682Electrical Wire, Cable, And Conduit

682.1 General Description

This work includes furnishing and installing wire, cable, conduit, junction boxes and grounding for electrical power for roadway electrical systems, such as roadway lighting, traffic signals, ramp meters, and intelligent transportation systems (ITS), among others, as indicated in the Contract. See Section 647 for traffic signal installations.

682.1.01 Definitions, Acronyms, and Abbreviations

Refer to General P rovisions 101 through 150. A. Definitions 1. Cable - a bundle of insulated electrical current conducting wires covered with a protective sheath relevant to the environment in which it is installed. 2. Conduit - a pipe, trough, or channel used for protecting electrical cable. Conduit can be metallic or non- metallic; rigid or flexible, depending on the application. Conduit trade sizes are commercially available based on diameter. See NEC for trade sizes. 3. Wire - metal that has been drawn into a thin strand or rod, usually having a round cross section. Wire is to meet the requirements within Section 922.

682.1.02 Related References

A. Standard Specifications Section 105—Control of Work Section 106—Control of Materials Section 107—Legal Regulations and Responsibility to the Public Find Section 205—Roadway Excavation Section 208—Embankments Section 500—Concrete Structures Section 615—Jacking or Boring Pipe Section 647 – Traffic Signal Installation Section 680—Highway Lighting Section 755—Electrical Work Section 800—Coarse Aggregate Section 801—Fine Aggregate Section 830—Portland Cement Section 832—Curing Agents Section 833—Joints Fillers and Sealers Section 853—Reinforcement and Tensioning Steel Section 854—Castings and Forgings Section 870—Paint Section 920—Lighting Standards and Towers Section 922—Electrical Wire and Cable Section 923—Electrical Conduit Section 924— Miscellaneous Electrical Materials Section 927—Luminaires, LED Section 942 – ITS General Requirements GDT 7 - Determining Maximum Density of Soil GDT 24a - Determining the Maximum Dry Density of Soils or Soil/Aggregate Mixtures Containing > 45% retained on the no. 10 sieve GDT 24b - Determining the Maximum Dry Density of Soils or Aggregate Containing > 5% retained on a 2 inch sieve using a 5.5-pound rammer and a 12 inch drop GDT 67 - Family of Curves Method for Determining Maximum Density of Soils B. Referenced Documents It is the Contractor's responsibility to utilize the standards, codes, manuals, and guidelines that apply to the work required to complete the work. All materials are to be consistent and compliant with the latest version or edition of the standards and industry practices as specified. American Association of State Highway Transportation Officials (AASHTO), American National Standards Institute (ANSI) American Society for Testing and Materials (ASTM) Insulated Cable Engineers Association (ICEA) Institute of Electrical and Electronics Engineers (IEEE) Illuminating Engineering Society of North America (IESNA) National Electric Code (NEC), (NFPA 70), current edition NESC (ANSI C2), current edition; National Electrical Safety Code (NESC) National Electrical Contractors Association (NECA) National Electrical Installation Standards (NEIS) National Electrical Manufacturer’s Association (NEMA) National Electrical Testing Association (NETA) Underwriter’s Laboratories, Inc. (UL) Local codes, regulations and rules within the work area. AASHTO, Clear zone and Horizontal Clearance Design Standards, latest edition ANSI/ICEA S-81-570-2012, standard for 600 Volt Rated Cables of Ruggedized design for Direct Burial installations as Single Conductors or assemblies of Single Conductors ANSI C119.1, Electric Connectors - Sealed Insulated Underground Connector Systems Rated 600 Volts, latest edition ANSI/NECA/IESNA 501-2006, Standard for Installing Exterior Lighting Systems ANSI/ NECA 101-2013, Standard for Installing Steel Conduit (Rigid, IMC, EMT) ANSI/NETA ATS, Standard for Acceptance Testing Specifications for Electrical Power Equipment & Systems ANSI/NETA ETT, Standard for Certification of Electrical Testing Technicians ASTM D 149, Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies, latest edition ASTM D 570, Standard Test Method for Water Absorption of Plastics, latest edition ASTM D 792, Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement, latest edition ASTM D 2105, Standard Test Method for Longitudinal Tensile Properties of “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe and Tube, latest edition ASTM D 2583, Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor, latest edition ASTM D 3035, Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on Controlled Outside Diameter, latest edition American Petroleum Institute (API) Specification 15LR, Specification for Low Pressure Fiberglass Line Pipe, latest edition Federal Specification W-C-1904-A, Conduit and Conduit Fittings Plastic, Rigid, latest edition Federal Specification WW-C-540a, Conduit, Metal, Rigid (Electrical, Aluminum) Institute of Electronic and Electrical Engineers (IEEE) Standard 81, Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Grounding System NEMA FB 2.10- 2013, Selection and Installation Guidelines for Fittings for Use With Non-Flexible Metallic Conduit or Tubing (Rigid Metal Conduit, Intermediate Metal Conduit, and Electrical Metallic Tubing) NECA-1-2010 (also ANSI and NEIS Approved) Standard for Good Workmanship in Electrical Construction, published by the National Electrical Contractors Association, Bethesda, MD. NECA 101-2006, Standard for Installing Steel Conduits (Rigid, IMC, EMT) (ANSI) NECA/NACMA 120-2006, Standard for Installing Armored Cable (AC) and Metal-Clad Cable (MC) (ANSI) (NACMA, National Armored Cable Manufacturer’s Association)

682.1.03 Submittals

A. Purchase List Before purchasing materials, electronically submit (in PDF format) the complete materials and structures list, including Shop Drawings, to the Engineer for approval. Include the manufacturer’s name, catalog number(s), and other descriptive data needed to clearly define each Item Acceptable conduit products are contained within QPL-5 B. Manufacturer’s Certifications Certification of Construction Items Secure supplier or manufacturer certifications, including mill certificates, guaranteeing the construction items were manufactured according to the Specifications. Ensure that the certificate shows that representative samples were tested, and test results conform to the specifications. Certification of Quantity Attach a copy of the bill of lading, sales order, or list showing the quantity of materials furnished for a specific project. Make this part of the certification by reference. C. Manufacturer’s Guarantees After the work is complete and accepted, obtain manufacturer’s guarantees for the mechanical and electrical equipment used. Provide these to the Engineer and the agency responsible for continued equipment maintenance.

