be designed to attach to the pole as shown on the plans. The pole shall include the mounting accommodations as shown on the plans.
The poles shall be tapered shafts having poly-sided or circular cross-sections. The pole shaft sections shall be slip fitted and shall provide at least 1 in. radial clearance from all interior devices. All tower shaft components shall be fabricated from high strength, low alloy, steel in accordance with AASHTO M 270; ASTM A5 95, grade A or B; ASTM A572, grade 220 55; ASTM A1011; ASTM A606, or ASTM A656, with a minimum yield strength of 50,000 psi. Sections which are slip fitted shall have slip joints with a minimum overlap of 1.5 times the diameter of the bottom of the upper section at the slip joint. Towers having slip joint construction shall be match marked at the factory and shall be shipped disassembled for assembly at the work site. Slip joints shall be marked to ensure that the 1.5 times diameter insertion is provided. All steel used in the base plate and shaft shall meet an impact property of 15 ft·lb 230 at 40°F in the longitudinal direction using the Charpy V-Notch test. This shall be an average of three tests per mill heat with no test below 10 ft·lb. A copy of the certified mill test reports for this steel and the Char py V-Notch test results shall be submitted. Sufficient information shall be furnished to demonstrate that this material is traceable to the mill heat number shown on the test report.
All tower shaft hardware including hardware for the handhole door, and the latch mechanism shall be stainless steel in accordance with ASTM A276, type 304 or 305, except where otherwise specified. 240 After fabrication, the pole shall be cleaned and galvanized . Galvanized steel towers, including the handhole, handhole door, base plate, mounting plate, and all other elements welded to th e shaft shall be hot-dip galv anized in accordance with AASHTO M 111 or ASTM A123. 2 . W e l d i n g The welding symbols and all information regarding location, type, size, welding sequence, and welding procedure specifications shall be shown on the working drawings. 250 Welds shall be smooth and cleaned of flux and spatter in accordance with AWS procedure. Minimum preheats for welds shall be 100°F for seams, and 225°F for circumferential welds. All welds shall be performed at the factory. Circumferential welds shall be backed-up welds with 100% penetration. Longitudinal welds shall have a minimum of 920.01 1152 60% penetration except within 2 ft of either side of the circumferential joint, the welds shall be backed-up and of 100% penetration. Base plate welds shall be 100% penetration. Circumferential welds and 100% penetration longitudinal welds shall be 100% ultrasonically inspected. The 60% penetration longitudinal welds shall be 100% 260 ultrasonically or radiographically inspected for soundness. Welding shall be performed in accordance with 711.32. Weld filler shall provide Charpy V Notch equal to or greater than 20 ft·lb at 0°F.
The manufacturer shall provide quality control, QC, inspection. The inspector shall be an AWS CWI, in accordance with AWS D1 .1. The NDT inspector shall be an independent non-destructive-testing inspector, certified as level II in RT, UT, or MT, or all as applicable. Copies of the inspection reports and NDT reports shall be provided to the Engineer. 270
The method for testing full penetration and partial penetration welds by the independent welding inspector shall be the same as specified above. b . B l a n k
Openings for handholes shall be reinforced to maintain the design strength of the pole. The handhole shall have a weatherproof gasket made of neoprene or silicone rubber. The gasket shall be formed for a forced fit around the handhole or be attached 280 by mechanical means. The door and hinges shall be the same type steel as the poles. The hinge pins and other securing hardware shall be stainless steel and tamperproof. The door shall be fabricated to allow for a padlock, which is not included in the hardware. The hasp used for padlocking shall be fabricated from stainless steel. Provisions shall be made to bolt the door securely shut. The door shall include a bugproof and weatherproof aperture with a minimum opening of 4 sq in. Nylon or non-corrosive screens, or other approved methods of bug proofing shall be furnished. Two bonding plates shall be furnished whic h are accessible through the pole handhole for connecting the ground wires. A connecti on shall be furnished for an additional ground wire on the outside of the pole near the base plate. 290
The ring shall be fabricated from ASTM A666, Type 304 stainless steel and shall have a removable raceway cover. The ring sh all be fabricated as an enclosed wire raceway to provide for the symmetrical mo unting of the luminaires. All structural connections shall be made with bolts and nuts. The luminaire ring shall be supported by means of stainless steel aircraft cables of seven strands with 19 wires per stra nd with a minimum breaking strength of 3,700 lb. 300
Luminaire rings shall be provided with either 6 or 12 - 2 in. diameter pipe fittings for luminaire attachment. The number of luminaires and their positions on the ring will 920.01 1153 be shown on the plans. Counterweights that provide an even weight distribution shall be installed on pipe fittings where luminaires are not shown.
