galvanized cable shall be extra high strength galvanized steel wire with a breaking strength of not less than 11,000 lb. Lashing shall be stainless steel, ANSI 30 0 series.
662.2.11 -Cable -in-Duct: 662.2.11 .1-Description: The work under this item covers the installation of a system as described in the Plans and Special Provisions suitable for an installation buried directly in the earth.
662.2.11 .2-Materials and Testing: The materials furnished and the testing necessary shall be as prescribed in the Plans.
662.2.12 -Service and Control Stations: 662.2.12 .1-General: The Contractor shall furnish and install service and control stations as noted on the Plans to serve the roadway lighting circuits. Service and control stations shall consist of cabinet (enclosure), all -weather padlock, control panel, conduit, cable, rock and earth excavation, backfill, concrete and steel reinforcement for the equipment pad, fencing and gate, transformer, grounding and all other incidentals for a complete and operable system as called for on the Plans. Cabinets, electrical equipment, grounding and miscellaneous items shall conform to size, rating and description shown on the Plans and applicable NEMA and ANSI Standards as well as the usual practices of the local utility company and the National Electrical Code. Conductors shall be neatly arranged in a workmanlike manner and laced with nylon cable straps. Cabinets (enclosures) shall be provided with nameplates and a wiring diagram of the circuits installed within the service and control station, sealed with a plastic cover and permanently attached to the inside of the door under a metal frame at a height of not less than one -half the door height. Photoelectric controllers shall be the twis tlock type, 120 volt, preset to "turn on" between one ( 1.0) and 3.5 footcandles. "Turn off" shall be at least two times the "turn on" level; however, "turn off" must be greater than three ( 3.0) and less than fifteen ( 15.0) footcandles. The unit shall meet all relevant NEMA Standards and shall be north oriented. Transformers shall be built in accordance with the latest revision of the ANSI -NEMA standards for outdoor type distribution transformers, as manufactured by G.E., Westinghouse or shall be approved equal. Two prints of shop drawings indicating the proposed dimensions and material specifications for the control center, cabinet (enclosure), and transformer, if required, shall be submitted for approval purposes within three weeks after the award of the Contract. These drawings will be reviewed by the Division at the earliest possible date and one print will be returned marked "Approved" or "Returned for Revisions as Noted." Eight sets of drawings shall then be submitted for final approval. Resubmissi on of drawings to obtain final approval by the Division shall not be considered as being just cause for delay in completion of any contract.
662.2.12 .2-Ground Mounted Cabinets: The entire assembly shall meet the requirements of NEMA Type 4 Standards. Framed overlapping doors shall be installed in the front of each cabinet for access to the panel interior, and they shall be hung on a substantial set of stainless steel hinges. The
663 doors shall be provided with three -point and two -point, vault -type latch a nd padlock lugs. The cover joints shall have returned lips and shall be provided with gaskets which shall prevent water from entering the panels. A rain shield shall be provided over the doors. Mounting plates and channels shall be provided within the c abinet for installing contractors, panelboards, auxiliary transformers, etc. The wiring shall be neatly arranged, laced and securely fastened in an approved manner. Chain link fences shall conform to the requirements of 712.8 of the Specifications and shall contain at least four signs (one per center of each of the four sides) with the legend `DANGER -HIGH VOLTAGE.' Rock and earth excavation shall be in accordance with 207 of the Specifications, as revised and amended. Adequate stainless steel screens and louvers shall be provided for the ventilation of internal equipment.
662.2.12 .3-Pole Mounted Cabinets: The lighting circuit protector and disconnect switch shall have a NEMA Type 4 enclosure with operator capable of being locked in either position. Disconnect switch and fuse, or circuit breaker shall be rated and furnished with fuse or breaker size as shown on the Plans. The framework steel and hardware used in the cabinet shall be stainless steel.
662.2.12 .4-Service Poles: Service points shown on the Plans are approximate only. Final location of service poles shall be determined in the field. Materials and costs for the connections to the service point will be paid for by the Contractor. The Contractor shall conform to utility company requirements for this item. The service pole grounding system shall be installed as part of the pole in accordance with the requirements of the local power company. All wiring on the poles shall be installed in steel conduits of sizes as shown on the Pl ans and shall be securely fastened to the service pole with pipe straps at not over four (4) foot maximum spacing. All pole line hardware used in the service poles and control stations shall be hot -dipped galvanized.
