1. Session 8 Type IX Crash Cushion CAT-350 Trinity Highway Products
CAT - Crash Attenuating Terminal
The Type IX CAT has more parts than any other End Terminal. It has been re-engineered to make it more difficult to install improperly. This was a major improvement however, it is often installed improperly.

2. Installation Instructions for Proprietary Guard Rail End Terminals
Std Draw Note – RBE-200 & 205 Crash Cushion Type IX both have notes “The Manufacture SHALL furnish two (2) sets of shop plans to the contractor with each installation”
Added to Sect of 2012 Std Specs: “Proprietary end treatments SHALL be installed according to the manufacturer’s assembly or installation instructions”
Should NOT LET THE CONTRACTOR BEGIN INSTALLATION BEFORE SUPPLYING YOU WITH THESE SHOP PLANS OR INSTALLATION INSTRUCTIONS – With this training I have attempted to follow the manuals as closely as possible but you and the contractor need these documents to properly do your jobs of installing and inspection propriety guardrail end terminals
What dose this statement mean??
Click
Note #3 has been on proprietary guardrail end treatment Standard Drawings for many years. How many of you have seen this note and required the Shop Drawings?
You should require this before allowing installation to begin. Probably all you need to do is require it once and the contractor will have the required information from that date forward.

3. Type IX Crash Cushion CAT-350 Trinity Highway Products
The CAT-350 is designed with a flimsy Nose, Breakaway Wood Post and Slotted Rail Panels that telescope through a Rectangular Plate Washer and Special Bolt Assembly that shreds the Rail Panels apart burning up the Kinetic Energy of the Crash and slowing the impacting vehicle in a controlled manner
Vehicles impacting beyond Post 4 are contained and redirected in a controlled manner – LON Post 4

4. Hit Type IX CAT Flimsy Nose Section crushed Post 1 & 2 Broken Off

5. Shredded Rail Panels after Telescoping 10 feet of Rail through Bolt Assembly

6. Type IX Crash Cushion CAT-350 Trinity Highway Products
Kentucky utilizes the CAT-350 in Median situations where guardrail or a crash cushion is needed because the CAT has guardrail on both sides. Therefore a vehicle hitting it on the backside is hitting guardrail and not the backside of guardrail post.

7. Type IX Crash Cushion CAT-350 Trinity Highway Products
KY EB Bluegrass Parkway & APD Route in Eastern KY
No Concrete
Pad is Required

8. Type IX Crash Cushion CAT-350 Standard Drawings
RBB-002 Guardrail and Bridge End Drainage for Twin Structures
RBB-003 Layout of Guardrail at Twin Structures (Depressed Median)
RBE-200 Crash Cushion Type IX
RBE-205 Crash Cushion Type IX-A
RBI-007 Crash Cushion Type IX Installation at Median Piers (Depressed Median)

10. Key components: 1. Channel Strut 2. Cable Assembly 3. Spacer Channel 4
Key components: 1. Channel Strut 2. Cable Assembly 3. Spacer Channel 4. Restraint Rod(2) 5. Knockout Tube(2) 6. Post Plates(2) 7. Soil Tubes(6) 8. Soil Plates(6) 9. Splice Bolt Assembly 4 4 1 3 5 6 5 2
Each CAT has a flexible 10 Gauge Nose & a notched first Post 1. Channel Strut 2. Cable Assembly 3. Spacer Channel to hold rail together as it telescopes back 4. Restraint Rods to keep rail from bowing out 5 Knockout tubes to remove Restraint Rods 6 Post Plates 7&8 Short Soil Tube Sleeves and Soil Plates
Plus Special splice bolt assembly
The following slides will show close ups of these items 9 9 1
Each Post 7&8

11. The Mounting Height of the Type IX CAT will remain @ 27 ¾”

12. Site Preparation Standard Drawing RBI-007
This Point Same Elevation
As Inside Pavement Edge
Site Preparation is critical for the proper performance of the CAT.

13. Site Preparation Standard Drawing RBB-002
Note: need fairly flat slopes (12:1) coming into the nose of the Type IX CAT.

14. Site Preparation Grading too steep – not 12:1 Min Inlet too close
I do not know why this cross is here. What we do in our daily jobs is to strive to eliminate crosses from our roadsides.
There is no apparent damage to CAT.
I do know that the Inlet is to close and the grading is too steep. You would be in an upward trajectory – not level - before you would hit the end of this Type IX.
SOLUTIONS:
Type VI Crash Cushion closer to pier and regrade to 12:1
Cap drop inlet, move upstream with new dropbox and pipe water to old box
What could we have
done differently here?

