Trinity REACT 350 User manual

.
REACT 350®Wide
60”/96”/120”
Assembly Manual
Revision A December 2012Part No. 115242B

Part No. 115242B
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REACT 350
®
Wide
60”/96”/120”
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 REACT 350
®
Wide 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 accepted by the
Federal Highway Administration for use on the national highway system under
strict criteria utilized by that agency. Energy Absorption Systems 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 Energy Absorption Systems at [phone]
or download from websites 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 REACT 350
®
Wide system information available to Energy Absorption Systems at the time of printing. We
reserve the right to make changes at any time. Please contact Energy Absorption Systems 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
Recommended Safety Rules for Assembly ..................................................................................4
Safety Symbols.............................................................................................................................5
Warnings and Cautions.................................................................................................................5
Limitations and Warnings..............................................................................................................6
System Overview..........................................................................................................................7
Recommended Tools....................................................................................................................8
Site Preparation/Foundation.......................................................................................................10
Assembly Procedures (60” Wide Systems) ................................................................................11
Assembly Procedures (96” and 120” Wide Systems).................................................................27
MP-3®Polyester Anchoring system............................................................................................44
Horizontal Assemblies ................................................................................................................46
MP-3 Assembly Cautions............................................................................................................48
Maintenance and Repair.............................................................................................................49
Visual Drive-By Inspection....................................................................................................49
Walk-Up Inspection...............................................................................................................49
Post-Impact Instructions .............................................................................................................50

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Customer Service Contacts
Energy Absorption Systems (a Trinity Highway Products company) is committed to the highest
level of customer service. Feedback regarding the REACT 350®Wide system, its assembly
procedures, supporting documentation, and performance is always welcome. Additional
information can be obtained from the contact information below:
Energy Absorption Systems:
Telephone: [phone] (USA Only)
[phone] (USA or International)
E-mail: [email protected]
Internet: Energy Absorption Systems
Trinity Highway Products, LLC http://www.energyabsorption.com http://www.highwayguardrail.com
Important Introductory Notes
Proper assembly of the REACT 350®Wide system is essential to achieve performance of the
system under appropriate federal and state criteria. These instructions should be read in their
entirety and understood before assembling the REACT 350®Wide system. These instructions
are to be used only in conjunction with the assembly of the REACT 350®Wide system and are
for standard assemblies only as specified by the applicable highway authority. In the event your
system assembly requires or involves deviation from standard parameters or, during the
assembly process a question arises, please contact the appropriate highway authority that
specified this system at this particular location for guidance. Energy Absorption Systems is
available for consultation with that agency. These instructions are intended for an individual who
is qualified to both read and accurately interpret them as written. They are intended for the
individual who is experienced and skilled in the assembly of highway products which are
specified and selected by the highway authority.
A set of product and project shop drawings will be supplied by Energy Absorption Systems. The
shop drawings will be for each section of the assembly. These drawings should be reviewed
and studied thoroughly by a qualified individual who is skilled in interpreting them before the
start of any assembly.

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Important: Read safety instructions thoroughly and follow the assembly
directions and suggested safe practices before assembling, maintaining, or
repairing the REACT 350®Wide system. Failure to follow this warning can result
in serious injury or death to workers and/or bystanders. It further compromises
the acceptance of this system by the FHWA. Please keep these instructions for
later use.
Warning: Ensure that all of the REACT 350®Wide system Warnings, Cautions,
and Important Statements within the REACT 350®Wide Manual are completely
followed. Failure to follow this warning could result in serious injury or death in
the event of a collision.
Recommended 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 REACT 350®Wide system.
Additional copies of this Manual are immediately available from Energy Absorption Systems by
calling [phone] or by email at customer[email protected]. This Manual
may also be downloaded directly from the websites indicated below. Please contact Energy
Absorption Systems if you have any questions concerning the information in this Manual or
about the REACT 350®Wide system.
Always use appropriate safety precautions when operating power equipment, mixing chemicals,
and when moving heavy equipment or the REACT 350®Wide components. Gloves, apron,
safety goggles, steel toe boots, and back protection shall 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 REACT 350®Wide Manual. Read
the Manual for complete safety, assembly, operating, maintenance, repair, and service
information.
Symbol Meaning
Safety Alert Symbol: Indicates Danger, Warning, or Caution. Failure to read
and follow the Danger, Warning, Safety, or Caution indicators could result in
serious injury or death to the workers and/or bystanders.
Warnings and Cautions
Read all instructions before assembling, maintaining, or repairing the REACT 350®Wide
system.
Warning: Do not assemble, maintain, or repair the REACT 350®Wide system
until you have read this Manual thoroughly and completely understand it. Ensure
that all Warnings, Cautions, and Important statements within the Manual are
completely followed. Please call Energy Absorption Systems 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.
Warning: Use only Energy Absorption Systems parts that are specified herein
for the REACT 350®Wide for assembling, maintaining, or repairing the REACT
350®Wide system. Do not utilize or otherwise comingle parts from other systems
even if those systems are other Energy Absorption Systems or Trinity Highway
Products 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 REACT 350®Wide system in any way. Failure to
follow this warning could result in serious injury or death in the event of a
collision.
Warning: Ensure that the REACT 350®Wide system 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.
Warning: Ensure that your assembly meets 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.

