energy absorption systems - trinity highway products

ENERGY ABSORPTION SYSTEMS

1 Part No. 618878

Created April 2012 All rights in copyright reserved

CONTROLLED RELEASING POST (CRP) RETROFIT FOR ET POST LOCATION 1

Instructional Manual

This Manual must be available to the worker overseeing and/or assembling the product at all times. For additional copies, contact Trinity Highway Products, LLC 800-527-6050.

All information, illustrations, and specifications in this Manual are based on the latest CRP Retrofit for ET Post Location 1 information available at the time of printing. We reserve the right to make changes at any time. For additional assembly detail for the applicable ET system, see the appropriate ET Assembly Manual.

IMPORTANT: These instructions are to be used only in conjunction with the assembly of the CRP Retrofit for ET Post Location 1. These instructions are for standard assembly specified by the appropriate highway authority only. In the event the specified system assembly, maintenance, or repair would require a deviation from standard assembly parameters, contact the appropriate highway authority highway engineer before proceeding. Trinity Highway Products, LLC representatives are available for input if required.

2 Created April 2012

All rights in copyright reserved

CUSTOMER SERVICE CONTACTS Trinity Highway Products, LLC is committed to the highest level of customer service. Feedback regarding the CRP Retrofit for ET Post Location 1, the assembly procedures, supporting documentation, and performance is always welcome. Additional information for materials and product specifications can be obtained by calling the telephone numbers or writing to the email address below:

TRINITY HIGHWAY PRODUCTS: Telephone: 800-644-7976 (U.S. Calls)

+1-214-589-8140 (International) E-mail: [email protected]

REGIONAL TELEPHONE CONTACTS: Dallas, Texas 800-527-6050 Centerville, Utah 800-772-7976 Elizabethtown, Kentucky 800-282-7668 Girard, Ohio 800-321-2755 Orangeburg, South Carolina 800-835-9307 International +1-214-589-8140

SUGGESTED SAFETY RULES FOR ASSEMBLY – MAINTENANCE - REPAIR * IMPORTANT SAFETY INSTRUCTIONS *

Always keep this Manual in a location where it is easily accessed by persons who assemble, maintain, or repair the CRP Retrofit for ET Post Location 1.



SAFETY SYMBOLS Below are the safety symbols that may appear on the CRP Retrofit for ET Post Location 1 or in the documentation. Read the entire Manual for suggested safety, assembly, maintenance, repair, and service information.

SYMBOL MEANING

SAFETY ALERT SYMBOLS indicate Danger, Warning, or Caution. Failure to read and follow the Danger, Warning, or Caution indicators could result in serious injury or death to workers and/or bystanders.

WARNING - READ MANUAL Read the Manual(s) and follow all warnings and safety instructions. Failure to follow this warning could result in serious injury or death to the workers. Only those persons who have the necessary skill, understanding and experience in the assembly of highway products should attempt this work. Assembly should only be attempted by those who have the ability to read, understand, and apply those instructions contained herein.

WARNINGS AND CAUTIONS Read all warnings, cautions, and instructions before assembling, maintaining, and repairing the CRP Retrofit for Post 1 for the ET system.

IMPORTANT: READ SAFETY INSTRUCTIONS THOROUGHLY AND FOLLOW THE SAFE OPERATION PRACTICES WHILE ASSEMBLING THE CRP Retrofit for Post 1 for the ET system. Failure to follow this warning could result in serious injury or death to workers and/or bystanders.



WARNING: Read the instructions carefully. Be familiar with the complete instructions for the CRP Retrofit for ET Post Location 1 before assembling or repairing the CRP Retrofit for ET Post Location 1. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Ensure that the necessary traffic control is set up and any debris that has encroached onto the traveled way or shoulder has been removed before beginning assembly or repairs. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Be sure adequate time is available for complete assembly before beginning the assembly process. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Do NOT perform assembly, maintenance, or repair of the CRP Retrofit for ET Post Location 1 when tired, ill, or under the influence of alcohol, drugs, or medication. Failure to follow this warning could result in serious injury or death in the event of a collision.



