433 ALASKA 2020 SECTION 660
660-1.01 DESCRIPTION. Furnish and install, modify, remove, or salvage one or more traffic
signal systems, flashing beacon systems, highway lighting systems, sign illumination systems, traffic count systems, electrical equipment on structures, falsework lighting, partial installations for future systems, or combinations thereof, as specified. Where an existing system is to be modified, reuse the existing material in the revised system as shown on the Plans or specified in the Special Provisions, and salvage or di spose of all other materials. When required by the Special Provisions, provide an on- site manufacturer’s representative to:
1.Energize and adjust the electrical system.
2.Provide acceptable instruction for the operation and maintenance of the electrical system.
660-1.02 DEFINITIONS . Use the definitions in NEMA TS 1- 1989, Traffic Control Systems ,
Section 1, Definitions, along with the following:
1.Electrolier . The complete assembly of pole, mast arm, luminaire, ballast, and lamp.
2.Luminaire. The assembly which houses the light source and controls the light emitted from the light source. Luminaires consist of hood (including socket), reflector, ballast or driver, and glass globe or refractor.
3.Lighting Standard. The pole and mast arm which supports the luminaire.
4.Vehicle . Any motor vehicle licensed for highway use by the State of Alaska.
660-2.01 MATERIALS. Use materials that conform to Section 740, the Materials Certification List,
the Plans, specifications, and the following: Concrete Section 501 (Class A) Grout Subsection 701- 2.03 Reinforcing Steel Section 503 Paint Subsection 708- 2.01 Steel Pipe Pile Section 715 Anchor Plate ASTM A709 Galvanizing Subsection 716- 2.07
1.Equipment List(s) and Drawings . Within 30 days after the Contract award, submit 8 collated copies of a portfolio of equipment and materials proposed for installation to the Department for review and approval. Include a table of contents in the portfolio(s) that includes each item’s intended use(s) and the following:
a.Materials on the Qualified Products List: A description that includes product name, manufacturer, model or part number, and the conditions listed for approval.
b.Materials Not on the Qualified Products Lis t: Catalog cuts that include the manufacturer’s name, type of product, size, model number, conformance specifications, and other data as may be required, including manufacturer’s maintenance and operations manuals, or sample articles.
c.Pole Package. A complete set of design, fabrication, and installation proposals for each signal and lighting pole. Include stamped engineering calculations, shop drawings, welding plans, equipment lists, and pole installation plans. 434 ALASKA 2020 d. Materials Not Requiring Certification: Incidental materials incorporated into the work (such as nuts, ties, bolts, washers, etc.) must meet all applicable Specifications and be installed per all manufacturer’s recommendations. Certification is not needed unless required by the Special Provisions or requested by the Engineer.
2.As-Built Plans . Prepare 3 complete sets of red lined as -built plans and keep them current with the construction. Detail in the as -built plans all construction changes made to the Plans. Include the following information on the appropriate sheets:
a.Location and depth of conduit runs
b.Station and offset of all junction boxes
c.Heights of signal faces and overhead signs
d.A list of equipment, including manufacturer, brand, and model number installed in each controller cabinet Furnish copies of the as -built plans at least twice a month during construction so that they may be reviewed for accuracy and completeness. Furnish any additional information required to clarify the as -built plans and correct all discrepancies. The Department will not make progress payments for the signal and illumination work completed until reviewing accurate as-built plans reflecting the construction progress. Correct any deficiencies before payment. Before final inspection of the work, submit 3 complete sets of as -built plans to the Engineer. You may substitute 2 colored copies of the as -built plans in lieu of keeping the 3 separate original copies. If you elect to do this, a sample of the method of copying must be approved before starting any work on the signal and lighting items.
3.Warranties, Guarantees, and Instruction Sheets . Deliver to the Enginee r all manufacturers’ warranties, guaranties, instruction sheets, and parts furnished with materials used in the work before the Department assumes maintenance responsibilities. CONSTRUCTION REQUIREMENTS
660-3.01 General.
1.Scheduling of Work . Complete each new traffic signal system, highway lighting system, and sign illumination system and ensure it is ready for operation before opening to traffic the corresponding section of new alignment. Do not place traffic signal systems in operation until the street li ghting is energized at controlled intersections. Install detector loops and underground conduit before applying new pavement. Do not pull conductors into conduit until the junction boxes are set to grade, crushed rock sumps are installed, grout is placed around the conduit, and metallic conduit is bonded. In vehicular undercrossings, place soffit lights in operation as soon as practicable after removing falsework from the structure. Place lighting for pedestrian structures in operation before opening the s tructure to pedestrian traffic.
2.Safety Precautions . Before starting work on existing street lighting circuits, de- energize the system by opening disconnect switches, and/or opening bypass switch plugs, and tagging each opened device as detailed in Part 4, Section 44, Article 440 of NESC. Where said SECTION 6 60 435 ALASKA 2020 circuits are under the control of an electric utility, obtain written assurance daily from the utility that the circuit being worked on has been de- energized. Post suitable signs at load centers when any of the c ircuits from that load center are being worked on.
3.Excavating and Backfilling. Excavate as required for the installation of junction boxes, conduits, foundations, and other appurtenances. Avoid unnecessary damage to streets, sidewalks, landscaping, and oth er improvements. Do not excavate wider than necessary for the proper installation of conduits, junction boxes, and foundations. Do not perform excavation until immediately before installing conduit and other appurtenances. Excavate trenches for installin g rigid metal conduit to a depth 6 inches below the bottom of the rigid metal conduit. Embed conduit between two 6- inch lifts of material that are free of rocks exceeding a 1- inch maximum dimension. Place the material from the excavation where it will not cause damage or obstruction to vehicular and pedestrian traffic or interfere with surface drainage. Dispose of all surplus excavated material according to Subsection 203- 3.01. Backfill excavations according to Section 204. Keep excavations after backfilling well- filled and maintained in a smooth and well -drained condition until permanent repairs are made.
4.Welding. Conform to Subsection 504- 3.01.7, and the requirements of the individual items.
5.Removing and Replacing Improvements . Replace or reconstruct improvements damaged by your operations such as sidewalks, curbs, gutters, pavement, base material, lawns and plants, and other improvements that are removed or broken with the same kind of material as found on the work, or with materials of equal or better qua lity. Leave the new work in satisfactory and serviceable condition. Whenever a part of a square or slab of existing sidewalk, curb and gutter, or driveway is broken or damaged, remove the entire square, section, or slab and reconstruct the concrete as abov e specified. Before removing the sidewalk, driveways, or pavement material, cut the outline of all areas to be removed in concrete sidewalks, driveways, and in pavements through completely with a saw. Make cuts neat and true and prevent shatter outside the removal area.