682.2 Materials

Furnish only new materials and equipment for this work. Ensure that materials meet the following requirements unless otherwise indicated: Material Section Portland Cement Concrete, Class A 500 Coarse Aggregate 800 Fine Aggregate 801 Cement Concrete Curing Materials 832 Bar Reinforcement for Concrete Structures 853.2.01 Gray Iron Castings 854.2.01 Paints (Field Painting) 870 Lighting Standards and Towers 920 Electric Wire and Cable 922 Electric Conduit 923 Miscellaneous Electrical Materials 924 Luminaires, LED 927 The Contractor shall furnish a letter to the Engineer certifying that all electrical materials used for the project comply with the Contract and have been listed by an OSHA approved NRTL to the appropriate UL Standard and bear the Mark of the NRTL. If any materials used in the project are found to be deficient, the Contractor will replace them at their own expense at no cost to the Department.

682.2.01 Delivery, Storage and Ha ndling

Refer to General Provisions 101 through 150.

682.3 Construction

Requirements Ensure that construction and installation of specified equipment, materials, components, and assemblies comply with the manufacturer’s requirements and recommendations and meet Standard Detail Drawings. General work practices for electrical construction shall be in accordance with NECA 1-2010, Standard for Good Workmanship in Electrical Construction (ANSI).

682.3.01 Personnel

A. Qualified Electricians Refer to Subsection 755.1.01 for the definition of a qualified electrician. Contractors and Sub-Contractors shall be approved by the Department to install roadway lighting, traffic signals, ramp meters, and ITS devices. Ensure that the Contractor performing this work is on the Department’s list of approved electrical contractors or electrical s ubcontractors.

682.4 Preparation

Before beginning work, pay applicable fees and obtain needed permits from power companies or governmental agencies. Before beginning any mechanized boring, trenching or digging call 811, GDOT and any other local agencies which may be in GDOT ROW for instructions and clearance. This must be done at least 72 hours in advance excluding weekends and holidays. Calls made after 4:30 PM count as the next day. Outline the areas to be excavated with white paint or flags before the utility location service is performed. Follow the Best Practice Guidelines published by the Common Ground Alliance (CGA), of which Georgia 811 is a member.

682.5 Fabrication

Ref er to General Provisions 101 through 150.

