Trinity REACT 350 Assembly Manual

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REACT 350

Wide

60"/96"/120"

Assembly Manual

Part No. 115242B

Revision A December 2012

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Summary of Contents for Trinity REACT 350

Page 1 ® REACT 350 Wide 60”/96”/120” Assembly Manual Part No. 115242B Revision A December 2012...
Page 2 The instructions contained in this Manual supersede all previous information and Manuals. All ® information, illustrations, and specifications in this Manual are based on the latest REACT 350 Wide system information available to Energy Absorption Systems at the time of printing. We reserve the right to make changes at any time.
Page 3: Table Of Contents
Table of Contents Customer Service Contacts ......................3 Important Introductory Notes ......................3 Recommended Safety Rules for Assembly .................. 4 Safety Symbols ..........................5 Warnings and Cautions ......................... 5 Limitations and Warnings ......................6 System Overview .......................... 7 Recommended Tools ........................8 Site Preparation/Foundation .......................
Page 4: Customer Service Contacts
REACT 350 Wide system. These instructions ® are to be used only in conjunction with the assembly of the REACT 350 Wide system and are for standard assemblies only as specified by the applicable highway authority. In the event your...
Page 5: Recommended Safety Rules For Assembly
This Manual must be kept in a location where it is readily available to persons who are skilled ® and experienced in the assembly, maintenance, or repair of the REACT 350 Wide system. Additional copies of this Manual are immediately available from Energy Absorption Systems by calling (888) 323-6374 or by email at customerservice@energyabsorption.com.
Page 6: Safety Symbols
Safety Symbols ® This section describes the safety symbols that appear in this REACT 350 Wide Manual. Read the Manual for complete safety, assembly, operating, maintenance, repair, and service information. Symbol Meaning Safety Alert Symbol: Indicates Danger, Warning, or Caution. Failure to read and follow the Danger, Warning, Safety, or Caution indicators could result in serious injury or death to the workers and/or bystanders.
Page 7: Limitations And Warnings
(approx. 820kg [1800 lb.]) to full size pickup trucks (approx. 2000 kg [4400 lb.]) as specified by the FHWA. A product can be certified for multiple Test ® Levels. The REACT 350 Wide is certified to the Test Level(s) as shown below: Test Level 1: 50 km/h [31 mph]...
Page 8: System Overview
System Overview ® REACT 350 Wide is a potentially reusable, redirective, non-gating crash cushion for hazards ranging in width from 1524 mm to 3048 mm (60" to 120"). It consists of energy- absorbing Cylinders. ® REACT 350 Wide system utilizes three types of Cylinders in a “staged” configuration to address both lighter cars and heavier, high center-of-gravity vehicles.
Page 9: Recommended Tools
Recommended Tools Documentation  Manufacturer’s Assembly Manual  Manufacturer’s Drawing Package Cutting equipment  Rebar cutting bit  Concrete drill bits – 22 mm (7/8”) x 178 mm [7”](*Two Fluted)  Concrete drill bits - 19 mm (3/4”) x 178 mm [7”] (*Two Fluted) ...
Page 10 Miscellaneous  Traffic control equipment  Lifting and moving equipment (A lifting device is preferred although a forklift can be used.) Minimum 5,000 lb. capacity required.  Compressor (100 psi) and Generator (5 kW)  Long pry bar  Drift pin ...
Page 11: Site Preparation/Foundation
Refer to Assembly Procedures for a complete list of instructions. Site Preparation/Foundation ® REACT 350 Wide (60”/96”/120”) should be assembled only on an existing or freshly placed and cured concrete base (28 MPa [4000 psi] minimum). Location and orientation of the concrete base and attenuator must comply with project plans or as otherwise determined by the resident project engineer.
Page 12: Assembly Procedures (60" Wide Systems)
Assembly Procedures (60” Wide Systems) ® Note: The Drawing Package supplied with the REACT 350 Wide (60”) must be used with these instructions for proper assembly and should take precedence over these general instructions. Deploy Traffic Control A traffic control plan appropriate to the complexity of the project should be prepared and ®...
