CHAPTER 16 – SIGNAL AND LIGHT POLES

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SIGNALS AND LIGHTING FIELD GUIDECHAPTER 16 – SIGNAL AND LIGHT POLESSIGNAL AND LIGHT POLESThe standards and requirements for installing traffic control signal and light poles are presentedin this chapter.16.1 Traffic Control Signal Poles16.1.1 MAST ARM POLES AND PEDESTALSMast Arm PolesA PA traffic control signal pole consists of a transformer base, avertical pole shaft, a mast arm truss, and where applicable, aluminaire shaft extension.The PA pole is a 21-foot high tapered octagonal pole shaft. Thereare three pole types; the PA 85, PA 90, and the PA 100.The tapered octagonal mast arm truss is attached to the top of theshaft. The mast arm consists of an upper and lower chord bracedtogether to form a truss. The length of the mast arm trusses rangesfrom 15 – 55 feet depending on the PA pole type.Figure 16-1: Type PA Mast Arm PoleA BA traffic control signal pole consists of a vertical pole shaft, a mastarm truss, and where applicable, a luminaire extension shaft. The BApole does not use a transformer base. Instead, a 10-inch by 12-inchaccess opening is provided in the pole shaft to access the wiring.The BA pole is a 21-foot 10-inch high round shaft. There are five poletypes; the BA 60, BA 65, BA 70, BA 75, and the BA 80.The round tapered mast arm truss is attached to the top of the shaft.The mast arm consists of an upper and lower chord braced togetherto form a truss. The length of the mast arm trusses ranges from 60- 80 feet depending on the BA pole type.Figure 16-2: Type BA Mast Arm PoleIf required in the contract documents, a luminaire shaft extension is installed atop the signal poleshaft. Luminaires mounted on the shaft extension tenons are typically 40 feet above theroadway.Signal and Light Poles16-1

SIGNALS AND LIGHTING FIELD GUIDEIf required by the contract documents, swing away hinges must beinstalled on the mast arm. The hinges must be installed in such amanner that the mast arm swings away from the intersection.Swing away hinges are used for traffic control signal systems that arelocated on house moving routes.Figure 16-3: Swing Away HingesBefore the project begins, the contractor must furnish to the engineer, for approval, fourcomplete sets of shop drawings as specified in the contract documents.The drawings must indicate all member materials and dimensions, section modules of the maincomponent parts, and other pertinent data and calculations.If approved by the engineer, one set of drawings must be distributed as specified in the contractdocuments.Figure 16-4: Shop DrawingsSignal and Light Poles16-2

SIGNALS AND LIGHTING FIELD GUIDEMast Arm Pole InstallationMast arm poles are plumbed by using the leveling nuts onthe foundation anchor rods.Poles must be carefully hoisted into position to avoiddamage to the finish. Damaged areas must be repaired asspecified in the contract documents.The access door of the transformer base must be orientedaway from the traffic, as specified in the contractdocuments, to allow service personnel to see theintersection while servicing the base.Figure 16-5: Signal Mast Arm Pole InstallationThe mast arm pole standard must be installed and tightened on the concrete foundation anchorrods as specified in the installation procedure as detailed in the contract documents.After all mast arm pole standard wiring is complete, the access opening covers (see Figure 16-5)must be sealed with 100% clear silicone sealant at final installation.Figure 16-6: Access Opening CoversSignal and Light Poles16-3

SIGNALS AND LIGHTING FIELD GUIDEPedestalsPedestal shafts and bases must be unpainted anodized aluminum, unless otherwise specified inthe contract documents.Pedestals consist of a shaft and a base. The base is designed to break away from the foundationwhen struck by a vehicle. A re-enforcing collar (wind collar) or a base with an extended neck andset screws is required with each pedestal installation.3-PieceRe-enforcingCollarBase with ExtendedNeck (Takes place of reenforcing collar)Figure 16-7: Pedestal Base and with Wind Collar and Integrated Wind CollarIf steel pedestal shafts are specified, the steel shaft must beconstructed of a welded 4-1/2 inch outside diameter steeltubing and a threaded 5-inch-long, 4-inch standard steel pipenipple. The nipple is welded to the end of the steel tube andmust follow American Welding Society requirements. SeeStandard Plate 8122 for all requirements.Apply anti-seize compound to all threaded surfaces includingset screws, door access bolt, and pedestal shaft.Figure 16-8: Steel Tubing and NippleThe contract documents may require pedestal shafts andbases to be painted. All painting of pedestal shafts and bases must be inaccordance with the contract documents. Pre-painted pedestal shafts andbases that have scratches or other type of damage will not be accepted.The pedestal base must have a threaded top and square transformer basedesign. For steel pedestal shafts, a 4-inch threaded steel pipe nipple must matewith the pedestal base.Four new anchor rods, with washers, and nuts must be furnished with eachpedestal base.The pedestal base access door must provide a positive closure with a fixedcatch on the inside bottom of the door and a bolt type locking mechanism onthe top. Anti-seize compound must be applied to the threads of the stainlesssteel hex-head bolt.Signal and Light PolesFigure 16-9: PaintedPedestal Shaft andBase16-4

