807HIGHWAY ILLUMINATION

807.01Description

This work shall consist of installing wire, cable, conduit, lighting standards, luminaires, lamps, and incidental materials in accordance with 105.03.

Lighting installations shall be in accordance with the National Electrical Code and the National Safety Code.

807.01

MATERIALS 10

807.02Materials

Materials shall be in acco rdance with the following:

Casting for Handholes ................................................. 922.17(a) Coarse Aggregate, Class D or Higher, Size No. 53 ..... 904.03 Conduit ........................................................................ 922.19 Highway Illumination Materials .................................. 920.01 Line Hardware ............................................................. 922.10(e)1 20 Reinforced Concrete Pipe ............................................ 907.02 Reinforcing Bars .......................................................... 910.01

Manufacturers’ descriptive and technical literature for major items shall be submitted for approval. Where it is normal trade practice to furnish a warranty, a warranty shall be furnished on all major items such as luminaires, lamps, poles, brackets, cable-duct, wire and cable, fuse co nnectors, and ballasts. The effective date of the warranty shall commence on the date of final acceptance. These items shall bear the seal of approval of the UL. 30

All flexible conduit shall be galvanized steel, polyvinyl jacketed, and watertight.

Reinforcing bars shall be epoxy coated.

CONSTRUCTION REQUIREMENTS

Existing highway illumination shall be maintained on all projects unless discontinuance of the highway illumination is specifically allowed.

807.03Working Drawings

Working drawings shall be submitted in accordance with 105.02 for light pole assemblies, luminaires, and external drive assemblies.

Working drawings for each luminaire model submitted shall include the luminaire specifications and data sheets.

For contracts not utilizing the QPL for Luminaires, working drawings for luminaires shall also include the Illumination Engineering Society of North America, IESNA, photometric distribution file if the file number varies from what is shown on 50 the plans. The IESNA photometric distribution file shall be in either Visual, developed by Acuity Brands Lighting, or AGi32 from Lighting Analysis, Inc.

Working drawings for conventional light pole shall show the outside shaft diameter, height, wall thickness, mast arm length and rise, mast arm diameter and 807.02

thickness, handhole details, grinding details, materials required, and complete anchor- bolt details including bolt circle-projection and hardware. If a breakaway base is required, its details shall be shown.

When requested, sufficient design data shall be furnished with the drawings to 60 verify that conventional light pole is in accordance with wind load, deflection, vibration, and breakaway requirements. All of the above shall be based on the light pole details shown on the plans. After approval, the Engineer shall be advised of where changes to the Installation Summary sheets are being made because of existing roadside conditions. Where necessary, additional light pole working drawings shall be submitted for approval.

If a light pole is designed to support a larger luminaire than that specified, such information shall be shown on the working drawings. A Type C certification in accordance with 916 shall be provided for the breakaway devices certifying that the 70 breakaway devices are in accordance with the breakaway criteria of the AASHTO Standard Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals.

Working drawings for high mast towers shall show the pole height, number of sections, the pole shaft data for each section, luminaire lowering ring assembly, handhole details, materials required, welding details, and complete anchor bolt details including bolt circle-projection and hardware.

If the high mast is a non-standard design, the following design calculations and 80 data shall be submitted for approval prior to the fabrication of a high-mast pole:

section modulus furnished at the base of the pole, at all splices, at the connection of the ring, and at least every 20 ft,

anchor bolts, 90

loading,

connection to the pole in accordance with 920.01(b)7.

The working drawings shall include the dimensions and wiring diagram of the standard connections of the external drive system.

807.04Excavation

All excavation for the roadway lighting installation shall be performed in 807.04

accordance with the dimensions, elevations , and grades shown on the plans or as directed. If class X material is encountered, foundation excavation shall be completed in accordance with 206.

Excavation may be accomplished either manually or with mechanical trenching equipment. The blades of road patrols or graders shall not be used to excavate the trenches. The depth of trenches shall be a minimum of 2 ft. Walls of trenches for cable-110 duct or conduit shall be essentially vertical. The bottoms of trenches shall be smooth and free from aggregate larger than 1/2 in. Bracing, shoring, and sheathing shall be provided as necessary. If the excavation, th rough accident or otherwise, is below the required level, the excess excavated area shall be refilled in a satisfactory manner with no additional payment. The accumulation of water in excavated areas shall be prevented by the use of pumps or other approved means. When rocks or other materials which might damage the cable-duct or conduit are encountered, the excavation shall be extended to a depth of at least 27 in. and backfilled with a 3 in. compacted layer of sand or earth containing no particles that would be retained on a 1/4 in. sieve. No extra payment will be made for this additional excavation or backfill. 120

If possible, excavation for concrete foundations shall be accomplished by means of drilling with an auger of sufficient size to admit the width of the foundation. Work shall be so scheduled that all open excavations are poured with concrete during the work day they are dug. No excavations shall remain open over night or over a weekend or holiday. Accumulated water shall be removed from the excavation before concrete is poured. If class X material is encountered, foundation excavation shall be completed in accordance with 206.02(b).

Where roadside shrub plantings interfere with the location of illumination installations, the plantings shall be reset at other locations and at such times as directed, all in accordance with 622. The cost of this work will not be paid for directly, but shall be included in the cost of other pay items.

