ITEM 682
VEHICLE AND PEDESTRIAN SIGNAL HEADS
682.1. Description.
This Item shall govern for furnishing and installing vehicle and pedestrian signal heads of the various types and sizes shown on the plans.
682.2.
Optical section.
Section --One housing case, housing door, visor and optical unit.
Face --One section or an assembly of two or more sections facing one direction.
Head --A uni-directional face or a multi-directional assembly of faces, including back plates and louvers, when required, attached at a common location on a support.
682.3. General.
The material, design and construction of signal heads shall be in accordance with the requirements set forth in the ITE standards except as noted herein.
All signal heads shall be in accordance with the TMUTCD.
Signal sections shall be constructed of a housing case, a housing door and a visor all made of the same material. All lenses shall be polycarbonate. Each signal section shall contain an optical unit and a terminal block. The signal sections shall be designed so they can be attached to each other and to mounting hardware.
Assembled signal sections shall not exhibit light leakage.
Unless otherwise shown on the plans, each signal section shall be designed for operation from a power supply of 120 volt, single phase, 60 Hz AC and with incandescent lamps conforming to ITE standards.
Unless otherwise shown on the plans, the Contractor shall furnish and install all traffic signal lamps.
682.4. Signal head components shall be either aluminum or polycarbonate. Unless otherwise shown on the plans, material selection shall be the option of the Contractor. Signal heads furnished for any one project shall be of the same material and manufacturer.
All material shall be accurately formed and free from defects affecting strength and appearance.
All material furnished by the Contractor shall be new.
(1) Aluminum.
Cast aluminum parts shall have a minimum tensile strength of 17,000 psi and sheet aluminum parts shall have a minimum tensile strength of 27,000 psi.
Aluminum materials shall conform to the following:
TYPE
Die
ASTM
B85
ALLOY
SG100A,
SC84B,
Permanent
Sheet mold
B209
B108 or S12A.
M1A.
(2) Polycarbonate.
Polycarbonate materials shall be ultraviolet-stabilized and shall meet the following physical property requirements:

TEST
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REQUIRED
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ASTM
--------
Gravity 1.17
Vicat F 305-325 D1525
Brittleness F
Self-extinguishing
Tensile Strength, yield, psi
Elongation at yield, percent
Shear, strength, yield, psi
8500 minimum
5.5-8.5 minimum
5500 minimum
D638
D638
D732
Izod impact strength, ft.-lb./in.
(notched, 1/8 in. thick)
Fatigue strength, psi at 2.5 mm
cycles
15 minimum
950 minimum
D256
D671
(3) Hardware.
All bolts, nuts, washers, lock washers, screws and other assembly hardware shall be galvanized steel, stainless steel or dichromate sealed aluminum, in conformance with Departmental Materials
Specification D-9-7120. When dissimilar metals are used, the metals shall be so selected or insulated to prevent corrosion.
(4) Gaskets in the optical unit shall be closed-cell silicone and shall withstand temperatures up to 250 F without permanent deformation or becoming brittle. Other gaskets shall be closed-cell neoprene.
Design.
(1) Housing Case.
(a) The housing case shall be one piece and shall be of either die cast aluminum alloy, permanent mold cast aluminum alloy or molded polycarbonate.
(b) Polycarbonate housing cases shall be a minimum of 0.090 inches thick and shall be ribbed for strength and durability.
(c) Both ends of each housing case shall be provided with an opening of two inches in diameter to accommodate mounting brackets.
(d) Each signal section shall be capable of being rotated 360 degrees about its mounting axis and shall be capable of being locked at 5-degree intervals. Locking shall be accomplished by the engagement of serrations in adjacent signal sections and in the mounting bracket assembly. Serrations shall be integral with the signal section and designed to insure flush alignment of the perimeters of the sections. Polycarbonate sections shall have additional strengthening ribs integral with the mating sides.
(e) Provisions shall be made for the attachment of the optical unit, housing door and for the signal head mounting arrangement shown on the plans. Provisions shall be made for attaching back plates, signs and sign lights of the types shown on the plans.
(2) Housing Door.
(a) The door of each housing case shall be one piece and shall accommodate the lens shown on the plans.
(b) Polycarbonate doors shall be a minimum of 0.090 inches thick.
(c) A gasket shall be provided between the aluminum door and housing case.
(d) The door shall be attached to the housing case by two stainless steel hinge pins spaced to hold the door in alignment when closed. Hinge pins shall be designed to remain in place under normal use.

