Divis~on of Safety and Traffic Engineering Maintenance operations section

STATE DEPARTMENT OF HIGHWAYS AND PUBLIC TRANSPORTATION

SPECIAL SPECIFICATION FOR

HIGHWAY TRAFFIC SIGNAL HEADS (ALUMINUM & POLYCARBONATE)

(ADJUSTABLE, EXPANDABLE TYPE)

1.0 GENERAL

1.1 The traffic control signal heads shall be in accordance with the latest revision of ITE Technical Report NO.1, except as noted below.

1.2 Each traffic signal face shall consist of a number of signal sections rigidly fastened together in such a manner as to present a continuous pleasing appearance.

1.3 The traffic signal head shall consist of a system of one or more signal faces, illuminated in a definite sequence by a remote timing device, which shall indicate to traffic approaching the signal face the right of way at the intersection or give warning of existence of a hazardous condition, thus facilitating an orderly movement of traffic through the intersection.

1.4 The electrical and optical system of the signal head shall, unless otherwise specified, be designed for operation from a power supply of 115 volt, single phase, 60 Hz alternating current and 60-150 watt lamps conforming to the latest ITE Standard for Traffic Signal Lamps. The traffic signal lamps are not to be furnished with the signal face or signal head.

1.5 The Invitation to Bid will specify the type of material (aluminum or polycarbonate) to be used in fabricating the traffic signal heads described herein. Structural requirements for each material are described in Paragraphs 3.1 and 3.2.

2.0 STANDARD SIGNAL FACE AND HEADS

2.1 The "Standard Signal Face" shall consist of three or more lenses, each mounted in an individual housing case. The signal face shall be for vertical or horizontal installation and shall be so assembled that the red lens will be located at the top if vertical mounted and at the left if horizontally mounted, the yellow lens at the center if vertically mounted and to the right of the red lens if horizontally mounted, and the green lens at the bottom of the signal face if vertically mounted three section signal face, or to the right of the yellow lens if a horizontal mounted three section signal face. If more than three sections are required on a signal face, the lens shall be arranged as shown on the attached drawings, however, the arrangement shall not be in conflict with arrangements as shown in the latest revision of the "Texas Manual on Uniform Traffic Control Devices for Streets and Highways."

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2.2 The "Standard Two-Way Signal Head" for vertical mounting shall consist of two "Standard Signal Faces" mounted in separate complete housing, attached to standard-pipe supporting arms, giving indications to traffic approaching the signal head from two directions. The standard-pipe supporting arms shall, unless otherwise specified, radiate from their point of support in a horizontal plane at angles 1800 apart.

2.3 The "Standard Three-Way signal Head" for vertical mounting shall consist of three "Standard Signal Faces" mounted in separate complete housings, attached to standard-pipe supporting arms, giving indications to traffic approaching the signal head form three directions. The standard-pipe arms shall, unless otherwise specified, radiate from their point of support in a horizontal plane at angles 1200 apart.

2.4 The "Standard Four-Way Signal Head" for vertical mounting shall consist of four "Standard signal Faces" mounted in separate complete housings attached to standard-pipe supporting arms, giving indications to traffic approaching the signal head from four directions. The standard-pipe supporting arms shall, unless otherwise specified, radiate from their point of support in a horizontal plane at angles 900 apart.

2.5 The "Standard Five-Way Signal Head" shall consist of five "Standard Signal Faces" mounted in separate complete housings, attached to standard-pipe supporting arms, giving indications to traffic approaching the signal head from five directions. The standard-pipe supporting arms shall, unless otherwise specified, radiate from their point of support in a horizontal plane at angles 72 0 apart.

2.6 All housing cases of each of the above multiple-way signal heads shall be rigidly attached, at top and bottom, to 1-1/2" (38 mm) (inside diameter) tubular supporting arms radiating from hubs at the vertical central axis of the head and rigidly attached thereto in a manner that will assure permanent alignment of the separate housings. The hub shall be designed to conform to the type of mounting attachment specified and provision shall be made for carrying the leads from each housing enclosed in the supporting arms to a single outlet in the mounting attachment. All units of the assembled head shall be of adequate strength for the purpose intended and shall be constructed of materials not affected by continuous exposure to corrosive atmospheres, particularly salt air.

