SECTION 800 -- TRAFFIC CONTROL DEVICES AND LIGHTING

SECTION 801 -- TRAFFIC CONTROLS FOR CONSTRUCTION AND

MAINTENANCE OPERATIONS
SECTION 802 -- GROUND MOUNTED SIGNS

SECTION 803 -- OVERHEAD SIGN STRUCTURES

SECTION 804 -- DELINEATORS

SECTION 805 -- TRAFFIC SIGNALS

SECTION 806 -- BLANK

SECTION 807 -- HIGHWAY ILLUMINATION

SECTION 808 -- PAVEMENT TRAFFIC MARKINGS

 SECTION 800 -- TRAFFIC CONTROL DEVICES AND LIGHTING

SECTION 801 -- TRAFFIC CONTROLS FOR CONSTRUCTION AND

MAINTENANCE OPERATIONS

801.01 Description.
Description. This work shall consist of furnishing, placing, and
maintaining signs, barricades, temporary pavement markings, and other traffic control
devices at construction and maintenance operations in accordance with 105.03.

MATERIALS

10 801.02 Materials.
Materials. Materials shall be in accordance with the following:

Construction Warning Lights ................................... 913.12

Delineator Posts .................................................. 910.15
Delineators ........................................................ 913.08
Field Paint......................................................... 909.04
Flashing Arrow Sign............................................. 913.13
Flexible Channelizer and Flexible Tubular Marker ......... 913.07.1
Flexible Delineator Posts........................................ 913.07
Pavement Marking Materials ................................... 913.14
20 Steel Posts ......................................................... 910.14
Temporary Highway Illumination Materials ................. 807
Temporary Panel Signs.......................................... 913.10(b)
Traffic Signal Materials and Equipment ...................... 913.15
Traffic Signs ...................................................... 802
Wood Sign Posts ................................................. 911.02(e)
Worksite Speed Limit Sign Assembly......................... 913.13.1

The background of construction signs shall be reflective sheeting in accordance

with 913.10(d)3, 913.10(d)5, or 913.10(d)6. The sheeting type used for construction
30 signs shall be the same for the entire project.

Steel sign posts need not be galvanized.

All temporary traffic control devices which will become the property of the
Department shall be a new product at the time of final acceptance.

574
 CONSTRUCTION REQUIREMENTS

801.03 General Requirements.

Requirements. The applicable requirements of the MUTCD
40 shall apply to the installation and materials for traffic control devices subject to the
requirements of 107.08 and 107.12. Effective January 1, 2001, a “Worksite Traffic
Supervisor” certified by the American Traffic Safety Service Association, ATSSA, or
approved equal certifying organization, shall be responsible for temporary traffic
control devices. The worksite traffic supervisor shall be responsible for the field layout,
placement, operation, maintenance, and removal of temporary traffic control devices. A
copy of the certification shall be provided to the Engineer prior to the start of
construction of temporary traffic control devices or if the worksite traffic supervisor
changes.

50 Regulatory control devices shall be erected only as directed.

Advisory speeds to be posted will be determined by the Department.

The names and telephone numbers of the superintendent and one other
responsible employee shall be furnished. Such employees shall be on call or available at
night, on weekends, or during other non-working periods to repair or replace all traffic
control devices which may become damaged or inoperative.

When traffic lanes are restricted and when specified as a pay item, a patroller
60 shall inspect and maintain traffic control devices. The patroller shall patrol the
construction zone and shall immediately correct, maintain, and repair traffic control
devices or notify the Contractor designated persons for immediate repair to such traffic
control devices. A full time patroller shall be on duty during periods when work is not
in progress.

Temporary traffic control devices shall be maintained continuously, except as

described herein, to ensure visibility and to protect the public. All reflective sheeting
backgrounds and lights shall be kept clean of foreign matter.

70 Except for construction warning lights and temporary signals, the ATSSA
brochure titled Quality Standards For Work Zone Traffic Control Devices will be used
as a guide to determine if temporary traffic control devices are Acceptable, Marginal,
or Unacceptable as defined in the brochure. Upon initial setup and phase changes of
temporary traffic control devices, all individual devices shall be of the Acceptable
classification. A device not completely covered or removed when the message does not
apply or when directed, will be considered unacceptable.

A temporary traffic control device will be deemed to be in non-compliance

when considered Unacceptable. A type of temporary traffic control device will be
80 deemed to be in non-compliance when 25 percent or more of the individual devices are
considered Marginal. Damages may be assessed in accordance with 105.14 for
non-compliance.

Non-compliance of construction warning lights will be in accordance with

801.12.

575
 All barricades, signs, or flashing arrow signs shall be moved from one location
and re-erected at another location as shown on the plans or as directed.

90 Temporary drainage structures, temporary concrete median barrier units, and

other temporary devices required and used for traffic maintenance shall remain the
property of the Contractor.

CONSTRUCTION REQUIREMENTS

801.04 Construction Signs.

Signs. Construction signs shall include the typical sign
standards or posts which support the sign, all necessary hardware, and specified
construction warning lights.

100 (a) Type A.

A. A type A sign shall consist of a construction sign as detailed in
the MUTCD or on the standard drawings which is 0.84 m2 (9 sq ft) or more in area.

(b) Type B.
B. A type B sign shall consist of a construction sign as detailed in
the MUTCD or on the standard drawings which is less than 0.84 m2 (9 sq ft) in area.

(c) Type C.
C. A type C sign shall consist of a construction sign which is not
detailed in the MUTCD or on the standard drawings and which is 0.84 m2 (9 sq ft) or
more but less than 3 m2 (33 sq ft) in area.

110 (d) Type D.

D. A type D sign shall consist of a construction sign which is not
detailed in the MUTCD or on the standard drawings and which is less than 0.84 m2
(9 sq ft) in area.

(e) Temporary Panel Sign.

Sign. A temporary panel sign shall consist of a sign
fabricated and constructed in accordance with 913.10(b) and which is greater than 3 m2
(33 sq ft). Temporary panel signs shall be mounted on treated wood posts as shown on
the plans and approved by the Department.

A route or lane closure notice sign shall consist of a construction sign type A
120 which indicates route or lane closure. The sign shall be mounted for a maximum of 14
calendar days and a minimum of seven calendar days before the closure date shown on
the sign. The sign shall be removed when the route or lane is closed.

Trailers in accordance with 910.14(f) may be used as supports for portable

construction signs. The trailer shall be located to hold the sign in a proper position. The
position of the tongue shall be so as to cause no hazard to traffic. Wheel chocks other
than sandbags shall not be used. The tongue may be pinned to reduce wind-induced
rolling if designed to pull up or break from vehicle impact. During nonworking hours,
trailers with signs that do not apply to existing conditions shall be stored in accordance
130 with 107.08(c).

576
 Sign posts and their foundations shall be located and constructed to hold signs in
a proper position; to resist swaying, turning, or displacement; and minimize the hazard
to motorists. No rigidly fixed sign supports will be permitted in exposed areas where it
would be practicable to utilize a breakaway or yielding type design. Signs shall be
completely covered or removed when the message does not apply.

If the work on a project, or a portion thereof, is not active, and the roadway is
open to unrestricted traffic, construction signs may be removed until work resumes.
140 Removal of such signs shall not relieve the Contractor of responsibilities or liabilities
described elsewhere herein.

801.05 Detour Route Marker Assembly.

Assembly. Detour route marker assemblies shall
be on a single post for a single route or may be on multiple posts for multiple routes.
When two routes are being detoured across a common roadway, each route shall be
shown by a separate detour route marker assembly. A detour route marker assembly-
multiple route shall be used for three or more routes across a common roadway.

801.06 Road Closure Sign Assembly.

Assembly. Road closure sign assemblies shall be
150 used at each road closure location where type III-A barricades or type III-B barricades
are used. Road closure sign assemblies shall not be used within lane closures where
adjacent lanes remain open to traffic, unless otherwise directed. Road closure sign
assemblies may be required at other locations as directed.

Permanent road closure sign assemblies shall be left in place after the contract is
completed and shall become the property of the Department. They shall be installed just
prior to final acceptance of the contract. Supports shall be painted with white field paint
for wood.

160 801.07 Barricades.

Barricades. Barricades shall include rails, posts, and all incidentals
necessary to complete this part of the work.

High intensity reflective sheeting shall be placed on specified rails of all

barricades. The colors for temporary barricades shall be orange and white, and for
permanent barricades red and white.

All type III barricades shall be skid mounted within pavement, shoulder, or
sidewalk areas, and on ground mounted posts in all other areas. Type III barricades
shall be used on all slopes which are 3:1 or flatter for roadway closures.
170
(a) Type III-A
III-A Barricade.
Barricade. The type III-A barricade shall have rails which are
reflectorized on one side and shall be used for roadway closures and lane closures
where traffic can approach from only one side.

(b) Type III-B

III-B Barricade.
Barricade. Type III-B barricades shall have rails which are
reflectorized on both sides and shall be used for roadway closures and lane closures
where traffic can approach the barricade from both sides.

(c) Permanent Type III Barricade.

Barricade. Permanent type III barricades shall be 3.6
180 m (12 ft) sections and shall be left in place after the contract is completed, and shall

577
 become the property of the Department. Permanent type III barricades shall be installed
just prior to final acceptance of the contract. All non-reflectorized wood and non-
galvanized steel shall be painted with white field paint. Such barricades shall otherwise
be in accordance with 801.07(a).

801.08 Cones, Flexible Channelizers, and Tubular Markers.

Markers. Cones shall be
made of a material to withstand impact without damage to striking vehicles. They shall
have a substantial base to restrict overturning. Cones and tubular markers shall be as
shown on the plans.
190
Cones shall be used only during temporary activities where portability is
advantageous and they remain in place and do not create a hazard to traffic. The use of
cones in lieu of drums will be permitted during daylight hours unless otherwise
directed.

Flexible channelizers and tubular markers shall be used in combination for

separating two-lane two-way traffic as shown on the plans or as directed. Flexible
channelizers or tubular markers shall be reflectorized with flexible encapsulated lens
reflective sheeting.
200
Cones, flexible channelizers, and tubular markers shall be secured in place
either by weighting or adhesives. The use of metal bases will not be permitted.

801.09 Drums.
Drums. Drums shall be molded orange polyethylene.

The shape of the drum shall appear basically cylindrical to the motorist from
any direction in any given application. The top outside diameter shall not exceed the
bottom outside diameter. Drums shall be multisided, elliptical or have a flattened side
to inhibit rolling.
210
The top section of the drum shall have at least one construction warning light
mounting bracket. The minimum drum height is exclusive of lifting handles or
construction warning light mounting brackets.

The drums shall stand on end, be stable against overturning, and shall be
internally or externally ballasted to resist wind speeds of up to 80 km/h (50 mph) and
gusts created by traffic. The mass (weight) of the ballast shall be 20-25 kg (45-55 lb).
The top of the drum shall be free from openings. Internally ballasted and externally
collar ballasted drums shall not be mixed in each continuous set-up.
220
Internal ballast shall be sandbags, a molded plastic base filled with sand and
closed with a locking cover, or a solid rubber base. The internal ballast shall be placed
in the lower ¼ of the drum. The ballast device shall be self-draining.

The external ballast shall be two rubber tire base collars. The tire base collars
shall have a circumferential contact with the road surface. The maximum diameter of
the tire base collar shall not exceed 900 mm (36 in.). The height of two tire base collars
at the outside edge shall not exceed 125 mm (5 in.). The rubber ballasting collars shall
be clean cut, proper in size, black in color, and not curved up at the edges. The interior

578
230 and exterior circumference of the collar shall not be slit or cut. Drums which are
external collar ballasted shall not be used in situations where the width of the collar
interferes with proper placement of the drum. The Department's Guidelines for
External Ballast will be used for determining acceptability of rubber tire base collars.

Upon impact by a vehicle traveling at a speed of 90 km/h (55 mph), the drum
and ballast device shall be of a type that permits the body of the drum to separate from
the base, thus allowing vehicles to easily pass over the base.

Flexible encapsulated lens reflective sheeting shall be used to achieve

240 reflectorization. Construction warning lights shall be used in accordance with 801.12
and as shown on the plans and shall be securely fastened to the mounting brackets.
Signs shall not be mounted on drums.

Permanent drums shall be left in place after the contract is complete, and shall
become the property of the Department. They shall be installed just prior to final
acceptance of the contract.

801.10 Temporary Pavement Marking.

Marking. Temporary pavement markings shall be
in accordance with 808.04 and 808.05. However, the dashed line pattern used on center
250 line and lane lines may be 1.2 m (4 ft) line segments on 12 m (40 ft) centers. Gore
areas shall be marked by outline only and may be 125 mm (5 in.) wide lines. All
temporary markings shall be maintained and replaced until they are no longer
applicable.

Where temporary pavement markings are to be placed on a pavement which has

existing markings, the existing markings which conflict with the temporary markings
shall be removed in accordance with 808.09.

When working under traffic, the temporary pavement markings shall be placed
260 before opening the lane to traffic. This shall include, but not be limited to, the marking
patterns of gore areas, outside edge line of deceleration and acceleration lanes, narrow
bridge markings, lane reduction transitions, lane lines, centerlines, and transverse
markings as appropriate.

If a pavement course is to be in place for a period greater than 14 calendar days,

all temporary pavement markings shall be placed in accordance with 808.04 and stop
lines shall be placed in accordance with 808.05. No-passing zones on all undivided two-
way roadways shall be identified with signs and centerline markings.

270 If the temporary pavement markings are to be in service from December 1

through the following March 31, such markings shall be placed in the standard
pavement marking pattern and applied prior to the suspension of the work, or within
seven work days after the Contractor is directed to place the markings.

579
 The prismatic reflectors shall be removed from snowplowable raised pavement
markers which conflict with the temporary traffic marking pattern. Snowplowable
raised pavement marker castings damaged by the removal of the reflector shall be
replaced in accordance with 808.10. New prismatic reflectors shall be mounted on
existing castings in accordance with 808.10 when the final traffic pattern is established.
280
Removal of temporary pavement markings shall be in accordance with 808.09.

(a) Temporary Pavement Marking Methods.

Methods. Pavement markings shall be
installed in accordance with 808.06.

1. Temporary Pavement Marking Tape.Tape. Temporary pavement marking

tape shall be applied in accordance with the manufacturer’s recommendations.
Temporary marking tape shall be new type I or type II material.

290 All temporary pavement marking tape shall be removed prior to placement of an
HMA overlay or final pavement markings.

a. Type I.I. Type I tape is a removable material. It may be used for

longitudinal and transverse markings. It shall be used for longitudinal and transverse
markings on the final surface.

Type I tape shall be removed without the use of solvents, grinding, abrasive
blasting, or other methods which may damage the pavement. All visible adhesive
residue shall be removed without use of solvents or grinding.
300
b. Type II.II. Type II tape is a non-removable material. It may be used
on PCCP to be removed or overlaid with an HMA course greater than 60 kg/m2
(110 lb/sq yd). If it is placed on HMA pavement, the tape shall be removed prior to the
recycling of the HMA material.

If it is necessary to remove type II tape, it shall be removed without the use of

solvents. All damage to the pavement shall be repaired.

2. Temporary Raised Pavement Marker.

Marker. The temporary raised pavement
310 marker shall be grade 1 or grade 2. When used, it shall be a supplement to other
temporary pavement markings. The color of the reflector shall be in accordance with
the other temporary pavement marking. The color of the shell of the grade 1 marker
shall be in accordance with the color of the other temporary pavement marking.

Temporary raised pavement markers shall be removed before the next layer of
pavement is placed and before the final pavement markings are applied. All damage to
the pavement shall be repaired.

3. Temporary Buzz Strips.

Strips. Temporary buzz strips shall be a set of
320 transverse markings. Durable marking material shall be used in accordance with
808.06(b). Temporary buzz strips shall be removed in accordance with 808.09 when no
longer required or as directed.

580
 (b) Quality Assurance Unit.
Unit. A quality assurance unit for longitudinal line
shall be 150 m (500 lft) on marked pavement in any combination or pattern, or portion
thereof. A quality assurance unit for transverse marking shall be each. If a marking
fails to be in accordance with the marginal standard as defined in the ATSSA Quality
Standards for Work Zone Traffic Control Devices, the quality assurance assessment
will be assessed in accordance with 801.03.
330
801.11 Temporary Illumination.
Illumination. The temporary highway illumination shall be in
accordance with applicable requirements of 807 except as modified herein.

The electric energy necessary to power the luminaires on a continuous basis is

the responsibility of the Contractor.

At completion of the contract work, the temporary illumination shall be

removed and shall remain the property of the Contractor. After removal of the
temporary illumination equipment, all holes and trenches shall be backfilled with B
340 borrow.

801.12 Construction Warning Lights.

Lights. Construction warning lights shall be
portable, lens directed, enclosed lights that emit an amber color. All warning lights
shall be mounted a minimum of 900 mm (36 in.) above the traveled way to the bottom
of the lens, unless otherwise directed. Lights not working shall be repaired or replaced
immediately. For each day that more than 5% of the required warning lights are not
operating, a sum equal to $4.00 per non-working light will be deducted from the
monies due the Contractor.

350 (a) Type A.

A. Type A lights shall be low intensity flashing warning lights
which are mounted on drums, vertical panels, or on specified construction warning
signs. These lights shall be visible on a clear night from a minimum distance of 900 m
(3,000 ft) when there is no external illumination directly on or in the immediate vicinity
of the light. They shall operate from dusk to dawn or when conditions exist which tend
to obscure vision. Traffic control devices used for maintaining traffic will not require
Type A warning lights during unobscured daylight hours.

(b) Type B.
B. Type B lights shall be high intensity, flashing, warning lights,
which are mounted on all road closure sign assemblies or as shown on the plans. These
360 lights shall be visible on a sunny day from a minimum distance of 300 m (1,000 ft)
when viewed without the sun directly on or behind the light.

(c) Type C.
C. Type C lights shall be steady burning warning lights which shall
be used with channelization devices. These lights shall be visible on a clear night from
a minimum distance of 900 m (3,000 ft) when there is no external illumination directly
on or in the immediate vicinity of the light. They shall operate from dusk to dawn or
when conditions exist which tend to obscure vision.

(d) Vehicle Warning Lights.

Lights. Vehicle warning lights shall be amber and shall
370 be a strobe light or a flashing, oscillating, or rotating directed beam light. They shall be
visible to all approaching traffic for a distance of 300 m (1,000 ft).

581
 801.13. Electronic Devices.
Devices.

(a) Flashing Arrow Sign.

Sign. Where specified, a flashing arrow sign shall be
furnished, installed, and maintained. It shall be operated continuously, when necessary,
to divert traffic.

The flashing arrow sign may be of the solar power assisted type only in
380 stationary operations when the horizontal or vertical curvature in the road is such that
motorists do not drive into and out of the beam width of the lighted arrow while within
sight of the sign.

(b) Changeable Message Signs.

Signs. This shall consist of furnishing, installing,
and maintaining a trailer-mounted, portable sign upon which varying electronically
generated messages will be displayed to traffic.

A malfunctioning sign shall be repaired or replaced within 24 h.

390 (c) Temporary Worksite Speed Limit Sign Assembly.

Assembly. This shall consist of
furnishing and placing portable speed limit signs as shown on the plans or as directed in
areas of work activity. The worksite speed limit flashing lights shall be activated when
the worksite speed limit is in effect. This shall be only where and while work is actually
in progress, and workers are present.

The worksite speed limit shall not be used for the entire length of a roadway
under construction unless there is actual work activity for the entire length of such
roadway. It shall not be activated at the beginning of the day, for the entire day, if
actual work is not being done all day in the work area.
400
The worksite speed zone signage shall be placed and maintained by the
Contractor. The worksite speed limit will be 45 mph, or 10 mph below the posted
speed limit for the roadway under construction, whichever is lower.

A worksite “Reduced Speed Ahead” sign shall be placed in advance of the first
sign assembly when the reduction in speed limit is greater than 15 mph.

(d) Temporary Traffic Signals.

Signals. This work shall consist of furnishing,
installing, and maintaining temporary traffic signals in accordance with 805 except as
410 modified herein.

Except as shown on the plans, all materials not furnished by the Department
shall remain the property of the Contractor after work is completed and the equipment
is removed.

