ONTARIO PROVINCIAL STANDARD SPECIFICATION

METRIC OPSS 2471 APRIL 2004

MATERIAL SPECIFICATION FOR SECTIONAL STEEL HIGH MAST LIGHTING POLES

TABLE OF CONTENTS 2471.01 2471.02 2471.03 2471.04 2471.05 2471.06 2471.07 2471.08 2471.09 APPENDICES 2471-A Commentary SCOPE REFERENCES DEFINITIONS SUBMISSION AND DESIGN REQUIREMENTS MATERIALS EQUIPMENT - Not Used PRODUCTION QUALITY ASSURANCE OWNER PURCHASE OF MATERIAL

2471.01

SCOPE

This specification covers the requirements for 25, 30. 35, 40, and 45 m base mounted sectional steel high mast lighting poles with a multisided cross-section. 2471.01.01 Significance and Use of Appendices

Appendices are not a mandatory part of this specification and must be invoked by the Owner. Appendix 2471-A is a commentary appendix to provide designers with information on the use of this specification in a Contract.

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2471.02

REFERENCES

This specification refers to the following standards, specifications, or publications: Ontario Provincial Standard Specifications, Construction OPSS 911 Coating Structural Steel Systems

Ontario Provincial Standard Specifications, Material OPSS 1704 Paint Coating Systems For Structural Steel

Ministry of Transportation Publications Structural Manual Division 1, Exceptions to the Canadian Highway Bridge Design Code Canadian Standards Association G40.20/G40.21-98 S6-00 W47.1-M92 (R2001) W48-01 W59-M1989 (R2001) W178.2-01 General Requirements for Rolled or Welded Structural Quality Steel/Structural Quality Steel Canadian Highway Bridge Design Code Certification of Companies for Fusion Welding of Steel Structures Filler Metals and Allied Materials for Metal Arc Welding Welded Steel Construction, (Metal Arc Welding) Certification of Welding Inspectors

Canadian General Standards Board 48.9712-2000 Non-Destructive Testing - Qualification and Certification of Personnel

American Association of State Highway and Transportation Officials LTS-4-M Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals

2471.03

DEFINITIONS

For the purpose of this specification, the following definitions apply: Engineer means a professional engineer licensed by the Professional Engineers of Ontario to practice in the Province of Ontario. Multisided means having either eight or twelve sides as specified in the Contract Documents.

2471.04 2471.04.01 2471.04.01.01

SUBMISSION & DESIGN REQUIREMENTS Submissions General

Six copies of shop drawings and welding procedures for the sectional steel high mast lighting pole shall be submitted to the Owner 14 Days prior to the start of fabrication.

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Each shop drawing and welding procedure shall bear the stamp and signature of an Engineer certifying that the shop drawings and welding procedures comply with the Contract Documents. 2471.04.01.02 Shop Drawings

The shop drawings shall include as a minimum, the following information: a) Dimensioned drawings, including elevations, sections, and details of the sectional steel pole. b) Equipment dimensions and exact weight, including final force of assembly. c) Detailed dimensional drawing showing the mounting arrangement of the winch assembly, head frame assembly, ring assembly, and the electrical panel assembly. d) Mill test certificate reports of all steel being used. e) Canadian welders certificates or equivalent qualifications. f) Detailed bill of materials.

g) Details of equipment nameplates. 2471.04.01.03 Welding Procedures

The welding procedure shall be supplied to the Owner and include as a minimum, the following information: a) Type and thickness of electrodes to be used, preheat and underpass temperatures, and the proposed method of filling the welds. b) The method to be used for the preparation of the edges and the measures taken to control the effects of distortion and shrinkage. c) The proposed methods and sequences of assembling and welding and the equipment to be used. 2471.04.02 Design

Sectional steel high mast lighting poles shall be according to CSA S6-00, AASHTO LTS-4M, Structural Manual, and as specified in the Contract Documents.

