Session 8 Type IX Crash Cushion CAT-350 Trinity Highway Products

Session 8Type IX Crash Cushion CAT-350

Trinity Highway Products

Installation Instructions for Proprietary Guard Rail End

Terminals Std Draw Note – RBE-200 & 205 Crash Cushion Type IX

both have notes “The Manufacture SHALL furnish two (2) sets of shop plans to the contractor with each installation”

Added to Sect 719.03 of 2012 Std Specs: “Proprietary end treatments SHALL be installed according to the manufacturer’s assembly or installation instructions”

Should NOT LET THE CONTRACTOR BEGIN INSTALLATION BEFORE SUPPLYING YOU WITH THESE SHOP PLANS OR INSTALLATION INSTRUCTIONS – With this training I have attempted to follow the manuals as closely as possible but you and the contractor need these documents to properly do your jobs of installing and inspection propriety guardrail end terminals

Type IX Crash Cushion CAT-350

Trinity Highway Products The CAT-350 is designed with a flimsy Nose,

Breakaway Wood Post and Slotted Rail Panels that telescope through a Rectangular Plate Washer and Special Bolt Assembly that shreds the Rail Panels apart burning up the Kinetic Energy of the Crash and slowing the impacting vehicle in a controlled manner

Vehicles impacting beyond Post 4 are contained and redirected in a controlled manner – LON Begins @ Post 4

Hit Type IX CATFlimsy Nose Section crushed

Post 1 & 2 Broken Off

Shredded Rail Panels after Telescoping 10 feet of Rail

through Bolt Assembly



Kentucky utilizes the CAT-350 in Median situations where guardrail or a crash cushion is needed because the CAT has guardrail on both sides. Therefore a vehicle hitting it on the backside is hitting guardrail and not the backside of guardrail post.



Type IX Crash Cushion CAT-350 Standard

Drawings RBB-002 Guardrail and Bridge End

Drainage for Twin Structures RBB-003 Layout of Guardrail at Twin

Structures (Depressed Median) RBE-200 Crash Cushion Type IX RBE-205 Crash Cushion Type IX-A RBI-007 Crash Cushion Type IX

Installation at Median Piers (Depressed Median)

Key components: 1. Channel Strut 2. Cable Assembly 3. Spacer Channel 4. Restraint Rod(2) 5. Knockout Tube(2) 6. Post Plates(2) 7. Soil Tubes(6) 8. Soil Plates(6) 9. Splice Bolt Assembly

1

1

2

3 4 4

5 56

Each Post 7&8

9 9

Site PreparationStandard Drawing RBI-007

This Point Same ElevationAs Inside Pavement Edge

Site PreparationStandard Drawing RBB-

002

Site PreparationGrading too steep – not 12:1

MinInlet too close

Side Slope to SteepRemember 4 inches in 5

feet

Grading too steep – Pavement & Grade Under

Rail Same Elev.

Installation of Soil Tubes and Soil Plates

KY Uses the 6 Post CAT-350 with 6 Soil Tubes with Soil Plates

The Soil Plates are placed on the downstream side of the post

Soil tubes and soil plates can be driven in permeable soil or if impermeable soil placed in 12” drilled hole with slots for soil plates cut by hand with a rock bar


Post are spaced @ 6’3” on centers Soil Tubes must be less than 4”

above finished grade If rock is encountered see

manufactures instructions


Post Placement

Post are only 3’6” long due to Soil Plates Notched side of Post 1 faces Post 2 Place Pipe Sleeves for Cable Assembly in

Post 1 & 2 before placement Post 1 & 2 are not secured to the Soil Tube

until the Strut is placed Post 3-6 are secured to the Soil Tube with

a 5/8” x 9 ½” Hex Bolt & Nut DO NOT overtighten bolts and deform

Tubes

Notched side of Post 1 faces Post 2

Place Pipe Sleeves for Cable Assembly in Post 1

& 2

Six Wood Post and Soil TubesStrut and Tubes @ Ground

Line

Installing the Strut Bolt goes through Strut, Soil Tube

and the Wood Post A washer is placed between the

Bolt head and the Strut and the Nut and the Strut

DO NOT OVERTIGHTEN bolts and deform Soil Tubes

Strut Bolt to Tight (slightly)Deforming Side of Soil Tube

No Washers

Strut and Soil Tubes at Ground Line

Installing the Wood Blockouts and Guardrail

NO Rail to Post connections at Post 3, 5 and 6 @ Post 3, 5 and 6 Attach 2 Blockouts to each

Post with two 5/8” x 24” Bolts and Nuts with Washers under the Bolt Head and the Nut

Two 10 Gage Slotted Rail Panels between Post 4 & 6 with plates welded to the backside on one end. Welded Plates placed at Post 4.