2.7 A metal spacer in place of the bottom pipe bracket will be acceptable for mUltiple-way span-wire and mast-arm mounted single heads.

2.8 Signal Faces to be installed vertically or horizontally on mast arms shall be mounted by hardware as called for in the item descriptions or shown on the attached drawings. Any signal heads to be installed vertically or horizontally on the signal pole shall likewise be mounted by hardware as called for in the item descriptions or shown on the attached drawings.

2.9 Unless otherwise called for in the item description or shown on the attached drawings, all supporting arm assemblies shall have threaded connections, not welded, and shall be assembled with full threaded crosses, not elbows.

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3.0 HOUSINGS

3.1 The silicon aluminum alloy traffic signal housing cases, also designated herein as optical-unit housings, shall be die cast of a silicon aluminum alloy by a process imparting a smooth homogenous finish. casting shall be accurately formed and free from pouring faults, sponginess, cracks, blow holes, or other defects affecting their strength and appearance.

All visors shall be of a silicon aluminum alloy and may be of cast material or of sheet material having a minimum thickness of 1/16" (1.6 mm) .

3.2 The polycarbonate traffic signal housing cases, also designated herein as optical unit housings, shall be a one piece polycarbonate resin material with sides, top and bottom integrally molded. The housing shall be at least 0.090 inches (2.3 mm) thick and shall be ribbed so as to produce the strongest possible assembly consistent with light weight. The terminal block shall either be securely mounted or may be integrally molded into the housing (see Section 10).

3.3 The signal housing cases, fittings, and accessories shall be of non-corrosive, rust resistant materials capable of withstanding constant exposure to sunlight and corrosive atmos~heres, including salt air, and shall provide adequate strength for the purpose for which it is utilized.

3.4 Provision shall be made for accommodation of the particular type of mounting specified and attachment of doors, optical units, and other such accessories as may be specified for the particular installation. All traffic signal housing cases when assembled, together with doors, lenses, and mounting attachments, shall comprise a dust and moistureproof housing for the optical units, connecting wiring, and terminal block. The housing cases shall be of such construction as to assure permanent alignment of the lens in the traffic signal face. Design of door, housing, and visor shall be such that no light is visible in the profile view of the traffic signal face.

3.5 Traffic control signal housing cases shall be of the sectional adjustable expandable type. The assembled housings for each signal face shall consist of three or more individual sections, each designed for housing a single complete optical unit. Individual signal sections shall be rigidly attached to form a single "Signal Face" either with at least four machine screws between each section or by the bolt and washer method. Complete signal faces shall provide positive locked positioning when used with serrated brackets, mast arm, or span wire fittings.

3.6 Portions of cases providing for attachment to supporting arms shall be molded with large bosses for the supporting arms. Each housing case shall be so attached to its supporting arm that it will be adjustable by rotation about its vertical axis in such a manner that any pair of adjacent cases may be adjusted individually to give indications in two direction as close as 15 degrees apart and may be rigidly clamped in any position throughout the range of adjustment. Provision shall be made for carrying the traffic signal leads enclosed in the mounting attachment.

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3.7 #Both the top and bottom of each traffic signal housing case shall be provided with an opening of two inches (50 mm) in diameter to accommodate 1-1/2" (38 rom) pipe brackets. A locking ring shall be integrally cast or molded around the bottqm opening. Around the top opening shall be either an integrally cast or molded locking ring or a separate splined locking ring designed to fit into notches. The locking rings shall have a minimum of 46 evenly spaced teeth and shall be so designed that the top and bottom rings will mate to provide a perfectly aligned signal head with flush connection between the outer circumference of the sections. Individual units shall be so manufactured that all units are interchangeable except for terminal blocks.

