PN 621416 HARP Created February 2016 - Trinity Highway · The HARP™ system is intended to be assembled, delineated, and maintained in accordance with specific local and federal

Created February 2016

HARP™

Product Description Assembly Manual

PN 621416

Part No. 621416 Created February 2016 www.trinityhighway.com 1 All rights in copyright reserved

HARP™ The HARP™ system has been tested pursuant to AASHTO Manual for Assessing Safety Hardware (“MASH”) TL-3 specifications. Based on a review of these crash test results, the FHWA determined that the HARP™ system is eligible for reimbursement under the Federal-aid Highway Program as a TL-3 device when assembled and maintained pursuant to the manufacturer’s instructions.

Product Description Assembly Manual

2525 Stemmons Freeway

Dallas, Texas 75207

Important: These instructions are to be used only in conjunction with the assembly, maintenance, and repair of the HARP™ 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 require a deviation from standard assembly parameters, contact the appropriate highway authority engineer. This system has been determined to meet the criteria for eligibility for reimbursement by the Federal Highway Administration for use on the national highway system under strict criteria utilized by that agency. Trinity Highway Products, LLC (“Trinity Highway”) 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 directly at (888) 323-6374.

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 HARP™ system information available to Trinity Highway at the time of printing. We reserve the right to make changes at any time. Please contact Trinity Highway to confirm that you are referring to the most current instructions.

Created February 2016 www.trinityhighway.com 2 All rights in copyright reserved

Table of Contents Customer Service Contacts .......................................................................................................... 3 Important Introductory Notes ........................................................................................................ 3 Safety Rules for Assembly ............................................................................................................ 4 Safety Symbols ............................................................................................................................. 5 Warnings and Cautions ................................................................................................................. 5 Limitations and Warnings .............................................................................................................. 6 HARP™ System Overview Post #1 .............................................................................................. 7 General Description ...................................................................................................................... 8

Recommended Documents, Items, and Tools .......................................................................... 8 Components ............................................................................................................................ 10 Optional Components ............................................................................................................. 13

HARP™ 4 CABLE SYSTEM ....................................................................................................... 14 HARP™ 3 CABLE SYSTEM ....................................................................................................... 15 Assembly .................................................................................................................................... 16

Site Survey .............................................................................................................................. 16 Post Placement ....................................................................................................................... 16 Post #1 Foundation Preparation ............................................................................................. 17 Anchor Post and Knee Brace Foundation Preparation ........................................................... 19 Posts #2 - #4 Foundation Preparation .................................................................................... 20 Concrete Pour ......................................................................................................................... 20 Assembly of HARP™ Release Post (top) ............................................................................... 21

Assembly of Posts #2- #4 ........................................................................................................... 24 CASS® Posts #2- #4 for 3 Cable Systems .............................................................................. 24 CASS® Posts #2- #4 for 4 Cable Systems .............................................................................. 25 NUCOR® Posts #2- #4 RIB-BAK® 4# for 3 Cable Systems ..................................................... 27 NUCOR® Posts #2- #4 RIB-BAK® 4# for 4 Cable Systems ..................................................... 28

Delineation .................................................................................................................................. 29 Tensioning and Field Connection ............................................................................................... 30 Maintenance ............................................................................................................................... 31 Repair After Impact ..................................................................................................................... 31 Trinity Highway Tension Log Form ............................................................................................. 32 Assembly Checklist ..................................................................................................................... 33


Customer Service Contacts Trinity Highway is committed to the highest level of customer service. Feedback regarding the HARP™ system, its assembly procedures, supporting documentation, and performance is always welcome. Additional information may be obtained from the contact information below:

Trinity Highway

Telephone: (888) 323-6374 (USA) +1 214 589 8140 (International)

Fax: (214) 589-8423

E-mail: [email protected]

Website: www.trinityhighway.com

Important Introductory Notes Proper assembly of the HARP™ system is critical to achieve performance that has been evaluated and accepted by the Federal Highway Administration (FHWA) per AASHTO MASH. These instructions should be read in their entirety and understood before assembling the HARP™ system. These instructions are to be used only in conjunction with the assembly of the HARP™ system and are for standard assemblies only as specified by the applicable highway authority. If you need additional information, or have questions about the HARP™ system, please contact the highway authority that has planned and specified this assembly and, if needed, contact Trinity Highway’s Customer Service Department. This product must be assembled in the location specified by the appropriate highway authority. If there are deviations, alterations, or departures from the assembly protocol specified in this Manual, the device may not perform as it was tested and accepted.

This system has been crash tested pursuant to AASHTO MASH criteria.

Important: DO NOT use any component part that has not been specifically crash tested and/or approved for this system during assembly, repair, or maintenance of this system.


This product has been specified for use by the appropriate highway authority and has been provided to that user who has unique knowledge of how this system is to be assembled. No person should be permitted to assist in the assembly, maintenance, or repair of this system that does not possess the unique knowledge described above. These instructions are intended for an individual who is qualified to both read and accurately interpret them as written. These instructions are intended only for an individual experienced and skilled in the assembly of highway products that are specified and selected by the highway authority.

