Trinity CASS S3 User manual

TrinityHighway.com 1 Part No. 620005
©2021 Trinity Highway Products, LLC
Revision F November 2021
CASS® S3 4:1
CAble Safety System
The CASS® S3 4:1 Cable Safety System (“CASS® S3”) has been tested to National Cooperative Highway Research
Program (“NCHRP”) Report 350 criteria and to American Association of State and Highway Transportation Officials
(“AASHTO”) Manual for Assessing Safety Hardware, 1st Edition-2009 (“MASH”) criteria, has been deemed eligible for
Federal-aid reimbursement on the National Highway System (“NHS”) by the Federal Highway Administration
(“FHWA”). The NCHRP Report 350 and MASH CASS® S3 Test Level 3 system can be placed on slopes 1V:4H or
flatter. The NCHRP Report 350 CASS® S3 Test Level 4 system can be placed on slopes 1V:6H or flatter. The MASH
CASS® S3 Test Level 4 can be placed on slopes 10:1 or flatter.
Production Description
Assembly Manual
15601 Dallas Parkway
Suite 525
Addison, Texas 75001
Warning: The state/specifying agency, distributors, owners, and contractors are
RESPONSIBLE for the assembly, maintenance, and repair of the CASS® S3. Failure
to fulfill these RESPONSIBILITIES with respect to the assembly, maintenance, and
repair of the CASS® S3 could result in serious injury or death.
Important: These instructions are for standard assembly specified by the
state/specifying 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 CASS® S3 information available to Trinity Highway at publication. We
reserve the right to make changes at any time. Please visit TrinityHighway.com/product-category/barriers/cable-
barriers/ to confirm the latest revision.

TrinityHighway.com 2 Revision F November 2021
Table of Contents
CASS® S3 Acronyms .................................................................................................................... 2
Customer Service Contacts/Important Introductory Notes ........................................................... 3
Limitation and Warnings ............................................................................................................... 4
General CASS® S3 Information .................................................................................................... 6
Ground Preparation and Barrier Alignment ................................................................................ 15
Line Post Assembly .................................................................................................................... 16
Post Placement .......................................................................................................................... 17
CASS® S3 Cable End Treatments .............................................................................................. 18
CCT Line Footings ..................................................................................................................... 20
CCT Posts Assembly ................................................................................................................. 21
Terminal Cables ......................................................................................................................... 22
Line Cables ................................................................................................................................ 23
Laying Out the Cable/Attaching the Cables to the Posts ........................................................... 26
Tensioning and Tension Meter ................................................................................................... 27
Delineation/Repairs .................................................................................................................... 29
Emergency Repairs .................................................................................................................... 30
Cable Tension Inspection Program ............................................................................................ 32
CASS® S3 Assembly/Repair Checklist ....................................................................................... 33
CASS® S3 Routine Inspection Checklist (File with Maintenance Records) ................................ 34
Appendix A: Flare Assemblies 30:1 Flare ................................................................................. 37
Appendix B: Cable Barrier Overlap ........................................................................................... 38
Appendix C: Encountering Rock ............................................................................................... 39
Appendix D: Base Plated Post Assembly .................................................................................. 40
CASS® S3 ACRONYMS! !
AASHTO American Association of State Highway and Transportation Officials
CASS® S3 The CASS® S3 4:1 Cable Safety System
CBOD Cable Barrier Overlap Distance
CCA CASS® Cable Anchor
CCT CASS® Cable Terminal
CFR Code of Federal Regulation
CRP Cable Release Post
FHWA Federal Highway Administration
MASH Manual for Assessing Safety Hardware
Median Ditch width (distance between break points)
MSC Minimum Strength Concrete
MUTCD Manual on Uniform Traffic Control Devices
NCHRP National Cooperative Highway Research Program
NHS National Highway System
OSHA Occupational Safety & Health Administration
PN Trinity Product Number
PPE Personal Protective Equipment
TL-3 Test Level 3
TL-4 Test Level 4
Trinity Highway Trinity Highway Products, LLC
1V:”x”H Slope Measurement-1 Foot Vertical Distance to “x” Foot Horizontal Distance

