620249 cass cen - trinity highwaytrinityhighway.com 6 revision a february 2020 general cass® cen...

Part No. 620249 © 2019 Trinity Highway Products, LLC TrinityHighway.com 1 Revision A February 2020

CASS® CEN

SYSTEM Product Description

Assembly Manual

Trinity Highway Products, LLC d.b.a.

2525 N. Stemmons Freeway

Dallas, Texas 75207

Important: These instructions are to be used only in conjunction with the assembly, maintenance, and repair of the CASS® CEN System. These instructions are for standard assembly specified by the appropriate highway authority only. In the event the specified system assembly, maintenance, or repair would result in a deviation from these assembly instructions, contact the appropriate highway authority engineer. This system has been successfully tested to the European Standard EN 1317-1, 2 on the highway system under strict criteria utilized by that agency. Trinity Highway Products, LLC dba Trinity Highway Products International (“Trinity Highway International”) representatives are available for consultation if required.

This manual must be available to the worker overseeing and/or assembling the product at all times. For additional copies, contact Trinity Highway International at +1 214 589 8140 or visit TrinityHighway.com.

The instructions contained in this manual supersede all previous information and manuals. All information, illustrations, and specifications in this manual are based on the latest CASS® CEN System information available to Trinity Highway International at the time of printing. Trinity Highway International reserves the right to make changes at any time. Please contact Trinity Highway International to confirm that you are referring to the most current instructions.

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TrinityHighway.com 2 Revision A February 2020

Table of Contents Customer Service Contacts .......................................................................................................... 3 Important Introductory Notes ........................................................................................................ 3 Safety Rules for Assembly ............................................................................................................ 4 Safety Symbols ............................................................................................................................. 4 Important Introductory Notes ........................................................................................................ 5

Important Notice ........................................................................................................................ 5 Introduction ............................................................................................................................... 5

General CASS® CEN System Information .................................................................................... 6 Applications ............................................................................................................................... 6 Post Spacing on a Curve .......................................................................................................... 6 System Components ................................................................................................................. 7 Where to Use CASS® CEN ....................................................................................................... 9 Product Overview ...................................................................................................................... 9 Recommended Tools .............................................................................................................. 10

Safety Instructions ...................................................................................................................... 11 CASS® CEN System Tested to EN 1317–1, 2 ............................................................................ 11 Ground Preparation and Barrier Alignment ................................................................................. 12

Ground Preparation ................................................................................................................ 12 Placing Sleeves when Encountering Solid Rock ..................................................................... 12 Placing Posts (Driven Post Option) when Encountering Solid Rock ....................................... 13

Cable Barrier End Treatment ...................................................................................................... 13 CASS® Cable Anchor (“CCA”) ................................................................................................ 13 Prefabricated Blocks ............................................................................................................... 14 Cast On-Site ........................................................................................................................... 14

Cable Attachment ....................................................................................................................... 15 Pre-Stretched Cable ............................................................................................................... 15 3-Cable CASS® CEN System ................................................................................................. 16 4-Cable CASS® CEN System ................................................................................................. 18

Tensioning and Field Connection ............................................................................................... 18 Delineation .................................................................................................................................. 20 Post and Post Foundation Assembly .......................................................................................... 21

Post Options ........................................................................................................................... 21 Sleeve for Concrete or Driven in Asphalt ................................................................................ 21 Concrete Footing with Sleeve ................................................................................................. 22 Pre-Stretched Cable Maintenance .......................................................................................... 22

Repair After Impact ..................................................................................................................... 23 System Repair ........................................................................................................................ 24

Emergency Repair ...................................................................................................................... 25 Lowering Cable for Crossover Access .................................................................................... 25 Vehicle Entanglement ............................................................................................................. 25 Cable Cutting Emergency ....................................................................................................... 25

Repair of a Cut or Damaged Cable ............................................................................................. 26 Tension Log Form ....................................................................................................................... 27 CASS® CEN Temperature / Tension Chart ................................................................................. 28



Customer Service Contacts Trinity Highway International is committed to the highest level of customer service. Feedback regarding the CASS® CEN System, its assembly procedures, supporting documentation, and performance is always welcome. Please contact Trinity Highway International for additional information:

Trinity Highway International:

Telephone

Asia / Pacific: +65 6276 3398 Middle East / Africa: +46 709 66 10 55 Americas: +1 214 589 8140 Europe: +44 1473 221105

Contact Link TrinityHighway.com/Contact

Website TrinityHighway.com

Important Introductory Notes Proper assembly of the CASS® CEN System is essential to achieve the performance that has been evaluated and CE certified per EN 1317-5. These instructions should be read in their entirety and understood before assembling the CASS® CEN System. These instructions are to be used only in conjunction with the assembly of the CASS® CEN System and are for standard assemblies only as specified by the appropriate highway authority. In the event your system assembly requires or involves deviation from standard parameters or, during the assembly process a question arises, please contact the appropriate highway authority that specified this system at this particular location for guidance. Trinity Highway International is available for consultation with that agency. These instructions are intended for an individual who is qualified to both read and accurately interpret them as written. They are intended for the individual who is experienced and skilled in the assembly of highway products which are specified and selected by the highway authority.