662.2.13 -Lighting Supports: 662.2.13 .1-Lighting Pole Type I, II and III -Steel: 662.2.13 .1.1-General Description: Each Lighting Pole, Type I, II and III shall consist of a pole shaft, removable pole top, luminaire support arm, base, support base (if required), anchor bolts, removable anchor bolt covers and any other accessories or hardware as required to make a complete installation as called for on the Plans or as directed by the Engineer. Spreads and mounting heights shall be as detailed on the Plans; tolerance for moun ting heights shall be plus or minus six (6) inches. All wiring shall be concealed within the pole shaft and luminaire support arm. Lighting Poles Type I, II, and III shall be certified to equal or exceed the requirements of AASHTO “Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals”, based on at least 90 mph wind loads, a luminaire weight of 50 lb. and a luminaire projected area of 1.1 sq ft. The maximum allowable pole deflection from vertical at the top of the pole, due to the weight of the arm and luminaire, shall be two percent (2%) of the total shaft length. The pole deflection from vertical is defined as the horizontal distance between the pole top centerline when the pole alone is installed plumb and th e pole top centerline after the arm
664 and luminaire combination is installed on the previously plumb pole, the measurement to be made without additional shaft adjustment. The fabricator shall certify to the above and maintain results of computations or tests to document compliance, for each type of lighting pole supplied.
662.2.13 .1.2-Pole Shaft: The pole shaft shall be an ASTM A595 Grade A Tube or fabricated from weldable grade, hot -rolled, commercial quality steel, meeting the requirements of ASTM A607, with a minimum yield strength of 55,000 psi after fabrication. The round shaft shall be fabricated in one piece from not less than # 11 manufacturer's standard gauge steel and be continuously tapered at 0.14 or 0.10 inch per foot. Two piece shafts, that assemble by telescoping the upper section over the lower section with a firm tapered fit, may be used for 40, 45, 50, 55 and 60 feet mounting heights. Each pole shaft shall include a J -hook wire support welded inside near the top, a handhole with cover a s noted on the plans (except for transformer bases), and a ground connector near the bottom. An opening shall be provided near the top of the shaft to provide a cable entrance from the shaft into the luminaire support arm.
662.2.13 .1.3-Luminaire Support Arm Types I and II: Luminaire support arms for Lighting Poles Types I and II shall be of constant diameter and fabricated from 2 inches pipe, having a wall thickness equal to Schedule 40 pipe and meeting the requirements of ASTM A50 1, or from 2 -3/8 inches steel tubular members with a nominal wall thickness equal to Schedule 40 pipe and having a minimum yield strength equal to ASTM A36. For arm spreads twelve ( 12) feet and less, the fabrication of the lower member may be of 1½ in pip e, having a wall thickness equal to Schedule 40 pipe. For arm spreads over eighteen (18) feet, the fabrication may be of 2½ inches pipe, having a wall thickness equal to Schedule 40 pipe, or a combination of 2½ inches and two ( 2) inches meeting the above requirements. The arm shall be attached to the pole so that it can transfer the full strength of the arm to the pole shaft. The truss type arm (Type I) shall consist of an upper and lower member joined near the luminaire end of the arm and securely joine d with vertical strut(s). The upper member shall be continuous and the wiring member. The vertical strut(s) shall be either oval, circular, rectangular or square in cross section and shall be made of steel meeting the physical requirements of ASTM A36. A two ( 2) inches slip fitting arrangement shall be provided at the tip of all arms.
662.2.13 .1.4-Luminaire Support Arm Type III: Luminaire support arms for Lighting Pole Type III shall be an ASTM A595 Grade A Tube or fabricated from weldable grade, hot rolled, commercial quality steel, meeting the requirements of ASTM A607, with a minimum yield strength of 55,000 psi after fabrication. The arm shall be cylindrical in cross section and uniformly tapered from butt to tip at 0.14 or 0.10 inches per feet. The arm shall be fabricated in one piece from not less than # 11 manufacturer's standard gage steel. The arm shall be attached to the pole so that it can transfer the full strength of the arm to the pole shaft. Two-piece arms may be used for spreads grea ter than thirty -four ( 34) feet. The outside luminaire support arm shall be a round tapered tubular member fabricated from material with a minimum yield strength of 36,000 psi after fabrication. Two -piece arms shall assemble by a telescoping joint. The t elescoping length of the joint shall not be less than
665 1½ times the diameter of the arm at the joint. The telescoping field joint shall not be welded but shall be keyed with a through bolt. A 2 inches slip fitting arrangement shall be provided at the tip of all arms.
662.2.13 .1.5-Bases: Anchor, support and approved breakaway bases shall be constructed of sufficient size and strength to fully develop the bending moment of the shaft. Each base shall be provided with four holes (slip base may have three) of sufficient size to accommodate the proper size anchor bolts to resist at yield stress, the bending moment of the shaft at its yield stress. All bases, except the transformer type, shall have the handhole centered approximately 18 inches above the botto m of the shaft located downstream of oncoming traffic. Anchor bases shall be one -piece fabricated from material meeting ASTM A27 Grade 65-35 or ASTM A36 of sufficient cross section to fully develop the ultimate strength of the pole. Galvanizing shall be i n accordance with ASTM A123. Breakaway bases (e.g. aluminum transformer, cast aluminum, fluted aluminum breakaway couplings, slip, etc.), if required, shall meet the dimensions and requirements as required by the Plans. All breakaway bases shall be certi fied for conformance to the AASHTO breakaway performance criteria. The aluminum transformer bases shall be nominally 20 inches high with an access door secured in place by stainless steel locking screws. All bearing plates shall be hot -dipped galvanized in accordance with ASTM A123. Washers shall be hot -dipped galvanized in accordance with ASTM A153. A tapped hole shall be provided for grounding. When aluminum transformer bases are used with unpainted weathering steel poles and bases, both the bottom of t he steel anchor base and the top of the aluminum transformer base shall be coated with a heavy film of zinc -rich paint.
