847 modified, which price shall be full compensation for the work described and specified herein and on the plans, including all parts, hardware and incidentals necessary to complete the work. No measurement or direct payment will be made for anchor bolts, the cost being considered as included in the unit price paid for foundations. 732- 1 Description: The work under this section shall consist of furnishing and installing electrical conduit, conductors, and pull boxes for traffic signals and highway lighting including jacking, drilling, excavating, backfilling, and compacting at the locations designated on the project plans and in accordance with the details shown on the plans and the requirements of these specifications. 732- 2 Materials: 732- 2.01 Electrical C onductors: Electrical conductors shall be stranded or single conductor, thermoplastic insulated electrical wire or cable. Conductors shall conform to the specifications of the NEC, UL, and other applicable industry standards. Wire and cable for traffic signal, highway lighting and other electrical systems shall be UL listed and rated for 600- volt operation. The UL label shall be present on each reel, coil or container of wire or cable. When requested, the contractor shall submit to the Engineer the manufacturer’s written certification that the product conforms to the requirements of these specifications. All single conductors, except detector lead- in cables, shall have plain, distinctive and permanent markings on the outer surface throughout the entire length showing the manufacturer’s name or trademark, insulation type letter designation, conductor size, voltage rating and the number of conductors in the cable. The wire shall be annealed copper and shall be uncoated unless otherwise specified. The wire shall be solid for number 10 AWG and smaller, conforming to the requirements of ASTM B3 for annealed bare copper wire. Conductors for sizes number 8 AWG and larger shall be stranded and shall conform to ASTM B8 for Class B stranding. Unless otherwise specified, the conductors shall be insulated with THW grade thermoplastic compound and shall meet the requirements of UL 83. Insulation colors shall be permanent and an integral part of the insulation and shall not be applied as a surface treatment of coating. The insulation thickness shall conform to the requirements of the NEC. TABLE OF CONTENTS INDEX 848 Conductor insulation shall be a solid color as specified in the conductor table unless otherwise specified. The color shall be continuous over the entire length of the conductor.
Conductors used for traffic signal and highway lighting systems shall conform to the requirements of the following table. The minimum conductor sizes shall be as shown in the following table unless otherwise specified. CONDUCTOR TABL E INSULATION CONDUCTOR CIRCUIT SIGNAL PHASE OR FUNCTION COLOR TYPE Minimum Thick.
Gauge (AWG) TYPE Vehicle Signals Red Interval Yellow Interval Green Interval Red Yellow Green THW THW THW 45 45 12 Pedestrian Signals Intl. Symbol Hand/Man Red Green THW THW 45 45 12 Pedestrian Push -Button Pedestrian Detection Orange THW 45 12 Series Lighting Series Loop Black THW 5 kv 150 8 S Highway Lighting Multiple Lighting Black THW 45 12 Lighting in Pole Pull box to Luminaire Black XHHW 30 12 S Sign Lighting Multiple Lighting Black THW 45 12 Common Common Lead White THW 45/60 12/8 Spares Unused Leads Brown or Black THW 45 12 Detection Detector Roadway Loops Black Orange THWN in PVC Tubing 15 31 14 S
Detection Loop Detector Lead in Cable Clear Black PE Foil Shield Vinyl 32 14/16/18 STP
Detection Magnetometer Lead in Cable Red Black Green White PE in PVC Jacket 18 18 18 18 S4C
Service Service Common Bond
Black White Green or Bare THW THW AS AS AS
AS AS
TABLE OF CONTENTS INDEX 849 CONDUCTOR TABL E Legend:
AS = As Specified; PE = Polyethylene; S = Stranded; STP = Stranded, twisted pair; S4C = Stranded, 4 Conductor
Roadway loop detector wire shall be a factory assembled combination of PVC tubing and wire. Loop detector wire shall be stranded number 14 AWG copper, rated at 600 volts with THWN insulation. The wire shall be enclosed in a factory extruded PVC flexible tubing by the wire manufacturer. Contractor assembly of the wire in the flexible tubing will not be acceptable. The PVC tubing shall be UL FR -1 rated at 105 degrees C and have a moisture absorption of less than 1 percent. The wall thickness shall be 31 ± 3 mils with a nominal inner diameter of 0.186 inches. The tubing shall be orange in color, be highly resistant to chemicals and oils, and have a dielectr ic strength of 900 volts per centimeter.
