Guardrail installation varies by type (e.g., highway W-beam vs. pedestrian railings), but the general process follows these key steps:

1. Planning & Compliance Check

Survey the site (road curvature, slope, traffic conditions).

Verify standards (MASH, AASHTO, OSHA, or local codes).

Mark layout (post spacing, rail height, and termination points).

2. Post Installation

For Highway Guardrails (W-Beam, Thrie-Beam, Cable):

Dig post holes (typically 24–30 inches deep).

Set posts (wood, steel, or concrete) at specified spacing:

W-beam: 6 ft 3 in (1.9 m) standard.

Thrie-beam: Up to 6 ft (1.8 m).

Cable barriers: 12.5–20 ft (3.8–6 m).

Backfill with concrete or compacted soil for stability.

For Pedestrian/Industrial Guardrails:

Anchor posts to concrete floors, walls, or steel structures.

Use base plates or embedded sleeves for rigidity.

3. Rail Assembly & Attachment

A. W-Beam & Thrie-Beam Guardrails

Attach rails to posts using bolted blockouts (for deflection).

Overlap rail sections (minimum 12 inches for continuity).

Install end terminals (energy-absorbing or flared for safety).

B. Cable Guardrails

String high-tension steel cables through posts.

Anchor cables at terminal ends with breakaway hardware.

C. Concrete Barriers (Jersey Barriers)

Precast segments are delivered and aligned.

Connected with rebar or pins for stability.

4. Termination & Impact Protection

End treatments (ET-Plus, MELT, or flared) to prevent spearing.

Crash cushions (if near fixed objects).

5. Inspection & Testing

Check post alignment, rail height, and bolt tightness.

Verify crashworthiness (for highway guardrails per MASH standards).

Ensure no hazardous gaps (e.g., OSHA’s 19-inch rule for workplaces).

Key Tools & Materials

Excavator / Auger (for post holes).

Torque Wrench (for bolt tightening).

Guardrail panels, posts, blockouts, terminals.