TrinityHighway.com 3 Revision F November 2021
Customer Service Contacts
Trinity Highway is committed to the highest level of customer service. Feedback regarding CASS®
S3, 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\Contact
Website:
www.trinityhighway.com
Trinity Highway Products, LLC
15601 Dallas Parkway
Suite 525
Addison, TX 75001
Important Introductory Notes
Proper assembly of CASS® S3 is essential to achieve the performance that has been evaluated and
deemed eligible for federal-aid reimbursement by the FHWA per NCHRP Report 350 and to AASHTO
MASH. These instructions are to be read in their entirety and understood before assembling CASS® S3.
These instructions are to be used only in conjunction with standard CASS® S3 assemblies specified by the
state/specifying agency. If you need additional information, or have questions about CASS® S3,
please contact the state/specifying agency that has planned and specified this assembly and, if
needed, contact Trinity Highway Customer Service. This product must be assembled in the location
specified by the state/specifying agency. If there are deviations, alterations, or departures from the
assembly instructions specified in this manual, the device may not perform as tested.
Note: The Metric conversion from Imperial in this manual uses a soft conversion.
A state/specifying agency’s careful evaluation of the site layout, vehicle population type and 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.
A set of product and project shop drawings will be supplied by Trinity Highway. The shop drawings will be
for each section of the assembly. These drawings are to be reviewed and studied thoroughly by a qualified
individual who is skilled in interpreting them.

TrinityHighway.com 4 Revision F November 2021
Limitations and Warnings
Trinity Highway, in compliance with NCHRP Report 350
and MASH, contracts with ISO 17025 A2LA accredited
testing laboratories to perform crash tests, evaluate
tests, and submit the test results to the FHWA for review.
CASS® S3 has been deemed eligible by FHWA as meeting the
requirements and guidelines of NCHRP Report 350 and
MASH, Test Level 3 (“TL-3”) and Test Level 4 (“TL-4"). These
tests typically evaluate product performance defined by
NCHRP Report 350 and MASH involving a range of vehicles
on roadways, NCHRP Report 350 and approximately 1,100kg
[2,420 lb.] for MASH) and full size pickup trucks (approximately
2,000 kg [4,400 lb.] for NCHRP Report 350 and approximately
2,270 kg [5,000 lb] for MASH) at 100 kph [62 mph]. For TL-4,
the vehicle is single-unit van truck, approximately 8,000 kg
[18,000 lb.] for NCHRP Report 350 and approximately 10,000
kg [22,000 lb] for MASH. The speed and angle for NCHRP
Report 350 is at approximately 80 kph [45 mph]/15 degrees
and 90 kph [56 mph]/15 degrees for MASH.
CASS® S3 is tested pursuant to the test matrix criteria
of MASH as designated by AASHTO and FHWA and
NCHRP Report 350 as designated by FHWA. The
FHWA AASHTO tests are not intended to represent
the performance of systems when impacted by every
vehicle type or in every impact condition existing on
the roadway. Every departure from the roadway is a
unique event.
Trinity Highway expressly disclaims any warranty or
liability for injury or damage to persons or property
resulting from any impact, collision or harmful contact
with its products, other vehicles, or nearby hazards or
objects by any vehicle, object or person, whether or not
the products were assembled in consultation with Trinity
Highway or by third parties.
CASS® S3 is intended to be assembled, delineated, and
maintained within specific state and federal guidelines. It
is important for the state/specifying agency the use of a
highway product to select the most appropriate product
configuration for site specifications.
The state/specifying agency’s careful evaluation of
the site layout, vehicle population type and 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 with the system, all debris must be
removed from the area immediately in compliance with
the most applicable agency policy. The specified CASS®
S3 must be evaluated and restored to its original specified
condition or replaced as the state/specifying agency
determines/requires, as soon as possible. Product
selection, approval, proper installation, and maintenance
of any highway product is the sole responsibility of the
state/specifying agency.
Safety Alert Symbols appear throughout this manual
and indicate Danger, Warning, Caution or Important
statements. Failure to read and follow these warnings
could result in serious injury or death in the event of
a vehicle impact with the system.
WARNING: Do not assemble, maintain, or repair
CASS® S3 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 have any questions
about instructions in this manual.
WARNING: Safety measures incorporating
appropriate traffic control devices and personal
protective equipment ("PPE") specified by the
state/specifying agency must be used to protect all
personnel while at the assembly, maintenance, or
repair site.
WARNING: Ensure the assembly site meets all
appropriate Manual on Uniform Traffic Control
Devices (“MUTCD”) and local standards.
WARNING: Only Trinity Highway parts that are
specified herein can be used for assembly,
maintenance, or repair on CASS® S3. Do not utilize
or otherwise commingle parts from other systems,
even if those systems are other Trinity Highway
systems. Such configurations have not been tested,
nor have they been approved 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 such an
UNACCEPTED system.
WARNING: Do NOT modify the CASS® S3 in any
way.
IMPORTANT: Trinity Highway makes no
recommendation whether use or reuse of any part of
CASS® S3 is appropriate or acceptable after system
impact. It is the responsibility of the state/specifying
agency and its engineers to make that determination.
IMPORTANT: It is the responsibility of the owner,
state/specifying agency to inspect CASS® S3 after
assembly is complete to ensure the instructions
provided in this manual have been strictly followed.
Danger: It is critical that the CASS® S3 posts are
placed in suitable soil that will allow the system to
fully perform in accordance with design
specifications. Should you have any questions

