725 HIGHWAY LIGHTING MATERIALS

725.01  GeneralFurnish luminaires, conduits, wire, switch gear and other electrical hardware that are listed with Underwriters Laboratories.

Ensure that each item of manufactured electrical apparatus as a unit has a durable nameplate identifying the manufacturer and manufacturer’s product identification. 

Only provide samples when required by the Laboratory.

725.02  Wire and Cable.  Ensure that each nonshielded wire or cable rated 0-2kV is single conductor, stranded copper with cross‑linked thermosetting polyethylene insulation, nonjacketed, meets the requirements of ICEA S-95-658/NEMA WC70 and is of UL Type RHHRHW‑USE except for conductors 10 AWG and smaller for which those with insulation meeting the requirements of UL Type XHHW may also be used.

Ensure that each non-shielded wire or cable rated 5000 volts (2400 volts working under the 2005 NEC) is single conductor, stranded copper with chemically cross-linked polyethylene insulation, nonjacketed, meets the requirements of ICEA S-96-659/NEMA WC71 and of UL Type MV-90 dry.

Ensure that each cable’s identification device defining its use is either a tag tied onto the cable or a band applied around the cable.  Ensure that cable tags are of copper, brass or plastic (except for tags within switch and device cabinets which shall be nonconducting) 1/32 inch (0.8 mm) minimum in thickness permanently fastened to the cables by means of cable tying straps.  Ensure that cable identifying bands are approximately 1/32 inch (0.8 mm) thick wrap completely around the cable and closed securely.  Ensure that each tag or band is marked using 1/4 inch (6 mm) minimum height embossed or engraved letters. 

Ensure that conductors shall be marked “CKT” followed by the circuit designation shown on the plans and that grounding conductors are marked “GND” and that neutral conductors are marked “NEU” and that hot conductors are marked “Line“ followed by “1” or “2” for single phase power or “Phase“ followed by “A“ or “B“ or “C“ for three phase power.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.03  Unit Type Duct-Cable Systems  Ensure that factory made cable-in-duct has conductors as specified, that the duct is high density polyethylene Type III, Class C, Category 5, Grade 34 conforming to NEMA TC‑7

 and that the duct has the manufacturer’s name and the year of manufacture included in the marking.

Conductors and neutrals will conform to 725.02.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.04  Rigid Galvanized Steel Conduit and Fittings  Ensure that rigid galvanized steel conduit complies with the requirements of ANSI C 80.1 and UL 6 Type I and that each length of conduit bears the UL label. Furnish fittings that comply with the requirements of ANSI/NEMA FB 1 AND ANSI/UL 514B.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.051 Polyvinyl Chloride Conduits and Fittings. Furnish polyvinyl chloride conduit EPC-40-PVC conforming with NEMA Standard TC 2 for normal above ground or below ground installation, either concrete encased or direct burial.  Use fittings conforming to NEMA Standard TC-2 references.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.052 Polyethylene Conduits and Fittings. Furnish polyethylene conduit EPEC-40-HDPE conforming to NEMA Standard TC 7 for below ground only installation, whether concrete encased or direct burial. Use fittings conforming to ASTM D3350.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.06  Polymer Concrete Pull Boxes.  Ensure that the polymer concrete pull box and cover is of aggregate bound with a polymer resin.  Ensure that the body of the box is of one piece construction.  Ensure that all surfaces of the box and cover are smooth and that the cover has a molded slip resistant surface.  Ensure that the cover is slip resistant and is labeled in clearly legible block letters 1 to 2 inches (25 to 50 mm) in height integral to the cover with the word “TRAFFIC”, “LIGHTING”, “ELECTRIC” or “TELEPHONE“ to designate the circuit(s) contained.  Ensure that the cover closely fits the opening and is secured by stainless steel bolts and hardware and that the threaded holes into which the cover bolts fasten are of open bottom design.  Ensure that the box and cover meet the structural requirements of Society of Cable Telecommunications Engineers Tier 15.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.07  Plastic Pull Boxes.  Ensure that the plastic pull box and cover is of high density ultraviolet stabilized molded polyethylene with a box wall thickness of at least 1/4 inch (6 mm). The box depth may be obtained through the use of extensions or stacking. Ensure that the cover is slip resistant and has in clearly legible block letters 1 to 2 inches (25 to 50 mm) in height integral to the cover the word “TRAFFIC”, “LIGHTING”, “ELECTRIC” or “TELEPHONE” to designate the circuit(s) contained.  Ensure that the cover closely fits the opening and is secured by stainless steel bolts and hardware and that the threaded holes into which the cover bolts fasten are of open bottom design.  The box shall meet the structural requirements of Western Underground Committee Guide 3.6.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.08  Portland Concrete Pull Boxes.

A.      Pull Box.  Ensure that the Portland concrete pull box is constructed of reinforced portland cement concrete.  When the box is precast, provide pull boxes from suppliers certified to Supplement 1073.  Ensure that the pull box cover is constructed according to 725.08.B and as shown on the plans.

B.      Pull Box Covers.  Furnish metal pull box covers that conform to the following requirements:

1.      Furnish 1/2-inch (13 mm) thick steel plate for the steel cover conforming to 711.01 with a 1/2-inch (13 mm) minimum flange around the edge and galvanized to conform to 711.02.  Display on the steel cover or on an attached brass or stainless steel plate (tag) clearly legible block letters 1 to 2 inches (25 to 50 mm) in height with the word “TRAFFIC”, “LIGHTING”, “ELECTRIC” or “TELEPHONE” to designate the circuit(s) contained.  Ensure that the word designating the use is in raised letters that are either integral to the steel cover or integral to a brass or stainless steel plate 1/16 inch (1.6 mm) in thickness securely mechanically attached to the steel cover at the four corners of the tag and at intervals 2 to 3 inches (50 to 75 mm) along the perimeter between corners.

