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Trinity Highway QuadGuard II Assembly Manual

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Summary of Contents for Trinity Highway QuadGuard II

  • Page 2 QuadGuard information available to Trinity Highway at the time of printing. We reserve the right to make changes at any time. Please contact Trinity Highway to confirm that you are referring to the most current instructions.

  • Page 3: Table Of Contents

    System Components ....................... 7  Foundation/Anchoring ......................... 12  Recommended Tools ........................13  Site Preparation/Foundation ....................... 15  Trinity Highway Approved Adhesive Anchoring System ............. 16  Vertical Assemblies ....................... 16  Anchor Assembly Cautions ....................17  Horizontal Assemblies ......................18  How to Determine Left/Right ....................20 ...

  • Page 4: Customer Service Contacts

    Customer Service Contacts Trinity Highway is committed to the highest level of customer service. Feedback regarding the ® QuadGuard II, its assembly procedures, supporting documentation, and performance is always welcome. Additional information can be obtained from the contact information below:...

  • Page 5: Safety Symbols

    QuadGuard II. Additional copies of this manual are available from Trinity Highway by calling (888) 323-6374, or by email at product.info@trin.net, or at trinityhighway.com. Please contact Trinity Highway if you have any ®...

  • Page 6: Limitations And Warnings

    This system is tested only to the test matrix criteria of NCHRP Report 350 as approved by FHWA. Trinity Highway expressly disclaims any warranty or liability for injury or damage to persons or property resulting from any impact, collision or harmful contact with products, other vehicles, or nearby hazards or objects by any vehicle, object or person, whether or not the products were assembled in consultation with Trinity Highway or by third parties.

  • Page 7: System Overview

    Quad-Beam Panels. Important: Trinity Highway makes no recommendation whether use or reuse of any part of the system is appropriate or acceptable following an impact. It is the sole responsibility of the project engineer and/or the local highway authority and its engineers to make that determination. It is critical that you inspect this product after assembly is complete to make certain that the instructions provided in this manual have been strictly followed.

  • Page 8: System Components

    System Components ® Below is a list of system components to be used in the repair of your particular QuadGuard configuration. Please call Trinity Highway customer support if you have any system questions (p. 3). Warning: Use only Trinity Highway parts that are specified herein for the ®...
  • Page 9 Mushroom Washer Flat Screw 5/8X8 1/2" Wide Die Spring, 6”, Wide 617045 116879 117458 Flat Screw 5/8X5”,G8, Narrow Die Spring, 1 1/2”, Narrow Rail Nut, Hex, 5/8” 116878 117459 003340 Rail Bolt, 5/8X2” Panel, Fender Assembly, QG Washer, Flat, 5/8” X 1 3/4" 003400 608236 003300...
  • Page 10 Nose, L, Narrow, W/Logo Nose, R, Narrow, W/Logo Bracket, Cart, Nose 611669 611680 605420 Bolt, Hex, 5/8” X 2 1/2", G5 Bolt, Hex, 1/4" X 3/4", G5 Bracket, Cartridge Support 118232 113518 605446 Bolt, Bt, 5/8” X 1 1/4", Hex Bolt, Hex, 5/8”...
  • Page 11 Bracket, Angle, 2” X 1”, Washer, Flat 3/8” X 1” Nut, Hex, 3/8” W/Holes 617387 118036 115960 Bolt, Hex, 3/8” X 1”,G5 Washer, Fender, 3/8” X 2” Bolt, Hex, 5/8” X 1 1/2", G5 113596 118038 113654 Bracket, Pull-Out Shim Kit, 1/8” X 3 5/8” X 8”(2) Washer, Lock, 3/4"...
  • Page 12 Stud, 3/4” X 7”, G5 Washer, Flat, 3/4” X 2” 619316 117542 118027 *See Trinity Highway Approved Adhesive Anchoring System section on page 16. Cartridge Assy, Type I Cartridge Assy, Type II 606027 606029 Parts in red are included in assemblies.

  • Page 13: Foundation/Anchoring

    (“P.C.C.”), 6” [152 mm] layer of asphalt over 6” [152 mm] layer of subbase, or 8” [203 mm] layer of asphalt with no subbase. Important: Only 18” [460 mm] threaded rods, utilizing Trinity Highway approved adhesive, can be used with asphalt foundations. Contact Customer Service for a complete list of approved adhesives (p. 3). Concrete Installations ®...