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about this, please contact the state/specifying
agency that specified CASS® S3 at this particular
location for guidance. Trinity Highway is available
for consultation with that agency.
Warning: Do not allow pedestrians or workers to
stand near this system, when under tension, in
circumstances where the cable may be impacted
or cut. Failure to follow this warning can result in
serious injury or death to the workers, bystanders
and/or pedestrians in the event of a vehicle
impact with the system.
Warning: It is imperative, before assembly, that
you contact a Trinity Highway representative and
state/specifying agency engineer for special
criteria for soils which do not meet or exceed
NCHRP Report 350 soil conditions. It is also
recommended that you consult your own soils or
structural engineer.
Warning: Be aware of hazards of using
compressed air (small objects may become
projectiles). Failure to follow this warning can
result in serious injury or death to the workers
and/or bystanders.
Warning: When drilling rock, it is the
responsibility of the installer to consult
Occupational Safety & Health Administration
(“OSHA”) silica respiratory standard 29 Code of
Federal Regulation (“CFR”) 1910.134 for debris
removal and ensure compliance.
Warning: Ensure that CASS® S3 delineation
used meets all federal, state/specifying agency
specifications.
Warning: CASS® S3 shall be placed on a
median or roadside without obstructions,
depressions, etc. that may significantly affect the
stability of an errant vehicle. Grading of the site
and/or appropriate fill materials may be required.
The assembler shall “flatten” or “round” various
topographical inconsistencies that could interfere
with the ability to consistently maintain the design
height (in relation to the terrain) of the cables.
To address assembly in rock, see Appendix C:
Encountering Rock.
Note: Based on soil conditions at the site, ANY or
ALL foundations may need larger/deeper concrete
footings or larger soil plates (for driven
applications) as determined by soil analysis.

