928 MATERIALS 10
807.02 Materials
Materials shall be in acco rdance with the following: Casting for Handholes ................................................. 922.17(a) Coarse Aggregate, Class D or Higher, Size No. 53 ..... 904.03 Concrete, Class A ........................................................ 702 Conduit ........................................................................ 922.19 Highway Illumination Materials .................................. 920.01 Line Hardware ............................................................. 922.10(e)1 20 Paint ............................................................................. 909 Reinforced Concrete Pipe ............................................ 907.02 Reinforcing Bars .......................................................... 910.01 Manufacturers’ descriptive and technical literature for major items shall be submitted for approval. Where it is normal trade practice to furnish a warranty, a warranty shall be furnished on all major items such as luminaires, lamps, poles, brackets, cable-duct, wire and cable, fuse co nnectors, and ballasts. The effective date of the warranty shall commence on the date of final acceptance. These items shall bear the seal of approval of the UL. 30 All flexible conduit shall be galvanized steel, polyvinyl jacketed, and watertight. Reinforcing bars shall be epoxy coated. CONSTRUCTION REQUIREMENTS Existing highway illumination shall be maintained on all projects unless discontinuance of the highway illumination is specifically allowed. 40
807.03 Working Drawings
Working drawings shall be submitted in accordance with 105.02 for light pole assemblies, luminaires, and external drive assemblies. Working drawings for each luminaire model submitted shall include the luminaire specifications and data sheets. For contracts not utilizing the QPL for Luminaires, working drawings for luminaires shall also include the Illumination Engineering Society of North America, IESNA, photometric distribution file if the file number varies from what is shown on 50 the plans. The IESNA photometric distribution file shall be in either Visual, developed by Acuity Brands Lighting, or AGi32 from Lighting Analysis, Inc. Working drawings for conventional light pole shall show the outside shaft diameter, height, wall thickness, mast arm length and rise, mast arm diameter and 807.02 929 thickness, handhole details, grinding details, materials required, and complete anchor- bolt details including bolt circle-projection and hardware. If a breakaway base is required, its details shall be shown. When requested, sufficient design data shall be furnished with the drawings to 60 verify that conventional light pole is in accordance with wind load, deflection, vibration, and breakaway requirements. All of the above shall be based on the light pole details shown on the plans. After approval, the Engineer shall be advised of where changes to the Installation Summary sheet s are being made because of existing roadside conditions. Where necessary, additional light pole working drawings shall be submitted for approval. If a light pole is designed to support a larger luminaire than that specified, such information shall be shown on the working drawings. A Type C certification in accordance with 916 shall be provided for the breakaway devices certifying that the 70 breakaway devices are in accordance with the breakaway criteria of the AASHTO Standard Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals. Working drawings for high mast towers shall show the pole height, number of sections, the pole shaft data for each section, luminaire lowering ring assembly, handhole details, materials required, welding details, and complete anchor bolt details including bolt circle-projection and hardware. If the high mast is a non-standard design, the following design calculations and 80 data shall be submitted for approval prior to the fabrication of a high-mast pole:
a.general dimensions of all component parts,
b.the maximum moments, the section modulus required, and the section modulus furnished at the base of the pole, at all splices, at the connection of the ring, and at least every 20 ft,
c.calculation of stresses in the ba se plate, connection attachment, and anchor bolts, 90
d.maximum deflection at the top of the structure under the specified loading,
e.the dimensions and wiring diagrams of the external drive system connection to the pole in accordance with 920.01(b)7. The working drawings shall include the dimensions and wiring diagram of the standard connections of the external drive system.
807.04 Excavation
All excavation for the roadway lighting installation shall be performed in 807.04 930 accordance with the dimensions, elevations , and grades shown on the plans or as directed. If class X material is encountered, foundation excavation shall be completed in accordance with 206.
a.Trench Excavation Excavation may be accomplished either manually or with mechanical trenching equipment. The blades of road patrols or graders shall not be used to excavate the trenches. The depth of trenches shall be a mi nimum of 2 ft. Walls of trenches for cable- 110 duct or conduit shall be essentially vertical. The bottoms of trenches shall be smooth and free from aggregate larger than 1/2 in. Bracing, shoring, and sheathing shall be provided as necessary. If the excavation, th rough accident or otherwise, is below the required level, the excess excavated area shall be refilled in a satisfactory manner with no additional payment. The accumulation of water in excavated areas shall be prevented by the use of pumps or other approved means. When rocks or other materials which might damage the cable-duct or conduit are encountered, the excavation shall be extended to a depth of at least 27 in. and backfilled with a 3 in. compacted layer of sand or earth containing no particles that would be retained on a 1/4 in. sieve. No extra payment will be made for this additional excavation or backfill. 120
b.Foundation Excavation If possible, excavation for concrete foundations shall be accomplished by means of drilling with an auger of sufficient size to admit the width of the foundation. Work shall be so scheduled that all open excavations are poured with concrete during the work day they are dug. No excavations shall remain open over night or over a weekend or holiday. Accumulated water shall be rem oved from the excavation before concrete is poured. If class X material is encountered, foundation excavation shall be completed in accordance with 206.02(b). 130
c.Landscape Replacement Where roadside shrub plantings interfere with the location of illumination installations, the plantings shall be reset at ot her locations and at su ch times as directed, all in accordance with 622. The cost of this work will not be paid for directly, but shall be included in the cost of other pay items. All slopes for foundation grading shall be sodded. Sod shall be placed in accordance with 621.
