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TrinityHighway.com

  

Unreleased May 2021 

 

 

Revision A November 2021 

 

Limitations and Warnings 

Trinity  Highway,  in  compliance  with  NCHRP-350, 
contracts  with  ISO  17025  A2LA  accredited  testing 
laboratories  to  perform  crash  tests,  evaluate  tests,  and 
submit the test results to the FHWA for review. 

CASS

®

          has          been  deemed  eligible  by  FHWA  as 

meeting the requirements   and   guidelines   of   NCHRP 
Report  350,  Test  Level  3  (TL-3).    These  tests    typically  
evaluate  product    performance    defined      by      NCHRP 
Report    350     involving     a     range     of vehicles    on    
roadways,     from   lightweight  cars (approx. 800 kg [1800 
lb.]) and full  size pickup   trucks   (approx. 2,000 kg  [4,400 
lb.]) at  100 kph [62 mph]. 

CASS

®

 is tested pursuant to the test matrix criteria of 

NCHRP  Report  350  as  designated  by  FHWA.  The 
FHWA  tests  are  not  intended  to  represent  the 
performance  of  systems  when  impacted  by  every 
vehicle type or in every impact condition existing on 
the  roadway.  Every  departure  from  the  roadway  is  a 
unique event. 

Trinity  Highway  expressly  disclaims  any  warranty  or 
liability  for  injury  or  damage  to  persons  or  property 
resulting from any impact, collision or harmful contact with 
its products, other vehicles, or nearby hazards or objects 
by  any  vehicle,  object  or  person,  whether  or  not  the 
products  were  assembled  in  consultation  with  Trinity 
Highway or by third parties. 

CASS

®

  is  intended  to  be  assembled,  delineated,  and 

maintained within the state/specifying agency and federal 
guidelines. It is important for the state/specifying agency 
specifying the use of a highway product to select the most 
appropriate product configuration for site specifications. 

The state/specifying agency’s careful evaluation of the 
site layout, vehicle population type and speed, traffic 
direction, and visibility are some of the elements that 
require  evaluation  in  the  selection  of  a  highway 
product. For example, curbs could cause an untested 
effect on an impacting vehicle.

 

After  an  impact  with  the  system,  all  debris  must  be 
removed from the area immediately in compliance with the 
most  applicable  state/specifying  agency  policy.  The 
specified CASS

®

 System must be evaluated and restored 

to  its  original  specified  condition  or  replaced  as  the 
state/specifying  agency  determines/requires,  as  soon  as 
possible. Product selection, approval, proper installation, 
and  maintenance  of  any  highway  product  is  the  sole 
responsibility of the state/specifying agency. 

 
 

 
 
 
Safety    Alert    Symbols    appear      throughout  this 
manual  and  indicate  Danger,  Warning,  Caution  or 
Important statements. Failure to read and follow these 
warnings  could  result in serious injury or death in the 
event of a vehicle impact with the system. 

WARNING:  Do   not   assemble,   maintain, or repair 
CASS

®

 until you have read this manual thoroughly and 

completely  understand  it.  Ensure  that  all  Danger, 
Warning,   Caution, and Important statements  within 
the    manual    are    completely  followed.    Please  call 
Trinity  Highway  at  (888)  356-2363  if  you  have  any 
questions about instructions in this manual. 

WARNING:  Safety  measures 

incorporating 

appropriate  traffic  control  devices    and    personal 
protective  equipment ("PPE")   specified  by 

the 

state/specifying agency  must    be used  to protect all 
personnel   while   at  the   assembly,  maintenance,  or 
repair site.   

WARNING:    Ensure  the  assembly  site  meets  all 
appropriate  Manual  on  Uniform  Traffic  Control 
Devices  (“MUTCD”)  and  state/specifying  agency 
standards. 

WARNING:    Only  Trinity  Highway  parts  that  are 
specified  herein  can  be  used  for  assembly, 
maintenance,  or  repair  on  CASS

®

.    Do  not  utilize  or 

otherwise commingle parts from other systems, even 
if  those  systems  are  other  Trinity  Highway  systems.  
Alternate      configurations  have  not  been  tested,  nor 
have  they    been  approved  for  use.  Assembly, 
maintenance  or  repairs  using  unspecified  parts  or 
accessories    is strictly prohibited.   Failure     to follow 
this   warning  could result   in   serious  injury or death   
in    the      event      of  a      vehicle  impact  with  such  an 
UNACCEPTED  system. 

WARNING:  Do NOT modify CASS

®

 in any way. 

