Standard Specifications for Road, Bridge, and Municipal Construction 2020 (M 41-10)

Reinforcing Steel

9-07

2. ASTM A513 steel tubes made from Grade 60 Carbon Steel Tube with a 1.625 inch

outside diameter and a 0.120 inch wall thickness. Both the inside and outside of
the tube shall be zinc coated with G40 galvanizing in accordance with ASTM A653.
Following zinc coating the tubes shall be coated in accordance with

Section 9-07.5(1)

item 1. The ends of the tube shall be capped to prevent intrusion of concrete or
other materials.

9-07.5(2) Corrosion Resistant Dowel Bars (for Cement Concrete Pavement

and Cement Concrete Pavement Rehabilitation)

Corrosion resistant dowel bars shall be 1½ inch outside diameter plain round steel bars or
tubular bars 18 inches in length and meet the requirements of one of the following:
1. Stainless Steel Clad dowel bars shall have a minimum 0.06 inches clad to a plain steel

inner bar meeting the chemical and physical properties of AASHTO M31, Grade 60,
or AASHTO M255, Grade 60. Stainless Steel Clad shall meet the chemical properties
of ASTM A276, Type 316L.

2. Stainless Steel Tube dowel bars shall have a minimum 0.06-inch-thick tube press-

fitted onto a plain steel inner bar meeting the chemical and physical properties of
AASHTO M31, Grade 60, or AASHTO M255, Grade 60. A lubricant/adhesive shall be
used between the tube and the plain steel bar to fill any voids. Stainless Steel Tube
material shall meet the chemical properties of ASTM A276, Type 316L.

3. Stainless Steel Solid dowel bars shall be ASTM A276, Type 316L.
4. Corrosion-resistant, low-carbon, chromium plain steel bars for concrete

reinforcement meeting all the requirements of ASTM A 1035 Alloy Type CS Grade
100 or Alloy Type CS Grade 120.

5. Zinc Clad dowel bars shall be 1½ inch solid bars or 1.625 inch outside diamter

by 0.120 inch wall tubular bars meeting the chemical and physical properties of
AASHTO M 31, Grade 60, or AASHTO M 255, Grade 60. The bars shall have a
minimum 0.035 inches A710 Zinc alloy clad to the plain steel inner bar or tube.
A710 Zinc shall be composed of: zinc: 99.5 percent, by weight, minimum; copper:
0.1 – 0.25 percent, by weight; and iron: 0.0020 percent, by weight, maximum.
Each end of tubular bars shall be plugged using a snug-fitting insert to prohibit any
intrusion of concrete or other materials.

6. Multicoated fusion bonded epoxy bars shall consist of an ASTM A615 bar with

alternating layers of ASTM A934 coating and an abrasion resistant overcoat (ARO).
The ASTM A934 coating shall form the base and there shall be two layers of each
coating material. The minimum thickness of the combined layers of the ASTM
A934 coating and ARO coating shall be 20 mils. The ARO shall meet the following
requirements:

Test

Method

Specification

Gouge Resistance

NACE TM0215, 30 kg wt., LS-1 bit @ 25°C

< 0.22 mm

Gouge Resistance

NACE TM0215, 50 kg wt., LS-1 bit @ 25°C

< 0.44 mm

Page 9-86

Reinforcing Steel

7. ASTM A513 steel tubes made from Grade 60 Carbon Steel Tube with a 1.625 inch

outside diameter and a 0.120 inch wall thickness. Both the inside and outside of
the tube shall be zinc coated with G90 galvanizing in accordance with ASTM A653.
Following zinc coating the tubes shall be coated in accordance with

Section 9-07.5(1)

item 1. The ends of the tube shall be capped to prevent intrusion of concrete or
other materials.

The surface of the finished cut-to-length corrosion-resistant, low-carbon, chromium
plain steel bars for concrete reinforcement meeting all the requirements of ASTM
A1035 dowels shall be provided with a hot-rolled, as-rolled finish, including mill scale.
The surface of all other finished cut-to-length dowels shall be provided with a smooth
“ground” or “cold drawn” finish.

Stainless Steel Clad and Stainless Steel Tube Dowel bar ends shall be sealed with a
patching material (primer and finish coat) used for patching epoxy-coated reinforcing steel
as required in

Section 9-07.3

, item

9-07.6

Tie Bars (for Cement Concrete Pavement)

Tie bars shall conform to the requirements of the Standard Specifications for Deformed
Billet Steel Bars for Concrete Reinforcement, AASHTO M31, Grade 60 and shall be
coated in accordance with ASTM A775 or corrosion-resistant, uncoated, low-carbon,
chromium deformed steel bars for concrete reinforcement meeting all the requirements of
ASTM A1035.

