4/28/2015 GuidelinesfortheInstallation,Inspection,MaintenanceandRepairofStructuralSupportsforHighwaySigns,Luminaries,andTrafficSignalsInspection

Bridges&Structures
GuidelinesfortheInstallation,Inspection,MaintenanceandRepairof
StructuralSupportsforHighwaySigns,Luminaries,andTrafficSignals
6.0BoltedConnections
Sign,signal,andlightingstructuresutilizeavarietyofboltedfastenersintheirconstruction.Theserangefrom
largeanchorrodsandhighstrengthboltedstructuralconnectionsto"secondary"fastenersforsigns,wind
beams,saddles,andthelike.FastenersalsoincludeUbolts,boltedclips,andsimilaritems.While
proceduresforinstallinghighstrengthboltsareestablishedinAASHTO,andrecommendedproceduresfor
anchorrodnutinstallationareprovidedherein,installationpracticesforothertypesofboltedfastenersvaries.
Ancillarystructuresaresubjecttovibrationduetofluctuatingwindloads.Unlessproperlytensioned,thiscan
causefastenerstobecomeloseandcontributetotheirfailure.Thoughtheimplicationoffailureofananchor
rodorboltinastructuralconnectionmayseemapparent,evensecondaryfastenersthatfailcanleadtosign
breakageandsmallitemsfallingintotraffic.Connectionsshouldbedesignedwithdueconsiderationofthe
fatiguestressesinducedbyvariationsinwindloads.

6.1HighStrengthBolts
Thedesign,specification,handling,installation,andinspectionofboltedjointsinsteelsupportstructures
shouldbeinaccordancewiththeSpecificationforStructuralJointsUsingASTMA325orA490Boltsdated
June,2000bytheResearchCouncilonStructuralConnections(RCSC).Onlyafewpointsespecially
importantforsupportstructuresarementionedintheseGuidelines.TheFederalHighwayAdministration
ReportNo.FHWASA91031,"HighStrengthBoltsforBridges"providesanindepthtreatmentofboltsupply,
installation,andtesting(thismanualisavailablefordownloadatfhwa.dot.gov/bridge).TheUboltsandother
detailsforconnectingluminaries,signs,andsignalheadstothestructurearenotdiscussed.The
manufacturersdesignthesedetails,andtherehavebeenfewproblemswiththesedetailsinthepast.
Structuraljointsforgalvanizedsteelsign,signal,andlightsupportstructuresshouldonlyutilizegalvanized
ASTMA325highstrengthboltsorgalvanizedASTMF1852twistofftype,tensioncontrolboltassemblies.
Thejointsshouldbebetweensteelmembers,anditisessentialthatthejointsbeproperlypretensionedto
resistvibration.Theseboltshaveaveryhighstrengthsothattheycansupplyhighforcestocompressthe
jointwhentheyaretightenedtotheirprescribedpretension.Thesejointsactuallycarryloadthrough
compressiongeneratedfrictiononthefayingsurfacesratherthanthroughthebolt.Thejoboftheboltisto
maintainthepretensionandtheassociatedprecompressionofthefayingsurfaces.
Whenapretensionedjointissubjecttocyclicfatigueloads,itactsasifthepiecespressedtogetherwere
actuallymonolithic(i.e.,theboltsthemselvesfeelonlyabout20percentoftheloadrange),withthemajority
oftheloadrangetransferredthroughthefayingsurfaces.Whenaboltedjointisnotproperlypretensioned,all
theloadrangeistransferredthroughtheboltsandtheymayquicklyfailbyfatigue.
GalvanizedASTMA325boltsandrelatedwashersandnutsareavailableeitherhotdipgalvanizedor
mechanicallygalvanized.Hotdipgalvanizingisrecommendedasitprovidesaheaviercoatingwith
correspondingincreasedlife.
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HeavyhexnutsshouldmeettherequirementsofASTMA563(GradeDHgalvanizedandlubricated)or
ASTMA194(Grade2Hgalvanizedandlubricated).Heavyhexnutdimensionsshouldmeettherequirements
ofANSI/ASMEB18.2.6.FlatgalvanizedcircularwashersshouldmeettherequirementsofASTMF436.
Washersshouldbeusedunderthenut.Iftheboltheadistobeturnedduringthetighteningprocedure,thena
washershouldalsobeprovidedunderthehead.Lockwashersshouldneverbeusedwithhighstrengthbolts.
Foroversizedholes,platewashers8mm(5/16inch)shouldbeusedratherthanflatwashers.Platewashers
shouldbestructuralgradesteelandshouldbegalvanized,ifusedwithgalvanizedfasteners.
Lockwashersshouldnotbeusedwithhighstrengthbolts.Theirvariabilityofdeformationunderloaddoesnot
provideforproperboltinstallationtension.
Compressiblewashertype,directtensionindicatorsshouldmeettherequirementsofASTMF959.Whenthe
directtensionindicator(DTI)isusedunderthenut,anASTMF436washershouldbeplacedbetweenthebolt
andthedirecttensionindicator.Whenthedirecttensionindicatorisusedunderthebolthead,anASTMF436
washerisrequiredundertheDTIwhentheDTIisplacedonanoversizedholeandbetweentheboltheadand
theDTIwhentheboltheadistheturnedelement.
Theboltlengthusedinaconnectionshouldbesuchthattheendoftheboltisflushwithorprojectingbeyond
thefaceofthenutwhenproperlyinstalled.

6.2StainlessSteelFasteners
Connectionsforstainlesssteelstructures,whicharerare,andaluminumstructuresutilizestainlesssteel
boltsandrelatedfasteners.Stainlesssteeloffersexcellentcorrosionresistance.
StainlessfastenersaremostoftensuppliedfromAmericanIronandSteelInstitute(AISI)Type304or316
stainlessmaterial.Type304isthemostcommon.Nutsandwashersshouldmatchthesteeltypeofthebolt
orfastener.StainlessfastenersshouldconformtotherequirementsofASTMF593,"StandardSpecification
forStainlessSteelBolts,HexCapScrews,andStuds"andASTMF594"StandardSpecificationforStainless
SteelNuts."Stainlesssteelboltsaresuppliedeitherhotfinishedorcoldfinished.ColdfinishedType304and
316boltshaveanultimatetensilestrengthof620MPa(90ksi),versus516MPa(75ksi)forhotfinished.
However,coldfinishedboltsareonlysuppliedifspecificallyspecifiedandarenotnormally"offtheshelf"
items.
Sinceinstallationtensionforstainlessfastenersisnotashigh,oraswellcontrolled,asitisforhighstrength
steelbolts,theuseoflockwashersiscommonwithstainlessfasteners.Lockwashersareplacedunderthe
nutandhelptoreducelooseningduetostructurevibrationandloadfluctuation.

6.3AluminumFasteners
Aluminumfastenersaresometimesusedformiscellaneousapplications,suchassignconnections.
Aluminumboltsarenotgenerallyusedinstructuralconnections,evenonaluminumsignstructures,duetoa
tendencytostretchandhenceloosenundercyclictensionloadings.
AluminumboltsshouldconformtoASTMB316"StructuralSpecificationforAluminumAlloyRivetandCold
HeadingWireandRods."Boltsareavailableinseveralalloytempers,with2024T4and6061T6themost
common.Offtheshelfboltsaretypicallyalloytemper2024T4,whichhasanallowableshearstressof96
MPa(14ksi)andanallowabletensionstressof158MPa(23ksi)asgiveninthe"AluminumDesignManual"
publishedbytheAluminumAssociation.