6.Salvaging or Reusing Electrical Equipment . Salvage and deliver existing electrical equipment, including controller assemblies, signal equipment, luminaires, lighting standards, signal poles and mast arms, service equipment, and junction box lids to a location indicated on the Plans, the Special Provisions, or by the Engineer. Jointly inventory, with the Engineer, all equipment and materials to be salvaged or reused. Perform the inventory within 15 days following the Notice to Proceed. Note on the inventory the location and condition of all materials to be salvaged or reused. When a controller assembly is to be salvaged, the salvaged material includes the controller unit, timing modules, switches, detector control units, conflict monitor unit, and all other equipment contained in the controller cabinet before Contract award. 436 ALASKA 2020 When existing electrical equipment is to be reused, furnish and install all necessary materials and equipment, including signal mounting brackets, new tap wires, fused disconnect kits, anchor bolts, nuts, washers, and concrete as required to complete the new installation. Clean, relamp, and recondition all traffic signal, flashing beacon, and lighting fixtures to be reinstalled according to Subsection 660- 3.01.8.b. You may el ect to use new equipment if you determine that it will be more cost effective than reusing the old equipment called for in the Plans and/or Special Provisions. If using new equipment, notify the Engineer when submitting the equipment list(s) and drawings per Subsection 660- 2.01.1. Include the submittals for the items proposed for use in lieu of the reused equipment with this submittal. Replace salvaged materials required to be reused and found to be unsatisfactory by the Engineer with new material. Replacem ent will be paid for as extra work under Subsection
109-1 05.
Remove and salvage electrical equipment without damage. Replace at your expense any of the above- mentioned electrical equipment that has been damaged or destroyed by your operations. Underground conduit, conductors, foundations, junction boxes, and detectors not reused become your property and must be removed from the highway right -of-way. If said materials, except conductors and cables, do not interfere with other construction they may, with approval, be abandoned in place with a credit taken by the Department. To limit future operation and maintenance concerns, remove all cables and conductors from any conduits that will be abandoned in place. Meet Subsection 660- 3.02 for foundations abandoned i n place. Repair holes left in the shafts of existing metal poles, due to removal of equipment or mast arms, by welding in a suitable disk, grinding smooth, and painting as provided for repair of damaged coatings in AASHTO M 36. As directed, repair or repl ace damaged existing metal poles that are to be relocated or reused in place. The Engineer will determine the extent of repairs or replacements. The Department will pay for the repairs or replacements ordered as extra work according to Subsection 109- 1.05. Refinish poles according to Subsection 660- 3.01.8. Fill holes formed by removing junction boxes and foundations with material equivalent to the surrounding material and compact to the same density.
7.Field Tests . Before acceptance of the work, perform the f ollowing tests on all electrical systems under this Section, in the presence of the Engineer. Furnish the necessary equipment needed to perform these tests. The Department reserves the right to retest, and the test results will govern the acceptance or rej ection of the installation. Replace or repair at your expense, and in an approved manner, any faults in material or any part of the installation revealed by these tests. Repeat the same test until no fault appears.
a.Continuity. Test each circuit for continuity. Test each loop detector circuit for continuity at two locations:
1.Loop detector at the junction box before splicing with the loop detector lead- in cable must have a value less than 0.5 ohms.
2.Loop detector and lead- in cable system at the traffic signal controller cabinet or detector cabinet after splicing in the junction box must have a value less than 5 ohms for single pair lead- in cable and 10 ohms for multi -pair lead- in cable. The continuity test ohm reading at the traffic signal controller cabinet or detector cabinet must be greater than the ohm reading measured at the loop detector at the junction box. SECTION 6 60 437 ALASKA 2020 b. Grounds. Test for grounds in each circuit by physically examining the installation to ensure that all required grounding bushings, bonding jumpers, and ground rods have been installed and are mechanically firm.
c.Insulation Resistance Test. Perform a megohm test on each circuit, between circuits, and between the circuit and a ground. Measure each detector loop and lead- in cable system at the traffic signal controller cabinet or at the detector cabinet between one loop detector lead-in conductor and the cabinet ground rod. Ensure the insulation resistance is not less than 100 megohms or the minimum specified by the manufacturer, measured at 500 volts DC. Disconnect all lamps and magnetometer sensing probes prior to the insulation resistance test. Document these tests in writing, for each circuit, and submit to the Engineer prior to acceptance of the system.
d.Inductance Test. Measure each detector loop and lead- in cable system at the traffic signal controller cabinet or detector cabinet. The inductance must be in the range of 50 to 500 microhenries.
e.Circuit. Energize every signal indication circuit with lamps installed before installing the load switches.
f.Func tional. Perform the following tests on each signal and lighting system after all of the component circuits have satisfactorily passed the tests for continuity, grounding, insulation integrity and circuitry.
1.Perform the functional test for each new traffic signal system by running at least 24 hours of flashing operation, followed by not less than 5 days of continuous, satisfactory operation. You may omit the flashing portion of the test for a modified signal system or if there was an existing signal maintain ed at this location during the construction activity. The Engineer and the final owner of the signal system will determine if the flashing operation will be required. If the system performs unsatisfactorily, correct the condition and repeat the test until the system runs for 5 days with continuous satisfactory operation. Do not start signal functional tests on a Friday, Saturday, Sunday, a legal holiday, or the day before the legal holiday. Initially turn on the system between 9:00 a.m. and 2:00 p.m. Before turning it on, ensure all equipment is installed and operable. This includes, but is not limited to, pedestrian signals and push buttons; signal face backplates and visors; vehicle detectors; highway lighting; and all regulatory, warning, and guide signs. Aim all signal faces as required by Subsection 660- 3.08.
2.Perform the functional test for each highway lighting system and sign illumination system until the systems burn continuously 5 days without the photocell, followed by a 5-day operational test usi ng the photocell.
3.Perform the functional test for each flashing beacon system for not less than 5 days of continuous, satisfactory operation.
4.Perform a continuous 5- day burning test on each pedestrian overcrossing and undercrossing lighting system before f inal acceptance. A shut down of the electrical system due to a power interruption does not constitute discontinuity of the functional test if the system is functional when the power is returned. 438 ALASKA 2020 8. Repairing Damaged Finishes . Examine all exterior surfaces for damage in the field, including new, reused, and State- furnished equipment. Repair damaged finishes as follows:
a.Galvanized. Repair damage to galvanized coatings in conformance with AASHTO M 36.
b.Painted.
1.Wash the equipment with a stiff bristle brush using a solution of water containing 2 tablespoons of heavy -duty detergent powder per gallon. After rinsing, wire brush all surfaces to remove all poorly bonded paint, rust, scale, corrosion, grease, or dirt. Remove any dust or residue remaining after wire brushi ng before priming.
2.You may use factory or shop cleaning methods for metals if equal to the methods specified herein.
3.Immediately after cleaning, coat all bare metal with pre- treatment, vinyl wash primer, followed by 2 prime coats of zinc chromate primer for metal.
4.Give signal equipment, excluding standards, a spot -finishing coat on newly primed areas, followed by 1 finishing coat over the entire surface.
5.Give ungalvanized standards 2 spot -finish coats on newly primed areas. You may apply all paint coats eit her by hand brushing or by approved spraying machines. Perform the work in a neat and workmanlike manner. The Engineer reserves the right to require the use of brushes for the application of paint, should the work done by the paint spraying machine prove u nacceptable.
660-3.02 Foundations .
1.Cast-in-Place and Precast Foundations . Use cast -in-place or precast, including cast -in-CMP, foundations for posts and poles in drilled or excavated holes. Use either precast or cast -in- place foundations for cabinets.
a.Form the entire controller foundation and the top 12 inches of pole or post foundations and give the top a smooth steel trowel finish. If foundation is precast, place the centerline of foundation at the station, offset, and elevation shown on the plans, and orient subsurface conduit stub for connection.
b.Place conduits in the center of the pole- post foundations with clearance allowed for bushings. If subsurface conditions prevent completing a drilled hole, and when approved, use a corrugated metal pipe (CMP) form as a substitute for the drilled hole. Consider the savings in concrete to offset the cost of supplying and installing the CMP form. No additional payment will be made for the CMP formed foundation.
c.When a CMP is used, over -excavate the area around the form enough to allow for proper compaction around the form. Backfill and compact according to Section 205, and Subsections 203- 3.04 and 660- 3.01. Use Select Material Type A or sand slurry as backfill material. Do not use water for drilling operations or for any other purpose where it may enter the hole.
d.Use controller cabinet anchor bolts as recommended by cabinet manufacturer and set with a template.
e.Place Class A concrete meeting Section 501. Place reinforcing steel meeting Section 503. If required, us e corrugated steel pipe that is at least 14 gage, meeting Subsection
707-2 01.