  • Page 14: Recommended Tools

    Concrete Drill Bits – 7/8” [22 mm] (Double-Fluted)  Grinder, Hacksaw or Torch (optional)  Drill Bits 1/16” through 7/8” Important: Trinity Highway recommends using double-fluted drill bits to achieve optimum tensile strength when applying an approved adhesive to the anchoring system (p. 16). Hammers ...
  • Page 15 Miscellaneous  Traffic Control Equipment  Lifting and moving equipment (A lifting device is preferred although a forklift can be used.) Minimum 5,000 lb. capacity required.  Air Compressor (100 psi minimum) and Generator (5 kW)  Long Pry Bar ...

  • Page 16: Site Preparation/Foundation

    Recommended dimension and reinforcement specifications for new concrete foundations are provided in Trinity Highway concrete foundation drawings, supplied with the system. The system may be assembled on a non-reinforced concrete roadway (minimum 8” [200 mm] thick). Deployment cross-slope shall not exceed 8% and should not twist more than 2% over the length of the system;...

  • Page 17: Trinity Highway Approved Adhesive Anchoring System

    Trinity Highway Approved Adhesive Anchoring System A Trinity Highway approved adhesive anchoring system is required to securely anchor crash cushions. Each approved adhesive kit contains adhesive, studs, nuts and washers. Both vertical and horizontal assemblies are possible using an approved adhesive anchoring system.

  • Page 18: Anchor Assembly Cautions

    Note: Use of the Trinity Highway approved vacuum drilling equipment is authorized to replace the blowing and brushing requirement of Step 3. 4) Apply Approved Adhesive Fill the borehole 100% full.

  • Page 19: Horizontal Assemblies

    Horizontal Assemblies The horizontal approved adhesive kit is the same as the vertical kit. Caution: Fill borehole 100% full so it is even with the surface of the hole per manufacturer’s instructions. 1) Follow the instructions supplied with your approved adhesive kit Apply approved adhesive to each anchor per instructions.
  • Page 20 QG2100126 Figure 4 Plans & Elevation (Five Bay systems with Tension Strut Backups shown, except as noted) 1) Cartridge 2) Diaphragm Quad-Beam Fender Panel 4) Nose 5) Monorail 6) Backup 7) Side Panel trinityhighway.com Revision D September 2019...

  • Page 21: How To Determine Left/Right

    How to Determine Left/Right To determine left from right when ordering parts, stand in front of the system facing the roadside feature. Your left is the system’s left and your right is the system’s right. Counting the Number of Bays One Bay consists of one Cartridge, one Diaphragm, two Fender Panels, etc.
  • Page 22 Measuring the Width ® The QuadGuard II system is available in seven (7) nominal widths:  24” [610 mm]  30” [760 mm]  36” [915 mm]  48” [1219 mm]  69” [1755 mm] – (Minimum 3 Bays Required) ...

  • Page 23: Parallel (Narrow) Systems

    Narrow (Parallel) Systems 610 mm [24”] Model No. QG2 _ _24 760 mm [30”] Model No. QG2 _ _30 915 mm [36”] Model No. QG2 _ _36 1219 mm [48”] Model No. QG2 _ _48 Figure 8 Narrow System(s) and Model Numbers trinityhighway.com Revision D September 2019...

  • Page 24: Assemble Parallel (Narrow)