807.05 Backfilling 140
All suitable materials removed from the excavated areas shall be used in refilling cable-duct and conduit trenches. No excavated materials shall be wasted without authorization. Materials authorized to be wasted shall be disposed of as approved. Backfill for trenches shall be placed in layers not to exceed 6 in., loose measurement. The first layer shall be sand or earth containing no particles or lumps that would be retained on a 1/4 in. sieve. The second layer shall contain no particles or lumps that would be retained on a 1 in. sieve. Subse quent layers shall contain no particles or lumps that would be retained on a 3 in. si eve. The second layer and each subsequent 807.05 931 layer shall be compacted with pneumatic hand-tampers to prevent any future settlement of the backfilled area. Backfilling of cable-duct and conduit trenches around 150 light pole foundations, handholes, manholes, and other structures shall be in accordance with the a pplicable provisions of 211. Fini sh grading of earthwork shall be accomplished in a satisfactory manner. 807.06 Placing Conduit Conduit shall be placed as shown on the plans and in accordance with applicable provisions of 805.11. Conduit shall be of a size to readily enable the passage of the cable-duct being used. Conduit installed under pavement shall extend a minimum of 2 ft beyond the edge 160 of the paved surface or improved shoulder. The ends of such conduit shall terminate a nominal 2 ft below the ground surface. The ends shall be pitched so as to provide a positive drain to the surrounding soil. The ends shall be protected by threaded cap fittings until the time of installation of cable or cable-duct. Threaded bushing fittings shall be used on all ends before cable installation. Conduits installed in bridge railing concrete sections shall terminate a minimum of 2 ft beyond the end of the bridge railing outside of the paved surface and a minimum of 2 ft under the ground surface. Existing conduit shall be extended as necessary to satisfy these requirements. 170 Hot dipped galvanized, malleable pipe stra ps and spacers shall be used to attach conduit to bridge structures. Galvanized steel conduit hangers or pipe clamps will not be allowed. Pipe straps of the proper size shall be installed 4 ft center to center along the conduit. When fastening pipe straps to concrete, a 3/8 in. by 2 1/2 in. galvanized steel lag screw, with an approved sleeve, shall be used; however, other approved expansion anchors may be used. The pipe strap and spacer shall be bolted to the steel beams. Conduit for service supply shall be mounted on a service pole, either company or 180 State owned, near the right-of-way line. For simple supply circuits, one straight, continuous, conduit riser shall be used. The top end shall terminate with a weatherhead device, and the lower end shall terminate at least 2 ft below ground level with a threaded grounding bushing fitting. Unless otherwise directed, the weatherhead shall be 24 ft above the ground. However, the act ual elevation of the weatherhead shall meet the requirements of the utility concerned.
807.07 Connections in Base of Light Pole Conductors shall be electrically bonded to each other, as required to satisfy circuit
requirements, by means of compression type fittings of the style and type shown on 190 the plans. Inhibitor compound shall be used on each compression connection. Conductor identification shall be maintained by connecting like color connectors. 807.07 932 A multiple conductor compression fitti ng shall be used to connect supply conductors and an insulating link used to provide an extension as shown on the plans. These fittings shall be covered with snap-on fiber or plastic covers designed to protect them from electrical contact. Taping will not be allowed. The bare extension of the supply conductor from the multiple fitting to the insulation link shall be no longer than necessary to admit the application of the snap-on cover for the multiple fitting. The pole circuits shall be connected by means of easily separated, single conductor connector kits. The connector kit on the “hot” side of the pole circuit shall be fused. The connector kit for the neutral side shall not be fused. Fuses shall be of the “KTK-10” series with a rated capacity three times the operating amperage of the luminaire. If the required capacity is not a st andard size, the next larger size fuse shall be used. The connector kit on the “hot” side of the pole circuit shall have the following features: 210
a.a line side and load side housing made of plastic or water resisting synthetic rubber suitable for direct burial in the ground or installation in sunlight,
b.a water seal between the two housings,
c.each housing permanently marked “Line Side” or “Load Side”,
d.a spring-loaded, 90% minimum conductivity, contact suitable for gripping the “KTK-10” cartridge fuse in each housing. These 220 contacts shall be fully annealed,
e.an interior arrangement for eac h housing that will adequately receive and rigidly maintain the fuse contacts,
f.a terminal on each housing desi gned for a crimp type connection to the conductor that securely retains the conductor in the proper position,
g.a water seal between th e conductor and the housing, 230
h.a disconnecting means that shall retain the fuse on the load side when disconnected and keep the conductive parts of the line side inaccessible,
i.sufficient silicone compound provided and used to lubricate the metal parts and the rubber housings or boots for easy assembly. 807.07 933 The neutral side connector kit shall be similar in all respects to that described for the hot side except that a dummy fuse shall be used for the purpose of completing the 240 electrical circuit. The bayonet disconnect feature of the connect or kits shall be part of the load side of both the neutral side and the hot side conductors. The line side shall have a socket to receive the bayonet. These k its shall be installed in the pole circuit between the luminaire terminals and the compression connection to the underground distribution circuit as shown on the plans. A separate insulated conductor shall be used to connect the neutral of the underground distribution circuit and the neutral of the pole circuit to the ground lug in the pole base from the point at which both neutrals are connected together by a compression connection. The bayonet disconnect features from the neutral side and the hot side connector kits as cited above shall be included in the sign structure circuitry when lumina ires are installed on the sign structures. 250 Consecutive roadway luminaires in a circuit shall be alternately connected to opposite load conductors R or B as specified in the plans to balance the load. Sign luminaires on individual structures shall be similarly connected.
