647Traffic Control Signal Installation

647.1 General Description

This section contains requirements for installing traffic control signal equipment, submittal processes, testing, warranty, and contractor’s signal maintenance responsibilities. The contractor shall install all equipment, poles, bases, wiring, and incidental materials required for a complete and functional traffic control signal installation according to this section. Traffic control signal installations include traffic signals, ramp meters, Pedestrian Hybrid Beacons (PHB), Rectangular Rapid Flashing Beacons (RRFB), flashing beacons, and school speed zone flashing beacons. The Department shall perform reviews and grant approval on projects constructed at intersections and any other location under the jurisdiction of the Department. For intersections and locations not under the jurisdiction of the Department, the local agency having jurisdiction shall perform reviews and grant approval. All specified traffic control signal equipment shall be installed without modification. The contractor shall install the traffic control signal equipment according to the contract. For traffic control signal installations, no deviations in the design and operation of the traffic control signal are permitted without the written approval of the Engineer. Table 1 provides a listing of roles, responsibilities and approval steps in the preconstruction and construction process. Table 1 – Approval Authority for Traffic Control Signals Constructed at Locations Under the Jurisdiction of GDOT Role or Department Nature of Approval Authority Reference Project Design and Operations Change Approval (Preconstruction) Engineer Review traffic control signal design or operation changes, if applicable 647.1 Product Materials Approval List (Preconstruction) Office of Traffic Operations Maintain QPL 48, Traffic Control Signal & ITS Equipment SOP 42 Project Traffic Control Signal Final Field Checks (Preconstruction) Construction Manager or designee (Office of Materials and Testing) Review traffic control signal pole submittal 647.1.03.E.1 State Bridge and Structural Design Engineer Review Mast Arm Pole Chart, if applicable 647.1.03.E.4 District Signal Manager Review the span wire sag calculations for new installations 647.3.06.K.2 Project Material Approval (Preconstruction) Construction Manager or designee (District Traffic Engineer) Prior to pole and mast arm order by the contractor, review for final location of poles and final length of mast arms based on field adjustments

647.1.03 E.1.

a through c Table 1 – Approval Authority for Traffic Control Signals Constructed at Locations Under the Jurisdiction of GDOT Role or Department Nature of Approval Authority Reference Project Material Approval (Preconstruction) Construction Manager or designee (Office of Traffic Operations) Review equipment submittal, except for traffic control signal poles 647.1.03.B.1 Construction Manager or designee (District Signal Manager) Verify exact equipment submitted by the contractor is listed in the QPL 647.1.03.B.3 Construction Manager or designee (District Traffic Engineer) Issue letter regarding the acceptability or rejection of the material submitted 647.1.03.B.4 Construction Manager or designee (State Signal Engineer) Written approval of product materials not listed on the QPL 647.1.03.C.1 Construction Manager or designee (State Signal Engineer) Resubmittal of rejected materials 647.1.03.C.2 Construction Manager or designee (State Signal Engineer) Written acceptance of the material submittal 647.1.03.C.3 Construction Manager or designee (State Signal Engineer) Replace the defective state-supplied equipment, if applicable 647.2.03.A Construction Manager or designee (District Signal Manager) Review and direct the disposal for removed or replaced traffic control signal equipment, including coordination with the District Traffic Signal Shop

647.3.01 E

Project Construction Phase Approval (Local) Power Utility Perform field inspection of power service 647.3.01.B.1.i Construction Manager or designee (District Traffic Engineer) Grant permission to begin work 647.3.01.D.1 Construction Manager or designee (District Signal Manager) Perform field inspection of traffic control signal installation process 647.3.03.B.4.a Office of Materials and Testing Review and approve anchor bolts 647.3.06.E.1.g Construction Manager Perform foundation concrete test (cylinder strength) 647.3.06.E.1.e Payment and Acceptance Approval (Construction) Construction Manager or designee (District Traffic Engineer) Recommend payment only after the successful completion of the operational test period

647.3.03 B.4.b

Construction Manager or designee (District Traffic Engineer) Issue written acceptance of project before Final Acceptance is granted 647.3.03.C Table 1 – Approval Authority for Traffic Control Signals Constructed at Locations Under the Jurisdiction of GDOT Role or Department Nature of Approval Authority Reference Payment and Acceptance Approval (Construction) Construction Manager District Signal Manager to provide letter to the Construction Manager showing the start, termination, suspension, or successful completion of the operational test.

647.3.03 C.1

Construction Manager or designee (District Traffic Engineer) Approve partial payment requests 647.5.01.B

647.1.01 Definitions, Acronyms, and Abbreviations

A. Definitions 1. Activation: a traffic control device becomes operational for the purposes of controlling traffic during the construction project. 2. Authority Having Jurisdiction (AHJ): refers to GDOT, counties, or local municipalities. 3. Construction Manager: representative of the Engineer from the District Construction Office. 4. Controller Cabinet Assembly: a controller cabinet assembly equipped with a controller unit and auxiliary equipment necessary to regulate a flow of motorized and non-motorized users at signalized intersection or meter the flow of traffic onto a full access-controlled road facility. 5. Controller Unit: that part of a controller assembly that can receive and analyze field inputs, reacting to those inputs per programmed timing parameters, and providing outputs to the proper signal indications. Refer to Section 925 for material specifications of the controller unit. 6. Failure: traffic control device or ancillary equipment element becoming unable to comply with the Project requirements and applicable standards described in the contract. 7. Field Cabinet: a cabinet used to house electronic devices for traffic control device installations, UPS, flashing beacon, or other auxiliary equipment as defined in the contract. 8. Make Ready Work: work required by utility companies to adjust the position of power and communication lines in advance of attaching traffic control signal or network infrastructure. 9. Operational Test: consists of field test performed by the Department (all sections), followed by a burn-in period of a minimum of 30 calendar days (all sections), a final inspection and acceptance. These tests verify completion according to the contract, full functionality of all systems and, if applicable, communication over the GDOT network. 10. Pedestrian Hybrid Beacon (PHB): an electrical device located primarily at mid-block locations to serve non- motorized users that is intentionally placed in a dark mode (no indications displayed) between periods of operation and, when operated, displays both steady and flashing traffic control signal indications (yellow and red) designed to control traffic. 11. Power Disconnect: Master switch to disconnect electrical power from the local utility to the traffic control signal. 12. Power Service: The point of electrical power provided by the local utility. Encompasses the power service drop and meter. 13. Ramp Meter: an electrical device located on a full access-controlled road facility that assigns motorized users the right-of-way as part of a lane merging process. 14. Rapid Rectangular Flashing Beacon (RRFB): an electrical warning device located primarily at mid-block locations to serve non-motorized users that is intentionally placed in dark mode (no indications displayed) between periods of operation and, when operated, displays a flashing warning (yellow) indication when actuated by pedestrians. 15. Repair Time: the time it takes, exclusive of requirements for mobilization, travel time, and/or the coordination of any lane closures, to diagnose, repair, and re-establish full functionality and operations of the site(s). 16. Response Time: the time it takes the contractor to mobilize repair technician(s) from the time they receive the problem notification from the Department and arrive at the site(s). 17. Submittal: documentation required by the contract that the contractor must submit for the Department’s review, acceptance, or approval. Submittals may include product cut-sheets, shop drawings, working drawings, material test reports, material certifications, Project progress schedules, and schedule updates. 18. Traffic Control Signal Installation: a complete installation with a controller assembly, detection systems and required accessories, including necessary cabling, wiring, detection systems, controller, and communications to comprise an operational traffic signal, ramp meter, PHB, or RRFB per the contract. 19. Traffic Control Signal: an electrical device that provides visual information for transportation users to manage the movements of motorized and non-motorized users, including traffic signal, ramp meter, PHB, and RRFB. 20. Traffic Signal: an electrical device that assigns the right-of-way to motorized and non-motorized users, as defined by the MUTCD. 21. Uninterruptible Power Supply (UPS): a power management device that serves a dual purpose of normalizing the flow of electricity from the power service and supplies backup power to the controller cabinet assembly when power is lost. B. Acronyms and Abbreviations The following acronyms, abbreviations, and terminology are used throughout the traffic control signal specifications. 1. AASHTO American Association of State Highway and Transportation Officials 2. ADA Americans with Disabilities Act 3. ANSI American National Standards Institute 4. API Application Programming Interface 5. ASTM American Society of Testing and Materials 6. ATMS Advanced Traffic Management System 7. AWG American Wire Gauge 8. AWW A.W. Williams Inspection 9. CALTRANS California Department of Transportation 10. CF Configuration Change Log 11. CRC Cyclic Redundancy Check 12. CSA Canadian Standards Association 13. DHCP Dynamic Host Configuration Protocol 14. DIN Deutsche Industrie Norm 15. DNS Domain Name System 16. EIA Electronic Industries Association 17. FCC Federal Communications Commission 18. FCS Frame Check Sequence 19. FHSS Frequency-Hopping Spread Spectrum 20. FHWA Federal Highway Administration 21. FYA Flashing Yellow Arrow 22. GDOT Georgia Department of Transportation 23. GND Ground Connection 24. GSM Global System for Mobile 25. GRS Galvanized Rigid Steel 26. HDPE High- Density Polyethylene 27. IEC International Electrotechnical Commission 28. IMSA International Municipal Signal Association 29. IP Internet Protocol 30. ITE Institute of Transportation Engineers 31. ITS Intelligent Transportation System 32. IVDS Intersection Video Detection System 33. LCD Liquid Crystal Display 34. LED Light Emitting Diode 35. LOFO Last On, First Off 36. MOT Maintenance of Traffic 37. MOV Metal Oxide Varistors 38. MPEG Moving Picture Experts Group 39. MUTCD Manual on Uniform Traffic Control Devices 40. MVDS Microwave Vehicle Detection System 41. NEC National Electrical Code 42. NEMA National Electrical Manufacturers Association 43. NESC National Electrical Safety Code 44. NPT National Pipe Thread 45. OD/ID Outer Diameter/Inner Diameter 46. PCA Printed Circuit Assembly 47. PCB Printed Circuit Board 48. PDF Portable Document Format 49. PHB Pedestrian Hybrid Beacon 50. PVC Polyvinyl Chloride 51. QPL Qualified Products List 52. RJ Registered Jack 53. RMS Root Mean Square 54. RRFB Rapid Rectangular Flashing Beacon 55. TEES Transportation Electrical Equipment specifications (CalTrans) 56. UL Underwriters Laboratories 57. UPS Uninterruptible Power Supply 58. USB Universal Serial Bus 59. UV Ultraviolet Light 60. VAC Voltage Alternating Current 61. VDS Vehicle Detection System 62. WDT Watchdog Timer 63. WMDS Wireless Magnetometer Detection System 64. WVDS Wireless Vehicle Detection System 65. XHHW XPLE High Heat-Resistant Water-Resistant 66. XLPE Cross- linked Polyethylene