Important: This manual is intended to provide guidance for all assemblies of the CASS® CEN System.

Danger: It is critical that the CASS® CEN System posts are placed in suitable ground/soil foundations that will allow the system to fully perform in accordance with design specifications. Should you have any questions about this, please contact the appropriate highway authority that specified the CASS® CEN System at this particular location for guidance. Trinity Highway International is available for consultation with that authority.

Important: DO NOT use any component part that has not been specifically specified herein for the CASS® CEN System during the assembly or repair. Failure to follow this warning could lead to serious injury or death in the event of a collision.


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Important: Read safety instructions thoroughly and follow the assembly directions and suggested safe practices before assembling, maintaining, or repairing the CASS® CEN System. Failure to follow this warning can result in serious injury or death to workers and/or bystanders. Please keep these instructions for later use and reference by anyone involved in the assembly of the product.

Warning: Ensure that all of the CASS® CEN System Danger, Warning, Caution, and Important statements within the CASS® CEN System manual are completely followed. Failure to follow this warning could result in serious injury or death in the event of a collision.

Safety Rules for Assembly * Important Safety Instructions *

This manual must be kept in a location where it is readily available to persons who are skilled and experienced in the assembly, maintenance, or repair of the CASS® CEN System. Additional copies of this manual are available from Trinity Highway International by calling +1 214 589 8140 or by visiting TrinityHighway.com/Contact. Please contact Trinity Highway International if you have any questions concerning the information in this manual or about the CASS® CEN System.

Always use appropriate safety precautions when operating power equipment and moving heavy equipment or CASS® CEN System components. A minimum of gloves, eye protection, safety-toe shoes, and back support must be used.

Warning: Safety measures incorporating appropriate traffic control devices specified by the highway authority must be used to protect all personnel while at the assembly, maintenance, or repair site.

Safety Symbols This section describes the safety symbols that appear in this CASS® CEN System manual. Read the manual for complete safety, assembly, operating, maintenance, repair, and service information.

Symbol Meaning

Safety Alert Symbol: Indicates Danger, Warning, Caution, or Important. Failure to read and follow Danger, Warning, Caution, or Important statement indicators could result in serious injury or death to workers and/or bystanders.

Warning: Failure to comply with these warnings could result in increased risk of serious injury or death as a result of a vehicle impact with a system that is not compliant with EN 1317.

Warning: Do not assemble, maintain, or repair the CASS® CEN System 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 International at +1 214 589 8140 if you do not understand these instructions.




Important Introductory Notes These instructions are to be used only in conjunction with the assembly, maintenance, or repair of the CASS® CEN System.

Proper deployment and maintenance of the CASS® CEN System is critical to achieve performance under appropriate local guidelines. Take the time to review this manual thoroughly before performing the necessary work. Do not attempt to assemble any CASS® CEN System without the proper plans and assembly manual from the manufacturer.

In the event your system assembly requires or involves special circumstances or, if during the assembly process, a question arises regarding a particular assembly step, contact Customer Service before proceeding (p. 3).

Important Notice These instructions only apply to the CASS® CEN System. These instructions are for standard assembly, maintenance and/or repairs only as specified by the applicable highway authority.

In the event your system assembly, maintenance and/or repairs involve special circumstances or questions arise regarding a particular step, contact Customer Service (p. 3).

Introduction These instructions must be read in their entirety and understood before performing any maintenance and/or repairs on the CASS® CEN System.

Important: Trinity Highway International makes no recommendation whether use or reuse of any part of the system is appropriate or acceptable following an impact. It is the sole responsibility of the local highway authority and its engineers to make that determination. It is critical that you inspect this product after assembly is complete to make certain that the instructions provided in this manual have been strictly followed.

Warning: Safety measures incorporating appropriate traffic control devices specified by the highway authority must be used to protect all personnel while at the assembly, maintenance, or repair site. Do not stand adjacent to this system when there is any risk that the cable may be impacted and/or severed when under tension.

Warning: Do NOT modify the CASS® CEN System in any way.



General CASS® CEN System Information

The CASS® CEN System is a 3-Cable or 4-Cable Guardrail System that has been designed and tested to meet EN 1317-1, 2, N2, H1, H2, L1, and L2. CASS® CEN System consists of 100 mm wide C-Channel Posts with Post Spacing of 3 m. Three (3) or four (4) pre-stretched (19 mm) Cables are placed in a Slot at the top of the Posts at heights of 510/620/730 mm (±25 mm) (3 Cable) or 510/620/730 mm (±25 mm) (4 Cable) above the ground. Plastic Spacers keep the cables properly positioned. A Stainless Steel Strap is placed over the Post between the top two cables.

Applications

CASS® CEN Systems can be assembled in sections of 75 to 3000 m in medians and on shoulders with slopes of less than 1V:6H.

On slopes that are less than 1V:6H, CASS® CEN Systems must be placed in a location so an errant vehicle can approach on a relatively smooth surface and be expected to impact CASS® CEN Systems at normal bumper height with all wheels still on the ground to avoid water drainage issues at the bottom of a ditch.

