Trinity Highway CAT-350 User manual

TrinityHighway.com 1 Part Number: 620291
©2021 Trinity Highway Products, LLC
December 2021
CAT®-350 System
Tangent Double-Sided End Terminal
The Crash Cushion Attenuating Terminal (“CAT®”) has been tested to National Cooperative Highway
Research Program (“NCHRP”) Report 350 criteria and has been deemed eligible for Federal-aid
reimbursement on the National Highway System (“NHS”) by the Federal Highway Administration (“FHWA”).
Product Description
Assembly Manual
15601 Dallas Parkway
Suite 525
Addison, Texas 75001
Warning: The local highway agency, distributors, owners, and contractors are
RESPONSIBLE for the assembly, maintenance, and repair of the CAT®. Failure to fulfill
these RESPONSIBILITIES with respect to the assembly, maintenance, and repair of the
CAT® could result in serious injury or death.
Important: These instructions are for standard assembly specified by the appropriate highway
agency. In the event the specified system assembly, maintenance, or repair would require a
deviation from standard assembly parameters, contact a Trinity Highway Products, LLC (“Trinity
Highway”) representative. This system has been deemed eligible by the FHWA for use on the
NHS under strict criteria utilized by that agency.
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 visit TrinityHighway.com/Products.
The information contained in this manual supersede all previous versions. The instructions, illustrations, and
specifications are based on the latest CAT® System information available to Trinity Highway at publication. We
reserve the right to make changes at any time. Please visit TrinityHighway.com/product-category/end terminals
to confirm the latest revision.

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December 2021
Crash Cushion Attenuating Terminal
The CAT® is a tangent, double-sided, re-directive/gating and energy absorbing attenuator/end terminal
available for use with various longitudinal highway barriers, in either unidirectional or bidirectional traffic
applications.

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Table of Contents
CAT® ACRONYMS ............................................................................................................................................. 4
Customer Service Contacts .................................................................................................................................. 4
Limitations and Warnings .................................................................................................................................... 5
Overview ............................................................................................................................................................. 6
Recommended Tools ........................................................................................................................................... 7
Site Preparation ................................................................................................................................................... 8
Post Placement ................................................................................................................................................... 9
Rigid Pavement and Rock ................................................................................................................................... 9
Inspect Shipment ................................................................................................................................................ 9
CAT® System Components/Hardware................................................................................................................ 12
Assembly Steps ................................................................................................................................................. 17
STEP 1A: CAT® and CAT® Tail – Post Layout 1-8 Connecting To 27 3/4” [705 mm] High Downstream
Single/Double Sided Guardrail .................................................................................................. 18
STEP 1B: CAT® and CAT® Tail – Post Layout 1-11 Connecting To 31” [787 mm] High Downstream
Single/Double Sided Guardrail................................................................................................... 19
STEP 2A: CAT® Tail - Post Assembly 7 & 8 Connecting To 27 3/4” [705 mm] High Downstream Single/
Double Sided Guardrail............................................................................................................. 20
STEP 2B: CAT® Tail - Post Assembly 7-11 Connecting To 31” [787 mm] High Down Stream Guardrail .... 21
STEP 3: CAT® Tube Assembly Short Tube 4’-6” [1.37 m] with Soil plate; Long Tube 6’-0” [1.83 m] ......... 22
STEP 4A: CAT® Post and Offset Block Assembly (Posts 3, 5, & 6) ........................................................... 23
STEP 4B: CAT® Post Assembly (Post 4) .................................................................................................. 24
STEP 4C: CAT® Post and Strut Assembly (Posts 1 & 2) ........................................................................... 25
STEP 5A: CAT® Tail - Guardrail Assembly Connecting To 27 3/4” [705 mm] High Downstream Single
Sided Guardrail ......................................................................................................................... 26
STEP 5B: CAT® Tail Anchor Bracket Assembly (For 27 3/4” [705 mm] High Downstream Single Sided
Guardrail Assembly) .................................................................................................................. 27
STEP 5C: CAT® Tail - Anchor Assembly Connecting To 27 3/4” [705] High Downstream Single Sided
Guardrail ................................................................................................................................... 28
STEP 6: CAT® Tail - Guardrail Assembly Connecting To 27 3/4” [705 mm] High Downstream Double
Sided Guardrail ......................................................................................................................... 29
STEP 7A: CAT® Tail - Guardrail Assembly Connecting To 31” [787 mm] High, 8” [200 mm] Offset Blocks,
MGS Downstream Guardrail ..................................................................................................... 30
STEP 7B: CAT® Tail - Guardrail Assembly Connecting To 31” [787 mm] High, 12” [300 mm] Offset
Blocks, MGS Downstream Guardrail ......................................................................................... 31
STEP 8: CAT® Tail - Guardrail Assembly With 9’- 4 1/2” Guardrail Panel Connecting To 31” [787 mm]
High Downstream MGS Guardrail ............................................................................................. 32
STEP 9A: CAT® 10 Gauge, Slotted/Welded Guardrail-2 Assembly ............................................................ 33
STEP 9B: CAT® Splice Assembly (At Post 6)............................................................................................. 34
STEP 10A: CAT® 12 Gauge, Slotted Guardrail-1 Assembly ......................................................................... 35
STEP 10B: CAT® Splice Assembly (At Post 4)............................................................................................. 36
STEP 10C: CAT® Spacer Assembly ............................................................................................................ 37
STEP 11: CAT® Nose Plate (10 Gauge) Assembly .................................................................................... 38
STEP 12: CAT® Side Plate (10 Gauge) Assembly .................................................................................... 39
STEP 13: CAT® Anchor Cable Assembly ................................................................................................... 40
STEP 14: CAT® Restraining Road Assembly (Posts 3 & 5) ........................................................................ 41
STEP 15: CAT® Knock Out Tube/Post Plate Assembly (Posts 4 & 6) ......................................................... 42
STEP 16: CAT® Delineation ...................................................................................................................... 43
CAT® System Assembly Checklist (File with Project Records) ........................................................................... 44
CAT® System Repair Checklist (File with Maintenance Records) ....................................................................... 45
CAT® System Routine Inspection Checklist (File with Maintenance Records) .................................................... 46
APPENDIX A: AASHTO Roadside Design Guide Roadside (Shoulder) Grading Detail ....................................... 47
APPENDIX B: AASHTO Roadside Design Guide Median Grading Detail ........................................................... 48
APPENDIX C: CAT® SS245 Repair Kit1 and CAT® Hardware Bags ................................................................. 49
NOTES .............................................................................................................................................................. 50

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CAT® ACRONYMS
AASHTO American Association of State Highway and Transportation Officials
BLON Beginning Length of Need
CAT® Crash Cushion Attenuating Terminal
CFR Code of Federal Regulation
FHWA Federal Highway Administration
MUTCD Manual on Uniform Traffic Control Devices
NCHRP National Cooperative Highway Research Program
NHS National Highway System
OSHA Occupational Safety & Health Administration
PPE Personal Protective Equipment
TL-3 Test Level-3
Trinity Highway Trinity Highway Products, LLC
Customer Service Contacts
Trinity Highway is committed to the highest level of customer service. Feedback regarding the
CAT®, its assembly procedures, supporting documentation, and performance is always welcome.
Additional information can be obtained from the contact information below:
Trinity Highway
Telephone
[phone] (USA)
[phone] (International)
Contact Link
TrinityHighway.com/Products
Website:
www.trinityhighway.com
Trinity Highway Products, LLC
15601 Dallas Parkway
Suite 525
Addison, TX 75001