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6.4InstallationofBoltsandFasteners
Allboltsandmiscellaneousfastenersmustbeinstalledinaccordancewithestablishedindustrypracticeor
manufacturer'srequirements.Thoughnotdesirable,someprocurementpracticesmayresultinsignstructures
beingerectedbyfirmswithlittleexperienceinproperinstallationofhighstrengthbolts.Inaddition,unlessa
contractoriserectingagroupofsignstructures,onlyafewhighstrengthboltsmaybeneeded.Wherethe
quantityoffastenersissmall,itmaynotberealistictoexpectthesameboltdocumentationandtestingas
wouldbeprovidedonasteelbridgeerectionproject.
Fastenercomponentsshouldbeprotectedfromdirtandmoistureinclosedcontainersatthesiteof
installation.Fastenercomponentsshouldnotbecleanedoflubricantthatispresentintheasdelivered
condition.Componentsthataccumulaterustordirtresultingfromplantorjobsiteconditionsshouldnotbe
incorporatedintothework.Galvanizedboltsthathavebeenfullypretensionedshallnotbereused.
Acommonboltedconnectioninancillarystructuresconsistsofboltedflangeorfaceplatesthatmatchface
toface.Suchconnectionsoccurattrusschordsplices,longmastarmsplices,armtopoleconnections,and
similarlocations.Accordingtofabricators,itisalmostimpossibletoachieveaperfectlyflatfayingsurfaceon
theflangedconnectionthatmatesattheexactanglewithaperfectlyflatfayingsurfaceontheopposing
flange.Thefabricatorshouldselectaweldtypeandprocedurefortheplatetotube(ormember)connection
thatminimizesmisalignmentanddistortionofthefayingsurfaces.Asstatedabove,theslopeofthesurfaces
ofpartsincontactwiththeboltheadornut,andthefayingsurfaces,shouldbeequaltoorlessthan1:20with
respecttoaplanethatisnormaltotheboltaxis,but100percentmatingbetweenthetwoflangeswillusually
notbeachieved.Compressiblematerials(suchasgaskets,insulation,orsheetsofothermetals)shouldnot
beplacedbetweentheseflanges,eventotrytoachievebettercontact.Tighteningofboltsshouldbe
performedinamannerthatbringsthefayingsurfacesup"evenly."Forflangetypeconnections,astar
tighteningpatternasshowninFigure8isrecommended.

Figure8.StarPatternTighteningSequence.
Forhighstrengthboltedjoints,accordingtotheRCSC,thesurfacesneedtobebroughtintofirmcontact,but
itisacceptabletohaveisolatedareaswherethereisnocontact.Thefactthatgapsmayexistinthefaying
surfacesdoesnotpreventtheboltpreloadfrombeingdeveloped.Theendplatethicknessisenoughtobridge
thegapsanddevelopthedesiredbolttension.ThesnugtightenedconditionisdefinedbytheRCSCasthe
tightnessthatisattainedwithafewimpactsofanimpactwrenchorthefulleffortofanironworkerusingan
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ordinaryspudwrenchtobringthepliesintofirmcontact.Thestructureshouldberejectedifthereismorethan
25percentofthesurfacevisiblynotincontactaftersnuggingthebolts.TheEngineerofRecordmayapprove
theuseofsteelshimsorrepairstothestructuretocorrectthisproblem.
ForhighstrengthboltedjointsusingASTMA325galvanizedbolts,allowablemethodsofinstallation,to
developtherequiredpretension,includetheturnofnutmethod,calibratedwrenchmethod,twistofftype
tensioncontrolboltmethod,ordirecttensionindicatormethod.ThesearedescribedinSection8oftheRCSC
Specification.ProceduresforeachinstallationmethodaredetailedinreportFHWASA91031,HighStrength
BoltsforBridges,AppendicesA2throughA6.Adetailedcoverageofhighstrengthboltingmayalsobefound
intheSteelStructuresTechnologyCouncil(SSTC)StructuralBoltingHandbook.
PreinstallationverificationtestingshouldbeperformedusingaSkidmoreWilhelmdeviceasindicatedin
Section7oftheRCSCSpecification.However,sinceancillarystructuresmaycontainonlyafewhigh
strengthbolts,thistestingisoftennotperformed.Highstrengthboltsshouldbeinspectedforproperbolt
tighteningasrequiredbytheRSCSSpecificationforthechosenmethodofboltinstallation.Theinspection
verificationdatashouldbeprovidedtotheowner'srepresentative.Whereconnectionsaremadeupoverhead
withonepiecesuspendedfromacrane,pretensioningandinspectionshouldbeperformedpriortoreleasing
theloadthusminimizinginducedstressesintothejoint.
Installationmethodsforfastenersotherthanhighstrengthstructuralboltsarenotstandardized.Aswithhigh
strengthbolts,properjointfitupthatdoesnotinducebendingintothebolts,selectionofproperboltlengthto
allowfullnutengagement,anduseofwashersmustbeadheredto.Itisrecommendedthatstainlessandmild
steelboltsbeinstalledtominimumtorquevalues.Thisatleastassuresaminimumbolttensionand
consistencybetweenmultipleboltsinaconnection.Itshouldbenotedthatitcouldbebeneficialtotheowner
toperformtorque/tensiontestingonnonstructuralboltstoestablishthetensionbeingprovidedforspecified
torques.Thiswouldallowformorecompletejointevaluation.
TheSpecialtySteelIndustryoftheUnitedStates(SSIUS)recommendsthatstainlessboltsbetightenedto
aninstallationtorquevaluethatvarieswithboltsizeasshowninTable3.
Table3StainlessSteelBolts
SizeDia,mm(in)

InstallationTorque
Type304KNmm(ftlb) Type316KNmm(ftlb)

12(1/2")

59(43)

62(45)

16(5/8")

127(93)

133(97)

20(3/4")

175(128)

181(132)

24(1")

393(287)

410(300)

GalvanizedmildsteelboltsandthreadedfastenerssuchasUboltsarealsousedinancillarystructures.
TheseincludetreadedfastenersconformingtoASTMA307aswellastotheSocietyofAutomotive
Engineers(SAE)Grades1and2.Typicalultimatetensilestrengthsarefrom420MPa(60ksi)to440MPa
(64ksi).ThesefastenersshouldbeinstalledtothetorquevaluesshowninTable4,andverifiedusinga
properlycalibratedtorquewrench.
Table4InstallationTorqueforMildSteelFasteners
BoltSize,Dia.mm(in) MinimumTorqueKNmm(ftLb)
10(3/8)
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12(1/2)

50(37)

16(5/8)

101(74)

20(3/4)

164(120)

22(7/8)

260(190)

Aluminumfastenersarenotrecommendedforstructuralconnections.Miscellaneousorsecondaryfasteners
ofaluminumshouldbeinstalledtotorquevalvessuppliedbythemanufacturer.

6.5AnchorRods
6.5.1General
Anchorrodsprovideattachmentofthestructuretoitsfoundation.Theycancarrylargeforces,particularlyfor
cantileverstructureswhereoverturningisresistedbyamomentatthebasewhichiscarriedthroughthe
anchorrodgroup.Thedesignandproperinstallationofanchorrodshastraditionallyreceivedlittletechnical
guidanceasitfellwhollyinneithertherealmofsteelstructuresnorconcretestructures.
The"SpecificationforSteeltoConcreteJointsUsingASTMF1554Grades36,55,and05SmoothAnchor
Rods,ASTMA615andA706Grade60DeformedBars,andAWSD1.1TypeBStuds"iscurrentlybeing
developedbytheResearchCouncilonStructuralConnectionsandmayeventuallybepublishedbythe
RCSC.Forthedesignstrengthoftheconcreteanchorage,thisspecificationreferstocurrentAmerican
ConcreteInstituteACI318criteria.Foruseinhighwayancillarystructures,theACIloadfactorsand
resistancefactorsmaybemodifiedbytheStatetobeconsistentwithAASHTOdesignprovisions.NCHRP
Report469alsoprovidesguidance.

6.5.2Materials
AnchorrodsaresuppliedinconformancewithASTMF1554"StandardSpecificationforAnchorBolts,Steel,
36,55and105KsiYieldStrength."ASTMF1554providesforthreedifferentgradesofanchorrods:Grade36
(paintedblueontheprojectingend),Grade55(paintedyellowontheprojectingend),andGrade105(painted
redontheprojectingend).Thespecifiedminimumyieldstrength(Fy)andspecifiedminimumtensilestrength
(Fu )foreachGradearegiveninTable5.
Table5TensilePropertiesforAnchorRods
TensileProperty
MinimumYieldStrengthFy,

ASTMF1554 ASTMF1554
ASTMF1554
ASTMA706
RodGrade36 RodGrade55 RodGrade105 BarsGrade60
248(36)

380(55)

720(105)

415(60)

400(58)

516(75)

860(125)

550(80)

