100 general provisions

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 out going 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. devices

7. Operating Manual. Furnish a complete manual including instructions on installation, operation and maintenance for each 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 nor no 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.
730 TRAFFIC SIGN AND SUPPORT MATERIAL

730.01 Steel Tube and Pipe. Furnish steel tube and pipe according to ASTM A 53, Grade B or ASTM A 501, except provide tubing for truss and end frame diagonals according to 711.01.

730.015 U-Channel Posts. Furnish U-channel posts fabricated from steel into a characteristic cross-section that may be used alone or paired to form a heavier post by being bolted together back to back. Furnish posts with a uniform cross section for their full length. Cut posts square to a length tolerance 1 inch (25 mm) and ensure that posts do not have ragged or sharp edges, or cracks or other imperfections affecting strength or durability. The back of the posts may be flat or contain raised longitudinal ribs.

Furnish posts meeting the deflection criteria of Supplement 1075. Furnish posts manufactured from rail or billet steel according to ASTM A 499, Grade 60.

Provide a yield type driven post without breakaway devices conforming to NCHRP 350 requirements. Provide a copy of the approval letter from FHWA.

Other material specifications may be accepted by the Department for drive posts conforming to the dimensional requirements listed below and on ODOT standard drawings and the performance requirements of NCHRP 350.

Furnish posts with a nominal weight before punching or galvanizing as follows:

Post Size Number	Weight lb/ft (kg/m)	Tolerances %
1	1.12 (1.7)	-3.5, +10.0
2	2.00 (3)	-3.5, +10.0
3	3.00 (4.5)	-3.5, +10.0

Furnish posts with 3/8-inch (10 mm) diameter holes accurately punched on the centerline spaced at 1-inch (25 mm) centers beginning not more than 1 1/8 inches (30 mm) from the top of the post through the entire length, to allow bolting the posts back to back, without redrilling, using 5/16-inch (8 mm) diameter bolts. Furnish posts that have been galvanized after punching according to 711.02.

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

730.016 Square Posts. Furnish square posts fabricated from steel according to ASTM A 1011 with a minimum yield strength of 60,000 pounds per square inch (415 MPa), with 7/16-inch (11 mm) diameter die-cut knockouts or open holes spaced on 1-inch (25 mm) on the centerline of all four sides, in true alignment and opposite each other. Furnish posts with the dimensional requirements conforming to the Department’s standard drawings. Furnish posts that have been finished with one of the following methods:

A. Both inside and outside of the post are hot-dip galvanized according to ASTM A 653 G-235.

B. The outside of the post has a zinc coating of 0.80 ounce per square foot (244 g/m²) followed by chromate conversion coating and a cross-linked polyurethane acrylic coating. The inside of the post has a zinc organic coating.

C. Provide a yield type driven post without breakaway devices conforming to NCHRP 350 requirements. Provide a copy of the approval letter from FHWA.

Other material specifications may be accepted by the Department for drive posts conforming to the dimensional requirements listed below and on ODOT standard drawings and the performance requirements of NCHRP 350.

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

730.02 Steel Anchor Bolts and Nuts. Furnish anchor bolts made of steel conforming to ASTM F1554 Grade 105, galvanized according to 711.02 at least 2 inches (50 mm) beyond the threads, with the end either bent or with a drilled and tapped steel plate. Furnish leveling nuts and anchor nuts capable of developing the full strength of the anchor bolt.

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

730.03 Steel Poles and Arms. Furnish poles and arms made of steel with a minimum yield strength of 52,000 pounds per square inch (359 MPa) and galvanized according to 711.02.

Furnish certified material according to Supplement 1093

730.04 Base and Arm Plates. Furnish support or pole anchor bases and arm attachment plates fabricated from steel plate according to ASTM A 36 (A 36M) or ASTM A 572 (A 572M), Grade 42. Weld plates to supports, poles, or arms both inside and outside with fillet welds equal to the wall thickness, or by AWS prequalified welding joints TC U4a-S or TC U4c-GF. The Contractor may use a cast steel base of equivalent strength.

Furnish certified material according to Supplement 1093

730.05 Handhole Covers. Furnish handhole covers for poles and overhead sign supports made of 0.109-inch (2.7 mm) galvanized steel or 0.125-inch (3 mm) nominal aluminum alloy.

Furnish certified material according to Supplement 1093.

730.06 Pole Caps. Furnish pole caps made of aluminum, galvanized ferrous metal, or zinc die casting.

Furnish certified material according to Supplement 1093.

730.07 Arm Caps. Furnish arm caps made of steel that cover at least 50 percent of the end area.

Furnish certified material according to Supplement 1093.