Warning: It is the responsibility of the installer to ensure that your assembly complies with all local specifications and standards. If you have any questions during the assembly of CASS® CEN System at a particular assembly site, contact the specifying highway authority immediately.

Warning: Use only Trinity Highway International parts that are specified herein for the CASS® CEN System for assembling, maintaining, or repairing the CASS® CEN System. Do not utilize or otherwise comingle parts from other systems even if those systems are other Trinity Highway International systems. Such configurations have not been tested, nor have they been deemed eligible for use. Assembly, maintenance, or repairs using unspecified parts or accessories is strictly prohibited.

Post Spacing on a Curve Complete the following steps to assemble the posts and/or post foundations along a curve:

1. When the cable is assembled on a curve, post spacing may need to be reduced based on the radius. Adequate foundations for CASS® Post(s) are essential. The recommended minimum radius is 200 m with Post Spacing of 3 m. Pay close attention to the lateral forces that the curved assembly applies to the foundation of the Posts. Contact Trinity Highway International if radius is less than 200 m.

Warning: CASS® CEN Systems with driven posts should not be assembled on a curve.

2. Weak soil conditions may necessitate a larger footing for the line posts, based on the radius of the curve.

Warning: It is imperative, before assembly, that you contact a Trinity Highway International representative and highway authority engineer for special criteria involving weak soil conditions. It is also recommended that you consult your own soils or structural engineer.


System Components Below is a list of components for CASS® CEN System Barrier and CASS® Cable Anchor (“CCA”) hardware for both 3 and 4 cable systems. Please see Trinity Highway International drawings for specific lists of components and quantities.

Note: The following components are not shown to scale. Anchor Bracket 4 Cable Anchor Bracket 3 Cable Hook Bolts

5882 5871 5134

C-Shaped Post 1.6 m Cable Spacer w/o Reflector Sleeve Cover – CASS® Post

5886 5700 Blk/5701 Amb/5702 Wht 5823

Post Strap Concrete Reinforcing Ring Post Cap

5824 5836 5821

STD Post - 1.2 m 420 mm Concrete Post Sleeve

Washer Ø24

5847 5869 3900


Nut M24 Washer Ø 24 Nut M19

3908* 105498 3710*

Nut M24 Left Hand Threads Nut M24 Right Hand Threads Washer Ø19

105496* 105967* 3700

Pipe Spacer Turnbuckle M24 x 450 mm Post Cap w/o Reflector

33932 5826* 5838 Blk/5835 Amb/5859 Wht

M24 SWAGED END LHT (RED)

M24 SWAGED END RHT (GREEN)

5873* 5874*

* Metric dimensions are for reference only. Parts are supplied to ASTM specifications.


Where to Use CASS® CEN The CASS® CEN System can be assembled in a median, on a shoulder, or on a slope (1V:6H) in sections of 75 m to 3000 m, and on curves with a minimum radius of 200 m (p. 6).

Product Overview

Technical Specification

Cable – 19 mm diameter 3 x 7 strands. Tensile strength 1370 N/mm2 minimum, pre-stretched to modulus of elasticity of 155 kN/mm2 based on an area of 148 mm2.

C-channel Post – 100 x 50 x 4 mm. Lengths 1.2 and 1.6 m.

Post Cap – recycled black plastic.

Spacer – 50 x 90 x 20 mm recycled black plastic.

Strap – 107 x 57 x 1 mm x 30 mm wide stainless steel.

Concrete Footing – 254 mm min. diameter x 600 mm min. depth (p. 22).

Sleeve for Concrete Footing – 120 x 60 x 3 mm min. Length 420 mm.

Sleeve Cover (Recycled Black Plastic)

Bearing Angle – 102 x 76 x 6.4 mm.

Hardware- ASTM A – 449 (bolts) and A-563 (nuts).

End Terminal – Anchor Bracket 203 x 102 x 12.7 x 356 mm.

Zinc Coating

C-channel Post to ASTM A-123

Sleeve to ASTM A-123

Bearing Angle to ASTM A-123

Cable to AASHTO M30, Type1 Class A coating

Hardware to ASTM A-153

Breakaway Anchor Angles to ASTM A123

Fittings

Turnbuckles

Warning: Use only Trinity Highway International parts that are specified herein for the CASS® CEN System for assembling, maintaining, or repairing the CASS® CEN System. Do not utilize or otherwise comingle parts from other systems even if those systems are other Trinity Highway International systems. Such configurations have not been tested, nor have they been certified for use. Assembly, maintenance, or repairs using unspecified parts or accessories is strictly prohibited.

Warning: It is the responsibility of the installer to ensure that your assembly complies with all local specifications and standards. If you have any questions during the assembly of CASS® CEN System at a particular assembly site, contact the specifying highway authority immediately.