All slopes for foundation grading shall be sodded. Sod shall be placed in accordance with 621.

807.05Backfilling 140

All suitable materials removed from the excavated areas shall be used in refilling cable-duct and conduit trenches. No excavated materials shall be wasted without authorization. Materials authorized to be wasted shall be disposed of as approved. Backfill for trenches shall be placed in layers not to exceed 6 in., loose measurement. The first layer shall be sand or earth containing no particles or lumps that would be retained on a 1/4 in. sieve. The second layer shall contain no particles or lumps that would be retained on a 1 in. sieve. Subse quent layers shall contain no particles or lumps that would be retained on a 3 in. si eve. The second layer and each subsequent 807.05

layer shall be compacted with pneumatic hand-tampers to prevent any future settlement of the backfilled area. Backfilling of cable-duct and conduit trenches around 150 light pole foundations, handholes, manholes, and other structures shall be in accordance with the a pplicable provisions of 211. Fini sh grading of earthwork shall be accomplished in a satisfactory manner.

807.06Placing Conduit

Conduit shall be placed as shown on the plans and in accordance with applicable provisions of 805.11. Conduit shall be of a size to readily enable the passage of the cable-duct being used.

Conduit installed under pavement shall extend a minimum of 2 ft beyond the edge 160 of the paved surface or improved shoulder. The ends of such conduit shall terminate a nominal 2 ft below the ground surface. The ends shall be pitched so as to provide a positive drain to the surrounding soil. The ends shall be protected by threaded cap fittings until the time of installation of cable or cable-duct. Threaded bushing fittings shall be used on all ends before cable installation.

Conduits installed in bridge railing concrete sections shall terminate a minimum of 2 ft beyond the end of the bridge railing outside of the paved surface and a minimum of 2 ft under the ground surface. Existing conduit shall be extended as necessary to satisfy these requirements. 170

Hot dipped galvanized, malleable pipe stra ps and spacers shall be used to attach conduit to bridge structures. Galvanized steel conduit hangers or pipe clamps will not be allowed. Pipe straps of the proper size shall be installed 4 ft center to center along the conduit. When fastening pipe straps to concrete, a 3/8 in. by 2 1/2 in. galvanized steel lag screw, with an approved sleeve, shall be used; however, other approved expansion anchors may be used. The pipe strap and spacer shall be bolted to the steel beams.

Conduit for service supply shall be mounted on a service pole, either company or 180 State owned, near the right-of-way line. For simple supply circuits, one straight, continuous, conduit riser shall be used. The top end shall terminate with a weatherhead device, and the lower end shall terminate at least 2 ft below ground level with a threaded grounding bushing fitting. Unless otherwise directed, the weatherhead shall be 24 ft above the ground. However, the actual elevation of the weatherhead shall meet the requirements of the utility concerned.

807.07Connections in Base of Light Pole

Conductors shall be electrically bonded to each other, as required to satisfy circuit requirements, by means of compression type fittings of the style and type shown on 190 the plans. Inhibitor compound shall be used on each compression connection. Conductor identification shall be maintained by connecting like color connectors.

807.07

A multiple conductor compression fitti ng shall be used to connect supply conductors and an insulating link used to provide an extension as shown on the plans. These fittings shall be covered with snap-on fiber or plastic covers designed to protect them from electrical contact. Taping will not be allowed. The bare extension of the supply conductor from the multiple fitting to the insulation link shall be no longer than necessary to admit the application of the snap-on cover for the multiple fitting.

The pole circuits shall be connected by means of easily separated, single conductor connector kits. The connector kit on the “hot” side of the pole circuit shall be fused. The connector kit for the neutral side shall not be fused. Fuses shall be of the “KTK-10” series with a rated capacity three times the operating amperage of the

luminaire. If the required capacity is not a standard size, the next larger size fuse shall

be used.

The connector kit on the “hot” side of the pole circuit shall have the following

features:

210

synthetic rubber suitable for direct burial in the ground or

installation in sunlight,

gripping the “KTK-10” cartridge fuse in each housing. These220

contacts shall be fully annealed,

and rigidly maintain the fuse contacts,

the conductor that securely retains the conductor in the proper

position,

when disconnected and keep the conductive parts of the line side

inaccessible,

metal parts and the rubber housings or boots for easy assembly.

807.07

933

The neutral side connector kit shall be similar in all respects to that described for

the hot side except that a dummy fuse shall be used for the purpose of completing the240

electrical circuit. The bayonet disconnect feature of the connector kits shall be part of

the load side of both the neutral side and the hot side conductors. The line side shall

have a socket to receive the bayonet. These kits shall be installed in the pole circuit

between the luminaire terminals and the compression connection to the underground

distribution circuit as shown on the plans. A separate insulated conductor shall be used

to connect the neutral of the underground distribution circuit and the neutral of the

pole circuit to the ground lug in the pole base from the point at which both neutrals are

connected together by a compression connection. The bayonet disconnect features

from the neutral side and the hot side connector kits as cited above shall be included

in the sign structure circuitry when luminaires are installed on the sign structures.250

Consecutive roadway luminaires in a circuit shall be alternately connected to opposite

load conductors R or B as specified in the plans to balance the load. Sign luminaires

on individual structures shall be similarly connected.