Panels are lapped to outside of rail at Post 6 to allow for Telescoping of the Rail Panels

Welded Plates on 10 Gage Rail Panel Placed at Post 4 with 12 Gage Rail Lapped over the 10

Gage Rail

Welded Plates on 10 Gage Rail Panel Placed at Post 4 with 12 Gage Rail Lapped over the 10

Gage Rail


Rail splice @ Post 6 - Eight Plate Washers (top and underside of rail) and 8 SPECIAL 5/8” x 1¾” Bolts with “CAT” on the Bolt Head

Special Splice Bolts (Top 1” unthreaded with “CAT” on the top of the bolt) are utilized to allow Telescoping Action

DO NOT SUBSTITUTE Bolts with “CAT” on the Bolt Head – these Bolts are necessary to allow the Rail to Telescope upon impact

Special CAT Bolts and Plate Washer Connection (Top and

Bottom)@ Post 6

Close up photo of the Special CAT Splice Bolt with “CAT” on top


Connect Welded Plates of 10 Gage Rail with 2 Wood Blockouts to Post 4 with 2 - 5/8” x 24” Hex Bolts and Nuts with Washers under the Bolt Head and the Nut

12 Gage Slotted Rail Panels positioned 8¼” long slots at Post 4, the four (4) ¾” diameter holes are positioned at Post 2

12 Gage Slotted Rail Panels are lapped outside of the 10 Gage rail at Post 4


Rail splice @ Post 4 - Eight Plate Washers (top and underside of rail) and 8 SPECIAL 5/8” x 1¾” Bolts with “CAT” on the Bolt Head

Special Splice Bolts (Top 1” unthreaded with “CAT” on the top of the bolt) are utilized to allow Telescoping Action

DO NOT SUBSTITUTE Bolts with CAT on the Bolt Head – these Bolts are necessary to allow the Rail to Telescope upon impact

12 Gage Rail Panels Lapped over 10 Gage Rail Panels @ Post 4 with Special

CAT Bolt and Rectangular Washer Connection

Splice Bolt Assembly Rectangular Washers on Top and Backside of Rail

Panels

Installing the Wood Offset Blocks and Guardrail

Spacer Channel @ Post 2 Attach the rail at Post 2 with 2 Wood Offset

Blocks, using a 5/8" X 25“ Post Bolt 2 Rectangular Washers and a Hex Nut

Before tightening the Rails and Offset Blocks to Post 2, install the Spacer Channel with 8 Bolts and Nuts between the rails downstream from post 2. Locate the Spacer Channel so that brace with the 1¼” diameter hole is closest to Post 2

Spacer Channel @ Post 2 Note Blockouts are loose – not properly Nailed @ Top

Post 1-3 Spacer Channel @ Post 2 and Restraint Rod @

Post 3

Spacer Channel

Restraint Rod

Assembling the Nose Section

Bolt the Side Plates to the end of each 12-Gage Rail Panel

Place the Tube Sleeve over Post 1 (Notched Post)

Nose Section is attached to Post 1 using a 5/8" X 25" post bolt

Narrow Wood Offset Blocks are placed between the Nose Section and the post

Bolt the Side Plates to the end of each 12-Gage Rail Panel

Tube Sleeve over Post 1Narrow Wood Post in place

Assembling the Nose Section Continued

Rectangular Washers are placed between the Bolt Head and Nose Section and the Hex Nut and the Nose Section. Excess threads should be cut off and peened.