15. Side Slope to Steep Remember 4 inches in 5 feet
I-64 – Cane Run Road – side slope was to steep and was re-graded.
You would be pushing gravel before you hit the end of this Type IX Crash Cushion.

16. Grading too steep – Note 6 RBI-007 Pavement & Grade Under Rail Same Elev.
I-64 – Cane Run Road
Remember Note 6 on Slide 8 which states “6. This point same elevation as inside pavement edge. “
SYRO notes say the top of rail should be approx. 27 inches above the edge of the pavement.
Problem begins with Concrete work which was to high, then Crash Cushion was likewise placed to high. Had to completely remove and rebuild.

17. “You CANNOT Disconnect Grading and Guardrail”
Per Bill Gulick
“You CANNOT Disconnect Grading and Guardrail”
You can have a PERFECTLY installed guardrail end treatment
BUT
If the grading around it is not proper you can have poor performance:
Grading coming into end treatment not flat enough so vehicle is flat when it hits rail
Slopes in advance, adjacent or run out with improper grading can/will have catastrophic consequences!!!

18. Installation of Soil Tubes and Soil Plates
KY Uses the 6 Post CAT-350 with 6 Soil Tubes with Soil Plates
The Soil Plates are placed on the downstream side of the post
Soil tubes and soil plates can be driven in permeable soil or if impermeable soil placed in 12” drilled hole with slots for soil plates cut by hand with a rock bar

19. Installation of Soil Tubes and Soil Plates
Post are 6’3” on centers
Soil Tubes must be less than 4” above finished grade
If rock is encountered see manufactures instructions

20. Installation of Soil Tubes and Soil Plates
Six Wood Post and Soil Tubes with Soil Plates on 6’3” centers and graded such that all of the Soil Tubes are less than 4” above finished grade.

21. Post Placement Post are only 3’6” long due to Soil Plates
Notched side of Post 1 faces Post 2
Place Pipe Sleeves for Cable Assembly in Post 1 & 2 before placement
Post 1 & 2 are not secured to the Soil Tube until the Strut is placed
Post 3-6 are secured to the Soil Tube with a 5/8” x 9 ½” Hex Bolt & Nut
DO NOT overtighten bolts and deform Tubes

22. Notched side of Post 1 faces Post 2

23. Place Pipe Sleeves for Cable Assembly in Post 1 & 2

24. Six Wood Post and Soil Tubes Strut and Tubes @ Ground Line

25. Installing the Strut
Bolt goes through Strut, Soil Tube and the Wood Post
A washer is placed between the Bolt head and the Strut and the Nut and the Strut
DO NOT OVERTIGHTEN bolts and deform Soil Tubes

26. Strut Bolt to Tight (slightly) Deforming Side of Soil Tube No Washers

27. Strut and Soil Tubes at Ground Line

28. Installing the Wood Blockouts and Guardrail
NO Rail to Post connections at Post 3, 5 and 6
@ Post 3, 5 and 6 Attach 2 Blockouts to each Post with two 5/8” x 24” Bolts and Nuts with Washers under the Bolt Head and the Nut
Two 10 Gage Slotted Rail Panels between Post 4 & 6 with plates welded to the backside on one end. Welded Plates placed at Post 4.
Panels are lapped to outside of rail at Post 6 to allow for Telescoping of the Rail Panels

29. Welded Plates on 10 Gage Rail Panel Placed at Post 4 with 12 Gage Rail Lapped over the 10 Gage Rail

30. Installing the Wood Blockouts and Guardrail
Connect Welded Plates of 10 Gage Rail with 2 Wood Blockouts to Post 4 with 2 - 5/8” x 24” Hex Bolts and Nuts with Washers under the Bolt Head and the Nut
12 Gage Slotted Rail Panels positioned 8¼” long slots at Post 4, the four (4) ¾” diameter holes are positioned at Post 2
12 Gage Slotted Rail Panels are lapped outside of the 10 Gage Rail at Post 4 so it can Telescope Properly

31. Welded Plates on 10 Gage Rail Panel Placed at Post 4 with 12 Gage Rail Lapped over the 10 Gage Rail
You start telescoping the 12 Gage Rail thru the Splice Assembly shredding the rail to begin slowing down the impacting vehicle. Then you get real serious about stopping the vehicle and begin telescoping the 10 Gage Rail thru the Splice Assembly shredding the 10 Gage Rail to finish decelerating the impacting vehicle.