MPa(ksi)
MinimumtensileStrengthFu ,
MPa(ksi)
ASTMF1554waspassedin1994,andisessentiallythesameasAASHTOM31490,althoughthereare
somedifferences.ASTMF1554Grade36isessentiallythesameasASTMA36orASTMA307GradeC,
andASTMF1554Grade105isequivalenttoASTMA193GradeB7.ASTM1554supercedesthese
specifications,andtheolderspecificationsshouldnolongerbereferencedforanchorrods.TheASTMA325
orA490specificationsshouldnotbespecifiedforanchorrods.TheA325andA490boltsareintendedforuse
instructuralconnections.
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Sincethefatiguestrengthofthesevariousgradesofanchorboltsisthesame,itisusuallynotworthwhileto
usetheGrade105anchorrods.Ifanexistingsupportstructure(notdesignedforfatigueinaccordancewith
the2001Specifications)hasGrade105anchorrodsthatweredesignedforstrengthonly,thesizeofthe
anchorrodsmaybemuchlessthanwouldbethecaseifGrade55orGrade36anchorrodswereused.
Consequently,thestressrangesintheseGrade105anchorrodsmaybemuchgreater,makingthem
particularlylikelytoexperiencefatiguecracking.Grade105anchorrodsshouldbeespeciallyevaluatedto
seeifstressrangescalculatedusingthe2001Specificationsarelargeenoughthatfatiguewouldbeexpected
tooccurquickly.Ifso,aninspectionoftherodsusingultrasonictestingmethodsmaybewarranted.
Forsimilarreasons,theuseofanchorrodsconformingtoASTMA722withminimumtensilestrengthof150
ksishouldbediscouraged,butmayoccurinsomeexistingstructures.Wheresuchrodshavebeenused,an
inspectionusingultrasonicsshouldbeperformed.
Anchorrodsarenormallysuppliedinoneofthefollowingshapes:
Bentanchorrods.TheserodsareF1554smoothanchorrodswiththeembeddedendbentastoform
ahook(Figure9).Theanchoragetotheconcreteisbymeansofthehook.Theadherencebetweenthe
shankandtheconcreteisnotreliableandshouldnotbecountedindesign.Grade105bentrods
shouldbeavoidedbecausetheyhavebeenshownbyJirsa,et.al.tostraightenbeforetheyreachany
othermorepredictablesteelorconcretemodeoffailure.
Headedanchorrods.TheserodsareF1554smoothanchorrodswithaheadintheembeddedend
(Figure10).Theanchoragetotheconcreteisobtainedbythehead.Typically,the"head"consistsof
oneormorenuts,witheitherheavywashersoraplatewasher.Forlightlyloadedanchorages,headed
studscouldalsobeutilized.
Deformedbars.Concretereinforcingbars(ASTMA70696,StandardSpecificationforLowAlloySteel
DeformedandPlainBarsforConcreteReinforcementmaybethreadedandusedforanchorrods.
OrdinaryreinforcingbarsconformingtoASTMA61596,StandardSpecificationforDeformedandPlain
BilletSteelBarsforConcreteReinforcementhavebeenusedinthepast.However,becauseof
possiblelowtoughness,ordinaryreinforcingbarsshouldnotbeusedfornonredundant,fatigue
susceptiblesupportstructuressuchascantileversandhighmastluminaries.Reinforcingbarsmay
relyonthedeformationsalongthebarforanchoragetotheconcrete,mayincludeanACIstandard
hook,ormaybethreadedontheembeddedendandutilizenutsandawasherforanchorage.The
tensilepropertiesofcommonGrade60reinforcingbarsarealsogiveninTable5.TheA706
specificationshouldbeusediftheanchorrodistobeweldedorusedinseismicapplications.
L=lengthofrod
Lh=lengthofhook
t=lengthofthreads

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Figure9.BentAnchorRod.

L=lengthofrod
H=heightofnutorhead
F=widthacrossflatsofheaddiameter
t1 =lengthofthreads(exposedend)
t2 =lengthofthreads(embeddedend)

Figure10.HeadedAnchorRod.
TheuseofUniformNationalCoarse(UNC)threadsarerecommended,especiallyforgalvanizedanchorrods,
althoughASTMF1554alsopermitsthelesscommon8UNseriesthreads.Thefullrangeofdiameters(1/4to
4inches)ofanchorrodswithUNCthreadscantheoreticallysustaintheovertappingofcorrespondingnuts
(requiredtoallowforzinccoatingfromgalvanizing)withoutstripping,whilethismaynotbetruefor8UN
threads.Itshouldbenotedhowever,thattheMichiganDepartmentofTransportationfeelsthattheuseof8
UNthreadsisadvantageous.Theyhavenotexperiencedanyproblemswiththreadstripping.
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Thethreadclass(tolerances)oftheanchorrodsshouldalsobespecified,andtypicallyClass2Ais
satisfactory.Class2Awillbeprovidedbydefaultifclassisnotspecified.
NutsontheembeddedorprojectedendoftheanchorrodshouldconformtoASTMA563nuts.The
recommendednutstyle,gradeandfinishareshowninTable6.Thistableisbasedontheappendixofthe
ASTMA563specification.
Table6AcceptableASTMA563Nut,Grade,FinishandStyleAndASTMF436WasherTypeandFinish
forThreadedAnchorRods
Anchor
Rod

AnchorRod
Sizemm(in.)*

F1554
Grade36

638
(1/411/2)

Finish

ASTMA563NutStyle,GradeandFinish

Plain
Hex:A,B,D,DHplainHeavyHex:A,B,
(uncoated)
DC,C3,DC,DHd ,Dh4:plain
Galvanized

Hex:A,B,DC,DHd Galvanizedand

ASTMF436Washer
TypeandFinishb
1plain
1galvanized

lubricated
HeavyHex:A,B,CC,C3,DC,DHd ,Dh4
galvanizedandLubricated
Over38100
(11/24)

Plain
(uncoated)

HeavyHex:A,B,CC,C3,DC,

Galvanized

HeavyHex:A,B,CC,C3,DC,

1plain

DHd ,Dh4plain
1galvanized

DHd ,Dh4galvanizedand
Lubricated
F1554
Grade55

638
(1/411/2)

Plain
Hex:A,B,DC,DHd plainHeavyHex:A,
(uncoated)
B,CC,C3,DC,DHd ,Dh4plain

1plain

Galvanized HeavyHex:A,B,CC,C3,DC,DHd ,Dh4

1galvanized

galvanizedandLubricated
A706
Grade60

Over38100(1
1/24)

Plain
HeavyHex:A,B,CC,C3,DC,DHd ,Dh4
(uncoated)
plain

1plain

Galvanized HeavyHex:A,B,CC,C3,DC,DHd ,Dh4

1galvanized

galvanizedandLubricated
F1554
Grade
105

638
(1/411/2)

Plain
(uncoated)

Hex:DC,DHd plainHeavyHex:CC,C3,

Galvanized

HeavyHex:DHd ,Dh4galvanizedand

1plain

DC,DHd ,Dh4plain
1galvanized

lubricated
Over38100
11/24

Plain
(uncoated)

HeavyHex:DHd ,Dh4plain

1plain

Galvanized

HeavyHex:DHd ,Dh4galvanizedand

1galvanized

lubricated
a ApplicableonlytoF1554Grade55anchorrods.
b Applicableonlyifwasherisrequired.
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cASTMA194nutsGrade2or2HareacceptableequivalentsforGradesCandDnuts.
d ASTMA194nutsGrade2HareacceptableequivalentsforGradesDHnuts.

*Note:Metricboltsizesandthreadsaredifferent,forsoftconversion1inch=25mm
Corrosionprotectionisparticularlyimportantforfatiguecriticalanchorrods,sincecorrosionpittingcan
degradethefatigueresistance.Anchorrods,nuts,andwashersthatareusedoutdoorsaretypically
galvanized.ASTMF1554permitshotdipgalvanizingbyASTMA153ClassCormechanicallydepositedby
ASTMB695,Class50.Thepurchasershouldspecifywhichoftheseprocessesshouldbeusedorstate"no
preference."Thehotdipprocessprovidesaheavierzinccoatingandlongerlife.Galvanizeddeformedbars
maybeusedandshouldbespecifiedbyreferencingASTMA767.Galvanizedanchorrodsshouldalwaysbe
shippedwiththenutspreassembledtotheanchorrodstoensuregoodfitandabilitytorunthenutdownthe
threadseasily.ThisshouldbespecifiedinthepurchaseorderbecauseitisnotrequiredintheASTM
specifications.
Therearetwotypesofwashersforanchorrods:standardwashersandplatewashers.Standardwashersare
ASTMF436washers.When"NormalHoles"areused,platewashersatleast5/16inchthickshouldbeused.
Platewashersshouldbestructuralgradesteelandbegalvanizedtomatchtheanchorrods.Beveledstandard
washersshouldbeusedwhentheouterfaceofthebaseplatehasaslopethatisgreaterthan1:20with
respecttoaplanethatisnormaltotheanchoraxis.Ifananchorboltisincorrectlyinstalledresultinginlarger
outofplumbness,speciallyfabricatedwashersmaybeneededtoallowproperbearingoftheconnected
parts.

