Installation Instructions

Transcription

1 Installation Instructions SRT POST Guardrail End Treatment Revised July 2005 TRINITY HIGHWAY SAFETY PRODUCTS, INC. BUILDING TOMORROW S HIGHWAY SAFETY SOLUTIONS TODAY

2 2 SRT TM 8-POST SYSTEM FOR SPECIFIC DETAILS, REFER TO THE STATE STANDARD DRAWING First run through of 8-Post SRT 37'-6" 4'-2" 4'-2" 4'-2" 4'-2" 4'-2" 4'-2" 6'-3" 6'-3" NOTES: 1. Alternate to long foundation tube without soil plate is short tube with soil plate. 2. Alternate to two 12'6" (3.81 m) long rail panel is one 25'0" (7.62 m) long rail panel

3 SRT TM 8-POST SYSTEM BILL OF MATERIAL ENGLISH (METRIC) (FOR QUANTITIES, SEE STATES OPTION(S)) PC QTY DESCRIPTION 9G 1 12/12.5'/6'3"/S (2.67/3.81/1.905/S) GUARDRAIL 30G 1 12/12.5'/6'3"/S (2.67/3.81/1.905/S) SRT-1 ANC (GUARDRAIL) 39G 1 12/12.5'/6'3"/S (2.67/3.81/1.905/S)SRT-2 (GUARDRAIL) 69G 1 12/25'/6'3"/S (2.67/7.62/1.905/S)SRT-2 (GUARDRAIL) 700A 1 CABLE ANCHOR BRACKET 705G 1 PIPE SLEEVE - 2" STD PIPE x 5 1/2" (50 STD PIPE x 150 PIPE) 740G* 2 6" x 8" x 4'6" x 3/16 (152 x 203 x 1375 x 4.8) TUBE SLEEVE 742G 2 6" x 8" x 6'0" x 3/16 (152 x 203 x 1830 x 4.8 TUBE SLEEVE (ALTERNATE TO USING 740G and 766G) 766G* 2 18" x 24" x 1/4" (460 x 610 x 16) SOIL PLATE 775G 1 6" x 8" x 5/8" (150 x 200 x 16) BEARING PLATE 907G 1 12 (2.67)/BUFFER/ROLLED (TERMINAL) 3000G 1 CABLE ASSEMBLY 3/4" x 6'6" (19 X 1981) 3300G 12 5/8" (16) WASHER 3340G V 5/8" HGR NUT 3360G V 5/8" DIA x 1 1/4" (16 DIA. x 35) HGR SPLICE BOLT 3380G 8 5/8" DIA. x 1 1/2" (16 DIA x 40) HEX HEAD BOLT 3478G* 4 5/8" DIA. x 7 1/2" (16 DIA x 190) HEX HEAD BOLT 3497G 2 5/8" DIA. x 9 1/2" (16 DIA x 240) HEX HEAD BOLT 3500G 2 5/8" DIA x 10" (16 DIA x 255) HGR POST BOLT 3580G 6 5/8" DIA x 18" (16 DIA x 460) HGR POST BOLT 3900G 1 1" (25) WASHER 3910G 2 1" (25) HEX NUT 4063B 6 WOOD POST 6" x 8" x 6'0" (150 x 200 x 1830) 4075B 6 WOOD BLOCK 6" x 8" x 14" (150 x 200 x 360) DR 5968G 14 16d NAIL SRT 6058B 2 WOOD POST 5 1/2" x 7 1/2" x 3'9" (140 x 190 x 1145) 9852A 1 STRUT 9960G 4 SLOT GUARD 9961G 1 3/8" x 3" x 4" (10 x 75 x 100) PLATE WASHER * OPTION TO THE 6'0" POST SLEEVE TUBE DELINEATION OPTIONS 6665B 1 16" x 16" (400 x 400) Striped (Yellow/Black) REFLECTIVE SHEETING 3

4 4 INSTALLING THE 8 POST SRT-350 TM Trinity Highway Safety Products, Inc.'s drawings for the SRT-350 TM 8 POST system should be used with these instructions. The states standard drawing(s) (and/or Trinity's) for this system need to be reviewed for details that will be specific to that state. The installation of the SRT-350 TM is very similar to the old BCT. The same equipment and expertise is required for both systems. Anyone who's had experience installing the BCT should have no difficulty installing the SRT-350 TM. MATERIALS As packaged, the 8 Post SRT system includes all materials needed for the installation of the 37'6" (11.43 m) of the SRT-350. Note that concrete footings or foundations are not required. TOOLS REQUIRED Tools required are those ordinarily used to install standard highway guardrail (HGR). They include 9/16", 15/16", 1 1/4" and 1 1/2" sockets and wrenches and such other equipment as augers and post pounders commonly used in driving posts. SITE PREPARATION Site grading is usually necessary for the proper placement of the steel tubes and the Controlled Release Terminal (CRT) posts. The states Standard drawings should be used for the site grading. It is suggested that this grading be completed before the start of the installation of the SRT-350 TM. INSTALLATION Be sure adequate time is allowed for "same day" complete installation. If the SRT TM is to be installed on a curve, see page 13 for the layout. If there are special field conditions encountered when installing the SRT TM System, contact Trinity to review the conditions. POST INSTALLATION The following instructions are for the installation of the Control Release Terminal (CRT) posts and foundation tubes with wood posts. POST LAYOUT Start at the end (post location 9) of the guardrail run (connection point for the terminal). The length of the installation is 37'6" (11.43 m). Layout the post locations starting at location 8 which is the first offset post. Use the following table to offset each post: (dimensions are to the center of the post). The offset points are measured from a tangent line of the guardrail run extending from post 9 towards post 1.

