982 Page 558982 MATERIALS FOR HIGHWAY SIGN AND DELINEATORS
982.1GENERAL REQUIREMENTS
A Certificate of Compliance will be furnished for each material item and will state that the item conforms to the required specification, with reference being made to the appropriate specification number.
982.2SPECIFIC REQUIREMENTS
A.Signs: 1.Sheet Aluminum: Sheet aluminum will meet the requirements of ASTM B209 for alloy 5052- H38 or alloy 6061-T6. The aluminum will be properly degreased and etched or treated with a light, tight, amorphous chromate coating. Sheet aluminum thickness requirements will be based on the maximum horizontal in place dimension of each sheet aluminum sign in accordance with the following: Horizontal Dimension of in Place Sign BlankRequired Sign Blank Thickness 30 inches and less 0.080 inch Over 30 inches 0.100 inch Sheet aluminum for signs used to overlay other sign surfaces will have a thickness of 0.063 inch. Cutout aluminum backing for removable letters, numerals, symbols, and borders will be a minimum of 0.032 inch thick aluminum sheet of alloy 6061-T6 or alloy 3003-H14. Route markers for use on guide signs will be 0.063 inch thick aluminum sheet of alloy 6061-T6. The sheared edges of blanks will be straight and free from tears and raggedness. 2.Extruded Aluminum: Extruded aluminum will meet the requirements of ASTM B221 for alloy 6061-T6 or alloy 6063-T6. No more than one 6 inch wide panel will be used in any sign. 3.Sign Molding: Side trim molding will be an aluminum extrusion designed for the sign panel extrusion with which it is used and will conform to ASTM B221 for alloy 6063-T6 or alloy 6061- T6. The sign molding will be of the same color as the sign face it accompanies. 4.Connections: U Clamp connections will be fabricated from ASTM A36 steel. The steel will be galvanized in accordance with ASTM A123. Fabrication will be completed prior to galvanizing. Z-bars and Angles used to mount sheet aluminum signs will meet the requirements of ASTM B308 for alloy 6061-T6. Post clips for wide flange posts will meet the requirements of ASTM B108 for alloy 356.0-T6. Bolts, nuts, and washers for mounting signs to aluminum backing hardware will be aluminum, conforming to the following: 982 Page 559Bolts - alloy 2024-T4 (ASTM B 211) Hex Nuts - alloy 6262-T9 (ASTM B 211) Lock Nuts - alloy 2017-T4 (ASTM B 211) Washers - alloy 2024-T4 (ASTM B 209) Bolts and nuts for attaching signs or attaching sign backing hardware to wood posts will conform to ASTM A307 and ASTM A563. Washers will conform to ASTM F436. Bolts, nuts, and washers will be galvanized in accordance with ASTM F2329. B.Perforated Tube Posts: Post material will meet impact performance (change in momentum) requirements for small sign supports contained in the current AASHTO "Standard Specifications for Structural Supports for Highway Signs, Luminaries, and Traffic signals." Perforated tube posts will conform to ASTM A1011 Grade 50 structural steel. Posts will be a square tube formed of 12 gauge steel, 0.105 inch thick, rolled to size. The tubing will be molded so the weld or flash does not interfere with telescoping. The posts will be hot dipped galvanized with a 1.25 ounce per square foot coating conforming to ASTM A123. As an alternate, the post will be given a triple coated protection by application of hot dip galvanized zinc conforming to ASTM A53, followed by a chromate conversion coating and a polyurethane exterior coating, with inside surfaces given corrosion protection by in-line application of zinc base organic coating after fabrication. The posts will be punched, bored, or have knockouts with 7/16 inch diameter holes on 1 inch centers of all four sides for the entire length of the posts. The post sections will be straight, with a smooth uniform finish and a minimum amount of play between telescoping sections. Holes and cutoff ends will be free of burrs and ragged edges. Bolts, nuts, and washers will conform to ASTM A307, ASTM A563, and ASTM F436, respectively, and will be galvanized in accordance with ASTM B695. C.Steel Posts: 1.Structural steel posts and stiffeners will conform to ASTM A36. Pipe posts will conform to ASTM A53 Type E or S Grade B, ASTM A501, or ASTM A500 Grade B. 2.Steel posts (structural and pipe) and stiffeners will be galvanized in accordance with ASTM A123. Welding, punching, and boring of the steel posts will be done before galvanizing. 