Trinity ET Plus 350 User manual

ENERGY ABSORPTION SYSTEMS
ET Plus® 350
Guardrail End
Treatment
Assembly Manual
Part No. 620292B Revised March 2010

www.highwayguardrail.com 1Revised: October 5, 2009
ET-PLUS™ Systems
Guardrail End Treatment
Instructional Manual
Trinity Highway Products, LLC.
2525 Stemmons Freeway
Dallas, Texas 75207
This Manual must be available to the workers at all times. For
additional copies, contact Trinity Highway Products, LLC. at
800-527-6050.
All information, illustrations, and specifications in this Manual are based
on the latest ET-PLUS™ systems information available at the time of
printing. We reserve the right to make changes at any time.
IMPORTANT: These instructions are to be used only in
conjunction with the installation of the ET-PLUS™systems.
These instructions are for standard installations specified by
the appropriate state/specifying agency. In the event the
specified systems installation requires or involves special
circumstances, contact the appropriate state/specifying
agency before proceeding. Trinity Highway Products, LLC.
representative is available for consultation, if required.
Revised: March 2010

www.highwayguardrail.com 2 Revised: March 2010
CUSTOMER SERVICE CONTACTS
Trinity Highway Products, LLC is committed to the highest level of customer
service. Feedback regarding the ET-PLUS™ systems, their installation
procedures, supporting documentation, and performance is always welcome.
Our goal is to enhance highway safety through innovation. Additional
information for materials and product specifications can be obtained by
calling the telephone numbers or writing to the email address below:
TRINITY HIGHWAY PRODUCTS, LLC:
Telephone: [phone] (U.S. Calls)
[phone] (International)
E-mail: productin[email protected]
REGIONAL TELEPHONE CONTACTS:
Dallas, Texas 800-527-6050
Centerville, Utah 800-772-7976
Elizabethtown, Kentucky 800-282-7668
Girard, Ohio 800-321-2755
Orangeburg, South
Carolina 800-835-9307
SUGGESTED SAFETY RULES FOR INSTALLATION
- MAINTENANCE - REPAIR
* IMPORTANT SAFETY INSTRUCTIONS *
Always keep this Manual in a location where it is easily accessed by persons
who install, maintain, or repair the ET-PLUS™ systems.
SAFETY SYMBOLS
Below are the safety symbols that may appear on the ET-PLUS™ systems or
in the documentation. Read the entire Manual for suggested safety,
assembly, installation, maintenance, repair, and service information.
SYMBOL MEANING
SAFETY ALERT SYMBOL
Indicates Danger, Warning, or Caution. Failure to
read and follow the Danger, Warning, and Safety or
Caution indicators could result in serious injury or
death to the workers and/or bystanders.
WARNING – READ MANUAL
Read the Manual(s) and follow all warnings and
safety instructions. Failure to follow this warning
could result in serious injury or death to the workers
and/or bystanders.