Wire marking tags shall be made of flame retardant reinforced epoxy tape 5.5 mils in thickness and 1/4 inch minimum width. The tape shall be flexibl e, resistant to oil and water, and have a pressure sensitive acrylic adhesive backing. The adhesive shall be a high tack adhesive with good adhesion to clean neoprene, hypalon, nylon and PVC insulation materials. The film material shall conform to the fl ame retardant requirements of UL 510 and be rated at 150 degrees C . Appropriate numbers and letters shall be printed on wire tags for conductor identification.
Shielded cable used for loop detector lead- in cable and telephone coordination interconnect circuits shall be two- conductor, stranded, twisted pair, aluminum -polyester foil shield with 100 percent coverage, tinned copper with polyethylene insulation, vinyl jacketed, rated at 600 volts and 60 degrees C, and shall be in conformance with UL and the following table: TABLE OF CONTENTS INDEX 850 TABLE FOR SHIELDED CABLE AWG Size Number 14 16 Stranding 19 x 27 19 x 29 Insulation Thickness, inches 0.032 0.032 Jacket Thickness, inches 0.035 0.032 Outside Diameter, inches 0.340 0.274 Ground Wire AWG Number 16 18 Nominal Capacitance* (pF/ft) 24 24 Nominal Capacitance** (pF/ft) 47 47 Notes:
* Capacitance between conductors. ** Capacitance between one conductor and another conductor connected to the shield.
Instrumentation cable normally used for magnetometer detectors shall be a number 20 AWG four -conductor, low -capacitance cable suitable for both conduit and direct burial. The cable shall be round and be less than 0.25 inches in overall diameter. The jacket shall be a weatherproof, high density, heavy duty, abrasion resistant, polyethylene material with a minimum thickness of 0.032 inches. The cable shall have an interior moisture penetration barrier to prevent capillary absorption of water and be suitable for a temperature range of -60 degrees C to +80 degrees C. Each conductor shall have thermoplastic insulation with a minimum thickness of 0.018 inches. The conductor to conductor capacitance shall not be greater than 18 picofarads per foot for adjacent pairs and 15 picofarads per foot for diagonal pairs with all other conductors disconnected.
IMSA cable shall be used only when specified on the plans. IMSA signal cables shall be polyethylene insulated cop per conductors, polyvinyl chloride jacketed, rated at 600 volts for use in underground conduit or as aerial cable conforming to International Municipal Signal Association Specification No. 19-1. The IMSA- 19 cable shall be provided with the number and size of conductors as specified on the plans. The cable shall use the standard IMSA colors for conductor insulation. The colors and tracers shall be permanent and an integral part of the insulation, and shall not be painted, surface coated, or adhered to surf ace. TABLE OF CONTENTS INDEX 851 732- 2.02 Electrical Conduit and Warning Tape: All conduit and fittings shall be listed by UL, and conform to NEC standards. Except as specified below, all conduit to be installed underground or in concrete structures shall be rigid Polyvinyl Chloride
Rigid Non -Metallic Conduit. PVC conduit and fittings shall be Schedule 40, heavy wall, manufactured from high impact material and shall be rated for use at 90 degrees C . All exposed conduit and fittings to be installed above ground shall be the rigid metal type manufactured of galvanized steel conforming to requirements of UL 6 for Rigid Metallic Conduit. Non- threaded couplings shall not be used. Rigid metal galvanized steel conduit bends shall be used for entering pull boxes that are spaced more than 150 feet apart. Intermediate metal conduit may be used in place of rigid metal conduit except for service risers. Galvanized intermediate metal conduit shall conform to the requirements of UL 1242. Intermediate metal conduit and fittings shall be manufactured from steel and work hardened to provide high strength. The exterior wall shall be hot -dip galvanized. Threads shall be fully cut and galvanized after cutting. All threaded fittings shall be the same as fittings approved for metal conduit. Flexible conduit shall be a liquid- tight flexible metal type and shall be used as specified. The conduit shall be a flexible galvanized steel core over which is extruded a PVC cover. Approved liquid- tight fittings shall be furnished and installed with the conduit. Sampling and testing procedures shall conform to UL Standards. Samples for testing, when requested by the Engineer, shall be furnished at no additional cost to the Department. Samples of conduit shall be tested by UL standards and be approved for use by the Engineer prior to installation on the project. Conduit warning tape shall be a 4 -mil inert plastic film specially formulated for prolonged use underground. All tape shall be highly resistant to alkalis, acids, and other destructive agents f ound in the soil. Tape shall have a continuous printed message warning of the location of underground conduits. The message shall be in permanent ink specifically formulated for prolonged underground use and shall bear the words, “CAUTION - ELECTRIC LINE BURIED BELOW” in black letters on a red background. 