730.08 Steel Hardware. Furnish bolts 5/8-inch (16 mm) diameter or larger according to ASTM A 325 (A 325M). Furnish bolts and screws less than 5/8-inch (16 mm) diameter according to SAE J429, Grade 5. Furnish nuts of all size, except anchor nuts and leveling nuts according to SAE J995, Grade 2. Furnish flat washers according to ANSI B18.22.1. Furnish lock washers according to ASME B18.21.1. Furnish U-bolts according to ASTM A 307. Furnish all hardware that is hot-dipped galvanized according to ASTM A 153 or mechanically galvanized according to ASTM B 695, Class 50.

Furnish certified material according to Supplement 1092 or 1093.

730.09 Stainless Steel. Furnish any AISI 300 or 400 series stainless steel.

Furnish certified material according to Supplement 1093.

730.10 Stainless Steel Hardware. Furnish stainless steel hardware according to ASTM A 320/A 320M (AISI 300 series). Furnish bolts, screws, nuts, washers, handhole cover chains, and U-bolts that are passivated commercial grade.

Furnish certified material according to Supplement 1092 or 1093.

730.11 Aluminum Sheet and Plate. Furnish sheets for extrusheet panels according to ASTM B 209 (B 209M), 3003-H18, or 5052-H38. Furnish sheets for flat sheet and overlay signs, and sign post reflectors, according to ASTM B 209 (B 209M), 3004-H38, 5052-H38, or 6061-T6. Furnish plates for sign support structures according to ASTM B 209 (B 209M), 6061-T6.

Furnish certified material according to Supplement 1092 or 1093.

730.12 Aluminum Extrusions. Furnish extruded panels and extrusions for extrusheet panels according to ASTM B 221 (B 221M), 6063-T6. For sign support structures, provide rolled or cold finished bar, rod, and wire according to ASTM B 211 (B 211M), 6061-T6; provide extruded bars, rods, shapes, and tubes according to ASTM B 221 (B 221M), 6061-T6.

Furnish certified material according to Supplement 1092 or 1093.

730.13 Aluminum Tube and Pipe. Furnish seamless pipe and seamless extruded tube according to ASTM B 241/B 241M, 6061-T6. Furnish extruded structural pipe and tube according to ASTM B 429, 6061-T6.

Furnish certified material according to Supplement 1092 or 1093.

730.14 Aluminum Castings. Furnish sand castings according to ASTM B 26/B 26M, 356-T6 or T7. Furnish permanent mold castings according to ASTM B 108, 356-T6 or T7.

Furnish certified material according to Supplement 1092 or 1093.

730.15 Aluminum Forgings. Furnish forgings according to ASTM B 247 (B 247M), 6061-T6.

Furnish certified material according to Supplement 1092 or 1093.

730.16 Aluminum Welding Rods. Furnish welding rods according to AWS ER-4043.

730.17 Aluminum Hardware. Furnish hardware according to:

	ASTM Designation	Alloy	Condition/ Temper
Bolts and screws	B 211 (B 211M)	2024 6061	T4 T6
Studs-welded	B 211 (B 211M)	1100	H16
Nuts-hex	B 211 (B 211M)	6061 6262	T6 T9
Nuts-lock	B 211 (B 211M)	2017	T4
Washers-flat	B 209 (B 209M)	Clad 2024 6061	T4 T6
Lock washers	B 211 (B 211M)	7075	T6
Rivets-solid	B 316/B 316M	6053 6061	T6 T6
Rivets-blind	B 316/B 316M	2017 2117 5052	F F F

In addition, provide break-mandrel aluminum blind rivets with a stainless steel or aluminum mandrel.

Furnish certified material according to Supplement 1092.

730.18 Reflective Sheeting Type F. Furnish sheeting according to ASTM D 4956, Type I, including supplemental requirement S1.

730.19 Reflective Sheeting Type G. Furnish Type G reflective sheeting according to Supplement 1049, and according to ASTM D 4956, Type III or IV, including supplemental requirement S1.

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

730.191 Reflective Sheeting Type G, Reboundable. Furnish Type G reboundable reflective sheeting according to Supplement 1049, and according to ASTM D 4956, Type III or IV, including supplemental requirements S1 and S2, with watermarks or other identification marks inconspicuously incorporated into the face of the sheeting on a repeating pattern if necessary to distinguish the sheeting from other similarly appearing sheetings.

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

730.192 Reflective Sheeting Type H. Furnish Type H reflective sheeting according to Supplement 1049, and according to ASTM D 4956, Type VII, VIII or X, including supplemental requirement S1.

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

730.193 Reflective Sheeting Type J. Furnish Type J reflective sheeting according to Supplement 1049, and according to ASTM D 4956, Type IX, including supplemental requirements S1.