SECTION 6 60 439 ALASKA 2020 f. Drill holes or use forms that are vertical and true to the locations shown in the Plans. When foundation excavation is complete, but before placing the concrete, remove all loose material to ensure that the foundation rests on firm, undisturbed ground.
g.If a reinforcing steel cage is required, place and secure it symmetrically about the vertical axis and securely block it to clear the sides of the foundation. Use a template to sec urely support all anchor bolt assemblies and conduit ends so they do not move during concrete placement. Protect anchor threads from contact with concrete during pour.
h.Do not permit surface water to enter the hole. Before placing concrete, remove all water that may have infiltrated in the hole. Thoroughly moisten both the forms and the ground before placing concrete. Pour each foundation in one continuous pour.
i.Do not erect or place posts, poles, and pedestals on the foundation until 7 days after placing t he concrete. Plumb the assembly according to Subsection 660- 3.08 by adjusting the nuts on the anchor bolts.
j.Replace, with no additional compensation, all finished concrete pile caps with anchor bolts that do not match the base plate of the pole or are out of plumb. Do not modify the anchor bolts or base plate to get the base plate set on the leveling nuts.
k.Install the bottoms of the bottom leveling nuts in a level plane within one inch of the top of concrete pile cap. Generously lubricate the bearing surfac e and internal threads of all top nuts with beeswax and tighten the top nuts according to the following:
1.Luminaire poles on frangible couplings: frangible coupling manufacturer’s instructions
2.Signal poles and luminaire poles without frangible couplings: Table 660- 1. TABLE 660 -1. TOP NUT ROTATION FOR TURN- OF-NUT PRETENSIONING OF DOU BLE-NUT MOMENT CO NNECTIONS Anchor Bolt Diameter, in. Nut Rotation beyond Snug Tight a,b,c F1554 Grade 36 F1554 Grades 55 and 105, A449, A615, and A706 Grade 60 ≤1 ½ 1/6 turn 1/3 turn >1 ½ 1/12 turn 1/6 turn
a.Nut rotation is relative to anchor bolt. The tolerance is plus 20 degrees (1/18 turn)
b.Applicable only to double-nut moment connections.
c.Use a beveled washer if the nut is not in firm contact with the base plate or if the outer face of the base plate is sloped more than 1:40.
3.High-tower lighting structures: Use direct -tension- indicating (DTI) washers to achieve anchor bolt preload as shown on the plans.
2.Pile Foundations .
a.Install pipe piles according to Sect ion 505.
b.Install pipe piles open- ended and to a minimum depth of 15 feet (less top projection).
c.Use CJP groove welds for all circumferential welds.
d.Inspect 100 percent of CJP welds using UT or RT. 440 ALASKA 2020 e. Backfill and compact the work hole around upper portion of each pile in 8- inch lifts with a soil-cement mixture. (minimum of 3 sacks of cement per cubic yard of soil).
f.Certify steel pipe piles by matching the stencils on the pipe piles (by 300 foot lots) to the physical and chemical tests for the applicable lot.
3.All Foundations .
a.When shown on the plans, install frangible couplings according to the manufacturers written installation instructions. Use shims furnished by the coupling manufacturer.
b.Provide new foundations and anchor bolts of the proper type and size for standards that are to be relocated. Install the anchor bolts on a bolt circle that matches the base plate.
c.Install a raised Type III junction box on the door side of the controller cabinet, and butt it against the cabinet’s foundation unless installing a one-piece cabinet/junction box foundation. Extend the top of the controller cabinet foundation 18 inches above the junction box and provide it with a 1- inch diameter drain. The drain connected to the cabinet interior must empty to the rear and above the ground. Place all conduits in the door side half of the foundation to provide adequate terminal block clearance. For one- piece cabinet/junction foundations, place the junction box opening at the elevation and orientation shown on the plans. For cabinets w ith two doors, place conduits in each half - cabinet to provide adequate terminal block clearance.
d.Existing foundations may be abandoned- in-place. However, remove the tops of the foundations, reinforcing steel, anchor bolts, and conduits to at least 12 inc hes below the roadway subgrade, sidewalk, or unimproved ground. Backfill the resulting hole with material equivalent to and compacted to the density of the surrounding ground.
660-3.03 CONDUIT . Install electrical conductors in conduit, except for overhead wiring, wiring
inside poles, and when otherwise specified. Use galvanized conduit and fittings that are rigid metal type and manufactured of mild steel or wrought iron.
1.If called for in the Plans, use rigid non- metallic type conduit. Where nonmetallic conduit is to be installed, use a rigid metal type conduit to run between a load- center and the nearest junction box. Use conduit routing as noted or detailed on the Plans; when it is not shown, use the routing as directed.
2.If conduit and fittings to be insta lled will be exposed to sunlight on the surfaces of poles or in structures and foundations, use rigid metal type.
3.Thread and ream the ends of all conduits, whether shop or field cut, to remove burrs and rough edges. Make cuts square and true so that the ends butt together for the full circumference. Do not use slip joint or running threads for coupling conduit. When a standard coupling cannot be used for coupling metal type conduit, use an approved threaded union coupling. Where the coating on ferrous metal conduit has been damaged, paint such damaged places with rust preventative paint.
4.Until wiring is started, cap all conduit ends with standard pipe caps or approved plug and coupling combinations. When caps are removed, provide the threaded ends with appr oved conduit grounding bushings.
5.Bury conduit at least 30 inches below the finished grade. However, under paved areas behind a curb, bury the conduit at least 18 inches below the top back of curb or abutting pavement, whichever is lower. See Subsection 660- 3.01.3 for backfill requirements. SECTION 6 60 441 ALASKA 2020 6. Install rigid metal conduit under existing pavements which are 30 feet wide or less by jacking. Unless trenching is called for in the Plans, install conduits under existing pavements greater than 30 feet wide by boring or drilling methods.
7.When encountering obstructions during jacking or drilling operations, obtain approval and cut small test holes in the pavement to clear the obstruction. Locate the bottom inside face of the borepit no closer than the catch point of a 1- 1/4:1 slope from the edge of pavement. Do not leave these pits unattended until the means of protection has been approved.
8.Keep the bottom of trenches for non- metallic conduit relatively free of sharp irregularities that would cause pinching and excessive bending of the conduit.
9.Ensure that the first 6 inches of backfill is free of rocks exceeding 1 inch maximum dimension.
10.Terminate the conduit entering the bottom of concrete junction boxes with a 90- degree sweep inside the box wall. Terminate conduit open ings not less than 5 inches above the bottom of all boxes, a minimum of 6 inches below the top of the Type IA boxes, and 12 inches below the top of Type II and Type III boxes. Extend conduits entering through the junction box wall a minimum of 2 inches bey ond the inside box wall, and ensure it is a minimum of 6 inches above the bottom of the box.
