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Trinity Highway CAT-350 Assembly Manual

Tangent double-sided end terminal
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Summary of Contents for Trinity Highway CAT-350

  • Page 2 The information contained in this manual supersede all previous versions. The instructions, illustrations, and specifications are based on the latest CAT® System information available to Trinity Highway at publication. We reserve the right to make changes at any time. Please visit TrinityHighway.com/product-category/end terminals...
  • Page 3 rash ushion Attenuating erminal The CAT® is a tangent, double-sided, re-directive/gating and energy absorbing attenuator/end terminal available for use with various longitudinal highway barriers, in either unidirectional or bidirectional traffic applications. TrinityHighway.com December 2021...

  • Page 4: Table Of Contents

    Table of Contents CAT® ACRONYMS ............................. 4 Customer Service Contacts ..........................4 Limitations and Warnings ............................ 5 Overview ................................6 Recommended Tools ............................7 Site Preparation ..............................8 Post Placement ..............................9 Rigid Pavement and Rock ........................... 9 Inspect Shipment ..............................9 CAT®...

  • Page 5: Cat® Acronyms

    Trinity Highway Products, LLC Customer Service Contacts Trinity Highway is committed to the highest level of customer service. Feedback regarding the CAT®, its assembly procedures, supporting documentation, and performance is always welcome. Additional information can be obtained from the contact information below:...

  • Page 6: Limitations And Warnings

    WARNING: Use only Trinity Highway parts that are whether or not the products were assembled in specified by Trinity Highway for use with the CAT® consultation with Trinity Highway or by third parties. for assembling, maintaining, or repairing the CAT®.

  • Page 7: Overview

    Overview The CAT® is a tangent, double-sided, re-directive/gating and energy absorbing attenuator/end terminal available for use with various longitudinal highway barriers, in either unidirectional or bidirectional traffic applications. The CAT® consists of CAT® 10/12 gauge slotted guardrail, CAT® 10 gauge nose/side plates, channel strut, CAT®...

  • Page 8: Recommended Tools

    Recommended Tools Documentation • Manufacturer’s CAT® System Product Description Assembly Manual (Current Version). • CAT® System Drawing(s). Current Version of Applicable CAT® and CAT® Tail Drawing. Personal Protective Equipment • Eye Protection • Work Gloves • Safety-Toe Shoes • Back Protection •...

  • Page 9: Site Preparation

    Important: Ensure that the CAT® application conforms to the AASHTO Roadside Design Guide, current edition. Important: Trinity Highway does not direct grading. Proper site grading must be accomplished before assembly of the CAT® in accordance with local guidelines OR the AASHTO Roadside Design Guide (see Appendix A and B), whichever is more stringent.

  • Page 10: Post Placement

    Carefully unpack and inspect all components for damage. Check the received parts against the packing list supplied with the system. If any parts are damaged, missing, or unspecified; do not attempt to assemble the system and contact Trinity Highway immediately (p. 4). TrinityHighway.com...
  • Page 11 Warning: Use only Trinity Highway parts that are specified by Trinity Highway for use with the for assembling, maintaining, or repairing the Do not CAT® CAT®. utilize or otherwise commingle parts from other systems even if those systems are other Trinity Highway Systems.
  • Page 12 CAT® TAIL COMPONENTS / HARDWARE SS220 SS224 FOR 27 3/4” DOWNSTREAM HEIGHT (Single (Double GUARDRAIL INSTALLATION Sided Tail) Sided Tail) CAT® Tail Guardrail 12’-6” [3.810 m] Cable Anchor Bracket 701A 8” X 8” x 5/8” [200 mm x 200 mm x 16 mm] Bearing 782G Plate (At Post 6) 1”...

