GALVANIZED STEEL POLES, MAST ARMS, AND MONOTUBE ASSEMBLIES
649-1 Description.
The work in this Section consists of furnishing and installing galvanized steel strain poles, galvanized steel mast arms , galvanized steel monotube assemblies , and galvanized steel CCTV poles in accordance with the details shown in the Contract Documents, subject to a five year warranty period as defined herein. The warranty period will apply only when poles, mast arms or st eel monotube assemblies are painted as called for in the Contract Documents.
649-2 Materials.
649-2.1 Pole Assembly: Use pole assemblies as shown in the Standard Plans when
standard mast arm assemblies , standard strain pole assemblies , or standard steel CCTV pole assemblies are required by the Contract Documents. Obtain poles, mast arm, and monotube assemblies from a fabrication facility that is listed on the Department’s Production Facility Listing. Producers seeking inclusion on the list shall meet the requirements of Section 105. Use coating products meet ing the requirements of Section 975. Use grouts meeting the requirements of Section 934 and listed on the Department’s Approved Product List (APL). Use water meeting the requirements of Section 923. Use membrane curing compounds meeting the requirements of Section 925.
649-2.2 Camera Lowering Device: Meet the requirements of 641 -2.2.
649-3 Fabrication.
Fabricate poles, mast arm, and monotube assemblies and miscellaneous hardware in accordance with the Contract Documents. Cut all materials to the final dimensions and complete all welding prior to galvanizing. Obtain all components for individual strain poles, mast arm and monotube assemblies from the same fabricator. Obtain the lumina ire and bracket from other sources, when necessary. Affix an aluminum identification tag which will be visible from the handhole or located inside the terminal box containing the information described in the Standard Plans . Before shipping, assemble monotube assemblies to assure proper fit. Monotube assemblies may be separated for shipment. For mast arms, use adequate manufacturing controls to assure proper fit, ensuring dimensional tolerance s are met and that mast arm to pole connections can achieve a snug -tight condition as defined in 649 -7. Ensure all components are protected from damage during shipping and handling by wrapping or other effective methods. Replace any component, which the Engineer determines is damaged beyond repair, at no additional cost to the Department. If components are wrapped for shipment, remove wrappings no later than five days after receipt of components or immediately if the wrappings become saturated. Post these instructions in brightly colored wording on the wrapper. Failure to comply with these instructions may lead to damag e of the coating system and will be cause for the rejection of the component. FY 2023-24 Return to Table of Contents
649-4 Coatings.
649-4.1 Galvanizing: Galvanize all components in accordance with ASTM A123, except
galvanize all fastener assemblies in accordance with Section 962. Use galvaniz ing methods which provide surfaces suitable for painting.
649-4.2 Surface Preparation: Prepare all galvanized surfaces to be painted in
accordance with ASTM D6386 and the manufacturer of the coating system’s specifications. Provide a clean and suitable ga lvanized surface that maximizes coating system adhesion. Measure the thickness of the zinc coating after completion of surface preparation using a magnetic thickness gage in accordance with ASTM A123. Ensure sufficient galvanizing remains on the substrat e to meet the requirements of ASTM A123 and the Contract Documents. Correct any deficient areas to the satisfaction of the Engineer at no additional cost to the Department.
649-4.3 Painting:
649-4.3 1 General: When required by the Contract Documents, pr ovide painted
poles, mast arms and monotube assemblies. Provide products from a fabricator on the Department’s list of Prequalified Painted Galvanized Steel and Aluminum Products Fabricators List. Provide products that will meet specification requirements throughout the warranty period. Meet the color requirement as specified in the Contract Documents. Provide the Engineer with two metal sample coupons, a minimum of 2 inches by 4 inches, painted concurrently and with the same paint as was used on the first LOT of any poles, mast arms and monotube assemblies delivered to the jobsite. Submit sample coupons and manufacturer product data sheets to the Engineer along with the delivery of the first shipment of any painted poles, mast arms or monotube assemblies de livered to the jobsite. At the time of their delivery, the sample coupons described in this paragraph shall match the color of the poles, mast arms and monotube assemblies to within 1ΔE when measured as specified in 975 -4. The Engineer will perform a visual color comparison between the delivered products and sample coupons. The Engineer may evaluate and document any color difference by measuring as specified in 975 -4. If the delivered sample coupons exhibit a difference in color from the poles, mast arms and monotube assemblies greater than 1ΔE then the sample coupons will be considered unacceptable and no payment shall be made for the materials which the sample coupon s represent. Those materials shall not be accepted by the Department until acceptable representative sample coupons in accordance with the requirements of this Section have been submitted to the Engineer.