5 Offset points are to be located by chord measurements at the center of the post equal to the nominal post spacing. Posts are to be approximately tangent to the railing at each post location. Post Location Post Spacing ft mm ft mm OFFSETS 3 (.091m) 3.5 (1.07m) 4 (1.22m) ft mm ft mm INSTALLING THE CRT POSTS Install the wood posts (PC-4063B) at locations 8 thru 3. These posts spaced at 4'-2" (1270 mm) may be driven. They may also be installed by drilling holes approximately 44" (1120 mm) deep. Insert the 6'0" (1830 mm) wood post into these holes and backfill. Note that in either case, the bottom of the upper 3 1/2" (90 mm) hole in the post is approximately at the finished grade. See Figure 1. Figure 1 5

6 6 PLACING FOUNDATION TUBES/WOOD POSTS Tube Options 6'0" (1830 mm) Tube, no Soil Plate No assembly required. Install the soil tube (PC-742G) as described below. 4'6" (1375 mm) Tube with Soil Plate Assemble the soil tubes and soil plates. Bolt the soil plate (PC-766G) to the foundation tube (PC-740G) with two 5/8" x 7 1/2" (16 mm x 190 mm) hex bolts and HGR nuts (no washers). DO NOT OVERTIGHTEN AND DEFORM THE TUBES Install the foundation tubes at locations 1 and 2. Use the strut for a guide for the spacing of the tubes. Note that the soil plate (if used) should be positioned on the downstream side of the post. DO NOT DRIVE TUBES WITH THE WOOD POST INSERTED. INSTALLATION OPTIONS (Best preference listed first) For permeable soil: If the soil is permeable so water will drain from the tubes, the tubes may be driven with an approved driving head. The optimum depth will have the top of the tube 2 5/8" (67 mm) above the finished grade. For non-permeable soil: Method A Tube Only: Drill a 12" (300 mm) pilot hole approximately 75" (1905 mm) deep and place the tube to the appropriate depth. The optimum depth will have the top of the tube 2 5/8" (67 mm) above the finished grade. Tube and Soil Plate: Drill a 12" (300 mm) pilot hole approximately 57" (1450 mm) deep and force the soil plate/tube assembly to the appropriate depth by impact or vibratory means with an approved driving head. The optimum depth will have the top of the tube 2 5/8" (67 mm) above the finished grade. Method B Same as method A, except the slots for the soil plates may be cut out by hand using a rock bar. Method C Same as method A, except drill three adjacent 12"(300 mm) holes or one 24" (610 mm) hole to accommodate the soil plate/tube assembly. Extra care must be taken to prevent settlement or lateral displacement of the tubes. If METHOD C is used, material should be placed in 6" (150 mm) lifts and compacted with pneumatic equipment to optimum compaction.