Recommended Tools Documentation

Manufacturer’s Assembly Manual

Manufacturer’s Drawing Package

Personal Protective equipment Safety Glasses

Gloves

Back Protection for Lifting

Safety-Toe Shoes

Hard Hat

Reflective Vest

Wrenches

Pipe Wrenches

Adjustable Spanner

Adjustable Jaw Wrenches

Imperial and Metric Wrenches Concrete equipment

Concrete Vibrator

Concrete Tools Cable equipment

Tension Meter (Trinity P/N 5878)

Infrared Thermometer (Trinity P/N 5709)

Abrasive Cutoff Blade

C-Clamps

Auger

Cable Pulling Tool (Trinity P/N 5850)

Locking Pliers

Duct tape

Pry Bars

Line/String

Plumb Line

Straight Edge

Level

Drift Pin

Tape Measure

Come-along (optional tensioning device)

Backhoe (optional tensioning device)

Marking Paint

Note: The above list of tools is a general recommendation only and should not be considered an exhaustive list. Depending on specific site conditions and the complexity of the assembly (or repair) specified by the appropriate highway authority, additional or fewer tools may be required. Decisions as to what tools are needed to perform the job are entirely within the discretion of the specifying highway authority and the authority’s selected contractor performing the assembly of the system at the authority’s specified site.


Safety Instructions Always use appropriate safety precautions when operating power equipment and mixing chemicals, and when moving heavy equipment or CASS® CEN System components. A minimum of gloves, eye protection, safety-toe shoes, and back protection must be used.

Important: Safety measures incorporating traffic control devices must be used to provide safety for personnel while at the assembly/maintenance/repairs site.

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 bystanders.

CASS® CEN System Tested to EN 1317–1, 2

Product Containment

Level

Impact Severity

level

Normalized working width,

class [m]

Normalized dynamic

deflection, class [m]

Normalized vehicle

intrusion, class [m]

Trinity CASS® CEN Center to Center 3 m Concrete footing or Soil embedment

N2 A W5 (1.6) 1.6 VI1 (0)

H1 A W5 (1.7) 1.7 VI7 (2.3)

H2 A W8 (2.7) 2.6 VI8 (3.2)

L1 A W5 (1.7) 1.7 VI7 (2.3)

L2 A W8 (2.7) 2.6 VI8 (3.2)


Ground Preparation and Barrier Alignment The CASS® CEN System shall be deployed on shoulders or medians with slopes of 1V:6H or flatter without obstructions, depressions, etc. that may significantly affect the stability of an errant vehicle. Grading of the site and/or appropriate fill materials may be required. The technician shall “flatten” or “round” various topographical inconsistencies that could interfere with the ability of workers to consistently maintain the design height (in relation to the terrain) of the cables.

Warning: It is imperative, before assembly, that you contact a Trinity Highway International representative and highway authority engineer for special criteria involving weak soil conditions. It is also recommended that you consult your own soils or structural engineer.

When the cable is placed on a ditch section and a vehicle can strike it after crossing the ditch, the appropriate highway authority policy must be followed when the slopes are steeper than 10:1 and the cable is in an area of 300 to 2400 mm from the ditch bottom.

Important: A flare rate of 30:1 or flatter is required if the barrier must be flared.

Layout Aligning the CASS® CEN System

Follow all procedures in the placement of the footing and/or post to insure proper alignment. To achieve this, it is suggested that a string line or other means be used to provide a consistent horizontal and vertical alignment that meets specifications.

Ground Preparation Make sure that the ground line is at the correct slope. Determine where the CASS® CEN shall start and stop, and mark a straight line between these two points. If prefabricated cables are specified, please see “Prefabricated Cables”. If assembled on a curve, minimum 200 m radius, follow and use the edge of the paved surface as a guide (p. 6).

Placing Sleeves when Encountering Solid Rock If solid rock is encountered within 230 mm of embedment depth of Post Sleeve, drill a 300 to 400 mm diameter hole in the rock. The hole must be 75 mm deeper than the required embedment depth and filled with 21 MPa concrete. The sleeve must be positioned as would be for the concrete footing including the recommended rebar ring.

If a solid rock is encountered and more than 230 mm depth into the rock is required to position the full sleeve, drill a 300 to 400 mm diameter hole 300 mm deep into the rock. The minimum depth to the bottom of the hole from the ground line shall be 460 mm. Cut off enough of the sleeve so the top will be just above the top of the ground line (concrete footing).

Note: There must be 75 mm of concrete below the sleeve. Fill the hole with 21 MPa concrete. The sleeve must be assembled the same as would be for the concrete footing (p. 22).


Placing Posts (Driven Post Option) when Encountering Solid Rock If solid rock is encountered within 230 mm of embedment depth of Post, drill a 150 to 175 mm diameter hole in the rock. The minimum depth to the bottom of the hole from the ground line shall be 460 mm. The Post must be placed in the center of the hole. Backfill the hole with compactable materials in 150 mm lifts and compact with pneumatic equipment to optimum compaction.

If solid rock is encountered and more than 230 mm of embedment depth into the rock is required to position the Post, drill a 150 to 175 mm diameter hole 300 mm deep into the rock. The minimum depth to the bottom of the hole from the ground line shall be 820 mm. The Post must be placed in the center of the hole. Backfill the hole with compactable materials in 150 mm lifts and compact with pneumatic equipment to optimum compaction.

Note: If compactable, the material removed from the hole may be used for backfill.