Page 13 3/4" flat washers and nuts provided with kit to anchor Monorail to foundation. Note: ® All holes in Monorail must be used to anchor the REACT 350 Wide (60”) to the foundation. Warning: Once the grout has hardened, torque nuts to 165 N-m [120 ft-lb].
Page 14 (See Figure 5). Figure 4 Identifying Cylinder/Diaphragm Assemblies Figure 5 ® Properly Assembled REACT 350 Wide (60) www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com All rights in copyright reserved...
Page 15 Attach Rear Cylinder Assemblies (Concrete Backup) For Concrete Backup, use bar washer as a template to locate and drill 22 mm diameter [7/8” diameter] holes to a depth of 100 mm + 13 mm -0 [4” + 1/2" -0]* into the Concrete Backup, four places as shown in Figure 6.
Page 16 ® Refer to the instructions included with the Horizontal MP-3 kit to anchor the rear Cylinder ® Assemblies to the Backup using 3/4" diameter x 6 1/2" long MP-3 Studs, 2” x 28” Bar Washers and 3/4" nuts provided with MP-3 kit. When oriented correctly, the letters “G” will be facing each other (See Figure 7a).
Page 17 Attach Rear Cylinder Assemblies (Self-Contained Backup) For the Self-contained Backup, anchor the Rear Cylinder Assemblies to the Backup using 3/4" diameter x 3” long hex bolts, Bar Washers, 3/4" lock washers and 3/4" hex nuts provided with the Backup Assembly. When oriented correctly, the letters “G” will be facing each other (See Figure 7b).
Page 18 Attach “F” Cylinder Assemblies 1. Disassemble “F” Cylinder/Frame Assembly. 2. Slide Diaphragm onto Monorail and against the “G” Cylinders. 3. Reassemble “F” Cylinder/Diaphragm Assembly onto “G” Cylinder Assemblies as shown in Figure 8. 4. Repeat the above steps to attach remaining two “F” Cylinder Diaphragm Assemblies. Figure 8 “F”...
Page 19 Attach “E” Cylinder Assemblies 1. Disassemble “E” Cylinder/Frame Assembly. 2. Slide Diaphragm onto Monorail and against “F” Cylinders. 3. Reassemble “E” Cylinder/Diaphragm Assembly onto “F” Cylinder Assemblies making sure the spacers are in place as shown in Figure 9. Figure 9 “E”...
Page 20 Attach “D” Cylinder Assemblies 1. Disassemble “D” Cylinder/Frame Assembly. 2. Slide Diaphragm onto Monorail and against “E” Cylinders. 3. Reassemble “D” Cylinder/Diaphragm Assembly onto “E” Cylinder Assemblies as shown in Figure 10. 4. Repeat the above steps to attach remaining three “D” Cylinder/Diaphragm Assemblies. Figure 10 “D”...
Page 21 Attach “C” Cylinder Assemblies 1. Disassemble “C” Cylinder/Frame Assembly. 2. Slide Diaphragm onto Monorail and against “D” Cylinders. 3. Reassemble “C” Cylinder/Diaphragm Assembly onto “D” Cylinder Assemblies as shown in Figure 11. Figure 11 “C” to “D” Cylinder Assembly Attachment www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com...
Page 22 10) Attach “B” Cylinder Assemblies 1. Remove Diaphragm from “B” Cylinder/Diaphragm Assembly. 2. Slide Diaphragm onto Monorail and against “C” Cylinders. 3. Reassemble “B” Cylinder/Diaphragm Assembly onto “C” Cylinder Assemblies as shown in Figure 12. Figure 12 “B” to “C” Cylinder Assembly Attachment www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com...
Page 23 11) Attach “A” Cylinder Assemblies 1. Remove Diaphragm from “A” Cylinder/Diaphragm Assembly. 2. Slide Diaphragm onto Monorail and against “B” Cylinders. 3. Reassemble “A” Cylinder/Diaphragm Assembly onto “B” Cylinder Assemblies as shown in Figure 13. Figure 13 “A” to “B” Cylinder Assembly Attachment www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com...
Page 24 12) Attach Monorail End Cap and Trigger 1. Use two 1/2” diameter x 2 1/2” bolts, two 1/2" diameter nuts, and Bar Washer to attach trigger to “A” Cylinder Assembly (See Figure 14). 2. Use hole in trigger to locate and drill 7/8” hole in center of Monorail as shown in Figure 3.
Page 25 Attach Nose Cover and Side Mount Reflectors 1. Ensure that the Nose Cover suits the site (See Nose Cover Selection below). Refer to local standards, applicable DOT regulations, specifications of the appropriate highway authority and “Manual on Uniform Traffic Control Devices” (MUTCD). Figure 15a Figure 15b Figure 15c...
Page 26 2. Align 1” diameter hole in nose cover with 1” diameter hole in Cylinder. 3. Screw #8 self-tapping screw into Cylinder punching through reflective tape and into the existing holes in nose cover until head of fastener is flush for all 10 places (See Figure 16).
