732 TRAFFIC SIGNAL MATERIAL

732.01 Vehicular Signal Heads, Conventional. Ensure that vehicular traffic signal heads conform to the ITE “Vehicle Traffic Control Signal Heads” standard. In conformance with the above standard, provide signal heads that are of cast nonferrous corrosion resistant metal.

Traffic signals consist of specified assemblies of optical sections containing 12-inch (300 mm) diameter lens opening, a housing, a door frame with stainless steel hinge pins and latching device, visor, wiring, and includes LED lamp in accordance with 732.04. Retention hardware for LED lamps, if sharing threaded hole with visor hardware, shall consist of minimum 1/2-inch (13 mm) long, set screw with retaining tab and captive wingnut or hex nut. All hardware shall be stainless steel and set screw shall be inserted into signal section door using visible, semi-permanent threadlocking compound. All hardware used to join optical sections together shall be stainless steel.

Furnish signal heads with required mounting hardware. Furnish signal face orientation to traffic by serrated rings or other devices on housing sections and mounting hardware. Permit adjustment in increments not greater than 5 degrees of rotation and not affected by wind gusts when locked. Furnish galvanized steel or aluminum spacers and drop pipes 1 1/2 inches (38 mm) nominal pipe size (1.90 inch (48 mm) actual diameter). Ensure that disconnect hangers have at least twelve terminals unless a greater number is required Tethered heads shall use ¾-inch unpainted cast aluminum span wire clamps and cable entrance adapters with integral tri-studs (no tri-stud inserts), stainless steel hardware, and a single steel-reinforced mounting hole. Free-swinging heads shall use cast iron span wire clamps and cable entrance adapters with tri-studs. A neoprene gasket placed under the clamp washer in the top signal section shall effectively seal the entrance adapter on the signal to make a waterproof connection and shall have a minimum thickness of 3/32 inch. The inside surface of the visors shall have a finish of flat black. All other exterior surfaces of the signal head and hardware shall have a finish of Federal Yellow or Gloss Black to closely agree with Federal Standard 595, Color 13655 or Color 17038, as specified in the plans. The coating system used shall be durable, uniform, and weather resistant.

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

732.02 Vehicular Signal Heads, Optically Programmed, 12-inch (300 mm) Lens. Ensure that the signal sections conform to applicable portions of the ITE standard and 732.01. Furnish and mount optical sections with a 12-inch (300 mm) lens size alone or in combination with additional sections of optically programmed or conventional optics types to form signal faces and heads. Furnish an optically programmed signal section that includes an LED lamp.

Balance adjusters, used only if specified, shall have a splined eyebolt design and splined external clamping body. All assembly hardware shall be stainless steel.

Furnish a visor with each signal section.

Cable entrance adapters shall be of the tri-stud type with stainless steel hardware. A neoprene gasket placed under the clamp washer in the top signal section shall effectively seal the entrance adapter on the signal to make a weatherproof connection and shall have a minimum thickness of 3/32 inch (2.5 mm)..

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

732.03 Vehicular Signal Heads, Optically Programmed, 8-inch (200 mm) Lens. Optically programmed signal heads with 8-inch (200 mm) lenses consist of a conventional 8-inch (200 mm) signal housing, reflector and door; and an extension portion which is attached in place of a conventional lens and which contains a lens system capable of optical programming. Furnish the conventional signal housing with reflector and wiring, and the optical programmable extension portion according to the applicable requirements of 732.01 and 732.02.

Furnish a cutaway visor with each signal section. Ensure that the signal sections include LED lamp.

Furnish manufacturer’s certifications verifying material meets specifications requirements.

732.04 Signal Lamps.

A. Optically Programmed and Pedestrian Signal Incandescent Lamps. Ensure that optically programmed and pedestrian signal incandescent lamps conform to the ITE A Standard for Traffic Signal Lamps and Table 732.04-1.

B. Vehicular Signal Incandescent Lamps. The use of vehicular signal incandescent traffic signal lamps is no longer permitted..

C. Vehicular and Pedestrian Light Emitting Diode (LED) Lamps. Prequalify vehicular and pedestrian LED lamps according to Supplement 1097.

Furnish LED signal lamp units that meet or exceed all the requirements of the current Institute of Transportation Engineers (ITE) publications - Vehicle Traffic Control Signal Heads (VTCSH) - Light Emitting Diode (LED) Circular Signal Supplement 2005; Pedestrian Traffic Control Signal Indications (PTCSI) - Part 2: Light Emitting Diode (LED) Pedestrian Traffic Signal Modules and Vehicle Traffic Control Signal Heads - Part 3: Light Emitting Diode (LED) Vehicle Arrow Traffic Signal Modules, unless otherwise stated herein. LED module shall be certified by the Intertek LED Traffic Signal Module Certification Program, and each unit shall have a decal indicating Intertek certification.

