Trinity Highway Vulcan User manual

Part No. 610435
Revision B October 2014
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Vulcan
®
Gate
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 Vulcan
®
Gate. These instructions are
for standard assemblies 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 accepted by the Federal Highway
Administration for use on the national highway system under strict criteria utilized
by that agency. 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 at [phone] or download
copies from the website listed below.
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 Vulcan
®
Gate
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.

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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
Application .................................................................................................................................... 7
Opening Options ........................................................................................................................... 9
Length of Need...................................................................................................................... 12
Vulcan Gate Tested Lateral Deflection ................................................................................. 12
Curves................................................................................................................................... 13
Slopes ................................................................................................................................... 13
Hills ....................................................................................................................................... 14
Ditch...................................................................................................................................... 14
Curbs..................................................................................................................................... 14
Trenches ............................................................................................................................... 14
Deployment................................................................................................................................. 15
Preparation............................................................................................................................ 15
Deployment ........................................................................................................................... 15
Recommended Tools ............................................................................................................ 17
Vulcan®Gate – Typical Layout .............................................................................................18
Anchoring (Transitions/CMB) ................................................................................................ 21
MP-3®Polyester Anchoring system ............................................................................................22
MP-3®Horizontal Assemblies ..................................................................................................... 24
MP-3®Assembly Cautions .......................................................................................................... 26
Operation .................................................................................................................................... 27
Maintenance and Repair............................................................................................................. 28

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Customer Service Contacts
Trinity Highway is committed to the highest level of customer service. Feedback regarding the
Vulcan
®
Gate, its assembly procedures, supporting documentation, and performance is always
welcome. Additional information can be obtained from the contact information below:
Energy Absorption Systems, Inc. dba
Trinity Highway
Telephone: [phone] (USA)
[phone] (International)
E-mail: [email protected]
Website: www.trinityhighway.com
Important Introductory Notes
Proper assembly of the Vulcan
®
Gate is critical to achieve performance that has been evaluated
and accepted by the Federal Highway Administration (FHWA) per NCHRP Report 350. These
instructions should be read in their entirety and understood before assembling the Vulcan
®
Gate. These instructions are to be used only in conjunction with the assembly of the Vulcan
®
Gate and are for standard assemblies only as specified by the applicable highway authority. If
you need additional information, or have questions about the Vulcan
®
Gate, 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, like other Trinity Highway systems, has been crash tested pursuant to NCHRP
Report 350 mandated 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.

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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.
A manufacturer’s drawing package will be supplied by Trinity Highway upon request. Each
system will be supplied with a specific drawing package unique to that system. Such drawings
take precedence over information in this Manual and shall 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 Vulcan
®
Gate. Failure to follow this warning can result in serious
injury or death to the worker and/or bystanders. It further compromises the
acceptance of this system by the FHWA. Please keep these instructions
available for use and reference by anyone involved in the assembly of the
product.
Warning: Ensure that all of the Vulcan
®
Gate Danger, Warning, Caution, and
Important statements within the Vulcan
®
Gate 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 assemble,
maintain, or repair the Vulcan
®
Gate. Additional copies of this Manual are immediately available
from Trinity Highway by calling [phone] or by email at [e-mail]. Please
contact Trinity Highway if you have any questions concerning the information in this Manual or
about the Vulcan
®
Gate. This Manual may also be downloaded directly from the website listed
below.
Always use appropriate safety precautions when operating power equipment, mixing chemicals,
and when moving heavy equipment or any Vulcan
®
Gate components. Gloves, apron, 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.

