SECTION 910 — HIGHWAY LIGHTING
910.1 DESCRIPTION —
This work is the furnishing, installation, erection, and wiring of the complete highway lighting system, including the electrical power supply and distribution system.
910.2 MATERIAL —
(a) Highway Lighting Material.
(b) Other Material.
Fine Aggregate. Type A or B — Section 703.1
Coarse Aggregate. Type A or C — Section 703.2
Class A Cement Concrete — Section 704
Expansion Joint Filler — Section 705.1
Paint — Bulletin 26
Reinforcement Bars — Section 709.1
Nonshrink Epoxy Grout — An acceptable type.
Nonshrink Mortar — Section 1001.2(e)
Caulking Compound — Section 705.8
Precast Concrete Products - Section 714
Plastic Marking Tape - Section 1101.12(f)
(c) Certification and Warranties.
Secure manufacturer's warranties or guarantees on electrical and mechanical equipment. Submit these warranties or guarantees to the Department at the project completion.
Submit material certification, as specified in Section 106.03(b)3.
For poles, submit a signed warranty from the manufacturer stating that specifications have been met.
910.3 CONSTRUCTION —
As shown on the Standard Drawings, as indicated, and as follows:
Comply with local government, electric utility company and State codes or requirements; the electrical regulations of the Department of Labor and Industry; and the applicable construction requirements of the NEC, NESC, and NBFU. Cooperate with the electric utility company or agency furnishing power to the system and meets its necessary service requirements. Acquire permits as specified in Section 107.02. If required, furnish certificates of approval from appropriate agencies. Upon work completion, submit to the Department five copies of "as-built" drawings, as directed, showing the date, any changes from the indicated system made during construction, and any revised circuit diagrams. Upon receipt, "as-built" drawing copies will be supplied to the agency maintaining the system. The acceptance of drawings will not relieve Contractor responsibility for erroneous or inconsistent dimensions, notations, or omissions or for the proper installation and operation of the electrical systems.
(b) Excavation for Pole Foundations.
Prior to placing forms, each foundation excavation will be inspected for the actual soil conditions encountered. Do not proceed with work until the foundation excavation is accepted. If required, the foundation design will be revised, based on actual conditions encountered.
Have completed forms accepted before concrete placement. Remove water from foundation holes prior to concrete placement.
(c) Trench Excavation and Backfill.
Satisfactorily remove and store topsoil encountered in the excavation. Excavate trenches for conduit runs parallel to the roadway, off the shoulder. Backfill the same day when possible. Remove rock within the excavation unless an alternate layout is authorized. Satisfactorily remove and dispose of unsuitable material including material below standard trench depth, as directed. Satisfactorily dispose of excess excavation.
Place plastic marking tape within the last layer of backfill material for the entire length of the trench.
Backfill trenches that will be under pavements or paved shoulders with suitable coarse aggregate, as specified in Section 703.2.
Before excavating, stake trench alignments which deviate from the indicated location, for inspection and acceptance. If the alignments extend the circuit length by more than 5% of the overall indicated circuit length, submit the layout for review and acceptance before proceeding.
(d) Pole Foundations.
Construct of Class A Cement Concrete, as specified in the applicable parts of Section 1001.3.
Prior to erection of high mast poles, mix, cure, and test samples of the foundation concrete in accordance with Department procedures.
Provide and place anchor bolts perpendicular to the top plane of the foundation. Use suitable templates or forms to hold the anchor bolts in position while placing concrete.
Thoroughly clean the exposed portion of anchor bolts and associated hardware.
Install individual electrical grounds for pole foundations. Where the resistance between pole and ground is greater than 25 ohms, install additional ground rods as required.
(e) Lighting Poles and Accessories.
Install poles plumb. Other than high-mast, use aluminum shims with aluminum bases; use stainless steel shims with other bases. Place shims under no more than three bolts of any base. As required to prevent corrosion, place caulking compound between the pole base and the concrete foundation or leveling pad, where bases are in contact with concrete. Orient the handhole in the direction of traffic, unless otherwise noted.
