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

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Title: Luminare base to high Author: tchism Last modified by: Commonwealth Office of Technology Created Date: 3/15/2002 2:15:45 PM Document presentation format – PowerPoint PPT presentation

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


1
Session 8Type IX Crash Cushion CAT-350Trinity
Highway Products
2
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

3
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

4
Hit Type IX CATFlimsy Nose Section crushedPost
1 2 Broken Off
5
Shredded Rail Panels after Telescoping 10 feet of
Rail through Bolt Assembly
6
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.

7
Type IX Crash Cushion CAT-350Trinity Highway
Products
No Concrete Pad is Required
8
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)

9
(No Transcript)
10
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
11
The Mounting Height of the Type IX CAT will
remain _at_ 27 ¾
12
Site PreparationStandard Drawing RBI-007
This Point Same Elevation As Inside Pavement Edge
13
Site PreparationStandard Drawing RBB-002
14
Site PreparationGrading too steep not 121
MinInlet too close
What could we have done differently here?
15
Side Slope to SteepRemember 4 inches in 5 feet
16
Grading too steep Note 6 RBI-007 Pavement
Grade Under Rail Same Elev.
17
Per Bill Gulick
  • You CANNOT Disconnect Grading and Guardrail

18
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

19
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

20
Installation of Soil Tubes and Soil Plates
21
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

22
Notched side of Post 1 faces Post 2
23
Place Pipe Sleeves for Cable Assembly in Post 1
2
24
Six Wood Post and Soil TubesStrut and Tubes _at_
Ground Line
25
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

26
Strut Bolt to Tight (slightly)Deforming Side of
Soil TubeNo Washers
27
Strut and Soil Tubes at Ground Line
28
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

29
Welded Plates on 10 Gage Rail Panel Placed at
Post 4 with 12 Gage Rail Lapped over the 10 Gage
Rail
30
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 so it can Telescope
    Properly

31
Welded Plates on 10 Gage Rail Panel Placed at
Post 4 with 12 Gage Rail Lapped over the 10 Gage
Rail
32
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

33
Special CAT Bolts and Plate Washer Connection
(Top and Bottom)_at_ Post 6 Properly Lapped
34
Close up photo of the Special CAT Splice Bolt
with CAT on top
35
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

36
12 Gage Rail Panels Lapped over 10 Gage Rail
Panels _at_ Post 4 with Special CAT Bolt and
Rectangular Washer Connection
37
Splice Bolt Assembly Rectangular Washers on Top
and Backside of Rail Panels
38
Panels are suppose to be lapped to outside of
rail at Post 4 6 to allow for Telescoping of
the Rail Panels
Improperly Lapped Cannot Telescope. The Rail will
Bind Up NOT Perform Properly
39
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

40
Spacer Channel _at_ Post 2 Note Blockouts are loose
not properly Nailed _at_ Top
41
Post 1-3 Spacer Channel _at_ Post 2 and Restraint
Rod _at_ Post 3
Spacer Channel
Restraint Rod
42
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

43
Bolt the Side Plates to the end of each 12-Gage
Rail Panel
44
Tube Sleeve over Post 1Narrow Wood Post in place
45
Assembling the Nose Section Continued
  • Rectangular Washers are placed between the 5/8 x
    25 Post 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

46
Nose section Bolted to the Side Plates and 5/8 x
25 Bolt with Rectangular Washer _at_ Post 1
47
Nose Section in Place With Nose Section Bolted to
the Side Plates Post 1 Side Plates Bolted to
Rail
48
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

49
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
50
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

51
Installing the Cable Anchor Assembly
  • After tightening a second Nut is added to each
    end of the Cable Assembly to prevent loosening

52
Anchor Cable through Post 2 and Spacer Channel
Washer and Double Nut
53
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

54
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.

55
Restraining Rod in Placewith Nuts inside and
out and Lockwashers on Inside
56
Restraining Rod is NOT pulled back snug and No
Lockwasher on the Inside
57
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

58
Knockout Blocks _at_ Post 4 6, Post Plates _at_ Post
4
59
Knockout Block with Post Plates _at_ Post 4
60
Type IX Assembly is Complete
61
Flared Type IX in median hit Note how it gated
62
Vehicles impacting beyond LON _at_ Post 4 are
contained and redirected in a controlled manner
63
Good Stuff to Know
  • 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.

64
  • If there are special field conditions encountered
    when installing the CAT-350, contact Trinity
    Engineering _at_1-800-644-7976 to review the
    conditions

65
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/

66
CAT-350Installation Manual
67
Type IX CAT-350 Approved Shop DrawingShows
everything very well
68
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
69
Q A Time2. See Anything Wrong??
Knock Out Block on wrong side of Post
70
Q A Time3. See Anything Wrong?? (3)
2. No Knockout Block
3. Post Plates Rotated
Post 4
Post 2
1. Offset Blocks not Nailed _at_ Top
71
Q A Time4. See Anything Wrong??
Post 6 Only 1 Lag Screw Not
Tight
Post 4 Only 1 Lag Screw In
Knockout Block
72
Q A Time5. See Anything Wrong??
Post 6
  • Improper Lap Left - Cannot Telescope Right -
    OK
  • 2. Only 1 Lag Screw
  • 3. Post Plates Belong _at_ Post 4
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