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Safety Symbols
This section describes the safety symbols that appear in this Vulcan
®
Gate 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 the Danger, Warning, Caution, or Important indicators
could result in serious injury or death to workers and/or bystanders.
Warnings and Cautions
Read all instructions before assembling, maintaining, or repairing the Vulcan
®
Gate.
Danger: 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 Vulcan
®
Gate 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 [phone] if you do not
understand these instructions. Failure to follow this warning could result in
serious injury or death in the event of a collision.
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. Failure to follow this warning could
result in serious injury or death in the event of a collision. The traffic control plan
established by the highway authority must always be observed in assembling or
utilizing this product.
Warning: Use only Trinity Highway parts that are specified herein for the
Vulcan
®
Gate for assembling, maintaining, or repairing the Vulcan
®
Gate. Do not
utilize or otherwise comingle parts from other systems, even if 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.
Warning: Do NOT modify the Vulcan
®
Gate in any way.
Warning: Ensure that the Vulcan
®
Gate and delineation used meet all federal,
state, specifying agency, and local specifications.
Warning: Ensure that your assembly meets all appropriate Manual on Uniform
Traffic Control Devices (MUTCD) and local standards.

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Warning: Use only Trinity Highway parts on the Vulcan
®
Barrier for assembly,
maintenance, or repair. The assembly or comingling of unauthorized parts is
strictly PROHIBITED. The Vulcan
®
Barrier and its component parts have been
accepted for state use by the FHWA. However, a comingled system has not
been accepted within the applicable criteria.
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.
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 the National Cooperative Research Highway Program 350
(NCHRP Report 350) “Recommended Procedures for the Safety Performance of Highway
Safety Features,” contracts with FHWA approved testing facilities to perform crash tests,
evaluation of tests, and submittal of results to the FHWA for review.
The Vulcan
®
Gate has been approved by FHWA as meeting the requirements and guidelines of
NCHRP Report 350. These tests typically evaluate product performance defined by Report 350
involving a range of vehicles on roadways, from lightweight cars (approx. 820 kg [1800 lb.]) to
full size pickup trucks (approx. 2000 kg [4400 lb.]). The Vulcan
®
Gate is certified to the Test
Level(s) as shown below:
Test Level 3: 2000 kg [4400 lb], 100 km/h [62 mph], 25 degrees
Test Level 4: 8000 kg [17,600 lb], 80 km/h [50 mph], 15 degrees
These FHWA directed tests are not intended to represent the performance of systems
when impacted by every vehicle type or every impact condition existing on the roadway.
This system is tested only to the test matrix criteria of NCHRP Report 350 as approved by
FHWA.
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 NCHRP Report 350 criteria. Every departure from the roadway is a unique event.
The Vulcan
®
Gate system is intended to be assembled, delineated, and maintained within
specific state and federal guidelines. It is important for the highway authority specifying the use
of a highway product 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 selection of a
highway product. For example, curbs could cause an untested effect on an impacting vehicle.
After an impact occurs, the debris from the impact should be removed from the area
immediately and the specified highway product should be evaluated and either restored to its
original, specified condition, or replaced, as the highway authority determines, as soon as
possible.

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Application
The Vulcan®Gate can be specified for use in many applications.
Some examples are:
Median or Roadside Placement
Emergency Cross-over Access
General road maintenance performed by road authorities, contractors, local
municipalities etc.
Road Construction
Lane Closures
Toll Plazas
Road Resurfacing
Excavation or Culvert Protection
Detours or Diversions
Bridge Repairs
Temporary or Permanent Placement
In order to design the most appropriate Vulcan®Gate system for a given site, this Manual helps
to answer the following questions:
Is the Vulcan®Gate appropriate for my site?
What is the application? What warrants the use of the Vulcan®Gate?
How long or short can the Vulcan®Gate be?
How much clear zone is available, and how much is required for the correct functioning
of the system?
Are there curves, slopes, or curbs present which may not suit the Vulcan®Gate?
The purpose of this Manual is to supply some basic application information about the
Vulcan®Gate and to detail its performance when tested to NCHRP Report 350.
If you would like further assistance, please contact Trinity Highway (see p. 3).