TrinityHighway.com 6 Revision F November 2021
General CASS® S3 Information
CASS® S3 is a 4-Cable Barrier consisting of steel S3 x 5.7# [S75 x 8] posts and four (4) pre-
stretched 3/4” [19 mm] wire rope cables. The posts can be driven, placed in a driven sleeve,
placed in a sleeve and concrete footing, placed in a sleeve in a mow strip, or base plated. One
inch [25 mm] or 3/4” [19 mm] fitting hardware can be used. The NCHRP Report 350 and MASH
CASS® S3 Test Level 3 system can be placed on slopes 1V:4H or flatter. The NCHRP Report 350 CASS®
S3 Test Level 4 system can be placed on slopes 1V:6H or flatter. The MASH CASS® S3 Test Level 4 can
be placed on slopes 10:1 or flatter
The bottom two (2) cables are retained by a hook bolt. The top two cables are placed in a slot at
the top of the post and separated with a plastic spacer. Cable heights are approximately 17.4”
[440 mm], 29.5” [750 mm], 38.1” [970 mm], and 41.7” [1060 mm]. A stainless steel strap is placed
around the post over the top cable.
The post spacing will be in accordance to the contract plans. The barrier is terminated either with
a CCT, or a CCA. Only use the CCA when not on the NHS or when it cannot be impacted
in either direction.
For 1V:6H or flatter slopes, a 12” [300 mm] diameter x 30” [762 mm] minimum depth concrete
footing is used. For slopes steeper than 1V:6H, the footing depth is increased by 6” [150 mm].
The footing depths can be increased if the soils do not meet or exceed the NCHRP Report 350
soil conditions. Contact Trinity Highway for these designs.
The Minimum Strength Concrete (“MSC”) for all concrete components of the CASS® S3 is
3,000 psi [21 MPa] or greater to meet the agency’s specifications.
NCHRP Report 350 CASS® S3
The CASS® S3 Test Level 3 can be installed anywhere on slopes 1V:10H or flatter.
For slopes steeper than 1V:10H and 1V:6H, see the Ground Preparation Section for additional
placement criteria. For slopes 1V:4H or flatter; but, steeper than 1V:6H, it must be installed 0 to
4’ [0-1.2 m] from the break point. For back slope applications, the installation must be a minimum
of 11’ [3.4 m] from the V-ditch center. The maximum post spacing is 21’ [6.4 m]. The minimum
post spacing is 10’-6” (3.2 m).
The CASS® S3 Test Level 4 can be placed on slopes 1V:6H or flatter. See the Ground Preparation
Section for additional placement criteria. The maximum post spacing is 21’ [6.4 m]. The minimum
post spacing is 10’-6” [3.2 m].
MASH CASS® S3
The CASS® S3 Test Level 3 can be installed anywhere on slopes 1V:10H or flatter.
For slopes 1V:4H or flatter; but, steeper than 1V:10H, it must be installed 0 to 4’ [0-1.2 m] from
the break point. For back slope applications, the installation must be a minimum of 11’ [3.4 m]
from the V-ditch center. The maximum post spacing is 10’-6” [3.2 m].
The CASS® S3 Test Level 4 can be placed on slopes 1V:10H or flatter. The maximum post
spacing is 10’-6” [3.2 m].

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CASS® Components
Below is a pictorial of components for CASS® S3 Hardware. Please see Trinity Highway
drawings for specific lists of quantities. All Trinity Part Numbers (“PN”) are provided for standard
parts only.
Note: The following components are not shown to scale.
PN: 3240G
PN:3245G
PN: 3300G
5/16” Flat Washer (F844)
5/16” Hex Nut (A563)
5/8” Flat Washer (F844)
PN: 3310G
PN: 3361G
PN: 3536G
5/8” Lock Washer
5/8” Hex Nut
1” Stud Flattened-RHT
PN: 3537G
PN: 3700G
PN: 3701G
1” Stud Flattened-LHT
3/4” Flat Washer (F844)
3/4” Flat Washer (F436)

