890.01 General.
TRAFFIC SIGNAL EQUIPMENT
890.01 General.
The following are the requirements for traffic signal equipment. These requirements may be supplemented or amended by the requirements given elsewhere in the proposal, on the plans, and on the details in the Special and Standard Highway Drawings. Requirements specified in these specifications shall comply with the latest editions of the NEC, and NESC. All equipment shall conform to the requirements of these specifications. Where cited Standard Publications and these specifications differ, the requirements of these specifications shall govern. For purposes of these specifications wherever the following terms or abbreviations are used, the meaning shall be interpreted as follows: A Amps AC Alternating Current ANSI American National Standards Institute ASTM American Society for Testing Materials AWG American Wire Gage DC Direct Current Hz Hertz IMSA International Municipal Signal Association ITE Institute of Transportation Engineers LED Light Emitting Diode MUTCD Manual on Uniform Traffic Control Devices NEC National Electrical Code NEMA National Electrical Manufactures Association NESC National Electrical Safety Code UL Underwriters Laboratories V Volts VA Volt Amps W Watts Descriptions and definitions of the equipment, words, and terminology used in these specifications are given in the MUTCD, the NEMA TS 2 -2016 Standards Publication, ITE publications, and the NEC.
890.02 Controller Unit.
Regardless of controller asse mbly type, all controller units shall be Advanced Transportation Controllers (ATC) conforming to this specification.
a.General Requirements. Advanced Transportation Controller (ATC) shall conform to the controller standard ATC 5201 v06.25 or later and requirements outlined in this specification. Where this specification and cited standards differ the requirements of this specification shall govern. Advanced Transportation Controllers used by the Alabama Department of Transportation (ALDOT) shall be on the MSDSAR.
b.Functional Requirements. The controller shall be NTCIP conformant for its application, conforming to the mandatory functional requirements of the latest NTCIP standards, unless otherwise specified. For the controller to be compliant with these specifications, the controller shall comply with the Protocol Requirement List (PRL) for the project. The PRL will indicate which mandatory and optional NTCIP functional requirements shall be required. A Protocol Implementation Conformance Statement (PICS) shall be supplied by the manufacturer with the material submittal to verify compliance with this specification and to indicate NTCIP functional requirements supported by the controller. The controller Application Programming Interface (API) shall conform to the API standard ATC 5401v02.17 or later. The controller shall be supplied with a printed and bound operations manual/maintenance manual containing circuit component schematics and programing instructions.
890.01 General.
A second copy of this information shall be provided on a thumb drive, CD or DVD ROM. All other functional requirements of the controller shall fully comply with the mandated requirements of the ATC Controller Standard 5201 V06.25 or later.
c.Engine Board Details. The SD Card socket referenced in ATC 5201 v06.25 shall be provided on the Engine Board. Any suitable electrical interface may be used. Physical access to this socket external to the controller is not required but is permitted. All other Engine Board details shall fully comply with the mandated requirements of ATC 5201 V06.25 or later.
d.Communication Interface Details. ATC shall have a minimum of one communication interface slot conforming to ATC 5201 v06.25 or later. ATC communications cards shall be available for the foll owing protocols: Public line, dial- up Single Mode Fiber License Free Radio Ethernet All other communication shall fully comply with the mandated requirements of the ATC Controller Standard 5201 V06.25 or later.
e.User Interface, Power Supply and Mechanical Details. All controllers shall be the keyboard entry type. The front panel keypad shall facilitate the entry of interval timing. All controllers shall be capable of timing entries via the keypad and via computer download, without need to open the unit and without special tools. The controller shall have a power switch. Power supplies, cables, and connectors shall be required as needed to provide power to the controller unit in the controller assembly. All other User Interface, Power S upply and Mechanical Details shall fully comply with the mandated requirements of the ATC Controller Standard 5201 V06.25 or later.
f.Parallel and Serial I/O Details. Parallel and Serial I/O details shall conform to ATC 5201 v06.25 or later based on the cabinet type. Parallel and Serial Input/output connections shall be supplied as required to support the cabinet environment and provide a fully functional controller assembly.
g.Environmental and Test Procedures. Environmental and Test Procedures shall f ully comply with the mandated requirements of ATC 5201 V06.25 or later.
1.ATC communications cards shall be available for environmental testing for the following protocols: Public line, dial- up Single Mode Fiber License Free Radio Ethernet
890.03 Controller Assembly.
The controller assembly shall be configured and bench -tested prior to installing the controller assembly. A Traffic Signal Technician from the State Signal Shop shall inspect the controller assembly prior to turning on the system.
a.Description. A controller assembly shall consist of a controller unit, conflict monitor, auxiliary devices, electrical devices, and other equipment as specified in the specifications, plans, or proposals, mounted and wired into a cabinet to make a complete operational traffic controller assembly. The plans will indicate type of controller assembly required.
b.Controller Assembly Type. Controller Assemblies shall be classified in the following categories: Type NEMA: NEMA TS2 Type 1 Cabinet with ATC Type ATC: ATC Cabinet Standard Latest Version with ATC
890.04 Type NEMA Controller Assembly.
890.04 Type NEMA Controller Assembly.
a.Requirements. All Type NEMA Controller Assemblies shall be NEMA TS 2 Type 1 and shall meet as a minimum, all applicable sections of NEMA Standards Publication TS 2 -2016, latest version. Where differences occur, this specification shall govern.
b.Cabinet. The cabinet shall be designed for base mount or pole mount as shown on the plans. The cabinet shall be clean -cut in design and appearance and con form to NEMA Standard TS 2 -2016, latest version, and these specifications. Where differences occur, this specification shall govern.
1.Fabrication Material. The cabinet shall be fabricated from shaped sheet aluminum.
2.Cabinet Dimensions. Unless otherwise indicated in the plans or proposal, pole mounted controller cabinets shall meet the dimensional requirements for a Size 5 cabinet per NEMA Standard TS 2 -2016 or later. Unless otherwise indicated in the plans or proposal, base mounted controller cabinets shall meet the dimensional requirements for a Size 6 cabinet per NEMA Standard TS 2 -2016 or later. The cabinet shall be large enough to provide ample space to house the controller unit, conflict monitor, auxiliary devices, electrical devices, and other equipment as specified in these specifications, plans or proposals. An alternative cabinet size may be used if a written request is submitted and approved. All cabinets shall be meet industry design standards.
3.Doors. Doors shall comply with NEMA Standard TS 2 -2016, latest version.
4.Gasketing. Gaskets shall comply with NEMA Standard TS 2 -2016, latest version. Gaskets shall be supported in a channel to prevent gasket fatigue/sagging.
5.Locks and Keys. Shall comply with NEMA Standard TS 2 -2016, latest version.
6.Shelves. The cabinet shall be supplied with at least two mounting shelves. The shelves shall comply with the requirements of NEMA TS 2 -2016, latest version. For base mounted cabinets a drawer with lid shall be mount ed below the bottom shelf for the storage of documents and to provide a work surface suitable for a laptop. For pole mounted cabinets a folding shelf mounted to the door shall be provided with a document storage compartment and a work surface suitable for a laptop.
7.Finish and Surface Preparation. Unless otherwise shown on the plans, the cabinet shall be aluminum finish and comply with the requirements of NEMA TS 2 -2016, latest version.
8.Cabinet Mounting. Cabinets shall be pole, base, or pedestal mou nted as indicated in the plans and cabinet mounting shall comply with the requirements of NEMA TS 2 -2016, latest version.
9.Cabinet Ventilation. Cabinet ventilation shall satisfy the requirements of NEMA TS 2 -2016. Louvered vents shall be located on the main cabinet door. The cabinet vent air filter shall be mounted on door and held firmly against the door by a spring or similar device.
c.Malfunction Management Unit. The Malfunction Management Unit (MMU) shall meet MMU2 requirements outlined in NEMA TS2 -2016, latest version.
d.Terminals and Facilities. Shall meet TS2 Type 1 requirements as specified in NEMA TS2 -2016, latest version, with the following additional requirements are listed below.
1.Power Strip
890.04 Type NEMA Controller Assembly.
A metal power strip shall be install ed within the cabinet to provide clean 120 VAC. This power strip shall be in addition to the convenience receptacle. The power strip shall contain a minimum of 4 NEMA 5 -15R receptacles spaced approximately 2.5 inches center to center. The sockets shall be arranged along a single axis with the blade sockets oriented perpendicular to that axis.
2.Light Fixture. Cabinet lighting shall be LED and meet the requirements of NEMA TS 2 -2016, latest version. The light on/off switch shall be a door actuated switch that turns the light On when the door is open and Off when the door is closed.
3.Police Panel Switches. The police panel shall contain only two switches, a SIGNAL ON/OFF switch, and an AUTO/FLASH switch. Switches shall be clearly and permanently la beled. The SIGNAL ON/OFF switch shall disconnect flasher and load switch outputs to the field and set Stop Time when switched to the OFF position. The signal shall follow the programmed startup sequence when returning from a dark condition. The AUTO/FLASH switch shall operate in accordance with NEMA TS2 -2016. The signal shall return from flashing operation in accordance with the MUTCD. There shall be no remote plug -in or manual control enable switch contained within the police panel area, unless specified i n the plans and proposal.
4.Maintenance Panel Switches. These switches shall be located inside the main cabinet door on the back side of the police compartment. All switches shall be clearly and permanently labeled. The following switches shall be provided: STOP TIME, AUTO/FLASH, SIGNAL ON/OFF. The STOP TIME switch shall be a two -position switch. The ON position shall manually set Stop Time in the controller. In the OFF position, Stop Time shall be enabled in the monitor. The AUTO/FLASH switch shall meet the requirements of NEMA TS 2 -2016. The signal shall return from flashing operation in accordance with the MUTCD. The SIGNAL ON/OFF switch shall disconnect flasher and load switch outputs to the field and set Stop Time when switched to the OFF positi on. The signal shall follow the programmed startup sequence when returning from a dark condition. A 24VDC override switch shall be provided, as described in NEMA TS2 -2016, to manually apply 24VDC to the load switches for diagnostic purposes during flash transfer operations. The switch shall be a spring -loaded push button.
