951TRAFFIC SIGNAL SUPPORTS

951.1DESCRIPTION—This work is the furnishing and installation of complete and operational traffic signal

supports for the mounting of traffic control devices, signs, and luminaires.

951.2MATERIAL—

• Traffic Signals-General. Section 950.2

• Certification. As specified in Section 106.03(b)3.

• Class A and AA Cement Concrete. Section 704

• Pre-molded Expansion Joint Filler. Section 705.1

• Reinforcement Steel. Section 709.1

• Conduit. Section 954.2(b)

• Non-shrink Mortar. Section 1001.2(e)

• Metal screening. Section 1101.02

• Ground Rod. Section 1101.11(j)

1.a Design and Acceptance. Design according to Publication 149 and LRFD Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals. Submit shop drawings according to Publication 149, including calculations for all special structures, for review and acceptance.

1.b Structural Material. Fabricate traffic signal structural material as specified in Section 1105.03, according to AWS D1.1, AWS D1.2, and according to the AASHTO M 270 (ASTM A709); Do not apply water to the base metal during plasma arc cutting. Bulletin 15 listing and shop inspection is required. Provide an AWS certified welding inspector (CWI) for welded steel or aluminum pole products as specified in Section

1105.01(g)3. Bulletin 15, shop inspection, and Section 1105 do not apply to painting of aluminum poles and

for the following non-welded items: cast aluminum poles, cast steel poles, and cast-iron poles. The Charpy V -Notch toughness test is required for load carrying tension members greater than 1/2 inch in thickness, as required for Zone 2, non- fracture critical criteria, according to the applicable AASHTO specifications. Provide steel poles that are either round or multi-sided with a minimum of eight sides. Provide testing and test methods according to AWS D1.1 or AWS D1.2 and as determined by the BDTD SMS. Provide non- destructive testing on 100% of full penetration groove welds and a random 25% of partial penetration groove welds of longitudinal seams on steel poles and arms. When inspecting full penetration seam welds, use radiographic test methods on mater ial less than 5/16- inch in thickness, and use radiographic or ultrasonic test methods on material 5/16- inch and greater in thickness. Use magnetic particle inspection on partial penetration seam welds. Provide non-destructive testing by ultrasonic test methods on random 25% of all pole to base plate

and arm to arm plate full penetration groove welds. For tube material less than 5/16-inch in thickness, have the fabricator submit a detailed ultrasonic testing procedure, including acceptance criteria, to the BDTD SMS for review and approval before testing. For all other welds on steel traffic poles, perform magnetic particle inspection on a minimum of 25% of the length of each weld. Provide inspection for the full length of the weld when less than 6 inches in length. For mast arm connections, perform testing of bolts, nuts, and washers, including initial rotational - capacity testing of assemblies, as specified in Section 1105.02(d)7. For aluminum traffic pole structures, perform fabrication and non-destructive testing as specified in Section 1101.01. Where less than 100% of the weld is non-destructively tested, and a rejectable defect is found, test 100% of the length of the weld. Where applicable, the Representative will select portions of welds to be tested. Perform and evaluate all non-destructive testing according to cyclically loaded non- tubular tension criteria.

1.c Support Shafts and Arms. Fabricate shafts and arms in any of the following shapes and styles:

Round Tapered.

• One longitudinal seam, continuously welded, and ground or rolled flush.

• Transverse butt welds are not acceptable.

• Uniform wall thickness.

• Uniform taper, 0.14-inch maximum and 0.07-inch minimum per foot of length.

Round Stepped.

• Round pipe sections, each with not more than one longitudinal seam continuously welded and ground or rolled flush. Join sections by a hot-swaged shrink fit continuously seal-welded to prevent entrance of water.

• Uniform wall thickness for each section.

• Maximum change in diameter between stepped sections not to exceed 2 1/8-inches.

Round Untapered.

• Maximum of one longitudinal seam, continuously welded, and ground or rolled flush.

• Uniform wall thickness and diameter.

• Transverse butt welds are not acceptable

Multi-Sided Tapered.

• Maximum of two longitudinal seams, continuously welded, and ground or rolled to a maximum bead height of 1/8-inch.