6.6BasePlateandHoles
ResearchdescribedinNCHRPReport412hasshownthatthebaseplateshouldbeatleastasthickasthe
anchorroddiametertoprovideforevendistributionoftheloadandtominimizepryingforces.Theminimum
distancefromthecenteroftheanchorrodholetotheedgeofthebaseplateshouldbetwotimesthenominal
diameteroftheanchorrod.
Baseplatesarenormallysuppliedshopweldedtothepostsorpole.Themostcommonpoletobaseplate
connectionisaweldsocketjoint,wherethecentralportionofthebaseplateiscutoutsothepolecanslip
intotheopening.Asaresult,particularlyforlargediameterpolessuchashighmastlights,thebaseplateis
inrealityabaseringwitharesultingdecreaseinplatebendingstiffness.Fieldinspectorshavereported
observingthebaseplatesactuallyflexbetweenanchorrodsforhighmastlightsduetonormalwindloads.
Thistendencycanbereducedbyuseofalargernumberofanchorrodsorathickerbaseplate.
Holesmaybethermallycutinthebaseplates.Inmostcases,theanchorrodholesinthebaseplateshould
be"ShearHoles"withthedimensionsshowninTable7,asrecommendedinNCHRPReport469.Research
byCookhasshownthatthissizeofholeisadequateforacorrecttransferofshearforcesfromthebaseplate
totheanchorrodsandtoallowplasticredistributionofshearforces.Ontheotherhand,ifanchorrodsarenot
requiredtotransfershear,onlyholeslabeledas"NormalHoles"inTable7areneeded.Thesenormalholes
arethesameholesrecommendedintheAISCManualofSteelConstructionforbaseplates.Theyare
oversizedtoallowforaneasyplacementofthebaseplateduringerection.
Table7NominalAnchorRodHoleDimensions
AnchorRodDiameterIn.* NominalAnchorRodHoleDimensionsa,b,in.*
ShearHoles
(diameter)
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1/2

5/8

11/16

5/8

13/16

13/16

3/4

15/16

15/16

7/8

11/16

19/16

11/4

113/16

11/4

19/16

21/16

11/2

113/16

25/16

13/4

21/16

23/4

>2

db +5/16

db +11/4

a Theuppertoleranceonthetabulatednominaldimensionsshallnotexceed1/16in.
b Theslightlyconicalholethatnaturallyresultsfrompunchingoperationswithproperlymatched

punchesanddiesinacceptable.
*Note:Metricboltsizesandthreadsaredifferent,forsoftconversion1inch=25mm

6.7AnchorRodJoints
Thereareseveraltypesofjointsforthebaseplatetofoundationconnection.Thesehaveevolvedwithin
particularindustries,withthesocalledthreadedshearandupliftjointanddoublenutmomentjointusedfor
nearlyallancillarystructures.Thesearecosteffectiveandprovidegoodperformancewhenproperlydesigned
andinstalled.
Thethreadedshearandupliftjointrestsdirectlyontheconcreteoronagroutpad(Figure11).Thebaseplate
ishelddownbynutsatopthebaseplate.Singlenutsaremostcommon,butdoublenutsaresometimes
used.Forproperjointperformance,thebaseplatemustbeindirectcontactwiththegroutandnotbe
supportedbylevelingnutsorshimpacts.Onetechniquetoachievefullgroutsupportistosetthebaseon
shimpactstoproperelevation,groutthebaseandthenremovetheshimsandgrouttheresultingvoids.Only
thencantheanchorrodsbefullypretensioned.Useofproprietaryprepackagedgroutmixes,socalled"non
shrinkgrout"isrecommendedandshouldbecarefullyinstalledtomanufacturers'recommendations.The
threadedshearandupliftjointscandevelopsomeresistancetobendingmomentasacouplebetween
compressivebearingforceonthegroutandtensileforcesintheanchorrods.Itmaybedifficulttoretainthe
pretensionintheanchorrodsundercyclicloadsasthebaseplatewearsthegrout.Forthesereasons,this
typeofjointisnotrecommendedbyNCHRPReport469forlargecantileveredsupportstructures,althoughit
isstillcommonlyusedformanyluminariesandsmalltrafficsignalsupports.Thistypeofjointissuitablefor
bridgesupportstructureswheretherearemultipleposts.

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Figure11.ThreadedShearandUpliftJoint.
Allthreeshapesofanchorrodswillperformcorrectlyinthistypeofjoint.Theanchorrodstransmitshearand
tension,whilecompressionforcesaretransmitteddirectlybybearingofthebaseplateontheconcreteand
arenotcarriedbytheanchorrods.Asaresultofthecompressionontheconcrete,frictionwillbedeveloped
betweenthebaseplateandtheconcrete.Shearfrictionstrengthshouldbecalculatedusingthefactoredload
combinationthatgivesminimumpossiblecompressionfromdeadloadalongwiththemaximumupliftthatis
consistentwiththelateralloadthatisbeingevaluated.Theeffectofliveloadshouldnotbeincludedwhen
calculatingtheshearfrictionstrengthunlesstheliveloadcausesthelateralloadoruplift.
Ifthefrictionstrength,isgreaterthanthefactoredappliedshearortorsiononthejoint,anchorrodsarenot
neededfortransmittingshearortorsion.Infact,ifthefrictionissufficienttohandletheshear,andifthereis
nouplift,thenanchorrodsare,intheory,notneededatallforserviceloads.Inthiscase,anchorrodsmust
beprovidedforstabilityduringerectionbutneednotbedesignedfortheserviceloads.Iftheanchorrodsare
designedonlyforthefactoredloadsduringerection,NCHRPReport469recommendsincludingaminimum
lateralshearloadequalto5.0percentoftheaxialloadfromdeadloadduringerection.Theanchorrodsmust
alsoresistaminimummomenttoaccountforanironworkeronthepoleasrequiredbyOSHA.
If,ontheotherhand,thefactoredloadsexceedthefrictioncapacityofthejoint,anchorrodsshouldbe
assumedtotransmittheentireshearbecausethefrictionmaynolongerbeeffectiveatthedeformationlevels
requiredtodeveloptheshearstrengthoftheanchorrods.Theshearstrengthoftheanchorrodsmaybe
takenasthesmallerofthesumofthesteelshearstrengthsofthecontributingindividualanchorrodsorthe
concreteshearstrengthoftheanchorgroup.
Wheneveranchorrodsareneededfortransmittingshearinthistypeofjoint,thebaseplateshouldhaveshear
holes.Also,inthesamecase,bearingoftheanchorrodonthewallsoftheshearholesshouldbechecked.
Asanoption,normalholescanbeprovidedinthebaseplateandplatewashershavingshearholescanbe
placedovertheanchorrodsandfieldweldedtothebaseplateafterthebaseisset.Theplatewashersand
weldsmustbedesignedtotransmitallcalculatedshearforcesandweldingmustconformtoapplicable
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portionsoftheAWSBridgeWeldingCode.
Indoublenutmomentjoints,thebaseplatestandsofffromtheconcretefoundationandbearsonleveling
nuts(Figure12).Thus,thebaseplateisattachedtoanchorrodsthroughdoublenuts:thelevelingnutanda
topnut(ornuts).Thistypeofjointmaybesuitableforanytypeofsupportstructureandisrequiredfor
cantileveredsupportstructuresdesignedbythe2001Specifications.Washersshouldbeusedunderboth
nuts,andbeveledwashersshouldbeusedifthemisalignmentexceeds1:40forthedoublenutmoment
joints.Doublenutmomentjointsareeasytolevelandplumbandarealsoveryreliablefortransmitting
momenttothefoundationtherefore,theyaresatisfactoryfornonredundantstructuresandseismicor
fatigueloadedstructuressuchashighwaysign,signal,andlightsupports.

