605 SECTION 658 OVERHEAD SIGN STRUCTURES 658.1 -DESCRIPTION : This item shall consist of the fabrication and erection of overhead frame, cantilever, butterfly, and span structure sign supports and fastening accessories in accordance with the requirements of the Pl ans and of these Specifications. All details not specified or not shown on the Plans shall conform to the details and requirements set forth in the following Specifications and publications:
i.West Virginia Department of Transportation, Division of Highway s, Standard Details Book Vol. II, Signing, Signals, Lighting, Markings, and ITS, latest issue, including revisions (further referenced to herein as the Standard Details). ii. The Manual on Uniform Traffic Control Devices for Streets and Highways, latest issue , as printed by the Federal Highway Administration, U.S. Department of Transportation (Referred to as the MUTCD). iii. Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals, 6th Edition, including revisions, American Association of State Highway and Transportation Officials. All material, fabrication, and installation requirements for overhead frame structures shall be included in the project Plans and shop drawings. 658.2 -MATERIALS : Materials furnished shall be of new stock conforming to the requirements of the Specifications, and shall meet the approval of the Engineer. 658.2.1 -Pipe: Non-tapered steel pipe used for arms, chords , support legs, and bracing shown on various Standard Detail sheets shall be seamless or welded pipe conforming to A500 Gr. B or C, API 5L X42 or X52, A53 Grade B, or A252 Grade 3. Non-tapered aluminum pipe used for chords and bracing shown on Standard Detail sheets TE5-1A and TE5 -1B shall conform to ASTM B221, ASTM B429, or ASTM B241, all Alloy 6061, temper T6. Tapered steel pipe used for arms and support legs shown on Standard Detail sheet TE4 -4B shall be manufactured from steel having a min. yield strength of 55,000 PSI after fabrication. Galvanized in accordance with ASTM A123. 658.2.2 -Plate: Flat steel plate used for chord plates, base plates, arm end plates, arm splice plates, and box flange plates shown on various Standard Detail shee ts shall conform to ASTM A572, Grade 42. Galvanized in accordance with ASTM A123. Flat steel plate used for gusset plates, saddle plates, hand hole plates, and stiffener plate shown on various Standard Detail sheets shall conform to ASTM A36. Galvanized in accordance with ASTM A123. Flat aluminum plate used for gusset plates and chord plates shown on Standard Detail sheets TE5 -1A and TE5 -1B shall conform to ASTM B209, Alloy 6061, temper T6. 658.2.3 -Structural Connection Bolt: Carbon steel structura l connection bolts and associated hardware shown on various Standard Detail sheets shall conform to the following 606 requirements. Bolts: ASTM F3125 Grade A325, Type I. Nuts: ASTM A563, Grade DH with lubricant contrasting with the color of the galvanizing. Washers: ASTM F436, Type I. All galvanized in accordance to ASTM B695. 658.2.4 -Friction Caps: Steel friction caps shown on various Standard Detail sheets shall conform to ASTM A653, designation CS, and shall be zinc electrodeposited coated in accorda nce with ASTM B633, Class 12. Aluminum friction caps shown on Standard Detail sheets TE5 -1A and TE5 -1B shall conform to ASTM B26, Alloy 356, temper F. 658.2.5 -Structural Shapes: Steel W10x77 beams as shown on Standard Detail sheets TE3-1 and TE3 -2 shall be standard wide flange shapes fabricated from steel conforming to ASTM A36 or ASTM A572 Grade 50. Steel conforming to ASTM A992 and dual certified to ASTM A572 Grade 50 may also be used. The beams shall be galvanized in accordance with ASTM A123. Steel WT8x25 tees as shown on Standard Detail sheets TE5 -1A and TE5 -1B shall be standard WT shapes fabricated from steel conforming to ASTM A36 or ASTM A572 Grade
50.Steel conforming to ASTM A992 and dual certified to ASTM A572 Grade 50 may also be used . The tees shall be galvanized in accordance with ASTM A123. 658.2.6 -U-Bolts: Carbon steel u -bolts and associated hardware shown on various Standard Detail sheets shall conform to the following requirements: Bolts: ASTM A307 Grade A. Nuts: ASTM A563A Hex. Flat washers: ASTM F844. All galvanized in accordance with ASTM F2329. 658.2.7 -Anchor Bolts: Steel anchor bolts and associated hardware shown on various Standard Detail sheets shall conform to the following requirements: Bolts: ASTM F1554 Grade 55. Nuts: ASTM F563 Grade A. Washers: ASTM F436. All galvanized in accordance with ASTM B695. 658.2.8 -Concrete: All concrete shall be Class B in accordance with Section 601. 658.2.9 -Reinforcing Steel: All reinforcing steel shall be meet the req uirements of Section 602. CONSTRUCTION METHODS 658.3 -FABRICATION : 658.3.1 -General : Before fabrication of any sign structure, the Contractor shall submit for the Engineer ’s approval complete detail drawings, eight copies, of each structure. This shall include drawings of all structural steel or aluminum framing and bracing, aluminum or steel castings, lighting fixtures and supporting brackets, sign brackets and any miscellaneous accessories f or the above. It is expressly understood that the review by the Engineer of these drawings relates to the requirements for strength and general details, and will not relieve the Contractor from responsibility for errors in detail, dimension, or quantity o f materials, etc. Overhead sign supports shall be fabricated in accordance with the Plans and this Specification. Any alternate design or significant departure from the Plans proposed by the Contractor must be presented in written or plan form for approv al. The Division will approve or disapprove alternate proposals in writing. All materials in any alternate proposal which is a 607 significant departure from the