2.      Furnish gray iron or ductile iron with a minimum thickness of 3/8 inch (9 mm) conforming to 711.14.  Certification is required.  Ensure that the word “TRAFFIC,” “LIGHTING”, “ELECTRIC,” or “TELEPHONE” is cast in the top surface of the cover forming letters 1 to 2 inches (25 to 50 mm) in height.

725.10  Junction Boxes.  Ensure that the junction boxes are iron castings hot‑dip galvanized in accordance with 711.02. Ensure that the junction boxes meet the requirements of NEMA ICS‑6‑Type 3.  When a drilled and tapped conduit entry is stipulated, ensure that the junction box has adequate wall thickness and that a boss has been cast into the box if necessary.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.11  Luminaires

A.      Optical System. Furnish a luminaire set to the photometric distribution stipulated in the plan and that the distribution along with the settings required to produce it are clearly indicated on a durable label affixed to the interior of the housing in a position readily apparent and easily read by a worker lamping the luminaire.

Furnish a luminaire with a borosilicate glass refractor free of striations and imperfections and embossed to clearly indicate the street side when the refractor may be installed in more than one position.  Ensure the refractor is held firmly in the housing, but is easily removed without the use of special tools.

Furnish a luminaire with an aluminum reflector with a specular polished reflective surface free from scratches.  Ensure the reflector is held firmly in the housing, but is easily removed without the use of special tools.

Furnish a luminaire with a socket for mogul base lamps where there is a choice of size for the application at hand.

Furnish a lamp socket with a large center contact spring providing a firm contact with the lamp base and lamp grips to prevent the lamp from loosening.  Ensure that the shell is shrouded in porcelain and that the wiring terminals and contacts are identified.

Ensure that socket position adjustments have positive indexing such as holes, lugs or notches and are not slots with infinite settings.

Ensure that socket adaptors are not necessary and not used.

B.      Lamps. Furnish a luminaire that has been provided with a lamp of the type and wattage specified and that each lamp has a clear glass envelope, a date recording feature and does not have any ballasting or starting components.

Furnish high pressure sodium lamps that are first line, high quality lamps having heat resistant clear glass envelopes with a quartz arc tube interior with horizontal initial lumens and approximate hours of life not be less than the values shown in Table 725.11-1.

TABLE 725.11-1

ANSI

WATTS

Horizontal Lumens
Initial

Economic Life
Hours

S62

70

5,800

14,000

S54

100

9,500

14,000

S56

150

16,000

16,000

S66

200

22,000

16,000

S50

250

27,500

16,000

S67

310

37,000

16,000

S51

400

50,000

16,000

S52

1,000

130,000

16,000

 

Furnish high pressure sodium lamps that produce a minimum of 80 percent of the initial lumen output at the end of economic life.

Furnish metal halide lamps that are first line, high quality lamps having heat resistant clear glass envelopes with a quartz arc tube interior with horizontal initial lumens and approximate hours of life not less than the values shown in Table 725.11-3.

TABLE 725.11-3

ANSI

WATTS

Horizontal Lumens
Initial

Economic Life
Hours

M57

175

14,000

4,000

M58

250

18,000

4,000

M59

400

32,000

10,000

M47

1,000

95,000

7,500

 

Furnish metal halide lamps that produce a minimum of 65 percent of the initial lumen output at the end of economic life.

Furnish low pressure sodium lamps that are first line, high quality lamps having heat resistant clear glass envelopes with a quartz arc tube interior with horizontal initial lumens and approximate hours of life not less than the values shown in Table 725.11-4.

TABLE 725.11-4

WATTS

Lumens
Initial

Economic Life
Hours

35

4,000

16,000

55

8,000

16,000

90

13,500

16,000

135

22,500

16,000

180

33,000

16,000

 

Furnish materials according to the Department’s Qualified Products List (QPL).

C.      Ballast. Ensure that the ballast is of an integral design contained within the luminaire housing.

If the ballast is to be wired line to line or phase to phase, ensure that the ballast has an isolated primary winding.  If the ballast is to be wired line to grounded neutral or phase to grounded neutral, the ballast may be either the isolated primary winding design or the auto transformer design.

Furnish a ballast (in conjunction with the starter in the case of high pressure sodium lamps) capable of starting and operating the lamp at ambient temperatures as low as ‑20 °F (‑30 °C).

At circuit voltage of nominal plus or minus 10 percent or the ballast manufacturer’s stated range if greater, ensure that the ballast can start (in conjunction with the starter in the case of high pressure sodium lamps) and operate the lamp within the lamp’s ANSI operating parameters for the full design life of the lamp.

Furnish a ballast capable of operation with the lamp in an open or short circuit condition for six months without significant loss of ballast life.

Furnish a starter of encapsulated solid state design capable of withstanding the temperatures encountered in the ballast compartment of the luminaire.

Ensure that the starter provides a timed pulsing with sufficient follow through current to completely ionize and start all lamps that meet published ANSI standards.

Ensure that the starter has push‑on type electrical terminations and is field replaceable with no adjustment necessary for proper operation.

Ensure that there is a barrier type terminal block for connection of the incoming electrical circuit.

D.      Housing. Furnish a housing of cast aluminum.

Ensure that the housing has a flat area on the top side on which a level may be placed and read by a worker leveling a mounted luminaire on an erected support.

Ensure that the door(s) providing access to the optical and electrical components have hinges and latches of corrosion resistant materials that remain securely closed during operation.