The traffic signal equipment shall be as specified, but may be either new or
used. Used equipment shall be in satisfactory working condition and will be approved
prior to use.

582
420 Two signal heads shall be displayed for each approach. Signals shall be
displayed overhead on a span, catenary, and tether utilizing an aircraft cable, unless
otherwise directed.

Electric energy necessary to power the temporary signal is the responsibility of

the Contractor. Prior to the start of construction, the schedule of activities shall be
coordinated with the power company.

The Contractor shall obtain permits from local officials, companies, or

individuals for the use of poles, right-of-way, or other property incidental to the
430 installation of temporary signals. Although entering into the contract implies permission
and authority to install conduit under pavement, sidewalks, and alleys, all damage to
underground utilities or interruption of such service shall be the responsibility of the
Contractor.

The location, spacing, and timing of signals will be determined by the Engineer.

An IMSA certified level II technician shall be available 24 h a day to respond

within 2 h for the maintenance of the traffic signal equipment.

440 Signal cable may be extended across bridges through conduit which shall be
attached to the underside of the coping. Type and spacing of clamps shall be approved
prior to installation.

Conduit shall be steel or plastic. Flexible conduit will be an acceptable alternate

for use as ground rod entry, magnetometer, or microloop installations.

The controller shall be solid state digital. When detection is required, the
controller shall be traffic actuated solid state, digital.

450 Vehicle detection, if required, shall be installed as shown on the plans or as

otherwise directed and shall be operational prior to signal activation.

801.14 Temporary Traffic Control Zone.

Zone. A temporary traffic control zone is a
work zone with frequently changing operation, a maximum duration of seven calendar
days; mobile operation; or a temporary traffic stoppage.

(a) Temporary Traffic Control Signs.Signs. Temporary traffic control signs

(TTCS) are construction signs in a temporary traffic control zone.

460 Trailer mounted TTCS shall be positioned such that the tongue and the method
of pinning shall minimize the hazard to motorists. Wheel chocks other than sandbags
shall not be used. During non-working hours, trailers with signs that do not apply to
existing conditions shall be stored in accordance with 107.08.

583
 TTCS shall not be mounted on barricades or other non-approved supports.
When the vertical mounting height for TTCS is between 300 mm and 450 mm (12 in.
and 18 in.) to the bottom of the sign, tripod supports may be used. When permitted for
use, the signs on tripod supports shall be installed so that the angle from vertical does
not exceed 30 degrees.
470
(b) Maintenance of Traffic for Mobile Operations.
Operations. Signs, flagging, flashing
arrow signs, and other required traffic control devices shall be furnished in accordance
with the details shown on the plans or as directed. The Engineer reserves the right to
stop work at any time to relieve traffic congestion.

(c) Traffic Control for Temporary Traffic Stoppage.

Stoppage. Traffic shall not be
permitted to pass directly beneath personnel or equipment working on an overhead
structure. Traffic stoppage during an overhead operation shall not exceed 20 min at one
time. There shall be enough time between consecutive stoppages to permit traffic to
480 return to normal flow.

Three working days prior to commencing work which necessitates temporary

stoppage of traffic, written notice shall be given to the Department and the Indiana State
Police that highway traffic shall be stopped temporarily at a specific location, time, and
date to accomplish specified work. Traffic shall be safely controlled during the
stoppage. The following minimum requirements shall be met.

1. On Multi-Lane
Multi-Lane Divided Highways.
Highways. Advance warning signs shall be
located as specified or as otherwise directed. For each direction of road closure two
490 flaggers shall be located at the site of the work and a minimum of two additional
flaggers shall be used to warn approaching traffic.

2. On Non-Divided
Non-Divided Highways.
Highways. Advance warning signs shall be located
as specified or as otherwise directed. For each direction of road closure, one flagger
shall be located at the site of the work and a minimum of one additional flagger shall be
used to warn approaching traffic.

801.15 Method of Measurement.

Measurement. Construction signs, detour route marker
assemblies, detour route marker assemblies-multiple routes, temporary worksite speed
500 limit sign assemblies, road closure sign assemblies, temporary changeable message
signs, and temporary raised pavement markers will be measured by the number of units
installed, maintained, and removed.

Temporary panel signs will be measured by the square meter (square foot).
Temporary panel sign supports, when required, will be measured by the meter (linear
foot), complete and in place.

Type III-A and type III-B barricades will be measured by the number of units
determined by dividing the total length of barricade installed, maintained, and removed
510 by 3.6 m (12 ft) sections. Permanent type III barricades will be measured by the
number of 3.6 m (12 ft) sections installed.

584
 Flashing arrow signs will be measured by the number of calendar days each unit
is operated.

Patroller will be measured by the number of calendar days during the phase or
phases of traffic control, as shown on the plans or as otherwise directed, that require
the patroller's presence. Each portion of a day will be measured as a whole day.

520 Temporary pavement markings will be measured by the meter (linear foot) of
material actually placed. Temporary buzz strips will be measured by the meter (linear
foot) for each strip, without regard to the number of passes required to attain the
specified height.

If, due to a Department initiated change or an approved expedited construction

schedule, it is necessary to remove temporary nonremovable pavement markings, such
removal will be measured in accordance with 808.11. The removal of existing
pavement markings which are in conflict with temporary markings, will be measured in
accordance with 808.11.
530
The removal and replacement of reflectors on existing snowplowable raised
pavement markers will be measured in accordance with 808.11.

Cones, flexible channelizers, and tubular markers will not be measured for
payment. Permanent tubular markers and flexible channelizers will be measured per
each.

Temporary illumination, temporary traffic signals, and maintaining traffic will

not be measured for payment.
540
801.16 Basis of Payment.
Payment. The accepted quantities of construction signs, detour
route marker assemblies, detour route marker assemblies-multiple routes, temporary
worksite speed limit sign assemblies, road closure sign assemblies, and temporary
raised pavement markers will be paid for at the contract unit price per each. Payment
for temporary worksite speed limit assemblies and temporary changeable message signs
will be made for the maximum number of such assemblies in place during the contract
time. Type III-A, type III-B, and permanent type III barricades will be paid for at the
contract unit price per each 3.6 m (12 ft) section.

550 If more than one construction sign is mounted on a common support with the
messages facing opposite directions, the largest sign will be paid for at the contract unit
price of the sign, and each additional sign will be paid for at one half the unit price of
the sign if it had been erected independently.

Temporary panel signs will be paid for at the contract unit price per square
meter (square foot) as shown on the plans. Temporary panel sign supports will be paid
for at the contract unit price per meter (linear foot), complete and in place.

Flashing arrow signs and patrollers will be paid for at the contract unit price per
560 day per each.

585
 Temporary pavement markings and temporary buzz strips, will be paid for at
the contract unit price per meter (linear foot) of material, complete in place, except as
set out below.

Permanent tubular markers and flexible channelizers will be paid for at the
contract unit price per each.

The removal of temporary nonremovable pavement markings caused by a

570 Department initiated change or an approved expedited construction schedule, and the
removal of existing pavement markings which are in conflict with temporary markings
will be paid for in accordance with 808.12.

The removal and replacement of reflectors on existing snowplowable raised

pavement markers will be paid for in accordance with 808.12.

Temporary illumination will be paid for at the contract lump sum price.

All traffic control devices and construction materials which are specified as
580 separate pay items and used for maintenance of traffic will be paid for as set out in the
Schedule of Pay Items.

The furnishing, placing, moving, removal, and maintenance of all other traffic
control devices will be paid for at the contract lump sum price for maintaining traffic.

The accepted temporary traffic signal, complete in place and later removed as
specified, will be paid for at the contract lump sum price.

Payment will be made under:

590
Pay Item Metric Pay Unit Symbol (English Pay Unit Symbol)
Metric Pay Item Metric Pay Unit Symbol
(English Pay Item English Pay Unit Symbol)

Barricade, _____ ............................................................... EACH

type
Barricade, III, Permanent ..................................................... EACH
Construction Sign, _____ ..................................................... EACH
type
600 Detour Route Marker Assembly ............................................. EACH
Detour Route Marker Assembly, Multiple Routes ........................ EACH
Drum, Permanent .............................................................. EACH
Flashing Arrow Sign.............................................................DAY
Flexible Channelizer, Permanent ............................................ EACH
Maintaining Traffic .................................................................LS
Patroller .........................................................................DAY
Road Closure Sign Assembly................................................. EACH
Road Closure Sign Assembly, Permanent .................................. EACH
Temporary Buzz Strips ......................................................m (LFT)
610 Temporary Changeable Message Sign ...................................... EACH

586
 Temporary Illumination ............................................................LS
Temporary Panel Signs.................................................... m2 (SFT)
Temporary Panel Sign Supports............................................m (LFT)
Temporary Pavement Marking, ______ mm .....................................m
width
(Temporary Pavement Marking, ______ in. .................................LFT)
width
Temporary Pavement Marking, Removable, _____mm ........................m
width
620 (Temporary Pavement Marking, Removable, _____in. ....................LFT)
width
Temporary Pavement Message Marking, ______ ......................... EACH
description
Temporary Pavement Message Marking, Removable, _____ ........... EACH
description
Temporary Raised Pavement Marker, _______ ........................... EACH
grade
Temporary Traffic Signal ..........................................................LS
Temporary Traffic Signal with Detectors........................................LS
630 Temporary Transverse Pavement Marking, _____mm .........................m
width
(Temporary Transverse Pavement Marking, _____in.......................LFT)
width
Temporary Transverse Pavement Marking, Removable, _____mm ..........m
width
(Temporary Transverse Pavement Marking, Removable, _____in. ......LFT)
width
Temporary Worksite Speed Limit Sign Assembly......................... EACH
Tubular Marker, Permanent .................................................. EACH
640
The cost of furnishing, installing, maintaining, and subsequent removal shall be
included in the cost of temporary raised pavement marker.

The cost of cleaning existing pavement and removal of buzz strips shall be
included in the cost of buzz strips. Damage to the pavement caused by removal of buzz
strips and temporary pavement markings shall be repaired as directed with no additional
payment.

No payment will be made for temporary pavement markings which are in the
650 standard pavement marking pattern, and which are to be in service from December 1
through the following March 31 due to the Contractor's failure to complete the work as
scheduled. However, payment will be made for these markings should the failure to
complete the work as scheduled be due to conditions beyond the Contractor's control.

The cost of the second application of temporary painted lines on new HMA
courses shall be included in the costs of temporary pavement markings.

The cost of furnishing, installing, maintaining, and subsequent removal of the

detour marker, route marker, or street or road name sign, cardinal directional marker,

587
660 directional arrow marker, posts which support the assembly, and all necessary
hardware shall be included in the cost of detour route marker assembly or detour route
marker assembly, multiple routes.

The cost of installing, maintaining, and subsequent removal of signs, type B

construction warning lights, assembly supports, and all necessary hardware shall be
included in the cost of road closure sign assembly.

The cost of furnishing all materials, erection, maintenance, removal, and

necessary incidentals shall be included in the costs of barricades.
670
Each construction sign, barricade, temporary worksite speed limit sign
assembly, temporary changeable message sign, or flashing arrow sign will be paid for
only once regardless of how many times each is moved, replaced, or how many times
each is altered to change the sign message. Payment will not be made for signs or
barricades used for the convenience of the Contractor.

If a temporary worksite speed limit sign assembly is not flashing when required
beginning 2 h after notification, or if such assembly is flashing when no work has been
taking place for 2 h or longer, $200.00 will be deducted from payment for such work
680 for each 4 h period after the Contractor is informed that such assembly is not
functioning properly.

If the Contractor elects to use more than two simultaneous operations during the
installation of snowplowable pavement markers or reflectors, the costs of required
traffic protection devices for additional operations shall be included in the cost of
maintaining traffic.

The cost of necessary flaggers; protection of traffic at structure foundations; and

furnishing, erecting, placing, maintaining, relocating, and removing lights, cones,
690 flexible channelizers, tubular markers, drums, delineators, temporary pavement
markings, or other devices as directed shall be included in the cost of maintaining
traffic.

Replacement of snowplowable raised pavement marker castings damaged due to

removing reflectors will not be paid for.

The cost of furnishing and placing cones or tubular markers in accordance with
801.08 and drums in accordance with 801.10, the watcher in accordance with 107.12,
repair or replacement of damaged or inoperative traffic control devices, and traffic
700 maintenance in accordance with 108.03 shall be included in the cost of maintaining
traffic.

Electric energy necessary to power luminaires and temporary traffic signals will
not be paid for.

588
 SECTION 802 -- GROUND MOUNTED SIGNS

802.01 Description.
Description. This work shall consist of furnishing the material for and
erecting traffic signs in accordance with these specifications and in reasonably close
conformance with the lines, grades, and locations shown on the plans. Signs shall be
installed as required unless written approval is obtained from the District Traffic
Engineer to make modifications at specific locations.

All signs shall be transported and stored in an upright fashion. Each sheet sign
10 face shall have the plastic side of the slip sheeting placed against it during transport and
storage. Microfoam padding shall be in place between signs with high intensity
sheeting. Panel signs shall be transported and stored in shipping containers so that the
faces do not touch anything. Signs shall be stored in such a manner that they are not on
the ground nor come in contact with surface run-off water. Signs shall be stored so that
moisture accumulation or heat build-up does not occur.

All signs shall be marked for identification. The marking shall consist of a
pressure sensitive material shown on the Department Approved Materials List, and
shall be applied to the back of the sign. The identifying message shall consist of
20 INDOT and the month and year the sign is installed. The message copy shall consist of
black lettering of a minimum of 25 mm (1 in.) in height. The marking background shall
be white. The marking for sheet signs shall be placed in the lower corner closest to the
center-line of the road. The marking for panel signs shall be placed on the bottom panel
on the end closest to the centerline of the roadway. The marking shall not be covered
by the sign's supports after installation of the sign.

MATERIALS

802.02 Materials.
Materials. Materials shall be in accordance with the following:
30
Paint and Enamel................................................. 909
Reinforcing Steel ................................................. 910.01
Sign Posts ......................................................... 910.14, 911.02(e)
Traffic Signs ...................................................... 913.10

Concrete shall be in accordance with 702, class A or B, or for packaged dry

concrete in accordance with 913.17.

CONSTRUCTION REQUIREMENTS
40
802.03 Location of Signs.
Signs. The location of each sign will be established
longitudinally and each location will be marked with the number of the respective sign,
either by a stake or by painting on the pavement. The locations of the sign supports
shall be staked, and the Engineer, who will either approve the locations or make
necessary changes, shall be informed. Sheet signs and posts shall not be ordered until
the exact number of signs and length of each post has been determined upon a field
investigation.

589
 The break-away stubs shall be installed prior to ordering the posts. Final length
50 of the break-away posts shall be determined by using the elevation of the finished stub
installation.

When the staked locations have been approved, the stakes shall be replaced with
signs and all work completed. All signs shall be placed at the proper elevation, offset,
level, and be oriented correctly. If specular reflection is apparent in any sign, the sign
face shall be adjusted to eliminate this condition with no additional payment.

The cost of furnishing all stakes and of performing the layout as described above
shall be included in the contract prices for the various specified pay items. No less than
60 two days notice shall be provided in advance of the time when staking or inspection is
required. Each request for staking or other engineering services required as above
described shall, except in emergency, cover sufficient work for no less than one full
day of the force needed for the work.

802.04 Excavation.
Excavation. Necessary excavation for sign installation shall be
completed to the levels and dimensions shown on the plans or as directed. Excavations
may be accomplished either manually or mechanically, but in no way shall the finished
pavement or shoulder section be damaged during such excavation. All material shall be
removed to the full depth as shown on the plans, except if class X material is
70 encountered during excavation, the work shall be performed in accordance with
206.02(b). All excavated material that is not needed to backfill and level the disturbed
area within 24 h after completion of the work shall be removed from the site.

802.05 Installing Posts and Signs.

Signs. Posts shall be as shown on the plans, firm in
the ground, and set at the required line and grade. Any post which is not acceptable
shall be removed and redriven. Posts shall be placed vertically and signs, when
attached, shall be aligned accurately.

The excavation for sign posts shall be made as nearly to neat lines as possible
80 and all parts of the sign post encasement poured against the soil or rock face without
forming, except in sandy soil, or as directed or permitted.

If forms for encasement are used, they shall not be removed in less than 18 h
after the concrete is poured. The backfill around the foundations shall be placed in 150
mm (6 in.) layers and each layer tamped. Posts set in concrete shall be held in proper
position during encasing and backfilling operations. Exposed concrete shall have a
smooth surface finished to the slope shown on the plans. Edges shall be beveled as
specified.

90 Flanged channel posts, when specified to be driven, may be driven by hand or

mechanical devices to the required line and grade and shall be approximately plumb.
During driving, posts shall be protected by a special driving cap. Any post bent or
otherwise damaged so as to be unfit for use in the finished work shall be removed from
the site and replaced with an acceptable post with no additional payment.

Square sign posts shall be as shown on the plans. Sign post foundations shall be
reinforced anchor base or unreinforced anchor base as shown on the plans. If sign post

590
 type A or sign post type B is specified, square sign posts may be used in lieu of such
types as shown on the plans. Splicing of square steel sign posts will not be permitted
100 for permanent new installations on contract work.

Signs shall be installed as shown in the plans. The signs shall be fastened to the
posts by bolts, locknuts, and metal and plastic washers in accordance with 913.10(a).
The plastic washer shall be installed next to the sign face with the sheeting, and the flat
metal washer shall be installed next to it, and then the bolt installed. The bolt shall be
installed with the bolt head on the face of the sign and the locknut on the back of the
post. Locknut shall be tightened sufficiently so that the sign is held firmly against the
post. If there is any sign face twisting or damage, the sign shall be replaced.

110 802.06 Removal or Relocation of Signs or Support Assemblies.

Assemblies. All existing
signs directed to be relocated and are within 0.6 m (2 ft) of a paved shoulder shall be
removed. The signs to be relocated shall be installed on new posts and the edges of the
signs shall be placed a minimum of 1.8 m (6 ft) outside of the edge of the paved
shoulder, or as directed. The post type and length shall be as directed.

Signs or support assemblies not directed to be relocated shall be removed as

shown on the plans or as otherwise directed. Such signs or support assemblies shall be
removed within five work days after the required replacement signs or support
assemblies are installed. Concrete foundations for wide flange support assemblies shall
120 be removed to a minimum depth of 0.3 m (1 ft.) below the ground surface. Concrete
foundations for channel post support assemblies shall be completely removed. After
concrete foundations have been removed, the area shall be backfilled with clean fill,
seeded or sodded in accordance with 621, or treated with a material which matches that
in the surrounding area.

802.07 Remove and Reset Roadway and Bridge Reference Signs. Signs. If existing
roadway and bridge reference signs interfere with the prosecution of other work, such
signs and posts shall be removed as directed. They shall be stored in the location
directed. They shall then be reinstalled within 15 m (50 ft) of their original longitudinal
130 location or as directed.

If new signs are to be installed on existing structures, the existing mounting

hardware, if adaptable, may be reused. Additional new hardware may be required to
complete the mounting. All such sign hangers protruding above the new signs shall be
cut off flush to the top of the signs. Splicing or overlapping of sign hangers will not be
permitted. All unused sign hangers and hardware shall be removed.

802.08 Shop Drawings of Signs and Sign Structures. Structures. Unless otherwise
specified, the Department will furnish two sets of shop drawings for panel and sheet
140 signs, except for the sheet signs illustrated in the Standard Highway Signs published by
the FHWA. Shop drawings for flanged channel posts and wide flanged posts will not be
required.

591
 802.09 Final Clean-Up
Clean-Up.. Before final acceptance, touching up of paint surfaces,
cleaning of exposed sign and support surfaces, leveling, and repair of the site as may be
necessary to ensure the effectiveness and neat appearance of the work shall be
performed.

