Trinity QuadGuard M Wide Assembly Manual

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PN 626824

Revision B April 2021

QuadGuar d

M Wide

Product Description Assembly Manual

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Summary of Contents for Trinity QuadGuard M Wide

Page 1 PN 626824 Revision B April 2021 QuadGuar d M Wide ® Product Description Assembly Manual...
Page 2 Please contact Ingal Civil Products to confirm that you are referring to the most current instructions. ® QuadGuard is a registered trademark of Energy Absorption Systems, Inc. Part No. 626824 © 2020 Trinity Highway Products, LLC ingalcivil.com.au Revision B April 2021...
Page 3: Table Of Contents
Determine Transition Type ....................12 Recommended Tools ........................13 Site Preparation/Foundation ....................... 15 Foundation/Anchoring ......................16 Trinity Highway Approved Adhesive Anchoring System ............. 17 Vertical Anchors ........................17 Anchor Assembly Cautions ....................18 Horizontal Anchors ........................ 19 System Assembly ........................22 ...
Page 4: Customer Service Contacts
Customer Service Contacts Trinity Highway is committed to the highest level of customer service. Feedback regarding the ® QuadGuard M Wide, its assembly procedures, supporting documentation, and performance is always welcome. Additional information can be obtained from the contact information below:...
Page 5: Safety Symbols
FHWA. Warning: ® Use only Trinity Highway parts on the QuadGuard M Wide for assembly, maintenance, or repair. The use of component parts not specified herein strictly prohibited.
Page 6: Limitations And Warnings
Features”, Trinity Highway contracts with FHWA approved testing facilities to perform and evaluate crash tests to prepare a crash test results report. Trinity Highway is then able to submit a Request for Federal Aid Reimbursement of Safety Hardware Devices to the FHWA for review.
Page 7: System Overview
Quad-Beam Fender 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 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 that may be used in your particular QuadGuard M Wide configuration. Verify parts delivered and system details with the BOM (Bill of Materials) and system drawings shipped with your system. Please call Ingal Civil Products if you have any system questions (p.
Page 9 Monorail Guide Monorail, 2 Bays, QG, G Monorail, 3 Bays, QG, G 10102534 10102311 10102312 Hinge Plate, Fender Panel Hinge Plate, Full Length Hinge Pin, Dia, Full Length 10102417 10102443 10102557 Tel ST 1 3/4X1 3/4X12 GAX10 Tel ST 2X2X12 GAX10 Pipe, 3/4 Schedule 80X2 5/16 10102907 10102908...
Page 10 Bracket,Cart,Hold Down,MASH Bracket,Cart Supt,Nose,MASH Washer, Bar, 10GAX2X14 10102211 10102212 10102210 Nose, L, QG M Wide Nose, R, QG M Wide 10102214 10102215 Bolt, Hex, 1/4X3/4, G5 Bolt, Hex, 1/4X1, G5 Bolt, Hex,3/8X1,G5 10102508 10102556 10103162 Bolt, Hex, 3/8X3 1/2, G5 Bolt, Hex, 5/8X2, G5 Bolt, Hex, 5/8X3 1/2, G5 10102510...
Page 11 Bolt, Hex, 5/8X4, G5 Bolt, Hex, 5/8X5, G8, P, F/T Flat Screw 5/8X8 1/2,G8 10102512 10102521 119163 Stud, M20 x 180mm, GR8.8 Bolt, Hex, 3/4X2, G8 Rail Bolt, 5/8X2 10102503 10102509 10102547 Nut, Hex, 1/4 Nut, Hex, 3/8 Rail Nut, Hex, 5/8 10102501 10102515 10102516...
Page 12 Washer, Fender, 3/8X2 Washer, Flat, 5/8X1 3/4 Washer, Flat, 3/4X2,Hvy 10102500 118038 10102548 Die Spring, 1 1/2 ODX3/4X6 Mushroom Washer Approved Adhesive 10102536 10102522 10102902 M20 Structual Nut Hex Galv Cartridge Assy, Type I Cartridge Assy, Type II 10102903 10102904 10102539 ingalcivil.com.au Revision B April 2021...
Page 13: Determine Transition Type
A proper Transition Panel or Side Panel must be used on each side of the Backup. A Side Panel is not needed when a Transition Panel is used. Several types of transitions are available for use with the QuadGuard M Wide (Figures 1 – 6). The correct Panel(s) to use will depend on ®...
Page 14: Recommended Tools
Concrete drill bits – 22 mm (Double-Fluted) • Grinder, Hacksaw or Torch (optional) Important: Trinity Highway recommends using double-fluted drill bits to achieve optimum tensile strength when applying an approved adhesive anchoring system (p. 17). ingalcivil.com.au Revision B April 2021...
Page 15 Hex Key (Allen) wrench: 3/8” 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 to make that determination.