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PN: 3710G
PN: 3711G
PN: 4099G
3/4” Hex Nut (A563)
3/4” Hex Nut (A194 2H)
Torpedo Cable Splice
PN: 4199B
PN: 4211G
PN: 4225G
3/4” Cable Wedge (3 x 7)
5/16” x 1 3/4” Hex Bolt (A307)
Cable Hook Bolt (A307)
PN: 4779G
PN: 4902G
PN: 4903G
3/4” x 4 1/2” Hex Bolt (A325)
1” Flat Washer (F436)
1” Hex Nut (A194 2H)
PN: 4959G
PN: 5225G
3/4” Heavy Square Nut
5/8” x 7 1/2” Rod (A193 B7)

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PN: 5633G
PN: 5634G
PN:5635G
Assembled 1” Cable Splice
3/4” Cable Field Splice Left
3/4” Cable Field Splice Right
PN: 5698G
PN: 5700B
Assembled 3/4” Cable Splice
4” Cable Spacer w/o Reflector
PN:5701B
PN: 5702B
PN: 5709B
4” Cable Reflector Spacer
Yellow
4” Cable Reflector Spacer
White
CASS® Thermometer
(Infrared)
PN: 5711G
PN: 5825G
PN: 5826G
3/4” Turnbuckle Open Body
Cable Lock Bolt (A307)
1” Turnbuckle Closed Body

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PN: 5836G
PN: 5837B
PN: 5839B
8” Concrete Reinforcing Ring
S3 Sleeve Cap Bottom
S3 Sleeve Post Cover
PN: 5840G
PN: 5850B
PN: 5851B
5’-0” Cable Field Repair
Section
CASS® Cable Pulling Tool
Reflector Median (LEFT)
PN: 5852B
PN: 5878B
PN: 5909G
Reflector Roadside (RIGHT)
CASS® Tension Meter
1” Field Wedge Open Left
PN: 5910G
PN: 5919B
1” Field Wedge Open Right
#4 x 2’-8” Rebar Rod

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PN: 6722G
PN: 9021G
5/8" X 8" ATR CHSL PT
A449
Bearing Angle
PN: 33903A
PN: 33908G
PN: 33909G
Driven Terminal Posts w/soil
Plates-S3 Posts 4-7
Terminal Post Sleeve-S3 Post
CRP-Cable Bracket
PN: 33910G
PN: 33916B
PN: 33934A
S3 Terminal Post-in Sleeve
Posts 4-7
CRP Reinforcing Cage
Bottom CRP (in Concrete)

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PN: 33935A
PN: 33936A
PN: 33952A
Top CRP
Bottom CRP (w/Soil Plate)
Driven Terminal Sleeve w/soil
Plates-S3 Posts 4-9
PN: 33955G
PN: 33989A
PN:34036G
S3 Terminal Post-in Sleeve
Posts 8 and 9
Driven S3 Terminal Post
w/Soil Plates-Posts 8 & 9
S3 Post-Driven
PN: 34037A
PN: 34038G
PN: 34039G
S3 Base Plated Post
Post Sleeve-Concrete Footing
27” Driven Sleeve
PN: 34045G
PN: 34047A
PN: 34049G
S3 Post-Concrete Footing
Driven Sleeve w/soil Plate
Post-30 3/4”
Standard Splice Post in
Sleeve

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PN: 105201B
PN: 105202T
PN: 105204G
Post Cap
S3 Post Strap
3/4” Stud Flattened-LHT
PN: 105205G
3/4” Stud Flattened-RHT
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.