WARNING: Do not assemble, maintain, or repair the CRP Retrofit for ET Post Location 1 until you have read this Manual thoroughly. Please call Trinity Highway Products at 800-644-7976 if you do not understand the assembly instructions. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Use only Trinity Highway Products parts on the CRP Retrofit for ET Post Location 1 for assembly, maintenance, or repair. The assembly or comingling of unauthorized parts is strictly prohibited. Failure to follow this warning will result in serious injury or death in the event of a vehicle impact with a system that has not been accepted by the Federal Highway Administration (“FHWA”). The CRP Retrofit for Post Location 1 and its component parts have been accepted for state use by FHWA. However, a comingled system has not been accepted.

WARNING: Do NOT modify the CRP Retrofit for ET Post Location 1 in any way. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Do NOT perform assembly, maintenance, or repair if the CRP Retrofit for ET Post Location 1 site, shoulder, or traveled area is covered or encroached by road debris. Failure to follow this warning could result in serious injury or death in the event of a collision.



WARNING: Safety measures incorporating traffic control devices must be used to protect all personnel while at the assembly, maintenance, or repair site. Failure to follow this warning could result in serious injury or death to workers and/or bystanders.

Trinity Highway Products offers an economical and effective truck mounted attenuator, the MPS 350, for the protection of workers in work zones. For more information on the MPS 350, call 800-644-7976 or visit the Trinity Highway Products website at www.highwayguardrail.com.

WARNING: Ensure that the entire work zone site is visible at all times. Failure to follow this warning could result in serious injury or death to the workers and/or bystanders.

WARNING: Use caution when working near public roads. Be mindful of nearby vehicles in motion. Failure to follow this warning could result in serious injury or death to workers and/or bystanders.

WARNING: Ensure that all guardrail products and delineation used meet all federal, state/specifying agency, and local specifications. Failure to follow this warning could result in serious injury or death in the event of a collision.



WARNING: Ensure that your assembly, repair, and maintenance meet all appropriate Manual on Uniform Traffic Control Devices (“MUTCD”) and local standards. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Ensure that the guardrail you assemble is terminated as dictated by the state/specifying agency, pursuant to FHWA acceptance. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Ensure that there is proper site grading for tube and post placement, as dictated by the state/specifying agency, pursuant to FHWA acceptance. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Ensure that all of the CRP Retrofit for ET Post Location 1 Warnings, Cautions, and Important statements within the CRP Retrofit for ET Post Location Manual are completely followed. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Always use safety precautions when performing assembly, maintenance, repair, mixing chemicals, and/or moving heavy equipment. Wear steel toe shoes, gloves, safety goggles, and back protection. Failure to follow this warning could result in serious injury or death to workers and/or bystanders.



CAUTION: Ensure before assembling, maintaining, or repairing the CRP Retrofit for ET Post Location 1 that no parts are frayed, damaged, or broken. Failure to follow this warning could result in serious injury to the workers and/or bystanders.

KNOW YOUR CRP RETROFIT FOR ET POST LOCATION 1 FOR SPECIFIC ASSEMBLY, MAINTENANCE, OR REPAIR DETAILS, REFER TO THE STATE/SPECIFYING AGENCY’S STANDARD DRAWING(S) AND/OR TRINITY STANDARD LAYOUT DRAWINGS

WARNING: Use only Trinity Highway Products parts on the CRP Retrofit for ET Post Location 1 for assembly, maintenance, or repair. The assembly or comingling of unauthorized parts is strictly prohibited. Failure to follow this warning could result in serious injury or death in the event of a vehicle impact with a system that has not been accepted by the Federal Highway Administration (“FHWA”). CRP Retrofit for ET Post Location 1 and its component parts have been accepted for state use by FHWA. However, a co-mingled system has not been accepted.