Figure12.DoubleNutMomentJoint.
Doublenutjointsarepretensionedbetweenthenutsonly,andthepretensionhasnoeffectonstrength.
ResearchreportedinNCHRPReport412hasshownthatthepretensiongivesslightlybetterfatigue
resistance,buttheeffectisnotthatsignificant.Theanchorrodbelowthelevelingnutisnotpretensionedbut
willstillseethefullcycleoffatigueloads.Moreimportantly,thepretensionensuresthatthereisagoodload
distributionamongthevariousanchorrods.Therefore,therearespecialtighteningproceduresforthesejoints.
Headedrodsanddeformedbarsarebestsuitedfordoublenutmomentjoints.Indoublenutmomentjoints,
anchorrodsaredesignedtoresistalltheaxialforces,moments,andshearsappliedtothejoint,evenifthere
isgroutunderthebaseplate.
Opinionsonwhetherornotgroutshouldbeusedwithdoublenutmomentjointsdiffer.Asnotedabove,ina
properlydesignedjoint,allloadsareresistedintheanchorrods.Duetothegreaterstiffnessoftheanchor
rodscomparedtothegrout,andthetendencyofthegrout,evenforsocalled"nonshrinkgrouts",toshrink,
thoughperhapsimperceptibly,belowthebottomofthebaseplate,littleloadtransfertothegroutislikelyeven
ifassumedsoindesign.Grout,ifwellinstalled,maypickuploadsduetoveryhighorunexpectedload
cases.Propergroutinstallationisdifficultwhenbaseplatestendtoberings,aswithlargelightpoles.A
meansmustbeprovidedtorestrictgroutflowinsidethebaseringwhilefullyfillingbeneathit.Forthese
reasons,andseverallistedbelow,groutingofdoublenutmomentjointsisgenerallynotrecommended:
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Itmaycrack,retainmoisture,andthenpromotecorrosion.
Itmakesitimpossibletoinspectandretightenbottomnutsifnecessary.
Inordertoplacethegroutafterthebaseplateisinplace,thestandoffdistancebetweenthetopof
concreteandthebottomofthelevelingnutmayexceedtherecommendeddistanceequaltothe
anchorroddiameter.
Wherebaseplatesarenotgrouted,astainlesssteelwiremeshshouldbeplacedaroundthebaseplateto
eliminatedebrisfromaccumulatingbeneaththebaseplateandkeepanimalsoutandprotectelectricalwiresif
present.
Thereisanunfortunatetrendtowardusingfewerverylargeanchorrods.Itisalwaysbettertousemore,
smalleranchorrodsthanfewer,biggeranchorrods.Especiallyifthefailuremodeisfatigueandthestructure
isnonredundant,itisessentialtohaveatleasteightanchorrodsintheanchorrodgroup.Intheeventofone
anchorrodfailurefromfatigue,theincreaseintheloadontheneighboringanchorrodsistolerableforthe
caseofaneightboltgroup,andtherewillbeweeksormonthstypicallybeforeasecondanchorrodfailsand
totalcollapseoccurs.Thisgivesthejointsomemeasureofredundancy,evenifthestructureisnon
redundant.Thefatiguefailureofoneanchorrodfromasixorfourboltgroup,however,mayleadtoimmediate
collapse.
IftheembeddedheadofanASTMF1554anchorrodisanutorisfastenedwithnuts,theheadnutorthe
nutsfasteningtheheadshouldbepreventedfromrotatingwhiletheanchorrodistightened.Twomethods
havebeenshowntopreventrotation:
Tackweldthenuttotheanchorrodontheunstressed(bottom)sideofthenutiftheASTMF1554rod
isagrade36rodoragrade55rod.
JamanothernutontheheadnutforanygradeofASTMF1554rod.
Neitherthetackweldnorthejamnutwillaffecttheultimateorfatiguestrengthoftherod.

6.8InstallationofAnchorRods
Properinstallationoftheanchorrodsistheresponsibilityofthefoundationcontractor,andinspectionand
testingistobeperformedbythefoundationcontractor.Recordsshouldbekeptofthedatesandresultsof
testingandinspection,andtheserecordsshouldbeavailablefortheEngineerofRecordortheir
representativetoreview.TheEngineerofRecordmayrequirethattheirrepresentativewitnesstheinspection
andtesting.
Priortoplacingtheanchorrodsintheconcrete,ananchorrodrotationcapacitytestshouldberunwithat
leastoneanchorrodfromeverylot.ThistestmayberuninaSkidmoreWilhelmdeviceorinamockupofthe
baseplateusingasmallpieceofplatewithoneholeofequivalentgrade,thickness,andfinish.Thetest
consistsofSteps2through14ofthetighteningprocedure(presentedlater),adaptedasnecessarybecause
thereisnopostorcrane,andthereisonlyoneanchorrod.NCHRPReport469recommendsthatthenutbe
rotatedatleasttotherequiredrotationgiveninTable8.Afterthetest,thenutsshouldberemovedand
inspectedfordamagetotheirthreads.
Thentheanchorrodisremovedfromthetestplateandrestrainedwhilethenutsareturnedontotheboltswell
pastthelocationofthelevelingnutandtopnutinthetestandbackedoffbyoneworkerusinganordinary
wrench(withoutacheaterbar).Thethreadsareconsidereddamagedifmorethanminimaleffortisrequiredto
turnthenut.Ifthereisnodamagetotheanchorrodornutduringthistest,theymaybeusedinthe
foundation.Ifthereisdamagetothethreadsoraninabilitytoattainatleasttheverificationtorque,thelotof
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anchorrodsshouldberejected.
Thoughthistestingmaynotbepracticalonsmallprojects,itisrecommendedwhereeconomicallyjustifiable
onlargerprojects.
Table8NutRotationforTurnOfNutPretensioning
AnchorRodDiameter,in*. NutRotationfromSnugTightConditiona,b,c
F1554Grade36

F1554Grades55and105
A615andA706Grade60

<11/2

1/6Turn

1/3Turn

>11/2

1/12Turn

1/6Turn

a.Nutrotationisrelativetoanchorrod.Thetoleranceisplus20degrees.
b.Applicableonlytodoublenutmomentjoints.
c.Beveledwashershouldbeusedif:a)thenutisnotinfirmcontactwiththebaseplateorb)
theouterfaceofthebaseplateisslopedmorethan1:40.
Therecommendedprocedureforinstallinganchorrodsinthefoundationisasfollows:
1. Anchorrodsshouldbeinstalledasagroupandshouldbesecuredagainstrelativemovementand
misalignment,suchaswithatemplatesetcomposedofringswithnutsonbothsidesattwolocations
alongthelengthoftheanchorrods.Oneoftheplatesorringsisusuallyabovethetopofconcreteand
isreusedasatemplate,seeFigures13and14.
2. Thetemplateset(orotherdevice)withanchorrodsshouldbesecuredinitscorrectpositionin
accordancewiththedrawings.
3. Theconcreteshouldbeplacedandcured.

Figure13.FourAnchorRodGroupinaTemplate.NoteTopisGalvanized.

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Figure14.TemplateSecuredtotheFormstoEnsureProperAlignment.NoteAnchorRod
ThreadsTapedtoPreventContaminationbyConcrete.
4. Ifatoptemplateisabovetheconcretesurface,itmayberemoved24hoursafterplacingtheconcrete.
5. Theexposedpartoftheanchorrodsshouldbecleanedwithawirebrushorequivalentandlubricated
withbeeswaxortoiletringwax.
6. Afteratleast24hours,theanchorrodsshouldbeinspectedvisuallytoverifythatthereisnovisible
damagetothethreadsandthattheirposition,elevation,andprojectedlengthiswithinthetolerancesof
theAISCCodeofStandardPracticeforSteelBuildingsandBridgesandthatthemisalignmentfrom
verticalisnomorethan1:40.Itisgoodpracticetouseasteelorwoodtemplatewiththeholepattern
tocheckthebaseofthepostandtheanchorrods.Thenutsshouldbeturnedontotherodswellpast
theelevationofthebottomofthelevelingnutandbackedoffbyoneworkerusinganordinarywrench
withoutacheaterbar.
7. Oncetheconcretehasreachedsufficientstrength,anchorrodsarereadytobesubjectedtoerection
loads.

6.9ProcedureforAnchorRodTighteningandFollowUpRetightening
Anchorrodjointsrequiresomelevelofpretensioning.Onlyinstallationofdoublenutmomentjointsiscovered
inthissectionsincesinglenutjointsaregenerallynotrecommendedforlargecantileveredstructures.
Requirementsforfatigueloaded,threadedshearandupliftjointsmaybederivedfromtheinstallation
requirementsofdoublenutmomentjoints.
The"turnofthenut"methodisprimarilyreliedupontoachieveacertainpretensionbetweenthedoublenuts
oftheanchorrods.Althoughtorqueisapoorwaytoinstallboltsandanchorrods,itistheonlyalternativefor
definingsnugtightconditions,inspection,andretightening.Lubricationofthethreadsoftheanchorrod,the
threadsofthenut,andthebearingsurfaceofthenutisrequiredforproperinstallation.Beeswaxandtoilet
ringwaxhavebeenshowntoprovidegoodlubrication.Inthisdocument,thesnugtightconditionforanchor
rodsisdefinedasnutstightenedtoatorquebetween20and30percentoftheverificationtorquecomputed
usingthefollowingequation:
Tv=0.12db FI
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Where
Tv=verificationtorque(inchkipsorkNmm)
db =nominalbodydiameteroftheanchorrod(inchesormm)
FI=installationpretension(kipsorkN)equalto50percentofthespecifiedminimumtensile
strengthofF1554Grade36rods,and60percentfortherestofthreadedfasteners.
ResearchbyTillandLefkehasshownthatavalueof0.12inthisrelationshipisadequateforcommonsizes
andcoatingsofanchorrods.(Note:thetorquein"inkips"canbemultipliedby83.3togetftlbandthetorque
inkNmmcanbemultipliedby0.73togetftlb).
Verylargetorquemayberequiredtoproperlytightenanchorrodsgreaterthan24mm(1inch)indiameter.A
"cheaterbar"suchasapipeorextensionhandleasmuchas3meters(10feet)longmayberequiredforthe
torquewrench.Forsnuggingthelevelingnuts,anopenendwrenchwitha3meter(10feet)longpipeor
extensionhandlewilltypicallysuffice.Tighteningthetopnutsforanchorrodsgreaterthan1inchindiameter
mayrequireeitherofthefollowing:
Ahydraulictorquewrench(Figure15)or
Aboxend"slug"or"knocker"wrenchwitha3meter(10ft),longpipeorextensionhandle.

