ITEM 686 TRAFFIC SIGNAL POLE ASSEMBLIES (STEEL)
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1 ITEM 686 TRAFFIC SIGNAL POLE ASSEMBLIES (STEEL) Description. This Item shall govern for designing, fabricating, furnishing and erecting steel traffic signal pole assemblies of the various types and sizes as shown on the plans General. All materials and construction methods shall conform to the requirements of this Item and the pertinent requirements of the following Items: Item 441, "Steel Structures" Item 442, "Metal for Structures" Item 445, "Galvanizing" Item 449, "Anchor Bolts" Item 656, "Foundations for Signs, Traffic Signals and Roadway Illumination Assemblies" Standard Pole Designs. Shop drawings shall not be required or submitted for traffic signal pole assemblies fabricated in accordance with this Item and the details shown on the plans. Any deviation from the plans will require submission of shop drawings of the complete assembly, including anchor bolts, in accordance with Item 441, "Steel Structures". Deviations which affect the basic structural behavior of the pole will be considered as optional pole designs Optional Pole Designs. Optional pole designs shall be subject to the following requirements and shall meet all other requirements of this Item. The designs shall conform to the AASHTO STANDARD SPECIFICATIONS FOR STRUCTURAL SUPPORTS FOR HIGHWAY SIGNS, LUMINAIRES AND TRAFFIC SIGNALS. Two (2) sets of complete design calculations shall be submitted for approval prior to submission of shop drawings. Computer printouts for design calculations will not be acceptable unless accompanied by sufficient other documentation which demonstrates methods used. Unless otherwise shown on the plans, the design calculations and six (6) sets of shop drawings shall be submitted to the Director of Design, Texas Department of Transportation, 125 East 11th Street, Austin, Texas The maximum design yield strength for anchor bolts shall be 380 megapascals. The maximum design yield strength for ASTM A 572 or A 595 materials shall be 345 megapascals. Pole assemblies shall be compatible with the foundation details, signal heads and other attachments shown on the plans Anchor Bolts. Unless otherwise shown on the plans, anchor bolts shall be alloy steel or medium-strength, mild steel as described in Item 449, "Anchor Bolts".
2 Materials. Metal used shall conform to Item 442, "Metal for Structures", except for measurement and payment, and the additional requirements as follows: Poles and Mast Arm Shafts ASTM A 570 Grade 345, A 572 Grade 345, A 588, A 595 Grade A, A 607 Grade 345, or A36MOD345 (1) Base Plates, Mast Arm Mounting Plates, or Access Hole Rings ASTM A 36, A 572 Grade 345, A 588, A 595 Grade A (2), or A36MOD345 (1) Luminaire Arms ASTM A 53 Grade A or B, A 501, A 595 Grade A (2), or A 715 Grade 345 Simplex Fittings for Luminaire Arms Connection or Pin Bolts Miscellaneous Plates and Gussets ASTM A 27 Grade , or A 148 Grade , or A 576 Grade 1021 (3), or A 36 (arm simplex only) ASTM A 325 (4) ASTM A 36 or equal (1) A36MOD345 is a special designation for a modified ASTM A 36 material with a higher specified yield strength and having other additional requirements as described in Item 442, Metal for Structures. (2) ASTM A 595 material used for other than pole and mast arm shafts need not be cold worked to ASTM A 595 requirements, but the basic material shall have 275 megapascals minimum yield strength prior to fabrication. (3) ASTM A 576 shall be suitable for forging and shall also have minimum tensile strength of 450 megapascals, minimum yield strength of 240 megapascals, and minimum elongation of 22 percent in 50 millimeters. (4) ASTM A 321 threaded rods may also be used for pin bolts and clamp-on mast arm connection bolts. Nuts for ASTM A 321 connection bolts shall be ASTM A 563 Grade DH heavy hex. ASTM materials A 570, A 572, A 607, or A 715 may have higher yield strengths but shall not have less elongation than the grade indicated. ASTM A 570 Grade 345 or ASTM A 595 Grade A materials shall also have a minimum yield strength of 345 megapascals and a minimum elongation of 18 percent in 200 millimeters or 23 percent in 50 millimeters prior to brake or tube forming operations. Material thicknesses in excess of those stipulated under ASTM A 570 will be acceptable providing the material meets all other ASTM A 570 requirements and the requirements of this Item. ASTM A 595 Grade A material shall have a minimum yield strength of 345 megapascals adjacent to base welds after fabrication. All the above steel, greater than 12.7 millimeters thick, except simplex fittings, bolts and miscellaneous steel, shall conform to the longitudinal Charpy V-notch requirements of ASTM A 572, Group 1, in accordance with Article
