SECTION 835 ELECTRICAL TRAFFIC CONTROL DEVICES
835.01 GENERAL. This section covers the material requirements for electrical traffic
control device components (including traffic signals, flashing beacons, and school flashers) that are supplied by the Contractor. Materials commonly provided by the Department are listed on the Project Install Items List (available on the Division of Traffic Operation’s webpage) and are not addressed in these specifications. Certain materials for electrical traffic control devices are included on the Department’s List of Approved Materials. Materials shall comply with the Manual on Uniform Traffic Control Devices (MUTCD) and the Division of Traffic Operation’s Traffic Signal Standard Detail Sheets. Materials shall be approved by the Engineer prior to utilization on a project. Once approval is given for a product, substitutions will only be permitted with written permission from the Engineer. If materials provided by the Contractor are not addressed in these specifications, contact the Division of Traffic Operations for approval before using on a project.
835.02 CONCRETE. Conform to Subsection 834.02.
835.03 STEEL REINFORCEMENT. Conform to Subsection 834.03.
835.04 GROUND RODS. Conform to Subsection 834.04. Use rods with a minimum
diameter of 5/8 inch and a minimum length of 8 feet. 835.05 CONDUIT. Ensure the conduit is the size specified on the plans and detail sheets.
835.05.01 Rigid Steel and Fittings. Conform to Subsection 834.05.01.
835.05.02 Schedule 40/80 PVC and Fittings. Conform to Subsection 834.05.02.
835.05.03 Stainless Steel and Fittings. Conform to Subsection 834.05.03.
835.05.04 Aluminum and Fittings. Conform to Subsection 834.05.04.
835.05.05 Condulent. Conform to Subsection 834.05.05.
835.05.06 Conduit Straps. Conform to Subsection 834.05.06.
835.05.07 Test/Pipe Plugs. Conform to Subsection 834.05.07.
835.06 ELECTRICAL JUNCTION BOX. Conform to Subsection 834.07. Provide a
junction box marked "Signal". If junction box has signal and main service wires, the box shall be marked as “Signal/Electric”. 835.07 MAST ARM POLES. Pole diameter and wall thickness shall be calculated in accordance with AASHTO’s Standard Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals, 2013-6th Edition with current interims. For mast arm poles, provide fatigue classification that is Category II, in accordance with Table 11.6-1 from the AASHTO Standard Specifications with galloping and natural wind gusts, and with a 25 year design life in accordance with Table 3.8.3-2. Provide poles and arms that conform to: 835-1
1.ASTM A595, grade A or B with minimum yield strength of 55 KSI, or
2.ASTM A572, grade 55, or 3) ASTM A53 Provide poles, anchor bolts, base plates, and all other hardware that are hot-dip galvanized per ASTM A123 or A153. Provide base plates that conform to ASTM A36, grade 36 or ASTM 572, grade 50. Ensure transverse plates have a thickness greater than or equal to 2 inches. Provide a base plate for the vertical pole that fits inside a 36 inch diameter concrete base. The anchor bolt circle shall not be more than 24.5 inches. The diameter of anchor bolts shall not be more than 2.25 inches. The bottom pole diameter shall not be less than 16.25 inches. Provide mill certifications as proof of compliance with the specifications. Provide poles that are anchor-based, hot-dipped galvanized inside and out. For anchor bolt design, pole forces shall be positioned in such a manner to maximize the force on any individual anchor bolt regardless of the actual anchor bolt orientation with the pole. Provide poles that are furnished complete with fully galv anized anchor bolts and hardware. The pole handhole shall be 25 inches by 6.5 inches. The handhole cover shall be removable from the handhole frame. On the frame side opposite the hinge, provide a mechanism on the handhole cover/frame that would permit placement of the Department's standard padlock as specified in Subsection 834.26. The handhole frame shall have two stainless studs installed opposite the hinge to secure the handhole cover to the frame. Secure cover with with stainless steel wing nuts and washers. The handhole cover shall be manufactured from 0.25 inch thick galvanized steel (ASTM A153) and have a neoprene rubber gasket permanently secured to the handhole frame to insure weather-tight protection. The hinge shall be adjustable and manufactured from 7 gauge stainless steel. The minimum clear distance between the transverse plate and the bottom opening of the handhole shall not be less than the diameter of the bottom tube of the pole but needs to be at least 12 inches. Provide a copper, stainless steel, or br ass grounding lug installed 180 degrees from the handhole opening and that is accessible from the handhole. Use