required pulleys, rollers, or sheaves and shaf ts shall be constructed from non-corrosive metallic materials. No component shall be used in the lowering device in excess of its 310 rating or in violation of the component manufacturer’s recommendation. This requirement shall be applicable, but not limited to, the compatibility of the cables and sheaves. There shall be three supports for the suspension cables. A roller system or one compatible sheave for the power cable sh all be located mid-point between two of the suspension supports. To prevent the cables from riding out of the grooves, cable guides shall be provided. The suspension cable sheaves shall have a minimum pitch diameter of 3 1/2 in. and the power cable sheave or individual rollers in a roller assembly shall have a minimum pitch diameter of 18 1/2 in. and shall be grooved to fit the power cable. 320 All components at the top of the pole shall be protected from the weather by a dome fabricated from steel in accordance with 920.01(b)1, fiberglass, or spun aluminum.
The dome shall be secured to the head frame assembly w ith at least eight fasteners around the perimeter of the dome. The dome shall be reinforced at the points of attachment and it shall be fitted to the head frame assembly so that no visible distortion occurs to the dome when it is properly in stalled. The dome attachment shall be designed to withstand pole vibration, ot her pole movement, and the design windload. The fiberglass dome shall be made of material that is not subject to cracking or other 330 deterioration because of aging.
strands with 19 wires each strand with a minimum breaking strength of 9,800 lb. The winch shall have a drum with a minimum diameter of 4 in. and drum flanges with a minimum diameter of 8 in. The drum shall be supported at each end by a rigidly mounted, permanently lubricated, bearing capable of carrying the design load. The winch drum shall be designed to allow the cable to lay in even consecutive layers. 340
The winch shall be driven by a self-locking, worm gear reducer. The gear reducer shall be permanently lubricated and totally enclosed in a cast aluminum or cast iron housing. The winch assembly shall be powered by an external drive system.
The external drive system shall be powered by a heavy duty reversing NEMA frame motor with an electromagnetic friction breaking mechanism rated at a minimum of 6 ft·lb of torque per motor horsepower (746 W). The brake shall be actuated each 920.01 1154 time the power to the motor is interrupted. The breaking mechanism shall be an 350 integral part of the motor housing. The motor operated drive shall have a factory set torque limiter or clutch. This clutch assembly shall be calibrated to position the ring at the top of the pole and not exceed 80% of yield strength of the cable. The external drive system shall operate with the 240/480 AC volt power available at the pole or incorporate a tr ansformer into the system. Th e external drive system may use either the luminaire power plug or a separate outlet with a 600 volt, 30 ampere rating. The external drive system shall be operated from a minimum distance of 25 ft from the pole. The control voltage for any handheld control equipment shall not exceed 120 volts. The handheld control equipment shall be shock proof. 360 The external drive system shall be cap able of operating all high mast pole installations. Working drawings shall be furnished in accordance with 105.02 and shall include the dimensions and the wiring diagram of the standard connections of the external drive system. The ex ternal drive system shall be mounted on a two-wheel cart with wheels at least 12 in. in diameter and the weight shal l be distributed so that it presents a balance load. 8. Cable Terminator The three luminaire ring support cables shall be attached to three stainless steel 370 helical compression springs incorporated into the cable terminating device. These springs shall be designed to compensate for inequalities in the cable lengths and to maintain adequate tension on the support cables through pole and cable thermal expansion and contraction.