  • Page 13: Cat® System Components/Hardware

    CAT® System Components/Hardware Below is a pictorial depiction of the components/hardware for CAT®. Please see the Trinity Highway drawings and pages 10, 11 and 49 of this manual for specific lists of components/hardware and quantities required for CAT® selected to be assembled.
  • Page 14 ID: L PN: 749G ID: J PN: 3100B ID: K PN: 9852A 6’-0” Tube Sleeve CAT® Wood Offset Block Post 1 Channel Strut ID: M PN: 983G ID: N PN: 3012G ID: O PN:769G CAT® 10 Gauge Nose Plate CAT® Cable Assembly 3/4” x 8’-0” Soil Plate-18”...
  • Page 15 ID: X PN: 705G ID: V PN: 3900G ID: W PN: 3380G 1” Round Washer 5/8” x 1.5” Hex Bolt CAT® Pipe Sleeve 2” x 5.5” ID: Y PN: 3478G ID: Z PN: 11G ID: AA PN: 3300G 5/8” x7.5” Hex Bolt Guardrail 12’-6”...
  • Page 16 ID: HH PN: 4252G ID: JJ PN: 4258G ID: KK PN: 3275G 3/8” Hex Nut 3/8” Lock Washer 3/8” x 24.5” Restraint Rod ID: LL PN: 3320G ID: MM PN: 3395G ID: NN 5/8” x 24 Hex Bolt 3/16” x 1.75” x 3” Rectangular CAT®...
  • Page 17 ID: RR PN: 3000G ID: SS PN: 4076B ID: TT PN: 3500G CAT® Cable Anchor 3/4” x 6’-6” 8” Wood Offset Block 5/8” x 10” GR Bolt A307 ID: UU PN: 9915A ID: VV PN: 10967G ID: WW PN: 4660B CAT®...

  • Page 18: Assembly Steps

    Assembly Steps To ensure an accurate assembly of the CAT® Terminal, it is recommended that steps 1A through 10C be completed in order. Steps 11 through 16 may be assembled in any order after Step 10C has been completed. ALL STEPS MUST BE COMPLETED. Below ground portions in some assembly steps are not shown for clarity.

  • Page 19: Step 1A

    1. Layout the post locations as shown above. 2. Layout and placement of the posts are critical to the assembly of the CAT®. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® assembling, Ensure proper site grading in accordance with the state/specifying...

  • Page 20: Step 1B

    2. Layout and placement of the posts are critical to the assembly of the CAT®. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or Ensure proper site grading in accordance with the state/specifying repairing the CAT®.

  • Page 21: Single/Double Sided Guardrail

    533G 2 EA 7 & 8 at locations established in Step 1A. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or repairing the CAT®. Do not utilize Ensure the Post spacing is as established in Step 1A. Failure to...

  • Page 22: Step 2B: Cat® Tail - Post Assembly 7-11 Connecting To 31" [787 Mm] High Down Stream Guardrail

    Step 1B. 2. Ensure the Post Heights are installed per the Post Height Table. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or repairing the CAT®. Do not utilize Ensure the Post Heights are installed per the Post Height Table.

  • Page 23: Step 3: Cat® Tube Assembly Short Tube 4'-6" [1.37 M] With Soil Plate; Long Tube 6'-0" [1.83 M]

    4. Ensure the tube sleeve height does not exceed 4” [100 mm] above finished 3340G 12 EA grade. Use only Trinity Highway parts WARNINGS that are specified herein for the CAT® System for assembling, Ensure the Soil Plates are assembled on the downstream side of the...

  • Page 24: Step 4A: Cat® Post And Offset Block Assembly (Posts 3, 5, & 6)

    3 EA Note: Post (Part F) and Block (Part H) assembly could be completed in advance to 4640G 6 EA reduce time on jobsite. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® assembling, maintaining, repairing the Ensure that the post is installed per the above drawing with the three CAT®.

  • Page 25: Step 4B: Cat® Post Assembly (Post 4)

    Do not over tighten the bolt and threads protruding beyond the nut. deform the tubes. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or repairing the CAT®. Do not utilize Ensure that the post is installed per the above drawing with the three or otherwise commingle parts from (3) holes at the top of the post.

  • Page 26: Step 4C: Cat® Post And Strut Assembly (Posts 1 & 2)

    3497G 2 EA 19271G 1 EA WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, Ensure the notched side of post 1 (Part E) is facing post 2 repairing the CAT®. Do not utilize or (Part F).

