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Trinity CASS S3 Assembly Manual

Cable safety system
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Summary of Contents for Trinity CASS S3

  • Page 2 In the event the specified system assembly, maintenance, or repair would require a deviation from standard assembly parameters, contact a Trinity Highway Products, LLC (“Trinity Highway”) representative. This system has been deemed eligible by the FHWA for use on the NHS under strict criteria utilized by that agency.

  • Page 3: Table Of Contents

    Occupational Safety & Health Administration Trinity Product Number Personal Protective Equipment TL-3 Test Level 3 TL-4 Test Level 4 Trinity Highway Trinity Highway Products, LLC 1V:”x”H Slope Measurement-1 Foot Vertical Distance to “x” Foot Horizontal Distance TrinityHighway.com Revision F November 2021...

  • Page 4: Customer Service Contacts/Important Introductory Notes

    For example, curbs could cause an untested effect on an impacting vehicle. A set of product and project shop drawings will be supplied by Trinity Highway. The shop drawings will be for each section of the assembly. These drawings are to be reviewed and studied thoroughly by a qualified individual who is skilled in interpreting them.

  • Page 5: Limitation And Warnings

    Limitations and Warnings Trinity Highway, in compliance with NCHRP Report 350 and MASH, contracts with ISO 17025 A2LA accredited testing laboratories to perform crash tests, evaluate Safety Alert Symbols appear throughout this manual tests, and submit the test results to the FHWA for review.
  • Page 6 Note: Based on soil conditions at the site, ANY or agency that specified CASS S3 at this particular ALL foundations may need larger/deeper concrete ® location for guidance. Trinity Highway is available footings larger soil plates (for driven for consultation with that agency.

  • Page 7: General Cass S3 Information

    For slopes steeper than 1V:6H, the footing depth is increased by 6” [150 mm]. The footing depths can be increased if the soils do not meet or exceed the NCHRP Report 350 soil conditions. Contact Trinity Highway for these designs. The Minimum Strength Concrete (“MSC”) for all concrete components of the CASS S3 is ®...
  • Page 8 Below is a pictorial of components for CASS S3 Hardware. Please see Trinity Highway ® drawings for specific lists of quantities. All Trinity Part Numbers (“PN”) are provided for standard parts only. Note: The following components are not shown to scale.
  • Page 9 PN: 3710G PN: 3711G PN: 4099G 3/4” Hex Nut (A563) 3/4” Hex Nut (A194 2H) Torpedo Cable Splice PN: 4199B PN: 4211G PN: 4225G 3/4” Cable Wedge (3 x 7) 5/16” x 1 3/4” Hex Bolt (A307) Cable Hook Bolt (A307) PN: 4779G PN: 4902G PN: 4903G...
  • Page 10 PN: 5633G PN: 5634G PN:5635G Assembled 1” Cable Splice 3/4” Cable Field Splice Left 3/4” Cable Field Splice Right PN: 5698G PN: 5700B Assembled 3/4” Cable Splice 4” Cable Spacer w/o Reflector PN:5701B PN: 5702B PN: 5709B 4” Cable Reflector Spacer 4”...
  • Page 11 PN: 5836G PN: 5837B PN: 5839B 8” Concrete Reinforcing Ring S3 Sleeve Cap Bottom S3 Sleeve Post Cover PN: 5840G PN: 5850B PN: 5851B 5’-0” Cable Field Repair CASS Cable Pulling Tool Reflector Median (LEFT) ® Section PN: 5852B PN: 5878B PN: 5909G Reflector Roadside (RIGHT) CASS...
  • Page 12 PN: 6722G PN: 9021G 5/8" X 8" ATR CHSL PT Bearing Angle A449 PN: 33903A PN: 33908G PN: 33909G Driven Terminal Posts w/soil Terminal Post Sleeve-S3 Post CRP-Cable Bracket Plates-S3 Posts 4-7 PN: 33910G PN: 33916B PN: 33934A S3 Terminal Post-in Sleeve CRP Reinforcing Cage Bottom CRP (in Concrete) Posts 4-7...
  • Page 13 PN: 33935A PN: 33936A PN: 33952A Top CRP Bottom CRP (w/Soil Plate) Driven Terminal Sleeve w/soil Plates-S3 Posts 4-9 PN: 33955G PN: 33989A PN:34036G S3 Terminal Post-in Sleeve Driven S3 Terminal Post S3 Post-Driven Posts 8 and 9 w/Soil Plates-Posts 8 & 9 PN: 34037A PN: 34038G PN: 34039G...
  • Page 14 PN: 105205G 3/4” Stud Flattened-RHT 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 local highway authority and its engineers to make that determination.
  • Page 15 Recommended Tools Documentation • Manufacturer’s CASS S3 4:1 CAble Safety System Assembly Manual (Current ® Version) • CASS S3 4:1 System Drawing(s). Current Versions of SS742 CASS ® ® (4:1 SLOPES) or SS743 CASS S3 (6:1 SLOPES) ® Personal Protective Equipment (PPE) •...

