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Trinity Highway QuadGuard CEN QI2405 Assembly Manual

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Summary of Contents for Trinity Highway QuadGuard CEN QI2405

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

  • Page 3: Table Of Contents

    Table of Contents Customer Service Contacts ......................3  Important Introductory Notes ......................3  Recommended Safety Rules for Assembly .................. 4  Safety Symbols ..........................5  Warnings and Cautions ......................... 5  Limitations and Warnings ......................6  ® QuadGuard CEN ......................... 7  Assembly ............................ 10  Recommended Tools ......................

  • Page 4: Customer Service Contacts

    If there are deviations, alterations, or departures from the assembly protocol specified in this Manual, the device may not perform as it was tested and accepted. This system, like other Trinity Highway International systems, has been crash tested pursuant to EN 1317-3 mandated criteria. Important:...

  • Page 5: Recommended Safety Rules For Assembly

    A set of product drawings are available from Trinity Highway International upon request. Such drawings should be reviewed and studied thoroughly by a qualified individual who is skilled in interpreting them before the start of any product assembly.

  • Page 6: Safety Symbols

    Manual thoroughly and completely understand it. Ensure that all Danger, Warning, Caution, and Important statements within the Manual are completely followed. Please call Trinity Highway International at +1 (214) 589-8140 if you do not understand these instructions. UNDER NO...

  • Page 7: Limitations And Warnings

    EN 1317-3, under those specific impact conditions. Trinity Highway International neither represents nor warrants that the impact results of these EN 1317-3 established test criteria prevent or reduce the severity of any injury to person(s) or damage to property.

  • Page 8: Quadguard ® Cen

    ® QuadGuard Figure 1 Plan & Elevation 1) CARTRIDGE 2) DIAPHRAGM 3) QUAD-BEAM FENDER PANEL 4) NOSE COVER 5) MONORAIL 6) BACKUP Revision C August 2014 www.trinityhighway.com All rights in copyright reserved...
  • Page 9 How to Determine Left/Right To determine left from right when ordering parts, stand in front of the system facing the roadside obstacle. Your left is the system’s left and your right is the system’s right (see Figure 2). Counting the Number of Bays One bay consists of one Diaphragm, two Fender Panels, etc.
  • Page 10 Measuring the Width ® QuadGuard is available in five (5) nominal widths: 1. 610 mm [24”] 2. 760 mm [30”] 3. 915 mm [36”] 4. 1753 mm [69”] 5. 2286 mm [90”] The nominal width of the system is the width between Side Panels behind the Backup (see Figure 4).

  • Page 11: Assembly

    Grinder, Hacksaw or Torch (optional)  Drill Motor  Drill Bits 1/16” - 7/8” Note: Trinity Highway International recommends using double-fluted drill bits to achieve required tensile strength if assembling with an epoxy anchoring system. Wrenches  Heavy duty impact wrench ...
  • Page 12 Hammers  Sledgehammer  Standard hammer 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) and Generator (5 kW) ...
  • Page 13 Assembly Procedures Note: ® The Drawing Package supplied with the QuadGuard CEN must be used with these instructions for proper assembly and should take precedence over these general instructions. 1) Determine Connection Panel Type A Connection Panel or Side Panel will be used on each side of the Backup. A Side Panel is not needed when a Connection Panel is used.