The form of the deformed bar shall be subject to approval by the Engineer.

Tie bars shall be free from dirt, grease, or other defects affecting the strength or bond
with the concrete.

9-07.7

Welded Wire Reinforcement

Welded wire for concrete reinforcement shall meet the requirements of ASTM A1064,
Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete.
Welded wire reinforcement manufacturers shall participate in the NTPEP Audit Program
for Reinforcing Steel (rebar) Manufacturers and shall be listed on the NTPEP audit
program website displaying that they are NTPEP compliant.

9-07.8

Deformed Wire

Deformed wire shall conform to the requirements of AASHTO M336, Deformed Steel
Wire for Concrete Reinforcement.

Deformed wire is noted in the Plans and Specifications by the letter D, followed by a
number indicating the cross sectional area of the wire; for example, D2, D5, D20, etc.

Reinforcing Steel

9-07

9-07.9

Cold Drawn Wire

Cold drawn wire shall conform to the requirements of AASHTO M336, Cold Drawn Steel
Wire for Concrete Reinforcement.

Cold drawn wire is noted in the Plans and Specifications by the letter W followed by a
number indicating the cross sectional area of the wire; for example, W2, W5, W20, etc.

9-07.10

Prestressing Reinforcement Strand

Prestressing reinforcement shall be ½-inch diameter for precast-prestressed concrete piles
and ½- or 0.6-inch diameter for pretensioned concrete girders, post-tensioned segmental
precast concrete girders, or cast-in-place prestressed concrete.

Prestressing reinforcement shall be mill bright high tensile strength seven wire low
relaxation strand conforming to the requirements of AASHTO M203, Grade 270.

All prestressing reinforcement furnished for a given structural member shall have a
maximum elongation differential of 3 percent at stress of 0.8 of the ultimate strength
of the prestressing steel. Each reel of prestressing reinforcement shall be accompanied
by a Manufacturer’s Certificate of Compliance, a mill certificate, and a test report. The
mill certificate and test report shall include the yield and ultimate strengths, elongation
at rupture, modulus of elasticity, and the stress strain curve for the actual prestress
reinforcing intended for use. All values certified shall be based on test values and actual
sectional areas of the material being certified.

For every five reels furnished, one sample, not less than 5½ feet long, shall be sent to the
Engineer for testing. Samples of the furnished reels with Manufacturer’s Certificate of
Compliance, a mill certificate, and test report may be shipped directly by the manufacturer
to the Engineer. An independent inspector, approved by the Contracting Agency, shall be
present during sampling and shall provide a written certification to the Engineer.

9-07.11

Prestressing Reinforcement Bar

High-strength steel bars shall conform to AASHTO M275, Type II.

Nuts shall conform to either ASTM A29 Grade C1045, or ASTM A536 Grade 100-70-
03, and shall be capable of developing the larger of either 100 percent of the minimum
ultimate tensile strength (MUTS), or 95 percent of the actual ultimate tensile strength
(AUTS), of the bar. The anchor nuts shall conform to the specified strength requirement
while permitting a maximum 5 degree misalignment between the nut and the bearing
plate. A minimum of three tests, each from a different heat, are required.

Couplers, if required, shall be AASHTO M169 Grade 1144, or equivalent steel, developing
the larger of either 100 percent of the MUTS, or 95 percent of the AUTS, of the bar. The
test shall be performed with the coupler having a one inch unengaged segment between
the two coupled bars. A minimum of three tests, each from a different heat, are required.

Page 9-88

Reinforcing Steel

For unbonded bars under dynamic loading, the connections shall withstand at least
500,000 cycles from 60 percent to 66 percent MUTS followed by at least 50 cycles
between 40 percent MUTS and 80 percent MUTS. A minimum of three tests, each from
a different heat, are required.

The Contractor shall supply a Manufacturer’s Certificate of Compliance in accordance
with

Section 1-06.3

for each bar. The Contractor shall supply a Manufacturer’s Certificate

of Compliance in accordance with

Section 1-06.3

for all nuts and couplers, confirming

compliance with the specified strength requirement.

For each heat of steel for high-strength steel bar, the Contractor shall submit two
samples, each not less than 5½ feet long, to the Engineer for testing.