802.10 Method of Measurement.

Measurement. Sheet signs and panel signs will be measured
150 by the square meter (square foot). Sheet signs will be measured as the smallest
dimensions of a square or rectangle large enough to make the sign. However, triangular
or trapezoidal signs will be measured as the smallest triangle or trapezoid required to
make the sign. If set out as pay items, letters, symbols, numbers, arrows, radii, or
accessories will be measured by the number of units of the sizes and types installed.
Sign borders will be measured by the meter (linear foot). Sign posts will be measured
by the meter (linear foot). Square sign posts will be measured from the top of the post
to the termination of the post in the anchor base as shown on the plans. Reinforcing
steel will be measured by the kilogram (pound) in accordance with 703.07. Concrete
foundations will be measured by the cubic meter (cubic yard) in accordance with
160 702.27. If class X material is encountered during foundation excavation, the quantity to
be measured will be that authorized and removed. No reduction will be made for
reinforcing steel, structural steel, or conduit. Structural steel will be measured by the
kilogram (pound). Such measurement will include the mass (weight) of breakaway
sections such as stubs, stiffeners, base plates, and fuse plates. For rigid sections, the
mass (weight) of the base plate will be included. Reference posts, including post, sign,
and hardware, will be measured by the number of units installed.

If the pay unit for sheet signs is shown in the Schedule of Pay Items as each, the
number of sheet signs specified, including posts, hardware, and erection, will be
170 measured by the number of units installed.

802.11 Basis of Payment.

Payment. The accepted quantities of sheet signs and panel signs
will be paid for at the contract unit price per square meter (square yard), for sign, sheet
or sign, panel as specified, of the type specified, with legend, of the thickness
specified, complete in place. Sign post will be paid for at the contract unit price per
meter (linear foot) for the type specified. Structural steel and reinforcing steel will be
paid for at the contract unit price per kilogram (pound). Concrete foundations will be
paid for at the contract unit price per cubic meter (cubic yard). Reference posts will be
paid for at the contract unit price per each, complete in place. If class X material is
180 encountered during a foundation excavation, payment will be made in accordance with
206.11(d).

The removal of signs, sign assemblies, supports, or concrete foundations will be

paid for at the contract unit price per each.

Payment will be made under:

592
 Metric Pay Item Metric Pay Unit Symbol
(English Pay Item English Pay Unit Symbol)
190 Pay Item Metric Pay Unit Symbol
Symbol (English Pay Unit Symbol)

Reference Post .................................................................. EACH

Reinforcing Steel, Sign Foundation....................................... kg (LBS)
Sign and Supports, Channel Post, Remove ................................. EACH
Sign and Supports, Wide Flange, Remove ................................. EACH
Sign Foundation, Concrete................................................m3 (CYS)
Sign, Overhead, Remove...................................................... EACH
Sign, Panel, _____, With Legend ....................................... m2 (SFT)
type
200 Sign Post, _____ .............................................................m (LFT)
type
Sign Post, Square, ______, Reinforced Anchor Base...................m (LFT)
type
Sign Post, Square, ______, Unreinforced Anchor Base ................m (LFT)
type
Structural Steel, Breakaway ............................................... kg (LBS)
Sign, Sheet, With Legend..................................................... EACH
Sign, Sheet, _____, With Legend, _________................................. m2
type thickness
210 (Sign, Sheet, _____, With Legend, _________.............................. SFT)
type thickness

The costs of all hardware necessary to assemble and attach the sign to its
structural supports, and all legend or copy if specified, shall be included in the cost of
sheet sign or panel sign.

The costs of all necessary hardware including sign hangers, clips, and U bolts
required for the mounting of signs to existing or new overhead sign structures shall be
included in the cost of the sign face.
220
The costs of the reinforced anchor base or unreinforced anchor base, angle
bolts, and rivets shall be included in the cost of sign post, square.

If new signs are to be installed on existing structures, the costs of cutting of

existing sign hangers to flush them to the tops of signs shall be included in the cost of
overhead sign removal. The cost of anchor bolts required for rigid post installation shall
be included in the cost of such posts. The costs of excavation, hauling, installation,
identification markings, and all necessary incidentals shall be included in the costs of
the pay items.
230
The costs of signs directed to be removed and relocated, including the sign
removal, existing post removal, all hardware necessary to attach the existing sign, and
existing sign installation shall be included in the cost of the new sign posts.

The cost of roadway and bridge reference signs and posts to be removed,
stored, and reinstalled shall be included in the costs of other pay items, unless

593
 otherwise specified. Roadway and bridge reference signs which are damaged by the
Contractor shall be replaced with no additional payment.

SECTION 803 -- OVERHEAD SIGN STRUCTURES

803.01 Description.
Description. This work shall consist of furnishing and erecting overhead
sign structures and sign lighting in accordance with these specifications and in
reasonably close conformance with the lines and grades and at locations shown on the
plans or as directed. Overhead sign structures are those which support signs over the
traveled way.

MATERIALS
10
803.02 Materials.
Materials. Materials shall be in accordance with the following:

Concrete, Class A, B, or C ..................................... 702

Overhead Sign Structures ....................................... 910.19
Reinforcing Steel ................................................. 910.01
Sign Lighting ..................................................... 913.11

CONSTRUCTION REQUIREMENTS

20 803.03 Shop Drawings.

Drawings. Prior to fabrication, six sets of shop drawings for all
overhead sign structures, except bridge brackets, shall be submitted in accordance with
711.05. Roadway cross sections and bridge dimensions shall be checked as applicable
in the field prior to preparation of shop drawings. If any discrepancies are found, the
Engineer shall be notified so necessary design revisions can be made prior to
preparation of the shop drawings. If the no-load camber is not shown on the plans, the
Contractor shall furnish this camber in the shop drawings.

803.04 Excavation.
Excavation. Excavation shall be in accordance with 802.04.

30 803.05 Placing Concrete.

Concrete. Placing concrete shall be in accordance with 702,
except that footings incorporated into sections of concrete barrier wall shall have a
Class 2, rubbed finish.

803.06 Erection.
Erection. The structure shall be handled carefully during loading,
shipment, unloading, and erection to avoid damage to any member of the structure. The
structure shall be inspected before unloading, during all operations, and until erection is
completed. Damage detected at any time shall be repaired before final acceptance.
When being erected, the structural members shall be lifted by means of nylon straps
placed around them, or by other approved methods which do not damage the structure.
40 Field welding of aluminum shall be in accordance with 803.07. Field welding of steel
shall be in accordance with applicable provisions of 711.32. The Contractor shall
ensure the proper fit of the structure to end bent extensions and of the end bent
extension to the foundation anchor bolts. When erection of the structure has been
started, it shall be completed that same day. The structure shall be loaded to prevent
vibration by attaching signs or lighting supports the same day. A minimum of two sign
support bracket assemblies will be required for all signs having a width greater than

594
 760 mm (30 in.). Signs 2.1 m (7 ft) or less in height shall have sign support bracket
assemblies mounted at a maximum spacing of 2.1 m (7 ft). Signs greater than 2.1 m
(7 ft) in height shall have sign support bracket assemblies mounted at a maximum
50 spacing of 1.5 m (5 ft). Sign overhang beyond the end bracket assembly shall be not
more than half the spacing of the bracket assemblies.

Nuts for cable span mounted signs shall be tightened so that the sign is held
firmly against the cable. There shall be no deformation or twisting of aluminum
sheeting, or damage to the reflective sheeting.

(a) Under Traffic.

Traffic. During the erection of overhead sign structures, traffic
shall be controlled in accordance with 801.14(c). The minimum requirement for a
traffic lane closure shall be as set out on the plans. Additional signs, barricades, and
60 other traffic control devices may be required as directed.

(b) Trusses.
Trusses. When placed on blocks to produce the required camber, the
truss sections shall fit together at the flange connections with a minimum gap of 1.5
mm (1/16 in.) on any flange assembly. The total of the gaps in any one connection shall
not exceed 3 mm (1/8 in.). Gaps shall be shimmed with tapered shims before tightening
the flange bolts.

All signs and walkway brackets shall be placed as close to the brace points as
possible. The Contractor shall verify that the dimensions are suitable for the type of
70 fixture to be supplied.

(c) Monotube.
Monotube. When placed on blocks to produce the required camber, beam
halves shall fit together at the flange connections with a minimum gap of 1.5 mm
(1/16 in.) on any flange assembly. Gaps shall be shimmed with tapered shims before
tightening the flange bolts.

(d) Cantilever.
Cantilever. Arms shall fit together at the flange connections between
sections with a minimum gap of 1.5 mm (1/16 in.) on any flange assembly. The total of
the gaps in any one connection shall not exceed 3 mm (1/8 in.). Gaps shall be shimmed
80 with tapered shims before tightening the flange bolts.

(e) Bridge Brackets.

Brackets. Bridge brackets shall be erected as shown on the plans.
Sign location may be shifted to avoid joints or stiffeners. Before placing aluminum in
contact with concrete, the concrete shall be coated with an aluminum-impregnated
caulking compound. Aluminum surfaces to be placed in contact with steel shall be
given one coat of zinc chromate before placement. Such aluminum surface shall be
coated with an aluminum-impregnating caulking compound. After the bolts have been
tightened, the excess caulking compound shall be removed. All openings around the
flanges shall be fully painted and shall be flush with the caulking compound.
90
803.07 Welding Aluminum Alloys for Highway Structures.
Structures. These specifications
apply to the welding of aluminum alloys used in sign structures, bridge rails, lamp
posts, etc. The welding terms used shall be interpreted in accordance with definitions
given in the latest edition of AWS Definitions "MD" Welding and Cutting, AWS A3.0.
The welding symbols used on plans shall be those shown in the latest edition of

595
 Standard Welding Symbols, AWS A2.0. Special conditions shall be fully explained by
added notes or details.

(a) Base Metals.

Metals. The aluminum alloys to be welded under these
100 specifications may be any of the following ASTM alloy designations:

1. wrought non-heat-treatable alloys 3003, 3004, 5052, 5083, 5086,

5456;

2. wrought heat-treatable alloys 6061, 6063; or

3. cast heat-treatable alloy 356.0.

Material used for permanent backing shall be at least equivalent in weldability to

110 the base metal being welded.

(b) Welding Processes.

Processes. These specifications include provisions for welding
by the gas metal-arc process and the gas tungsten-arc process. Other processes shall not
be used except as permitted.

(c) Filler Metal.

Metal. Bare wire electrodes for use with the gas metal arc process
and welding rods for use with the gas tungsten-arc process shall be in accordance with
the latest edition of Specifications for Aluminum and Aluminum Alloy Welding Rods
and Bare Electrodes, ASTM B 285 or AWS A5.10. Tungsten electrodes for the gas
120 tungsten-arc process shall be in accordance with in the latest edition of Specifications
for Tungsten-Arc Welding Electrodes, ASTM B 297 or AWS A5.12.

Filler metals to be used with particular base metals shall be as shown in the table
below. Other filler metals may be used if approved.

Base Metal Filler Metal

3003 to 3003 .......................................................... ER1100
3004 to 3004 .......................................................... ER4043
5052 to 5052 .......................................................... ER5356*
130 5083 to 5083 .......................................................... ER5183
5086 to 5086 .......................................................... ER5356*
5456 to 5456 .......................................................... ER5556
6061 to 6061 .......................................................... ER5356*
6063 to 6063 .......................................................... ER5356*
356.0 to 6061 ......................................................... ER4043
356.0 to 6063 ......................................................... ER4043
*ER5183, ER5356, and ER5556 may be used interchangeably for these base metals.

596
140 Filler metals shall be kept covered and stored in a dry place at relatively
uniform temperatures. Original rod and wire containers shall not be opened until time
to be used. Rod and wire shall be free of moisture, lubricant, or other contaminants.
Spools of wire temporarily left unused on the welding machine shall be kept covered to
avoid contamination by dirt and grease collecting on the wire. If a spool of wire is to be
unused for more than a short length of time, it shall be returned to the carton and the
carton tightly sealed.

(d) Shielding Gases.

Gases. Shielding gases shall be welding grade or better.
Shielding gas for gas metal-arc welding shall be argon, helium, or a mixture of the two,
150 approximately 75% helium and 25% argon. Shielding gas for gas tungsten-arc welding
done with alternating current shall be argon. Shielding gas for gas tungsten-arc welding
done with direct current, straight-polarity, shall be helium.

Hose used for shielding gases shall be made of synthetic rubber or plastic.
Natural rubber hose shall not be used. Hose which has been used previously for
acetylene or other gases shall not be used.

(e) Preparation of Materials.

Materials. Joint details shall be in accordance with design
requirements and detail drawings. The location of joints shall not be changed without
160 approval.

Edge preparation shall be by sawing, machining, clipping, or shearing. Gas

tungsten-arc or gas metal-arc cutting may also be used. Cut surfaces shall meet the
ANSI surface roughness rating value of 1000. Oxygen cutting shall not be used.

Surfaces and edges to be welded shall be free from fins, tears, and other defects
which would affect adversely the quality of the weld. Dirt, grease, forming or
machining lubricants, or any organic materials shall be removed from the areas to be
welded by cleaning with a suitable solvent or by vapor degreasing.
170
On all edges and surfaces to be welded, the oxide shall be removed just prior to
welding by wire brushing or by other mechanical methods such as rubbing with steel
wool or abrasive cloth, scraping, filing, rotary planing, or sanding. If wire brushing is
used, the brushes shall be made of stainless steel. Hand or power driven wire brushes
which have been used on other materials shall not be used on aluminum. Where
mechanical methods of oxide removal are found to be inadequate, a standard chemical
method shall be used. Welding shall be done within 24 h after chemical treatment.
When gas tungsten-arc welding with direct current straight-polarity is being used, all
edges and surfaces to be welded shall have the oxide removed by a standard chemical
180 method.

Welding shall not be done on anodically treated aluminum unless the condition
is removed from the joint area to be welded.

(f) Welding Procedure.

Procedure. All butt welds requiring 100% penetration, except
those produced with the aid of backing, shall have the root of the initial weld chipped
or machined out to sound metal before welding is started from the second side. Butt
welds made with the use of backing shall have the weld metal fused with the backing.

597
 Where accessible, backing for welds, that are subject to computed stress or which are
190 exposed to view on the completed structure and which are not otherwise parts of the
structure, shall be removed and the joints ground or machined smooth. In tubular
members, butt welds subjected to computed stresses shall be made with the aid of
permanent backing rings or strips.

The procedure used for production welding of any particular joint shall be the
same as used in the procedure qualification for that joint.

All welding operations, either shop or field, shall be protected from air currents
or drafts so as to prevent any loss of gas shielding during welding. Adequate gas
200 shielding shall be provided to protect the molten metal during solidification. The work
shall be positioned for flat position welding whenever practicable. In both shop and
field, all weld joints shall be dry at time of welding.

The size of the electrode, voltage and amperage, welding speed, gas or gas
mixture, and gas flow rate shall be suitable for the thickness of the material, design of
joint, welding position, and other circumstances attending the work. Gas metal-arc
welding shall be done with direct current, reverse polarity. Gas tungsten-arc welding
shall be done with alternating current or with direct current, straight polarity.

210 When the joint to be welded requires specific root penetration, a sample joint
shall be made and a macro etched cross section of the weld to demonstrate that the joint
welding procedure to be used is attaining the required root penetration. The sample
joint shall have a length of at least 0.3 m (1 ft) and shall be welded with the electrode,
polarity, amperage, voltage, speed, gas mixture, and gas flow rate that are proposed to
be used in production welding. Evidence on record may be accepted in lieu of the
preceding test.

Where preheat is needed, the temperature of preheat shall not exceed 177EC
(350EF) for heat-treated alloys and 316EC (600EF) for nonheattreated alloys. The
220 temperature shall be measured by temperature indicating crayons or by pyrometric
equipment. Heat-treated alloys shall not be held at the maximum preheat temperature or
at temperatures near the maximum for more than 30 min.

(g) Weld Quality.

Quality. Regardless of the method of inspection, the acceptance or
rejection of welds shall be determined by the following conditions:

1. Cracks in welds or adjacent base metal will not be acceptable.

2 Copper inclusions will not be acceptable.

230
3. Porosity in excess of that permitted by Appendix IV, Section VIII,
of the ASME Boiler and Pressure Vessel Code will not be
acceptable.

4. Lack of fusion, incomplete penetration, or tungsten or oxide

inclusions will be acceptable only if small and well dispersed.

598
 Undercut shall be no more than 0.3 mm (0.01 in.) deep when its direction is
transverse to the primary stress in the part that is undercut. Undercut shall be no more
240 than 0.8 mm (1/32 in.) deep when its direction is parallel to the primary stress in the
part that is undercut. No overlap shall be allowed. All craters shall be filled to the full
cross section of the welds. Welds having defects greater than the levels of acceptance
specified herein shall be considered as rejected unless corrected in accordance with
803.07(i).

(h) Inspection.
Inspection. To determine compliance with 803.07(g), all welds shall be
inspected visually. In addition, all welds subjected to computed stress shall be inspected
by the dye penetrant method except as specified below. For highway sign structures,
the dye penetrant method shall be used on butt welds in columns and main chord
250 members; on fillet welds connecting columns to bases and main chord members,
including the associated flanges, gussets, or main load carrying brackets or members;
and on fillet welds connecting flanges to the main truss chord members. The dye
penetrant tests shall be performed in accordance with the requirements of ASTM E
165, method B, procedures B-2 or B-3. Dye penetrant inspection may be omitted
provided that the inspector examines each layer of weld metal with a magnifier of 3X
minimum before the next successive layer is deposited.

(i) Corrections.
Corrections. In lieu of rejection of an entire piece or member containing
welding which is unacceptable, the corrective measures listed below may be permitted
260 if approval is obtained prior to making each repair. Defective welds shall be corrected
by removing and replacing the entire weld, or as follows:

1. For cracks in welds or base metal, determine full extent of crack by

dye penetrant method or other positive means. Remove crack
throughout its length and depth, and reweld.

2. For excessive porosity and lack of fusion, remove defective portions

and reweld.

270 3. For copper or tungsten inclusions, remove defective portions and

reweld.

4. For excessive concavity of crater, undercut and undersize weld,

clean and deposit additional weld metal.

5. For Overlap, reduce it by removal of excess of weld metal.

The defective areas shall be removed by chipping or machining. Oxygen cutting

shall not be used. Before rewelding, the joint shall be inspected to ensure that all of the
280 defective weld has been removed. If dye penetrant has been used to inspect the weld,
all traces of penetrant solutions shall be removed with solvent, water, heat, or other
suitable means before rewelding.

(j) Qualification of Procedures, Welders, and Welding Operators.

Operators. Joint
welding procedures which are to be employed in executing contract work under these
specifications shall be qualified previously by tests prescribed in Part B, Section IX, of

599
 the ASME Boiler and Pressure Vessel Code. The qualifications shall be done with no
additional payment. Evidence of previous qualification of the joint welding procedures
to be employed may be accepted.
290
All welders and welding operators to be employed under these specifications
shall be qualified previously by tests in accordance with Part B, Section IX, of the
ASME Boiler and Pressure Vessel Code and 916. Evidence of previous qualification of
the welders and welding operators to be employed may be accepted. The same process
and type of equipment that is required for execution of the construction work shall be
used in qualifying welders and welding operators.

803.08 Removal of Overhead Signs and Sign Structures.

Structures. Existing overhead
signs and sign structures such as box trusses, cantilevers, monotubes, twin cantilevers,
300 or tri-chord trusses shall be removed as shown on the plans or otherwise directed. Such
existing overhead signs and sign structures shall be removed within five work days after
the required replacement signs and sign structures are completely installed. After
overhead signs or structures have been removed, their foundations shall be removed to
a minimum depth of 0.3 m (1 ft) below the ground surface. The area shall be backfilled
with clean fill, reseeded or sodded in accordance with 621, or replaced with a material
which matches that in the surrounding area.

803.09 Final Clean-Up

Clean-Up.. Final clean-up shall be in accordance with 104.07 and
802.09.
310
803.10 Method of Measurement.
Measurement. Span overhead sign structures, overhead sign
structures, bridge bracket assemblies, and sign lighting installations will be measured
by the number of units of each type installed. Concrete foundations will be measured by
the cubic meter (cubic yard) within neat lines as shown on the plans or as revised. No
deductions will be made for reinforcing steel, structural steel, or conduit. Reinforcing
steel will be measured by the kilogram (pound) in accordance with 703.07. If class X
material is encountered during a foundation excavation, measurement will be made in
accordance with 206.10.

320 Sign lighting installation, including all connectors, wiring, conduit, and
miscellaneous hardware, except luminaires, will be measured per each type of lighting
installed.