• Transverse butt welds are not acceptable.

• Uniform wall thickness.

• Uniform taper, 0.14-inch maximum and 0.07-inch minimum per foot of length.

• Minimum of eight sides.

1.d Additional items.

Cable Support.

• Weld a cable support to the inside top of the shaft.

Grounding.

• Weld a UL-Listed grounding lug, capable of accommodating a No. 6 AWG stranded copper cable, to the inside of the shaft adjacent to the handhole.

Handholes.

• Provide handholes in the shaft of the poles, as shown on the Standard Drawings.

• Reinforce the area to develop the minimum guaranteed yield strength of the shaft.

• Furnish a cover and keeper chain for each handhole.

Wire Inlets.

• Provide a wire inlet at each signal head or at each electrically operated sign location.

• Weatherproof each inlet with an insulated grommet.

• Provide a deburred hole, 2 1/2-inch minimum diameter, in the flange plate and shaft, which serves as a wire entrance into the arm from inside the shaft.

• Provide Type LB access fittings from Type II mounted controller cabinet into pole shaft and in pole shafts for pedestrian pushbuttons.

Anchor Bases.

• Fabricate the base clean, smooth, and of the dimensions necessary for adequate pole mounting and structural support.

• Provide holes for anchor bolts.

• Fabricate the base to telescope over the shaft and be secured in place by welding.

Galvanizing. Section 1105.02(s) and as follows:

• Galvanize steel shafts and arms, including those manufactured of high strength and corrosion resistant steels, according to ASTM A123 (AASHTO M 111).

• Galvanize accessories and hardware according to ASTM A153 (AASHTO M 232).

• Shaft and Arms. AASHTO M 270/ASTM A709, Grade 36 or Grade 50, ASTM A36, ASTM A53, ASTM A572 Grade 50, ASTM A501 and A595.

• Luminaire Mounting Arms. Section 1101.03.

• Anchor (Base) Plates, Flange Plates, and Gusset Plates. AASHTO M 270 (ASTM A709), Grade

• Miscellaneous Shapes, plates and bars. AASHTO M 270 (ASTM A709), Grade 36. ASTM A36, ASTM, ASTM A572 Grade 50 and ASTM A992.

• Flange Plate Assembly Bolts, Nuts and Washers. ASTM F3125 Grade A325, ASTM 563 and ASTM F436. Mechanically galvanize according to ASTM B695. Furnish bolts, nuts, and washers for testing purposes and test as specified in Section 1050.02(c)7.b.

• Shaft and Arm Caps. Galvanized steel (C-coat) cast iron or cast aluminum.

• Handhole CH and hole Cover Plates. AASHTO M 270 (ASTM A709), Grade 36. ASTM A36, ASTM, ASTM A572 Grade 50, and ASTM A1011.

• Pipe Caps. AASHTO M 270 (ASTM A709), Grade 36. ASTM A36, ASTM, ASTM A572, ASTM A1011, or ASTM B26

• Galloping Mitigation Device, as shown on the Standard Drawings.

3.a Aluminum.

• Support. One length, 4 1/2-inch minimum outside diameter aluminum pipe, Schedule 40, ASTM B210, or B221, Alloy 6063-T6.

• Bases. Cast aluminum, ASTM B26, or B 108, Alloy 356- T6; aluminum plate, ASTM B209, Alloy 6061-T6.

• Pole Tops. Aluminum.

3.b Steel.

• Support. One length, 4 1/2-inch minimum outside diameter steel pipe, Schedule 40, ASTM A53, Type F.

• Base. Steel casting, ASTM A27, Grade 65-35; gray iron casting, ASTM A126, Class 26; steel plate, AASHTO M 270 (ASTM A709), Grade 36.

and a rounded top cap to minimize injuries.

• Anchor Bolts. ASTM F1554.

• Hex Nuts. ASTM A563M/A63.

• Washers. ASTM F436.