Paints and Related Materials

9-08

Paints and Related Materials

9-08.1 Paint

9-08.1(1) Description

Paints used for highway and bridge structure applications shall be made from materials
meeting the requirements of the applicable Federal and State Paint Specifications,
Department of Defense (DOD), American Society on Testing of Materials (ASTM), and The
Society for Protective Coatings specifications in effect at the time of manufacture. The
colors, where designated, shall conform to

Section 9-08.1(8)

9-08.1(2) Paint Types

9-08.1(2)A

Vinyl Pretreatment

Vinyl pretreatment shall be a two-component basic zinc chromate-vinyl butyral wash
primer conforming to DOD-P-15328 (Formula 117 for Metals) and SSPC Paint 27. Zinc
chromate shall be the insoluble type. The paint shall be supplied as two components that
are mixed together just prior to use.

9-08.1(2)B

Galvanizing Repair Paint, High Zinc Dust Content

Galvanizing repair paint shall conform to Federal Specification MIL-P-21035B.

9-08.1(2)C

Inorganic Zinc-Rich Primer

Inorganic zinc-rich primer shall be a two-component, self-curing, inorganic zinc-rich paint,
conforming to either AASHTO M300 or SSPC Paint 20 Type I.

9-08.1(2)D Vacant
9-08.1(2)E

Epoxy Polyamide

Epoxy polyamide primer shall be a two-component system conforming to MIL-DTL-24441
or SSPC Coating Standard No. 42.

9-08.1(2)F

Primer, Zinc-Filled, Single-Component, Moisture-Cured

Polyurethane

Zinc-rich primer shall meet the following requirements:

Vehicle Type: Moisture-cured polyurethane.
Pigment Content: 80 percent minimum zinc by weight in dry film.
Volume Solids: 60 percent minimum.
Minimum wt./gal. 22.0 pounds.

Illumination, Signal, Electrical

9-29

3. The locking mechanism(s) shall be tested as follows:

a. The locking mechanism shall be cycled 250 times (locked, then unlocked again)

at room temperature (60-80°F). If there is more than one identical locking
mechanism, only one needs to be cycled in this manner.

b. Temperature changes should be limited to no more than 60°F per hour.
c. The security lid shall be cooled to and held at -30°F for 15 minutes. The locking

mechanism shall then be cycled once to verify operation at this temperature.

d. The security lid shall be heated to and held at 120-122°F for 15 minutes.

The locking mechanism shall then be cycled once to verify operation at this
temperature.

e. The security lid shall be temperature adjusted to and held at 110°F and

95 percent humidity for 15 minutes. The locking mechanism shall then be
cycled once to verify operation at this temperature and humidity.

9-29.2(5)C

Standard Duty Non-Concrete Junction Boxes

Non-concrete Junction Boxes shall be tested as defined in the ANSI/SCTE 77 Tier 15 test
method using the test load of 22,500 pounds (minimum) in place of the design load during
testing. In addition, the Contractor shall provide a Manufacturer Certificate of Compliance
for each non-concrete junction box installed.

9-29.2(5)D

Heavy-Duty Boxes and Vaults

Heavy-Duty Junction Boxes, Cable Vaults, and Pull Boxes shall be load tested to
46,000 pounds. The test load shall be applied vertically through a 10 by 20 by 1-inch
steel plate centered on the lid with an orientation both on the long axis and the short axis
of the junction box. The test load shall be applied and released ten times on each axis.
The deflection at the test load and released state shall be recorded for each interval. At
each interval the test box shall be inspected for lid deformation, failure of the lid or frame
welds, vertical and horizontal displacement of the lid frame, cracks, and concrete spalling.
After the twentieth loading interval the test shall be terminated with a 60,000 pound load
being applied vertically through the steel plate centered on the lid and with the long edge
of steel plate orientated parallel to the long axis of the box.

Heavy-Duty Junction Boxes will be considered to have withstood the 46,000 pound test
if none of the following conditions are exhibited:
1.  Permanent deformation of the lid or any impairment to the function of the lid.
2.  Vertical or horizontal displacement of the lid frame.
3.  Cracks wider than 0.012 inches that extend 12 inches or more.
4.  Fracture or cracks passing through the entire thickness of the concrete.
5.  Spalling of the concrete.

Page 9-200

Illumination, Signal, Electrical

Heavy-Duty Junction Boxes will be considered to have withstood the 60,000 pound test
if all of the following conditions are exhibited:
1.  The lid is operational.
2.  The lid is securely fastened.
3.  The welds have not failed.
4.  Permanent dishing or deformation of the lid is ¼ inch or less.
5.  No buckling or collapse of the box.