    Assemble Narrow (Parallel) Determine Backup and Transition Type ® QuadGuard II is available with a Tension Strut Backup or a Concrete Backup. Refer to Figures 9 and 10, along with the Backup Assembly drawing, to determine which type of Backup is being deployed. A Transition Panel or Side Panel must be used on each side of the Backup.
  • Page 25 Note: The proper Transition Panel or Side Panel must be used for impact performance of the system. The correct Panel(s) to use will depend on the direction of traffic and what type of barrier ® or roadside obstacle the QuadGuard II is shielding.
  • Page 26 QuadGuard II (p. 16). A Trinity Highway approved adhesive anchoring system is required to securely anchor crash cushions and other common highway devices. Each approved adhesive kit contains adhesive, studs, nuts and washers. Both vertical and horizontal assemblies are possible using an approved adhesive anchoring system.
  • Page 27 FULLY CURED CONCRETE BACKUP SEE MANUFACTURER’S DRAWING PACKAGE BACKUP FACE PLATE APPROVED ADHESIVE WITH 3/4” X 6 1/2” STUD Figure 18 Anchoring Backup Face Plate to Concrete Backup TENSION STRUT BACKUP Figure 19 Anchoring Tension Strut Backup to Foundation trinityhighway.com Revision D September 2019...
  • Page 28 Improper alignment at the Monorail Sections will prevent proper system collapse during impact (Figure 23). Anchor each Monorail section using an approved Trinity Highway adhesive kit. See Figure 20 and the approved adhesive instructions included with the adhesive kit. It is important to attach each segment of Monorail in alignment from the back to the front of the system (±1/4”...
  • Page 29 Backup and Monorail Placement for Tension Strut Backup It is important to align each segment of Monorail from the back to the front of the system (±1/4” [6 mm]). Anchor each Monorail section using the provided Trinity Highway approved adhesive kit.
  • Page 30 Attach Side Panels and/or Transition Panels to Backup Assembly Attach Transition Panel or Side Panel to side of Backup using 5/8” X 2” rail bolt and 5/8” rail nut (two places - top and bottom holes only). See Backup Assembly drawing(s) below. Note: A Side Panel is not needed when a Transition Panel is used.
  • Page 31 Attach Monorail Guides Attach Monorail guides to Diaphragm as follows: Insert 3/4" x 2” G8 hex bolt through Monorail guide and Diaphragm, oriented as shown in Figure 25. Secure with 3/4" lock washer and 3/4" hex nut (typical 4 places). See also Diaphragm Assembly drawing.
  • Page 32 Attach Fender Panels Important: Do not mix the 5/8” rail nuts (large) with the 5/8” hex nuts (small) (Figure 28). Figure 28 Rail Nuts are Oversize Starting at the Backup, attach left and right Fender Panels shown on page 32 and Fender Panel Assembly drawing.
  • Page 33 1 1/2” SPRING BACKUP OR DIAPHRAGM 5/8” HEX NUT (SMALL) SIDE PANEL, FENDER PANEL, OR TRANSITION PANEL 5/8” X 1 3/4” FLAT WASHER DIAPHRAGM MUSHROOM WASHER 5/8” RAIL NUT (LARGE) 5/8” RAIL BOLT 5/8” RAIL NUT (LARGE) 5/8” X 5” FLATHEAD SOCKET SCREW FENDER PANEL KEEP CENTER HOLE EMPTY...
  • Page 34 Step 6 Check Diaphragm spacing to ensure 36” [915 mm] between rear faces of consecutive Diaphragms, as shown in Figure 30 and Fender Panel Assembly drawing. Step 7 Once proper spacing has been achieved, tighten the Mushroom Washer Assembly (small hex) nut until it reaches the end of the threads.
  • Page 35 Attach Cartridge Support Brackets (Figure 32) Attach lower Cartridge Support Bracket to front and back of all Diaphragms and front of Backup, as shown in Figures 32 to 35 and Backup Assembly drawings. Note: 24” [610 mm] wide systems do not have Side Cartridge Support Brackets: 30” [760 mm], 36”...
  • Page 36 TENSION STRUT BACKUP [30” shown] STEP I MOUNT CARTRIDGE SUPPORT BRACKET STEP II MOUNT LOCKING BAR CONCRETE BACKUP FACE PLATE CARTRIDGE CARTRIDGE SUPPORT BRACKET SUPPORT BRACKET CARTRIDGE SUPPORT TENSION STRUT BACKUP BRACKET IS WELDED TO FACE PLATE OF CONCRETE BACKUP Figure 35 Figure 34 Lower Cartridge Support Bracket...
  • Page 37 Attach Steel Nose Assembly A) Install two (2) 5/8” X 2” hex bolts and one (1) 5/8 X 2 1/2” hex bolt with Pullout Bracket through Diaphragm side plate. Fasten all three (6 total) bolts with 5/8” rail nuts on each side and tighten (Detail 36A).
  • Page 38 HEX BOLT 1/4 X 3/4 LOCK WASHER 1/4” HEX NUT 1/4” Detail 36C Total Six 1/4-20 Fasteners Nose Cartridge Support Bracket Detail 36C Detail 36D Note height of Nose Cartridge 5/8” X 1 1/4" Support Bracket. The Cartridge 5/8” FLAT HEX SOCKET sits 2”...
  • Page 39 11) Checking the System Assembly Recheck to ensure that all fasteners are properly tightened throughout the system (anchor bolts, etc.). See torque requirements below. Check all Fender Panels. If they do not fit tightly against the underlying Fender Panel, system realignment may be necessary (Figure 37). Verify the top of the Steel Nose is 32 1/8”...
  • Page 40 Figure 38 Cartridge Placement Type 2 Type 1 Figure 39 Five Bay System trinityhighway.com Revision D September 2019...