647.1.02 Related References

A. GDOT Standard Specifications 1. Section 105—Control of Work 2. Section 106—Control of Materials 3. Section 107—Legal Regulations and Responsibility to the Public 4. Section 108—Prosecution and Progress 5. Section 150—Traffic Control 6. Section 500—Concrete Structures 7. Section 501—Steel Structures 8. Section 535—Painting Structures 9. Section 615—Jacking or Boring Pipe 10. Section 631—Dynamic Message Signs 11. Section 636—Highway Signs 12. Section 639—Strain Poles for Overhead Sign and Signal Assemblies 13. Section 645—Repair of Galvanized Coatings 14. Section 680—Highway Lighting 15. Section 681—Lighting Standards and Luminaires 16. Section 682—Electrical Wire, Cable, and Conduit 17. Section 700—Grassing 18. Section 755—Electrical Work 19. Section 800—Coarse Aggregate 20. Section 801—Fine Aggregate 21. Section 832—Curing Agents 22. Section 833—Joint Fillers and Sealers 23. Section 850—Aluminum Alloy Metals 24. Section 852—Miscellaneous Steel Materials 25. Section 853—Reinforcement and Tensioning Steel 26. Section 854—Castings and Forgings 27. Section 861—Piling and Round Timber 28. Section 870—Paint 29. Section 886—Epoxy Resin Adhesives 30. Section 910—Sign Fabrication 31. Section 911—Sign Posts 32. Section 912—Sign Blanks and Panels 33. Section 913—Reflectorizing Materials 34. Section915—Mast Arm Assemblies 35. Section 922—Electrical Wire and Cable 36. Section 923—Electrical Conduit 37. Section 924—Miscellaneous Electrical Materials 38. Section 925—Traffic Control Signal Equipment 39. Section 926 – Wireless Communications Equipment 40. Section 927 – Wireless Communications Installation 41. Section 935—Fiber Optic System 42. Section 936— Closed Circuit Television (CCTV) 43. Section 937— Detection Systems 44. Section 939—Communications and Electronic Equipment 45. Section 942—ITS General Requirements B. Referenced Documents Standards and documents referenced throughout this Section are provided in Table 2. Table 2 – Referenced Documents AASHTO Roadside Design Guide, latest edition Americans with Disabilities Act (ADA), Chapter 6 Curb Ramps and Pedestrian Crossings IMSA Wire and Cable Specifications Manual on Uniform Traffic Control Devices (MUTCD), latest edition NFPA 70, National Electrical Code, latest edition National Electrical Safety Code (NESC) NEMA TS 1, Traffic Control Systems NEMA TS 2, Traffic Controller Assemblies with NTCIP Requirements, latest edition UL 1449, Standard for Surge Protective Devices

647.1.03 Submittals

A. General 1. All submittals shall consist of a single file in electronic PDF file format as specified herein. 2. All submittals shall be submitted to the Construction Manager. 3. All incidental materials required for any pay item shall be contained in the submittal regardless of whether it was listed in the specifications. 4. Do not submit partial submittals for a pay item. 5. Items with long procurement times, such as poles, may be submitted separately to accommodate work schedule. 6. Do not procure or install materials or components proposed on the contract until material submittals or shop drawings are submitted for review and approved by the Department. 7. The Department will not be liable for any equipment or material purchased, work done, or delay incurred prior to the Department’s approval of said equipment or material through the materials submittal data process. 8. The Department will approve or reject all submittals within 21 calendar days of receipt of a complete package, unless otherwise specified or indicated by the Department. 9. Do not interpret approval of the submittals as approval of any deviation unless such deviation is identified in writing in the submittal cover letter. 10. Any failure of the Department to discover or note any unsatisfactory material will not relieve the contractor of his responsibility for providing a complete operable Traffic Control device installation as called for under the terms of the contract. B. Material Selection 1. Use only product materials that are on the Department’s QPLs. These products have been evaluated by the Department and may be used without sampling or pre-testing. They include, but are not limited to: a. QPL-5 Electrical Conduit b. QPL-34 Work Zone Traffic Control Devices c. QPL-35 Drive Type Galvanized Steel Sign Posts d. QPL-46 Traffic Markings Producers e. QPL-48 Traffic Signal & ITS Equipment f. QPL-52 Overhead Signs Supports, Strain Poles, and Lighting Standards g. QPL-61 Reinforcement Steel Rolling Mills h. QPL-63 Ground Mounted Breakaway Sign Supports i. QPL-69 Flexible Delineator Post j. QPL-71 Glass Beads k. QPL-72 Guy Wire/Span Cable l. QPL-75 Inductive Loop Sealants m. QPL-76 Raised Pavement Markers and Channel Markers n. QPL-78 Traffic Signal Pull and Junction Boxes o. QPL-80 Highway Sign Manufacturers 11. Submit a letter to the Construction Manager stating which QPL items will be used. Submittal letter shall include QPL number and product description. 12. The Construction Manager or designee will determine that the construction item is the same material identified on the appropriate QPL and will acknowledge receipt of these items in the project diary or as required by the construction manual. Support poles are verified by the Office of Bridge and Structures. 13. The Construction Manager or designee will notify the contractor of the acceptability of any accessories not covered by the QPL for use on the project. C. Material Submittal Process 1. Written approval of product materials not listed on the QPL is required from the Construction Manager or designee. 2. The Construction Manager or designee may determine that submitted material is approved, in which case no further action is required. If rejected, the Contractor shall re-submit materials within 21 calendar days of notification of rejection. Resubmittal of subsequent materials for review shall be considered the start point of a new approval cycle as described. 3. The Construction Manager or designee will advise, in writing, as to the acceptability of the material submitted. D. Submittal Costs 1. No separate measurement or payment will be made for submittal costs. 2. All costs associated with reproduction of submittal material documents, samples, and mailing expenses shall be the responsibility of the contractor and are not subject to reimbursement by the Department. 3. All submittal material becomes the property of the Department. E. Submittal Requirements 1. Steel Strain Pole, Concrete Strain Pole, or Steel Pole Certification a. Prior to ordering signal poles, locate utilities and stake the Right-of-Way for the purpose of adjusting pole locations, if necessary. Coordinate with the District office and local agencies to verify the location of any buried traffic/ITS communication lines. The Department is not a member of 811. b. Obtain approval from the Construction Manager or designee for any design deviation from the contract. c. Final pole locations will be approved by the Construction Manager or designee. Determine the final length of mast arms based on field adjusted pole locations. d. Instruct the supplier or manufacturer of the strain poles or steel poles with mast arms to submit a certification, including mill certificates to the Construction Manager and: Georgia Department of Transportation Office of Materials and Testing 15 Kennedy Drive Forest Park, GA 30297 e. Instruct the supplier or manufacturer to include the following in the certification: A statement that the items were manufactured according to the specifications, including the specification section number Project number f. Instruct the supplier or manufacturer to send the transmittal letter to the Department in PDF file format. g. Prepare shop drawings and related signal strain pole design calculations, following the vertical clearance requirements and span wire sag requirements. h. Show roadway and pole base elevations on the drawings. Account for any pole locations that deviate from the proposed plans. i. Show all dimensions and material designations of the designs on the drawings. See Section 501.1 for the shop drawing requirements for poles and anchor bolts. j. Submit all shop drawings and related signal strain pole design calculations to the Construction Manager. The pole submittal information will be forwarded to the State Bridge and Structural Design Engineer for review and approval. k. Provide bending moment at yield to determine the foundation size according to the signal strain pole foundation drawings. Obtain written approval prior to pole fabrication and installation. l. Upon acceptance of the pole certification, provide one copy of the design calculations and shop drawings to the agency responsible for maintaining the traffic control signal installation. 2. Traffic Control Signal Item Certification a. Submit material catalog product numbers and descriptions to the Department and maintaining agency. b. Reference the P.I. number and QPL number for the following traffic control signal items: Signal faces (vehicular and pedestrian) LED signal modules (vehicular and pedestrian) Mounting hardware Controller units Controller cabinet assemblies UPS Detection system Monitors Cable Load switches Blank-out signs Lane use signals Preformed cabinet bases Other related signal equipment (including conduit, pullboxes, grounding electrodes, enforcement indications, etc.) 3. Test Results Submittals a. Submit applicable quality control testing from the manufacturers for the following items: Controller unit Controller cabinet assembly Conflict monitor testing Detection system testing Signal cable and inductance loop wire Other operational testing required by the Department b. Provide a copy of the applicable test result submittals to the maintaining agency, if different than the Department. c. Refer to Section 647.3 for details on testing requirements. 4. Mast Arm Pole Charts a. For locations with mast arm pole installations, submit Mast Arm Pole Chart for review and approval by the State Bridge and Structural Design Engineer. The Mast Arm Pole Chart shall be a drawing formatted on an 11 in. x 17 in. (279 mm x 432mm) ANSI B sheet showing the following in both plan and cross-section views: Curb lines Location of mast arm pole based on utility information and field location verified by contractor. (Final location of mast arm pole shall meet the criteria for setback from the road as specified in the AASHTO Roadside Design Guide and in the Standard Detail Drawings.) Distance labeling from both adjacent curbs to mast arm pole Distance labeling along mast arm from pole to curb and from curb to each proposed traffic signal face Directional arrow Street names Position of luminaire arms b. Once the Master Arm Pole Chart is approved, use the distances measured to the proposed traffic signal face locations when ordering the mast arm to verify that the mast arm is fabricated with pre-drilled holes for traffic signal face wiring in the correct locations.