732- 2.03 Pull Boxes: Precast reinforced concrete pull boxes, covers and extensions shall be installed and located as shown on the project plans and shall be the size specified. TABLE OF CONTENTS INDEX 852 Chipped or cracked pull boxes, covers, and extensions will not be accepted. Portland cement concrete shall conform to the requirements of Section 1006 of the specifications for Class B concrete. When requested by the Engineer, pull boxes, covers, and extensions shall be furnished for testing at no additional cost to the Department. Covers shall be marked as follows: “A.D.O.T. ELECTRICAL HIGH VOLTAGE” Markings shall be clearly defined and uniform in depth and shall be placed parallel to the long side of the cover. Letters shall be 1 inch high. 732- 2.04 Metal Junction Boxes: Metal junction boxes and covers for installation in concrete structures shall be fabricated from a minimum of 16 gage type 304 stainless steel. All seams shall be continuously welded and shall conform to the dimensions and details shown on the project plans. A neoprene gasket with a thickness of 1/8 inch shall fit between the box and the cover. The cover shall be made to fit securely and shall be held in place with a minimum of four stainless steel machine screws. Tabs for ease of installation may be attached to the junction box at the option of the contractor. 732- 3 Construction Requirements: 732- 3.01 Installation of Electrical Conduit and Pull Boxes: Conduit runs shown on the project plans shall be changed to avoid underground obstructions as directed by the Engineer. The contractor may, at its option and at no additional cost to the Department, use a larger size conduit than specified provided the larger size is continuous for the entire length of the run from outlet to outlet. Reducing couplings will not be permitted. Changes in the location and size shown on the project plans shall be documented by the contractor and submitted to the Engineer. The PVC conduit shall be cut square and trimmed to remove all rough edges. Conduit connections shall be of the solvent weld type. Purple primer conforming to the requirements of ASTM F656 shall be applied to the joined surfaces prior to use of cement. The joint cement shall be the gray PVC cement conforming to the requirements of ASTM D2564. Where a connection is made to steel conduit, the coupling used shall be a PVC female adapter. TABLE OF CONTENTS INDEX 853 Expansion fittings shall not be installed in PVC conduit runs between two pull boxes unless otherwise specified. Expansion fittings shall be installed in conduit runs in which both en ds of the conduit are fixed in place such as between two foundations. Expansion fittings shall be installed in conduit runs which cross any expansion joint in a concrete structure. Approved expansion fittings shall allow for a linear thermal expansion of up to 6 inches. If a trench has to be left open overnight, a minimum of 6 inches of backfill material shall be used as a protective cover to eliminate contraction of the conduit system. The backfill material shall be removed if final inspection by the Engineer has not been made. Backfill containing large rock, paving materials, cinders, large or sharply angular substance, or corrosive material, shall not be placed in an excavation where materials may damage raceways, cable, or other substructures or prevent adequate compaction of fill or contribute to corrosion of raceways, cables or other substructures. Where necessary to prevent physical damage to the raceway or cable, protection shall be provided in the form of granular or selected material, suitable ru nning boards, suitable sleeves, or other approved means. Excavation and backfill shall be in accordance with the requirements of Subsection 203- 5 of the specifications. All PVC conduit shall be stored and handled in an approved manner to minimize ultraviol et deterioration due to exposure to sunlight. Conduits in protected areas such as behind curbs, in sidewalks, etc., that are not subject to any vehicular traffic shall be at a minimum depth of 18 inches. Conduits installed under roadways, driveways or any open areas where it is possible for vehicles to drive and conduits with conductors that have voltages over 250 volts, shall be at a minimum depth of 30 inches. When conduit in protected and open areas cannot be installed at the minimum depths, it shall be encased in