Ensure that the silicone rubber, ethylene propylene terpolymer, dacron felt or other durable gaskets and seals supplied by the manufacturer either as part of the basic luminaire or as options are in good condition and properly installed at the socket entry, between the refractor and reflector and any other location where such gaskets or shields are part of the luminaire and options.

Ensure that the exterior finish of the luminaire is a light gray color unless otherwise specified.

Furnish a glare shield of aluminum or opaque plastic material when specified. Furnish a shield supplied by the manufacturer of the luminaire.

E.      Conventional Luminaries. Ensure that the luminaire housing doors may be opened, closed, removed or installed without the use of tools.

Ensure that the clamp for the slip‑fit mounting accommodates both 1 1/4 inch (32 mm) and 2 inch (50 mm) nominal pipe mounting bracket.  Ensure that a stop is provided as part of the housing to prevent over insertion of the bracket into the housing.  Ensure that the clamp engages at least 4 1/2 inches (115 mm) longitudinally along the arm of the bracket arm between the extremes of a minimum of two clamping points.  Ensure that the mounting clamp provides for leveling of the luminaire to the specified transverse and longitudinal position with respect to the roadway.

Ensure that the luminaire is equipped with a device indicating the direction and amount of tilt over a range of zero to five degrees in any direction with indications at level, three degree tilt and five degree tilt all accurate to one half degree.  Ensure that the indicating device is clearly readable in daylight from a distance of 50 feet (15 m) and in no way alters or reduces the amount of light from the luminaire.  Ensure that the indicating device is constructed of a transparent container having one horizontal surface which is curvilinear in any vertical cross section for supporting an indicator and a damping fluid.  Ensure that the damping fluid is a liquid which shall be suitable for operation at ‑40 °F (‑40 °C) and that the transparent container is fabricated from clear ultraviolet‑inhibited acrylic or similar material.

Ensure that the glare shield will cut off the upward component of light and that it does not reduce the total output of the luminaire more than 3 percent.

Ensure that the luminaire has a label or decal indicating the type of source and wattage rating.  Ensure that, with the luminaire installed in its normal operating position, the label or decal is clearly legible in daylight at a distance of 50 feet (15 m).  Ensure that the labeling is in accordance with the provisions of NEMA Publication OD‑150 or EEI Publication TDJ‑150.

Ensure that the complete conventional luminaire assembly including the lamp and all options including, when required, the glare shield does not weigh more than 75 pounds (34 kg).

Furnish materials according to the Department’s Qualified Products List (QPL).

F.      Wall Mounted Underpass Luminaires. Ensure that the assembly is weatherproof and sealed against dust.

Ensure that a wire entry for the incoming power is provided on both of the vertical side surfaces of the housing, that each entry is drilled and tapped for 3/4-inch (19 mm) conduit and that the unused entry is properly closed with the screw type plug supplied by the manufacturer.

Ensure that the luminaire housing doors may be opened, closed, removed or installed without the use of special tools.

Ensure that the housing can be mounted onto a vertical flat surface by means of cap screws or bolts through the wall side of the housing.

Ensure that the luminaire has the option for protecting the glass refractor with a guard or shield that is integral to the luminaire and does not have to be removed to gain access to the lamp or ballast.

Furnish materials according to the Department’s Qualified Products List (QPL).

G.     High Mast / Low Mast Luminaires. Ensure that luminaires with a symmetric distribution shall have an initial intensity of no more than 100 candela per 1000 lamp lumens at nadir and no more than 325 candela per 1000 lamp lumens at angles between 55 and 65 degrees above nadir.

Ensure that luminaires with an asymmetric distribution or a long and narrow distribution shall have an initial intensity of no more than 175 candela per 1000 lamp lumens at nadir and no more than 425 candela per 1000 lamp lumens at angles from 66 through 73 degrees above nadir.

Ensure that the output efficiency of the luminaire shall be not less than 65 percent of the bare lamp lumens.  The luminaire shall emit at least 25 percent but no more than 35 percent of the bare lamp lumens at vertical angles of at least 60 degrees above nadir but no more than 90 degrees above nadir.

Ensure that no portion of the arc tube of the lamp shall be viewable at angles of 70 degrees or more above nadir.

Ensure that the photometric distribution is produced by an optical assembly consisting of a reflector alone or in combination with a refractor which redirects the output of a lamp mounted in a socket therein and that the reflector and refractor (if used) are each of a one piece design.

Ensure that the optical assembly is field rotatable to align the light distribution horizontally independent of the orientation of the arm supporting the luminaire.

Ensure that a luminaire for use with a 1000 watt lamp has an auxiliary lamp support that engages the outer end of the lamp envelope.

Ensure that the luminaire is of substantial design adequate to operate at mounting heights up to and including 150 feet (45 m) and wind velocities up to and including 90 mph (145 km/h).

Ensure that the luminaire mounts by means of a slip fit onto a horizontal 2-inch (50 mm) pipe and that the luminaire’s integral mounting provides adjustment for leveling but remains secure and does not twist about the mounting pipe of the bracket when subjected to the vibration and wind loads of the installation.

Ensure that the maximum weight of the complete luminaire does not exceed 75 pounds (34 kg) and the maximum projected area does not exceed 3.5 square feet (0.3 m2).

Furnish materials according to the Department’s Qualified Products List (QPL).