Trinity Highway will supply drawing SS-755 with each HARP™ shipment. Details contained in SS-755 must be studied thoroughly by a qualified individual who is skilled in interpreting them before the start of any product assembly.

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

Warning: Ensure that all of the HARP™ system Danger, Warning, Caution, and Important statements within this HARP™ system Manual are completely followed.

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 HARP™ system. Additional copies of this Manual are available from Trinity Highway by calling (888) 323-6374 or by email at [email protected]. Additionally, this Manual may be accessed at www.trinityhighway.com. Please contact Trinity Highway if you have any questions concerning the information in this Manual or about the HARP™ system.

Always use appropriate safety precautions when operating power equipment and when moving heavy equipment or the HARP™ system components. Work gloves, safety goggles, safety-toe shoes, and back protection should be used.

Safety measures incorporating traffic control devices specified by the highway authority must be used to provide safety for personnel while at the assembly, maintenance, or repair site. Assembler must follow the traffic control plan that has been established by the highway authority that has directed the assembly and maintenance of this product.


Safety Symbols This section describes the safety symbols that appear in this HARP™ system Manual. Read the Manual for complete safety and assembly 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, and may result in serious injury or death in the event of a vehicle impact with the HARP™ system.

Warnings and Cautions Read all instructions before assembling, maintaining, or repairing the HARP™ system.

Warning: Failure to comply with these warnings could result in increased risk of 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).

Warning: Do not assemble, maintain, or repair the HARP™ 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 at (888) 323-6374 if you do not understand any portion of this Manual.

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. Ensure that your assembly meets all appropriate Manual on Uniform Traffic Control Devices (MUTCD) and local standards. Assembler must follow the traffic control plan that has been established by the highway authority that has directed the assembly and maintenance of this product.

Warning: Do NOT modify the HARP™ system in any way.

Warning: Ensure that the HARP™ system and delineation used meet all federal, state, specifying agency, and local specifications.

Warning: Ensure that there is proper site grading for HARP™ system as dictated by the state or specifying agency, pursuant to the AASHTO Roadside Design Guide.

Warning: Ensure that this assembly conforms with the guidance provided by the AASHTO Roadside Design Guide, including, but not limited to, those regarding placement on or adjacent to curbs.


Limitations and Warnings Trinity Highway, in compliance with AASHTO’s Manual for Assessing Safety Hardware (MASH), contracts with FHWA approved testing facilities to perform crash tests, evaluation of tests, and submittal of results to the Federal Highway Administration for review.

The HARP™ system has been approved as meeting the requirements and guidelines of MASH for Test Level 3 (TL-3). These tests evaluate product performance with a range of vehicles from lightweight cars (approx. 1100 kg [2420 lb.]) to full size pickup trucks (approx. 2270 kg [5000 lb.]). The HARP™ system is accepted by the FHWA to the Test Level shown below:

Test Level 3: 100 km/h [62 mph]

These tests are not intended to represent the performance when impacted by every vehicle type, nor every impact condition existing on the roadway. The tests are performed to measure impacts involving vehicles specified by MASH, under specific impact conditions.

Trinity Highway neither represents nor warrants that the impact results of these federally established test criteria prevent or reduce the severity of any injury to person(s) or damage to property. These tests only demonstrate the occurrence of certain results following an impact within MASH criteria. Every departure from the roadway is a unique event.

The HARP™ system is intended to be assembled, delineated, and maintained in accordance with specific local and federal guidelines. It is important for the highway authority to select the most appropriate product configuration for its site specifications. Careful evaluation of the site lay out, vehicle population type; speed, traffic direction, and visibility are some of the elements that require evaluation in the proper selection of a highway product.

After an impact occurs, the debris from the impact should be removed from the area immediately and the HARP™ system should be evaluated and restored to its original specified condition or replaced as the highway authority determines as soon as possible.

Warning: Use only Trinity Highway parts that are specified herein for the HARP™ system for assembling, maintaining, or repairing the HARP™ system. Do not utilize or otherwise comingle parts from other systems even if those systems are other Trinity Highway systems. Such configurations have not been tested, nor have they been accepted 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 an UNACCEPTED system.