welds that are in accordance with sections 1 through 8 of the American Welding Society (AWS) D1.1 Structural Welding Code-Steel (2010). Use tackers and welders that are qualified in accordance with the code. Provide a tube that contains only one longitudinal seam weld. Use tube longitudinal seam welds that are free of cracks and excessive undercuts and performed with automatic processes. Visually inspect all welds. Inspect longitudinal welds with magnetic particle examination techniques. Provide calculations and drawings that ar e stamped and certified by a Professional Engineer licensed in the Commonwealth of Kentucky. Provide materials and products that are manufactured in the United States of Amer ica. Provide shop drawings specifying pole height, arm length(s), bolt circle diameter, bolt diameter, and details of the handhole cover assemblies. Provide mast arm poles that are of monotube design similar to the one depicted in the Contract. Provide mast arms that have a maximum 3 degree rise. Arms should have a rise more than 1 degree. The diameter of the mast ar m shall not be greater than 21 inches at the attachment to the pole. Mast arm poles shall include holes for attachment of necessary signal equipment (pedestrian signals, pedestrian de tectors, supplemental signal heads, signs, cameras, etc.). No vibration mitigation device should be considered on mast arm poles. If specified, provide two, 2 inch blind half couplings installed 3 feet from the top of the pole. Provide mast arm poles with a permanently affixed label 6 feet from the bottom of the base plate on the outside with the following information:
1.Manufacturer 835-2
2.Moment
3.Order number Provide a detailed analysis of the pole. The detailed analysis shall be stamped and certified by a Professional Engineer licensed in the Commonwealth of Kentucky. The detailed analysis shall include, but not be limited to, the following calculations:
1.Group I, II, III, IV load combinations as listed in Table 3.4-1 of the AASHTO Standard Specifications.
2.Dimensions and weights for all attachments. This includes areas used for wind, ice (total exterior area of the attachments) and fatigue loads, drag coefficients, projected areas, velocity pressures, and wind forces for each segment.
3.For group loads II, III, and IV, which have wind loads, calculations for each controlling "worst case" wind direction for any aspect of the design (anchor bolts, pole sizing, etc.). For dual arm structures, the wind load shall be analyzed for the perpendicular to each arm and a 45 degree angle between the two arms for Group loads II and III.
4.All structural properties for poles, anchor bolts and base plates. This includes the pole’s diameter, thickness, section modulus, moment of inertia, and cross sectional area.
5.Calculations for each member including: loads, section properties, member forces (axial, shear, bending, and torsion), member deflections (angular and linear), member stresses (actual and allowable), and the combined stress ratio (csr).
6.Fatigue calculations for all fatigue related connections. Provide the corresponding detail, stress category, and example from Table 11.9.3.1-1 of the AASHTO Standard Specifications. In fatigue calcula tions, the effective throat thickness of a complete joint penetration groove weld shall be the thickness of the thinner part joined, per AISC J2.1a.
7.Vertical deflection for galloping of arms. Shall be limited to 8 inches. 8) Horizontal deflection limits for vertical supports in Section 10.4.2.1 of the AASHTO Standard Specification.
835.08 WOOD POLES. Conform to Subsection 834.23.
835.09 ANCHOR BOLTS. Conform to Subsection 834.17. Provide mast arms with a
minimum of six fully galvanized anchor bolts. There shall be two steel templates provided per pole. Depending on the design, one of the supplied templates might be critical for the structural integrity of the headed part of the anchor bolt. Templates shall be contained within a 26.5 inch diameter. All templates shall be fully galvanized to the requirements of ASTM A153. 835.10 BRACKETS. Conform to Subsection 834.15.02.
835.11 ARC FLASH WARNING STICKER. Install a 4 inch by 6 inch Arc Flash
Warning sticker in the center of the outer side of mast arm pole doors. The sticker shall be Metalcraft PLY695 Premium STYLEMARK label (or approved equal) with 0.007 inch thickness, with UV white polycarbonate material, and with MC53FL pressure sensitive adhesive. The sticker shall have two colors of black and custom color orange. 835.12 ANCHORS. Conform to Subsection 834.29.
835.12.01 30 Inch Long Rock Anchor. Conform to Subsection 834.29.01.
835-3
835.12.02 53 Inch Long Rock Anchor. Conform to Subsection 834.29.02.
835.12.03 8-Way 135 Inch Anchor Rod . Conform to Subsection 834.29.03.