807.08Placing Wire and Cable

All underground distribution conductors shall be continuous runs between splice

points. Unless otherwise authorized, splice points shall be inside the bases of light

poles, inside handholes, in service distribution boxes, at point of connection to power260

supply in switch boxes, or in junction boxes. All splices shall be made with the proper

connector in accordance with 807.07.

Cable-duct shall be placed either in a trench or plowed into place. Cable-duct shall

be installed without sharp bends or kinks and in straight runs so as to enable

withdrawal of a conductor and the installation of new conductor without additional

excavation or backfill.

Plowed cable-duct shall be installed at a minimum depth of 2 ft in a single cavity270

gored into the earth by a vibrating plow blade. The equipment used for plowing the

cable-duct shall be designed specifically for that purpose with the power and versatility

to easily and accurately bury the various sizes of cable-duct under all normal soil

conditions. This equipment shall place the cable-duct without twisting, kinking, or

damaging it in any way. Dragging or pulling the cable-duct from the start of the

trenching operation will not be allowed. Where two ducts are to be installed parallel

to each other, the distance between them shall be no less than 12 in. and no more than

24 in.

The plastic duct of the cable-duct shall be terminated 4 in. above the top of280

foundations or 4 in. inside handholes with sufficient excess conductors as directed. All

terminations of this plastic duct shall be beveled and free from any sharp edges or

burrs. Insulation of the electrical conductor shall not be damaged when cutting the

duct.

807.08

934

The underground distribution circuit shall be protected by galvanized steel

conduit when installed under pavement, in road shoulders, or elsewhere as shown on

the plans or as directed.

290

Cable-duct shall be pulled through the entire length of galvanized steel conduit if

at all possible. If this is not possible, written authorization shall be obtained to allow

the duct to be cut away and the conductors installed in the conduit with a minimum of

2 ft of duct extended into the conduit. Where so authorized, the plastic duct shall be

terminated in the proper transition fitting attached to the end of the conduit and each

conductor of the cable-duct assembly shall continue undamaged and uninterrupted

through the galvanized steel conduit to the other end of the conduit where a transition

to the cable-duct shall be used again and the cable-duct shall continue uninterrupted

to the next designated splice point. All transitions from galvanized steel conduit to

cable-duct shall be accomplished with the proper adapter. This adapter shall provide a300

durable, watertight transition that has a smooth uniform interior.

The location of underground conduits or cable-ducts shall be marked with cable

markers. The marker shall be placed at all changes in direction, where the underground

distribution circuit is split, and at a maximum of 400 ft intervals on straight runs. Cable

markers shall be a slab of concrete 2 ft square by 4 in. thick, with the word “Cable”

die impressed into the surface of the marker, a minimum depth of 3/8 in. with letters a

minimum of 2 in. high. Arrows showing the direction of the cable shall be die

impressed or saw-cut a minimum depth of 3/8 in. into the marker surface.310

Curing of the concrete shall be in accordance with 702.22. The cable marker shall

have a smooth metal trowel finish without scaling.

Cable-duct shall enter the bottom of the conduit riser with a sweeping radius bend

and continue up the riser to within 3 in. of the top of the conduit riser. At this point the

plastic duct shall be terminated and the conductors shall continue uninterrupted and

undamaged into the service cabinet, underpass switchbox, or through the weatherhead

with sufficient excess to make the required connections.320

Where a cable-duct underground distribution circuit is run through conduit

installed in bridge coping, the duct shall be cut away and the conductors shall be

installed in the conduit with at least 2 ft of duct extended into the conduit. The

conductors, through this transition, shall be continuous between authorized splice

points. Where more than one light pole is to be installed on the same side of the bridge

structure and connected to the same distribution circuit, the cables pulled between

these light poles shall be of the same type and size used in the cable-duct underground

distribution circuit.330

807.08

935

Aerial cable for overhead distribution circuits shall be supported and terminated

as shown on the plans. The aerial cable shall have a sag of no more than 5% of the

distance between lighting poles except where slack spans are indicated on the plans.

Aerial cables shall have a minimum vertical clearance of 18 ft.

807.09Lighting Handholes

Handholes shall not be placed in areas subject to flowing or ponding water.

Handholes shall be installed with the top flush with adjoining surfaces. Precast340

handholes with integral bottoms will be considered acceptable.

Multiple compression fittings and insulating links installed in handholes shall be

taped and waterproofed by application of an approved waterproofing device. The

insulation around the area to be waterproofed shall be cleaned before applying the

waterproofing device. These waterproofing devices shall be designed for insulating

multi-conductor cables with a minimum voltage carrying capacity of 600 volts.

Handholes of an alternative material will be allowed as a substitute for a street

and alley handhole providing that they meet the requirements of 922.17(b) and can be350

placed at a location which meets both of the following conditions:

handhole is to be located; and

it is protected by guardrail, non-mountable curb, a structure, or an

non-traversable ditch.