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Figure 1 – System Overview
TRANSITION
VULCAN
®
BARRIER
HINGE
HINGE
ANCHORED
LONGITUDINAL
BARRIER
WHEEL JACKS
TRANSITION
ANCHORED
LONGITUDINAL
BARRIER
WORKZONE AS REQUIRED
(SEE DRAWINGS FOR DESIGN LENGTHS)

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Opening Options
Figure 2a
Figure 2b
Figure 2c
610158 610158
610158 610158
610158 610158
REMOVE THIS SECTION
TO OPERATE IN
DIRECTION SHOWN

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Figure 2d
Figure 2e – Open along Vulcan
®
Barrier
Figure 2f – Open Middle Opposite
REMOVE THIS SECTION
TO OPERATE IN
DIRECTION SHOWN
610158 610158
610158 610158
610158 610158
Note: Gate can be
opened in either
direction when
opened in the middle.

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Figure 3 – Vulcan
®
Gate Hinge (PN 610158)
Figure 4 - Vulcan
®
Transition (PN 616199)
A
NCHOR HOLES
GATE DIRECTION
ARROW
CENTER
CONNECTION PIN
LATCH PIN
HINGE JOINT

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Length of Need
Length of need (L.O.N.) is defined as the total length of a longitudinal barrier needed to shield
an area of concern as determined by the highway authority specifying the use of this product. It
is also described as that part of a longitudinal barrier or terminal designed to contain and
redirect an errant vehicle. The L.O.N. varies depending on what use the Vulcan®Gate is being
specified for by the highway authority.
The Vulcan®Gate is deployed as a barrier gate which can be placed in the middle of the
longitudinal barrier or Vulcan®Barrier when all criteria of design drawings are met. The Vulcan®
Gate is deployed longitudinally and incorporates various sections of Vulcan®Barrier that require
specific opening sizes.
Vulcan®Gate Tested Lateral Deflection
The Vulcan®Gate, since it is made up of the Vulcan®Barrier, has been considered to pass all
NCHRP Report 350 test criteria where maximum dynamic deflection was experienced. The TL-3
deflection results on the Vulcan®Gate for the 2000P @ 25 degrees was 3’-7” [1.1 m]. This test
was directly positioned at the hinge and transition of the unit to determine vehicle interaction.
2000 kg Pick-up Truck Test – Vulcan®Gate
Deflection is 3’-7” [1.1 m] for the 25 degree impact at 100 kph [62 mph] (TL-3)
Deflection calculations are based on the TL-3 Beginning Length Of Need (B.L.O.N.).
The TL-3 results for the 2000P @ 25 degrees are taken directly from the NCHRP Report 350
test results and represent the maximum dynamic deflection experienced.
Dynamic deflection represents the maximum amount of lateral movement of the system. Testing
has confirmed that the permanent static deflection is approximately 10% less than the dynamic
deflection.

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Curves
The ends of each section are constructed with knuckles that interlock with those of other
segments. The end knuckles are vertically aligned to accept a steel connecting pin. The pin
securely joins the sections for maximum impact performance. The sections can swivel up to 6
degrees at the pin for easy positioning around work areas or following road contours (see Figure
5).
Typical placement of Vulcan
®
Gate should be in straight runs with minimal curvature.
Important: In order to limit system deflection in critical areas such as past the
work zone or other roadside features, placement of the limiting spacers between
the barrier segments is required.
Figure 5
Slopes
Cross-slopes
The Vulcan
®
Gate may be placed on cross-slopes up to
5% [3 deg.] (see Figure 6).
Figure 6
Longitudinal Slopes
For Vulcan
®
Gates placed on slopes that exceed 5% [3 deg.] call Trinity Highway customer
support (see p. 3).
Figure 7
MINIMUM CURVE
RADIUS R35 M [125’]
5% [3 DEG.]