835.12.04 Rod. Conform to Subsection 834.29.04.
835.13 METER SOCKET. Provide a meter socket that is 125 AMP, that has copper-
aluminum line, that is ringless, and that has load lugs. Provide a meter socket with a bypass. Provide a meter socket with a 1 inch bolt on hub that is NEMA 3R UL rated for commercial use, and that accommodates overhead and underground feeds. Meter socket shall be certified by UL or third party that it meets North American Standards. Meter socket shall include an arc flash warning sticker that conforms to the one described in Subsection 834.24.
835.14 SAFETY SWITCH. Provide a safety switch disconnect that is 60 AMP, 250 volt,
3-wire, 2-pole, and 2-fuse in a NEMA 3R enclos ure. Provide an enclosure that has a 1 inch size bolt on hub. Provide a bolt pattern on the hub that aligns with predrilled holes on the enclosure. Provide a line cover shield. Provide a safety switch that is UL approved and shall be marked in accordance with the National Electrical Code Article 230.66. Disconnect shall include a Maximum Available Fault sticker that conforms to the one described in Subsection 834.25.
835.15 PADLOCKS. Conform to Subsection 834.26.
835.16 Messenger/Guy/Tether Cable and Hardware.
835.16.01 Messenger, Guy, and Tether Cable. Provide messenger, guy, and tether
cable that consists of "class A", zinc-coated, high-strength steel of the specified strength and extra galvanized per ASTM A475-03. Provide a minimum of 3/8 inch diameter and 7 strands with minimum breaking strength 10,800 pounds. Use 10,800 pound or 15,400 pound wire.
835.16.02 Strandvise. Provide a strandvise that has an automatic jaw type dead-end
for 3/8 inch galvanized steel messenger. Use Reliable #5202L or approved equal.
835.16.03 Strandlink. Provide a strandlink that is a splice for 3/8 inch galvanized steel
messenger. Use Reliable #5042 or approved equal.
835.16.04 Cable Rings. Provide cable rings that are designed for installation on a 3/8
inch-7 strand galvanized steel messenger cable. Provide cable rings that are fabricated from round edge high carbon steel wire that are galvanized after forming. Provide wire size that is 0.090 inch x 0.190 inch (nominal). Provide 3 inch (nominal) cable ring size to accommodate a 2 inch (maximum) cable bundle size. Provide cable rings that are designed to be installed and removed without tools and without damage to the messenger cable.
835.16.05 Bull Rings. Provide bull rings that are weldless 1 inch steel with a nominal
I.D. of 4 inches. Provide a bull ring for the working load limit as specified in contract. Provide working load limits as follows: Type A-10,800 pounds and Type B-15,400 pounds.
835.16.06 Guy Guard. Guy guard shall be 8 feet long, made of yellow plastic, and be
fully rounded. 835-4
835.17 WIRE AND CABLE. Use wire and cable that is plainly marked in accordance
with the provisions of the National Electrical Code.
835.17.01 Ground Wire. Ground wires connected directly to ground rods, cabinets,
transformer bases, services, poles and between bushings shall be copper grounding conductors that are 4 AWG, solid, and bare unless otherwise specified. All grounding conductors 6 AWG and smaller shall be insulated in green color per NEC for all circuit grounds.
835.17.02 Service Wire. Use service entrance conductors that are 6 AWG, stranded,
copper, and Type USE-2. Use conductors that are colored coded according to the National Electric Code.
835.17.03 Signal Cables. Provide signal cables that are 14 AWG, stranded, and copper
with the number of conductors indicated. Cables shall conform to IMSA 19-1. Use 3, 4, 5, or 7 conductors (5 and 7 being the most common) as specified in the Contract.
835.17.04 Loop Wire. Provide loop wire that is 14 AWG, stranded, copper and that
conforms to IMSA 51-7.
835.17.05 Loop Lead-In Cable. Provide loop lead-in cable that is 14 AWG, stranded,
copper, paired conductors, electrically shielded, a nd that conforms to IMSA 19-2. This cable shall only be 1 pair.
835.17.06 Radio Cable. Provide RG-213/U coaxial cable consisting of pre-assembled
cable with connectors. Provide connectors that are crimp type, silver plated with gold center pin, and that have Teflon/TPX insulation. The copper wire shall be stranded. Provide a connector that is waterproof. Use RF Industries RFN 1006 3E or approved equal.
835.17.07 Video Cable. Provide video cable that is #20 AWG, 75 Ohms, and solid
conductor. Use Belden 8281 or approved equal.