SIGNALS AND LIGHTING FIELD GUIDEAs shown in Figure 16-11, one NRTL listed ground lug wire connectormust be mounted with a single bolt on the sidewall, 3 inches fromthe door and 8 inches above the bottom of the base. The connectormust accommodate a 6 AWG copper ground wire and must have aslot head screw to connect the ground wire.Pedestal InstallationThe pedestal foundations must be installed as required by thecontract documents. The pedestal base must be secured toanchorages of the concrete foundations or screw-in steelfoundations utilizing nuts and washers as specified in the contractdocuments.Figure 16-10: Pedestal Base AccessDoorThe contract documents for each traffic control signal system projectwill dictate whether a pedestal concrete foundation or a pedestalscrew-in foundation is to be installed by the contractor.The pedestal base must be plumbed with galvanized steel shimsonly.See Standard Plate 8129 for additional requirements.Figure 16-11: Ground Lug WireConnectorFigure 16-12: Pedestal Screw-inSteel FoundationFigure 16-14: Pedestal ConcreteFoundationFigure 16-13: Galvanized Steel ShimsSignal and Light Poles16-5

SIGNALS AND LIGHTING FIELD GUIDEThe access door of the base must be oriented away from trafficto allow maintenance personnel to see the intersection whileservicing the base.As shown in Figure 16-16, pedestal caps must be either steel oranodized cast aluminum based on the material of the pedestalshaft. The pedestal cap must be the same color as the pedestalshaftFigure 16-15: Access Door OrientationFigure 16-16: Pedestal Cap16.2 Light PolesMnDOT light poles:1. Must be in accordance with MnDOT 3811 and the current edition of AASHTO StandardSpecifications of Structural Supports for Highway Signs, Luminaires, and Traffic Signals.2. If providing breakaway poles, the poles must be certified from the manufacturer that thepole meets specifications as specified in the current edition of AASHTO StandardSpecifications of Structural Supports for Highway Signs, Luminaires, and Traffic Signals.3. Must have a nominal 2 3/8-inch schedule 40 tenon for slip fit luminaire installation.4. Davit or mast arm must have an upward angle from horizontal of 3 degrees /- 2 degrees.There are several of types of light poles MnDOT uses. The most common types of poles used onMnDOT lighting systems are: Stainless steel 40-foot and 49-foot breakawayAluminum alloy 40-foot and 49-foot breakawayCoated (galvanized) steel bridge and barrier 40-foot and 49-foot nominal height nonbreakawayHigh mast light towersSignal and Light Poles16-6

SIGNALS AND LIGHTING FIELD GUIDE16.2.1 DEFINITION AND OVERVIEWA lighting unit is defined as follows:A lighting unit includes the light pole, internal wiring with fuse holder and fuse to the luminaire,above ground splices, wire holder, stainless steel woven wire cloth, and luminaire. Underpassluminaires are lighting units even though they do not include some of these components. Thefoundation is not considered as part of this definition.The type of light pole required for each project will be shown in contract documents.Light poles that are specified by MnDOT are fabricated from stainless steel, high strength steel,or aluminum.Light poles fabricated from aluminum must have a factory installed vibration dampener.Light poles must be fabricated in accordance with MnDOT 3811.Within 15 days after the contract approval notice mailing date, the contractor must furnishevidence to the engineer, in writing, that orders have been placed for all components of thelighting units required for the project.The contractor must submit to the engineer, for approval by the district’s traffic engineer, sets ofprints of required shop detail drawings of the light poles and anchor rods, in accordance with2471.3.B. For high mast lighting installations, the contractor must submit final reproducibledrawings in accordance with 2471.3.B. The drawings must be distributed after approval, to thefollowing:1.2.3.4.Contractor’s fabricatorContractorEngineerDistrict traffic engineerAll light poles must be approved before installation.The Engineer’s acceptance of shop drawings will not relieve the contractor of full responsibilityfor submission of complete and accurate drawings and for the accurate assembly and fitting ofall structural members.Signal and Light Poles16-7

SIGNALS AND LIGHTING FIELD GUIDE16.2.2 TYPES OF LIGHT POLESStainless Steel 40‐Foot and 50‐Foot BreakawayStainless Steel Pole: Slip fit high base 16 sided Typically single davit (6 feet - 12 feet) Mounts on Design E and H foundations Can be double davit in areas such as goresFigure16-17:BreakawayStainlessSteelAluminum Alloy 40‐Foot and 49‐Foot BreakawayAluminum Alloy Pole: Transformer base (bolt on) Typically single davit (6 feet - 12 feet) Mounts on Design E and H foundations Can be double davit in areas such as goresFigure 16-18: Aluminum Alloy BreakawaySignal and Light Poles16-8