3.Cantilever structural supports will be fabricated steel in accordance with the following: a.Shapes, plates, bars, sheets, and strips equal to or over 0.23 inches thick will conform to ASTM A709, Grade 36 or ASTM A992. Sheets and strips under 0.23 inches thick will conform to ASTM A1011 Grade 36. 982 Page 560b.Pole and tubular members will conform to ASTM A709 Grade 36 and Grade 50, A53 Grade B, A242, A1011 Grade 36, or A595 Grade A or B. A595 material will be limited to 3/8 inch maximum thickness. Structural support material with a thickness of 1/2 inch to 2 inches will satisfy Charpy V-Notch toughness test requirements of 15 foot-pounds at 40°F. For material over 2 inches, contact the Office of Bridge Design for Charpy impact requirements. 4.High-strength bolts for structural steel joints, including nuts and washers, will conform to Section 972. D.Wood Posts: Wood posts will be Western Red Cedar. They will be construction grade in compliance with the Standard Grading Rules of the Western Wood Products Association. Posts will be surfaced four sides. E.Sign Bridges and Overhead Cantilever Sign Supports: Sign bridges and overhead cantilever sign supports will be constructed in accordance with the details in the plans and at the locations shown. 1.Design Specifications: The current edition of the AASHTO Standard Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals, including all subsequent interims. a.Wind load will be calculated using the 50 year mean recurrence interval basic wind speed. b.The cantilever supports, including anchor bolts, will be designed for fatigue in accordance with Fatigue Importance Category I. This is to include truck-induced gust loads, natural wind gust loads, and unless installed with approved vibration mitigation devices, will also include galloping loads. Details for any proposed vibration mitigation devices must be submitted with the shop plans for review by the Department prior to fabrication. Supporting documentation (historical and research data) verifying the damping characteristics of the specific mitigation device for the intended structural support application must accompany the submittal. 2.General: a.Cantilever arms will be truss type members. Mono-tube or single member arms are not allowed. b.No splices of any kind will be permitted in the vertical pole members. c.Truss type sign supports will have a minimum of 8 anchor bolts. d.Anchor bolts and rods will be provided with leveling nuts, top nuts, washers, and jam nuts. e.All members and components will be galvanized after fabrication in accordance with ASTM A123, A153, or F2329 as applicable. 982 Page 5613.Shop Plans: Plans and design calculations for the sign support structure (including anchor bolts or anchor rods) will be prepared by a Professional Engineer registered in the State of South Dakota. Prior to fabrication, the Contractor will submit shop plans and design calculations to the Department for the Department’s opportunity for review. Any review by the Department of the shop plans and design calculations is limited to general conformance with the contract plans and specifications only. The Contractor will send an email with the shop plans and design calculations attached as a PDF to the Project Engineer, Region Traffic Engineer, and Office of Bridge Design. Upon request, the Project Engineer will provide the Contractor the appropriate email addresses. Within 28 calendar days of receiving the shop plans and design calculations, the Office of Bridge Design will respond to the Contractor in one of the following ways: 1) No Exceptions Noted; 2) Returned for Revision; or 3) Not Required for Review. If the Department’s response states, “Returned for Revision”, the Contractor must make the revisions and resubmit the shop plans and design calculations for review as specified above. The Contractor will not begin fabrication or construction of the work contained in the shop plans until the Department has confirmed, in writing, a completed review with a response of “No Exceptions Noted” or “Not Required for Review”.
