a.Code. All work shall be done in accordance with the requirements given in the current edition of the National Fire Protection Association "NFPA 70, "National Electrical Code" (NEC) and the regulations and standards of the power company providing service.
1.Electrical Contractor License. The Contractor responsible for the performance of the work under this specification section shall be licensed as an Electrical Contractor authorized to perform electrical work by the Alabama Board of Electrical Contractors in accordance with the “Alabama Electrical Contractors Act” and said contractor’s license shall be in good standing. Upon “Notice to Proceed”, the Contractor shall submit copies of their Electrical Contractor license to the designated Working Group: Design Bureau’s Traffic Engineering Division for their review and approval. Copies shall also be transmitted to the Project Manager. The Working Group’s email address is TrafficDesignSubmittals@dot.state.al.us.
2.Electrical Journeyman License. At least one out of every three people in each work crew shall be a Journeyman licensed by the Alabama Board of Electrical Contractors and shall be in good standing. Journeymen shall be present and shall have direct involvement with all work required for the installation and operational testing of electrical materials and equipment.
4.Technical Certification Approval and Identification Card. The Contractor shall submit copies of the technician certifications (i.e., Journeyman licenses and IMSA technician certificates) to the designated Working Group: Design Bureau’s Traffic Engineering Division for their review and approval. The Working Group’s email address is TrafficDesignSubmittals@dot.state.al.us. Upon review and if qualified, each technician will be issued an approved Workers Identification Card by the Department. Technicians shall be in possession of their worker certification at all times and show their certification identification card as often as asked by the Engineer. Failure to provide said proof to the Engineer will result in a stop work being placed upon the applicable work until such a time that proof of meeting these technician requirements is met. Technicians with expired or suspended certification shall not be allowed to conduct work. Contract time will not be stopped if the Contractor is unable to provide adequate proof or qualified staff. SECTION 750 ROADWAY LIGHTING Work shall not begin on the installation of electrical or roadway lighting materials and related equipment until copies of the licenses and certifications have been approved by the Engineer.
c.Electrical Power. The entity (City, County, State, etc.) that will be responsible for the eventual operation and maintenance of the roadway lighting system will make application for electrical service upon notification that power service will be required. The Contractor shall inform the Engineer when power service is required at least 30 calendar days prior to the need of the power service. This same entity will be responsible for the cost of the service connection and the monthly service billings thereafter. Electrical power shall be the power system shown on the plans which will usually be a single phase, 3-wire, 480 Volt-AC system. Power shall be provided by a transformer that does not provide power to any other equipment.
d.General Conduit System Installation Requirements. Conduit shall be installed in accordance with the details shown on the plans or as directed by the Engineer. Rigid Nonmetallic Conduit (RNC) may be installed as a substitute for Nonmetallic Underground Conduit with Conductors (NUCC) if it is the same size and schedule as the NUCC. Conduit routing shown on the plans is diagrammatic only. Actual routing shall be in the most prudent manner as approved by the Engineer. Underground conduit depth shall be24 inches {600 mm}, minimum, unless shown otherwise on the plans. All conduit ends (except NUCC and HDPE) shall be put together in couplings to form a smooth raceway for cables. Bushings and duct sealant shall be installed at all conduit terminations to protect the insulation of the conductors and to prevent debris from entering the conduit. Conduits shall be joined by approved methods prescribed by the manufacturer of the conduit. When conduit is installed for future use, the ends of the conduit shall be capped with a fitting listed for this purpose to prevent water and other foreign matter from entering the conduit system. The Contractor shall seed and mulch disturbed areas as directed by the Engineer. The seeding and mulching of disturbed areas shall be paid for by the appropriate Erosion Control pay items as shown in the plans. Before beginning excavation, the Contractor shall determine the location of all utilities in the vicinity. Utilities shall not be damaged during construction. Conduit shall be located to avoid potential conflict with the future installation of guardrail, signposts, and other equipment and devices. A minimum of 12 inches {300 mm} clearance shall be provided between the finished lines of conduit runs and existing underground utilities. Where the underground conduit run is adjacent to concrete walls, piers, footings, etc., a minimum of 4 inches {100 mm} of undisturbed earth or firmly compacted soil shall be maintained between the conduit and the adjacent concrete. Unless shown otherwise on the plans, trenches shall not be excavated in existing pavement or paved shoulders to install conduit. When it is necessary to place conduit under an existing pavement, the conduit shall be installed in accordance with the requirements given in Section 756. Unless approved otherwise by the Engineer, trenches shall not remain open after normal work hours each day. Liquid Tight Flexible Metal Conduit (LFMC) or Liquid Tight Flexible Non-metallic Conduit (LFNC) as shown on the plans or directed by the Engineer shall be installed where conduits cross an expansion or open joint on bridges, barrier rails or structure. The LFMC or LFNC shall be 36 inches {900 mm} in length and shall have a sag of not more than 3 inches {75 mm} between the fixed ends of the rigid conduit. e.Junction Boxes. The types of junction box shall be: TYPE INSTALLATION LOCATION BOX MATERIAL Type 1 Installed flush with grade. Non-Metallic Type 2 Installed on the surface of a structure. Metal Type 3 Installed flush with surface of a structure. Non-Metallic Type 4 As Shown on the Plans As Shown on the Plans