concrete. Where specified due to shallow trenching depths, the conduit shall be encased in a minimum of 3 inches of concrete. The conduit shall be supported with masonry block or brick on 10- foot centers, during encasement, so that the condui t will be completely encased. Installation of conduit for underground primary service shall conform to the utility company requirements, local codes and the Special Provisions. Conduit installed in railroad right -of-way shall be to the depth specified by the railroad company. Except for factory bends, conduit bends shall have a radius of not less than that specified in the NEC. Conduit shall be bent without crimping or flattening, using the longest radius practicable. TABLE OF CONTENTS INDEX 854 Existing underground conduit to be incorporated into a new system shall be cleaned and blown out with compressed air. Conduit for future use shall have a number 8 AWG bare bond wire installed with at least 2 feet of pull wire doubled back into the conduit and capped. A 3-inch “Y” shall be cut into the face of the curb directly over conduit located under curbs. The contractor shall place warning tape in all trenches in which new conduit is placed. All warning tape shall be buried at a depth of 6 to 8 inches below the finished grade. Conduit entering pull boxes shall terminate a minimum of 3 inches inside the box wall. The conduit shall be between 2 and 4 inches above the bottom of the pull box and shall be sloped to facilitate pulling of conductors. Conduit entering through the bottom of a pull box shall be located near the sides and ends in order to leave the major interior portion clear. At all outlets, conduits shall enter from the direction of the run and allow for expansion and contraction. Rigid metal conduit bends shall be used for entering pull boxes that are spaced more than 150 feet apart. The bends shall be 90 degrees and be of the same diameter as the connecting conduit. The bends shall be wrapped with an approved PVC tape. Conduit ends shall be capped with conduit end cap fit tings until wiring is started. When end caps are removed, PVC ends shall be provided with an approved conduit end bell. End bells shall be installed prior to the installation of the conductors. Approved insulated grounding bushings shall be used on steel conduit ends. Conduit embedded in concrete structures shall be securely attached to the reinforcing steel at intervals of approximately 12 inches. Expansion fittings shall be installed where conduit crosses expansion joints in the structure. Where bonding is not continuous, expansion fittings shall be provided with a bonding jumper of number 6 AWG flexible wire. Where it is not possible t o use expansion fittings, sleeves of sufficient size shall be installed to provide a minimum 1/2- inch clearance between the conduit and the inside wall of the sleeve. The sleeve shall be discontinuous at the expansion joints. All existing conduits and conduit embedded in concrete structures shall be cleaned out with a mandrel and blown out with compressed air. Conduit shall be installed under existing pavement by jacking or drilling methods approved by the Engineer. Open trench excavation across an existing roadway shall not be permitted without the written permission of the Engineer. Jacking and drilling pits shall be kept 2 feet clear of the edge of the pavem ent. Pull boxes shall be installed in accordance TABLE OF CONTENTS INDEX 855 with the details shown on the project plans and the standard drawings. Pull boxes shall be installed flush with the finished grade and when in concrete shall have a 1/2 -inch felt expansion joint installed around all sides of the pull box. Junction boxes placed in concrete structures shall be flush with the finished concrete surface. 732- 3.02 Wiring Procedures:
Wiring shall conform to the regulations and codes listed in Subsection 730- 3 of the specifications, and of the NEC, and shall be UL listed and bear the UL labels and the following requirements: The conductors shall be pulled into runs in a smooth continuous manner, avoiding contact with sharp objects that might damage the insulation. Approved lubricants shall be used for inserting conductors in conduit. Before installation, conductor ends shall be taped for moisture protection until connections are made. Conductors shall have a minimum of 36 inches of slack from the conduit end bell in the pull box. All ungrounded ballast primary leads shall be protected with fused in-line connectors. Unfused in- line connectors shall be installed on all ballasts econdary leads. In- line connectors shall be fused with fast - acting, high- interrupting capacity fuses with a fault current rating of 100 kiloamperes at 600 volts AC. The in- line connectors shall be watertight, non- locking and rated at 600 volts AC.