a.Welding and weld inspection will be done in accordance with the latest edition of ANSI/AWS D1.1 Structural Welding Code. b.Approved Welding Procedure Specifications (WPS) are required for all welding. WPS's will be based upon Procedure Qualification Testing (PQT) in accordance with the latest edition of ANSI/AWS D1.1 Structural Welding Code. c.The steel pole-to-base-plate connection will be a full-penetration groove-welded connection with a backing ring as described in the AASHTO Standard Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals. d.If welded connections are used subsequent to galvanizing, the weld details and the procedure for preparing the surface for welding and repainting the galvanizing with zinc-rich paint after welding will be included with the shop plans. e.The Department’s Bridge Construction Engineer will be notified as to what date fabrication will begin. This notification will be provided a minimum of 30 calendar days prior to fabrication. The Bridge Construction Engineer will at that time arrange for fabrication inspection. Fabrication will not begin until authorization has been given by the Department’s Bridge Construction Engineer. F.Fixed Base Assemblies: 1.Base Plates: Base plates will conform to ASTM A36. The base plates will be galvanized in accordance with ASTM A123. Welding, punching, and boring of the base plates will be done before galvanizing. 2.Anchor Bolts and Anchor Rods: Anchor bolts and anchor rods will conform to Section 972. 982 Page 562G.Slip Base Assemblies: 1.Base Plates and Friction Fuse Plates: Base plates and friction fuse plates will conform to ASTM A36. The plates will be galvanized in accordance with ASTM A123. Welding, punching, and boring of the plates will be done before galvanizing. 2.Bolts, Nuts and Washers: Bolts, hex nuts, and washers used in conjunction with base plates or friction fuse plates will conform to ASTM F3125 Grade A325, except 1/2 inch and 5/8 inch bolts conforming to ASTM A449 are permissible instead of Grade A325. Bolts, hex nuts, and washers will be covered with zinc coating (hot dip galvanized) per ASTM F2329. 3.Shims: Shims used in conjunction with base plates or friction fuse plates will be covered with a zinc plating (electro-deposited zinc) as per ASTM B633. H.Reflective Sheeting: 1.Grade: The reflective sheeting will be of the Type conforming to ASTM D4956 specified in the plans. 2.General Characteristics: The reflective sheeting will be free from ragged edges, cracks, and extraneous materials. There will be no more than four splices per 50 yard length. Splices will be made by overlapping the sheeting a minimum of 3/16 inch. 3.Fabrication: The background for signs will be sheet reflective material applied to aluminum backing. The preparation of the aluminum surface and the sheeting application will be in complete compliance with the recommendations of the manufacturer. All legend and border utilizing the color black will be vinyl or screen printed black, non- reflectorized material. All other legend and border will be of the same type of sheeting as the background of the same sign. 4.Application: Reflective sheeting will be applied to properly prepared aluminum (degreased and etched or treated with a light, tight, amorphous chromate coating) with mechanical equipment in a manner prescribed by the sheeting manufacturer. Sign faces comprising two or more pieces or panels of reflective sheeting must be carefully matched for color during sign fabrication to provide uniform appearance and brilliance, day and night. Alternate, successive width sections of either sheeting or panels must be reversed and consecutive to ensure that corresponding edges of reflective sheeting lie adjacent on the finished sign. Reflective sheeting for extruded aluminum sign panels will be of the pressure sensitive type. Splicing of the sheeting will not be allowed except those splices permitted by the sheeting manufacturer. The sheeting will be rolled over the edge of the extrusion 1/4 inch to prevent an open surface on the finished sign face. Reflective sheeting for sheet aluminum signs will be of the pressure sensitive or heat activated type. Splicing of the sheeting will not be allowed except those splices permitted 982 Page 563by the sheeting manufacturer. Splices will not be permitted on signs which are screen processed with transparent color. 