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Limitations and Warnings
Energy Absorption Systems, 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 Federal Highway Administration for
review.
The REACT 350®Wide system has been approved by FHWA as meeting the requirements and
guidelines of NCHRP Report 350 TL-1, TL-2, and TL-3. These tests typically evaluate product
performance by closely simulating actual impacts involving a typical range of vehicles on our
roadways, from lightweight cars (approx. 820kg [1800 lb.]) to full size pickup trucks (approx.
2000 kg [4400 lb.]) as specified by the FHWA. A product can be certified for multiple Test
Levels. The REACT 350®Wide is certified to the Test Level(s) as shown below:
Test Level 1: 50 km/h [31 mph]
Test Level 2: 70 km/h [43 mph]
Test Level 3: 100 km/h [62 mph]
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 350 as approved by
FHWA.
These tests are not intended to represent the performance of products when impacted by every
vehicle type or every impact condition.
Energy Absorption Systems does not represent nor warrant that the results of these controlled
tests show that vehicle impacts with the products in other conditions would necessarily avoid
injury to person(s) or property. Impacts that exceed criteria capabilities of the product may not
result in acceptable impact performance as outlined in NCHRP Report 350, relative to structural
adequacy, occupant risk, and vehicle trajectory. Energy Absorption Systems expressly
disclaims any warranty or liability for injury or damage to persons or property resulting from any
impact, collision, or harmful contact with products, other vehicles, or nearby hazards or objects
by any vehicle, object or person, whether or not the products were assembled by or under the
direction of Energy Absorption Systems or by third parties.
The REACT 350®Wide system is intended to be assembled, delineated, and maintained in
accordance with specific state and federal guidelines. It is important to select the most
appropriate product configuration for a site. The customer should be careful to properly select,
assemble, and maintain the product. Careful evaluation of the site geometry, vehicle population
type, speed, traffic direction, and visibility are some of the elements that require evaluation in
the proper selection of a safety appurtenance. For example, curbs could cause an untested
effect on an impacting vehicle.
After an impact occurs, the product should be restored to its original condition as soon as
possible. When a potentially reusable safety product is impacted, it is still necessary to restore
the product to its original length and inspect all the components as necessary.

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System Overview
The REACT 350
®
Wide is a potentially reusable, redirective, non-gating crash cushion for
hazards ranging in width from 1524 mm to 3048 mm (60" to 120"). It consists of energy-
absorbing Cylinders.
The REACT 350
®
Wide system utilizes three types of Cylinders in a “staged” configuration to
address both lighter cars and heavier, high center-of-gravity vehicles. Its modular design allows
the system length to be tailored to the design speed of a site. Refer to the REACT 350
®
Wide
Product Manual to determine the appropriate length system for a given speed.
Impact Performance
REACT 350
®
Wide systems have successfully passed the requirements stipulated in NCHRP
Report 350, at Test Level 1, 2 and 3 tests, with both the light car and pickup at speeds of up to
100 km/h [62 mph] at angles up to 20 degrees.
During head-on impacts, within the NCHRP 350 criteria, the REACT 350
®
Wide travels rearward
and crushes to absorb the energy of impact. When impacted from the side, within that same
criteria, it has been shown to safely redirect the vehicle back toward its original travel path and
away from the hazard.
Figure 1
REACT 350
®
Wide (60”) Orientation