3.8 Any open end of an assembled beacon face housing shall be plugged with an ornamental cap and gasket.

4.0 HOUSING DOOR

4.1 The housing door of each traffic signal housing shall be a one piece polycarbonate resin material or die cast in a silicon aluminum alloy with an approximate 8-inch (200 mm) or 12-inch (300 mm) diameter circular opening for the lens as specified on the Invitation to Bid. The door must be of the same material as the housing.

A. Silicon aluminum alloy door. The door shall be provided with hinges and lugs for attachment to the main body casting, so spaced as to hold the door in perfect alignment when closed. The door shall be securely gasketed to the traffic signal housing with a weatherproof gasket.

B. Polycarbonate resin door. The door shall be attached to the housing by means of two stainless steel hinge pins, or by polycarbonate hinge pins which are an integrally molded part of the housing door.

4.2 Two stainless steel wing screws shall be installed on the side of the door to provide for opening and closing the door without the use of special tools. Wing screws shall have a flat-bearing surface or stainless steel flat washer to prevent gouging of the housing door by the wing screws. Wing screws shall remain captive in the housing door when the door is open. Alternately, and if a polycarbonate resin traffic signal head is used, a positive latching mechanism integrally molded into the housing and housing door is acceptable.

5.0 VISORS

5.1 Each traffic signal housing door shall be equipped with an easily detachable standard tunnel visor (unless otherwise shown in the plans). The visor shall be a polycarbonate resin or a silicon aluminum alloy to match the housing and door. The visor shall be rigidly attached to the door with rust resistant connections in a manner that will prevent the leakage of light and moisture throughout the periphery of attachment.

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5.2 The visor on the front of each door shall:

be circular in section have a downward tilt of 2 to 8 degrees encompass approximately 300 degrees of the lens extend outward from the face of the lens a minimum of 9-1/2" (240 mm) for 12-inch (300 rom) diameter lens and 7 inches (180 rom) for 8-inch (200 rom) diameter lenses (measured at its outer visible circumference) be of such design that the encircled portion of the lens will not be visible in the profile view of the traffic signal face be open at the bottom so as to prevent the accumulation of snow and dirt

5.3 Heads may be shipped with visors detached. If heads are shipped with visors attached, visors shall be easily removed and replaced without damage to visor or signal head.

6.0 OPTICAL SYSTEM

6.1 Each lens shall be provided with an optical unit consisting of a reflector assembly with leads to the terminal block (which is to be furnished in each complete traffic signal face assembly) together with all bolts, nuts, screws, clips, hinges, lugs and incidentals necessary for mounting the various parts of the optical assembly.

6.2 The optical system shall consist of a red, yellow, yellow arrow, green, or green arrow lens with a nominal size of 8-3/8 inches (210 mm) or 12 inches (300 rom) as specified. Lenses shall be permanently marked, in an inconspicuous manner, indicating the top of the lens and the name or trademark of the manufacturer. Lenses in a polycarbonate housing shall be injection molded of a polycarbonate material; lenses in a silicon aluminum alloy housing shall be either polycarbonate or glass. Lenses of glass shall have high transmission value, have a specific gravity of not less than 2.50, and conform to all ITE specifications.

6.3 Lenses and optical system shall be capable of withstanding continuous illumination of a 116 watt lamp in an 8-inch (200 rom) head, and a 150 watt lamp in a 12-inch (300 mm) head without distortion of lenses. Lens and reflector designs shall conform to ITE Standard (ITE Report #1) and to American Standards Association #D-10.1-1958UDC 657.057 optical specifications.

6.4 Each lens and reflector assembly shall be designed such that the reflector and lens form essentially a sealed unit. This shall be accomplished through the use of a precision molded neoprene gasket. The gasket shall marry the lens to the reflector to form this unit.