All LED signal lamp units shall be the latest model currently in production and new. Equipment no longer being manufactured shall not be accepted, even if it meets the following specifications.

LED signal lamp units shall conform to the following criteria:

1. Physical and Mechanical Requirements

a. The LED traffic signal lamp unit shall be designed as a retrofit replacement for existing incandescent signal lamps and shall not require any special tools for installation. The 12" (300 mm) retrofit replacement LED traffic signal lamp unit shall fit into existing traffic signal housings built to ITE VTCSH standards

without modifications.

b. Installation of a retrofit replacement LED traffic signal lamp unit into an existing signal housing shall only require removal of the existing lens and incandescent lamp. The new unit shall fit securely in the housing door and connect to existing electrical wiring or terminal block by means of simple connectors. Removal of the reflector is optional.

c. Each LED signal lamp unit shall be identified on the back side with the following:

(1) Manufacturer’s name and trademark

(2) Part number

(3) Serial number (must be unique for each unit)

(4) Voltage rating

(5) Power consumption (watts and volt-ampere)

(6) Vertical indexing indicator (i.e., “up arrow”, or the word “UP” or “TOP”) if specific orientation of the module is required.

(7) Date of manufacture (minimum information required - month & year)

Single units shall have identification markings as to the type and color of the module. Bi-Modals shall be marked with module type.

Each LED signal lamp unit shall have a label placed on the unit certifying compliance to ITE standards for color and luminance.

d. The LED traffic signal lamp unit shall be a single, self-contained device, not requiring on-site assembly for installation into an existing traffic signal housing.

e. The assembly and manufacturing process for the LED traffic signal lamp unit assembly shall be such as to assure all internal LED and electronic components are adequately supported to withstand mechanical shock and vibration from high winds and other sources. The LED signal lamp shall survive 3 drops of 42 inches onto a smooth concrete surface without any loosening or breaking of internal components, or change in operation.

f. The lens of the LED signal lamp unit shall be capable of withstanding ultraviolet light (direct sunlight) exposure for a minimum time period of five years without exhibiting evidence of deterioration.

g. Ensure that lenses will withstand a 42-inch (1.0 meter) drop test, are a minimum of 1/8 inch (3 mm) thick, and are free of bubbles and imperfections. The lenses shall be smooth on the outside with no external facets to prevent dirt and debris build up.

h. Each LED traffic signal lamp unit shall comprise a UV stabilized polymeric outer shell, multiple LED light sources, and a regulated power supply.

i. If red or yellow lenses are tinted, they shall match the wavelength (chromaticity) of the LED. Do not furnish green tinted lenses.

j. An optical assembly shall diffuse the light output and provide uniform illumination across the entire surface of the lens and eliminate the visibility of the individual LEDs to the observer. The optical assembly shall be used for all ball modules and shall be optional on arrow and pedestrian modules.

k. The LED traffic signal lamp unit shall be designed for universal installation in both span wire and standard/stationary pole mount applications.

l. The Arrow pattern produced by the Arrow LED traffic signal lamp units shall conform to the VTCSH standard for color, size and shape. The Arrow LED traffic signal lamp units shall not require a specific orientation or have a variance in light output, pattern or visibility for any mounting orientation.

m. LED pedestrian signal lamp units shall be designed as a retrofit replacement, modular or screw in unit for the message bearing surface of a 12" (300 mm) pedestrian traffic signal, type A-2, housing.

n. The LED pedestrian signal lamp unit shall fit into existing pedestrian signal housings without the need to modify the housing. Installation of the retrofit replacement LED pedestrian signal lamp unit into an existing 12" (300 mm) pedestrian signal housing shall only require the removal of the existing message bearing surface, existing lamp components (i.e. lens, lamp module, gaskets, and reflector) and insertion of the retrofit replacement into the area once occupied by the removed assembly.

o. The single pedestrian module shall be designed to display a full “HAND” icon and a full “Walking” Person icon that complies with standards for this (icon) symbol for the size specified.

p. LED traffic signal lamp units shall be visible at 450 feet (137 meters) during sway conditions (extended view) until obscured by the visor.

q. The module shall be designed to detect catastrophic loss of the LED load. Upon sensing the loss of the LED load, the module shall present a resistance of at least 250K Ohms across the input power leads within 300 msec.

r. Turn-On and Turn-off time is less than 75 msec. Also, low voltage Turn-Off is less than 35 Volts.