SIGNALS AND LIGHTING FIELD GUIDEBridge and Barrier Poles 40‐Foot and 49‐Foot Galvanized steel Non-breakaway High base 6-bolt base plate Two access door assembly Single and double davit Mounted on barrier (center median and bridgebarrier foundations)Figure 16-19: Bridge and Barrier PolesHigh Mast Light Towers COR-TEN steel (weathering steel) High base design Typically 100 feet or 120 feet Typically ring assembly holds 3 to 4luminairesFigure 16-20: High Mast TowerSignal and Light Poles16-9

SIGNALS AND LIGHTING FIELD GUIDE16.3 Installation for Signal and Light Poles16.3.1 ANCHOR ROD CONSIDERATIONSThe anchor rod connection is a critical component of foundations and pole structures. Theprimary functions of anchor rod connections are to attach a pole to a foundation and safelytransmit loads from the pole into the foundation. Failure of anchor rod connections could leadto collapse of the pole. Therefore, it is imperative to follow the installation instructions andrequirements in accordance with the pole manufacturer, the current edition of AASHTO LRFDSpecifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals, andMnDOT contract documents.Lift and safely move poles without damage. Avoid abrasion during lifting operations. Do not dragthe poles on the ground and use natural or synthetic fiber slings and chokers for lifting. Protectthe pole finish from coming in direct contract with the ground surface and metal hardware usedfor lifting and rigging. Repair any finish surface damage in accordance with the manufacturer’srequirements.Before standing poles on foundations:1. Verify the anchor rod pattern matches the base plate hole pattern.2. Verify the required anchor rod grade by locating the steel die stamped gradeidentification on the end of the anchor rod projecting above the concrete.3. Verify anchor rods meet projections for a properly secured pole, and meet AASHTO stubheight requirements when breakaway is required.4. Verify anchor rods are clean, not damaged, and plumb.5. Verify nuts can be turned down on the anchor rods to the foundation and backed off byhand or by one worker using an ordinary wrench without a cheater bar.6. Verify the base plate opening accommodates conduits and ground rod electrodes.7. Ensure the pole is free of dirt or other foreign material, and8. Inspect poles for damage.As shown in Figure 16-21 and 16-22, clean and brushon an anti-seize and lubricating compound referred toas “bridge grease” to the exposed threads of allanchor rods (bolts) and nuts and the bearing surfaceof all nuts and washers just before installing signalservice cabinets, mast arm poles, pedestals, lightpoles, lighting service cabinets, or other types ofstructures on anchor rods.Figure 16-21: Apply Anti-Seize “Bridge Grease” toBearing SurfacesBearing surface means the plane of contact betweenthe washer and the nut or bolt head being turnedwhen tightening the anchor rod (bolt) connection. Upto 70% of the friction of an anchor rod connectioncomes from turning the nut against the washer.Signal and Light Poles16-10

SIGNALS AND LIGHTING FIELD GUIDEUse bridge grease on bearingsurfaces and threads of nuts andanchor rods to reduce frictionwhen tightening the connection.Ensure a clean work area toprevent dirt from contaminatingbridge grease on nuts, washers,and anchor rods. Contaminants willcause friction between the anchorrod and nut and therefore impedenut rotation to achieve propertightening of the connection.Clean anchor rods, nuts andwashers and re-apply bridgegrease if more than 24 hours haspassed since earlier application orthe anchor rods, nuts, or washershave become wet after applyingbridge grease.Figure 16-22: Apply Anti-Seize “Bridge Grease” to Bearing SurfacesInstallation ProceduresTo install anchor rods, use fixed-sized wrenches designed to tighten nuts on anchor rods such asopen-end wrenches, closed end or box end wrenches, combination wrenches, slugging wrenches,iron workers spud wrenches, or socket wrenches sized specifically for turning nuts. Do not usepipe wrenches and adjustable type wrenches for tightening anchor connections.Pipe wrenches are used in plumbing for gripping round cylindrical thingslike threaded pipe to tighten and loosen. Do not use pipe wrenches fortightening nuts on anchor rods.Figure 16-23: Do Not Use Pipe WrenchesSignal and Light Poles16-11

