SECTION 16530 PIER 94 HIGH MAST LIGHTING PART 1 - GENERAL 1.01 SCOPE A. Replace existing high mast lighting poles M and N located at Pier 94. B. Provide templates of existing pole foundation M and N to ensure new pole base plate will match existing pole foundation, bolt size and pattern. C. Remove and dispose of existing high mast lighting poles and maintain existing pole foundations and electrical raceway and wiring. D. Provide new high mast system complete with new pole to mount on existing pole foundation, motorized lowering ring and LED type fixtures. E. New high mast systems shall interface with existing modified lighting controlled circuits shown on drawings. F. All high mast components shall be new and warranted. 1.02 EXISTING CONDITIONS A. High mast lighting pole foundations are approximately 8 high. B. Lighting controlled circuits consist of three circuits at each pole (2 full lighting circuits and 1 security lighting circuits). Only two circuits at each pole shall be used (1 for full lighting and winch system and 1 for security). C. Circuits are 480V, 3-phase, 3-wire system. 1.03 SUMMARY A. New high mast system will consist of removal and disposal of existing high mast lighting poles, new structural high mast design to mount on existing pole foundation, new mechanical/electrical lowering system design and new lighting design. 1.04 DESCRIPTION A. High mast system shall include but not limited to the following: 1. 80 high mast poles including head frame and lowering ring. 2. Internal winch assembly. 3. Internal circuit wiring. 4. 12 (minimum) high mast LED lighting fixtures per pole for normal and security lighting. B. Provide new high mast system consisting of new structural high mast design to mount on existing pole foundation. Obtain templates of existing pole foundation and submit to pole manufacture to ensure base plate will match existing pole foundation, bolt size and pattern. 16530-1
C. Provide new lighting design with an average of 5 fc (foot-candle) for full lighting and average of 1 fc for security. 1.05 REQUIRED SUBMITTALS A. Provide design and shop drawings for the following: 1. 80 high mast assemblies, including head frame, lowering ring and internal hoisting assembly. 2. Internal winch assembly. 3. High mast lighting fixtures. 4. Lighting study for full lighting and security lighting for areas as indicated by the PORT of San Francisco. 5. Electrical design. 6. Structural design. B. Additional Submittals: PART 2 - PRODUCTS 1. Structural drawings and calculations shall be completed by a California licensed engineer, and submitted for review by the Port of San Francisco Project Manager. Approval is a prerequisite to fabrication. 2. Worker Qualifications: See paragraph 3.02, A herein. 2.01 HIGH MAST POLES A. Poles shall be Valmont Industries, Inc. Catalog No. HM080-SPCL-LD25, or approved equal. B. Poles shall be 80 feet high and shall include shaft, handhole, support plate, anchor base and nuts. The pole complete with lowering device and luminaries in place shall be capable of withstanding a sustained wind velocity of not less than 80 MPH with gusts up to 130% at three seconds. Poles shall be fabricated from high strength low alloy steel conforming to ASTM A588. C. Tapered tube type to be used for pole sections shall meet tensile strength requirements of ASTM A595, Grade B or ASTM A572 Grade 65. D. Sectional poles shall consist of round and multi-tapered steel tubes with a standard taper of 0.14 inches per foot. Sectional pole sections shall telescope such that the upper section slip-fits the section below by a minimum of 2 inches less than 1.5 times the upper section inside diameter. E. Shaft shall be prime-painted in accordance with painting specification contained herein. Steel used in fabricating the shaft shall have minimum yield strength of 65,000 psi following fabrication. Pole sections shall be fabricated from material per ASTM a-572, Fr. A. F. Shaft shall have a 10 by 30 minimum reinforced handhole to allow adequate clearance for installing, maintaining and servicing the internal lowering device. Handhole reinforcement with a minimum of 1 thick reinforcing bar frame. The bar frame shall be sized such that it will not interfere with the operation of the lowering device. The handhole opening shall begin approximately 15 up from the base of the pole. Opposite the handhole shall be a support plate for mounting of the winch assembly and circuit breakers. A handhole cover shall be provided with a gasketed, padlockable cover. 16530-2
G. The anchor base shall be integrally welded base plate designed to meet or exceed the strength of the adjacent pole shaft section. The base plate connection shall be full penetration butt weld with a backup bar. H. Each base plate of each high mast pole shall be field verified to accommodate existing bolt pattern type, anchor bolt circle diameter, bolt projection, and shall be drilled to match the existing bolt circle. Each of the existing bolt circles shall field verified. I. Testing and inspection of welds: The contractor or manufacturer shall employ and pay all costs of an approved testing laboratory to make in-shop ultrasonic tests for base plate welds of all steel poles for compliance with design criteria. Any defective weld shall be chipped out, re-welded and retested. Certification of welds shall be furnished by the testing laboratory and results submitted to the PORT of San Francisco Engineer on record. Welds shall be refinished to the same quality as the pole finish to protect from the elements. When certification of welds has been approved, installation of high mast light systems may begin. J. Pole to be galvanized coating inside and out per ASTM A-123. 