HARP™ System Overview Post #1

Figure 1

Bolt, Hex, 1/2”X7”

Bolt, Hex, 5/8X2”

Shear Strap

Washer, Lock 5/8”

Anchor Post

Keeper Plate, Front

Nut, Hex, 5/16”

Nut, Hex, #8, SS

Bolt, Hex 5/8” X 6.5”

Knee Brace

Nut, Hex, 1/2"

Screw, Socket, #8-32X3”, SS

Bolt, Hex, 5/8”X6.5”

Nut, Hex, 1/2"

Trigger Brace

Release Post

Nut, Hex, 5/8”

Bolt, Hex, 1/2"X1.5”

Bolt, Hex, 1/2"X1.5”

Trigger Brace

Trigger Brace

Trigger Brace

Washer, Lock, #8, SS

Front Notched Plate, 1/4"

Washer, Lock, 5/16”

Washer, 5/16”

Bolt, Hex, 5/16”X1.5”

Nut, Hex 5/8”

Rear Notched Plate, 3/4"

Keeper Plate, Rear

FrontBack

Nut, Hex, 5/8”

Nut, Hex, 1/2” Washer, Lock,

1/2”

Washer, Flat, 5/16”


Danger: Orientation of HARP™ Keeper and Notched plates is critical. Ensure HARP™ Front/Rear Notched/Keeper plates are assembled with the corner chamfer up and to the right looking from the front of the system.

General Description The HARP™ is designed to anchor MASH, EN 1317-1, 2 or NCHRP Report 350 cable barrier systems, featuring three (3) or four (4) cables (wire ropes).

Important: Maintaining proper cable tension is critical to system performance.

Important: The cable tension must be checked at least twice a year. A tension meter will be necessary to determine the actual cable tension value. The tension value determination is based on the cable temperature measured with an infrared thermometer.

Recommended Documents, Items, and Tools Documentation

Manufacturer’s Assembly Manual for HARP™

Drawing SS-755 for HARP™

Cable Barrier Manufacturer’s Drawing(s)

Personal Protective equipment

Safety Glasses

Gloves

Safety-Toe Shoes

Back Protection (when required)

Hard Hat

Reflective Vest (MUTCD compliant)

Cutting equipment

Abrasive Saw to cut 3/4" cable

Wrenches

SAE Combination Wrench Set to include a minimum of (1) 1-1/16” wrench, (1) 7/8” wrench, (2) 15/16” wrench, (2) 3/4” wrench, (1) 9/16” wrench, (1) 1/2” wrench, (1) 3/8” wrench

Various SAE sockets, corresponding with above wrenches

Ratchet and extensions for above sockets

Two (2) 10” Crescent wrenches

One (1) 9/16” Hex Key (Allen) wrench


Concrete

Vibrator (stinger type)

Finishing/margin/gauging trowels

Shovels

Masonry brush

Four (4) 8” C-Clamps, to hold Post #1 in place while concrete cures

2pcs of 2”x4”x4’ boards, to hold Post #1 in place while concrete cures

Miscellaneous

Traffic control equipment (as required)

Marking Paint

Chalk Line

3’ Straight Edge

Tape Measure, minimum 30’

Standard 2’ Level

Small Level – (to insert into tubes to ensure tubes are plumb)

Drift tool/pin

1/2” Punch

Come-along Puller

Cable Puller/Clamp

Tension Meter

Equipment/tools to apply tension to 3/4" cable

Flat head screwdriver

Hammer

IR thermometer

Water Pump Pliers

Pliers

Locking Pliers

36” auger for Post #1

12” auger for Post(s) #2- #4

Note: The above list of tools is a general recommendation. Depending on specific site conditions and the complexity of the assembly specified by the appropriate highway authority, additional or fewer tools may be required. Decisions as to what tools are required 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.


Components

HARP™, Front Notched Plate, 1/4"

HARP™, Rear Notched Plate, 3/4"

HARP™, Front Keeper Plate, [20GA]

620682 1 620683 1 620684 1

HARP™, Rear Keeper Plate, [20GA]

HARP™, Knee Brace HARP™, Release Post W/Decal

620685 1 620693 1 621200 1

HARP™, Shear Strap HARP™, Sleeve for CASS® Posts

HARP™, Anchor Post

620635 1 620735 ** 620692 1

Important: Trinity Highway 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.

** Quantity varies per system. Please refer to Bill of Materials on sheet 1- 3 of DWG SS-755.


HARP™, Sleeve 4” for Nucor® Posts

HARP™, Trigger Brace HARP™, Post, S3 for CASS®

620728 ** 620686 4 620736 ** Nucor®, Rib-Back® 4# x 4’ Nucor®, Sleeve Cap CASS®, Sleeve Cap

400006 ** 400011 ** 5837 ** Hex Nut, 1/2" Hex Nut, 5/16" Hex Nut, 1"

115939 6 3245 ** 3908 ** Hex Nut, #8, SS Hex Nut, 5/8” Hex Bolt, 5/8” x 2”

115916 4 3350 7 3404 3

** Quantity varies per system. Please refer to Bill of Materials on sheet 1 - 3 of DWG SS-755.


Hex Bolt, 5/8” x 6.5”, G5 Hex Bolt, 5/16” x 1.5”, G5 Hex Bolt, 1/2” x 7”, G5

4467 2 105286 5 118529 2 Hex Bolt, 1/2" x 1.5”, G5 Socket Screw, #8-32x3, HD,

SS Lock Washer, #8, SS

3288 4 117012 4 118077 4 Lock Washer, 5/16” Lock Washer, 5/8” Lock Washer, 1/2”