662.2.13 .1.6-Anchor Bolts: Anchor bolts shall be of sufficient size and strength to fully develop the bending moment of the shaft. A nchor bolts (unless otherwise directed on the Plans) shall be fabricated from ASTM F1554, Grade 55. Each bolt shall have the thread end galvanized for a length sufficient to extend down through the grout and into the concrete foundation. Each bolt shall be provided with a regular hex nut or heavy hex nut (anchor bases to have two hex nuts) that shal l be hot dipped galvanized. Hex nuts shall be regular meeting ASTM A563 Grade A for ¼ inch -1½ inches sizes and shall be heavy hex for sizes over 1½ inches to four ( 4) inches.
662.2.13 .1.7-Galvanizing: The pole shaft, luminaire support arm, pole top, ha ndhole cover, anchor base and slip base shall be galvanized in accordance with ASTM A123. Galvanized coatings damaged for any reason shall be repaired by the application of a zinc rich paint conforming with 711.21 of the Specifications. The places to be painted shall be thoroughly cleaned before the paint is applied.
662.2.13 .1.8-Marking: Each pole shall be identified by control station number (as applicable), circuit number (as applicable), wattage and pole number with adhesive labels applied six (6) feet above the grade line normal to the roadway. Adhesive labels shall be designed to be exposed to the weather. Legend shall be three ( 3) inches black on white.
662.2.13 .1.9-Drawings for Approval Purposes: Two prints of shop drawings indicating the proposed dimensions and material specifications for each of the components
666 involved shall be submitted by the Contractor for approval purposes within three weeks after the award of Contract. These drawings will be reviewed by the Division at the earliest possible date and one print will be returned marked "Approved" or "Returned for Revisions as Noted." Eight sets of drawings shall then be submitted for final approval. Appropriate action shall be taken by the Contractor after final approval to insure that the earliest possible erection of these items can be achieved. Resubmission of drawings to obtain final approval by the Division shall not be considered as being just cause for delay in the completion of any contract.
662.2.13 .1.10 -Mill Test Reports and Certification: Mill test reports or certifications of conformance to specifications for materials and design will be required for all materials incorporated into the work. The following shall be supplied b y the Contractor prior to acceptance of the structures:
following chart, shall include both physical and chemical descriptions of the material as supplied to the fabricator. W hen physical properties are altered during fabrication, the M.T.R. covering chemical composition will be supplemented by certified test reports indicating the physical properties of this material after fabrication. ii. Certification of Conformance to the Specifications for all remaining material not covered by M.T.R. as noted in the following chart. iii. Certification that all welding was performed by operators qualified as follows: steel welders to AWS and aluminum welders to ASME. iv. Certification of Conformance to the Specifications for the Design of all components not completely dimensioned and detailed on the Standard Drawing.
TABLE 662.2.13 .1.10 COMPONENT MATERIALS M.T.R. CERTIFICATIONS Tubes for arms and poles X Base castings X Anchor bolts X Pole tops, misc. fittings and hardware X Fabricated or cast -type arm connections X Galvanizing Welding Rod X
662.2.13 .2-Lighting Pole Type IV -Wood: 662.2.13 .2.1-General Description: Each Type IV Wood Pole shall consist of an upright shaft fitted with necessary hardware to make the installation complete as detailed on the contract Plans. All wood poles shall meet the requirements of Section 710.8.
662.2.13 .2.2-Luminaire Support Ar ms: Luminaire support arms for Type IV Lighting Poles shall be of constant diameter and fabricated from two ( 2) inches pipe, having a wall thickness equal to Schedule 40 pipe and meeting the requirements of ASTM A501, or from 2 -3/8 inch OD steel tubular m embers with a nominal wall thickness equal to Schedule 40 pipe and having a minimum yield strength equal to ASTM A36. For arm
667 spreads over eighteen ( 18) feet, the fabrication may be of 2½ inches pipe having a wall thickness equal to Schedule 40 pipe, or a combination of 2 ½ inches and two ( 2) inches, meeting the above requirements. The method of attachment to the pole shall be that as suggested by the support arm manufacturer and approved by the Engineer. A two ( 2) inch slip fitting arrangement shall be provided at the tip of all arms.