Plumb high-mast poles, using the leveling nuts supplied with the anchor bolts.
Unless otherwise indicated, install bracket arms at right angles to the pavement edge with arms securely fastened to the pole shafts. Install luminaires and ballasts in accordance with the manufacturer's instructions or as directed.
Fasten an acceptable brass identification plate to the roadway side of the pole, 6 feet above the foundation.
Select one or more poles for the static load test, described in Section 1101.02, for compliance before the remainder of the poles are erected.
Within the same general area, use similar pole types and similar materials.
Field-assemble two-piece pole shafts by overlapping bolted sections.
Field-welding of poles or accessories will not be permitted.
(f) Supervision (High-Mast Installations).
Have a manufacturer's representative available on site to assist in supervising the field assembly and erection of high-mast poles. The pole section mating and alignment will be checked prior to the erection of the pole. Have the representative instruct Department personnel in the proper procedures for raising and lowering the luminaire ring and in the recommended maintenance care of the poles.
Request the electric utility company to be present during erection of poles within 200 feet of their aerial electric lines.
Support conduits firmly and rigidly in place by acceptable methods, in a manner to prevent dislodging, while placing concrete or while performing other operations. If possible, install conduits under roadways before placing the pavement. If this is not possible, install a 3-inch diameter or larger, rigid steel conduit for a sleeve. To install this sleeve, jack, auger, or bore under pavements, shoulders, sidewalks, railway tracks, and other areas where directed. Water boring is not permitted. Extend this sleeve under the roadway approximately 2 feet beyond the outside paved edge. Place the lighting conduit through this sleeve.
Grind the cut ends of metallic conduit to remove rough edges. Do not use defective conduit. Thread steel conduit for couplings and fittings. Immediately prior to assembly, coat threaded parts with dull red primer. Wipe clean after assembly.
Weld plastic conduit joints with solvent, in accordance with the conduit manufacturer's recommendations.
Make conduit bends and offsets, either in the shop or in the field. When making bends and offsets, do not damage the protective coating. Do not reduce the interior diameter of the bend. Form the bend on a radius at least twelve times the conduit diameter, but not less than 18 inches. Use manufactured sweep bends whenever possible.
If conduit work is temporarily suspended, satisfactorily seal the ends of partially installed conduit runs. If necessary to open ends for cleaning or testing, reseal them upon completion. Seal conduits in control cabinets.
Install conduit expansion and deflection joint fittings at each structure expansion joint as shown on Bridge Standard Drawings.
As soon as possible after installation, ground steel conduit and provide electrical continuity on structures, as specified in Section 910.3(q). Connect fittings, junction boxes, and other appurtenances to the conduit on a structure, so electrical continuity is maintained. Provide conduit expansion joints with an external bonding jumper.
Either paint or tape exposed portions of concrete-encased steel conduit to be placed underground. Either paint with two coats of Protective Coating for Conduits or cover with tape, spirally wrapped with a minimum of overlap, after applying a primer. Do either, in accordance with the manufacturer's instructions.
Clean conduit runs after installation by pulling a stiff wire brush, the size of the conduit, through the conduit. Then, test the conduit by pulling a ball mandrel, having a diameter of at least 85% of the inside diameter of the conduit, through each conduit run. Where the mandrel fails to pass, either clean the conduit without injury to the conduit walls or replace the conduit.
Securely fasten the conduits to electrical equipment using devices acceptable for the conduit used.
Attach conduit to wood poles with 1/8-inch thick galvanized steel straps and galvanized lag screws. Provide 5 feet maximum spacing between straps.
Use a watertight conduit fitting for each conduit connected to watertight enclosures.
Do not install pull wires in the conduit, unless indicated.
(h) Cable Installation.
Avoid damaging cable insulation when removing cable from drums or reels, or during installation of the cable. Manually, remove the cable from the drum or reel and place the cable. Notify the Engineer when cable is to be placed. Do not proceed without the Engineer being present, unless otherwise directed.