(e) Two stainless steel wing screws or wing nuts shall be installed on the side of the door or the side of the housing to provide for opening and closing the door without the use of tools. Wing screws or wing nuts shall have a flat bearing surface or stainless steel flat washer to prevent gouging of the housing door. The wing screws or wing nuts shall remain captive when the door is open.
(3) Visor.
(a) Unless otherwise shown on the plans, each housing door shall have a standard tunnel visor as described herein. The visor material shall have a minimum thickness of 0.075 inch for polycarbonate and
0.050 inch for aluminum. The visor shall be rigidly attached to the housing door with corrosion resistant connectors.
(b) The visor shall be easily removed and replaced without damage to the visor or the completed signal head assembly. Louvers shall be attached when shown on the plans.
(c) Unless otherwise shown on the plans, the visors for vehicle signal sections shall:
-
- have a downward tilt of 2 to 8 degrees relative to the perpendicular to the plane of the housing door.
- encompass approximately 300 degrees of the lens.
- extend outward from the face of the lens a minimum of 9-1/2 inches for 12-inch diameter lenses and
7 inches for 8-inch diameter lenses.
- be open at the bottom.
(d) Each pedestrian signal section shall be furnished with a three- sided visor shielding the top and sides, extending out from the surface of the lens a distance of six to nine inches.
(e) The same type visor shall be used throughout the project.
(4) Lens for Vehicle Signal Sections.
(a) Each lens shall be either red, yellow, yellow arrow, green, or green arrow. Masks may be used to form arrows. The lens shall be round with a nominal diameter of 8 or 12 inches. Lens type, color and size shall be as shown on the plans.
(b) Each lens shall be permanently marked, in an inconspicuous manner, indicating the top of the lens and the name or trademark of the manufacturer.
(5) Lens for Pedestrian Signal Sections.
(a) Each lens shall be square with a nominal size of 9 x 9 inches or 12 x 12 inches as shown on the plans.
(b) Unless otherwise shown on the plans, the lens shall display the words "WALK" or "DONT
WALK". The letters shall be at least 3 inches high for 9 inch lens and 4.5 inches high for 12 inch lens.
(c) When shown on the plans, symbols shall be used. Symbols shall be a minimum of 6 inches high and 3.5 inches wide for 9 inch lens and a minimum of 9 inches high and 5.25 inches wide for 12 inch lens.
(d) Unless otherwise shown on the plans, the WALK and the DONT WALK, word or symbol, indications shall be in separate signal sections. The WALK indication shall be white. The DONT WALK indication shall be orange.

(6) Reflector.
(a) The reflector shall be approximately parabolic in section and reasonably free from chips, bubbles, streaks and wrinkles. The reflecting surface shall be free of flaws, scratches and defacements. The light from a 200 watt incandescent lamp shall be invisible through the reflector.
(b) The reflector shall be specular Alzak aluminum or aluminized polycarbonate.
(7) Lamp Receptacle.
(a) The lamp receptacle shall be of weatherproof construction. A lamp grip shall be provided to prevent the lamp from loosening by vibration. The lamp receptacle shall be rotatable for proper lamp orientation.
(b) Each lamp receptacle shall be wired with two flexible, insulated, color coded wires not smaller than No. 18 AWG.
(8) Lamp.
(a) Unless otherwise shown on the plans, the traffic signal lamp shall meet the following requirements.
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Type of Signal Section
All pedestrian
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Light length
Minimum lumens wattage
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(b) The glass envelope of each lamp shall be indelibly marked to show the manufacturer's identification, the rated voltage, the rated lumens, the rated average life and orientation of the lamp for proper burning position.
(9) Optical Unit.
(a) The optical unit shall meet ITE standards for light color and distribution. All parts of the optical unit shall withstand the heat generated by continuous illumination of a 70 watt lamp in an 8 or 9 inch signal section, and a 150 watt lamp in a 12 inch signal section without distortion or discoloration.
(b) The reflector, lamp receptacle and lens shall form a dust tight, water tight unit. A closed-cell silicone gasket shall be used to seal the lens to the reflector.
(c) The reflector holder and lamp receptacle holder shall be rigidly fastened in place by hinges and/or lugs for easy removal of the assembly. It shall not be necessary to remove the assembly from its supports for relamping or cleaning the reflector.