682.6 Construction

682.6.01 Conduit, Pull and Junction Box and Cable Installation Requirements

A. General Requirements for Conduit 1. Install the specified size, type (rigid galvanized steel [RGS], HDPE, PVC) and quantity of conduit at the locations according to the Contract. Refer to the NEC for maximum allowable conduit fill percentages. Obtain written approval from the Engineer prior to installing conduit other than the size, type or quantity specified in the Contract. 2. Cut and ream conduit as follows: a. Cut metallic conduit threads and then ream the ends. b. Ream other conduit as necessary to ensure pull ropes or cables can be properly pulled through. c. Cut conduit ends square. d. Ensure that conduit ends butt solidly in the joints to form a smooth raceway for cables. e. Ensure that all chips, burrs, and sharp edges have been removed. 3. Ensure conduit joints form a watertight seal by doing the following: a. Coat metallic conduit threads with a suitable corrosion resistant thread sealant that is UL Listed to UL1356 such as Rector-Seal T plus 2, or thermoplastic seal approved by the Engineer, and then securely connect them per ANSI/NECA/IESNA 501-2006 Standard for Installing Exterior Lighting Systems, or ANSI/ NECA 101-2013, Standard for Installing Steel Conduit (Rigid, IMC, EMT). 1) Form fiber cement conduit joints with hot tar, asphalt, or bitumen paint, then drive tightly per NEMA FB 2.10- 2013 Selection and Installation Guidelines for Fittings for Use With Non-Flexible Metallic Conduit or Tubing (Rigid Metal Conduit, Intermediate Metal Conduit, and Electrical Metallic Tubing). See “other threaded connections” in Table 2-2 for tightening torque values. 2) Use a suitable sealant on conduit joints as recommended by the conduit manufacturer and as approved by the Engineer. 4. Install bushings in conduit to protect the conductors. 5. Build conduit runs in straight lines where possible. 6. Separate power cables from fiber cables except inside poles. 7. Use flexible conduit only where shown in the Standard Detail Drawings or in the Contract. 8. Clear all water from the conduit and debris before installing any cabling. 9. Conduit Couplings a. Make every effort to minimize the use of couplings. There shall be no more than three (3) couplings in a 20 foot linear section of a conduit run. b. Couplings shall be airtight and watertight. All couplings shall be installed in accordance with the conduit and coupling manufacturer’s recommendations. c. Use an approved HDPE to polyvinyl chloride conduit (PVC) coupling or an underground-type conduit adhesive where joining conduit or conduit bodies of dissimilar materials, such as HDPE-to-PVC sweeps into pull boxes or installing into pull box conduit terminators. d. Coupling of metallic conduit shall be accomplished only by hydraulic press-on or electro-fusion coupling methods unless otherwise approved by the Engineer e. For metallic aluminum conduit, use compression couplings of seamless tool-grade tubular aluminum with sealing barbs and center stop. f. Use hydraulic compression duct coupling tools and follow all manufacturer’s installation procedures, fully inserting both conduit sections to the coupling center stop. g. Use pre-fabricated electro-fusion couplings that are field-installed using the coupling manufacturer’s recommended automatic self-monitoring fusing machine and installation procedures. h. In constricted spaces, it is acceptable to use alternate coupling methods and elbow geometry with approval by the Engineer, such as band clamp/locking ring solutions or mechanical bolt-on solutions. 10. Install insulated grounding/bonding bushings to protect conductors. If sweeps are necessary, use long sweep bends with a radius of at least 6 times the conduit’s nominal diameter, unless otherwise specified. 11. Ensure that empty conduit for future wire or cable and conduit with existing wires and cables has a pull tape as described in Section 682.6.01.J installed. Secure pull tape at each open end and at each pull box. 12. Continuous conduit runs shall not exceed 360° in bends without a junction box or cabinet. 13. Provide four (4) copies of the as-built documentation for underground conduit boring from the Contractor to include conduit quantity, size, location, depth, and pull box information. One copy will stay at the installation; one copy goes to the Engineer; one copy goes to the Office of Design Policy & Support Roadway Lighting Group and the last copy goes to the maintaining agency. B. Installing Conduit and Fittings on Poles 1. Install a weather head at the end of exterior conduit runs on a pole or other structure to prevent moisture or other matter from entering the conduit. All weather heads shall have the proper plastic or neoprene insert for the wires to pass through. 2. Ream the ends of the conduit after cutting or creating threads as necessary. Make sure that there are no burrs or sharp edges to damage wire insulation. 3. Cut ends square, and butt solidly in the joints to form a smooth raceway for cables. 4. Ensure a watertight seal at joints. 5. Ensure that conduit on pole exteriors are mounted with galvanized, two-hole straps or clamps. Place clamps no more than 3 feet from junction boxes, condulets, or weather heads. Place at 3-foot maximum intervals elsewhere. 6. Fasten the clamps to wood poles with galvanized screws or lag bolts at 3-foot maximum intervals. 7. Do not install conduit risers on concrete, steel, or mast arm poles unless approved by the Engineer. 8. After installation, ensure that the conduit or fitting placement has not warped or distorted any condulet, terminal, control, or junction box. 9. Ensure that RGS conduit terminated at poles is grounded to the pole ground rod using an insulated grounding/bonding bushing and bonded in the pull box to the supply source via an effective ground-fault current path per the NEC. C. Installing Conduit on Structures 1. Install conduits, condulets, hangers, expansion fittings, and accessories on structures according to the Contract and the following, unless otherwise specified. 2. Provide proper support hardware for all conduit attached to structure in accordance with the manufacturer’s recommendations. Support hardware shall be installed as specified by the NEC. 3. Run conduit parallel to beams, trusses, supports, pier caps, etc., as directly as possible. 4. Install horizontal runs in a slight grade (0.25%) without forming low spots that may prevent proper drainage. 5. Run conduits with smooth, easy bends to ensure cables can be easily pulled through. Hold the conduit ends in boxes with locknuts and insulated grounding/bonding bushings to protect the conductors. Use a minimum bend radius of 36 in. (900 mm) and maximum bend angle of 90º. 6. When not specified in the Contract, submit the type and method for attachment to structures to the Engineer for approval. 7. Do not clamp or attach conduit to bridge beam flanges. D. Installing Conduit Underground 1. Conduit installed underground must be Type II conduit as described in Section 923, unless otherwise approved by the Engineer. 2. Use direct burial conduit, encased conduit or conduit duct banks installed in a trench excavated according to the Contract dimensions and lines. Unless specified in the Contract, do not excavate trenches in existing pavement or surfaced shoulders to install conduit. 3. Install the conduit by directional boring, trenching and backfilling, or other approved means. When placing conduit under existing pavement; bore at least 36 inches beneath the base of the pavement. Obtain the Engineer’s approval prior to installing conduit by means of boring method. 4. Provide at least 18 inches finished cover, unless otherwise specified. 5. Determine the location of electrical lines, drainage, or utility facilities in the area before excavation. Digging or excavation within 18 in. of existing utilities must be performed by hand. 6. Place conduit where it will not conflict with proposed guardrail, sign posts, etc. 7. Where possible, provide at least 12 in. between the finished lines of the conduit runs and utility facilities such as gas lines, water mains, and other underground facilities not associated with the electrical system. 8. When the conduit run is adjacent to concrete walls, piers, footings, etc., or when the conduit is encased between the encasement and the adjacent concrete, maintain at least 4 in. of undisturbed earth or firmly compacted soil between the conduit and adjacent concrete. 