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 958–971 of 1,248.