725.12  Polyethylene, Fiberglass Reinforced, Pull Box with Polymer Concrete Cover and Support Ring  Ensure that the pull box body is of fiberglass reinforced high density ultraviolet stabilized molded polyethylene with a polymer concrete cover support ring and polymer concrete cover.  Ensure that the body of the box is of one piece construction.  Ensure that the body of the box has a wall thickness of at least 1/4 inch (6 mm).  Ensure that the cover support ring is permanently integrated into the box.  Ensure that the cover is slip resistant and has in clearly legible block letters 1 to 2 inches (25 to 50 mm) in height integral to the cover the word “TRAFFIC”, “LIGHTING”, “ELECTRIC” or “TELEPHONE” to designate the circuit(s) contained.  Ensure that the cover closely fits the opening and is secured by stainless steel bolts and hardware and that the threaded holes into which the cover bolts fasten are of open bottom design.  Ensure that the box and cover meet the structural requirements of Society of Cable Telecommunications Engineers Tier 5.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.15  Circuit Cable Connections and Terminations. Ensure that each connector or terminator is of the same voltage rating as the wire being connected or terminated except that 600 volt connectors may be used with 5000 volt (secondary service) cable used in 600 volt service for the highway lighting circuits.

Ensure that each connector or terminator is a compression style which fully encloses the conductor(s) and is of high strength copper alloy not a metal other than copper which has been plated. Ensure that each connector used for a “butt” splice is a sleeve type with a “stop” in the center.

A.      Termination of Oversize Wire. Ensure that each cable terminal of each device can properly accommodate the size of the wire being terminated. If a terminal of adequate size cannot be furnished, ensure that a short length of smaller wire is connected to the oversize conductor through the use of a proper butt style crimp connector or a terminal block, that no strands have been cut back in the oversize conductor to make the connection and that the smaller wire is rated to carry the full ampacity of the circuit protection device.

B.      Fused Pull-Apart Connection. Ensure that each fused pull-apart cable connector kit is a molded synthetic rubber housing consisting of a female line side with two ports and a male load side with one port containing a socket type fuse holder wherein the fuse also acts as the pin for the load connection which is designed to break the circuit when the two halves of the connector body are separated.  Ensure that the assembled kit is rated for direct burial and exposure to sunlight.  Ensure that the metal parts of connector are of copper with a conductivity of 90 percent, have individual compression connections for each wire on the line side, have a crimp connection for the wire on the load side and have annular spring on the socket for each end of the fuse.  Ensure that the fuse holder is for a standard midget 13/32 × 1 -1/2-inch (10 × 38 mm) fuse.  Ensure that the fuse is rated 600 VAC, 100,000 AIC and does not have a glass body.  Ensure that each cable port is sized for the wire or cable entering the entering the port and that there is a closure for the second line port if it is not to be used.

C.      Unfused Pull-Apart Connection. Ensure that each unfused pull-apart cable connector kit is a molded synthetic rubber housing consisting of a female line side with two ports and a male load side with one port containing a line side socket and load side pin making a connection which is designed to break the circuit when the two halves of the connector body are separated.  Ensure that the assembled kit is rated for direct burial and exposure to sunlight.  Ensure that the metal parts of connector are of copper with a conductivity of 90 percent, have an individual compression connection for each wire on the line side, have a crimp connection for the wire on the load side, and have an annular spring on the socket for the pin.  Ensure that each cable port is sized for the wire or cable entering the port and that there is a closure for the second line port if it is not to be used.

D.      Unfused Bolted Connection. Ensure that each unfused re-enterable cable connector kit is a rigid molded plastic sleeve closed on each end by a molded synthetic rubber female end housing having one or two ports as needed containing space in which the connection is made by crimping a lug onto each wire and then bolting all of the lugs together.  Ensure that the assembled kit is rated for direct burial and exposure to sunlight. Ensure that the metal parts of connector are of copper with a conductivity of 90 percent and that each connecting bolt has a self-locking nut.  Ensure that each wire enters through a port sized for the wire and that there is a closure for the port if it is not to be used.

E.      Unfused Permanent Connection. Ensure that each cable splicing kit is a rigid transparent molded body having as many as two ports on each which allows the completed splice to be completely encapsulated by filling the mold with a resin compound. Ensure that the actual conductor connections are made using one time use compression connectors and that each wire or cable enters the mold through its own port.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.16 Ground Rods. Ensure that each ground rod is 1 inch (25 mm) in diameter and 10 feet (3 m) in length with a driving point on the lower end.  If of other than circular cross section, ensure that the periphery of the rod is 3.2 inches (80 mm) or more.  Ensure that the rod is of solid construction and is either stainless steel jacketed steel, copper clad steel or hot dipped galvanized steel in accordance with ASTM A 153, Class B-1.

Ensure that the rod bears a label denoting that it is UL listed.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.19 Power Service Components. Furnish the materials and equipment comprising a service pole, including service equipment, that meets the following requirements.

A.      Service Entrance Conduit. Ensure that the service entrance or riser conduit is rigid galvanized steel with a rain tight galvanized steel service entrance head (weatherhead) threaded to fit the conduit containing a composition insert for three conductors.

B.      Service Disconnect. Ensure that the service disconnect is a properly rated fused switch of the ampacity specified and solid neutral. Ensure that the service fuses are cartridge fuses on the load side of the switch.

C.      Lighting Contactor. Ensure that the lighting contactor is of the open type electromagnetically held.

Ensure that control of the contactor is through a photocell connected through a “HAND‑OFF‑AUTOMATIC” selector switch accessible only with the contactor enclosure open.  Ensure that the control circuit is a separate circuit with its own protection.

D.      Lighting Circuit Protection. Ensure that separate protection is provided on the load side of the lighting contactor for each lighting circuit and that such protection will open all line or phase conductors of the respective circuit should a fault occur on any one line or phase conductors.