649-4.3 2 Responsible Party Warranty: When the Co ntract Documents call for
painted galvanized steel poles, mast arms or monotube assemblies, the Contractor shall designate a responsible party to accept responsibility. The responsible party designated by the Contractor must execute and submit to the Depar tment a form, provided by the Department, prior to the first delivery to the jobsite of any painted poles, mast arms or monotube assemblies, stipulating that the responsible party accepts responsibility for ensuring the coating system adhesion and color retention requirements as specified in 975 -4 are met for a period of five years after final acceptance in accordance with 5 -11. The responsible party shall also bear the continued responsibility for performing all remedial work associated with repairs of any adhesion or color retention failure as defined in Section 975, as to which notice was provided to the responsible party within the five-year warranty period. Failure to timely designate the responsible party will result in the Contractor being the respons ible party unless otherwise agreed to in writing by the Department. The responsible party shall be either the Contractor or the fabricator. When the responsible party is the fabricator, the responsible party shall be one of the fabricators listed on FY 2023-24 Return to Table of Contents the Prequalified Painted Galvanized Steel and Aluminum Products Fabricators List . This list may be viewed on the Department’s website at the following URL: https://www.fdot.gov/c onstruction/Engineers/PaintedPoleSuppliers.shtm Upon final acceptance of the Contract in accordance with 5 -11, the Contractor’s responsibility to ensure that the coating system adhesion and color retention requiremen ts specified in 975 -4 will terminate. The obligations of the responsible party set forth in this Section shall start at final acceptance of the Contract in accordance with 5 -11 and continue thereafter until expiration of the five-year warranty period.
649-5 Remedial Work.
During the painting warranty period, the responsible party shall perform all painting remedial work necessary to meet the requirements of this Specification at no cost to the Department. Such remedial work shall be performed within 180 days of notification of a failure by the Department or by the determination of the Statewide Disputes Review Board . Failure to perform such remedial work within the time frame specified will result in the work being performed by other forces at the responsib le party’s cost. If the responsible party is the fabricator, the fabricator will be removed from the Prequalified Painted Galvanized Steel Poles and Aluminum Products Fabricators List for a minimum of six months or until payment in full for the correction of the deficiencies or defects has been made, whichever is longer. If the responsible party is the Contractor, the Department will suspend, revoke , or deny the responsible party’s certificate of qualification under the terms of Section 337.16(d)(2), Florida Statutes, for a minimum of six months or until payment in full for the correction of the deficiencies or defects has been made, whichever is longer.
649-6 Statewide Disputes Review Board.
The Statewide Disputes Review Board in effect for this Contract will resolve any and all disputes that may arise involving administration and enforcement of this Specification related to the painting remedial work performed during the warranty period . The Responsible Party and the Department acknowledge that use of th e Statewide Disputes Review Board is required, and the determinations of the Statewide Disputes Review Board for disputes arising out of this Specification will be binding on both the Responsible Party and the Department, with no right of appeal by either party. Meet the requirements of 8 -3.
649-7 Installation.
Install foundations in accordance with Section 455. Do not install poles, mast arm poles, or monotubes until the foundation has achieved 70% of the specified 28 -day concrete strength and verifying t est results have been submitted to the Engineer. Determine concrete strength from tests on a minimum of two test cylinders prepared and tested in accordance with ASTM C31 and ASTM C39. Before erecting the pole, clean the top of the foundation of any laitan ce, oils, grease or any other deleterious materials. Erect strain poles in an orientation which considering the rake and the application, cable forces will produce a plumb pole. Erect monotubes plumb at the time of installation. Plumb the pole supporting m ast arms after the mast arms, traffic signals or sign panels have been placed. If the traffic signals and/or sign panels are not in place within two working days after the mast arm is erected, furnish and install a 3 foot x 2 foot blank sign panel on the bottom of each FY 2023-24 Return to Table of Contents mast arm within 6 feet of the mast arm tip and plumb the pole. Re -plumb the pole supporting mast arms after installation of traffic signals and sign panels. Install ASTM F3125, Grade A325 bolt, nut and washer assemblies in accordance with the following. Use bolt, nut and washer assemblies that are free of rust and corrosion and are lubricated properly as demonstrated by being able to easily hand turn the nut on the bolt thread for its entire length. Tighten nuts to a snug -tight condition to bring the faying surfaces of the assembly into firm contact with plies solidly seated against each other, but not necessarily in continuous contact . Snug-tight is defined as the maximum nut rotation resulting from the full effort of a person using a n ordinary spud wrench. Visually inspect the connection after snugging all bolts, ensuring firm contact has been achieved at a minimum between faying surfaces beneath bolts within one bolt diameter of bolt hole edges. Re-snug bolts in a connection where faying surfaces are not in firm contact. After bringing the faying surfaces to a snug -tight condition, tighten nuts in accordance with Table 460-7, Nut Rotation from the Snug -Tight Condition. Maintain as close to uniform c ontact pressure as possible on the faying surfaces during snugging and turn-of-nut process by utilizing suitable erection methods and a bolt tightening pattern that balances the clamping force of each bolt, as closely as possible, with the equal clamping f orce of a companion bolt. Base plate installation steps are as follows:
1.Clean and lubricate the exposed threads of all anchor bolts. Clean and lubricate the threads and bearing surfaces of all leveling nuts. Re -lubricate the exposed threads of the anchor bolts and the threads of the leveling nuts if more than 24 hours has elapsed since earlier lubrication, or if the anchor bolts and leveling nuts have become wet since they were first lubricated.
