.
These 3 parameters are tested for different vehicles at different speeds and rated accordingly.
| Test Level | Vehicle type | Vehicle weight (kg) | Speed (km/hr) | Angle (degrees) |
| TL-1 | Passenger car | 1100 | 50 | 25 |
| Pick-up truck | 2270 | 50 | 25 | |
| TL-2 | Passenger car | 1100 | 70 | 25 |
| Pick-up truck | 2270 | 70 | 25 | |
| TL-3 | Passenger car | 1100 | 100 | 25 |
| Pick-up truck | 2270 | 100 | 25 | |
| TL-4 | Passenger car | 1100 | 100 | 25 |
| Pick-up truck | 2270 | 100 | 25 | |
| Single-unit trucks | 10,000 | 90 | 15 | |
| TL-5 | Passenger car | 1100 | 100 | 25 |
| Pick-up truck | 2270 | 100 | 25 | |
| Trailer | 36,000 | 80 | 15 | |
| TL-6 | Passenger car | 1100 | 100 | 25 |
| Pick-up truck | 2270 | 100 | 25 | |
| Trailer | 36,000 | 80 | 15 |
The following videos show real MASH tests of the level TL-3
What if a barrier doesn’t pass the MASH test
If a barrier fails the MASH test, it cannot be deployed on the road and is sent for redesign. Every minor detail of the barrier impacts its performance.
The shape and weight of concrete barriers, the number of wires in the cable barriers, the flexibility of the w-beam guardrails and the terminal ends of any roadside barriers.
When a barrier fails a MASH test, engineers adjust the small design details to achieve the desired results. Once they make the improvements, they test the barrier again.
Choosing the right MASH-rated barrier
The right barrier rating depends on the following factors:
- The location: Urban roads or highways
- The traffic load
- Hazards
- Speed limit
- Usage: Temporary or permanent
TL-1 and TL-2 barriers are usually water-filled and used for temporary installation during construction or maintenance projects. Legend Hire’s Lo-Ro water-filled barriers and available in TL-1 and TL-2 ratings.
TL-3 rated barriers are the most common and are used on urban roads permanently. For instance, our Deltabloc concrete barriers are certified to TL-3 level. This means the barrier was tested with a 2270kg vehicle travelling at 100km/hr, impacting the barrier at an angle of 25 degrees.
Highway authorities commonly use TL-4 and TL-5 rated barriers to handle heavier vehicles traveling at higher speeds.
In extreme conditions, engineers install TL-6 rated barriers, robust structures that can stop trailer trucks traveling at high speeds and sharp impact angles, even though they don’t use them frequently.
To find the right rated barrier for your specific requirements, you can rely on Legend Hire’s team. Our engineers and experts can guide you on the right barrier choice that is compliant and fit for your project.
Legend Hire’s rated and certified crash barriers
Crash barrier ratings are important for road safety. ASBAP requires all the barriers in Australia to be MASH-certified.
Legend Hire offers crash barriers for hire that are MASH-certified and approved by Austroads to be used in Australia. Explore our range of crash barriers and road safety equipment.