The cable terminator shall incorporate a separate eye bolt on the bottom of the device for the attachment of a cable or ch ain to hold the luminaire ring in a raised position while the winch cable or winch assembly is being inspected or repaired. The cable terminating device shall be designed to prevent the device from catching on the slip joint of the structure. 380
The lightning rod, air terminal, shall shield the head frame assembly cover and the outer edge of the luminaires within a 45° electrostatic shielded cone. The grounding system shall include bonding plates, grounding clamps, four copper weld grounding rods, a grounding conductor, air terminal, lightening rod, and other incidental connectors. All hardware shall be stainless steel, brass, copper, copper alloy, or equally corrosion-resistant metal. Bonding plates, with a minimum contact surface area of 8 sq in., shall be installed 390 at locations shown on the plans. The bonding plates shall be welded to the tower shaft during the time of manufacturing. The grounding conductor shall be secured to the bonding plates by a two-bolt pressure plate clamp connector having a minimum of 4 in. of contact with the copper. At the point of termination, the grounding conductor shall extend beyond the bonding plate a minimum of 3 in. 920.01 1155 Each ground rod clamp shall have a minimum of 1 1/2 in. of contact between the grounding conductor and the ground rod. The grounding conductor shall be continuous between the bonding plates inside the tower shaft handhole and the grounding rod termination point. 400 Bends of conductors shall form an angle of 90° or more. Unsupported conductors shall have a radius of bend 8 in. or greater.
shall be a hooked deformed reinforcing bar or a hooked smooth bar. The bolts shall be in accordance with ASTM A615 modified to a minimum yield stre ngth of 75,000 psi. The top 12 in. of each anchor bolt, nut, and washer shall be hot-dip galvanized in accordance with ASTM A153 or be mechani cally galvanized and in accordance with 410 the coating thickness, adherence, and quality requirements of ASTM B695, class 55. (c) Wire and Cable Lighting circuit cables for direct burial shall be enclosed in polyethylene conduit.
This conduit shall be in accordance with ASTM D3485 either medium density Type II, class C or high density Type III, class C smooth wall, coilable polyethylene conduit for preassembled wire and cable. The diameter of the conduit shall be 1 1/4 in for the standard 4-No. 4 conductor cable. 420
The cable shall consist of four separate electrically insulated conductors installed in the duct so any one conductor may be ea sily removed without damage to the other two. The conductors shall not be cabled or twisted together. The conductors shall be stranded copper of the No. 4 AWG size. Conductors shall be stranded in accordance with ASTM B8, class B. Each conductor shall be insulated with crosslinked polyethylene manufactured in accordance with Insulated Power Cable Engi neer Association standard WC 70/ICEA 430 S-95-658-1999, Nonshielded 0-2kV Cables . Each conductor shall have a 600-volt rating, be UL listed, and have an XHHW conductor temperature rating not to exceed either 90°C in dry conditions and 75°C in wet conditions. Each of the four conductors shall be imprinted at regular intervals with the following description: Type XHHW; 600 volt; UL; the conductor’s AWG size and metal or alloy; the manufacturer’s name, trademark, or other distinctive marking by which the product can be readily identified. Identification coding of the conductors shall be accomplished by complete color 440 coding. Color coding of the insulation shall be homogeneous throughout the entire 920.01 1156 depth and length of the jacket. The colors shall include one black, one white, one red, and one green.
This wiring shall consist of two 1/C No. 10 AWG, 600 volt, THWN or MTW insulation, stranded copper wire. 4. Sign and Underpass Wiring The wiring from the switch box to the last luminaire shall be 3/C copper stranded 450 No. 10 AWG conductors and shall have imprinted at regular intervals along the length of the insulation jacket the following designation: No. 10 AWG, type MTW or THWN, or Gasoline and Oil Resistant II or AWM, 600 volt, UL. The conductor classifications shall be UL listed and have the following minimum temperature ratings: MTW 90°C, THWN 75°C, and AWM 105°C. It shall be installed in 3/4 in. conduit between the breaker box and luminaires.
conductor shall be No. 6 AWG stranded copper with 600 volt, XHHW-XLP type insulation.
The power cable shall be a 4/C No. 10 AWG copper insulated electrical cable Type “SO” modified for a repetitive reeling operation. It shall be in accordance with 470 ASTM B3, ASTM B173, and IPCEAS-19-83. Conductor insulation shall be in accordance with ASTM D1693 and IPCEAS- 19-81, Paragraph 3.12. The sheath or jacket shall meet or exceed IPCEAS-19-81, Paragraph 7.6.20.1.1. Conductors shall be color coded. The power cable shall have a heavy-duty 600 volt, AC 30 amp rated electrical plug capable of disconne ction in a safe manner under load conditions. The electrical plug shall be moisture resistant and waterproof at both transition points.