662.2.13 .3-Lighting Pole Type V and VII -Aluminum: 662.2.13 .3.1-General Description: Each Lighting Pole Type V "Luminaire Support Arm Mounted" shall consist of a pole shaft, removable pole top, luminaire support arm, base, support base (if required), anchor bolts, removable anchor bolt covers and any other accessories or hardware as required to make a complete installation as called for on the Plans or as directed by the Engineer. Each Lighting Pole Type VII "Luminaire P ost Top Mounted" shall consist of a pole shaft, base, anchor bolts, removable anchor bolt covers and any other accessories or hardware as required to make a complete installation as called for on the Plans or as directed by the Engineer. Spreads and mounting heights shall be as detailed on the Plans; tolerance for mounting heights shall be plus or minus six (6) inches. All wiring shall be concealed within the pole shaft and luminaire support arm. Lighting Poles Type V and VII shall be certified to be equal or exceed the requirements of AASHTO “Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals”. Type V shall be based on at least 90 mph wind loads, a luminaire weight of 50 lb. and a luminaire projected area o f 1.1 sq. feet. Type VII shall be based on 90 mph, ignore the weight and 2.5 sq. feet. The maximum allowable pole deflection from vertical at the top of the pole, due to the weight of the arm and luminaire, shall be two percent (2%) of the total shaft length. The pole deflection from vertical is defined as the horizontal distance between the pole top centerline after the arm and luminaire combination is installed on the previously plumb pole, and measurement to be made without additional shaft adjustment. The fabricator must certify to the above and maintain results of computations or tests to document compliance for each type of lighting pole supplied.
662.2.13 .3.2-Pole Shaft: The pole shaft shall be one -piece, cylindrical, tapered seamless (or one continuous longitudinal weld) tubing which shall have mechanical properties not less than t hat listed for ASTM B221, B429, B241, Alloy 6061 T -6 or Alloy 6063 -T6 after fabrication. Two -piece shafts that assemble by telescoping the upper section over the lower section with a firm tapered fit, may be used for 40, 45, and 50 f eet mounting heights. Each pole shaft shall have a J -hook wire support inside near the top, a handhole with cover as noted on the Plans (except for transformer bases) and a ground connector near the bottom. Minimum wall thickness (unless otherwise approved by the Engineer) shall be 0.188 inch for Type V Poles and 0.125 inch for Type VII poles. The top of shaft OD for “Luminaire Post Tope Mounted” shall be three ( 3) inches unless otherwise approved by the Engineer.
662.2.13 .3.3-Luminaire Support Arm: The Luminaire Support Arm shall be aluminum pipe or tapered aluminum tubing which shall have the mechanical properties not less than that listed for ASTM B221, B429, B241 Alloy 6061 T -6 or Alloy 6063 -T6 after fabrication. A two ( 2) inch slip fitting arrangem ent shall be provided at the tip of all arms.
668 662.2.13 .3.4-Bases: Anchor, support and approved breakaway bases shall be constructed of sufficient size and strength to fully develop the bending moment of the shaft. Each base shall be provided with four holes (three if approved by the Engineer) of sufficient size to accommodate the proper size anchor bolts to resist at yield stress, the bending moment of the shaft at its yield stress. All bases, except the transformer type, shall have a handhole centered approximately eighteen ( 18) inches above the bottom of the shaft located downstream of oncoming traffic. Anchor bases shall be made from Alloy ASTM B108 as detailed on the Plans or as directed by the Engineer. Support bases shall be fabricated from stee l conforming to ASTM A36, with galvanizing in accordance with ASTM A123. Aluminum transformer bases shall meet the requirements as identified in the fourth paragraph of 662.2.13.1.5. Breakaway bases (e.g. aluminum transformer, cast aluminum, fluted alumi num breakaway couplings, slip etc.), if required, shall meet the dimensions and requirements as required by the Plans. All breakaway bases shall be certified for conformance to the latest AASHTO breakaway performance criteria.
662.2.13 .3.5-Anchor Bolts: Anchor bolts shall be of sufficient size and strength to fully develop the bending moment of the shaft. Anchor bolts (unless otherwise directed on the Plans) shall be fabricated from ASTM F1554, GRADE 55 . Each bolt shall have the threaded end galvanize d for a length sufficient to extend down through the grout and into the concrete foundation. Each bolt shall be provided with a regular hex nut or heavy hex nut (anchor bases to have two hex nuts) that shall be hot dipped galvanized. Hex nuts shall be re gular meeting ASTM A563 Grade A for ¼ inch to 1½ inches sizes and shall be heavy hex for sizes over 1 ½ inches to four ( 4) inches.
662.2.13 .3.6-Marking: Each pole shall be identified as required in 662.2.13.1.8.
662.2.13 .3.7-Drawings for Approval Pur poses: Shop Drawings shall be submitted, approved and applied as required in 662.2.13.1.9.
662.2.13 .3.8-Mill Test Reports and Certification: Mill test reports or certifications of conformance to specifications for materials and design shall be supplied as required in 662.2.13.1.10.