f.Nonmetallic Underground Conduit with Conductors. Nonmetallic Underground Conduit with Conductors (NUCC) shall be installed in accordance with the manufacturer's recommendations. SECTION 750 ROADWAY LIGHTING If plowing is proposed for the installation of the NUCC, the manufacturer’s recommended installation practices shall be submitted to the Engineer prior to beginning the installation. If the Engineer is not satisfied with the Contractor’s performance and knowledge once installation begins, the Contractor shall arrange for a manufacturer’s representative experienced in plowing methods to be at the jobsite until the Engineer determines that the Contractor is capable of properly installing the NUCC. If rock or other obstructions hinder plowing operations, the Engineer may require that conductor routes be pre-ripped to locate rock or hidden obstructions. Obstructions may be removed or the conductors routed around them as approved by the Engineer. If the "Plow Pulling" method is used, the plow operator shall have an acceptable method to ensure that the manufacturer’s recommended maximum tensile force on the NUCC is not exceeded. If at any time the Engineer determines the installation is not in full compliance with the intent of the manufacturer’s recommended practices, the operation shall stop until a manufacturer’s representative can further instruct the Contractor’s personnel in the deficient areas. If the "Chute Plowing" method is used, special attention shall be given to the conductor feed chute dimensions.
g.Conductor Installation.
1.Splices and Taps in Conductors. Splices and taps in conductors shall only be made in junction boxes and pole bases. They shall be made with solderless split bolt connectors. Splices and taps shall be protected in sealed silicone gel filled enclosures designed for splicing wire which provide a waterproof connection and to ensure the required electrical insulation. Silicone gel filled enclosures shall be re-enterable; shall be UV resistant, listed for temperatures from -40 C to 90 C; and shall be impact and abrasion resistant. The enclosure shall be sized as shown in the following table: Conductor Size Gel Enclosure Size #4 AWG and smaller #2 #2 AWG #2.5 or Mini wedge Larger than #2 AWG #3
2.Pulling Conductors into Conduit. Conductors shall not be pulled into a conduit until the installation of the conduit is complete. Conductors in conduits shall be carefully pulled into place using approved methods so that the conductors will not be damaged. Powdered soapstone, talc, or other inert lubricant specifically designed for the purpose shall be used when pulling conductors through the conduit. All conductors within a single conduit shall be pulled at the same time and shall be handled and installed in such a manner as to prevent kinks, bends or other distortion which could damage the conductor and outer covering. When conductors are pulled through hand holes, pole shafts, etc., a pad of firm rubber or other suitable materials shall be placed between the conductors and the edges of the opening to prevent damage to the conductors.
h.Grounding. All metal poles and metal enclosures containing electric wires and/or equipment shall be grounded. Exothermic welds or other approved connectors shall be used to connect the grounding conductor to the ground rods. A continuous grounding conductor, either bare or having a green colored insulation, shall be extended from the service ground to all equipment and shall be used for grounding purposes only.
i.Lightning Protection. Lightning protection shall be installed as shown on the plans at all poles greater than or equal to 75 feet {22.8 m} in height.
j.Foundations. For bidding purposes, the size and configuration of reinforced concrete foundations will be shown on the plans for the designated ranges of pole heights The Engineer will inform the Contractor if changes are required to the depth of concrete foundation required at each pole. Changes in the depth of foundations may be made based on a review the Contractor's design submittal. The Contractor will be notified of any such changes upon completion of this review. If no changes are required, the Contractor shall install the as-bid sizes of foundations. SECTION 750 ROADWAY LIGHTING Care shall be taken to properly orient the anchor bolts of concrete foundations so that the luminaire assembly will be in proper alignment with the roadway. All spoils or excavated material shall be disposed offsite by the Contractor or as directed by the Engineer. Conduits shall be accurately placed, oriented in the proper direction to accommodate future extension, and securely held in place to prevent movement. Concrete shall then be placed in the excavated area against undisturbed earth below the finished ground line. The concrete shall be placed in an approved form above ground line to the top of the foundation. All exposed edges of the concrete shall have a 3/4 inch {19 mm} chamfer. The top of the foundation shall be level and shall be placed to properly orient the luminaire assembly with the roadway. For breakaway poles, the finished foundation shall have a maximum 4 inch {100 mm} "Breakaway Support Stub Height Measurement" as defined in the AASHTO Roadside Design Guide, Chapter 4.2.