9-29.3

Fiber Optic Cable, Electrical Conductors, and Cable

9-29.3(1) Fiber Optic Cable

All fiber optic cables shall be single mode fiber optic cables unless otherwise specified in
the Contract. All fiber optic cables shall meet the following requirements:
1. Compliance with the current version of ANSI/ICEA S-87-640. A product data

specification sheet clearly identifying compliance or a separate letter from
manufacturer to state compliance shall be provided.

2. Cables shall be gel free, loose tube, low water peak, and all dielectric with no metallic

component.

3. Cables shall not be armored unless specified in the Contract.
4. Cables shall be approved for mid-span entries and be rated by the manufacturer for

outside plant (OSP) use, placement in underground ducts, and aerial installations.

5. Fiber counts shall be as specified in the Contract.
6. Fibers and buffer tubes shall be color coded in accordance with the current version

of EIA/TIA-598.

7. Fibers shall not have any factory splices.
8. Outer Jacket shall be Type M (Medium Density Polyethylene). Outer jacket shall

be free from holes, splits, blisters, or other imperfections and must be smooth and
concentric as is consistent with the best commercial practice.

9. A minimum of one (1) rip cord is required for each cable.
10. Cable markings shall meet the following additional requirements:

a. Color shall be white or silver.
b. Markings shall be approximately 3 millimeters (118 mils) in height, and

dimensioned and spaced to produce good legibility.

c. Markings shall include the manufacturer’s name, year of manufacture, the

number of fibers, the words “OPTICAL CABLE”, and sequential length marks.

d. Sequential length markings shall be in meters or feet, spaced at intervals not

more than 1 meter or 2 feet apart, respectively.

Illumination, Signal, Electrical

9-29

e. The actual cable length shall not be shorter than the cable length marking.

The actual cable length may be up to 1 percent longer than the cable length
marking.

Cables with initial markings that do not meet these requirements will not be
accepted and may not be re-marked.

11. Short term tensile strength shall be a minimum of 600 pounds (lbs). Long term tensile

strength shall be a minimum of 180 pounds (lbs). Tensile strength shall be achieved
using a fiberglass reinforced plastic (FRP) central member and / or aramid yarns.

12. All cables shall be new and free of material or manufacturing defects and

dimensional non-uniformity that would:
a. Interfere with the cable installation using accepted cable installation practices;
b. Degrade the transmission performance or environmental resistance after

installation;

c. Inhibit proper connection to interfacing elements;
d. Otherwise yield an inferior product.

13. The fiber optic cables shall be shipped on reels with a drum diameter at least

20 times the diameter of the cable, in order to prevent damage to the cable. The
reels shall be substantial and constructed so as to prevent damage during shipment
and handling. Reels shall be labeled with the same information required for the cable
markings, with the exception that the total length of cable shall be marked instead of
incremental length marks. Reels shall also be labeled with the type of cable.

9-29.3(1)A

Singlemode Fiber Optic Cable

Single-Mode optical fibers shall be EIA/TIA 492-CAAB or ISO/IEC 11801 Type OS2, low
water peak zero dispersion fibers, meeting the requirements of ITU-T G.652.D.

9-29.3(1)B

Multimode Optical Fibers

Where multimode fiber optic cables are specified in the Contract, the optical fibers shall
be one of the following types, as specified in the Contract:
1. Type OM1, meeting the requirements of EIA/TIA 492-AAAA-A or ISO/IEC 11801.

The fiber core diameter shall be 62.5 µm.

2. Type OM2, meeting the requirements of EIA/TIA 492-AAAB-A or ISO/IEC 11801.

The fiber core diameter shall be 50 µm.

All multimode optical fibers shall have a maximum attenuation of 3.0 dB/km at 850nm
and 1.0 dB/km at 1300nm. Completed cable assemblies shall be rated for 1000BaseLX
Ethernet communications.

Page 9-202

Illumination, Signal, Electrical

9-29.3(2) Electrical Conductors and Cable

9-29.3(2)A

Single Conductor

9-29.3(2)A1 Single Conductor Current Carrying

All current carrying single conductors shall be stranded copper conforming to ASTM B3
and B8. Insulation shall be XLP (cross-linked polyethylene) or EPR (Ethylene Propylene
Rubber), Type USE or USE-2, and rated for 600-volts or higher.