11.Furnish foundations with conduits as shown on the Plans. Extend the conduits a maximum of 2 inches vertically above the foundation and slope towards the handhole opening.
12.At low points in all conduit runs, install a drain and sump containing approximately 2 ft 3 of coarse concrete aggregate material. Compact aggregate used for sump as directed to prevent settlement of foundations, junction boxes, or adjacent improvem ents. Place additional drains adjacent to all junction boxes and structures, regardless of the method of conduit placement used. The drains must be a 3/8- inch hole drilled in the bottom of the lower straight section of the sweep elbow. Prevent scraping of conductors by deburring drilled drain holes in conduit. Wrap the exterior of the hole with approved filter cloth material and secure it as directed or approved by the Engineer.
13.Provide conduits for future use with grounding bushings, bonded to ground, and capped with an approved plastic insert type plug. Install a polypropylene pull rope with 200 pound minimum tensile strength in all conduits that are to receive future conductors. Double back at least 2 feet of pull rope into the conduits at each end.
14.Mark all underground conduit with a continuous strip of polyethylene marker tape that is 4 mils thick and 6 inches wide. Mark the tape with a black legend on a red background and bury it 9 inches (±3 inches) below the finished grade. Lay two strips of marker tape side- by- side under all road crossings.
15.Where new junction boxes are placed in existing rigid metal conduit runs, fit the conduit with threaded bushings and bond them.
16.Seal the conduit leading to soffit, wall, or other lights or fixtures below the grade of the junction box by using an approved sealing fitting and sealing compound.
17.Clean existing underground conduit to be reused in the new system before pulling in the new cables , as follows:
a.Conduits with reused conductors. Wherever the Plans show reusing existing conduits that contain in service cables, clean them using compressed air. Existing cables that will be reused may be left in the conduits while you clean them. 442 ALASKA 2020 b. Conduits with no reused conductors. Ream with a mandrel or cylindrical wire brush and blow out with compressed air.
c.Use a heavy -duty air compressor that delivers at least 125 cubic feet per minute of air at 110 psi.
18.Use conduit of larger size than shown on the Plans, when desired. If used, it must be for the entire length of the run from junction box to junction box. Reducing couplings are not allowed. Increase the size of the junction boxes and perform any additional work at the foundations due to the use of larger size conduit, without extra compensation.
19.Conduits may require routing under or over existing culverts or storm drain systems and other underground utilities with additional drains and aggregate sumps at the low spots.
20.When extending existing conduits or installing junction boxes in existing conduit runs, extend the conduit into the proposed junction box or foundation using drains, elbows, and bonding as required for new installations. When adjusting junction boxes, shorten or lengthen existing conduits to meet clearance requirements. Complete extensions and modifications to exist ing conduits using the same size and types of materials.
21.Cut off abandoned conduits flush with the inside wall or bottom of junction boxes.
22.Install expansion fittings, as detailed on the structure plans, where the conduit crosses an expansion joint in the structure. Provide each expansion fitting with a bonding jumper equivalent to a stranded, No. 6 AWG, copper wire, or equivalent copper braid. Use expansion- deflection fittings that are waterproof and permit a 3/4 inch expansion and contraction and a 3/4 inch deflection without deformation.
660-3.04 JUNCTION BO XES. Furnish pre- cast reinforced concrete junction boxes of the sizes
and details shown on the Plans. Use cast iron lids. Emboss the word TRAFFIC on the lids of all junction boxes that contain any traf fic signal conductors. Emboss the word LIGHTING on the lids of all other junction boxes. Install junction boxes at the approximate locations shown on the Plans or when a location is not specific, locate the junction boxes as directed. You may, at your expense, install additional junction boxes to facilitate the work. Locate junction boxes so they are not in the roadway, sidewalk, or pathway surfaces. Where practical, place junction boxes shown in the vicinity of curbs adjacent to the back of curb with their long dimension parallel to the curb. Do not locate junction boxes in drainage collection areas. Effectively ground the covers of all junction boxes with metal covers. Use a 3- foot tinned copper braid for Type IA Junction Boxes and a 6- foot tinned copper braid for Type II and Type III Junction Boxes. Bed the entire bottom of all junction boxes on coarse concrete aggregate material of a minimum depth of 18 inches. Place the top of junction boxes flush with the sidewalk grade or top of adjacent curb. When located in an unpaved section adjacent to a paved shoulder, locate the junction box 1 inch below the finished grade. Install flush with the surface in paved areas. Adjust as directed the junction boxes located in areas requiring grading. Adjust junction boxes located in seeded areas to 2 inches below the surface. Locate junction boxes immediately adjacent to the pole or fixture they serve with the following limitations: SECTION 6 60 443 ALASKA 2020 1. 300 feet maximum for any single cable conduit run or any conduit run that exclusively contains 2 or fewer 2/C No. 12 AWG loop lead- in cables.
2.190 feet maximum for any other conduit runs.
3.If the limitations require additional junction boxes, locate them on equal spacing subject to the above limitations.
660-3.05 WIRING. Install power conductors s erving the cabinet sized such that their ampacity
rating is greater than the cabinet total connected load. Make wiring neat in cabinets by cabling wires together with self -clinching nylon ties. Terminate all spare conductors on terminal blocks. Attach all conductors, including spares, to terminal blocks with “spade” type terminal lugs. Furnish additional terminal blocks if enough locations are unavailable in existing terminal blocks. Do not splice conductors within cabinets, poles, signal heads, and luminai res. Pull conductors into conduit only after junction boxes are set to grade, crushed rock sumps are installed, grout is placed around the conduit, and grounding bushings have been installed on all conduits .
1.Pull conductors by hand or by approved commercially built cable -pulling equipment that is specially designed for that purpose. Do not pull cable by any other means. Equip the cable pulling device with a force limiting circuit and force gauge.
2.Use wire -pulling lubricant when placing the cables and conductors in conduit. Do not allow the tension of the wire or cable to exceed the manufacturer’s recommend allowable tension for the conductor or cable.
3.When adding new conductors to a conduit with existing conductors, remove all conductors and clean the condu it with a mandrel or brush. Pull both old and new conductors through as a unit. In a new installation, pull all conductors through the conduit as a unit.
4.Leave at least 1 foot of slack in the bottom of each signal or combination signal and lighting pole of each signal conductor or cable. Neatly leave at least 3 feet of slack illumination and signal conductor or cable curled up in the bottom of each junction box or splice location.
5.Separate the neutral for pedestrian push button circuits from the signal light circuit neutral.
6.Run all signal and feeder conductors continuously without splices from a terminal block located in a cabinet, compartment, or signal head, to a similarly located terminal block. When modifying an existing signal system, splice existing c onductors (cables) to new conductors (cables) as required to complete the signal, opticom, and interconnect systems. Make these splices only in pole bases, signal terminal compartments, or the controller cabinet.
7.Route highway illumination cable through each lighting pole designated for connection to that cable’s circuit. Do not splice illumination cable between a load center and a pole or between poles. Join the individual conductors by using non- insulated, overlap type pressure connectors. Insulate with m astic-lined heat shrink tubing or 2 layers of one- half lapped UL listed electrical tape. Do not use wire binding screws, studs, or nuts. Stagger splices to minimize the overall diameter.