835.17.08 Video Power Cable. Cable shall be a #22 stranded copper cable with six
conductors, UL 2464, and PVC coating.
835.17.09 Ethernet Cable. Use General Cable GenSpeed 5000 CAT 5e Outside Plant
Cable 8 wire PN: 5136100 or approved equal. The cable shall meet or exceed the following specifications: Performance: ANSI/TIA/EIA 568B (Category 5e) MIL-C-24640A Water Penetration Propagation Delay: 583 ns @ 100 MHz Return Loss @ 100 MHz: 20.1 DB Frequency Range: 1-350 MHz Physical characteristics: Nominal Outside Diameter: 0.230 in Insulation Type: Polyolefin Maximum Pulling Tension: 25 lbs Maximum DC Resistance: 9.38 Ohms/100m Mutual Capacitance @ 1kHz: 17 pF/100m 835-5 Operating Temperature: -45 ºC to 80 ºC
835.17.10 Splicing. Conform to Subsection 834.13.
835.18 TRAFFIC LOOP ENCAPSULANT. Provide a non-shrink, non-stringing,
moisture cure, one-part, polyurethane traffic loop encapsulant suitable for use in both asphalt and concrete pavements. Encapsulant shall provide a void-free encapsulation for detector loop wires and adequate compressive yield strength and flexibility to withstand heavy vehicular traffic and normal pavement movement. Use one-quart tubes of loop sealant that are suitable for use with a standard caulking gun. The Engineer may reject the product if any physical property renders the material unsuitable. Ensure that the cured encapsulant has the following properties: TRAFFIC LOOP ENCAPSULANT REQUIREMENTS AND PRICE ADJUSTMENT SCHEDULE Test Specification 100% Pay 90% Pay 80% Pay 70% Pay 50% Pay (1) Hardness (3) 25-29 20-24 15-19 14 (ASTM D 2240) 35-65 30-70 71-75 76-80 81-85 86 Tensile Strength, psi (3) (ASTM D 412) 150 min. 145 min. 140-144 135-139 130-134 129 Elongation, % (2, 3) (ASTM D 412) 125 min. 120 min. 115-119 110-114 105-109 104 Density, lb/gal 8. 30-8.49 8.20-8.29 8.10-8.19 8.09 (ASTM D 1875) 9.00-11.00 8.50-11. 50 11.51-11.60 11.61- 11.70 11.71-11.80 ≥ 11.81 Tack-free Time, hours (ASTM C 679) 24 max. 24.5 max. 24.6-25.0 25.1-25.5 25.6-26.0 26.1 C o m p l e t e D r y T i m e , hours (KM 64-447) 30 max. 30.5 max 30.6-31.0 31.1-31.5 31.6-32.0 32.1 Chemical Interactions: (KM 64-446) Motor Oil No Effect Deicing Chemicals No Effect Gasoline Slight Swell Hydraulic Brake Fluid No Effect
1.If allowed to remain in place, the Department will review materials performing in this range on a project-by-project basis to determine if removal of the material is warranted.
2.Tested at a 2- inch per minute pull rate.
3.7-day cure 835.19 NON-SHRINK GROUT. Provide non-shrink grout from the Department’s List of Approved Materials. 835-6
835.20 BACKER ROD. Provide backer rod that has closed cell polyethylene foam.
Provide a backer rod that is 1/2 inch diameter. Provide backer rod that has the minimum density of 2.0 pounds/cubic feet using the ASTM D 1622 test method and tensile strength of 50 PSI using the ASTM D 1623 test method. Provide backer rod that has the maximum water absorption of 0.03 gm/cc using ASTM C 1016 test method.
835.21 WARNING TAPE. Conform to Subsection 834.33.
835.22 LIGHTING POLES. Conform to Subsection 834.15.
835.23 BANDING. Conform to Subsection 834.28.
835.24 GROUNDING LUGS. Conform to Subsection 834.27.
835.25 HUB PLATES. Use aluminum hub plates.
835.25.01 Hub Plate Without Conduit Hub. Use hub plate with 1.5 inch NPS. Use
Pelco Products SE-0357 or approved equal.
835.25.02 Hub Plate With Conduit Hub. Use hub plate with 1.5 inch NPS and 1.25
inch NPT conduit hub. There shall be an aluminum threaded plug for the conduit hub. Use Pelco Products SE-0382 or approved equal.