Cable Barrier End Treatment The CASS® CEN System barrier is normally terminated by the CCA. Other options, including NCHRP Report 350 and MASH compliant terminals, are available. Contact Customer Service for more information (p. 3).

CASS® Cable Anchor (“CCA”) The CCA consists of a concrete anchor block, an Anchor Bracket to secure the cable to the anchor block, Hook Bolts, and Pipe Spacers. Bearing Angles are required if the Driven Post option is chosen.

The concrete anchor block is 21 MPa or greater strength to meet an agency’s specifications. The anchor block can be pre-cast or cast in place and must be a minimum of 3 m long, 1.5 m wide, and 1.5 mm deep (p. 14).

Caution: Agency standards or soil conditions may require a larger footing.

Eight (8) M19 Hook Bolts for the Anchor Bracket are placed in the footing before the concrete is poured (Figure 1).

Figure 1 – Hook Bolts

Note: Illustrations are for general reference only. Consult specific site assembly drawings for details.



Prefabricated Blocks If a CCA using concrete anchor blocks is specified and prefabricated (pre-cast), ensure to only excavate soil from behind the system leaving the soil nearest the Cable Guardrail undisturbed.

Cast On-Site If the Anchor Blocks are cast in place, determine the proper location and excavate a 1.5 m x 3 m x 1.5 m hole (WxLxD).

Start by marking all locations of the standard CASS® CEN System Posts. Begin from the upstream position and mark the location of the first CASS® Post 3 m from the connecting point of the Cables at the CCA Bracket. Continue to mark every Post location at the specified Post Spacing (3 m) until you reach the downstream CCA Block. A maximum of 3 m distance must remain between the last CASS® Post and the connecting point of the Cables to the CCA Bracket. This means that there could be a distance that is less than the Specified Design Deflection Post Spacing between the last and second-to-last CASS® Posts.

Use a prefabricated bolt frame that can be cast directly into the concrete. If ground conditions require special attention, a simple mold can be used. Mount the Anchor Bracket to the Hook Bolts of the Anchor Block. The Anchor Bracket must be located at the centerline of the Anchor Block in both directions.

Note: Contact Customer Service for additional Hook Bolt or prefabricated bolt frame information (p. 3).

Once the concrete has reached 21 MPa with the Hook Bolts (5134) embedded, the anchor bracket is secured to the footing with Ø19 flat washers (3700) and M19 hex nuts (3710). If you have any questions about the CASS® Cable Anchor, please contact Customer Service (p. 3).

Figure 2 – Anchor Bracket mounted on Anchor Block

Figure 3 – Three & Four Cable Brackets



The first CASS® CEN System post is placed 3 m from the anchor bracket. The post can be in a driven sleeve, a concrete footing with a sleeve, or driven per the contract plans. When the post is driven, the Bearing Angles of the CCA must be attached to the post at grade. The second CASS® CEN System post is placed 3 m on center from the first CASS® CEN System post.

The threaded rods of the cable end fittings are secured to the anchor bracket with a 24 mm or 25 mm flat washer (F436) and two (2) M24 or 25 mm hex nuts (A194 2H).

The cable spacers at the first CASS® CEN System post shall be metal pipe spacers.

Cable Attachment Once the posts are in place and cables are attached to the anchor bracket, cable can then be inserted into the posts. The cable can be field cut from a reel of cable.

Pre-Stretched Cable Standard Lengths

Standard cable lengths are 300 to 600 m. These lengths can be field cut from cable reels.

Non-Standard Lengths

The non-standard lengths to complete the assembly can cut from a reel of cable.

When the cable is cut from a reel, the last piece of cable removed from the reel can be field spliced to the end of the cable from a new reel to complete the cable length using a field applied Torpedo Cable Splice (Figure 4).

Important: Ensure one wire of the cable is bent over the end of the wedge after the wedges are properly seated. Ensure no more than two (2) threads of the coupling are showing after completing and closing the field applied torpedo cable splice.

Figure 4 – Field Applied Torpedo Cable Splice


The right-hand fitting end of the anchor is placed at the anchor bracket and secured as per the Cable Barrier End Treatment instructions.

The cables are connected with a turnbuckle that has right and left threads (Figure 5).

Figure 5 - Cable Splice with Turnbuckle

Each threaded rod must be threaded a minimum of 38 mm into the turnbuckle (visible in the sight hole) to assure the continuity of the strength of the cable. The cables are unspooled and connected in this manner until the anchor is reached at the other end of the run.

3-Cable CASS® CEN System The cables are placed in the post slots, one cable at a time, with bottom cable first. Once the bottom cable is in place, a Cable Spacer (5700) is attached to each post (Figure 6).

Figure 6 - 1st Cable with Cable Spacer Attached

Sight Holes


After the middle cable is added to each post, a Cable Spacer and Post Strap are stacked above (Figure 7).

Figure 7 - 2nd Cable, Spacer, and Stainless Steel Strap Assembled

The top cable is then attached (Figure 8) and topped by a CASS® Post Cap.

Figure 8 - 3rd Cable Attached

It is recommended before tensioning that for runs of cable greater than 1500 m, the cable must be pulled at 500 m intervals to remove slack. A check should be made to see if any of the turnbuckles would interfere with the posts during the tensioning process. If this is the case, remove the post(s) or the cables from the post.

