Wisconsin WisDOT Standard Specifications (within FDM) — Section 657

Effective with the December 2018 Letting 484 2019 Standard Spec ifications Section 657 Poles, Arms, Standards, and Bases

657.1Description

(1)This section describes providi ng poles, arms, standards, and b ases for lighting and traffic signals.

657.2Materials

Revise 657.2 to require contractor furnished monotube poles and arms. 657.2.1 Poles 657.2.1.1 General

(1)Furnish poles from the department's QPL. Submit a materials list and accompanying certificate of

compliance certifying that the poles incorporated into the work conform to the specified design criteria and other contract requirements.

(2)Include hand holes with a bolt -on access cover as the plans sh ow. Provide a grounding L-clip welded

directly opposite the hand hole on the in side wall of the pole.

(3)Weld base plates to the pole shaft. Identify the pole type and wall thickness using 1/2-inch lettering

stamped under the hand-hole bef ore galvanizing steel poles.

(4)Complete welding before galvanizing steel poles. Clean exterio r surfaces of steel poles after welding

to ensure they are free of loose rust and mill scale, dirt, oil or grease, and other contaminants before zinc coating. Zinc coat as specified in 641.2.8 . Ensure that the coating is tight, free from rough areas or slag, and presents a uniform appearance. Clean after manufac turing is complete to remove loose and foreign material.

(5)Furnish aluminum or galvanized steel shims matching the pole m aterial.

(6)Furnish identification plaques as the plans show.

657.2.1.2 Monotube Poles

(1)Furnish steel monotube poles zinc coated according to ASTM A123. Design conforming to the edition

of AASHTO design specifications and fatigue category the plans show. 657.2.1.3 Type 2 and 3 Poles

(1)For Types 2 and 3 poles, design support structures conforming to the AASHTO Standard Specification

for Structural Supports for High way Signs, Luminaires, and Traffic Signals as published in the 1994, - A wind speed of 80 mph with a 1.3 gust factor. - Dead and live load related to a 25-foot trombone mast arm wit h 5-section signal head and a pair of twin 15-foot luminaire arms mounted on the pole as the plans show. 657.2.1.4 Other Pole Types

(1)Design support structures, consisting of poles and arms, confo rming to the minimum wall thickness the

plan details show and to AASHTO Standard Specifications for Str uctural Supports for Highway Signs, Luminaires and Traffic Signals, 6th Edition, and Interim Revisi ons. Use a design life of 50 years. Design to withstand a 3 second gu st wind speed of 90 mph. Do no t use the alternative method for wind pressures described in appe ndix C of those AASHTO standard specifications. No fatigue analysis is required.

(2)Construct poles of materials having sufficient rigidity that, with material installed as the plans show, the

centerline of the shaft is vertical. Ensure that lighting poles nominally 40 feet or less in length are made of one piece and round in cross-section.

(3)Incorporate vibration da mpeners as the plans show.

657.2.2 Monotube Arms

(1)Furnish steel monotube arms z inc coated according to ASTM A123. Design conforming to the edition

of AASHTO design specifications and fatigue category the plans show.

(2)Furnish monotube arms from the department's QPL. Submit a materials list and accompanying

certificate of compliance cert ifying that the arms incorporated into the work conform to the specified design criteria and other contract requirements.

1.Furnish a mounting device w elded to the pole end of the mon otube arm that allows the attachment of the

arm to a pole as the plans show.

2.Furnish stiffeners or gussets if required between the arm t ube and the arm mounting device to provide

adequate strength to resist side loads.

3.Furnish a clean, uniform nat ural finish. No paint or other corrosion preventive mai ntenance coating is

required.

Effective with the December 2018 Letting 485 2019 Standard Spec ifications (3) After welding and before zinc coating, clean the exterior surfa ces of each arm free of all loose rust and mill scale, dirt, oil or grease, and other foreign substances.

(4)Apply zinc coating as specified for sign bridge components in 641.2.9 Ensure that the zinc coating is

tight, free from rough areas or sl ag, and presents a uniform ap pearance.