662.2.13 .4-Lighti ng Pole Type X -Steel High Mast: 662.2.13 .4.1-General Description: Each Lighting Pole Type X shall consist of pole shaft, anchor base, anchor bolts and nuts, lowering devices and any other accessories or hardware as required to make a complete installation as called for on the Plans or as directed by the Engineer. Moun ting heights, number and type of luminaires shall be as detailed on the Plans. Tolerance for mounting heights shall be plus or minus twelve (12) inches. Any manufacturer's warranties, expressed or implied, shall become the property of the Division. A co mplete service manual including instruction on installation, operation and maintenance shall be furnished for each lowering device, winch assembly and power drive system furnished on each project. Lighting Poles Type X shall be certified to be equal or ex ceed the requirements of AASHTO "Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals," based on the Final Deflected Pole Position Method and the following:
669 Wind Velocity = 90 mph Number of Luminaires = 8 Weight of Luminaires = 70 lbs. Each (560 lbs. total) Area of Lumiares = 2.0 sq. ft Each (16.0 sq. ft. total) Weight of Mounting Head = 370 lbs. Area of Mounting Head = 3.5 sq. f eet
662.2.13 .4.2-Pole Shaft: The pole shaft shall be made from one to six continuously tapered circular or twelve sided sections which shall either telescope with each other or be shop buttwelded by electric arc welding. Steel used in fabricating the shaft shall be either galvanize d steel (hot -dipped according to ASTM A123) or weathering steel with a minimum yield strength of 55,000 psi after fabrication and shall have one or two longitudinal welds. Materials shall be galvanized steel unless otherwise indicated on the Plans as weat hering steel. All poles on any one project shall be of the same type construction for pieces and sections. Straightness tolerance shall be ½ inch in twenty (20) feet. The inside surface of the shaft shall be relatively smooth to provide a cable raceway. Projections on the inside of the pole (such as backup rings) shall not exceed 3/8 inch projection in the area between the handhole and the top flange. Minor sections of galvanized coatings (of pole shaft, pole support assembly and circular luminaire rin g assembly) damaged for any reason shall be repaired by the application of a zinc rich paint conforming with 711.21 of the Specifications. The places to be painted shall be thoroughly cleaned before the paint is applied. The lap joint produced by telescoping shall have a minimum length of one and one - half diameters of the shaft at the joint measured at the minimum diameter of the inner telescoping section. No transverse welding shall be permitted to secure the overlapping telescoping joints. Overlap areas on weathering steel poles shall be shop painted in accordance with 688. The outside of the lower pole shall be coated so a minimum of one (1)inch below the bottom edge of the upper pole is covered (after erection). The inside of the upper pole shall be coated so a minimum of six (6) inches above the top edge of the lower pole is covered (after erection). In addition the intersection of each overlap joint on the outside shall be sealed with a commercial silicone buildin g sealant such as Dow Corning 795. The numbering shall be applied in such fashion that the marks shall be unobtrusive after assembly. In the bottom section of the shaft shall be an access door with stainless steel hinged door, neoprene door gasket and ha sp (welded inside to the reinforcing frame, sleeve or plate) with an all-weather padlock. The door shall be sufficient size to allow the internal machinery (winch and gear box) to be disconnected from its mountings and removed through the door. An additi onal handhole may be provided for wiring access. All handholes or openings in the shaft shall be properly designed and fabricated to avoid stress risers by use of an internal reinforcing sleeve or a reinforcing frame with full penetration welds or other a pproved method. Each pole shall be identified by control station number (as applicable), circuit number (as applicable), wattage and pole number with adhesive labels applied eight ( 8) feet above the base plate normal to the nearest roadway. Adhesive lab els shall be designed to be exposed to the weather. This legend shall be five ( 5) inches black on white.
670 662.2.13 .4.3-Anchor Base: The anchor base (cast or rolled steel) shall be constructed of ASTM A36 minimum for galvanized steel or ASTM A588 for weathering steel and shall be of sufficient size and strength to fully develop the bending moment of the shaft. It shall be welded to th e shaft by a full penetration weld. The weld must be made with a backup ring, or other approved procedure, or be welded from both sides.
662.2.13 .4.4-Anchor Bolts: Anchor bolts shall be of sufficient size and strength to fully develop the bending momen t of the shaft. Anchor bolts shall be fabricated from ASTM A1554 Gr.55. Each bolt shall have the threaded end galvanized for a length sufficient to extend down through the grout and into the concrete foundation. Each bolt shall be provided with two heav y hex nuts and two heavy washers. Both nuts and washers shall be hotdipped galvanized. Detailed properties, dimensions, bolt circles and appropriate backup calculations for anchor bolts for each type pole supplied shall be submitted to and approved by th e Division before fabrication.
662.2.13 .4.5-Miscellaneous Hardware: Miscellaneous other hardware not covered by other specifications shall as a minimum comply with the following:
ASTM A501.
be Yoloy high strength, low alloy steel or approved equal.