7 The finished guardrail height will generally be 27 3/4" (706 mm) above the finished grade. The tubes should not project more than 4" (100 mm) above the finished grade. INSTALLING FOUNDATION TUBES WHEN ENCOUNTERING ROCK If rock is encountered when installing the tube(s), use the following procedures, unless there is a more restrictive state specification. If rock is encountered and 20" (510 mm) or less depth is required to complete the installation of the full tube, drill a 12"-16" (300 mm-400 mm) diameter hole in the rock. The hole should be drilled 2" (50 mm) deeper than required embedment depth. Place in the bottom 2" (50 mm) of the hole for drainage granular material or small pieces of the drilled rock. Backfill and compact the hole after installing the tube. If compactable, the material removed from the hole may be used for the backfill. If rock is encountered and more than 20" (510 mm) depth is required to install the full tube, drill a 12"-16" (300 mm-400 mm) diameter hole 22" (560 mm) deep into the rock. Install the tube in the hole. Cut off the embedded portion so the guardrail will be installed at the proper mounting height. Place in the bottom 2" (50 mm) of the hole for drainage granular material or small pieces of the drilled rock. Backfill and compact the hole after installing the tube. If compactable, the material removed from the hole may be used for the backfill. INSTALLING WOOD POSTS IN TUBES Insert pipe sleeve (PC-705G) in post (PC-6058B) and install in steel tube at location 1. (Note: A metal band must be around the post under the post bolt hole.) Install other (PC-6058B) post in steel tubes at location 2. (Note: A metal band must be around the post under the post's bolt hole.) INSTALLING THE STRUT Place the slotted yokes of the ground strut (PC-9852A) over the foundation tubes at the base of posts 1 and 2. A 5/8" X 9 1/2" (16 mm x 240 mm) hex head bolt are used to attach the strut to the foundation tube. Note that the bolt goes through the strut, the foundation tube and the wood post. The bolt should be installed from the embankment side. A washer is placed between the bolt head and the strut and the nut and the strut. DO NOT OVERTIGHTEN AND DEFORM TUBES. INSTALLING WOOD BLOCKOUTSAND RAIL PANELS NOTE: Do not bolt the guardrail panel to posts 7 and 8. At post locations 7 and 8, bolt the wood blockout (PC-4075B) to the wood post (PC-4063B) using a 5/8" x 18" (16 mm x 460 mm) post bolt, a hex nut, and a round washer. The washer is installed between the wood post and the nut. Toe nail the blockouts to the posts to prevent them from rotating. The nails should be installed on each side of the blockout. 7

8 8 Guardrail panels (PC-30G and PC-39G and PC-69G) have two (2) sets of slots. These slots should be between posts 1 and 2, 2 and 3, 3 and 4, and 5 and 6. The guardrail panels should be installed so that the slot guard attachment holes are at the end of the slots away from the end of the terminal. See Figure 2. Toward Post 1 FIGURE 2 The 12'6" (3.81 m) guardrail panel (PC-39G) or 25'0" (7.62 m) guardrail panel (PC-69G) slots should be between posts 3 and 4 and posts 5 and 6. The 12'6" (3.81 m) guardrail panel (PC-30G) anchor bracket holes will be between post 1 and post 2. At post location 9, splice and post bolt the 12'6" (3.81 m) rail panel (PC-9G) or the 25'0" (7.62 m) rail panel (PC-60G) to the run of guardrail with hardware provided by the standard guardrail supplier. The terminal rail should be lapped in the direction of traffic unless the agency's policy dictates otherwise. 12'6" (3.81 m) PANEL OPTION At post location 6, splice the 12'6" (3.81 m) rail panel to the 12'6" (3.81 m) rail panel (PC-39G) with eight (8) 5/8" x 1 1/4" (16 mm x 32 mm) splice bolts and hex nuts. At post locations 4, 5, and 6, bolt the rail panel and wood blockout to the wood post using a 5/8" x 18" (16 mm x 460 mm) post bolt, a hex nut, and a round washer. The washer is installed between the wood post and the nut. At post location 3, splice the 12'6" (3.81 m) rail panel (PC-39G) to the 12'6" (3.81 m) rail panel (PC-30G) with eight (8) 5/8" x 1 1/4"(16 mm x 32 mm) splice bolts and hex nuts. Bolt the rail panels and wood blockout to the wood post using a 5/8" x 18" (16 mm x 460 mm) post bolt, a hex nut, and a round washer. The washer is installed between the wood post and the nut. At post locations 1 and 2, bolt rail panel to the wood posts using a 5/8" x 10" (16 mm x 255 mm) post bolt, a hex nut, and a round washer. The washer is installed between the wood post and the nut. The wood offset block should be secured to prevent it from rotating. This can be done by toe nailing the block to the post or the post to the block