Specifications shall conform to the requirements of current AASHTO and ASTM Specifications. The Division will not approve substitution of material or design detail changes which constitute a reduction in quality, workmanship or strength of the structures. Ends of sections shall be cut true and smooth, free from burrs and ragged breaks. Open ends o f tubular sections shall be capped as shown on the Plans. Drain holes and handholes shall be provided wherever shown or necessary. Sign supports, either aluminum or steel, shall be void of circumferential welding except at the base, flanges, or intersec tion of diagonals. The welding of steel shall be in accordance with the requirements of American Welding Society D1.1 and shall be done by qualified welders. Aluminum Alloy Welding shall be accomplished in accordance with subsection 658.4. The loading , transporting, unloading, and piling of structural materials shall be conducted so that the metal will be kept clean and free from injury in handling. Structural materials shall be stored above the ground upon platforms, skids, blocks, or other supports. They shall be kept free from accumulation of dirt, oil, acids, or other foreign matter. Any structural material which has been deformed shall be straightened by approval methods before being laid out, punched, drilled, or otherwise worked upon in the sho p. Sharp kinks or bends will be cause for rejection. Where required or indicated on the Plans, a sufficient number of reinforced handholes and electrical wire inlets and outlet fittings shall be built into the structures. Where a cable passes through a hole or runs along a surface at any point through or on the complete assembly, such holes and surfaces shall be deburred and void of any sharp edges through or along the surface. A “J” hook shall be provided on the inside of the top of the vertical suppo rt on which the electrical wiring shall be placed as shown on the Detail Drawings. 658.3.2 -Structures Utilizing Galvanized Steel : The flanges at the center of the cross beam and at the ends of the horizontal arms shall be fastened to the tapered or straight sections by means of two circumferential welds. One of the circumferential welds shall firmly weld the outside of the flange to the tube. Any alternate flange connection offered shall be designed to develop fully the strength of the tubular sect ions being jointed together by means of the flange connection. It is essential that all exposed surfaces of the completed steel structure by finished with a galvanized coating. The frame shall be fabricated into sections as large as can be handled in pickling and galvanizing tanks and then dipped as complete units, ready for field bolted connections wherever possible. Field welding and the need for repairing zinc coatings damaged by assembly shall be kept to an absolute minimum. Galvanized coatings da maged for any reason shall be repaired by the application of a zinc rich paint conforming to the requirements of subsection 711.21. The places to be painted shall be thoroughly cleaned before the paint is applied. 658.3.3 -Structures Utilizing Weatheri ng Steel: Overhead sign structures of weathering steel are to have a natural weathering finish and shall be kept clear of all paint, grease, or other agents which will tend to cause an uneven finish on the posts. Any identification marks shall be painted on the bottom of the base plates, inside faces of loose column components and the top surface of horizontal members. All structures shall be delivered to the job site at least three months prior to completion of the work and stored in a manner that will a llow them to obtain initial natural weathering. If they are stacked on the job site during this period, they shall be 608 rotated at least once each two months. All members shall be shop cleaned in accordance with subsection 615.6.4, utilizing commercial bla st cleaning throughout. No corrosion inhibitors shall be used in the processes. All welding shall conform to the requirements of AWS D1.1. 658.4 -WELDING OF ALUMINUM ALLOYS : These specifi cations apply to the welding of aluminum alloys used in sign structures, bridge rails, lamp posts, etc. The welding terms used in these specifications shall be interpreted in accordance with the definitions given in the latest edition of AWS Definitions —Welding and Cutting (AWS A3.0) of the American Welding Society. The welding symbols used on plans shall be those shown in the latest edition of Standard Welding Symbols (AWS A2.0) of the American Welding Society. Special conditions shall be fully explained by added notes or details. 658.4.1 -Base Metals: The aluminum alloys to be welded under these specifications may be any of the following alloy designations (ASTM designations):
i.Wrought non -heat-treatable alloys Alloy 3003 , Alloy 3004 , Alloy 5052 , Alloy 5083 , Alloy 5086 , Alloy 5456 ii. Wrought heat -treata ble alloys Alloy 6061 , Alloy 6063 iii. Cast heat -treatable alloys Alloy 356.1 , Alloy A356.2 658.4.1.1 -Materials used for permanent backing shall be at least equivalent in weldability to the base metal being welded. 658.4.2 -Welding Processes: These Specifications include provisions for welding by the gas metal -arc process and the gas tungsten -arc process. Other processes shall not be used except as permitted by the Engineer. 658.4.3 -Filler Metal: Bare wire electrodes for use with gasmeta l-arc process and welding rods for use with the gas tungsten -arc process shall conform to the requirements of the latest edition of Specifications for aluminum and aluminum alloy rods and bare electrodes AWS A5.10. Tungsten electrodes for the gas tungste n-arc process shall conform to the requirements of the latest edition of Specifications for Tungsten -Arc-Welding Electrodes, AWS A5.12. Filler metals to be used with particular base metals shall be as shown in Table 658.4.3. Other filler metals may be u sed as approved by the Engineer. 