www.highwayguardrail.com 3 Revised: March 2010
WARNINGS AND CAUTIONS
Read all warnings, cautions, and instructions before installing/
maintaining/repairing the ET-PLUS™ systems.
IMPORTANT: READ SAFETY INSTRUCTIONS THOROUGHLY
AND FOLLOW THE SAFE OPERATION PRACTICES WHILE
INSTALLING THE ET-PLUS™ systems. Failure to follow this warning
could result in serious injury or death to the workers and/or
bystanders.
WARNING: Read the instructions carefully. Be familiar with the
complete instructions for the ET-PLUS™ systems before installing,
maintaining, or repairing the ET-PLUS™ systems. Failure to follow
this warning could result in serious injury or death in the event of a
collision.
WARNING: Ensure that the necessary traffic control is setup and any
debris that has encroached onto the traveled way or shoulder has
been removed, before beginning installation or repairs. Failure to
follow this warning could result in serious injury or death in the event
of a collision.
WARNING: Be sure adequate time is available for complete
installation, before beginning the installation process. Failure to
follow this warning could result in serious injury or death in the event
of a collision.
WARNING: Do NOT perform installation, maintenance, or repair of
the ET-PLUS™ systems when tired, ill, or under the influence of
alcohol, drugs, or medication. Failure to follow this warning could
result in serious injury or death in the event of a collision.
WARNING: Do not install, maintain, or repair the ET-PLUS™
systems, until you have read this Manual thoroughly. Please call
Trinity Highway Products, LLC at 800-644-7976, if you do not
understand the installation instructions. Failure to follow this warning
could result in serious injury or death in the event of a collision.
WARNING: Use only Trinity Highway Products’ parts on the ET-
PLUS™ systems for installation, maintenance, or repair. The
installation or co-mingling of unauthorized parts is strictly prohibited.
Failure to follow this warning could result in 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”). The ET-
PLUS™ systems and its component parts have been accepted for
state use by FHWA. However, a co-mingled system has not been
accepted.
WARNING: Do NOT modify the ET-PLUS™ systems in any way.
Failure to follow this warning could result in serious injury or death in
the event of a collision.
WARNING: Do NOT perform installation, maintenance, or repair, if
the ET-PLUS™ systems site, shoulder, or traveled area is covered or
encroached by road debris. Failure to follow this warning could result
in serious injury or death in the event of a collision.
WARNING: Safety measures, incorporating traffic control devices,
must be used to protect all personnel, while at the installation,
maintenance, or repair site. Failure to follow this warning could result
in serious injury or death to the workers and/or bystanders. .
WARNING: Ensure that the entire work zone site is visible at all
times. Failure to follow this warning could result in serious injury or
death to the workers and/or bystanders.
WARNING: Use caution when working near public roads. Be mindful
of vehicles in motion nearby. Failure to follow this warning could
result in serious injury or death to the workers and/or bystanders.
WARNING: Ensure that all Guardrail products and delineation used
meet all federal, state/specifying agency, and local specifications.
Failure to follow this warning could result in serious injury or death in
the event of a collision.

www.highwayguardrail.com 4Revised: October 5, 2009
WARNING: Ensure that your installation, repair, and maintenance
meet all appropriate Manual on Uniform Traffic Control Devices
(MUTCD) and local standards. Failure to follow this warning could
result in serious injury or death in the event of a collision.
WARNING: Ensure that the Guardrail you install is terminated, as
dictated by the state/specifying agency, pursuant to FHWA
acceptance. Failure to follow this warning could result in serious
injury or death in the event of a collision.
WARNING: Do NOT install SYTP™ at location 1. Failure to
follow this warning could result in serious injury or death in the
event of a collision.
WARNING: Do NOT install 6’0” CRT post at location 1. Failure to
follow this warning could result in serious injury or death in the
event of a collision.
WARNING: Do NOT bolt the rail panel to the post at location 1 in
any of the ET-PLUS™ systems. Failure to follow this warning
could result in serious injury or death in the event of a collision.
WARNING: Do NOT bolt the rail to the HBA™ post at location 2.
Failure to follow this warning could result in serious injury or death
in the event of a collision.
WARNING: Ensure that there is proper site grading for tube and
post placement, as dictated by the state/specifying agency,
pursuant to FHWA acceptance. Failure to follow this warning
could result in serious injury or death in the event of a collision.
WARNING: Ensure that the proper Leaveout (specified area of
open space in the pavement) around the posts is reserved and
filled with state/specifying agency approved backfill material that
will not prevent movement, for any posts installed in rigid
pavement such as any thickness of concrete or asphalt. Failure to
follow this warning could result in serious injury or death in the
event of a collision.
WARNING: Ensure that all of the ET-PLUS™ systems Warnings,
Cautions, and Important statements within the ET-PLUS™
systems Manual are completely followed. Failure to follow this
warning could result in serious injury or death in the event of a
collision.
WARNING: Always use safety precautions when performing
installation, maintenance, repair, mixing chemicals, and/or moving
heavy equipment. Wear steel toe shoes, gloves, safety goggles,
and back protection. Failure to follow this warning could result in
serious injury or death to the workers and/or bystanders.
WARNING: Ensure all wood blocks or composite blocks used with
steel posts are routered. Failure to follow this warning could result
in serious injury or death in the event of a collision.
WARNING: Ensure that this installation conforms with the
guidance provided by the AASHTO Roadside Design Guide,
including, but not limited to, those regarding placement on curbs.
Failure to follow this warning could result in serious injury or death
in the event of a collision.
WARNING: Any grout, backfill, or other materials (such as
concrete, asphalt, or soil) must be low enough so as not to
obstruct, constrain, or otherwise engage the bearing plate. Failure
to eliminate the interaction of soil or materials with the bearing
plate will hinder the performance of the ET-PLUS™ systems and
could result in serious injury or death in the event of a collision.
CAUTION: Ensure before installing, maintaining, or repairing the
ET-PLUS™ systems that no parts are frayed, damaged, or broken.
Failure to follow this warning could result in serious injury to the
workers and/or bystanders.
Revised: March 2010