The handhole shall be backfilled with sand or earth containing no particles that360

would be retained on a 1/4 in. (6.3 mm) sieve. The backfill shall be placed as shown

on the plans. No additional payment will be allowed for this backfill.

807.10Concrete Foundations For Light Poles

Foundations shall be class A concrete in accordance with 702. Footings may be

either round or square in shape as shown on the plans.

Anchor bolt circle dimensions shall be furnished and the anchor bolts shall be in

accordance with 920.01(a)7. A rigid template shall be used to center the anchor bolts

in the foundation. Unless otherwise specified, the template shall be oriented so that the370

mast arm of the light pole is perpendicular to the center line of the roadway.

Each foundation installation shall have provisions for grounding the light pole in

accordance with 807.12. The tops of the concrete foundations shall be constructed

level and only shims used to rake the light pole will be allowed. Shims shall not be

used with break-away couplings. Each foundation shall have an imprinted arrow or

arrows on the top of the foundation to indicate the direction of the cable duct run.

807.10

936

Foundations for high mast towers shall be constructed prior to constructing

foundations for conventional roadway lighting.380

If the sidewalls of the excavated areas remain firm and stable, concrete may be

poured directly against the dirt below the level of the top 6 in. form. Otherwise, the

concrete foundation shall be fully formed by means of a paper preformed liner or other

approved means. However, the foundation shall be formed to the proper size for the

top 6 in. before concrete is poured. If a paper liner is used, it may be withdrawn as the

concrete is placed or it may be left in place permanently. If the liner is left in place, all

voids between the excavation walls and the form shall be filled and compacted using

coarse aggregate No. 53. If the liner is withdrawn, the top 12 in. of the foundation shall390

remain formed until the concrete has obtained initial set.

Precast foundations shall be complete with reinforcing bars, tie bars, anchor bolts,

and entry sleeves located to provide a level mounting for the light pole after

installation. The grounding coil, as shown on the plans, may be used for grounding

light pole set on precast foundations. Foundation backfill shall consist of coarse

aggregate No. 53.

Foundation projection above the finished grade shall be as shown on the plans.

The excavated material may be used for this grading if it is not granular in nature and

will readily stabilize and support the growth of sod. If the excavated material is

unsuitable, it shall be properly disposed of and approved materials used. The area shall

be sodded. Sodding will be in accordance with 621.

807.11Placing Light Poles

The light pole assembly shall consist of a metal pole, a shoe base, a frangible410

breakaway base or coupling where shown on the plans, and a metal mast arm for

attaching the luminaire. The unit shall be assembled on the ground. Pole circuit wiring

shall be installed and the luminaire shall be attached prior to erection. The factory

finish of the pole assembly shall be protected from mars, blemishes, scratches, or other

damage. Slings and chokers for lifting purposes shall be of nylon or other approved

material. Chains, metal rope, or other abrasive materials shall not be used for lifting

devices. If damage to the factory finish occurs, repair or replacement shall be as

directed.

The base plate shall be designed to carry the pole assembly. The plate assembly420

shall be supported by a transformer base, which shall be in accordance with the

breakaway requirements in the AASHTO LRFD Specifications for Structural Supports

for Highway Signs, Luminaires, and Traffic Signals.

807.11

937

After erection and attachment to the foundation, the pole assembly shall be plumb.

The luminaires shall be level in both horizontal areas. Shims shall not be used with

breakaway couplings. Shimming will be allowed on other types of installations to rake

the pole assembly to obtain the desired attitude of the luminaire where the combined

weight of the pole and mast arm requires it and the luminaire saddle will not allow the

adjustment. The mast arm shall be perpendicular to the axis of roadway travel unless430

special orientation is noted on the plans. Unless otherwise specified, the lighting

system shall consist of metal pole supports for the luminaires with an underground

electrical supply system.

High mast tower pole sections shall be mechanically fitted in the field using

factory supplied hydraulic jack or hoist puller that shall produce a minimum force of

10,000 lb per side. Field assembly procedures and assembly apparatus requirements

shall be submitted for approval. Field welds will not be allowed except where shipping

limitations prevent permanent factory assembly. Prior approval for field welds is440

required.

The pole shall be erected on the lower set of the anchor bolt nuts and secured with

the top nuts. The adjustments to plumb the pole shall be made prior to the final

tightening of the top nuts.

The pole shall be plumbed under no wind conditions before sun-up, after

sun-down, or on an overcast day. The deviation from vertical shall not exceed 1/4 in.

within any 10 ft of height.

450

When installing the high mast power cable, one end of the power cable shall be

securely connected to the luminaire ring. The other end of the power cable shall be

secured to the support and terminated 3 ft below this support with a heavy duty three-

wire electrical plug. Adjustments of the three support cable lengths shall be made prior

to lowering the ring for the first time. After the support cables have been adjusted and

the luminaires installed on the ring, at least one complete cycle operation of the ring

shall be conducted on each structure.

As shown on the plans, should the ring provide more luminaire attachment

positions than luminaires to be installed, counterweights of the same weight of the460

luminaire shall be installed on those positions.