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Recommended Tools
Documentation
• Manufacturer’s CASS® S3 4:1 CAble Safety System Assembly Manual (Current
Version)
• CASS® S3 4:1 System Drawing(s). Current Versions of SS742 CASS® S3
(4:1 SLOPES) or SS743 CASS® S3 (6:1 SLOPES)
Personal Protective Equipment (PPE)
• Eye Protection
• Work Gloves
• Back Protection
• Safety-Toe Shoes
• Reflective Vest
• Apron
Wrenches
• Pipe Wrenches
• Adjustable Spanner
• Adjustable Jaw Wrenches
• Imperial and Metric Wrenches
Concrete equipment
• Concrete Vibrator
• Concrete Tools
Cable/Miscellaneous equipment
• Traffic Control Equipment and Plan per local standards and the MUTCD
• Cable Tension Meter (PN-5878B)
• CASS™ Thermometer (Infrared) (PN-5709B)
• Abrasive Cutoff Blade/Saw
• C-Clamps
• CASS® Cable Pulling Tool (PN-5850B)
• Locking Pliers
• Duct tape
• Pry Bars
• Line/String
• Plumb Line
• Straight Edge
• Level
• Drift Pin
• Tape Measure
• Come-along/Lever chain hoist (3 ton minimum capacity)
• Backhoe (optional tensioning device)
• Chain (5 ton minimum capacity) of appropriate length for tensioning equipment
• Marking Paint
• Post Pounder
• Auger
Note: The provided list of tools is a general recommendation and should not be considered
an extensive list. Depending on specific site conditions and the complexity of the
assembly specified by the appropriate agency, the required tools may vary. Decisions as
to what tools are needed to perform the job are entirely the responsibility of the specifying
agency and the agency’s selected contractor performing the assembly of the system at
the agency’s specified assembly site.

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Ground Preparation and Barrier Alignment
CASS® S3 shall be placed on a median or roadside without obstructions, depressions, etc. that
may significantly affect the stability of an errant vehicle. Grading of the site and/or appropriate fill
materials may be required. The assembler shall “flatten” or “round” various topographical
inconsistencies that could interfere with the ability to consistently maintain the design height (in
relation to the terrain) of the cables. To address assembly in rock, see Appendix C: Encountering
Rock.
Warning: It is imperative, before assembly, that you contact a Trinity Highway
representative and state/specifying agency engineer for special criteria involving
soil conditions not meeting or exceeding NCHRP Report 350 soil conditions. It is
also recommended that you consult your own soils or structural engineer.
Note: Based on soil conditions at the site, ANY or ALL foundations may need larger/deeper
concrete footings or larger soil plates (for driven applications) as determined by soil analysis.
Ground Preparation
When CASS® S3 is placed in a median, use the following criteria for locating the system:
Ensure that the finished grade (side slope) is 1V:4H or flatter.
When the NCHRP Report 350 CASS® S3 is placed on a ditch section and the
side slope is 1V:4H or flatter; but, steeper than 1V:6H, the maximum offset
from the hinge point is 4’ [1.3 m] and minimum offset from the bottom of the
ditch is 11’ [3.3 m]. According to FHWA and AASHTO, on side slopes
steeper than 1V:10H, the cable median barrier (including CASS® S3) cannot
be placed within 1’ to 8’ [0.3m to 2.4 m] from the ditch line.
When the MASH CASS® S3 is placed on a ditch section and the side slope
is 1V:4H or flatter; but steeper than 1V:10H, the maximum offset from the
hinge point is 4’ [1.3 m] and minimum offset from the bottom of the ditch is
11’ [3.3 m]. When the side slope is 1V:10H or flatter, CASS® S3 can be placed
anywhere in the median.
Barrier Alignment
Follow all procedures in the placement of the footing and/or post to ensure proper alignment. It
is suggested that a string line or other means be used to provide a consistent horizontal and
vertical alignment that meets specifications. If assembled on a horizontal curve, a minimum 650
foot [198 m] radius is required. If assembled on a sag vertical curve, the K value is ≥ 100’ [30
m]. See “Assembly on a Curve” Section.
CASS® S3 can be placed on the roadside in front of slopes 1V:2H or flatter. Use a minimum
distance of 2’ [0.6 m] in front of the hinge point to the center of the post.
Use the state/specifying agency or agency’s guardrail terminal standards for grading and
widening for the CCT.
There may be instances where a break will be required in the cable run. In these circumstances
proper overlap of the terminals is required in order to prevent a vehicle from passing through the
protected area. Depending on the location of the cable with respect to the direction of traffic, there
are two situations which can occur. See Appendix B for recommended overlaps.

