920HIGHWAY ILLUMINATION MATERIALS

920.01Highway Illumination Materials

All luminaires, lamps, fuse kits, wire and cable, and major equipment shall be approved new material bearing the UL seal of approval or meet their standards.

Descriptive and technical literature shall be furnished for approval on all equipment prior to purchase and incorporation into the work.

Warranties for all major equipment shall be in accordance with 807.02. 10

Conventional light poles shall be aluminum or steel and shall be in accordance with AASHTO LRFD Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals.

For conventional light poles, design wind velocity shall be 120 mph. The maximum horizontal deflection of the pole under maximum loading conditions shall 20 not exceed a deflection angle of 1° 40" from the vertical axis of the pole for any 1 ft section of the pole along the entire length of the pole. Poles shall be designed for the Service I, Service II, Extreme I, and Strength I load combination states. The light pole shall be designed to support an ice load of 3 lb/sq ft applied to the full perimeter of all members. Vibration dampers shall be furnished as recommended by the manufacturer. The manufacturer may use drag coefficients based on actual wind tunnel tests or they shall use the drag coefficients in Table 3.8.7-1. The pole shall also be designed for the Fatigue I load combination state should signs or other appurtenances be specified for mounting on the pole.

Conventional light poles shall be designed to support a 53 lb luminaire with an effective projected area of 2.4 sq ft. When larger luminaires are specified, the light poles shall be designed to support the larger luminaires and this shall be shown on the light pole working drawings.

Conventional light poles shall have a 4 in. by 8 in. reinforced handhole centered 18 in. above the base of the pole, unless installed with a transformer base, and a cover attached with a minimum of two stainless steel hex head bolts. The pole shall have a removable pole cap and a wire support hook to support the vertical drop of the wire by a service drop clamp attached to the cable. A wiring hole with a 1 in. inside diameter 40 grommet shall be provided where the mast arm is attached. Pole bases shall be designed for mounting on anchor bolts equally spaced on an 11 1/2 in. or 14 1/2 in. diameter anchor bolt circle. Anchor bolt covers shall be furnished.

Hardware shall be type 304 or 305 stainl ess steel in accordance with ASTM A276, except where otherwise specified. 920.01

For conventional light poles, a 1/2 in. by 13 UNC threaded grounding nut or other approved method shall be provided near the bottom of and shall be accessible through the handhole for attaching the ground wire. The ground wire shall be No. 6 AWG soft-50 drawn, solid copper in accordance with ASTM B3.

Mast arms less than 8 ft in length shall either be single member or truss type, except that mast arms for poles on bridge deck shall be truss type. Single member arms shall be a tapered tube, oval shaped, at the pole end with the long dimension in the vertical plane, welded to a pole plate an d bolted, or clamped, to the shaft with a minimum of four 1/2 in. bolts. Mast arms 8 ft and over in length shall be truss type. The upper member shall be a tapered tube, oval shaped, at the pole with the long dimension in the horizontal plane. The lower member may be standard pipe. Both members shall be welded to a pole plate and bolted or clamped to the pole. 60

A minimum of four 1/2 in. bolts at the upper member and a minimum of two 3/8 in. bolts at the lower member shall be used if a pole plate configuration is used to attach the mast arm to the pole. Mast arms that are clamped to the pole shall have a minimum of four 1/2 in. bolts per clamp. Mast arms shall provide an enclosed raceway for the wiring and shall be free of burrs and rough edges. Each arm shall be furnished with a 2 in. nominal pipe size slipfitter. The maximum rise of the truss style arm shall be as set out in the table and shall be measured vertically from the centerline of the free end of the truss to a plane through th e centerline of the upper arm bracket after loading. 70

Mast Arm Length, ft Maximum Rise, ft 9 or less 4 10 to 14 5 15 to 19 5.5 20 to 25 6 26 to 30 8

Light poles shall be constructed to provide a nominal luminaire mounting height above the roadway pavement as shown on the drawings. The elevations of foundations above or below the edge of the pavement shall be controlled by existing roadside conditions. The effective mounting height shall be determined by field measurement prior to placing an order for the poles.

A variation in the nominal mounting height of ±1 ft is allowed so that the “Effective Mounting Height”, foundation to luminaire, of the light standards may be 80 supplied for 40 ft nominal mounting height.

920.01

Elevation of Foundation Top with Respect to the Near Road Edge, ft Effective Mounting Height, Foundation to Luminaire, ft +7.00 to +5.01 34 +5.00 to +3.01 36 +3.00 to +1.01 38 +1.00 to -1.00 40 -1.01 to -3.0 42 -3.01 to -5.00 44 -5.01 to -7.00 46

The effective mounting heights for other nominal mounting heights deviate from the table by the difference in nominal height and 40 ft.