609 TABLE 658.4.3 Base Metal Filler Material 3003 to 3003 ER1100 3004 to 3004 ER4043 5052 to 5052 ER5356 * 5083 to 5083 ER5183 5086 to 5086 ER5356 * 5456 to 5456 ER5556 5670B to 6061 ER4043 * 5670B to 6063 ER4043 * 356.1 to 6061 ER4043 A356.2 to 6063 ER4043 6061 to 6063 ER4043 or ER5356 6061 to 6061 ER4043 or ER 5356 6063 to 6063 ER 4043 or ER5356 * ER5183, ER5356, and ER 5556 may be used interchangeably for these base metals. Filler metals shall be kept covered and stored in a dry place at relatively uniform temperatures. Original rod or wire containers shall not be opened until time to be used. Rod and wire shall be free of moisture, lubricant, or other contamina nts. Spools of wire temporarily left unused on the welding machine shall be kept covered to avoid contamination by dirt and grease collecting on the wire. If a spool of wire is to be unused for more than a short length of time, it shall be returned to the carton and the carton tightly resealed. 658.4.4 -Shielding Gases: Shielding gases shall be welding grade or better. Shielding gas for gas metal -arc welding shall be argon, helium, or a mixture of the two (approximately 75 percent (75%) helium and 25 percent (25%) argon). Shielding gas for gas tungsten -arc welding done with alternating current shall be argon . Shielding gas for gas tungsten -arc welding done with direct current, straight -polarity, shall be helium. Hose used for shiel ding gases shall be made of synthetic rubber or plastic. Natural rubber hose shall not be used. Hose which has been previously used for acetylene or other gases shall not be used. 658.4.5 -Preparation of Materials: Joint details shall be in accordance with design requirements and detail drawings. The locations of joints shall not be changed without the approval of the Engineer. Edge preparation shall be by sawing, machining, clipping, or shearing. Gas tungsten -arch or gas metal -arc cutting may also be used. Cut surfaces shall meet the American Standards Association surface roughness rating value of 1,000. Oxygen cutting shall not be used. Surfaces and edges to be welded shall be free from fins, tears, and other defects which would adversely affe ct the quality of the weld. Dirt, grease, forming or machining lubricants or any organic materials shall be removed from the areas to be welded by cleaning with a suitable solvent or by vapor degreasing. On all edges and surfaces to be welded, the oxid e shall be removed just prior to welding by wire brushing or by other mechanical methods such as rubbing with steelwool or abrasive 610 cloth, scraping, filing, rotary planning, or sanding. If wire brushing is used, the brushes shall be made of stainless stee l. Hand or power driven wire brushes which have been used on other materials shall not be used on aluminum. Where mechanical methods of oxide removal are found to be inadequate, a standard chemical method shall be used. Welding shall be done within 24 hours after chemical treatment. When gas tungsten -arc welding with direct current, straight polarity is being used, all edges and surfaces to be welded shall have the oxide removed by a standard chemical method. Welding shall not be done on anodically treated aluminum, unless the condition is removed from the joint area to be welded. 658.4.6 -Welding Procedure: All butt welds requiring 100 percent (100%) penetration, except those produced with the aid of backing, shall have the root of the initial we ld chipped or machined out to sound metal before welding is started from the second side. Butt welds made with the use of backing shall have weld metal thoroughly fused with the backing. Where accessible, backing for welds that are subject to computed st ress or which are exposed to view on the completed structure and which are not otherwise parts of the structure, shall be removed and the joints ground or machined smooth. In tubular members, butt welds subjected to computed stresses shall be made with th e aid of permanent backing rings or strips. The procedure used for production welding of any particular joint shall be the same as used in the procedure qualification for that joint. All welding operations, either shop or field, shall be protected from air currents or drafts so as to prevent any loss of gas shielding during welding. Adequate gas shielding shall be provided to protect the molten metal during solidification. The work shall be positioned for flat position welding whenever practicable. In both shop and field, all weld joints shall be dry at the time of welding. The size of the electrode, voltage and amperage, welding speed, gas or gas mixture, and gas flow rate shall be suitable for the thickness of material, design of joint, welding position and other circumstances attending the work. Gas metal -arc welding shall be done with direct current, reverse polarity. Gas tungsten -arc welding shall be done with alternating current or with direct current straight polarity. When the joint to be welded requires specific root penetration, the Contractor shall make a sample joint and a macroetched cross section of the weld to demonstrate that the joint welding procedure to be used will attain the required root penetration. The s ample joint shall have a length of at least one ( 1) foot and shall be welded with the electrode, polarity, amperage, voltage, speed, gas mixture and gas flow rate that are proposed to be used in production welding. The Engineer, at their discretion, may accept evidence on record in lieu of the preceding t est. Where preheat is needed, the temperature of preheat shall not exceed 350° F for heat - treated alloys or 600° F for non -heat-treated alloys. The temperature shall be measured by temperature indicating crayons or by pyrometric equipment. Heat treated alloys shall not be held at the maximum preheat temperature or at temperatures near the maximum for more than 30 minutes. 