118097 5 118100 3 118082 2 CASS® Stud Cable Assembly 1” RT

Round Washer, 1" Round Washer, Wide, 5/16”

5910 ** 4902 ** 3240 10



CASS® Cable Lock Bolt 5/16” Nucor™ SML Hook Bolt 5/16” Nucor™ LRG Hook Bolt 5/16”

5825 ** 400017 ** 400016 **

Optional Components

5” x 24” “Left” yellow/black chevrons

5” x 24” “Right” yellow/black chevrons

CASS® Cable Assembly 50’ LT/RT

5851 ** 5852 ** 6306 **



HARP™ 4 CABLE SYSTEM

Figure 2 - Four Cable System

Warning: Posts 2 thru 4 can be either Nucor® Rib-Bak® 4# OR CASS® S3 x 5.7#. THE POSTS CANNOT BE MIXED.

Important: Field tolerances are available for system assembly. Please refer to DWG SS-755 for field tolerance information.

Post 1

Post 2

Post 3

Post 4

Back

Two (2) 3/4” 3x7 Pre-Stretched Galvanized Cables near top

Two (2) 3/4” 3x7 Pre-Stretched Galvanized Cables

Front


HARP™ 3 CABLE SYSTEM

Figure 3 - Three Cable System


Important: Field tolerances are available for system assembly. Please refer to DWG SS-755 for field tolerance information.

Post 1

Post 2

Post 3

Post 4

Two (2) 3/4” 3x7 Pre-Stretched Galvanized Cables near top

One (1) 3/4” 3x7 Pre-Stretched Galvanized Cable

Back

Front


Assembly Caution: Always use appropriate safety precautions when operating powered equipment, mixing chemicals, and moving heavy equipment or the HARP™ system components. Work gloves, safety goggles, safety-toe shoes, back protection, and any other appropriate personal protective equipment (PPE) should be used.


Site Survey □ Ensure contractor has located and marked any underground structures and/or utilities

prior to excavation.

□ Ensure proper grading, per AASHTO Roadside Design Guide, has been completed.

Post Placement Measure area and layout pattern for post holes #1- #4.

Figure 4 – Top View Hole and Post Placement

C-T-C= Center to Center

Post #2

12” Diameter

12” Diameter

12” Diameter

36” Diameter

10’-6” C-T-Cof foundations



Post #3

Post #4

Post #1

Note: Post #1 is offset 6” towards Post #2 and not at center of Post #1 foundation.


Post #1 Foundation Preparation Use a 36” auger to drill a hole that is a minimum 7’ deep (36” diameter at bottom) for Post #1.

Assemble rebar cage per drawing SS-755 and insert into hole at proper location specified.

Figure 5 – Rebar Cage Post #1

Important: Assembler may supply rebar for HARP™ foundations; however, all rebar MUST meet or exceed listed specifications, shown on Trinity Highway Drawing SS-755. Rebar does not fall under the “mixed components” warning.

Important: Post #1 is offset 6” towards Post #2 (towards front) and not at center of Post #1 foundation.

Post #1

TO REDUCE STANDING WATER, FILL KNEE BRACE ANCHOR (TUBE) (620693) WITH CONCRETE TO GRADE LEVEL

BACK FRONT

2” (

-1/8

”, +

1/2”

)

(2 1

/2")

CL

EA

R, D

O N

OT

CE

NT

ER

(3’-

10

1/2

")

(7’

-0”)

REBAR #5X79 1/2"

(Ø3’-0”)

REBAR RING #3X30” O.D.

(6’-6”) REBAR #3X30” (14 EA. @ EQUAL SPACES)


Figure 6 - Top View Post #1 Rebar

Rebar Component

Rebar for Post 1: 14 pieces of #3 x 30”OD ASTM A615, Grade 60

12 pieces of #5 x 79 1/2” ASTM A615, Grade 60

Use welding equipment (weld per AWS D1.4) or rebar tie wire as appropriate.

Danger: Location of rebar is critical.

Note: Rebar is available for order with system.

12 EA. @ EQUAL SPACES

REBAR #5x79 1/2", A615 GR 60

7 3/16” 10 3/4"

3”

REBAR RING #3x30”OD, A615 GR 60, 12” MIN OVERLAP

BACK FRONT


Anchor Post and Knee Brace Foundation Preparation Preassemble HARP™ Anchor Post (620692) to HARP™ Knee Brace (620693).

Figure 7

1. Place HARP™ Knee Brace (620693) on HARP™ Anchor Post (620692) as indicated

above.