www.highwayguardrail.com 5Revised: October 5, 2009
KNOW YOUR ET-PLUS™ SYSTEMS
ET- PLUS™ (TL-3)
50' (15.24 m) SYSTEM
For specific installation, maintenance, or repair details,
refer to the state/specifying agency’s standard drawing(s).
(This drawing represents one (1) version of the 50' (15.24 m) systems)
Alternates for Foundation Tubes
At post locations 1 and 2, the alternates to long foundation tube without soil plate
are:
•Hinged Breakaway™ (“HBA™”) post
•Short tube with soil plate
•HBA™ post at location 1, Steel Yielding Terminal Post™
(“SYTP™”) at location 2
•Long foundation at location 1, SYTP™ at location 2
•Short foundation with soil plate at location 1, SYTP™ at
location 2
The alternate to two (2) 12' 6" (3.81 m) long rail elements is one (1)
25’ 0” (7.62 m) long rail element.
For post locations 3 through 8 (50’ (15.24 m) system), alternates
are:
•All short tubes without soil plates and breakaway wood
posts
•All HBA™ posts
•All CRT posts
•All SYTP™
•Any combination of above options, as accepted by the
FHWA and dictated by the state/specifying agency
Revised: March 2010

www.highwayguardrail.com 6Revised: October 5, 2009
ET-PLUS™ (TL-3)
37’ 6" (11.43 m) SYSTEM
For specific installation, maintenance, or repair details,
refer to the state/specifying agency’s standard drawing(s).
(This drawing represents one (1) version of the 37' 6” (11.43 m) systems)
Alternates for Foundation Tubes and Posts
At post locations 1 and 2, the alternates to long foundation tube
without soil plate are:
•HBA™ post
•HBA™ post at location 1 and SYTP™ at location 2
•Long foundation tube or short tube with soil plate at
location 1 and SYTP™ at location 2
For post locations 3 through 7 (37’ 6” (11.43 m) system),
alternates are:
•All short tubes without soil plates and breakaway wood
posts
•All HBA™ posts (HBA™ post required at location 8)
•All CRT posts
•All SYTP™ (SYTP™ required for location 8)
•Any combination of above options, as accepted by the
FHWA and dictated by the state/specifying agency
Revised: March 2010

www.highwayguardrail.com 7Revised: October 5, 2009
ET-PLUS™ (TL-2)
25' (7.62 m) SYSTEM
For specific installation, maintenance, or repair details,
refer to the state/specifying agency’s standard drawing(s).
(This drawing represents one (1) version of the 25' (7.62 m) systems)
Alternates for Foundation Tubes, Rail Panels, and Posts
At post locations 1 and 2, the alternates to long foundation tube
without soil plate are:
•HBA™ post
•HBA™ post at location 1 and SYTP™ at location 2
•Long foundation tube or short tube with soil plate at
location 1 and SYTP™ at location 2
The alternate to two (2) 12' 6" (3.81 m) long rail elements is one (1)
25’ 0” (7.62 m) long rail element.
For post locations 3 through 4 (25’ (7.62 m) system), alternates
are:
•Short steel foundation tubes without soil plates and
breakaway wood posts or SYTP™ in tubes
•All HBA™ posts
•All CRT posts
•All SYTP™
Revised: March 2010