807.08 Placing Wire and Cable (a) Underground All underground distribution conductors shall be continuous runs between splice
points. Unless otherwise authorized, splice points shall be inside the bases of light poles, inside handholes, in service distribution boxes, at point of connection to power 260 supply in switch boxes, or in junction boxes. All splices shall be made with the proper connector in accordance with 807.07.
1.Through Cabl e-duct in Trench Cable-duct shall be placed either in a tren ch or plowed into place. Cable-duct shall be installed without sharp bends or kinks and in straight runs so as to enable withdrawal of a conductor and the installation of new conductor without additional excavation or backfill. Plowed cable-duct shall be installed at a minimum depth of 2 ft in a single cavity 270 gored into the earth by a vibrating plow blade. The equipment used for plowing the cable-duct shall be designed specifically for that purpose with the power and versatility to easily and accurately bury the various sizes of cable-duct under all normal soil conditions. This equipment shall place the cable-duct without twisting, kinking, or damaging it in any way. Dragging or pulling the cable-duct from the start of the trenching operation will not be allowed. Where two ducts are to be installed parallel to each other, the distance between them shall be no less than 12 in. and no more than 24 in. The plastic duct of the cable-duct shall be terminated 4 in. above the top of 280 foundations or 4 in. inside handholes with sufficient excess conductors as directed. All terminations of this plastic duct shall be beveled and free from any sharp edges or burrs. Insulation of the electrical conducto r shall not be damaged when cutting the duct. 807.08 934 2. Through Cable-duct in Conduit The underground distribution circuit shall be protected by galvanized steel conduit when installed under pavement, in road shoulders, or elsewhere as shown on the plans or as directed. 290 Cable-duct shall be pulled through the entire length of galvanized steel conduit if at all possible. If this is not possible, written authorization shall be obtained to allow the duct to be cut away and the conductors installed in the conduit with a minimum of 2 ft of duct extended into the conduit. Where so authorized, the plastic duct shall be terminated in the proper transition fitting attached to the end of the conduit and each conductor of the cable-duct assembly sh all continue undamaged and uninterrupted through the galvanized steel conduit to the other end of the conduit where a transition to the cable-duct shall be used again and the cable-duct shall continue uninterrupted to the next designated splice point. All transitions from galvanized steel conduit to cable-duct shall be accomplished with the proper adapter. This adapter shall provide a 300 durable, watertight transition that has a smooth uniform interior. 3. Cable Markers The location of underground conduits or cable-ducts shall be marked with cable markers. The marker shall be placed at all changes in direction, where the underground distribution circuit is split, and at a maximum of 400 ft intervals on straight runs. Cable markers shall be a slab of concrete 2 ft square by 4 in. thick, with the word “Cable” die impressed into the surface of the marker, a minimum depth of 3/8 in. with letters a minimum of 2 in. high. Arrows showing the direction of the cable shall be die impressed or saw-cut a minimum depth of 3/8 in. into the marker surface. 310 Curing of the concrete shall be in accordance with 702.22. The cable marker shall have a smooth metal trowel finish without scaling. (b) In Conduit Risers Cable-duct shall enter the bottom of the conduit riser with a sweeping radius bend and continue up the riser to within 3 in. of the top of the conduit riser. At this point the plastic duct shall be terminated and the conductors shall continue uninterrupted and undamaged into the service cabinet, underpass switchbox, or through the weatherhead with sufficient excess to make the required connections. 320
c.Through Conduit in Bridge Coping Where a cable-duct underground distribution circuit is run through conduit installed in bridge coping, the duct shall be cut away and the conductors shall be installed in the conduit with at least 2 ft of duct extended into the conduit. The conductors, through this transition, shall be continuous between authorized splice points. Where more than one light pole is to be installed on the same side of the bridge structure and connected to the same dist ribution circuit, the cables pulled between these light poles shall be of the same type and size used in the cable-duct underground distribution circuit. 330 807.08 935 (d) Aerial Cable Aerial cable for overhead distribution circuits shall be supported and terminated as shown on the plans. The aerial cable shall have a sag of no more than 5% of the distance between lighting poles except where slack spans ar e indicated on the plans. Aerial cables shall have a minimu m vertical clearance of 18 ft.
807.09 Lighting Handholes Handholes shall not be placed in areas subject to flowing or ponding water.
Handholes shall be installed with the top flush with adjoining surfaces. Precast 340 handholes with integral bottoms will be considered acceptable. Multiple compression fittings and insulating links installed in handholes shall be taped and waterproofed by application of an approved waterproofing device. The insulation around the area to be waterproofed shall be cleaned before applying the waterproofing device. These waterproofing devices shall be designed for insulating multi-conductor cables with a minimum voltage carrying capacity of 600 volts. Handholes of an alternative material will be allowed as a substitute for a street and alley handhole providing that they meet the requirements of 922.17(b) and can be 350 placed at a location which meets both of the following conditions:
a.there is no evidence of vehicl es traveling over the area where the handhole is to be located; and
b.it is located a minimum of 15 ft from the edge of pavement, unless it is protected by guardrail, non-mountable curb, a structure, or an non-traversable ditch. The handhole shall be backfilled with sand or earth containing no particles that 360 would be retained on a 1/4 in. (6.3 mm) sieve. The backfill shall be placed as shown on the plans. No additional payment will be allowed for this backfill.