9. Unless specified in the Contract, do not excavate conduit trenches through existing pavement or surfaced shoulders. Install the conduit under the existing pavement by jacking, boring, or using other approved means. 10. When the Contract specifically allows a trench through an existing pavement or surfaced shoulder, restore the pavement, surface, base, and subgrade to the Engineer’s satisfaction. All costs associated with this restoration shall be included in the conduit installation price. 11. Excavate trenches as follows: a. Cut trenches on a slight longitudinal grade (0.25% minimum) for drainage, unless otherwise specified. b. When the grade cannot be maintained all one way, grade the duct lines from the center in both directions, down to the ends. Avoid pockets or traps where moisture may accumulate. d. Tamp the trench bottom as necessary for a firm conduit foundation. It should be compacted to the density of the surrounding undisturbed soil. Ensure the trench bottom is smooth and free of bricks, rock or other material that could damage the conduit or cable before the trench is backfilled. e. Support pipe and other structures at least every 10 ft. to prevent damage with approved support mechanisms. Furnishing, installing, and removing sheeting, bracing, and supports will not be paid for separately. Cost of these items shall be included in the overall bid price. 12. Before excavating, follow the instructions in Section 682.4 (above). 13. If necessary due to obstructions, slightly change the locations of conduit runs, pull boxes, etc., as approved by the Engineer. 14. Obstructions to Excavation Make the following allowances around obstructions: a. Where possible, provide at least 12 in. (300 mm) between the finished conduit runs and utility facilities, such as gas lines, water mains, and other underground facilities not related to the electrical system. b. Where the conduit run is adjacent to concrete walls, piers, footings, etc., maintain at least 4 in. (100 mm) of undisturbed earth or firmly compacted soil between the conduit and the adjacent concrete c. When rock is in the bottom of the trench, install the conduit on a bed of compacted, fine-grain soil at least 4 in. thick. 15. Conduit installed for fiber optic cable installation shall have a detectable tone or locator wire No. 14 (AWG) minimum with insulation suitable for direct burial applications. The locator wire shall have no splices. E. Installing Encased Conduit Place in locations shown in the Contract unless otherwise specified by Engineer. Construct as follows: 1. Conduit shall be Type II, as described in Section 923, unless otherwise approved by the Engineer. 2. Construct encasement using Class A concrete that meets requirements in Section 500. 3. Use precast concrete encasement only if approved by the Engineer. 4. Excavate trenches as follows: a. Cut trenches on a slight longitudinal grade (0.25% minimum) for drainage, unless otherwise specified. When the grade cannot be maintained all one way, grade the duct lines from the determined high point in both directions down to the ends. Avoid pockets or traps where moisture may accumulate. b. Tamp the trench bottom as necessary for a firm conduit foundation. It should be compacted to the density of the surrounding undisturbed soil. c. Support pipe and other structures at least every 10 ft. to prevent damage with approved support mechanisms. Furnishing, installing, and removing sheeting, bracing, and supports will not be paid for separately. Cost of these items shall be included in the overall bid price. 5. Before excavating, follow the instructions in Section 682.4 above. 6. If necessary due to obstructions, slightly change the locations of conduit runs, pull boxes, etc., as approved by the Engineer. 7. Obstructions to Excavation Make the following allowances around obstructions: a. Where possible, provide at least 12 in. (300 mm) between the finished conduit runs and utility facilities, such as gas lines, water mains, and other underground facilities not related to the electrical system. b. Where the conduit run is adjacent to concrete walls, piers, footings, etc., maintain at least 4 in. (100 mm) of undisturbed earth or firmly compacted soil between the conduit and the adjacent concrete. c. When the conduit is encased, maintain at least 4 in. (100 mm) of undisturbed earth or firmly compacted soil between the encasement and adjacent concrete. 8. Construct encasement under pavements or surfaces so that it extends at least 12 in. (300mm) beyond the outside edges of pavement, paved shoulders, sidewalks, or curbs, when no shoulder or sidewalk is indicated. 9. Ensure that the end of installed conduit extends at least 6 in. (150mm) beyond the encasement. 10. Place 3 in. (75 mm) of concrete in the trench bottom to support the conduit. 11. Plug the conduit ends temporarily to keep concrete or foreign material out, then place the conduit in the trench. 12. Do not encase conduit in concrete until tested, inspected, and approved by the Engineer. 13. Cure concrete encasement according to Subsection 500.3.05.Z, with a curing period of 24 hours. 14. Cover the conduit with at least 3 in. of concrete. F. Backfilling Over Underground Conduit 1. When applicable, do not backfill encased conduit until the concrete encasement has cured at least 24 hours. 2. Once the Engineer has inspected and approved the installation, promptly backfill to the required grade. Use soil without rocks or other foreign matter. Backfill with approved material in layers no deeper than 6 in. loose depth up to the original ground level. 3. Compact each layer to one hundred percent (100%) of the maximum laboratory dry density as determined by GDT 7, GDT 24a, GDT 24b, or GDT 67, whichever applies . G. Directionally Boring Conduit 1. Conduit used for directional boring shall be as specified within Section 923.2.03 2. Suitable pits or trenches shall be excavated for the boring operation and for placing end joints or termination connectors of conduit when required. Pits or trenches shall be securely sheeted and braced where necessary to prevent caving. 3. Bore width shall not exceed 125 percent of the conduit diameter specified within the Contract. 4. Contractor shall produce documentation showing the directional bore location, path, and depth of each section of conduit. The documentation shall be provided to the Engineer and have an accuracy within 2 percent. 5. Where directional boring is required under railroads, highways, streets, or other facilities, construction shall be done in the manner that will not interfere with the facility operation and shall not weaken the roadbed or structure. Roadway pavement, subgrade, roadbed, paved shoulder, or unpaved median shall not be disturbed or excavated without written authorization by the Engineer. In these areas, any broken or damaged boring rod/stem, boring head (including transmitter/transponder locating heads and cutter heads), couplings (including back reaming, swivel or connector couplings), or any other material that cannot be retrieved as part of the pullback operation shall become the property of the Department and shall be abandoned in place unless otherwise authorized in writing by the Engineer. There shall be no additional payment for abandoned material. 6. Continuously monitor the location and alignment of the pilot drill progress to ensure compliance with the proposed installation alignment and to verify depth of the bore. Monitor by manual plotting based on location and depth readings provided by the locating/tracking system or by computer-generated bore logs. Readings or plots shall be obtained on every drill rod and provided to the Engineer on a daily basis for as-builts electronically in PDF format. 7. Monitoring drilling fluids, such as the pumping rate, pressures, viscosity, and density, during the pilot bore, back reaming, and/or pipe installation stages shall be undertaken to ensure adequate removal of soil cuttings and to ensure that the stability of the borehole is maintained. a. Drilling fluid pressures should not exceed that which can be supported by the overburden (soil) pressure to prevent heaving or a hydraulic fracture of the soils. 1) At no time, shall the flow pressure exceed 500 psi and should normally not exceed 200 psi. 2) Excess drilling fluids shall be contained at the entry and exit points until recycled or removed from the site. 3) Ensure that all drilling fluids are disposed of in a manner acceptable to the appropriate local, state, and federal regulations. 