  • Page 41: Flared (Wide) Systems

    Wide (Flared) Systems (Min. 3 Bays) 1755 mm [69”] Model No. QG2 _ _ 69 (Min. 3 Bays) 2285 mm [90”] Model No. QG2 _ _ 90 10 Deg. Varies - (Min. 6 Bays) 3200 mm [126”] Model No. QG2 _ _ 126 Figure 40 Wide System(s) and Model Numbers trinityhighway.com...

  • Page 42: Assemble Flared (Wide)

    Assemble Wide (Flared) Important: ® The Manufacturer’s Drawing Package supplied with the QuadGuard II must be used with these instructions for proper assembly and should take precedence over these general instructions. Determine Backup and Transition Type ® The QuadGuard II is available with a Tension Strut Backup or a Concrete Backup. See Figures 41 and 42, along with the Backup assembly drawing, to determine which type of Backup is being deployed.
  • Page 43 Important: The proper Transition Panel or Side Panel must be used to perform as crash tested. The correct Panel(s) to use will depend on the direction of ® traffic and what type of barrier or roadside obstacle the QuadGuard II is shielding.
  • Page 44 QuadGuard II (p. 16). A Trinity Highway approved adhesive anchoring system is required to securely anchor crash cushions and other common highway devices. Trinity Highway approved adhesive features high pullout strength, vibration resistance, and durability. Each approved adhesive kit contains adhesive, studs, nuts and washers.
  • Page 45 FULLY CURED CONCRETE BACKUP (SEE MANUFACTURER’S DRAWING PACKAGE) BACKUP FACE PLATE APPROVED ADHESIVE WITH 3/4" X 6 1/2” STUD Figure 50 Anchoring Backup Face Plate to Concrete Backup TENSION STRUT BACKUP APPROVED ADHESIVE WITH 3/4" X 7” STUD Figure 51 Anchoring Tension Strut Backup to Foundation trinityhighway.com Revision D September 2019...
  • Page 46 (2), 5/8” lock washer and 5/8” hex nut (6 places) as shown in Figure 52 and Detail 52a. Verify that any applicable Transition Panels fit properly before anchoring Backup. Drill anchor boreholes in foundation using the Backup as template. Anchor the Backup to the foundation using Trinity Highway approved adhesive kits supplied with the ® QuadGuard II (p.
  • Page 47 3) Anchor the Monorail A) Monorail Placement for Concrete Backup (Figure 53) Locate Monorail on foundation with side of Monorail on the construction line and rear edge of Monorail 10” forward of front face of Concrete Backup. Orient the Monorail so that the Monorail tongues face Backup (Figure 53).
  • Page 48 Backup and Monorail Placement for Tension Strut Backup It is important to align each segment of Monorail from the back to the front of the system (±1/4” [6 mm]). Anchor each Monorail section using the provided Trinity Highway approved adhesive kit.
  • Page 49 4) Attach Side Panels and/or Transition Panels to Backup Assembly (Figure 57) a. Attach Hinge Plate to the Transition Panel or Side Panel using 5/8” rail bolt and 5/8” rail nut (two places – top and bottom holes only). b. Attach Transition Panel or Side Panel assembly to Backup using 5/8” hex bolt, 5/8” lock washer and 5/8”...
  • Page 50 5) Attach Monorail Guides Attach Monorail guides to Diaphragm as follows: Insert 3/4” x 2” G8 hex bolt through Monorail guide and Diaphragm (Figure 58). Check orientation and secure hex bolt with 3/4” lock washer and 3/4” hex nut (typical two places per guide).
  • Page 51 7) Attach Hinge Plate onto Fender Panels Important: Do not mix the 5/8” rail nuts (large) with the 5/8” hex nuts (small). Figure 61 Rail Nuts are Oversize Important: For proper impact performance, wide systems must use Hinge Plates. Attach Hinge Plate on each Fender Panel using two (2) 5/8” rail bolts and two (2) 5/8” rail nuts, using top and bottom holes only, leaving the center-hole open as shown in Figure 62.
  • Page 52 Step 2 Slide the Fender Panel forward until the holes in the Fender Panel line up with the holes in the forward Diaphragm. Step 3 Use a drift pin to align the center hole of the Fender Panel with the center hole of the Diaphragm.
  • Page 53 5/8” RAIL NUT (LARGE) DIAPHRAGM 6” DIE SPRING OR BACKUP LONG SLOT IN FENDER PANEL MUSHROOM WASHER QUAD-BEAM FENDER PANEL HINGE PLATE PANEL ALREADY ATTACHED TO DIAPHRAGM OR BACKUP Figure 63A Figure 63B Mushroom Washer Attachment Mushroom Washer Orientation Step 6 Check Diaphragm spacing to ensure 36”...
  • Page 54 9) Attach End Cap Using 5/8” x 3 1/2” G5 hex bolt, 5/8” hex nut and 5/8” lock washer, attach the End Cap to the front of the first Monorail segment. Figure 65 Monorail End Cap Assembly trinityhighway.com Revision D September 2019...
  • Page 55 10) Attach Cartridge Support Brackets Attach Cartridge Support Bracket to all Diaphragms and Backup as shown in Figures 66 - 69, the Backup Assembly drawing, and the Diaphragm Assembly drawing. DIAPHRAGM CARTRIDGE SUPPORT BRACKET DIAPHRAGM CARTRIDGE SUPPORT BRACKET Figure 66 Diaphragm with Cartridge Support Bracket CARTRIDGE SUPPORT BRACKET...
  • Page 56 Figure 69 Extra-Wide First Diaphragm with Cartridge Support Bracket (See Drawing Package) 11) Attach Nose Assembly See pages 36 and 37 for Nose Assembly instructions. 12) Checking the System Assembly Recheck to ensure that all fasteners are properly tightened throughout the system (anchor bolts, etc.).
  • Page 57 13) Cartridge Placement Ensure the Adjustable Cartridge Support in the Nose is attached correctly (p. 36). The top surface of the Nose Cartridge should be horizontal. ® To complete the assembly of a QuadGuard II, place the appropriate Cartridge in each Bay and Nose section of the system.