2471.05 2471.05.01

MATERIALS Steel

Steel for pole masts and base plates shall be according to CSA G40.20/G40.21, Grade 350 WT, for High Strength, Weldable, Notch Tough Steel. All structural steel shall be new and shall be certified to be impact tested per heat to Category 3 and shall satisfy Charpy V-Notch test requirements of 27 Joules for Grade 350 WT at minus 30C. Silicon content in steel shall be less than or equal to 0.06 %. 2471.05.02 Electrodes

Electrodes for welding shall have a low hydrogen content and shall be according to CSA W48.

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2471.07 2471.07.01

PRODUCTION Tolerances

Fabrication shall be according to the dimensions on the stamped and signed shop drawings. The dimensions of the completed section steel high mast lighting pole shall be within the following tolerances: a) Overall height of pole mast 5 mm for every 1 m in height. b) Cross sectional diameter where less than 500 mm, 1.0%, where greater than 500 mm, 0.75%. c) Maximum offset of the pole mast on its overall length measured from a chord at the extremities and the centerline of the mast, shall not exceed 0.2% of its overall length. d) Maximum offset of the shaft wall on any 3 m length of pole mast shall not exceed 5 mm. e) Offset between the centerline of the top section of the pole and the centerline of the bottom section of the pole shall not exceed 150 mm. f) Offset between the centerline of the base plate and the center of the pole mast at base shall not exceed 5 mm.

g) Dimension across flats shall not exceed 1.0%. h) Wall thickness shall be within the tolerance permitted in CSA G40.20/G40.21. 2471.07.02 Pole Mast and Base Plate

The pole mast shall be of a multisided cross-section shape. The pole sections shall be tapered construction so that a number of sections may be assembled by means of an overlapping press fit to form a tapered steel pole of desired length. The pole mast shall be cold formed from sheet steel and each section shall be fabricated with one or two continuous longitudinal welds. The welds shall be single V and shall be made from the outside of the structure. Throat thickness shall be according to the minimum sizes permitted by CSA W59, to ensure a minimum of 60% to an almost complete joint penetration. Penetration required at slip joints and lap splices shall be 100%. One circumferential shop splice per section will be permitted. Circumferential splice welds shall be sound, continuous, complete penetration groove welds. An internal backup strip shall be used at the joint. The splice shall be 100% radiographed or ultrasonically tested and the quality of the welded joints shall be according to CSA W59. Test results shall be made available to the Owner. In the area of the lap splice there shall be no protrusions preventing proper alignment of the section. Any excess weld material shall be removed by grinding to form a smooth and uniformly tapered section. Each pole shall be supplied with a reinforced handhole complete with a cover. The cover shall have provision for padlocking and shall be fitted with a silicone rubber gasket such that upon locking the cover shall be tightly fitted to the handhole. Each pole shall be capable of supporting a total maximum load of 2,000 kg with a combined effective projected area of all the luminaires, shroud and shields not exceeding 4.0 m2.