658.4.7 -Weld Quality: Regardless of the method of inspection, the acceptance or rejection of welds shall be determined by the fol lowing conditions: i Cracks in welds or adjacent base metal will not be acceptable. 611 ii Copper inclusions will not be acceptable. iii Porosity in excess of that permitted by Appendix IV, Section of the ASME Boiler and Pressure Vessel Code will not be acceptable. iv Lack of fusion, incomplete penetration, or tungsten or oxide inclusions will be acceptable only if small and well dispersed. Undercut shall not be more than 0.01 inch deep when its direction is transverse to the primary stress in the part that is undercut. Undercut shall not be more than 1/32 inch deep when its direction is parallel to the primary stress in the part that is undercut. No overlap shall be allowed. All craters shall be filled to the full cross section of the welds. Welds having defects greater than the levels of acceptance specified above shall be considered as rejected unless corrected in accordance with subsection 658.4.9. 658.4.8 -Inspection: To determine compliance with subsection 658.4.7, all welds shall be visually inspected an d, in addition, all welds subjected to computed stress shall be inspected by the dye penetrant method except as specified in subsection 658.4.8.3. 658.4.8.1 -For highway sign structures, the dye penetrant method shall be used on butt welds in columns and main chord members, and on fillet welds connecting columns to bases and main chord members, including the associated flanges, gussets, or main load carrying brackets or members; also, on fillet welds connecting flanges to the main truss chord m embers. 658.4.8.2 -The dye penetrant tests shall be performed in accordance with the requirements of ASTM E165, Method B, Procedures B -2 or B -3. 658.4.8.3 -Dye penetrant inspection may be omitted provided that the inspector examines each layer of weld me tal with a magnifier of 3X minimum before the next successive layer is deposited. 658.4.9 -Corrections: In lieu of rejection of an entire piece or member containing welding which is unacceptable, the corrective measures listed below may be permitted by the Engineer, whose approval shall be obtained prior to making each repair. 658.4.9.1 -Defective welds shall be corrected by removing and replacing the entire weld, or as follows:
i.Cracks in welds or base metal: Determine full extent of crack by dye penet rant method or other positive means. Remove crack throughout its length and depth, and reweld. ii. Excessive porosity, lack of fusion: Remove defective portions and reweld. iii. Copper or tungsten inclusions: remove defective portions and reweld. iv. Excessive concavity of crater, undercut, undersize weld: Clean and deposit additional weld metal.
v.Overlap: Reduce by removal of excess weld metal. 612 658.4.9.2 -The defective areas shall be removed by chipping or machining. Oxygen cutting shall not be use d. Before rewelding, the joint shall be inspected to assure that all the defective weld has been removed. If dye penetrant has been used to inspect the weld, all traces of penetrant solutions shall be removed with solvent, water, heat, or other suitable means before rewelding. 658.4.10 -Qualification of Procedures, Welders and Welding Operators: Joint welding procedures which are to be employed in executing contract work under these specifications shall be previously qualified by tests prescribed in Part B, Section IX, of the ASME Boiler and Pressure Vessel Code. The qualifications shall be at the expense of the Contractor. The Engineer, at their discretion, may accept evidence of previous qualification of the joint welding procedures to be employed. All welders and welding operators to be employed under these specifications shall be previous ly qualified by tests as prescribed in Part B, Section IX, of the ASME Boiler and Pressure Vessel Code. The Engineer, at their discretion, may accept evidence of previous qualification of the welders and welding operators to be employed. The same process and type of equipment that is required for execution of the construction work shall be used in qualifying welders and welding operators. 658.5 -ERECTION : 658.5.1 -General: All structures shall be installed at the points designated on the Plans or by the Engineer in accordance with these specifications, the Plans, and approved shop drawings and shall be erected in reasonably close conformity to the locations, elevations, and angles shown on the Plans or esta blished by the Engineer. Erection of sign structures shall be in accordance with the applicable provisions of the current edition of the Specifications and the requirements given below. The Contractor shall provide all tools, equipment and appliances necessary for the expeditious handling of the work, all of which shall be subject to the approval of the Engineer. Materials and workmanship not previously inspected will be inspected on the site of the work and all rejected material shall be removed from the site of the work. The Contractor shall take full responsibility for checking all cross sections at approved structure locations to determine final support lengths. Necessary support lengths shall be determined in accordance with the road way overhead clearance requirements shown in the Plans or Standard Details. Before proceeding further, the Contractor shall initially establish the location of each structure in accordance with the Plans or as directed by the Engineer and shall mark ea ch site with construction stakes. The Contractor shall furnish stakes, paint, other materials, and labor for performing the locating and staking as described. When the sites have been staked and are ready for inspection, the Contractor shall inform the E ngineer, who will check and approve the site or make necessary changes. Centerline station information will be furnished to the Contractor by the Engineer. All existing or proposed assembly locations are approximate. In cases where an existing assembly , including supports, is to be removed and replaced with a new assembly, the new assembly shall be located as close as possible to the original with a minimum of twenty (20) feet of clearance between the existing foundation and the new foundation unless otherwise approved by the Engineer. 