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

730.20 Nonreflective Sheeting. Furnish non-reflective sheeting according to ASTM D 4956, except provide sheeting that does not incorporate any optical elements.

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

730.22 Silk Screen Inks. Furnish opaque and transparent process color inks used in the silk screen process that the manufacturer of the reflective sheeting accepts and warrants according to Supplement 1049. Use inks that provide a tough, durable film of uniform thickness and appearance on the sign surface. Furnish transparent process color inks used in the reverse screen process according to the color specification limits in ASTM D 4956, Table 17.

730.23 Transparent Electronic Cuttable Films. Furnish transparent electronic cuttable films the manufacturer of the reflective sheeting warrants according to Supplement 1049. Use films that provide a uniform appearance on the sign surface. Furnish films according to the color specification limits in ASTM D 4956, Table 17.
731 SIGN LIGHTING AND ELECTRICAL SIGNS MATERIAL

731.01 Mercury Vapor Luminaire. Furnish mercury vapor luminaires that are complete lighting units consisting of a housing door frame, refractor lens, reflector, socket, and lamp. Ensure that the luminaire has a weatherproof optical system.

Ensure that the projected height of the luminaire including mounting device is not more than 11 inches (280 mm) high when positioned to provide optimum illumination of a sign face, 12 1/2 feet (3.8 m) high.

Furnish luminaire housing that:

A. Is cast aluminum having either a natural finish or a gray baked acrylic enamel.

B. Is adequately reinforced and capable of containing and supporting the reflector and lamp socket.

C. Has a suitably attached but readily removable flexible permanent-set and heat-resistant waterproof gasket between the housing and door frame, which when compressed when the door frame is closed forms a weatherproof seal.

Furnish weepholes in the luminaire housing or cover as required for drainage.

Ensure that the door frame is either cast aluminum of the same finish as the housing or an aluminum extrusion with an anodized finish. Hinge the door frame on one edge, and fasten the door in place with spring loaded latches requiring no tools to open. Furnish stainless steel hinges, latches, and other external hardware. Ensure that the hinge retains the door frame in a secure condition when the door frame is opened and does not allow unintentional separation.

Furnish borosilicate glass, or its equivalent, refractor or lens of the optical system capable of withstanding thermal shock and the impact of freezing rain or hail. Furnish a waterproof seal between refractor or lens and the door frame consisting of a heat-resistant gasket or elastic cement.

Furnish an aluminum reflector to a shape that distributes light uniformly over the sign face, in conjunction with the lens or refractor supplied with the luminaire with the surface of the reflector finished to preserve the original reflective characteristics.

Ensure that the mercury lamp sockets are a mogul screw shell with a large center contact spring providing firm contact with the lamp base. Furnish a porcelain-shrouded socket that includes lamp grips.

Ensure that the manufacturer has provided, in addition to catalog cuts submitted for determination of compliance, complete photometric data for each type luminaire as used with a 175-watt, H39KB-175 lamp. Ensure that the photometric performance data is certified by the manufacturer or a qualified independent testing laboratory. The minimum data required includes a tabulation of illumination values at the centers of 1 foot (0.3 m) square areas over a vertically-oriented 10  10 foot (3.0  3.0 m) square grid with the luminaire positioned 4 feet (1.2 m) in front of the vertical centerline of the grid and 1 foot (0.3 m) below the bottom edge of the grid. Ensure that the data includes:

A. Maximum value obtained.

B. Minimum value obtained.

C. Average of the 100 measured values.

D. Ratio of the maximum to minimum values obtained no greater than 6.0.

E. Maximum ratio of illumination values obtained in any two contiguous areas.

Measure illumination using a cosine-corrected receptor in the plane of the grid with the receptor optical axis perpendicular to the plane of the grid. Ensure that the spectral response of the measuring device conforms to the CIE (Commission Internationale de l’Eclairage) standard “photopic” response. Ensure that the luminaire meets the following illumination requirements when tested under the above conditions:

1. Maximum illumination on any 1 foot (0.3 m) square area of 50 foot-candles (540 lx).

2. Average of the individual measurements of at least 20 foot-candles (215 lx).

3. Ratio of the maximum and minimum values obtained no greater than 6.0.

4. Maximum ratio of values obtained in any two contiguous areas no greater than 2.0.

The Engineer may require the following special test to confirm that a mercury-vapor luminaire meets the weatherproof requirements. Mount a luminaire complete with mounting connections and electrical conduit connections in a manner simulating actual service. Apply a water spray, adjusted to be equivalent to a driving rain, to the top, sides, and bottom for a period of one hour. Any entrance of water resulting in wetting of a normally live electrical component, or internal part of the optical assembly, is cause for rejection.

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