In circuits where the voltage does not exceed 600 volts AC, splices shall be made utilizing approved spring -type wire connectors. Soldered connections will not be permitted unless so specified. The insulation for the splice shall consist of two layers of electrical rubber tape, four layers of plastic electrical tape and two layers of friction tape. The tapes shall be securely applied over the bare wire splice area and back onto the original insulati on a minimum of 1 inch. A minimum of three coats of approved liquid waterproof splicing compound shall then be applied to the splice. The finished splices shall be such that their electrical and mechanical characteristics and insulation quality are equal to those of the original cable. Conductors shall be spliced only in pull boxes, terminal compartments, pedestals, or cabinets. Splices for high- voltage series lighting conductors shall be made from an approved splice kit. The splices shall consist of ei ther molded rubber plug -in connectors or epoxy resin mold type splice insulating kits and shall be rated at 5 kilovolts. The finished splice shall make a sealed waterproof connection which shall be equal to the original cable conductors and insulation. TABLE OF CONTENTS INDEX 856 Cable used for detector lead- in and telephone interconnect circuits shall be run continuous and unspliced to the controller cabinet. Unless otherwise shown on the plans, one lead- in cable shall be installed per loop detector except for 6 foot by 6 foot loop detectors. Signal circuit conductors for each mast arm mounted signal assembly shall be continuous without splicing from the pull box, adjacent to the pole, to the terminal blocks in the mast arm assembly.
All conductors shall be tagged to identify their circuit number or function with wire marking tags. The tag identification shall correlate with the conductor schedule shown on the project plans. The tags shall be furnished and installed by the contractor. Each tag shall be wrapped entirely around the conductor twice. Each signal wire shall be tagged as to phase, color indication, and function such as vehicle indication, pedestrian indication, or pedestrian push button (Phase 1 - Red, Yellow, Green, etc). Each phase group shall also be tied together and tagged. Each lighting circuit wire shall be tagged to identify the circuit number and other types of circuits. Black wires used as spares shall be tagged as spares.
Prior to control cabinet installation, the contractor shall apply 120 volts to signal circuits and verify equipment is operational. The Department will connect field wiring inside the control cabinet.
The contractor shall connect field wiring to the load center terminals. Lighting circuits shall be energized for 100 hours as directed by the Engineer prior to final acceptance. Failures occurring during this test period shall be corrected. Wires shall be tagged in control cabinets, load center cabinets, pull boxes, terminal compartments of signal mounting assemblies, or wherever splicing occurs. 732- 3.03 Bonding and Grounding: All metallic enclosures such as cabinets, pedestals, poles, conduit and cable sheaths shall be bonded to form a continuous grounded system. Non -metallic portions of the system such as PVC conduit shall have a bare copper bond wire or a green insulated copper bond wire installed with suitable connections to form a continuous grounded system. In all traffic signal conduits, the copper bond wire shall have green insulation. TABLE OF CONTENTS INDEX 857 The insulation shall be removed from the bond wire in pull boxes from the point at which the wire leaves the bell end of the conduit. At each service disconnect, cabinet foundation, or where otherwise specified, an approved copper -plated ground rod shall be installed. Each ground rod shall be a one- piece solid rod of the copper weld type or approved equal and shall be a minimum of 5/8 inch in diameter and 10 feet in length. The rod shall be driven vertically into the ground to a minimum of 9 feet below the surface. The ground rod may be located in a pull box. The service equipment neutral and the system grounding bond shall be connected to the ground rod with a copper -plated bolt or a brass bolt on the ground clamp. Pole foundati ons shall have 25 feet of number 4 AWG bare copper conductor coiled and placed at the bottom of the excavation before concrete is poured. The conductor shall be connected to the pole grounding screw in the hand hole with an approved lug connector. A ground resistance test shall be performed for each installed ground rod prior to final connection of the utility service. Pole foundation coil grounds shall be tested as determined by the Engineer in the field. The ground resistance shall be measured with a three -terminal, fall of potential, direct reading, battery- powered earth tester with a 0.50- to 500- ohm