32. Installing the Wood Blockouts and Guardrail
Rail Post 6 - Eight Plate Washers (top and underside of rail) and 8 SPECIAL 5/8” x 1¾” Bolts with “CAT” on the Bolt Head
Special Splice Bolts (Top 1” unthreaded with “CAT” on the top of the bolt) are utilized to allow Telescoping Action
DO NOT SUBSTITUTE Bolts with “CAT” on the Bolt Head – these Bolts are necessary to allow the Rail to Telescope upon impact

33. Special CAT Bolts and Plate Washer Connection (Top and Bottom) @ Post 6 & Properly Lapped
Special CAT Bolt and Rectangular Washer Connection to facilitate telescoping and shredding of the Guardrail to burn up the Kinetic Energy of the Crash

34. Close up photo of the Special CAT Splice Bolt with “CAT” on top
Pass around one of the special bolts with the top 1” not threaded so you can only tighten the bolt only so much. Allows the Slotted Rail Panels to Telescope through the Splice Bolt Assembly and Shred the Rail.

35. Installing the Wood Blockouts and Guardrail
Rail Post 4 - Eight Plate Washers (top and underside of rail) and 8 SPECIAL 5/8” x 1¾” Bolts with “CAT” on the Bolt Head
Special Splice Bolts (Top 1” unthreaded with “CAT” on the top of the bolt) are utilized to allow Telescoping Action
DO NOT SUBSTITUTE Bolts with CAT on the Bolt Head – these Bolts are necessary to allow the Rail to Telescope upon impact
The 8 Rectangular Plate Washer and 8 Special Bolts with “CAT” on top of the bolt and the top 1” of the shank unthreaded allow the rail panels to Telescope through the bolt and washer Assembly and shred the rail to burn up the Kinetic Energy of the Crash

36. 12 Gage Rail Panels Lapped over 10 Gage Rail Post 4 with Special CAT Bolt and Rectangular Washer Connection
12 Gage Rail Panels Lapped over 10 Gage Rail Post 4 with Special CAT Bolt and Rectangular Washer Connection to facilitate telescoping and shredding of the Guardrail to burn up the Kinetic Energy of the Crash

37. Splice Bolt Assembly Rectangular Washers on Top and Backside of Rail Panels
Even with the Special CAT Bolts tightened completely the Splice Bolt Assembly often will be a little loose. You may be able to jiggle it – this is OK.

38. Panels are suppose to be lapped to outside of rail at Post 4 & 6 to allow for Telescoping of the Rail Panels
Improperly Lapped Cannot Telescope.
The Rail will Bind Up & NOT Perform Properly

39. Installing the Wood Offset Blocks and Guardrail Spacer Channel @ Post 2
Attach the rail at Post 2 with 2 Wood Offset Blocks, using a 5/8” X 25” Post Bolt 2 Rectangular Washers and a Hex Nut
Before tightening the Rails and Offset Blocks to Post 2, install the Spacer Channel with 8 Bolts and Nuts between the rails downstream from post 2. Locate the Spacer Channel so that brace with the 1¼” diameter hole is closest to Post 2

40. Spacer Channel @ Post 2 Note Blockouts are loose – not properly Nailed @ Top

41. Post 1-3 Spacer Channel @ Post 2 and Restraint Rod @ Post 3

42. Assembling the Nose Section
Bolt the Side Plates to the end of each 12-Gage Rail Panel
Place the Tube Sleeve over Post 1 (Notched Post)
Nose Section is attached to Post 1 using a 5/8" X 25" post bolt
Narrow Wood Offset Blocks are placed between the Nose Section and the post

43. Bolt the Side Plates to the end of each 12-Gage Rail Panel

44. Tube Sleeve over Post 1 Narrow Wood Post in place

45. Assembling the Nose Section Continued
Rectangular Washers are placed between the 5/8” x 25” Post Bolt Head and Nose Section and the Hex Nut and the Nose Section. Excess threads should be cut off and peened.
Bolt the Nose Section to the side plates, using eight 5/8" X 1- ¼ “ Slice Bolts and Hex Nuts

46. Nose section Bolted to the Side Plates and 5/8” x 25” Bolt with Rectangular Washer @ Post 1

47. Nose Section in Place With Nose Section Bolted to the Side Plates & Post 1 Side Plates Bolted to Rail

48. Installing the Cable Anchor Assembly
Slide one end of the Cable through the Pipe Sleeve at the base of Post 1.
Place the Bearing Plate over the cable stud with the 5” dimension up and the 3” down
Place a Washer and Nut over the end of the Cable Assembly and tighten
Prevent the bearing plate from rotating by driving two nails along its top edge and bending them over

49. Bearing Plate not oriented properly (5” not up) and not Nailed @ Top Does have Double Nut & Washer
Bearing Plate with
2 bent nails
preventing rotation

50. Installing the Cable Anchor Assembly
Slide the other end of the Cable through the Pipe Sleeve at the top of Post 2 and then through the 1¼” diameter hole in the Spacer Channel
Place a 1” Washer over the end of the Cable Assembly and secure with a Nut and tighten on this end
Restrain the cable with vise grips to avoid twisting the cable