Connectors shall be a compression type of the proper size with only one conductor per groove in the fitting. They shall be designed specifically for use on aluminum and copper conductors, prefilled with an oxide inhi bitor, and installed with a hydraulic tool according to the manufacturer’s specifications . After installation, the connectors shall be fully insulated and weatherproofed. The connectors installed in underground handhole shall be taped and then waterproofed as shown on the plans. 920.01 1157 (d) Luminaires Underpass, Roadway, and High Mast models shall be selected from the QPL of Luminaires. 490
the plans. Luminaires, including primary fuse protection, surge protection devices, power drivers, and other major components, shall be rated for a minimum operational life of 50,000 hours at 77°F. Luminaires shall be a single, self-contained device, not requiring on-site assembly for installation. Connectors shall be crimp or cage-clamp type. 500 All internal components shall be adequately supported to withstand mechanical shock and vibration. Luminaires shall be tested in accordance with ANSI C136.31, 2G loading or ANSI C136.31, 3G loading for luminaires on bridges. Testing about all axes shall be accomplished with a single luminaire. Luminaires shall include gasketing that will completely seal out dust, moisture, and insects from the interior of the optical assembly and retard the formation of an undesirable film from gaseous vapors on the interior of the optical assembly. The optical assembly shall be rated at IP 66 or better in accordance with ANSI/IEC 60529. Power drivers, and surge protection devices shall be rated at IP 65 or better. 510 Light sources supplied for luminaires shall be electrically compatible with the luminaires. Luminaires shall include an integrally built-in power driver. The luminaire shall operate satisfactorily in temperatures from -40°F to 122°F with an input voltage variation of ±10% of the rated operating voltage specified. Power consumption, wattage, shall not exceed that which is show n on the plans. The lu minaire power factor shall be 0.9 or greater. The power driver, or combination of power drivers if more than one is used in the luminaire, shall have a Mean Time To Failure, MTTF, of 1,000,000 hrs as determined 520 by Telcordia SR 332, Issue 3 or MIL-HDBK-217F methodology. The MTTF estimate shall be for the driver as a complete and functioning unit. Total Harmonic Distortion, THD, of the power driver shall not exceed 20% as verified by ANSI C82.77. Roadway lighting luminaires shall have a precision-cast aluminum housing with weatherproof finish. Refractors or lenses shall be scratch resistant and made from high impact, heat-resistant glass, or UV inhibited, high impact polycarbonate plastic. If utilized, reflectors shall be detachable and made of highly specular aluminum. 530 Luminaires shall have seven wire photocontrol receptacle in accordance with ANSI C136.41 with shorting cap for adaptive lighting control. 920.01 1158 Luminaires shall exhibit a color temperature in the range of 3500K to 4500K per ANSI C78.377 and a minimum Color Rendering Index of 70 as verified by the IESNA LM-79 test. A Surge Protection Device, SPD, shall be included to protect the luminaire from damage and failure from transient voltage and currents. The SPD shall conform to UL 540 1449 and shall be tested in accordance with, and survive, the procedure in ANSI/IEEE C62.41.2 definitions for standard and op tional waveform for location category C- High. Once the surge current has subsided, the SPD shall automatically restore normal operation and reset to a state ready to receive the next surge. Luminaires shall comply with Title 47 CFR Part 15, Class A on unlicensed transmissions in a business, commercial, or industrial environment.
Underpass and post top mounted luminaires shall be protected against salt spray and conform to ASTM B117, 2,000 hrs time horizon. 550 Luminaires shall include vandal shields when installed on an underpass or signs on bridge brackets and when otherwise specified. The vandal shield shall be made of a tough durable plastic, such as Lexan, mounted in a rugged galvanized steel or aluminum frame, and shall withstand severe impact without being damaged or allowing the refractor to be damaged. It shall be fastened securely to the luminaire so it cannot be removed from the outside and shall not interfere with the light distribution pattern. It shall protect the face of the refractor and if ventilation is necessary, the ventilating apertures shall be arranged so that they do not admit a probe of a diameter greater than 1/4 in. 560 Luminaire shall be aimable toward the required direction.
