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Trinity Highway CASS TL3 Product Description Assembly Manual

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Summary of Contents for Trinity Highway CASS TL3

  • Page 2 This manual must be available to the worker overseeing and/or assembling the product at all times. For additional copies, contact Trinity Highway at (888) 356-2363 or visit TrinityHighway.com/Products. The information contained in this manual supersede all previous versions. The instructions,...

  • Page 3: Table Of Contents

    National Highway System OSHA Occupational Safety & Health Administration Trinity Part Number Personal Protective Equipment TL-3 Test Level-3 Trinity Highway Trinity Highway Products, LLC 1V: “x”H Slope Measurement-1 Foot Vertical Distance to “x” Distance TrinityHighway.com Unreleased May 2021 Revision A November 2021...

  • Page 4: Customer Service Contacts

    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

    (approx. 2,000 kg [4,400 Warning, Caution, and Important statements within lb.]) at 100 kph [62 mph]. the manual are completely followed. Please call Trinity Highway at (888) 356-2363 if you have any CASS ® is tested pursuant to the test matrix criteria of questions about instructions in this manual.
  • Page 6 ® CASS at this particular location for guidance. Trinity Highway is available for consultation with that state/specifying agency. Warning: Do not allow pedestrians or workers to stand near this system,...

  • Page 7: General Cass Information

    Check the received parts against the packing list supplied with the system to verify that all parts were received. If parts are damaged or missing from the shipment or unspecified parts were part of the shipment, do not attempt to assemble the system; contact Trinity Highway immediately.
  • Page 8 PN: 3240G PN:3245G PN: 3300G 5/16” Flat Washer (F844) 5/16” Hex Nut (A563) 5/8” Flat Washer (F844) PN: 3310G PN: 3361G PN: 3536G 5/8” Lock Washer 5/8” Hex Nut 1” Stud Flattened-LHT PN: 3537G PN: 3700G PN: 3701G 1” Stud Flattened-RHT 3/4”...
  • Page 9 PN: 4099G PN:4190G PN: 4199B Torpedo Cable Splice Cable End Casting 3/4" Cable Wedge (3 x 7) PN: 4211G PN: 4779G PN: 4902G 5/16” x 1 3/4” Hex Bolt (A307) 3/4” x 4 1/2” Hex Bolt (A325) 1” Flat Washer (F436) PN: 4903G PN: 4959G PN: 5225G...
  • Page 10 PN:5635G PN: 5698G PN: 5700B 3/4” Cable Field Splice Right 3/4” Cable Splice 4” Cable Spacer w/o Reflector PN: 5701B PN: 5702B PN: 5709B ® 4” Cable Reflector Spacer 4” Cable Reflector Spacer CASS Thermometer Yellow White PN: 5711G PN: 5823B PN: 5824T ®...
  • Page 11 PN: 5836B PN: 5837B PN: 5838B ® 8” Concrete Reinforcing Ring S3 Sleeve Cap, Bottom CASS C Post Cap PN: 5839B PN: 5840G PN: 5850B ® S3 Sleeve Cover Terminal 5’-0” Cable Field Repair CASS Cable Pulling Tool Post Section PN: 5851B PN: 5852B PN: 5878B...
  • Page 12 PN: 6722G PN: 9021G PN: 33901G 5/8" X 8" ATR CHSL PT A449 Bearing Angle C-Shaped Driven Post PN: 33902G PN: 33903 PN: 33908G C-Shaped Post Driven S3 Terminal Posts Terminal Post Sleeve–S3 w/Soil Plates-Posts 4-9 Post PN: 33909G PN: 33910G PN: 33912G CRP-Cable Bracket S3 Terminal Post –...
  • Page 13 3/4” Stud Flattened-LHT 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 state/specifying agency and its engineers to make that determination.

  • Page 14: Recommended Tools

    Recommended Tools Documentation • ® Manufacturer’s CASS CAble Safety System Assembly Manual (Current Version). • ® CASS System Drawing(s). Current version of SS-720 Personal Protective Equipment (PPE) • Eye Protection • Work Gloves • Back Protection • Safety-Toe Shoes • Reflective Vest •...

  • Page 15: 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 16: Line Post Foundation Placement

    Assembly on a Curve Horizontal Curve Complete the following steps to place the posts or post foundations along a curve. 1. When the cable is placed on a curve, post spacing may need to be reduced based on the radius. 2.
  • Page 17 Sleeve in Poured Concrete Footing Complete the following steps for placing a sleeve in a poured concrete footing. 1. Place a plastic cap (PN-5833) on the bottom of the foundation sleeve (PN-33985G) or tape the bottom end of the foundation sleeve to prevent the concrete from coming into the tube.