The pole and mast arm shall be in acco rdance with ASTM B221, alloy 6063-T6, 90 and of sufficient diameter and wall thickness to withstand the design loads. The pole shall be tapered full length or tapered in the middle with the top or bottom approximately 1/3 of the pole of constant cross-section. The minimum wall thickness for poles on breakaway couplings and steel slip bases shall be 0.219 in. Poles on transformer bases or shoe anchor bases installed without breakaway devices are exempted from this minimum wall thickness requirement. An inner tube extension, or sleeve, fitted inside the main tube shaft, is permissible to increase the wall thickness of the shaft starting at the bottom of the shoe base and extending upward towards the top of the pole. The sleeve or tube extension shall be no less than 3 ft in length, fabricated from aluminum alloy 6063-T4 and heat treated to produce a T6 temper after 100 placing in the shaft. The minimum wall thickness of the combination of shaft and sleeve shall be 0.219 in. Attaching plates or clamps for aluminum mast arms shall be in accordance with ASTM B241, alloys 6061-T6, 6063-T6, 356.0-T6, or 5052-H32. The bottom end of the shaft shall be welded to a one-piece cast aluminum shoe anchor base of 356.0-T6 aluminum alloy in accordance with ASTM B26 for sand castings or ASTM B108 for permanent mold castings or equal and provided with four slotted holes for anchor bolts and the shaft’s full length shall be heat treated to produce a T6 temper. The top of the shaft shall be provided with a removable aluminum pole cap. The shaft shall have no longitudinal welds. After fabrication, the shaft shall be cleaned to a satin finish and wrapped for protection during shipping and handling. 110

The material for these light poles shall be round, tapered structural marine aluminum sheet in accordance with ASTM B209, alloy 5086-H34, and of sufficient diameter and wall thickness to withst and the design loads. The minimum wall thickness for poles on breakaway couplings and steel slip bases shall be 0.219 in. Poles on transformer bases or shoe anchor bases installed with no breakaway devices are exempted from the minimum wall thickness requirement. The anchor base shall be 920.01

one-piece cast aluminum in a ccordance with ASTM B26, alloy 356.0-T6. The base casting for the formed and welded shaft shall be designed to be inserted a minimum of 120 12 in. into the shaft and bonded to the shaft with a weatherproof structural epoxy adhesive that fully develops the required strength as specified by the design criteria. After fabrication, the shaft shall be cleaned to a satin finish and wrapped for protection during shipping and handling.

The pole and base plate shall be fabr icated from steel in accordance with ASTM A572, A595, or A1011 with a minimum yield strength of 50,000 psi. Single member mast arms and the upper members of truss type mast arms shall be fabricated from steel in accordance with ASTM A572 or A595 with a minimum yield strength of 130 50,000 psi. The lower member of truss type arms may be fabricated from standard steel pipe in accordance with ASTM A53 w ith a minimum yield strength of 36,000 psi. After fabrication, the pole and mast arm shall be thoroughly cleaned and galvanized in accordance with ASTM A123.

Steel poles shall be tapered 0.14 in./ft and shall be round, octagonal, or dodecagonal. The design load shall be used to determine the pole diameter and wall thickness. Design calculations stamped by an Indiana registered professional engineer shall be submitted with the working drawings. The pole shall have one longitudinal electrically welded joint. A steel base plate shall be welded to each pole and provided 140 with four slotted holes for the anchor bolts.

All welds on steel poles shall be performed at the factory. Base plate welds shall be 100% penetration. Circumferential welds shall be backed-up welds with 100% penetration. Longitudinal welds shall be a minimum of 60% penetration. The 100% penetration welds shall be ultrasonically inspected and all other welds shall be inspected by magnetic particle. Welding sh all be performed in accordance with

711.32

Timber poles for highway light pole shall be in accordance with 922.10(b).

All light poles, except high mast towers, those protected by bridge end bents or retaining walls, and those placed along sidewalks, pedestrian pathways, and bicycle pathways shall be installed on breakaway devices. All breakaway devices on a contract shall be of the same type and manufacturer.

Breakaway devices shall be in accordance with AASHTO LRFD Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals as 160 modified in 920.01(a)1.

A certification from the manufacturer shall be furnished with the shop drawings stating the breakaway devices conform to the breakaway criteria of the AASHTO 920.01

LRFD Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals.

The anchor bolts for transformer bases shall be in accordance with 920.01(a)7. The anchor bolt circle for transformer bases shall be 15 in. The bolt holes in the 170 transformer base may be slotted. The pole shall be bolted to the transformer base with four 1 in. diameter galvanized steel bolts.

An approved handhole in the transformer base may be substituted for the 4 in. by 8 in. handhole specified in 920.01(a)1.

Breakaway couplings may be used with aluminum poles with mounting heights up to 50 ft and with steel poles that weigh 600 lb or less. The couplings shall be furnished with necessary hardware includi ng a two-piece cover. Couplings shall be 180 installed in accordance with the manufacturer’s instructions and recommended clearance between the top of the foundation and the bottom of the breakaway coupling.