(10) Back Plate.
(a) The back plate shall be attached to vehicle signal faces when shown on the plans.
(b) Back plates shall be a minimum thickness of 0.050 inch for aluminum and 0.090 inch for polycarbonate. Unless otherwise shown on the plans, back plates shall be made of the same material as the signal housing.
(c) The back plate shall extend around the periphery of the signal face a distance of 8 inches for faces with 8 inch lens and 5 inches for faces with 12 inch lenses.
(11) Terminal Block.
(a) The terminal block body shall be of one-piece molded construction using phenolic materials. The block shall consist of permanently identified electrical sections, each section consisting of two (2) 6-32 or 8-
32 x 5/16 inch binding head screws and a conducting metal strip between the screws. The block shall be rated for a minimum of 20 ampere, 250 volt service and section to section breakdown voltage shall be a minimum of 1600 volts AC rms. All metal parts shall be nickel plated brass.
(b) The terminal block shall be securely mounted to the housing case in an accessible position internally in the signal section.
(c) Each vehicle signal section shall have a terminal block containing a minimum of six (6) sections.
(d) Each pedestrian signal section shall have a terminal block containing a minimum of three (3) sections.
(12) Mounting Attachments.
Mounting attachments shall be as shown on the plans.
(13) Colors.
Unless otherwise shown on the plans, traffic signal heads shall be Federal Yellow No. 13538 of
Federal Standard 595. Back plates, louvers and the inside of visors shall be flat black.
(a) The colorant required shall completely impregnate the polycarbonate material. The inside of polycarbonate visors shall be provided with two (2) coats of high grade flat black finish paint.
(b) All exposed metal surfaces, except for back plates, louvers and the inside of visors, of the assembled traffic signal head shall be given two (2) separately baked on coats of high grade enamel. The back plates, louvers and inside of the visors shall be provided with two (2) coats of high grade flat black finish paint.
682.6. Construction Methods.
(1) Assembly.
(a) Individual signal sections in multi-section faces shall be assembled, in accordance with manufacturer's recommendations, to form a rigid signal face.
(b) Signal heads shall be assembled and mounted as shown on the plans.
(c) Any openings in an assembled signal head shall be closed with a plug. The plug shall be of the same material and color as the head.

(2) Wiring.
(a) Each optical unit shall be wired to the terminal block located in that signal section by means of solderless wire connectors or binding screws and spade lugs.
(b) All sections of a multi-section signal face shall be wired to the section terminal block(s) in which the traffic signal cable is terminated. The color coding on leads from the individual optical units shall be maintained throughout the signal head except for the traffic signal cable. All connections to terminal blocks, except field wiring, shall be made using solderless wire connectors or binding screws and spade lugs. Field wiring shall be made using binding screws and spade lugs.
682.7. Certification.
All traffic signal heads shall conform to ITE strength requirements. The
Contractor shall supply written certification of compliance from the manufacturer.
682.8. This Item will be measured by each vehicle signal section, by each pedestrian signal section, by each back plate and by each louver complete in place.
682.9. Payment.
The work performed and materials furnished in accordance with this Item and measured as provided under "Measurement" will be paid for at the unit price bid for "Pedestrian Signal
Section", "Vehicle Signal Section", "Back Plate", or "Louver" of the various types and sizes specified. This price shall be full compensation for furnishing, assembling and installing the signal sections, back plates and louvers; for all mounting attachments; and for all labor, tools, equipment and incidentals necessary to complete the work.