4) The Contractor’s work will be immediately suspended whenever drilling fluids seep to the surface other than in the boring entrance or exit pit. The Contractor must propose a method to prevent further seepage and must remove and dispose of any drilling fluid on the surface prior to resuming the boring operation. 8. The pullback rate should be determined to maximize removal of soil cuttings and minimize discomposure of the ground surrounding the borehole. The pullback rate shall also minimize over cutting of the borehole during the back-reaming operation to ensure that excessive voids are not created resulting in post installation settlement. Any surfaces damaged by the work shall be restored to their preconstruction conditions. The Contractor shall be responsible for all costs associated with the restoration. 9. The distance that the excavation extends beyond the end of the bore will depend upon the character of the excavated material but shall not exceed 2 feet in any case. This distance shall be decreased on instructions from the Engineer if the character of the material being excavated makes it desirable. 10. Once the directional boring is begun, the operation shall be carried on without interruption, insofar as practical. 11. The pits or trenches excavated to facilitate boring operations shall be backfilled immediately after the boring has been completed. 12. The boring shall proceed from a surface staging area provided for the boring equipment and workers and approved by the Engineer. The holes shall be bored mechanically. Excavated material shall be placed near the top of the working pit and disposed of as required. The use of water or other fluids in connection with the boring operation will be permitted only to the extent necessary to lubricate cutting. Jetting will not be permitted. 13. Excavation will not be paid for separately, according to the provisions in Sections 205 and 208. 14. In unconsolidated soil formations, a gel-forming colloidal drilling fluid consisting of at least 10 percent high- grade, carefully processed bentonite may be used to consolidate excavated material, seal the walls, and furnish lubrication for subsequent removal of material and immediate back reaming/installation of conduit. 15. Allowable variation from line and grade established by the Engineer shall be a maximum of 2 percent. Any voids that develop during the installation operation and are determined by the Engineer to be detrimental to the work shall be pressure grouted with an approved mix. 16. Directional boring operations inherently include the risk of encountering under grade obstructions that begin to alter the bore direction. The Engineer shall be notified immediately if an obstruction occurs. a. Attempts at corrective measures to restore the proper bore alignment should include but are not limited to boring deeper or shallower (if minimum pipe depth can be maintained), moving the boring head to the right or left of the obstruction, or attempting to bore through the obstruction (if other than solid rock). b. To restore the bore alignment, a minimum of three attempts shall be made to the Engineer’s satisfaction at each encountered obstruction with different corrective measures. If a suitable bore alignment cannot be restored, the Engineer may authorize a relocation of the bore. c. Unsuccessful boring attempts shall be paid in accordance with Sections 682.6 and 682.7, using the obstruction location as one end of the measured length of directional boring. H. Jacking Conduit 1. Refer to the requirements of Section 615. I. Constructing Pull and Junction Boxes 1. Ground Mounted Pull Boxes a. Install pull boxes according to the type, design, dimensions, and locations shown in the Contract. b. For pull box construction and material details, see Section 924.2.02 c. Pull boxes shall be installed at least 12 feet away from active lanes. Pull boxes for traffic signals may be less than 12 ft. from active lanes but must have appropriate traffic rated covers. d. Ground mounted pull boxes shall be installed per Article 300.5 of the NEC. Trenching, cover, and back fill requirements of Table 300.5 shall apply. e. Orient pull boxes with the longest dimension parallel to the roadway. f. Include provisions for drains in pull box excavations as specified. g. When applicable, do not locate pull boxes on the curb side of the signal pole in the intersection radius return. h. Install the pull box at a location that is level with the surrounding ground or pavement. Do not place a pull box in a ditch or depression. Unless otherwise shown in the Contract Documents, when installed either in a sidewalk or in the ground, the top of the pullbox shall be level with the sidewalk or ground surface. 2. Above Grade Junction Boxes a. Construct pull boxes according to the design, dimensions, and locations shown in the Contract. b. For junction box construction and material details, see Section 924.2.02 c. Junction boxes are to be installed in the locations as indicated within the Contract, unless otherwise directed by the Engineer. d. Junction and pull boxes should be used where necessary to facilitate the pulling of wire or cable. Article 314 of the NEC provides minimum sizing and installation requirements for junction and pull boxes used in wiring systems. e. Position the box and secure it to a structural or rigidly supported member. Members may be made of metal or fiberglass suitable for the application. f. Attach conduit or cable fittings to the box per the manufacturer’s instructions and insure that they are watertight. g. Feed conductors into the box and make connections. h. All connections should be insulated and watertight. Provide adequate strain relief for the conductors in accordance with manufacturer’s recommendations. i. Secure the box cover to the box using corrosion resistant fasteners and a suitable gasket, making a watertight seal. 3. Embedded Junction Boxes a. Construct pull boxes according to the design, dimensions, and locations shown in the Contract. b. For junction box construction and material details, see Section 924.2.02 c. Use the proper size box per the Contract (ref. Article 314 in the NEC which provides minimum sizing and installation requirements for junction and pull boxes used in wiring systems). d. Position the box and secure it to a rigidly supported member in the hole. Members shall be made of metal or fiberglass suitable for the application. The top lip of the box should be flush with the finish height of the concrete fill. e. Attach conduit or cable fittings to the box per the manufacturer’s instructions and ensure that they are watertight. f. Feed conductors into the box and make connections. g. All connections shall be insulated and watertight. Provide adequate strain relief for the conductors. h. Secure the box cover to the box using a suitable gasket and making a watertight seal. i. Make sure that all conduit or cable entering the box is properly supported in accordance with NEC Article 314.23. 4. Conduit Termination in Pull and Junction Boxes a. Conduit shall be terminated in junction and pull boxes as shown in the Contract. b. Conduits terminated in concrete pull boxes shall be installed into factory-installed knockout windows only, which shall be fully grouted and sealed around all conduits and to the full thickness of the box wall. c. Conduits terminated in metallic junction boxes shall be installed into factory-installed knockout windows only and fitted with properly sized couplings. d. Conduits terminated in polymer pull boxes shall be installed into factory-installed conduit terminators; conduit adhesive sealants recommended by the terminator and conduit manufacturers shall be used. e. After installing conduit, seal the conduit entrance holes in pull or junction boxes per the manufacturer’s recommendations and to the Engineer’s satisfaction. f. Plug unused entrance holes and openings that may be used in the future. Use suitable plastic, bituminous fiber, or other approved plugs that keep foreign matter out. 5. Drainage in Pull and Junction Boxes a. Provide non-metallic pull and junction boxes with a drainage hole unless the application or the Engineer dictate otherwise. b. Provide a drainage system for each ground-mounted box to ensure that no water accumulates inside the box. J. Pull Tape 1. Install pull tape, by hand pulling, blowing, or via vacuum method, into each empty conduit during conduit installation. 