Overhead sign structures to be removed will be measured by the number of

structures removed.

803.11 Basis of Payment.

Payment. The accepted quantities of span overhead sign
structures, overhead sign structures, bridge bracket assemblies, and sign lighting
installations will be paid for at the contract unit price per each, all complete in place.
330 Concrete foundations will be paid for at the contract unit price per cubic meter
(cubic yard) complete in place. Reinforcing steel will be paid for at the contract unit
price per kilogram (pound). All necessary hardware for mounting signs to overhead
sign structures will be paid for in accordance with 802.10.

600
 Overhead sign structures to be removed will be paid for at the contract unit
price per each of the type specified.

Payment will be made under:

340 Pay Item Metric Pay Unit Symbol (English Pay Unit Symbol)

Bridge Bracket Assembly ..................................................... EACH

Overhead Sign Structure, _____ ............................................. EACH
type
Overhead Sign Structure, _____, Remove.................................. EACH
type
Reinforcing Steel, Sign Foundation....................................... kg (LBS)
Sign Circuit Installation, _____, _____ Luminaires....................... EACH
type no.
350 Sign Foundation, Concrete................................................m3 (CYS)
Span Overhead Sign Structure, _____ ...................................... EACH
type

The costs of removal of signs, sign assemblies, sign lighting circuitry, supports,
concrete foundations, backfill material, sodding, seeding, and necessary incidentals
shall be included in the cost of overhead sign structure, remove.

The costs of excavation, backfill, and necessary incidentals shall be included in

the costs of the pay items unless class X material is encountered during foundation
360 excavation. Payment for such class X material will be made in accordance with
206.11(d).

SECTION 804 -- DELINEATORS

804.01 Description.
Description. This work shall consist of furnishing and erecting
delineators in accordance with these specifications and in reasonably close conformance
with the lines and grades and at locations shown on the plans. Delineators shall be
installed as required unless approval is obtained from the District Traffic Engineer to
make modifications at specific locations.

MATERIALS
10
804.02 Materials.
Materials. Materials shall be in accordance with the following:

Delineator Posts .................................................. 910.15

Flexible Delineator Posts........................................ 913.07
Reflective Elements .............................................. 913.08

The types of delineators shall be:

(a) D1 - single white or single yellow;

20
(b) D2 - double white or double yellow.

601
 Hardware for mounting delineators on posts shall be aluminum alloy 2024-T4;
galvanized steel bolts 4.8 mm (3/16 in.) diameter with vandal proof nuts or lock-nuts;
or aluminum pull-through blind rivets 4.8 mm (3/16 in) diameter.

CONSTRUCTION REQUIREMENTS

804.03 Delineators and Barrier Delineators.

Delineators. Delineators shall be placed as
30 shown on the plans or in accordance with the AASHTO Manual for Signing Interstate
Highways. A delineator shall not block an entrance. The delineator shall be moved a
distance not to exceed one quarter of the basic spacing. If the conflict still exists, the
delineator shall be eliminated. Delineators shall be installed at the back side of
guardrail. When the guardrail run ends, and additional delineators are required, they
shall be installed a minimum of 600 mm (2 ft) from the edge of the shoulder. Barrier
delineators shall be used on temporary concrete barrier, concrete median barrier,
concrete railing, and guard rail as shown on the plans or as specified. Delineator
reflector units shall be positioned so as to be clearly visible for a distance of 305 m
(1,000 ft) on tangent sections or at maximum visibility distances on curves. These
40 locations shall be established under normal weather and atmospheric conditions when
illuminated by the upper beam of standard automobile headlights.

804.04 Posts.
Posts. Posts shall be installed in accordance with applicable provisions
of 802.

804.05 Flexible Delineator Posts.

Posts. These posts shall be installed according to the
manufacturer's recommended instructions and shall be set so that the top is no more
than 13 mm (1/2 in.) from any vertical plane through the bottom. The erected height
shall be in accordance with the MUTCD.
50
804.06 Method of Measurement.
Measurement. Delineators with posts, delineator posts, and
flexible delineator posts will be measured by the number of units of the type specified.

804.07 Basis of Payment.

Payment. The accepted quantities of delineator with post,
delineator post, and flexible delineator post, if set out as a separate pay item, will be
paid for at the contract unit price per each for the type specified, complete in place.

Payment will be made under:

60 Pay Item Pay Unit Symbol

Delineator Post ................................................................. EACH

Delineator Post, Flexible...................................................... EACH
Delineator with Post, _____ .................................................. EACH
type

602
 SECTION 805 -- TRAFFIC SIGNALS

805.01 Description.
Description. This work shall consist of furnishing miscellaneous
materials, not furnished by the Department, and installing traffic signals in accordance
with these specifications and in reasonably close conformance with the lines, grades,
and locations shown on the plans or as directed.

MATERIALS

10 805.02 Materials.
Materials. Materials shall be in accordance with the following:

Aggregate, Class A, B, C, D, or E size No. 8 .............. 904.02

Castings for Handhole ........................................... 910.05(b)
Concrete, Class A, B, or C ..................................... 702
Reinforced Concrete Pipe ....................................... 907.02
Traffic Signal Materials and Equipment ...................... 913.15
Treated Lumber .................................................. 911.02

The proposed work shall be examined in order to determine what materials not
20 furnished by the Department are required to complete the contract. The Department
will furnish only the materials specified on the Department Furnished Materials special
provision. If materials to be furnished by the Contractor are listed, the list is only a
guide for estimating purposes. All additional materials required to complete an
operating installation as specified shall be furnished.

Signal handholes shall be class III reinforced concrete pipe as shown on the
plans.

Wood poles to be furnished shall be in accordance with the current ANSI

30 specifications and dimensions. They shall be of the length and class specified, be fully
treated in accordance with 913.15(e)2, and dry. Minimum circumference at the top and
at a point 1.8 m (6 ft) from the butt shall be in accordance with ANSI specifications.

Steel strain poles greater than 7.3 m (24 ft) in length shall be in accordance with
913.15(e)1b.

CONSTRUCTION REQUIREMENTS

805.03 General Requirements.

Requirements. The Contractor shall maintain existing traffic
40 signals in operation until the Engineer determines that the progress of the work
necessitates their removal. The new installation shall not interfere with the operation of
the existing signal. The work shall proceed in such a manner that the signals are not out
of service at any two adjacent intersections at any time. When the operation of an
existing traffic signal must be interrupted before the new signal is placed in operation,
the traffic shall be controlled at all times. The work shall be scheduled so that the
interruption is limited to a minimum amount of time and at off peak hours. When a new
span, catenary, and tether are to be installed on an existing structure, the work shall be
done so as not to damage the structure. Tether cable will not be required on a flasher

603
 installation. If an existing structure is damaged, it shall be repaired or replaced as
50 directed with no additional payment. The new span and catenary installation shall not
interfere with the operation of the existing traffic signal. Traffic shall be controlled at
all times during the changeover when the existing traffic signal is turned off and the
new signal is turned on. This changeover shall take place such that the interruption is
limited to a minimum amount of time.

When directed, temporary stop signs shall be erected at the intersection. When
no work is in progress, the intersection shall have at least two operating signal faces for
each approach. When the new installations are completed, any existing signal
equipment and materials including wood poles, steel poles, and cast-iron handhole rings
60 and covers which have not been used in the new installation shall be carefully removed.
Regardless of the right to materials found on the project, as set out in other sections of
these specifications, these items shall be stored at a secure site and salvaged by the
appropriate governmental agency. The Contractor shall be responsible for any damage
or loss of this equipment and shall repair or replace the same with no additional
payment.

All existing painted signal equipment to be reused, such as pedestals, bases,

controller cabinets, signals heads, signal weatherheads, pipe arms, shall be cleaned and
painted with two coats of highway yellow enamel. Aluminum poles and mast arms shall
70 not be painted.

Existing concrete foundations, which have not been used in the new installation,
shall be removed to a minimum of 100 mm (4 in.) below the adjacent grade. The
openings shall be filled with concrete and the surface finished and broomed, if they are
located in sidewalk areas. Otherwise, they shall be filled with acceptable material
conforming with the surrounding area. Existing signal handholes to be removed, shall
be filled after removing rings and covers, with B borrow with a minimum of 100 mm
(4 in.) of concrete on top to bring it up to grade in a sidewalk area. Surfaces shall be
finished and broomed. Otherwise, they shall be filled with acceptable material
80 conforming with the surrounding area.

The signal controller timings will be provided and the Engineer shall be present
when the signal intersection is to be placed in operation.

All electrical wiring terminations and splices; controller and cabinet set-up; and
testing, review, and turn-on of all operational apparatus at each location shall be done
by or in the presence of and under the responsible charge of an employee of the
Contractor who holds a Level II Traffic Signal Electrician certification which has been
granted by the International Municipal Signal Association. Supervision of non-
90 electrical, traffic signal related construction work and traffic control shall be done by a
person holding a Level I Work Zone Traffic Safety Specialist certification which has
been granted by the International Municipal Signal Association, or an equivalent
certification approved by the Department.

Before starting work, the Contractor shall provide the names of the Level II
Traffic Signal Electricians and Level I Work Zone Traffic Safety Specialists who have
been assigned to perform signal related work, and a photocopy of each such person's

604
 certification card. If the Level II Traffic Signal Electricians or Level I Work Zone
Traffic Safety Specialists are dismissed from the work, all signal related work requiring
100 such certified personnel on the project site shall cease until the names and photocopies
of certification cards for replacement personnel are provided to the Engineer.

Electrical work shall be executed in accordance with the requirements of the

National Board of Fire Underwriters, the State Fire Marshal, and the power company
which will furnish the electric service. The work shall be in accordance with any local
regulations that may apply. The Department will arrange and provide for power service
which the power company will bring to the point designated on the plans. Prior to the
start of construction, the schedule of activities shall be coordinated with the power
company and they shall be contacted again at least 14 days prior to the time the service
110 work is to be completed.

The Department will obtain permits from local officials, companies, or

individuals for the use of poles, right-of-way, or other property incidental to the
installation of traffic signal. Although entering into the contract implies permission and
authority to cut into and push under pavement, sidewalks, and alleys, any damage to
underground utilities or interruption of such service shall be the responsibility of the
Contractor. The Contractor shall be in accordance with local regulations as well as
107.07. Protective devices shall be in accordance with 107.11 and 801.

120 The location of signal heads, controllers, signal poles, signal cantilever
structures, detector housing, disconnect hangers, and other installation items will be
shown on the plans. However, a change in the location of an item may be ordered
during the progress of the work. The work shall be completed as shown on the plans
except for those changes specifically authorized in writing.

805.04 Pole Installation.

Installation. Metal poles shall be erected on concrete foundations
and shall be reasonably plumb after installation of signal heads. The handhole side of
the pole shall be at right angles to the direction of the mast arm or span, catenary, and
tether. Signal cables shall be brought up inside the poles. Any steel pole, mast arm, or
130 hardware not galvanized or painted with baked enamel shall be painted with two coats
of rust inhibiting aluminum paint. Paint shall be applied in accordance with 619 with
the exception that commercial blast cleaning of the steel will not be required. All rust,
scale, and dirt shall be cleaned from the metal surface so that paint adheres to the
surface.

The construction of concrete foundations shall be in accordance with 805.13.

Wood poles shall be set a minimum of 2.1 m (7 ft) in the ground and raked 300 mm
(12 in.).

140 805.05 Placing Signal Heads.

Heads. Mast arm and span mounted signal heads shall
have 5.2 m (17 ft) minimum and 5.8 m (19 ft) maximum clearance over the roadway
unless there are visual obstructions which require lowering the signal head. A signal
head over the roadway shall not have a clearance of less than 4.6 m (15 ft). Such signal
heads shall be located over the intersection as shown on the plans. Such signal heads
shall have a uniform clearance, which will be determined. Signal heads not mounted
over a paved roadway, on the top or side of a pole, shall not be less than 3 m (10 feet)

605
 nor more than 4.6 m (15 ft) above the sidewalk or, if none, above the pavement grade
at the center of the roadway. Signal faces shall be directed to the proper approach lane
in each direction. Pedestrian signal faces shall be mounted with the bottom of the
150 housing at not less than 2.1 m (7 ft) nor more than 3 m (10 ft) above the sidewalk. The
pedestrian signal shall be in line with the pedestrian's vision at the appropriate
crosswalk being used. Pedestrian push-buttons shall be mounted at a height of 1.1 to
1.2 m (3 1/2 to 4 ft) above the sidewalk as shown on the plans. A pedestrian actuated
signal sign shall be mounted immediately above the push-button.

Signal heads shall be assembled and wired with one conductor, THW, stranded
wire. Where splices are made, a 0.6 m (2 ft) minimum length of cable or wire in excess
of that required for a continuous run shall be provided. Splices shall be twisted together
and soldered or approved type connectors used. Each splice shall be completely
160 insulated by wrapping with an approved tape and sealed with an approved electrical
coating material. Splices shall be made in such manner that the connections are
moisture proof. The cables coming out of the signal weatherhead shall be looped to
form a drip loop. The drip loop shall be made so that the cables coming out of the
weatherhead loop down below the elevation of the weatherhead to prevent water from
following the cable into the weatherhead. If used, the splice indicated above shall be
located in the top of the coils of cable forming the drip loop.

Signal heads shall not be installed until all other work has been completed. If it
becomes necessary to mount signal heads for more than 2 h before the lights are to be
170 turned on, the signal heads shall be hooded by placing sacks or similar cover over them
so as to conceal them from traffic. Hooded signal heads are not permitted to be in place
for more than five days. No signal head shall be left over night with the lights out
unless it is hooded. Signal heads shall be securely mounted. The polycarbonate signal
face shall be used only when securely supported on both ends of the assembly. In a
span cable installation, a tether cable would satisfy this requirement.

805.06 Grounding.
Grounding. All signal supports, signal controller supports, and entrance
switches shall be grounded in accordance with the applicable requirements of 807.12.

180 805.07 Wire and Cable Installations.

Installations. All cable runs attached to utility poles shall
have code clearance relative to utility cables. They shall be no less than 5.5 m (18 ft)
above the ground level except over railroad tracks when a minimum of 8.2 m (27 ft)
clearance shall be maintained. All cable runs shall be installed in continuous lengths
without splices between terminals except when necessary at handholes, junction boxes,
pole signal bases, and pedestal bases. The type of cable and the number of conductors
as well as the gage shall be as shown on plans unless otherwise specified.

Cable rings shall be used to support the signal cable on the signal span cable.
They shall be spaced 300 mm (12 in.) on center. Cable shall be pulled through the
190 conduit to the terminal panel in the controller cabinet. Caution shall be used to prevent
damage to the cable when it is being pulled through conduit.

Coded cable conductors shall be used throughout the installation. Cable

conductors shall be tagged at all detector housing, handholes, pole signal bases, and
controller cabinets. Tags shall consist of an aluminum blank of sufficient size to be

606
 stamped with not less than 5 mm (3/16 in.) high all upper case letters which identify the
cables by their use and phase. The following are the uses which shall be indicated by
the tags:

200 (a) Power

(b) Pedetrian Signals

(c) Pedestrian Actuation

(d) Signal-Phase Identification

(e) Detection Loop Identification

210 Loop identification shall consist of the following:

Inside of the Detector Housing, the loop wires of each loop shall be tagged
with, in ____________, out ____________, as shown on the plans.
Loop Number Loop Number

Inside of the Controller Cabinet, each lead-in cable shall be tagged within 150
mm (6 in.) of the terminal strip connection with: Lane designation, Phase Number,
Loop Number, and when applicable with loop system number, and speed trap according
with the plans.
220
Phase identification shall consist of the single number "1", "2", "3," etc., which
corresponds to the phase diagram for the respective intersection. Tags shall be securely
fastened to the cable with a non-corroding material. The tagging material and fastening
shall be approved prior to proceeding with this work. The color coded wires shall be
connected properly. The white wire shall be the common or ground. Wire used for all
identical indications of any individual phase shall be color coded and, where possible,
shall use red wire to connect red lenses, orange wire to connect yellow lenses, and
green wire to connect green lenses. Signal heads shall be assembled and wired before
installed. The testing of the loops shall be documented in the Loop Testing Table
230 provided by the State.

805.08 Controller Cabinet, Signal Service, and Detector Housing Installation.

Installation.
The controller cabinet shall be mounted securely on a pole, pedestal, or concrete
foundation. All cabinets on concrete foundations shall be installed with the anchor bolts
inside. Controller cabinets on poles or pedestals shall be mounted at a height of 970
mm (38 in.) " 50 mm (2 in.). Pole mounted controller cabinets shall be fastened with
two stainless steel bands as shown in the plans. Signal cables and lead-in cable shall be
run in conduit from the controller cabinet to the signal support base and to detector
housing as indicated on the plans. Galvanized steel elbows shall be used on the detector
240 housing as shown on the plans.

The Contractor shall wire the entrance switch and bring service cable up the
riser and out the weatherhead and leave 1.2 m (4 ft) of cable outside the weatherhead.
The utility company, at their option, may bring the service cables to the load side of the

607
 entrance switch. Meter bases, if required, shall be obtained from the power company
and any service connection or miscellaneous charges shall be assumed by the
Contractor.

A minimum of 300 mm (12 in.) and a maximum of 450 mm (18 in.) of loop
250 wire duct will be permitted in the detector housing for each loop lead.
High-early-strength concrete in accordance with 305.06(a), shall be used in the
installation of detector housings, except where a portion of the road is closed or where
there is no vehicular traffic, then class A concrete may be used. The concrete shall be
placed flush with existing surface and shall be covered with a steel plate during the
setting time.

805.09 Loop Wire Detector Installation.

Installation. This work shall consist of placement
and testing of loop wire detectors in accordance with the installation details shown on
the plans.
260
MATERIALS

Loop wire shall be in accordance with 913.15(f)4e(2). Loop detector sealant

shall be in accordance with 913.15(f)4e(3).

Loops shall be of a regular octagon shape with side of 0.75 m (2.5 ft) in length.
An outline shall be laid out and painted where the loops shall be sawed. The loop
locations shall be subject to the review and approval of the District Traffic Engineer.
The District Traffic Engineer shall be notified 48 h prior to such field review.
270
The slots shall be saw-cut as shown on the plans. Slots shall be thoroughly
cleaned and dried before the installation of loop wires. The specified number of turns
shall be placed in the slot and gently tamped with a blunt non-metallic tool. A sash cord
or backer rod shall be placed above the wire after tamping. The number, size,
arrangement, and locations of loops shall be as shown on the plans. Loop spacing shall
be adjusted to avoid pavement joints. Loop wire shall be pressed into the saw slot with
a blunt nonmetallic tool. Loop wire shall only be bent at angles of 120 degrees or
greater. All loops shall be wired clockwise as viewed from above. Loops shall be wired
with four turns and in a series unless otherwise specified. Joints shall be overlapped
280 such that the saw cut at the corner is full depth. The sealant shall be poured into the
saw cut making a water tight seal. The splice of the loop wire and lead-in cable shall be
soldered and waterproofed at the detector housing. Waterproofing shall consist of the
use of heat shrink tubing which has an internal coating sealant material. The heat shrink
tubing shall not be heated by means of a direct flame tool. Loop wire and lead-in cable
shall be tagged according to the plans and 805.07. The black lead-in wire shall be
spliced to the loop wire which goes back to the field. Such wire shall be tagged as
"Out/Loop (No.)". The white lead-in wire shall be spliced to the loop wire which
comes in from the field. Such wire shall be tagged as "In/Loop (No.)".

608
290 TESTING

The Contractor shall meter all new loop wire detectors or a new bank of loop
wire detectors by means of instruments capable of measuring electrical values for
installed loop wires and lead-in cables. The instruments shall measure inductance in
microhenries, resistance in ohms, induced A.C. voltage in volts, and leakage resistance
in megohms. All measuring tests shall be performed at the detector housing before the
loop wire is spliced to the lead-in cable, and at the cabinet after the loop wire is spliced
to the lead-in cable.

300 (a) Megohm Test Before Splice is Made at Detector Housing for Loop Wire.
Wire.
One of the megohm probes shall be connected to ground and the other probe shall be
connected to the "in" or "out" loop wire. The remaining loop wire shall be isolated.
The test shall then be performed.

