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

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

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Type IX Crash Cushion CAT-350Trinity 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 _at_ Post 4

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Hit Type IX CATFlimsy Nose Section crushedPost
1 2 Broken Off
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Shredded Rail Panels after Telescoping 10 feet of
Rail through Bolt Assembly
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Type IX Crash Cushion CAT-350Trinity Highway
Products

• 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.

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Type IX Crash Cushion CAT-350Trinity Highway
Products
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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)

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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
4
4
1
3
5
5
6
2
9
9
1
Each Post 78
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Site PreparationStandard Drawing RBI-007
This Point Same Elevation As Inside Pavement Edge
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Site PreparationStandard Drawing RBB-002
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Site PreparationGrading too steep not 121
MinInlet too close
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Side Slope to SteepRemember 4 inches in 5 feet
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Grading too steep Pavement Grade Under Rail
Same Elev.
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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

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Installation of Soil Tubes and Soil Plates

• Post are spaced _at_ 63 on centers
• Soil Tubes must be less than 4 above finished
  grade
• If rock is encountered see manufactures
  instructions

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Installation of Soil Tubes and Soil Plates
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Post Placement

• Post are only 36 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

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Notched side of Post 1 faces Post 2
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Place Pipe Sleeves for Cable Assembly in Post 1
2
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Six Wood Post and Soil TubesStrut and Tubes _at_
Ground Line
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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

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Strut Bolt to Tight (slightly)Deforming Side of
Soil TubeNo Washers
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Strut and Soil Tubes at Ground Line
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Installing the Wood Blockouts and Guardrail

• NO Rail to Post connections at Post 3, 5 and 6
• _at_ 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

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Welded Plates on 10 Gage Rail Panel Placed at
Post 4 with 12 Gage Rail Lapped over the 10 Gage
Rail
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Welded Plates on 10 Gage Rail Panel Placed at
Post 4 with 12 Gage Rail Lapped over the 10 Gage
Rail
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Installing the Wood Blockouts and Guardrail

• Rail splice _at_ 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

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Special CAT Bolts and Plate Washer Connection
(Top and Bottom)_at_ Post 6
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Close up photo of the Special CAT Splice Bolt
with CAT on top
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Installing the Wood Blockouts and Guardrail

• 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

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Installing the Wood Blockouts and Guardrail

• Rail splice _at_ 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

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12 Gage Rail Panels Lapped over 10 Gage Rail
Panels _at_ Post 4 with Special CAT Bolt and
Rectangular Washer Connection
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Splice Bolt Assembly Rectangular Washers on Top
and Backside of Rail Panels
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Installing the Wood Offset Blocks and
GuardrailSpacer Channel _at_ 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

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Spacer Channel _at_ Post 2 Note Blockouts are loose
not properly Nailed _at_ Top
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Post 1-3 Spacer Channel _at_ Post 2 and Restraint
Rod _at_ Post 3
Spacer Channel
Restraint Rod
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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

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Bolt the Side Plates to the end of each 12-Gage
Rail Panel
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Tube Sleeve over Post 1Narrow Wood Post in place
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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

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Nose section Bolted to the Side Plates And
Rectangular Washer _at_ Post 1
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Nose Section in Place With Nose Section Bolted to
the Side Plates Post 1 Side Plates Bolted to
Rail
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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

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Bearing Plate not oriented properly (5 not up)
and not Nailed _at_ Top Does have Double Nut
Washer
Bearing Plate with 2 bent nails preventing
rotation
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Installing the Cable Anchor Assembly

• 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

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Installing the Cable Anchor Assembly

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

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

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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.

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Restraining Rod in Placewith Nuts and Washers
inside and out
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Visible Slot for Restraining Rod Because No
Washer on Inside
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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

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Knockout Blocks _at_ Post 4 6, Post Plates _at_ Post
4
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Knockout Block with Post Plates _at_ Post 4
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Type IX Assembly is Complete
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Flared Type IX in median hit Note how it gated
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Vehicles impacting beyond LON _at_ Post 4 are
contained and redirected in a controlled manner
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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.

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• If there are special field conditions encountered
  when installing the CAT-350, contact Trinity
  Engineering _at_1-800-644-7976 to review the
  conditions

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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/

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CAT-350Installation Manual
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Type IX CAT-350 Approved Shop DrawingShows
everything very well
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Q A Time1. See Anything Wrong?? (5)
1. Rectangular Washer
2. Cable Loose
3. Cable not double nutted
4. Bearing Plate upside down
5. Bearing Plate Not nailed _at_ top
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Q A TimeSee Anything Wrong??
Knock Out Block on wrong side of Post
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Q A TimeSee Anything Wrong?? (3)
2. No Knockout Block
3. Post Plates Rotated
1. Offset Blocks not Nailed _at_ Top
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Q A TimeSee Anything Wrong??
Post 6 Only 1 Lag Screw Not
Tight
Post 4 Only 1 Lag Screw In
Knockout Block