E.      Photoelectric Cell. Ensure that the photoelectric control is a twist‑lock plug-in, utility grade, solid state, cadmium sulfide type of the proper voltage, rated for 1000 watts maximum load, with integral surge protection, a fail‑safe mode in which the lighting circuits will remain energized, and a hermetically sealed case. Ensure that the nominal “turn on” level is 1 footcandle (10 lux) vertical and that the nominal “turn‑off” level is 6 footcandles (65 lux) vertical with tolerances of 20 percent for the specified values.  Ensure that the photocell has a time delayed response that will not respond to flashes of light from lightning, headlights of passing vehicles or emergency vehicle strobes and beacons.  Ensure that the photoelectric control mounting bracket has a EEI‑NEMA locking‑type receptacle.

F.      Switchgear Enclosure. Ensure that components are mounted on a removable back panel of 14 gage or heavier enameled steel rather than directly on the back wall of the enclosure and that the back panel mountings do not penetrate the walls of the enclosure.

Ensure that a neutral terminal bar of adequate ampere rating and with holes in number and of size to terminate each conductor separately is provided in each enclosure where neutral conductors are to be terminated.  Ensure that an equipment grounding conductor terminal bar of adequate ampere rating and with holes in number and of size to terminate each conductor separately is provided in each enclosure where grounding conductors are to be terminated.  When there is no code or utility company prohibition, a combination neutral and equipment grounding conductor bar may be furnished.

Ensure that an enclosure containing a disconnect switch with an external operating handle allows that handle to be padlocked in either the “OFF” or the “ON” position.

Ensure that the enclosure containing the service disconnect switch has an interlock to prevent the door from being opened when the switch is in the “ON” position

Ensure that the enclosure provides for padlocking the door. 

Ensure that each switchgear enclosure is a NEMA ICS‑1‑110.15 Type 4 fabricated from No. 16 gage or heavier AISI Type 302 or 303 annealed stainless steel with fully welded seams and a brushed finish.

All fasteners used in assembly of the enclosures shall conform to ASTM A 320/A 320M (AISI‑300 series).

G.     Wiring Schematic, Wiring Diagram, Placards. Furnish both a schematic diagram and a wiring diagram of the entire power service from the power company service transformer secondary connection through the lighting branch circuit connections in triplicate with two copies delivered to the project and the third copy placed in the service disconnect enclosure.  The Engineer will ensure that one of the two copies delivered to the project is filed with the project records and the other is delivered to the maintaining agency .

Ensure that each placard to be attached to an apparatus enclosure is of multiple layers of plastic thermally bonded together to provide a plate of at least 1/8 inch (3 mm) in thickness with engraved plain block letters at least 1/2 inch (12 mm) in height.  Ensure that placards designating the function of the apparatus contained in an enclosure or other such information are of white letters on a black placard.  Ensure that placards warning of high voltage possibly present in an enclosure or other such warning are of white letters on a red placard.

H.     Customer Service Pole. Furnish a wood pole that complies with Supplement 1072.  Ensure that the pole and any cross arms or pole key is Southern Pine or Western Red Cedar, full length, pressure treated in compliance with specifications of the American Wood Preservers Association using either creosote or pentachlorophenol.  Ensure that the retention of preservative in Southern Pine is 7.5 pounds (120 kg) of creosote by assay or 0.38 pounds (6 kg) of pentachlorophenol by lime‑ignition assay per cubic foot (cubic meter) of wood.  Ensure that the retention of preservative in Western Red Cedar is 16 pounds (256 kg) of creosote by assay or 0.8 pounds (13 kg) of pentachlorophenol by lime‑ignition assay per cubic foot (cubic meter) of wood.  Ensure that the pole is 35 feet (10.5 m) minimum in length and Class 4 or heavier and conforming to ANSI 05.1 Specifications and Dimensions for wood poles. Ensure that the pole is reasonably straight without pronounced sweep or short crooks.

Ensure that all pole hardware, including racks, braces, straps, guy anchors, guy wire, clamps, bolts, nuts, washers, screws, nails, etc. is hot dip galvanized in accordance with 711.02.

Ensure that the grounding conductor is fastened to the pole with copper clad, rolled point staples of adequate size.

Ensure that the grounding conductor molding is either wood or plastic, in sections not less than 8 feet (2.4 m) long, of sufficient width and groove depth to completely enclose the grounding conductor.

Ensure that each pole anchor is of malleable iron or galvanized steel, 6 inch (150 mm) minimum diameter, two‑way or four‑way expanding type. Ensure that each anchor rod is 5/8 inch (16 mm) minimum diameter, 8 feet (2.4 m) minimum length galvanized steel with thimble eye. Ensure that each guy wire is 3/8 inch (10 mm) minimum diameter, conforming to ASTM A 475, galvanized steel.

725.20  Multiple Cell Polyvinyl Chloride Conduit and Fittings. Ensure that the multiple cell conduit consists of inner ducts conforming to NEMA TC-8 type DB in an outer conduit conforming to NEMA TC-2 (type EPC-40 or EPC-80 as specified except that size shall be the true inside diameter) in a factory preassembled unit.  Ensure that fittings are factory made couplings that couple inner ducts and the outer conduit simultaneously, maintain the continuity and indexing of the inner ducts and are of a push fit design mechanically locked in place.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.21  Luminaire Supports. Ensure that the complete luminaire support from the luminaire(s) down through the connection to the foundation or other structure to which the luminaire support is attached conforms to the requirements of AASHTO’s Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals.  Ensure that the combined stress ratio above the first field joint is greater than the combined stress ratio at the base of the pole.

The design wind speed for all areas of the State shall be 90 mph (145 km/h).

The Department may require various tests including destructive tests at either the factory or on site prior to acceptance of a support in which case the Department’s representative will supervise the Contractor and/or manufacturer as the appropriate entity performs the tests on supports selected at random by the Department from the lot produced for the project.  Ensure that any support damaged by the testing is replaced at no additional cost to the Department.