8.Install all loops in 1- inch rigid schedule 80 PVC conduit in the road way and to the nearest junction box. Run loop lead- in cable continuously without splices from the controller cabinet to the curbside detection junction box nearest the loop being spliced to the lead- in cable. Splice the loop(s) to the lead- in cable by sold ering at the junction box and encapsulating in a waterproof splice kit. 444 ALASKA 2020 Multiple loop configurations must have the individual lead- ins, multiple pair, or single pair brought to the controller cabinet for termination. Make series connection of loop lead- ins in the controller cabinet only. Wind all loops in the same direction with the starting lead marked with an “S.” Connect the black conductor of the pair shown in Table 660- 2 to the “S” designated conductor of the loop. Connect multiple loop detectors in the same lane so that the adjacent loops are in alternating directions clock wise (CW), counter clock wise (CCW), etc.
9.When splicing loop detectors to multi -pair loop lead- in cables, complete the work according to the following.
a.See the Plans for the identi fying number assigned to each loop detector and the loops assigned to each loop lead -in cable. Using this information, splice the loop detector tails to the paired conductors found in each lead- in cable, using the color code in Table 660- 2. TABLE 660 -2 MULTIPLE PAIR LOOP LEA D-IN COLOR CONNECTIO N SCHEDULE
b.Remove a short section of cable jacket and only cut the shielded pairs dedicated to loop detectors being spli ced. Run these pairs, without splices, to the controller cabinet.
c.Strip the insulation from the ends of the conductors. With the loop and lead- in conductors parallel to one another, twist the bare ends together and then solder them together.
d.Insulate and s eal each soldered connection with a mastic lined heat shrink tubing; crimp the ends of the heat shrink tubing with a pair of needle nose pliers.
e.First, crimp and then solder spade terminals to the ends of the shielded pairs in the controller cabinet.
10.Maintain the electrical isolation between shields and do not allow the drain wires to come in contact at any point other than the ground bus in the cabinet. Tie all drain wires to the ground bus at the controller cabinet.
11.Encapsulate illumination cable conduc tor splices in a rigid, 2- piece, transparent, snap together, plastic mold specifically designed for each splice type. Encapsulate all loop lead- in cable splices in rigid, transparent, PVC molds filled with re- enterable polyurethane electrical insulating and sealing compound. Furnish splice kits rated for 1000 volts AC operation and direct burial. Provide re- useable four piece molds that are held together with stainless steel hose clamps. Two pieces form a cylinder and two flexible end caps seal the ends an d allow the conductor entry. Use molds with dimensions suitable for the splice made, encase the cable jackets, and have fill and vent funnels. Insert a loose woven polyester web that allows a full 1/4 inch of insulating compound to flow between the splice and the inside of the mold. Fill the PVC molds with re- enterable Loop Detector Number Colored Pair The lowest numbered loop detector Red and Black The second lowest numbered loop detector Blue and Black The third lowest numbered loop detector White and Black The fou rth lowest numbered loop detector Green and Black The fifth lowest numbered loop detector Brown and Black Usually a spare pair Yellow and Black SECTION 6 60 445 ALASKA 2020 polyurethane electrical insulating and sealing compound that cures transparent, is nontoxic, is non- corrosive to copper, and does not support fungi or mold growth.
12.Use molds with dimensions suitable for the splice, to encase the cable jackets, to be rated for 600 volts, and have fill and vent funnels for epoxy resin. Fill the splice mold bodies with epoxy resin that is resistant to weather, aromatic and straight chain solvents, and that will not sustain combustion. When filling the mold bodies of loop lead- in and telemetry cable splices, use a compound that provides re- entry capabilities.
13.Permanently identify all cables and single wire conductors by labeling all pole bases and cabinets, at eac h detector loop tail/lead- in cable and illumination cable splices, and in junction boxes adjacent to lighting and signal poles. When modifying an existing system, label all new and existing lighting cables/conductors with circuit numbers at locations noted above. If the existing circuits are not identified, the Engineer will provide the required circuit numbers.
14.Label the cables used in the signal and illumination systems with the following legends:
a.Use the legends included in Table 740- 2, for the cables l isted.
b.Use the loop number shown on the Plans to label each tail of all loop detectors and the paired loop lead- in conductors in the controller cabinet.
c.For interconnect cables, use the first letter of the direction the cable follows to the adjacent inters ection on each cable. Add a number suffix if more than one cable is routed to the adjacent intersection.
15.Furnish the two types of identification tags listed below that feature hand written legends. Write the legends specified neatly and legibly, using a bl ack marking pen recommended by the tag manufacturer. Replace at no expense to the State all identification tags the Engineer deems illegible.
a.Use identification cable ties for labeling loop detector tails and the paired conductors included in each loop lead -in cable in the controller cabinet. Furnish identification cable ties made of nylon that feature a nonmagnetic stainless steel locking device embedded in the head and a tag attached "flag style" to the head. Use cable ties consisting of a single strap wi th a minimum size tag of 3/4 inch by 3/8 inch.
b.To label all other cables, use cable tags made of nylon reinforced vinyl impervious to the elements and which will not tear. Provide tags with a 4 inch by 1- 3/4 inch minimum size that attach flag style at one corner to a single strap. Furnish yellow tags for labeling all signal and interconnect cables and red tags for labeling lighting and feeder cables.
16.Terminate the control and power cables as shown in Table 740- 2.
17.Connect telemetry cable to a Type No. 66B3- 50 terminal block. Start the wiring at the top with Pair No. 1. Connect the incoming cable from the computer to the left side of the terminal block, and connect the outgoing cable to the next intersection to the right side.
18.Wire luminaires using No. 10 AW G illumination tap conductors that run from the fused disconnect kit in the pole base. Install a fused splice connector between the line and luminaire ballast tap conductors in the base of every pole equipped with a luminaire. Attach the conductors to the connector halves with setscrew type pressure connectors. Provide the plug and socket assembly so that the fuse remains in the load side plug without 446 ALASKA 2020 exposing live metal parts when the connector separates and the coil springs are not included in the current carrying circuit. Make the fused connectors readily accessible from the handhole. Install tap conductors to prevent slack when their ends touch the top of the foundation.
660-3.06 BONDING AND GROUNDING. Make the following mechanically and electrically
secure: metallic cable sheaths, metal conduit, non- metallic conduit grounding wire, ballast and transformer cases, service equipment, sign switches, pedestrian push buttons, metal poles, and pedestals. Normally non- current -carrying conductive materials enclos ing electrical conductors or equipment, or forming part of such equipment, must be electrically connected to earth ground, and must be connected together and to the electrical supply source in a manner that establishes an effective ground- fault current pat h. All installations must comply with the grounding and bonding requirements of NEC Article 250. Install main or system bonding jumper as applicable at the service as required by NEC Article 250. Install copper grounding electrode conductors (GEC), size d per NEC Table 250.66, or #6 AWG, whichever is larger. Install copper equipment grounding conductors (EGC) for each circuit or raceway, sized per NEC Table 250.122, or #12 AWG, whichever is greater. Where conduits are installed for future conductors, the EGC may be omitted. Furnish threaded- type grounding bushings made of malleable iron or steel with a zinc or galvanized finish. Use bushings with an insulated throat, a tin- plated copper saddle for attaching the grounding conductors, and stainless steel s et screws. Retrofit all existing spare conduits that will contain new cables exclusively with new grounding bushings. Whenever you reuse an existing conduit that contains no EGC, install a bare or insulated size 8 AWG copper wire as the EGC. Where conduits are installed for future conductors, the above mentioned copper wire may be omitted. Install a bare or insulated copper conductor in all conduit as the EGC. Attach grounding conductors to each end of the metal conduit using insulated throat grounding bush ings. Leave 12 inches of slack between each grounding bushing. Allow clearance for bushings when installing conduits in foundations. Bond breakaway type standards and pedestals by using 2 conductors from the conduit, one attached with a ground rod clamp to an anchor bolt and the other connected to the lower portion of the shaft. Bond standards with frangible coupling type bases by attaching one conductor from the conduit to the lower portion of the shaft. Use conductor from the conduit to the shaft that is 48 inches long. Solidly ground one side of the secondary circuit of a transformer.