  • Page 18: Cass ® Cable End Treatments

    6. Allow the footing to attain the required concrete strength before disturbing the foundations, including the placement of posts. Precast Concrete Footings The precast concrete footings will be fabricated in forms and installed the same as if placed in an augured or punched hole. Post Placement Posts ®...
  • Page 19 line posts are placed with sleeve in a concrete footing, a sleeve with a soil plate, or a driven post with a soil plate. See Figure 2 for the footing locations and spacing. 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.

  • Page 20: Cct Line Footings

    Bottom CRP with Soil Plate The Bottom CRP with Soil Plate assembly, size based on soil conditions, can be driven or placed in an augured hole. The soil plate can be either welded or bolted to the bottom CRP (See Figure 3). Complete the following steps for assembling the CCT Bottom CRP with Soil Plate: 1.
  • Page 21 Note: These sleeves are different than the standard line post sleeves. 2. Punch or auger a minimum 12” [300 mm] diameter x 36” [0.91 m] deep hole for the concrete footing. 3. Pour the MSC in the hole with the top of the footing flush with the finished grade. 4.

  • Page 22: Cct Posts Assembly

    CCT Posts Assembly Terminal Posts The CCT consists of three (3) CRPs and six (6) S3 x 5.7# [S75 x 21] terminal line posts (positioned in a sleeve or a driven post). Cable Release Post (CRP) – Post 1 to Post 3 Complete the following steps for the placement of the CRP.

  • 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 posts (PN-33903A) at post locations 4 through 9 with an appropriate driving head/equipment.

  • Page 24: Line Cables

    Installing the Cables on the terminal posts: 1. The CRP 1 cable attached to CRP 1 will use the top two holes on line terminal posts 4 through 9. 2. The CRP 2 cable attached to CRP 2 will use the middle two holes on line terminal post 9;...
  • Page 25 2. Place the other threaded end in the turnbuckle. 3. While rotating the turnbuckle, prevent the two threaded ends from rotating. Rotate the turnbuckle until both threaded ends are into the turnbuckle beyond the 1-1/2” [38 mm] mark. See Figure 7 for the complete assembly. Field Applied Fittings with Turnbuckle There are two situations where a field applied fitting will be used: either when a fitting is required to complete an assembly;...
  • Page 26 5. Once the wedge is inserted, use a hammer and drift pin or other appropriate tool to seat the wedge by hitting on the triangular end of the casting. Several hits should be made to seat the wedge. 6. A heavy hex nut (PN-3908G for 1” fitting) or heavy square nut (PN-4959G for 3/4” fitting) has to fit inside the housing.

  • 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.

  • Page 28: Tensioning And Tension Meter

    It is recommended before tensioning, that for runs of cable greater than 5,000’ [1,525 m], to pull the cable at intervals of 3,000’ [915 m] to remove excess slack. Ensure no turnbuckles or torpedo splices will interfere with the posts during the tensioning. If there are any, remove the post(s) or the cables from the post.

  • Page 29: Delineation

    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 30: Repairs

    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 tension meter and adjustments made at the turnbuckles to bring the cable to the correct tension based on the cable ®...

  • Page 31: Emergency Repairs

    Repair for CASS Impact (CRP Involved) ® When the system has been impacted and CRP is involved, follow the steps below: 1. Inspect the damaged system and determine what material will be required to make the repairs. 2. For the CRPs that have been impacted, inspect the top and bottom post for damage. Repair and replace any damaged posts.
  • Page 32 Removing Entangled Cable from a Vehicle When the cable is entangled with a vehicle that must be towed away, remove the entangled cable by lifting one or more of the cables up over the vehicle. During this operation, if any of the line posts entangled with the cable start to lift up out of the sleeves, the lifting must be stopped and the posts removed from the cable.

  • Page 33: Cable Tension Inspection Program

    Temperature/Tension Chart. Cable Tension Inspection Program Trinity Highway 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 IR thermometer for the cable temperature.

  • Page 34: Cass ® Assembly/Repair Checklist

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

  • Page 35: Cass ® 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 and all of its components shall be inspected for damage after ®...

  • Page 36: Cass ® C-Channel Temperature/Tension Chart

    CASS C-Channel Temperature / Tension Chart ® Pre-Stretched Cable °F Tension (lbf)* ° C 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: Tension Log Cable Safety System

    Tension Log CAble Safety System™ Project Owner:_______________________________________________________________ Project Number: __________________ Project Description: _________________ CASS™ Version: __________________ Trinity Highway Drawing #: ___________ Date Checked: __________________ By: _____Company/State/specifying 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 TrinityHighway.com Revision A November 2021...

  • Page 39: Appendix B: Cable Barrier Overlap

    Appendix B: Cable Barrier Overlap TrinityHighway.com Revision A 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/specifying agency specification.

  • Page 41: Appendix D: Base Plated Post Assembly

    7. Tighten the nuts to a snug position with an appropriately sized wrench or socket and the lock washer is flat with a minimum of two (2) threads showing. Note: Base plated post assembly for below grade applications, contact Trinity Highway. TrinityHighway.com...

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