635PULL, SPLICE, AND JUNCTION BOXES

635-1 Description.

Furnish and install pull, splice, and junction boxes as shown in the Plans.

635-2 Materials.

635-2.1 General: Use pull and splice boxes listed on the Department’s Approved

Product List (APL).

635-2.2 Pull and Splice Boxes:

635-2.2 1 General: Use only boxes that meet the requirements of Section 996 and

are listed on the Department’s Approved Product List (APL). Ensure b ox bodies and covers are free of flaws such as cracks, sharp, broken, or uneven edges, and voids. Ensure in-ground boxes have an open bottom design.

635-2.2 2 Marking: Mark boxes in accordance with 996 -5.

635-2.2 3 Dimensions: Unless otherwise shown in the Plans, provide pull and

splice boxes with dimensions in accordance with 996 -5.

635-2.3 Junction Boxes:

635-2.3 1 Fabrication: Provide galvanized steel, aluminum or NEMA 4X non-

metallic junction boxes. Ensure all attachment hardware is Type 316 or 304, passivated stainless steel. Ensure the outside surface has a smooth, uniform finish. Ensure boxes are free of burrs, pits, sharp corners and dents. Ensure all welds are neatly formed and free of cracks, blow holes, and other irregularities.

635-2.3 1.1 Aerial Junction Boxes: Unless otherwise shown in the Plans,

provide aerial junction boxes with minimum inside dimensions of 8 inches wide by 8 inches long and at least 3 inches deep.

635-2.3 1.2 Mounted Junction Boxes: Provide mounted junction boxes

fabricated of 5052 sheet aluminum alloy with a minimum thickness of 1/8 inch. Ensure all mounted junction boxes have a hinged door and lock as specified in Section 676. Unless otherwise shown in the Plans, provide mounted junction boxes for the following installations: For pole and cabinet mounted installations, provide junction boxes with minimum inside dimensions of 13 inches long by 10 inches wide and at least 3 inches deep. For base mounted installations, provide junction boxes with minimum inside dimensions of 21 inches long by 10 inches wide and at least 8 inches deep.

635-2.3 1.3 Embedded Junction Boxes: Provide weatherproof embedded

junction boxes for use in concrete structures or traffic railing s. Include gasketed weatherproof covers made of the same materi al as the box and stainless steel, tamper resistant screws for securing the cover. Fabricate galvanized steel boxes and their covers from steel meeting the requirements of ASTM A36 and galvanized in accordance with ASTM A123. For embedded junction boxe s not exposed to vehicular impacts, provide the following types of junction boxes. Where the structure’s environmental classification is slightly or moderately aggressive, provide a galvanized steel or NEMA 4X (non-metallic) box, FY 2023-24 Return to Table of Contents as approved by the Enginee r. Where the structure’s environmental classification is extremely aggressive, provide a NEMA 4X (non-metallic) box, unless otherwise directed by the Engineer. For embedded junction boxes exposed to vehicular impacts, provide a galvanized steel box reg ardless of the structure’s environmental classification.

635-2.3 2 Barrier Terminal Blocks: Provide a barrier terminal block with a

minimum of ten positions and rated at 600 VAC in all aerial and mounted junction boxes. Ensure each terminal block positio n has two screws electrically connected by a shorting bar or other Department approved method. Ensure all terminal block positions are numbered sequentially.

635-3 Installation.

635-3.1 General: Do not install power and communication cables in the same bo x unless

otherwise shown in the Plans. When signal or 120 volt (or greater) power is present, ground all metal covers in accordance with Section 620. Ensure metal junction boxes are grounded and bonded in accordance with the NEC Section 314.4.

635-3.2 Pull and Splice Boxes: Install pull and splice boxes in accordance with Standard

Plans, Index 635-001. Ensure pull and splice boxes are sized for the amount of cable to be placed inside. Ensure that the pull or splice box cover is flush with the co ncrete apron or sidewalk. Do not install pull or splice boxes in roadways, driveways, parking areas, or public sidewalk curb ramps. Avoid placing pull and splice boxes in low -lying locations with poor drainage. Ensure that pull and splice boxes house fiber optic cable without subjecting the cable to a bend radius less than 14 times the diameter of the cable. Install identification plates according to the box manufacturer’s instructions.

