Section 660 High Mast Lighting

660.1 Description
(1) This section describes constructing a caisson or pile foundation for a high mast light tower, and
providing a high mast lighting tower.
660.2 Materials
660.2.1 General
(1) Furnish materials conforming to the following:
Concrete ......................................................................................................................................................... 501
Luminaires ...................................................................................................................................................... 659
Steel piling ...................................................................................................................................................... 550
Steel reinforcement......................................................................................................................................... 505
(2) If not furnished as part of an assembly, use stainless steel threaded fasteners.
(3) Use grade A, A-FA, A-S, A-T, A-IS, A-IP, or A-IT concrete conforming to 501 as modified in 716.
Provide QMP for class II ancillary concrete as specified in 716.
660.2.2 Pole Shafts
(1) Furnish pole shafts constructed of structural steel conforming to ASTM A709 grade 50 or engineer-
approved equivalent and zinc coated conforming to ASTM A123. Furnish pole shafts with a consistent
taper from bottom to top, except the lower section may be expanded to accommodate the required
apparatus. Furnish poles constructed in 40-foot to 50-foot sections using single thickness steel plate,
except the length of the top section may be shorter to provide the required pole height. Provide the
engineer with 3 copies of mill test reports that show the material used in pole shafts, anchor bases,
and anchor rods conforms to this specification.
(2) Provide a reinforced access door opening in the base of the pole shaft that secures with a cover.
Furnish a cover made with stainless steel hinges that bolts shut with stainless steel hex bolts and is
weather tight. Fit the cover with a stainless steel padlock hasp and install a department-furnished
padlock.
(3) Secure the opening below the base plate with a stainless steel or galvanized steel rodent screen.
(4) Design the base plate so water does not accumulate on the top surface of the base plate inside the
pole.
(5) Before zinc coating of the pole or base plate, number each anchor rod hole in sequence on the base
plate or around the bottom of the pole. Locate the numbers so they are not obscured by the zinc
coating or covered by installed nuts.
660.2.3 Anchor Rods, Templates, Washers, and Nuts
(1) Attach the pole to the concrete base with at least 8 anchor rods. For each rod, furnish 2 nuts for
securing the bottom anchor plate-template, a leveling nut, bottom washer, top washer, and 2 top nuts.
Do not use lock washers.
(2) Furnish anchor rods conforming to ASTM F1554 grade 55 and Supplementary Specification S4, ASTM
A563 heavy hex nuts, and ASTM F436 washers.
(3) Furnish anchor rods with the top 12 inches and bottom 6 inches having a Unified National Radius roll
thread.
(4) Furnish anchor rods, washers, leveling nut, and 2 top nuts hot-dip zinc coated conforming to ASTM
A153, class C, supplemented by ASTM F2329. As a minimum, zinc coat the top threaded portion of
the rod plus one inch.
(5) Furnish a steel top template and a steel bottom anchor plate-template as part of each anchor
assembly. Provide a top template of sufficient gauge to hold the anchor rods securely in position at the
top, and resist racking or twisting during the pour. Remove the top template after the concrete has set.
Use a 1/2-inch-thick bottom anchor-plate template and secure it to each anchor rod. Do not weld
templates to anchor rods. Install anchor rods and templates conforming to plan details.
660.2.4 Lowering Device
(1) Equip the poles with a mechanical lowering system that allows servicing the luminaires and associated
electrical and mechanical apparatus from the ground. Furnish lowering devices from a department-
approved series and manufacturer and with a 10-year warranty against failure of its components.