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Important: A flare rate of 30:1 or flatter is required if the barrier must be flared,
transverse across the median, or if CASS® S3 must change in
direction (See Appendix A).
Assembly on a Curve
Horizontal Curve
Complete the following steps to place the posts or post foundations along a curve.
1. When the cable is placed on a curve, post spacing may need to be reduced based on
the radius.
2. Weak soil conditions may necessitate a larger/deeper footing for the line posts, based on
the radius of the curve.
3. When placing posts on a curve, use the table below to adjust the spacing as required:
Curve Radius
Post Spacing (NCHRP Report 350)
Post Spacing (MASH)
0 to 650’ [0 to 198 m]
CASS® S3 is not recommended
CASS® S3 is not recommended
651’ to 1,300’
[198 m to 396 m]
10’-6” [3.2 m] post spacing or less (as
specified by state/specifying agency)
10’-6” [3.2 m] post spacing or less
(as specified by state/specifying
agency)
Greater than 1,301’
[396 m]
21’ [6.4 m] post spacing or less (as
specified by state/specifying agency)
10’-6” [3.2 m] post spacing or less
(as specified by state/specifying
agency)
Note: If any of the post spacing for a particular radii grouping is larger than the contract
specifications, use the contract specification post spacing.
Vertical Curve
For a sag vertical curve, the recommended minimum K value is 100’ [30 m]. There is no K
value limit for crest vertical curves.
K= L / (g1-g2)
L = length of vertical curve in feet [meters) between the two tangents
g1 = grade of tangent in
g2 = grade of tangent out
When the minimum sag vertical curve value is not met, the use of intermediate terminals at the
low point of the sag curve is recommended to minimize the cables from rising beyond the
allowable height tolerance relative to grade.
Line Post Foundation Placement
Warning: If the post cannot be placed, pursuant to these assembly
instructions, because of soil conditions, or any other environmental factor,
please contact the appropriate state/specifying agency immediately! NEVER
attempt to place posts if these assembly instructions cannot be complied with.

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Post Alignment
Lay out the post alignment and post spacing according to the contract specifications.
Maximum post spacing for the NCHRP Report 350 CASS® S3 is 21’-0” [6.4 m]; Maximum
post spacing for MASH CASS® S3 is 10’-6” (3.2 m].
Driven Foundation Sleeve With and Without Soil Plate
Complete the following steps for a driven foundation sleeve assembly.
1. Drive the foundation sleeve (PN-34039G) or foundation sleeve with soil plate (PN-
33952A) with an appropriate driving head. During the driving process ensure that the
sleeve is aligned, properly oriented (with interior tabs 15” [375 mm] from the top of the
tube sleeve and the 3” [75 mm] side parallel to the roadway), soil is prevented from
coming up into the sleeve, and the sleeve is not damaged.
Sleeve in Poured Concrete Footing
Complete the following steps for placing a sleeve in a poured concrete footing.
1. Place a plastic cap (PN-5837B) on the bottom of the foundation sleeve (PN-34038G) or
tape the bottom end of the foundation sleeve to prevent the concrete from coming into the
tube.
2. Punch or auger a minimum 12” [300 mm] diameter x 30” [762 mm] deep hole for the
concrete footing.
3. Pour the MSC in the hole, ensuring the concrete is flush with the finish grade.
4. Place the foundation sleeve in the poured concrete footing. Ensure that the sleeve is
positioned plumb, flush with the top of the footing, a minimum of 3” [75 mm] from the edge
of the footing, properly oriented (with interior tabs 15” [375 mm] from the top of the tube
sleeve and the 3” [75 mm] side parallel to the roadway) and in alignment. Consolidate the
concrete to remove air pockets in compliance with applicable state specifications for
similar applications.
5. Place a rebar ring (PN-5836B) around the top of the sleeve 2” to 3” [50 mm to 75 mm]
from the top of the footing.
6. Smooth off the top of the concrete footing with a slight crown from the sleeve.
7. Allow the footing to attain the required concrete strength before disturbing the foundations,
including the placement of posts.
Sleeve in a Mow Strip
Trinity Highway may allow the use of an alternate line post footing if the system is installed with
an acceptable mow strip application. Please contact Trinity Highway for additional details. If the
mow strip is not acceptable, follow the steps in “Sleeve in Poured Concrete Footing” section.
Precast Concrete Footings
The precast concrete footings will be made in forms and fabricated the same as if placed in an
augured or punched hole.
Post Placement
Posts
The CASS® S3 posts can be driven, placed in a driven sleeve, placed in a sleeve in a concrete
footing (poured or precast), or mounted to a concrete surface.