k.Installation of Luminaire Poles. Luminaire poles shall be installed in a vertical position. Erection shall be accomplished carefully to prevent marring the finish or otherwise damaging the pole. When lighting is to be installed on a bridge, the Contractor shall, before ordering the poles, examine the bridge plans or the completed bridge, whichever is applicable, to determine the exact nature of the proposed or existing details which will accommodate the luminaire poles. Any discrepancies between the plans and an existing bridge structure shall be immediately reported to the Engineer. The Contractor shall verify that the pole anchor bolts, base plate bolt pattern, and pole assembly (including tenon mounting holes, multiple pole sections, and hand-hole orientation) are coordinated for proper orientation of lowering devices and luminaires to the roadway as shown on the plans. A screen made from 1/4 inch {6.4 mm} mesh galvanized wire cloth shall be fabricated and inserted in the pole base to prevent rodents, etc. from entering the pole. Backfill for direct burial fiberglass poles shall be as recommended by the pole manufacturer. Care shall be taken to assure the bracket arm is properly aligned.
l.Installation of Luminaires. The light control surfaces and glassware shall be cleaned after installation. Cleaning shall be performed in accordance with the luminaire manufacturer’s recommendations. Luminaires shall be leveled, plumbed, and installed as per the manufacturer’s recommendations to achieve the most suitable light pattern. The Contractor shall verify that the lamp socket is in the proper position to produce the optimum lighting pattern for each luminaire not to just meet minimum. Each luminaire shall be adjusted to provide the most effective light pattern as directed by the Engineer after installation.
m.Testing Insulation. The insulation of all lighting circuits will be tested by the Engineer at the load side of the contactors or circuit breakers. Prior to testing, the contractor shall disconnect all luminaires from the system by either unplugging fuse disconnects or opening pole breakers. For 480-volt systems,tests shall be made with a 500-volt DC Megger Tester. For 240-volt systems, tests shall be made with a 250-volt DC Megger Tester. Any reading of 250,000 ohms to ground or higher is satisfactory. Any reading of less than 250,000 ohms to ground is unacceptable and shall be corrected to the approval of the electrical inspector. The Engineer may conduct additional insulation testing after the completion of the operational testing. (n)Ground Resistance Testing. The resistance to ground will be tested by the Engineer at each lighting control center. The test will be conducted using a null balance earth tester with auxiliary ground rods placed 50 feet {15.24 m} and 100 feet {30.48 m}, respectively, from the tested ground rod. A reading of 25 ohms or less is satisfactory. Any reading over 25 ohms will require the installation of additional ground rods to be placed in a pattern as directed by the Engineer. The Engineer may conduct additional ground resistance testing after the completion of the operational testing. Once complete, the contractor shall reconnect all luminaires and close all pole breakers. SECTION 750 ROADWAY LIGHTING
o.Testing Luminaire Lowering Devices. The Contractor shall perform a functional test on all luminaire lowering devices. Tests shall be performed in the presence of the Engineer. The test shall be performed on the final completed lighting assembly with all luminaires and other components installed. The test shall be performed as follows:
6.Repeat unlatching, lowering, raising and latching three times. If latching or unlatching failures occur, or if any other problems occur during the test, the Contractor shall make corrections and repeat the complete test in the presence of the Engineer.
p.Operational Testing of the System. The Contractor shall perform full operational testing of the completed lighting system after the completion of the installation of all equipment and materials, including all miscellaneous items of work required for the complete lighting system. The operational testing will not begin until the testing of the insulation, resistance to ground, and luminaire lowering devices has been completed and accepted by the Engineer. The Engineer will set the date that the operational testing will begin. The Contractor shall provide all installation and operational instructions for all lowering devices before the operational testing of the system will be allowed to begin. An operational test shall be the full operation of all components of the lighting system for a period of 30 calendar days. During this test period, the Contractor shall perform all necessary adjustments (including re-aiming of luminaires) and replace all malfunctioning parts of the equipment required to place the system in a fully operational condition. Extra compensation will not be given for adjustments, maintenance, repairs and replacements during the test period. The initial test period will be suspended as directed by the Engineer during the time that the entire lighting system is not in full operation. The 30-calendar day operational test period shall be restarted or repeated if required by the Engineer due to repeated failure of the lighting system. The Engineer will perform a final inspection of the lighting system at the completion of the operational testing. If all items of work in the contract have been completed, the Engineer will suspend contract time charges during the operational testing. Upon completion of the operational testing, field tests may be conducted by the Engineer to verify that the required lighting levels and uniformity ratios are being provided. Any adjustments to the lighting system necessary to meet the design criteria shall be done at the Contractor’s expense.
q.Warranties, Guarantee and Maintenance. The State shall be protected from any defect in the lighting system by the following: The Contractor shall provide the manufacturer’s warranties to the State for all electrical and mechanical equipment. The Contractor warrants equipment and guarantees workmanship for satisfactory in-service operation of the electrical and mechanical equipment and related components for a period of one year following the date of completion of the operational check period. Maintenance repair work may be required for long duration contracts. In the case of long duration contracts the Contractor shall perform maintenance repair work on the lighting system (equipment, devices, structures and hardware) from the end of the one year warranty period until the end of contract time charges. Maintenance repair work during this time period will be paid for as "Extra Work" in accordance with the requirements given in