807.12Grounding

Ground wire shall be No. 4 AWG solid bare copper. Ground rods shall be 1/2 in.

diameter by 8 ft long copper weld ground electrodes except where larger sizes are

specified. The top of the ground rod shall be driven at least 6 in. below grade. Ground

rods shall not be installed within the light pole sign structure, or high mast tower

foundations.

807.12

938

The ground wire shall be connected to the top or side of the ground rod. The470

ground rod, ground wire connection shall be made by a thermo weld process. The wire

and ground rod shall be free of oxidized materials, moisture, and other contaminants

prior to inserting the wire and the ground rod into the properly sized mold. The welding

material shall sufficiently cover and secure the conductor to the rod. The completed

connection shall be non-porous.

As an acceptable substitute to this process, a mechanical ground grid connection

of an approved type may be used. Tap type clamps, parallel type clamps, U-bolt flat

clamps, and crossover clamps will not be accepted.

480

Luminaire poles shall be grounded by connecting the free end of the ground wire

to the grounding lug in the transformer base or pole. The free end of the ground wire

shall enter the pole base through the entry sleeve installed in the foundation.

The neutral conductor of the underground distribution circuit shall be connected

to the ground lug in the transformer base or pole. This connection shall include a

quick-disconnect type connector kit so that in the event of a pole knockdown the

connection will readily break without damage to the buried conductor.

The breaker boxes for the sign and underpass circuits shall be grounded by490

connecting the free end of the ground wire to the neutral grounding terminal in the

breaker box and connecting this terminal to a grounding lug securely fastened to the

metal interior of the breaker box. The conduit terminating in the breaker box and the

sign or underpass luminaire housing shall have a good, clean, tight connection and act

as a grounding conductor for these luminaires. The neutral conductors of the feed and

distribution circuits for underpass and sign illumination shall be connected to the

neutral grounding terminal in the switch box or breaker box. The neutral conductor of

the distribution circuit for underpass and sign illumination shall be grounded in each

luminaire by connecting a jumper from the neutral terminal of the luminaire to a

ground lug fastened to the metal housing of the luminaire.500

Sign structures shall be grounded at one sign column by connecting the free end

of the grounding wire at that column to the grounding lug in the column base.

A Type I service for supply of electrical energy shall consist of a conduit riser to

a weatherhead. This conduit shall be grounded at the lower end by means of a standard

strap grounding connection to the ground wire and ground rod. A Type II service shall

consist of a multiple number of conduits from underground to the bottom of the service

cabinet and a single conduit to a weatherhead from the top of the service cabinet. All

of these conduits shall be connected by a single ground wire from the grounding510

terminal to a grounding bushing for each conduit within the interior of the service

cabinet. In addition a ground wire from the grounding terminal of the service cabinet

shall be connected through a conduit to a ground rod.

Bridge railing conduits shall be grounded at each end of the bridge railing by

807.12

939

means of a standard grounding strap connected to a ground wire and ground rod. The

ends of the conduits terminating in a bridge anchor location shall provide ground

continuity by means of a grounding bushing on each conduit end and the connection

of the bushing to a ground wire.

520

All equipment used in the highway lighting system shall be grounded. If

necessary, additional grounding shall be installed as directed.

807.13Luminaires

Luminaire installation shall consist of the physical placing of the luminaire. Each

installation shall include the furnishing and placing of the light source as designated.

Luminaires shall be compatible with other lighting materials as specified in 920.01.

530

Each luminaire shall be leveled in both directions in the horizontal plane after the

light pole has been erected and adjusted. Rotary adjustment of the mast arm and

vertical adjustment of roadway luminaires to obtain an installed level position in both

directions shall be accomplished by means of the bolted saddle arrangement used to

attach the luminaires to the mast arm. For certain light source types such as metal

halide lamp socket positions may be shown on the plans by type of Illuminating

Engineering Society of North American, IES, and light pattern. The specified lamp

socket position or comparable arrangement of LEDs shall be used to obtain the desired

light pattern delivery. Proper connections shall be made to provide operation at the540

voltage being supplied. Replacements needed because of faulty or incorrect voltage

connections shall be made with no additional payment. All roadway luminaires

provided for an intersection, interchange, or contiguous highway segment shall be the

same type, model, and wattage.

Connections in which plain and galvanized steel are in contact shall be protected

such that aluminum surfaces shall receive one coat of zinc chromate primer. Steel

surfaces shall be prepared in accordance with 619.08(a), and 619.08(d), and painted

with the structural steel paint system in accordance with 619.09(a). All paint shall be550

allowed to cure before assembly. Conduit fittings, if required, shall be watertight.

Required conduit shall be either rigid or flexible as necessary. Conduit shall not be

clamped to a sign panel.

Sign luminaires shall be mounted on overhead sign structures on two metal

channels located at the extremity of the sign walkway support brackets. The distance

between lighting unit support channels shall be 7 in. These channels shall be located

in such a manner that they readily receive the mounting bolts from the rear of the sign

luminaire. The installation of the sign luminaire shall consist of the physical placement

of the luminaire on the channels.560

807.13

940

Sign luminaires shall be connected to a phase conductor and a neutral conductor.