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7.0 REFLECTORS

7.1 The reflector shall be approximately parabolic in section, made of high quality clear glass, reasonably free from chips, bubbles, streaks, and wrinkles. The outer surface shall be silvered by a chemical or electrical deposition to such thickness that the lighted filament of a 200 watt incandescent lamp will be invisible through the silvered coating and shall then be protected by an electrically deposited copper coating. The silver coating shall be so applied that no foreign substance (solid, liquid or gas) can penetrate between the two materials and so it will be impossible for the silver to be peeled off from the glass. Over the copper coating there shall be placed a heat resisting backing of high grade enamel.

7.2 Alzak reflectors will be accepted as alternates. These reflectors shall be made of specular Alzak aluminum the thickness of the anodic coating to be a minimum of 0.0001 inches (0.0025 mm) or its equivalent, spun or drawn from metal not less than 0.025 inches (0.635 mm) thick equipped with a bead or flange on the outer edge to stiffen th.e reflector and insure its being held true to shape.

7.3 Polycarbonate reflectors will be accepted as alternates, provided the light color and distribution of the unit meets the ITE standard cited in paragraph 6.3.

7.4 The reflecting surface shall be totally free of flaws, scratches, defacements or mechanical distortion.

8.0 LAMP RECEPTACLE

8.1 The lamp receptacle shall be of weather-proof molded construction capable of withstanding without deterioration the high temperatures within the optical unit during operation and shall be equipped with a lamp grip to render it impossible for the lamps to be loosened by vibration. The receptacle in the 8-inch (200 mm) signals furnished shall be set so as to place the filament of a standard 60 or 67 watt lamp in the proper focal position with respect to the reflector. The receptacle in the 12-inch (300 mm) signals shall be set so as to place the filament of a standard 150 watt lamp in the proper focal position with respect to the reflector. Lamp receptacles shall be rotatable to place the opening between the filament leads up.

8.2 Reflector holder and lamp receptacle holder. The reflector holder and lamp receptacle holder shall consist of a. structure of such design as to securely hold the reflector and lamp receptacle. It shall be provided with hinges and/or lugs so spaced as to give clearance to the hinges or lugs for the door and rigidly hold the reflector in place. Materials used in the construction of the above parts shall be of rust resisting material and not sUbject to corrosion when sUbjected to continued exposure in corrosive atmospheres, particularly salt air.

9.0 WIRING

9.1 Each reflector assembly shall be provided with two flexible insulated color coded leads no smaller than No. 18 American Wire Gauge. These leads are to be securely fastened to the lamp socket and connected to the terminal block by means of solderless wire connector or binding screws and spade lugs.

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10.0 TERMINAL BLOCKS

10.1 Each optical unit shall be wired to a terminal block mounted in the signal section housing that unit. Additionally, each mUltiple section signal face assembly shall be provided with a 6-post terminal strip (minimum) in the top section of the assembly. The section terminals shall be wired to the top-mounted common terminal, ready for field installation. All terminal blocks shall be securely mounted in an accessible position and shall be of weatherproof molded construction, equipped with identified terminals for signal and field wires. Binding screws shall be provided for the field wires. Binding screws for solderless connectors shall be provided for the interior wires.

10.2 If specified, a Terminal Compartment shall be provided for the side of pole-mounted signal heads in addition to the signal face assembly terminal block specified in 10.1 above. The terminal compartment shall be located as called for in the item description and drawings.

The Terminal Compartment shall be equipped with a readily accessible moisture-proof cover and weatherproof molded-construction connector block with identified terminals for signal and field wires. Separate terminals shall be provided for the interior wires and the field wires. In addition to the interior wires required in 10.1, the supplier is also required to furnish and install all other leads necessary to connect the terminal block of the mUltiple section face to the terminal block in the Terminal Compartment. Each lead shall be brought to a separate terminal in the Terminal Compartment except that the commons from one housing can all be brought to the same terminal in the Terminal Compartment. The color coding on leads from the individual optical units shall be maintained from the lamp holder to the individual terminals in the signal head Terminal Compartment except that the commons from each housing shall be grouped and carried to one terminal. The wiring shall be so arranged that anyone optical unit can be individually illuminated through connections to terminals in the Terminal Compartment.