2. Install the pull tape after conduit testing has been completed. 3. Install and secure 5 feet of slacked pull tape in each empty conduit or cell at each vault. 4. Install and secure 5 extra feet of pull tape inside conduit being used and secured on each end for future use. 5. Secure the pull tape by tying it to the duct plug for the conduit in which it is installed. K. Conduit Detection (Tracer) Wire 1. Install conduit detection wire in conduit used for fiber optic communications and where specified within the Contract. 2. If more than one conduit is being installed in a single bore, only one conduit detection wire is required. 3. The conduit detection wire shall be continuous and un-spliced between pull boxes or vaults and shall enter the pull boxes or vaults at the same location as the conduit for which it is installed. Coil and secure 5 extra feet of conduit detection wire in each pull box or vault. 4. Bonding wire suitable for direct burial may be used in place of conduit detection wire but shall be approved by the Engineer. L. Direct Buried Conductors 1. Direct buried conductor packages used shall be as described in Section 922.2.01 2. Do not unreel and pull package into the trench from one end. Unreel and lay them alongside the trench, then lay them in the trench as follows: a. Serpentine the cables slightly in the trench to allow for settling of earth. b. Do not allow cable to crossover in the trench. 3. Excavate trenches as follows: a. Cut trenches on a slight longitudinal grade (0.25% minimum) for drainage, unless otherwise specified. When the grade cannot be maintained all one way, grade the duct lines from the determined high point in both directions down to the ends. Avoid pockets or traps where moisture may accumulate. b. Cut the trench walls vertical. c. Tamp the trench bottom as necessary for a firm foundation. d. Sheet and brace the trenches when required. e. Adequately support conductor package and any other support material exposed in trenches if support is necessary to prevent damage. Include furnishing, installing, and removing sheeting, bracing, and supports in the Contract Prices for other items, as they pertain. 4. Before excavating, follow the instructions in Section 682.4 above. 5. If necessary due to obstructions, slightly change the locations of conductor package, as approved by the Engineer. 6. Obstructions to Excavation Make the following allowances around obstructions: a. Where possible, provide at least 12 in. (300 mm) between the finished package runs and utility facilities, such as gas lines, water mains, and other underground facilities not related to the electrical system. b. Where the package run is adjacent to concrete walls, piers, footings, etc., maintain at least 4 in. (100 mm) of undisturbed earth or firmly compacted soil between the package and the adjacent concrete. M. Installing Cable in Conduit 1. Cable used shall be as described in Section 922.2.01 2. Use cable with conduit as specified within the Contract. 3. When cable is brought through the base of the lighting standard or junction box, leave enough slack to allow the connections to be made outside the standard or box. The cable shall extend a minimum of 12 in. into the standard from the base plate before the outer covering is removed to minimize moisture and contaminants. 4. Carefully pull cables into place in conduits using approved methods so that the cable is installed without electrical or mechanical damage. Install as follows: a. Use powdered soapstone, talc, or other inert lubricants when placing conductors in conduit. b. Handle and install conductors carefully to prevent kinks, bends, or other distortions that could damage the conductor or outer covering. c. Pull all cables within a single conduit at the same time. d. When pulling cables through hand holes in pole shafts, etc., place a pad of firm rubber or other suitable material between the cable and the opening edges to prevent cable damage. N. Splicing Cable 1. Make splices only in above grade junction boxes and pole bases unless otherwise shown in the Contract. Underground splicing is not allowed without specific approval from the Engineer. 2. Splice conductors according to the National Electrical Code and the splice manufacturer’s recommendations. Splices are subject to the Engineer’s approval. 3. Make splices watertight. 4. When making straight or line splices in the same-sized conductors, use tin-plated copper compression tubular splices. 5. When making splices in different-sized conductors or conductors with different terminating directions: a. Use tin-plated copper compression ring tongue terminals on each conductor. b. Bolt the conductors/terminals together with stainless steel or high strength silicone bronze hardware. 6. Use locknuts, pal nuts, or lock washers to keep connections tight. Do not use split bolt connectors. 7. Use an oxidation inhibitor compound on aluminum conductor connections. 8. After making a conductor splice, insulate it with heat-shrinkable tubing, supplied by the manufacturer, with an adhesive coating on the inner wall. a. Use shrink tubing with insulation thickness equal to or greater than the insulation thickness of the conductor. b. Use UL listed heat-shrinkable tubing that meets ANSI C119.1 (latest edition) requirements for submersible and direct buried splices. c. When connections are bolted together, wrap the bolted connection with cloth tape before applying the heat-shrinkable tubing. d. Use proper diameter tubing for the conductor and connection and pad sharp points and edges on splices to prevent the heat-shrinkable tubing from splitting during shrinking. e. Place the shrink tubing to have at least 3 in. (75 mm) of seal length on the conductor beyond the splice after the tube is fully recovered. O. Electrical Service Point Installation 1. Electrical service point equipment shall be installed in accordance with the Contract and/or Standard Drawings. This would include any cabinets, disconnect switches, meter bases, service rack equipment and support hardware as well as additional conduit, service entrance heads, wood poles and grounding equipment. 2. Enclosures and cabinets shall be in accordance with Section 924.2.11 3. Disconnect switches shall be in accordance with Section 924.2.12 4. Circuit breakers shall be in accordance with Section 924.2.06 5. All equipment shall be grounded in accordance with Section 682.6.01 P 6. All equipment is to be sized and installed in accordance with NEC. P. Grounding 1. Ground rods are to be sized as indicated in Section 924.2.01. 2. Connect neutral/grounding conductors to the ground rod at all control points and to the ground wire cast in pole foundations. Use the type and size of continuous neutral/grounding conductors shown in the Contract and all connections shall be done using an exothermic weld. 3. Meet the minimum requirements of the NEC. 4. Use the shortest possible ground lead that leads directly to a grounding source. 5. All components, including mounting hardware, shall be grounded and bonded per manufacturer’s recommendations and NEC. Dress and route grounding conductor separately from all other controller cabinet assembly wiring. 6. Grounding to water or other pipes, such as metallic conduit, is not an acceptable grounding connection means. 7. Install ground rods at locations shown in the Contract. Install ground rods in one of the following ways: a. Driven Ground Rods 1) Drive single ground rods vertically until the top of the rod is at least 12 in. (300 mm) below the finished v. 2) Attach a length of No. 6 AWG, bare solid, soft drawn, or medium-hard drawn copper ground wire to the ground rod. Use suitable ground rod clamps. 3) Connect the wire to the standard base grounding nut. 4) Cutting ground rod short to match grade is not acceptable. b. Laid Ground Rods When sufficient penetration cannot be obtained in the above manner, place the following ground rod system: 1) Place 3 parallel ground rods at least 6 ft. (1.8 m) center-to-center horizontally and at least 12 in. (300 mm) below the finished ground. 2) Join and fasten these rods to the grounding nut of the standard base with No. 6 AWG, bare solid, soft drawn or medium hard drawn copper ground wire and suitable clamps.