The luminaires shall be alternately connected to opposite phase conductors to balance

the load. The connections in the base of the sign structure shall be in accordance with

. Conductor splicing shall be in junction boxes, in-ground handholes, inside

handholes of sign structures, and circuit breaker enclosures. All sign luminaires

provided for an interchange or contiguous highway segment shall be the same model.

Underpass luminaires shall be mounted on the vertical side surfaces of bridge bent570

structures or suspended by means of pendants supported by angle-iron struts or clips

fastened to the structural beam members of the bridge. All parts of the pendent pipe

assembly shall be hot-dipped galvanized after threads are cut. Silicone caulking

compound shall be applied to the threads during assembly of the pendent. Underpass

luminaires may require separately mounted ballasts which shall be installed in close

proximity to the luminaires.

Underpass luminaires shall be connected to a phase conductor and a neutral

conductor. The luminaires shall be alternately connected to opposite phase conductors

to balance the load. Conductor splicing will only be allowed in junction boxes, in-580

ground handholes, and circuit breaker enclosures. All underpass luminaires provided

for an interchange shall be the same model.

The aiming of the luminaires shall be as shown on the plans. During the aiming

and adjustment process, the luminaire shall be oriented to conform to its raised position

and the ring properly tethered to prevent rotation. The long axis of the luminaire shall

be parallel to the aiming direction as shown on the plans. All high mast luminaires

provided for an interchange shall be the same model and wattage.

590

A non-prorated manufacturer’s written warranty, against loss of performance,

defects in materials and defects in workmanship, shall be provided to and in favor of

the Department. The warranty shall cover a period of 10 years from the date of

shipping of the luminaire. The warranty shall cover all components of the luminaire,

including but not limited to driver and light source. Loss of performance is defined to

include, but is not limited to, the luminaire or any of its components falling out of

compliance with the specification in place at the time of installation, which includes

but is not limited to the following: there is no light output from 10% or more of the

LEDs, the luminaire is operating below the lumen maintenance curve, or the color600

temperature shifts more than 500K outside of the specified color temperature range.

The warranty shall stipulate that repaired or replacement luminaires shall be shipped

to the appropriate Department District Office, at no cost to the Department, within 30

days after the manufacturer’s receipt of failed luminaires. Replacement luminaires

shall be the same model or a model that is equal to, or better, in terms of photometrics,

energy consumption, and reliability. Warranty documents shall include the

manufacturer’s name, address to which failed luminaires are to be shipped for

807.13

941

replacement, and the contact person’s name, phone number, and email address.

Warranty documents shall provide the estimated life cycle of the lamp, LEDs, plasma

emitter and power driver. A Type C certification in accordance with 916 shall be610

provided for the luminaires.

807.14Sign, Underpass, Roadway, High Mast Lighting Location, and

Luminaire Identification

All high mast towers, roadway light poles, underpass lighting installations, and

sign lighting installations shall have an identification code number as shown on the

plans. In addition, each luminaire at a sign or underpass installation shall be

individually identified with a single capital letter.

The code number shall be displayed on the light pole, sign structure column, and620

high mast tower as shown on the plans. The underpass code number shall be displayed

near the breaker box at a location as directed.

The code number for the light pole and sign structure column shall be applied to

the pole, as specified by the manufacturer, by using individual, pressure sensitive,

adhesive backed tags. The code number for the high mast tower shall be applied to an

aluminum plate which is mounted with spacers away from the structure as shown on

the plans.

A luminaire identification sticker shall be provided on each luminaire and on the630

light pole or tower that supports the luminaire. The sticker shall be titled

“LUMINAIRE” and contain the following: light source type, luminaire manufacturer,

model, wattage, LED or lamp model, power drive model, surge protection device

model, date of shipping, and warranty period. The luminaire identification sticker shall

be attached underneath the light pole/tower ID tag, shall face the roadway, and shall

have 3/4 in. lettering, and be no greater than 8 in. by 8 in.

807.15Service Point Power Entry

The utility’s requirements for service locations shall be coordinated. Unless

otherwise specified, a pole shall be furnished for the service point. If the utility requires640

metering or is specified on the plans of the lighting system, a meter socket shall be

obtained from and installed in accordance with the requirements of the utility.

Grounding shall be in accordance with 807.12 and shall be a part of the service

installation.

Energy shall be provided with 120/240 V service or 240/480 V service with the

proper KW capacity on poles located immediately inside the right-of-way at locations

designated on the plans. Electrical materials incorporated in the work shall be

compatible with the service voltages supplied by the local utility.

650

The service voltages supplied by the local utility shall be checked for compliance

with the planned voltages. If a discrepancy exists, it will be resolved as directed before

work is started or any electrical equipment is purchased.

807.15

942

Service point installations shall be of two types as shown on the plans.

This service point installation shall consist of class 5 timber pole, 2 3/4 in.

galvanized steel conduits, weatherhead, photocell, and multiple relay switch. The660

conduit riser shall be fastened and supported on the pole by means of galvanized hook

pipe straps and secured to the pole by means of a galvanized lag screw all of the proper

size for the conduit being installed. Cable-duct shall be installed in the conduit riser in

accordance with 807.08(c). The conductors shall extend beyond the weatherhead a

minimum of 4 ft. The conductors outside of the weatherhead shall be ringed to prevent

moisture from entering the conduit enclosure.