(5)After manufacturing is complete, clean the exterior surfaces of each pole free of all loose scale, dirt, oil

or grease, and other foreign substances. 657.2.3 Trombone Arms

(1)Design aluminum trombone arms as specified in 657.2.1.3 based on the completed maximum loading

configuration the plans show. Furnish shop drawings conforming to 105.2.1 that show the width, depth, length, and thickness of a ll members. Also list the ASTM alloy designation and strength of each aluminum member on the shop drawings.

(2)Submit a materials list and acco mpanying certificate of compliance certifying that the trombone arms

incorporated into the work conform to the specified design crit eria and other contract requirements. Also send a copy of the certificat e of compliance and a copy of the shop drawings to the department's electrical engineer for informational review.

(3)Ensure that the design incorporates all of the following:

1.Round or oval upper and lower aluminum members welded to on e or more tubular vertical struts.

2.A mounting clamp welded to t he pole end of the trombone arm for attachment to a round pole.

3.Gussets at the joints betwe en the main arm tubes and the arm clamps designed to resist side loads.

4.A horizontally adjustable strut to allow mounting five 12-i nch signal faces with backplates.

5.A clean, uniform, natural a luminum finish. D o not paint or apply other anti-corrosion coatings.

6.A wiring raceway entrance th rough the upper mounting bracke t.

7.Vertically adjustable throug h plus or minus 10 degrees as the plans show.

657.2.4 Luminaire Arms 657.2.4.1 Aluminum Luminaire Arms

(1)Design aluminum luminaire arms as specified in 657.2.1.3 to withstand in-service field loadings

including loads imposed by components attached to the arms. Furnish shop drawings conforming to 105.2.1 . Include the dimensions of all members, list the ASTM alloy de signation of aluminum members, and show weld details.

(2)Submit a materials list and acco mpanying certificate of compliance certifying that the luminaire arms

(3)Make luminaire arms out of extruded aluminum. Ensure that the arms are clean with a uniform natural

aluminum finish. Do not paint or apply other anti-corrosion coa tings.

(4)Furnish an extruded aluminum fixture welded to the pole end of the luminaire arm that allows the arm

to be clamped to a round pole dimensioned as the plans show. Fu rnish mounting clamps with stainless steel bolts, nuts, and washers conforming to ASTM A320. 657.2.4.2 Luminaire Arms Steel

(1)Under the Luminaire Arms Steel bid items provide steel luminair e arms conforming to 657.2.2 .

657.2.5 Traffic Signal Standards

(1)Furnish standards consisting of extruded seamless aluminum all oy 6061-T6 manufactured conforming

to ASTM B241, or porthole extruded aluminum alloy 6061-T6 manufactured conf orming to ASTM B429. Also conform to the following:

1.Threaded on one end, tapered, and conforming to national pipe threading dimensions and normal practice.

2.Outside dimensi on of 4 1/2 inches.

3.Schedule 80 aluminum pipe.

(2)Ensure that the manufacturer has indent printed the ASTM and a lloy designations 2 inches above the

threading on the outside of each standard usin g 1/4-inch dies. 657.2.6 Bases

(1)Furnish cast aluminum alloy pedestal and transformer bases fro m the department's QPL and meeting

the design criteria specified in 657.2.1.3 . Ensure that castings are true to pattern in form and dimensions and free from defects affecting strength or service life.

Effective with the December 2018 Letting 486 2019 Standard Spec ifications (2) Submit a materials list and acco mpanying certificate of compliance certifying that the bases incorporated into the work conform to the specified design crit eria and other contract requirements.

(3)If the engineer requests, provide one randomly selected sample pedestal base per traffic signal

location. The department will base acceptance of all pedestal b ases at that traffic signal location on destructive tests of that sample base.

(4)Thread casting collars for pedestal bases to mate with the tra ffic signal standards furnished under the

contract.

(5)Use mounting washers for transformer bases conforming to the m anufacturer's instructions.