Important: For long runs of cable, the connection to the turnbuckle must be checked at every location to ensure the cable has not unthreaded during the laying out or slack pulling process. The rod threads must be seen through the sight holes on each end of the turnbuckle.


4-Cable CASS® CEN System (Step 1) Two cables are placed in the post slots, one cable at a time, with bottom cable(s) first. Once the bottom two (2) cable(s) are positioned, a Cable Spacer is attached to each post. (Step 2) Place the middle cable in all of the posts. A Cable Spacer and Post Strap are then attached. (Step 3) Attach the top cable and place a Post Cap on top of the post.

Figure 9 – 4th Cable Attached

Tensioning and Field Connection Once all of the cables have been attached to the posts, the field connection and tensioning can take place.

The tension placed on the cables is determined by the temperature of the steel cable. An accurate infrared thermometer must be on site at the point of tensioning to obtain the correct steel cable temperature. Please reference the CASS® Temperature/Tension Chart (p. 28).

Field Splice - Wedge Option

Each CASS® CEN System assembly will require field splice connections. The field splice must be correctly applied to ensure the connection will not separate.

Complete the following steps to make the field splice:

1. Make sure that the cable has a clean square cut by using a saw with an abrasive blade or an electric band saw.

2. Insert the cut end of the cable into the field casting through the triangular end.

3. With the cable inside the casting, the cable is separated with two flat head screw drivers so the tapered triangular wedge can be inserted.

4. The wedge is inserted into the cable with the smaller diameter end towards the triangular hole.

Note: All three strands of the cable must be placed in the appropriate grooves of the wedge

5. Make sure the wedge is pushed 13 mm beyond the end of the cable (± 3 mm).

6. Once the wedge is inserted, use a hammer to seat the wedge by hitting on the triangular end of the casting. Several hits should be made to seat the wedge.

7. After the wedge is properly seated, one wire of the cable must be bent over the end of the wedge.

Step 1

Step 2

Step 3


8. Place a 25 mm nut inside the casting, insert the 25 mm threaded rod through the hole of the casting and thread onto the threaded rod. The threaded rod must be threaded into the fitting until all threads are utilized or the rod is against the end of the cable.

Important: Swage fitting must follow swaging tool manufacturer’s instructions.

9. A cable pulling tool along with pulling equipment is used to add tension to the cables (p. 26 / Step 7 / Figure 16).

Danger: Extreme care should be taken to ensure that the cable gripper is attached to the cable in such a location that if it slips, the chain or gripper will not hit workers. This can be done by attaching the gripper near the end of the cable when marking it for cutting. After the cable has been cut, the gripper should be attached several posts away from where the connection is to be made. The equipment used for pulling the cable should be placed opposite the connection location or downstream from it. It is recommended any tensioning equipment be parallel to and as close as possible to the cable.

10. Once the fittings are attached, the cable is pulled again and connected to the Anchor using right-hand fittings (swaged or wedged).

11. Reference the Temperature/Tension Chart to determine proper tension and adjust by turning the turnbuckles (p. 28).

Figure 10

Note: The middle cable and then the top cable are tensioned using the same procedure.

Keep a cable tension record on the Tension Log Form (p. 27).

If there were any posts or cables removed due to the turnbuckles interfering with post(s):

1. Any removed posts or cables must be reattached. 2. Check tension at intermittent locations along the run to ensure the cable is properly tensioned. 3. Adjust the cable at intermittent turnbuckles if necessary.


Important: It is recommended that cable tension be checked approximately three to four weeks after initial assembly and adjustments made as required.

Delineation The specifying agency establishes all post delineation criteria. Delineation is available on every Post Cap or Cable Spacer used with the CASS® CEN System (Figure 11).

Important: Ensure system delineation used meet all specifying agency and local specifications.

Figure 11 – Reflective Sheeting on Cable Spacer & Post Cap

Tension Meter

Important: Review tension meter manufacturer’s operating instructions prior to tensioning the cable.

Infrared Thermometer

Important: Review infrared thermometer manufacturer’s operating instructions prior to tensioning the cable.

Warning: Infrared light is harmful if shined into anyone’s eyes.


Post and Post Foundation Assembly

Important: All C-Channel Posts shall be alternately rotated 180 (Figure 12).

Post Options The CASS® CEN System posts can be driven, placed in a Driven Sleeve, placed in a Concrete Post Sleeve in a concrete footing (poured or precast), or mounted to a concrete surface. Driven CASS® CEN System posts are 1.6 m long. For posts placed in a sleeve, the posts are 1.2 m. For posts mounted to a concrete surface, the post is approximately 0.80 m long.

Figure 12 –C-Channel Post Orientation and Rotation

Sleeve for Concrete or Driven in Asphalt

1. Lay out the post alignment and post spacing according to contract specifications.

2. Drive the Concrete Post Sleeve (5869) in asphalt only with an appropriate driving head.

Figure 13 – Concrete Post Sleeve for Concrete Footing or Asphalt


Concrete Footing with Sleeve 1. Concrete footings are a minimum of 254 mm in diameter and 600 mm deep.