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Each pole shall be supplied with the appropriate mounting plate, brackets, and other materials of attachment required for the installation of the raising and lowering equipment. The mounting plate and brackets shall be fillet welded inside the pole as shown in the shop drawings. Nuts for securing the electrical panel shall be welded to the back of the mounting plate at each mounting hole as shown in the Contract Documents. A lifting bracket, remote cable hook, and ground lug shall be fillet welded inside the pole beneath the handhole opening as specified in the Contract Documents. A 12-gauge steel channel 41 x 22 mm complete with a metal cable clamp for the sensor wiring shall be fillet welded inside the pole at appropriate locations and as indicated in the Contract Documents to support the teck cable. A 42 mm diameter schedule-40 pipe shall be welded to the inside of the pole as indicated in the Contract Documents. The head frame shall be assembled to the pole by means of a tenon system. The tenon shall be compatible with the raising and lowering device. In the tenon mounting system, a circular plate with nominal thickness of 12 mm shall be mounted to the top of pole with a sound, continuous fillet weld. The plate shall have a circular opening through the centre equal to the outside diameter of the tenon and the tenon shall be inserted into the opening and welded to the plate with a sound, continuous fillet weld. The tenon shall have an outside diameter and length compatible with the raising and lowering device and a nominal tenon wall thickness of 5 mm. The pole section joints shall be slip fitted connections as indicated on the shop drawings. Joint details shall not interfere with the raising or lowering of the luminaire assembly. Depending on pole length, the slip joint connection shall be 2.5 or 3.0 times the top outside diameter of the joined section as shown on the shop drawings. The maximum overlap shall be such that the height of the completed mast complies with the permitted overall tolerance. Shop pre-assembly shall be carried out for the purpose of checking the fit of the sections. The manufacturer shall determine the necessary compressive assembly forces and lap lengths to be achieved during the preassembly operation to ensure the final field assembly will meet the requirements of the Contract Documents. Assembled sections shall be permanently marked so they can be field assembled in the same relative orientation. The location and size of the marks and the marking medium shall not interfere with the slip joint. The pole base plate shall be circular and of the size specified in the Contract Documents. All edges of the base plate shall be ground to a radius of 3 mm. 2471.07.03 Welding

All welding shall be according to CSA W59 and shall be undertaken by a manufacturer fully approved according to CSA W47.1. Before welding commences, the Canadian Welding Bureau Qualification Certificates for each person to be employed on the work shall be made available to the Owner. Such certificates shall be current and shall indicate the positions the operator is qualified to weld. Welds connecting the shaft to base and for the circumferential splices shall be full strength complete penetration, 100% radiographed or ultrasonically examined, and shall be according to CSA W59 for dynamically loaded structures. Welds within the lap of the slip joints plus an additional 150 mm extending from the slip joint shall be ground to remove all protrusions. The welds after grinding shall be full strength complete penetration, 100% radiographed or ultrasonically examined.

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2471.07.04 2471.07.04.01

Coating Galvanize

All surfaces of components shall be hot dip galvanized according to OPSS 911. The specified zinc coating to be applied shall be in an amount not less than 610 g/m2. This application shall result in a minimum nominal thickness of 87 microns. 2471.07.04.02 Paint Coating

After galvanizing and prior to painting, the pole shall be checked thoroughly for continuity and smoothness. The pole shall then be paint coated according to OPSS 911 with the paint coating meeting the requirements of OPSS 1704. The colour of the finish coat shall be grey. Pre-assembly shall be carried out as not to damage the coatings of the pole. If damage to the coatings of the pole is encountered during the shop pre-assembly, corrective measures shall be taken by the manufacturer subject to the approval of the Owner. 2471.07.05 Identification Nameplate

Each sectional steel high mast lighting pole shall have an identification nameplate showing the following: a) Pole identification number. b) Contract number. c) Pole manufacturers name or trademark. d) Date of manufacture. e) Luminaire manufacturers name. f) Luminaire distribution type.

g) Raising and lowering equipment manufacturers name. The nameplate shall be made of stainless steel and shall be securely attached to the outside upper part of the handhole cover by rivets. A neoprene or rubber gasket shall be placed between the handhole cover and the nameplate to prevent corrosion effects. 2471.07.06 Quality Control

The manufacturer shall certify that the sectional steel high mast lighting poles comply with the strength and material requirements of the Contract Documents. The manufacturer shall have an inspector to inspect and test the sectional steel high mast lighting poles. The manufacturers inspector shall be certified for testing bridges according to CSA W 178.2. The certification shall be either Level II or Level III for the methods used as required by CAN/CGSB 48.9712. The manufacturer's inspector shall inspect the place of manufacture of the sectional steel high mast lighting poles while work on the units is being performed and shall inspect and examine the plant records and certificates, the materials used, and the fabrication process and shall conduct any tests as may be considered necessary. The manufacturer shall submit two copies of the completed inspection reports to the Owner. The inspection report shall be completed and certified by the manufacturer's inspector.