2.Verify that the nuts can be turned onto the bolts past the elevation corresponding to the bottom of each in -place leveling nut and be backed off by the effort of a person using an ordinary spud wrench, without employing a pipe extension on the wrench handle.
3.Turn the leveling nuts onto the anchor bolts and align the nuts to the same elevation less than or equal to one bolt diameter from the top of the foundation .
4.Place structural plate washers on top of the leveling nuts; one washer corresponding to each anchor bolt.
5.Install the base plate onto the leveling nut washers, place structural plate washers on top of the base plate; one washer corresponding to each anchor bolt, and turn full or half-size anchor nuts onto the anchor bolts.
6.Tighten anchor nuts against the top of the base plate t o a snug-tight condition in a star pattern. A star tightening pattern is one in which the nuts on opposite or near opposite sides of the bolt circle are successively tightened in a pattern resembling a star. For an 8 bolt circle with bolts sequentially numbered 1 to 8, tighten nuts in the following bolt order: (1, 5, 7, 3, 8, 4, 6, 2).
7.Tighten leveling nuts to a snug -tight condition in a star pattern. The distance from the bottom of the leveling nuts to the top of the concrete must not exceed one anchor bolt diameter after tightening .
8.Tighten each full -size retainer nut until it is in firm contact with the top surface of the anchor nut; then while preventing the anchor nut from rotating, tighten the retainer nut until it is snug tight using a star pattern. Before final tightening of the retainer nuts, mark the reference position of each snug -tight nut on one flat with a corresponding reference mark on the FY 2023-24 Return to Table of Contents anchor nut and base plate on each bolt. Then w hile preventing the anchor nut from rotating, incrementally turn the retainer nuts using a star pattern until achieving the required nut rotation specified in Table 649-1. Turn the nuts at least two full tightening cycles (passes). After tightening, verify the nut rotation. Do not exceed the Table 649-1 value by more than 20 degrees.
9.Install a screen over the gap between the base plate and foundation concrete in accordance with 649 -8, or place a structural grout pad in accordance with 649 -9. Table 649-1 Anchor Bolt Diameter (inches) Nut Rotation from Snug -Tight Condition ≤ 1-1/2 1/3 turn > 1-1/2 1/6 turn
649-7.1 Camera Lowering Device Installation: Meet the requirements of 641 -4.4.
649-8 Screen Installation.
On steel strain poles and steel monotube assemblies, install a screen that will prevent vermin and debris from entering the gap between the bottom of the base plate and the top of the concrete foundation. Cover the entire gap with a wire screen, the bottom horizontal wire of which shall be in full contact with the surface of the concrete foundation and the top horizontal wire of which shall not extend beyond the top surface of the base plate. For the screen, use standard grade plain weave galvanized steel w ire cloth with 1/2 inch x 1/2 inch mesh and 0.063 inch diameter wires. Vertical screen wires shall not extend beyond the top and bottom horizontal wires of the screen. Use one continuous section of screen with only one overlapping splice where the ends com e together and overlap the layers 3 inches minimum. Attach the screen to the vertical side of the base plate with self -tapping stainless steel screws (No. 8, 1/2 inch long) with stainless steel washers (1/4 inch inside diameter). Drill pilot holes into the base plate to facilitate screw installation. Install screws on 9 inch centers maximum and at least one screw shall be installed through the overlapping splice to clamp the layers together. Also clamp the overlapping splice layers together just above the c oncrete foundation with an all stainless steel fastener assembly consisting of a machine screw (No. 8, 5/8 inch long), nut and two flat washers (1/4 inch inside diameter) and lock washer. Tightly clamp the screen layers between the flat washers.