(b) Megohm Test Before Splice is Made at Detector Housing for Lead-in
Lead-in
Cable.
Cable. The two wires of the lead-in cable at the cabinet shall be twisted together and
taped. The shield of the lead-in cable shall be grounded in the cabinet. At the detector
housing, one megohm probe shall be connected to ground and the other probe shall be
connected to one of the lead-in wires. The remaining lead-in wire shall be isolated. The
310 test shall then be performed.

(c) Megohm Test After Splice is Completed at Cabinet.

Cabinet. This test shall be
performed after the splice at the detector housing is completed. A water solution of 15
ml (one tablespoon) of baking soda per 0.5 L (pint) of water shall be placed in a metal
container. The metal container shall be grounded and the splice shall be fully
submerged in the solution for 2 min. With the splice submerged, the megohm test shall
be performed at the cabinet on the end of the lead-in cable.

(d) Vehicle Simulator Test.

Test. This test shall be performed after all other tests
320 are completed and after all connections have been made at the controller in the cabinet.
This test shall be performed by dragging a test vehicle across the loops using a
non-conducting string. The test vehicle shall be fabricated with an 2.4 m (8 ft) length of
No. 6 bare copper wire formed into a circle. The two ends shall then be electrically
spliced. The detector unit amplifier shall record a call as the test vehicle is dragged
across the loop. It shall cancel the call as the test vehicle leaves the loop.

(e) Acceptance Criteria.

Criteria. The Contractor shall record all test readings, in
triplicate, on tabular forms provided by the Department or by copying the one included
elsewhere herein. The Contractor shall complete, sign, and date the forms before
330 submitting them to the District Traffic Engineer. The District Traffic Engineer will use
these forms for recording the Department's readings on the corresponding space
provided.

In order for the loop detector installation to be accepted, the electrical values
shall be as follows:

609
 1. Inductance shall be between 80 and 800 FH. Inductance shall be
determined by means of digital readout meter which drives the field
loop system.
340
2. Resistance shall be less than or equal to 8 ohms.

3. Voltage shall be less than or equal to 3 V.

4. Induced A.C. voltage and leadage resistance shall be greater than

100 megohms.

Loop wire and/or lead-in cable failing to meet this requirement shall be replaced
at no cost to the State.
350
805.10 Magnetometer and Microloop Detectors. Detectors. Before installation of
Magnetometer or Microloop probes the Contractor shall confirm the adequacy of the
magnetic field intensity, to be sure that the range is suitable for their operation.
Arrangement of probes shall be located at maximum distance from steel support under
bridges. Probes shall be installed with their long dimension vertical, and with the cable
end at the top. Probes shall be firmly supported, so the lateral and vertical motion is
restricted. Probes shall be connected in series. The splice shall be soldered by means of
hot iron, or pouring or dripping without flames, with rosin core solder and shall be
insulated and waterproofed in accordance with the manufacturer's specifications.
360
805.11 Steel Conduit.
Conduit. Conduit shall be installed to a depth of no less than 0.6 m
(2 ft) or more than 1.5 m (5 ft) below the finished grade unless otherwise specified or
approved. Pockets or traps where moisture might accumulate shall be avoided. Conduit
shall be placed under existing pavement by approved jacking or drilling methods.
Pavement shall not be disturbed without permission. If permission is granted, cuts in
pavement areas shall be no greater than 600 mm (24 in.) wide. All cuts in the pavement
and sidewalk areas shall be sawed. Sidewalk removal and replacement shall be to the
nearest tooled joint. Jacking and drilling pits shall be kept at least 0.6 m (2 ft) clear of
the edge of any type of pavement or paved shoulder. Excessive use of water that may
370 cause undermining of the pavement shall be avoided. Continuous conduit runs shall not
exceed 76 m (250 ft) in length, unless otherwise indicated on the plans.

Expansion fittings as detailed on structure plans shall be installed where conduit

crosses an expansion joint in the structure. Where it is deemed inadvisable to install
expansion fittings in closely confined areas, the installation of approved flexible tubing
may be permitted. Such expansion joints or tubing shall be the same size as the conduit.
Any existing underground conduit to be incorporated into a new signal installation shall
be cleaned with a mandrel and blown out with compressed air before cable is drawn
into pipe. All new conduit runs shall be cleaned and swabbed before cables are
380 installed. All conduit ends shall be capped and shall remain capped until the Contractor
is ready to pull cable into the conduit, at which time the caps shall be removed and
conduit bushings placed on each end to protect the cable. The inside surface of the
conduit shall be kept clean. Conduit to be installed, indicated on the plans for future use
of signal cables, shall be left in place with a pull cord on it’s entire length.

610
 Larger size conduit may be used with no additional payment, but when it is
used, it shall be for the entire length of the run from outlet to outlet. Conduit runs as
shown on the plans are for bidding purposes only and may be changed, with
permission, to avoid underground obstructions. A change order may be authorized if
390 the conduit runs can be made on the opposite side of the street to that shown on the
plans in order to avoid obstruction and traffic inconvenience or to avoid unnecessary
tearing up of existing pavement.

805.12 PVC Conduit.

Conduit. The method of installing PVC conduit under-ground shall
be the same as for steel conduit where applicable except trenches for the conduit shall
be backfilled with 50 mm (2 in.) of sand before the conduit is placed in the trench.
Materials excavated may be used for backfill, if approved. If the engineer deems it
necessary, approved B borrow shall be placed over the conduit to a depth of 300 mm
(12 in.) and the remainder of the trench shall be filled with excavated material.
400
805.13 Foundations.
Foundations. Foundations for traffic signal poles, cabinets, and pedestals
of the type specified shall be constructed, or existing M foundations shall be modified,
as shown on the plans or as directed. Pedestal bases shall be plumb and firmly attached
to the anchor bolts either by using leveling nuts or shims if top of the foundation is not
level. Grouting shall be used when necessary to fill any gap between pedestal base and
foundation. Pipe pedestals shall be screwed tightly into the bases and secured with a
stainless steel pin. Power and signal cables shall then be pulled from the base into the
cabinet. Curing of concrete shall be in accordance with 702.21.

410 During excavation of the foundation, all material shall be removed to the full
depth as shown on the plans, except if class X material is encountered, the work shall
be performed in accordance with 206.02(b).

805.14 Final Clean-Up

Clean-Up.. When the installation is completed, all disturbed
portions of sidewalk, pavement, shoulders, driveways, sod, etc., shall be cleaned and
any excess excavation or other materials shall be disposed. All cutting in the sidewalk
and pavement areas shall be done with a saw. Sidewalk removal and replacement shall
be to the nearest tool joint. Unless otherwise direction, cuts in pavement areas shall be
no greater than 300 mm (12 in.) in width.
420
805.15 Method of Measurement.
Measurement. Traffic signal head, pedestrian signal head,
pedestrian push button, controller cabinet foundation, M foundation modified to P-1
foundation, signal steel strain pole, signal wood pole, signal cantilever structure, signal
support foundation, signal service, disconnect hanger, magnetometer detector,
microloop detector, loop detector delay amplifier, signal handhole, signal detector
housing, span catenary and tether, and span catenary for flasher will be measured by
the number of units installed.

Conduit of the type specified will be measured by the meter (linear foot) from
430 outside to outside of foundations. Signal cable and signal interconnect cable will be
measured by the meter (linear foot).

611
 The accepted quantities for payment for electrical signal or loop lead-in cable
will be the quantities shown in the Schedule of Pay Items. Such quantities may be
corrected if they are in error by more than 25%.

Saw cut for roadway loop detector and sealant will be measured by the meter
(linear foot) for the full depth of slot cut in the pavement as shown on the plans or as
directed.
440
If class X material is encountered during foundation excavation, measurement
will be made in accordance with 206.10.

Traffic signal installation or modernization, flasher installation or

modernization, miscellaneous equipment for traffic signals, and final cleanup in
accordance with 805.14 will not be measured for payment.

805.16 Basis of Payment.

Payment. Traffic signal installation, flasher installation, traffic
signal modernization, and flasher modernization, all of the type and the location
450 number specified, will be paid for at a contract lump sum price.

If specified as pay items, traffic signal controller and cabinet, traffic signal
head, pedestrian signal head, pedestrian push button, controller cabinet foundation, M
foundation modified to P-1 foundation, signal steel strain pole, signal wood pole, signal
cantilever structure, signal support foundation, signal pedestals, signal service,
disconnect hanger, magnetometer detector, microloop detector, loop detector delay
amplifier, signal handhole, signal detector housing, span catenary and tether, and span
catenary for flasher will be paid for at the contract unit price per each. Conduit of the
type specified, signal cable, interconnect cable, electrical signal cable, loop lead-in
460 cable, and saw cut for roadway loop detector and sealant will be paid for at the contract
unit price per meter (linear foot).

Class X excavation will be paid for in accordance with 206.11.

Miscellaneous equipment for traffic signals will be paid for at a contract lump
sum price.

Payment will be made under:

470 Metric
Metric Pay Item Metric Pay Unit Symbol
(English Pay Item English Pay Unit Symbol)
Pay Item Metric Pay Unit Symbol (English Pay Unit Symbol)

Controller and Cabinet, _____, ____ Phase................................ EACH

type no.
Controller and Cabinet, Flasher, _____ .................................... EACH
type
Controller Cabinet Foundation, _____ ...................................... EACH
type
480 Controller Cabinet Foundation, M, Modify to P-1........................ EACH
Disconnect Hanger ............................................................. EACH

612
 Flasher Installation, Location No. ____ .........................................LS
Flasher Modernization, Location No. ____ .....................................LS
Handhole, Signal ............................................................... EACH
Loop Detector Delay Amplifier, ____ Channel............................ EACH
no.
Magnetometer Detector ....................................................... EACH
Microloop Detector ............................................................ EACH
Miscellaneous Equipment for Traffic Signals ...................................LS
490 Pedestrian Push Button ........................................................ EACH
Pedestrian Signal Head, _____, _________................................ EACH
type lens size
Saw Cut for Roadway Loop and Sealant..................................m (LFT)
Signal Cable, _____, No. ____ Copper, ____C/____ ..................m (LFT)
type no. conductors/size
Signal Cantilever Structure, Mast Arm ______ m ........................ EACH
length
(Signal Cantilever Structure, Mast Arm ______ ft. ...................... EACH)
length
500 Signal Detector Housing ...................................................... EACH
Signal Interconnect Cable, _____, No. ____ Copper, ____C/____ ..m (LFT)
type no. conductors/size
Signal Pedestal, ______ m .................................................... EACH
length
(Signal Pedestal, _______ ft ................................................. EACH)
Signal Pole, Wood, ______, ______ m ..................................... EACH
class length
(Signal Pole, Wood, ______, ______ ft. .................................. EACH)
class length
510 Signal Service................................................................... EACH
Signal Strain Pole, Steel, ______ m ......................................... EACH
length
(Signal Strain Pole, Steel, _______ ft. ..................................... EACH)
length
Signal Support Foundation, _____ mm x _____ mm x _____ mm ..... EACH
(Signal Support Foundation, _____ in. x _____ in. x _____ in. ....... EACH)
Span and Catenary for Flasher ............................................... EACH
Span, Catenary, and Tether................................................... EACH
Traffic Signal Head, ____ Way, ____ Section, _______________ ..... EACH
520 no. no. lens sizes & colors
Traffic Signal Installation, _____, Location No. ____ ........................LS
type
Traffic Signal Modernization, _____, Location No. ____ ....................LS
type

The costs of all wiring, hardware, anchor bolts, and associated equipment
required to operate the intersections shall be included in the cost of controller and
cabinet, flasher.

613
530 The costs of signal face hook-up wire, pole plates and arms for side mounts,
mid-mast arm mount, pipe arms, signal brackets, visors, louvers, bulbs, span hanger,
backplates, balance adjuster, weatherhead, and all additional hardware required to
assemble a combination of signal faces as shown on the plans shall be included in the
costs of traffic signal head or pedestrian signal head.

The costs of the push button, pedestrian actuated signal sign, and all hardware
required to complete the installation shall be included in the cost of pedestrian push
button.

540 The costs of concrete, conduits, grounding bushings, ground rod, ground wire,
drainage, and all hardware required to complete the installation shall be included in the
cost of controller cabinet foundation.

The costs of the base plate, metal skirt base plate, anchor bolts, handhole and
cover grounding lug, 50 mm (2 in.) pipe cable entrance, J hook, and top cover as
shown on the plans shall be included in the cost of signal strain pole, steel.

The costs of downguys, anchor rods, downguy guards, and hub-eyes as shown
on the plans, and all hardware required to complete the installation shall be included in
550 the cost of signal pole, wood.

The cost of all hardware including the metal skirt base plate, where necessary,
to complete the installation as shown on the plans shall be included in the cost of signal
cantilever structure.

The costs of concrete, reinforcing steel, conduits, ground rod, ground wire,
grounding bushings, and all hardware required to complete the installation shall be
included in the cost of signal support foundation.

560 The costs of the pedestal metal base, pedestal pole, pole cap when necessary,
anchor bolts, and all hardware required to complete the installation shall be included in
the cost of signal pedestal.

The costs of weatherhead, 25 mm (1 in.) conduit riser, entrance switch, 25 mm

to 50 mm (1 in. to 2 in.) conduit reducer, ground rod, ground wire, and all hardware
required to complete the installation, including the meter base when required and
supplied by the utility company shall be included in the cost of signal service.

The costs of the detector unit, lead-in cable, and all work necessary for proper
570 installation shall be included in the cost of magnetometer detector or microloop
detector.

The costs of the slot cut on the pavement, sash cord, backer rod, loop sealant,
and all testing in accordance with 805.09 shall be included in the cost of saw cut for
roadway loop and sealant.

614
 The costs of all work and hardware required to properly install overhead or
underground signal cable as shown on the plans or as directed shall be included in the
cost of signal cable and signal interconnect cable.
580
The costs of the independent shelf mount unit or card-rack unit, and power
module shall be included in the cost of loop detector delay amplifier.

The costs of concrete reinforcing pipe, ring and cover, eye bolts, hardware,
handhole bottom, and aggregate under the handhole bottom as shown on the plans shall
be included in the cost of handhole, signal.

The costs of aluminum casting, enclosure concrete, steel conduit and elbow, and
all hardware required to complete the installation shall be included in the cost of signal
590 detector housing.

The costs of steel pole bands or straight eye bolts, span, catenary, and tether of
wire rope cables, cable rings, type A support cable, wire rope clips, safety cable,
thimble, service sleeve, and all hardware required to complete the installation as shown
on the plans shall be included in the costs of span, catenary, and tether for signal, or
span and catenary for flasher.

The costs of excavation, backfill, final cleanup in accordance with 805.14, and
necessary incidentals shall be included in the costs of the pay items.
600
SECTION 806 -- BLANK

SECTION 807 -- HIGHWAY ILLUMINATION

807.01 Description.
Description. This work shall consist of installing wire, cable, conduit,
lighting standards, luminaires, lamps, and incidental materials in accordance with these
specifications and in reasonably close conformance with the lines, grades, and locations
shown on the plans or as directed.

Lighting installations shall be in accordance with the National Electrical Code

and the National Safety Code.
10
807.02 Maintenance of Highway Illumination.
Illumination. Existing highway illumination
shall be maintained on all projects unless discontinuance of the highway illumination is
specifically permitted.

MATERIALS

807.03 Materials.
Materials. Materials shall be in accordance with the following:

Aggregate (stone) size No. 53.................................. 904.02

20 Castings for Handholes .......................................... 913.15(h)
Concrete, Class A ................................................ 702
Conduit ............................................................ 913.15(j)
Highway Illumination Materials................................ 913.11

615
 Line Hardware.................................................... 913.15(f)
Paint................................................................ 909
Reinforced Concrete Pipe ....................................... 906.02
Reinforcing Steel ................................................. 910.01

Manufacturers' descriptive and technical literature for major items shall be

30 submitted for approval. Where it is normal trade practice to furnish a warranty, a
warranty shall be furnished on all major items such as luminaires, lamps, poles,
brackets, cable-duct, wire and cable, fuse connectors, and ballasts. The effective date
of the warranty shall commence on the date of final acceptance. These items shall bear
the seal of approval of the UL.

All flexible conduit shall be galvanized steel, polyvinyl jacketed, and watertight.

CONSTRUCTION REQUIREMENTS

40 807.04 Excavation.
Excavation. All excavation for the roadway lighting installation shall be
performed in accordance with the dimensions, elevations, and grades shown on the
plans or as directed. If class X material is encountered, foundation excavation shall be
completed in accordance with 206.

(a) Trench Excavation.

Excavation. Excavation may be accomplished either manually or
with mechanical trenching equipment. The blades of road patrols or graders shall not be
used to excavate the trenches. The depth of trenches shall be a minimum of 0.6 m
(2 ft). Walls of trenches for cable-duct or conduit shall be essentially vertical. The
bottoms of trenches shall be smooth and free from aggregate larger than 13 mm
50 (1/2 in.). Bracing, shoring, and sheathing shall be provided as necessary. If the
excavation, through accident or otherwise, is below the required level, the excess
excavated area shall be refilled in a satisfactory manner with no additional payment.
The accumulation of water in excavated areas shall be prevented by the use of pumps or
other approved means. When rocks or other materials which might damage the
cable-duct or conduit are encountered, the excavation shall be extended to a depth of at
least 700 mm (27 in.) and backfilled with a 75 mm (3 in.) compacted layer of sand or
earth containing no particles that would be retained on a 6.3 mm (1/4 in.) sieve. No
extra payment will be made for this additional excavation or backfill.

60 (b) Foundation Excavation.

Excavation. If possible, excavation for concrete foundations
shall be accomplished by means of drilling with an auger of sufficient size to admit the
width of the foundation. Work shall be so scheduled that all open excavations are
poured with concrete during the work day they are dug. No excavations shall remain
open over night or over a weekend or holiday. Accumulated water shall be removed
from the excavation before concrete is poured. If class X material is encountered,
foundation excavation shall be completed in accordance with 206.02(b).

(c) Landscape Replacement.

Replacement. Where roadside shrub plantings interfere with
the location of illumination installations, the plantings shall be reset at other locations
70 and
at such times as directed, all in accordance with 622. The cost of this work will not be
paid for directly, but shall be included in the costs of other pay items.

616
 All slopes for foundation grading shall be sodded. Sod shall be placed in
accordance with 621.

807.05 Backfilling.
Backfilling. Wherever practicable, all suitable materials removed from
the excavated areas shall be used in refilling cable-duct and conduit trenches. No
excavated materials shall be wasted without authorization. Materials authorized to be
80 wasted shall be disposed of as approved. Backfill for trenches shall be placed in layers
not to exceed 150 mm (6 in.), loose measurement. The first layer shall be sand or earth
containing no particles or lumps that would be retained on a 6.3 mm (1/4 in.) sieve.
The second layer shall contain no particles or lumps that would be retained on a 25 mm
(1 in.) sieve. Subsequent layers shall contain no particles or lumps that would be
retained on a 75 mm (3 in.) sieve. The second layer and each subsequent layer shall be
compacted with pneumatic hand tamps to the satisfaction of the Engineer to prevent any
future settlement of the backfilled area. Backfilling of cable-duct and conduit trenches
around lighting standard foundations, handholes, manholes, and other structures shall
be in accordance with the applicable provisions of 211. Finish grading of earthwork
90 shall be accomplished in a satisfactory manner.

807.06 Placing Conduit.

Conduit. Conduit shall be placed as shown on the plans and in
accordance with applicable provisions of 805.11. Conduit shall be of a size to readily
permit the passage of the cable-duct being used.

Conduit installed under pavement shall extend a minimum of 0.6 m (2 ft)

beyond the edge of the paved surface or improved shoulder. The ends of such conduit
shall terminate a nominal 0.6 m (2 ft) below the ground surface. The ends shall be
pitched so as to provide a positive drain to the surrounding soil. The ends shall be
100 protected by threaded cap fittings until the time of installation of cable or cable-duct.
Threaded bushing fittings shall be used on all ends before cable installation.

Conduits installed in bridge railing concrete sections shall terminate a minimum

of 0.6 m (2 ft) beyond the end of the bridge railing outside of the paved surface and a
minimum of 0.6 m (2 ft) under the ground surface. Existing conduit shall be extended
as necessary to satisfy these requirements.

