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Curve TRINITI HIGHWAY CASS S4 Product Description Assembly Manual

29" high cable safety system
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  • Page 2 CASS S4 29” High ® CAble Safety System The CASS S4 29” High CAble Safety System (“CASS S4(29)”), 3-cable, has been tested to National ® ® Cooperative Highway Research Program (“NCHRP”) Report 350 criteria and has been deemed eligible for Federal-aid reimbursement on the National Highway System (“NHS”) by the Federal Highway Administration (“FHWA”) as a Test Level 3 (“TL-3”) system when installed on slopes which are 6:1 or flatter.

  • Page 3: Table Of Contents

    Table of Contents CASS S4(29) Acronyms ......................2 ® Customer Service Contacts ......................3 Important Introductory Notes ......................3 Limitation and Warnings ........................ 4 General CASS S4(29) Information ....................6 ® CASS S4(29) Components ......................6 ® Recommended Tools ........................13 Ground Preparation and Barrier Alignment .................

  • Page 4: Customer Service Contacts

    Customer Service Contacts Trinity Highway is committed to the highest level of customer service. Feedback regarding CASS ® S4(29) its assembly procedures, supporting documentation, and performance is always welcome. Additional information can be obtained from the contact information below: Trinity Highway (888) 356-2363 (USA) Telephone +1 214 589 8140 (International)

  • Page 5: Limitation And Warnings

    Limitations and Warnings Trinity Highway, in compliance with NCHRP Report 350, contracts with ISO 17025 A2LA accredited testing laboratories to perform crash tests, evaluate tests, and Safety Alert Symbols appear throughout this submit the test results to the FHWA for review. manual and indicate Danger, Warning, Caution or Important statements.
  • Page 6 Danger: It is critical that CASS S4(29) posts are ® Note: Based on soil conditions at the site, ANY or ALL placed in suitable soil that will allow the system to foundations may need larger/deeper concrete footings fully perform accordance with design or larger soil plates (for driven applications) as...

  • Page 7: General Cass ® S4(29) Information

    General CASS S4(29) Information ® CASS S4(29) is a 3 Cable Barrier consisting of a 4” wide galvanized steel S4 x 7.7# [S100 x 11.5] and ® three (3) pre-stretched 3/4” [19 mm] wire rope cables. The posts can be driven, placed in a driven sleeve, placed in a sleeve and concrete footing, placed in a sleeve in a mow strip, or base plated.
  • 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-RHT PN: 3537G PN: 3700G PN: 3701G 1” Stud Flattened-LHT 3/4”...
  • Page 9 PN: 4099G PN: 4190G PN: 4199B Torpedo Cable Splice Cable End Housing 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: 5698G PN: 5700B PN: 5701B Assembled 3/4” Cable Splice 4” Cable Spacer w/o Reflector 4” Cable Reflector Spacer Yellow PN: 5702B PN: 5707T PN: 5708B 4” Cable Reflector Spacer Stainless Steel Post Strap Sleeve Cover – CASS Post ® White PN: 5709B PN: 5711G...
  • Page 11 PN: 5852B PN: 5878B PN: 5909G Reflector Roadside (RIGHT) CASS Tension Meter 1” Cable Field Splice Left ® PN:5910G PN: 5919B PN: 6722G 1” Cable Field Splice Right #4 x 2’-8” Rebar Rod 5/8" X 8" ATR CHSL PT A449 PN: 9021G PN: 33903A PN: 33908G...
  • Page 12 PN: 33909G PN: 33910G PN: 33916B CRP-Cable Bracket S3 Terminal Post – in Sleeve CRP Reinforcing Cage PN: 33934A PN: 33935A PN: 33936A Bottom CRP (in Concrete) Top CRP Bottom CRP (w/Soil Plate) PN: 33952A PN: 33953G PN: 33956G Driven Terminal Sleeve w/Soil CASS TL-3 Post in Sleeve CASS...
  • Page 13 PN: 33976A PN: 33982G PN: 33983G 30 3/4” Driven Sleeve w/Soil 27” CASS TL-3 Post Sleeve CASS TL-3 Splice Post ® ® Plate (CASS TL-3 Post) (Driven) PN: 33993A PN:105204G PN: 105205G CASS TL-3 Base Plated Post 3/4” Stud Flattened-LHT 3/4”...

  • Page 14: Recommended Tools

    Recommended Tools Documentation • Manufacturer’s CASS S4 29” High CAble Safety System Product Description ® Assembly Manual (Current Version). • CASS S4(29) System Drawing(s). Current Version of SS730 TL-3 6:1 3C ® Personal Protective Equipment (PPE) • Eye Protection • Work Gloves •...

  • Page 15: Ground Preparation And Barrier Alignment

    If assembled on a horizontal curve, a minimum 650 foot [198 m] radius is required. If assembled on a sag vertical curve, the K value is ≥ 100’ [30 m]. See “Assembly on a Curve” Section.