Install cable in the conduit, using acceptable methods and pull with cable grips. Simultaneously pull cables within a single conduit, but do not damage the cable by overpulling. Use a dynamometer when pulling other than by hand. If required, use pulling lubricant of a type recommended by the cable manufacturer. Use extreme care when pulling cable through handholes in pole shafts. Place a pad of firm rubber or other similar material around the bottom edges of the opening to protect cables from rough edges or protrusions.
Where guide rail is to be erected or other surface features are to be constructed within the immediate area, clearly locate underground conduits by aboveground markers or by other acceptable methods.
Provide enough slack cable in junction boxes and light pole bases to permit exterior splicing. Neatly arrange the spliced cables or coil in junction box or pole base.
Prevent entry of moisture into the cable at all times during installation. Seal ends of cable as required until final splices are made.
Line splice in an acceptable manner. Make splices with pre-molded, waterproof, disconnectable connector kits. Where breakaway bases are used, use only breakaway type connectors for connections to the pole. Provide kits rated for 600 volts. Line splice only at pole bases or junction boxes. Do not splice cables inside conduits.
For the phase and neutral wires, use seven-strand No. 10 AWG insulated wire for the line taps from the feeder cable to the ballast. Use conductors of the same material as in the feeder cables. Provide taps to the feeder cables similar to those for line-splicing. Wire nuts are not acceptable for cable taps. Provide adequate size connectors for the wire sizes involved. Provide individual fusing for all conventional poles. Fuse the tap with a 6 to 10-ampere fuse, midget size, 250-volts rating. Fuse the phase wire only. Furnish and install circuit-identifying tags on control and distribution circuit cables, where they connect to equipment located in service cabinets and vaults, and on cables in junction boxes and pole shafts. Use fiber or other acceptable nonconducting tags, not less than 3/4-inch in diameter, and not less than 1/32-inch thick. Legibly stamp identification markings on the tags, using small tool dies. Securely tie each tag to the proper conductor, using plastic or nylon cord.
Use direct burial cable in direct burial conduit for all underground installations unless otherwise indicated. Minimum underground wire size is AWG#8 copper cable.
(i) Cable Duct.
When indicated, install similar to conduits, as specified in Section 910.3(g) and in accordance with manufacturer's instructions.
Check the luminaires for the proper lamp socket position, in accordance with the lamp distribution indicated, before placing on the pole top or arms. Uniformly adjust and level luminaires. Immediately prior to the illumination test, and after other work has been completed, clean light control surfaces, refractors, and reflectors, using an acceptable cleaner, to provide the maximum light output. Clean, in accordance with the luminaire manufacturer's recommendations. Provide luminaires with a weather resistant decal that indicates lamp wattage. Provide a decal that is visible from the ground.
(k) Service Pole Installation.
Position the service pole inside the right of way, where indicated, and mount a meter base on the pole, in accordance with the utility company's requirements. Have the meter installed by the utility company.
Install poles, in accordance with the current specifications and standards of NELA, EEI, and NESC. The minimum depth of holes for setting wood poles 30 to 40 feet in length is 6 feet, measured from the low side on sloping ground. Dig holes with vertical sides and with a diameter large enough to permit use of a mechanical tamper around the pole. Have each pole inspected and accepted before backfilling. Deposit acceptable backfilling material around the poles and mechanically tamp, in layers of not over 4 inches. Place backfill material around the pole to drain water away.
Guy service poles, if necessary. Install cone anchors 7 feet below ground level. After placing the anchor, backfill the hole with acceptable coarse aggregate for a depth of 2 feet above the anchor, then tamp during backfilling. Backfill the remaining hole with the excavated material, then thoroughly tamp.
Place guys, then have them inspected and accepted before conductors are strung. Install a guy guard if the guy is adjacent to the roadway.
(m) Photoelectric Control Device.
Use a plug-in device, for ease of replacement. Install the device with its detector area facing north.
(n) Enclosure Installation.