BILL OF MATERIAL ENGLISH (METRIC) CRP RETROFIT FOR POST 1 FOR THE ET SYSTEM (FOR SPECIFIC MATERIALS AND QUANTITIES, SEE STATE SPECIFYING AGENCY OPTION(S))

PN QTY Description

3240G 2 5/16” (8 mm) FLAT WASHER (F844)

3245G 2 5/16” (8 mm) HEX NUT (A563)

3300G* 1 5/8” (16 mm) FLAT WASHER (F844)

3340G* 1 5/8” (16 mm) HEX NUT (A563)

3700G** 2 3/4” (19 mm) HEX WASHER

3704G** 1 3/4” (19 mm( HEX NUT

4211G 2 5/16” x 1 3/4” (8 mm x 44 mm) HEX BOLT (A307)

4254G 2 3/8” (10 mm) FLAT WASHER

4255G 2 3/8” (10 mm) FENDER WASHER

4261G 2 3/8” X 1 1/2" (10 mm x 38 mm) HEX BOLT

5410G* 1 5/8” x 11” (16 mm x 279 mm) Hex Head Bolt

6405G 2 3/8” (10 mm) NUT

33909G 1 CABLE BRACKET

34070A 1 CRP LOWER POST

34071A 1 CRP UPPER POST

34073G 2 GUARD PLATE

105280G** 1 3/4” x 10 1/2"** (19 mm x 267 mm) Hex Head high Strength Bolt

*TO BE USED WITH GROUND CHANNEL STRUT

**TO BE USED WITH GROUND ANGLE STRUT



ASSEMBLING THE CRP RETROFIT FOR ET POST LOCATION 1

Use Trinity Highway Products drawings for the CRP Retrofit for ET Post Location 1 with these instructions. See Figure 1 for assembly with a Ground Channel Strut and Figure 2 with an Angle Channel Strut.

WARNING: Ensure that there is proper site grading for tube and post placement as dictated by the state/specifying agency, pursuant to FHWA acceptance. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Ensure that the proper leave out (specified area of open space in the pavement) around the posts is reserved and filled with state/specifying agency approved backfill material that will not prevent movement, for any posts assembled in rigid pavement such as any thickness of concrete or asphalt more than 2 inches in thickness. Failure to follow this warning could result in serious injury or death in the event of a collision.

WARNING: Ensure that all guardrail products and delineation used meet all federal, state/specifying agency, and local specifications. Failure to follow this warning could result in serious injury or death in the event of a collision.



FIGURE 1: CRP RETROFIT POST w/ GROUND CHANNEL STRUT

FIGURE 2: CRP RETROFIT POST / GROUND ANGLE STRUT



MATERIALS

As packaged, CRP Retrofit for ET Post Location 1 includes all materials needed for assembly.

RECOMMENDED TOOLS

The following list shows recommended tools for the CRP Retrofit for ET Post Location 1. However, since repair is directed by the state/specifying agency, they may have more specific guidelines. • 9/16” (14 mm) Socket or Wrench • 15/16” (24 mm) Socket or Wrench • 11/4” (32 mm) Socket or Wrench • 11/2” (38 mm) Socket or Wrench • Channel lock pliers • Sledge hammer • Post removal tool and other normal guardrail

tools

SITE PREPARATION

WARNING: Ensure that there is proper site grading for tube as dictated by the state/specifying agency, pursuant to FHWA acceptance. Failure to follow this warning could result in serious injury or death in the event of a collision.

ASSEMBLY

The CRP Retrofit for ET Post Location 1 should be per the following assembly. See Figure 1 for assembly with a Ground Channel Strut and Figure 2 with an Angle Channel Strut. If there are special field conditions encountered, contact the state/specifying agency. Trinity Highway Products, LLC 800-644-7976 is available to assist the state/specifying agency if needed.



