834FINAL 20181218

834.01 GENERAL. This section covers the requirements for lighting materials.

Materials shall be approved by Engineer prior to utilization on a project. Certain lighting materials are included on the Department’s List of Approved Materials.

834.02 CONCRETE. Use Class A concrete. Conform to Subsections 601.02 and

601.03.

834.03 STEEL REINFORCEMENT. Steel reinforcement shall have minimum yield

strength of 60,000 psi and meet ASTM A615.

834.04 GROUND RODS. Provide composite shaft ground rods consisting of a pure

copper exterior that has been inseparably, molten-welded to a steel core. Use copper-clad style ground rods with a minimum plating thickness of 10 mils. Rods shall be certified to conform to ANSI/NEMA GR1. Equip the rods with copper or bronze clamps that are the correct size for the rod being used.

834.04.01 Conventional Poles, Lighting Cabinets, and Services. Use rods with a

minimum diameter of 5/8 inch and a minimum length of 8 feet.

834.04.02 High Mast Lighting Poles. Use rods with a minimum diameter of 3/4 inch

and a minimum length of 10 feet. 834.05 CONDUIT. Ensure the conduit is the size specified on the plans and detail sheets.

834.05.01 Rigid Steel and Fittings. Provide conduit from the Department’s List of

Approved Materials. Use rigid steel conduit fittings that: are zinc coated, meet the requirements of ANSI C-80.1, and have UL6 Certification.

834.05.02 Schedule 40/80 PVC and Fittings. Provide conduit from the Department’s

List of Approved Materials. Use schedule 80 polyvinyl chloride fittings having the same chemical and physical properties as the conduit with which it is to be used and meeting the requirements of UL 514B. Use joints that are made in accordance with the manufacturer's recommendations. Each conduit and fitting shall bear the Underwriters Laboratories, Inc. label. Other components shall conform to the following: Boxes UL514C, Covers UL514D, and Enclosures UL50. All PVC bushings shall be end bell type.

834.05.03 Stainless Steel and Fittings. Use stainless steel meeting the requirements

of ASTM A240/A240M. Use joints that ar e made in accordance with the manufacturer's recommendations. Each conduit and fitting shall bear the Underwriters Laboratories, Inc. label.

834.05.04 Aluminum and Fittings. Use aluminum meeting the requirements of

ANSI C80.5, and UL 6A. Use fittings meet ing the requirements of NEMA 3R and UL 514B. Use joints that are made in accordance with the manufacturer's recommendations. Each conduit and fitting shall bear the U nderwriters Laboratories, Inc. label. 834-1

834.05.05 Condulent. Use condulent that conforms to UL 514B and NEMA 3R.

Fittings shall conform to UL6/ANSI C80.1 and sh all be fabricated with the same materials as the conduit connected to it.

834.05.06 Conduit Straps. Use two-hole conduit straps. Fittings shall conform to

UL6/ANSI C80.1 and shall be fabricated with the same materials as the conduit connected to it.

834.05.07 Test/Pipe Plugs. Provide test/pipe plugs that are galvanized steel, ABS

plastic, or aluminum mechanical type with a wing nut for actuation of a compression plate and o-ring for a good seal. Provide the test/pipe plug with a rubber grommet that expands inside the conduit to seal the conduit.

834.06 Ducted Cable.

834.06.01 Cable . Use stranded annealed copper cable conforming to ASTM B8 and

ASTM B3 and rated for 600 volts. Use material that conforms to either the applicable requirements of ICEA Standard S-19-81, with thermoplastic insulation of GRS rubber base conforming to Appendix K(A) of ICEA and listed by UL as Type USE-2 for direct burial; or the application requirements of ICEA Standard S-66-524, with thermo-setting insulation of cross link polyethylene conforming to the requirement of Column “A” of ICEA and listed by UL as Type USE-2. Use cable and conductors that are preinstalled in the duct. Outside insulation of wire shall state “PROPERTY OF KYTC 502-564-0501”.

834.06.02 Duct. Use polyethylene duct with a minimum tensile strength of 3,000 psi

for secondary cable underground. Provide for 40 percent maximum fill. Conform to NEMA TC7 EPEC-A. The color code of the duct shall be gray for DOT.

834.07 ELECTRICAL JUNCTION BOX (BELOW GROUND). Provide a junction

box & cover that meets or exceeds ANSI/SC TE 77 2017, tier 15. Provide a junction box marked "Lighting”. If junction box has signal and main service wires, the box shall be marked as “Lighting/Electric”. Covers shall be attached with a minimum of two 3/8 inch stainless steel hex head lag bolts and washers. Stackable boxes are permitted. Use lids with a nonslip surface with pull slots for ease of removal.