5.Legend: Message and borders will be type, reflective material, and color specified. Either removable copy or non-removable copy will be allowed. Non-removable copy may be screen processed or direct applied. a.Removable Copy: Letters, numerals, symbols, borders, and route markers will be demountable, cut-out legend consisting of reflective sheeting applied to flat sheet aluminum backing. Letters, numerals, symbols, and borders will be fabricated using a minimum of 0.032 inch thick aluminum sheet of ASTM B209 6061-T6 or 3003-H14 alloy. The aluminum will be properly degreased and etched or treated with a light, tight, amorphous chromate coating. Each letter, numeral, symbol, border, and route marker will be supplied with 9/64- inch mounting holes at no greater spacing than eight inches on center and will be secured to the sign surface with 1/8-inch aluminum blind rivets. The heads of the rivets will be painted the color of the legend. The finished letters, numerals, symbols, borders, and route markers will be clean cut, sharp, and have essentially a plane surface. b.Non-removable Copy: 1)Screen Process: Message and borders will be processed on reflective sheeting using mechanical equipment, materials, and operational methods and procedures as prescribed by the sheeting manufacturer. Processing will be accomplished by the direct or reverse screen method using opaque or transparent processing material as required. Screening may be accomplished either before or after application of the sheeting to the base panels, conditional upon the method recommended by the sheeting manufacturer. Freehand painting will not be permitted on any part of the finished sign face. 2)Direct Applied: Cut-out message and borders will be reflective sheeting or opaque lettering film applied directly to clean, dust free, reflective sheeting background. Message and borders will be applied in accordance with the operational methods and procedure prescribed by the sheeting manufacturer. The finished letters, numerals, symbols, and borders will be cut with smooth regular outline, free from ragged or torn edges. Mounting holes will not be drilled or punched in any part of the nonremovable copy. 6.Color: The reflective sheeting will meet the color specification limits and luminance factors listed in Tables 1-4 when tested in accordance with ASTM E1347 or ASTM E1349. Fluorescent retroreflective materials will be tested in accordance with ASTM E991. The reflective sheeting will maintain the colors and luminance factors provided in the appropriate tables throughout its service life. Warning signs, except those for bicycle and shared use path facilities, will be fluorescent yellow. Warning signs for bicycle and shared use path facilities will be fluorescent yellow green. All pedestrian and school signs will be fluorescent yellow green. 982 Page 564Table 1 Chromaticity Coordinates (corner points) 1 2 3 4 Color X Y X Y X Y X Y White 0.303 0.300 0.368 0.366 0.340 0.393 0.274 0.329 Red 0.648 0.351 0.735 0.265 0.629 0.281 0.565 0.346 Orange 0.558 0.352 0.636 0.364 0.570 0.429 0.506 0.404 Brown 0.430 0.340 0.430 0.390 0.518 0.434 0.570 0.382 Yellow 0.498 0.412 0.557 0.442 0.479 0.520 0.438 0.472 Green 0.026 0.399 0.166 0.364 0.286 0.446 0.207 0.771 Blue 0.078 0.171 0.150 0.220 0.210 0.160 0.137 0.038 Table 1: Daytime Color Specification Limits for Retroreflective Material with CIE 2 Standard Observer and 45/0 (0/45) Geometry and CIE Standard Illuminant D65. Table 2 Chromaticity Coordinates (corner points) 1 2 3 4 Color X Y X Y X Y X Y White 0.475 0.452 0.360 0.415 0.392 0.370 0.515 0.409 Red 0.650 0.348 0.620 0.348 0.712 0.255 0.735 0.265 Orange 0.595 0.405 0.565 0.405 0.613 0.355 0.643 0.355 Brown 0.595 0.405 0.540 0.405 0.570 0.365 0.643 0.355 Yellow 0.513 0.487 0.500 0.470 0.545 0.425 0.572 0.425 Green 0.007 0.570 0.200 0.500 0.322 0.590 0.193 0.782 Blue 0.033 0.370 0.180 0.370 0.230 0.240 0.091 0.133 Table 2: Nighttime Color Specification Limits for Retroreflective Material with CIE 2 Standard Observer and Observation Angle of 0.33 , Entrance Angle of +5 and CIE Standard Illuminant A. Table 3 Chromaticity Coordinates (corner points) 1 2 3 4Luminance Factor (Y %) Color X Y X Y X Y X Y Min Max Fluorescent Orange0.583 0.416 0.535 0.400 0.595 0.351 0.645 0.355 25 None Fluorescent Yellow0.479 0.520 0.446 0.483 0.512 0.421 0.557 0.442 45 None Fluorescent Yellow Green0.387 0.610 0.369 0.546 0.428 0.496 0.460 0.540 60 None Fluorescent Green0.210 0.770 0.232 0.656 0.320 0.590 0.320 0.675 20 30 Table 3: Daytime Color Specification Limits and Luminance Factors for Fluorescent Retroreflective Material with CIE 2 Standard Observer and 45/0 (0/45) Geometry and CIE Standard Illuminant D65. 