Page 27 Cylinders are the primary redirecting component of the REACT 350 Wide (60”). Ensure all Steel Struts inside Cylinders are oriented as shown in Figure 17. Figure 17 ® Assembled REACT 350 Wide (60”) – Plan view www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com All rights in copyright reserved...
Page 28: Assembly Procedures (96" And 120" Wide Systems)
Assembly Procedures (96” and 120” Wide Systems) ® Note: The drawing package provided with the REACT 350 Wide (96”/120”) must be used with these instructions for proper assembly and should take precedence over these general instructions. Note: Refer to pages 9 and 10 for “Recommended Tools” and “Site Preparation/Foundation.
Page 29 3/4" diameter x 7” long studs using instructions included with kit. After grout is hardened, use 3/4" flat washers and nuts provided with kit to anchor Monorail to foundation. ® Note: All holes in Monorail must be used to anchor to REACT 350 Wide (96”/120”) to the foundation. Warning: Once the grout has hardened, torque nuts to 165 N-m [120 ft-lb].
Page 30 Backup, and the letters will descend as you move toward the front of the system (See Figure 21). Figure 20 Identifying Cylinder/Diaphragm Assemblies Figure 21 ® Properly assembled REACT 350 Wide (96”/120”) www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com All rights in copyright reserved...
Page 31 5a) Attach Rear Cylinder Assemblies (Concrete Backup) For Concrete Backup, use Bar Washer as a template to locate and drill 22 mm diameter [7/8” diameter] holes to a depth of 100 mm + 13 mm -0 [4” + 1/2" -0]* into the Concrete Backup, four places as shown in Figure 22.
Page 32 Refer to the instructions included with the Horizontal MP-3 kit to anchor the Rear Cylinder Assemblies to the Backup using 3/4" diameter x 6 1/2" long MP-3 studs, 2” x 28” Bar Washers and 3/4" nuts provided with MP-3 kit. When oriented correctly, the letters “H” will be facing each other (See Figure 23a).
Page 33 5b) Attach Rear Cylinder Assemblies (Self-Contained Backup) For the Self-Contained Backup, anchor the Rear Cylinder Assemblies to the Backup using 3/4” diameter x 3” long hex bolts, Bar Washers, 3/4” lock washers and 3/4” hex nuts provided with the Backup Assembly. When oriented correctly, the letters “H” will be facing each other (See Figure 23b).
Page 34 Attach “G” Cylinder 1. Disassemble “G” Cylinder/Frame Assembly. 2. Slide Diaphragm onto Monorail and against “H” Cylinders. 3. Reassemble “G” Cylinder/Diaphragm Assembly onto “H” Cylinder Assemblies as shown in Figure 24. 4. Repeat the above steps to attach remaining two “G” Cylinder/Diaphragm Assemblies. Figure 24 “G”...
Page 35 Attach “F” Cylinder Assemblies 1. Disassemble “F” Cylinder/Frame Assembly. 2. Slide Diaphragm onto Monorail and against “G” Cylinders. 3. Reassemble “F” Cylinder/Diaphragm Assembly onto “G” Cylinder Assemblies as shown in Figure 25. Figure 25 “F” to “G” Cylinder Assembly Attachment www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com...
Page 36 Attach “E” Cylinder Assemblies 1. Disassemble “E” Cylinder/Frame Assembly. 2. Slide Diaphragm onto Monorail and against “F” Cylinders. 3. Reassemble “E” Cylinder/Diaphragm Assembly onto “F” Cylinder Assemblies as shown in Figure 26. Repeat the above steps to attach remaining three “E” Cylinder/Diaphragm Assemblies. Figure 26 “E”...
Page 37 Attach “D” Cylinder Assemblies 1. Disassemble “D” Cylinder/Frame Assembly. 2. Slide Diaphragm onto Monorail and against “E” Cylinders. 3. Reassemble “D” Cylinder/Diaphragm Assembly onto “E” Cylinder Assemblies as shown in Figure 27. Figure 27 “D” to “E” Cylinder Assembly Attachment www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com...
Page 38 10) Attach “C” Cylinder Assemblies 1. Disassemble “C” Cylinder/Frame Assembly. 2. Slide Diaphragm onto Monorail and against “D” Cylinders. 3. Reassemble “C” Cylinder/Diaphragm Assembly onto “D” Cylinder Assemblies as shown in Figure 28. Figure 28 “C” to “D” Cylinder Assembly Attachment www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com...
Page 39 11) Attach “B” Cylinder/Diaphragm Assemblies 1. Without disassembling “B” Cylinder/Diaphragm Assembly, slide onto Monorail and against “C” Cylinders. 2. Assemble “B” Cylinder/Diaphragm Assembly onto “C” Cylinder Assemblies as shown in Figure 29. Figure 29 “B” to “C” Cylinder Assembly Attachment www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com...