Securely mount enclosures for housing the control equipment. Padlock the enclosures.
(p) Junction Boxes.
Have any required change in box location reviewed and accepted before installing.
Excavate, then construct or install the box. Satisfactorily backfill around the box and dispose of excess or unsuitable material.
When using precast junction boxes with knockouts, remove the knockouts, then tightly grout the conduit or conduit sleeves in place with nonshrink mortar.
Suitably ground lighting poles, underpass luminaires, and metal junction boxes on structures by connecting to structure mounted steel conduit or, when using structure mounted non-metallic conduit, to a continuous grounding conductor in the conduit.
Provide one ground rod for structures up to 500' in length. Provide one ground rod at each end of structures over 500' in length. Ground structure mounted steel conduit with a No. 4 uninsulated copper ground conductor. Provide a separate insulated or uninsulated continuous ground conductor of the same AWG size and material as the circuit conductors for structures using nonmetallic conduit. Install the ground conductor with the circuit conductors. Connect the ground conductor to the ground rod or rods using either an exothermic weld or a bronze connector clamp.
(r) Galvanize Repair.
Satisfactorily repair field damage to any galvanized finishes by painting with two coats of Zinc Dust-Zinc Oxide Paint (Bulletin 26), in accordance with ASTM-A 780, or with an acceptable equal.
(s) Power Supplies.
Make arrangements with the local electric utility company for electrical service for the lighting system.
Furnish and install the required number of wooden poles for the power supplies with the necessary auxiliary equipment (crossarms, brackets, meter base, transformers, cutouts, lightning arresters, conduit, insulators, switches, fuses, circuit breakers, contactors, photoelectric controls, enclosures, and grounding) to provide complete electrical service for the entire lighting system. Components of the complete power supply system to be furnished and installed will be subject to review and acceptance.
(t) Buried Cable and Conduit Markers.
Set the markers flush with the ground and directly over the trench.
Perform the following tests and record test data on the Department Test Forms listed. Provide electrical energy and furnish personnel and equipment as required to complete the tests. Correct any defects disclosed by the tests. Perform the tests in the presence of an authorized representative of the Department.
4225A Ground Rod Test
4225B Conductor Insulation Resistance Test
4225C Circuit Performance Test
4225D Highway Illumination Test (Conv.)
4225F High Mast Lighting Test
4225G Static Load Test (Conv.)
Satisfactorily demonstrate that circuits are continuous and free from short circuits and from unspecified grounds. Provide a resistance to earth-ground, for each ground rod installed, of not more than 25 ohms. If not met with one rod, supply and install additional ground rods until this requirement is met or as determined by the Engineer.
The resistance to ground of conductors for direct buried cable is to be as shown in the following table at 60F, when measured with a 1,000 volt megger:
Insulation Resistance (Megohms-min./1000')
Wire Size (AWG)
RHW, RHH, USE
Take voltage readings, with load and without load, at the power supply side of the control cabinet main breaker. The readings with load must be within ±5% of nominal voltage (Typically either 120 volts or 240 volts). Take voltage readings at the last light of each circuit. A voltage reading is acceptable if it is within 5% of the reading with load at the supply point.
Take current (ampere) readings with a full lighting load on the load side of each distribution breaker in the control cabinet. A current reading is acceptable if it does not exceed 75% of the breaker rating.
Energize and operate the lighting system, including automatic control(s), for 168 consecutive hours. At each control cabinet, supply a service voltage graphic record covering the test period, with the installed electrical equipment in normal operation (lights on at night and off in daytime). After the lights have been energized for at least 100 hours burning time, and after dark, take footcandle readings at road level. Use a light meter meeting the following requirements:
Lowest full scale not exceeding 2.0 footcandles or equivalent sensitivity.
Calibrated by a recognized testing laboratory within the past year and bearing the certificate of calibration.
Take footcandle readings, where directed. Give particular attention to points where low illumination is most likely to occur, usually midway between luminaires.