Ensure that the support identification labels are adhesive labels with silver white reflective characters on a reflective green background meeting the requirements of 730.18.

Furnish certified luminaire supports according to Supplement 1091

A.      Light Poles. Ensure that the deflection of the pole from vertical when placed under the load of the bracket arm, and a weight of 75 pounds (35 kg) in place of each luminaire does not exceed an angle of 1 degree 10 minutes when tested in accordance with Supplement 1025 and that certified copies of the results obtained from the deflection tests are furnished the Laboratory.

A pole and arm constructed from either aluminum or steel but not a combination of the two may be furnished.

Ensure that each bracket arm is made from straight or tapered stock round or ovaliptic in cross section not less in size than 2 inch (50 mm) nominal pipe.

Ensure that the luminaire end of each bracket arm has an outside diameter equal to 2 inch (50 mm) pipe, is straight for a distance of eight inches (203 mm), with the longitudinal axis canted not less than 1 degree and not more than 4 degrees above horizontal.

Ensure that the bracket has an internal raceway with a minimum internal diameter of 1 3/32 inches (28 mm) free of projections and obstructions, which, when assembled to the shaft, will permit installation of luminaire supply conductors without insulation damage and which will not require bending the conductors to a radius less than 3 inches (75 mm).

Ensure that the pole does not have more than two sections, that the shorter section of a sectional is at the top and that the shorter section of a sectional pole is not less than 10 feet (3 m) in length.  Ensure that the pole sections are joined by telescoping the bottom of the upper section over the top of the lower section for a minimum length of 1 1/2 times the external diameter of the bottom of the upper section, driving the joint tight, and securing by through bolting with a stainless steel hex head bolt of a minimum diameter of 5/8 inch (16 mm).

Ensure that a pole section does not have more than one longitudinal, automatically electrically welded seam and no transverse seams.  Ensure that the longitudinal welded seam is neat and uniform in appearance, that the weld is not less than the thickness of the base material and that the bead height does not exceed 1/16 inch (2 mm).  Ensure that the wall thickness is uniform throughout, except at the weld bead. Ensure that the cross section of the pole is circular, or multi-sided with no less than eight sides and that the difference between the major and minor diameters of poles of circular cross section or the difference between the maximum and minimum distances across corners for poles of multi-sided cross section, measured at any point along the longitudinal axis, does not exceed 3/16 inch (5 mm).

Ensure that steel poles are tapered tubes with a true continuous taper not less than 0.06 inches per foot (1.5 mm per 300 mm) and not more than 0.16 inches per foot (4.0 mm per 300 mm).

Ensure that aluminum poles, either spun or cold rolled, are a true continuous taper except for the top and bottom sections which may be straight, that no more than 40 percent of the total shaft length is straight, and that the average rate of shaft taper including straight portions of the shaft is not less than 0.06 inches per foot (1.5 mm per 300 mm) and not more than 0.16 inches per foot (4.0 mm per 300 mm).

Ensure that the full design strength of the pole shaft section in bending can be transmitted through the base plate into the transformer base or the anchor bolts without permanent bending of the base plate or failure of the pole shaft to base plate connection.

Ensure that there is a “J” hook inside the pole just below the top on which to hang the pole and bracket cable support assembly.

Ensure that nonstructural castings for aluminum poles, including the pole cap are of ASTM B 26/B 26M or B 108, Alloy S 5 A, Condition F.

Ensure that steel poles and bracket arms are hot dipped galvanized after fabrication in accordance with the requirements of 711.02.

Furnish aluminum poles and bracket arms in natural aluminum with a satin brushed surface. 

Ensure that each light pole is identified by a raised or engraved marking applied to the edge of the base plate which identifies the manufacturer and the year that the pole was manufactured and that such marking remains legible after the pole has been galvanized.

Ensure that bolts, nuts, washers and other fasteners used to assemble the light pole are of galvanized steel conforming to 711.02, stainless steel conforming to ASTM A 320/A 320M (AISI‑300 series) or silicon bronze conforming to ASTM B 98M (B 98).

Ensure that each non-frangible steel transformer base is capable of transmitting the design dead, live, ice and wind loads of the light pole to be mounted on it to the foundation without failure or permanent deformation, has a flush door permanently attached by means of a top‑mounted continuous stainless steel hinge, and is made from steel conforming to ASTM A36/A 36M hot dip galvanized after fabrication.

Ensure that each frangible aluminum transformer base is capable of transmitting the design dead, live, ice and wind loads of the light pole to be mounted on it to the foundation without failure or permanent deformation, has a flush aluminum door permanently attached by means of a top‑mounted continuous stainless steel hinge, and bears easily found and read durable labeling as to which AASHTO frangibility criteria the base meets. Ensure that the base has been tested and accepted by the FHWA as complying with the 1985 AASHTO frangibility requirements .

Ensure that the bolts and nuts used to fasten the base plate of the pole to the transformer base are heavy hex conforming to ASTM A 307 and galvanized in accordance with 711.02.  When either the top or the bottom of an aluminum transformer bases is to be fastened against non‑galvanized steel, ensure that both the steel and the aluminum mating surfaces have been coated with a heavy film of zinc rich paint.

Ensure that the anchor bolts are steel with 55,000 psi (380 Mpa) minimum yield strength, that the threaded ends of the bolts and nuts are galvanized in accordance with 711.02 for at least 2 inches (50 mm) beyond the threads and that the nuts are capable of developing the full strength of the anchor bolt and are galvanized in accordance with 711.02.