5.Cabinet Main and Auxiliary Circuit Breakers. The main circuit breaker shall turn off all power to the cabinet. The main breaker shall be rated at 30 A. Incoming power shall be r outed through the main breaker and cabinet suppressor -filter before powering any equipment or devices. The AC service shall follow a short path to the main breaker and cabinet suppressor -filter. The wiring shall be routed such that no severe bends shall oc cur along the path to the cabinet suppressor. The auxiliary breaker shall be rated at 15 A and be located beyond the main breaker and cabinet suppressor. A secondary auxiliary breaker rated at 15 A shall be provided and located beyond the main breaker and cabinet suppression to protect a cabinet mounted power strip.
6.Cabinet Suppressor- Filter. The cabinet shall be supplied with a suppressor, HESCO HE1750R or approved equal.
7.Signal Bus Contactor. The signal bus contactor shall be a solid -state relay, St ruthers -Dunn Model 418AXXL -120VAC, or approved equal.
8.Cabinet Power Supply. The Cabinet Power Supply (CPS) shall be a shelf mountable unit meeting the requirements of NEMA TS2 -2016, latest version.
9.Signal Load Switch Arrestors. Shall be HESCO HE103C -9 or approved equal. 10.Protection of Loop Detectors (External Surge Protection).
890.04 Type NEMA Controller Assembly.
Shall use a three -terminal device, HESCO VLP7 or approved equal, or may opt to use a pluggable device. If pluggable detection suppression is used it shall be HESCO HE6 LC-6 or approved equal.
11.Replacing Transient Protection. All transient protection devices shall be replaceable without removing any panels.
12.SDLC Bus. A SDLC Bus shall be provided with a minimum of 7 SDLC connectors.
13.Detector Rack (16 Channel). Detector Racks provided shall house 1 BIU and be capable of providing 16 channels of detection. Racks shall have 8 positions for combinations of 2 and 4 channel detector cards up to 16 channels of detection or may have 4 positions which allow for up to 16 c hannels of detection utilizing half width 4 channel detector cards (approx. 1.12” wide). The rack shall utilize SDLC to interface with the controller. The detector rack shall be connectorized to accept an input termination panel harness.
14.Input Termination Panel (16 Channel). A 16 Channel Input Termination Panel shall be provided for each detector rack. The termination panel shall come with a pre -wired harness which connects to the detector rack.
15.Output Facility (16 Channel). The Output Facil ity shall be configured for 16 output channels. It shall house 2 BIUs and utilize SDLC to interface with the controller and MMU. The field output wires shall terminate at the bottom of the facility and signal load switch arrestors shall be located directly above the field output terminals.
e.Auxiliary Devices. Auxiliary devices as defined in NEMA Standard Publication TS 2 -2016, latest version, shall conform to the requirements of NEMA Standard Publication No. TS 2 -2016, latest version.
f.Type NEMA Cabinet Configurations. Unless otherwise specified, all cabinets shall be configured for 16 output channels. Where detection is required, a minimum of one 16 Channel Detector Rack shall be required. Additional 16 Channel Detector Racks shall be required as need ed up to 64 channels of detection. Only load switches and detector cards needed to provide the required signalization and detection shall be required. Detector Racks shall be mounted to the top shelf of the cabinet when possible. Where shelf space is inade quate, compact components may be utilized such as detector racks which support half width BIUs (approx. 1.2” wide) and half width 4 channel detector cards (approx. 1.2” wide). The Controller, MMU, and CPS shall be placed on the bottom shelf. Required equipment shall be neatly arranged within the cabinet. Output facilities shall be mounted on the back of the cabinet near the bottom. Power distribution components shall be mounted on the right side of the cabinet near the bottom. The power strip shall be mounted on the right side of the cabinet near the top. Input termination facilities shall be mounted on the left side of the cabinet. Terminals and Facilities shall not be mounted less than 6” from the bottom of standard base mount cabinets. Termi nals and Facilities shall not be mounted less than 3” from the bottom of standard pole mount cabinets. A Standard Base Mount Cabinet shall be a NEMA TS2 -2016 Size 6 Cabinet (Approx. 52”x44”x24”). A Standard Pole Mount Cabinet shall be a NEMA TS2 -2016 Size 5 Cabinet (Approx. 48”x30”x16”).
890.05 Type ATC Controller Assembly.
a.Definitions. ADU Auxiliary Display Unit LV Low Voltage – 50 Volts DC or less HV High Voltage – 120 VAC CMU Cabinet Monitor Unit HDFTR High Density Flash Transfer Relay HDSP -FU High Density Switch Pack / Flasher Unit
890.04 Type NEMA Controller Assembly.
PCB Printed Circuit Board SIU Serial Interface Unit
b.Requirements. Type ATC Controller Assemblies shall meet, as a minimum, Advanced Transportation Controller (ATC) Cabinet Standard, latest version. Where differences occur, this specification shall govern. A Type ATC Controller Assembly shall consist of a Controller Unit, CMU, ADU, Service Assembly, SB1/SB2 and DC Power Bus, AC Clean Power Bus, and Input and Output Assemblies , as required, with associated Termination Assemblies, wired into a cabinet to make a complete and operational Controller Cabinet Assembly. Assemblies and components shall be provided as indicated in specifications, plans, or proposals. Assemblies or compo nents not specified or indicated in the plans, which are needed to provide a complete operational controller cabinet assembly shall be provided. Assemblies shall be rack mountable and completely removable from or installable in the Cabinet Cage without rem oving any other equipment and using only a standard # 2 Phillips screwdriver. Assemblies shall be supplied with enough cabling to allow mounting in any position in the cage enabling a neat and clean install. All wiring shall be routed in such a way that is neat and does not interfere with the installation or removal of other auxiliary or standard components. All High -voltage components and wiring (over 50 V) shall not be exposed and shall be adequately protected from accidental contact. All equipment in the cabinet shall be clearly and permanently labeled. Marker strips shall be provided below item they identify and must be visible after installation. Marker strips shall be easily written upon with ball point pen or pencil. Top and bottom guides shall be pro vided for PCB -based plug -in components. Circuit breakers, switches, fuses, and indicators shall be visible and accessible when the Cabinet door is open (not behind other equipment). The cabinet shall be wired in such a way that the intersection can remain in flash while removing the input/output assemblies or controller. Door switches shall be powered by 24 or 48VDC. Cables and wiring shall not travel directly from device to device but shall be bundled, managed, and routed along rack rails. All grounding and neutral cables shall have sufficient slack to allow for future testing with a clamping style meter. Type ITS Controller Assemblies shall be designed to allow for conversion from 120 VAC to 48 VDC output and vice versa.
c.Cabinet Housing. ATC Controller Assembly Cabinet Housings shall meet the requirements specified in Caltrans Transportation Electrical Equipment Specifications 2009 with Errata No. 2, hereafter referred to as TEES 2009.
890.04 Type NEMA Controller Assembly.
Cabinet Housings including ventilation, doors, locks, gaskets, etc. shall conform to TEES 2009 Chapter 6 Section 2. The housings shall be constructed of aluminum with stainless steel hardware, and shall have a Natural Finish, unless otherwise specified. The police panel shall contain only two switches, a SIGN AL ON/OFF switch, and an AUTO/FLASH switch. Switches shall be clearly and permanently labeled. The SIGNAL ON/OFF switch shall disconnect flasher and switch pack outputs to the field and set Stop Time when switched to the OFF position. The signal shall follow the programmed startup sequence when returning from a dark condition. The AUTO/FLASH switch shall allow normal operation when in the AUTO position. In the FLASH position the switch shall set the traffic signal in flashing operation and set stop time. The signal shall return from flashing operation in accordance with the MUTCD. There shall be no remote plug -in or manual control enable switch contained within the police panel area, unless specified in the plans and proposal. Cabinets shall have a plaque or other durable label inside the door stating the output voltage of the cabinet.
d.Cabinet Cage. The cabinet shall contain an EIA 19 -inch rack cage meeting the requirements of TEES 2009 Chapter 6 Section 3; the location of the drawer and assembl ies in the cabinet cage shall be as indicated in these specifications unless otherwise specified in plans, contract documents, or proposals.
e.Cabinet Lighting. Two LED light sources shall be mounted on the inside of the cabinet, one near the top of the front of the cabinet and one near the top of the back of the cabinet such that they illuminate all equipment mounted in a vertical plane with the front and back of the cabinet rack. Each light source shall provide a minimum of 700 lumens of visible light. At turn -on, the lighting fixture shall provide the minimum required lumens of visible light within 30 seconds. All electrical circuits associated with cabinet lighting shall be protected such that they do not generate radio frequency interference or power line transients that can affect the operation of any equipment located in the cabinet. On/Off switches for cabinet lighting shall be door actuated switches that turn the lighting on when one or more doors are open and off when all doors are closed.
f.Cab inet Drawer. A telescopic slide out drawer for document storage shall be provided for base mount and standard pole mount cabinets. The Drawer Unit shall be mounted across the EIA rails and shall have a non -conductive top, locking provision when fully exten ded, and lip or handle for pulling. The height of this unit shall be 1U. The mounting location of this drawer shall be as indicated in these specifications unless otherwise specified in the plans, contract documents, or proposals.
g.Service Assembly. Cabinets shall contain a 1 -HDFU Service Assembly unless a 2 -HDFU Service Assembly is required for the cabinet to function properly for the application for which it is specified. A 2 - HDFU Service Assembly shall be provided if specified in the plans, contrac t documents, or proposals. Breakers located on the service assembly shall be shielded to prevent accidental contact. The Service Assembly shall be modular and shall be mounted on the left of the EIA rail when viewed from the front.