9-29.3(2)A2 Grounding Electrode Conductor

Grounding electrode conductor shall be bare or insulated stranded copper. The insulation
shall be green or green with a yellow tracer.

9-29.3(2)A3 Equipment Grounding and Bonding Conductors

Equipment grounding and bonding jumper conductors shall be bare or green insulated,
stranded copper with cross-linked polyethylene insulation rated USE and 600-volts, with
the exception that the equipment grounding and bonding jumper conductors installed
between junction box, pull box, or cable vault frame and lids shall be tinned, braided
copper.

9-29.3(2)A4

Location Wire

Location wire shall be steel core copper clad minimum size AWG 14 insulated conductor.
The insulation shall be orange High Molecular Weight High Density Polyethylene
(HMHDPE).

9-29.3(2)B

Multi-Conductor Cable

Two-conductor through 10-conductor unshielded signal control cable shall have stranded
copper conductors and shall conform to International Municipal Signal Association (IMSA)
signal cable 20-1.

9-29.3(2)C

Aluminum Cable Steel Reinforced

Triplex or Quadraplex Type ACSR neutral self-supporting aerial conductors of the
appropriate size for aluminum conductors shall be used where required in the Contract.
The neutral conductor shall be the same size as the insulated conductor. All conductors
shall be stranded.

9-29.3(2)D

Pole and Bracket

Pole and bracket cable shall be a two-conductor cable rated for 600-volts. The individual
conductors shall be one red and one black 19-strand No. 10 AWG copper, assembled
parallel. The conductor insulation shall be 45-mil polyvinyl chloride or a 600-volt-rated
cross-linked polyethylene. The Jacketing shall be polyethylene or polyvinyl chloride not
less than 45 mils thick. If luminaires with remote ballasts are specified in the Contract, this
same cable shall be used between luminaire and ballast for both timber and ornamental

Illumination, Signal, Electrical

9-29

pole construction. If the luminaire requires fixture wire temperatures greater than 75°C,
the outer jacket shall be stripped for that portion of the cable inside the luminaire.
The single conductors shall then be sheathed with braided fiberglass sleeving of the
temperature rating recommended by the luminaire manufacturer.

9-29.3(2)E

Two-Conductor Shielded

Two-conductor shielded (2CS) cable shall have stranded 14 AWG (minimum) conductors
and shall conform to IMSA Specification No. 50-2.

9-29.3(2)F

Detector Loop Wire

Detector loop wire may be 12 or 14 AWG stranded copper wire, IMSA 51-3.

9-29.3(2)G

Four-Conductor Shielded Cable

Four-conductor shielded cable (4CS) shall consist of a cable with four stranded 18 AWG
conductors with polypropylene insulation, an aluminized polyester shield, water-blocking
material in the cable interstices, and a 26-mil minimum outer jacket of polyethylene. The
four-conductor assembly shall be twisted six turns per foot. Each conductor shall have a
different insulation color. Overall cable diameter shall be 0.25 inch maximum. Capacitance
between adjacent pairs shall be 18 pf per foot and 15 pf per foot between diagonal pairs.
The capacitances shall not vary more than 10 percent after a 10-day immersion test with
ends exposed in a saturated brine solution.

9-29.3(2)H

Three-Conductor Shielded Cable

Three-conductor shielded cable (3CS) for the detector circuit for optical fire preemption
receivers shall consist of three 20 AWG conductors with aluminized mylar shield and
one No. 20 drain wire, all enclosed with an outer jacket. All wires shall be 7 by 28
stranded tinned copper material. Conductor insulation shall be rated 75°C, 600 volt.
The drain wire shall be uninsulated. Conductor color coding shall be yellow, blue, and
orange. DC resistance of any conductor or drain wire shall not exceed 11 ohms per
1,000 feet. Capacitance from one conductor to the other two conductors and shield
shall not exceed 48 pf per foot. The jacket shall be rated 80°C, 600 volt, with a minimum
average wall thickness of 0.045 inch. The finished outside diameter of the cable shall be
0.3 inch maximum.

9-29.3(2)I

Twisted Pair Communications Cable

Twisted Pair Communications Cable shall meet RUS Specification 1755.390 and shall be
AWG22 conductor. The cable shall have a petroleum compound completely filling the
inside of the cable and rated for OSP (Outside Plant) applications.

9-29.3(3) Wire Marking Sleeves

Wire marking sleeves shall be full-circle in design, non-adhesive, printable using an
indelible ink and shall fit snuggly on the wire or cable. Marking sleeves shall be made from
a PVC or polyolefin, and provide permanent identification for wires and cables.