657.2.7 High-Strength Bolts

(1)Furnish zinc-coated type 1 bolt/nut/washer assemblies conformi ng to 506.2.5 and as follows:

- Furnish 2 flat washers with each bolt/nut/washer assembly. Us e the size, number, type, and configuration of hardened flat washers the DT I manufacturer recommends for bolt diameters greater than 1 1/8 inches. - Ensure that all bolt/nut/washer assemblies of a given size co me from the same rotational-capacity lot, are shipped in sealed and labeled cont ainers, and are accompanied b y a certified report of test or analysis giving the results of the supplier's rotational-capacity testin g. No field rotational-capacity testing is required. - Furnish 3 or more additional bolt/nut/washer assemblies of ea ch size for pre-installation testing. - Submit 2 or more additional bo lts and 3 or more additional nu ts and washers of each size for department mechanical testing. The contractor need not submit components f rom a lot and heat the department previously approved.

(2)Furnish zinc-coated direct tension indicating (DTI) washers co nforming to ASTM F959 type 325.

Ensure that DTIs have identifyi ng marks applied by the manufacturer. Provide the engineer with 2 copies of the DTI manufacturer's instructions showing acceptable installation configurations. Provide 3 or more additional DTIs as required for pre-installation testin g. Also provide the engineer with at least two 0.005-inch metal feeler gauges. 657.2.8 Anchor Assemblies for Light Poles on Structures

(1)Furnish anchor rods conforming to ASTM F1554 , grade 55 and Supplementary Specification S4,

ASTM A563 heavy hex nuts, and ASTM F436 washers all hot-dip galvanized according to ASTM A153, class C, supplemented by ASTM F2329.

(2)For each rod, furnish 4 nuts fo r securing the top and bottom a nchor plate-templates, a leveling nut,

bottom washer, top washer, and 2 top nuts. Do not use lock washers.

(3)Furnish a steel top and bottom anchor plate-template as part o f each anchor assembly. Provide a top

template of sufficient gauge to hold the anchor rods securely in position at the top, and resist racking or twisting during the pour. Do not weld templates to anchor ro ds.

657.3Construction

657.3.1 General 657.3.1.1 Installation

(1)Install a grounding lug either i nside the base or pole as requ ired to connect equipment grounding

conductors. 657.3.1.2 Welding

(1)Perform shop welding as the pl ans show and conforming to the f ollowing:

For steel poles and arms: AWS D 1.1, Structural Welding Code - Steel. For aluminum poles and arms: AWS D 1.2, Structural Welding Code - Aluminum.

(2)Do not weld in the field without the engineer's written approval. The engineer will only allow field

welding for repairs in noncritical locations and when a departm ent-approved individual competent to perform inspections is present during the welding. Perform fiel d welding using personnel qualified under AWS D 1.5, Bridge Welding Co de for steel or AWS D 1.2, Structural Welding Code - Aluminum for aluminum. 657.3.2 Poles

(1)Clean each pole before installation.

(2)Secure type 9, 10, 12, and 13 st ructures to anchor assemblies conforming to the procedures

enumerated in department form DT2321 . Complete department form DT2321 for each structure. Indicate the parties responsible for the installation and submi t the form to the engineer for inclusion in the permanent project record.

(3)After completing erection using normal pole shaft raking techn iques, ensure that the centerline of the

shaft is vertical.

Effective with the December 2018 Letting 487 2019 Standard Spec ifications (4) Install identification pl aques as the plans show. 657.3.3 Arms 657.3.3.1 General

(1)Install trombone, monotube, and luminaire arms to supportings tructures at the height and alignment

the plans show. Clamp luminaire arms to the pole and rake so th e initial level of the luminaire tenon is plus 3 degrees.

(2)Install traffic signal heads wit hin 5 days after monotube arms are erected to control vibration. Contact

the bureau of structures if signal heads cannot be installed wi thin those 5 days. 657.3.3.2 High-Strength Bolts 657.3.3.2.1 Handling and Storage

(1)Store bolts/nut/washer assemblies and DTIs in closed containers in a protected shelter to protect them

from dirt and moisture until us ed. Maintain fastener system components as nearly as possible in the as-manufactured condition until installed. Remove from storage only as needed and pr omptly return unused components to storage. 657.3.3.2.2 Pre-installation Testing

(1)Notify the engineer before performing the required field pre-installation testing.