635-3.2 1 Placement and Spacing: Place pull and splice boxes as shown in the

Plans and at the following locations, unless directed otherwise by the Engineer:

635-3.2 2 Electronic Box Marker: Equip all pull and splice boxes buried below

finish grade with an electronic box marker inside the pull or splice box to mark the location. Ensure that the electronic box marker i s a device specifically manufactured to electronically mark and locate underground facilities. Ensure that the electronic box marker includes circuitry and an antenna encased in a waterproof polyethylene shell. Ensure that the outer shell is FY 2023-24 Return to Table of Contents impervious to minerals, chemicals, and temperature extremes normally found in underground plant environments. Ensure that the electronic box marker does not require any batteries or active components to operate. Ensure that electronic box markers used to mark fiber opti c cable and general telecom applications are orange in color and operate at 101.4 kHz. Ensure that the electronic box marker’s passive circuits produce an RF field when excited by a marker locator to direct the locator to the marker’s position. Ensure that the electronic box marker has a minimum operating range of 5 feet from the marker locator.

635-3.3 Aerial Junction Boxes: Install aerial junction boxes in accordance with Standard

Plans, Index 634-002.

635-3.4 Mounted Junction Boxes: Install mounted jun ction boxes in accordance with

Standard Plans, Index 676-010. Ensure that the bottom surface of pole mounted junction boxes is a minimum of 4 feet above the finished grade.

635-3.5 Cable Terminations: Make cable terminations in junction boxes in accordanc e

with Section 632. Route and form the cable to allow access to the terminal screws. Do not cover the terminal identification numbers with the cable.

635-4 Relocation of Pull, Splice, and Junction Boxes.

Relocation of pull, splice, and junction boxes shal l consist of removing an existing box and installing the box at the location shown in the Plans. Restore the area of the box removal and relocation to the condition of the adjacent area. The costs for restoration will be included in the Contract unit price of the relocation. Boxes damaged due to the Contractor’s operations must be replaced by the Contractor at no cost to the Department. Replacement boxes must be of the same material and size of the existing box, unless directed otherwise by the Engineer.

635-5 Warranty.

Ensure all pull, splice, and junction boxes have a manufacturer’s warranty covering defects for a minimum of one year from the date of final acceptance in accordance with 5 -11 and Section 608. Ensure the warranty includes providing replacem ents, within 30 calendar days of notification, for defective parts and equipment during the warranty period at no cost to the Department or the maintaining agency.

635-6 Method of Measurement.

The Contract unit price each for pull, splice, and junction bo x, furnished and installed, will consist of the pull, splice, and junction box including all required hardware for the type of box and location as specified in the Contract Documents, and all labor and materials necessary for a complete and accepted instal lation.

635-7 Basis of Payment.

Price and payment will be full compensation for all work specified in this Section, except grounding. No separate payment will be made for the removal of pull, splice, and junction boxes. Payment will be made under: Item No. 635- 2- Pull and Splice Boxes - each. Item No. 635 - 3- Junction Boxes - each. FY 2023-24 Return to Table of Contents SECTION 639 ELECTRICAL POWER SERVICE ASSEMBLIES

639-1 Description.

Power service assemblies are utilized for signals, lighting, ITS, and other roadway applications. Install electrical power service assemblies for either overhead service or underground service in accordance with the details shown in Standard Plans, Index 639-001 or 639-002. Coordinate with the power company to provide electrical service to the locations shown in the Plans. Consult and c ooperate with the power company when power is needed at the service point. Furnish and install only those parts of the met ering equipment or co nnections that are required by the power company in the locality involved.

639-2 Definitions.

639-3 Materials.

639-3.1 Weatherhead: Use a weatherhead made of a copper free aluminum alloy with

three electrical service wire entrance holes, meeting National Electric Code ( NEC) requirements.

639-3.2 Conduit: Use conduit meeting the requirements of Section 630. Meet the

requirements of Section 562 for coat ing all field cut and threaded galvanized pipe.

639-3.3 Electrical Service Wire: For signal and ITS service points, u se stranded copper

wire with XHHW (cross -linked polyethylene (XLPE) high heat -resistant, water -resistant) insulation, rated at 600 V in dry and wet condition s, no smaller than No. 6 AWG for connection s between service disconnect and traffic and ITS cabinets, unless otherwise shown in the Plans. For lighting service points, use single-conductor cable Type THWN-2 no smaller than No. 6 AWG fo r connections between service disconnect and load center .

639-3.4 Meter Base: Use meter bases approved by the local electric power company.

639-3.5 Service Disconnect:

FY 2023-24 Return to Table of Contents