1.1-HDFU Service Assemb ly The Service Assembly shall house: one HDSP/FU, a Cabinet Suppressor– Filter, BBS landing wire terminals, one GFCI convenience receptacle (duplex NEMA 15 -5R format), four 3 Amp HDFU output fuses, five Circuit Breakers, and a Raw AC+ terminal block having 5 screw terminals. The following circuit breakers shall be provided: Main, AC Clean, GFCI/Fans/Lights, FU 1, and Output Assembly. The Main breaker shall be 30A; all others shall be 15A.
2.2-HDFU Service Assembly
890.04 Type NEMA Controller Assembly.
The Service Assembly shall house: two HDSP/ FU, a Cabinet Suppressor– Filter, BBS landing wire terminals, one GFCI convenience receptacle (duplex NEMA 15 -5R format), eight 3 Amp HDFU output fuses, six Circuit Breakers and a Raw AC+ terminal block having 5 screw terminals. The following circuit breake rs shall be provided: Main, AC Clean, GFCI/Fans/Lights, FU 1, FU 2, and Output Assembly. The Main breaker shall be 30A; all others shall be 15A.
h.AC Clean Power Bus Assembly. The AC Clean Power Bus shall include eight NEMA 5 -15R receptacles, to provide AC Clean Power to the Controller Unit, the Cabinet DC Power Supply, and other assemblies and devices. The AC Clean Power Bus shall be mounted across the EIA rails on the back of the cabinet cage. The assembly shall be hinged to allow access to the back of assemblies mounted to the opposite side of the cage.
1.SB1/SB2 and DC Power Bus Assembly. The SB1/SB2 and DC Power Bus Assembly shall include eight DB25 d -submodular socket connectors to interconnect the SB1/SB2 communication ports of the assemblies and controller. It shall include a termination circuit at the end of the connections (S8) (Serial Bus Through) to prevent radio frequency signal reflection. The assembly shall have one Phoenix Contact plug block or approved equal to bring power from the Cabinet DC Power Supply to the Bus; DC Power shall be distributed to the Cabinet Assemblies through seven Phoenix Contact receptacle blocks or approved equal. Copper traces for the DC voltages shall support at least 10 Amp. The SB1/SB2 and DC Power Bus shall be m ounted across the EIA rails on the back of the cabinet cage. The assembly shall be hinged to provide easy access to the back of the assemblies mounted to the opposite side of the cage.
j.Input Assembly (24 -48 Channel). The Input Assembly shall be a 3U high rack mounted assembly providing twelve slots of 22/44 pin PCB sockets. The Input Assembly rack shall be designed in a manner to prevent bowing or sagging. The 24 Channel Input Assembly shall contain one Serial Interface Unit (SIU) mated to a DIN 96-pin connector and shall house twelve 2 -channel detection modules, or six 4 -channel detection modules, or a combination of 2 & 4 channel detection modules up to 24 channels. The 24 Channel Input Assembly shall also have a provision for an Opto Technician Pan el on the front of the assembly with four LED call indicators for the Opto circuits in the SIU and four switches to place calls on the Opto circuits in the SIU. A CDC interface shall be provided on the back of the input assembly for interface between the S IU and a four Opto input termination panel. The Opto Technician Panel and termination panel shall be provided as required or if specified in the plans, contract documents, or proposals. The 48 Channel Input Assembly shall contain 2 SIUs and shall house twe lve half -width (approx.1.14”) 4- channel detection modules or a combination of 2 & 4 channel detection modules up to 48 channels of detection. CDC ports shall be provided, for both SIUs, on the back of the 48 Channel Input Assembly to provide interface with the Opto circuits of the SIUs.
890.04 Type NEMA Controller Assembl y.
k.Field Input Termination Assembly (24 -Channel). The 24 -Channel Field Input Termination Assembly shall be coupled with the 24 -Channel Input Assembly and shall have positions for landing 24, two -wire inputs and their associ ated earth ground wires. The Field Input Termination Assembly shall have positions for 12 Detection Module Suppressors. Detection Module Suppressors required shall be supplied with the cabinet. The 24 - Channel Field Input Termination Assembly shall be mount ed across the EIA rails in the back of the cabinet and it shall be hinged to provide access to the back of the assemblies mounted on the opposite side of the cabinet. Two 24- Channel Field Input Termination Assemblies shall be coupled with a 48 -Channel Input Assembly.
l.Output Assembly (16 -32 Channel). The Output Assembly shall have a STOP TIME (ON/OFF) switch and SIGNALS (AUTO/FLASH) switch on the front of the assembly. The STOP TIME switch shall be a two position switch. The ON position shall manually set Stop Time in the controller. In the OFF position, Stop Time shall be enabled in the monitor. The AUTO/FLASH switch shall allow normal operation when in the AUTO position. In the FLASH position the switch shall set the traffic signal in flashin g operation and set stop time. The signal shall return from flashing operation in accordance with the MUTCD. A 24VDC momentary bypass switch shall also be provided on the front of the output assembly to provide 24VDC to the HDSPs for troubleshooting during flash mode. A 5A breaker shall be provided on the front of the Output Assembly for every 4 channels of output. Breakers and switches shall be shielded to prevent accidental contact. The Output Assembly shall accommodate one Cabinet Monitor Unit (CMU). The Output Assembly shall be easily configurable for 48VDC or 120VAC heads.
1.Output Assembly (16 Channel) The Output Assembly shall be a 3U high rack mounted assembly. The Output Assembly shall accommodate eight HDSP/FUs, providing 48 output circuits. The Output Assembly shall accommodate one SIU to provide interface and control via system SB1/SB2.
2.Output Assembly (32 -Channel) The Output Assembly shall be a 6U high rack mounted assembly. The Output Assembly shall house sixteen HDSP/FUs and shall provide ninety -six output circuits. The Output Assembly shall accommodate two SIUs to provide interface and control via system SB1/SB2.
m.Field Output Termination Assembly (16 Channel). A 16-Channel Field Output Termination Assembly shall be couple d with the 16 -Channel Output Assembly and shall house High- Density Flash Transfer Relays (HDFTR). The HDFTRs and Flash Program Blocks (FPB) shall be provided to control and select the color (red, yellow, or dark) during flash mode. HDSP Suppressors shall b e provided at the field terminals for the protection of the HDSPs. Each HDFTR position shall be labeled with the number of its associated HDSP (1 -16). Each FPB position shall be labeled with the number of its associated channel (1 -16) The Field Output Term ination Assembly shall be provided with 16, 6 -position Phoenix Contact terminal block model number 18 -04-94-6 plugs and 18 -61-19-6 sockets or approved equal. Each Load Terminal Block receptacle shall be labeled with the number of its associated channel (1 -16). Additional labels shall be provided to clearly indicate which terminals correspond to the red, yellow, and green switch pack outputs. The color of these labels shall match the color of their associated output (red, yellow, or green). One Field Output Termination Assembly shall be provided with each 16 -channel cabinet, while two Field Output Termination Assemblies shall be provided with each 32 Channel Output Assembly. The 16 -Channel Field Output Termination Assembly shall be mounted across the EIA rail s on the back of the cabinet cage. The assembly shall be hinged to provide access to the HDSP Suppressors, and the back of assemblies mounted to the opposite side of the cabinet cage.
890.04 Type NEMA Controller Assembly.
n.Cabinet Components.
1.High -Density Switch Pack / Flasher Unit (HDSP -FU). The HDSP- FU shall be an EDI - Model 2202- HV or approved equal for 120VAC (High Voltage) output cabinets. The HDSP- FU shall be an EDI – Model 2202- LV or approved equal for 48VDC (Low Voltage) output cabinets.
2.Cabinet Monitor Unit (CMU). The CMU shall be an EDI – Model 2212- HV or approved equal for 120 VAC (High Voltage) output cabinets. The CMU shall be an EDI – Model 2212- LV or approved equal for 48 VDC (Low Voltage) output cabinets.
3.Serial Interface Unit (SIU). The SIU shall be an EDI - Model 2218 or approved equal.
4.Auxiliary Display Unit (ADU). The ADU shall be an EDI - Model 2220 or approved equal.
5.Cabinet DC Power Supply (CPS). The CPS shall be an EDI – Model 2216 or approved equal for High Voltage Cabinets (120 VAC Output). An EDI – Model 2217 or approved equal may be utilized in smaller more compact cabinet configurations that do not require the power level of the EDI – Model 2216 power supply or do not utilize a 19- inch rack. The CPS shall be an EDI – Model 2248 or approved equal f or Low Voltage Cabinets (48 VDC Output).
6.High -Density Flash Transfer Relay (HDFTR). The HDFTR shall be an Struthers -Dunn Model 21H or approved equal.
7.Main Contactor (MC). The MC for High Voltage Cabinets (120VAC Output) shall be a solid -state relay, Struthers - Dunn Model 428- AXXL-48VDC or approved equal. The MC for Low Voltage Cabinets (48VDC Output) shall be a solid state relay, Struthers -Dunn Model 429- AXXL-48VDC or approved equal.
8.Cabinet Suppressor- Filter. The cabinet shall be equipped with a Cabinet Suppressor– Filter, HESCO HE -1750R or approved equal.
9.HDSP Suppressor. The HDSP Suppressor shall be a HESCO HE103C -9 or approved equal.
10.Detection Module Suppressor. The Detection Module Suppressor shall be a HESCO HE6LC -6 or approved equal.
o.Type ATC Controller Cabinet Assembly Configurations. Termination Assemblies shall be installed on the back of the cabinet cage near the bottom of the cabinet. Input Termination Assemblies shall be installed below the Output Termination Assemblies. A Model 2216 or 2248 CPS, if utilized, shall be installed in the top U on the back of the cabinet cage. Bus Assemblies shall be installed on the back of the cabinet cage in the first available U’s from the top.