Note: Weak soil conditions may necessitate a larger footing for line posts.

2. Concrete strength must be 21 MPa or stronger if necessary to meet local specifications.

3. The concrete footing can be poured in augured or punched holes. Pre-cast footings can be placed in augured or punched holes.

4. The 420 mm or other steel sleeve is utilized (p. 21).

5. Duct tape can be placed on the bottom end of the sleeve to prevent the concrete from coming up from the bottom.

6. It is recommended that a #3 rebar ring is placed around the top of the sleeve 50 to 75 mm from the top of the footing.

7. Insert sleeve and center in concrete after it is poured.

Note: A vibrator is helpful to insert the sleeve into the concrete footing and eliminate air pockets. The sleeves must be plumb. Use a string line and level to keep the sleeves on alignment.

8. It is recommended that a plastic cover be placed on the post to keep debris out of the sleeve.

Figure 14 - Plastic Cover for Sleeve

Pre-Stretched Cable Maintenance Ensure cable tension review schedule is in compliance with the local highway authority’s specifications. Cable tension must be checked a minimum of once every twelve months. The tension value is established based on the steel cable temperature. Please reference the CASS® Temperature/Tension Chart on page 28.

Important: Read safety instructions thoroughly and follow the suggested safe practices before assembling, maintaining, and repairing the CASS® CEN System. Failure to follow this warning can result in serious injury or death to the worker and/or bystanders. Please keep these instructions for later use.

Warning: Ensure that all of the CASS® CEN System Danger, Warning, Caution, and Important statements within the CASS® CEN System manual are completely followed. Failure to follow this warning could result in serious injury or death in the event of a collision.


Repair After Impact

Danger: If it is necessary to totally remove the fitting ends from the turnbuckle, the tension must first be de-tensioned, possibly fully released, by means of a cable gripper and a come-along, backhoe, or other mechanical means. Failure to follow this warning can result in serious injury or death to the worker and/or bystanders. Please clear all pedestrians, law enforcement, emergency personnel, and any individuals not specifically authorized by the appropriate highway authority to repair a cable under tension, after any impact to the system. An impact may damage or weaken the tensioned cable and special care must be taken to clear everyone in the area of an impacted system.

After an impact, the system will require repair. Impact testing conducted in conformance with EN 1317-1, 2 indicates that the cables, under many circumstances and depending upon severity of the impact, can remain close to the original height after impacts and may provide some level of performance prior to repair. Even with this capability, it is strongly recommended that the system be repaired as soon as possible and thoroughly assessed by an appropriate highway authority. A careful visual inspection must be used to determine if any broken, worn, torn, and/or damaged parts need to be replaced. Replacing parts to the CASS® CEN System is a decision that must be made by the appropriate highway authority.

It is recommended that for impacts with larger vehicles in the test matrix, the cable be checked to determine if it needs to be re-tensioned.


System Repair 1. Inspect system damage and create a parts list for required repairs.

Important: Wear appropriate PPE such as gloves, safety-toe shoes, and eye protection during system repair.

2. Remove the damaged posts. The posts should come out of the sockets easily (driven posts will have to be pulled out of the ground). During very cold weather and in Northern climates, the post may become frozen into the socket. Successful means of extraction have utilized propane torches or a hammer drill to break up the ice. If approved by the highway authority, calcium chloride (a common deicing chemical) can also be mounded over the top of the ice for 24 hours prior to removal of the post.

Important: Check with the local highway authority before using deicing chemicals.

3. Place new posts in place of damaged ones. The C-channel posts shall be paired with every other post being rotated 180 degrees (Figure 15).

Figure 15 – C-Channel Post Orientation and Rotation

4. If this is a three cable system, place the bottom cable in the post slot, followed by the appropriate white, amber, or black Cable Spacer.

a. Place the middle cable in the post slot, followed by the appropriate Cable Spacer. Place the Post Strap on the post above the middle cable.

b. Place the top cable in the post slot (p. 17).

5. If this is a four cable system, place the two (2) bottom cables in the post slot.

a. Place the 3rd cable in the post slot, followed by the appropriate white, amber or black Cable Spacer.

b. Place the stainless steel strap on the post, above the 3rd cable.

c. Place the top cable in the post slot (p. 18).

6. If Post Caps are used, place them on top of each post. Reflective caps may be required by the local highway authority.

7. Depending on the severity of the impact, after the repair, the cable might have to be re-tensioned. The tension on the cable should be checked with the tension meter and adjustments made at the turnbuckles to bring the cable to the correct tension based on the steel cable temperature and the values on the CASS® CEN System Temperature / Tension Chart (p. 28).

Note: The reflective sheeting may be placed on the Cable Spacers, Post Caps, or Post Straps of the CASS® CEN System.


Emergency Repair

Caution: Individuals not specifically designated to perform emergency repairs by the appropriate highway authority must stand clear of the repair zone.

Lowering Cable for Crossover Access To resume traffic flow after an accident or to get emergency vehicle(s) access to the accident site, crossover access through the cable may 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 (driven posts will have to be pulled out of the ground). The cable can be held down and the traffic or emergency vehicle(s) can pass over it.