Effective with the December 2017 Letting 496 2018 Standard Specifications
 (2) When fully raised, provide a method of securing the luminaire ring to the fixed head assembly. Show
either a bottom latch or a top latch system for securing the luminaire ring on the drawings submitted
for the engineer's review.
(3) Design top latch systems to provide the operator with a way to determine whether the raising
operation is complete and the luminaire ring is secure. The operator observing clutch slippage does
not meet this requirement.
(4) If securing the luminaire ring to the fixed head assembly, provide a means to relieve tension from the
lowering cables onto the winch assembly. Provide strain relief devices that allow removing the winch
assembly for servicing while the luminaire ring is fully lowered and blocked up.
(5) Ensure that the lowering device operates off one leg of the line feeding the pole and uses a portable
drive motor that plugs into the line.
(6) Provide adjustable torque limiters in the winch system or drive motor to prevent excessive stress on
the lowering cables, and to allow for proper tensioning against the fixed head assembly.
(7) For systems where the lifting cables meet on a transition plate, provide access to the top of the plate
from the hand-hole, when the ring is fully raised, to allow cable tension adjustment. Furnish 7x9
stainless steel lifting cables. Do not use antirotational cables.
660.2.5 Fixed Head Assembly
(1) The fixed head assembly shall include no moving parts, except for the necessary pulleys, rollers, and
sheaves that guide the lowering ring, lowering cables and electrical conductors during the lowering
operation. For the fixed head assembly, use chromated or stainless steel. Use pulleys, rollers,
sheaves, and associated bearings, bushings, and shafts made of corrosion-resistant materials. Use
permanently lubricated and sealed bearings and bushings.
(2) For systems that use a roller assembly to support the power chord at the head frame, use an
assembly made of rollers mounted between highly corrosion resistant steel plates. Ensure the power
chord rides on at least 6 rollers made from acetate resin mounted on stainless steel pins. Furnish a
roller assembly with a minimum bending radius of 7 inches. If using a pulley, use a minimum radius of
8 inches.
(3) Furnish stainless steel lifting cable sheaves with a minimum radius of 3 inches. Use sheaves with
permanently lubricated bronze bearings and a stainless steel pin. For the depth of the vee on the
pulley, use at least the diameter of the cable. Provide guards to prevent the cable from lifting off the
pulley.
(4) Protect all of the head assembly with covers, screens, or shields, to prevent entrance of dirt, moisture,
ice accumulation, nesting of insects or birds or other contaminants that may harm the head assembly
and operation of the lowering device.
660.2.6 Luminaire Ring
(1) If the plans show unused luminaire tenons, install a counterweight equal in weight to a luminaire, and
close the unused tenon off with a threaded cap.
(2) Furnish either a stainless steel, or a structural steel zinc coated ring. Zinc coat conforming to ASTM
A123.
(3) Furnish a luminaire ring centering system designed to protect both the pole shaft and the luminaire
ring assemble and with a 10-year warranty against failure of its components. Ensure that the system
operates successfully in winds up to 30 mph. Also ensure that the ring can travel smoothly and
unimpeded over the entire length of the pole shaft.
660.2.7 Aviation Lights
(1) Furnish aviation lights, associated electrical circuits, and detailing the plans show.
660.2.8 Lightning Rod
(1) Furnish silver tipped lightning rod of engineer-approved design mechanically attached to the pole shaft
or head assembly, and electrically connected to the pole shaft.
660.2.9 Miscellaneous Fittings
(1) Use stainless steel miscellaneous fittings, fasteners, and hardware.
660.2.10 Drive Motor Set
(1) Furnish a universal portable motor system compatible with the particular lowering system used and
capable of powering that system for any combination of the pole height and luminaire load
configuration. Ensure that the drive motor set consists of a 120 volt AC motor, a matching transformer,
power connection cables, and a motor control switch.

Effective with the December 2017 Letting 497 2018 Standard Specifications
 660.3 Construction
660.3.1 Design Calculations and Shop Drawings
(1) Design high mast lighting support structures conforming to AASHTO Standard Specifications for
Structural Supports for Highway Signs, Luminaires and Traffic Signals, 6th Edition, and Interim
Revisions. Design the completed unit to withstand static and dynamic loads the unit will be subjected
to in service. Use a design loading that provides for installation of the full complement of 6 luminaires
and the operation of the lowering device.
(2) Design the high mast light tower and foundation using a design life of 50 years with a wind importance
factor of 1.00. Design to withstand a 3 second gust wind speed of 90 mph. Do not use the alternative
method for wind pressures described in appendix C of the AASHTO standard specifications.
(3) Design the pole and its connections, including but not limited to the welds and anchor rods, to the
AASHTO fatigue category I criteria. Use the fatigue importance factors for category I tabulated in the
AASHTO standards.
(4) Use poles that are round or polygonal in section, and designed so that the horizontal pole deflection in
any direction at the design wind velocity with a gust effect factor does not exceed 5 percent of the pole
height. Measure the horizontal deflection from the vertical plane passing through the centerline of the
pole at its base. The pole height is the distance from the bottom of the base plate to the top of the
shaft, excluding the fixed head assembly.
(5) Submit for review, 2 sets of structural design calculations for each type of pole and anchor assembly
showing that the design conforms to the specifications. Submit to the engineer for review, 5 complete
sets of shop drawings and component lists, showing the pole, its alloy identification, plate thickness,
weld details, weld procedures, and tolerances; the anchor assembly; the fixed head assembly; the
lowering device; luminaire ring; other required apparatus; and tightening procedures for bolted
connections other than the mast-to-anchor assembly connection. Ensure that design calculations and
shop drawings are signed, sealed, and dated by a professional engineer registered in the state of
Wisconsin.
(6) If any substantial changes from previously submitted calculations and drawings are made, submit the
revisions to the engineer for review.
660.3.2 High Mast Foundations
660.3.2.1 General
(1) If any twisting, racking, or other movement of the anchor rods out of plumb, projection, or pattern, or
any damage to the threads exists the engineer will reject the entire base.
(2) Maintain the clear distance between the soil and the reinforcing steel cage using the means the plan
detail shows. Do not weld the anchor rods to each other, the reinforcing steel cage, and the templates
or to any other component of the foundation. Protect anchor rod threads above the top of the
foundation level from concrete splash.
(3) Place the concrete in one continuous pour without construction joints. Cure exposed portions of
concrete foundations as specified in 502.3.8.1. Wait until the concrete has attained 3500 psi
compressive strength or 7 equivalent days as specified in 502.3.10 before erecting the tower.
660.3.2.2 Augured Foundations
(1) Construct as specified for concrete bridges in 502.3.
(2) Produce the holes for foundations by auguring. The contractor may install a suitable casing at the
same time as the auguring. Make the augured hole vertical and uniform in section. Fill irregularities in
the cylindrical surface of uncased holes outside the nominal diameter with concrete. If the top of the
hole caves in, the engineer may require the contractor to auger the hole deeper to obtain the required
depth and section.
660.3.2.3 Pile Type Foundations
(1) Drive piles as specified in for steel piling in 550.
660.3.3 Pole Shafts
660.3.3.1 General
(1) Weld or telescope pole sections together so that the splice length is equal in strength and rigidity to
the remainder of the pole shaft.
(2) Before and during erection, examine the pole sections for scratches and mars, and treat them by first
removing rust and then coating the damaged area with an engineer-approved cold zinc coating
compound. Remove markings placed on the pole for purposes of fabrication, shipping, or erection.