660-3.07 TRAFFIC CON TROLLER ASSEMBLIES. Prepare each solid- state, traffic controller
assembly to operate various traffic signal devices as shown on the Plans. The controller must provide right -of-way, clearance, and other indications using duration and sequence as determined by preset programming. Details of operation for the complete controller assembly must be according to the traffic phases; preferential phase sequence and concurrence; signal indications; signal indication sequence; detection requirements; and other details shown on the Plans or as specified herein. At the time the controller cabinet and equipment are delivered for testing, or if ordered prior to purchase, submit the following for each controller assembly called for in the Plans:
a.Two blackline sets of controller cabinet schematic wiring diagrams SECTION 6 60 447 ALASKA 2020 b. Two copies of the manufacturer’s maintenance and operations manuals for the equipment in the cabinet The schematic wiring diagrams must show all circuits and parts in detail. Clearly identify all parts by name or number. Submit the final wiring diagrams for each controller assembly in an AutoCad Drawing Interchange File format (DXF, DWG, etc.). Use only the default font style and line type distributed with a basic AutoCad package.
1.Shop Tests . Deliver the controller units, auxiliary equipment, and fully wired cabinet (including wiring diagrams and manuals) to a designated test location. All items must arrive together. Partial shipments will not be accepted and will be returned to the vendor. Allow 6 weeks for shop testing. All equipment must meet the operational and functional requirements of the Plans and Specifications when tested according to NEMA Standard TS 1- 1989, Traffic Control Systems . If a partial failure occurs at any step in the test (physical, environmental, or operational), you may make on- site repairs within 10 days after notification of the malfunction. The test will then be restarted at the beginning of t he category in which malfunction occurred. Failing to make repairs within 10 days after notification will result in rejection. If equipment malfunctions twice in the same category, the equipment will be rejected. When equipment is rejected, return the ent ire package (including the cabinet) freight collect to the vendor. Submit the new equipment, with a different serial number, for testing. Do not use rejected equipment on signal projects within the State of Alaska. Testing after equipment rejection for fai lure to comply with specification requirements will be at your expense. The Department will make deductions to cover the costs of such testing from any moneys due or which may become due to you under this Contract. A failure is any occurrence that results in other than normal equipment operation. The equipment is considered to have failed if any of the following occur:
a.The controller unit malfunctions
b.The load switch produces incorrect signal indications
c.The signal conflict monitor fails to satisfy the contract requirements After the shop test is satisfactorily completed, you will be notified to pick up the tested and marked equipment at the test site. Pick up the successfully tested equipment within 2 weeks of notification and deliver to the work site. Suc cessful test completion does not relieve you of equipment warranty obligations as specified in Subsection 660- 2.01.3 or field testing as specified in Subsection 660 -3.01.7. Copies of shop test results will be sent to you, the vendor, and the State Material s Engineer.
2.Controller Cabinet Installation.
a.Where the cabinet is mounted on a concrete pedestal foundation, place a 1- inch drain hole or pipe with screen in the foundation, connecting to the cabinet and emptying above the ground line.
b.Place a 3/8- inch fil let of silicone caulking between each controller cabinet and the concrete slab foundation to prevent dust and dirt from entering the cabinet. 448 ALASKA 2020 c. When called for in the Plans or Special Provisions, add 2 inches of approved foam insulation within the bottom of the cabinet between the control equipment and the concrete base. Design all wiring, terminals, and other items to allow sufficient room for the insulation.
d.On Precast Controller Foundations. When called for in the Plans or Special Provisions, place a 3/8- inch thick, 2- piece exterior grade plywood board on the bottom of the cabinet and under the foam insulation. Place the plywood within the controller cabinet, and do not extend under it. Make holes to allow for the conduits entering the cabinet. Place a pliable sealant composed of a silicon caulking compound between the plywood board and the cabinet and between the plywood board and all the conduits.
e.Place a ground rod in the Type III junction box next to the cabinet or in the foundation of the cabinet if it is precast foundation.
f.See Subsection 660- 3.05 and Section 740 for wiring requirements.
3.Controller Operation . Provide the following operations.
a.Wire the controller cabinet to flash the yellow signals on the main street or highway, and the red signals on the cross streets and left turn lanes.
b.Make the flashing circuit independent of the controller unit. They must remain in operation upon shutdown of the controller or removal of the controller from the cabinet.
c.Wire the controller cabinet so that removal of the conflict monitor causes the intersection to go into flashing operation.
d.Accomplish transfer to flashing operation by relays between the normal load switching device and the field terminals.
e.Do not operate pedestrian pushbuttons at more than 24 volt s.
f.Controller Priorities. Prioritize the drives, controls and equipment so that each device, control, or item of equipment overrides the operation of those items listed below it:
1.Power failure
2.Power restart
3.Flashing
4.Railroad preemptor
5.Emergency vehicle preemptor
6.Phase selector
7.Interconnect
8.Time switch
9.Normal controller unit operation
4.Preemption. Provide the following preemption operations when called for on the Plans or as specified in the Special Provisions. SECTION 6 60 449 ALASKA 2020 a. General. Preemption units must use the controller unit functional inputs and timings to the largest extent possible. Signal load switching control must remain with the controller unit.
b.Railroad Preemption. The Railroad Preemption Routine must consist of 4 functional intervals in the order listed below:
1.Enter Preemption Interval.
a.Energize a 120 VAC alarm circuit which may be used for a sign, bell, or beacon.
b.Immediately advance to the pedestrian clearance interval of any walk that is being displayed. On any phase other than the track clearance phase(s), abbreviate the pedestrian clearance interval by a timer with a minimum range of 0-30 seconds.
c.Following the pedestrian clearance period, the controller must advance into and time normally the vehicle clearance intervals.
d.If the preemption is received while in the track clearance phase(s), skip step
b.and (c) above.
2.Track Clearance Interval.
a.Provide a timing period to allow sufficient green clearance time for any vehicles that may be stopped on or immediately behind the railroad tracks. The timing must be adjustable over a range of 0 to 30 seconds.
b.Following the track clearance period, the controller must advance into and time normally the vehicle clearance interval(s).
3.During Preemption Interval. Allow the controller to operate normally with the exception of not serving those phases that conflict with the railroad crossing. Keep this interval in effect until the preemption call is removed.
4.Leaving Preemption Interval.
a.De-energize alarm circuit.
b.Immediately advance to the active phase normal pedestrian and/ or vehicle clearance interval(s).
c.The controller must advance to those phases that were omitted under preemption control when complete control is returned to the controller unit.
c.Emergency Equipment Preemption. The Emergency Equipment Preemption Routine must consist of 3 functional intervals in the order listed below:
1.Enter Preemption Interval.
a.Energize a 120 VAC alarm circuit which may be used for a sign, bell, or beacon.
b.Immediately advance to the pedestrian clearance interval of any walk that is being d isplayed. On any phase other than the track clearance phase(s), abbreviate the pedestrian clearance interval by a timer with a minimum range of 0-30 seconds. 450 ALASKA 2020 (c) Following the pedestrian clearance period, the controller must advance into and time normally the vehicle clearance intervals.
d.If the preemption call is received while in the preempt phase(s), skip step (b) and (c) above.