IMPORTANT: 

Trinity 

Highway 

makes 

no 

recommendation whether use  or  reuse  of any part of 
CASS

®

    is  appropriate  or  acceptable    after    system 

impact. It is the responsibility of the state/specifying 
agency and its engineers to make that determination. 

IMPORTANT:  It is the responsibility of the  applicable 
owner, state/specifying agency, or specifier to inspect 

CASS

®

    after  assembly  is  complete  to  ensure  the 

instructions provided in this manual have been strictly 

followed.

 

 

 

Summary of Contents for CASS TL3

Page 1: ......

Page 2: ...of CASS could result in serious injury or death Important These instructions are for standard assembly specified by the state specifying agency In the event the specified system assembly maintenance o...

Page 3: ...Channel Temperature Tension Chart 35 Tension Log Cable Safety System 36 Appendix A Flare Assemblies 30 1 Flare 37 Appendix B Cable Barrier Overlap 38 Appendix C Encountering Rock 39 Appendix D Base P...

Page 4: ...emblies specified by the appropriate state specifying agency If you need additional information or have questions about CASS please contact the state specifying agency that has planned and specified t...

Page 5: ...ted and restored to its original specified condition or replaced as the state specifying agency determines requires as soon as possible Product selection approval proper installation and maintenance o...

Page 6: ...hnical engineer Warning Be aware of hazards of using compressed air small objects may become projectiles Failure to follow this warning can result in serious injury or death to the workers and or byst...

Page 7: ...stic spacers keep the cables positioned at approximately 4 100 mm on center from each other A stainless steel strap is placed around the post below the top cable The post spacing will be in accordance...

Page 8: ...5 16 Hex Nut A563 5 8 Flat Washer F844 PN 3310G PN 3361G PN 3536G 5 8 Lock Washer 5 8 Hex Nut 1 Stud Flattened LHT PN 3537G PN 3700G PN 3701G 1 Stud Flattened RHT 3 4 Flat Washer F844 3 4 Flat Washer...

Page 9: ...le Wedge 3 x 7 PN 4211G PN 4779G PN 4902G 5 16 x 1 3 4 Hex Bolt A307 3 4 x 4 1 2 Hex Bolt A325 1 Flat Washer F436 PN 4903G PN 4959G PN 5225G 1 Hex Nut A194 2H 3 4 Heavy Square Nut 5 8 X 7 1 2 HAS SUPE...

Page 10: ...Spacer w o Reflector PN 5701B PN 5702B PN 5709B 4 Cable Reflector Spacer Yellow 4 Cable Reflector Spacer White CASS Thermometer PN 5711G PN 5823B PN 5824T 3 4 Turnbuckle Open Body Sleeve Cover CASS Po...

Page 11: ...m CASS C Post Cap PN 5839B PN 5840G PN 5850B S3 Sleeve Cover Terminal Post 5 0 Cable Field Repair Section CASS Cable Pulling Tool PN 5851B PN 5852B PN 5878B Reflector Median LEFT Reflector Roadside RI...

Page 12: ...Driven Post PN 33902G PN 33903 PN 33908G C Shaped Post Driven S3 Terminal Posts w Soil Plates Posts 4 9 Terminal Post Sleeve S3 Post PN 33909G PN 33910G PN 33912G CRP Cable Bracket S3 Terminal Post i...

Page 13: ...04G PN 105205G 27 C Post Sleeve 3 4 Stud Flattened LHT 3 4 Stud Flattened RHT Important Trinity Highway makes no recommendation whether use or reuse of any part of the system is appropriate or accepta...

Page 14: ...ff Blade Saw C Clamps CASS Cable Pulling Tool PN 5850B Locking Pliers Duct tape Pry Bars Line String Plumb Line Straight Edge Level Drift Pin Tape Measure Come along Lever chain hoist 3 ton minimum ca...

Page 15: ...r flatter FHWA and AASHTO guidance for ANY NCHRP 350 cable system placed on side slopes steeper than 1V 10H shall not be placed within 1 to 8 0 3m to 2 4m from the ditch line Barrier Alignment Follow...

Page 16: ...meters between the two tangents g1 grade of tangent in g2 grade of tangent out When the minimum sag vertical curve value is not met the use of intermediate terminals at the low point of the sag curve...

Page 17: ...ng to attain the required concrete strength before disturbing the foundations including the placement of posts Sleeve in Mow Strip When a mow strip is used that meets the criteria in drawing SS 720 sl...

Page 18: ...post spacing according to contract specifications and drive the post PN 33901G with an appropriate driving head equipment 2 The height from the finished grade to the top of the post is approximately 2...