Hot-dipped galvanized, malleable pipe straps and spacers shall be used to attach
conduit to bridge structures. Galvanized steel conduit hangers or pipe clamps will not
110 be permitted. Pipe straps of the proper size shall be installed 1.2 m (4 ft) center to
center along the conduit. When fastening pipe straps to concrete, a 9.5 mm (3/8 in.) by
63 mm (2 1/2 in.) galvanized steel lag screw, with an approved sleeve, shall be used;
however, other approved expansion anchors may be used. The pipe strap and spacer
shall be bolted to the steel beams.

617
 Conduit for service supply shall be mounted on a service pole, either company
or State owned, near the right-of-way line. For simple supply circuits, one straight,
continuous, conduit riser shall be used. The top end shall terminate with a weatherhead
device, and the lower end shall terminate at least 0.6 m (2 ft) below ground level with a
120 threaded grounding bushing fitting. Unless otherwise directed, the weatherhead shall be
7.3 m (24 ft) above the ground. However, the actual elevation of the weatherhead shall
meet the requirements of the utility concerned.

807.07 Connections in Base of Lighting Standards.

Standards. Conductors shall be
electrically bonded to each other, as required to satisfy circuit requirements, by means
of compression type fittings of the style and type shown on the plans. Inhibitor
compound shall be used on each compression connection. Conductor identification shall
be maintained by connecting like color connectors.

130 A multiple conductor compression fitting shall be used to connect supply

conductors and an insulating link used to provide an extension as shown on the plans.
These fittings shall be covered with snap-on fiber or plastic covers designed to protect
them from electrical contact. Taping will not be permitted. The bare extension of the
supply conductor from the multiple fitting to the insulation link shall be no longer than
necessary to admit the application of the snap-on cover for the multiple fitting.

The pole circuits shall be connected by means of easily separated, single

conductor connector kits. The connector kit on the "hot" side of the pole circuit shall be
fused. The connector kit for the neutral side shall not be fused. Fuses shall be of the
140 "KTK" series with a rated capacity three times the operating amperage of the luminaire.
If the required capacity is not a standard size, the next larger size fuse shall be used.

The connector kit on the "hot" side of the pole circuit shall have the following
features:

(a) a line side and load side housing made of plastic or water resisting
synthetic rubber suitable for direct burial in the ground or installation in
sunlight;

150 (b) a water seal between the two housings;

(c) each housing permanently marked "Line Side" or "Load Side";

(d) a spring loaded, 90% minimum conductivity, contact suitable for

gripping the "KTK" cartridge fuse in each housing. These contacts shall
be fully annealed;

(e) an interior arrangement for each housing that will adequately receive and
rigidly maintain the fuse contacts;
160
(f) a terminal on each housing designed for a crimp type connection to the
conductor that securely retains the conductor in the proper position;

(g) a water seal between the conductor and the housing;

618
 (h) a disconnecting means that shall retain the fuse on the load side when
disconnected and keep the conductive parts of the line side inaccessible;
and

170 (i) sufficient silicone compound provided and used to lubricate the metal
parts and the rubber housings or boots for easy assembly.

The neutral side connector kit shall be similar in all respects to that described
for the hot side except that a dummy fuse shall be used for the purpose of completing
the electrical circuit. The bayonet disconnect feature of the connector kits shall be part
of the load side of both the neutral side and the hot side conductors. The line side shall
have a socket to receive the bayonet. These kits shall be installed in the pole circuit
between the luminaire terminals and the compression connection to the underground
distribution circuit as shown on the plans. A separate insulated conductor shall be used
180 to connect the neutral of the underground distribution circuit and the neutral of the pole
circuit to the ground lug in the pole base from the point at which both neutrals are
connected together by a compression connection. The bayonet disconnect features from
the neutral side and the hot side connector kits as cited above shall be included in the
sign structure circuitry when luminaires are installed on the sign structures.
Consecutive roadway luminaires in a circuit shall be alternately connected to opposite
load conductors R or B as specified in the plans to balance the load. Sign luminaires on
individual structures shall be similarly connected.

807.08 Placing Wire and Cable.

Cable.
190
(a) Underground Through Cable-duct
Cable-duct.. All underground distribution
conductors shall be continuous runs between splice points. Unless otherwise authorized,
splice points shall be inside the bases of lighting standards, inside handholes, in service
distribution boxes, at point of connection to power supply in switch boxes, or in
junction boxes. All splices shall be made with the proper connector in accordance with
807.06.

1. Cable-duct
Cable-duct.. Cable-duct shall be placed either in a trench or plowed
into place. Cable-duct shall be installed without sharp bends or kinks and in straight
200 runs so as to permit withdrawal of a conductor and the installation of a new conductor
without additional excavation or backfill.

Plowed cable-duct shall be installed at a minimum depth of 0.6 m (2 ft) in a

single cavity gored into the earth by a vibrating plow blade. The equipment used for
plowing the cable-duct shall be designed specifically for that purpose with the power
and versatility to easily and accurately bury the various sizes of cable-duct under all
normal soil conditions. This equipment shall place the cable-duct without twisting,
kinking, or damaging it in any way. Dragging or pulling the cable-duct from the start of
the trenching operation will not be permitted. Where two ducts are to be installed
210 parallel to each other, the distance between them shall be no less than 300 mm (12 in.)
nor more than 600 mm (24 in.).

619
 The plastic duct of the cable-duct shall be terminated 100 mm (4 in.) above the
top of foundations or 100 mm (4 in.) inside handholes with sufficient excess conductors
as directed. All terminations of this plastic duct shall be beveled free from any sharp
edges or burrs. Insulation of the electrical conductor shall not be damaged when cutting
the duct.

2. Cable Markers.
Markers. The location of underground conduits or cable-ducts
220 shall be marked with cable markers. The marker shall be placed at all changes in
direction, where the underground distribution circuit is split, and at a maximum of 122
m (400 ft) intervals on straight runs. Cable markers shall be a slab of concrete 0.6 m (2
ft) square by 100 mm (4 in.) thick, with the word "Cable" die impressed into the
surface of the marker, a minimum depth of 10 mm (3/8 in.) with letters a minimum of
50 mm (2 in.) high. Arrows showing the direction of the cable shall be die impressed or
sawcut a minimum depth of 10 mm (3/8 in.) into the marker surface.

Curing of the concrete shall be in accordance with 702.21. The cable marker
shall have a smooth metal trowel finish without scaling.
230
(b) Underground Through Conduit.
Conduit. The underground distribution circuit
shall be protected by galvanized steel conduit when installed under pavement, in road
shoulders, or elsewhere as shown on the plans or as directed.

1. Cable-duct
Cable-duct.. Cable-duct shall be pulled through the entire length of
galvanized steel conduit if at all possible. If this is not possible, written authorization
shall be obtained to permit the duct to be cut away and the conductors installed in the
conduit with a minimum of 0.6 m (2 ft) of duct extended into the conduit. Where so
authorized, the plastic duct shall be terminated in the proper transition fitting attached
240 to the end of the conduit and each conductor of the cable-duct assembly shall continue
undamaged and uninterrupted through the galvanized steel conduit to the other end of
the conduit where a transition to the cable-duct shall be used again and the cable-duct
shall continue uninterrupted to the next designated splice point. All transitions from
galvanized steel conduit to cable-duct shall be accomplished with the proper adapter.
This adapter shall provide a durable, watertight transition that has a smooth uniform
interior.

2. Cable Markers.
Markers. Cable markers shall be in accordance with
807.07(a)2.
250
(c) In Conduit Risers.
Risers. Cable-duct shall enter the bottom of the conduit riser
with a sweeping radius bend and continue up the riser to within 75 mm (3 in.) of the
top of the conduit riser. At this point the plastic duct shall be terminated and the
conductors shall continue uninterrupted and undamaged into the service cabinet,
underpass switchbox, or through the weatherhead with sufficient excess to make the
required connections.

(d) Through Conduit in Bridge Coping.

Coping. Where a cable-duct underground
distribution circuit is run through conduit installed in bridge coping, the duct shall be
260 cut away and the conductors shall be installed in the conduit with at least 0.6 m (2 ft) of
duct extended into the conduit. The conductors, through this transition, shall be

620
 continuous between authorized splice points. Where more than one lighting standard is
to be installed on the same side of the bridge structure and connected to the same
distribution circuit, the cables pulled between these lighting standards shall be of the
same type and size used in the cable-duct underground distribution circuit.

(e) Aerial Cable.

Cable. Aerial cable for overhead distribution circuits shall be
supported and terminated as shown on the plans. The aerial cable shall have a sag of no
more than 5% of the distance between lighting poles except where slack spans are
270 indicated on the plans. Aerial cables shall have a minimum vertical clearance of 5.5 m
(18 ft).

807.09 Lighting Handholes.

Handholes. Handholes shall not be placed in areas subject to
flowing or ponding water. Handholes shall be installed with the top flush with adjoining
surfaces. Precast handholes with integral bottoms will be considered acceptable.

Multiple compression fittings and insulating links installed in handholes shall be

taped and waterproofed by application of an approved waterproofing device. The
insulation around the area to be waterproofed shall be cleaned before applying the
280 waterproofing device. These waterproofing devices shall be designed for insulating
multi-conductor cables with a minimum voltage carrying capacity of 600 volts.

Heavy weave fiberglass reinforced polymer concrete service boxes will be

permitted as an acceptable substitute for a street and alley handhole providing that they
can be placed at a location which meets both of the following conditions:

(a) there is no evidence of vehicles traveling over the area where the
handhole is to be located; and

290 (b) it is located a minimum of 4.6 m (15 ft) from the edge of pavement,
unless it is protected guardrail, unmountable curb, a structure, or an
untraversable ditch.

The handhole shall be backfilled with sand or earth containing no particles that
would be retained on a 6.3 mm (1/4 in.) sieve. The backfill shall be placed as shown on
the detail sheet of the plans. No additional payment will be allowed for this backfill.

807.10 Concrete Foundations For Lighting Standards.

Standards. Foundations shall be
class A concrete in accordance with 702. Footings may be either round or square in
300 shape as shown on the plans.

Anchor bolt circle dimensions shall be furnished and the anchor bolts shall be in
accordance with 913.11(a)7. A rigid template shall be used to center the anchor bolts in
the foundation. Unless otherwise specified, the template shall be oriented so that the
mast arm of the lighting standard is perpendicular to the center line of the roadway.

Each foundation installation shall have provisions for grounding the lighting
standard in accordance with 807.12. The tops of the concrete foundations shall be
constructed level and only shims used to rake the lighting standard will be permitted.
310 Shims will not be permitted with break-away couplings. Each foundation shall have an

621
 imprinted arrow or arrows on the top of the foundation to indicate the direction of the
cable duct run.

Foundations for high mast towers shall be constructed prior to constructing

foundations for conventional roadway lighting.

(a) Cast-in
Cast-in-Place
-Place Foundations.
Foundations. If the sidewalls of the excavated areas remain
firm and stable, concrete may be poured directly against the dirt below the level of the
top 150 mm (6 in.) form. Otherwise, the concrete foundation shall be fully formed by
320 means of a paper preformed liner or other approved means. However, the foundation
shall be formed to the proper size for the top 150 mm (6 in.) before concrete is poured.
If a paper liner is used, it may be withdrawn as the concrete is placed or it may be left
in place permanently. If the liner is left in place, all voids between the excavation walls
and the form shall be filled and compacted using size No. 53 aggregate. If the liner is
withdrawn, the top 300 mm (12 in.) of the foundation shall remain formed until the
concrete has obtained initial set.

(b) Precast Foundations.

Foundations. Precast foundations shall be complete with
reinforcing bars, tie bars, anchor bolts, and entry sleeves located to provide a level
330 mounting for the lighting standard after installation. The grounding coil, as shown on
the plans, may be used for grounding lighting standards set on precast foundations.
Foundation backfill shall consist of compacted size No. 53 aggregate.

(c) Grading of Foundations.

Foundations. Foundation projection above the finished grade
shall be as shown on the plans. The excavated material may be used for this grading if
it is not granular in nature and will readily stabilize and support the growth of sod. If
the excavated material is unsuitable, it shall be properly disposed of and approved
materials used. The area shall be sodded. Sodding will be in accordance with 621.

340 807.11 Placing Lighting Standards.

Standards.

(a) Lighting Standards Under 24 m (80 ft) in Height.

Height. The lighting standard
assembly shall consist of a metal pole, a shoe base, a frangible breakaway base or
coupling where shown on the plans, and a metal mast arm for attaching the luminaire.
The unit shall be assembled on the ground. Pole circuit wiring shall be installed and the
luminaire shall be attached prior to erection. The factory finish of the pole assembly
shall be protected from mars, blemishes, scratches, or other damage. Slings and
chokers for lifting purposes shall be of nylon or other approved material. Chains, metal
rope, or other abrasive materials will not be permitted for lifting devices. If damage to
350 the factory finish occurs, repair or replacement shall be as directed.

622
 After erection and attachment to the foundation, the pole assembly shall be
plumb. The luminaires shall be level in both horizontal areas. Shims will not be
permitted with breakaway couplings. Shimming will be permitted on other types of
installations to rake the pole assembly to obtain the desired attitude of the luminaire
where the combined weight of the pole and mast arm requires it and the luminaire
saddle will not permit the adjustment. The mast arm shall be perpendicular to the axis
of roadway travel unless special orientation is noted on the plans. Unless otherwise
specified, the lighting system shall consist of metal pole supports for the luminaires
360 with an underground electrical supply system.

(b) High Mast Lighting Standards of 24 m (80 ft) Height and Over. Over. High
mast light pole sections shall be mechanically fitted in the field using factory supplied
hydraulic jack or hoist puller that shall produce a minimum force of 44.5 kN (10,000
lb) per side. Field assembly procedures and assembly apparatus requirements shall be
submitted for approval. Field welds will not be permitted except where shipping
limitations prevent permanent factory assembly. Prior approval for field welds is
required.

370 The pole shall be erected on the lower set of the anchor bolt nuts and secured
with the top nuts. The adjustments to plumb the pole shall be made prior to the final
tightening of the top nuts.

The pole shall be plumbed under no wind conditions before sun-up, after
sun-down, or on an overcast day. The deviation from vertical shall not exceed 6.5 mm
(1/4 in.) within any 3 m (10 ft) of height.

When installing the high mast power cable, one end of the power cable shall be
securely connected to the luminaire ring. The other end of the power cable shall be
380 secured to the support and terminated 0.9 m (3 ft) below this support with a heavy duty
three wire electrical plug. Adjustments of the three support cable lengths shall be made
prior to lowering the ring for the first time. After the support cables have been adjusted
and the luminaires installed on the ring, at least one complete cycle operation of the
ring shall be conducted on each structure.

807.12 Grounding.
Grounding. Ground wire shall be No. 6 solid bare copper. Ground rods
shall be 13 mm (1/2 in.) diameter by 2.4 m (8 ft) long copper-weld ground electrodes
except where larger sizes are specified. The top of the ground rod shall be driven at
least 150 mm (6 in.) below grade. Ground rods shall not be installed within the lighting
390 standard, sign structure, or high mast tower foundations.

The ground wire shall be connected to the top or side of the ground rod. The
ground rod, ground wire connection shall be made by a thermo weld process. The wire
and ground rod shall be free of oxidized materials, moisture, and other contaminates
prior to inserting the wire and the ground rod into the properly sized mold. The
welding material shall sufficiently cover and secure the conductor to the rod. The
completed connection shall be nonporous.

623
 As an acceptable substitute to this process, a mechanical ground grid connection
400 of an approved type may be used. Tap type clamps, parallel type clamps, U-bolt flat
clamps, and crossover clamps will not be accepted.

Luminaire standards shall be grounded by connecting the free end of the ground
wire to the grounding lug in the transformer base or pole. The free end of the ground
wire shall enter the pole base through the entry sleeve installed in the foundation.

The neutral conductor of the underground distribution circuit shall be connected

to the ground lug in the transformer base or pole. This connection shall include a
quick-disconnect type connector kit so that in the event of a pole knockdown the
410 connection will readily break without damage to the buried conductor.

The breaker boxes for the sign and underpass circuits shall be grounded by
connecting the free end of the ground wire to the neutral grounding terminal in the
breaker box and connecting this terminal to a grounding lug securely fastened to the
metal interior of the breaker box. The conduit terminating in the breaker box and the
sign or underpass luminaire housing shall have a good, clean, tight connection and act
as a grounding conductor for these luminaires. The neutral conductors of the feed and
distribution circuits for underpass and sign illumination shall be connected to the neutral
grounding terminal in the switch box or breaker box. The neutral conductor of the
420 distribution circuit for underpass and sign illumination shall be grounded in each
luminaire by connecting a jumper from the neutral terminal of the luminaire to a ground
lug fastened to the metal housing of the luminaire.

Sign structures shall be grounded at one sign column by connecting the free end
of the grounding wire at that column to the grounding lug in the column base.

A type I service for supply of electrical energy shall consist of a conduit riser to
a weatherhead. This conduit shall be grounded at the lower end by means of a standard
strap grounding connection to the ground wire and ground rod. A type II service shall
430 consist of a multiple number of conduits from underground to the bottom of the service
cabinet and a single conduit to a weatherhead from the top of the service cabinet. All of
these conduits shall be connected by a single ground wire from the grounding terminal
to a grounding bushing for each conduit within the interior of the service cabinet. In
addition a ground wire from the grounding terminal of the service cabinet shall be
connected through a conduit to a ground rod.

Bridge railing conduits shall be grounded at each end of the bridge railing by
means of a standard grounding strap connected to a ground wire and ground rod. The
ends of the conduits terminating in a bridge anchor location shall provide ground
440 continuity by means of a grounding bushing on each conduit end and the connection of
the bushing to a ground wire.

All equipment used in the highway lighting system shall be grounded. If

necessary, additional grounding shall be installed as directed.

624
 807.13 Luminaire Installation.
Installation. Luminaire installation shall consist of the
physical placing of the luminaire. Each installation shall include the furnishing and
placing of the lamp as designated.

450 (a) Roadway Luminaires.

Luminaires. Each luminaire shall be leveled in both directions
in the horizontal plane after the light standard has been erected and adjusted. Rotary
adjustment of the mast arm and vertical adjustment of roadway luminaires to obtain an
installed level position in both directions shall be accomplished by means of the bolted
saddle arrangement used to attach the luminaires to the mast arm. Lamp socket
positions may be shown on the plans by type of Illuminating Engineering Society of
North American (IES) light pattern. The specified lamp socket position shall be used to
obtain the desired light pattern delivery. Proper connections shall be made to provide
ballast operation at the voltage being supplied. Replacements needed because of faulty
or incorrect voltage connections shall be made with no additional payment.
460
(b) Sign Luminaires.
Luminaires. Connections in which plain and galvanized steel are in
contact shall be protected such that aluminum surfaces shall receive one coat of zinc
chromate primer. Steel surfaces shall receive one coat of inorganic zinc primer
followed by one coat of aluminum paint. All paint shall be permitted to dry before
assembly. Conduit fittings, if required, shall be watertight. Required conduit shall be
either rigid or flexible as necessary. Conduit shall not be clamped to a sign panel.

Sign luminaires shall be mounted on overhead sign structures on two metal

channels located at the extremity of the sign walkway support brackets. The distance
470 between lighting unit support channels shall be 180 mm (7 in.). These channels shall be
located in such a manner that they readily receive the mounting bolts from the rear of
the sign luminaire. The installation of the sign luminaire shall consist of the physical
placement of the luminaire on the channels.

Sign luminaires shall be connected to a phase conductor and a neutral conductor.

The luminaires shall be alternately connected to opposite phase conductors to balance
the load. The connections in the base of the sign structure shall be in accordance with
807.06. Conductor splicing shall be in junction boxes, in-ground handholes, inside
handholes of sign structures, and circuit breaker enclosures.
480
(c) Underpass Luminaires.
Luminaires. Underpass luminaires shall be mounted on the
vertical side surfaces of bridge bent structures or suspended by means of pendants
supported by angle-iron struts or clips fastened to the structural beam members of the
bridge. All parts of the pendent pipe assembly shall be hot-dipped galvanized after
threads are cut. Silicone caulking compound shall be applied to the threads during
assembly of the pendent. Underpass luminaires may require separately mounted ballasts
which shall be installed in close proximity to the luminaires.