1.Standard Large Base Mount Shall be Calt rans Cabinet Housing 1B (Approx. 67”H x 24”W x 30”D) Doors required 2 (1 front, 1 back) Base mount Requires 24 Detector inputs and 16 Channels output (Expandable to 72 detectors and 32 channels output as required) The ADU shall be installed in the top U of the cabinet. The next 3 U’s shall be reserved for the controller unit. The 6 U’s immediately below the controller shall be reserved for Input Assemblies. The drawer shall be installed below the space reserved for the Input Assemblies. The Output Assembly shall be installed in the first available U’s beneath the drawer. All assemblies shall be mounted a minimum of 6” above the bottom of the cabinet.
890.04 Type NEMA Controller Assembly.
2.Standard Pole Mount / Small Base Mount Shall be Caltrans Cabinet Housing 2 (Approx. 46”H x 24”W x 20”D) Doors required 2 (1 front, 1 back) Pedestal, pole, or base mount (Base mount will require a Type 332/336 Base Adaptor; Pole Mount will require a Cabinet Housing 2 Pedestal Adaptor) Pole mounts shall be located on the same side as the door hinge in su ch a manner that a technician can observe the signal and display of controller at the same time Requires 24 Detector Inputs and 16 Channels Output. The ADU shall be installed in the top U of the cabinet. The next 3 U’s shall be reserved for the controller unit. The 6 U’s immediately below the controller shall be reserved for Input Assemblies. The drawer shall be installed below the space reserved for the Input Assemblies. The Output Assembly shall be installed in the first available U’s beneath the drawer. The Service Assembly shall be installed at the bottom of the Cabinet Cage.
3.Compact Shall be approximately 25”H x 16”W x 17”D Doors required 1 (1 front) Pedestal or pole mount Pole mounts shall be located on the back or side in such a manner that a techn ician can observe the signal and display of controller at the same time. Deviations for compact cabinet from this specification: A single -point latch is allowed. The compact cabinet may have an alternative door handle but shall have a provision for padlock ing. No drawer is required. Assemblies are not required to be 19 -inch rack mountable. The input and output cards may share a combined Input/Output Assembly. The cabinet shall be capable of providing at a minimum the following combinations of input and outp ut: 16 Detector Inputs/4 Channels Output, 12 Detector Inputs/6 Channels Output, and 8 Detector Inputs/8 Channels Output. No separate Serial Bus or Power Bus Assemblies are required. Only one spare clean AC NEMA 5 -15R receptacle is required and one spare DC Power Phoenix connector is required. SB1/SB2 Connections may be limited to those required for a fully functional Controller Cabinet Assembly. Assemblies may be combined into more compact assemblies so long as overall Controller Cabinet Assembly function i s preserved. Assemblies shall be hinged to allow access to termination facilities on the interior of the cabinet. Only termination facilities for the above listed combinations of inputs and outputs are required.
890.09 Interconnect Cable.
890.06 Controller Assembly Documentation.
1.Serial Number. A serial number shall be engraved or stenciled on the cabinet. The serial number shall be the same number as the controller unit serial number.
2.Data Label. A data label shall be placed on the inside of the cabinet door to provide the following information: Manufacturer’s name – All equipment installed cabinet Date of Manufacture Wiring Schematics Number Controller Model Number Controller Serial Number Conflict Monitor Model Number Conflict Monitor Serial Number Time Clock Model Number (If applicable) Time Clock Serial Number (If applicable) Communication Device Model Numbers (If applicable) Communication Device Serial Numbers (If applicable) Project Number or Transportation Department P.O. Number.
3.Wiring Diagram. One copy of the cabinet wiring diagram shall be supplied as well as a copy of the following: Operations Manuals for all equipment Base Mounting Template (if required) Additional prints, diagrams, and manuals shall be available upon re quest at no additional charge. Cabinet prints shall include flash color change instructions for all phases and all overlaps. Cabinet prints shall be keyed to show every input and every output from every terminal. If prints use multiple ground and neutral busses, busses shall be numbered. All grounds and neutrals shall be keyed to the busses that they are connected to. Cabinet prints shall show every connector.
890.07 Remote Detection and Interconnect Protection.
Each remote detector input line an d interconnect line, as it enters the cabinet shall be furnished with a surge protection device that meets or exceeds the following requirements. Unit shall be capable of withstanding 10,000 A 10:20 microsecond standard waveform surges a minimum of 50 time s. Unit shall have internal follow -current limiters (resistive elements). Unit shall self -extinguish within 8.3 milliseconds after the trailing edge of surge. Unit shall not have thermal circuit breakers in place of limiters. Limiter resistance shall be between 0.15 and 0.39 . Unit shall have a mounting plate for easy removal and replacement and shall be mounted in the controller cabinet in a neat workmanlike manner.
890.08 Vehicular Loop Detector.
a.General. Vehicle loop detector units shall be card rack units meeting the requirements of NEMA TS2-2016, latest version. NEMA TS1 shelf mounted detectors may be used in existing NEMA TS1 cabinets if specified. NEMA TS1 detectors shall meet the latest NEMA TS1 stan dards.
890.09 Interconnect Cable.
a.Description. Interconnect cable shall be used to transmit information between intersections or other control points in a traffic control system.
890.10 Electrical Power Service Assembly.
b.Materials. Interconnect cable shall conform to the requirements of th is specification unless otherwise specified on the plans or in the proposal. If in such case that the plans designate fiber optic cable material be used for the interconnect cable, then Section 729 shall apply.
c.Underground Interconnect Cable. Undergrou nd interconnect cable, for closed loop systems, shall be shielded and conform to the requirements of Rural Electrification Administration (R.E.A.) Specification PE - 39, filled telephone cable, No. 19 AWG, 6 pair. Underground interconnect cable for time bas e coordination shall conform to the requirements of IMSA 20 -1 No. 14 AWG, 9 conductors.
d.Aerial Interconnect Cable. Self-supporting aerial interconnect cable, for closed loop systems, shall be shielded and conform to the requirements of Rural Electrific ation Administration (R.E.A.) Specification PE - 38, No. 19 AWG, 6 pair. Standard aerial interconnect cable, for closed loop systems, attached to a messenger strand in the field, shall conform to the requirements of Rural Electrification Administration (R.E .A.) Specification PE - 22, No. 19 AWG, 6 pair. Self-supporting aerial interconnect cable, for time base coordination, shall conform to the requirements of IMSA 20 -3, No. 14 AWG, 9 conductors. Standard aerial interconnect cable, for time base coordination , attached to a messenger strand in the field, shall conform to the requirements of IMSA 20 -1, No. 14 AWG, 9 conductors.
e.Interconnect Cable Support Wire. A support cable, whether separate or integral to aerial interconnect cable, having a minimum diameter of 0.25 inch {6.35 mm} shall be provided for interconnect cable that is not self -supporting. Support cable shall be steel wire strand Class A (double galvanized) and conform to the requirements of ASTM Standards Publication No. A 475 -89, “Standard Spe cifications for Zinc -Coated Wire Strand”.
f.Cable Attachment Hardware. Attachment hardware shall be stainless steel or non -corrosive material and shall be provided with tensile strength adequate for application.
890.10 Electrical Power Service Assembly.
a.Description. Electrical power service assembly shall consist of equipment to provide a pole attached raceway and disconnect switch for use with power cable routed from the service entrance to the controller cabinet and nearest supporting structure wit h luminaire. The electrical power service assembly shall include a weatherhead, conduit and fittings, a disconnect switch with enclosure, and attachment clamps. Electrical power service shall be in accordance with these specifications, NEC requirements, local utility codes, and on the details shown in the Special and Standard Highway Drawings.
b.Materials. Materials shall be tested and approved by a nationally recognized testing laboratory and shall meet the following requirements. 1.Service Pole (Wood Pole). Service pole shall be southern yellow pine treated in accordance with the latest American Wood -Preserver’s Association (AWPA) standards and shall conform with the requirements given in Section 833. Unless otherwise noted on the plans, service pole used for service lateral drop shall be a 35 foot Class 3 wood pole and shall conform to the requirements of ANSI Standards Publication No. 05.1- 1992, “American National Standards for Wood Poles – Specifications and Dimensions”. The poles shall not hav e more than 180 degrees of twist in grain over the full length and the sweep shall be no more than 4 inches {100 mm}.
2.Attachment Hardware. Attachment hardware shall meet the requirements as shown on the details in the Special and Standard Highway Drawin gs.
890.10 Electrical Power Service Assembly.
3.Conduit. Conduit shall conform to the requirements specified in this Section.
4.Weatherhead. Weatherhead shall be made of a copper -free aluminum alloy or galvanized ferrous material.
5.Electrical Cable. Phase or current carrying conductors shall be of the type RHH, RHW, USE, or XHHW. Conductors shall be stranded annealed copper with not less than 98 percent conductivity and shall be insulated for 600 V or more with rubber insulation and a neoprene jacket, or with cross - linked polyethylene insulat ion. The size of the conductor, voltage rating and type of insulation shall be clearly marked on the conductor in a color that contrasts with the color of the insulation. Service wire to supply the controller shall be No. 6 AWG, stranded copper, two condu ctors rated for dry and wet conditions. The equipment grounding conductor shall be a bare conductor or shall be identified by a continuous green insulation. Grounded conductors (neutrals) shall be identified by a continuous white color insulation. Service wire to supply the traffic signal luminaries shall be No. 8 AWG, stranded copper, three conductors rated for dry and wet conditions. The equipment and pole grounding conductor shall be a bare conductor or shall be identified by a continuous green insulati on. Grounded conductors (neutrals) shall be identified by a continuous white color insulation.
6.Meter Base. When a meter base is required, meter base shall be a meter base approved by the local electric power company.