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 also be assembled on reinforced or non-reinforced concrete roadway (minimum 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: Foundation/Anchoring
Foundation/Anchoring Important: It is the responsibility of the local DOT to ensure that this assembly conforms to the AASHTO Roadside Design Guide. Warning: It is the responsibility of the installer to ensure that your assembly procedure meets all appropriate Safe Work Australia, WorkSafe NZ, or state & territory authorities.
Page 18: 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 19: Anchor Assembly Cautions
4) Apply Approved Adhesive Fill the borehole 100% full. Caution: Fill borehole 100% full so it is even with the pavement surface per manufacturer’s instructions. 5) Add the Washers and Nuts Place a flat washer onto the stud then thread a nut on until the end of the stud is flush with the nut (Figure 8).
Page 20: Horizontal Anchors
Horizontal Anchors The horizontal approved adhesive kit is the same as the vertical kit. Caution: Fill borehole 100% full so it is even with the vertical concrete surface per manufacturer’s instructions. 1) Follow the instructions supplied with your approved adhesive kit Apply approved adhesive to each anchor per instructions.
Page 21 FRONT TYPE I TYPE II CARTRIDGES BACK CARTRIDGES Figure 10 Plan View 32 1/8” Figure 11 Elevation View 6 Bay TL-3 1) Backup Quad-Beam Fender Panel 3) Nose 4) Cartridge 5) Diaphragm 6) Monorail ingalcivil.com.au Revision B April 2021...
Page 22 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. Counting the Number of Bays One Bay consists of one Cartridge, one Diaphragm, and two Fender Panels.
Page 23: System Assembly
System Assembly Warning: If the QuadGuard system has been supplied pre-assembled, it will have transport bolts with warning tag installed in the monorail. Th ese monorail bolt s are used to hold the system together while in transit and therefore are for transportation purposes only.
Page 24 (p. 24, Detail A). It is important to align each segment of Monorail from the back to the front of the system within 6 mm along the length. Anchor each Monorail section using the Trinity Highway approved adhesive kits provided.
Page 25 100 mm TENSION STRUT BACKUP M20 x 180mm ANCHOR MONORAIL CENTERLINE CONSTRUCTION LINE CONCRETE PAD Figure 16 Backup and Monorail Location for Tension Strut Backup Drill 22 mm diameter by 145 mm boreholes using the Monorail as a template. Do not drill through foundation.
Page 26 Attach Side Panels and/or Transition Panels to Backup Assembly A. Attach Hinge Plates to Backup (three (3) places on each side of Backup) using a 5/8” rail bolt, lock washer, and hex nut. B. Attach Transition Panel or Side Panel to Hinge Plate using a 5/8” rail bolt and rail nut (two places - top and bottom holes only).
Page 27 Attach Monorail Guides Attach Monorail guides to Diaphragm as follows: Insert 3/4X2” G8 hex bolt through Monorail guide and Diaphragm with a shim placed between them and oriented as shown in Figure 20. Secure with 3/4” lock washer and 3/4” hex nut (typical 4 places).
Page 28 7) Attach Hinge Plates to Diaphragm Attach Hinge Plates to each Diaphragm so the hinge pivot is toward the front of the system. Insert 5/8”X4” hex bolts through all hinges. Secure each bolt with 5/8” lock washer and hex nut (Figure 23). (Typical three places per side on Diaphragms 2-6) Insert Full Length Pin and secure with 1/4X1”...
Page 29 Note: Starting at the Backup, attach left and right Fender Panels shown below in Step(s) 4 & 5 with each tapered end pointing toward the rear of the system. Step 1 Place the Fender Panel so that the center of the slot of the backup Hinge Plate is lined up with the approximate center of the slot in the Fender Panel.
Page 30 Step 5 The Mushroom Washer must lay flat against the Fender Panel with its standoff completely through the Fender Panel slot (Detail B). DIAPHRAGM OR BACKUP LONG SLOT IN 6” DIE SPRING FENDER PANEL 5/8 RAIL NUT (LARGE) FENDER PANEL MUSHROOM MUSHROOM WASHER...
Page 31 Attach End Cap Attach the End Cap to the front of the first Monorail segment, as shown below and the Monorail Assembly drawing. MONORAIL 5/8 LOCK WASHER 5/8X3 1/2 G5 HEX BOLT 5/8 HEX NUT END CAP Figure 29 Monorail End Cap Attachment ingalcivil.com.au Revision B April 2021...