B.      Light Towers. Ensure that the structural design of the light tower is based on a load of six luminaires or the actual number of luminaires to be installed whichever is greater.  Ensure that the structural design of the light tower is based on each luminaire weighing 75 pounds (34 kg) and having an effective projected area of 3.5 square feet (0.3 m2) or the actual weight and effective projected area of each luminaire whichever is greater.  Ensure that the structural design of the light tower is based on the head frame assembly with lowering device weighing 340 pounds (154 kg) and having a projected area of 5.3 square feet (0.5 m2) or the actual weight and effective projected area of the head frame and lowering device whichever is greater.

Ensure that the luminaire lowering device (consisting of the luminaire ring, the head frame, the winch, the power cables and all miscellaneous mechanical and electrical equipment mounted in or on the pole) and the pole are compatible with each other.

1.      Luminaire Ring. Ensure that the luminaire ring assembly is fabricated from steel which conforms to ASTM A 36/A 36M and that the ring is fitted with a separate 2 inch (50 mm) nominal steel pipe mounting arm directly attached to the ring for each luminaire.

Ensure that the luminaire ring is supported by three wire ropes equally spaced around the ring.  Ensure that the three wire ropes are of the same material and construction.  Ensure that the wire rope for this purposed is 3/16 inch (5 mm) minimum diameter and either galvanized steel hoisting cable or aircraft grade stainless steel control cable composed of 7 strands of 19 wires each. Ensure that each wire rope support cable is connected to the ring by a corrosion resistant device that will allow the connection to develop the full breaking strength of the wire rope while permitting ready adjustment of the length of the wire rope to level the ring.  Ensure that the ring is equipped with a minimum of three spring loaded roller tipped centering arms equally spaced around the ring that are in continuous contact with the pole shaft and that the guide arm rollers are of a nonabrasive, water resistant material.

Ensure that the luminaire ring is equipped with three positive latching devices equally spaced around the ring that latch to the head frame supporting the ring in the raised position allowing tension to be removed from the lifting cables. Ensure that all moving parts of each latching device are part of the ring portion of the latch assembly and that each latch assembly incorporates a reflectorized flag that is clearly discernible from the ground when the ring is latched to the head frame.  Ensure that the latching sequence shall not exert a horizontal force sufficient to cause an excess of 4 g’s acceleration upon the luminaires.

Ensure that the luminaire ring is equipped with a NEMA 4 corrosion resistant junction box for the connections between the main power cord bringing power to the ring and the separate power cords for each luminaire.  Ensure that each power cord has copper conductors of adequate size and insulation, that each power cord is of suitable construction, and that each power cord enters the junction box through a weather tight cord connector. Ensure that there is a cord support capable of withstanding a load of 1 1/2 times the weight of the main power cord without damage to the cord transmitting the weight of the main power cord directly to the ring.  Ensure that there is a weather tight power inlet on the luminaire ring which allows the main power cord in the base of the tower to connect to the ring when the ring is in the lowered position.  Ensure that the junction box is equipped with a 600 volt class terminal block for the connections between the main power cord, the luminaire power cords and the power inlet cord.  Ensure that each luminaire ring is identified by a raised or engraved marking applied in a prominent location which identifies the manufacturer and the year that the ring was manufactured and that such marking remains legible after the ring has been galvanized

2.      Head Frame Assembly. Ensure that the head frame is fabricated from steel which conforms to the requirements of ASTM A 36/A 36M. Ensure that the head frame assembly is equipped with pulleys for the wire ropes hoisting cables and rollers for the main power cord to the luminaire ring.  Ensure that each hoisting cable sheave has a tread diameter of at least 20 times the cable diameter for galvanized cable and 25 times the cable diameter for stainless steel cable, that the groove for the hoisting cable has a semi‑circular in cross section with a radius of one‑half the cable diameter plus 1/64 inch (0.4 mm), that the sheave has an oil‑impregnated bronze bushing and that the shaft on which the sheave turns is of stainless steel.  Ensure that the rollers for power cord run on AISI 304 stainless steel shafts between cold‑rolled steel plates. Ensure that bending radius of the power cord is not less than 7 inches (180 mm).  Ensure that keeper bars have been provided over the power cord and ring support cables to keep them in their respective tracks.  Ensure that a guide is provided to separate the individual cables as they pass between the head frame and the top of the pole.  Ensure that the head frame mechanism is protected from the weather by a domed cover of either copper free spun aluminum or fiberglass.  Ensure that each head frame is identified by a raised or engraved marking applied in a prominent location which identifies the manufacturer and the year that the head frame was manufactured and that such marking remains legible after the head frame has been galvanized.

3.      Transition Plate. Ensure that there is a transition plate between the ring support cables and the main hoisting cable.  Ensure that the luminaire ring support cables are secured to the transition plate by shop applied, swage‑type fittings designed to develop a connection strength equal to the breaking strength of the cable and prevent abrasion of the cable by the transition plate.  Ensure that there is a cord support capable of withstanding a load of the weight of the main power cord plus a wind load on the cord equal that of a 30 mph (48 km/h) wind perpendicular to the full length of the cord without damage to the cord connecting the main power cord to the transition plate.

4.      Hoisting Winch. Ensure that the winch is of cast iron and steel construction with an integral enclosed lubricant bathed worm and gear drive having a reduction great enough to be self‑locking.  Ensure that the winch has a pulling capacity at least five times greater than that required to lift the load.  Ensure that the winch drum diameter is not less than 4 inches (100 mm), that the drum flange diameter is at least 3 inches (75 mm) greater than the diameter of the drum.  Ensure that there is a cable guide or follower to prevent cable buildup at the ends of the winch drum. Ensure that the support plate for the winch bears a durable tag which identifies the manufacturer, manufacturer’s model and year of manufacture for the lowering device.