2. Insert four (4) 1/2 x 1-1/2” Hex Bolts (3288) through flanges on HARP™ Knee Brace and HARP™ Anchor Post.

3. Place 1/2” Hex Nuts (115939) on 1/2” x 1-1/2” Hex Bolts (3288) and tighten securely.

4. Insert HARP™ Anchor Post (620692) into rebar cage as drawing indicates to ensure the HARP™ Anchor Post is plumb (see p. 17). Use two (2) pieces of 2” x 4” lumber x 4’ length and four (4) 8” C-Clamps (neither is supplied by Trinity Highway) or other means to support the HARP™ Anchor Post at the correct orientation and depth. The HARP™ Anchor Post MUST be fully supported and held in place until the concrete properly cures.

Important: Proper placement of HARP™ Anchor Post and Rebar cage is critical to the performance of the system. It is recommend the HARP™ Knee Brace Anchor (620693) be filled with concrete to grade level – to reduce standing water.

Post 1

BACK

FRONT

Stub plate protrudes from concrete foundation, see drawing SS-755 for height and tolerances.


Posts #2 - #4 Foundation Preparation Use a 12” auger to drill minimum 32” deep holes for Posts #2- #4.

1. Preassemble CASS® Sleeve Cap (5837) to bottom of CASS® Tube Sleeve (620735) –or– Nucor® Sleeve Cap (400011) to bottom of Nucor® Tube Sleeve (620728) – depending on post/tube combination chosen for Posts #2- #4 (see drawing SS-755).

Note: All concrete work will typically be done at the same time as Post #1.

Warning: Posts #2- #4 can be either Nucor® Rib-Bak® 4# OR CASS® S3 x 5.7#. THE POSTS CANNOT BE MIXED.

Concrete Pour 1. Pour 3000 psi minimum concrete into post 1 hole (with rebar cage and Anchor Post in

place). Ensure concrete is vibrated per applicable specifications and Anchor Post “stub” height is as specified in Drawing SS-755.

2. Pour 3000 psi minimum concrete into post holes #2- #4. Ensure concrete is vibrated per applicable specifications.

3. Per drawing SS-755, insert Tube Sleeve (for Posts #2- #4) assembly into wet concrete as well as #3 x 8” rebar ring (5836, if supplied by Trinity Highway). Vertical #4 x 28” rebar rods (602733, if supplied by Trinity Highway) are required for HARP™ assemblies utilizing Nucor® Rib-Back® 4# posts with 15” Tube Sleeves (620728). No vertical rebar is required for assemblies utilizing CASS® S3 x 5.7# posts with 29” Tube Sleeves (620735). Proper placement of Tube Sleeves and rebar is critical to the performance of the system. Ensure Tube Sleeves and rebar are properly oriented (hole must be 90 degrees to the centerline of the system) and plumb relative to the ground (see Figure 8a/8b).

Figure 8a - CASS® Figure 8b - Nucor®

Important: All concrete must be tested to ensure a minimum compressive strength of 3000 psi is achieved prior to Assembly of Top steps. These are minimum requirements; follow all regulatory specifications provided by project owner which may exceed stated minimums.

POST, RIB-BAK® 4#x4’

SLEEVE, 4” OD

(1 1/4")

WASHER, FLAT 5/16”

WASHER, LOCK 5/16”

NUT, HEX 5/16”

BOLT, HEX 5/16”x 1-1/2” G5

POST, CASS®

(1 1/4")

WASHER,FLAT 5/16”


NUT, HEX 5/16”

CASS® POST SLEEVE BOLT, HEX 5/16”x 1-1/2” G5


Assembly of HARP™ Release Post (top) 1.) Preassemble HARP™ Release Post (621200) with HARP™ Front/Rear

Notched/Keeper plates, per drawing SS-755.

The HARP™ Front Keeper Plate (620684) is sandwiched between the HARP™ Front Notched Plate (620682) and the HARP™ Release Post (621200).

Danger: Orientation of HARP™ plates is critical. Ensure plates are assembled with the corner chamfer up and to the right looking from the front of the system (see p. 7).

Note: Front plates are 9” high.

The HARP™ Rear Keeper Plate (620685) is sandwiched between the HARP™ Rear Notched Plate (620683) and the HARP™ Release Post.

Note: Rear plates are 8” high.

From the front of the HARP™ Release Post (621200), insert two (2) 1/2” x 7” (118529) bolts in the two holes provided. Place two (2) 1/2” lock washers (118082) on 1/2” bolts, then two (2) 1/2” nuts (115939) onto bolts and tighten with wrenches until lock washers are fully compressed.

Place HARP™ Release Post (621200) with HARP™ Front/Rear Notched/Keeper plates preassembled on stub plate protruding from concrete foundation at post #1 of the HARP™ Anchor Post (620692) (see Figure 9).

Place a 5/16” flat washer (3240) on to two (2) 5/16” x 1-1/2” bolts (105286) and insert bolts from the top or bottom of the Release post plate through the Anchor Post plate. Orientation of 5/16” x 1-1/2” bolts (105286) is not critical. The preferred orientation is from the top, for ease of assembly/maintenance and to avoid close proximity of concrete footing in working/assembly area.