2.02 LOWERING SYSTEM DEVICES A. The lowering system shall be Holophane Catalog No. LD25, or approved equal. B. Lowering system shall consist of head frame, luminaire/lowering ring and winch assembly including motor. C. The head frame structure shall be zinc coated steel and attached to the pole securely with stainless steel hardware. The head frame shall include a minimum of two nominal diameter steel hoisting cable sheaves for each lowering cable. Cable sheaves shall be spaced so all vertical cable paths are parallel to each other. Cable sheaves shall be made of hot rolled steel and be manufactured by splitting and spin-forming the sheave blank. The cross-section of the spin formed sheave groove shall have a radius 0.005 to 0.009 greater than half the nominal cable diameter. The sheave shall be corrosion resistant. Oil impregnated sintered bronze bushings shall be pressed into the steel sheave hub and shall ride on 304 stainless steel shafts. D. A minimum of three stainless steel hoisting cables rated for lifting two times the entire assembly alone. E. The power cord roller assembly shall consist of rollers mounted between two cold-rolled steel plates to ensure power cord does not fall off roller track with a keeper bar on each end to keep the power cord on track during pole erection and during normal operation. The rollers with steel plates shall be spaced to allow the power cord to ride smoothly. Plates shall be corrosion resistant. Rollers to be mounted on AISI 304 stainless steel shafts. A minimum of four rollers shall be provided to allow minimal bending radius of the power cord, and also be spaced so that vertical power cord paths are parallel. F. The head frame shall be provided with a corrosion resistant metallic cover to enclose all internals for protection from the outdoor elements and is attached with stainless steel hardware. G. The head frame shall include guides for each cable assembly of the lowering ring for latching into place when lowering ring is raised. A locking mechanism shall be provided to lock lowering ring into place when raised with means of unlocking for service and maintenance from the ground when being lowered. H. The latching and locking of each latching mechanism shall be signaled to an indicator that will be 16530-3
visible from the ground. The latching mechanism shall not be impaired by formation of ice and shall not require adjustment after the original installation. I. The luminaire ring shall be fabricated to support 12 high-mast fixtures and designed to protect both the pole and shaft while lowered or raised. Luminaire ring shall be stainless steel or galvanized steel. J. Power cable shall be provided with suitable number of conductors rated for the voltage and current carrying capacity for the total load with a maximum voltage drop of 3% and EPR insulation suitable for at least 105 degree C. K. All terminations shall be weather tight wiring chamber through weather tight cable connections. L. Luminaire ring shall be provided with rollers for the centering arm with water-resistant, non-marking material. Spring loaded centering arm design shall be provided for tapered high mast poles which will center the luminaire ring while ascending and descending along the pole. The arm system shall be capable of keeping the ring concentric with the pole in winds up to 30 MPM. All hardware shall be stainless steel. M. Ultimate support of the 12 luminaire ring shall not be sacrificed by individual or total spring failure. 2.03 WINCH SYSTEM A. Assembly: 1. Winch and motor assembly shall be internally located in the pole. 2. Winch motor shall be rated for existing electrical service. Transformer shall be provided as necessary. The transformer shall be properly sized and rated to power a winch motor, and shall be located in the base of the pole and be accessible through the handhole. 3. Motor shall be controlled by a polarity reversing switch connected to a 20 remote cord. 4. The winch shall have an ultimate strength of five times the lifted load with which it will be used. The winch shall include an integral drag brake on the worm shaft to prevent free spooling of the winch. The winch shall be designed for at least intermittent power operation, but also have hand cranked capability. 5. The winch shall be rewound with stainless steel cord of sufficient length to maintain at least four (4) complete wraps on the drum after the device has been lowered to its lowest position. The drum shall be supported at both ends and keepers shall be provided to ensure that uncoiled cable will rewrap onto the drum. 2.04 CIRCUIT BREAKERS AND CABLING SYSTEM A. Feeder circuits shall terminate at 3 phase circuit breakers in a NEMA 3R enclosure installed within the base of the pole so that the circuit breakers are operable through the handhole and interface with existing lighting controls for full lighting, security lighting and winch power. B. Circuit run shall be continued to the luminaire ring by means of a heavy duty cable. A weather tight twist-lock connector for each circuit shall be installed at the lower end of the cable to disconnect cable and permit lowering of luminaire ring for servicing. A water tight cap shall be provided for twist-lock connecter when each cabling systems are not in use. 16530-4