2. Photometric Requirements

a. The red and orange lamps shall be manufactured using AlInGaP (Aluminum-Indium-Gallium-Phosphide) technology or other LEDs with lower susceptibility to temperature degradation than AlGaAs (Aluminum-Gallium-Arsenic). AlGaAs LEDs will not be permitted. Green and yellow lamps shall be manufactured using Indium Gallium Nitride.

b. Each LED traffic signal lamp unit shall meet minimum laboratory light intensity values, color (chromaticity), and light output distribution as described in ITE VTCSH – LED Circular Signal Supplement.

c. Arrow LED traffic signal lamp units shall be designed so that when operated over the specified ambient temperature and voltage ranges, the signal is clearly visible and attracts attention for a distance of at least 1300 feet (400 meters) under normal atmospheric conditions..

d. Measured chromaticity coordinates of LED traffic signal lamp units shall conform to the chromaticity requirements of the following table, for a minimum period of 60 months, over an operating temperature range specified in section AD. Each LED traffic signal lamp unit shall meet the minimum requirements for light output for the entire range from 80 to 135 volts.

Chromaticity Standards

Red	Y: not Y: not greater than 0.308 or less than 0.998 - x
Yellow	Y: not Y: not less than 0.411 nor less than 0.995 – x nor less than 0.452
Green	Y: not Y: not less than 0.506 - 0.519x nor less than 0.150 + 1.068x nor more than 0.730

e. LED pedestrian signal lamp units shall be designed so that when operated over the specified ambient temperature and voltage ranges, the signal shall attract the attention of, and be readable to, a viewer (both day and night) at all distances from 10 feet (3 meters) to the full width of the area to be crossed.

f. The measured chromaticity coordinates of LED pedestrian signal lamp units shall conform to the chromaticity requirements of Section 5.3, Color and the associated Figure C of the PTCSI standard, for a minimum period of 60 months, over an operating temperature range specified in section AD@. Each LED traffic signal lamp unit shall meet the minimum requirements for light output for the entire range from 80 to 135 volts.

3. Electrical

a. Each unit shall incorporate a regulated power supply engineered to electrically protect the LEDs and maintain a safe and reliable operation. The power supply shall provide capacitor filtered DC regulated current to the LEDs according to the LED manufacturer’s specification.

b. The LED traffic signal lamp unit shall operate on a 60 Hz AC line voltage ranging from 80 volts RMS to 135 volts RMS. The circuitry shall prevent flickering over this voltage range. Nominal rated voltage for all measurements shall be 120 ± 3 volts RMS.

c. All unit types shall be operationally compatible with the traffic signal equipment that each type is designed and intended to interface with. This equipment includes all controllers, conflict monitors, current monitors, switch pack and flashers currently in use by the Ohio Department of Transportation. The LED traffic signal lamp unit shall be operationally compatible with all TS-1, TS-2, 170 and 2070 controllers, NEMA TS-1 conflict monitors (including so-called NEMA plus features such as dual indication detection and short yellow time detection); NEMA TS-2 Malfunction Management Units; and 33x cabinet Type 210ECL and 2010ECL conflict monitors (including red monitoring and so-called plus features such as dual indication detection and short yellow time detection) currently used by the Department. In the case of conflicts between specifications, the latest ODOT specifications will control.

e. Two, captive, color coded, 600 V, 20 AWG minimum jacketed wires, 3 feet (0.9 m) long, conforming to the National Electric Code, rated for service at 221 °F (105 °C), are to be provided for an electrical connection.

f. The LED signal shall operate with a minimum 0.90 power factor.

g. Total harmonic distortion (current and/or voltage) induced into an AC power cabinet bus by any sample of 10 signal lamp units shall not exceed 20 percent. This value may be calculated using the root-mean-square combination of the measured harmonic distortion from one sample LED signal lamp unit.

h. LED signal lamp units and associated on-board circuitry shall conform to the requirements in Federal Communications Commission (FCC) Title 47, Sub Part B, Section 15 regulations concerning the emission of electronic noise.

i. The LED signal lamp units shall incorporate circuitry to ensure that they show no evidence of illumination for input voltages below 35 volts. LED signal lamp units shall be illuminated (unregulated illumination) for all input voltages higher than 45 volts AC but less than 80 volts AC. They shall have fully regulated illumination for applied voltages of 80 volts through 135 volts AC. Proof of the intended function of this circuitry shall be accomplished by connecting the lamps to a variable voltage source and slowly raising the applied voltage from zero volts up to 135 volts, and then slowly lowering the applied voltage from 135 volts to zero volts.

j. Proposed LED signal lamp units shall be less than or equal to the base wattage shown below at 77 °F (25 °C).