Provide bolts and all associated hardware that are galvanized as specified in Section 1105.02(s) , ASTM A153, or by another acceptable method conforming to the coating thickness, adherence, and quality requirements of ASTM A153. Provide anchor bolts that are galvanized to the top 8 inches of the bolts. Furnish template prints for setting anchor bolts with each support.

and dressed by the mill as to grade and mark as specified in the grading rules and basic provisions of the American Lumber Standards (PS-20-70) by a lumber grading or inspection bureau or agency. If dressed, the grade mark shall be applied after dressing.

a sample and corresponding Federal Color Number, that conforms to the color specified, to Municipality and Representative for approval at least 60 days before ordering the traffic signal support poles. Clamps, brackets, banding, strapping, and/or connections placed on powder coated supports shall match the color of supports. Powder coated supports are to be galvanized with surfaces mechanically etched by brush blasting followed by preheating of the zinc coated substrate to a temperature of 450F for a minimum of one hour in a gas fired convection oven. Apply powder coating electrostatically and cure in a gas-fired convection oven by heating the zinc coated substrate to a minimum temperature of 350F and a maximum temperature of 400F. Provide thermosetting powder resin that provides both intercoat as well as substrate fusion adhesion that meets 5A or 5B according to ASTM D3359. Supports are to be wrapped in 3/16-inch-thick ultra-violet inhibited plastic-backed foam and cradled in a 1.0-inch-thick rubberized foam base for transportation. Provide painted matching hardware for all powder coated supports.

951.3CONSTRUCTION—Section 950.3, and as follows:

the actual soil conditions encountered. Do not proceed with the work until the excavation is accepted. If necessary, revise the foundation design based on the soil conditions encountered. Before submitting the revised design for approval, obtain the signature and seal of a Professional Engineer registered in the State. Foundation locations may be changed to avoid underground obstructions, with written permission of the Representative.

wire clamps. Orient the anchor bolt template to obtain the proper angle of the mast arm. Place concrete as specified in the applicable parts of Section 1001.3. Place concrete to the finish height . Place Class AA concrete for pedestrian stub pole foundations that are integrated into curb as specified in Section 676.3. Backfill around the foundation in 6-inch layers with selected on-site material, then compact mechanically to the density of the undisturbed earth. Dispose of excess or unsuitable material. Place 1/2 inch pre-molded, expansion joint filler between the foundation and existing concrete sidewalks and pavements. After placing concrete, do not install supports for a minimum of 72 hours and the concrete meets compressive strength requirements for Class A as specified in Section 704.

on the anchor bolts to adjust the vertical support rake to provide a vertical set when the load is added. Connect the ground wire to the grounding lug. After installing supports, tighten anchor nuts as specified in Section 948.3(e) and Section 1105.03(j). Place non-shrink mortar or metal screening, providing a drain hole in the mortar or screening. Place mortar or screening vertically at the outside edge of the base plate.

support connections are not allowed. Check for vertical alignment of the mast arm after signals, brackets,

signs, luminaires, and signal cable are in place. Adjust leveling nuts to correct alignment as needed.

on all new, retrofitted, and updated strain poles. All new mounting hardware is required to attach span and tether wires to the signal supports, including span wire clamps and dead- end, feed-thru strand vises with stainless steel bails. Provide equipment certifications and sources of supply to the Department for approval before installation. Allow enough span wire and tether wire length to make sag adjustments after fastening. After installing signal cable, signal heads, and signs, adjust sag of span wire. Check for vertical alignment of strain pole and adjust leveling nuts as needed to correct alignment.

3.a. Foundation Mounted Stub Poles. Place Class A concrete for cast-in-place foundation. Install exposed conduit as shown in the Standard Drawings.

3.b. Curb Mounted. Place Class AA concrete curb, including blister if applicable, as specified in Section 630.3. Install exposed conduit as shown in the Standard Drawings.

3.c. Sidewalk Mounted. Place Class A concrete as specified in Section 676.3. Install exposed conduit as shown in the Standard Drawings.

the coating. Pad and handle all components during loading, unloading, and installation. If the coating becomes chipped, scratched, blistered, or otherwise damaged, it must be repaired according to the coating manufacturer’s recommendations at no additional cost to the Department.

951.4MEASUREMENT AND PAYMENT—