613 658.5.2 -Excavation: The Contractor shall perform excavations for each concrete foundation to the depths and dimensions shown on the Plans. The excavation shall be made in accordance with the applicable provisions o f the Specifications. The Contractor shall contact WV 811 and shall notify all applicable WV 811 non - participating utilities prior to beginning excavation or conduit jacking activities. The Contractor shall hand dig to locate lines or open cut in areas of possible conflict, as determined by the Engineer. The Contractor shall also be responsible for locating and verifying Division owned underground conduit to avoid conflict or damage. All such work shall be incidental to the Contract bid items. All cos ts associat ed with any disruption of services as a result of the Contractor’s activities shall be the Contractor’s sole responsibility. Earth augers, if used shall be of the same diameter as the footings. Where a trench is required, it shall be only as wide and l ong as is necessary to accommodate the work. If rock or boulders are encountered during the excavation, they shall be removed to a depth sufficient, in the judgement of the Engineer, to obtain the stability necessary to support the sign structure. The S tandard Detail drawings are compiled on the basis of average soil conditions. Soil conditions surrounding specific foundations may require larger foundations. The Contractor shall adjust the foundation dimensions if directed to do so by the Engineer. Any work in such cases shall be performed without change in the unit bid price. If a foundation is to be installed within the area of an existing concrete or asphalt surface, the concrete or asphalt shall be carefully opened by drilling, saw cutting, or o ther suitable methods approved by the Engineer that will not cause unnecessary damage to the surrounding surface. The Contractor shall remove all excavated material from the site that is not needed for backfill or, if permitted by the Engineer, shall sp read this material out in the area immediately surrounding the foundation location to the satisfaction of the Engineer. The Contractor shall restore all disturbed areas to within reasonable conformity of their original conditions by grading, seeding, mulc hing, and/or fertilizing as directed by the Engineer. These operations and required materials shall be paid for incidental to the Contract bid items. 658.5.3 -Conduit and Ground Rods: All overhead sign structures shall have conduit and ground rods, reg ardless of whether they have sign lighting or other electrical components. A two ( 2) inch diameter galvanized conduit shall be furnished and installed in the support foundations at locations as specified on the Plans. The conduit shall terminate above the top of the foundation and shall be fitted with a two ( 2) inch capped grounding bushing above the foundation. The lower end of the conduit shall emerge from the side of the footing to be joined to conduit from the junction box. Ground rods shall be c opper clad steel, ¾ inches in diameter with a minimum length as noted on the Plans and shall be one piece. Sectional or segmented ground rods are not permitted. The ground rods shall be complete with ground clamp and square head bolt. 658.5.4 -Foundati on Placement: The foundations shall be of Class B concrete, reinforced, of the types shown on the Plans. Steel reinforcement, anchor bolts and conduit for the footings shall be as shown on the Plans. All concrete for each foundation shall be placed in one placement with no construction joints. Each foundation shall typically be installed with a pedestal as shown on the Standard Details. All pedestals shall be square to a depth of six (6) inches minimum below ground level. Each of the two pedestals on each end of box truss span structures shall be constructed at the 614 same elevation. For foundations which are within or project into a concrete or asphalt surface utilized by pedestrians, Americans with Disabilities Act (ADA) walkway specification requir ements shall be met as directed by the Engineer. In such cases, the following guidelines shall be followed:
i.Unless unachievable due to right of way restrictions, the foundation shall be placed such that a forty -eight ( 48) inch minimum wide walkway is maintained from the edge of the foundation to the roadside edge of the walkway. This measurement shall not inclu de curbs constructed with a joint separating the curb and walkway. ii. If it is not possible to maintain a forty -eight ( 48) inch wide walkway, the pedestal portion of the foundation above grade shall be eliminated, and the top of the foundation shall be const ructed flush with the walkway. In this case, the width of the walkway shall be measured from the roadside edge of the structure base plate to the roadside edge of the walkway. This measurement shall not include curbs constructed with a joint separating t he curb and walkway. This measurement shall not be restricted to less than thirty -two ( 32) inches, and the continuous longitudinal length over which the walkway is restricted to less than forty -eight ( 48) inches shall be for no