2.Preempt Phase Interval. Hold the controller in the preempt phase(s) until the call is removed.
3.Leaving Preemption Interval. When the preemption call is removed, the controller unit must immediately revert to normal operation.
660-3.08 SIGNAL AND LIGHTING STRUCTURES. Install signal and lighting equipment
according to the details shown on the Plans and the following: Remove all burrs and sharp edges from inside and outside of all holes before passing conductors through the walls of posts, poles, mast arms, signal heads, and other equipment. Install photoelectric control units to face the north sky. When installed on the top of steel poles, install the bracket in the center of the rain cap. Secure it with a locknut and make watertight with a fillet of silicone caulking compound. When installed on wood poles or Type 1 or 1A Load Centers, couple the bracket to the end of a rigid metal condui t.
1.Electrolier Installation . Before installation, check the socket position in the luminaire to verify that it corresponds to the setting indicated in the instructions for the light distribution type shown on the Plans. Set the pole with a slight rake, by plumbing the side of the tapered pole away from the road. After the pole has been plumbed, level the luminaire as recommended by the manufacturer.
2.Wood Pole Installation. Place the poles in the ground to at least 6 feet deep. After setting each wood pole in the ground, backfill the space around the pole with selected earth or sand, free of rocks 4 inches or larger, or deleterious material. Place in layers approximately 4 inches thick and thoroughly compact with mechanical tampers. Provide overhead equipment a minimum vertical clearance of 18 feet from bottom of equipment to the pavement.
3.Signal Pole Installation . Install signal poles so the side opposite the mastarm, or combination of mastarms, is vertical in its final deflected position. Provide a 1- inch drain hole in the grouted base. Run this drain from below the top of the conduits to outside of the grouted area.
4.Signal Head Mounting. Support bracket mounted signal heads, as shown on the Plans, by mounting brackets consisting of watertight assemblies of 1 -1/2 inch nominal diameter standard steel pipe and malleable iron or brass pipe fittings. All members must be either plumb or level, symmetrically arranged, and securely assembled. Construct these so that all conductors are concealed within the assembly . Attach vehicle and pedestrian signal head mounting hardware to the side of pole that faces away from traffic. Aim through- phase vehicle signal faces at a point located a distance from the face as shown in Table 660- 3. If 2 through -signal faces are not vi sible from this point at a height of 42 inches above finished grade, consult the Engineer for corrective measures. SECTION 6 60 451 ALASKA 2020 Direct pedestrian signal heads at the center of the crosswalk on the opposite side of the street. TABLE 660 -3 THROUGH- SIGNAL AIMIN G POINT The horizontal dimension between the center of a terminal compartment or axis of a signal face and the axis of an immediately adjacent signal face must be a minimum of 22 inches in side mounted frames and 11 inches in post top installations. At each signal location, construct a terminal compartment into the mounting brackets. Fit each compartment with a terminal block containi ng 12 poles, each with 2 screw -type terminals. Each terminal must accommodate at least 3 No. 14 AWG conductors. Provide a rain-tight cover, giving ready access to the terminal block. Provide a bronze terminal compartment of sufficient strength to remain intact in event the pole is knocked down. Provide cast -iron slip -fitters, where used without integral terminal compartment. For post -top mounting of bracket mounted signals, cast the terminal compartment with an integral slip- fitter. For post -top mounting of a 1 way signal head, you may use a slip- fitter without a terminal compartment. The slip- fitter must fit over a 4- inch standard pipe or 4- 1/2 inch outside diameter end of tapered standard. Provide each slip- fitter with 2 rows of cadmium plated steel set sc rews, with 3 screws in each row to secure the assembly in plumb position. Where signal heads are side mounted on poles, the terminal compartment must be designed for and securely bolted to the pole. Mount pole side mounted pedestrian and traffic signal heads on the back side of pole unless noted or detailed otherwise on the Plans. Mount the pole/post mounted traffic signal heads so that no portion of the backplates are hidden by the pole/post. Equip the signal heads with positive brass lock rings and fitti ngs designed to prevent heads from turning due to external forces. Lock ring and connecting fittings must have serrated contacts. Equip signal head assembly for suspension from mast arm with a ferrous or bronze plumbizer. Do not mount signal heads within 12 inches either side of a mast arm extension splice. Do not install signal heads at any intersection until all other signal equipment, including the controller, is in place and ready for operation at that intersection, unless the faces are not directed tow ard traffic or unless the faces are adequately covered. Side-mount pedestrian signals using a 2- piece, hinge connected, cast aluminum bracket that mounts directly between the pole and the side of the signal head housing. Limit clearance 85th Percentile Speed (mph) Minimum Visibility Distance (feet) 20 175 25 215 30 270 35 325 40 390 45 460 50 540 55 625 60 715 452 ALASKA 2020 between the head and pole to 3 inches. The bracket must properly fit round poles 4 inches or greater in diameter and allow a minimum rotation of 30 degrees when mounted on a 4- inch pole. Include a rain- tight 12 -position terminal block within the mounting bracket.
5.Pedestrian Push Button Installation. Install the push button and sign on the crosswalk side of the pole. Install indicator lights when specified. Pedestrian push button signs must conform to the details in the ASDS. Install push button signs and The Meaning of Pedestrian Signals stickers, R9- 4, above each push button. Use R10- 4B (R or L) push button signs with the arrow pointing in the direction of the appropriate crosswalk. Install the sticker immediately above the push button and below the sign. When channel is us ed for mounting push button signs, tap the top and bottom sign bolts into the pole.
6.High Tower Lighting System Installation . Install the high tower poles as recommended by the manufacturer. Provide the erection plan to the Engineer prior to installing poles. Attach the luminaire to the bracket arm by means of a bracket entry and lamp support assembly. Install the lowering system including head frame, luminaire support ring, winch(s), hoisting assembly, and electric motor. Adjust the luminaire reflectors unt il all are oriented in the same direction and they provide the asymmetrical light distribution pattern shown on the illumination sheets.
7.Underpass Lighting System Installation . Mount the fixture as detailed on the drawings so that the axis of the lamp is perpendicular to the axis of the underpass.
8.Flashing Beacon Installation. When installing flashing beacons adjacent to or in conjunction with a traffic signal system, install the flasher control in the controller cabinet.