ASSEMBLING CRP BOTTOM POST

Complete the following steps to assemble CRP Bottom Post at Post Location 1:

1. Remove the existing wood post or the remnant of a damaged post from the Tube.

2. Orient the CRP Bottom Post (PN-34070A) per Figure 1 or 2.

3. Insert the post into the existing Tube so that the bolt hole in the Tube and the post are aligned.

ASSEMBLING GUARD PLATES WITH A GROUND CHANNEL STRUT (SEE FIGURE 1).

Complete the following steps to attach the Guard Plates with a Channel Ground Strut (See Figure 1). 1. Place the slotted yokes of the Ground Channel

Strut over the Foundation Tubes at posts 1 and 2.

2. Place a Guard Plate (PN-34073G) on each side of the Foundation Tube at post 1 on the outside of the slotted yokes of the Ground Channel Strut.

3. From the embankment side, insert a 5/8” (16 mm) x 11” (279 mm) hex head bolt (PN-4510G) through the Guard Plates, the slotted yokes, Foundation Tube, and CRP Bottom Post. Place a flat washer (PN-3300G) between the bolt head and the Guard Plate and the Guard Plate and the nut.

4. Place a 5/8” (16 mm) hex nut (PN-3340G) on the end of the bolt.

5. Tighten the nut to a snug position. (The designer does not recommend a torque requirement.)



ASSEMBLING GUARD PLATES WITH A GROUND ANGLE STRUT (SEE FIGURE 2).

Complete the following steps to assemble the Guard Plates with a Ground Angle Strut (See Figure 2).

1. Place a Guard Plate (PN-34073G) on each side of the Foundation Tube at post.

2. Place the angle Ground Strut on the embankment side of the Foundation Tube outside of the Guard Plate.

3. From the embankment side, insert a 3/4” (19 mm) diameter 10 1/2” (267 mm) hex head high strength bolt (PN-105280G) through the Guard Plates, the Ground Angle Strut, Foundation Tube, and CRP Bottom Post. Place a flat washer (PN-3700G) between the bolt head and the Ground Angle Strut and the nut and the Guard Plate.

4. Place a 3/4” (19 mm) hex nut (PN-3704G) on the end of the bolt.

5. Tighten the nut to a snug position. (The designer does not recommend a torque requirement.

ASSEMBLING CRP UPPER POST (SEE APPROPRIATE FIGURE 1 OR FIGURE 2)

Complete the following steps to assemble the CRP Upper Post after the Lower Post has been placed: 1. Assemble the CRP Upper Post (PN-34071A)

at Post 1 by aligning the ears of the CRP Upper Post and the CRP Lower Post.

2. Insert a 5/16” (8 mm) diameter x 1 3/4” (44 mm) hex head bolt (PN-4211G) in each of the 3/8” (10 mm) holes in the CRP Lower Post and CRP Upper Post Plates. For the inserted bolts, place a 5/16” (8 mm) washer (PN-3240G) under the 5/16” (8 mm) hex nut (PN-3245G). Tighten the bolt. (There is no torque requirement for these bolts.)



ASSEMBLING THE STRUT AT POST 2

See the appropriate ET Assembly Manual for attaching the Ground Strut to Post 2.

RAIL PANELS

See the appropriate Instructional Manual for the assembly of the Rail Panels.

ASSEMBLY OF THE EXTRUDER HEAD

Complete the following steps to attach the Extruder (Head).

1. Place the Extruder Head over the end of the Rail Panel.

Note: The Extruder (Head) can be used on the left or right hand shoulder.

2. Push the Extruder (Head) as far as it will go on the Rail Panel, making sure the Rail Panel is in the Extruder Channel Chute.

3. Attach the Extruder Channel Chute approximately parallel to the ground. The Extruder (Head) attachment tabs have 3 holes in each tab to provide alignment with holes in the post.