more than twenty -four (24) inches. The width of the restriction shall be minimized as much as possible within the available right of way. The anchor bolts shall be set accurately by means of a template in the position shown on the drawings and held rigidly in the forms so as to avoid displacement during the placement of concrete. The steel reinforcement and conduit shall be properly placed and secured before the placement of concrete. The Contractor shall make periodic checks of the bolt positions and elevations during concrete placement operations. It is essential that the distance between the centers of anchor bolt groups of the two foundations of a span structure be exactly the span lengths shown on the Plans. The exposed surfaces of all foundations constructed with pedes tals as shown in the Standard Details shall be given a Class 1, ordinary finish as defined in Section 601. 658.5.5 -Backfilling: If any backfilling is required, excavations shall be backfilled with random material, approved by the Engineer, in horizonta l layers not to exceed four ( 4) inches after compaction. Each lift shall be compacted to the satisfaction of the Engineer. Testing is not required. All surplus material shall be removed from the right -of-way and the backfill finished flush with surrou nding natural ground, including replacement of any damaged facilities or appurtenances. The Contractor shall restore all areas disturbed by this excavation or other operations within reasonable conformity to their original conditions including grading, seeding, mulching and/or fertilizing as directed by the Engineer. No separate payment will be made for backfilling materials or operations. 658.5.6 -Structure Installation: 658.5.6.1 -General: All structures depicted in the Standard Details shall have the support legs installed with the anchor bolts fully tightened before installation of the arms or chords. The individual sections of any box truss span structure made up of multiple sections shall be spliced together for the full length of one span befo re lifting into place. In addition, all sign panels, lighting and other accessories required thereon, as described elsewhere in the Specifications, shall be fully installed before lifting the box truss into place. 615 Two-Tube -Span and One -Tube -Span structu res as shown on Standard Detail sheets TE3-1 and TE3 -2 shall have the entire span assembled and fully tightened before lifting the span into place. The arm splice connections of Heavy Single Arm Cantilevers and Light Single Arm Cantilevers as shown on Sta ndard Detail sheets TE4 -4A and TE4 -4B may be assembled after lifting the section attaching to the support leg into place and fully tightening the structural connection bolts. The field assembling of the component parts of a structure shall be done in a m anner not likely to produce damage by twisting, bending, or otherwise deforming the metal. Signs required to be installed prior to erection or immediately after erection as described herein shall be covered in a manner approved by the Engineer if determin ed to be necessary due to operational considerations. 658.5.6.2 -Installation Preparation: Proper condition and lubrication of hardware associated with anchor bolts and structural bolted connections is critical to proper installation. Only un -weathered hardware components in new condition shall be used. Fastener components shall be protected f rom dirt and moisture in closed containers at the site of installation. Fastener components shall not be cleaned of lubricant that is present in the as delivered condition. Components that accumulate rust or dirt resulting from plant or job -site conditio ns shall not be incorporated into the work. Galvanized structural connection bolts that have been fully pretensioned shall not be reused. If a new structure is to be placed on existing foundation(s) and connected to existing anchor bolts, all washers and nuts for the connection shall be replaced with new. All nuts shall be pre -coated with a lubricant as specified herein. Prior to snug tightening of any nuts or bolts, lubricant shall be applied to the bolt threads if the threads of the bolts have not been lubricated, were last lubricated more than twenty -four (24) hours prior, or have gotten wet since they were last lubricated. Beeswax or toilet ring wax may be used. If the bolt heads are turned in order to tighten a connection, the Contractor shall apply lubricant to the face of the washer that the bottom of the bolt head is to be tightened against. If pre -coated nuts have gotten wet, lubricant shall be reapplied to the threads and the bearing surface face of the nut. Prior to erection, the following steps shall be taken by the Contractor:
1.Inspect the s eparate components of the structure for bent or damaged members, damaged coatings, distortion, blemishes, scratches, cracks, and defective fabrication that would affect proper erection, durability, or structure performance. Localized defects in the galvan izing coating shall be repaired in accordance with the requirements of ASTM A780. Any member slightly bent or twisted shall have all defects corrected in an approved manner before being placed. The Engineer may direct the Contractor to not proceed with th e erection of any structure if any serious defects warranting further assessment and possible rejection are found.
2.Verify that there will be no potential fit -up problems when the components of the structure are assembled. Insure connecting plates will fi t with no burrs or other seating inhibitors. If more than 25 -percent (25%) of the surface area of the face of a flange bolted to the face of another component, or surface area of the underside of a structural bolt head or nut, is visible after snugging of the bolts this shall be cause for rejection.