Page 9-204

Illumination, Signal, Electrical

9-29.4

Messenger Cable, Fittings

Messenger cable shall be ⅜-inch, 7-wire strand messenger cables conforming to ASTM
A475, extra-high-strength grade, 15,400-pound minimum breaking strength, Class A
galvanized.

Strain insulators shall be wet process porcelain, conforming to EEI-NEMA Class 54-2
standards for 12,000-pound ultimate strength.

Down guy assembly shall consist of an eight-way steel expanding anchor, having a
minimum area of 300 square inches, made of pressed steel, coated with asphalt or similar
preservative, and fitted with a ¾-inch minimum guy eye anchor rod 8 feet long. As an
alternate to expanding anchors, screw-type anchors with two 8-inch helix, 3½-inch pitch,
1-inch by 7-foot guy anchor rod, and rated for 7,000-pound maximum torque may be
installed.

All pole hardware, bolts, plate rods, hangers, clips, wire guards, and pole bands shall be
hot-dip galvanized in conformance with the requirements of AASHTO M232.

9-29.5 Vacant
9-29.6

Light and Signal Standards

Light standards (including light standards with Type 1 or Type 2 luminaire arms) and
signal standards (including Types I, II, III, IV, V, PPB, PS, RM, FB, and CCTV) shall be in
accordance with the details shown in the Plans, as specified in the Special Provisions and
as outlined herein, provided that only one luminaire arm type shall be used throughout
the project.

Fabrication of light and signal standards shall conform to the applicable requirements of

Section 6-03.3(14)

Light standard, signal standards, slip base hardware and foundation hardware shall be
hot-dip galvanized in accordance with AASHTO M111 and ASTM F 2329. Where colored
standards are required, standards shall be powder-coated after galvanizing in accordance
with Section 6-07.3(11). The standard color shall be as specified in the Contract.

Materials for steel light and signal standards, and associated anchorage and fastening
hardware, shall conform to Sections

unless otherwise

specified in one of the following documents:
1. The steel light and signal standard fabricator’s preapproved plan as approved by

the Washington State Department of Transportation and as identified in the Special
Provisions.

2. The steel light and signal standard fabricator’s shop drawing submittal, including

supporting design calculations submitted as a Type 2E Working Drawing in
accordance with

Section 8-20.2(1)

and the Special Provisions.

Illumination, Signal, Electrical

9-29

9-29.6(1) Steel Light and Signal Standards

Steel plates and shapes for light and signal standards shall conform to ASTM A36, except
that structural shapes may conform to ASTM A992. Shafts for light and signal standards,
except Type PPB signal standards, shall conform to ASTM A572 Grade 50. Shafts and
caps for Type PPB signal standards, slipfitters for type PS I, FB, and RM signal standards,
and all pipes shall conform to ASTM A53 Grade B. Base plates for light standards shall
conform to ASTM A572, Grade 50, except as otherwise noted in the

Standard Plans

for

fixed base light standards. Base plates for signal standards shall conform to ASTM A36.
Connecting bolts shall conform to ASTM F3125 Grade A325. Fasteners for handhole
covers, bands on lighting brackets, and connector attachment brackets shall conform to
ASTM F593.

Light and signal standards shall be hot-dip galvanized in accordance with ASTM F 2329
and AASHTO M232.

Steel used for light and signal standards shall have a controlled silicon content of either
0.00 to 0.06 percent or 0.15 to 0.25 percent. Mill test certificates verifying the silicon
content of the steel shall be submitted to both the galvanizer and the Engineer prior to
beginning galvanizing operations.

9-29.6(2) Slip Base Hardware

Slip plates and anchor plates for light standards and for Type FB and RM signal standards
shall conform to the requirements of ASTM A572 Grade 50. The keeper plate shall be
28 gage, conforming to ASTM A653 coating designation G 90. Clamping bolts for slip
base assemblies and slip base adapters shall conform to ASTM F3125 Grade A325.
Studs and bolts for slip base adapters shall conform to ASTM F3125 Grade A325. Nuts
shall conform to ASTM A563 Grade DH. Hardened washers shall conform to ASTM
F436. Plate washers shall conform to ASTM A36, and also shall conform to the flatness
tolerances specified in ASTM F436 for circular washers.

Galvanized bolts shall meet

Section 9-06.5(4)

9-29.6(3) Timber Light Standards, Timber Strain Poles, Timber Service Supports

All timber poles used in illumination or traffic signal systems shall be Douglas fir, machine
shaved, roof sawed, conforming to the latest ANSI Specifications and Dimensions for
Wood Poles.