5.      Winch Drive Unit (Portable Power Unit). Ensure that the winch drive unit is powered by a heavy duty reversing drill motor, minimum 560 W (3/4 horsepower) rating, 120 volt.  Ensure that there is a mechanical slip clutch torque limiter incorporated into the output shaft and that there is a placard on the portable winch drive unit giving the settings and instructions for care of the torque limiter.   Ensure that there is a separately packaged dry type isolated winding transformer included to permit operation of the drill motor from the lighting circuit by plugging into the luminaire power cord outlet in the base of the tower.  Ensure that the cord outlet and plug for connecting the motor to the transformer are NEMA L5-15 devices.   Ensure that he hoisting rate is between 15 and 25 feet per minute (4 and 8 m/min).  Ensure that the hand control switch incorporates 20 feet (6 m) of cable to allow operation of the lowering device from a position away from the pole and not beneath the ring and luminaires. Ensure that each winch drive unit frame is identified by a raised or engraved marking applied in a prominent location which identifies the manufacturer and the year that the portable power winch drive unit was manufactured and that such marking remains legible after final finish has been applied to the frame.

6.      Connection of Tower to Lighting Circuit. Ensure that there is a separate terminal block for each conductor of the supply circuit in the base of the tower, and that there are enough spaces on the blocks to allow the incoming circuit to split into three outgoing directions in addition to the feed to the tower itself.  Ensure that the terminal block has set screw style terminations, sized for 4 AWG - 1/0 AWG for the incoming and outgoing lighting circuit and 12 AWG - 10 AWG for the tower wiring.  Ensure that there is a circuit breaker in a NEMA 4 enclosure located electrically after the terminal blocks for the lighting circuit and before the power cord leading up the tower to the luminaires.  Ensure that the breaker enclosure is internally mounted and that the breaker is readily accessible through the tower hand hole.  Ensure that the circuit breaker is a bolt on design, sized at 15 amperes with a minimum interrupting capacity of 14,000 amperes for 480 volt circuits or sized at 20 amperes with a minimum interrupting capacity of 10,000 amperes for 240 volt circuits and is of a single handle rather than a tied handle design with one pole for each line or phase conductor. Ensure that cord connector, plug and inlet on the ring for electrical power to the luminaires are NEMA L8-20 devices for 480 volt systems or are NEMA L6-30 devices for 240 volt systems.

7.      Operating Manual. Furnish a complete manual including instructions on installation, operation and maintenance for each type of the following: lowering device, winch assembly and portable power winch drive unit.

8.      Shaft. Ensure that shaft of the tower is of not more than four round or multi-sided tapered steel sections for towers up to and including 100 feet (30 m), five sections for towers over 100 feet (30 m) up to and including 120 feet (37 m), and six sections for towers over 120 feet (37 m).  Ensure that the shaft is of steel having a minimum yield strength of 55,000 psi (379 MPa).  Ensure that the shaft sections are joined by telescoping the bottom of the upper section over the top of the lower section for a minimum length of 1 1/2 times the external diameter of the bottom of the upper section or two feet (0.6 m) whichever is greater and driving the joint tight.  Ensure that the sections have been pre‑fitted and match‑marked at the factory. Ensure that the inside surface of the shaft is relatively smooth and that there are no more than two longitudinal welds which shall be made by automatic electric arc welding.  Ensure that the longitudinal seam welds have complete penetration, are of uniform density, are no thinner than the shaft material and not more than 20 percent thicker than the shaft material.  Ensure that the base plate is fabricated from steel which conforms to the requirements of ASTM A 36/A 36M and that the shaft is joined to the base plate using the American Welding Society prequalified joint TC‑U4a‑S or TC‑U4c‑GF.  Ensure that the hand hole in the shaft is properly reinforced to avoid stress risers and that the reinforcements are welded to the shaft using a joint and techniques designed to insure total penetration plus an outside fillet equal to the thickness of the shaft material.  Ensure that all welds in the shaft satisfy AWS D 1.1 Structural Welding Code Article 9.25.3 for tensile stress when tested either by the ultrasonic method or by an approved alternate method, and that certified results are furnished to the Laboratory.  Ensure that the door is fabricated from the same type steel as the shaft, is attached with a continuous stainless steel hinge having non-removable stainless steel hinge pins, fits the opening closely, and is securely held shut.  Ensure that there are provisions for padlocking the handhole door closed and that each tower has been furnished with a vandal resistant padlock having a bronze or brass lock body and a corrosion‑protected steel shackle keyed to the key number specified by the maintaining agency.  Ensure that there are two holes, tapped 1/2-13, 180 degrees apart provided at the base of the tower for the grounding conductors.  Ensure that the shaft shall be hot dipped galvanized after fabrication in accordance with the requirements of 711.02.  Ensure that each shaft is identified by a raised or engraved marking applied to the edge of the base plate which identifies the manufacturer and the year that the shaft was manufactured and that such marking remains legible after the pole has been galvanized.

9.      Anchor Bolts and Nuts. Ensure that each anchor bolt is steel conforming to ASTM F1554, Grade 55, and galvanized in accordance with 711.02. at least 2 inches (50 mm) beyond the threads.  In lieu of a bent end, an anchor bolt with the lower end threaded and inserted into a steel plate of approved size and thickness which has been drilled and tapped to receive the anchor bolt may be furnished.  Ensure that the nuts used with each anchor bolt are capable of developing the full strength of the anchor bolt.

725.22  Plastic Caution Tape. Furnish tape that is an inert material, approximately 6 inches (150 mm) wide composed of polyethylene plastic, highly resistant to alkalis, acids or other chemical components likely to be encountered in soils.  Furnish tape that is bright red with identifying printing “ELECTRIC” in black letters on one side only.  Furnish tape in continuous rolls with the identifying lettering repeated continuously the full length of the tape.