Effective with the December 2017 Letting 498 2018 Standard Specifications
 (3) After erecting and plumbing, ensure the completed pole, with attachments, appears straight and
vertical throughout its height, except if distorted by the effects of wind or sunlight or both. Do not
perform the final plumbing of the pole on a sunny day.
660.3.3.2 Telescoped Poles
(1) Overlap the sections at least 1 1/2 times the outside diameter of the larger section at the joint. Test fit
the sections at the factory to ensure pole straightness and accuracy of the mating surfaces.
(2) In the field, measure the joint overlap as follows: On the male end, make a chalk mark at a distance
from the end equal to the required overlap plus one foot. Then make the connection so that the
distance from the end of the female section to the chalk mark is one foot.
(3) Upon erection, ensure the surface of the telescoped sections present a permanent barrier to moisture
entering the faying surfaces.
660.3.3.3 Welded Poles
(1) Shop weld pole shafts and attachments conforming to AWS D 1.1, Structural Welding Code - Steel
and as follows:
1. Use complete-penetration welds for pole sections joined by circumferential welds and inspect all welds.
2. Inspect all circumferential welds, all full penetration welds, and a random 25 percent of partial penetration
longitudinal welds.
3. Inspect full penetration welds by either radiographic or ultrasound inspection methods.
4. The contractor may inspect partial penetration welds by the magnetic particle method.
5. Make longitudinal welds to 60 percent depth penetration, except in any location within 6 inches of a
circumferential weld or within the joint overlap area plus 6 inches, then make these welds to 100 percent
depth penetration.
6. The contractor may repair a circumferential weld once without the engineer's permission.
7. Ensure that other weld repairs are engineer-approved.
(2) Do not weld in the field without the engineer's written approval. The engineer will only allow field
welding for repairs in noncritical locations and when a department-approved individual competent to
perform inspections is present during the welding. Perform field welding using personnel qualified
under AWS D 1.5, Bridge Welding Code for steel.
660.3.4 Anchor Assembly
(1) Secure masts to anchor assemblies conforming to the procedures enumerated in department form
DT2321. Complete department form DT2321 for each structure. Indicate the parties responsible for
the installation and submit the form to the engineer for inclusion in the permanent project record.
660.3.5 Lowering Device, Head Assembly and Luminaire Ring
(1) Construct conforming to plan details and manufacturer's instructions.
(2) Before erecting the fixed head assembly, the engineer will inspect it on the ground.
660.3.6 Acceptance
(1) Before acceptance each high mast lighting tower demonstrate to the engineer that electrical and
mechanical systems function properly.
660.4 Measurement
(1) The department will measure the High Mast Foundation bid items as a single lump sum unit for each
foundation acceptably completed.
(2) The department will measure the High Mast Lighting Tower bid items as a single lump sum unit for
each tower acceptably completed.
660.5 Payment
(1) The department will pay for measured quantities at the contract unit price under the following bid
items:
ITEM NUMBER DESCRIPTION UNIT
660.0100 High Mast Foundation (location) LS
660.0200 High Mast Lighting Tower (location) LS
(2) Payment for the High Mast Foundation bid items is full compensation for providing steel piling and
concrete, including extra concrete required around uncased holes, for reinforcing steel; for anchor
rods, templates, nuts, and washers; for electrical conduit; for excavating and auguring; and for
backfilling, disposing of surplus material, and restoring the site.

Effective with the December 2017 Letting 499 2018 Standard Specifications
 (3) Payment for the High Mast Lighting Tower bid items is full compensation for providing the pole; for
providing a drive motor set, fixed head assembly, luminaire ring, and lowering mechanism with
associated mechanical and electrical components, an electrical grounding system, the pole sequence
and circuit identification plaques, nuts, and washers, fittings, hardware, aviation lights, and lightning
rod; for connecting to the electrical distribution system; and for providing slugging wrenches for each
size of nut.
(4) The department will pay separately for luminaires under the Luminaires bid items of 659.

Effective with the December 2017 Letting 500 2018 Standard Specifications