647.2 Materials

647.201 Delivery, Storage, and Handling A. Include shipping and handling fees in the Contractor’s base price. B. Be responsible for equipment, components, and materials prior to installation and final acceptance. C. Take precautions to protect materials from theft, vandalism/tampering, dents, scratches, dust, temperature, weather, cutting, paint, and other hazardous conditions prior to installation. D. Replace damaged or lost material as required by the Department.

647.2.02 Tools and Equipment

A. Furnish equipment, tools, and superintendence for the completion of the work to be done in accordance wi\ntract. B. Verify equipment and tools mobilized for the work are in 100% working order and calibrated, if applicable, such as loop and ground testing equipment, prior to placing it in commission for the project. C. Verify equipment and tool operators are trained and qualified before operating equipment on the project.

647.2.03 State-Supplied Equipment

A. Coordinate with the Construction Manager or designee to receive Traffic Control Signal Equipment from the Department. B. contractor shall acknowledge receipt of equipment, noting an itemized list of equipment and quantities, on Department 592 form. C. Inspect the equipment for damage and verify that equipment will power on within 14 calendar days after receiving the equipment. 1. Report to the Department, in writing, that the state-supplied equipment was received in good condition and operates when power is properly applied. 2. Notify the Department in writing if the state-supplied equipment is defective. The Construction Manager or designee will coordinate the replacement of defective equipment. 3. If no written dissent is received after 14 calendar days or if equipment is installed in the field, the Department shall consider this equipment to be satisfactory and accepted. D. Supply new, like kind equipment to replace any state-supplied equipment that is lost or damaged while in contractor’s possession.

647.2.03 State-Supplied Equipment

See Section 925 for traffic control signal equipment specifications.

647.3 Construction

647.3.01 Construction Management Requirements

A. Contractor Superintendent 1. Submit the name of the Traffic Control Device Contractor Superintendent and a summary of the individual’s relevant experience and qualifications to the Department for approval. 2. Do not change the Traffic Control Device Contractor Superintendent without the prior written approval of the Department. 3. Traffic Control Device Contractor Superintendent or designee shall be present to supervise work performed by subcontractors. 4. Provide a Qualified Electrician as defined in Section 755 when installing and connecting the power service to the traffic control equipment. B. Utility Coordination 1. Utility Permit Application a) Establish the electrical power service for each traffic control device as specified in the contract. b) Furnish or install equipment and materials that shall become part of the regional utility facility. c) Coordinate such work with the utility representatives. d) Furnish and install additional power outlet strips in new and existing equipment racks if needed for the new equipment. e) Furnish equipment and materials and perform work in accordance with the contract and applicable utility agency standards and procedures. f) Meet standards required by utility companies as related to the equipment, materials, and installation associated with attachment to related power service feeds. g) Test the power utility service to confirm voltage levels and current capacity and the serviceability of any circuit connected to the traffic control device. h) Power utility representatives are not authorized to revoke, alter, or waive any requirements or design of materials or facilities provided under the specifications. i) The inspection of the contractor’s work by the utility providers or the failure to inspect the contractor’s work by the utility provider representatives shall not relieve the contractor of any requirements of the specifications. j) Notify the Department and the utility providers’ representatives of planned work. 2. Utility Maintenance a) The contractor shall be responsible for establishing utility services and ongoing monthly costs related to utility services until Final Acceptance of the traffic control devices. b) After Final Acceptance, provide an orderly transfer of the services and permits to the local government or maintaining agency. 3. Utility Adjustments a. Refer to the local utility for utility clearance requirements. b. Verify make ready work has been completed. C. As Built Plans 1. Provide detailed as-built plans of the work performed. 2. Submit within 30 calendar days after completion of installation or as otherwise specified in the contract. 3. Show all changes and deviations from the original plans using electronic PDF file format, with markup shown in red text and lines. 4. Include all materials and installation work, along with all structural elements, assemblies and communications for each traffic control device in the as built plans. 5. Provide the following information regarding electrical service: a. Address of the service pole. b. Power services from the meter base, including all cables from the service point. c. The electric provider’s name, the account number and the meter base information. d. Show routes and locations of the final cable installation. 6. Include any other device-specific details that are required in the individual specifications. D. Traffic Control Signal Equipment Modification and Removal 1. The Department may continue to maintain project related traffic control devices after issuance of Notice to Proceed. The Construction Manager or designee will coordinate the contractor assuming responsibilities for maintenance, operations, and response to existing traffic control devices at the time work begins. 2. Remove existing signal equipment that is not used in the final installation when the new signal equipment is operational. 3. Carefully remove equipment to minimize damage and retain it in its original form. This equipment may include: a. Strain poles, including the foundation down to 3 ft. (0.9 m) below ground level finished grade. b. Timber poles shall be completely removed, including the portion below ground level. c. Controller cabinet assembly, including contents, preformed cabinet base, and work pads. d. Original traffic signal faces, including span wire support. e. CCTV cameras f. Vehicle and pedestrian detection systems g. Other equipment not retained in the final installation. 4. Verify that unused equipment is secured and disposed of in accordance with all regulations and the Department’s specifications. 5. Replace traffic control signal equipment that the Construction Manager or designee determines has been damaged or destroyed during installation, modification, or removal of the traffic control signal, at no expense to the Department. Replace with new material. 6. If the Department finds that the existing material shown in the contract to be relocated is unsatisfactory, replace with new material. The costs shall be paid for at contract prices, if applicable, or as extra work. 7. Remove old traffic signal faces by the end of the day that the new signal equipment is placed in operation. Remove all other signal equipment within 7 calendar days after operations of the newly installed equipment. E. Equipment Disposal 1. Return all removed or replaced traffic control signal equipment to District Traffic Signal Shops unless otherwise noted in the contract or as directed by the Construction Manager or designee. 2. Provide an inventory list and arrange a mutually agreeable delivery time with the Construction Manager or designee 24 hours in advance. 3. Contractor shall be responsible for proper disposal of all materials not returned to the District Traffic Signal Engineer.