Place a 5/16” flat washer (3240), a 5/16” lock washer (118097), and a 5/16” nut (3245) on each bolt and tighten until lock washers are fully compressed.

Place HARP™ Shear Strap (620635) to stub plate protruding from concrete foundation at post #1 of the HARP™ Anchor Post (620692) (see Figure 9).

Insert three (3) 5/8” x 2” bolts (3404) from the top of the HARP™ Shear Strap plate through the HARP™ Anchor Post plate (see Figure 9).

Place a 5/8” lock washer (118100) and a 5/8” nut (3350) on each bolt and tighten until lock washer is fully compressed.

Danger: Direction of 5/8” x 2” bolts (3404) insertion is critical.

Figure 9 Note: HARP™ Knee Brace, rebar, and concrete foundation omitted for clarity.

Stub plate of HARP™ Anchor Post (620692) protruding from concrete footing.


2.) Assembly of HARP™ Trigger Braces

Preassemble four (4) HARP™ Trigger Braces (620686) into two assemblies.

A. Using two (2) HARP™ Trigger Braces (620686), place them together by matching up the mating ends (see Figure 10).

B. Insert two (2) #8-32 SS x 3” Socket Head bolts (117012) through holes provided.

C. Place a #8 SS lock washer (118077) and #8 SS Hex Nut (115916) on each bolt. Tighten assembly using a Hex Key Wrench and Wrench until lock washer is fully compressed.

D. Repeat above set of steps for second set of Trigger Braces.

Figure 10 – Trigger Brace Orientation

Important: Ensure the #8-32 Socket Head Bolts (117012) are already tightened in the above steps to the HARP™ Trigger Braces (620686) and are oriented (Socket Head is Up – direction of bolt is critical) per drawing SS-755.

E. Place HARP™ Trigger Braces (620686) on the outside of the HARP™ Release Post and HARP™ Knee Brace protruding from concrete foundation at post #1.

F. Attach Trigger Braces by inserting two (2) 5/8” x 6.5” (4467) bolts through each Trigger Brace assembly through the hole provided on the Release Post and Knee Brace.

G. At the top location (of the Release Post), place one (1) 5/8” nut (PN 3350) on to 5/8” bolt and hand tighten nut against the assembly. Then back off this nut by 1/4 turn. Place a second 5/8” nut on the same 5/8” bolt and finger-tighten it snug against the first 5/8” nut. Ensure the first 5/8” nut hasn’t tightened against the assembly. Use two wrenches to tighten the second 5/8” nut against the first 5/8” nut.

Danger: Ensure the bolt is still free to rotate and nuts are tightened against each other securely.

H. Repeat above step(s) for bottom location of the Trigger Brace at the Knee Brace.


3.) Assembly of Cable to HARP™ Release Post (see Figure 11).

Use figure below to attach 3/4” cable to the 1” CASS® Stud Cable Assembly (5910).

Figure 11

Note: Depending on the cable barrier being selected, this step may require three or four cables. Only 1” cable fittings are permitted to be used at Post #1. If the cable barrier system being utilized uses 3/4” cable fittings, do NOT use those at Post #1. Carefully insert 1” Threaded Rod from CASS® Stud Cable Assembly (5910) into Rear/Front Keeper/Notched plates one at a time so as to not damage the Keeper Plates. Place one (1) 1” Flat Washer (4902) on each 1” Threaded Rod and two (2) 1” Hex Nuts (3908).

Important: Ensure at least two threads of the 1” Threaded Rod extend beyond the back of the second nut and tighten second nut against first nut. Ensure all 1” Threaded Rods at Post #1 have “seated” and are not pressing against the two keeper plates.

Important: Only CASS® Stud Cable Assembly 1” RT (5910) can be used at Post #1.

Figure 12

INSERT WEDGE PAST CABLE END (3/8” TO 1/2”). FOLD ONE (1) CABLE WIRE OVER WEDGE SEAT WEDGE & CABLE BEFORE CLOSING THE SPLICE.

CASS® STUD CABLE ASSEMBLY 1” RT (5910)

3/4” CABLE

WASHER, ROUND 1”

NUT, HEX 1”

SECOND HEX NUT

1” THREADED ROD

1” THREADED ROD


Assembly of Posts #2- #4 Insert proper posts (CASS® or Nucor®) into Tube Sleeves at post locations #2- #4. Attach posts to hole in Tube Sleeves utilizing one (1) 5/16” x 1-1/2” Hex Bolt (105286), two (2) 5/16” flat washers (3240) one (1) 5/16” lock washer (118097) and one (1) 5/16” Hex Nut (3245) as drawing SS-755 indicate. Assembler may use either hole.

Warning: Posts #2- #4 can be either Nucor® Rib-Bak® 4# OR CASS® S3 x 5.7#. THE POSTS CANNOT BE MIXED.

CASS® Posts #2- #4 for 3 Cable Systems

Important: Use only CASS® Lock Bolts (5825) to secure 3/4” Wire Rope to Posts #2- #4 when using CASS® posts.