682.7 Quality Acceptance and Testing

682.7.01 Conduit and Conductor Testing

A. Testing Conduit Test the installed conduit with a mandrel in the Engineer’s presence as follows: 1. Test every conduit after the conduit is installed and before cable or pull tape is installed. 2. Perform testing on all conduit types in this Specification, including but not limited to each conduit in duct banks. 3. Thoroughly clean the conduits so they are free of any dirt, metal particles, water or other liquids or debris before performing the mandrel test. 4. Use a mandrel 2 in. long and 0.25 in. smaller in diameter than the conduit. 5. Ream the duct opening to remove burrs or foreign matter. 6. Thoroughly clean the duct in accordance to manufacturer’s recommendations. 7. Provide and install a weatherproof cap at each open end after test is completed. 8. Repair conduits that the mandrel will not pass through. If repairs cannot be made to the Engineer’s satisfaction, remove and replace the conduit at no additional cost to the Department. B. Testing Conduit Detection (Tracer) Wire 1. Perform a continuity or tone test after installation to confirm that a continuous run of conduit detection wire was installed between pull boxes or vaults. 2. Prepare a test plan, supplying equipment, conducting the test and documenting the results. 3. Submit a test plan at least 15 working days prior to the desired testing date. 4. Testing shall not begin until the Engineer has approved the test plan, and all tests shall be conducted in the presence of the Engineer. C. Testing Conductors Caution: There is a risk of electrical shock when performing this test. This test should only be performed by qualified personnel that have electrical testing safety training compliant with or equivalent to ANSI/NETA ETT, Standard for Certification of Electrical Testing Technicians. Even though insulation is a dielectric material there will be very small amounts of current that leak through it. The amount of current that leaks depends on the strength of the insulation, its moisture content, and its temperature. Measurements should be taken when the relative humidity is below 50% and the electrical system temperature is below 86°F (30°C), but above the dew point temperature. During each one (1) minute test, if the resistance value decreases it is likely that the conductor or cable is wet or contaminated. The conductors can be dried by passing compressed dry nitrogen through the cable or conduit. If this fails, the system should be evaluated for contamination. Inspect all insulation for signs of contamination, degradation, and mechanical damage or abrasion. Any defective cable shall be replaced at no additional cost to the Department. Prior to connecting service to the newly installed system test the insulation resistance per the following procedure: Before beginning the test, make sure that the following precautions are observed: 1. The cable or wiring assembly should be disconnected from the system and NOT energized. 2. Set or hang the meter. Do not hold the meter in hands in case of transient voltages. 3. Discharge any conductor capacitance before and after each test. 4. Wear insulating rubber gloves when connecting or disconnecting test leads. 5. Don’t use an insulation tester near explosive agents. 6. Follow all of the meter manufacturer’s safety precautions. The test meter manufacturer will provide the meter connection instructions as well as instructions for operation of the meter. The following tests must be conducted, and the listed data below recorded on the test form (or Engineer approved equivalent) which must be completed and submitted to the Engineer for approval. Use multiple copies as required. Using the Step Voltage Test method to measure the insulation resistance, each branch circuit must be tested from the service cabinet through the end of the branch circuit to include all contractor installed conductors and splices within the circuit, all in accordance with the meter manufacturer’s instructions. Perform insulation resistance test on each conductor with respect to ground and adjacent conductors and measure insulation resistance of each bus way or conduit assembly, phase-to-phase and phase-to-ground. Record all relevant data using the format in the table below. Be sure to discharge any line capacitance after each test. 1. Apply 250V DC, test duration shall be one (1) minute and measure resistance and record the required information. 2. Apply 500V DC, test duration shall be one (1) minute and measure resistance and record the required information. Insulation resistance values shall be within 5 percent of manufacturer’s published data. If the manufacturer’s published data is not available, the measured insulation resistance shall be 100 meg-ohms or greater. Values of insulation resistance less than this or the manufacturer’s recommendations shall be investigated. In the event of failure, individual conductor runs between poles and/or splice locations should be tested to determine the problem and resolve it. The system’s minimum insulation resistance should be 25 meg-ohms. Electrical Insulation Resistance Verification Tests Project Number: ________________________ Location: _______________________________ Tested By: ____________________________ Date:___________________________________ Data Type of Cable or Wire Coil Number Manufacture Date Cable Length ft Conductor Size Insulation Temperature °F Ambient Temperature °F Meg-Ohms at 250 VDC Test Duration Min. Meg-Ohms at 500 VDC Test Duration Min. 1. Measure the service voltage between the phase conductors before turning the circuit breaker on at the service point. Also measure the service voltage between each phase conductor and the neutral or ground. 2. After observing the proper voltage as indicated in the Contract, turn the circuit breaker on and repeat the voltage measurements. 3. After the circuit has been energized for at least 10 minutes, measure the load current in each phase conductor and in the neutral at the service point. 4. Ensure that the current in the phase conductors is balanced and that there is no current in the neutral. D. Grounding 1. Test electrode to verify that this grounding system produces a resistance of 25 ohms or less. If not, add more ground rods as necessary, connected with No. 6 AWG solid copper wire at 8 ft. (2.4 m) on center and re-test. Up to four (4) total ground rods can be installed if necessary. 2. For extended distances between ramp meter and VDS, additional grounding may be required by the manufacturer. 3. When testing for resistance verify the ground is dry. 4. Submit all ground test results. E. Final Acceptance After successful completion of the test procedure, each conduit and conductor shall go through a burn-in period for 30 consecutive days of normal operation. During the burn-in period, the Contractor shall ensure that all Contractor-supplied equipment operates without failures of any type. If any equipment component malfunctions or fails to provide the specified functionality during the 30-day burn-in period, the Contractor shall replace or repair the defective equipment. After the malfunctioning component(s) has been repaired or replaced to the satisfaction of the Engineer, the Contractor shall begin a new 30-day burn-in period. The new 30-day burn-in period shall apply only to equipment components supplied by the Contractor. In the event of a failure or malfunctioning of equipment furnished by others that prevents the 30-day burn-in test from continuing, the Engineer will suspend the burn-in test and resume when the other equipment failures are corrected. F. Contractor Warranty and Maintenance 1. Contractor shall provide a one-year manufacturer support (usual and customary warranties) period for all electrical wire, cable, and conduit materials furnished. This shall include all Contractor or manufacturer activities related to maintenance, removal, and replacement of electrical wire, cable, and conduit materials in warranty during the support period. 2. The manufacturer warranty support period shall begin upon successful completion of acceptance testing. 3. All manufacturer warranties shall be continuous throughout the period and state that they are subject to transfer to the Department.