  • Page 16: Ground Preparation And Barrier Alignment

    To address assembly in rock, see Appendix C: Encountering Rock. Warning: It is imperative, before assembly, that you contact a Trinity Highway representative and state/specifying agency engineer for special criteria involving soil conditions not meeting or exceeding NCHRP Report 350 soil conditions. It is also recommended that you consult your own soils or structural engineer.

  • Page 17: Line Post Assembly

    Important: A flare rate of 30:1 or flatter is required if the barrier must be flared, transverse across the median, or if CASS S3 must change in ® direction (See Appendix A). Assembly on a Curve Horizontal Curve Complete the following steps to place the posts or post foundations along a curve. 1.

  • Page 18: Post Placement

    Sleeve in a Mow Strip Trinity Highway may allow the use of an alternate line post footing if the system is installed with an acceptable mow strip application. Please contact Trinity Highway for additional details. If the mow strip is not acceptable, follow the steps in “Sleeve in Poured Concrete Footing”...

  • Page 19: Cass® S3 Cable End Treatments

    Driven Posts Complete the following steps for a driven post assembly. 1. Lay out the post alignment and post spacing according to contract specifications and drive the post (PN-34036G) with an appropriate driving head equipment. 2. The height from the finished grade to the top of the post is approximately 3’-10” [1.17 m] Posts in Sleeve Complete the following steps for a post in the sleeve assembly 1.
  • Page 20 Based on soil conditions at the site, the CCT may need larger/deeper concrete anchors or larger soil plates (for driven applications) as determined through soil analysis. Bottom CRP with Concrete Footings Place the Bottom CRP (PN 33936A) in a minimum 18” [450] diameter x 5’-0” [1.50 m] deep reinforced MSC footing.

  • Page 21: Cct Line Footings

    Complete the following steps for assembling the CCT Bottom CRP with Soil Plate: 1. Lay out the four (4) footings. 2. Punch or auger a pilot hole approximately 4’-0” [1.92 m] or deeper for the Bottom CRP with soil plate if the post is not completely driven. Place the Bottom CRP with soil plate in the hole.

  • Page 22: Cct Posts Assembly

    Terminal Line Precast Concrete Footings-Posts 4 to 9 The precast concrete footings will be made in forms and fabricated the same as if placed in an augured hole. The precast footing will be placed in a punched or augured hole. Terminal Line Driven Foundation Sleeve with a Soil Plate-Posts 4 to 9 Complete the following steps for placement of a driven foundation sleeve with a soil plate.

  • Page 23: Terminal Cables

    Terminal Line Driven Post with Soil Plate – Posts 4 to 9 Complete the following steps for the placement of a driven post with a soil plate: 1. Drive post (PN-33903A) at post locations 4 through 7 and post (PN-33989A) at post locations 8 and 9 with an appropriate driving head/equipment.

  • Page 24: Line Cables

    C. Place the CRP Cable Bracket (PN-33909G) on the threaded end. The angle end of the bracket is placed up (See Figure 3). D. Place a flat washer (PN-4902G) and hex nut (PN-4903G) on the threaded fitting on the cable. Thread the nut approximately halfway on to it. Place on the fitting a second hex nut up against the first nut E.
  • Page 25 Lengths less than 1,000’ [305 m] can be supplied with a factory applied fitting (right–hand fitting) on one end, or the lengths can be cut from a continuous reel and a field applied fitting placed on both ends Cable Splices There are three types of cable splices that can be utilized.
  • Page 26 Perform the following steps to complete a splice using a field applied fitting and a turnbuckle: 1. Ensure that the cable has a clean square cut by using a saw with an abrasive blade tool or an electric band saw. 2.

  • Page 27: Laying Out The Cable/Attaching The Cables To The Posts

    The cables can be laid out one (1) cable at a time or multiple at the same time. The Trinity Highway Shop Drawings supplied for the project is used to determine what cables need to be used where. The cables are identified as top (CRP-1), low top CRP-1X), high bottom (CRP-3), and bottom (CRP-2).