Figure15.AHydraulicTorqueWrenchTighteningAnchorRodNutstoAchieveNeededRotation.
Theboxendwrenchmaybemovedbyimpactwithasledgehammerorbytheeffortsofseveralworkers.
Inadequatelytightenedboltscanleadtofatiguefailuresandfurtherlooseningofthenutsundercyclicloading.
Alesslikelyoutcomeoffailuretofollowthetighteningprocedureisovertightenedrodsandassociated
plasticdeformationandstrippingofthethreads,whichmayrequireremovalandreplacement.
Thefollowingstepsprovidearecommendedanchorboltinstallationandtighteningprocedure:
1. Theproperpositionoftheanchorrodsandtheproperholepatternonthepostareverified(preferably
withatemplate).
2. Itshouldbeverifiedthatthenutscanbeturnedontotherodswellpasttheelevationofthebottomof
thelevelingnutandbackedoffbyoneworkerusinganordinarywrenchwithoutacheaterbar.
3. Ifthreadsofanchorrodswerelubricatedmorethan24hoursbeforeplacingthelevelingnutorhave
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beenwetsincetheywerelubricated,theexposedthreadsoftheanchorrodshouldberelubricated.
Levelingnutsshouldbecleaned,threadsandbearingsurfaceslubricated.
4. Thelevelingnutsareplacedontheanchorrodsandmadelevel.
5. Levelingnutwashersshouldbeplaced.
6. Next,thepostorendframeisbroughtinandpositionedwithacrane.
7. Thepostorendframeisplumbedorthebaseplateleveled(asshownontheerectiondrawings)and
theanchorrodsaretightened.Thefollowingistheinstallationsequencefordoublenutmomentjoints
usingthe"turnofthenut"methodofpretensioning.
8. Topnutwashersshouldbeplaced.
9. Threadsandbearingsurfacesofthetopnutsshouldbelubricated,placed,andtightenedtothesnug
tightconditioninastarpattern.
10. Levelingnutsshouldbetightenedtothesnugtightconditioninastarpattern.
11. Atthispoint,theinstallationcrewshouldverifyifbeveledwashersarenecessary.Beveledwashers
maybenecessaryunderthelevelingortopnutifanyfaceofthebaseplatehasaslopegreaterthan
1:20and/oranynutcouldnotbebroughtintofirmcontactwiththebaseplate.Ifanybeveledwasheris
required,theinstallationcrewshoulddisassemblethejointasnecessary,addthebeveledwasher(s)
andretighten(inastarpattern)tothesnugconditiontopandlevelingnuts.
12. Beforeturning,thereferencepositionofthetopnutinthesnugtightconditionshouldbemarkedwitha
suitablemarkingononeflatwithacorrespondingreferencemarkonthebaseplateateachbolt.Top
nutsshouldbeturnedinincrementsinastarpattern(atleasttwofulltighteningcycles)tothenut
rotationspecifiedinTable8.Aftertightening,thenutrotationshouldbeverified.
13. Theloadmaybereleasedfromthecrane.
14. Atorquewrenchshouldbeusedtoverifythatatorqueatleastequaltothecomputedverification
torque,Tv,isrequiredtoadditionallytightenthelevelingnutsandthetopnuts.Aninabilitytoachieve
thistorqueshouldbeinterpretedtoindicatethatthethreadshavestrippedandshouldbereportedto
theEngineerofRecord.
15. Afteratleast48hours,thetorquewrenchshouldbeusedtoverifythatatorqueatleastequalto110
percentoftheverificationtorque,Tv,isrequiredtoadditionallytightenthelevelingnutsandthetop
nutsontheanchorrods.Aninabilitytoachievethistorqueshallbeinterpretedtoindicatethatthe
threadshavestrippedandshouldbereportedtotheEngineerofRecord.
16. Thenutsontheanchorrodsshouldbepreventedfromlooseningunlessamaintenanceplanisinplace
toverifyatleastevery4yearsthatatorqueequaltoatleast110percentoftheverificationtorque,Tv,
isrequiredtoadditionallytightenthelevelingnutsandthetopnuts.Jamnutsorotherlockingdevices
maybeusedtopreventnutloosening.
Tackweldingthenuttotheanchorrodontheunstressed(top)sideofthetopnuthasbeenusedsuccessfully
topreventlooseningortopreventtheftofthenuts,althoughthiswouldnotbeallowedunderAWSD1.1and
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thereforecannotberecommended.Ifitisused,onlyASTMFl554Grade36orGrade55rod,orGradeA706
reinforcingbarshouldbetackwelded.Undernocircumstanceshouldanynutbetackweldedtothewasheror
thebaseplatenorshouldthelevelingnutbetackwelded.

7.0ManagementofInventory
Collectionofinventoryinformationandtheabilitytoorganizeandcategorizetheinventoryisparamountforan
ancillarystructureinspectionprogram.Thissectiondetailscollectionofsuchinformationanddevelopmentof
ausefuldatabase.

7.1CollectionofInventoryInformation
Oneofthebiggestproblemsininspectionofancillarystructuresisthelackofinformation.Rarelyarethe
structuresnumberedforeasyidentification.Historicalrecordssuchasasbuiltplans,maintenancerepairs,
andinstallationofnewsignpanelsarehardtofind.Onlynowaremanystatesbeginningtoassignstructures
numbersduringdesignand/orfabricationsimilartobridgestructures.Suchrecordsareveryimportantdueto
themanychangestothedesignspecificationsofsignstructuresovertheyears.Anotherproblemisthat
fabricatorshavesubstituteddesigndrawingswiththeirownshopdrawings.Whilethisisanacceptable
practice,itaddsanotherlayerofdocumentationthatismanytimeslost.
Forthesereasonstheinitialcollectionofinventoryinformationonancillarystructuresiscritical.Keypiecesof
informationincluderoute,milepost,GPScoordinates,routeassociation(ifnotonmainline),county,town,etc.
Photosandsignmeasurementsareimportanttohelpidentifystructures,asseeninFigure16.Thefollowing
sectionondatabasedevelopmentgivesacompletelistingthathasbeenusedinNewJerseyforinventory
purposes.

Figure16.InspectorMeasuresSignPanelDuringInventory/InspectionOperation.

7.2DatabaseDevelopment
Thelargeamountofdatacollectedtoproperlyinventoryasignstructurewarrantsasophisticateddatabase
thatcansortandprioritizeaccordingtostructuretype,age,location,material,ratingsandrepairpriorities.
Thegoalistohaveadatabaseusefultothefieldinspector,programmanager,andmaintenanceandrepair
personnel.Eachcanthendrawontheirdesiredinformation.Thedatabasecanbeasimplespreadsheetbut
usuallyinvolvesamoresophisticatedprogramlikeMicrosoftAccessorOracle.
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7.3ExampleInventoryChecklist
ThechecklistbelowisreferencedfromtheNewJerseyDepartmentofTransportationOverheadSign
DatabaseProgram.Theseareitemsdeemedimportanttothatparticularagency,andwillofcoursevary
somewhatwithindividualStateneeds.Manyitemsinvolvethephysicallocationofthestructure,the
personnelinvolvedwiththeinventory/inspection,specificsaboutthestructureitself,importantdimensions
andattachments.
NJDOTRequiredInventory/InspectionInformation
DateInspected
PreviousInspectionDate
InspectionType
CycleNumber
RecommendedInspectionFrequency
CountyCode
MunicipalityCode
Latitude/Longitude
Route
Milepost
LocationDescription
TrafficControlRequirements
ContractNumber
ConsultantFirmName
ConsultantProjectManager
ConsultantTeamLeader
ConfirmingRegisteredPE
StructureName
StructureConfiguration
NumberofTrussSections
MaterialType
InServiceStatusandDate
OverallSpanLength
MinimumVerticalClearance
LeftandRightLateralClearance
NumberofTraveledLanes
NumberofSigns
AreaofeachSign
InstallationYear
PlansAvailable?
Walkway?
Lighting?
Modificationsinceconstruction
DamageReports
ElementRatings
ElementRepairs

7.4InventoryNumbering
Aninventorynumberingschemeisrequiredforallancillarystructures.Theinventorynumberisusuallythe
keypieceofdatathatanydatabaserelatesto.Itcanbesequentialalongaroute,andcontaininformation
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relevanttolocationsuchasCountyandTownCoding.Itishighlyrecommendedthatafteranancillary
structurenumberisassignedthenumberbeimmediatelystenciledontotheexistingsign.Documentation
shouldflowfromthefieldtothesigndesignersothatanynewstructureswouldnotbeassignedthatspecific
inventorynumber.
Oneproblemwithsignstencilingisthatmanystructuralsupportsareonshouldersthataretargetsfor
roadwaygrime,saltsprayandsnowplows.Properpositioningofthesignnumbershouldconsiderthese
effects.Thestencilcanbeplacedabovethesprayofsaltoronthebacksideofthestructure.Anotheroption
mightbetostencilthesignbridgeinsteadofthesupportingtowermembers,ortostampthenumberinwith
metalstamps.