Complete the required static load tests specified in Section 1101.02(a)1.
Guarantee the satisfactory in-service operation of all mechanical and electrical equipment, and related components of the entire lighting system including lamps, for a period of 180 days. The guarantee begins the day after the lighting system is fully operational, as determined by the Engineer, after satisfactory completion of all lighting system related work and satisfactory completion of the 168-hour performance test specified in Section 910.3(u).
The energizing cost during the guarantee period will be borne by others. Perform the following at the onset of and during the guarantee period:
Execute the in-service guarantee notification Form CS-4225H, provided by the Department.
Commence repairs within one calendar day following notification to person designated on Form CS-4225H, unless otherwise directed by the owner of the lighting system.
Guarantee all repairs and/or material replacements for the balance of the guarantee period, or 30 days, whichever is the longer period.
Repair work not performed within the guarantee period, or any extension periods, will be considered latent defects as specified in Section 107.16(b).
Any and all repairs necessary as the direct result of external causes will be performed by others. Examples of external causes are lightning strikes, vehicular impact, objects driven through the underground circuit, trenching through installed circuits, etc.
Issuance of certificate of acceptance or final settlement of the contract is not consequential to the in-service guarantee period described herein. The guarantee period is not a part of the contract time.
910.4 MEASUREMENT AND PAYMENT —
(a) Junction Boxes.
Each, for the type indicated.
(b) Poles (Conventional).
Each, for the type and height indicated.
Includes either frangible or breakaway base (when indicated) and arm.
(c) Poles (High-Mast).
Each, for the height indicated.
Includes the lowering device and wiring from the line splice to the luminaire ring.
The winch drive unit will be considered incidental to the total number of poles constructed.
Each, for the length indicated.
(e) Luminaires (Conventional).
Each, for the wattage and mounting indicated.
Include complete wiring from luminaire ballast to line splice.
(f) Luminaires (High-Mast).
Each, for the wattage indicated.
Includes complete wiring from the luminaire-ring terminal board to the luminaire ballast.
Each, for the wattage and mounting indicated.
Includes complete wiring, conduit, and necessary mounting provisions from the line splice at the junction box to the luminaire.
Each, for the wattage indicated.
Includes mounting and wiring, as directed.
(i) Pole Foundations.
Each, for the type indicated.
Includes excavation, concrete, anchor bolt assemblies, reinforcement bars, conduit, ground rod, ground rod clamp, grounding conductor, backfilling, and satisfactory disposal of surplus material.
(j) Cable and Conduit Markers.
Includes excavation, concrete, backfilling, and satisfactory disposal of surplus material.
Includes fittings, joints, bends, grounds, protective coatings, and other required appurtenances. Does not include conduit in pole foundations.
Unless otherwise authorized, no allowance will be made for additional conduit lengths as a result of deviation from the indicated conduit location.
No allowance will be made for coiling or looping cable slack lengths inside pole bases or junction boxes, when additional lengths of cable are required for splicing. An allowance will be made for cable entry into each pole base from the trench to the handhole.
Unless otherwise authorized, no allowance will be made for additional cable lengths, or cable size, as a result of deviation from the indicated cable location.
The ground wire and ground rod specified for structures are considered incidental to the circuit cables. Splices, and fuses when specified, are also considered incidental to the circuit cables.
Includes excavation, backfilling, temporary and permanent plastic trench markers, and satisfactory surplus material disposal. No allowance will be made for rock excavation or for any other subsurface condition encountered.
Unless otherwise authorized, no allowance will be made for additional trench lengths as a result of deviation from the indicated trench locations.
(p) Pull Wire.
When indicated or directed.
(q) Complete Power Supply System.
Includes service pole and all necessary power supply equipment.
(r) Testing of Entire Lighting System.
Includes furnishing personnel, equipment, and electrical energy required for all tests.
(s) Conduit Sleeve.
Includes all work required to install conduit sleeve as specified in Section 910.3(g). Does not include circuit conduit passing through the sleeve.
Most Current Supplement
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