LEDs shall be connected so that the loss of one LED will not result in the loss of the entire luminaire. LED circuitry shall prevent flickering to the unaided eye at the voltage specified on the plans and the range indicated herein. LEDs shall deliver a minimum of 85% of the initial rated lumens after 50,000 hours of operation at 130°F ambient temperature as indicated by LM-80 lumen 570 maintenance test of the light source as calculated by IESNA TM-21, L85 > 50,000 hrs. A passive thermal management system to dissipate the heat generated by operation shall be provided. Fans or other mechanical cooling systems shall not be used.
The thermal management system shall maintain temperatures during the operation of the luminaire to be within the limits established by the Power Driver Lifetime and LM-80 testing. 580 920.01 1159 b. Light Emitting Plasma Luminaires Plasma emitters shall deliver a minimum of 70% of the initial lumens after 50,000 hrs of operation.
against vibration. 590
bolt slipfitter capable of adapting to a 2 in. mounting bracket that is adjustable ±5° for leveling. Luminaires shall be adjustable in the horizontal and vertical directions to meet the specified IESNA light distribution pattern. Luminaire weight shall not exceed 53 lb and its projected area shall not exceed 2.4 sq ft. 600
Sign and underpass luminaires shall be LED and operate on no more than 150W of power. Sign luminaires shall have a shield that blocks the view of the refractor from an approaching motorist. This shall be accomplished by the design of the housing or by a shield fabricated from sheet aluminum, approximately 0.05 in. thick, and of sufficient size to be fastened onto the horizontal edge of the refractor holder with self tapping screws and placed between the refractor and approaching traffic. Aluminum and steel structural members for luminaire supports shall include 610 aluminum conduit, conduit clamps, fittings, and stainless steel screws.
All circuit breaker enclosures shall be NEMA 4/5. 1. Circuit Breakers for Type II Service Point The cabinet and hardware shall be weatherproof and rain tight. The enclosure shall have provisions for padlocking. The fastener and mounting hardware shall be plated brass, stainless steel, or aluminum. The enclosure shall be made of 14 gauge aluminum, or 14 or 16 gauge stainless steel. The circuit breaker operating handles for 620 manual tripping shall be concealed inside the enclosure. Computation of branch circuits shall be based on the National Electrical Code Standard Limitation of loading breakers to 80% of their rated current. Additional details shall be as shown on the plans. 920.01 1160 2. Circuit Breakers fo r Sign and Underpass Circuits Sign and underpass circuit protection shall be provided by two single pole, 240 volt AC, 120 volt for 120/240 volt service, circuit breakers with ampere rating of 200% of the normal load. The circuit breakers shall have provisions for padlocking 630 externally. The circuit breaker operating handles for manual tripping shall be concealed inside the enclosure. The enclosur e shall be made of aluminum or stainless steel. Additional details shall be as shown on the plans.
The enclosure shall be furnished with two single pole, 30 ampere, 480 volt AC circuit breakers with a minimum symmetrical RMS interrupting capacity of 14,000 amperes. The breakers shall be accessible through the pole handhole. The circuit breaker operating handles for manual tripping shall be external to the enclosure. The enclosure shall be made of aluminum or stainless steel. Additional details shall be as 640 shown on the plans.
These breakers shall have the following features:
temperature changes over their operating environment of -40°F to 185°F,
the ON position.
Multiple relay switches with photocell receptacles shall have a two-pole relay for 660 connection to a 120/240 or 240/480 volt, three-wire, single phase, 60 Hz power supply. The relay switch components shall match the service voltage being supplied. The unit shall contain two single pole circuit breakers with a minimum rated capacity to withstand 100% of the rated ampere load. The circuit breakers shall trip at not less than 125% of the rated load capacity. Control circuit arresters for lighting protection and a manual control selector switch shall be included within the unit. The enclosure shall be a cast aluminum weatherproof case, with a hinged cover, having provisions for padlocking and a hanger for pole or wall mounting.
A Type C certification in accordance with 916 shall be provided for the materials in this section unless otherwise specified. 920.01 1161
The junction box shall be polymer concrete , of concrete-gray color, with a cover rating of 20,000 lb. (i) Handholes Handholes shall be in accordance with 922. 17 except the cover shall be with the logo imprint of “LIGHTING”. 680