Retrofit	Wattage
12@ R 12” Red Ball	12 or less
12@ Y 12” Yellow Ball	22 or less
12@ G 12” Green Ball	15 or less
12@ Y 12” Yellow Arrow	10 or less
12@ G 12” Green Arrow	l9 or less

4. Environmental Requirements

a. Green and red LED traffic signal lamp units shall be rated for use in the ambient operating temperature range of -40 °F to +166 °F (-40 °C to +74 °C). Yellow signal lamps shall be rated at a range of -13 °F to +77 °F (-25 °C to +25 °C).

b. The unit shall consist of a housing that is a sealed watertight enclosure that eliminates dirt contamination and allows for safe handling in all weather conditions. The LED signal lamp unit shall be sealed against dust and moisture intrusion per the requirements of NEMA Standard 250-1991 for Type 4 enclosures to protect all internal LED and electrical components.

5. Documentation Requirements. Each LED traffic signal lamp unit shall be provided with the following documentation:

a. Installation instructions.

b. The manufacturer name, brand and model number of all LEDs used shall be provided, along with the LED manufacturer’s recommended drive current and degradation curves.

6. Warranty. The LED signal lamp unit shall be repaired or replaced by the manufacturer if it exhibits a failure due to workmanship or material defects within the first 60 months of field operation.

The LED signal lamp unit shall be repaired or replaced by the manufacturer if, when operating over the specified operating ambient temperature and voltage ranges, the unit does not meet or exceed all minimum luminous intensity requirements as defined in the specifications during the first 60 months of field operation.

The measured chromaticity coordinates of LED signal lamp units shall conform to the requirements for chromaticity in the specifications over the temperature range provided in the Specifications for the duration of the warranty period.

The manufacturer shall provide a written warranty against defects in materials, workmanship and luminous intensity for LED signal lamp units for a period of 60 months after installation of LED signal lamp units. Replacement LED signal lamp units shall be provided within 10 days after receipt of failed LED signal lamp units at no cost, except the cost of shipping the failed units.

An LED pedestrian signal lamp unit shall be repaired or replaced by the manufacturer if the signal lamp unit does not attract the attention of, or is not readable to, a viewer (both day and night) at all distances from 10 feet (3 meters) to the full width of the area to be crossed when operated over the specified operating ambient temperature and voltage ranges.

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

732.05 Pedestrian Signal Heads. Furnish pedestrian signal heads that conform to the ITE Pedestrian Traffic Control Signal Indications. Furnish signal heads that are complete units made up of two optical compartments with no leakage of light from one compartment to another. Ensure that the signal heads alternately display the symbol of an upraised hand in Portland orange and the symbol of a walking person in white light. Do not furnish outline style symbols. Furnish material for housings that consist of cast or sheet, corrosion resistant, non-ferrous metal. Adequately reinforce the housings. Ensure that the lens frames are non-ferrous metal or polycarbonate material.

Ensure that the lenses are glass or ultraviolet and impact-resistant plastic and display the legend with translucent symbols within an opaque black background.

Seal the lens to the door frame by the use of a weatherproof seal. Furnish an elastomeric gasket between the door frame and housing to ensure a dust and weatherproof seal.

Use a signal head design that provides adequate dissipation of heat.

Fit each compartment of pedestrian signal heads with a visor that is at least 7 inches (175 mm) in length or, in lieu of visors, protect the entire face with a sunshade fastened close to the lens. Furnish a black grid sunshade fabricated of high impact resistant plastic with a nominal depth of 1 1/2 inches (38 mm) and consisting of horizontal members spaced at not more than 1/2-inch (13 mm) and vertical members spaced appropriately.

Furnish pedestrian signal heads with required mounting brackets. Furnish either pipe type brackets or, when compatible with the mounting position required by the plans, two-piece hinged type brackets that support the signal head close to the pole.

Furnish 1 1/2-inch (38 mm) galvanized steel pipe brackets with necessary fittings and adapters, and that are one-way or two-way as required. Orient the signal face to crosswalks by selective meshing of serration rings or other devices provided on housings and mounting brackets. Make adjustment in increments not greater than 5 degrees of rotation and that is not affected by wind gusts when locked.