  • Page 28: Tensioning And Tension Meter

    4. Place the low top cable in the notch at top of the post (See Figure 9). Place a spacer (PN-5700B (black), PN-5701B (yellow) or PN-5702B (white)) on top of the cable. 5. Place the top cable on top of the spacer. Place a post strap (PN-105202T) on top of the cable (See Figure 10).
  • Page 29 Important: Completely review the manufacturer’s manual included with the CASS S3 tensioning meter prior to tensioning of the cable. ® Important: Ensure that the tension meter is set for pre-stretched cable. Important: Completely r eview the infrared thermometer manufacturer’s manual prior to tensioning of the cable. Warning: Infrared light is harmful if shined into the eyes.

  • Page 30: Delineation/Repairs

    It is suggested for the terminal CRP that reflective sheeting (PN- 5851 or PN-5851) be affixed to delineate them, which could help to reduce some impacts. Trinity Highway makes no guarantees they meet the minimum specifications, comply with MUTCD requirements or comply with state/specifying agency requirements.

  • Page 31: Emergency Repairs

    Cables to the Post” section. For the CCT cables, see the “Terminal Cables” section. Depending on the severity of the impact, after the repair, the cable may need to be re-tensioned, Trinity Highway recommends the tension of the cable be checked with the CASS tension meter.
  • Page 32 To reduce the amount of the cable damage during cutting and limit fraying, tape must be wrapped around the cable and the cut made through the tape. Some agencies have also cut through the turnbuckle itself. This may help to reduce the maintenance/repair effort. When cutting through a turnbuckle, ensure that all posts, both upstream and downstream for a distance of 50’- 0”...

  • Page 33: Cable Tension Inspection Program

    ® Cable Tension Inspection Program Trinity recommends the cable tension be checked at least once a year. The tension value is established based on the cable temperature, which can be taken using an infrared thermometer for the cable temperature. If an infrared thermometer is not available, obtain the air temperature from a reliable source in the immediate area and not influenced by other factors.

  • Page 34: Cass ® S3 Assembly/Repair Checklist

    ® (File With Project/Maintenance Records) Performed by: Date: Location: ______________________________________________________________________ Ensure only Trinity Highway CASS S3 parts are used for the assembly/repair of CASS □ ® ® and that all parts are free of damage. (p 4) Ensure required traffic control is in place to conduct CASS S3 assembly/repair.

  • Page 35: Cass S3 Routine Inspection Checklist (File With Maintenance Records)

    Date: _____________________________________________________________ Location: _____________________________________________________________ Trinity Highway recommends the state/specifying agency develop and administer their own end terminal inspection program, based on location of unit, volume of traffic and impact history. Important: CASS S3 and all of its components shall be inspected for damage ®...
  • Page 36 CASS S3 Temperature / Tension Chart ® Pre-Stretched Cable ° C °F Tension (lbf)* 7500 33.3 7300 32.5 7100 31.6 7000 31.1 6800 30.3 6600 29.4 6500 28.9 6300 28.0 6100 27.1 6000 26.7 5800 25.8 5600 24.9 5500 24.4 5300 23.6 5100...
  • Page 37 CAble Safety System™ Project Owner:_______________________________________________________________ Project Number: __________________ Project Description: _________________ CASS™ Version: __________________ Trinity Highway Drawing #: ___________ Date Checked: __________________ By: _____Company/Agency: __________ IR Temperature of Steel: ______________ Corresponding Chart Lbf. Tension:_____ _________________________________________________________________________________________________________ ALWAYS check tension in a tangential (NON-radii) section of the cable installation, a minimum of 500 LF from a terminal.

  • Page 38: Appendix A: Flare Assemblies 30:1 Flare

    Appendix A: Flare Assemblies 30:1 Flare Appendix B: Cable Barrier Overlap TrinityHighway.com Revision F November 2021...

  • Page 39: Appendix B: Cable Barrier Overlap

    Appendix B: Cable Barrier Overlap TrinityHighway.com Revision F November 2021...

  • Page 40: Appendix C: Encountering Rock

    Appendix C: Encountering Rock Assembling Foundation Tubes or Posts when Encountering Rock Foundation Tubes Complete the following steps to assemble foundation tubes when encountering rock: 1. Select Option A or Option B below when encountering rock, unless there is a more restrictive state or specifying agency specification.

  • Page 41: Appendix D: Base Plated Post Assembly

    Appendix D: Base Plated Post Assembly The base plated post (PN-34037A) must be placed on a concrete surface 6” [150 mm] or more in depth (See Figure 11). The post length varies per concrete elevation. Complete the following steps for the base plated post assembly. 1.

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