Underpass luminaires shall be connected to a phase conductor and a neutral

490 conductor. The luminaires shall be alternately connected to opposite phase conductors
to balance the load. Conductor splicing will only be allowed in junction boxes, in
ground handholes, and circuit breaker enclosures.

625
 (d) High Mast Luminaires.
Luminaires. The aiming of the luminaires shall be as shown
on the plans. When the aiming process is being done the luminaire shall be oriented to
conform to its raised position and the ring properly tethered to prevent rotation during
the aiming adjustment. The long axis of the luminaire shall be parallel to the aiming
direction indicated on the plans.

500 807.14 Sign, Underpass, Roadway, and High Mast Lighting Location
Identification.
Identification. All high mast towers, roadway light standards, underpass lighting
installations, and sign lighting installations shall have an identification code number as
shown on the plans. In addition, each luminaire at a sign or underpass installation shall
be individually identified with a single capital letter.

The code number shall be displayed on the light standard, sign structure
column, and high mast tower as shown on the plans. The underpass code number shall
be displayed near the breaker box at a location as directed.

510 The code number for the lighting standard and sign structure column shall be
applied to the pole, as specified by the manufacturer, by using individual, pressure
sensitive, adhesive backed tags. The code number for the high mast tower shall be
applied to an aluminum plate which is mounted with spacers away from the structure as
shown on the plans.

807.15 Service Point Power Entry. Entry. The utility's requirements for service
locations shall be coordinated. Unless otherwise specified, a pole shall be furnished for
the service point. If the utility requires metering of the lighting system, a meter socket
shall be obtained from and installed in accordance with the requirements of the utility.
520 Grounding shall be in accordance with 807.11 and shall be a part of the service
installation.

Energy shall be provided with 120/240 V service or 240/480 V service with the
proper KW capacity on poles located immediately inside the right-of-way at locations
designated on the plans. Electrical materials incorporated in the work shall be
compatible with the service voltages supplied by the local utility.

The service voltages supplied by the local utility shall be checked for
compliance with the planned voltages. If a discrepancy exists, it will be resolved as
530 directed before work is started or any electrical equipment is purchased.

(a) Types of Service Points.

Points. Service point installations shall be of two types
as shown on the plans.

626
 1. Type I Service Point.
Point. This service point installation shall consist of
class 5 wood pole, 70 mm (2 3/4 in.) galvanized steel conduits, weatherhead, photo cell
and multiple relay switch. The conduit riser shall be fastened and supported on the pole
by means of galvanized hook pipe straps and secured to the pole by means of a
galvanized lag screw all of the proper size for the conduit being installed. Cable-duct
540 shall be installed in the conduit riser in accordance with 807.07. The conductors shall
extend beyond the weatherhead a minimum of 1.2 m (4 ft). The conductors outside of
the weatherhead shall be ringed to prevent moisture from entering the conduit
enclosure.

2. Type II Service Point.

Point. This service point installation shall consist of a
service cabinet with a single galvanized steel or aluminum conduit riser to the
weatherhead. A multiple number of galvanized steel conduits shall extend from the
bottom of the service cabinet in accordance with 807.05. Underground cable-duct shall
be installed in accordance with 807.07(c). Connections, connectors, and fixtures shall
550 be as shown on the plans.

The service cabinet shall be secured to the pole by means of a galvanized steel
channel post or other approved device.

(b) Sign and Underpass Circuits.

Circuits. The illumination circuits for sign structures
with an overhead power supply shall be protected by circuit breakers mounted on the
end support.

Circuits for adjustable end support sign structures, bridge bracket signs, or
560 underpasses shall be protected by circuit breakers mounted on the bridge or sign
structure and connected to the underground distribution circuit in a handhole.

Circuits for sign structures with an underground power supply shall be protected
by fuse connector kits in the base of the sign support. The fuse connector kits shall
include bayonet disconnect features for the "neutral" side and "hot" side.

(c) Multiple Relay Switches.

Switches. Unless otherwise specified, wood pole,
multiple relay switches, service cabinet, photocells, photocell receptacles, weatherhead,
conduit, and other miscellaneous items shall be furnished and installed as a part of the
570 service point.

807.16 Testing of Highway Lighting System.

System.

627
 (a) Testing Lighting Circuitry.
Circuitry. All necessary equipment and apparatus
properly calibrated for testing the lighting circuits shall be furnished. The supplying
utility shall be given advance notice of the test scheduling so their representative may
witness the testing procedures if desired. Each main lighting circuit, including its
branches, shall be tested for insulation resistance and continuity after it is completely
installed but before the pole circuits, underpass circuits, sign circuits, and grounding
580 circuits are connected. The insulation resistance test shall be made with a megohm
meter and the resistance to ground shall be no less than 50 megohms in all lighting
circuit power cables. The meter shall be set for the voltage rating of the insulation. The
continuity test shall be made with an ohmmeter properly scaled for measuring the
resistance of the power cables. This test shall verify the following:

1. That each power cable is continuous to its termination points.

2. That the cable coding at junction and termination points is consistent

with cable coding at the supply point.
590
3. That power cables are not crossed with the neutral or each other.

4. That the main circuit through each of its branches does not have
unusual resistance values.

The entire completed installation shall be tested by circuit or by such portions as

may be selected and at night if directed. Tests shall demonstrate the following:

1. That all power, lighting, and control circuits are continuous, free
600 from short circuits, and free from unspecified grounds.

2. That all circuits are properly connected in accordance with

applicable wiring diagrams.

3. That all circuits are operable which shall be demonstrated by

continuous operation of each lighting circuit for at least 1 h.

4. That voltage at the ends of each lighting circuit and at inter points is
within allowable limits. A maximum of 10% voltage drop will be
610 permitted for each complete circuit.

(b) Testing and Inspecting Luminaires.

Luminaires. The lighting system from the service
point through the last luminaire shall be subjected to 14 days of normal operation prior
to final acceptance. This testing procedure may be conducted separately on each circuit
or on the entire system.

Normal operation is defined as the luminaires being on during the darkness

hours and off during the daylight hours as controlled by the service point photocells and
relay switches. Malfunctioning equipment shall be replaced or repaired before final
620 inspection. The pattern of light delivered to the pavement by roadway and high mast
luminaires will be inspected at night. At this inspection, the proper tools, equipment,
and personnel shall be available to make all adjustments. These items shall specifically

628
 include a bucket truck capable of reaching all luminaires in the system, safety
equipment, and a level to determine the proper luminaire position.

807.17 Pay Item and Installation Summary Sheets.

Sheets. Prior to final inspection, two
sets each of shop drawings, installation summary, and pay item summary marked Final
Record shall be furnished for the light standards as installed. The installation summary
shall show the effective mounting height, arm length, foundation elevation, pay item,
630 type of base, and catalog number or drawing for each light standard furnished. The pay
item summary shall indicate the pay item, quantity, effective mounting height, arm
length, and type of base for each type of lighting standard furnished.

807.18 Method of Measurement.

Measurement. Luminaire, light standard with mast arm, high
mast standard, identification number, connector kit, multiple compression fitting,
insulating link, foundation, handhole, service point, and cable marker will be measured
by the number of units installed. Pole circuit conductor and circuit conductor in conduit
will be measured by the meter (linear foot). Pole circuit conductor will be measured
from the base of the lighting standard to the terminal block of the luminaire. Pole line
640 extension will be measured in a straight line between each pole.

Conductor in bridge conduit will be measured by the meter (linear foot) from
end to end of conduit or from the end of conduit to the last bridge light pole foundation
entry. An allowance of 1.5 m (5 lft) will be made for each foundation entry. An
allowance of 0.6 m (2 lft) will be made for each junction box.

Removal of existing light structure, which shall include the pole, mast arm, and
foundation, will be measured by the number of units removed.

650 Cable-duct and conductor in underground duct or conduit will be measured by

the meter (linear foot) as follows:

(a) From the Face of the Concrete Foundation to the Center of the Handhole
or Face of the Next Concrete Foundation.
Foundation. An allowance of 1.5 m (5 lft) will be made
for each entry at foundations. An allowance of 0.6 m (2 lft) will be made at handholes
for connection purposes.

(b) From Lighting Standard Bases or Handholes to Switch Boxes at

Underpasses.
Underpasses. An allowance of 1.2 m (4 lft) will be made at the switch box for electrical
660 connections.

(c) From End to End of the Conduit when the Cable is in Conduit under a
Roadway Surface or Shoulder.
Shoulder. No measurement will be made of cable-duct in conduit
where it is part of a service point, sign installation, or underpass lighting system.

807.19 Basis of Payment.

Payment. Luminaire will be paid for at the contract unit price
per each for the type and wattage specified. Service point will be paid for at the
contract unit price per each for the type specified. Light pole will be paid for at the
contract unit price per each for the estimated mounting height, length of mast arm, and
670 base type specified.

629
 Lighting foundation, concrete, with grounding will be paid for at the contract
unit price per each for the size specified. If class X material is encountered during
lighting foundation excavation, payment will be made for such excavation in
accordance with 206. Partial payment for lighting foundation in the amount of 80% will
be made if all such work is complete except for finish grading and sodding. The
remaining percentage of payment will be made upon completion of the finish grading
and sodding.

680 Connector kit will be paid for at the contract unit price per each for fused or
unfused, as specified. Multiple compression fitting and insulation link will be paid for
at the contract unit price per each for waterproofed or nonwaterproofed, as specified.
Cable-duct marker, high mast tower winch drive, and handhole, lighting will be paid
for at the contract unit price per each. Sign, underpass, and roadway lighting location
identification will be paid for at the contract unit price per each. Circuit installation will
be paid for at the contract unit price per each for the type, structure number, and
number of luminaires specified. Light structure, remove and portable tower lighting
drive system will be paid for at the contract unit price per each.

690 Wire will be paid for at the contract unit price per meter (linear foot) for the
designation, copper gage, housing, and number of conductors specified. Pole circuit
cable, THWH, stranded will be paid for at the contract unit price per meter (linear foot)
for the copper gage and number of conductors specified. Conduit, steel, galvanized,
50 mm diameter will be paid for at the contract unit price per meter. (Conduit, steel,
galvanized, two inches diameter will be paid for at the contract unit price per linear
foot).

Payment will be made under:

700 Pay Item Metric Pay Unit Symbol (English Pay Unit Symbol)
Metric Pay Item Metric Pay Unit Symbol
(English Pay Item English Pay Unit Symbol)

Cable-Duct Marker ............................................................ EACH

Cable, Pole Circuit, THWH, No. ____ Copper, Stranded,
___ ___/C...................................................................m (LFT)
Circuit Installation, Str. No. ____, ____ Luminaires ..................... EACH
no.
Conduit, Steel, Galvanized, 50 mm ...............................................m
710 (Conduit, Steel, Galvanized, 2 in. .............................................LFT)
Connector Kit, Fused .......................................................... EACH
Connector Kit, Unfused ....................................................... EACH
Handhole, Lighting ............................................................ EACH
High Mast Tower Winch Drive .............................................. EACH
Insulation Link, Nonwaterproofed ........................................... EACH
Insulation Link, Waterproofed ............................................... EACH
Lighting Foundation, Concrete, with Grounding,
_____ mm x _____ mm x _____ mm ..................................... EACH
(Lighting Foundation, Concrete, with Grounding,
720 _____ in. x _____ in. x _____ in. ........................................ EACH)

630
 Light Pole, High Mast, ________ m E.M.H............................... EACH
(Light Pole, High Mast, ________ ft. E.M.H. ........................... EACH)
Light Pole, Roadway, ________ m E.M.H.,
________ m Mast Arm, ________ Base .................................. EACH
(Light Pole, Roadway, ________ ft. E.M.H.,
________ ft. Mast Arm, ________ Base................................. EACH)
Light Structure, Remove ...................................................... EACH
Luminaire, High Mast, _____, _____ Watt ................................ EACH
type
730 Luminaire, Roadway, _____, _____ Watt.................................. EACH
type
Multiple Compression Fitting, Nonwaterproofed.......................... EACH
Multiple Compression Fitting, Waterproofed .............................. EACH
Portable Tower Lighting Drive System ..................................... EACH
Service Point, _____........................................................... EACH
type
Sign, Underpass, and Roadway Lighting Location
Identification .................................................................. EACH
Wire, ___________, No. ____ Copper,
740 designation
in ________, ___ ___/C .................................................m (LFT)
housing

The costs of lamps, ballast, optical systems, weatherproof housings, and

electrical connections shall be included in the cost of luminaire.

The costs of the mast arm, J-support hook for pole circuit, handhole with cover,
shoe base, transformer base or frangible coupling if required, installation on the
foundation with the pole circuit, and luminaire installation shall be included in the cost
750 of light pole.

The costs of the pole; lowering system including winch assembly, power cable,
and support cable; concrete pad; luminaire ring; anchor bolts and nuts; lightning rod
assembly; grounding system; and all incidental materials necessary to complete the
installation shall be included in the cost of light pole, high mast. The costs of
excavation, concrete, sleeves for cable duct, reinforcing steel, backfill, finish grading,
and sodding shall be included in the cost of lighting foundation.

The costs of aerial distribution service, drops to sign structures branching off
760 from the pole line extension, weatherheads and risers required to connect the line
extension to the underground electrical distribution circuit, all anchorage, guy wires,
hardware, aerial cable, electrical connections, wood poles, and incidentals required to
complete the pole line extension shall be included in the cost of cable, pole circuit.

The costs of snap-on covering in light pole base and waterproof covering in
underground handhole shall be included in the cost of multiple compression fitting.

The costs of circuit breakers; breaker enclosures; conduit; flexible conduit;

conduit fittings; grounding; weatherhead; aerial cable termination; and incidentals

631
770 required from the last luminaire to the point of attachment by the utility, the bottom of
the riser at the structure base, or the connector kits in the base of the sign supports shall
be included in the cost of circuit installation.

The cost of maintaining highway illumination during the contract time shall be
included in the costs of other pay items.

SECTION 808 -- PAVEMENT TRAFFIC MARKINGS

808.01 Description.
Description. This work shall consist of furnishing and installing, or
removing, pavement traffic markings and snowplowable raised pavement markers in
accordance with the MUTCD, these specifications and as shown on the plans. Markings
shall be installed as required unless written approval is obtained from the District
Traffic Engineer to make modifications at specific locations.

MATERIALS
10
808.02 Materials.
Materials. Materials shall be in accordance with the following:

Cones .............................................................. 801.08

Epoxy .............................................................. 913.14(b)3
Glass Beads ....................................................... 913.09
Preformed Plastic ................................................ 913.14(b)2
Snowplowable Raised Pavement Markers .................... 913.14(d)1
Thermoplastic..................................................... 913.14(b)1
Traffic Paint....................................................... 909.05
20
CONSTRUCTION REQUIREMENTS

808.03 General Requirements.

Requirements. Permanent pavement markings shall be placed on
the surface course in a standard pavement marking pattern. Center lines shall be placed
on two-way two-lane roads, lane lines shall be placed on multi-lane divided roads, and
both center lines and lane lines shall be placed on multi-lane undivided roads. The
markings shall be of the same material as the existing pavement markings or any
durable pavement marking material.

30 The pavement shall be cleaned of all dirt, oil, grease, excess sealing material,
excess pavement marking material and all other foreign material prior to applying new
pavement traffic markings. New paint pavement markings may be placed over sound
existing markings of the same color. New thermoplastic, preformed plastic, or epoxy
markings may be applied over sound existing markings of the same type if permitted by
manufacturer’s recommendations, a copy of which shall be supplied to the Engineer
prior to placement; otherwise, existing markings shall be removed in accordance with
808.09 prior to placement of the new markings. Removal of pavement marking material
shall be in accordance with 808.09. The pavement surface shall be dry prior to applying
pavement traffic markings.
40
Control points required as a guide for pavement traffic markings shall be spotted
with paint for the full length of the road to be marked. Control points along tangent

632
 sections shall be spaced at a maximum interval of 30 m (100 ft). Control points along
curve sections shall be spaced so as to ensure the accurate location of the pavement
traffic markings. The location of control points shall be approved prior to the pavement
traffic marking application.

808.04 Longitudinal Markings.

Markings. All longitudinal lines shall be clearly and
sharply delineated, straight and true on tangent, and form a smooth curve where
50 required. Lines shall be square at both ends, without mist, drip or spatter.

A solid line shall be continuous. A broken line shall consist of 3 m (10 ft) line
segments with 9 m (30 ft) gaps.

All lines shall be gapped at intersections unless otherwise specified or directed.

The actual repainting limits for no-passing zone markings will be determined by
the Engineer.

60 A new broken line placed over an existing broken line shall laterally match the
existing broken line, and the new line segments shall not extend longitudinally more
than 10% beyond either end of the existing line segments.

(a) Center Lines.

Lines. Center lines shall be used to separate lanes of traffic
moving in opposite directions. All center line markings shall be yellow in color and
100 mm (4 in.) in width. They shall be placed such that the edge of the marking,
nearest to the geometric centerline of the roadway, shall be offset 100 mm (4 in.) from
the geometric centerline.

70 The center line of a multi-lane roadway shall be marked with a double solid
line. The two lines forming the double solid line shall be spaced 200 mm (8 in.) apart
and shall be equally offset on opposite sides of the geometric centerline.

The center line of a 2-lane, 2-way roadway, where passing is allowed in both
directions, shall be marked with a broken line.

The center line of a 2-lane, 2-way roadway, where passing is allowed in one
direction only, shall be marked with a double line, consisting of a broken line and a
solid line. The broken line and the solid line shall be spaced 200 mm (8 in.) apart and
80 shall be equally offset on opposite sides of the geometric centerline. The solid line shall
be offset toward the lane where passing is prohibited. The broken line shall be offset
toward the lane where passing is permitted.

(b) Lane Lines.

Lines. Lane lines shall be used to separate lanes of traffic moving
in the same direction. Normal lane line markings shall be white in color and shall be
125 mm (5 in.) wide on freeways, interstates and toll roads, and 100 mm (4 in.) wide
on all other roads. They shall be offset 100 mm (4 in.) to the right of longitudinal
pavement joints or divisions between traffic lanes. Normal lane lines shall be marked
with white broken lines. White solid lines shall be used to mark lane lines only when
90 specified or directed.

633
 (c) Edge Lines.
Lines. Edge lines shall be used to outline and separate the edge of
pavement from the shoulder. Edge line markings shall be 100 mm (4 in.) in width and
shall be placed such that the edge of the marking nearest the edge of the pavement shall
be offset 100 mm (4 in.) from the edge of the pavement except as otherwise directed.
Right edge lines shall be marked with a white solid line and left edge lines shall be
marked with a yellow solid line.

(d) Barrier Lines.

Lines. Barrier lines shall be used as specified or directed. Barrier
100 line markings shall be solid lines of the size and color specified or as directed.

808.05 Transverse Markings.

Markings.

(a) Transverse marking lines shall be used as specified or directed to

delineate channelizing lines, stop lines, crosswalk lines, and parking
limit lines. The markings shall consist of all necessary lines, of the width
specified or directed and shall be in accordance with the MUTCD.

(b) Pavement Message marking shall be used as specified or directed for

110 railroad crossing approaches, intersection approaches, crosswalk
approaches, handicap parking spaces, and other messages applied to the
pavement with pavement marking material. The markings shall consist of
all necessary lines, words, and symbols as specified or directed, and
shall be in accordance with the MUTCD.

808.05.1 Curb Markings.

Markings. Curb markings shall consist of reflectorized paint
which shall cover the face and top of the curb. The existing curb and gutter area shall
be cleaned of dirt, dust, oil, grease, moisture, curing compound, and unsound layers of
other materials before paint is applied to the curb surface.
120
808.06 Pavement Marking Material Application and Equipment.
Equipment. All double line
markings, such as a no passing zone or the center line of an undivided multi-lane
roadway, shall be applied in one pass.

Stop lines and crosswalk lines for new or modernized traffic signal installations
shall be durable pavement marking material. For this application, preformed plastic
may be used on concrete if permitted by manufacturer's recommendations. However,
for contract completion dates in winter months when conditions do not permit
application of durable markings, traffic paint markings may be substituted with an
130 appropriate unit price adjustment if approved by the Engineer.