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Recommended Tools
Documentation
Manufacturer’s Assembly Manual
Manufacturer’s Drawing Package
Cutting equipment
Rebar cutting bit
Concrete drill bits – 22 mm (7/8”) x 178 mm [7”](*Two Fluted)
Concrete drill bits - 19 mm (3/4”) x 178 mm [7”] (*Two Fluted)
Grinder, Hacksaw or Torch (optional)
Drill motor
Energy Absorption Systems recommends using two fluted drill bits to achieve optimum tensile
strength when applying the MP-3®anchoring system.
Hammers
Rotohammer
Sledgehammer
Wrenches
Heavy duty impact wrench
Standard adjustable wrench
1/2" drive sockets: 9/16", 11/16", 3/4", 15/16", 1 1/8", 1 1/4"
1/2" drive Deep sockets: 15/16", 1 1/4"
1/2" drive Ratchet and attachments
1/2" drive Breaker bar - 24" long
1/2" drive Torque wrench: 200 ft-lb
Allen wrench: 3/8
Impact Wrench: 1/2"
Screwdrivers
Screw Gun or Standard Drill with adapter chuck for small screws/bolts
Flat Screwdriver
Phillips Screwdriver
Personal Protective equipment
Safety Glasses
Gloves
Steel toe shoes
Apron for MP-3®application

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Miscellaneous
Traffic control equipment
Lifting and moving equipment (A lifting device is preferred although a forklift can be
used.) Minimum 5,000 lb. capacity required.
Compressor (100 psi) and Generator (5 kW)
Long pry bar
Drift pin
Tape measure 7.5 m [25’]
Chalk line
Nylon bottle brush for cleaning 7/8” drilled holes
Rags, water, and solvent for touch-up
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
needed 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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Note: Refer to Assembly Procedures for a complete list of instructions.
Site Preparation/Foundation
A REACT 350®Wide (60”/96”/120”) should be assembled only on an existing or freshly placed
and cured concrete base (28 MPa [4000 psi] minimum). Location and orientation of the concrete
base and attenuator must comply with project plans or as otherwise determined by the resident
project engineer.
Recommended dimension and reinforcement specifications for new concrete pads are provided
in Energy Absorption Systems concrete pad drawing, supplied with the system.
The REACT 350®Wide (60”/96”/120”) may be assembled on a non-reinforced concrete roadway
(minimum 200 mm [8”] thick). Deployment cross-slope shall not exceed 8% and should not twist
more than 2% over the length of the system; the pad surface shall have a light broom finish.
Caution: Accurate placement of all steel rebar is critical to avoid interference
with the concrete anchor bolts.
Inspect Shipping
Before deploying the REACT 350®Wide, check the received parts against the shipping list
supplied with the system. Make sure all parts have been received.

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Assembly Procedures (60” Wide Systems)
Note: The Drawing Package supplied with the REACT 350
®
Wide (60”) must be used with
these instructions for proper assembly and should take precedence over these general
instructions.
1) Deploy Traffic Control
A traffic control plan appropriate to the complexity of the project should be prepared and
understood by all parties before the REACT 350
®
Wide (60”) is deployed.
Deploy appropriate work zone safety devices in conformance with the regulations, plans,
and specifications of the appropriate highway authority, prior to beginning the deployment
and keep them present through all phases of assembly.
2) Mark the System Location
Typically the basepoint of the REACT 350
®
Wide (60”) will be the midpoint of the hazard at
its front face. This may change if bidirectional traffic or expansion joints are present.
Note that the REACT 350
®
Wide (60”) with Concrete Backup, when properly deployed,
appears to be an extension of the object which it is shielding.
Extend a chalk line from the basepoint, perpendicular to the hazard face, or as determined
by project engineer, to a distance greater than the maximum length of the REACT 350
®
Wide (60”) (refer to the drawings provided). This chalk line will become the centerline for
the REACT 350
®
Wide (60”).
Mark a construction line parallel to the centerline and offset 165 mm [6.5”] to one side. The
edge of the Monorail will be placed on this line (See Figure 2).
Note: The Backup and pad should be assembled per the project plans supplied with the
system and be fully cured before proceeding.
Figure 2b
System Location – Self-Contained Backup
Figure 2a
System Location – Concrete Backup

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3) Assemble Monorail
Starting at the Backup and working toward the front of the system, lay the Monorail
sections down using the construction line as a guide (See Figures 2a and 2b). Refer to the
Monorail Assembly drawing for proper order of the segments. It is important to attach each
segment of Monorail in alignment from the back to the front of the system (± 6 mm [1/4”]).
Use the holes in the Monorail as a template to locate and drill holes, 22 mm [7/8”] diameter
x 140 mm [5 1/2"] deep into the concrete pad. Use vertical MP-3 kits to anchor 3/4”
diameter x 7” long studs using instructions included with kit (See Figure 3). After grout is
hardened, use 3/4" flat washers and nuts provided with kit to anchor Monorail to
foundation.
Note: All holes in Monorail must be used to anchor the REACT 350
®
Wide (60”) to the
foundation.
Warning: Once the grout has hardened, torque nuts to 165 N-m [120 ft-lb].
Refer to Table B on Page 46 for hardening times.
Figure 3a
Monorail Assembly Figure 3b
Monorail Assembly