All timber poles shall be gained according to industry standards. A dated nail or metallic
date plate shall be set in the gain evidencing the year of treatment of the timber pole.

All poles shall be treated with pentachlorophenol in accordance with

Section 9-09.3(1)

Tops shall be sawed before treatment. Where holes are bored in poles to accommodate
hanging bolts for brackets, transformers, guy assemblies, or other accessories, such holes
shall be painted with a solution of the above preservative.

Page 9-206

Illumination, Signal, Electrical

9-29.6(4) Welding

Welding of steel structures shall be in accordance with AWS D1.1/D1.1M, latest edition,
Structural Welding Code, and

Section 6-03.3(25)

9-29.6(5) Foundation Hardware

Anchor bolts for Type PPB, PS, I, FB, and RM signal standards shall conform to the
requirements of ASTM F1554, grade 55. Nuts shall meet the requirements of ASTM
A563, grade A. Washers shall meet the requirements of ASTM F844 or F436.

Anchor bolts, and associated nuts and washers, for Type CCTV, II, III, IV, and V signal
standards and luminaire poles shall conform to

Section 9-06.5(4)

. Anchor rods conforming

to ASTM A449 may be substituted, provided that the galvanized ASTM A449 anchor rods
having an ultimate tensile strength above 145 ksi shall be tested for embrittlement in
accordance with either ASTM A143 (if the rod length is equal to or greater than five times
the bolt diameter) or ASTM F606 Section 7 (if the rod length is less than five times the
nominal bolt diameter).

All foundation hardware shall be 100 percent hot-dip galvanized in accordance with
AASHTO M111 and ASTM F 2329.

9-29.7

Luminaire Fusing and Electrical Connections at Light Standard Bases,

Cantilever Bases, and Sign Bridge Bases

9-29.7(1) Unfused Quick-Disconnect Connector Kits

Unfused quick-disconnect connector kits shall conform to the following requirements:
1. The copper pin and copper receptacle shall be a crimped type of connection or

a stainless steel set screw and lug connection to the cable. The receptacle shall
establish contact pressure with the pin through the use of a tinned copper or copper
beryllium sleeve spring and shall be equipped with a disposable mounting pin. The
receptacle shall be fully annealed. Both the copper pin and receptacle shall have a
centrally located recessed locking area adapted to be complementarily filled and
retained by the rubber housing.

2. The plug and receptacle housing shall be made of water-resistant synthetic

rubber that is able to be buried in the ground or installed in sunlight. Each housing
shall provide a section to form a water-seal around the cable, have an interior
arrangement to suitably and complementarily receive and retain the copper pin or
receptacle, and a section to provide a water-seal between the two housings at the
point of disconnection.

3. The kit shall provide waterproof in-line connector protection with three cutoff

sections on both the line and load side to accommodate various wire sizes. All
connections shall be as described in item “1” above. Upon disconnect, the connector
shall remain in the load side of the kit.

Illumination, Signal, Electrical

9-29

9-29.7(2) Fused Quick-Disconnect Kits

Fused quick-disconnect kits shall provide waterproof in-line fuse protection. The kit shall
provide three cutoff sections on both lines and load side to accommodate various wire
sizes. All connections shall be as described in item “1” above. Upon disconnect, the fuse
shall remain in the load side of the kit.

Fuses furnished for all lighting circuits shall be capable of handling the operating voltage
of the circuit involved and shall have the following characteristics:
1. Fuses shall be capable of indefinitely supporting 110 percent of the rated load.
2. Fuses shall be capable of supporting 135 percent of the rated load for approximately

1 hour.

3. A load of 200 percent of rated load shall effectively cause instantaneous blowing of

the fuse.

4. Fuses shall be rated as listed below and shall be sized to fit the fuse containers

furnished on this project, according to the manufacturer’s recommendations
therefore.

5. Fuses shall be listed by a Nationally Recognized Testing Laboratory.

Luminaire Size

Service Voltage

480V

240V

120V

1,000W

10A

15A

30A

750W

10A

20A

700W

10A

20A

400W

10A

15A

310W

10A

250W

10A

200W

10A

175W

10A

150W

100W

70W

50W

LED*

10A

20A

*Applies to all LED luminaires, regardless of wattage. Fuses for LED
luminaires shall be slow blow.