7.Service Disconnect. Enclosure Ca binet: The cabinet shall conform to NEMA standards, made of galvanized steel, aluminum, stainless steel or other material approved by the Engineer. The enclosure shall have a hinged door with a padlock. Padlock No. 3210 keyed for a No. 3 key shall be provi ded. One key shall be hung within the controller cabinet. Circuit Breaker: A manually resettable circuit breaker shall be installed, which has a current rating of the circuit to which electrical power is provided. Transient Protective Device: A surge light ning arrestor rated for a maximum permissible line to ground voltage of (175 V AC) shall be installed, meeting the requirements of NEMA standards for surge arrestors.
8.Photoelectric Control Units. The photoelectric control shall meet the design and testi ng requirements of ANSI C136.10. The photoelectric control unit shall also: be a dusk -to-dawn sensor attached to the service pole or as specified by the plans; have relay contacts that are single -pole, single -throw (SPST), normally closed (NC); contain built -in surge and lightning protection; have a direct load rating of 1000 Watts incandescent load and 1800 volt -amperes for High Pressure Sodium; have a rated life at full load of at least 5,000 on -off operations. upon failure leave the lumin aires turned on as a notification of needed maintenance; be able to operate over the range of 105 -130V, 60 Hz. AC (120 V Nominal); have over voltage protection for the control components and the load circuit by the means of an expulsion type surge arrester capable of passing the surge outlined in ANSI C136.10; be calibrated for a "Turn -on" setting of 2.6 footcandles and a "Turn -off" setting not exceeding 0.6 times the "Turn -on" setting; have a control housing that is UV resistant. The photoelectric co ntrol shall have a cadium -sulfide light sensitive element. The base shall have an integral, locking type, brass 3 prong plug according to NEMA SH16 -1962 and a neoprene gasket that meets IEEE/NEMA publications. Photoelectric control units shall be installed facing north; however, if obstructions are such that this is not possible then they shall be installed facing south.
890.11 Uninterruptable Power Supply Systems.
890.11 Uninterruptable Power Supply Systems.
a.General. Uninterruptable Power Supply/Battery Backup Systems are to be used at intersections utilizing only LED indications. For intersection traffic control, there are two types of systems: On -line and Line-interactive. On-line systems use a “double conversion” method that converts/rectifies the AC input to DC power, passes power through the power bank, then converts/inverts power back to AC for the use by the equipment. In this method, the batteries are in constant use, thus requiring a method to swap-out bad batteries without shutting down the system and the equipment it supplies power to. Line-interactive systems (battery backup/standby UPS) pass power through an inverter/converter type device utilizing the line power as the primary power source for the equipment, leaving the battery bank as the secondary power source and charging or maintaining the charge of the battery bank. Some filtering of the line power is accomplished through this system. Should the line power fail, the battery bank will activate, becoming the primary power source for the equipment.
b.Cabinet.
1.Convenience Receptacle. One 15 A GFI duplex outlet shall be provided inside the cabinet.
c.Physical Requirements.
1.Firmware. System Firmware shall be included for the operational needs of the system. The user/operator shall be able to access the system, without requiring any additional equipment, to adjust system parameters and read logged events. The system firmware shall be upgradeable via a USB or local area network RJ 45 port.
2.Display. The unit inside the cabinet shall contain a display showing the status of the unit. The following is a minimum data set to display: • Battery status or charge status • Current operation of system (on or off battery if line -interactive system) • AC line output voltage and current draw • AC line input voltage • Power status (system on or off)
3.Temperature. The UPS shall be capable of operating in the temperature range of - 29°F to +165°F { -34°C to +74°C}.
4.Communication. The UPS shall be capable of using a USB and/or an Ethernet port (RJ45) for local control using a laptop PC or through a remote connection via modem or Ethernet.
5.Battery Bank. The battery bank shall be comprised of one or two types of systems; unmanaged or managed. An unmanaged battery bank will generally consist of standard automotive/marine type batteries that do not monitor or control the charge/discharge of the battery. Typical types of batteries are flooded cell, VRLA, AGM, etc. A managed battery bank will generally consist of some sort of small battery pack that has internal electronics in the pack to manage the charge/discharge of the battery. This type of battery bank is maintenance free.
a.Unmanaged. The battery terminals shall have a protective covering on them to prevent accidental spark or shorting. The batteries used shall utilize either bolt insert stud terminals or flag terminals. “Keyed” pigtail connection cables shall be provided with 5/16 inch {8 mm} stud sized ring/lug thermals to connect to the batteries. The system shall have a full battery management system that includes active or equalized balancing as well as temperature, voltage, and amperage of charge or
890.11 Uninterruptable Power Supply Systems.
discharge monitoring to maximize the life of the batteries. Battery harness connections, between the controller and the batteries, shall be made through the use of “keyed” connectors to prevent shorting and for the ease of battery replacement. The harness shall allow for the battery bank or batteries to be quickly and easily connected in order and keyed to ensure proper polarity without the need for any special tools. Each batter y bank or battery shall contain a fuse or breaker, sized to protect the system against shorting or battery failure.
b.Managed. The battery bank shall include a protective connection system to prevent accidental spark or shorting. The battery bank shall internally control, monitor, and balance temperature, voltage, and amperage of charge/discharge, providing maintenance -free operation for a minimum of five (5) years. The battery bank harness connections between the UPS and the battery bank shall be made with m ilitary connectors or similar barrel connectors to ensure easy replacement and prevent shorting, battery failure, and ensure polarity is proper without the need for any special tools. The battery bank shall be capable of being charged via a 120 VAC chargin g device.
d.Physical Requirements. Unit shall be compatible with traffic signal electronics. The unit shall be able to run a traffic signal cabinet in battery back -up mode with no operational issues initiated by the unit. The system shall be equipped with a manual bypass switch (normal/bypass minimum) that will not interrupt power to the controller. The “Normal” position shall indicate that the system is in operation. The “Bypass” position shall indicate that the line power is not coming into the system, system off -line, allowing for maintenance and testing of the system without interfering with the operation of the signal equipment. The transfer from utility power to battery power, and vice versa, shall not interfere with the normal operation of the traffic signal controller, conflict monitor, or any other peripheral devices within the traffic signal controller assembly. Shall provide a minimum of 1400VA, 1000 watts peak load at 120°F {49°C} Shall has an output voltage of 120 VAC, 60 Hz ±3 Hz, < 5% THD. Shall provide a method of sending a signal or information to the signal controller to alter the operation of the signal from normal mode to flashing operation based on conditions in the system to extend the operation of the signalized intersectio n. The system shall also be capable of transmitting this information to the use/agency to advice of the change in signal operation. The system shall maintain an event log of the last 1000 events. The log file shall be in a standard ASCII text format. This log shall contain, at a minimum, the following items: • Date and Time of event • Type of event • Duration of event • Battery status • Input line voltage status The system shall be equipped with lightning surge protection compliant with IEEE/ANSI
C.62.41 latest edit ion and meet all current UL1449 standards. The lightning surge protection shall be provided to the utility line voltage coming into the system. Shall be capable of producing a fully regenerated, conditioned, pure 120 VAC sine wave output at all times within a voltage input range of 85 VAC to 145 VAC. This output shall be maintained regardless of the battery state. Shall be capable of operating, with no loss in output quality, while having the input power supplied by a generator.
890.11 Uninterruptable Power Supply Systems.
The system shall be abl e to operate at 120% of the load capacity of the system for a minimum of 60 seconds before transferring to direct line -in power. Shall maintain the direct line- in power until the overload condition has been cleared for a minimum of 30 seconds. There shall be no change in operation should loss of utility power occur. The system shall continue to provide AC power until the batteries are depleted or power is restored. Restoration of line power, after depletion of the batteries, shall cause the system to resume conditioned power operations without user assistance. The system shall be capable of starting -up, providing power without the presence of the input line power. Should the inverter/condition fail in the system, the input line power shall be transferred directly to the output of the system. The system shall run a self -diagnostic upon start -up and be capable of running a diagnostic, from the front panel, while the system is running without any effect on the system operation. The front panel of the system shal l display, at a minimum, the following conditions: • AC line status • UPS battery status (charging, percent charged, etc.) • System faults • System Bypass status • Load capacity/status
1.On -Line Systems The system shall provide, at a minimum, 3 contact closures. On e of these shall indicate “Inverter Failure”. The others shall be user programmable as required, The system shall provide an automatic power transfer to live power upon inverter/system failure.
2.Line -Interactive Systems The system shall provide, at a m inimum, 3 contact closures. One of these shall indicate “UPS on Batteries”. The others shall be user programmable as required. The system shall automatically transfer to line power if the output load exceeds 150% of the design load for more than 5 seconds. This transfer shall stay in effect until the load has been cleared for more than 30 seconds. The system shall have the capability of bypassing the utility line voltage whenever the utility line voltage is outside of the manufacturer’s default or user- programmed voltage range by ±2VAC.
e.Testing/Acceptance Requirements. Shall be capable of running a minimum of 5 hours based on the following conditions: • 8-phase cabinet, controller & malfunction management unit set on a 90 second cycle • 10 – 3-section, 12”, LED ball signal heads • 2 – 16”, pedestrian heads • No detectors
f.Documentation/Warranty Requirements. A minimum of two (2) sets of operational and maintenance manuals shall be provided with the system. This shall cover all aspects of the system from the installation to general/special maintenance issues. Also two (2) sets of cabinet wiring schematics depicting locations of each component and electrical interconnection drawings. One (1) of the required copies can be furnished in digital format. The following shall be provided by the manufacturer: • Model & Serial numbers shall be visible on all electrical components • Power and current requirements • Temperature range • Weight and dimensions
890.13 Vehicular Signal Heads.
• Required mounting equipment • Response time and sensitivity • Requir ed software • Manufacturer’s recommended capabilities • Any limitations, requirements, or potential hazards associated with the operation of maintenance of the device. All product documentation shall be written in the English Language. The UPS system shall be warranted to be free of defects in material and workmanship for a period of THREE YEARS from the date of installation. During the warranty period, the supplier shall repair with new materials or replace at no charge any product cont aining a warranty defect. All materials returned from warranty repairs shall be made through the product distributor at no additional charge. Warranty repairs/replacement shall not exceed two weeks from date of return to the distributors.