Page 19: ...ole for the concrete footing 3 Fabricate a rebar cage in accordance with project shop drawing requirements A standard spiral rebar cage that may be applicable is PN 33916B See Figure 3 4 Place the reb...

Page 20: ...ost is to be aligned with the soil plate on the downstream side of the post Drive the post so that the top of the Bottom CRP does not protrude more than 4 100 mm above the finished grade 3 Backfill th...

Page 21: ...ertically as shown in Figure 4 If the state specifying agency requires a deeper footing the length of the vertical re bars will be the footing depth minus 4 100 mm The two vertical re bars do not have...

Page 22: ...e placement of the terminal line posts in the sleeve 1 Place the post sleeve cover PN 5839B on the bottom end of the terminal line post PN 33910G 2 Place posts in sleeves 4 to 9 The cover will be loca...

Page 23: ...n 1 and is placed on the front side traffic side of the line terminal posts the CRP 2 cable PN 5818G starts at CRP 2 post location 2 and is placed on the back side away from traffic of the line termin...

Page 24: ...ch reel The precut cable has a right hand fitting on one end and left hand fitting on the other end The cables are placed on the reel with the left hand fitting placed on the reel first The right hand...

Page 25: ...able Splice PN 5633G and Figure 7b for 3 4 Cable Splice PN 5698G Perform the following steps to complete a splice using a field applied fitting and a turnbuckle 1 Ensure that the cable has a clean squ...

Page 26: ...usings one of which has threads on it a threaded ring and two 2 triangular wedges See Figure 8 Warning The distance from the torpedo splice to any other fitting must be 100 30 m or greater Perform the...

Page 27: ...needed to complete the assembly 2 Attach the right hand threaded end of the cable to the terminal or Anchor cables Use the factory applied fitting with a turnbuckle method or field applied fittings wi...

Page 28: ...m a reliable source in the immediate area and not influenced by other factors See the CASS Temperature and Tension Chart for the tension requirements at the back of the manual The means of placing ten...

Page 29: ...ng tool from the cable Check the tension on the cable If a higher tension is needed rotate the turnbuckle while the cables are restrained to prevent twisting 9 Replace any posts removed during the ten...

Page 30: ...pacted If an impact occurs and a CCT CRP is not involved usually only the line or terminal posts will have to be replaced and the cables re inserted in the posts or attached to the post Follow the ste...

Page 31: ...y be necessary To provide this access remove cables from several posts upstream and downstream of the desired opening The opening width can be adjusted by removing posts from the ground sleeves The ca...

Page 32: ...together 4 Connect one end of the splice cable to one end of the cut cable with a connector 5 Apply another connector to the other end of the splice cable and the end of the cut cable 6 Assemble the c...

Page 33: ...n a total of 4 6 1 3 m the connection can be made with a left and right threaded field applied fittings and a turnbuckle 1 Remove 4 6 1 3 m of cable from the cable run 2 Place a left hand threaded fit...

Page 34: ...ure the top of the Bottom CRP s does not protrude more than 4 100 mm above the finished grade p 18 9 Ensure the bent part of the Cable Anchor Bracket at CRP 1 2 and 3 is up and hooked over the Top CRP...

Page 35: ...um consistof Visual Drive By Inspections Recommended Frequency Monthly Check for damage caused by vehicle impacts Check for damage caused by impacts from snowplow mowing or roadway operations Check fo...

Page 36: ...600 4 24 9 45 5500 7 24 4 50 5300 10 23 6 55 5100 13 22 7 60 5000 16 22 2 65 4800 18 21 4 70 4600 21 20 5 75 4500 24 20 0 80 4300 27 19 1 85 4100 29 18 2 90 4000 32 17 8 95 3800 35 16 9 100 3600 38 16...

Page 37: ...______________ Bottom __________ Bottom __________ Bottom ______________ _________________________________________________________________________________________________________ Loc ___Actual Lbf Lo...

Page 38: ...TrinityHighway com 37 Revision A November 2021 Appendix A Flare Assemblies 30 1 Flare...

Page 39: ...TrinityHighway com 38 Revision A November 2021 Appendix B Cable Barrier Overlap...

Page 40: ...dation tube so the top of the tube will be flush with finished ground C Follow the steps in C and D in Option A above Foundation Tubes with Soil Plates For Foundation with Tubes with Soil Plates remov...

Page 41: ...ds and adhesive in the holes according to the manufacturer s recommendations Note A 5 8 16 mm mechanical anchor with a pull out strength of 10 000 lbs 4 536 kg can also be used 4 Allow the adhesive to...

Page 42: ......

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