834.07.01 Type A. The top dimension of the junction box shall be at least 25 inches

by 15 inches. The depth shall be at least 27 inches. The cover shall be at least 2 inches in depth.

834.07.02 Type B. The top dimension of the junction box shall be at least 20 inches

by 15 inches. The depth shall be at least 12 inches. The cover shall be at least 1 3/4 inches in depth.

834.07.03 Type C. The top dimension of the junction box shall be at least 38 inches

by 26 inches. The depth shall be at least 30 inches. The cover shall be at least 3 inches in depth.

834.07.04 Aggregate. Use #57 aggregate below the depth of the junction box. The

aggregate shall conform to AASHTO M43.

834.07.05 Geotextile Filter Fabric Type IV. Conform to Section 843.

834-2

834.08 ELECTRICAL JUNCTION BOX BARRIER WALL. Construct junction

boxes from a 1/4 inch A36 steel plate and the junction box cover from a 1/8 inch A36 plate. Junction boxes shall be at least 2 feet 1/2 inch in length, 6 inches in height, and 9 3/8 inches in depth. The steel shall be bent inward on the top and sides so that the bolts/nuts can be installed for the cover. The bottom portion of the junction box shall have a 1/4 inch slope so that the junction box can drain on the bottom side. The cover shall be at least 2 feet 1/2 inch by 6 1/3 inches. There shall be at least five 1/2 inch holes added to the cover with three on the top of the cover at least 4 1/4 inches (8 inch spacing) from the side and one hole on each side, 4 inches from the top of the cover. All holes in the cover shall be at same location as the welded stainless steel nuts on the junction box. Provide boxes that have been galvanized in accordance with ASTM A123. Fittings shall be UL listed and CSA-certified concrete tight on the outside of the junction box conduit connection. Use 5 3/8 inches UNC x 1 inch stainless steel hex head bolts for the cover connection to the junction box. Five additional spare bolts shall be placed in each junction box. Each hex bolt shall have a corresponding tack weld 3/8 inch stainless steel nut connected to the 1 inch tab at the top/sides of the junction box. There shall be a 1/4 inch thick by 1 inch closed–cell neoprene gasket installed along the top and the sides that have bolts installed. All gaskets shall be attached to the junction box with an adhesive recommended by the manufacturer of the gasket. There shall be a 1/8 inch by 1 1/2 inch by 1 1/2 inch mounting tab with a 1/2 inch hole welded to the box on each top side of the junction box. There shall be conduit knockouts for the conduit that is required in the contract.

834.09 ELECTRICAL JUNCTION BOX ABOVE GROUND. Construct junction

boxes from a 1/4 inch A36 steel plate and the junction box cover from a 1/8 inch A36 plate. The junction box shall be at least 8 inches in length, 6 inches height, and 4 inches in depth. Fittings shall be UL listed and CSA-certified concrete tight on the outside of the junction box conduit connection. Use a sealing lock nut and a conduit bushing on the inside for all conduit penetrations. Grounding lug shall be installed on the side wall of the junction box. The lug should be centered and be sized to receive all the wire sizes that are indicated on the plan sheet. Boxes shall have no knockouts or as required. Use at least four 3/8 inch UNC by 1 inch stainless steel hex head bolts for the cover connection to the junction box. Four additional spare bolts shall be placed in each junction box. If a box is enlarged, additional bolts, equally spaced along the rim of the box, shall be required. Each hex bolt shall have a corresponding tack weld 3/8 inch stainless steel nut connected to the 1 inch tab at the top of the junction box. If a larger box than the above dimensions is utilized, contact the Division of Traffic Operations for verificat ion of preferred bolt pattern. There shall be a 1/4 inch thick by 1 inch closed–cell neoprene gasket installed along the top that has bolts installed. All gaskets shall be attached to the junction box with an adhesive recommended by the manufacturer of the gasket. 834.10 WIRE. For all multiple circuit roadway lighting wires, use single-conductor AWG copper wire of sizes specified in the Contract. Use stranded wire for all circuit conductors, except for ground wires connected directly to ground rods, between bushings, and connected to electrical cabinets. Outsid e insulation of wire shall state “PROPERTY OF KYTC 502-564-0501”.

