Section 636 — Traffic Signal, Traffic Counter, Lighting, and Electrical Systems

AND ELECTRICAL SYSTEMS

Description

636.01This work consists of installing, modifyi ng, relocating, or removing traffic signals, traffic counter, flashing beacons, highway lighting, sign illumination, communication conduits, and electrical systems or provisions for future systems.

Material

636.02Conform to the following Subsections: Backer rod 712.01(f) Electrical material 721.01 Joint sealant and crack fillers 712.01(a) Lighting material 721.02 Underground precast concrete utility structures 725.09(d)

Construction Requirements

636.03Regulations and Codes. Provide material and workmanship conforming to the standards of the National Electrical Code (NEC), local safety code, UL, NEMA, Insulated Cable Engineers Association (ICEA), and IMSA. Obtain permits, arrange for inspections, and pay fees necessary to obtain electrical service. Provide luminaires with crashworthy supports. Notify the CO, local traffic enforcement agency, utility companies, or railroad company at least 7 days before operational shutdown to coordinate connections or disconnections to an existing utility or system.

636.04General. At least 14 days before starting system installation work , submit a list of propose d equipment and material according to Subsection 104.06. Include the manufacturer’s name, size, and identification number of each item. Supplement the list with drawings and wiring diagrams showing locations and details of equipment and wiring. Obtain approval for the exact location of the systems. Remove structures and obstructions according to Section 203. Salvage material that meets requirements for reuse in the work. Excavate and backfill according to Section 209. Construct minor concrete according to Section 601. Install signs according to Section 633. If roadways are to remain open to traffic, maintain the existing systems in operation until final connection to the modified circuit to minimize traffic disruptions.

636.05Conduit. Cut conduit so the ends are smooth. Connect conduit sections with couplings to butt the ends of both condui ts squarely against each other inside the couplings. Provide a metal expansion and deflection fitting where conduit crosses a structural expansion joint. 770 Install conduits continuous between outlets with at least couplings to allow pulling conductors. End conduit with bell fittings or bushings. Provide pull wires for conduits designated for future cable installation. Remove and replace crushed, deformed, or damaged conduit. Maintain conduits clean and dry and protect ends of conduit with plugs, caps, or fittings. Size pull boxes to provide for termination of the conduit and connection of the conductors. 636.06 Traffic Signal and Lighting Systems. Provide systems conforming to the MUTCD or state adopted supplements to the MUTCD for the state in which the system is located. Design systems to operate according to IMSA or NEMA or both.

636.07Traffic Counter and Traffic Counter Components. Obtain approval of traffic counter and traffic counter components before installation. Mount a fan inside the cabinet and position to direct the majority of airflow over the traffic counter and modem. Mount a fan thermostat at the top of the cabinet and minimize its interference with other cabinet components. Run the fan until the cabinet temperature decreases 20 degrees below the turn- on temperature. Before powering-on equipment within the cabinet provide a copy of the following:

(a)Voltages for solar power supplies; and

(b)Telephone number, IP address, or both, for communication devices. If using solar -powered panels, include a mini mum 20 -watt solar panel (that can produce at least 36 watt hours per day) and a minimum 12- volt, C100 36 -ampere- hour, gel type battery that can power the cabinet electrical components for at least 25 days. Frame the solar panel with bronze anodized extruded aluminum. Mount a weatherproof connection on the back of the solar panel to connect the output cable to the solar panel cable. Ensure all cell modules have been approved for application in NEC Class I, Division 2, Group D hazardous location. Mount and orient the cabinet to provide an unobstructed, direct line of sight to the roadways that contain count station and vehicle detection equipment when cabinet door is opened. Install traffic counter and communications devices inside cabinet. Identify and labe l loop wires inside each pull box in which the loop wires enter. Maintain consistent wiring identification and labeling when entering the cabinet and with connection to the traffic counter. Use water resistant material for wiring identification and labelin g. Obtain approval for loop wire assignments at all locations.

636.08Rectangular Rapid -Flashing Beacons. Provide and install rectangular rapid -flashing beacons according to the MUTCD.

636.09Traffic Loop. Do not install loops when the pavement is wet. S aw cut, wire, and seal loop wires on the same day. Do not allow vehicular traffic to pass over an open saw cut unless protected. 771 Wet cut clean, smooth, well -defined, ⅜-inch wide saw cuts at a depth to allow 2 to 2½ inches of cover without damaging the ad jacent pavement. Drill 1½ -inch diameter loop corners matching the saw cut depth. For the lead -in channel, saw clean, smooth, well -defined, 5/8-inch- wide cuts providing a minimum cover of 2 inches. Ensure saw cuts are straight with less than ½ -inch error in a 10 -foot line. Saw cut the lead -in to the pull box as close as possible to the edge of pavement. Thoroughly clean the saw cut of foreign material with compressed air and water blasting. Dry the joint with compressed air. Install the loop wire in one continuous length at the bottom of the cut using a 3/16- to ¼- inch thick rounded, smooth wood paddle. Install without kinks, curls, or other damage to the w ire or its insulation. Replace damaged wires. Hold the loop wire in place with 1- inch lengths of ½ -inch backer rod spaced at 2 -foot intervals. For the number of loop wire turns, conform to Table 636-1. Table 636-1