(2)Lubricate high-strength bolt thr eads with a wax-based lubrican t before testing. Test bolt/nut/washer

assemblies with DTIs in all the configurations used for installation.

(3)Perform pre-installation testi ng in the field conforming to th e procedures enumerated in department

form DT2322 for each bolt/nut/washer/DTI siz e and configuration installed. Provide the engineer with the test results by submitti ng 2 copies of department form DT2322 . 657.3.3.2.3 Bolt Installation

(1)Do not begin bolt installation without the engineer's approval .

(2)Lubricate high-strength bolt thr eads with a wax-based lubrican t before installation.

(3)Tension high-strength bolts usi ng DTIs. Install the DTI on the bolt with the protrusions facing away

from the connected materials. Install bolt/nut/washer assemblies with DTIs in the same configuration used for pre-installation testing.

(4)Tighten conforming to department form DT2322 to provide the correct insta llation tension. During the

operation, ensure no rotation o f the part not turned by the wrench. Snug systematically from the most rigid part of the connection to the free edges. Repeat until th e full connection is in a snug condition and the faying surfaces are in firm contact. Systematically tig hten the connection required number of refusals is achieved. If the gaps on the DTI are completely clo sed, discontinue tightening.

(5)Perform QC testing as specified in 506.3.12.3.3.3 for tensioning with DTIs. The engineer may verify

bolt installation by periodically testing with a feeler gauge. 657.3.4 Standards

(1)Thread traffic signal standards into their pedestal bases with out damaging the threads. Ensure that the

base is level on its concrete foundation and the standard is vertical after all connections are tight. 657.3.5 Bases

(1)Before installing, clean the mill scale, oil, and foreign mate rial off transformer bases, traffic signal

pedestal bases, and other aluminum bases.

(2)Install transformer bases conf orming to the manufacturer's ins tructions.

657.3.6 Anchor Assemblies for Light Poles on Structures

(1)Install anchor rods and templates conforming to plan details a nd the light standard manufacturer’s

recommendations.

657.4Measurement

(1)The department will measure the bid items under this section a s each individual unit acceptably

completed. 657.5 Payment Revise 657.5 to change install bid items to contractor-p rovided for poles, monotube arms, and steel luminaire arms.

(1)The department will pay for measured quantities at the contrac t unit price under the following bid

items: ITEM NUMBER DESCRIPTION UNIT

657.0100 Pedestal Bases EACH

Effective with the December 2018 Letting 488 2019 Standard Spec ifications 657.0200 - 0299 Transformer Bases Breakaway (size) EACH

657.0300 - 0399 Poles (type) EACH

657.0400 - 0499 Traffic SignalS tandards Aluminum (length) EACH

657.0500 - 0559 Monotube Arms (length) EACH

60 - 0599 Trombone Arms (length) EACH

657.0600 - 0699 Luminaire Arms Si ngle Member (clamp size) (leng th) EACH

657.0700 - 0799 Luminaire Arms Tru ss (type) (clamp size) (lengt h) EACH

657.0800 - 0825 Luminaire Arms Steel (length) EACH

657.6005 Anchor Assemblies Light Poles on Structures EACH

(2)Payment for Pedestal Bases and the Transformer B ases bid items is full compensation for providing

the pedestal base including grou nding lugs and related mounting hardware; for leveling shims; and for corrosion prevention. The department will pay for sample pedestal bases, provided under 657.2.6 , at the contract unit price for Pedestal Bases.

(3)Payment for the Poles bid items is full compensation for provi ding poles including grounding lugs and

related mounting hardware; for hardware and fittings necessary to install the pole; for leveling shims; and for corrosion prevention.

(4)Payment for the Traffic Signal Standards Aluminum bid items is full compensation for providing the

standards.