3.Apply protective coating materials if aluminum components are to be attached to concrete, masonry, or steel if the steel is neither galvanized nor stainless. If to be attached to steel which is neither galvani zed nor stainless, the aluminum points of 616 contact shall be coated with a zinc chromate primer or as called for on the Plans, and the steel shall be coated at the points of contact with a suitable priming paint followed by a coat of aluminum paint. If to b e attached to concrete or masonry, the points of contact shall be coated with a heavy coat of an alkali -resistant bituminous paint.
4.Verify that the foundations are set to the proper elevation and anchor bolts are set in the correct pattern and orientation, are of the correct size, and are plumb with the specified extension and thread length above the top of concrete.
5.Just prior to erection, the aluminum shall be thoroughly cleaned, and any accumulations of oil, grease, dirt or foreign materials shall be rem oved using an approved solvent cleaner. 658.5.6.3 -Installation Procedure: The following steps shall be followed during the erection procedure:
1.Clean the anchor bolts with a wire brush or equivalent and lubricate the anchor bolts as described herein if t his has not already been done.
2.If the structure is to be placed on existing foundation(s) and connected to existing anchor bolts, the Contractor shall verify that it is possible to turn a new properly lubricated nut onto each anchor bolt by hand below the elevation where the leveling nut will be initially placed. If this is not possible, the installation procedure shall be suspended and this issue shall be reported to the Engineer and in turn referred to the Traffic Engineering Division for further directi on.
3.Place and level the foundation leveling nuts with washers on top. Initial placement of the leveling nuts shall be no more than ¼ -inch above the top of the foundation.
4.Bring the support leg(s) into position for placement. Insure anchor bolts and the bolt holes in base plate are properly aligned. No cold working of the anchor bolts shall be allowed. No cutting or reaming of holes will be allowed without prior approval from the Traffic Engineering Division.
5.Place the support leg(s). The Contractor s hall take due care to avoid damaging the anchor bolt threads during this process. If the structure has multiple support legs, one support leg shall be placed and fully tightened into place at a time.
6.With the support leg as plumb as possible, adjust the leveling nuts as needed. The gap between the top of concrete and the bottom of each leveling nut shall not exceed the diameter of the anchor bolt after this process is completed.
7.Fully tighten the anchor bolt top nuts in accordance with Materials Procedu re (MP)
658.05.06 The tightening process shall be documented and transmitted to the
Traffic Engineering Division in accordance with MP 658.05.06. When the snug tightening portion of MP 658.05.06 is completed, the Contractor shall verify that all nuts and washers were brought into firm contact with the base plate. Beveled washers may be necessary under the leveling or top nut if any face of the base plate has a slope greater than 1:20 and/or any nut could not be brought into firm contact. If it is determin ed that beveled washers are required, the support leg shall be disassembled from the anchor bolts and the erection procedure shall be restarted using the beveled washers. Beveled washers shall be manufactured of the same material as the base plate and shal l be galvanized. Beveled washers shall be square with the length of each side being equal to or greater than the diameter of the normal washers. The minimum thickness of the beveled washers shall be the thickness of the normal washers 617 8. Release any load by c rane or other erection device. The anchor bolt nuts must be properly tightened before removal of the crane. If problems exist such as the anchor connections are loose after release, then repeat the nut tightening procedure.
9.Lift the structure arms or spa n into place. The Contractor shall be responsible for determining and selecting appropriate lift points in order to not overstress the structural components or attachments during lifting.
10.Once components that are attached using structural connection bolt s are lifted into place and lubrication is applied to the hardware components as required, the bolts shall be snug tightened and then fully tightened immediately. The snug tightening procedure used shall be the same as described for the anchor bolts in MP 658.05.06. The procedure for fully tightening the bolts is described in Section 658.5.6.3.1. Once span structures are lifted into place and proper alignment is verified, they shall be secured to the support legs by installing and tightening the u -bolts immediately.
11.Check structure. If problems exist, such as loose arm connections or showing gaps, the load must be removed from the area in question and steps repeated as necessary. If this requires loosening structural connection bolts that have already been fully tightened, the bolts shall be replaced.