890.12 Span Wire Assembly.
a.Description. Messenger cable shall be attached to supporting structures to support traffic signal heads, signs, and electrical cables.
b.Materials.
1.Steel Wire Strand. Steel wire strand shall be Class A (double galvanized) and shall c onform to the requirements of ASTM A 475 -89.
2.Messenger Cable. Messenger cable used to support signal heads shall be 3/8 inch {9.5 mm} nominal diameter, 7 wires twisted into a single strand. Messenger cable shall be extra high -strength grade with a mini mum breaking strength of 15,400 pounds {68.4 kN}.
3.Tether Cable. Tether cable attached to the bottom of signal heads shall be 1/4 inch {6.4 mm} nominal diameter, 3 wires twisted into a single strand. Tether cable shall be utilities grade with a minimum breaking strength of 3,150 pounds {14.0 kN}.
890.13 Vehicular Signal Heads.
a.ITE Standard Publications. Traffic signal heads and LED modules shall conform to the latest applicable ITE standards and specifications for Vehicle Traffic Control Signal Heads (VTCSH). 48VDC LED signal indications shall meet ITE requirements for color and intensity and shall meet any future requirements applicable to 48 VDC indications. Traffic signal heads shall be assembled and mounted per the MUTCD.
b.Separate Illumination. Each lens of a signal head shall be illuminated by a separate LED Module.
c.Housing, Door, and Visor. Shall be cast aluminum alloy, unless otherwise specified. Materials shall meet ITE VTCSH specifications.
d.Trunnions, Brackets, and Susp ensions. All trunnions, brackets, and suspensions used for assembling and mounting vehicle traffic control signal faces shall be entirely weather -tight. Wire entrance fittings for signal heads and span wire hangers shall be cast aluminum tri -stud with alum inum span wire hinge with stainless steel nuts, bolts, and washers. Wire raceway areas within brackets, trunnions and suspensions shall be of adequate size to carry all necessary wires without crowding, and raceway surfaces shall be free of sharp edges or protrusions that might damage insulation on wires. Suspensions for mast arm or span wire mounting shall include a device to permit adjustment for proper vertical alignment of the signal head.
890.13 Vehicular Signal Heads.
e.Exterior Finish. All exterior parts of the signal head exce pt the lens, the insides of visors, and the entire surface of louvers or fins shall be finished of the best quality of synthetic resin enamel that is colored black or federal highway yellow. A combination color scheme may be used in lieu of either an all -black or an all -federal highway yellow. A combination color scheme may consist of an all -black face with an all-federal highway yellow body. No other combination color schemes or the mixing of allowed color schemes shall be used within an intersection or project unless noted otherwise on the plans. The inside of the visors and the entire surface of louvers or fins shall be painted dull black. The exterior finish shall satisfy the latest ITE VTCSH specifications.
f.Back Plates. Backplates shall be installe d as shown on the plans. Backplates shall have a 5 inch {127 mm} border constructed of black metal with a 2 inch {51 mm} fluorescent yellow retroreflective material applied to the front of the backplate along its outer border.
g.Signal Head Cover. Signal head covers shall be opaque, black, and cover the signal head. The cover shall be weather and ultraviolet resistant. A garden or trash bag shall not be an acceptable cover. The cover shall be so designed so that it will not collect/hold water in the bot tom of the cover. The Contractor shall submit the proposed cover and method of attaching the cover over the signal head to the Engineer for approval.
h.Programmed Vehicular Signal Head. Programmed vehicular signal heads shall utilize an LED light source. They shall meet the requirements of the latest ITE VTCSH specifications. Exceptions shall be made for electrical mating requirements. The signal head shall have a means to limit visibility of projected light. The signal head shall be capable of lim iting visibility of the signal indication to the parameters specified in the plans. Programmed vehicular signal heads shall be internally optically programed or shall utilize electronic steerable beam or other similar technology to provide the required zon e of visibility. Louvers or other devices placed within the visor to limit visibility shall not be used, unless specified in the plans.
1.Lamps. Lamps used in traffic signal heads shall conform to the standards set forth in the ITE latest Standard for Tra ffic Signal Lamps, not smaller than 125 V, 8000+ hour rated life clear bulb in accordance with the following: 12 inch {300 mm} Red lens 150 or 165 W 3 inch light center length 12 inch {300 mm} Yellow lens 69 W 3 inch light center length 12 inch {300 mm} Green lens 116 W 3 inch light center length
2.Wiring. Each lamp receptacle shall be provided with coded No. 18 AWG {1.06 mm} or larger wires type TEW, 600 V, securely fastened to the socket. A suitable terminal block for connection of the wires from the socket and the incoming wires to the traffic signal head shall be provided in the signal housing.
3.Reflectors. Reflectors shall be specular Alzak finished aluminum or an approved equal. Reflectors shall be mounted in a cast aluminum reflector support attached to the housing, or shall be an integral reflector and support of formed sheet aluminum. The reflector assembly shall be pivoted to the housing, and shall be designed so that it can be swung out or easily removed without the use o f any tools. The method of mounting and fastening reflectors shall be sufficiently rigid to secure proper alignment between the lens and reflector when the door is closed. The construction of the signal head and its components shall be such that the fit be tween the reflector and the lens will eliminate all possibility of false indicators. Reflectors shall have an opening in the back for the lamp socket.
4.Lenses. Lenses shall be of glass; the quality and processing of which shall be the best for the purpo se. The composition must be durable on prolonged exposure to weather; all lenses shall be
890.13 Vehicular Signal Heads.
uniformly colored throughout the body, true to size and form, and free from any streaks, wrinkles, chips, or bubbles that in any way detract from their efficiency or use. Each lens shall have pressed on its flange the word "TOP" to indicate the proper positioning of the lens in the door for obtaining the light distribution required, together with the diameter and other designations including the name or trademark of th e manufacturer needed for proper application and help in purchasing replacements. A nominal 12 inch {300 mm} circular convex lens shall have an outside diameter of from 11.938 inches to 12.031 inches {303 mm to 306 mm}. A nominal 9 inch {225 mm} rectangula r lens shall have minimum over- all dimensions of 9 inches by 8.75 inches {228 mm by 222 mm}. A nominal 12 inch {300 mm} rectangular lens shall have minimum over -all dimensions of 12 inches by 12 inches {305 mm by 305 mm}. All lenses shall comply with the d esign designated by ITE for the use intended. The color of the lens shall be of a color approved for use by ITE for the use shown on the plans.
i.LED Modules.
1.General Requirements. Shall meet the latest ITE VTCSH Specifications. Shall satisfy the opti onal VTCSH requirements for failed state impedance. Aluminum -Gallium -Arsenic (ALGaS) LED technology shall not be use; other LED technology less susceptible to temperature degradation shall be used.
2.120VAC LED Modules. Shall be operationally compatible w ith NEMA TS1 & TS2, Type 170 & 2070 controllers, and ATC controllers, conflict monitors with plus features, malfunction management units, and cabinet monitor units (CMUs) currently used by the Alabama Department of Transportation and any other State govern ment entities.
3.48VDC LED Modules. Shall be operationally compatible with low voltage ITS cabinets and CMUs. Round indications shall operate at a maximum typical wattage of 5.0 Watts or less at 25 degrees Celsius for red, 9.0 Watts or less for yellow, an d 7.0 Watts or less for green indications. Arrow indications shall operate at a maximum typical wattage of 4.0 Watts or less at 25 degrees Celsius for red, 7.5 Watts or less for yellow, and 5.0 Watts or less for green indications. Arrow Indications shall operate at any orientation in the signal head. Minimum wattage for 48VDC LED modules shall be 2.0 Watts unless otherwise specified by ITE.
4.Warranty Requirements. All LED traffic signal lamp units shall be warranted against failure due to workmanship and material defects during the first 60 months of field operation. The LED signal lamp units shall also be warranted to meet or exceed the minimum luminous intensity values during the first 60 months of operation. This warranty shall be includ ed with each LED signal module, in writing, by the manufacturer. The warranty shall include a commitment by the manufacturer to replace all failed LEDs at no cost the Department.
l.Lenses for LEDs. The lens for an LED signal lamp unit shall be a UV stabi lized polymeric lens that is sealed to the LED housing to prevent dust and moisture from entering the unit.
m.LEDs for Replacing Lamps in Existing Incandescent Signal Heads. The LED traffic signal lamp unit shall be designed as a retrofit replacement fo r existing signal lamps, which will not require any special tools for installation. The 12" retrofit replacement LED traffic signal lamp unit shall fit into existing traffic signal housings without modifications to the housing. Installation of a retrofit r eplacement LED traffic signal lamp unit into an existing signal housing shall only require removing the existing lens and incandescent lamp, fitting of the new unit securely in the dousing door, and connecting the unit to existing electrical wiring or term inal block by means of simple connectors. The LED retrofit shall not require the removal of the reflector.