Anchor bolts shall be 1 in. with 8NC rolled threads in accordance with ASTM A307. The minimum length of threads shall be 6 in. Mean diameter of rod stock shall be 0.918 in. ±0.011 in. and out-of-round tolerance shall be ±0.012 in. The top 10 in. of the bolt shall be galvanized in accordance with ASTM F2329 or

mechanically galvanized in accordance with ASTM B695, Class 55. Anchor bolts

shall be in accordance with 910.19(b). The bolts shall be a minimum of 36 in. in length190

for poles 8 in. outside diameter or less and 48 in. in length for poles 9 in. or 10 in.

outside diameter. In addition to the minimum length, the bolt shall have a 4 in. right

angle bend at the unthreaded end. The anchor bolts in bridge structures shall be as

shown on the plans.

The high mast pole, base, anchor bolts, lowering device, installed fixtures, and

associated appurtenances shall be designed to withstand a minimum wind speed of

120 mph using applicable design criteria in accordance with AASHTO LRFD

Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic200

Signals. Minimum design criteria for high mast tower heights from 60 ft to 120 ft shall

be an effective projected area of 14.70 sq ft and a weight of 740 lb to account for 6

luminaires and a 6 place lowering ring. Criteria for high mast tower height from 125 ft

to 200 ft shall be an effective projected area of 26.70 sq ft and a weight of 1,065 lb to

account for 12 luminaires and a 12 place lowering ring. If larger fixtures are used, the

actual size and weight shall be used in the design of the pole.

The Contractor shall be responsible for the accuracy of the dimensions and the

proper fit of all material and equipment furnished with the pole. The Contractor shall

provide all applicable manufacturers’ warranties for material and workmanship.210

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External lowering devices shall 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 A595, grade A or B; ASTM A572, grade220

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·lb230

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 Charpy 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 the shaft shall be hot-dip galvanized in accordance with

AASHTO M 111 or ASTM A123.

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

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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.

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 attached280

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 which are accessible through the pole handhole

for connecting the ground wires. A connection 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 shall be fabricated as an enclosed wire

raceway to provide for the symmetrical mounting 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 strand 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.

The head frame shall be made of ASTM A666, Type 304 stainless steel. All

required pulleys, rollers, or sheaves and shafts shall be constructed from non-corrosive

metallic materials. No component shall be used in the lowering device in excess of its310

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 shall 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 with 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 installed. The dome attachment shall be

designed to withstand pole vibration, other pole movement, and the design windload.

The fiberglass dome shall be made of material that is not subject to cracking or other330

deterioration because of aging.

The winch cable shall be 5/16 in. diameter galvanized steel aircraft cable of seven

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 an350

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 transformer into the system. The 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 capable 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 external drive system shall be mounted on a two-wheel cart

with wheels at least 12 in. in diameter and the weight shall be distributed so that it

presents a balance load.

The three luminaire ring support cables shall be attached to three stainless steel370

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 chain 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 installed390

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.

Anchor bolts for high mast poles shall be furnished in a pre-clustered form and

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 strength 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 mechanically galvanized and in accordance with410

the coating thickness, adherence, and quality requirements of ASTM B695, class 55.

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 easily 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 Engineer Association standard WC 70/ICEA430

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 color440

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.

The wiring from the switch box to the last luminaire shall be 3/C copper stranded450

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.

This cable shall be triplex secondary distribution cable consisting of two insulated

conductors and a steel reinforced bare copper messenger neutral. The insulated460

conductor shall be No. 6 AWG stranded copper with 600 volt, XHHW-XLP type

insulation.

The wiring from the terminal box on the ring through the last luminaire shall be

in accordance with 920.01(c)4.

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 with470

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 disconnection 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 inhibitor, 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

Underpass, Roadway, and High Mast models shall be selected from the QPL of

Luminaires.490

Luminaires shall be compatible with the lighting materials specified herein and in

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 shown on the plans. The luminaire 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 determined520

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.

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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 UL540

1449 and shall be tested in accordance with, and survive, the procedure in ANSI/IEEE

C62.41.2 definitions for standard and optional 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 lumen570

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

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1159

Plasma emitters shall deliver a minimum of 70% of the initial lumens after 50,000

hrs of operation.

Metal halide luminaires shall utilize a power driver. External capacitors or igniters

shall not be used. Metal Halide lamps used in high mast luminaires shall be supported

at both ends with mechanical spring grips or other means to hold the lamp secure

against vibration.

590

Roadway luminaires shall have a strong, easily operated, positive latch on the

street side of the housing with a hinge and a safety catch that prevents accidental

unhinging on the house side of the refractor or lens holder. They shall include a four

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 include610

aluminum conduit, conduit clamps, fittings, and stainless steel screws.

All circuit breaker enclosures shall be NEMA 4/5.

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 for620

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

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 padlocking630

externally. The circuit breaker operating handles for manual tripping shall be

concealed inside the enclosure. The enclosure 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 as640

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 for660

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.

Handholes shall be in accordance with 922.17 except the cover shall be with the

logo imprint of “LIGHTING”.680