  • Page 16: Line Posts Foundation Placement

    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. Weak soil conditions may necessitate a larger/deeper footing for the line posts, based on the radius of the curve.
  • 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-5747B) on the bottom of the foundation sleeve (PN-33982G) or tape the bottom end of the foundation sleeve to prevent the concrete from coming into the tube.

  • Page 18: Post Placement

    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 CASS S4(29) posts can be driven, placed in a driven sleeve, placed in a sleeve in a concrete ®...
  • Page 19 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 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 2). Complete the following steps for assembling the CCT Bottom CRP with Soil Plate: 1.
  • Page 21 4. Place the foundation sleeve in the poured concrete footing. The sleeve is to be positioned plumb, flush with the top of the footing, ensure that the sleeve is aligned a minimum of 3” [75 mm] from the edge of the footing and the 3” [75 mm] side parallel to the roadway), and in alignment.

  • 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 8.5] 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

    1. Drive post (PN-33903A) at post locations 4 through 9 with an appropriate driving head/equipment. 2. Follow Steps 3 and 4 in the “Terminal Line Posts in Driven Sleeve-Posts 4 through 9” section above. Terminal Cables The cables used in the CCT are pre-stretched, consisting of three (3) precut cables with factory applied fittings (Option A) on each end;...

  • Page 24: Line Cables

    3. The CRP 3 cable attached to CRP 3 will use the bottom two holes on line terminal posts 4 through 9. 4. The cables are attached to the posts using cable lock bolts (PN-5925G) (See Figure 5). 5. Insert the non-threaded end of the bolt in one of the two required holes and place the bolt around the cable and insert the threaded end in the other required hole (either orientation of the cable lock bolt is...
  • Page 25 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 6 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 Note: All three bundles of the cable are to be located in the appropriate grooves of the wedge. 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 housing. Several hits should be made to seat the wedge.

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

    8. On this same cable, follow Steps 1-7 to assemble the cable in the fitting. 9. Place the two (2) Torpedo Cable pieces together and connect them with the threaded ring. Tighten the connection with a pipe wrench(s), ensuring no more than two threads are shown after the connection.

  • 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. Check to make sure 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 Warning: Infrared light is harmful if shined into the eyes. Warning: Read and understand the directions provided for the CASS Cable ® pulling tool. Warning: Extreme care should be taken to ensure that the C A S S cable ® pulling tool is attached to the cable in such a location that if it slips, the chain or pulling tool will not hit anyone.

  • Page 30: Delineation

    Delineation The state/specifying agency will establish the criteria for delineation of the line posts. The delineation is typically provided on the spacer used to separate the cables. 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.

  • Page 31: Emergency Repairs

    Note: The reflective sheeting may be placed on the spacer for CASS S4(29) based on the ® state/specifying agency’s specification. Repair for CASS S4(29) Impact (CRP Involved) ® When the system has been impacted and CRP is involved, follow the steps below: 1.
  • Page 32 by loosening the two large nuts on the terminal cable end. DO NOT COMPLETELY REMOVE EITHER OF THE NUTS! Repairing a Cut or Damaged Cable Following are various methods to repair cables that have been cut or damaged: Method 1 – Splicing the Cable Splicing the cable may be necessary if a cable is cut or damaged during an impact.

  • Page 33: Cable Tension Inspection Program

    Method 4 – Using Field Applied Fitting Connections Only (No Cables) If the damaged cable, after cutting, is less than a total of 4’-6” [1.3 m], the connection can be made with a left and right threaded field applied fittings and a turnbuckle. 1.

  • Page 34: Cass ® S4(29) Assembly/Repair Checklist

    CASS S4(29) Assembly/Repair Checklist ® (File With Project/Maintenance Records) Performed by: Date: Location: ______________________________________________________________________ □ Ensure only Trinity Highway CASS S4(29) parts are used for the assembly/repair of CASS ® ® and that all parts are free of damage. (p 4) □...

  • Page 35: Cass S4(29) Routine Inspection Checklist (File With Maintenance Records)

    CASS S4(29) Routine Inspection Checklist ® (File with Maintenance Records) Performed by: _____________________________________________________________ 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 S4(29) and all of its components shall be inspected for...

  • Page 36: Cass ® S4(29) Temperature/Tension Chart

    CASS S4(29) 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

    3 Cable 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 Created November 2021...

  • Page 39: Appendix B: Cable Barrier Overlap

    Appendix B: Cable Barrier Overlap TrinityHighway.com Created 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 specifying highway state/specifying agency specification.

  • Page 41: Appendix D: Base Plated Post Assembly

    Appendix D: Base Plated Post Assembly The base plated post (PN-33993A) must be placed on a concrete surface 6” [150 mm] or more in depth (See Figure 11). The post length varies per concrete elevation. The center of the yielding holes are approximately 2’-6 1/4”...

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