The Terminal Block installed in the Terminal Compartment shall be equipped with Pressure-Type Connectors having a minimum capacity of two No. 12 A.W.G. solid-copper conductors per connector and shall be provided with barriers and rated for 25 amperes, 250-volt service. This mUltiple-connector terminal block is to be equipped with a minimum of twelve sets of connectors, with separate terminals for the interior and the fieldwire connections. Any variations from the above requirements will be covered in the item description and drawings.

Use of Terminal Compartments containing terminal blocks does not eliminate the requirement of terminal block specified above under 10.1.

11.0 MOUNTING ATTACHMENTS

11.1 All mounting attachments shall be of adequate strength for the purpose intended and shall be constructed of materials not affected by continued exposure to sunlight or corrosive atmospheres, particularly salt air. All non-metallic hardware shall be polycarbonate material impregnated with glass fibers.

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Provision shall be made for carrying the signal leads enclosed in the mounting attachment. The mounting attachment, together with supporting arms and assembled housings, shall comprise a dust-and-moisture-proof enclosure for optical units and lead w1r1ng. Mounting attachments shall be of one of the following types as specified for the particular head on the item description and attached drawings.

(A) Span-Wire Mounting. The span-wire mounting attachment shall consist of a cable clamp to receive a suspension cable of 3/8" (10 rom) diameter together with a suitable connection to the signal head. The mounting shall provide a "balance adjuster"

between the signal head and span wire capable of permitting freedom of movement with reference to the point of suspension. The signal head shall be adjustable by rotation about its vertical axis in a horizontal plane and the mounting attachment shall be so constructed that the head may be firmly clamped in any position throughout the range of adjustment. The mounting shall provide a suitable outlet for wiring from the signal head tilted downward and so constructed as to effectively seal the interior of the head from dust and moisture and prevent undue abrasion of signal wiring. Mountings for signal-head units not balanced at the point of support shall be provided with a suitable compensating device to insure that the signal head will assume a normally-vertical position.

(B) Mast-Arm Mounting. The mast-arm signal-head mounting shall be as shown on the item description and attached drawings.

(C) Side-of-Pole Mounting. Supports for side-of-pole mounting of the signal head in a vertical position shall be 1-1/2" (38 mm) (nominal diameter) standard pipe bracket arms, attached to the top and bottom of the signal head. The signal head shall be adjustable, by rotation of the various signal faces about their vertical axis, throughout a radial angle of 360' and shall be capable of being rigidly clamped in any position throughout the range of adjustment. The mounting assembly shall consist of two standard-pipe sections extending 12-3/4" (325 mm) from and at right angles to the axis of rotational adjustment of the signal head. Both supports shall have running threads at lest 1-1/4" (32 mm) long at the pole connection end. Provision shall be made for carrying the wire from the signal head enclosed in the bottom support and an outlet tilted downward for the wiring shall be provided, adjacent to the pole connection end, tapped and plugged for 1-1/4" (32 mm) conduit. Any variations to this design are shown in the item description and attached drawings.

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(D) Top-of-Post Mounting. Supports for top-of-posts mounting of the si9nal head in a vertical position shall be 1-1/2" (38 mm) (nominal diameter) standard pipe bracket arms attached to the top and bottom of the signal head. The mounting assembly shall consist of a slipfitter connection, as either the hub or as a part of the hub of the bottom pipe-arm assembly, for attachment around the top of a 4-1/2" (115 mm) outside diameter pipe. The signal head shall be adjustable, by rotation about its vertical axis in a horizontal plane, throughout a radial angle of 360' and the mounting attachment shall be so constructed that the head may be firmly clamped in any position throughout the range of adjustment. The slipfitter connection shall be of pleasing appearance and of adequate strength, capable of holding the signal head rigidly in place and effectively sealing the interior of the pipe from moisture.