890.14 Pedestrian Signal Heads.
If proper orientation of the LED unit is required for optimal performance, prominent and permanent directional markings (an "UP arrow") for correct indexing and orientation shall exist on the unit. The manufacturer’s name, serial number, model number, manufactured date, and other necessary identification shall be permanently marked on the backside of the LED traffic signal lamp unit. A label shall be placed on the unit certifying compliance to ITE standards. The LED traffic signal lamp unit shall be a single, self -contained device, not requiring on -site assembly for installation into an existing incandescent traffic signal housing.
n.Submittal Data Required for LEDs. Each LED traffic signal lamp unit shall be provided with the following data: Complete and accurate installation wiring guide; Contact name, address, and telephone for the representative, manufacturer, or distributor for warranty repair; Schematics for all electronics. The Contractor shall submit a copy of a test report certified by an independent laboratory that the LED traffic signal lamp model submitted meets ITE Standard for light distribution, chromaticity, and power (consumption, po wer factor, and harmonic distortion). In addition, the independent lab report shall specify the drive current being supplied to individual LEDs within the unit. Designs which require LEDs to be operated
o.Bi -Modal Signal Head. Shall contain a bi -modal LED module. A bi -modal LED module shall have separate yellow and green circuits or yellow and yellow circuits. The bi -modal module shall meet the latest applicable ITE VTCSH specifications. The indications shall only be used for flashing yellow arrow assembl ies. The signal head shall be constructed in accordance with the requirements of the MUTCD.
890.14 Pedestrian Signal Heads.
a.General. All pedestrian signal heads shall conform to the latest requirements of the ITE Pedestrian Traffic Control Signal Indicators (PTCSI) specification and be assembled in accordance with the latest edition of the MUTCD.
b.LED Pedestrian Signals. 120 VAC Light Emitting Diode (LED) pedestrian signal heads shall conform to all applicable ITE standards and specifications for LED pedestrian traffic signals. 48 VDC LED pedestrian signal modules shall meet ITE requirements for color and intensity and shall meet any future requirements applicable to 48 VDC indications. 48 VDC LED pedestrian signal modules shall operate at a maximum typical wattage at 25 degrees Celsius of 8.0 Watts for the Portland Orange hand, 7.0 Watts for the Lunar White man, and 5.5 Watts for the Portland Orange countdown. Pedestrian signal heads shall be assembled and mounted per the latest edition of the MUTCD.
890.15 Pedestrian Detectors.
a.General. Pedestrian detectors shall conform to the American with Disabilities Act Accessi bility Guidelines, Section 14.2.5(1) “Crossing Controls”, dated 1994.
b.Materials. Pedestrian detector shall be capable of actuation by a force equal to or less than 5 -pound force {22.2N}. A control button shall be raised or flush and shall be a minimum of 2 inches {50.8 mm}. The microswitch shall be dustproof, water- resistant type. The splice between the cable and the detector leads shall be waterproof. The pipe or other protective cable covering to the detector housing shall be secure. The detec tor shall be provided with a housing to prevent the entrance of water.
890.19 Junction Box.
Where a push button is attached to a pole, the housing shall be shaped to fit the curvature of the pole and secured to provide a rigid installation. Saddles shall be provided to make a neat fit when required. Where a push button is to be mounted on top of a post, the housing shall be provided with a slip-fitter fitting and screws for securing rigidly to the post.
c.Hardware. Hardware and fittings shall be constructed of galvanized steel or non -corrosive metal.
890.16 Signal Cable.
a.Description. Signal cable shall be used to supply electrical power to vehicle and pedestrian signal heads, lane control signals, electrically powered signs, and pedestrian detectors.
b.Materials. Signal cable shall conform to the requirements of IMSA Specification No. 20 -1, polyethylene insulated, polyethylene jacketed communication cable. Unless otherwise noted on the plans, signal cable conductors shall be stranded copper, No. 14 AWG. The number of conductors shall be provided as follows:
890.17 Loop Detector Wire.
a.Description. Loop detector wire shall be used to provide a zone of detection (sensor loop) where the passage or presence of a vehicle in the zone causes a decrease in the inductance of the loop.
b.Materials.
1.Wire. Wire shall be Type USE -2, Type RHH, or Type RHW -2 XLP, 600 V cross -link polyethylene insulated cable. All loop wire shall have an insulation thickness of 0.045" (45 mils). Wire shall be No. 12AWG. Wire shall have a stranded conductor of 7 -10 strands that is soft annealed stranded wire of not less than 98 percent conductivity. The outer jacket shall be surface printed indicating the manufacturer, national research testing laboratory listing, maximum rated voltage, AWG size, the proper type letter or letters for the type of wire or the IMSA specification number every two feet {0.6 m} or less. Preformed loops that are listed on the MWSAR may be used.
2.Loop Sealant. Proposed loop sealant shall be included in the proposed material submittal as required in Section 730.
890.18 Loop Detector Lead -In Cable.
a.Description. Loop detector lead -in cable shall be used to connect the sensor loop to the input termination panel.
b.Materials. Loop detector lead -in cable shall conform to the requirements of IMSA Specification No. 50 -2, polyethylene insulated, polyethylene jacketed shielded, loop detector lead- in cable. The cable shall have stranded tinned copper conductors, No. 12 AWG. The cable shal l have two conductors individually insulated in a twisted pair configuration. The cables shall be spliced with a 2 -part epoxy underground power splice kit.
890.19 Junction Box.
a.Description. Junction box shall be provided to splice loop wires to shielded lead -in-cable, to allow access to ground rods located beneath sidewalks, and to decrease friction drag of pulling underground cable through conduit.
890.20 Conduit.
b.Materials.
1.Junction Box. Shall be capable of withstanding a vertical load test of 20,000 pounds {9.07 metric tons} over a 10 inch {254 mm} by 10 inch {254 mm} area. Junction boxes located within a roadway, sidewalk, or concrete island shall be of polymer concrete construction. Junction boxes located elsewhere may be constructed of HDPE or fiberglass, u nless otherwise specified. Regardless of the construction, all junction boxes shall satisfy the load testing requirements. On a given project, boxes located in roadways, sidewalks, and concrete islands shall be of the same construction and be from the same manufacturer; likewise, junction boxes used elsewhere on the project shall all be of the same construction (HDPE or fiberglass) and come from the same manufacturer. Junction box shall conform to the dimensions shown on the details in the Special and Stand ard Highway Drawings.
2.Junction Box Cover. All junction boxes shall be supplied with a heavy -duty cover tested to 20,000 pounds {9.07 metric tons} over a 10 inch {254 mm} by 10 inch {254 mm} area. Covers located within a roadway, sidewalk, or concrete island shall be of polymer concrete or metal construction. Covers located elsewhere may be constructed of a composite material, unless otherwise specified. Regardless of the construction, all lids shall satisfy the load testing requirements. On a given project, covers located in roadways, sidewalk, and concrete islands shall be of the same construction and be from the same manufacturer; likewise, covers used elsewhere on the project shall all be of the same construction and come from the same manuf acturer. The junction box shall have a locking cover. The junction box cover shall be embossed with “TRAFFIC SIGNALS” in standard block type not less than 1.5 inches {38.1 mm} in height.
890.20 Conduit.
a.Description. Conduit furnished shall be metallic or non -metallic, of the size specified on the plans.
b.Rigid Metal Conduit (RMC). Rigid metal conduit, couplings, and fittings shall be galvanized steel, meeting the requirements given in UL 6. Couplings and fittings shall be threaded.
c.Rigid Nonmeta llic Conduit (RNC). Rigid nonmetallic conduit shall be Schedule 40 or Schedule 80 PVC and shall meet the requirements given in UL 651.
d.Liquid- tight Flexible Metal Conduit (LFMC). Liquid -tight flexible metal conduit shall meet the requirements given in UL 360. The thermoplastic covering shall be oil resistant. Connectors shall be either angle or straight and be UL listed for the intended use. LFMC shall be installed where conduits cross an expansion or open joint on bridges, barrier rails and other structures and shall be installed at other expansion locations as directed by the Engineer. The LFMC shall be a maximum of 36 inches {1800 mm} long and shall not sag more than 3 inches {150 mm} between the fixed ends of the rigid conduit.
e.Liquid -tight Flexible Non -Metallic Conduit (LFNC). Liquid -tight flexible non -metallic conduit shall meet the requirements given in UL 1660.
890.21 Supporting Structures.
a.General. Supporting structures (metal traffic signal pole, prestressed concrete traffic signal pole, mast arm pole, and pedestal pole) used for mounting signal equipment shall conform to the requirements of Section 718 and Section 891.
b.Metal and Concrete Supporting Structure Features. Handholes with covers sha ll be provided to facilitate installation and wiring. Adapter with provisions for overhead wiring and wire entrance shall be provided for the top of the pole. A grounding connection shall be provided adjoining the base.
890.25 Video Detection System.
When painting of the supporting structure is specified by the plans or proposal, the supporting structure shall have two primer coats applied at the factory or point of fabrication and two additional coats of high -grade exterior grade enamel applied in the field. Paints shall conform to the applicable portions of Section 855.
c.Timber Poles. Timber poles shall be southern yellow pine treated in accordance with the latest American Wood -Preserver’s Association (AWPA) standards and conform to the requirements of Section 833. Unless otherwise noted on the plans, timber poles used for supporting traffic signals shall be Class 5 and shall conform to the requirements of ANSI Standards Publication No. 05.1 -1992. The poles shall not have more than 180 degrees of twist in grain over the ful l length and the sweep shall be no more than 4 inches {100 mm}. When required, guy wires shall be provided of adequate strength and shall meet the requirements of ASTM A 475 -89. Guy wire anchors shall be expanding or screw type with a minimum guy tension o f 8000 pounds {35 kN}.
890.22 Luminaire Extension Assembly.
a.Description. Luminaire extension assembly shall consist of an extension arm and a LED luminaire. The luminaire assembly shall conform to the requirements of this specification, unless otherwi se specified on the plans, in the proposal, and on the details in the Special and Standard Highway Drawings.
b.General. The luminaire shall be of the horizontal type for IES Type III medium cutoff, distributing an asymmetrical light pattern.
c.Materials.
1.Luminaire Extension Arm. Unless otherwise shown on the plans, the extension arm shall be 12 feet {3.7 m} in length. Stud mounting bolts and brackets shall be provided.
a.Photoelectric Control Unit. A photoelectric control unit shall be provided and conform to the requirements of the Institute of Electrical and Electronic Engineers (IEEE) and NEMA.
b.LED Luminaire. LED Luminaires shall meet the requirements of Section 889 and the plans.