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Hills
The Vulcan
®
Gate has the ability to conform to a hill up to 20:1 (see Figure 8). Please note the
maximum longitudinal slope in Figure 7.
Figure 8
Ditch
The Vulcan
®
Gate has the ability to conform to a ditch up to 20:1 (see Figure 9). Please note the
maximum longitudinal slope in Figure 7.
Figure 9
Curbs
The Vulcan
®
Gate should NOT be placed directly against curbs that can prevent its lateral
movement (see Figure 10).
Trenches
The Vulcan
®
Gate should NOT be placed directly up to trenches or excavations where the
necessary deflection of the system in the event of an impact may result in barrier failure.
Reference to accepted working widths is detailed in the deflection summary (see p. 12).
Figure 10
1
20
1
20

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Deployment
Preparation
Begin preparing for deployment by thoroughly reviewing the specified barrier location, layout,
and orientation as per the approved traffic management plan.
Determine the number of segments required for the site. The deployed length of each Vulcan
®
segment is 13’-6” [4 m]. A visual inspection should be carried out to confirm the suitability of all
segments. Should visible damage be evident in any segments, they should be sent for
inspection and refurbishment prior to use.
Warning: The correct safety equipment and approved traffic management must
be used as required for any deployment using the Vulcan
®
Barrier.
Important: The Vulcan
®
Barrier is designed to stack up to three (3) segments
in height so provision must be made to lift from a height of 7’-10 1/2" [2.4 m] plus
the tray height (Stiffner).
Deployment
1. Begin deployment at the upstream traffic end of the site and work downstream. Work
from the non-traffic side of the assembly whenever possible. Unloading proceeds much
faster if one person remains on the truck and two people work on the ground. If site
conditions permit, a fourth person can drive the truck so that the segments can be
unloaded continuously as the job progresses.
2. Align the segments according to the specified configuration and layout in the traffic
control plan.
Caution: Refer to the deflection on page 12 when determining minimum
clearance between barrier and roadside feature.
Caution: The existence of any cross-slopes in excess of 5% (3 deg.) or curbs
may create an untested effect on the impacting vehicle.

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3. Insert two (2) transitions (one at the beginning of the system and one at the end) and
attach to existing longitudinal barrier. Anchor adjacent barrier only as specified per
manufacturer’s instructions.
Important: Attach the hinge sections to transitions with connecting pins.
Ensure top tab of pins are on swinging side of gate and that gate direction arrows
are pointing to the median opening (see Figure 11).
Figure 11
4. Bring the segments together and insert a connecting pin through the overlapping end
knuckles at each joint. Push the pin in until it is flush with the top of segments.
Spacers (PN 614552) are used to minimize joint rotation. Trinity Highway recommends
inserting spacers for optimum performance and minimum lateral deflection.
5. After the system is in place and pinned together, make sure the jacks on each Vulcan
®
Barrier section are in the raised position and all barriers are completely settled on the
roadway.
6. Check to make sure all connection pins remove easily. Lubricate as needed (WD40) and
reposition Vulcan
®
and Hinge if necessary.
Important: Ensure that the deflection limiting spacers are inserted between all
segments where the minimum deflection of the system is desired at Beginning of
Length Of Need (B.L.O.N.).
Detail A

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Recommended Tools
Vulcan®Gate Manual
Transport truck
Sledge hammer
Pry bar
Generator (power for optional accessories)
A truck mounted crane or forklift suited to a minimum 400 kg (900 lb.) lift and appropriate
slinging gear
7/8” Concrete drill bits (*Double Fluted)
Grinder, hacksaw, or torch (optional)
Drill motor
Drill bits: 1/16” through 7/8”
Trinity Highway recommends using double fluted drill bits to achieve optimum tensile
strength when mounting the MP-3®anchoring system.
Rotary hammer drill
Standard hammer
Heavy duty impact wrench
1/2” drive sockets: 9/16”, 11/16”, 3/4", 15/16”, 1 1/8”,1 1/4"
Ratchet and attachments for the above sockets
Breaker bar: 1/2" x 24”
Torque wrench: 300 ft-lb
Crescent wrench: 12”
Impact wrench: 1/2"
Lubrication (WD40)
Manufacturer’s print package
Applicable location, layout, orientation, and construction plans
Traffic control equipment (as required)
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.

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Vulcan®Gate – Typical Layout

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616950 (SHOWN)
Figure 12 – Long Section Swings Either Way