982 Page 565Table 4 Chromaticity Coordinates (corner points) 1 2 3 4 Color X Y X Y X Y X Y Fluorescent Orange0.625 0.375 0.589 0.376 0.636 0.330 0.669 0.331 Fluorescent Yellow0.554 0.445 0.526 0.437 0.569 0.394 0.610 0.390 Fluorescent Yellow Green0.480 0.520 0.473 0.490 0.523 0.440 0.550 0.449 Fluorescent Green0.007 0.570 0.200 0.500 0.322 0.590 0.193 0.782 Table 4: Nighttime Color Specification Limits for Fluorescent Retroreflective Material With CIE 2 Standard Observer and Observation Angle of 0.33 , Entrance Angle of +5 and CIE Standard Illuminant A. I.Concrete Footings: Concrete footings will conform to Section 462. J.Object Markers: 1.Description: Object markers will be adhesive coated reflective sheeting permanently bonded to sheet aluminum backing. Object markers will be of the size and color specified. Type 1, 2, 3, and 4 object markers will conform to the following requirements: a.Type 1 object markers will consist of a yellow 18" x 18" reflector unit. b.Type 2 object markers will consist of a yellow 6" x 12" or size specified reflector unit. c.Type 3 object markers will consist of a yellow and black 12" x 36" reflector unit. The yellow and black stripe pattern will be 6” black and 4” yellow. d.Type 4 object markers will consist of a red 18” x 18” reflector unit. 2.Reflective Sheeting: The reflective sheeting will be Type XI conforming to ASTM D4956. In addition to the requirements stated above, the reflective sheeting will maintain the colors provided in the appropriate tables contained in Section 982.2 H.6 throughout its service life. 3.Fabrication: The aluminum will be a 0.063 inch thick sheet conforming to the requirements of ASTM B 209 for alloy 6061-T6 or 5052-H38. The aluminum will be properly degreased and etched or treated with a light, tight, amorphous chromate coating. The reflective sheeting will be applied to properly treated base panels with mechanical equipment in a manner specified by the sheeting manufacturer. 982 Page 5664.Shape and Holes: Object markers will be punched or sheared to size with 1½” radius corners. Mounting holes will be as follow: a.Type 1 object markers will have 2 holes 1/4 inch in diameter 20 inches center to center. b.Type 2 object markers will have 2 holes 1/4 inch in diameter 8 inches center to center. c.Type 3 object markers will have 2 holes 1/4 inch in diameter 30 inches center to center. d.Type 4 object markers will have 2 holes 1/4 inch in diameter 20 inches center to center. 5.General Requirements: The finished object markers will be free of burrs, scratches, and damaged reflective sheeting and will have essentially a plane surface. 6.Object Marker Posts: Posts will be flanged channel section fabricated from hot rolled carbon steel bars or carbon steel bars and shapes produced from standard rail steel. The posts will meet the minimum physical properties of ASTM A499, Grade 60. The posts will meet the chemical properties of ASTM A1 for rails 30 pounds per foot and heavier. The posts will be painted with a baked on high quality dark green enamel. All punching, boring, cutting, or shearing will be done prior to painting. Prior to any punching or boring, the weight of the post will be a minimum of 1.12 pounds per foot with a tolerance of plus or minus 5%. The post length will be as specified within a tolerance of plus or minus 1 inch. The post will be punched or bored with 3/8 inch diameter holes on 1.0 inch centers beginning 1.0 inch from the top of the post. Each post must contain a minimum of 30 holes. The post may be punched full length. The bottom of the post will be pointed for ease of installation. The posts will be machine straightened and have a smooth uniform finish, free from defects affecting strength, durability, or appearance. The allowable tolerance for straightness will be 1/4 inch in 5 feet. K.Delineators: 1.Description: Delineators will be adhesive coated reflective sheeting permanently bonded to sheet aluminum backing. 2.Reflective Sheeting: The reflective sheeting will be Type XI conforming to ASTM D4956. In addition to the requirements stated above, the reflective sheeting will maintain the colors provided in the appropriate tables contained in Section 982.2 H.6 throughout its service life. 3.Fabrication: The aluminum will be a 0.063 inch thick sheet conforming to the requirements of ASTM B209 for alloy 6061-T6 or 5052-H38. The aluminum will be properly degreased and etched or treated with a light, tight, amorphous chromate coating. The reflective sheeting will be applied to properly treated base panels with mechanical equipment in a manner specified by the sheeting manufacturer. 