Furnish two-piece hinged brackets of cast aluminum with stainless steel hinge pins, and when closed will be secured by a tamperproof bolt. Ensure that the mounting incorporates a terminal block for quick disconnect of field wiring. Ensure that the mounting design permits attachment to the pole by banding, bolting or by lag screws in the case of wood poles.

Finish signal exterior surfaces black with enamel coating. Finish interior surfaces of visors flat black.

Furnish pedestrian signal head types according to Table 732.05-1.

TABLE 732.05-1

Signal Head Type

Symbol Height, Inches, (mm)

Light Source

6 (152)

9 (229)

LED

9 (229)

LED

If specified, furnish the types listed below:

A. Type A1. Furnish a signal head that utilizes the housings of two 8-inch (200 mm) lens type vehicular traffic sections connected together to form a vertical unit. Ensure that the sections have square lenses. Ensure that the upper lens displays the symbol of an upraised hand in portland orange and the lower lens will display the symbol of a walking person in white.

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

B. Type A2. Furnish a signal head that utilizes the housings of two 12-inch (300 mm) lens type vehicular traffic sections connected together to form a vertical unit. Ensure that the sections have square lenses with the same symbol position as Type A1. Furnish materials according to the Department’s Qualified Products List (QPL).

C. Type D2. Furnish a single housing signal head with a lens in one piece or in two sections, one for each message. Color and mask the lens to display in portland orange the symbol of an upraised hand from the left compartment and the symbol of a walking person in white from the right compartment. Install a lamp in each compartment. The upraised hand and the walking person symbols may be integral in the same compartment.

D. Countdown.

1. Operation.

a. Display driver shall be designed to allow individual LED failures without affecting other LEDs in the same display.

b. The countdown timer shall be of the “smart” type, which continuously samples the timing intervals presented by the pedestrian signal load switch driver(s) in order to “learn” the programmed timing being used by the controller.

c. During interval sampling time, the countdown timer numerical display shall be blank.

d. Sampling time to determine interval settings shall take a maximum of two complete signal cycles.

e. The unit shall be capable of displaying a countdown commencing at the onset of the pedestrian clearance interval and reaching zero at the end of the pedestrian clearance interval.

f. Any interruption of the flashing pedestrian clearance display, e.g., preemption, timing plan change, during a countdown display shall immediately cause blanking of the countdown numerals. The countdown timer shall “re-learn” the pedestrian clearance interval upon return to normal service after preemption or immediately following a change in walk clearance time associated with a timing plan change.

2. Type A2. The top section shall be identical to the 12 inch (300 mm) Type D2 pedestrian signal. The bottom section shall consist of a countdown display in a 12 inch (300 mm) housing.

3. Type D2. The left side of the signal section shall consist of an integral hand/walking person display. The right side compartment shall contain the countdown display.

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

732.06 Pedestrian Pushbuttons. Furnish pushbuttons of sturdy construction that consist of a base housing and a removable cover. Furnish components that provide a pushbutton with normally open contacts and that include all electrical and mechanical parts required for operation.

Ensure that the design of the pushbutton and its associated contacts and housing are sturdy and resistant to mechanical shocks and abuse. Ensure that a concentrated force of 50 pounds (225 N) applied to the button or any exposed portion does not damage the unit or misadjusts the contacts. Furnish a housing with a curved back surface for mounting on poles of various diameters. Integrate the curved surface with the housing or supply an adapter with a flat back type housing. Attach the cover assembly to the housing by stainless steel machine screws, resulting in a weatherproof and shockproof assembly. Furnish a hole threaded for a 1/2-inch (13 mm) pipe in the housing for conduit attachment purposes. Paint external surfaces yellow with enamel paint of Color 13655, Federal Standard 595 , unless specified otherwise in the Plans..

Ensure that the maximum force required to operate the pushbutton is 5 pounds (22.5 N). Furnish a raised or flush pushbutton with a minimum of 2 inches at its smallest dimension.

Furnish pedestrian pushbutton signs that are a minimum of 0.07-inch steel or 0.10-inch aluminum. Ensure that the legends and backgrounds are baked enamel paint for steel signs and enamel paint or non-reflective sheeting for aluminum signs.

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

732.07 Loop Detector Units.

A. NEMA TS-1. Ensure that the loop detector units comply with the requirements of NEMA TS-1, section 15, with the following modifications. Furnish shelf mounted loop detector units that are powered from 120 volts. Use solid state isolated output units for all controller applications where directly connected to a solid state digital controller unit. Ensure that the conductors in the cable harness for loop input pins are twisted three to five times per 1 foot (300 mm).