807.10 Concrete Foundations For Light Poles Foundations shall be class A concrete in accordance with 702. Footings may be either round or square in shape as shown on the plans. Anchor bolt circle dimensions shall be furnished and the anchor bolts shall be in
accordance with 920.01(a)7. A rigid template shall be used to center the anchor bolts in the foundation. Unless otherwise specified, the template shall be oriented so that the 370 mast arm of the light pole is perpendicu lar to the center line of the roadway. Each foundation installation shall have provisions for grounding the light pole in accordance with 807.12. The tops of the c oncrete foundations shall be constructed level and only shims used to rake the light pole will be allowed. Shims shall not be used with break-away couplings. Each foundation shall have an imprinted arrow or arrows on the top of the foundation to indicate the direction of the cable duct run. 807.10 Foundations for high mast towers shall be constructed prior to constructing foundations for conventional roadway lighting. 380
a.Cast-in-Place Foundations If the sidewalls of the excavated areas remain firm and stable, concrete may be poured directly against the dirt below the level of the top 6 in. form. Otherwise, the concrete foundation shall be fully formed by means of a paper preformed liner or other approved means. However, the foundation shall be formed to the proper size for the top 6 in. before concrete is poured. If a paper liner is used, it may be withdrawn as the concrete is placed or it may be left in place permanently. If the liner is left in place, all voids between the excavation walls and the form shall be filled and compacted using coarse aggregate No. 53. If the liner is withdrawn, the top 12 in. of the foundation shall 390 remain formed until the concrete has obtained initial set.
b.Precast Foundations Precast foundations shall be complete with reinforcing bars, tie bars, anchor bolts, and entry sleeves located to provide a level mounting for the light pole after installation. The grounding coil, as shown on the plans, may be used for grounding light pole set on precast foundations. Foundation backfill shall consist of coarse aggregate No. 53.
c.Grading of Foundations 400 Foundation projection above the finished grade shall be as shown on the plans. The excavated material may be used for this grading if it is not granular in nature and will readily stabilize and support the growth of sod. If the excavated material is unsuitable, it shall be properly disposed of and approved materials used. The area shall be sodded. Sodding will be in accordance with 621. 807.11 Placing Light Poles
a.Light Poles Under 45 ft in Height The light pole assembly shall consist of a metal pole, a shoe base, a frangible 410 breakaway base or coupling where shown on the plans, and a metal mast arm for attaching the luminaire. The unit shall be assembled on the ground. Pole circuit wiring shall be installed and the luminaire shall be attached prior to erection. The factory finish of the pole assembly shall be protected from mars, blemishes, scratches, or other damage. Slings and chokers for lifting purpos es shall be of nylon or other approved material. Chains, metal rope, or other abrasive materials shall not be used for lifting devices. If damage to the fa ctory finish occurs, repair or replacement shall be as directed. The base plate shall be designed to car ry the pole assembly. The plate assembly 420 shall be supported by a transformer base, which shall be in accordance with the breakaway requirements in the AASHTO LRFD Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals. 807.11 After erection and attachment to the foundation, the pole assembly shall be plumb. The luminaires shall be level in both horizontal areas. Shims shall not be used with breakaway couplings. Shimming will be allowed on other types of installations to rake the pole assembly to obtain the desired attitude of the luminaire where the combined weight of the pole and mast arm requires it and the luminaire saddle will not allow the adjustment. The mast arm shall be perpendicu lar to the axis of roadway travel unless 430 special orientation is noted on the plans. Unless otherwise specified, the lighting system shall consist of metal pole supports for the luminaires with an underground electrical supply system. (b) High Mast Towers of 60 ft Height and Over High mast tower pole sections shall be mechanically fitted in the field using factory supplied hydraulic jack or hoist puller that shall produce a minimum force of 10,000 lb per side. Field assembly proce dures and assembly apparatus requirements shall be submitted for approval. Field welds will not be allowed except where shipping limitations prevent permanent factory assembly. Prior approval for field welds is 440 required. The pole shall be erected on the lower se t of the anchor bolt nuts and secured with the top nuts. The adjustments to plumb the pole shall be made prior to the final tightening of the top nuts. The pole shall be plumbed under no wind conditions before sun-up, after sun-down, or on an overcast day. The devia tion from vertical shall not exceed 1/4 in. within any 10 ft of height. When installing the high mast power cabl e, one end of the power cable shall be securely connected to the lu minaire ring. The other end of the power cable shall be secured to the support and terminated 3 ft below this support with a heavy duty three-wire electrical plug. Adjustments of the three support cable lengths shall be made prior to lowering the ring for the first time. After the support cables have been adjusted and the luminaires installed on the ring, at least one complete cycle operation of the ring shall be conducted on each structure. As shown on the plans, should the ring provide more luminaire attachment positions than luminaires to be installed, counterweights of the same weight of the 460 luminaire shall be installed on those positions.