890.23 Concrete Foundations.
All concrete foundat ions or footings shall conform to the requirements of Section 718.
890.24 Signs.
The R10 -12 sign, R10- 4B sign, and any sign indicated on the plans as a part of the signal installation shall conform to the requirements of Section 880.
890.25 Video Detecti on System.
a.Camera. The camera enclosure shall have the following features and functionality: Provide real time detection; Operate from 0% to 100% humidity; Include a lens with an automatic iris; Be easily field replaceable; Shall be clearly identified with the focal length and aperture; Shall be resistant to vibration and resistant to shock when installed for operation.
b.Camera Enclosure. The camera enclosure shall have the following features and functionality: Shall be a NEMA Type 4 encl osure;
890.26 Pri ority Control System, Traffic Signal Preemption.
Shall be fabricated from corrosion resistant aluminum; Shall be finished in a light -colored UV and weather resistant paint; Shall be provided with a sunshield; Shall have a sunshield shall be designed to divert water flow to the sides of the sunshie ld.
c.Camera and Enclosure Assembly. The camera in the enclosure shall have the following features and functionality: Shall have a heater mounted toward the front of the enclosure; Weight of all components shall not exceed 10 pounds {4,54 kg}. All devices required for maintaining the internal temperature and faceplate temperature shall be integral to the environmental enclosure. The heater shall not interfere with the operation of camera electronics and shall not cause interference with the video si gnal. The weight shall include the environmental enclosure, complete with camera, fittings, heater, and transformers.
d.Camera Mounting Assembly. The camera mounting assembly shall have the following features: Shall have all stainless steel or aluminum construction; Shall meet the support requirements of the camera manufacturer; Shall be equipped with lightening lightning protection; Connections shall be mounted on the rear of the enclosure; All connections shall have liquid tight fittings.
e.Processor. The processor shall be rack or shelf mounted in a controller cabinet and shall have a RS232 serial port. The processor shall provide video output (BNC) for connecting a television monitor for testing purposes and for connection to video transmit ter provided by others. The video output (BNC) shall be located at the front of the processor. The processor shall be plugged into a NEMA -5-15R receptacle located in the controller cabinet. The processor shall be capable of detecting vehicle presence in 8 user -defined detection zones. When the vehicle is in the detection zone, the detection zone shall change color or intensify on the screen to verify proper operation of the detection system.
f.Video Interface Panel and Cables. The video interface panel sh all provide facilities to protect against damage from lightning. Coaxial cable and power cable shall meet the requirements of vehicle detection manufacturer.
g.Two Channel and Four Channel Detector Unit. All detector units shall be compatible with Detector Rack Configuration 2 as described in NEMA TS2-2016, latest version.
890.26 Priority Control System, Traffic Signal Preemption.
a.Priority Control Systems. The priority control system shall be either acoustically (sound) activated, optically act ivated, or GPS (Global Positioning System) activated. All equipment and components shall meet or exceed all NEMA TS1 and TS2, as well as, Type 170, Type 2070 and ATC and ITS weather exposure durability requirements.
b.Operational Requirements. The priori ty control system shall be capable of providing preemption information to NEMA TS1, NEMA TS2, Type 170, Type 2070, and ATC traffic controllers used by the ALDOT. The priority control system shall be capable of setting time limits for how long a call can be held, when the call is dropped after a vehicle passes, or if the call is lost. Acoustically activated systems shall be able to detect and respond to a preemption call from an emergency or priority vehicle at a minimum of 1000 feet {300 meters} from a roadway intersection. All other systems shall be able to detect and respond to a preemption call from an emergency or priority vehicle at a minimum of 2500 feet {760 meters} from a roadway intersection. Setup and programming of the priority control system shall be accomplished using current ALDOT computer operating software.
890.26 Priority Control System, Traffic Signal Preemption.
c.Log File. The priority control system shall maintain a log file of at least 2000 of the most recent priority calls. This log file shall be downloadable in a standard ASCII, delimite d format. Each call record for all systems shall contain the following four items: Time & Date: shall indicate the time and date the call was made; Direction: indicates the direction from which the call was made; ID: identifies what vehicle or device made the request; Duration: indicates the total amount of time the call was active. The following are additional requirements for optical and GPS activated systems: User: department or agency that used the system; Level: priority level used.
d.Sof tware. The manufacturer's software shall be provided for the operation of the system. One software package shall be provided for each detection system. Software updates and revisions shall be provided to the ALDOT as updated by the manufacturer at no addit ional cost. The software shall not require a licensing fee. All setup, controller program, and diagnostic software shall be provided and shall run on Microsoft Windows based operating systems. Software updates shall be provided free of charge. On-line help screens shall be provided as an integral part of the system software. Interface software shall be capable of real -time viewing of the system activity.
e.Documentation Requirements. A minimum of 2 sets of operational and maintenance manuals shall be prov ided with the system. These manuals shall cover all aspects of the system from the installation to maintenance. The following data shall also be provided by the manufacturer: Model & Serial numbers shall be visible on all electrical components; Power and current requirements; Acceptable operational temperature ranges; Weight and dimensions; Required mounting equipment; Operating frequency where needed; Detection range; Response time and sensitivity; Required software; Manufacturer's advertised product capabilities; Any limitations, requirements, or potential hazards associated with the operation or maintenance of the device.
f.Warranty. Final payment will not be made until a written warranty is provided by the Contractor and accept ed by the Engineer in writing. The warranty shall be a written guarantee from the distributor or manufacturer that the priority control system will be fully functional and will remain free of defects in material and workmanship for a period of one year fro m date of acceptance. During the warranty period, the distributor or manufacturer shall repair with new materials, or replace at no charge, any device, product, or other material containing a warranty defect. All warranty repairs shall be made through the distributor or manufacturer at no additional charge. Warranty repair or replacement parts shall be provided within two weeks from date of return to the distributor or manufacturer. The warranty will not begin until the traffic signal installation "30 -day o perational check period" is complete.
891.01 General.
SECTION 891 STRUCTURAL MATERIALS FOR TRAFFIC CONTROL DEVICES AND HIGHWAY LIGHTING
891.01 General.
All materials used in the fabrication of overhead roadway sign, traffic signal, luminaire and traffic surveillance structural supports shall meet the requirements of the AASHTO Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals, 2009 Edition (hereinafter referred to as the AASHTO Sign Specifications ). AASHTO material specifications shall govern in lieu of ASTM material specifications when an AASHTO equivalent specification exists for all references within any referenced specification.
891.02 Steel.
a.General . All grades of steel listed in the AASHTO Standard Specifications for Highway Bridges are applicable for welded structural supports for overhead roadway signs, luminaries, traffic signals and traffic surveillance and shall have a specified yield strength not less than 35 ksi {241 MPa}, unless otherwise specified on the contract plans, or within this Section. The specifications for steels other than ASTM and AASHTO shall be submitted to the Bridge Engin eer for approval, prior to design. The contractor shall supply the Bridge Engineer with a copy of the steel specification corresponding to the steel that is being used if the steel is not covered by ASTM or AASHTO specifications.
b.Fabrication . Within 3 0 days after the award of the contract, the Contractor shall notify the Bridge Engineer in writing of the name and address of the fabricator of the structural steel. The notification shall include the fabricator's proposed fabrication schedule. Evidence of the fabricator's qualifications and experience shall be furnished if requested by the Bridge Engineer. No material shall be fabricated before the Department has been notified where the fabrication order has been placed and the shop drawings have been revi ewed and approved for distribution. The Fabricator is responsible for notifying the Bridge Engineer of any fabrication work to be done outside of their facility, the name and address of the outside fabricator, and the proposed fabrication schedule. The Fab ricator of the structures shall give the Bridge Engineer at least 30 days notice by submittal of a BBF -11 Form (Notice of Intent to Begin Fabrication) prior to the beginning of fabrication to allow time for arrangements to be made for an ALDOT inspector to be present during fabrication. All steel structures shall be fabricated in a plant certified by the American Institute for Steel Construction for “Standard for Bridge and Highway Metal Component Manufactures (CPT)”. Welding of steel members shall be in ac cordance with the AWS D1.1/D1.1M: 2015 Structural Welding Code —Steel 23 rd Edition (hereinafter referred to as the AWS Structural Welding Code). Welders shall be certified in accordance with the AWS Structural Welding Code. All welds shall be visually inspected and be free of cracking and undercutting. High Mast lighting assembly pole to base plate welds shall be magnetic particle or ultrasonically tested. Circumferential butt welds shall not be allowed on overhead roadway sign structure uprights. All circ umferential welds on steel poles shall be tested by ultrasonic for wall thickness of 5/16 inch {8 mm} or greater, or radiographic testing for wall thickness less than of 5/16 inch {8 mm}. All requirements of Section 1.4.2 of the AASHTO Sign Specifications shall be observed when welding and testing the poles. The longitudinal weld on the female section of lap splices shall be either one hundred percent full penetration, with quality assurance by ultrasonic inspection per the AWS Structural Welding Code, or s hall be reinforced externally to ensure the development the full yield stress of the pole. The handling and storing of materials, during and after fabrication, shall be done in such a manner that the metal or galvanized finish is not damaged. Material that is damaged may be rejected. Material shall be stored off the ground and properly drained. Loose members and fasteners shall be stored in boxes, crates, kegs or barrels. Support structures shall be free from sharp edges and irregularities, and any misfits or structural deficiencies. All members must fit together well and make for an easy an d quick erection. All components shall be protected from damage during fabrication, handling and transportation to the site. Unless approved by the Engineer, none of the components shall be delivered to the site until such time as the entire structure (l ess sign faces) can be erected.
Source: Alabama Standard Specifications for Highway Construction, 2022 Edition. Pages 829–854 of 934.