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Driven Posts
Complete the following steps for a driven post assembly.
1. Lay out the post alignment and post spacing according to contract specifications and drive
the post (PN-34036G) with an appropriate driving head equipment.
2. The height from the finished grade to the top of the post is approximately 3’-10” [1.17 m]
Posts in Sleeve
Complete the following steps for a post in the sleeve assembly
1. Place the post sleeve cover (PN-5823B) on the bottom end of the CASS® S3 post
(34045G).
2. Place the post in the sleeve so it rests on the first tab in the sleeve or bottom of the sleeve
and the sleeve cover is located at the top of the sleeve.
3. The height from the finished grade to the top of the post is approximately 3’-10” [1.17 m].
Base Plated Post
For Base Plated Post Assembly, see Appendix D.
CASS® S3 Cable End Treatments
CASS® S3 is terminated with either a CCT or a CCA.
CCT
The CCT consists of four (4) CRP (Bottom CRP and Top CRP) and six (6) S3 x 5.7# [S75 x 8]
terminal line posts. The cables are terminated at the CRP, one at each post. The terminal line
posts are placed with sleeve in a concrete footing, a sleeve with a soil plate, or a driven post with
a soil plate.
See Figure 1 for the footing locations and spacing.
Figure 1
CRP Offset

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Based on soil conditions at the site, the CCT may need larger/deeper concrete anchors or larger
soil plates (for driven applications) as determined through soil analysis.
Bottom CRP with Concrete Footings
Place the Bottom CRP (PN 33936A) in a minimum 18” [450] diameter x 5’-0” [1.50 m] deep
reinforced MSC footing. The footing is reinforced with a spiral rebar cage.
Complete the following steps for the placement of the Bottom CRP in the concrete footing:
1. Lay out the four (4) CRP footings.
2. Punch or auger the appropriate hole for the concrete footing.
3. Fabricate a rebar cage in accordance with project/shop drawing requirements. A standard
spiral rebar cage that may be applicable is PN-33916B (See Figure 2).
4. Place the rebar cage in the footing hole, ensuring a minimum of 3” [75 mm] of concrete
surrounds the cage on all sides and the cage is approximately 3” [75 mm] from the top of
the footing (finished grade). Place the Bottom CRP in the center of the spiral rebar cage,
ensuring the top of the post is no more than 4” [100 mm] above the finished grade. See
Figure 3 for the orientation of the post.
5. Place the MSC in the hole. Consolidate the concrete to remove air pockets in compliance
with applicable state specifications for similar applications.
6. Smooth off the top of the concrete footing with a slight crown from the sleeve.
7. Allow the footing to attain the required concrete strength before disturbing the foundations,
including the placement of posts.
Bottom CRP with Soil Plate
The Bottom CRP with Soil Plate assembly, size based on soil conditions, can be driven or placed
in an augured hole. The soil plate can be either welded or bolted to the bottom CRP (See Figure
2).
Figure 2
CRP Footing Details