835.26 CELL ANTENNA. Antennas shall work with all major cell phone companies.
835.26.01 AP Double Cell Antenna Magnetic/Threaded Bolt Mount. Use AP-CCG
with magnetic mount, AP-CCG with Threaded Bolt mount, or approved equal. Antennas shall meet the following requirements: Dimensions: A 2 inch (51 mm), B 4 inch (102 mm), and C 6.8 inch (173 mm) Mounting Styles: Magnetic or threaded bolt Frequencies: Cellular/LTE = 824-896 MHz; 1850-1995 MHz; 698-798 MHz; 1710-1770 MHz; 2110-2170 MHz; 2570-2620 MHz GPS = 1575.42 MHz VSWR: 1.5:1 or less at resonant point Gain: 3.0 dBi Radiation Pattern: OMNI Directional Polarization: Vertical Radome: Glass Filled Polypropylene Cable Length: 15 feet (4.5 m) (Adhesive and Threaded Bolt Mount) Temperature: −40 °C to 85 °C ( −40 °F to +185 °F) operating and storage Humidity: (non-condensing) - 5% to 95% operating and storage Military Spec MIL-STD 810 conformance to thermal, mechanical shock, and humidity 835-7
835.26.02 Welded Wideband Directional Antenna. Use Comtelco Y42700WB or
approved equal. Antennas shall meet the following requirements: Termination Options: Type A: 12 inch Teflon pigtail with N connector Gain: 10dBi/8dBd Frequency @ VSWR 698- 2800MHz F to B Ratio: 20dB Vert Beamwidth: 40º Horiz Beamwidth: 40º Power Rating: 150 watts Impedance: 50 ohms Material: Aluminum booms, 3/16 inch solid welded elements Radome: 3 inch UV inhibited ABS Length: 13.5 inches Weight: 2 pounds Mounting: 2 1/2 inch mast maximum Flat Plate Area: 0.12 square feet Wind Rating: 125 MPH Wind Load: 8.1 pounds N-Female, Includes Mounting Hardware
835.27 FUSED CABLE CONNECTOR KIT. Conform to Subsection 834.11.
835.28 WARRANTIES. Conform to Subsection 834.34.
835.29 DOCUMENTATION. Conform to Subsection 834.35.
835-8 SECTION 836 - DURABLE PREFORMED PAVEMENT MARKINGS TYPE I TAPE
836.01 GENERAL. Use preformed pavement marking material consisting of white or
yellow films with retroreflective optics incorporated to provide immediate and continuing retroreflection. Use preformed pavement marking material capable of adhering to new dense and open graded asphalt surfaces, during the paving operation, or portland cement concrete by a pre- coated pressure sensitive adhesive. The Engineer may require a primer to precondition the pavement surface. Ensure that the markings conform to pavement contours by the action of traffic. Ensure that, after application, the markings are immediately ready for traffic. Ensure that these markings provide long term reflectivity, as determined in the following performance requirements, when applied according to the manufacturer’s instructions. Ensure that the preformed markings are suitable for use one year after the date of receipt when stored according to the manufacturer’s recommendations.
836.02 Requirements.
836.02.01 Composition. U se retroreflective preformed pavement markings
consisting of a mixture of high quality polymeric materials, pigments, and retroreflective optics distributed throughout its base cross sectional area.
836.02.02 Reflectance. Ensure that the whi te and yellow markings have the
following minimum reflectance values as measured according to the testing procedures of ASTME 1701. Measure the coefficient of retr oreflective luminance and express the value as millicandelas per square meter per lux [(mcd/m2)lx-1]. MINIMUM REFLECTANCE Color Entranc e Observatio n Minimum Reflectance Angle Angle White 88.76º 1.05º 500 minimum Yellow 88.76º 1.05º 500 minimum
836.02.03 Skid Resistance. Ensure that the surface of the retroreflective
material provides an initial minimum skid resistance value of 45 BPN when tested according to ASTM E 303.
836.02.04 Patchability. Ensure that the pavement marking material is capable
of use for patching worn areas of the sa me type according to the manufacturer’s recommendations.
836.02.05 Material Quality. Replace any material used as longitudinal or
intersection markings that fails minimum reflecti vity values or fails due to loss of adhesion or complete wear through. Minimum replacement zone is 300 feet of roadway length or one intersection marking.
836.03 APPROVAL. The Department will approve Type I pavement marking tape based
on conformance to KM 64-207 and this section. 836-1
Source: Kentucky Standard Specifications for Road and Bridge Construction, 2019 Edition. Pages 657–664 of 718.