  • Page 27: Sided Guardrail

    (2) bolt threads protruding beyond the nut. WARNINGS Ensure the Single Sided CAT® Tail is not used in a median application Use only Trinity Highway parts that where the opposing traffic can impact the blunt end of the CAT® Tail are specified herein for the CAT®...

  • Page 28: Step 5B: Cat® Tail Anchor Bracket Assembly (For 27 3/4" [705 Mm] High Downstream Single Sided Guardrail Assembly)

    3340G 8 EA bolt threads protruding beyond the nut. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or Ensure the Cable Anchor Bracket is assembled between Posts 6 repairing the CAT®. Do not utilize and 7 and the welded plate is towards Post 7.
  • Page 29 7. Ensure two (2) nails are assembled as shown in the Bearing Plate Detail to prevent the plate from rotating. Nails are not included in the quantities. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or Ensure the Bearing Plate is placed on the Cable Assembly with the repairing the CAT®.

  • Page 30: Step 6: Cat® Tail - Guardrail Assembly Connecting To 27 3/4" [705 Mm] High Downstream Double Sided Guardrail

    4 EA bolt threads protruding beyond the nut. 3500G 4 EA WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or Ensure Rectangular Washers are assembled between Guardrail repairing the CAT®. Do not utilize Bolt head and the CAT®...

  • Page 31: Guardrail

    8 EA (2) bolt threads protruding beyond the nut. 3500G 4 EA WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for Ensure Rectangular Washers are assembled between Guardrail assembling, maintaining, Bolt head and the CAT® Tail Guardrail at Post 8. Ensure the CAT®...

  • Page 32: Step 7B

    3540G 2 EA 3520G 4 EA WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for Ensure Rectangular Washers are assembled between Guardrail assembling, maintaining, Bolt head and the CAT® Tail Guardrail at Post 8. Ensure the CAT®...

  • Page 33: Step 8

    5. Tighten all threaded hardware to a snug position with a minimum of two (2) bolt threads protruding beyond the nut. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for Ensure Rectangular Washers are assembled between Guardrail...

  • Page 34: Step 9A: Cat® 10 Gauge, Slotted/Welded Guardrail-2 Assembly

    5. Tighten all threaded hardware to a snug position with a minimum of two (2) bolt threads protruding beyond the nut. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or repairing Ensure that CAT® Hex Bolts and CAT® Plate Washers are used for the CAT®.

  • Page 35: Step 9B: Cat® Splice Assembly (At Post 6)

    3. Tighten threaded hardware to a snug position with a minimum of two (2) bolt threads protruding beyond the nut. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for CAT® Ensure CAT® Hex Bolts with the...

  • Page 36: Step 10A: Cat® 12 Gauge, Slotted Guardrail-1 Assembly

    (2) bolt threads protruding beyond the nut. 3395G 16 EA WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or repairing Ensure that CAT® Hex Bolts and Plate Washers are used for the the CAT®.

  • Page 37: Step 10B: Cat® Splice Assembly (At Post 4)

    3. Tighten threaded hardware to a snug position with a minimum of two (2) bolt threads protruding beyond the nut. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for CAT® Ensure CAT® Hex Bolts with the...

  • Page 38: Step 10C: Cat® Spacer Assembly

    3. Tighten all threaded hardware to a snug position with a minimum of two (2) bolt threads protruding beyond the nut. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or Ensure the Spacer Channel CAT® is assembled per the repairing the CAT®.

  • Page 39: Step 11: Cat® Nose Plate (10 Gauge) Assembly

    9916A 1 EA 5. Cut off excess Bolt Threads (Part R) and peen excess threads. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® System assembling, maintaining, or repairing the CAT®...

  • Page 40: Step 12: Cat® Side Plate (10 Gauge) Assembly

    3. Tighten all threaded hardware to a snug position with a minimum of two (2) bolt threads protruding beyond the nut. WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® for assembling, maintaining, or Ensure the CAT® 10 Gauge Side Plates are assembled on the repairing the CAT®.