662.2.13 .4.6-Welding: All welding sh all conform to AASHTO "Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals", Section l.4.2 ( A) through (D). Welding must be certified to performance by operators qualified as follows: Steel welders to AWS and aluminum welders to ASME. Longitudinal joints in the tapered sections of the pole shaft shall be made only by automatic electric arc welding. Transverse butt -welds may be used, but only under closely controlled shop conditions. Winch mount plate and em ergency stop ring wields shall be fillet welds. All welds in the shaft shall be tested and certified by close visual inspection or approved alternate methods (such as ultrasonic or magnetic particle). One hundred percent (100%) of the full penetrationse ctions of longitudinal seam welds shall be radiographically inspected and a random ten percent (10%) of the partial penetration section of the longitudinal seam welds shall be inspected by the magnetic particle method.
662.2.13 .4.7-Lowering Devices: 662.2.13 .4.7.1 -General Description: The integral luminaire lowering mechanism or devices shall be compatible with the pole design and shall consist of a head frame assembly, a luminaire ring assembly and a hoisting assembly. The system shall permit lumin aire maintenance at ground level, provide for disconnection of the electrical service at the pole base, provide a convenient means of energizing the lighting assembly when it is at ground level, support eight (8) 70 lb. luminaires in a symmetrical arrangem ent and include power cables and all miscellaneous electrical equipment in the pole necessary to provide a complete and workable device. All bolts and machine screws shall be secured in a manner that will preclude their becoming loosened by vibration. St ar washers, jam nuts, self -
671 locking nuts, locktite, etc., may be used to secure nuts and machine screws. Sheave pins shall be secured by means of washers and cotter keys or pins, not welded.
662.2.13 .4.7.2 -Head Frame Assembly: The head frame structures hall be galvanized steel, attached to the pole by a steel slipfitter and secured by the appropriate stainless steel setscrews. It shall consist of all necessary pulleys and rollers to guide the hoisting cables and electrical cable. The head frame shalls upport six (6), six (6) inches diameter steel hoist cable sheaves or six (6), five ( 5) inches diameter cast aluminum hoist cable sheaves with oil -impregnated, sintered bronze bushing with stainless steel shafts. The three hoisting cables shall be stainless steel 7 x l9 aircraft cord of 3/l6 inch diameter. The minimum tread diameter for the hoisting cable sheaves shall be 20 times the cable diameter for galvanized cable and 25 times the cable diameter for stainless steel cable. The hoisting cable sheave groove cross -section shall be semicircular with a radius of one -half the cable diameter plus l/64 inch . The power cable shall not be bent at a radius less than five times the cable diameter and the groove cross -section shall prevent the cable from rolling out of the groove if the cable is twisting. All power cable sheaves and rollers shall be suspended on stainless steel shafts fitted with self -lubricating bushings or be fabricated of self -lubricating material. All head frame sheaves will have kee pers to keep cables engaged during operation. The head frame assembly shall be protected from the weather by an aluminum cover. Positive latching devices shall be incorporated into the luminaire ring assembly. These devices shall be designed to prevent any movement of the luminaire ring assembly when it is latched to the top of the pole and tension is removed from the luminaire ring support cables. Latching shall be accomplished by the alternate raising and lowering of the luminaire ring assembly by the winch and hoisting assembly and there shall be no moving latch parts or springs attached to the head frame assembly. Reflectors or flags shall be provided to indicate when the luminaire ring assembly is completely and securely latched to the head frame a ssembly. All moving parts of the latching mechanism shall be attached to the luminaire ring assembly and serviceable from the ground.
662.2.13 .4.7.3 -Luminaire Ring Assembly: The luminaire ring shall be fabricated of six (6) inches steel channel, hot di pped galvanized with the appropriate number of two ( 2) inches nominal galvanized steel pipe mounting arms. The luminaire ring shall be wired with TypeS.O. power cable or equivalent and Type ST distribution cable with insulation suitable for at least l05 C. All electrical cords shall be attached to the weathertight wiring chamber through weathertight cable connections. A prewired 600 volt terminal block and a secondary lightning arrester shall be provided in the weathertight chamber. A weathertight twis tlock power inlet shall be provided on the chamber to allow testing of the luminaires while in the lower position. Roller -contact, spring -loaded centering arms shall be provided to stabilize and center the luminaire ring during raising or lowering operati ons and to eliminate shock to the lamps from impact of the luminaire ring with the pole. The rollers for the centering arms shall be of a water -resistant, non -marking material with oil -impregnated sintered bronze bushings. All axle shafts for arms and ro llers shall be stainless steel.
662.2.13 .4.7.4 -Housing Assembly (Winch Assembly): The winch shall have an ultimate strength of five times the lifted load with the number of layers of cable with which
672 it will be used. The winch shall have a 30 to l worm gear reduction ratio and include an integral drag brake on the worm shaft to prevent free spooling of the winch. The winch shall be designed for at least intermittent power operation, but also have hand crank capability. The winch shall be prewound with galvanized steel ¼ inch, 7 x l9 aircraft cord of sufficient length to maintain at least four complete wraps on the drum after the device has been lowered to its lowest position. The drum shall be supported at both ends and keepers shall be provided to en sure that uncoiled cable will rewrap onto the drum. A portable power unit is required (one per project). Its motor shall be the heavy -duty reversing type with a stalling torque at least twice that required to operate the device. The motor shall drive th e winch through the torque limiter coupling to limit the lifting force. The hoisting rate shall be between twelve ( 12) and twenty -five ( 25) feet per minute. The motor shall be controlled by a reversing switch connected by a twenty ( 20) foot remote cord. The portable power unit shall be provided with a portable enclosed and encapsulated transformer to stepdown the parent voltage to 120 volts to operate the power unit. All electrical connections from the transformer to the power cord and from the transformer to the power unit shall be twistlock caps and plugs.