834.10.01 Conventional Lighting. Use No. 12 AWG copper wire as leads and

grounding from pole bases to luminaire head. Use a green insulated grounding conductor from the grounding system to the grounding terminal in luminaire. All wire shall be rated as Type USE-2 (UL rated) with the exception of wire that goes from the fuse connector kit to the luminaire head which can be TYPE THHN-2 or THWN-2 (UL rated). 834-3

834.10.02 High Mast Lighting. All wire shall be rated as Type USE-2 (UL rated)

except for the electrical power cord that runs from the bottom of the high mast pole to the luminaire ring junction box. The high mast power cord shall be a four conductor #8 AWG or 3 conductor #10 AWG, type SO, extra flexible, rated for 600 volts.

834.10.03 Service. All wire shall be rated as Type USE-2 (UL rated). Install copper

service entrance conductors on the service poles sized as specified by the NEC.

834.10.04 Markings and Color Code. All grounding conductors 6 AWG and smaller

shall be insulated in green color per NEC for all circuit grounds.

834.10.05 Ground Wire. All grounding wires shall be #4 bare solid copper wire.

This wire shall be connected to bonding bushings, ground rods, poles, services, and electrical cabinet grounds. 834.11 FUSED CABLE CONNECTOR KIT. Use a fused connector kit that completely encloses and protects the fuse against damage from water and weather. Use a spring loaded contact between the fuse and fuse holder. Ensure that the springs are not a part of the current carrying circuit. Ensure that line and load side terminals of the fused connector kit positively connect to the conductors. Ensure that the fused connector kit can be repeatedly disconnected without damage to the watertight seals and terminals or without a reduction in conductivity. Provide a fused connector kit designed to break away without damage. Construct the load side housing to retain the fuse when disconnected, and permanently mark it “LOAD” or “LOAD SIDE”. Use fast-acting and high interrupting capacity type fuses with a rating of 6 amperes. 834.12 FUSES . Use fast-acting and high interrupting capacity type fuses. Use 13/32 inch by 1.5 inch fuses that are rated for 600 volts. Use fuses that protect circuits having a fault current capacity of up to 100,000 amperes AC. Use fuses tested to carry 110 % of their rated capacity and that open at 135% in one hour or less.

834.13 SPLICING. There shall be no split bolts allowed for circuit wiring. Terminals

strips or ground lugs are allowed for grounding. The splices shall be waterproof and shall be of the correct size for the wire used.

834.13.01 Two or Multiple Way Splices. Use Raychem GTAP-2(B18) splice kit or

approved equal.

834.13.02 One Way Splices. Use butt splices that are copper and of the correct

conductor range. Vinyl mastic insulating pad shall be self-fusing, rubber-based insulating compound laminated to a flexible, all-weather grade PVC 7 mils backing per ASTM D1000. The pad shall be designed to insulate, moisture-seal, and pad all electrical connections up to 600 volts. Pad shall resist abrasion, moisture, alkalis, acids, copper corrosion, and varying weather conditions including sunlight. Pad shall be compatible with all solid dielectric cable insulations, and splicing compounds and shall be suitable for both indoor and outdoor applications over a temperature ra nge of zero degrees to 100 degrees F without loss of physical or electrical properties. Pad shall also meet ASTM D257 and D570 for composite backing and mastic. Pad shall be 3M 2200 series or approved equal. Use 3M brand #88 electrical tape or approved equal. 834-4

834.14 MARKERS FOR BURIED CABLE. Use 24 inches by 24 inches by 4 inches

deep pre-cast concrete markers with letters, numbers, and arrows cast in the concrete. Impress the word “Lighting”, appropriate directional arrow, and circuit identification number on each marking slab. Use letters that are neat, clearly legible, and approximately 4 inches high and 3 inches wide. Ensure that the stroke is 0.5 inch wide and 0.25 inch deep. Do not pour markers in place or chisel letters in concrete. No substitution of rural Right of Way markers will be allowed. Class A concrete shall be used.

834.15 LIGHTING POLES. Lighting pole design shall be in accordance with loading

and allowable stress requirements of AASHTO ’s Standard Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals, 2013-Sixth Edition with current interims. Provide materials and products that are manufactured in the United States of America. Luminaire poles shall meet or exceed 2014 NEC Sections 410.30 and 410.64. Mounting hardware shall meet or exceed ASTM F1554-7e1, grade 55 with a yield strength of 105 KSI. Install a 4 inch by 4 inch Arc Flash Warning sticker on the center of the outer side of the handhole cover. The sticker shall be a Metalcraft PLY695 Premium STYLEMARK label (or approved equal) with 0.007 inch thickness, with UV white polycarbonate material, and with MC53FL pressure sensitive adhesive. The sticker shall have two colors of black and custom color orange.