Page 40 12) Attach “A” Cylinder/Diaphragm Assembly 1. Without disassembling “A” Cylinder/Diaphragm Assembly, slide onto Monorail and against “B” Cylinders. 2. Assemble “A” Cylinder/Diaphragm Assembly onto “B” Cylinder Assemblies as shown in Figure 30. Figure 30 “A” to “B” Cylinder Assembly Attachment www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com...
Page 41 13) Attach Monorail End Cap and Trigger 1. Use two 1/2" diameter x 2 1/2" bolts, two 1/2" diameter nuts, and Bar Washer to attach trigger to “A” Cylinder Assembly (See Figure 31). 2. Use hole in trigger to locate and drill 7/8” hole in center of Monorail as shown in Figure 3.
Page 42 14) Attach Nose Cover and Side Mount Reflectors 1. Ensure that the Nose Cover suits the site (See Nose Cover Selection below). Refer to local standards and “Manual on Uniform Traffic Control Devices” (MUTCD) Figure 32c Figure 32a Figure 32b For traffic on Left For traffic on Right For traffic on Both...
Page 43 2. Align 1” diameter hole in Nose Cover with 1” diameter hole in Cylinder. 3. Screw #8 self-tapping screw into Cylinder punching through reflective tape and into the existing holes in Nose Cover until head of fastener is flush for all 10 places (See Figure 33).
Page 44 Cylinders are the primary redirecting component of the REACT 350 Wide (96”/120”). Ensure all Steel Struts inside Cylinders are oriented as shown in Figure 34. Figure 34 ® Assembled REACT 350 Wide (120”) – Plan View www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com All rights in copyright reserved...
Page 45: Polyester Anchoring System
Instructions before starting. 1) Prepare the Concrete Pad ® The anchor bolts (studs) that anchor the REACT 350 Wide system Backup and/or Monorail sections to the concrete pad must be those shipped in the kit or of high strength steel (830 MPa [120,000 psi] minimum tensile strength or equal).
Page 46 3) Clean the Holes Blow the concrete dust from the hole using oil-free compressed air. Thoroughly brush it with a stiff-bristled brush and then blow it out again. If the hole is wet, completely flush it with water while brushing. Then blow it clean using oil-free compressed air. 4) Mix the Resin and Hardener ®...
Page 47: Horizontal Assemblies
Table B Approximate Hardening Times in hours Temperature Hardening Times (hours) Recommended Concrete Torque Bit Size No Promoter With Promoter >26 >80 N/R* 22-26 70-79 16-21 60-69 10-15 50-59 40-49 -1-3 30-39 1 1/2 <-1 <30 N/R** *Not recommended **Contact Customer Service Department for more information Horizontal Assemblies ®...
Page 48 5) Insert Studs into Holes ® Push stud through part to be anchored and into hole. Twist the stud in the MP-3 grout to wet the threads. Note: In horizontal applications the stud should be flush with the top of the nut (See Figure 35). Figure 35 MP-3 Horizontal Application ®...
Page 49: Mp-3 Assembly Cautions
MP-3 Assembly Cautions 1) Shelf life ® ® If the shelf life of the MP-3 has expired (See MP-3 kit for expiration information), mix a ® small amount of MP-3 in the proportions of one part A to two parts B by volume. If the material does not set according to the instructions, contact Energy Absorption Systems for guidance.
Page 50: Maintenance And Repair
After an impact, always follow the “Post Impact Instructions.” ® 1) Check to see if there is evidence of an impact. Check to verify that the REACT 350 Wide (60”/96”/120”) is fully extended from the Backup. If it is not, a walk-up inspection will be necessary.
Page 51: Post-Impact Instructions
5) Inspect for bent Diaphragms and other damaged parts. Replace all damaged parts ® before putting REACT 350 Wide (60”/96”/120”) back into service. 6) Pull system out to original length and reattach trigger. See Figure 36 for pullout hardware assembly.
Page 52 www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com All rights in copyright reserved...
Page 53 www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com All rights in copyright reserved...
Page 54 Notes: www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com All rights in copyright reserved...
Page 55 Notes: www.energyabsorption.com Revision A December 2012 www.highwayguardrail.com All rights in copyright reserved...
Page 56 2525 Stemmons Freeway Dallas, Texas 75207 888-323-6374 (USA only) 214-589-8140 (Outside USA) www.energyabsorption.com www.highwayguardrail.com...