8.0InspectionVariables
8.1TypesofInspections
Thereareseveralinspectiontypesdependingonthecircumstancesofthesignstructure.Theseinspection
typesfollowthosetypicallyperformedforbridgeinspections.

8.1.1InitialInspection
Thisinspectionshouldtakeplaceshortlyafterthesignstructureisconstructed.Itiscommonforboltson
signstructures,shortlyafterinstallation,tobecomelooseandshouldberecheckedwithin60daysafter
constructioniscomplete.

8.1.2Routine
Thiscansimplyconsistofagroundlevelinspectionwithnoattempttoclosetrafficlanes.Thistypeof
inspectionisrecommendedduringthefirstphasesofasignstructureinspectionprogramtoobtaininventory
informationandquicklylookfordeficiencies.However,sincemanystructuraldeficienciessuchasweld
cracksintheoverheadtrusscannotbeidentifiedfromagroundlevelinspection,thistypeofinspectionisnot
recommendedtooccurnormallyinsubsequentinspectioncycles.However,asstatedinthe'TrafficControl'
portionoftheseguidelinescyclicgroundlevelinspectionsmaysupplementanInDepthinspectiondueto
severetrafficrestrictions.

8.1.3InDepth
Thistypeofinspectionisrecommendedasatypicalinspectionofasignstructure.Theinspectionwillbe
'HandsOn'asdiscussedinthefollowingsection.

8.1.4InterimInspection
ThiswouldberecommendedbytheInspectorifasignstructureisfoundtohavedeficienciesorother
problemsthatrequiremorefrequentinspectionthanthetypicalinspectionfrequency.AnInterimInspection
mightalsoberequiredaftertemporaryrepairsaremadetothesignstructure.Forexample,somemeasures
areimmediatelytakenwhencracksarefoundintheoverheadsigntruss.Thismaybesimplyremovingthe
signpanelstoreducewindload,installationofadampener,oractuallycompletingrepairssuchastheuseof
fibercompositematerialtotemporarilyrestrainthecrackedconnection.

8.1.5DamageInspection
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Thisinspectionisprovidedafterasignisdamaged.Thiscouldincludetrafficimpactonthepost,anover
heighthitofthetrussorsignpanels,etc.

9.0InspectionFrequency
Determiningthefrequencyforancillarystructureinspectionisdependentonseveralfactors.Oneismaterial
type.Forexample,aluminumtrusstypespanstructureshaveshownincreasedproblemsduetofatigue
deficiencies.Highstrengthanchorrodshavebeenmoreproblematicthanmildsteel.Frequencycanalsobe
basedonstructuralredundancy.Cantileversignstructuresupportsonlyhaveonemainsupportinsteadoftwo
ormorewithspantypestructures.Signstructuresassociatedwithanotherstructuresuchasabridge
mountedsignmaybeinspectedasthebridgeisinspectedduringanormaltwoyearfrequency.Manyowners
areinitiatingsignstructureprogramsanddeterminingfrequencyafterthefirstcycleiscompleteand
deficienciescanbecategorized.Anotherpreviouslydiscussedfactoristrafficcontrolandtheproblems
associatedwithaccess.
Someguidelinesforinspectionfrequenciesareasfollows:
MaterialIssues:Sinceithasbeendeterminedthataluminumsignbridgesareproblematic,itis
recommendedthatatwoyearfrequencyofindepthinspectionsbeconducted.Todetermineif
materialissuesarerelevantpriortoafullscaleinspectionprogramissetinmotionasample
projectthatinspects10%ofthestructureinventorymaybeprudent.
RedundancyIssues:Forcantileverandothernonredundantstructuresafouryearfrequencyis
recommended.
TypicalSignBridges:Atypicaltwotower,twoorfourpostsignbridgewithasteelsuperstructureneedonly
beinspectedhandsoneverysixyears.Routineorgroundinspectionscanbeconductedmorefrequentlyto
checkcorrosionofpostsorconnectionproblems.
TrafficIssues:If'severe'restrictionsexist,asdiscussedinthe'TrafficControl'sectionoftheseguidelines,
frequenciesstatedabovecanbeextendedbutsupplementedbyroutinegroundinspections.

10.0InspectionPrioritiesandPlanning
Theancillarystructureinspectionprocessshouldnotproceeduntilastructureinventoryhasbeencompleted.
Onlythencanproperplanningtakeplace.ManyStateDepartmentsofTransportationhavestartedtheir
structureinspectionprogramusingthefollowingstrategy:
1. Performfieldreconnaissanceandcollectinventoryinformation
2. Performarandomsamplinginspectionprojectofperhaps10%oftotalinventory
3. Basedonfindingsofsampleproject,prioritizeandcontinuefullinspectionprogram.
ExamplePriorities
Aluminumsignbridges
SignBridgeswithlongspan
NonRedundantcantileversignstructures
SignStructuresgreaterthan20yearsold
SignStructureswheresignpanelsizesexceedsthoseoriginallydesignedfor.
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11.0RequiredResources
11.1SuggestedPersonnelRequirements
InspectionofancillarystructuresisnotrequiredbyFederalRegulations,norarethereanyrequirementsfor
thosepersonwhoconductsuchinspections.
Inspectionofancillarystructureshassimilaritiestohighwaybridgesbutalsosomespecialcircumstances
thatshouldbeaddressed.ThequalificationsforbridgeinspectionpersonnelasgivenintheNationalBridge
InspectionStandards(23CFR650),aresummarizedbelowwithsuggestedspecialmodificationsforancillary
structures.
ProgramManagerTheprogrammanagerisinchargeofthescoping,scheduling,costcontrol,andquality
assurance.MinimumqualificationsshouldbeaProfessionalEngineerorhaveaminimumof10yearsof
experienceinstructuresinspectionsinaresponsiblecapacityandhavecompletedcomprehensivetraining
basedontheGuidelinesfortheInstallation,Inspection,MaintenanceandRepairofStructuralSupportsfor
HighwaySigns,LuminariesandTrafficSignals.
TeamLeaderHavequalificationsspecifiedforProgramManagerorhaveaminimumof5yearsof
experienceinstructureassignmentsinaresponsiblecapacityorNICETLevelIIIorIVcertificationin
StructureInspectionandhavecompletedacomprehensivetrainingprogrambasedontheGuidelinesforthe
Installation,Inspection,MaintenanceandRepairofStructuralSupportsforHighwaySigns,Luminariesand
TrafficSignals.Inaddition,theTeamLeadershouldbetrainedinworkzonetrafficcontrolsuchastheNHI
Course38003DesignandOperationofWorkZoneTrafficControl.
AninspectionteamwillusuallyconsistofaTeamLeaderandanAssistant.AssistantTeamLeader
qualificationscanbeprojectspecific.Duetotheextentofweldedmembersfoundinmostancillary
structures,itisdesirableforatleastoneteammembertohaveexperienceinvisualweldinspectionaswell
astraininginlocatingandrecognizingfatiguecracking.
Allinspectionpersonnelshouldbeabletophysicallyperformthework.Althoughbuckettrucksaretypically
usedtoaccessthesignbridge,anadequateindepthinspectioncannotbefullyperformedfromthebucket
andsomeclimbingwillberequired.