12.0 MATERIAL AND COLORS (POLYCARBONATE SIGNAL FACES AND/OR SIGNAL HEADS ONLY)

12.1 All material used in construction of major traffic signal components shall be polycarbonate resin. This material shall withstand 70 foot-pounds (95 Joules) of impact without fracture or permanent deformation.

12.2 Material for hardware shall be polycarbonate resin or corrosion resistant metal of adequate strength for the intended purpose.

12.3 The color of the completed traffic signals shall be Federal Yellow with the exception of the underside of the visors which shall be painted a flat black. The yellow color shall be completely impregnated in the resin material.

12.4 If metal mounting attachments are supplied with polycarbonate signal faces and/or signal heads, the mounting attachments shall satisfy paragraph 13.1.

13.0 PAINT AND PAINTING (METAL SIGNAL FACES AND/OR SIGNAL HEADS)

13.1 Before shipment, all exposed metal surfaces except for the inside of the visors of the assembled traffic signal head shall be given two coats, separately baked on, of high grade highway yellow enamel. The inside of the visors shall be provided with two coats of high grade dull black finish paint. Any variation in color of enamel required will be covered in the item description.

13.2 If polycarbonate mounting attachments are supplied with metal signal faces and/or signal heads, the mounting attachments shall satisfy paragraphs 12.1 through 12.3.

14.0 CRATING AND MARKING

14.1 Signal Heads. Each signal head shall be delivered completely wired, fully assembled and ready for immediate installation.

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Each signal head and each signal face purchased as an individual unit shall be crated separate and complete by itself. Appropriate parts list shall be placed inside each signal head or signal face unit. Each signal head shall be tagged showing Manufacturer, Type, and Catalogue Number. The outside of each signal head and signal face crate shall be marked to show the Manufacturer, Type and Catalogue Number of the item as well as the Requisition Number and Contract Number on which it was delivered.

The crates for all but standard signal faces and vertical mounted standard one-way signal heads shall be constructed of wood. Each wood crate for a one-way horizontal mounted traffic signal head shall be strong enough to support the weight of five additional crated one-way horizontal mounted traffic signal'heads. Each wood crate for a standard two-way signal head shall be strong enough to support the weight of four additional crated signal heads of the same design. Each wood crate for a standard three-way and standard four-way signal head shall be strong enough to support the weight of two additional signal heads of the same design.

The crates for the standard signal faces hnd vertical mounted standard one-way signal heads may be constructed of sturdy cardboard. Each crate shall be strong enough to support the weight of six additional signal faces or signal heads of the same design.

Each bidder shall submit with his bid the catalogue data and complete specifications covering the equipment he proposes to furnish. He shall also furnish a parts catalogue with list of prices and discounts which will be allowed the state for purchase of maintenance replacement repair parts.

14.2 Visors. The signal heads can be delivered without the visors attached. The visors for each individual signal head or signal face shall be packed in a separate package or carton. Each package of visors shall be placed inside the crate with the signal head or signal face to which the visors belong. If the visors are attached to the signal face, they shall be easily removed and replaced without damage to visor or beacon face.

15.0 MEASUREMENT

15.1 Measurement shall be made of each "Standard Traffic Signal Face" or "Standard Two-Way (or Three-Way, Four-Way, etc., as the case may be) Traffic Signal Head (Polycarbonate resin or Silicon Aluminum Alloy) ­Type A" complete which shall include all optical units (bulbs excepted) together with doors, visors, terminal blocks, and accessories assembled in housing, with supports and equipped with mounting attachments of the type specified and painted, all as specified herein, and delivered f.o.b. to the point specified in the bid invitation. Measurement of hardware shall be made of each hardware assembly as shown on the item description.

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16.0 PAYMENT

16.1 Payment will be made at the contract unit price bid per each "standard Traffic Signal Face" or "Standard Two-Way (or Three-Way, Four-Way, etc., as the case may be) Traffic Signal Head (Polycarbonate Resin or Silicon Aluminum Alloy) - Type A" measured as prescribed above. Payment for hardware items will be made at the contract unit price bid per each hardware assembly as described on the bid invitation.

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