807.12 Grounding Ground wire shall be No. 4 AWG solid bare copper. Ground rods shall be 1/2 in.
diameter by 8 ft long copper weld ground electrodes except where larger sizes are specified. The top of the ground rod shall be driven at least 6 in. below grade. Ground rods shall not be installed within the light pole sign structure, or high mast tower foundations. 807.12 938 The ground wire shall be connected to the top or side of the ground rod. The 470 ground rod, ground wire connection shall be made by a thermo weld process. The wire and ground rod shall be free of oxidized materials, moisture, and other contaminants prior to inserting the wire and the ground rod into the properly sized mold. The welding material shall sufficiently cover and secure the conductor to the rod. The completed connection shall be non-porous. As an acceptable substitute to this pr ocess, a mechanical ground grid connection of an approved type may be used. Tap type clamps, parallel type clamps, U-bolt flat clamps, and crossover clamps will not be accepted. 480 Luminaire poles shall be grounded by connecting the free end of the ground wire to the grounding lug in the transformer base or pole. The free end of the ground wire shall enter the pole base through the entry sleeve installed in the foundation. The neutral conductor of the underground distribution circuit shall be connected to the ground lug in the transformer base or pole. This connection shall include a quick-disconnect type connector kit so that in the event of a pole knockdown the connection will readily br eak without damage to the buried conductor. The breaker boxes for the sign and underpass circuits shall be grounded by 490 connecting the free end of the ground wire to the neutral grounding terminal in the breaker box and connecting this terminal to a grounding lug securely fastened to the metal interior of the breaker box. The conduit terminating in the breaker box and the sign or underpass luminaire housing shall have a good, clean, tight connection and act as a grounding conductor for these luminaires. The neutral conductors of the feed and distribution circuits for underpass and sign illumination shall be connected to the neutral grounding terminal in the switch box or breaker box. The neutral conductor of the distribution circuit for underpass and sign illumination shall be grounded in each luminaire by connecting a jumper from the neutral terminal of the luminaire to a ground lug fastened to the metal housing of the luminaire. 500 Sign structures shall be grounded at one sign column by connecting the free end of the grounding wire at that column to the grounding lug in the column base. A Type I service for supply of electrical energy shall consist of a conduit riser to a weatherhead. This conduit shall be grounded at the lower end by means of a standard strap grounding connection to the ground wire and ground rod. A Type II service shall consist of a multiple number of conduits fr om underground to the bottom of the service cabinet and a single conduit to a weatherhead from the top of the service cabinet. All of these conduits shall be connected by a single ground wire from the grounding 510 terminal to a grounding bushing for each conduit within the interior of the service cabinet. In addition a ground wire from the grounding terminal of the service cabinet shall be connected through a conduit to a ground rod. Bridge railing conduits shall be grounde d at each end of the bridge railing by 807.12 939 means of a standard grounding strap connected to a ground wire and ground rod. The ends of the conduits terminating in a bridge anchor location shall provide ground continuity by means of a grounding bushing on each conduit end and the connection of the bushing to a ground wire. 520 All equipment used in the highway lighting system shall be grounded. If necessary, additional grounding shall be installed as directed.
807.13 Luminaires
a.Installation Luminaire installation shall consist of the physical placing of the luminaire. Each installation shall include the furnishing and placing of the light source as designated. Luminaires shall be compatible with other lighting materials as specified in 920.01.
1.Roadway Luminaires Each luminaire shall be leveled in both directions in the horizontal plane after the light pole has been erected and adjusted. Rotary adjustment of the mast arm and vertical adjustment of roadway luminaires to obtain an installed level position in both directions shall be accomplished by means of the bolted saddle arrangement used to attach the luminaires to the mast arm. For certain light source types such as metal halide lamp socket positions may be shown on the plans by type of Illuminating Engineering Society of North American, IE S, and light pattern. The specified lamp socket position or comparable arrangement of LEDs shall be used to obtain the desired light pattern delivery. Proper connections sh all be made to provide operation at the 540 voltage being supplied. Replacements needed because of faulty or incorrect voltage connections shall be made with no add itional payment. All roadway luminaires provided for an intersection, interchange, or contiguous highway segment shall be the same type, model, and wattage.
2.Sign Luminaires Connections in which plain and galvanized steel are in contact shall be protected such that aluminum surfaces shall receive one coat of zinc chromate primer. Steel surfaces shall be prepared in accordance with 619.08(a), and 619.08(d), and painted with the structural steel pain t system in accordance with 619.09(a). All paint shall be 550 allowed to cure before assembly. Conduit fittings, if required, shall be watertight. Required conduit shall be either rigid or fl exible as necessary. Conduit shall not be clamped to a sign panel. Sign luminaires shall be mounted on overhead sign structures on two metal channels located at the extremity of the sign walkway support brackets. The distance between lighting unit support channels shall be 7 in. These channels shall be located in such a manner that they readily receive the mounting bolts from the rear of the sign luminaire. The installation of the sign luminaire shall consist of the physical placement of the luminaire on the channels. 560 807.13 940 Sign luminaires shall be connected to a phase conductor and a neutral conductor. The luminaires shall be alternately connected to opposite phase conductors to balance the load. The connections in the base of th e sign structure shall be in accordance with
807.06 Conductor splicing shall be in junction boxes, in-ground handholes, inside handholes of sign structures, and circuit breaker enclosures. All sign luminaires provided for an interchange or contiguous highway segment shall be the same model. 3. Underpass Luminaires
Underpass luminaires shall be mounted on the vertical side surfaces of bridge bent 570 structures or suspended by means of pendants supported by angle-iron struts or clips fastened to the structural beam members of the bridge. All parts of the pendent pipe assembly shall be hot-dipped galvanized after threads are cut. Silicone caulking compound shall be applied to the threads during assembly of the pendent. Underpass luminaires may require separately mounted ballasts which shall be installed in close proximity to the luminaires. Underpass luminaires shall be connected to a phase conductor and a neutral conductor. The luminaires shall be alternately connected to opposite phase conductors to balance the load. Conductor splicing will only be allowed in junction boxes, in- 580 ground handholes, and circuit breaker enclosures. All underpass luminaires provided for an interchange shall be the same model.