www.highwayguardrail.com 8Revised: October 5, 2009
BILL OF MATERIAL ENGLISH (METRIC)
WARNING: Use only Trinity Highway Products’ parts on the ET-
PLUS™ systems for installation, maintenance, or repair. The
installation or co-mingling of unauthorized parts is strictly
prohibited. Failure to follow this warning could result in 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”). The ET-PLUS™ systems and its component parts have
been accepted for state use by FHWA. However, a co-mingled
system has not been accepted.
ET-PLUS™ SYSTEMS
(For specific materials and quantities, see state/specifying agency’s option(s))
PN Description
9G 12/12.5'/6’ 3"/S (2.67/3.81/1.905/S) (Guardrail)
32G 12/12.5"/6' 3"/S (2.67/3.81/1.905/S) ANC (Guardrail)
60G 12/25'/6' 3"/S (2.67/7.62/1.905/S) (Guardrail)
62G 12/25'/6' 3"/S (2.67/7.62/1.905/S) ANC (Guardrail)
704A Cable Anchor Bracket
705G Pipe Sleeve - 2" STD Pipe x 51/2" (50 STD Pipe x 150
Pipe)
740G* 6" x 8" x 4' 6" x 3/16 (152 x 203 x 1375 x 4.8) Tube Sleeve
749G 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* 18" x 24" x 1/4" (460 x 610 x 16) Soil Plate
782G 8" x 8" x 5/8” (200 x 200 x 16) Bearing Plate
995A ET-PLUS™ Extruder (Head)
3000G Cable (Assembly) 3/4" x 6' 6" (19 x 1981)
3300G 5/8" (16) Round Washer
3340G 5/8" (16) HGR Nut
3360G 5/8" DIA. X 11/4" (16 DIA. x 35) Splice Bolt (HGR)
3478G 5/8" DIA. x 71/2" (16 DIA. x 190) Hex Head Bolt
3497G 5/8" DIA. x 91/2" (16 DIA. x 240) Hex Head Bolt
3500G 5/8" DIA. x 10" (16 DIA. x 255) HGR Post Bolt
3580G 5/8" DIA. x 18" (16 DIA. x 460) HGR Post Bolt
3701G 3/4" (19) Washer
3704G 3/4” (19) HEX Nut
3717G 3/4“ x 21/2" (19 x 75) Hex Head Bolt (High Strength)
3718G 3/4" x 3” (19 x 75) Hex Head Bolt (High Strength)
3900G 1" (25) Round Washer
3910G 1" (25) Hex Nut
4063B Wood Post 6" x 8" x 6' 0" (150 x 200 x 1830) CRT
4075B Wood Block 6" x 8" x 14" (150 x 200 x 360) DR
4076B Wood Block - 6” x 8” x 14” (150 x 200 x 360) DR
4147B Wood Post - 51/2” x 71/2” x 3’ 9" (140 x 190 x 1145)
4254G 3/8” (10) Round Washer
4255G 3/8” (10) Fender Washer 11/2” OD (38)
4258G 3/8” (10) Lockwasher
4261G 3/8” DIA. X 11/2" (10 x 38) Hex Head Bolt
4228B 3/8” x 4" (10 x 100) Lag Screw
4388G 7/16” (11) Hex Nut
4389G 7/16” (11) Round Washer
4390G 7/16” DIA. x 11/2” (11 x 38) GR. 5 Hex Head Bolt
4393G 7/16” (11) Lockwasher
5148G 3/4” DIA. X 91/2” (19 DIA. x 240) Hex Head Bolt (High
Strength)
4699G 3/4” (19) Lockwasher
Revised: March 2010

www.highwayguardrail.com 9Revised: October 5, 2009
PN Description
6321G 3/8” x 2’ (10 x 50) Hex Head Bolt (High Strength)
6405G 3/8” (10) Hex Nut
6907B Polymer Block 4” x 71/2” x 14” (100 x 187 x 350) [King
Block]
14329G#3’ 65/8” SYTP Stub
14578G#6’ Steel Yielding Terminal Post (SYTP)
33871A#ET HBA Post #1 Top
33873A#ET HBA Post #1 and #2 Bottom
33874A#ET HBA Post #3 - #8 Bottom
33877A#ET HBA Post #2 - #8 Top
9852A#Strut (and Yoke Assembly)
33875G#6' 6" (1980) Angle Strut ET HBA
33795G# 6’ 6” (1980) Angle Strut
33730G#6’ 71/2” (1980) Angle Strut
33847G#6’ 91/8” Angle Strut
*Option to the 6’0” Post Sleeve Tube
#Review the state/specifying agency’s standard drawings of these
systems, for details that are specific to the project or site locations.
Delineation Options
PN Description
6206B Right Side 13” x 27 1/2” (325 x 700) Reflective Sheeting
6207B Left Side 13” x 27 1/2” (325 x 700) Reflective Sheeting
6668B Either Side 12” x 12” (305 x 305) Reflective Sheeting
(Typically 2 required)
Revised: March 2010