9 using 16d hot-dipped galvanized nails. The nails should be installed approximately 3" (75 mm) from the top of the post or block, one on each side. 25'0" (7.62 m) PANEL OPTION At post locations 4, 5, and 6, bolt the 25'0" (7.62 m) rail panel (PC-69G) and wood blockouts to the wood posts using a 5/8" x 18" (16 mm x 460 mm) post bolt, a hex nut, and a round washer. The washer is installed between the wood post and the nut. At post location 3, splice the 25'0" (7.62 m) rail panel to the 12'6" (3.81 m) rail panel (PC-30G) with eight 8 5/8" x 1 1/4" (16 mm x 32 mm) splice bolts and hex nuts. Bolt the rail panels and wood blockout to the wood post using a 5/8" x 18" (16 mm x 460 mm) post bolt, a hex nut, and a round washer. The washer is installed between the wood post and the nut. At post locations 1 and 2, bolt the rail panel to the wood posts using a 5/8" x 10" (16 mm x 255 mm) post bolt, a hex nut, and a round washer. The washer is installed between the wood post and the nut. The wood offset block should be secured to prevent it from rotating. This can be done by toe nailing the block to the post or the post to the block using 16d hot-dipped galvanized nails. The nails should be installed approximately 3" (75mm) from the top of the post or block, one on each side. INSTALLING SLOT GUARDS Install the slot guards (PC-9960G) with the deflector angle closest to the elongated slots. Each slot guard is bolted to the backside of the guardrail panels with six (6) 5/8" x 1 1/4" (16 mm x 32 mm) splice bolts and hex nuts. It is suggested that the slot guards and the cable anchor bracket (PC-700A) be installed on the rail panels before going to the work site. This will expedite the installation. INSTALLING THE CABLE ANCHOR ASSEMBLY The cable anchor bracket (PC-700A) is bolted to the backside of the guardrail panel using eight (8) 5/8" x 1 1/2" (16 mm x 38 mm) hex head bolts, eight (8) hex nuts, and eight (8) round washers. The round washer is installed between the bolt head and the rail panel on the traffic side. Slide one end of the cable (PC-3000G) into the cable anchor bracket and the other end through the sleeve in post 1. Place a 1" (25 mm) washer on the end of the cable that extends through the cable anchor bracket. Place the bearing plate (PC-775G) so that the open side of the V-notch is at the top and connect it to post 1 by driving a nail through each of the 2 holes provided, bending the nails to attach the bearing plate. Place the plate washer (PC-9961G) on the end of the cable. Secure each end of the cable with a 1" (25 mm) hex nut and tighten. Restrain the cable with vise grip pliers at the end being tightened to avoid twisting the cable. Make sure the nuts are tight and the cable is taut. 9

10 10 BEARING PLATE ORIENTATION INSTALLING THE END SECTION Install the end section (PC-907G) by connecting it to the end of the guardrail panel with four (4) 5/8" x 1 1/4" (16 mm x 32 mm) splice bolts and hex nuts.

11 SRT-350 TM 8 POST INSTALLATION CHECK LIST STATE: DATE: PROJECT: LOCATION: The rail height is in accordance with the plans (generally 27 3/4" [706 mm] above the finished grade). The steel tubes do not protrude more than 4" (100 mm) above the finished grade measured by the AASHTO 5'0" (1.5 m) cord method. Site grading may be necessary to meet this requirement. It should be done before the start of the installation of the SRT TM. The bolts at the top of the steel tubes are not overtightened and collapsing the walls of the steel tubes. The 6" x 8" (150 mm x 200 mm) bearing plate at post 1 is correctly positioned and the anchor cable is taut and correctly installed (it should be rechecked after installation to be sure is hasn't relaxed). A nail is driven through each of the hole, and bent to prevent the plate from rotating. The rail panel is not attached to the posts at locations 7 and 8. No rectangular washers are used on the face of the rail. Slot guards are in place and oriented correctly. Rail panels are oriented and lapped correctly. Blockouts have been toe nailed to the posts. The backfill material around the posts is properly compacted. The Controlled Released Terminal (CRT) post has two 3 1/2" (90 mm) breakaway holes (checked prior to installation). They should be located parallel to the roadway with the bottom of the top hole located approximately at the finished grade. The tube bolts are installed with the nuts on the pavement side of the tube for ease of future removal. Posts 1 and 2 have a metal band around them under the post bolt hole. 11

12 12 MAINTENANCE/REPAIR INSTRUCTIONS FOR SRT-350 TM 8 POST SYSTEM GUARDRAIL END TERMINAL MAINTENANCE Maintenance consists of periodically checking the system to see that the cable is taut, the nuts have not been removed from the cable, and the blockouts have not rotated. REPAIR (1) At the accident site, setup necessary traffic control and then remove any debris that has encroached onto the traveled way or shoulder. Install any necessary delineation necessary for the damaged system. Take inventory of the damaged system and determine what parts are reusable and what parts need to be replaced. (2) (3) (4) (5) (6) (7) Obtain those parts that need to be replaced. With the replacement parts, return to the repair site. To expedite the rail installation, it is suggested that any new rail panel(s) brought to the repair site should have the slot guards already bolted to it to minimize work zone repair time. The slot guards on the damaged rail panel(s) can be removed back at the maintenance yard and used on the next repair. Disconnect and remove the damaged rail from the posts. Remove the broken posts in the steel tubes. Remove any damaged Controlled Release Terminal (CRT) posts. After the site has been cleared of damaged debris, the system can be reconstructed following the installation instructions.

13 THE LAYOUT OF THE SRT-350 TM ON A CURVE REFER TO OFFSET TABLE ON PAGE 5 Outside of Curve Edge of Shoulder The SRT offsets are measured from the edge of shoulder from the start of the SRT System. Inside of Curve Tangent Line The SRT offsets are measured from a tangent line from the start of the SRT System. If an offset places a post on the shoulder, then the face of the rail should be on the edge of the shoulder for that offset