3 The silicon content of all steel shall be controlled to ensure high quality galvanizing and to avoid discoloration. All materials furnished by the Contractor shall be new Fabrication. Fabrication and welding shall be in accordance with Item 441, Steel Structures, the ANSI/AWS STRUCTURAL WELDING CODE D1.1, the details shown on the plans and the requirements of this Item. Conformance to the plans and other approved drawings does not relieve the Contractor of the responsibility for providing proper fit of components. Shafts for poles and mast arms may be round or octagonal and shall be tapered as shown on the plans. Bolted slip joints overlapping a minimum of 1.5 diameters are permissible in mast arms 12 meters and longer. Circumferential welds, other than at the ends of the shafts, will not be allowed. The exterior of longitudinal seam welds shall be ground or otherwise smoothed to the same appearance as other shaft surfaces. Longitudinal seam welds for shaft sections shall have 60 percent minimum penetration. Longitudinal seam welds shall have 100 percent penetration when within 150 millimeters of circumferential base welds. A maximum of two (2) longitudinal seam welds may be made in shaft sections. Welding of longitudinal seams shall be done in a manner that will minimize acid entrapment during later galvanizing. Luminaire arm connections to the pole shall be with simplex fittings. Castings for simplex fittings shall be true to pattern in form and dimensions with no sharp unfilleted angles or corners. The fittings shall have no defects affecting their strength and appearance. Fabrication Tolerances: Part Dimension Tolerance (millimeters) Poles and Mast Arm Shafts Base and Mast Arm Mounting Plates Anchor Bolts Assembled Shafts Length Thickness Deviations from flats or ida Straightness Attachment locations Overall Thickness Deviations from flat Spacing between holes Bolt hole size Length Threaded Length Galvanized Length Angular Orientation (1) Centering Twist ± , in 3.0 m ± , in 610 ± 3.2 ± 1.6 ± 13 ± in deg in 15.2 m (1) The angular orientation tolerance between mounting plates and between mounting plates and base plate shall be three (3) in 305.
4 Unless otherwise shown on the plans, mast arms shall be fabricated straight in the unloaded condition. Fabricated sections and associated parts shall be galvanized in accordance with Item 445, "Galvanizing". Terminal blocks, cover plates and gaskets as shown on the plans shall be in place for shipment. Terminal block hardware shall be nickel plated brass. The design wind speed specified on the plans shall be permanently identified on the pole base plate and mast arm mounting plate surfaces and shall be visible after erection. Each traffic signal pole assembly shall be delivered as a complete unit with fittings and hardware either installed or packaged in such a manner that all parts remain with their associated major components during shipment. All components of a shipment shall be identified with a weatherproof tag. This tag shall identify manufacturer, contract number and date and destination of shipment Construction Methods. Traffic signal poles shall be located as shown on the plans, except that the Engineer may shift the poles, within design guidelines, where necessary to secure a more desirable location or to avoid conflict with utilities. Unless otherwise shown on the plans, the Contractor shall stake and the Engineer will verify all traffic signal pole locations. Foundations shall be constructed in accordance with Item 656, "Foundations for Signs, Traffic Signals and Roadway Illumination Assemblies". Anchor bolts shall be oriented as shown on the plans. Erection of poles near any overhead or underground utilities shall be accomplished using established industry and utility safety practices. The Contractor shall consult with the appropriate utility company prior to beginning such work. Threads of anchor bolts shall be coated with pipe joint compound prior to installation of nuts when erecting the pole. Lower anchor bolt nuts shall be retightened against the base plate after the upper nuts are tight. A slug wrench and sledge is recommended for tightening nuts. After the traffic signal pole assembly has been plumbed and all nuts are tight, each anchor bolt nut shall be tack welded in two (2) places to its washer and each washer shall be tack welded to the base plate in two (2) places. No welding is to be made to the bolt. Galvanizing in tack weld areas shall be repaired using zinc-rich paint in accordance with Item 445, "Galvanizing". The exposed upper threads of the anchor bolts shall be cleaned of pipe joint compound and coated with zinc-rich paint to seal the bolt thread-nut joint. No grout shall be placed between the base plate and the foundation Measurement. This Item will be measured as each traffic signal pole assembly complete in place.
5 Payment. The work performed and materials furnished in accordance with this Item and measured as provided under "Measurement" will be paid for at the unit price bid for "Traffic Signal Pole Assemblies (Steel)" of the various types and sizes specified. This price shall be full compensation for furnishing, fabricating, galvanizing, assembling and erecting the pole upon a foundation; for furnishing and erecting required mast arms and luminaire arms; for furnishing and placing anchor bolts, nuts, washers and templates; and for all other materials, labor, tools, equipment and incidentals necessary to complete the work, except as shown below. Foundations will be paid for under Item 656, "Foundations for Signs, Traffic Signals and Roadway Illumination Assemblies".
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