This service point installation shall consist of a service cabinet with a single

galvanized steel or aluminum conduit riser to the weatherhead. A multiple number of670

galvanized steel conduits shall extend from the bottom of the service cabinet in

accordance with 807.06. Underground cable-duct shall be installed in accordance with

(a). Connections, connectors, and fixtures shall be as shown on the plans

The service cabinet shall be secured to the pole by means of a galvanized steel

channel post or other approved device.

The illumination circuits for sign structures with an overhead power supply shall

be protected by circuit breakers mounted on the end support.680

Circuits for adjustable end support sign structures, bridge bracket signs, or

underpasses shall be protected by circuit breakers mounted on the bridge or sign

structure and connected to the underground distribution circuit in a handhole.

Circuits for sign structures with an underground power supply shall be protected

by fuse connector kits in the base of the sign support. The fuse connector kits shall

include bayonet disconnect features for the “neutral” side and “hot” side.

807.16Testing of Highway Lighting System690

All necessary equipment and apparatus properly calibrated for testing the lighting

circuits shall be furnished. The supplying utility shall be given advance notice of the

test scheduling so their representative may witness the testing procedures if desired.

Each main lighting circuit, including its branches, shall be tested for insulation

resistance and continuity after it is completely installed but before the pole circuits,

underpass circuits, sign circuits, and grounding circuits are connected.

807.16

943

The insulation resistance test shall be made with a megohm meter and the700

resistance to ground shall be no less than 50 megohms in all lighting circuit power

cables. The meter shall be set for the voltage rating of the insulation. The continuity

test shall be made with an ohmmeter properly scaled for measuring the resistance of

the power cables. This test shall verify the following:

consistent with cable coding at the supply point.

710

other.

have unusual resistance values.

The entire completed installation shall be tested by circuit or by such portions as

may be selected and at night if directed. Tests shall demonstrate the following:

free from short circuits, and free from unspecified grounds.

applicable wiring diagrams.

continuous operation of each lighting circuit for at least 1 h.

points is within allowable limits. A maximum of 10% voltage730

drop will be allowed for each complete circuit.

The lighting system from the service point through the last luminaire shall be

subjected to 14 days of normal operation prior to final acceptance. This testing

procedure may be conducted separately on each circuit or on the entire system.

Normal operation is defined as the luminaires being on during the darkness hours

and off during the daylight hours as controlled by the service point photocells and

relay switches. Malfunctioning equipment shall be replaced or repaired before final740

inspection. The pattern of light and correlated color temperature delivered to the

pavement by roadway, high mast, and underpass luminaires will be inspected at night.

At this inspection, the proper tools, equipment, and personnel shall be available to

make all adjustments. These items shall specifically include a bucket truck capable of

807.16

944

reaching all luminaires in the system, safety equipment, and a level to determine the

proper luminaire position.

Within 30 calendar days after completion of the work, as-built drawings shall be

submitted in electronic format to the Engineer. The lighting as-built drawings shall

indicate the as-built location of light poles, high mast towers, service points, conduit750

runs, and lighting handholes.

807.17Pay Item and Installation Summary Sheets

Prior to final inspection, two sets each of installation summary and pay item

summary, each marked Final Record, shall be furnished for the light pole as installed.

The installation summary shall show the effective mounting height, mast arm length,

foundation elevation, pay item, type of base, and catalog number or drawing for each

light pole furnished. The pay item summary shall indicate the pay item, quantity,

effective mounting height, mast arm length, and type of base for each type of light

pole furnished.760

807.18Method of Measurement

Luminaire, light pole with mast luminaire arm, high mast tower, identification

number, connector kit, multiple compression fitting, insulating link, foundation,

handhole, service point, and cable marker will be measured by the number of units

installed. Pole circuit conductor and circuit conductor in conduit will be measured by

the linear foot. Pole circuit conductor will be measured from the base of the light pole

to the terminal block of the luminaire. Pole line extension will be measured in a straight

line between each pole.

770

Conductor in bridge conduit will be measured by the linear foot from end to end

of conduit or from the end of conduit to the last bridge light pole foundation entry. An

allowance of 5 lft will be made for each foundation entry. An allowance of 2 lft will

be made for each junction box.

Removal of existing light structure, which shall include the pole, mast arm, and

foundation, will be measured by the number of units removed.

Cable-duct and conductor in underground duct or conduit will be measured by the

linear foot as follows:780

handhole or face of the next concrete foundation. An allowance of

5 lft will be made for each entry at foundations. An allowance of 2

lft will be made at handholes for connection purposes.

An allowance of 4 lft will be made at the switch box for electrical

connections.

790

807.17

945

roadway surface or shoulder. No measurement will be made for

cable-duct in conduit where it is part of a service point, sign

installation, or underpass lighting system.

807.19Basis of Payment

Luminaire will be paid for at the contract unit price per each for the type specified.

Service point will be paid for at the contract unit price per each for the type specified.

Light pole will be paid for at the contract unit price per each for the estimated mounting

height, length of mast arm, and base type specified. High mast tower will be paid for800

at the contract unit price for the specified mounting height.