scale or digital read- out. The 25- ohm reading shall be approximately at mid scale. The test shall be performed according to the manufacturer’s instructions and OSHA requirements. Two auxiliary copper clad ground rods shall be driven into the ground a minimum of 3 feet. The lateral spacing for each test rod shall be given in writing on the test report form and the spacing shall be approved by the Engineer . All tests shall be performed in the presence of the Engineer and test results shall be written down, dated, and given to the Engineer for approval. Each ground rod or foundation ground shall be isolated with the bond wires disconnected when the test is being performed. The resistance to ground shall be 25 ohms or less. If it is not, additional ground rods shall be installed as required at least 15 feet from the original ground and shall be bonded to it. The test shall then be repeated for multiple grou nds as necessary to achieve proper grounding below 25 ohms. As many additional ground rods shall be installed as is necessary to achieve proper grounding of 25 ohms or less. The test shall be performed when the soil is dry. The contractor shall not add any chemical, or salt solutions to any portion of the grounding system. All grounding rods and foundation grounds to be tested shall be installed a minimum of 10 days prior to testing unless otherwise determined by the Engineer in the field. TABLE OF CONTENTS INDEX 858 732- 3.04 Service: Service system components and their installation shall conform to regulations and codes listed in Subsection 730- 3 of the specifications, NEC, UL, local applicable codes, and the requirements of the utility company providing service. Service risers shall be PVC -mold or galvanized steel as specified. Fastening of the service risers shall be done through the use of suitable straps and wood screws a minimum of 1- 1/2 inches in length. Tape, nails or other means of attachment shall not be used. Plywood backing boards, when required, shall be 3/4- inch, medium density, paper faced and of an appropriate size to mount all the necessary components. An approved primer and two finish coats of light gray paint, conforming to Section 1002 of the specifications, and acceptable to the Engineer, shall be applied to the plywood before the components are mounted. Special care shall be taken t o ensure that the edges are well sealed. All safety switch and multi -breaker enclosures shall be provided with a padlock to prevent unauthorized persons from operating equipment of disconnects. Padlocks will be furnished by the Department. Meter sockets, when required, shall be approved by the serving utility company. They shall be furnished and installed by the contractor. The meter socket shall be located as shown on the project plans. Meter service inspection shall be approved by the Engineer prior t o service connection by the utility company. If work is required on existing high voltage and series lighting circuits, the contractor shall obtain daily safety circuit clearance from the Department and the serving utility company prior to any work being done. Signs painted “Danger -High Voltage” and “Arizona Department of Transportation” shall be installed permanently by the contractor on all Department electrical service structures. These signs will be furnished by the Department. Fused cutouts on the vol tage side of a series lighting service structure shall be pulled out and safety signs shall be furnished by the contractor and posted on the cutouts before any work is done. The signs shall be painted “Danger -High Voltage” and shall give the name of the company doing the work. 732- 4 Method of Measurement: Conductors (for lighting) will be measured by the linear foot for each gage size as follows:
TABLE OF CONTENTS INDEX 859
Conductors (for signals and lighting) will be measured as a complete unit of work. This method of measurement shall be used for signal and lightin g conductors shown in the signal conductor schedule on the project plans. No measurement or direct payment will be made for conductors in poles and pull boxes, the cost being considered as included in the contract price for the pole and pull box items. Con duit will be measured by the linear foot for each diameter size as follows:
Pull boxes will be measured as a unit for each pull box. 732- 5 Basis of Payment: 732- 5.01 Conductors (for Lighting): The accepted quantities of conductors (for lighting), measured as provided above, will be paid for at the contract unit price per linear foot, which price shall be full compensation for the item, complete in place. 732- 5.02 Conductors (for Signals and Lighting): Conductors (for signals and li ghting), measured as provided above, will be paid for at the contract lump sum price, which price shall be full compensation for the work, complete in place. TABLE OF CONTENTS INDEX