Page 32 Attach Lower Cartridge Support Brackets Attach lower Cartridge Support Bracket to the front and back of all Diaphragms and also to the front of the Backup as shown below. Mount Cartridge Support Bracket DIAPHRAGM Cartridge Support Bracket Figure 30 Lower Cartridge Support Bracket Assembly TENSION STRUT BACKUP STEP 1 Attach Cartridge...
Page 33 Nose Assembly STEEL NOSE ASSEMBLY Views A - D Figure 32 NOSE ASSEMBLY (p. 51) A. Pre-assemble each Nose Assembly half with 5/8X5” hex bolt, 5/8X1 3/4” flat washer, bar washer, 3/4” schedule 80 pipe, and 5/8” rail nut (three (3) places per half (Detail A &...
Page 34 HINGE PLATES PULLOUT BRACKET 1/4X3/4 HEX BOLT 1/4 HEX NUT 5/8X2 HEX BOLT Cartridge Support Nose Bracket Detail D Detail C Steel Nose not shown for clarity NOSE PANEL PULLOUT BRACKET 5/8 HEX NUT 5/8 RAIL NUT Detail E Detail F Inside View: Nose Cover Cut Away Inside view back of front diaphragm showing nuts against...
Page 35 Note: Detail G shows proper placement of Cartridge Nose Support Bracket. 820mm CARTIRDGE SUPPORT BRACKET Note height of Cartridge support Bracket. The Cartridge sits at the same level as the other Detail G Bays to the rear. 3/8X1 HEX BOLT 3/8X1 HEX BOLT CARTIRDGE HOLD DOWN...
Page 36 Checking the System Assembly Ensure 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 Panel, system realignment may be necessary (Figure 34). Top of Steel Nose is 820mm above grade (p.
Page 37: Quadguard ® M Wide Final Inspection Checklist
QuadGuard ® M Wide Final Inspection Checklist Site Location: ___________________________ Date: __________________________________ Inspector: _________________________________ Refer to the QuadGuard M Wide manual and / or drawing package. ® o Clearance of 650mm behind rear Fender Panels for stroke (p. 13) o Anchor nuts are torqued to manufacturer specification (p. 17) o Cartridges are level and the same height in each Bay (p.
Page 38: Maintenance And Repair
Maintenance and Repair Inspection Frequency ® Inspections for QuadGuard M Wide 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 once a year. Visual Drive-By Inspection 1) Is there is evidence of an impact? If so, perform a walk-up inspection.
Page 39: Post-Impact Instructions
Post-Impact Instructions 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 project 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 40 7) Remove all crushed Cartridges from within the system. 8) Check to see that the Diaphragms are in usable condition. Diaphragms which are bowed or have bent legs must be replaced. 9) Check that the Fender Panels are properly attached with the Mushroom Washer Assemblies.
Page 41: Parts Ordering Procedure & Drawings
Parts Ordering Procedure & Drawings Make a list of all damaged parts from the System Components section in this manual (p. 7 – 11). Answer the following questions in the spaces provided. This information is necessary to receive the proper parts. QuadGuard M Wide Ordering Information Chart ®...
Page 42 10102536 Washer, Mushroom, Forged M20 Structual Nut Hex Galv 10102539 Warning: Use only Trinity Highway parts that are specified herein for assembling, Do not utilize or otherwise ® maintaining, or repairing the QuadGuard M Wide. comingle parts from other systems even if those systems are other Trinity Highway systems.
Page 43: Quadguard ® M Wide Tension Strut Backup
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Page 44: Concrete Pad
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Page 45: Tension Strut Backup
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Page 46: Monorail Assembly
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Page 47: Diaphragm Assembly
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Page 50: Shim Kit
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Page 51: Fender Panel Assembly
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Page 52: Nose Assembly
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Page 53: Transition To Safety Shape Barrier
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Page 54: Transition To Single Slope
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Page 55: Transition To Vertical Barrier
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Page 56 NOTES: ingalcivil.com.au Revision B April 2021...
Page 57 NOTES: ingalcivil.com.au Revision B April 2021...
Page 58 www.ingalcivil.com.au sales@ingalcivil.com.au 1300 446 425...