SIGNALS AND LIGHTING FIELD GUIDEAnchor Rod SecurementEnsure the top of the anchor rod extends at least one threadbeyond the top surface of the top nut. An anchor rod end insidethe top nut where no threads extend beyond the top surface ofthe nut and the top nut is not fully engaged on the anchor rod aftertightening is not acceptable.Place nuts, washers, and pole base plate on the anchor rods in theinstallation order required by the manufacturer and contractdocuments. Do not remove required nuts or washers from theconnection. Do not add extra washers or additional hardware tothe anchor rod connection.Figure 16-24: Insufficient Anchor RodProjectionMnDOT anchor rod connections used to attach stainless steel lightpoles and signal poles to foundations are a typical double-nutconnection. In this connection, there are top nuts and leveling nutsthat sandwich the base plate.Aluminum light poles and signal pedestal use a single-nutconnection may be used to attach the pole to the foundation. Inthis connection, the base plate rests directly on the foundation andtop nuts are used to tighten the anchor rod connections.Figure 16-25: Double-nut ConnectionUse the anchor rod connection required by the pole manufacturer.Follow the standoff distances required by the pole manufacturerwhen installing double-nut connections. If no standoff distance isprovided by the manufacturer, use the AASHTO recommendedstandoff distance of less than one bolt diameter. Standoff distanceis defined as the clear distance between the bottom of the levelingnut and the top of the concrete for double-nut anchor rodconnections.Figure 16-26: Single-nut ConnectionUse hardened flat washers under the nuts being turned fortightening in the anchor rod connection unless the manufacturer does notspecify it in their installation instructions. For example, the manufacturerfor the cast aluminum frangible transformer base does not require ahardened flat washer under the top nut being turned.Do not use lock washers in anchor bolt connections unless otherwiseindicated by the manufacturer.Tighten anchor rod connections to full tension as required by themanufacturer and the contract immediately following placement of thepole on its foundation.Signal and Light PolesFigure 16-27: StandoffDistance16-12

SIGNALS AND LIGHTING FIELD GUIDEDuring snug tightening and final tightening turn the nuts in a star tightening orcrisscross pattern and in at least two full tightening cycles (passes).AASHTO Standard Specifications for Structural Supports for Highway Signs,Luminaires, and Traffic Signals defines “snug tight” as the maximum nut rotationresulting from the full effort of one person on a 12-inch-long wrench or equivalent.MnDOT 2402.G.2.c(4) Turn-of-Nut Tightening defines “snug tight” as the minimaluse of an impact wrench or the full effort of an adult using an ordinary spud wrenchto bring all plies of the connection together in firm contact.Figure 16-28:Tightening AnchorRodsLoose anchor rod connections on traffic signal and light poles can significantly shorten the life ofthe overall structure (pole and foundation). Following the required anchor rod tighteningprocedure and construction inspection can help prevent loose anchor rod connections.16.3.2 TRAFFIC CONTROL SIGNAL MAST ARM POLEINSTALLATIONInstall traffic control signal mast arm poles in accordance withthe pole manufacturer requirements and the contract.There is a 1 inch lip or flange that overhangs on the mast armtransformer base. This 1 inch lip partially covers the levelingnuts. If the leveling nuts are set too low on the anchor rods awrench head will not fit between the top of the foundationand the bottom edge of the 1 inch lip for access to the levelingnut. A wrench must be applied to both the top nuts and theleveling nuts to ensure proper tightening of the anchor rodconnections.The manufacturer recommends a standoff distance of 3/8” to1/2”. If a wrench cannot be applied onto the leveling nuts setthe leveling nuts to the recommended standoff distance.Standoff distance is defined as the clear distance between thebottom of the leveling nut and the top of the concrete fordouble-nut anchor rod connections.Figure 16-29: Flange Overhang on BaseFollow 2565.3.Q for tightening anchor rod connections on traffic control signal mast arm poles.Figure 16-30: Recommended Standoff Distance Mast Arm Pole Transformer BaseSignal and Light Poles16-13

SIGNALS AND LIGHTING FIELD GUIDE16.3.3 ALUMINUM LIGHT POLE AND CAST ALUMINUM FRANGIBLE TRANSFORMER BASEINSTALLATIONInstall aluminum light poles with cast aluminum frangible transformer bases in accordance withthe pole and base manufacturer’s installation instructions and MnDOT Specification 2545.3.H.Use shims in accordance with Standard Plate 8129 under the base if leveling is required. Do notuse leveling nuts. The top nuts with the required 1/2-inch-thick washers sometimes called“holddown washers” are used to secure the base tightly to the foundation, bringing all the pliesof the connection together. This is called a single-nut connection as required by the polemanufacturer.As shown in Figure 16-4, this particular manufacturer posts the installation instructions on ayellow caution sticker affixed to the back inside wall of every base that is AASHTO approved fo

The PA pole is a 12-foot high taperedoctagonal pole shaft. There are three pole types; the PA 85, PA 90, and the PA 100. The tapered octagonal mast arm truss is attached to the top of the shaft. The mast armconsists of an upper and lower chord braced together to form a truss. The length of the mast arm trusses ranges

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