Required Number of Loop Wire Turns

Required Number of Loop

Wire Turns Number of Turns

≤ 200 3 >200 to 500 4 >500 to 700 5 If the loop wire crosses a crack or joint, use a plastic sleeve that extends 4 inches on each side of the crack or joint. Provide extra loop wire in the sleeve for joint expansion and contraction. Twist the loop lead -in wires 6 twists per foot from the loop to the pull box. Do not twist different loop pairs together. Color code the wires of each loop using colored vinyl electrical tape for identification of separate loops inside each pull box, as shown in Table 636-2 . Coil 18 inches of lead -in slack in the pull box for each loop. Table 636-2

Loop Labeling Convention

Loop # of Identifiers Color Loop 1 1 Red Loop 2 1 White Loop 3 1 Green Loop 4 1 Blue Loop 5 2 Red Loop 6 2 White Loop 7 2 Green Loop 8 2 Blue Before applying sealant, test the loop and lead- in for continuity and resistance by applying a 1000-volt megohmmeter between each end of the loop lead- in and the nearest reliable electrical ground. If no available ground exists, establish a ground for the measurement. Record the location and megohmmeter readings and submit readings and test equipment data to the CO. Replace the loop if the insulation resistance measure to earth ground is greater than 100 megohms at 500 volts direct current, the inductance is less than 50 microhenries or more than 800 microhenries, wire resistance is less than 1.75 ohms per 700 feet, or the loop quality factor is less than 5 at 50 kilohertz. Install inductive loops with dedicated saw cuts and separate PVC conduits for each sensor lead -in cable from the edge of pavement to the first pull box. 772 Apply sealant to the saw cuts with the backer rods in place. Do not produce air bubbles when applying sealant . Remove excess sealant and finish level with the pavement. Follow the manufact urer’s recommendations for sufficient time for the sealant to harden before allowing traffic to cross the loops. Repeat the resistance and continuity test after sealant is applied. Report the second test for comparison with the first test report. Preformed inductive loops with 3 to 5 turns of #14 AWG cable with an insulation of XLPE (cross-linked polyethylene) encased in PVC pipe may be used as an alternative for use in new construction. Loop dimensions and spacing, based on lane width are shown in Table 636-3. Table 636-3

Loop Dimensions and Spacing

Lane Width, feet Loop Dimension, feet Spacing to Centerline, feet 12 6 x 6 3 11 5 x 5 3 10 5 x 5 2.5

636.10Testing and Demonstration Period for Traffic Counters. Before energizing portions of the system, demonstrate that the conductor system is clear and free of short circuits, open circuits, and unintentional grounds. Repair or replace faulty circuits. After energizing the system, demonstrate that all electrical componen ts work properly. Repair or replace faulty electrical components. Conduct an on- site verification test according to ASTM E2300, Type I -2 with a 10 percent tolerance. For each loop tested, provide two human observers to count for the minimum duration of 15 minutes and at least 50 vehicles. If the test would likely last greater than 30 minutes to attain the 50-vehicle threshold, then test vehicles driven over the loops being tested should be considered. Conduct the test at an approved date and time. Upon completion of construction at a location as shown in the plans the site will be placed in full scale operation for a 30- day demonstration period. Repair defects or complete necessary adjustments during the demonstration period. If failures occur during this de monstration period, perform repairs within 2 days. If necessary repairs are not completed within 3 days of notification, stop the demonstration period and resume only after such repairs and replacement of materials have been made, inspected, and approved.

636.11Warranties, Guarantees, and Instruction Sheets. If installations are permanent, deliver the manufacturer’s warranties, guarantees, instruction sheets, and parts lists at the final inspection. Within each cabinet, store one laminated copy of the cab inet wiring diagram and the field wiring diagram showing loops, pull boxes, and conduit runs inside two one -gallon re -sealable storage bags, one inside the other. Provide an electronic copy of each document to the CO.

636.12Relocations. Use material equi valent to existing material, unless present codes require different or improved material. Existing material may be salvaged and reused if material and installation methods used meet the requirements of applicable codes and ordinances. 773 636.13 Acceptance. Material for traffic signal, traffic counter, lighting and electrical systems will be evaluated under Subsections 106.02 and 106.03. Installation of traffic signal, traffic counter, lighting and electrical systems will be evaluated under Subsections 106.02 and 106.04. Excavation and backfill will be evaluated under Section 209. Installation of signs will be evaluated under Section 633. Minor concrete will be evaluated under Section 601. Removal of structures and obstructions will be evaluated under Section 203.

Measurement

636.14Measure the Section 636 pay items listed in the bid schedule according to Subsection 109.02 and the following as applicable: For relocations, do not measure additional line or connections necessary to place the fixture at the new location.

Payment

636.15The accepted quantities will be paid at the contract price per unit of measurement for the Section 636 pay items listed in the bid schedule. Payment will be full compensation for the work prescribed in this Section. See Subsection 109.05 . Progress payments for lump sum pay items will be prorated based on total work completed under this Section.