660-3.09 MAINTAINING TEMPORARY AND EXISTING ELECTRICAL SYSTEMS. Keep in
effective operation during the progress of the work all existing electrical systems (traffic signal, highway and street lighting, flashing beacon, and sign illumination), and approved temporary replacements except when shutdown is permitted to allow for alterations or final removal of the systems. Temporary replacement equipment must be compatible with existing equipment used in the Region. Limit traffic signal shutdowns to the period Sunday through Thursday between the hours of 9:00 p.m. to 6:00 a.m., unless otherwise specified in Subsection 643- 3.08. Do not allow lighting system shutdowns to interfere with the regular lighting schedule. Obtain written approval before performing any work on existing systems. Notify the l ocal traffic enforcement and maintenance agencies at least 24 hours before the operational shutdown of a traffic signal system. Provide necessary traffic control under Section 643. Where an existing system is being modified, the Department will pay for wor k not shown on the Plans or Special Provisions that is considered necessary to keep all or part of the existing system in effective operation as extra work as provided in Subsection 109- 1.05. Once commencing work on the project, provide all maintenance for temporary and existing electrical facilities. The State will pay for the electrical power for the above mentioned electrical systems. The above maintenance does not include previous damage such as burned out lamps, non-operative detection, or other malfunctioning equipment. Present written documentation of all non-functioning and malfunctioning electrical equipment before commencing work on the project. You and the Engineer will inspect this equipment jointly. If work begins on the Project and the SECTION 6 60 453 ALASKA 2020 Engineer does not receive written notice, this is considered evidence that all equipment is functional and operational. Give the Engineer the name and 24- hour phone number of the person maintaining the existing and temporary electrical facilities. Commence repair work within 1 hour of notification for traffic signal systems. Ascertain the exact location of existing conduit runs, direct burial cable, junction boxes, and all underground utilities before using equipment that may damage such facilities or interfere wit h any system. Where roadways are to remain open to traffic and existing lighting systems are to be modified, complete work each day so the lighting system will be in operation by sunset. When you work on a traffic signal system, keep a record of all work performed in a diary located in the controller cabinet. Furnish a diary for each temporary system. Make sure each entry is printed legibly and includes:
1.The dates and times you began and completed your work, and the names of the crewmembers completing the work.
2.The characteristics of the equipment failure or faulty operation evident before repair.
3.The changes made or corrective actions taken.
4.The printed name and signature of the person responsible for making the repairs or changes. Keep temporary electric al installations in effective operation until they are no longer required. Salvage all original and Department -provided equipment according to the provisions in Subsection 660- 3.01.6 and remove all other materials from the project.
660-3.10 FALSEWORK L IGHT ING. When required by the Special Provisions, install falsework
lighting where vehicular traffic with or without pedestrian traffic crosses through or under structure falsework. Provide illumination of the portal faces of falsework during the hours from dusk to dawn. Provide illumination of the pavement and pedestrian openings through or under falsework 24 hours a day. Submit a plan for the proposed lighting installations and do not commence falsework construction until the Engineer has reviewed such plans. The Engineer will make a subsequent review after you place falsework lights in operation. Falsework lighting equipment remains your property and must be removed from the site of the work upon completion of the project or when directed.
660-4.01 METHOD OF MEASUREMENT. See Section 109 and the following:
Item 660.0009.____, Bored Casing . By the linear foot along the slope of the bored or jacked casing for the actual length bored or jacked, in place. Item 660.0011.____, Traffic Loop. By each loop unit, complete and in place, including all conduit, conductors, and other equipment to the nearest junction box. Item 660.0013.____, Relocate Electrolier . By each complete unit, removed, relocated, reinstalled, and functional.
660-5.01 BASIS OF PA YMENT. Sign removal a nd reinstallation required to install foundations,
conduits, and junction boxes is subsidiary. Minor conduit routing changes as directed are 454 ALASKA 2020 subsidiary to existing contract pay items. All concrete required to complete the foundations is subsidiary. If no i tem for Bored Casing is included in the bid schedule, boring is subsidiary to other items of work. If the Engineer orders soffit lights or lighting for pedestrian structures placed in operation before permanent power service is available, the Department wi ll pay the cost of installing and removing temporary power service as extra work under Subsection 109- 1.05. Furnishing, installing, maintaining (including power), and removing falsework lighting is subsidiary to the items of work involved in the structure that requires the falsework lighting. Payment will be made under: PAY ITEM Item Number Item Description Unit 660.0001.____ Traffic Signal System Complete, LS 660.0002.____ Flashing Beacon System Complete, LS 660.0003.____ Highway Lighting System Comp lete, LS 660.0004.____ Sign Illumination System Complete LS 660.0005.____ Structure Illumination System Complete LS 660.0006.____ Traffic Count System Complete LS 660.0007.____ Temporary Signal System Complete, LS 660.0008.____ Temporary Illumination System Complete LS 660.0009.____ Bored Casing, ___ Inch Minimum Diameter LF 660.0010.____ High Tower Lighting System Complete LS 660.0011.____ Traffic Loop EACH 660.0012.____ Underpass Lighting System Complete LS 660.0013.____ Relocate Electrolier EACH 455 ALASKA 2020 SECTION 661 ELECTRICAL LOAD CENT ERS
661-1.01 DESCRIPTION . Furnish and install load center assemblies at the locations indicated in
the Plans. Modify existing load centers when indicated. Use load centers of the following types as shown on the load c enter detail sheets: Type 1: Pad mounted with underground service (large) Type 1A: Pad mounted with underground service (small) Type 2: Post mounted with underground service Type 3: Pole mounted with overhead service
661-2.01 MATERIALS. Use materials that conform to Section 740, the Materials Certification List,
the Plans, specifications, and the following. Concrete Section 550, Class B Grout Subsection 701- 2.03 Reinforcing Steel Section 503 Wood Posts . Construction grade, 6 x 6 inch nominal dimension S4S D ouglas Fir, Hem -Fir, Western Larch, Western Hemlock, Mountain Hemlock or Southern Pine meeting Standard Grading and Dressing Rules , West Coast Lumber Inspection Bureau. Treat the posts according to Section 714. Load Center . NEMA 3R enclosure constructed of zinc-coated A60 finish sheet steel per ASTM A653 and ASTM A924, with no external screws, bolts, or nuts. Shop coat cabinet components with a 2- part urethane paint undercoat and 2- part urethane finish coats. Finish coats must be standard white for removable panels and non- gloss silver -gray, closely matching FSS No. 5950 Color No. 36622, for the enclosure. The load center must be labeled as a unit by a State of Alaska- approved independent electrical testing laboratory (such as UL, ETL, CSA, etc.) defined by ANSI Standard Z34.1 Third -Party Certification Programs for Products Processes and Services and conform to applicable published standards noted herein, the Plans, and Special Provisions. The load center must be marked with the maximum available fault curr ent and the date the fault current calculation was performed. The marking must be sufficiently durable to withstand the environment. The load center must be labeled as service entrance equipment. Panelboards . Load panels in load centers must conform to FS S W -P-115C, Type 1 - Circuit Breaker Panelboards; UL 67 - Panelboards ; and NEMA PB1 - Panelboards with Molded Case Circuit Breakers . The rated voltage of the panels must be as noted on the load center summary in the Plans, 120/240 volts or 240/480 volt sin gle phase or 120/208 volt or 277/480 volt three- phase. The ampacity rating of panels must not be less than the ampacity noted on the load center summary, 100 amps minimum, at rated voltage. Provide separate copper neutral and ground buses. A label must be applied to the exterior of the panelboard indicating the potential arc flash hazard at the enclosure. The label must comply with NEC 110.16(A) and must include the information required by NFPA 70E, including the estimated arc flash incident energy as calc ulated per IEEE 1584. Circuit Breakers . Use bolt -on type circuit breakers with a copper bus. The series rated interrupting capacity of the circuit breakers in the panels must not be less than shown on the load center summary, or 10,000 AIC minimum, at rated voltage. Ensure that the circuit breakers installed are rated to be operated in the ambient temperatures to which they will be exposed.
Source: Alaska Standard Specifications for Highway Construction, 2020 Edition. Pages 461–482 of 584.