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When the sectional steel high mast lighting poles have been delivered to the Working Area and prior to installation, the manufacturer's inspector shall inspect these to ensure they meet the requirements of the Contract Documents. 2471.07.07 Testing

Visual inspection of the sectional steel high mast lighting poles shall be performed by welding inspectors certified by the Canadian Welding Bureau according to CSA W178 at a Level III category or working under a Level II inspector. Non-destructive testing of the sectional steel high mast lighting poles shall be performed by an ultrasonic or radiograph technician or both, certified by the Certifying Agency Natural Resources Canada CANMET to Level 2 or Level 3 according to CAN/CGSB 48.9712. 2471.07.08 Packaging and Shipment

Each pole shall be shipped complete with hardware suitably packaged to ensure that all parts are delivered as an entity. A complete parts list shall be included in the shipment. Sectional steel high mast lighting poles shall be packaged using wood blocks for separation between poles. Cardboard shall be placed around the sectional steel high mast lighting poles where a steel securing strap is located. Sectional steel high mast lighting poles shall be loaded, delivered, and off-loaded at the designated areas. Sectional steel high mast lighting poles shall be subject to inspection during and on completion of off-loading. If damage is encountered during the off-loading inspection, the Contractor shall be responsible for the necessary corrective measures subject to the approval of the Owner.

2471.08 2471.08.01

QUALITY ASSURANCE Welding

Welding shall be subject to inspection by both visual and non-destructive testing. The procedure and technique for visual and non-destructive testing shall be according to CSA W59, Clause 7 and 8. The manufacturer shall submit corrective welding procedures to the Owner for approval, for repair of welds not meeting the requirements of the Contract Documents. 2471.08.02 Inspection

Sectional steel high mast lighting poles are subject to inspection by the Owner at any time. The manufacturer shall notify the Owner of the dates that fabrication, testing, and delivery will take place. The manufacturer shall provide the Owner with access to the place of manufacture during fabrication for the purpose of inspecting plant records and certificates, materials, manufacturing processes, and to make or witness or both any tests as may be considered necessary to provide quality assurance.

2471.09

OWNER PURCHASE OF MATERIAL

Payment at the price specified in the purchasing order shall be full compensation for all labour, Equipment, and Material for the supply and delivery of the sectional steel high mast lighting poles to the destination at the time specified. The cost of all testing, except that performed by the Owner, shall be included in the price.

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Appendix 2471-A, Commentary for OPSS 2471, April 2004 Note: This appendix does not form part of the standard specification. It is intended to provide information to the designer on the use of this specification in a Contract.

Design Action/Consideration The design should specify the following in the Contract Documents: Pole design. (2471.04.02) Locations of 42 mm diameter schedule 40 pipe; teck cable support; lifting bracket; remote cable hook; ground lug; nuts for securing the electrical panel on the back of the mounting plate; and pole base plate. (2471.07.02) Identification nameplate information. (2471.07.05)

Related Ontario Provincial Standard Drawings OPSD 2450.010 OPSD 2450.011 OPSD 2450.020 OPSD 2450.021 OPSD 2453.010 OPSD 2453.050 OPSD 2454.010 OPSD 2458.01 OPSD 2460.01 OPSD 2460.02 High Mast Lighting Pole 25, 30, and 35 m Octagonal Pole with Double Base Plate High Mast Lighting Pole 25, 30, and 35 m 8-Sided Pole High Mast Lighting Pole 40 & 45 m Octagonal Pole with Double Base Plate High Mast Lighting Pole 40 m and 45 m 12-Sided Pole High Mast Lighting Pole Cable Holder and Storage Hook High Mast Lighting Pole Nameplate Details High Mast Lighting Pole Double Base Plate Details High Mast Lighting Luminaire Support Ring Assembly High Mast Lighting Pole Wiring Diagram 600/347 V, 3-Phase High Mast Lighting Pole Wiring Diagram 120/240 V, 1-Phase

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