Vehicle Entanglement Whenever a vehicle is entangled in the cable, the first step that must be undertaken is to move or drive the vehicle as close to the centerline of the cable system as is feasible, in order to reduce tension. When the cable is entangled with a vehicle that must be towed away, remove the entangled cable by lifting one or more of the cables up over the vehicle. During this operation, if any of the line posts entangled with the cable start to lift up out of the sleeves, the lifting should be stopped and the post(s) removed from the cable. Once the post(s) are removed, the cable can be lifted up over the vehicle.

Cable Cutting Emergency In life threatening or emergency situations the cable can be cut. If the cable was put under additional tension due to the accident, the tension can be reduced at the turnbuckles closest to the impact. The threads outside of the turnbuckle must be marked, and the turnbuckle backed off no more than 19 mm. Wrap duct tape around the cable to reduce the amount of cable fraying before the cut is made through the tape. Some agencies have also cut through the turnbuckle itself. A turnbuckle cut point will reduce maintenance / repair work. When cutting through a turnbuckle, ensure all upstream and downstream posts are removed a minimum distance of 16 m from the cut point to prevent turnbuckle or fitting interference.

The cut cable will move away a short distance from the cutting point. A minimum of gloves, eye protection, safety-toe shoes, and back support must be used while cutting.

Danger: All personnel or bystanders are strictly prohibited from standing upstream or downstream from the point of an emergency repair cut.


Repair of a Cut or Damaged Cable Below are various methods to repair cable that has been cut or damaged.

METHOD 1 – Splicing the Cable

Splicing the cable may be necessary if a cable is cut or damaged during an impact, which is rare. The length of the cable must be 16 m or longer to make the splice.

1. Re-cut the ends of the cable to ensure the ends are clean and smooth.

2. Refer to pages 15 – 19 to determine an appropriate cable splice connection.

3. If an accurate length of cable is used for the splice section, two cable splice connectors will be required to connect the cables together.

4. Connect one end of the splice cable to one end of the cut cable with a connector.

5. Next, apply another connector to the other end of the splice cable and the end of the cut cable.

6. Once the fittings are attached, the cable is pulled again and connected to the Anchor using right-hand fittings (swaged or wedged) (p. 19).

7. Assemble the cable splice connector by using a cable gripper and a come-along, backhoe, or other mechanical means.

Figure 16 – Mechanical Means

8. Check the cable with the tension meter and infrared thermometer to adjust the turnbuckles using the CASS® CEN Temperature / Tension Chart (p. 28).

If the cable splice has been cut accurately, the tension may be obtained by turning the turnbuckles at each side of the cut.

Important: If the tension cannot be obtained at the turnbuckles at each side of the splice, it may be necessary to re-tension the cable at the end of the cable run where the field splice was made. A cable field splice repair must be removed, measured, re-cut, and re-connected with the correct tension (p. 28). Some assemblies may have cable field splices at all locations and measuring, cutting, and re-connecting can be done at any location.


Please make extra copies and fill out Tension Log Form(s) for your project files.

Trinity Highway International CASS® CEN System

Tension Log Form PROJECT NAME: ______________________________________________________________ RUN: _____________________________ WEATHER: ___________________________ STA. ______________________________ TO STA. ___________________________________

INITIAL TENSION TENSION RECHECK DATE: ______________________ DATE: ____________________

TURNBUCKLE STATION: ________________________________________

CABLE CABLE CHART MEASURED CABLE CHART MEASURED TEMP LOAD LOAD TEMP LOAD LOAD

B ______ _________ _________ ______ _________ _________ MB ______ _________ _________ ______ _________ _________

MT ______ _________ _________ ______ _________ _________ T ______ _________ _________ ______ _________ _________

TURNBUCKLE STATION: __________________________________________

CABLE CHART MEASURED CABLE CHART MEASURED CABLE TEMP LOAD LOAD TEMP LOAD LOAD

B ______ _________ _________ ______ _________ _________

MB ______ _________ _________ ______ _________ _________

MT ______ _________ _________ ______ _________ _________ T ______ _________ _________ ______ _________ _________

RECORDED BY: __________________________RECORDED BY: _________________________

Page _______ of ______ Pages


CASS® CEN Temperature / Tension Chart

Pre-Stretched Cable

°F Tension (lbf)* C kN -15 7500 -26 33.3

-10 7300 -23 32.5

-5 7100 -21 31.6

0 7000 -18 31.1

5 6800 -15 30.3

10 6600 -12 29.4

15 6500 -9 28.9

20 6300 -7 28.0

25 6100 -4 27.1

30 6000 -1 26.7

35 5800 2 25.8

40 5600 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 16.0

105 3500 41 15.6

110 3300 43 14.7

115 3100 46 13.8

120 3000 49 13.3

125 2800 52 12.5

130 2700 54 12

135 2600 57 11.6

140 2500 60 11.1

Tolerance: –200 to + 800 pounds [-0.9 to + 3.6 kN]


Notes:

620249 cass cen - trinity highwaytrinityhighway.com 6 revision a february 2020 general cass® cen...

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