DETAIL A (p. 26)

Figure 13 CASS® 3 CABLE SYSTEM


WIRE ROPE 3/4"

CASS® POST

GRADE LINE

CASS® SLEEVE CAP

CASS® POST SLEEVE

CASS® LOCK BOLT

CASS® LOCK BOLT

CASS®

LOCK BOLT HEX NUT

HEX NUT

HEX NUT

REBAR RING

CONCRETEFOUNDATION

GRADE LINE

SIDE CLOSEST TO TRAFFIC


CASS® Posts #2- #4 for 4 Cable Systems

Important: Use only CASS® Lock Bolts (5825) to secure 3/4” Wire Rope to Posts #2- #4 when using CASS® posts.

WIRE ROPE 3/4"

CASS® POST

GRADE LINE

CASS® SLEEVE CAP

CASS® POST SLEEVE

CONCRETE FOUNDATION

REBAR RING

HEX NUT

CASS® LOCK BOLT

HEX NUT

DETAIL A (p.26)




CASS®

LOCK BOLT

CASS®

LOCK BOLT


Detail A

POST, CASS®

(1 1/4")



NUT, HEX 5/16”

BOLT, HEX 5/16”x 1-1/2” G5

CASS® POST SLEEVE


NUCOR® Posts #2- #4 RIB-BAK® 4# for 3 Cable Systems

Important: Use only Nucor® Lock Bolts to secure 3/4” Wire Rope to Posts #2- #4 when using Nucor® Posts.

* Nucor® SML Hook Bolt 5/16” (400017) ** Nucor® LRG Hook Bolt 5/16” (400016)

Figure 17 NUCOR® RIB-BACK® 4#

3 CABLE SYSTEM


3 CABLE SYSTEM

DETAIL B (p. 29) SIDE CLOSEST TO TRAFFIC

WIRE ROPE 3/4"

NUCOR® RIB-BAK® POST

GRADE LINE

NUCOR® SLEEVE

NUCOR® SLEEVE CAP

GRADE LINE

REBAR RING

REBAR

NUT, HEX

NUCOR® BOLT, HOOK *

NUT, HEX


NUCOR® BOLT, HOOK **

NUT, HEX

CONCRETE FOUNDATION


NUCOR® Posts #2- #4 RIB-BAK® 4# for 4 Cable Systems

Important: Use only Nucor® Lock Bolts to secure 3/4” Wire Rope to Posts #2- #4 when using Nucor® Posts.

* Nucor® SML Hook Bolt 5/16” (400017) ** Nucor® LRG Hook Bolt 5/16” (400016)

WIRE ROPE 3/4"

GRADE LINE


GRADE LINE

REBAR RING

REBAR

NUT, HEX

NUT, HEX

NUT, HEX


4 CABLE SYSTEM


4 CABLE SYSTEM

NUCOR® RIB-BAK® POST

NUCOR® SLEEVE

NUCOR® SLEEVE CAP



NUCOR®

BOLT, HOOK **

DETAIL B (p. 29)

CONCRETE FOUNDATION


Detail B

String a 3/4" cable (supplied by cable barrier system) as shown on drawings for three cable or four cable applications. Attach cables to posts utilizing proper 5/16” locking hook bolts and 5/16” hex nuts as specified by drawing.

Delineation Apply delineation as per state specification and MUTCD. Trinity Highway has two delineators which are properly sized for the HARP™.

5” x 24” “Left” yellow/black chevrons (5851)

5” x 24” “Right” yellow/black chevron (5852)

NUCOR® RIB-BAK® 4# x 4’

(1 1/4")



NUT, HEX 5/16”

BOLT, HEX 5/16”x 1-1/2” G5

SLEEVE, 4” OD


Tensioning and Field Connection Once the cable is in place between the Cable End Brackets, the final field connection and tensioning can be performed.

Field Splice

Each HARP™ system assembly will require one set of field connections to complete the deployment. The Field Splices must be correctly applied to ensure the connection will not separate.

See cable barrier manufacturer’s instructions for field splices specific to your cable barrier application.

Danger: No fittings or turnbuckles are permitted within 50’ of Post #1.

Cable Tension

The tension placed on the cable is to be determined by cable barrier manufacturer and cable temperature at the time of tensioning (refer to manufacturer Tension and Temperature specification). An accurate infrared thermometer must be used to obtain the correct cable temperature.

Important: Do not allow bystanders or workers to stand near the HARP™ system when under tension or in circumstances where the cable may be impacted or cut.

Important: Proper tensioning is critical to system performance.

Important: It is required that HARP™ system cable tension be checked 3 to 7 days after the initial tensioning and adjustments made as required.

Note: Trinity Highway strongly recommends a record of the tensioning be recorded and placed with the assembly and/or maintenance records. A Tensioning Log Form is provided in the back of this Manual.