662.2.13 .4.8-Wire Rope: 662.2.13.4.8.1-Materials for the stainless steel cables shall conform to the Chemistry of ASTM A492 type 302 or 304. The wire used in steel cable shall be cylindrical and s mooth and of uniform high quality. The finished cable shall be uniform in construction and securely laid, free from kinks, loose wires, loose strands, splits, cold shuts or other defects. A suitable type of friction - preventive compound having noncorrosiv e properties shall be impregnated into the wire rope. The individual wires and strands composing the wire rope shall be shaped into the exact helical position they will have in the finished wire rope, so that if the wire rope is cut or severed there is no tendency for the measured diameter of the wire rope at the unseized cut ends to increase by more than the amount specified in Table 662.2.13.4.8.
TABLE 662.2.13 .4.8 Construction, Physical Properties of Stainless Steel Wire Rope Nominal Diameter of Wire Rope
on Diameter (Plus Only)
Increase of Diameter
Strength Stainless Steel
Weight per 100 feet (Pounds) 5/32 .016 .017 2,400 4.50 3/16 .018 .019 3,700 6.50 7/32 .018 .020 5,000 8.60 1/4 .018 .021 6,400 11.00 5/16 .022 .024 9,000 17.30 3/8 .026 .027 12,000 24.30
Flexible steel wire rope covered by this specification shall be of 7 x 19 construction. The type of construction for the respective diameters, the dimensional tolerances and the physical properties shall be as specified in Table 662.2.13.4.8. Wire ropes hall be 7x19 aircraft cable.
673 662.2.13 .4.8.2 -Quality conformance testing shall consist of all the inspections such as workmanship and physical appearance previously specified. The sample wire rope shall pass the breaking strength test and stretch tests as specified below.
has been removed from the head or starting end of the first manufacturing reel for each lot of wire rope. ii. Lot-A lot shall consist of not more than 20 ,000 feet of wire rope of the same construction and diameter produced continuously by one machine or by one series of progressive processing machines.
662.2.13 .4.8.3 -Breaking Strength: The wire rope specimen shall be selected from the sample from each l ot. The specimen shall be no less than twenty -four ( 24) inches in length, and where necessary, swaged terminals conforming to MIL -T-781 (do not use ball end fitting) and accompanying hardware may be used to facilitate installation of the specimen in the j aws of the testing machine. The distance between the jaws of the testing machine with the sample shall be no less than ten (10) inches. The breaking strength shall be determined by use of a tensile testing machine in accordance with applicable requiremen ts of ASTM E8. The breaking strength shall conform to the requirements of Table 662.2.13.4.8 for qualification.
662.2.13 .4.8.4 -Stretch Test: One specimen from each sample of wire rope selected as specified in 662.2.13.4.8.2 shall be tested to determine the percent stretch. The total length of the wire rope specimen to be tested shall not be less than twenty -four ( 24) inches. Where necessary, swaged terminals and accompanying hardware may be used to facilitate installation of the specimen in the jaws of the test machine. The amount of stretch shall be determined on a tension testing machine in accordance with ASTM E8. The specimen shall be l oaded to one percent (1%) nominal breaking strength shown in Table 662.2.13.4.8 to straighten the wire rope. While the specimen is under tension, an adequate gauge length shall be marked off the wire rope between the jaws of the testing machine. The spe cimen shall then be loaded to 60 percent (60%) of minimum breaking strength and measured to elongation under load. From this data the stretch shall not exceed 1.5 percent (1.5%) .
662.2.13 .4.8.5 -Certification: Upon request, the wire rope manufacturer sh all furnish a certified test report showing that the wire rope manufacturer's product satisfactorily conforms to this Specification. The test report shall include, as a minimum, actual results of the tests specified.
662.2.13 .4.9-Drawings for Approval Purposes: Two prints of shop drawings indicating the proposed dimensions and material specifications for the poles and lowering devices shall be submitted by the Contractor for approval purposes within three weeks after the award of the Contract. These drawings will be reviewed by the Division at the earliest possible date and one print will be returned marked "Approved" or "Returned for Revisions as Noted." Eight sets of drawings shall then be submitted for final approval. Appropriate actions hall be taken by the Contractor after final approval to insure that the earliest possible erection of these items can be achieved. Resubmission of drawings to obtain final approval by the Division shall not be considered as being just cause for delay in t he completion of any contract.