647.3.02 Warranty and Maintenance

A. General 1. See Section 150. 2. If a traffic signal that is the responsibility of the contractor is not functioning: a. Non-Emergency Commence work on this signal within 48 hours of the written notice from the Department. Failure to respond will result in a per calendar day charged against monies due or that may become due until the maintenance work is started. See Section 108. In addition, the cost of labor and material will be charged by the Department if the Department takes corrective action using its own forces or local municipality forces. The contractor shall be responsible for all materials, equipment, and expertise necessary to correct signal malfunction or repair. The Department or local municipality shall not be held responsible or liable for alleged damage to the signal or as a result of the signal malfunction due to problems that may occur after the Department or local municipality forces make repairs. Emergency If the Department determines that the signal malfunction or failure is an operational hazard, take corrective action within three hours of the first attempt of notification. Response shall be considered only when qualified personnel and equipment are provided. Failure to respond within three hours shall result in a non-refundable deduction of money of $1,000.00 with an additional charge of $500.00 per hour thereafter until qualified personnel and equipment arrive onsite and begin corrective action. In addition, the cost of labor and material will be charged by the Department if the Department takes corrective action using its own forces or local municipality forces. The Department shall not be held responsible or liable for alleged damage to the signal or as a result of the signal malfunction due to problems that may occur after Department or local municipality forces make emergency repairs. The contractor shall be responsible for all materials and equipment necessary to correct signal malfunction or repair. Final Acceptance will not be given until payment for such work is received. B. Maintenance 1. Provide maintenance support services and assume responsibility of existing traffic control devices, the Department’s communications network, and ancillary equipment damaged by the contractor, including labor, equipment, and materials associated with the repair or replacement of said materials and equipment from the first day of field impact continually until project acceptance. Refer to Section 105 for requirements. 2. Provide maintenance support services during construction between construction initiation and project acceptance by the Department as follows: a. See Section 105 for requirements. The Department reserves the right to deduct the cost of maintenance activity from monies due or to become due the contractor if the contractor fails to remedy unsatisfactory maintenance within 48 hours after receipt of such notice. b. During the construction period, the Construction Manager or designee will send a written problem notification of the issue. c. Provide a technical support phone line and the ability to provide replacement parts/material for both warranty and non-warranty repair. d. Provide full technical support, including material and labor, and consultation to the Department or a user that is responsible for maintenance of the traffic control devices during the contract. e. Enter a precise description of repair work performed into the log book (supplied by the Department and located in the controller cabinet assembly). f. The Department will designate representatives and alternates as contact persons for the contractor. 3. Provide maintenance support services following project acceptance during the remaining warranty period. The traffic control device equipment manufacturer(s) or the party designated by the manufacturer(s) shall be responsible for providing repairs or replacements for failed equipment as follows: a. During the warranty period, the Department’s coordinator of maintenance or designee will send problem notification to the manufacturer(s) or the party designated by the manufacturer(s). b. The manufacturer or designated party shall respond to the Department, the Department’s designee, or maintaining agency within one business day of receiving the problem notification. c. As requested by the Department, the Department’s designee, or maintaining agency, perform remote diagnostic tests and provide a technical support phone line to assist with troubleshooting and repair activity. d. Furnish replacements for any non-critical part or equipment found to be defective during the warranty period at no cost to the Department, the Department’s designee, or maintaining agency within 14 calendar days of notification by the Department. e. Provide firmware or software updates provided by the manufacturer associated with the system at no cost to the Department, the Department’s designee, or maintaining agency during the warranty period. f. Updates provided by the manufacturer or the party designated by the manufacturer shall not degrade the original functionality of the product under warranty. C. Warranty 1. Provide manufacturer’s warranties on electrical, electronic, or mechanical equipment furnished, except state- supplied equipment. 2. Verify that warranties are consistent with those provided as customary trade and industry standard practices; or as otherwise specified in the contract. 3. Verify that warranties are continuous and state that they are subject to transfer. 4. Acceptance or approval of the work does not waive warranties where required by the specifications. Final Acceptance will not be granted until all warranties are received. 5. Repair and/or replace all equipment and material supplied under the contract that have been determined by the Department to not meet specifications. 6. The Department reserves the sole right to determine suitability or unsuitability of the supplied equipment and material. The contractor shall bear the total cost of delivery and transportation related to the repair and replacement of equipment and material throughout the duration of the contract unless otherwise approved by the Department. 7. Transfer to the Department any warranties remaining on all items after Final Acceptance. Perform transfer at 12:01 AM of the day following acceptance.

647.3.03 Testing

A. Department Responsibilities 1. The Department will observe, provide inspection and testing oversight, review, accept, and reject inspections and operational tests. 2. During the Operational Test: a. The Department will notify the Contractor upon failure or malfunction of equipment. b. If the contractor does not provide the services enumerated above under the contract responsibilities, the Department or its authorized agents may, in the interest of public safety, take emergency action. c. The Department will deduct costs from the monies due or to become due the contractor under the contract as a result of these emergency actions. d. Such action by the Department will not void any guaranties or warranties or other obligations set forth in the contract. B. Test Results Submittal 1. Submit the results of the testing of the following items to the Construction Manager. 2. A copy of the test result submittals shall be provided to the maintaining agency. 3. Submit test results of the following applicable items: a. Controller and Cabinet Testing from Manufacturer (Including conflict monitor) b. Inductance Loop Detector or other Detection System Testing c. IP Communications d. Audible Pedestrian Pushbuttons e. UPS f. Railroad Preemption g. Connected Vehicle Devices h. Other specialized equipment by other agency (e.g. emergency pre-emption, bus rapid transit, etc.)

647.3.04 Construction Requirements

A. General 1. Traffic Control Signal installations shall meet the appropriate NESC requirements. 2. Comply with NEC requirements and Section 680.3 for grounding and bonding requirements for the power service. 3. The NEC will apply up to the power service termination within the traffic control device cabinet. Beyond that point, IMSA shall apply unless stated otherwise in this Section. 4. No splicing of cables or exposed wiring is permitted except for loop wires to loop lead-in cable. 5. Provide wiring entry and exits that are made at the side or underneath components; no exposed top entry or exits are permitted. This requirement extends to enclosures, junction boxes, support arms, or any other externally exposed devices. 6. Route and secure wiring and cabling to avoid sharp edges and to avoid conflicts with other equipment or cabling. 7. Electrical work shall comply with applicable requirements of the local power utility. 8. Install equipment in new or existing rack space in accordance with the equipment manufacturer’s recommendations, including mounting, interconnection wiring and electrical service. 9. Furnish and install mounting hardware and incidental materials, including fasteners and auxiliary supporting frames/brackets, as recommended by the manufacturer. 10. Furnish and install hardware, materials, wiring/cabling, configuration, and any other incidental items necessary for fully operational components and subsystems shown in the contract and Section 647, except when specifically identified as existing or as work to be performed by the Department. 11. Cables, Conduit, and Power Service a. Cables Furnish and install electrical cables for traffic control devices and the power service as required by the Contract. Identify all conductors of all cables by color and number. Identify the conductor function in as-built documentation included in the controller cabinet assembly documentation. Cut unused conductors to a length that can reach any appropriate terminal. Bend back unused conductors over their outer jackets and individually tape them. Install cabling inside new hollow metal or concrete support poles unless otherwise specified. Neatly install and route cabling to minimize movement in the wind and chafing against the pole, device, or bracket. Use weatherheads on all nipple and exposed conduit openings. Form a drip loop at the weatherhead and route cabling to minimize water entry into the cable connector. Use a 24 in. (600 mm) diameter drip loop where cables enter a weatherhead. b. Conduit Where devices are installed on existing wood poles, install power service cabling on the wood poles in rigid metal conduit risers. Provide conduit with a minimum 1 in. (25 mm) diameter for power service cabling. c. Install meter base per Standard Details. Do not install the meter base on the cabinet. d. Safety switch For aerial power service attachments, install on signal poles at the top of the pole. For underground power service, install a minimum of 15 feet high above ground. Safety switches shall not be installed on the cabinet. 12. Surge Protection Devices a. Protect all copper wiring and cabling entering the controller cabinet assembly by surge protection devices as specified in this section and Section 925 minimum requirements. b. Use a minimum No. 16 AWG grounding for each surge protection device, or larger if recommended by the surge protection device manufacturer. c. Use insulated green wire and connect the ground wire directly to the ground buss bar. d. Do not daisy chain the grounding wires of other devices, including other surge protection devices. e. Label all surge protection devices with silk-screened lettering on the mounting panel. f. Furnish and install all necessary transient surge protection device to protect detector and controller cabinet assembly equipment. 13. Grounding a. Ground the controller cabinet assemblies, controller, poles, pullboxes, and conduit to reduce extraneous voltage to protect personnel or equipment. b. Ground all span wire and down guy assemblies as shown on Standard Detail Drawings. Bond all span wire together and bond to ground at every pole. c. Provide permanent and continuous grounding circuits with a current-carrying capacity high enough and an impedance low enough to limit the potential above the ground to a safe level. d. Join the grounding electrodes and connect them to the grounding buss of the controller cabinet assembly with No. 6 AWG solid copper wire. e. Use the shortest possible ground lead to the grounding source. f. All components, including mounting hardware, shall be grounded and bonded per manufacturer’s recommendations and NEC. Dress and route grounding wires separately from all other controller cabinet assembly wiring. B. Installation of Grounding Conductors and Electrodes 1. Install grounding electrodes of size, length and material specified in Section 682. 2. Ground any pole-mounted equipment to the pole, except 336 controller cabinet assemblies and power service if pole mounted. 3. Install grounding electrodes adjacent to the traffic signal pole bases, preformed controller cabinet assembly bases, and in pullboxes to protect the grounding system. 4. Install a minimum of 3 grounding electrodes for each pole, pedestal and the controller cabinet assembly. 5. Grounding electrode stacking may be permitted in areas where ground conditions allow. The contractor shall coordinate with the Construction Manager or designee to have a Department representative observe stacked electrode installation. 6. Test electrodes according to Section 682. Report final test results. 7. Timber Poles a. Use a minimum No. 6 AWG solid copper wire bonded to the grounding electrode and extending upward to a point perpendicular to the uppermost span. b. Place wire staples no greater than 2 ft. (600 mm) apart to secure the ground wire to the pole. c. Connect the span wire to the pole ground using copper split bolt connectors 8. Cabinets a. All cabinets Connect the power company neutral, conduit ground, and grounds of equipment housed in the controller cabinet assembly to the buss-bar. Use a No. 6 AWG solid copper wire bonded between the buss and grounding electrode. Connect neutral conductors to the controller cabinet assembly buss-bar and ground them at each terminal point. Ground the controller cabinet assembly with a No. 6 AWG solid copper wire between the buss-bar to the grounding electrodes. Bends shall not exceed 4 in. (100 mm) radius. b. 336 Cabinet Assembly Provide a separate grounding electrode for pole mounted controller cabinet assemblies. Do not use the pole ground as the cabinet assembly ground. Bond the pole grounding electrode to the pole mounted cabinet assembly’s grounding electrode.