C. Furnish for installation three separate cabling systems: 1. Normal lighting. 2. Security lighting. 3. Winch system D. The cabling system shall be of type suitable for this specific application and shall comply with applicable codes. 2.05 LUMINAIRES A. Luminaires shall be Holophane catalog No.HMLED2 12 4K AH G AW FD2 P7 PSC High Mast Gen 11 luminaire, utilizing 12 LED COB modules enclosed with borosilicate glass refractor, opened fixture, IP 66 rated LED modules UL, listed 1598, with symmetric IES Type V distribution or approved equal. B. Luminaires shall be provided with standard NEMA 7 pin receptacle with shorting cap for future connections for wireless and dimming controls. C. Available voltage at existing poles is 480V, 3-phase, 3-wire. D. The luminaires shall be provided with 100,000 hour, 61,410 lumen, 12 chip-on-board (COB) LED Wide Type, UL Listed 1598 @ 40C E. The maximum weight of the luminaires shall not exceed 70 pounds. F. The housing shall be die cast aluminum and shall provide a weather tight environment for all components and shall pass the UL listed to operate in 40 degree C ambient. The cast aluminum bracket arm clamp shall allow for +/- 3 degree adjustment for leveling the luminaire. All components shall be of non-corrosive material or have positive corrosion protection and the complete fixture shall be 3G vibration tested. Provide pre-treatment and painting process yields a finish that achieves a scribe creep age rating of 8 (ASTM D1654) after over 5,000 hours exposure to salt fog chamber (ASTM B117). G. Luminaire shall have Class I rated LED drivers rated for 100,000 hours life at 25C, L80 at 100,000. Luminaire s surge protection shall meet ANSI/IEEEC62.41 category C high for AS voltage, C low for AH voltage. The luminaire must function normally and show no evidence of failure upon completion of the test. H. All driver components shall be factory tested and pre-wired to the quick disconnect. I. Luminaire s optical assembly shall be symmetric distribution. J. Fixture shall be provided with dark sky cutoff. PART 3 - INSTALLATION 3.01 REQUIREMENTS A. All electrical installations shall confirm to the codes and standards outlined in this Section. In general, and unless otherwise indicated on drawings, follow equipment manufactures written instructions for 16530-5
installation of electrical equipment. 3.02 WORKMANSHIP A. Qualifications: All electrical work shall be performed by electricians who have completed an apprenticeship training program for electricians approved by the California Division of Apprenticeship Standards, each of whom shall have a minimum of five (5) years of journeyman level experience performing similar electrical work in similar facilities. Workers performing electrical work on medium voltage switchgear shall have a minimum of five years experience working with medium voltage. The Contractor shall require the workers hired to perform electrical work on this Contract to submit documentation proving that these training and experience requirements are met. Prior to engaging the workers on the electrical work, the contractor shall submit an AFFIDAVIT to the Port identifying the workers and stating that each of the electrical workers meet these minimum requirements. B. Ensure that all equipment and materials fit properly in their installations. C. Perform any required work to correct improperly fit installations at no additional expense to the City. 3.03 INSTALLATION OF POLES, HIGH MAST LUMINARES, AND LOWERING DEVICES A. Optical assemblies shall be inspected and cleaned prior to hoisting to final operating position. B. Poles shall be assembled and cleaned prior to erection on foundation. Any damage to the finish caused during erection shall be repaired and restored to its specified condition. C. Contractor to provide or clean weep holes under the base of the pole to prevent accumulation of moisture. D. Pole leveling nuts shall be adjusted to make the poles true and vertical, after which any space between the base and the existing concrete footing shall be packed with grout. E. Luminaire assemblies shall be checked for loose nuts, bolts, rivets, screws, equipment finish, position of reflector, ballast and electrical connections before raising to top of pole. F. Contractor shall have a manufacturer s representative on site to inspect assembly and setting of all high mast lights. Manufacturer s representative shall submit a written report confirming all high mast lights are installed per the manufacturer s recommendations. 3.04 TESTING OF HIGH MAST LUMINARES & LOWERING DEVICES A. Contractor shall test all systems of high mast luminaires to ensure they are working properly after electrical connection is made. Each high mast shall be tested individually. Contractor shall demonstrate that the high mast lights are operational at the request of the Engineer. B. Contractor shall also test lowering device for proper operation. Contractor shall also demonstrate that the lowering devices are operation at the request of the Engineer. END OF SECTION 16530-6