  • Page 41: Step 13: Cat® Anchor Cable Assembly

    8. Ensure two (2) nails are assembled as shown in Bearing Plate Detail to prevent the plate from rotating. Nails are not included in the quantities. Use only Trinity Highway parts WARNINGS that are specified herein for the CAT®...

  • Page 42: Step 14: Cat® Restraining Road Assembly (Posts 3 & 5)

    3. Tighten the nuts to a snug position, ensuring a minimum of two threads are 3275G 2 EA showing. WARNINGS Use only Trinity Highway parts that are specified herein for the Ensure no washers are placed between the nut and the outside face CAT® assembling, of the CAT®...

  • Page 43: Step 15: Cat® Knock Out Tube/Post Plate Assembly (Posts 4 & 6)

    3. Tighten threaded hardware to a snug position with a minimum of two (2) bolt threads protruding beyond the nut. 9921G 2 EA 19261G 2 EA WARNINGS Use only Trinity Highway parts that are specified herein for the CAT® assembling, Ensure the CAT® Knock Out Tubes are assembled horizontally maintaining, repairing the on the upstream side of Posts 4 and 6.

  • Page 44: Step 16: Cat® Delineation

    Note: Manufacturer suggests that user provide delineation (reflective sheeting) as required by the state/specifying agency for terminals. Trinity Highway offers two (2) specific reflective sheeting options for an additional charge. Trinity Highway makes no guarantees they meet the minimum specifications, comply with MUTCD requirements or comply with state/specifying agency requirements.

  • Page 45: Cat® System Assembly Checklist (File With Project Records)

    Location: □ 1. Ensure only Trinity Highway CAT® parts are used for the assembly of the CAT® System and that all parts are free of damage. (pp 5 & 6) 2. Ensure required traffic control is in place to conduct CAT® assembly. (p 5) □...

  • Page 46: Cat® System Repair Checklist (File With Maintenance Records)

    Location: □ 1. Ensure only Trinity Highway CAT® parts are used for the assembly of the CAT® System and that all parts are free of damage. (pp 5 & 6) 2. Ensure required traffic control is in place to conduct CAT® assembly. (p 5) □...

  • Page 47: Cat® System Routine Inspection Checklist (File With Maintenance Records)

    Repair using only Trinity Highway parts that are specified for use within this CAT® Product Description Assembly Manual. If no end terminal inspection program exists, Trinity Highway recommends visual drive-by inspections at least once every month and walk-up inspections every six (6) months. These...

  • Page 48: Appendix A: Aashto Roadside Design Guide Roadside (Shoulder) Grading Detail

    Appendix A AASHTO Roadside Design Guide Roadside (Shoulder) Grading Detail CAT® Roadside (Shoulder) Grading Detail Detail derived from information contained in the AASHTO Roadside Design Guide, 4 Edition 2011 TrinityHighway.com December 2021...

  • Page 49: Appendix B: Aashto Roadside Design Guide Median Grading Detail

    Appendix B AASHTO Roadside Design Guide Median Grading Detail NOTE: Refer to AASHTO Roadside Design Guide, 4 Edition 2011, Section 5.6.2.2 Slopes, pp 5-46 through 5-48 for slope criteria. CAT® MEDIAN Grading Detail Detail derived from information contained in the AASHTO Roadside Design Guide, 4 Edition 2011 TrinityHighway.com December 2021...

  • Page 50: Appendix C: Cat® Ss245 Repair Kit1 And Cat® Hardware Bags

    Appendix C CAT® SS245 Repair Kit1 and CAT® Hardware B CAT® SS245 Repair Kit1, (Above Ground Only) 50245L CAT® 12 gauge, Slotted Guardrail-1, 12’-6” [3.810 m] CAT® 10 gauge, Slotted/Welded Guardrail-2, 12’-6” [3.810 m] 130A CAT® Side Plate 984G CAT® Channel Strut 9852A CAT®...

  • Page 51: Notes

    NOTES: TrinityHighway.com December 2021...

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