4.High Mast Luminaires The aiming of the luminaires shall be as shown on the plans. During the aiming and adjustment process, the luminaire shall be oriented to conform to its raised position and the ring properly tethered to prevent rotation. The long axis of the luminaire shall be parallel to the aiming direction as shown on the plans. All high mast luminaires provided for an interchange shall be the same model and wattage. 590
b.Warranty A non-prorated manufacturer’s written warranty, against loss of performance, defects in materials and defects in workmans hip, shall be provided to and in favor of the Department. The warranty shall cover a period of 10 years from the date of shipping of the luminaire. The warranty shall cover all components of the luminaire, including but not limited to driver and light source. Loss of performance is defined to include, but is not limited to, the luminaire or any of its components falling out of compliance with the specification in place at the time of installatio n, which includes but is not limited to the following: there is no light output from 10% or more of the LEDs, the luminaire is operating below the lumen maintenance curve, or the color 600 temperature shifts more than 500K outside of the specified color temperature range. The warranty shall stipulate that repaired or replacement luminaires shall be shipped to the appropriate Department District Office, at no cost to the Department, within 30 days after the manufacturer’s receipt of failed luminaires. Replacement luminaires shall be the same model or a model that is equal to, or better, in terms of photometrics, energy consumption, and reliability. Warranty documents shall include the manufacturer’s name, address to which failed luminaires are to be shipped for 807.13 941 replacement, and the contact person’s na me, phone number, and email address. Warranty documents shall provide the estimat ed life cycle of the lamp, LEDs, plasma emitter and power driver. A Type C certifica tion in accordance with 916 shall be 610 provided for the luminaires. 807.14 Sign, Underpass, Roadway, High Mast Lighting Location, and Luminaire Identification All high mast towers, roadway light poles, underpass lighting installations, and sign lighting installations shall have an identification code number as shown on the plans. In addition, each luminaire at a sign or underpass installation shall be individually identified with a single capital letter. The code number shall be displayed on the light pole, sign structure column, and 620 high mast tower as shown on the plans. Th e underpass code number shall be displayed near the breaker box at a location as directed. The code number for the light pole and sign structure column shall be applied to the pole, as specified by the manufacturer, by using individual, pressure sensitive, adhesive backed tags. The code number for the high mast tower shall be applied to an aluminum plate which is mounted with spacer s away from the structure as shown on the plans. A luminaire identification sticker shall be provided on each luminaire and on the 630 light pole or tower that supports the luminaire. The sticker shall be titled “LUMINAIRE” and contain the following: light source type, luminaire manufacturer, model, wattage, LED or lamp model, power drive model, surge protection device model, date of shipping, and warranty period. The luminaire identification sticker shall be attached underneath the light pole/tower ID tag, shall face the roadway, and shall have 3/4 in. lettering, and be no greater than 8 in. by 8 in. 807.15 Service Point Power Entry The utility’s requirements for service locations shall be coordinated. Unless otherwise specified, a pole shall be furnished for the service point. If the utility requires 640 metering or is specified on the plans of the lighting system, a meter socket shall be obtained from and installed in accordance with the requirements of the utility. Grounding shall be in accordance with 807.12 and shall be a part of the service installation. Energy shall be provided with 120/240 V service or 240/480 V service with the proper KW capacity on poles located immediat ely inside the right-of-way at locations designated on the plans. Electrical materi als incorporated in the work shall be compatible with the service voltages supplied by the local utility. The service voltages supplied by the local utility shall be checked for compliance with the planned voltages. If a discrepancy exists, it will be resolved as directed before work is started or any electrical equipment is purchased. 807.15
a.Types of Service Points Service point installations shall be of two types as shown on the plans.
1.Type I Service Point This service point installation shall consist of class 5 timber pole, 2 3/4 in. galvanized steel conduits, weatherhead, photocell, and multiple relay switch. The 660 conduit riser shall be fastened and supported on the pole by means of galvanized hook pipe straps and secured to the pole by means of a galvanized lag screw all of the proper size for the conduit being installed. Cable-duct shall be installed in the conduit riser in accordance with 807.08(c). The conductors shall extend beyond the weatherhead a minimum of 4 ft. The conductors outside of the weatherhead shall be ringed to prevent moisture from entering the conduit enclosure.