674 662.2.13 .4.10 -Mill Test Reports and Certification: Mill test reports or certificates of conformance to specifications for materials and design will be required for all materials incorporated into the work. The followings hall be supplied by the Contractor prior to acceptance of the structures:
following chart, shall include both physical and chemical descriptions of the material as supplied to t he fabricator. When physical properties are altered during fabrication, the M.T.R. covering chemical composition will be supplemented by certified test reports indicating the physical properties of this material after fabrication. ii. Certification of Con formance to the Specifications for all remaining material not covered by M.T.R. as noted in the following chart. iii. Certification of Conformance to the Specifications for the design of all components not completely dimensioned and detailed on the Standar d drawing.
TABLE 662.2.13 .4.10 COMPONENT MATERIALS M.T.R. CERTIFICATIONS Tubes for poles X Base Castings X Anchor bolts X Pole tops, lowering devices, cable, misc., fittings, and hardware X Galvanizing X Welding Rod X
662.2.14 -Navigation Lighting System: The Contractor shall furnish and install a navigation lighting system as indicated on the Plans. The navigation lighting system shall consist of control center, enclosure, power service, conduit, cable, junction boxes, navigation light unit, photoelectr ic unit, electrical work, electrical tests and all other incidentals for a complete and operable system as called for on the Plans.
662.2.14 .1-General: The installation, equipment, materials and workmanship, except as specifically modified, shall be in accordance with applicable provisions of the following publications, codes and regulations in effect on the date of the invitation for bids: • National Electrical Code • American National Standards Institute • National Electrical Manufacturer's Association • Insulated Power Cable Engineers Association • U.S. Coast Guard Publication, "A Guide to Bridge Lighting" • Enclosure 6 to COMDTINST Ml6590.5 • Federal Aviation Administration, “Obstruction Marking and Lighting" AC70/7460 -lF • Regulations of local power company
In the event of conflict in any requirements of the above standards, the Engineer will determine which authority is applicable.
675 Two prints of shop drawings indicating the proposed dimensions and material specifications for the control center, enclosure, tran sformer, if required , and navigation light unit shall be submitted for approval purposes within three weeks after the award of the Contract. These drawings will be reviewed by the Division at the earliest possible date and one print will be returned marked "Approved" or "Returned for Revisions as Noted". Eight sets of drawings shall then be submitted for final approval. Resubmission of drawings to obtain final approval by the Division shall not be considered as being just cause for delay in completion of any contract. After the installation is completed, the Contractor shall conduct a continuous 24 -hour operating test for approval. In addition, final acceptance of any installation will not occur until 30 days of operation termed satisfactory by the Engin eer.
662.2.14 .2-Navigation Lighting (Surface): 662.2.14 .2.1-General: Navigation lights shall be securely mounted to the bridge structure or substructure and shall show through a horizontal arc of 360° for green lights and show through a horizontal arc of l80° for red lights as specified or detailed in the Plans. They shall be pivot -swivel mounted or pedestal mounted as specified. The pivot mounted lights shall have a locking mechanism and service -retrieving chain made of corrosion - resistant non -plastic material. The navigation lights shall have one or two lenses with one or two lamps as specified but unless otherwise noted, are to have one lens with one lamp. The lamps shall be 100 -W, 120 -V, rated at 5 -years. The lenses shall be fresnel glass eight (8) inches. The signal housing shall be made of aluminum, silicon bronze or cast bronze and shall be watertight with weather -proof gaskets. The hangar stem shall be 1½ inches minimum galvanized steel pipe or 1½ inches minimum stainless steel pipe. The mo unting bracket and hangar housing shall be cast silicon bronze with stainless steel pivot and shall be watertight. The cable shall be #16 S. O. minimum and all connections shall be watertight. Any other structural connections shall be watertight and of g ood quality non -corrosive construction. The pedestal mounted light shall meet all of the aforenamed light, lamp, lens, signal housing, cable and structural connection requirements. The pedestal mounted stem itself shall be similar to and meet the requirement of the pivot mounted hangar stem requirements. Navigation lights shall be provided with supports constructed of steel meeting ASTM A36. Each fixture shall be individually protected by "in the line" fuses as manufactured by ESNA Corporation, Bussman Manufacturing Division of McGraw - Edison Company, HOMAC, or approved equal. The photoelectric control for navigation lights shall provide automatic switching of circuits. The unit shall be oriented as nearly as possible to face the northern sky. Initial settings shall be thirty -five ( 35) footcandles for "turn on" and fifty-eight ( 58) footcandles for "turn off". The unit shall be housed in a weatherproof enclosure of the twistlock type. The unit shall be "fail safe", i.e., failure of the electronic circuit will "turn on" the navigation lights. The unit shall be suitable for operation in three -wire, 120/240 Volt, 60 Hz. Circuits.
662.2.14 .2.2-Power Service: Power shall be received at a location noted on the Plans or as directed by the Engineer. Power wi ll be 120/240 Volt single phase, 60 Hz., three -