682.8 Measurement

A. Conduit Underground conduit, conduit duct banks, encased conduit, conduit on structures, directionally bored conduit, and jacked conduit will be measured for payment by the type and size installed per linear foot, tested and accepted. Unless otherwise specified in the Contract, all installation-related costs shall be included in the overall cost of the specified conduit. B. Pull Boxes and Junction Boxes Pull boxes and junction boxes will be measured for payment by the type and size installed per each and accepted. This shall include any excavation and backfill, bushing, couplers or any mounting hardware necessary to complete the installation. C. Conduit Detection Wire Conduit detection wire installed in existing conduit will be measured for payment by the linear foot amount installed and accepted. Payment for installing conduit detection wire in existing conduit will be paid for at the Contract unit price per linear foot. Such payment will be full compensation for furnishing, installing, and testing the wire. D. Cable and Conductors Cables and conductors will be measured for payment by the linear foot amount installed and accepted. Payment for installing cable and conductors will be paid for at the Contract unit price per linear foot. Such payment will be full compensation for furnishing, installing, and testing the cable and conductors. E. Electrical Service Equipment Electrical service equipment shall be measured and paid for at the Contract unit price per each installed service point installed and accepted. This will include all cabinets, enclosures, conduit and connectors, conductors, equipment racks including support beams and cross-bracing, ground rods and grounding conductors within the Contract or Standard Drawings to ensure proper operation. F. Grounding Unless specifically stated within the Contract, ground rods and related grounding conductors and equipment outlined within the Contract and Section 682.6.01 P will not be paid for separately.

682.8.1 Limits

Refer to General Provisions 101 through 150.

682.9 Payment

Payment will be made under: Item No. 682 Cable, type___. (AWG) No.___ Per linear foot Item No. 682 Multi-conductor cable, type___ (No. of each size and AWG No.) Per linear foot Item No. 682 Conduit, Rigid (size) Per linear foot Item No. 682 Conduit, Nonmetal, type 2 (size) Per linear foot Item No. 682 Conduit, Nonmetal, type 3 (size) Per linear foot Item No. 682 Conduit, Flexible (size) Per linear foot Item No. 682 Conduit, Fiberglass (size) Per linear foot Item No. 682 Conduit Detection Wire Per linear foot Item No. 682 Conduit Duct Bank (size) Per linear foot Item No. 682 Innerduct, (size) Per linear foot Item No. 682 Electrical Communication Box (type) Per each Item No. 682 Electrical Communication Box Rehabilitation Per each Item No. 682 Electrical Junction Box (size and type) Per each Item No. 682 Main Service Pick Up Point Per each Item No. 682 Pull Box, Types 2, 3, 4, 4S, 5, 5S, 6, and 7 Per each Item No. 682 Directional Bore (Size) Per linear foot

682.9.01 Adjustments

General Provisions 101 through 150.