  • Page 14: Connection Panel Types

    Connection Panel Types If a system is placed in a location where traffic will be approaching from the rear of the system, a Connection Panel is necessary. Figures 6, 7, 8, and 9 show the standard panel types. There are variations for each panel type. The specific panel needed will depend on system and site conditions.
  • Page 15 Anchor the System Cross-slope of assembled location shall not exceed 8% and not vary (twist more than 2% from front to back). For these conditions, a leveling pad is required. The anchors must have a pull out strength of 82.3 kN (18,500 lbs) and a shear strength of 109 kN (24,500 lbs). Test Parameters The best overall measure of anchor performance is load capacity.
  • Page 16 (Top view of concrete pad) Locating Construction Line 2) Anchor the Backup and Monorail See Figures 12 through 14 (showing Backup and Monorail deployment). For minimum foundation requirements, Consult the Trinity Highway International Customer Service Department (see p. 3). Locate Tension Strut Backup and Monorail on foundation with side of Monorail on the construction line (see Figure 13).
  • Page 17 A) Tension Strut Backup Assembly (Figure 13) Locate the Backup and Monorail on the pad with the side of the Monorail on the construction line (see Figure 13). Verify that applicable Connection Panels fit properly before anchoring Backup. Drill anchor holes to appropriate depth in the pad using the Backup as a template.
  • Page 18 3) Attach Side Panels / Connection Panels to Backup Assembly Attach the Connection Panel or Side Panel as appropriate to each side of the Backup. See Figures 15 - 16 and the drawing package for more information. Note: A Side Panel is not needed when a Connection Panel is used. TENSION STRUT BACKUP SIDE PANELS SHOWN USE CONNECTION PANELS...
  • Page 19 4) Attach Monorail Guides Attach Monorail Guides to Diaphragms as shown in Figure 17 and the Diaphragm Assembly drawing. Figure 17 Monorail Guides 5) Attach Diaphragms (Narrow Systems) Orient a Diaphragm so that the front face of the Quad-Beam™ Panel faces toward the nose of the system (see Figure 18).
  • Page 20 Figure 18 Diaphragm Orientation Figure 19 Initial Diaphragm Spacing Revision C August 2014 www.trinityhighway.com All rights in copyright reserved...
  • Page 21 7) Attach Bumper Assemblies Bays 1 and 2 of all systems are outfitted with Bumper Assemblies as shown in Figures 20a and 20b. First Diaphragm On the first Diaphragm, the Bumper Assemblies are attached to the rear of the Diaphragm only.
  • Page 22 Second Diaphragm (*except 3 Bay Systems) On the second Diaphragm, the Bumper Assemblies are attached to the front and rear of the Diaphragm. Orient Bumper Assemblies front and rear with the small holes facing the second Diaphragm and fasten with 1/2" x 5” hex bolts, 1/2" x 1 3/8” flat washers, and 1/2" nuts (see Figures 23 and 24).
  • Page 23 Third Diaphragm (*Second Diaphragm for 3 Bay Systems) On the third Diaphragm*, the Bumper Assemblies are on the front side of the Diaphragm only. Orient Bumper Assemblies with the small holes facing the front of the third Diaphragm and, using the top holes, fasten with 1/2" x 3” long hex bolts, 1/2" x 1 3/8” flat washers, and 1/2" nuts as shown in Figures 25 and 26.
  • Page 24 8) Attach Fender Panels (Narrow Systems) Caution: Do not mix the 5/8” hex nuts (small) rail nuts (large) with the 5/8” rail nuts (large). The rail nuts are oversize (see Figure 27). Starting at the last bay, assemble left and right Fender Panels (see Figure 28). Attach the front of each Fender Panel to the Diaphragm in front using two rail bolts and rail nuts (large) per side.
  • Page 25 Be sure Mushroom Washer lays flat against the Fender Panel (see Figure 29). Standoff on Washer must be seated completely through slot. Figure 29 Figure 30 Mushroom Washer Orientation Fender Panel Gap for Narrow Systems Caution: Do not mix the 5/8” hex nuts (small) with the 5/8” rail nuts (large). The rail nuts are oversize (see Figure 31).
  • Page 26 Figure 33 Fender Panel Gap for Wide Systems 5/8” HEX NUT (SMALL) DIAPHRAGM 1-1/2” DIE SPRING MUSHROOM WASHER 5/8” FLATHEAD SOCKET SCREW Figure 34 Mushroom Washer Attachment for Wide Systems Starting at the last bay, attach left and right Fender Panel (see Figure 35). Attach the Hinge Plate at the front of the Fender Panels to the Diaphragm in front using three 5/8”...
  • Page 27 1-1/2” DIE SPRING 5/8” HEX NUT (SMALL) BACKUP LAST DIAPHRAGM FENDER PANEL MUSHROOM WASHER 5/8” X 4” HEX BOLT 5/8” LOCK WASHER 5/8” HEX NUT (SMALL) 5/8” X 8-1/2”, G8 FLATHEAD SOCKET SCREW Figure 35 Fender Panel Assembly for Wide Systems Check diaphragm spacing to ensure 915 mm [36”] between rear face of consecutive Diaphragms (see Figures 36 and 37).
  • Page 28 Figure 37 Proper spacing between Bays (Wide System shown) 10) 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 (see Figure 38). Figure 38 Monorail End Cap Attachment Revision C August 2014...
  • Page 29 11) Attach Cartridge Support Brackets Note: 610 mm [24”] Wide systems do not have Side Support Brackets. 760 mm [30”] and 915 mm [36”] Wide systems have Side Support Brackets welded to the Diaphragms. Figure 39 Figure 40 610 mm [24”] wide Diaphragm 760 mm [30”] and 915 mm [36”] wide Diaphragm Attach Cartridge Support Bracket to Backup and all diaphragms that Support Cartridges as...
  • Page 30 Figure 43 Cartridge Support Bracket Attachment to Tension Strut Backup 12) Attach Nose Attach the Nose Belt to the Fender Panels using six 5/8” x 5” long hex bolts, twenty 5/8” flat washers, and eighteen 5/8” hex nuts through the Belt Clamps as shown in Figures 44 - 45 and the Nose Assembly drawing.
  • Page 31 Attach the flat washers so they are flush with the outside humps of the Fender Panels (see Figure 45). Figure 45 13) Checking the System Assembly At this point recheck to ensure that all fasteners are properly tightened throughout the system (anchor bolts, etc.) (see Table A).
  • Page 32 Warning: Placing Cartridges in the Nose or first Bay (and second Bay for 5, 6, & 8 Bay systems) may result in unacceptable crash performance as described in European Standard EN 1317:2000. Figure 46 Typical Cartridge Placement 15) Attach Fender Panels Note: D o not mix the 5/8”...
  • Page 33 Figure 47 ® Completed QuadGuard CEN for narrow roadside obstacles (6 Bay system shown) Figure 48 ® Completed QuadGuard CEN for wide roadside obstacles (6 Bay system shown) Revision C August 2014 www.trinityhighway.com All rights in copyright reserved...