982 Page 5674.Shape and Holes: Delineators will be punched or sheared to size with 3/4 inch radius corners. Mounting holes will be as follows: a.The 4 inch x 4 inch delineators will have 2 holes 1/4 inch in diameter 4 inch center to center on a diagonal line between opposite corners. b.The 4 inch x 8 inch delineators will have 2 holes 1/4 inch in diameter 5 inch center to center along the vertical axis. 5.General Requirements: The finished delineators will be free of burrs, scratches, and damaged reflective sheeting and will have essentially a plane surface. 6.Delineator Posts: Posts will be flanged channel section fabricated from hot rolled carbon steel bars or carbon steel bars and shapes produced from standard rail steel. The posts will meet the minimum physical properties of ASTM A499, Grade 60. The posts will meet the chemical properties of ASTM A1 for rails 30 pounds per foot and heavier. The posts will be painted with a baked on high quality dark green enamel. All punching, boring, cutting, or shearing will be done prior to painting. Prior to any punching or boring, the weight of the post will be a minimum of 1.12 pounds per foot with a tolerance of plus or minus 5%. The post length will be as specified within a tolerance of plus or minus 1 inch. The delineator post will be punched or bored with 3/8 inch diameter holes on 1.0 inch centers beginning 1.0 inch from the top of the post. Each post must contain a minimum of 30 holes. The post may be punched full length. The bottom of the post will be pointed for ease of installation. The posts will be machine straightened and have a smooth uniform finish, free from defects affecting strength, durability, or appearance. The allowable tolerance for straightness will be 1/4 inch in 5 feet. 983 Page 568983 COLD APPLIED PLASTIC PAVEMENT MARKINGS AND LEGENDS
983.1GENERAL REQUIREMENTS
This material will consist of a homogeneous mixture of resins, plasticizers, fillers, pigments, and glass beads. The marking material will be designed to adhere to Portland cement concrete pavement or asphalt concrete pavement. Reflectorized plastic pavement marking will consist of a homogeneous, extruded, prefabricated, pliant polymer material of specified thickness and width, which will contain abrasion resistant ceramic or ceramic coated beads bonded in a highly durable polyurethane topcoat. The material will be fabricated with a patterned surface that presents a near vertical face to traffic to maximize retroreflectance. The pavement marking material will be capable of being affixed to the pavement surface by means of a pre- coated, pressure sensitive adhesive. An adhesive activator supplied by the manufacturer will be utilized on applications of this material, except on newly installed asphalt when the surface temperature is 80˚F or above, or when the material is inlayed at the time asphalt is being installed.
983.2SPECIFIC REQUIREMENTS
A.Reseal Test: The plastic marking material will reseal to itself when tested. Cut two 1 inch x 3 inch pieces of plastic. Overlap these pieces face to face for an area of 1 square inch on a flat steel plate with the adhesive backing material remaining in place. Center a 2.2 pound weight over the 1 square inch overlap area and place in an oven at 190ºF for one hour. After cooling to 77ºF, the pieces will be inseparable without tearing. B.Pull Test: The plastic will require a pull of 8 to 20 pounds to break. The elongation will be no greater than 50%. The specimens for this test will be Type 1 prepared in accordance with ASTM D638. 1 square inch pieces of carborundum extra coarse emery cloth or its equivalent may be applied at each end of the test specimens to prevent the plastic adhesive from adhering to the test equipment. The break resistance will be based on an average of at least 3 samples, and the rate of pull will be 1/4 inch per minute. This test will be conducted at a temperature of 70 to 80ºF. C.Support Test: A test specimen cut to dimension of 1 inch by 6 inch will support a dead load of 6 pounds for 30 minutes. This test will be conducted at a temperature of 70 to 80ºF. D.Color: The plastic marking material will meet the color specification limits and luminance factors listed in Tables 1 and 2 when tested in accordance with ASTM E1347 or ASTM E1349. The plastic marking material will maintain the color and luminance factors provided in the following tables throughout its service life.