647.3.05 Installation of Traffic Control Devices

A. Controller Cabinet Assembly 1. Location a. Locate in accordance with the contract. b. If field conditions require the controller cabinet assembly location needs to be moved, the following criteria shall be met: Controller cabinet assembly and technician work pads shall remain within the provided right-of-way. Locate controller cabinet assembly away from the edge of pavement or curb line to prevent damage from errant vehicles and protect maintenance personnel. Position the front panel door of the controller cabinet assembly away from the intersection, providing a view of the vehicular and pedestrian traffic signal faces for technicians. Comply with ADA sidewalk horizontal clearance requirements. This includes when controller cabinet assembly doors are open. Avoid low lying and drainage areas likely to collect and hold surface water. 2. Installation a. Install pole or base-mounted as indicated in the contract. b. Verify controller cabinet assembly prefabricated base does not extend more than 9 in (225 mm) above final grade. c. Seal base-mounted controller cabinet assemblies to their base using silicone-based sealer. Pliable sealant used shall not melt or run at temperatures as high as 212 ºF (100 ºC). d. Mount ground-mounted cabinet to prefabricated base. e. Install technician pad in front and rear of the controller cabinet assembly door, and if applicable in front of UPS auxiliary cabinet door. See Standard Detail Drawings for pad information. f. Close all unused conduits in the controller base with an appropriately sized PVC cap. Do not permanently affix the conduit cap to the conduit. 3. Controller Cabinet Assembly Field Wiring a. Install cabling and conductors the comply with NEC, UL and IMSA. b. Install all cabling and conductors in a neat and secured fashion. c. Cut signal conductor cables, inductance loop lead-in cable or other detection system cabling, and fiber optic drop cable to provide 10 ft. (3 m) of slack inside the controller cabinet assembly or pullbox adjacent to the controller cabinet assembly. Neatly coil and organize wire in the bottom of the controller cabinet assembly. d. Use at least No. 6 AWG wire for the conductors between service drop and AC+ and the AC- terminals. e. Do not mount electrical meter to the controller cabinet assembly. Submit power pedestal or other method of providing location for mounting. f. Label all field terminals and conductors to identify the specific field input. g. Crimp terminal connections to conductors with a ratchet-type crimping tool that does not release until the crimping operation is completed. h. Supply the controller cabinet assemblies with wiring diagrams, schematic drawings, pin assignment charts, and manuals for circuits and components. Store these documents in the controller cabinet assembly in a resealable, weathertight container. i. Label individual conductors with a label maker using UV-protected labels and attach to each wire/cable and cover with transparent tape. B. Auxiliary Controller Cabinet Assembly Equipment 1. Provide auxiliary controller cabinet assembly equipment or special purpose equipment with connecting harnesses, if necessary, or as shown in the contract. 2. Position the equipment in the controller cabinet assembly. Additional wiring may be necessary to install the equipment. Verify additional cabling meets appropriate specifications for the application, is enclosed in NEMA enclosure and is neatly secured. 3. Connect the auxiliary equipment to appropriate cable harness, pre-mounted rack, or socket. C. Controller Unit 1. Identify the controller unit and other auxiliary equipment by model and revision numbers. These numbers shall agree with previously submitted and approved catalog submittals. 2. Assemble the controller unit, controller cabinet assembly, and auxiliary equipment to provide the operational phasing sequence specified in the contract. 3. Verify the controller unit functions as a unit with the controller cabinet assembly. 4. Verify controller unit and auxiliary equipment are provided AC power from receptacles marked for controller power. 5. Controller units shall be purchased with the Department’s firmware preinstalled (current version). Firmware version shall be considered current as of the activation date. 6. For ramp metering application, verify the Watchdog Timer Muzzle Jumper is selected on the field input/output module of the controller unit. This is required for operating with a 208 monitor. D. Conflict Monitor 1. Mount conflict monitor in a rack with appropriate connectors to attach to the wiring harness. 2. Program the conflict monitor according to the signal operation indicated in the contract before activation of the traffic control device. 3. Provide conflict monitoring programming tools to the maintaining agency. 4. Configure and equip the conflict monitor to monitor all red signal indication. 5. Verify that the red output for unused or vacant load bays or output slots is jumpered to 120 VAC+. 6. At ramp meters, mount model 208 monitor in rack and program the monitor per the contract. E. Signal Poles and Support 1. General Installation Requirements a. See Section 501 for signal pole materials certification and Section 925 for traffic control signal equipment. b. Refer to the contract for pole locations. c. Where necessary, adjust pole location to avoid utility conflicts. Relocations greater than 5 ft. (1.5 m) shall require updates to the design plans. d. Provide minimum clearance distances between the signal pole and the roadway as specified in the contract. NOTE: Field drilled holes to any traffic signal pole or mast arm pole requires written approval from the Office of Bridge and Structural Design. e. Concrete Testing The Construction Manager may create concrete cylinders for testing during the pour. The Construction Manager shall the make cylinder and submit it for testing to the Office of Materials and Testing. If the concrete foundation fails to meet the requirements and is not accepted, the foundation shall be replaced upon notification of failure. f. Verify that the pole foundations and pedestals with the anchor-type base that meet the requirements of Section 500 and Section 639. g. The Office of Materials and Testing will inspect the anchor bolts. If approved, the Office of Materials and Testing will display the inspector’s hammer stamp mark on the top of the bolt. h. Instruct the supplier to furnish a mill certificate that shows the alloy and physical properties of the steel used in fabricating the anchor bolts. The bolts may be subjected to a tensile and shear strength test. i. Do not install or locate poles without the Department’s approval. j. Install pole foundations according to soil zones identified in the Standard Detail Drawings. k. After installing poles and applying the load of the signal span, inspect them for plumb and for the horizontal position of the mast arm, when applicable. l. Verify all threads of the nut are threaded onto the anchor bolt. m. Power Service Attachment Install a service bracket and insulator on one pole at each intersection to attach power service wire as specified in the contract. Install a disconnect box on the controller cabinet assembly pole at each intersection to attach power service. Underground services may utilize a ground mounted power service assembly. n. Install poles to which controller cabinet assemblies are attached with mounting plates, bolts, nipples, and at least two (2) 2.5 in. (64 mm) threaded openings at the top and at least two (2) 2.0 in. (50 mm) at the bottom of the pole. o. Galvanized Finish (Steel Poles) Correct deficiencies by using the leveling nuts on the anchor bolts or by adjusting the mast arm. After the Department approves the pole installation, provide an acceptable method of protecting the area between the pole base and the top of the foundation to prevent the accumulation of debris. The Department will examine the pedestals and poles for damaged paint or galvanizing. Restore the finish coating where necessary. If the finish or galvanized steel materials is scratched, chipped, or damaged, the material will be rejected. The finish shall be replaced as specified under Section 645 with the Department’s approval. For poles or arms that need galvanization, thoroughly clean the steel poles and arms and touch up non-galvanized parts with i-d red or original-type primer. p. Attach the fittings to the poles as specified by the manufacturer. The fittings may include: Cast aluminum cap Pole clamp hardware for span wire attachment Weatherhead with chase nipples and couplings Galvanized elbow with bushing installed by cutting the pole and welding in place around the entire circumference 2. Concrete Strain Poles a. Provide concrete strain poles that meet the requirements of Section 639 and Standard Detail drawings. b. Verify pole hole orientations for pedestrian signal faces, pedestrian pushbutton stations, luminaire arms, etc., with the Department prior to proceeding with traffic control signal installation. For poles at controller cabinet assembly location, provide at least two (2) 2.5 in. (64 mm) openings at the top of pole and at least two (2) 2.0 in. (50 mm) threaded openings at the bottom. c. Provide caissons or foundations that conform to the Construction Detail for Strain Pole and Mast Arm Pole Foundations in the Standard Detail Drawings. d. Determine the required foundation size based on the manufacturer’s specified bending moment at yield for each pole. e. Rake the poles during installation to provide a pole that is plumb once the load is applied. f. Install concrete strain poles so that the angle of variance between the eye bolt on the pole and the span wire is less than 10 degrees. g. Plug all unused holes. Use grout or threaded fittings. Match the finish of the pole. 3. Steel Strain Poles a. Verify that anchor bolts, reinforcing bars, and grounding electrodes conform to Section 639 and Section 852 and are placed in the excavation. b. Support the anchor bolts with a template to provide the proper bolt circle for the pedestal or pole to be installed. c. Install anchor bolts without modifications. Refer to signal details for proper installation. d. Wire the reinforcing bars together or to the anchor bolts. e. Wire the conduits in the base to the reinforcing bars for support. Verify that they are accessible above and beyond the foundation’s finish level. f. Before pouring the foundation concrete, determine that the anchor bolt orientation is correct so that the tensile load is divided between at least two anchor bolts. Pour and vibrate the concrete with the Department present. 4. Mast Arms a. Install mast arms that can accommodate signal face mounting hardware and that adhere to the manufacturer’s recommended procedures and Section 925 and Section 915. Do not add holes. b. Seal the openings in the mast arms to prevent pests from entering. c. Align the mast arm to allow the traffic signal faces to hang plumb at the correct height without using extensions. d. Verify all mast arms are galvanized unless indicated otherwise in the contract. NOTE: Submit a Mast Arm Pole Chart to the Department and the Office of Bridge and Structural Design for review and approval as described in Section 647.1.03.E.4. e. Verify pole hole orientations for pedestrian signal faces, pedestrian pushbutton stations, luminaire arms, etc., with the Department prior to proceeding with traffic control signal installation. 