Bolt the Nose Section to the side plates, using eight 5/8" X 1- ¼ “ Slice Bolts and Hex Nuts

Nose section Bolted to the Side Plates And

Rectangular Washer @ Post 1

Nose Section in Place With Nose Section Bolted to the Side Plates

& Post 1 Side Plates Bolted to Rail

Installing the Cable Anchor Assembly

Slide one end of the Cable through the Pipe Sleeve at the base of Post 1.

Place the Bearing Plate over the cable stud with the 5” dimension up and the 3” down

Place a Washer and Nut over the end of the Cable Assembly and tighten

Prevent the bearing plate from rotating by driving two nails along its top edge and bending them over

Bearing Plate not oriented properly (5” not up) and not

Nailed @ Top Does have Double Nut & Washer

Bearing Plate with 2 bent nails

preventing rotation


Slide the other end of the Cable through the Pipe Sleeve at the top of Post 2 and then through the 1¼” diameter hole in the Spacer Channel

Place a 1” Washer over the end of the Cable Assembly and secure with a Nut and tighten on this end

Restrain the cable with vise grips to avoid twisting the cable


After tightening a second Nut is added to each end of the Cable Assembly to prevent loosening

Anchor Cable through Post 2 and Spacer Channel – Washer and Double Nut

Installing the Buckling Restraining Rods

Install the Buckling Restraining Rod in the slot (behind Post 5) of the 10-Gage Rail Panels and in the Slot (behind Post 3) of the 12-gage Rail Panels

The Restraining Rod is threaded on each end

A Nut, Lock Washer and another Nut is placed on each end of the Restraining Rod

Installing the Buckling Restraining Rods

The completed assembly is inserted through the Holes in the Rail Panel, with one Nut and Lock Washer on the inside of the Rail Panel and the other Nut on the outside of the Rail Panel

The Buckling Restraining Rod Assembly is placed in the smaller Slotted Hole

The outside Nuts are snugged up to the rail panels, the inside nuts are then snugged up to the inside of the rail panels.

Restraining Rod in Placewith Nuts and Washers

inside and out

Visible Slot for Restraining Rod Because No Washer on Inside

Installing the Knockout Blocks and Post Plates

Connect the Knockout Blocks to the upstream side (toward the nose) of Posts 4 and 6 with two (2) 3/8" X 2" Lag Screws and a Flat Washer placed under the Lag Screw Head.

The Knockout Blocks should be installed parallel to the ground and should be located 4” down from top of the Post

Attach Post Plates to the top of Post 4 with a 5/8" X 7½” Hex Bolt and Nut

Knockout Blocks @ Post 4 & 6, Post Plates @ Post 4

Knockout Block with Post Plates @ Post 4

Type IX Assembly is Complete

Flared Type IX in median hit

Note how it gated

Vehicles impacting beyond LON @ Post 4 are contained and redirected in a controlled

manner

Good Stuff to Know

Backup plate required at Post 7 Included with each CAT-350

shipment is a can containing bags of attachment hardware. These bags are individually tagged showing the location of the posts where the hardware in that bag is to be used. This is extremely helpful.

If there are special field conditions encountered when installing the CAT-350, contact Trinity Engineering @1-800-644-7976 to review the conditions

CAT-350Installation Instructions

The Installation Instructions for the CAT-350 can be accessed at:

http://www.highwayguardrail.com/products/pdfs/CAT-Manual.pdf

All of Trinity Highway Products can be accessed at:

http://www.highwayguardrail.com/

CAT-350Installation Manual

Type IX CAT-350 Approved Shop Drawing

Shows everything very well

Q & A Time1. See Anything Wrong??

(5)

1. Rectangular Washer

2. Cable Loose3. Cable not double

nutted4. Bearing Plate

upside down

5. Bearing PlateNot nailed @ top

Q & A TimeSee Anything Wrong??

Knock Out Block on wrong side

of Post

Q & A TimeSee Anything Wrong?? (3)

1. Offset Blocks notNailed @ Top

2. No Knockout Block

3. Post Plates Rotated

Q & A TimeSee Anything Wrong??

Post 4 Only 1 Lag ScrewIn Knockout Block

Post 6 Only 1 Lag Screw

& Not Tight

Documents

Session 8 Type IX Crash Cushion CAT-350 Trinity Highway Products