Ensure that the electrical connections for four-channel shelf-mounted units either are the 19-pin MS connector, as required by the foregoing specification, or consist of four connectors of the type required for single-channel shelf-mounted detector units.

If specified, design detector unit electrical connection plugs or wiring harness such that any multi-channel shelf-mounted detector unit may be readily replaced with single-channel detector units. Accomplish this by furnishing only units with the connector type required for single-channel shelf-mounted detector units, or by wiring the controller back panel to single-channel harnesses which are, in turn, plug-connected to an adapter harness which is mated to the multi-channel connector of the detector unit.

Furnish loop detector unit with an LED or LCD display indication of call strength (∆L/L or equivalent). This display shall be a bar graph or numerical display with at least eight (8) discrete levels indicated.

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

B. NEMA TS-2. Furnish loop detector units according to NEMA Standards TS-2.

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

732.08 Loop Detector Units, Delay and Extension Type. Ensure that the loop detector units of this type comply with the requirements of NEMA TS-1, section 15. Furnish shelf-mounted loop detector units that are powered from 120 volts. Use solid state isolated output units for all controller application where directly connected to a solid state digital controller unit. When specified, apply the provisions of 732.07 for possible replacement of multi-channel units with single channel units.

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

732.11 Signal Supports. Furnish signal poles and mast arms that are tapered tubes of a true continuous taper. Furnish tubes that are circular or regular polygons with six or more sides. Ensure that any measurements of circular tube diameter at a specific point along the longitudinal axis do not vary by more than 3/16-inch (5 mm). Ensure that the taper is between 0.54 and 1.3 percent.

Fabricate mast arms of the true continuous taper type in two portions joined by overlapping of sections with the overlap being at least 1 1/2 diameters as determined by the largest diameter of the outer portion. Assemble the sections with a 5/8-inch (16 mm) minimum stainless steel or galvanized steel hex head through-bolt.

Ensure that there is not more than one longitudinal, automatically electrically welded seam on circular poles. Ensure that the welded seams are neat and uniform in appearance and have a thickness not less than the base material and a bead height not exceeding 1/16-inch (2 mm). Ensure that the wall thickness at each pole or arm cross-section is of uniform thickness, except at weld beads. Do not place transverse seams or welds on true continuous taper type poles or arms. Weld according to 513.17.

After fabrication, hot-dip galvanize poles and arms according to 711.02.

Do not use guy rods or truss-type arms. Furnish poles and mast arms with attachment plates and gussets. Assemble using high-strength bolts with the connection developing the full moment-resisting capability of the arm. Do not allow the butt diameter of mast arms to exceed the nominal diameter of the pole at the point of attachment.

Fit poles with a welded-on cast or plate steel base designed to mount on an anchor bolt foundation and ensure that each pole includes the furnishing of anchor bolts and conduit ells for installation in the foundation. Furnish at least one 2-inch (50 mm) diameter conduit ell for installation in each foundation. Furnish conduit ells made from steel complying with 725.04; however, if they connect to non-metallic conduit, ensure that they are of the same non-metallic material.

Use steel anchor bolts conforming to ASTM F1554, Grade 105 and galvanized according to 711.02. Ensure that the galvanizing extends at least 2 inches (50 mm) beyond the threads. Ensure that ends either are bent or have a drilled and tapped steel plate as shown on the plans.

Ensure that the poles include a handhole near the base oriented as required. Reinforce the handhole with a welded-on steel frame with a grounding lug and fit it with a cover plate fastened by stainless steel screws. Ensure that the poles also include a cable and wire support J-hook welded near the top and a removable pole cap. Design poles and arms so their interiors conceal wiring and their mast arms include grommeted wire outlets for the signal heads. Furnish hanger clamps with clevises on the mast arms for the signal heads as required. Ensure that arm caps are made of steel and cover at least 50 percent of the end area.

Ensure that signal poles combining provisions for roadway lighting include an additional handhole located opposite the mast arm flange with the poles’ J-hook located above.

Furnish pedestrian pushbutton access holes and blind half couplings for controllers and pedestrian signal heads as required. Plug any unused holes.

Furnish certified materials according to Supplement 1094.

732.12 Strain Poles. Furnish signal strain poles for the attachment of span wire that are steel tapered tubes according to the requirements of 732.11. Ensure that all poles include a removable pole cap, and messenger wire clamps with clevis and shackle unless otherwise specified.