(a) Traffic Paint.

Paint.

1. Application.
Application. Standard dry and fast dry traffic paint shall be applied
only when the pavement temperature is 5EC (40EF) or above. Waterborne traffic paint
shall be applied only when the pavement temperature is 10EC (50EF) or above.
Standard dry or fast dry traffic paint will only be permitted between October 1 and the
following April 30.

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140 The wet film thickness of the traffic paint shall be a minimum of 380 Fm
(15 mils). Painted lines and markings shall be immediately reflectorized by applying
glass beads at a uniform minimum rate of 0.7 kg/L (6 lb/gal.) of traffic paint.

2. Equipment.
Equipment. Traffic paint shall be applied with a spray type machine
capable of applying the traffic paint under pressure through a nozzle directly onto the
pavement. The machine shall be equipped with the following: an air blast device for
cleaning the pavement ahead of the painting operation; a guide pointer to keep the
machine on an accurate line; at least two spray guns which can be operated individually
or simultaneously; paint agitator(s); a control device to maintain uniform flow and
150 application; an automatic device which will provide a broken line of the required
length; and an automatic glass bead dispenser which is synchronized with the marking
application. When fast drying traffic paint or waterborne traffic paint is used, the
machine shall be capable of heating the paint to application temperatures in accordance
with 909.05.

A brush or small hand propelled machine, designed for that purpose, may be
used if approved to apply some painted markings.

(b) Durable Pavement Marking Material.

Material. Durable pavement marking
160 material consists of thermoplastic, preformed plastic, or epoxy.

1. Thermoplastic.
Thermoplastic.

a. Application.
Application. Thermoplastic marking material shall be used on
asphalt pavements unless otherwise specified or directed. The pavement surface shall be
primed with a binder material in accordance with the manufacturer's recommendations.
Thermoplastic marking shall be applied in molten form by spray, extrusion, or ribbon
type extrusion airless spray when the pavement temperature is 10EC (50EF) or above.
The average thickness of each 910 mm (36 in.) length of thermoplastic marking shall be
170 no less than 2.5 mm (3/32 in.) nor more than 5 m (3/16 in.). Immediately following the
application of the thermoplastic markings, additional reflectorization shall be provided
by applying glass beads to the surface of the molten material at a uniform minimum rate
of 2.9 kg/10m2 (6 lb/100 sq ft) of marking.

b. Equipment.
Equipment. The machine used for the spray application of
thermoplastic markings shall consist of a kettle for melting the material and an
applicator for applying the markings. All of the equipment required for preheating and
applying the material shall maintain a uniform material temperature within the specified
limits, without scorching, discoloring or overheating any portion of the material.
180
The machine shall be equipped with the following: an air blast device for
cleaning the pavement ahead of the marking operation; a guide pointer to keep the
machine on an accurate line; at least two spray guns which can be operated individually
or simultaneously; agitators; a control device to maintain uniform flow and application;
an automatic device which will provide a broken line of the required length; and an
automatic glass bead dispenser which is synchronized with the marking application.

2. Preformed Plastic.
Plastic.

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190 a. Application.
Application. The Contractor shall provide the Department with
original copies of all necessary current manufacturer’s installation manuals prior to
beginning installation work. No installation work shall begin prior to the Department's
receipt of these manuals. These manuals will become the property of the Department.

Preformed plastic shall be applied when the air temperature is a minimum of

16EC (60EF) and rising, and the pavement temperature is a minimum of 21EC (70EF).
Preformed plastic shall not be applied if the ambient temperature is expected to drop to
below 7EC (45EF) within 24 h after application. The pavement surface shall be primed
with a binder material in accordance with the manufacturer's recommendations. The
200 pavement surface shall be primed prior to the placement of preformed plastic transverse
markings.

If there is a dispute regarding installation, the manufacturer shall provide a

properly trained representative to ensure that the installation is performed in accordance
with the manufacturer's recommendations.

b. Equipment.
Equipment. The equipment for applying preformed plastic,
furnished in rolls, shall be a portable hand-propelled machine capable of carrying and
applying at least two rolls of 100 mm (4 in.) to 150 mm (6 in.) widths. The machine
210 shall be equipped with a guide pointer to keep the machine on an accurate line. The
machine shall also be equipped with guide rollers and a pressure roller. The pressure
roller may be a separate unit. The machine shall feed the marking material from its
original carton through the guide rollers and under the pressure roller onto the
pavement. The pressure roller shall be a minimum of 50 mm (2 in.) wider than the
width of the marking material and shall weigh a minimum of 91 kg (200 lb). The
machine shall also be capable of removing the backing paper from the marking material
during the application process. Preformed plastic furnished in strip, symbol, or legend
form shall be applied with suitable equipment such as hand rollers.

220 3. Epoxy.
Epoxy.

a. Application.
Application. Epoxy shall be used on portland cement concrete
pavement unless otherwise specified or directed. This material shall be applied only
when the pavement temperature is 5EC (40EF) or above. The wet film thickness of the
epoxy marking material shall be a minimum of 380 Fm (15 mils). Immediately
following the application of the epoxy markings, additional reflectorization shall be
provided by applying glass beads to the surface of the wet marking at a uniform rate of
9.8 kg/10m2 (20 lb/100 sq ft) of marking.

230 b. Equipment.
Equipment. The machine used to apply the epoxy marking material
shall precisely meter the two components, produce and maintain the necessary mixing
head temperature within the required tolerances, all in accordance with the
manufacturer's recommendations. The machine shall be equipped with a high pressure
water blast device ahead of a high pressure air blast device, both as an integral part of
the gun carriage, for cleaning the pavement ahead of the marking application. The
machine shall also be equipped with the following: a guide pointer to keep the machine
on an accurate line; at least two spray guns which can be operated individually or

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 simultaneously; an automatic device which will provide a broken line of the required
length; and automatic glass bead dispensers which is synchronized with the marking
240 application.

808.07 Marking Protection and Maintenance of Traffic.

Traffic. Protection of the
traveling public, of the pavement marking crews, and of the pavement markings shall
be provided during the marking operation through the use of proper equipment, traffic
control devices, safety devices and proper procedures. Traffic control devices shall be
placed in accordance with 107.11. Flaggers shall be provided for traffic control as
directed.

(a) Vehicle Signs.

Signs. Each vehicle in the marking operation shall display the
250 slow moving vehicle emblem when operating at speeds of 40 km/h (25 mph) or less.
The slow moving emblems shall be removed when the vehicles are operating at speeds
greater than 40 km/h (25 mph). The paint crew signs shall be 600 mm (24 in.) high by
2400 mm (96 in.) wide, with 300 mm (12 in.) series C black letters on an orange
encapsulated lens reflective background. Type A and C flashing arrow signs shall be in
accordance with 913.13.

(b) Vehicle Warning Lights.

Lights. All amber flashing warning lights and amber
strobe lights mounted on vehicles used in the marking operation shall be in accordance
with 801.12(d). All vehicles used in the marking operation shall have a minimum of
260 one flashing amber warning light or amber strobe light which is visible in all directions.

(c) Cones.
Cones. Cones shall be used to protect marking material which requires
more than 60 s drying time. Cones shall remain in place until the marking material is
dry or firm enough not to track or deform under traffic. Cones shall be removed as
soon as possible and shall never be left in place overnight. Edge lines shall not require
protection with cones.

The maximum spacing of cones shall be as follows:

40 MPH or less over 40 MPH

Broken Lines every line segment every 5th line segment
Solid Lines 6 m to 9 m
(20 ft to 30 ft)
270
(d) Front Escort Vehicles.
Vehicles. A front escort vehicle shall be used if the marking
vehicle extends across the center line while operating. This front escort vehicle shall be
equipped with a forward facing paint crew sign, a rear facing slow moving vehicle
emblem, and a red flag mounted at least 3 m (10 ft) above the pavement.

(e) Marking Application Vehicles.

Vehicles. Marking application vehicles such as
edgeliner or centerliner trucks shall have a rear facing type A or type C flashing arrow
sign, an amber flashing warning light mounted near the center of the truck bed and an
amber strobe light mounted on each rear corner of the truck bed. The amber flashing
280 warning light and the amber strobe lights shall be mounted on retractable supports and
shall be operated at a height of 3.7 m (12 ft) above the pavement unless otherwise
directed.
637
 (f) Rear Escort Vehicles.
Vehicles. If cones are not required, rear escort vehicle shall
follow a marking application vehicle at a distance of 30 to 150 m (100 to 500 ft). If an
additional rear escort vehicle is required due to drying time or heavy traffic volume, it
shall follow the first rear escort vehicle at a maximum distance of 300 m (1,000 ft), and
may operate in the travel lane or on the paved shoulder.

290 If cones are required, the cone setting truck shall follow the marking application
vehicle and shall be followed by a rear escort vehicle. The cone pick up truck shall be
followed by another rear escort vehicle.

All rear escort vehicles shall be equipped with a rear facing type C flashing
arrow sign mounted above a rear facing paint crew sign. On two-lane two-way roads,
this type C flashing arrow sign shall be operated with the arrowhead turned off. The
supply truck may be used as a rear escort vehicle providing it is empty and is equipped
with the required traffic control devices.

300 808.08 Warranty for Durable Pavement Marking Material.

Material. Durable pavement
marking material shall be warranted against failure resulting from material defects or
method of application. The material shall be warranted to retain its color, reflectivity,
adherence to the pavement and shall be free of other obvious defects or failures.

All pavement traffic markings which have failed to meet the warranted
conditions shall be replaced with no additional payment.

For the terms of the warranty a unit shall be defined as a 305 m (1,000 ft)
section of line of specified width in any combination or pattern.
310
The warranty period shall be 180 days beginning with the last working day for
the total contract as defined in the final acceptance letter, but not prior to November 1
of the calendar year in which the last pavement markings were installed. If more than
3% of a unit or 3% of the total of any one intersection or set of transverse markings
fails, the failed portion shall be replaced. All pavement markings required to be
replaced under the terms of this warranty shall be replaced within 60 days of the
notification of failure.

On Federal aid contracts, the 180 day warranty shall apply only to thermoplastic
320 pavement marking material.

808.09 Removal of Pavement Markings.

Markings. Pavement markings which conflict
with revised traffic patterns and may confuse motorists shall be removed immediately
before, or immediately following, any change in traffic patterns as directed or
approved.

638
 Removal of pavement markings shall be to the fullest extent possible without
materially damaging the pavement surface. Pavement marking removal methods shall
be sandblasting, steel shot blasting, waterblasting, grinding or other approved
330 mechanical means. Grooving will not be permitted. Grinding will only be permitted
when removing thermoplastic or epoxy pavement markings. Painting over existing
pavement markings to obliterate them will not be permitted.

When a blast method is used to remove pavement markings, the residue,

including sand, dust and marking material, shall be vacuumed concurrently with the
blasting operation or removed by other approved methods. Accumulation of sand, dust
or other residual material, which might interfere with drainage or constitute a traffic
hazard, will not be permitted.

340 All damage to the pavement caused by pavement marking removal shall be
repaired by approved methods with no additional payment.

808.10 Snowplowable Raised Pavement Markers.

Markers. Snowplowable raised
pavement markers shall be used as supplemental delineation at the locations shown on
the plans or as directed.

(a) Surface Preparation.

Preparation. The pavement or bridge deck surface shall be
cleaned of dirt, dust, oil, grease, moisture, curing compound, and loose or unsound
layers of all materials which would interfere with the proper bonding of the marker to
350 the pavement or bridge deck.

(b) Location.
Location. Marker locations shall be accurately laid out and approved
prior to the installation operation. Markers shall not be located on surfaces that show
visible evidence of cracking, checking, spalling or failure of underlying materials.
Markers shall not be located within the intersection of a public road. Any marker
location, which falls on any of the restricted areas, shall be moved a longitudinal
distance not to exceed 10% of the required marker spacing. If this adjusted location still
falls within a restricted area, then that marker location shall be deleted. Marker
locations shall be as shown on the plans.
360
(c) Reflector Color.
Color. The color combinations of the reflectors shall be as
shown on the plans unless otherwise directed. When replacement prismatic reflectors
are specified, such reflectors shall not be ordered until the quantity and color
combinations have been determined and approved.

(d) Installation.
Installation. Marker installation shall be in accordance with the
manufacturer's recommendations. The pavement surface temperature and the ambient
temperature shall be at least 10EC (50EF). The pavement surface shall be dry at the
time of marker installation. The installation slot shall be clean and dry before the
370 adhesive is applied. The slot shall be filled with sufficient adhesive to provide a water
tight seal between the marker base and the pavement, and to fill all voids between the
marker base and the surfaces of the slot. The marker shall be placed in the slot so that
the tips of the snowplow deflecting surfaces are below the pavement surface.

639
 If the pavement surface is newly placed HMA, the pavement shall be allowed to
cure for two days prior to installing the markers.

Installation of markers on new concrete pavement or bridge decks or on newly

overlaid bridge decks shall not be done until after the pavement or bridge deck is ready
380 to be opened to traffic as specified elsewhere herein.

The number of slots cut in one day shall not exceed the number of markers
which will be installed in that day. No slots shall be left open overnight.

(e) Removal of Markers.

Markers. Markers designated for removal shall be as located
on the plans or as otherwise specified or directed. If the pavement surface or bridge
deck surface is to be removed, the markers shall be removed prior to any surface
removal operation.

390 The markers shall be removed with a jack hammer or other approved
equipment. Care shall be taken so as not to damage the marker base during its removal.
The area of the pavement or bridge deck disturbed by the marker removal shall not
exceed 75 mm (3 in.) in depth nor 75 mm (3 in.) out from all sides of the marker base.
The marker removal operation shall stop if it is determined that excessive damage is
occurring to the pavement, bridge deck or marker base.

The resulting holes shall be filled with the appropriate patching material as
described herein or as otherwise directed. Concrete pavement which is to be overlaid as
part of the contract and HMA pavement shall be patched with HMA intermediate
400 materials. Concrete pavement which is not to be overlaid as part of the contract and
concrete bridge decks shall be patched with magnesium phosphate concrete patching
material. Overlaid bridge decks and bridge decks which are to be overlaid as part of the
contract shall be patched with patching material which is compatible with the deck
overlay material. All patching material shall be placed in accordance with the
appropriate specifications for the patching material.

Removed markers shall remain the property of the Department unless otherwise
specified.

410 Removed snowplowable raised pavement markers shall be delivered to the

District Traffic Division. The markers shall be delivered in 210 L (55 gal.) metal
containers with lids which may be sealed. The metal containers shall be furnished either
by the Contractor or by the District Traffic Division as specified in the contract.
Approximately 50 markers shall be placed in each container. Each container shall be
labeled as to how many markers it contains.

All metal containers used for delivering removed markers will remain the
property of the Department when no longer required for the contract.

420 (f) Replacement of Prismatic Reflectors.

Reflectors. Reflectors designated for
replacement shall be as shown on the plans or as otherwise directed. Prior to placement
of the new reflector, the castings shall be cleaned of all remaining butyl pad materials.
All loose or foreign material shall be satisfactorily removed by sandblasting, wire

640
 brush, or other approved mechanical means. Removed reflectors shall be disposed of
properly off the project site.

808.11 Method of Measurement.

Measurement. Broken lines, placed or removed, will be
measured as 1/4 of the total distance in meters (linear feet) of the broken line pattern
after excluding gaps for intersections or other openings. Solid lines will be measured as
430 the total distance in meters (linear feet) of solid lines placed or removed. The material,
type, color, or width of broken or solid lines to be removed will not be considered
when measuring such lines for payment.

Transverse marking lines will be measured as the total distance in meters

(linear feet) of lines placed or removed. Curb markings will be measured by the meter
(linear foot) along the front face of the curb. The "No Parking Any Time" sign will be
measured in accordance with 802.10. Pavement message markings will be measured by
the total number of each type placed. A railroad crossing pavement message marking
shall include the two R's, the X, and the three stop lines per traffic lane. Railroad
440 crossing pavement message markings will be measured by the total number of each
marking placed. Lane indication arrow pavement message markings will be measured
by the number of lane indication arrowheads placed. Removal of pavement message
markings will be measured in square meters (square yards) using areas shown in the
following table. The material will not be considered when measuring such markings for
payment.

Pavement Message Markings Table

Description Area
450
"Ahead" .......................................................2.6 m2 (3.1 SYS)
Combo Arrow ................................................2.6 m2 (3.1 SYS)
"Exit" ..........................................................2.1 m2 (2.5 SYS)
"Left" ..........................................................2.1 m2 (2.5 SYS)
"Only" .........................................................2.1 m2 (2.5 SYS)
Railroad "R" ..................................................0.5 m2 (0.6 SYS)
"Right".........................................................2.7 m2 (3.2 SYS)
"RXR" .........................................................6.4 m2 (7.7 SYS)
"School" .......................................................3.3 m2 (3.9 SYS)
460 "Stop"..........................................................2.2 m2 (2.6 SYS)
Straight Arrow................................................1.2 m2 (1.4 SYS)
"Turn" .........................................................2.2 m2 (2.6 SYS)
Turn Arrow ...................................................1.4 m2 (1.7 SYS)
"XING"........................................................2.1 m2 (2.5 SYS)

Snowplowable raised pavement markers will be measured by the number placed or

removed. Prismatic reflectors will be measured by the number furnished and installed.
Each 2-way prismatic reflector will be measured as one reflector. No measurement will
be made of the adhesive or the hole patching material used in the placement or removal
470 of snowplowable raised pavement markers.

641
 808.12 Basis of Payment.
Payment. Lines and transverse markings placed will be paid for
at the contract unit price per meter (linear foot) for the material, type, color, and width
specified. Curb markings will be paid for at the contract unit price per meter (linear
foot) for curb painting, of the color specified. The "No Parking Any Time" sign will be
paid for in accordance with 802.11. Pavement message markings placed will be paid
for at the contract unit price per each, for the material and message specified. Lines and
transverse markings removed will be paid for at the contract unit price per meter (linear
foot). Pavement message markings removed will be paid for at the contract unit price
480 per square meter (square yard).

Snowplowable raised pavement markers, furnished and installed, or removed

will be paid for at the contract unit price per each. Prismatic reflectors will be paid for
at the contract unit price per each. Each 2-way prismatic reflector will be paid for as
one reflector.

If no pay items are shown in the Schedule of Pay Items for the required
permanent pavement markings, a change order will be executed.

490 Payment will be made under:

Metric Pay Item Metric Pay Unit Symbol

(English Pay Item English Pay Unit Symbol)
Pay Item Metric Pay Unit Symbol (English Pay Unit Symbol)

Curb Painting, ________ ...................................................m (LFT)

color
Line, ________, ______, _______, _______ mm...............................m
material type color width
500 (Line, ________, ______, _______, _______ in. ...........................LFT)
material type color width
Line, Remove.................................................................m (LFT)
Pavement Message Marking, ________, _________ ..................... EACH
material message
Pavement Message Marking, Remove .................................. m2 (SYS)
Prismatic Reflector............................................................. EACH
Snowplowable Raised Pavement Marker ................................... EACH
Snowplowable Raised Pavement Marker, Remove........................ EACH
Transverse Marking, ________, ______, _______, _______ mm............m
510 material type color width
(Transverse Marking, ________, ______, _______, _______ in. ........LFT)
material type color width
Transverse Marking, Remove ..............................................m (LFT)

The cost of metal containers for disposal of removed snowplowable raised

pavement markers, if furnished by the Contractor, shall be included in the costs of
other pay items. The cost of picking up and returning such metal containers, if
furnished by the District Traffic Division, shall be included in the costs of other pay
items.
520

642
 The cost of delivering removed and packaged snowplowable raised pavement
markers to the designated location shall be included in the cost of transportation of
salvageable materials.

The cost of removal of existing prismatic reflectors shall be included in the cost
of prismatic reflectors.

Glass beads, binder material for thermoplastic and preformed plastic, adhesive
for snowplowable markers, patching material for snowplowable marker removal,
530 pavement cleaning, removal of excess or loose existing pavement marking material
where new pavement markings are being placed in the same locations, and all necessary
incidentals shall be included in the costs of the pay items.

643