5. Pedestrian Pedestals a. Install aluminum pedestal poles that adhere to Section 850 on breakaway aluminum bases that meet the requirements for breakaway construction. See Section 925 for breakaway base requirements. See the Standard Detail Drawings for Pole and Foundation Details. b. Secure at least four anchor bolts in a concrete foundation as shown in the Construction Detail. c. As an alternate to a concrete foundation, install a pedestal pole foundation anchor assembly (Section 925.2.21.E). d. Install the foundation until the top of the base plate is level with the ground. e. Slide bolt heads through the keyhole and under the base plate against the bolt head keepers with threads up. f. Adhere to the manufacturer’s instructions for installation. g. Use a universal driving tool with the correct kelly bar adaptor and bolts supplied with the tool. h. Attach driving tool assembly to the foundation base plate using the bolts provided with each foundation. Be sure to align the tool soothe holes in the tool line up with the proper bolt circle on the foundation. i. Stand the foundation, with the attached drive tool assembly, upright and attach the drive-tool-foundation to the kelly bar. j. Raise the kelly bar until the foundation swings free of the ground. k. Maneuver the kelly bar until the point of the foundation is over the marked installation location. l. Lower the kelly bar until the point of the foundation is forced into the ground and the helix is flush with the ground surface. m. Verify the shaft of the foundation is plumb by checking the shaft with a level on two sides that are at least 90 degrees from each other. n. Recheck the shaft to be sure it is plumb when the foundation has penetrated 1 ft. (300 mm) into the ground. o. When the base plate of the foundation is 1 in. (25 mm) to 2 in. (50 mm) above the ground line, remove driving tool. p. Contain the wiring inside the pole or in approved hardware. Do not allow conduit outside the pole. q. Position the pedestal pole plumb and high enough to clear the pedestrian’s signal face as shown in the contract. r. Verify that the bottom of the pedestrian signal housing including brackets at the preferred mounting height of 10 ft. (3 m) above the ground line. If conditions dictate, or specified in the contract, pedestrian signal housings may be mounted at a minimum of 7 ft. (2.1 m) above the ground line s. If using a vehicle signal housing, verify pole is adequate to give traffic signal face a height of 12 ft. (3.6 m). 6. Timber Poles a. Timber poles do not require the use of concrete for filling the cavity around the pole base. b. Use timber poles that meet the requirements of Section 861 and Section 639. c. Use Class II for all signal support poles. Use Class IV for aerial loop lead-in or communication cable if approved by the Department. Poles shall be inspected and include AWW stamp. d. Use guy wires with guy timber poles as shown in the contract. e. Use guy helper cables with separate guy wires when helper signal span cables are indicated in the contract. NOTE: Never attach down guy wires to eye bolts. Attach down guy wires to angle guy attachment only and install insulating rods on all down guy installations as detailed on Standard Detail Drawings. F. Power Disconnect 1. See Section 924 for material requirements. 2. Install a power disconnect box at each intersection as shown in the contract and Standard Detail Drawings. G. Uninterruptable Power Supply (UPS) 1. General a. Install UPS according to the contract. b. Install UPS and battery bank in accordance with manufacturer’s recommendations. c. With the UPS submittal, provide calculations for determining the size of the inverter and batteries based on the power requirements for each location. d. Verify that all auxiliary items are included in the power calculations. e. Verify the submittal specifies the model number and the firmware revision that is being supplied. 2. Refer to the contract for the appropriate external cabinet mounting installation, if applicable. a. Type A mounting shall be typically used for installing at locations with an existing traffic control device cabinet. Total of 8 bolts per cabinet with 2 flat washers per bolt and 1 K-lock nut per bolt Cabinet mounting bolts shall be: a) 18-8 Stainless Steel Hex Head (Fully Threaded) b) 0.375 in. (10 mm) – 16 X 1 in. (25 mm) Washers shall be: a) Designed for 0.375 in (10 mm) bolt b) 18-8 Stainless Steel 1 in OD round flat type c) K-lock washer shall be: 1) 18-8 Stainless Steel, Hex Nut Assembled with Free-Spinning Tooth Washer 2) 0.375 in. (10 mm) – #16 Screw size External cabinet couplings to the controller cabinet shall provide a conduit for power connections between the Model 332 Cabinet and the external cabinet. a) The couplings shall consist of three parts and meet the following requirements: 1) 2 in. Nylon Insulated, Steel Chase Nipple 2) 2 in. Sealing, Steel Locknut 3) 2 in. Nylon Insulated, Steel Bushing b) Provide external cabinet with all bolts, washers, nuts, and cabinet-cabinet coupler fittings for mounting the external cabinet to the Cabinet. b. Type B mounting shall be typically used for locations with a new traffic controller cabinet and foundation. The cabinet installation shall provide the external battery cabinet as a base mount cabinet on the same foundation as the Cabinet. Connections between the cabinets shall be through conduit in the cabinet base. The external cabinet shall be installed so that it is centered on the 30 in. (762 mm) left side of the cabinet. Bolt UPS cabinet to pre-fab base. UPS cabinet opening shall be larger than the pre-fab base opening. H. Traffic Signal Faces 1. General a. Place traffic signal faces according to the contract. If a change to traffic signal placement is required, the revised location shall be approved by the Department in advance of installation and in compliance with the MUTCD. b. Verify all traffic signal faces at an installation have the same appearance for the signal faces and the LED modules. 2. Vertical clearance a. Measure the vertical clearance from the pavement to the lowest part of the assembly, including brackets and backplates. b. For traffic signal faces located above the roadway, provide vertical clearance that is a minimum of 17 ft. (5.2 m), 18 ft. (5.5m) preferred minimum, and a maximum of 19 ft. (5.8 m) above the roadway surface. c. For traffic signal faces located on a pole, provide vertical clearance that is a minimum of 12 ft. (3.6 m) and a maximum of 19 ft. (5.8 m) above the sidewalk or pavement grade of the center of the highway, whichever grade is higher. d. Adjust signal faces on the same approach to have the same vertical clearance. 3. Housing a. Mount one aluminum reinforcing support plate in the top of the red (top) section of all three and four- section traffic signal face for the installation of mounting hardware. b. Provide traffic signal faces that use stainless steel hardware and are weathertight. c. Provide traffic signal faces that sealed for mounting in all possible configurations. d. Provide traffic signal faces that have housing door that positively latches using two eyebolts and wing nuts. e. Verify the signal door has hinge lugs molded on one side and two latch jaws are molded on the other side. f. When constructing side by side signal sections, verify that both doors can open at the same time (butterfly). g. When doors are open, verify that the door will remain attached to housing h. Verify bottom section has drainage holes. 4. Wiring a. Connect the signal cable to the wire in each traffic signal face to provide the correct signal indication when the cables are connected to the controller cabinet assembly back panels. b. Use wire nuts to make the connections to the LED signal modules lead-in. c. Make all connections in the top section of the traffic signal face. d. Do not splice cables. e. Verify that the black signal conductor jacket is inserted into the traffic signal face a minimum of 6 in. (150 mm). 5. Optically Programmable Signal Faces a. Install optically programmable (OP) traffic signal faces as shown in the contract, and as directed by the manufacturer. b. Mount OP signal faces securely or tether them to limit movement. c. Mask the OP lamp for directing visibility under the Department’s supervision. d. Tether traffic signal faces that have tunnel visors longer than 12 in. (300 mm). e. Attach traffic signal faces to mast arms using rigid mounting brackets. f. Adjust traffic signal faces on mast arms so that all red indications on the same mast arm are at the same elevation. 6. Ramp Meter Signal Faces a. Install ramp metering traffic signal faces as shown in the contract. b. Mount and adjust ramp metering signal faces as per the Standard Detail Drawings. c. Mount and adjust ramp meter enforcement device (light) as per the Standard Detail Drawings. d. The enforcement device shall be able to be viewed from downstream on the ramp. 7. Lane Use Signal Faces a. Install lane control signal faces for reversible lane systems as shown in the contract. b. Center each signal over the lane or lanes under signal control. c. Leave a vertical clearance for blank-out signs shall be a minimum of 17 ft. (5.2 m) above the roadway surface. d. Use a spirit level to verify that the bottom edge of each sign is horizontal. e. Label all LED modules with their turn on date on the backside of the LED insert. I. Pedestrian Signal Faces 1. Install pedestrian signal faces as directed in the contract. 2. Install the pedestrian signal faces as shown on the Standard Detail Drawings. 3. Leave a vertical clearance from the bottom of the pedestrian signal face to the ground at a preferred height of 10 ft. (3 m) unless specified in the contract or by the Department. 4. Use serrated locking devices that firmly hold the pedestrian signal faces in the required alignment. J. Cable 1. General a. Install and connect electrical cable to the proper equipment to produce an operating traffic control signal system. b. All wiring from the control cabinet assembly input and output files to field terminations shall be in accordance with IMSA, NEMA, UL, and the Department’s Traffic Signal Wiring Standards. Referenced IMSA specification cables and applications can be found in Section 925. c. Make a minimum 1 ft. (300 mm) diameter 3-turn weather drip loop as shown in the Standard Detail Drawings at the entrance to each traffic signal face. d. Neatly tie signal cables leaving a structure or weatherhead to enter a signal fixture. Tie the cables to the messenger cable as illustrated in the Standard Detail Drawings. 