1. Sign Structures Updates: Helpful Tips for Inspectors
March, 10, 2015
30 seconds
Anthony – (performs greeting)
Anthony Stakston, Wisconsin DOT
Ancillary Structure Engineer

2. Introduction Ancillary Structure Engineer
SW Region (Madison) – Patrick Gavinski
SW Region (La Crosse) – Dave Bohnsack
SE Region – Tom Heydel (Signs),
Derrin Wolford (Signals) &
Jason Zemke (C Structures & Retaining/Noise Walls)
NE Region – Brady Rades
NC Region – Anthony Stakston
NW Region – Kyle Harris

3. And Overhead Sign Supports
Section 641 Sign Bridges
And Overhead Sign Supports
Updated in Wisconsin Standard Specifications 2015 Edition
Specify Additions and Exceptions to high-strength bolt requirements, and DTI (Direct Tension Indicators).
Require tightening procedures for mast arm to pole shaft connections on shop drawings.

4. And Overhead Sign Supports
Section 641 Sign Bridges
And Overhead Sign Supports
Updated in Wisconsin Standard Specifications 2015 Edition
Allow structure installation after concrete attains 3,500 psi compressive strength or 7 equivalent days.
Require a certificate of compliance for bolting within pre-assembled truss sections.
Specify profiling for painted galvanization repair or metalizing for areas greater than 10 square inches.

5. Section 657 Poles, Arms, Standards, and Bases
Updated in Wisconsin Standard Specifications 2015 Edition
Require the contractor to provide monotube bolt/nut/washer assemblies.
Require the department to provide the contractor with tightening procedures for other department-provided components.
Require tightening procedures for arm-to-pole connections on shop drawings.

6. Section 657 Poles, Arms, Standards, and Bases
Updated in Wisconsin Standard Specifications 2015 Edition
Specify contractor-furnished high-strength bolts and DTI for monotube arms.
Require structure installation on anchor bolts according to department form DT2321.
Department pays separately for concrete foundations and provides anchor assemblies.

7. Section 654 Bases
Updated in Wisconsin Standard Specifications 2015 Edition
Reference construction requirements in 636 for drilled shaft foundations, and for rectangular bases.
Allow structure installation after concrete attains 3500 psi compressive strength or 7 days equivalent.

8. Construction & Materials Manual 5-70: Ancillary Structures
Updated in December 2014
DTIs Included
Construction Inspection Checklist for Ancillary Structures
Traffic Signal Poles and Arms for Monotube Types 9, 10, 12 and 13
Sign Structures
High Strength Bolt Assemblies
Anchor Bolt Assembly
Concrete Footing
Signs and Blanks
Initial Inspection after Structure Erection

9. Direct Tension Indicator (DTI) Issues
Contractor needs to compress the DTI to one more than the average found in Table 3 from DT2322, Ancillary Structures Pre-Installation Verification Test of High Strength Bolts per lot.
Inspector needs to field verify the appropriate number of DTIs are compressed with the contractor supplied ” feeler gauge.

10. Direct Tension Indicator (DTI) Issues
Contractor shall NOT install any High Strength Bolts with DTIs until the pre-installation testing is complete.
Contractors have been installing High Strength Bolts with DTIs and planning on going out and finish tightening afterwards, and this is not in accordance with specifications.

11. DTI / Bolt Radius Issue On large bolt sizes (> 1 ½” A325).
Radius Tolerance at the base of the bolt head is 0.03” to 0.09”. Bolts have been found with 0.175” radius (out of tolerance – Red).
Need to check for tolerance of bolt radius by putting the washer on and seeing if the dimples of the DTI washer touch the bolt head .

12. A325 Bolts vs. A490 Bolts
Only A325 Bolts are allowed on Wisconsin DOT Projects.
If A490 Bolts are shown in the shop drawings, the contractor needs to provide an updated PE stamped shop drawings with A325 bolts in place of A490 bolts.

13. Post / Mast Arm Connections: Washers
Washers are not allowed between the friction surfaces.

14. Post / Mast Arm Connections: Washers
If washer are shown in the shop drawings between the friction surfaces, the contractor needs to provide an updated PE stamped shop drawings with no washers between the friction surfaces.
Friction Surface

15. High Strength Steel Anchor Rods:
DT2321, High Strength Steel Anchor Rod Installation Tensioning Record
Snugging: 20% to 30% of Verification Torque on both the top nut and leveling nut following the star pattern on form. Two cycles shall be performed prior to next step.
Snugging can be verified with torque wrench or may be estimated.
Grade 55 Rods Only

16. Lock Washers:
Lock Washers are not allowed on anchor bolt and high strength bolt connections.

17. Anchor Bolts: 2014 Carryover Construction Projects:
Weld Between Base Plate and Post
2014 Carryover Construction Projects:
Weld can be too thick where the standard washer cannot rest on the base plate.
Type 9 & 10 Monotube Traffic Signal Only

18. Anchor Bolts: 2014 Carryover Construction Projects:
Weld Between Base Plate and Post
2014 Carryover Construction Projects:
Supplier (Millerbernd Manufacturing Company) will provide washers with a notch cut out of them, so the can rest on the base plate (Temporary Fix).
Full top washer will need to be added above the notched washer to achieve the proper connection between the nut.
Type 9 & 10 Monotube Traffic Signal Only

19. 2015 Construction Projects: Type 9 & 10 Monotube Traffic Signal Only
Anchor Bolts:
Weld Between Base Plate and Post
2015 Construction Projects:
Supplier (Millerbernd Manufacturing Company) has fixed the issue by reducing the diameter of the vertical pole. The base diameter has been reduced to 11.25”.
Type 9 & 10 Monotube Traffic Signal Only

20. Monotube Traffic Signal Bases:
Stay in Place Forms (Sonotubes, etc.) are not allowed.
Traffic signal bases should be constructed per FDM S.D.D.
Any deviation from what is show in S.D.D. (i.e. stay in place forms) need to be designed and stamped plans submitted to Project Engineer to be allowed.

21. Monotube Traffic Signal Bases:
Alex Crabtree (BOS) - Contact if hitting water, cave-ins, etc. for allowable solutions.
Construction Joints – below wing (allowed but not preferred). Need to have written approval from Alex Crabtree prior to allowing.

22. Monotube Traffic Signal & Sign Structure Bases:
Alex Crabtree - Bureau of Structures - Design
(608)

23. Sign Structure Initial Inspection:
Documents needed to be submitted to Ancillary Structures Engineer prior to initial inspection:
Shop drawings for contractor supplied sign structures.
DT2321 Form – High Strength Steel Anchor Rod Installation Tension Record
DT2322 Form – Ancillary Structures Pre-Installation Verification Test of High Strength Bolts

24. Sign Structure Initial Inspection:
Initial Inspections needs to be completed before the traffic signal is turned on for Traffic Signal Monotubes.
New sign structures shall be inspected within 2 weeks of notification by the DEPARTMENT.
Consultant shall provide a draft report with the list of deficiencies 1 week following the inspection.

25. Ancillary Structure
Engineers:
Ancillary Structure Engineer –
Anthony Stakston, PE
(715)