11.2ToolsandEquipment
Eachinspectionteamshouldbefullyequippedtoperformthestructuralinspections.Additionalequipment
maybeneededsincesignstructureinspectorsroutinelymakeminorrepairs.Thereasonminorrepairsmay
beattemptedduringtheinspectionprocessistoavoidanotherworkzonesetuptoperformaminorrepair.
Suchminorrepairsmayincludebolttightening,replacementoffastenerssuchascotterpins,andpaint
touchup,alongwithreplacingmissingpolecaps,anchorrodnutcoversandhandholecovers.
Thelistbelowiswhatwouldbeconsideredas'ToolsoftheTrade'forthesignstructureinspector.
WorkZoneprotectionandtrafficcontrolequipment,includingsigns,trafficconesandflags(in
compliancewiththeMUTCDandlocalrequirements).
Personalsafetyequipment,includinghardhats,reflectivehighvisibilityvests,goggles,faceshields,
harnesses(orbelts),andlanyards.(AllOSHAapproved).
Basicaccessequipment,suchasastepladder,extensionladder,andrope
Toolsforinspection,includingchippinghammers,pocketknives,screwdriversorawls,magnifying
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glass,magnet,flashlights,mirrors.Thehammerisanexcellenttoolfortestinganchorrods.Themirror
isforinspectingcircumferentialweldswhileclimbingthetruss.Amagnetcanconfirmwhetherthe
materialissteeloraluminum,asaluminumisnonmagnetic.
Toolsformeasuring,suchasaplumbbob,levels,foldingrulers,tapes,calipers,thicknessgauges
Wrenches,allenwrenches,screwdriversforremovingaccesspanelsandboltcovers
Torquewrenchforbolttighteningorcheckingbolttension
Digitalcamerafordocumentation
Shovelandbrushcutters
Markingutensilssuchaslumbercrayonsorkeel,paintsticks,soapstone,centerpunch
GPSrecommendedsincemanysignslooksimilar,evensignpanels,andareroutinelyreplaced
withoutcompletenotificationtoallparties.
Electronicdeviceformeasuringverticalclearancesisrecommended.
Equipmenttonumberthesigns,eitherpaintstenciling,adhesivetape,paintmarkers,etc.
NonDestructivetestequipmentsuchasultrasonictesting,dyepenetrant,ormagneticparticle.
Remotecamerasforhighmastlighting
Buckettruck,seeexplanationbelow
Whilefreeclimbingfromtheshoulderorwithladders,Figure17,canaccessmanysignstructures,themost
typicalwaythesignstructureisaccessedisbyuseofavehiclemountedaccessbucket,Figure18.These
vehiclesarecommonlyusedbycableandtelephonecompaniesandarereadilyavailableforrent.Formost
ancillarystructuresa30'boomissufficient.Accessvehiclesmustbeoperatedinaccordancewithrequired
safetyprocedures.

Figure17.InspectorClimbingStructure.

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Figure18.BucketTruckMostCommonWaytoAccessSignStructure.

11.3TrafficControl
Oneofthemostdifficultchallengesfortheinspectionandevaluationofoverheadsignstructuresisthatof
accessforinspectionpersonnel.ThischallengearisesfromtheneedtosatisfyMaintenanceandProtection
ofTraffic(MOT)safetyrequirementswhilecontrollingcostswithinacceptablelimits.Suchaccessstrategies
includenightwork,mobilelaneclosures,andotherinnovativemethodsforshorttermlaneclosures.Atthe
heartoftheabilitytogaininspectionaccessisdeterminationofwhatareasofthesestructuresaremost
criticalandhowoftenshouldtheybeinspected.
Itissuggestedthatacostbenefitratiobedevelopedforeachoverheadsigninspectionprojectthatconsiders
inspectionaccess,inspectiondetail,MOTcostandoverallsafety.Somesuggestionsforeacharepresented
belowwiththekeydeterminingfactordefinedasthelaneclosurerestrictions.Allsuggestionscomplywiththe
basicrequirementsdiscussedinthe'ManualforUniformTrafficControlDevices'(MUTCD).
Itisrecommendedthatnightworkbealastresortinplanninganinspectionprogram.Thesmallfatigue
cracksinatypicalsigntrussaredifficultenoughtospotduringdaytimeinspectionhours.Ifinspectionsare
performedatnight,adequatelightingmustbeprovided.Belowareseveralconsiderationsindevelopingasign
inspectionstrategydrivenbyclosurerestrictions.
MinimalLaneClosureRestrictionsAnexampleofminimalrestrictionswouldbetheallowanceofdouble
laneclosuresduringnormalworkhoursbetween8AMand5PM.Forthisscenarioitissuggestedthat
conventionalstationarytypeMOTbeused.Theclosure,sinceofatemporarynature,shouldbeeasily
deployedandremoved.TypicalMOTequipmentwouldbeafabricsignconformingtoNCHRP350.Fabric
signsalloweasydeploymentoverrigidmetal.Also,conesshouldbeusedoverbarrelsorbarricadesagainto
alloweasysetupandremoval.IfmoresubstantialMOTequipmentisrequiredmeansotherthanastationary
setupshouldbeinvestigated.Undertheselaneclosurerestrictionsacompletefullhandsoninspection
shouldbescheduledasrecommendedinthe'InspectionFrequency'sectionofthisdocument.
ModerateLaneClosureRestrictionsAnexampleofamoderateclosurerestrictionwouldbelimitedclosure
timesuchasa10AMto2PMwindowforadoublelaneclosure.Aconventionalstationaryclosurecouldbe
consideredifafull8hourwindowcanbescheduledusingsinglelaneclosuresduringthemorningand
afternoonhours.Anefficientinspectiondaymightallowforamorningsinglelaneclosureencompassing
severalsignstructuresthatcanbeexpandedintoadoublelaneclosureat10AM.Itisrecommendedthat
undermoderatelaneclosurerestrictionsafullhandsoninspectioncouldbecompletedperthefrequency
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recommendedinthe'InspectionFrequency'sectionofthisdocument.
SevereLaneClosureRestrictionsAnexampleofaseverelaneclosurerestrictionwouldbenodaytime
doublelaneclosuresallowed.Inthiscase,thebestoptionwouldbeamobilenighttimeclosure.Toreduce
theriskofmissingdeficienciesduringthenighttimeinspectionsasmuchoftheworkaspossibleshouldbe
completedduringthedayusingsinglelaneclosures.Anexamplewouldbetheuseofsingleleftandrightlane
closuresduringthedaytoinspectthepost,base,foundationandtrusstopostconnections.Thenighttime
workwouldthereforeberestrictedonlytotheinteriortraveledlanesfocusingjustonthetrussweldsandsign
connections.Insteadofafullhandsoninspectionwithfrequenciesrecommendedinthe'Inspection
Frequency'sectionoftheseguidelines,amodifiedstrategymightbeneeded.Thismaybeanalternatecyclic
combinationofhandsonandshoulderinspectionstominimizethefulllaneclosures.

11.4Safety
Itishighlyrecommendedthateveryancillarystructureinspectionprogramhaveadetailedsafetyplan
submittedpriortoworkcommencing.Signstructureinspectionsareoneofthemosthazardoustypesof
structuralinspections.Theyusuallyoccuradjacenttolivetraffic.Thesignstructuresaremanytimeslocated
atthe'gore'orexitareasofhighspeedroadswhereworkzonesafetysetupscanbeextremelydifficultto
setup.Inaddition,itisroutinethattheinspector'climb'thestructure,whicharecomplicatedduetoangled
diagonalsandslipperystructuralmembers.
Whenclimbingasignorotherancillarystructureatwolanyardsystemoffersthebestprotectionwithone
lanyardalwayssecuredtothestructure,seeFigure19.Goodgrippingbootssimilartoonesamountain
climberwouldusearerecommended.Toperformaclimbinginspectioneverythingwornorcarriedbythe
inspectormustbesecurelyattachedtohim/hersonothingcandroporhangbelowthebottomofthe
structure.Thereportingofinspectionfindingsmaybehandledbyuseofaradioattachedtotheinspector
throughwhichfindingsarerelayedtoanotetakerontheground.Sincethetravelingpublicmaybeconcerned
whenobservingsomeoneclimbingasignstructure,somestatesplaceavariablemessagesignstating
"WorkersOverhead"asinformationalaid.
Listedbelowaretypicalcontentsofasafetyplan:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

SafetyPlanOfficerforInspectionfirm
SafetyOrganization
SafetyIncidentReportProceduresandForms
FallSafetySpecifications
OperationofBucketorlifttruckguidelines
HospitalLocations
LatestManualofUniformTrafficControlDevices(MUTCD)
Specificworkzonetrafficsetupsfor'gore'areas
Mandatorypersonalsafetyequipment
FirstAidKit

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Figure19.InspectorUsesDoubleLanyardSystem.
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FederalHighwayAdministration|1200NewJerseyAvenue,SE|Washington,DC20590|202
3664000

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