2. Traffic signal face a. Install one 7-conductor signal cable for each signal phase and right turn overlap from the controller cabinet assembly to the appropriate signal face. b. From this leftmost traffic signal face, install a 7-conductor signal cable to every other traffic signal face on the same phase, if present. c. The standard wiring color code for vehicular signal faces shall be in accordance with Table 3. Table 3 – Vehicular Signal Face Wiring Standards Signal Indications/ Function 3-Section Signal Indications Seven Conductor Cable 5-Section Head 4-Section FYA and Right Turn Overlaps 3-Section FYA and Right Turn Overlaps Solid Ball Signal Indications (Typ. Phases 2, 4, 6, and 8) Protected Only Turn Signal Indications (Typ. Phases 1, 3, 5, and 7) Red Red Wire N/A Red Wire N/A N/A Yellow Orange Wire N/A Orange Wire N/A N/A Green Green Wire N/A Green Wire N/A N/A Red Arrow N/A White Wire with Black Tracer N/A White Wire with Black Tracer White Wire with Black Tracer Yellow Arrow N/A Black Wire Black Wire Black Wire Black Wire Flashing Yellow Arrow N/A N/A Orange Wire (Bi-Modal Indication Only) Orange Wire Orange Wire Green Arrow N/A Blue Wire Blue Wire Blue Wire N/A Neutral White Wire White Wire White Wire White Wire White Wire 3. Pedestrian signal face a. Install one 7-conductor signal cable from the controller cabinet assembly to each location with a pedestrian signal face. b. Seven-conductor cable can operate either one or two pedestrian signal faces. c. The standard wiring color code for pedestrian signal faces shall be in accordance with Table 4. 4. Ramp meter signal face a. Install one 7-conductor signal cable for each lane of the ramp meter operation from the controller cabinet assembly. b. The wiring color code for ramp meter signal faces shall be in accordance with Table 5. Table 5 – Ramp Meter Signal Face Wiring Standards Signal Indications/Function 3-Section Signal Heads Seven Conductor Cable Color Red Red Wire Yellow Orange Wire Green Blue Wire Neutral White Wire Spare(s) White Wire with Black Tracer, Black and Blue Wires Red, Orange, and Green Wires Red, Orange, and Green Wires Red, Orange, Blue and Green Wires NOTE: 3-Section Bi-modal FYA shall use same wiring standard as a 4-section FYA. Table 4 – Pedestrian Signal Face Wiring Standards Signal Indications/Function Seven Conductor Cable Phases 2 and 6 Phases 4 and 8 Don’t Walk Red Wire Orange Wire Walk Green Wire Blue Wire Neutral White Wire White Wire K. Span Wire 1. Span Wire Sag Minimum Sag Requirements a. Meet minimum sag requirements specified by the pole manufacturer. b. Span wire used with strain pole installation shall have a minimum 5% sag. c. Span wire used with timber pole installation shall have a minimum 2.5% sag. 2. Span Wire Sag Calculation Requirements a. Sag is the amount of vertical drop measured from the pole attachment point to lowest part of the span. b. Allowable sag is calculated by measuring the longest distance between poles and multiplying by the desired percentage of sag, unless specified by the pole manufacturers. c. Calculate attachment points for the messenger strand at the signal pole according to the Standard Detail Drawings. d. Provide the Construction Manager or designee with sag calculations for review and approval. 3. Span Wire Type a. Use minimum 0.375 in. (9.5 mm) span wire to support traffic signal faces, signal conductors, and other hardware only. Larger messenger cable shall be used as required based on span calculations. b. Use minimum 0.25 in. (6.35 mm) messenger cable to support the aerial communications cable plant and aerial loop lead installations. c. All messenger strand installations shall include standard industry bonding and grounding including NEC Article 770 and NESC Section 9. d. Ground all span wire and down guy assemblies as shown on Standard Detail Drawings. Bond all span wire together and bond to ground at every pole. e. All cabling and messenger installed shall meet the requirements provided by the utility pole owner. f. Install span wire and messenger wire where specified in the contract and in accordance with the Standard Detail Drawings. g. Use helper cables where specified in the contract and on the Standard Detail Drawings. h. For construction of a box or modified box span, use bullrings. Be consistent throughout the intersection in use of bull rings or strand vices. If bull rings are not used, strand vices shall be interlocked. 4. Span Wire Cable Mounting a. When using aluminum wrap or aluminum ties, space at a maximum of 6 in. (150 mm) increments. b. Aluminum wrap shall have at least three turns of wrap. c. Use lashing wire only for aerial loop lead-in and fiber optic cabling. 5. Installation a. Attach cables to messenger cable using lashing wire, aluminum ties, or lashing rods. b. Verify that messenger strand clearances conform with local utility company standards. c. Only use lashing rods that are of the same material as the messenger strand. d. If lashing rods are used, use lashing rods sized for the cables and messenger strand. e. Before erecting the messenger strand, determine the suspension strand length to span the distance between the poles. f. Run the messenger strand from structure to structure without splicing. g. Drill wood poles to receive the eye bolts so that the span wire and eyebolt at each connection form a straight angle. h. The angle of variance shall be continuously maintained at less than 10 degrees. i. Attach down guy wires to guy hooks. Use a minimum 0.375 in. (9.5 mm) messenger cable for down guys. j. Make stranded messenger cable attachment points with the appropriate size strand vices or two bolt suspension clamps. k. Use standoff brackets as needed to prevent damage from poles, trees, or other structures. L. Underground Cable for Signal Circuits 1. Install underground cable for signal circuits includes cable, with conduit, as shown in the contract. 2. Do not exceed 40% conduit fill per the NEC. 3. Pull cables into conduits without electrical or mechanical damage. 4. Pull all cables through a single conduit simultaneously. 5. Pull cables by hand only. The use of trucks or other motorized equipment is not permitted, unless approved by the Department. If mechanical pulling is approved, do not exceed the manufacturer’s tension rating for the cable. 6. Pull cables with a cable grip that firmly holds the exterior covering of the cable. 7. Handle and install the conductors to prevent kinks, bends, or other distortion that may damage the conductor or outer covering. 8. Use powdered soapstone, talc, or other inert lubricants to place conductors in conduit according to manufacturer’s recommendations. 9. When pulling cables through hand holes, pole shafts, etc., use a pad of firm rubber or other material between the cable and the opening edges to prevent cable damage. 10. Splicing of signal conductors is not permitted. M. Communications Cable See Section 935 for fiber optic cable communication system requirements. N. Pullboxes 1. Install pullboxes as shown in the contract. 2. Verify that pullboxes conform to the Standard Detail Drawings. 3. Do not relocate pullboxes on the curb side of the signal pole in the intersection radius return. 4. Horizontal adjustments of less than 5 ft. (1.5 m) may be made to pullbox locations to avoid obstacles, if necessary. 5. Orient pullboxes with the longest dimension parallel to the roadway. 6. Include provisions for drains in pullbox excavations as specified. 7. Do not place the aggregate for the drain until the Department approves the excavation. 8. Do not set the pullbox until the aggregate is in place. 9. Obtain the Department’s approval and begin backfilling and installing the frame and cover. 10. The distance between pullboxes in a run of conduit shall not be greater than 100 ft (30 m), unless otherwise shown in the plans or approved by the Engineer, except for fiber optic cable. 11. Set the pullboxes in place, level, and install conduits. a. Conduit entrance shall be through the open bottom in Types 1, 2, 3, 4S, and 5S. b. Conduit entrance shall be directly through cored holes in the side walls in Types 4 and 5. c. Conduit entrance shall be through the conduit terminators in Types 6 and 7. 12. Where conduit entrance shall be through the side wall in Types 4 and 5, or for conduit other than the terminator size provided in Types 6 and 7, use field cored conduit entrance holes in the side wall of the box. All field coring shall be made with a diamond-tipped masonry hole saw and according to the pullbox manufacturer’s recommendations. 13. Use an approved HDPE to EPVC coupling or an underground-type conduit adhesive where joining conduit or conduit bodies of dissimilar materials, such as HDPE-to-EPVC sweeps into pullboxes or installing into pullbox conduit terminators. 14. Install the pullbox at a location that is level with the surrounding ground or pavement. Do not place a pullbox in a ditch or depression. Unless otherwise shown in the contract, when installed either in a sidewalk or in the ground, the top of the pullbox shall be level with the sidewalk or ground surface. 15. Metal lids or covers shall be properly grounded. O. Conduit and Fittings 1. Install conduit by type (GRS, HDPE, PVC) as shown in the contract. 2. Refer to the NEC for conduit fill percentages. Install additional conduits as necessary to meet 40 percent maximum fill. 3. Verify that conduit conforms to Section 682, Section 923, and Section 925 with the addition of flexible conduit only where shown in the Details or as directed to do so in writing by the Construction Manager or designee. 4. Use the conduit size specified in the contract. Obtain a supplemental agreement from the Department prior to installing conduit other than the size specified in the contract. 5. See Section 682.3 for the construction of underground conduit. 6. See Section 682.3 for the construction of encased conduit. 7. See Section 682.3 for the construction of backfilling conduit. 8. In addition to the installation requirements of Section 682: a. Coat metallic conduit threads with red- or white-lead pipe compound, thermoplastic, or Teflon seal. Verify that they are securely connected. b. Install bushings in the conduit to protect the conductors. P. Blank- out Signs 1. Install blank-out signs as shown in the contract. 2. Fasten the signs to a stationary structure or to a messenger strand support system. 3. Center each sign over the lane or lanes under sign control, where applicable. 4. Leave a vertical clearance for blank-out signs as shown in the contract. 5. Use a spirit level to verify that the bottom edge of each sign is horizontal. Q. PHB Installation Requirements 1. Install PHB as shown in the contract. 2. Install solar or electrical power service as indicated in the contract. 3. Provide pedestrian detection system, controller cabinet assembly and necessary components for a fully functional PHB. R. RRFB Installation Requirements 1. Install RRFB as shown in the Contract. 2. Install solar or electrical power service as indicated in the contract. 3. Provide pedestrian detection system. S. Flashing Beacon 1. Furnish and install the flashing beacon controller at the locations shown in the contract. 2. Install it as a complete unit (solid state flasher and field cabinet with time clock, if applicable) and verify that it conforms to this section. 3. Install solar or electrical power service as indicated in the contract.