2.Type II Service Point This service point installation shall consist of a service cabinet with a single galvanized steel or aluminum conduit riser to the weatherhead. A multiple number of 670 galvanized steel conduits shall extend from the bottom of the service cabinet in accordance with 807.06. Underground cable-duc t shall be installed in accordance with 807.08(a). Connections, connectors, and fixtures shall be as shown on the plans. The service cabinet shall be secured to the pole by means of a galvanized steel channel post or other approved device. (b) Sign and Underpass Circuits The illumination circuits for sign structures with an overhead power supply shall be protected by circuit breakers mounted on the end support. 680 Circuits for adjustable end support sign structures, bridge bracket signs, or underpasses shall be protected by circuit breakers mounted on the bridge or sign structure and connected to the underground distribution circuit in a handhole. Circuits for sign structures with an underground power supply shall be protected by fuse connector kits in the base of the sign support. The fuse connector kits shall include bayonet disconnect features for the “neutral” side and “hot” side. 807.16 Testing of Highway Lighting System 690
a.Testing Lighting Circuitry All necessary equipment and apparatus properly calibrated for testing the lighting circuits shall be furnished. The supplying utility shall be given advance notice of the test scheduling so their representative may witness the testing procedures if desired. Each main lighting circuit, including its branches, shall be tested for insulation resistance and continuity after it is completely installed but before the pole circuits, underpass circuits, sign circuits, and grounding circuits are connected. 807.16 943 The insulation resistance test shall be made with a megohm meter and the 700 resistance to ground shall be no less than 50 megohms in all lighting circuit power cables. The meter shall be set for the voltage rating of the insulation. The continuity test shall be made with an ohmmeter prop erly scaled for measuring the resistance of the power cables. This test shall verify the following: 1. That each power cable is continuous to its termination points.
2.That the cable coding at junction and termination points is consistent with cable coding at the supply point.
3.That power cables are not crossed with the neutral or each other.
4.That the main circuit through each of its branches does not have unusual resistance values. The entire completed installation shall be tested by circuit or by such portions as may be selected and at night if direct ed. Tests shall demonstrate the following:
1.That all power, lighting, and control circuits are continuous, 720 free from short circuits, and free from unspecified grounds.
2.That all circuits are pr operly connected in accordance with applicable wiring diagrams.
3.That all circuits are operab le which shall be demonstrated by continuous operation of each lighting circuit for at least 1 h.
4.That voltage at the ends of each lighting circuit and at inter points is within allowable limits. A maximum of 10% voltage 730 drop will be allowed for each complete circuit.
b.Testing and Inspecting Luminaires The lighting system from the service point through the last luminaire shall be subjected to 14 days of normal operatio n prior to final acceptance. This testing procedure may be conducted separately on each circuit or on the entire system. Normal operation is defined as the luminaires being on during the darkness hours and off during the daylight hours as controlled by the service point photocells and relay switches. Malfunctioning equipment shal l be replaced or repaired before final 740 inspection. The pattern of light and correl ated color temperatur e delivered to the pavement by roadway, high mast, and underpass luminaires will be inspected at night. At this inspection, the proper tools, equipment, and personnel shall be available to make all adjustments. These items shall sp ecifically include a bucket truck capable of 807.16 944 reaching all luminaires in the system, safety equipment, and a level to determine the proper luminaire position. Within 30 calendar days after completion of the work, as-built drawings shall be submitted in electronic format to the Engineer. The lighting as-built drawings shall indicate the as-built location of light poles, high mast towers, service points, conduit 750 runs, and lighting handholes.
807.17 Pay Item and Installation Summary Sheets
Prior to final inspection, two sets each of installation summary and pay item summary, each marked Final Record, shall be furnished for the light pole as installed. The installation summary shall show the effective mounting height, mast arm length, foundation elevation, pay item, type of base, and catalog number or drawing for each light pole furnished. The pay item summary shall indicate the pay item, quantity, effective mounting height, mast arm length, and type of base for each type of light pole furnished. 760
807.18 Method of Measurement
Luminaire, light pole with mast luminaire arm, high mast tower, identification number, connector kit, multiple compression fitting, insulating link, foundation, handhole, service point, and cable marker will be measured by the number of units installed. Pole circuit conductor and circuit conductor in conduit will be measured by the linear foot. Pole circuit conductor will be measured from the base of the light pole to the terminal block of the luminaire. Pole line extension will be measured in a straight line between each pole. Conductor in bridge conduit will be measured by the linear foot from end to end of conduit or from the end of conduit to the last bridge light pole foundation entry. An allowance of 5 lft will be made for each fo undation entry. An allowance of 2 lft will be made for each junction box. Removal of existing light structure, which shall include the pole, mast arm, and foundation, will be measured by the number of units removed. Cable-duct and conductor in underground duct or conduit will be measured by the linear foot as follows: 780
a.From the face of the concre te foundation to the center of the handhole or face of the next conc rete foundation. An allowance of 5 lft will be made for each entry at foundations. An allowance of 2 lft will be made at handholes for connection purposes.
b.From light pole bases or handholes to switch boxes at underpasses. An allowance of 4 lft will be made at the switch box for electrical connections. 790 807.17 945 (c) From end to end of the conduit when the cable is in conduit under a roadway surface or shoulder. No measurement will be made for cable-duct in conduit where it is part of a service point, sign installation, or underpass lighting system.