  • Page 34: Maintenance And Repair

    Maintenance and Repair ® The QuadGuard CEN is considered to be a potentially reusable system. The system must be inspected after each impact and must be manually pulled out to its original length. Depending on the impact, components may get damaged and need replacement. Important: After an impact, always follow the “Post-Impact Instructions”...

  • Page 35: Post-Impact Instructions

    8) Make all necessary repairs as described above. Refer to Post-Impact Instructions for more information. ® 9) Note the location and condition of the QuadGuard CEN system and any work done in the Impact Attenuator Inspection Logbook under the date of this inspection. If further repair is necessary, note repair request date in logbook.
  • Page 36 ® 7) Pull the QuadGuard CEN forward slowly until the system reaches its original length. Have someone watch the system during repositioning to be certain previously undetected damage does not cause the Diaphragms to bind or pull out improperly. 8) Remove all crushed Cartridges from within the system. 9) Check to see that the Diaphragms are in usable condition.
  • Page 37 11) Check gaps between Fender Panels. On the bidirectional side of the system, the maximum gap allowed for these overlapping parts (including Fender Panels overlapping panels behind the system) is 20 mm [0.78”] for narrow systems (see Figure 30). For wide systems, the maximum gap allowed is 25 mm [1.0”] (see Figure 33).

  • Page 38: Parts Ordering Procedure

    Parts Ordering Procedure Make a list of all damaged parts using part descriptions shown in Figure 52 or 53. Circle the appropriate system attributes below. This information is necessary to receive the proper parts. System width: 610 mm [24”], 760 mm [30”], 915 mm [36”], 1753 mm [69”], 2286 mm [90”] Backup type: Tension Strut Connection Panel(s) on which side? Left, Right, Both, None...
  • Page 39 Figure 53 ® QuadGuard CEN Components (for wide roadside obstacles) Revision C August 2014 www.trinityhighway.com All rights in copyright reserved...

This manual is also suitable for:

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