649-9 Structural Grout Pads.
On mast arm support structures, install a structural grout pad in accordance with the Standard Plans and manufacturer’s instructions. Prior to grout placement, flush the top of the foundation with water to remove any dirt and debris. Mix grout to a fluid state in accordance with the manufacturer’s recommendations. Test the grout fluidity using ASTM C939 Flow Cone Method. Discard any grout with an unacceptable efflux time. Do not use mechanical means to push or vibrate the grout. Clean any excess grout from the base plate. Verify that water inside the pole will drain freely through the installed drain hole.
649-10 Method of Measurement.
The Contract unit price each for poles, mast arms, and monotube assemblies, furnished and installed, will include all materials specified in the Contract Documents, including the FY 2023-24 Return to Table of Contents foundation, cover plates, caps, clamps, blank sign panel, luminaire bracket, all labor, equipment, miscellaneous materials and hardware necessary for a complete and acceptable in stallation. The Contract unit price for removal of poles, mast arms, and monotube assemblies will include the removal of all attachments (arms, vehicle signals, light fixtures, pedestrian signals, pedestrian detectors and other incidentals). When removal of the pole and partial foundation removal is called for, remove the pole, foundation, and all accessories or attachments (including pole keys, dead men, guying apparatus, conduit, anchor bolts and reinforcing steel) to a minimum depth of four feet below existing grade. When removal of the pole and complete foundation removal is called for, completely remove the pole including the foundation and all accessories or attachments as listed above.
649-11 Basis of Payment.
Price and payment will be full compensation for all work specified in this Section. Sign panels and si gnal assemblies will be paid for separately. Payment will be made under: Item No. 649 - Steel Mast Arm Assembly - each. Item No. 649 - Steel Monotube Assembly - each. Item No. 649 - Steel Strain Pole - each. Item No. 649- Steel CCTV Pole - each. FY 2023-24 Return to Table of Contents SECTION 650 VEHICULAR TRAFFIC SIGNAL ASSEMBLIES
650-1 Description.
Furnish and i nstall vehicular traffic signal assemblies as shown in the Plans and Standard Plans. For additional requirements rel ated to mounting and attaching the assemblies , see Section 659.
650-2 Materials.
Use vehicular signal assemblies that meet the requirements of Section 995 and are listed on the Department’s Approved Product List (APL). Vehicular traffic signal assemblies must meet the requirements of Section 603 and the I nstitute of Transportation Engineers (ITE) Standard for Vehicle Traffic Control Signal Heads. Provide vehicular traffic signal assemblies as a complete and functioning unit. Components include, but are not limited to, signal housing, light emitting diode (LED) signal modules, visors, backplates, and assembly hardware. All sections of multi -section assemblies must be from the same manufacturer.
650-3 Installation.
650-3.1 Preassembly: Pre-assemble the signal heads when more than one signal section
is required prior to installation at the site. Furnish signal heads with LED modules, backplates, and visors. Use tunnel visors unless otherwise specified in the Contract Documents. Install the LED circular module in the door so that the UP arrow or the word UP o r TOP is in the up orientation of the signal housing. Install the LED arrow modules in the signal housing door in the direction of the intended use.
650-3.2 Positioning of Signals: Consider the locations of the installed signals as shown
in the Plans as sufficiently flexible as to allow for unanticipated field conditions at the site. The Engineer will direct any variations from the locations shown. Position adjacent signal faces no closer than 8 feet apart measured horizontally at 90 degrees to the traffic flow between centers of faces. Regardless of the results of any scaled dimensions, consider the location shown in the Plans to be approximate. Position a signal face mounted on a span wire or mast arm as near as practical to the line of the driver’s nor mal view. Ensure that all sections are of the same manufacturer and the section assemblies are uniform in appearance and alignment.
650-3.3 Clearances: Unless directed otherwise by the Engineer for unusual
circumstances at the site, provide a vertical c learance of not less than 17 feet-6 inches and not more than 19 feet for traffic signals placed over the roadway. Measure such clearance for each span directly under the most critical signal assembly (in regards to clearance) for that span. Place signal assemblies on each span as near as practical to the same elevation as the critical signal assembly. Ensure that the lowest point on pedestal -mounted and side -mounted signal heads is 12 feet above finished grade at the point of their installation.
650-3.4 Aiming of Signal Indication: For proper lateral orientation, aim signals after
installing and before locking them in position. FY 2023-24 Return to Table of Contents
Source: Florida Standard Specifications for Road and Bridge Construction, 2024 Edition. Pages 880–885 of 1,299.