9-29.8 Vacant

Page 9-208

Illumination, Signal, Electrical

9-29.9

Ballast, Transformers

Heat-generating components shall be mounted to use the portion of the luminaire upon
which they are mounted as a heat sink. Capacitors shall be located as far as practicable
from heat-generating components or shall be thermally shielded to limit the fixture
temperature to 160°F.

Transformers and inductors shall be resin-impregnated for protection against moisture.
Capacitors, except those in starting aids, shall be metal cased and hermetically sealed.

No capacitor, transformer, or other device shall employ the class of compounds identified
as polychlorinated biphenyls (PCB) as dielectric, coolants, or for any other purpose.

9-29.9(1) Ballast

Each ballast shall have a name plate attached permanently to the case listing all
electrical data.

A Manufacturer’s Certificate of Compliance, in accordance with

Section 1-06.3

, meeting

the manufacturer’s and these Specifications’ requirements, shall be submitted by the
Contractor with each type of luminaire ballast.

Ballasts shall be designed for continuous operation at ambient air temperatures from
20°F without reduction in ballast life. Ballasts shall have a design life of not less than
100,000 hours. Ballasts shall be designed to operate for at least 180 cycles of 12 hours
on and 12 hours off, with the lamp circuit in an open or short-circuited condition and
without measurable reduction in the operating requirements. All ballasts shall be high
power factor (90 percent).

Ballasts shall be tested in accordance with the requirements of current ANSI C 82.6,
Methods of Measurement of High-Intensity-Discharge Lamp Ballasts. Starting aids for
ballasts of a given lamp wattage shall be interchangeable between ballasts of the same
wattage and manufacturer without adjustment.

Ballast assemblies shall consist of separate components, each of which shall be capable
of being easily replaced. A starting aid will be considered as a single component. Each
component shall be provided with screw terminals, NEMA tab connectors or a single
multi-circuit connector. All conductor terminals shall be identified as to the component
terminal to which they connect.

Ballasts for high-pressure sodium lamps shall have a ballast characteristic curve which
will intersect both of the lamp-voltage limit lines between the wattage limit lines and
remain between the wattage limit lines throughout the full range of lamp voltage. This
requirement shall be met not only at the rated input voltage of the ballast, but also
the lowest and highest input voltage for which the ballast is rated. Throughout the
lifetime of the lamp, the ballast curve shall fall within the specified limits of lamp voltage
and wattage.

Illumination, Signal, Electrical

9-29

All luminaires ballasts shall be located within the luminaire housing. The only exception
shall be ballasts to be mounted on lowering assemblies and shall be external to, and
attached to the fixture assembly.

Ballast Characteristics for High Pressure Sodium (HPS) and Metal Halide (MH) Sources
shall be:

Source

Line Volt.

Lamp

Wattage

Ballast Type

Input Voltage

Variation

Lamp Wattage

Variation

HPS

any

70 400

Mag. Reg. Lag

10%

18%

HPS

any

750 1000

Auto Reg. Lead CWA

10%

30%

any

175 400

Mag. Reg. Lag

10%

18%

any

1000

Auto Reg. Lead CWA

10%

30%

9-29.9(2) Transformers

The transformers to be furnished shall be indoor/outdoor dry type transformers rated as
shown in the Plans. The transformer coils, buss bar, and all connections shall be copper.
Transformers, 7.5 KVA and larger shall be supplied with two full capacity taps, one at
5 percent and one at 10 percent below the normal full capacity.

9-29.10 Luminaires

All luminaires shall have their components secured to the luminaire frame with ANSI
300 series chrome-nickel grade stainless steel, zinc dichromate-coated steel, or ceramic-
coated steel hardware. The luminaire slipfitter bolts shall be stainless steel, hot-dip
galvanized steel, zinc dichromate-coated steel, or ceramic-coated steel. All internal
luminaire assemblies shall be assembled on or fabricated from either stainless steel or
galvanized steel. The housing, complete with integral ballast, shall be weathertight.

The temperature rating of all wiring internal to the luminaire housing, excluding the pole
and bracket cable, shall equal or exceed 200°F.

All luminaires shall be provided with markers for positive identification of light source
type and wattage in accordance with ANSI C136.15-2011, with the exception that LED
luminaires shall be labeled with the wattage of their conventional luminaire equivalents –
the text “LED” is optional. Legends shall be sealed with transparent film resistant to dust,
weather, and ultraviolet exposure.

Standard Specifications for Road, Bridge, and Municipal Construction 2020 (M 41-10) - page 51