Important: If additional tension is needed during final tensioning or maintenance operations, the 1” threaded rods (part of 5910) at Post #1 may be used to provide more tension, by tightening the two 1” nuts further against the Release Post.

Important: Ensure at least two threads of the 1” Threaded Rod extend beyond the back of the second nut and tighten second nut against first nut. Ensure all 1” Threaded Rods at Post #1 have “seated” and are not pressing against the two keeper plates.

Important: Every six months, cable tension must be checked and all parts visually inspected for damage from maintenance operations (such as snow plow or mowing), unrecorded impacts, or vandalism.

Important: Copy and complete checklists in back and then place into project file.


Maintenance All maintenance decisions are the sole responsibility of the highway authority specifying this product for use on their roadways. Visual inspections should be performed on a regular basis to verify that the system has not been impacted, and that the cable fittings are securely seated in the Release Post.

Cable tension must be verified as directed by the highway authority specifying this product for use at least every six (6) months by measuring the tension with an appropriate tension meter. Refer to the temperature-tension chart in manufacturer’s cable barrier instruction manual.

Repair After Impact It is recommended that the system be repaired as soon as possible and its suitability for continued use on the roadway be thoroughly assessed by the appropriate state or specifying agency who owns this product and is responsible for its maintenance.

Any part or parts of the HARP™ system which appear broken, worn, torn, and/or damaged must be replaced. Post-impact evaluation of the HARP™ system must be made by the appropriate state or specifying agency.

Replace any damaged HARP™ parts, following the instructions found in the Assembly section of this Manual. The HARP™ system must then be properly tensioned based on the temperature-tension chart found in manufacturer’s cable barrier instruction manual.

Important: Trinity Highway 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.

Important: Use only Trinity Highway parts that are specified herein for the HARP™ system for assembling, maintaining, or repairing the HARP™ system. Do not use pats that cannot be clearly identified as a part of the HARP™ system.

Important: Damaged HARP™ parts must be replaced with new parts. No attempt should be made to straighten, weld, or otherwise repair and/or reuse damaged parts.

Important: After repair, it is required that the cable tension be checked 3 to 7 days after the initial tensioning of the cable and adjustments made as required.

Warning: Use only Trinity Highway parts that are specified herein for the HARP™ system for assembling, maintaining, or repairing the HARP™ system. Do not utilize or otherwise comingle parts from other systems even if those systems are other Trinity Highway systems. Such configurations have not been tested, nor have they been accepted 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 an UNACCEPTED system.

Important: Copy and complete checklists in back and then place into project file.


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

Trinity Highway Tension Log Form HARP™ System

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


Please make extra copies and completely fill out this form for your project file.

Assembly Checklist

Assembly performed by: _______________________________________________________

Assembly date: ______________________________________________________________

Assembly location: ___________________________________________________________

□ Ensure all necessary site grading is completed before assembly of the HARP™ system.

□ Verify suitable soil/foundation strength meets minimum MASH criteria to allow the system to fully perform in accordance with design specifications.

□ Ensure post holes are plumb and have the proper depth, diameter, and layout for Post locations #1- #4.

□ Ensure concrete foundations have a minimum of 3000 psi breaking strength and are properly vibrated prior to cable tensioning or assembly of HARP™ Release post components.

□ Posts #2- #4 can be either Nucor® Rib-Bak® 4# OR CASS® S3 x 5.7#. THE POSTS CANNOT BE MIXED.

□ Ensure Posts #2– #4 are attached to tube sleeve using 5/16” bolts.

□ Verify all fasteners are attached and tightened according to specifications.

□ Ensure keeper/notched plate orientation with the corner chamfer up and to the right as viewed from the front of the system (see p. 7).

□ Ensure all three (3) shear strap bolts are correctly oriented from the top (see page 21).

□ Ensure direction/orientation of bolt(s) which go through keeper/notch plates (see page 21).

□ Ensure system cables are at the correct height for post location(s) #2– #4 (see pages 24, 25, 27, and 28).

□ Ensure no fittings / turnbuckles are within 50’ of Post #1 and only CASS® Stud Cable Assembly 1” RT (5910) are utilized at Post #1 (see page 23).

□ Verify 5/8” bolts which attach the HARP™ Trigger Braces to the HARP™ Release Post and HARP™ Knee Brace are free to rotate (see page 22).

□ Ensure the HARP™ Trigger Braces are joined with proper orientation for “locking” the notched arms to allow Stainless Steel socket screws to insert correctly (from top) and the Stainless Steel hex nuts are tightened snug to compress the Stainless Steel lock washers (see page 22).

□ Ensure cable is tensioned per cable barrier manufacturer’s specifications.

□ Ensure delineation is appropriate per local specifications.


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888.323.6374 (USA) +1 214.589.8140 (International)2-16

www.trinityhighway.com

For more complete information on Trinity Highway products and services, visit us on the web at www.trinityhighway.com. Materials and specifications

are subject to change without notice. Please contact Trinity Highway to confirm that you are referring to the most current instructions.