807.19 Basis of Payment
Luminaire will be paid for at the contract unit price per each for the type specified. Service point will be paid for at the contr act unit price per each for the type specified. Light pole will be paid for at the contract unit price per each for the estimated mounting height, length of mast arm, and base type specified. High mast tower will be paid for 800 at the contract unit price for the specified mounting height. Lighting foundation, concrete, with grounding will be paid for at the contract unit price per each for the size specified. If class X material is encount ered during lighting foundation excavation, payment will be made for such excavation in accordance with 206. Partial payment for lighting foundation in the amount of 80% will be made if all such work is complete except for finish grading and sodding. The remaining percentage of payment will be made upon completion of the finish grading and sodding. 810 Connector kit will be paid for at the contract unit price per each for fused or unfused, as specified. Multiple compression fitting and insulation link will be paid for at the contract unit price per each for wate rproofed or non-waterproofed, as specified. Cable-duct marker, high mast tower winch driv e, and handhole, lighting will be paid for at the contract unit price per each. Sign, underpass, and roadway lighting location identification will be paid for at the contract unit price per each. Circuit installation will be paid for at the contract unit price per each for the type, structure number, and number of luminaires specified. Light structure, remove and portable tower lighting drive system will be paid for at the contract unit price per each. 820 Wire will be paid for at the contract unit price per linear foot for the designation, copper gauge, housing, and number of conductors specified. Pole circuit cable, Type THWN, stranded will be paid for at the contract unit price per linear foot for the copper gauge and number of conductors specified. Conduit, steel, galvanized, 2 in. diameter will be paid for at the contract unit price per linear foot. Payment will be made under: Pay Item Pay Unit Symbol Cable, Pole Circuit, THWN, No. _____ Copper, Stranded, _____ _____/ C ............................................... LFT Cable-Duct Marker .................................................................... EACH Circuit Installation, Str. No. ___, ____ Luminaires ................... EACH no. Conduit, Steel, Galvanized, 2 in. ............................................... LFT 807.19 946 Connector Kit, Fused ................................................................. EACH Connector Kit, Unfused ............................................................. EACH Handhole, Lighting .................................................................... EACH High Mast Tower, ____ ft E.M.H. ............................................ EACH 840 High Mast Tower Winch Drive ................................................. EACH Insulation Link, Non-Waterproofed .......................................... EACH Insulation Link, Waterproofed .................................................. EACH Light Pole, ___ ft E.M.H.,___ ft Mast Arm, ___ Base .............. EACH Light Structure, Remove ........................................................... EACH Lighting Foundation, ____ Concrete, with Grounding .............. EACH type Luminaire, High Mast ............................................................... EACH Luminaire, High Lumen Roadway ............................................ EACH Luminaire, Low Lumen Roadway ............................................. EACH 850 Luminaire, Sign ......................................................................... EACH Luminaire, Underpass................................................................ EACH Multiple Compression Fitting, Non-Waterproofed ................... EACH Multiple Compression Fitting, Waterproofed ............................ EACH Portable Tower Lighting Drive System ..................................... EACH Service Point, _____ .................................................................. EACH type Sign, Underpass, and Roadway Lighting Location Identification ....................................................... EACH Wire, ____, No. _____ Copper, in ____, ____ ___ /C .............. LFT 860 designation gauge housing The cost of circuit breakers; breaker en closures; conduit; flexible conduit; conduit fittings; grounding; weatherhead; aerial cable termination; and incidentals required from the last luminaire to the point of attachment by the utility, the bottom of the riser at the structure base, or the connector kits in the base of the sign supports shall be included in the cost of circuit installation. If not listed in the Schedule of Pay Items, the cost of connector kit, fused or unfused, multiple compression fitting and insulation link, waterproofed or non- 870 waterproofed, shall be included in the cost of the other items. The cost of aerial distribution service, drops to sign structures branching off from the pole line extension, weatherheads and risers required to connect the line extension to the underground electrical distribution circuit, all anchorage guy wires, hardware, aerial cable, electrical connections, timber pol es, and incidentals required to complete the pole line extension shall be included in the cost of cable, pole circuit. The cost of the mast arm, J-support hook for pole circuit, handhole with cover, shoe base, transformer base or frangible coupling if required, installation of the pole 880 on the foundation with the pole circuit shall be included in the cost of light pole. 807.19 947 The cost of the pole; lowering system including winch assembly, power cable, and support cable; concrete pad; luminaire ring; anchor bolts and nuts; lightning rod assembly; grounding system; and all incident al materials necessary to complete the installation shall be included in the cost of high mast tower. The cost of excavation, concrete, sleeves for cable-duct, non-metal pipe, reinforcing bars, backfill, finish grading, and sodding shall be included in the cost of lighting foundation. The cost of wood poles, multiple rela y switches, service cabinet, photocells, 890 photocell receptacles, weatherhead, conduit, and other miscellaneous items shall be included in the cost of the service point. The cost of lamps, LED arrays, plasma emitters, drivers, optical systems, weatherproof housings, surge protection devices, electrical connections, and installation of the luminaire on the pole shall be included in the cost of luminaire. The cost of snap-on coverings in light pole bases and waterproof coverings in underground handholes shall be included in the cost of multiple compression fitting. The cost of maintaining highway illumination during the life of the contract and the preparation and transmittal of as-built drawings shall be included in the cost of other pay items.
Source: Indiana Standard Specifications, 2024 Edition. Pages 948–971 of 1,248.