4. Place the Extruder (Head) against the CRP Top Post (See Appropriate Figure 1 or 2).

5. Place a 3/8” (10 mm) Flat Washer (PN-4254G) on a 3/8” (10 mm) diameter x 1 1/2” (38 mm) hex head bolt (4261G).

6. Insert the bolt through the top and bottom tabs of the Extruder (Head) and the flange of the CRP Upper Post.

7. Place a 3/8” (10 mm) fender washer (PN-4255G) under a 3/8” (10 mm) hex nut (PN-6405G) on the end of the inserted bolt.



ASSEMBLING THE CABLE ANCHOR BRACKET ON GUARDRAIL PANEL

See the appropriate ET Assembly Manual for attaching the Cable Anchor Bracket.

ATTACHING THE CABLE ANCHOR ASSEMBLY

Complete the following steps to attach the Cable Anchor assembly (See Appropriate Figure 1 or 2):

1. Slide one end of the Cable (PN-3000G) into the Cable Anchor Bracket and the other end through the hole between the Upper and Lower CRP Posts at Post Location 1.

2. Place a 1" (25 mm) flat washer (PN-3900G) and one (1) 1” (25 mm) hex nut (PN-3910G) on the end of the Cable that extends through the Cable Anchor Bracket.

3. Place the Cable Bracket (PN-33909G) on the cable end placed between the Upper and Lower CRP Posts.

4. Place a 1” (25 mm) washer and one (1) 1” (25 mm) hex nut on the end of the Cable.

5. Restrain the Cable with vise grip pliers at the end being tightened to avoid twisting of the Cable.

6. Tighten the hex nuts on the cable ends, until the Cable is taut. The Cable is considered taut when it does not deflect more than 1 inch when pressure is applied by hand in an up or down direction.

WARNING: Ensure that all Guardrail products and delineation used meet all federal, state/specifying agency, and local specifications. Failure to follow this warning could result in serious injury or death in the event of a collision. Do not overtighten the cable.



CRP RETROFIT FOR ET POST LOCATION 1 INSTRUCTIONAL CHECKLIST STATE: ___________________________ PROJECT: _________________________ DATE: ____________________________ LOCATION: ________________________ o The finished guardrail height meets the height

for the specific guardrail assembly. o The required site grading is completed before

the start of deployment of the CRP RETROFIT FOR ET POST LOCATION 1.

o The Anchor Cable is taut and correctly attached (the Cable should be rechecked after attachment to be sure it hasn’t relaxed). The taut Cable does not deflect more than 1 inch, when pressure is applied by hand in an up or down direction.

o The Rail Panel is not attached to the post at Post Location 1.

o No rectangular washers are used on the face of the rail.

o Rail Panels are oriented correctly and lapped in the direction of traffic unless the agency's policy dictates otherwise.

o If backfilled, the backfill material around the posts is properly compacted.

15 Created March 2012


ASSEMBLING THE STRUT AT POST 2

See the appropriate ET Assembly Manual for attaching the Ground Strut to Post 2.

RAIL PANELS

See the appropriate Instructional Manual for the assembly of the Rail Panels.

ASSEMBLY OF THE EXTRUDER HEAD

Complete the following steps to attach the Extruder (Head).

1. Place the Extruder Head over the end of the Rail Panel.

Note: The Extruder (Head) can be used on the left or right hand shoulder.

2. Push the Extruder (Head) as far as it will go on the Rail Panel, making sure the Rail Panel is in the Extruder Channel Chute.

3. Attach the Extruder Channel Chute approximately parallel to the ground. The Extruder (Head) attachment tabs have 3 holes in each tab to provide alignment with holes in the post.

4. Place the Extruder (Head) against the CRP Top Post (See Appropriate Figure 1 or 2).

5. Place a 3/8” (10 mm) Flat Washer (PN-4254G) on a 3/8” (10 mm) diameter x 1 1/2” (38 mm) hex head bolt (4261G).

6. Insert the bolt through the top and bottom tabs of the Extruder (Head) and the flange of the CRP Upper Post.

7. Place a 3/8” (10 mm) fender washer (PN-4255G) under a 3/8” (10 mm) hex nut (PN-6405G) on the end of the inserted bolt.

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