Disclaimer: This article provides general educational information only. It is not a substitute for professional engineering or legal advice. Always seek guidance from a qualified Traffic Engineer and verify requirements with the relevant road authority before selecting or installing any barrier system.
When planning or setting up roadworks in Victoria, choosing the right road safety barrier system can make the difference between a safe, compliant worksite and one that exposes workers and road users to unnecessary risk.
While a qualified Traffic Engineer must always complete detailed barrier design and deflection checks, Traffic Management Designers (TMDs) and planners play an important role in the early planning phase.
Understanding which road safety barrier types suit different site conditions and how their cost, containment and test level compare allows early, confident decisions during Traffic Guidance Scheme (TGS) development.
This guide summarises the main temporary road safety barrier systems used in Victoria and across Australia, including their typical operating speeds, test levels, and cost considerations as outlined in AS 3845.1 and the Austroads Guide to Temporary Traffic Management (AGTTM).
Understanding Test Levels (TL) under AS 3845.1
Every approved temporary road safety barrier in Australia is crash-tested to a recognised Test Level (TL) under AS 3845.1 or equivalent international standards, such as MASH or NCHRP 350.
Each level defines the impact energy the barrier can safely contain and redirect, determined by vehicle mass and speed:
Always confirm the Test Level matches the posted speed and site risk. For example, a TL-2 barrier cannot be used at a 100 km/h site unless the speed has been reduced and approved by the relevant authority.
Road Safety Barrier Types Breakdown
The following summaries outline typical applications and test levels for awareness only. Actual suitability depends on site-specific conditions, nature of work, regulatory approvals, and professional engineering judgment.
1. Water-Filled Barriers
Typical Speed Environment: ≤ 50 km/h (indicative only)
Test Level: TL-1
Relative Cost: Low
Common Use: Urban roadworks, short-term lane closures, pedestrian protection
Water-filled barriers are lightweight plastic modules joined and filled on site. Once filled, they provide visual separation and low containment — suitable only for low-speed environments.
Ideal for: Low-speed local roads, council works, and footpath projects.
Avoid where: Traffic speeds exceed 50 km/h or heavy vehicles are present.
Budget insight: Lowest setup and hire cost. Ideal for short-duration, low-risk works on Victorian urban roads.
2. Concrete Barriers (Unpinned)
Typical Speed Environment: ≤ 60 km/h (indicative only)
Test Level: TL-2
Relative Cost: Medium-Low
Common Use: Moderate-speed works, constrained environments
Unpinned concrete barriers rely on mass for stability. They may shift slightly under impact but offer moderate containment where anchorage is not feasible.
Ideal for: Dividing lanes, bridge works, or arterials in built-up areas.
Avoid where: Speed limits exceed 70 km/h or deflection clearance is limited.
Budget insight: Balanced safety and cost. Moderate hire and installation costs with minimal surface preparation.
3. Concrete Barriers (Pinned)
Typical Speed Environment: ≤ 100 km/h (indicative only)
Test Level: TL-3 or TL-4 (system-dependent)
Relative Cost: High
Common Use: High-speed or long-term works, including freeway upgrades
Pinned concrete barriers are anchored to the pavement to reduce deflection and improve containment. They are the benchmark for Victorian freeway and arterial projects managed under Major Road Projects Victoria (MRPV) or VicRoads.
Ideal for: Freeways, medians, and long-term construction corridors.
Avoid where: Pavement cannot accommodate drilling or anchor plates.
Budget insight: Higher setup and removal costs, but essential for compliance and worker protection on high-speed corridors.
4. Steel Barriers (Unpinned)
Typical Speed Environment: ≤ 80 km/h (system-dependent) (indicative only)
Test Level: TL-2
Relative Cost: Medium
Common Use: Mid-speed or short-term projects requiring fast setup
Unpinned steel barriers sit on the road surface without anchors. They combine flexibility, rapid installation, and moderate containment, with predictable deflection under impact.
Ideal for: Mobile works, resurfacing, or staged closures.
Avoid where: Space is tight or higher containment is needed.
Budget insight: Medium hire cost, low labour input, and fast turnaround — a cost-effective option for mobile or night works.
5. Steel Barriers (Pinned)
Typical Speed Environment: ≤ 100 km/h (indicative only)
Test Level: TL-3
Relative Cost: High
Common Use: Long-term, high-speed, or multi-stage projects
Pinned steel barriers combine modular flexibility with strong containment. They are lighter than concrete, faster to install, and approved for high-speed corridors when properly anchored.
Ideal for: Freeway upgrades and dual carriageway separations across Victoria.
Avoid where: Pavement anchoring is impractical or frequent relocation is required.
Budget insight: Higher upfront hire cost but reduced setup labour. Ideal for multi-stage, high-speed works where flexibility and compliance are key.
Other Considerations
Beyond core barrier types, always review the following:
- End treatments and transitions: Each barrier must terminate with an approved treatment. Factor this early in your layout and costing. End treatments and transitions are critical for compliance and liability protection. Using non-approved or incorrectly installed treatments can render the entire system non-compliant and may void approvals or insurance coverage. Always confirm both the barrier and its associated end treatment are listed on the relevant authority’s approved-products register.
- Deflection and working width: Confirm system-specific deflection data before finalising your Traffic Management Plan.
- Authority requirements: VicRoads and local councils may specify minimum Test Levels for particular road classes. Always verify compliance before installation. Requirements and approvals differ between jurisdictions. This guide references Victorian standards and practices; always confirm the latest state or territory-specific regulations before implementation. Responsibility for design, selection, installation, and inspection lies with the qualified Traffic Engineer, accredited contractor, or project authority. Modus Engineering’s role is limited to providing educational insight.
- Regular inspection and maintenance are required to ensure temporary or permanent barriers remain stable and effective. Damage, misalignment, or ballast loss must be rectified immediately to maintain compliance.
- Budget insight: Early coordination with your Traffic Engineer prevents rework due to non-compliance or missing end treatments in your TGS design.
Making Cost-Informed Decisions
Each road safety barrier system offers a balance of cost, containment, and constructability.
- Water-filled barriers: Low cost, quick setup, limited containment.
- Concrete barriers: Strong containment, heavier handling.
- Steel barriers: Mid-range cost, fast to deploy, adaptable for different work stages.
Road safety barrier cost depends on the system type, Test Level, and installation method.
By understanding these trade-offs, designers and contractors can align design intent with client budgets and project risk avoiding last-minute redesigns or compliance issues.
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A quick reference guide to the best type of barrier based on the requirements of the project/site
STILL UNSURE WHICH BARRIER IS RIGHT FOR YOUR PROJECT?
Even with compliant systems, residual risk always exists. Barriers reduce but cannot eliminate hazard exposure. Safe work methods, clear signage, and speed management remain essential.
Modus Engineering supports clients with traffic safety insights and compliance awareness, ensuring every project begins on an informed foundation.
Common types include water-filled barriers, concrete barriers (pinned and unpinned), and steel barriers. Each suits different speed zones and project durations.
AS 3845.1 is the Australian Standard for the design, testing, and performance of road safety barriers. It ensures systems perform predictably under impact.
Temporary safety barriers are used during roadworks to separate workers from live traffic. Choice depends on speed, road geometry, and expected impact risk.
Costs vary by system type, Test Level, and installation method. Water-filled systems are the most economical, while pinned steel and concrete systems cost more but offer higher containment.
While standards like AS 3845.1 apply nationally, implementation can differ. In Victoria, VicRoads and MRPV have specific requirements for the approval and deployment of temporary barriers.