(5)Payment for the Trombone Arms and Luminaire Arms bid items is full compensation for providing arms

including related mounting hardware and leveling shims.

(6)Payment for the Monotube Arms and Luminaire Arms Steel bid items is full compensation for providing

arms; for high-strength bolt/nut/w asher assemblies and DTIs inc luding those required for testing; and for providing related mounti ng hardware, leveling shims.

(7)Payment for Anchor Assemblies Li ght Poles on Structures is ful l compensation for furnishing and

installing the anchors assemblies on structu res. For other inst allations, the department will either furnish anchor assemblies or include them as incidental to the Concrete Bases bid items as specified in 654.

(8)The department will pay separately for concrete foundations un der 654.

Effective with the December 2018 Letting 489 2019 Standard Spec ifications Section 658 Traffic Signals

658.1Description

(1)This section describes providing traffic signal faces, pedestr ian signal faces, programmable traffic

signal faces, push buttons, and signal mounting hardware.

658.2Materials

(1)Submit a complete list of traffic signal compone nts and hardwa re provided under the contract.

(2)Furnish materials from the department's QPL as follows:

- Traffic signal faces including si gnal housing, backplates and LED modules. - Pedestrian signal faces including signal housing and LED modules. - Pedestrian push buttons. - Signal mounting hardware.

(3)For traffic signal faces: furnis h signal housings, visors, LED modules, backplates, and cut away or

tunnel type visors as the plans show.

(4)For pedestrian signal faces: furnish signal housings, LED modu les, and visors. For 16-inch heads,

furnish a z-crate visor.

(5)For Pedestrian push buttons: furnish a standard R 10-3b or R 1 0-3e series sign. In clude directional

arrows on the sign as the plans show.

(6)For programmable traffic signal faces: furnish electronically programmable traffic signal faces, visor,

and backplate with LED illumination sources conforming to the f ollowing: - Fully programmable with a portable electronic device. - Programmable for both horizonta l and vertical viewing angles. - Programmable light intensity.

(7)For signal mounting hardware: furnish weather tight mounting h ardware. Protect mounting hardware

from the elements before installation. Use corrosion resistant poly bracket shims.

658.3Construction

(1)Cover traffic signal faces and pedestrian signal faces with a hood or turn away from view by the

traveling public until the sig nal is accepted for use and activated.

(2)For pedestrian signal faces: a llow for side-fire connection wi thout conflict between the mounting

bracket and the door hinge.

(3)For Pedestrian push buttons: pro vide a 3/4-inch diameter push button mounting hole for wiring

purposes in standards or poles . De-burr the holes after sawing and before installing the wire. Use IMSA 50-2 loop lead-in cable to wire the push button to the con ductors in the base. Band R 10-3b or R 10-3e series sign directly above each push button.

(4)For signal mounting hardware: seal voids using silicon or rubberized caulking or similar material as the

engineer approves. Mount traffi c and pedestrian signal faces so that they are immovable.

658.4Measurement

(1)The department will measure the EACH bid items under this section as each individual unit acceptably

completed.

(2)The department will measure the Signal Mounting Hardware bid i tems as a single lump sum unit for

each intersection acceptably completed.

658.5Payment

(1)The department will pay for measured quantities at the contrac t unit price under the following bid

items: ITEM NUMBER DESCRIPTION UNIT

658.0100 - 0199 Traffic Signal Face (sections) (size) EACH

658.0400 - 0499 Pedestrian Signal Face (inch) EACH

658.0500 Pedestrian Push Buttons EACH

658.1100 - 1199 Programmable Tra ffic Signal Face (sections) (si ze) EACH

658.5069 Signal Mounting Hardware (location) LS

(2)Payment for the Signal Face bid items and Pedestrian Push Butt ons is full compensation for providing

a complete and functioning assembly.

(3)Payment for the Signal Mounting Hardware bid items is full compensation for providing mounting

hardware, including spacers.

Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 493–497 of 601.

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656 Electrical Service

658 Traffic Signals