Furnish anchor bolt foundation type strain poles that include a welded-on cast or plate steel base, bolt covers, a handhole, and a J-hook, as required by 732.11, and that also include at least one 2-inch (50 mm) cable entrance with a weatherhead and a welded blind half-coupling. Ensure that the poles include the furnishing of anchor bolts and conduit ells for installation in the foundation. Furnish at least one 2-inch (50 mm) diameter conduit ell for installation in each foundation. Furnish steel conduit ells that comply with 725.04; however, if they connect to non-metallic conduit, ensure that they are of the same non-metallic material.

Furnish certified materials according to Supplement 1094.

732.13 Wood Poles. Furnish wood poles that conform to ANSI 05.1 “Specifications and Dimensions for Wood Poles”, that are made of Southern Pine or Western Red Cedar, and that are full-length pressure treated according to 725.19.

732.14 Down Guy Assemblies. Furnish expanding or screw type anchors capable of withstanding a guy tension of 8000 pounds (35 kN) when installed in firm moist soil. 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 all pole and attachment hardware is hot dip galvanized in accordance with 711.02.

Furnish 3/8-inch (10 mm) minimum diameter guy wire that conforms to 732.18 and ensure that all accessories have a rated loading strength equal to or greater than the messenger wire minimum breaking strength.

Furnish porcelain strain insulators of the wet process type.

Furnish an 8 feet (2.4 m) minimum length guy guard made of impact and ultraviolet light resistant yellow plastic that is fastened to the guy wire.

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

732.15 Pedestals. Fabricate pedestals for the support of traffic control equipment of 4-inch (100 mm) schedule 40 steel or aluminum pipe. Fit the steel pipe with a welded-on base of plate or cast steel, or when specified thread the steel pipe into a gray cast iron transformer type base. Furnish galvanized steel pedestals according to 711.02. Thread aluminum pipe into an aluminum cast transformer type base. Design pedestals to mount on an anchor bolt foundation and include the furnishing of anchor bolts and conduit ells for installation in the foundation.

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

732.16 Conduit Risers. Ensure that risers have conduit and fittings according to 725.04 and the weatherhead is made of aluminum or galvanized ferrous metal and threaded.

732.17 Cable Support Assemblies. Ensure that the cable grip used with cable support assemblies is of the proper size and strength for the cables and is of the flexible “closed” or “split with rod” type, of stainless steel or tin coated bronze, and equipped with a single “U” eye bale. Ensure that the smallest cable grip permitted has a minimum rated breaking strength of 250 pounds (1.1 kN).

Ensure that the slings for cable supports are made from copper clad or galvanized multi-strand steel wire with an overall diameter of not less than 1/8-inch (3 mm) and a breaking strength of at least 400 pounds (1.7 N). Use thimbles to form eyes at each end of the sling with grooves to match the wire. Adjust the sling to the proper length with the wire at each thimble lapped and secured with split bolt clamps.

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

732.18 Messenger Wire

A. Wire. Furnish seven strand ASTM A475 Class B Utilities Grade or stronger messenger wire except 1/4-inch (6 mm) seven strand messenger wire must be High Strength Grade or stronger. Furnish 1/4-inch (6 mm) seven strand ASTM A475 Class B High Strength Grade or stronger tether wire. Furnish all wire per ASTM A475 with the following modifications:

18.2 Tags are not required on lengths less than 1000 feet (300 m).

B. Accessories. For messenger wire ensure all accessories have a rated loading strength equal to or greater than 73 percent of the messenger wire minimum breaking strength. For breakaway tether installations, accessories within the turnbuckle-tensioned portion of the tether span shall have strength equal to or greater than 73 percent of the breaking strength of 1/4-inch, 7-strand ASTM A 475 High Strength Grade Wire rope, or 3460 pounds (15.4 kN). Other portions of the tether assembly shall use accessories strength equal to or exceeding the wire rope used in that portion. S-hooks shall be made of mild low-carbon galvanized steel and of the wire size indicated on the plans; larger wire sizes and higher-strength steel S-hooks shall not be substituted. Safety tie wire shall be 304 or 316 stainless steel, 1×19 stranded, 1/8-inch (3 mm) with stainless steel wire rope clips. If used, lead sheet to wrap tether wire in breakaway anchors shall be commercially pure lead of thickness 0.030 to 0.042 inches (0.75 to 1.0 mm).

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

732.19 Cable and Wire. Furnish cable and wire meeting the requirements of Table 732.19-1 and rated at 600 volts with conductors of copper unless otherwise specified. Ensure that the cable or wire jacket is indelibly marked at intervals of not more than 6 feet (2 m) with nomenclature stating the size, the type, the organization specifying the type, and the manufacturer’s name or trademark.