12.If not installed prior to lifting the arms or chords into place (required for box truss spans), all signs to be attached to the structure arms or chords shall be installed immediately after the attachment hardware for the arms or chords are fully tightened. 658.5.6.3. 1-Structural Connection Bolt Tightening: After snug tightening has been accomplished, apply the appropriate rotation to the turning elements in the same sequence as snug tightening. Rotation shall be i n accordance with Table 615.5.6.3B. Full tightening of each bolt shall be accomplished in approximately 10 - seconds using a hydraulic torque wrench meeting the requirements specified herein, or impact wrenches of adequate capacity. 658.6 -METHOD OF MEASU REMENT : 658.6.1 -Class B Concrete Footing, Reinforced, Overhead: The quantity of work done for Class B Concrete Footings, Reinforced, Overhead will be measured in cubic yards, complete in place and accepted, as determined by the dimensions on the Plans or Contract documents, subject to adjustment as provided for in subsection 104.2 and 109.2. 658.6.2 -Overhead Sign Structures: Measurement for payment for overhead sign structures will be based on each unit complete in place, which will include the various elements of the structure consisting of vertical end support u nits, horizontal units, vertical sign brackets, structural framing for signing if required, sign lighting support hardware if required (horizontal brackets, pads, bolts, nuts, plates, etc.) and any other accessories or hardware as required to make a comple te installation as called for on the Plans or as directed by the Engineer. 658.7 -BASIS OF PAYMENT : The quantities, determined as provided above, shall be paid for at the contract unit price for the items listed below, which prices and payment shall be full compensation for furnishing all the materials and doing all work prescribed in a workmanlike and acceptable manner, including staking out footings and stakes therefore; excavating for footings rega rdless of the type of material 618 encountered; constructing and removing forms; furnishing and installing reinforcing steel, anchor bolts, washers and nuts; furnishing and installing electrical grounding and conduit sleeves; furnishing, placing, finishing and curing the concrete; furnishing and placing grout as required by the Plans; fabrication, delivery and erection of each overhead sign; and including all tools, equipment, supplies and incidentals necessary to complete the work. All incidental work and materials for which no basis of payment is provided will be considered as completely covered by the prices bid for the items included in the contract. 658.8 -PAY ITEMS : ITEM DESCRIPTION UNIT 658001 -* Class B Concrete Footings, Reinforced, Overhead Cubic Yard 658005 -* Overhead Sign, Two Tube Span Each 658006 -* Overhead Sign, One Tube Span Each 658007 -* Overhead Sign, Double Arm Cantilever Each 658008 -* Overhead Sign, Butterfly Cantilever Each 658009 -* Overhead Sign, Single Arm Cantilever (Heavy) Each 658010 -* Overhead Sign, Single Arm Cantilever (Light) Each 658011 -* Overhead Sign, Steel Box Truss Span Each 658012 -* Overhead Sign, Aluminum Box Truss Span Each 658013 -* Overhead Sign, Frame Each * Sequence Number 619 SECTION 659 SIGN LIGHTING 659.1 -DESCRIPTION : Sign lighting shall consist of furnishing and installing or modifying sign illumination systems, including all necessary accessories, in accordance with the Plans and the following Specifications or as directed by the Engineer. All electrical equipment shall conform to the standards of the National Electrical Manufacturers Association (NEMA), the Underwriters ’ Laboratories, Inc. (UL), or the Electronic Industries Association (EIA), whichever is applicable. In add ition to the requirements of the Plans and these Specifications, all materials and workmanship shall conform to the requirements of the National Electrical Code (NEC), referred to as the Code; the American Society for Testing Materials (ASTM); the American National Standards Association (ANSI); The American Wire Gauge (AWG), and any local ordinances which may apply. Wherever reference is made in these Specifications to the Code or to the standards mentioned above, the references shall mean the code or standard, including revisions, that is in effect at the time of the award of the contract. 659.2 -MATERIALS : The materials furnished and used shall be new, except as may be specifically provided on the Plans. The mat erials shall be manufactured, handled, and used in a workmanlike manner to insure a completed installation in accordance with the Plans and Specifications. All electrical materials shall conform to the special requirements and to the Standardization Rules of the Institute of Electrical and Electronic Engineers, IPCEA and, when governing, shall also conform to the National Electrical Code, local and special laws or ordinances, and the Underwriter ’s Laboratories. 659.2.1 -Electrical Material Documentation and Certification: All work, equipment, and documentation shall conform to 715.43. 659.2.2 -Conduit: All conductors shall be run in conduit, except for overhead or temporary installations and where conductors are run inside poles. Conduit to be installed underground, on the surface of poles, or in structures, except as shown on the Plans, shall be Type R, Type F, Type P, or Type H as follows:
i.Type R (Rigid Steel Conduit) shall meet the requirements of Section 715.42.10.1. ii. Type F (Flexible, Liquid -Tight Conduit) shall meet the requirements of Section
715.42.10 2.
iii. Type P (Polyvinyl Chloride Conduit) shall meet the requirements of Section
715.42.10 3.
iv. Type H (High Density Polyethylene Conduit) shall meet the requirements of Section
715.42.10 4.
Standard and expansion couplings and other fittings for the Type P conduit shall all be of the same materials as the conduit. Other fittings for metal conduit shall be threaded malleable iron conforming to the requirements of ASTM A338 and shall be galvani zed in accordance with the requirements of ASTM A153. The size of conduit used shall be as shown on the Plans or as specified. If size is not shown on the Plans, the National Electrical Code shall govern as to the necessary conduit size.
Source: West Virginia Standard Specifications for Road and Bridge Construction, 2023 Edition. Pages 625–639 of 1,006.