51. Installing the Cable Anchor Assembly
After tightening a second Nut is added to each end of the Cable Assembly to prevent loosening

52. Anchor Cable through Post 2 and Spacer Channel – Washer and Double Nut

53. Installing the Buckling Restraining Rods
Install the Buckling Restraining Rod in the slot (behind Post 5) of the 10-Gage Rail Panels and in the Slot (behind Post 3) of the 12-gage Rail Panels
The Restraining Rod is threaded on each end
A Nut, Lock Washer and another Nut is placed on each end of the Restraining Rod
The Buckling Restraining Rod helps to prevent the Guard Rail Panels from buckling out upon impact when Rail begins telescoping back thru the Shredder Bolts and Rectangular Washer Assembly.

54. Installing the Buckling Restraining Rods
The completed assembly is inserted through the Holes in the Rail Panel, with one Nut and Lock Washer on the inside of the Rail Panel and the other Nut on the outside of the Rail Panel
The Buckling Restraining Rod Assembly is placed in the smaller Slotted Hole
The outside Nuts are snugged up to the rail panels, the inside nuts are then snugged up to the inside of the rail panels.

55. Restraining Rod in Place with Nuts inside and out and Lockwashers on Inside
Without the nuts inside and out and lockwasher washer on the inside the rods can slide around and eventually fall out.

56. Restraining Rod is NOT pulled back snug and No Lockwasher on the Inside

57. Installing the Knockout Blocks and Post Plates
Connect the Knockout Blocks to the upstream side (toward the nose) of Posts 4 and 6 with two (2) 3/8" X 2" Lag Screws and a Flat Washer placed under the Lag Screw Head.
The Knockout Blocks should be installed parallel to the ground and should be located 4” down from top of the Post
Attach Post Plates to the top of Post 4 with a 5/8" X 7½” Hex Bolt and Nut
Knockout Blocks knock out the Restraining Rods

58. Knockout Blocks @ Post 4 & 6, Post Plates @ Post 4
I-64 – Cane Run Road

59. Knockout Block with Post Plates @ Post 4

60. Type IX Assembly is Complete

61. Flared Type IX in median hit Note how it gated
I-64 WB at Elkhorn Creek. The Type IX is a gating End Terminal or Crash Cushion

62. Vehicles impacting beyond LON @ Post 4 are contained and redirected in a controlled manner
These photos were taken with a flash at night on Tates Creek Rd at New Circle Rd in Lex.
You can observe how the impacting vehicle was contained and prevented from crossing the median. The Type IX performed as Designed.

63. Good Stuff to Know
Included with each CAT-350 shipment is a can containing bags of attachment hardware. These bags are individually tagged showing the location of the posts where the hardware in that bag is to be used. This is extremely helpful.

64. If there are special field conditions encountered when installing the CAT-350, contact Trinity to review the conditions

65. CAT-350 Installation Instructions
The Installation Instructions for the CAT-350 can be accessed at:
All of Trinity Highway Products can be accessed at:

66. CAT-350 Installation Manual

67. Type IX CAT-350 Approved Shop Drawing Shows everything very well

68. Q & A Time 1. See Anything Wrong?? (5)
1. Rectangular Washer
2. Cable Loose
3. Cable not double
nutted
4. Bearing Plate
upside down
I-64 EB at Midway
Left off Rectangular Washer.
Did not Double Nut Cable.
Cable not taught.
Bearing Plate not oriented properly
Bearing Plate not nailed at top.
5. Bearing Plate
Not top

69. Q & A Time 2. See Anything Wrong??
Knock Out Block
on wrong side
of Post
I-64 – Cane Run Road
Note the Knock OutBlock at Post 4 is on the wrong side of the post, it will not knock out the restraining rod as intended.

70. Q & A Time 3. See Anything Wrong?? (3)
2. No Knockout Block
3. Post Plates Rotated
Post 4
Blockout at Post 2 or Post 4 not Nailed at Top.
No Knockout Tube at Post 4
Post Plates Rotating
Post 2
1. Offset Blocks not
Top

71. Q & A Time 4. See Anything Wrong??
Post 6
Only 1 Lag Screw
& Not Tight
Only 1 lag screw not 2 as required.
Lag Screw not tight enough but does have the required washer.
Post 4
Only 1 Lag Screw
In Knockout Block

72. Q & A Time 5. See Anything Wrong??
Post 6
Improper Lap –Left - Cannot Telescope Right - OK
2. Only 1 Lag Screw
3. Post Plates Post 4
Only 1 lag screw not 2 as required.
Lag Screw not tight enough but does have the required washer.