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4) Locate and Identify Cylinder/Diaphragm Assemblies
With the exception of the last row, all Cylinder/Diaphragm assemblies are shipped
assembled. Each Cylinder is marked with a letter ranging from A to G. These letters
correspond to the drawings that came with the REACT 350
®
Wide (60”). The letter will be
located on the upper end of each Cylinder, facing inward as shown in Figure 4.
When the REACT 350
®
Wide (60”) is properly assembled, the Cylinders will be oriented as
shown in Figure 5. The two Cylinders marked “G” will be against the Backup, and the
letters will descend as you move toward the front of the system (See Figure 5).
Figure 4
Identifying Cylinder/Diaphragm Assemblies
Figure 5
Properly Assembled REACT 350
®
Wide (60)

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5) Attach Rear Cylinder Assemblies
(Concrete Backup)
For Concrete Backup, use bar washer as a template to locate and drill 22 mm diameter
[7/8” diameter] holes to a depth of 100 mm + 13 mm -0 [4” + 1/2" -0]* into the Concrete
Backup, four places as shown in Figure 6.
Note: Accurate location of these holes is critical to ensure smooth assembly. The holes
in the “G” Cylinder should be used to check vertical alignment before drilling.
*Note: this dimension takes precedence over standard MP-3
®
instructions of 127 mm [5”]
minimum.
Figure 6
Drilling Anchor Holes

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Refer to the instructions included with the Horizontal MP-3
®
kit to anchor the rear Cylinder
Assemblies to the Backup using 3/4" diameter x 6 1/2" long MP-3
®
Studs, 2” x 28” Bar
Washers and 3/4" nuts provided with MP-3 kit. When oriented correctly, the letters “G” will
be facing each other (See Figure 7a).
Note: The rear Cylinder assemblies are not attached to a Diaphragm when shipped. Also note
that they have the letter “G” marked on them.
Warning: Once the grout has hardened, torque nuts to 165 N-m [120 ft-lb].
Refer to Table B on Page 46 for hardening times.
Figure 7a
Attaching Rear Cylinder Assemblies to Concrete Backup

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5) Attach Rear Cylinder Assemblies
(Self-Contained Backup)
For the Self-contained Backup, anchor the Rear Cylinder Assemblies to the Backup using
3/4" diameter x 3” long hex bolts, Bar Washers, 3/4" lock washers and 3/4" hex nuts
provided with the Backup Assembly. When oriented correctly, the letters “G” will be facing
each other (See Figure 7b).
Note: The Rear Cylinder Assemblies are not attached to a Diaphragm when shipped. Also
note that they have the letter “G” marked on them.
Figure 7b
Attaching Rear Cylinder Assemblies to Self-Contained Backup

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6) Attach “F” Cylinder Assemblies
1. Disassemble “F” Cylinder/Frame Assembly.
2. Slide Diaphragm onto Monorail and against the “G” Cylinders.
3. Reassemble “F” Cylinder/Diaphragm Assembly onto “G” Cylinder Assemblies as
shown in Figure 8.
4. Repeat the above steps to attach remaining two “F” Cylinder Diaphragm Assemblies.
Figure 8
“F” to “G” Cylinder Assembly Attachment

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7) Attach “E” Cylinder Assemblies
1. Disassemble “E” Cylinder/Frame Assembly.
2. Slide Diaphragm onto Monorail and against “F” Cylinders.
3. Reassemble “E” Cylinder/Diaphragm Assembly onto “F” Cylinder Assemblies making
sure the spacers are in place as shown in Figure 9.
Figure 9
“E” to “F” Cylinder Assembly Attachment

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8) Attach “D” Cylinder Assemblies
1. Disassemble “D” Cylinder/Frame Assembly.
2. Slide Diaphragm onto Monorail and against “E” Cylinders.
3. Reassemble “D” Cylinder/Diaphragm Assembly onto “E” Cylinder Assemblies as
shown in Figure 10.
4. Repeat the above steps to attach remaining three “D” Cylinder/Diaphragm Assemblies.
Figure 10
“D” to “E” Cylinder Assembly Attachment