Lighting foundation, concrete, with grounding will be paid for at the contract unit

price per each for the size specified. If class X material is encountered during lighting

foundation excavation, payment will be made for such excavation in accordance with

206. Partial payment for lighting foundation in the amount of 80% will be made if all

such work is complete except for finish grading and sodding. The remaining

percentage of payment will be made upon completion of the finish grading and

sodding.

810

Connector kit will be paid for at the contract unit price per each for fused or

unfused, as specified. Multiple compression fitting and insulation link will be paid for

at the contract unit price per each for waterproofed or non-waterproofed, as specified.

Cable-duct marker, high mast tower winch drive, and handhole, lighting will be paid

for at the contract unit price per each. Sign, underpass, and roadway lighting location

identification will be paid for at the contract unit price per each. Circuit installation

will be paid for at the contract unit price per each for the type, structure number, and

number of luminaires specified. Light structure, remove and portable tower lighting

drive system will be paid for at the contract unit price per each.

820

Wire will be paid for at the contract unit price per linear foot for the designation,

copper gauge, housing, and number of conductors specified. Pole circuit cable, Type

THWN, stranded will be paid for at the contract unit price per linear foot for the copper

gauge and number of conductors specified. Conduit, steel, galvanized, 2 in. diameter

will be paid for at the contract unit price per linear foot.

Payment will be made under:

Pay Item Pay Unit Symbol

830

Cable, Pole Circuit, THWN, No. _____ Copper,

Stranded, _____ _____/C ............................................... LFT

Cable-Duct Marker .................................................................... EACH

Circuit Installation, Str. No. ___, ____ Luminaires................... EACH

no.

Conduit, Steel, Galvanized, 2 in. ............................................... LFT

807.19

946

Connector Kit, Fused ................................................................. EACH

Connector Kit, Unfused ............................................................. EACH

Handhole, Lighting .................................................................... EACH

High Mast Tower, ____ ft E.M.H. ............................................ EACH840

High Mast Tower Winch Drive ................................................. EACH

Insulation Link, Non-Waterproofed .......................................... EACH

Insulation Link, Waterproofed .................................................. EACH

Light Pole, ___ ft E.M.H.,___ ft Mast Arm, ___ Base .............. EACH

Light Structure, Remove ........................................................... EACH

Lighting Foundation, ____ Concrete, with Grounding.............. EACH

type

Luminaire, High Mast ............................................................... EACH

Luminaire, High Lumen Roadway ............................................ EACH

Luminaire, Low Lumen Roadway ............................................. EACH850

Luminaire, Sign ......................................................................... EACH

Luminaire, Underpass................................................................ EACH

Multiple Compression Fitting, Non-Waterproofed ................... EACH

Multiple Compression Fitting, Waterproofed............................ EACH

Portable Tower Lighting Drive System ..................................... EACH

Service Point, _____.................................................................. EACH

type

Sign, Underpass, and Roadway Lighting

Location Identification ....................................................... EACH

Wire, ____, No. _____ Copper, in ____, ____ ___ /C .............. LFT860

designation gauge housing

The cost of circuit breakers; breaker enclosures; conduit; flexible conduit; conduit

fittings; grounding; weatherhead; aerial cable termination; and incidentals required

from the last luminaire to the point of attachment by the utility, the bottom of the riser

at the structure base, or the connector kits in the base of the sign supports shall be

included in the cost of circuit installation.

If not listed in the Schedule of Pay Items, the cost of connector kit, fused or

unfused, multiple compression fitting and insulation link, waterproofed or non-870

waterproofed, shall be included in the cost of the other items.

The cost of aerial distribution service, drops to sign structures branching off from

the pole line extension, weatherheads and risers required to connect the line extension

to the underground electrical distribution circuit, all anchorage guy wires, hardware,

aerial cable, electrical connections, timber poles, and incidentals required to complete

the pole line extension shall be included in the cost of cable, pole circuit.

The cost of the mast arm, J-support hook for pole circuit, handhole with cover,

shoe base, transformer base or frangible coupling if required, installation of the pole880

on the foundation with the pole circuit shall be included in the cost of light pole.

807.19

947

The cost of the pole; lowering system including winch assembly, power cable,

and support cable; concrete pad; luminaire ring; anchor bolts and nuts; lightning rod

assembly; grounding system; and all incidental materials necessary to complete the

installation shall be included in the cost of high mast tower. The cost of excavation,

concrete, sleeves for cable-duct, non-metal pipe, reinforcing bars, backfill, finish

grading, and sodding shall be included in the cost of lighting foundation.

The cost of wood poles, multiple relay switches, service cabinet, photocells,890

photocell receptacles, weatherhead, conduit, and other miscellaneous items shall be

included in the cost of the service point.

The cost of lamps, LED arrays, plasma emitters, drivers, optical systems,

weatherproof housings, surge protection devices, electrical connections, and

installation of the luminaire on the pole shall be included in the cost of luminaire.

The cost of snap-on coverings in light pole bases and waterproof coverings in

underground handholes shall be included in the cost of multiple compression fitting.

900

The cost of maintaining highway illumination during the life of the contract and

the preparation and transmittal of as-built drawings shall be included in the cost of

other pay items.