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

TABLE 732.19-1 CABLE AND WIRE

Cable or Wire	Number of Conductors	Wire Gage	Specification or type	Conductor Type	Notes
Signal Cable	As specified	As specified	IMSA 19-1 IMSA 20-1	Copper, color coded, stranded
Interconnect cable	As specified	As specified	IMSA 19-1 IMSA 20-1	Copper, color coded, stranded
Interconnect cable	Twisted pairs as specified	As specified	RUS PE-39 IMSA 19-2 IMSA 20-2	Copper, color coded, solid
Interconnect cable, integral, messenger type	As specified	As specified	IMSA 19-3 IMSA 20-3	Copper, color coded, stranded
Interconnect cable, integral, messenger type	Twisted pairs as specified	As specified	IMSA 19-4 IMSA 20-4	Copper, color coded, solid	[2]
Loop detector wire	Single conductor	14 AWG	IMSA 51-5	Copper, stranded
Loop detector lead-in cable	Two conductor	14 AWG	IMSA 50-2	Copper, twisted pair, stranded, shielded
Power cable	Two conductor	As specified	UL: RHH/RHW/ USE or HHW, cross linked polyethylene with an insulation thickness of 0.045 inch (1.14 mm) (min.)	Copper, stranded	[3]
Service cable	Two conductor (duplex)	As specified		Aluminum,[1] twisted, stranded
Ground Wire	Single conductor		UL: RHH/RHW/USE or XHHW, cross linked polyethylene	Copper, stranded	[4]
Loop detector lead-in cable, direct burial	As specified	12 or 14 AWG, or as specified	IMSA 19-6 IMSA 20-6	Copper, stranded
Loop detector lead-in cable, Integral messenger type	As specified	12 or 14 AWG, or as specified	IMSA 19-4 IMSA 20-4	Copper, stranded

Notes

[1] Copper conductors may be substituted

[2] ANSI/ICEA Cable shall have: Solid insulations, Full count color coding, 8-mil shield, and 772 kHz attenuation compliance. All other specifications are manufacturer’s option unless specified.

[3] Three-conductor cable may be specified. Permitted substitution: 2 (or 3) single conductor cable.

[4] Minimum size is equal to the power or service cable, whichever is larger.

732.20 Power Service. Furnish risers for power service that are 1 to 1 1/2-inch (25 to 38 mm) diameter conduit and fittings according to 725 Furnish weatherheads that are threaded and made of aluminum or galvanized ferrous metal. Include a disconnect switch with enclosure.

732.21 Disconnect Switch with Enclosure. Ensure that the switch enclosure is a UL listed watertight lockable stainless steel NEMA Type 4 supplied with the conduit hubs listed on the enclosure UL label. Furnish an enclosure that contains as a minimum a single-throw, 2 pole, solid neutral, fused safety disconnect switch (or circuit breaker) UL listed as suitable for a service disconnect with a minimum capacity of 30-amperes at 240 VAC. Ensure that the unit can be padlocked in both the “ON” and “OFF” positions.

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

732.22 Backplates. Furnish louvered backplates constructed of wrought sheet aluminum, according to ASTM B 209 (B 209M), 6061-T6, .050 inch (1.3 mm) minimum thickness. Louvers shall be at least 8 percent of the total backplate area. Backplate base metal shall be anodized to maximize paint adhesion according to Mil-A-8625, Type II or Type I. Furnish backplates painted on both sides with at least two coats of flat black alkyd enamel paint or polyester powder coat (no epoxy) closely matching FED-STD-595b-37038. Furnish a backplate that extends 5 inches (125 mm) beyond the outside of the signal assembly on all sides. The overall outside shape of the installed backplate shall be rectangular. The backplate shall allow no gaps between the backplate and the signal head or between signal sections. A 2-inch (50 mm) wide continuous outside border of fluorescent yellow reflective sheeting shall be applied to the front of the backplate. Border shall not be applied over the louvers. Reflective sheeting shall be Type H or J listed on the Department’s Qualified Products List. Prepare backplate surfaces in accordance with 630.04 prior to applying the reflective material. All assembly and mounting hardware shall be stainless steel conforming to 730.10. If used, machine nuts shall be thread-deforming or nylon locknuts. Rivets shall not be used for mounting the backplate to the signal head. A minimum of four mounting points shall be used on each signal section for attaching the backplate. Furnish all mounting hardware.