  • Page 58: Quadguard ® Ii Final Inspection Checklist

    ® QuadGuard II Final Inspection Checklist Date: __________________________________ Site Location: ___________________________ Inspector: ______________________________ ® Refer to the QuadGuard II manual and/or drawing package. Minimum clearance of 30” behind rear Fender Panels for movement (p. 15) Proper Transition Panel is used for the type of barrier (p. 24, 42) Every borehole and slot in Backup and Monorail is utilized (p.

  • Page 59: Maintenance And Repair

    Maintenance and Repair Inspection Frequency Inspections are recommended as needed based upon volume of traffic and impact history. Visual Drive-By Inspections are recommended at least once a month. Walk-Up Inspections are ® recommended at least twice a year for QuadGuard II Narrow systems on asphalt (p.

  • Page 60: Post-Impact Instructions

    Trinity Highway makes no recommendation or suggestion regarding this determination. Each impact is unique. Warning: ®...
  • Page 61 Caution: Use eye protection and gloves when refurbishing the Mushroom Spring Assembly. Do not place fingers underneath an assembled Mushroom Washer. Parts may suddenly shift and fingers may be pinched. If the spring is still under compression as the nut is nearing the end of the bolt, to prevent injury, make sure that the spring is restrained with a clamp so it does not suddenly release when nut is removed from the Mushroom Washer Bolt.
  • Page 62 12) Remove damaged Nose Assembly and attach the new Nose (p. 36 and 37). Important: Trinity Highway makes no recommendation whether use or reuse of any part of the system is appropriate or acceptable following an impact. It is the sole responsibility of the project engineer and/or the local highway authority and its engineers to make that determination.

  • Page 63: Parts Ordering Procedure

    Parts Ordering Procedure Make a list of all damaged parts using part descriptions shown on the components pages 7 - 11 and on the system images (p. 63 and 64). Answer the following questions in the spaces provided. This information is necessary to receive the proper parts. ®...
  • Page 64 Figure 76 ® QuadGuard II for Narrow Roadside Obstacles trinityhighway.com Revision D September 2019...
  • Page 65 Figure 77 ® QuadGuard II for Wider Roadside Obstacles trinityhighway.com Revision D September 2019...
  • Page 66 Notes: trinityhighway.com Revision D September 2019...
  • Page 67 Notes: trinityhighway.com Revision D September 2019...

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