647.3.06 Training Requirements

See Section 937.4 for training requirements for vehicle detection systems.

647.4 Measurement

647.4.01 General

Traffic control signal items complete, in place, and accepted of the kind, size, and type specified are measured as follows: A. Traffic Signal Installation Complete and fully functional Traffic Signal installation, vehicular detection and pedestrian detection systems excepted, will be paid for by lump sum, including furnishing labor, materials, tools, equipment, and incidentals required to complete the work unless otherwise specified in this section. Materials included in this pay item include: 1. Controller Cabinet Assembly and required interior components. 2. Controller unit. 3. All signal conductors (excludes wiring associated with detection systems). 4. Span wire and guy wires, if applicable. 5. Vehicle signal faces with backplates. 6. Pedestrian signal faces. 7. Pull boxes and conduits containing traffic control signal power service, signal conductors, inductance loop lead-in cables, communications drop cable, auxiliary devices and spare conduits. 8. Power service installation and monthly charges prior to acceptance 9. Grounding conductors and electrodes. 10. Maintenance of equipment prior to acceptance. The type of detection system specified in the contract shall be measured according to Section 937.4. B. Ramp Meter Installation Complete and fully functional Ramp Meter installation, vehicular detection system excepted, will be paid for by lump sum, including furnishing labor, materials, tools, equipment, and incidentals required to complete the work unless otherwise specified in this section. Materials included in this pay item include: 1. Controller Cabinet Assembly and required interior components. 2. Controller Unit. 3. All signal conductors (excludes wiring associated with detection systems). 4. Vehicle signal faces with backplates. 5. All signs and beacons. 6. Pull boxes and conduits containing ramp meter power service, signal conductors, inductance loop lead-in cables, communications drop cable, auxiliary devices and spare conduits. 7. Power service installation and monthly charges prior to acceptance. 8. Grounding conductors and electrodes 9. Maintenance of equipment prior to acceptance. The type of detection system specified in the contract shall be measured according to Section 937.4. C. PHB Installation Complete and fully functional PHB installation will be paid for by lump sum, including furnishing labor, materials, tools, equipment, and incidentals required to complete the work unless otherwise specified in this section. D. RRFB Installation Complete and fully functional RRFB installation will be paid for by lump sum, including furnishing labor, materials, tools, equipment, and incidentals required to complete the work unless otherwise specified in this section. E. Flashing Beacon Installation Complete and fully functional flashing beacon installation will be paid for by lump sum, including furnishing labor, materials, tools, equipment, and incidentals required to complete the work unless otherwise specified in this section. F. School Speed Zone Flashing Beacon Installation Complete and fully functional School Speed Zone Flashing Beacon installation will be paid for by lump sum, including furnishing labor, materials, tools, equipment, and incidentals required to complete the work unless otherwise specified in this section. G. Traffic Signs Highway signs are measured and paid for under Section 636. H. Strain Poles Strain poles are measured and paid for under Section 639. I. Conduit for Communications Conduit for underground, trunk line communications is measured under Section 682.

647.4.02 Limits

General Provisions 101 through 150.

647.5 Payment

647.5.01 General

1. The lump price bid for traffic control devices covers all items of work in this section including furnishing labor, materials, tools, equipment, and incidentals required to complete the work. It excludes only the vehicle detection and pedestrian detection systems for applicable devices, which are paid for in Section 637. 2. Costs for installation shall include operation and maintenance costs until written acceptance is issued by the Construction Manager. 3. Include payment for removal; disposal of existing pavement, shoulder surface, base and sub-grade; and restoration to original condition in the contract price for the items to which they pertain. These will not be paid for separately. 4. Furnishing, installing, and removing sheeting, bracing, and supports will not be paid for separately, but is included in the contract prices for other items. 5. No additional payment will be made for testing and storing state-supplied or contractor-furnished traffic control signal equipment. 6. No payment will be made for individual items unless a pay item is included in the contract for the specific item. 7. Payment will be made under: Item No. 647 Traffic Signal Installation no- Per lump sum Item No. 647 Ramp Meter Installation no- Per lump sum Item No. 647 PHB Installation no- Per lump sum Item No. 647 RRFB Installation no- Per lump sum Item No. 647 Flashing Beacon Installation, no- Per lump sum Item No. 647 School Speed Zone Flashing Beacon no- Per lump sum Payment for various elements of traffic control devices will be as shown in the contract. B. Partial Payment Prior to commencement of the work, the contractor shall initiate a partial payment process for the lump sum traffic signal pay items by submitting a written payment schedule of the installation items for consideration and approval by the Construction Manager. The submittal should consider staged work. The Engineer’s determination of any progress amount paid shall be final. In the event a submittal is not provided, the following schedule below shall be utilized. Underground (pullboxes (if not paid for separately), and conduits) 20% Overhead (span, vehicle signal faces, pedestrian signal faces) 30% Cabinet, contents, and base (cabinet must be fully wired to signal and be ready for operation including written final acceptance from the Construction Manager or designee) 50% C. Additional Items Payment items related to Section 647 are described in the following sections: Strain Poles Section 639 Highway Lighting Section 680 Lighting Standards and Luminaries Section 681 Electrical Wire, Cable, and Conduit* Section 682 Grassing Section 700 Timber Poles Section 639 and Section 861.2.02 Sign Blanks Section 912 Reflectorization Materials Section 913 Detection Systems Section 937 * Payment for communications conduit installation will be as described in Section 682. All other conduit installation as required for a traffic control signal installation shall be measured and payment made as part of the complete traffic control signal installation.

647.5.02 Adjustments

General Provisions 101 through 150.