834.15.01 Conventional Poles. Provide conventional poles that consist of a tapered

pole having a base affixed to the lower end, a bracket arm (if required), and a transformer base. Furnish an opening near the top of the pole to provide for a cable entrance from the pole to the bracket arm to provide a smooth cable guide (rubber grommet) for wiring. Equip the top of the pole with a weatherproof, removable top cap shall with stainless steel fasteners. Provide this base with four slot ted holes to receive the anchor bolts and four tapped holes for securing the bolt covers. Also provide four removable bolt covers. A ground lug shall be located immediately opposite the hand hole and shall be tapped for a 3/8 inch 16 UNC ground bolt. A ground lug shall be supplied with the pole. All poles shall have a vibration dampening system. Ensure that the pole manufacturer provides permanent marking on the pole base or other suitable location, giving the pole design number and other identification data so poles may be compared with material brochures or drawings. Provide each pole with a 4 inch by 6 inch handhole at a height of between 12 inches and 18 inches above the pole base. Provide an aluminum handhole cover secured with stainless steel screws. If the pole is used for a top mounted fixture, the tenon shall be sized according to the manufacturer of the fixture being installed. The minimum diameter of the tenon shall be 1 1/4 inch. Provide a detailed analysis and schematic of the pole that is stamped and certified by a Professional Engineer licensed in the Commonw ealth of Kentucky. The detailed analysis shall include, but not be limited to, the following calculations:

834.15.02 Brackets. Use single member bracket arms for 4 foot and 6 foot mast arm

assemblies. Use single or double member bracket arms for 8 foot mast arm assemblies. Use double pipe assemblies for 10, 12, and 15 foot mast arm assemblies. Double pipe assemblies consist of upper and lower members securely joined by means of vertical struts. Provide the pole end of the bracket arm with a cast or plate footing or clamp for positioning the assembly on the pole. The attachment point from arm to pole shall provide a weather resistant raceway for wiring (rubber grommet).

834.15.03 Transformer Bases. Provide aluminum bases that conform to AASHTO’s

Standard Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals, 2013-Sixth Edition with current interims. Ensure that each base has the following outside dimensions (+/- 1 inch): 17 inches hi gh, 15 inches by 15 inches square bottom, and 12 inches by 12 inches square top. Ensure that bases have a trapezoidal door with the following minimum dimensions (+/- 1 inch): 11 inches high, 9 inches across the bottom, and 7.5 inches across the top. Construct the door of a high density polyethylene material in a color that matches the base. Provide each base with four of the following galvanized steel components: loose bearing plates (anchor washers), lock washers, and connecting bolts/nuts. Use connecting bolts of the same diameter and strength as the anchor bolts. Submit mill test reports on the connecting bolts. The manufacturer shall specify the bolt circle and physical dimensions of the base bottom to ensure a proper foundation fit. Provide each transformer base with a 1/2 inch, 13 UNC tapped hole or other suitable provisions for grounding purposes. Install a 4 inch by 6 inch Arc Flash Warning sticker centered at the top on the outside of each door. The sticker shall be Metalcraft PLY695 Premium STYLEMARK label (or approved equal) with 0.007 inch thickness, with UV white polycarbonate material, and with MC53FL pressure sensitive adhesive. The sticker shall have two colors of black and custom color orange. The wording on the arc flash sticker shall be: “WARNING. Arc Flash Hazard. Appropriate PPE required. Failure to comply can result in death or injury. Refer to NFPA 70E.”

834.15.04 High Mast Poles. Use loading based on a basic wind speed of 90 mph with

a design life/recurrence interval of 50 years and designed to fatigue category of I. Use welds that are in accordance with sections 1 through 8 of the American Welding Society (AWS) D1.1 Structural Welding Code-Steel (2015). Use tackers and welders that are qualified in accordance with the code. Use tube longitudinal seam welds that are free of cracks and excessive undercuts, performed with automatic processes, and visually 834-7 inspected. Inspect longitudinal welds with magnetic particle examination techniques. Inspect ultrasonically and radiographically the circumferential butt welded pole and arm splices. Provide calculations and drawings that ar e stamped and certified by a Professional Engineer licensed in the Commonwealth of Kentucky. Provide poles on the Contract that are of the same design and manufacturer. Use poles that are designed for twelve fixtures per pole. Use the combined effective projected area (EPA) and weight of the fixtures and lowering device that are determined by the fixture manufacturer. Provide calculations that include the pole, base plate, and anchor bolt analysis. Provide pole calculations that are analyzed at the pole base, along the pole at 5 foot intervals, and at each slip joint splice. A detailed analysis of the pole shall be submitted. The detailed analysis shall include, but not be limited to, the following calculations:

834.16.01 Luminaire Ring. Provide a luminaire ring that is constructed of 6 feet by

2 feet galvanized structural steel. Prewir e the luminaire ring and include a weatherproof junction box and test receptacle for ground level testing of the luminaires. If a special cable is required for ground level testing, supply one cable with each portable power unit specified on the contract. Provide a ring that includes the appropriate number of installed 2 inch steel luminaire mounting tenons. Provide a luminaire ring that has spring loaded iris arms or spring loaded rollers to keep the ring concentric around the pole during raising and lowering. Design the iris arms as shown on the specification sheets in the plans. Provide spring and spring mounting hardware that are stainless steel. Provide a latching mechanism that consists of three high strength, marine grade aluminum latch housings and three stainless steel latch pins. Each latch will include a spring to compensate for pole deflection. Latching and unlatching shall be accomplished by alternately raising and lowering the luminaire ring. Latching may also be accomplished by rotation of the latch pin or travel of the pin through a mechanical circuit. Provide latch housing that are an enclosed design with the only opening at the bottom. Provide housing with a flared entrance bell to align the latch pin. Include a reflective indicator flat that indicates when the latching is complete.

834.16.02 Winch Assembly. Provide a winch assembly that consists of a winch drum

and gearbox mounted in the pole and an external power unit. Provide a winch that has a load rating of at least 1,200 pounds with a gear ratio of not less than 30:1. Include a failsafe brake system to prevent freewheeling of the winch drum. Provide a portable external power unit that consists of a drill motor, torque limiter, step down transformer for 480 volt operation, and a remote switch. The remote switch shall have a cord that is 20 feet long so that the operator can back away from the pole. Ensure the power and winch unit are fully compatible with the Holophane LD-5 portable lowering device or approved equal. 834-9

834.17 ANCHOR BOLTS. The anchor bolt design shall follow NCHRP Report 494

Section 2.4 and NCHRP 469 Appendix A specifications. Anchor bolts shall be designed for the orientation that would provide the maximum stress on any individual bolt. Use anchor bolts that conform to the requirement of ASTM F1554-7e1. Hooked smooth anchor bolts shall be Grade 55 while straight headed bolts may be Grade 55 or 105. Anchor bolts shall be fully galvanized. Provide each anchor bolt with two galvanized hex nuts as well as one flat and one lock washer. Provide nuts that equal or exceed the proof load of the bolts strength. Provide bolts that are hot-dip galvanized to the requirements of either ASTM A123 (fabricated products), ASTM A153 (har dware items), or ASTM F 2329 (hardware items). Protect anchor bolt threads from damage during shipping. Provide Mill Test Reports on anchor bolts. 834.18 LUMINAIRES. Use luminaires that provide light levels conforming to AASHTO’s Roadway Lighting Design Guide, 2005 Edition with current interims.

834.18.01 Conventional. Provide luminaires that are arranged for IES type II

distribution or as otherwise specified in the contract. Provide a 2 inch slip-fitter for mounting. Mainline fixtures shall be 250 watt HPS or LED equivalent and shall be mounted on 40 foot poles. Ramp fixtures shall be 150 watt HPS or LED equivalent and shall be mounted on 30 foot poles.

834.18.02 High Mast. Fixtures shall be 1,000 watt HPS/LED equivalent mounted on

100/120 foot poles or 400 watt HPS/LED equivalent mounted on 80 foot poles with lowering devices. Provide luminaires that meet the following criteria:

834.18.03 Light Emitting Diode (LED) Luminaires.

834.19 LAMPS. Provide high-pressure sodium or light-emitting diode lamps with the

following minimum initial light output:  Type A - 9,500 lumens HPS or LED equivalent  Type B - 16,000 lumens HPS or LED equivalent  Type C - 28,000 lumens HPS or LED equivalent  Type D - 50,000 lumens HPS or LED equivalent  High Mast - 140,000 lumens or LED equivalent

834.20 BALLASTS. Provide a built in constant wattage transformer type ballast for

specified voltage and wattage (high pressure sodium only).

834.21 STARTERS. Provide an igniter that is designed to work with all brands and types

of 60 Hz HPS ballast and that directs the high voltage spike directly into the lamp without being directed to the lamp through the ballast windings. A cycling or extinguished lamp shall not adversely affect the igniter or the ballast. Provide an igniter that is totally epoxy encapsulated in a metal or plastic can. Ensure the igniter can be open circuit tested with power applied for 48 h at 100 ˚C with constant monitoring of the case temperature. Provide an igniter that is Payne-Sparkman ULI-050s or ULI-100s (or approved equal) that is appropriate for ballast wattage. 834.22 LIGHTING CONTROL CABINET. Provide aluminum control cabinet plus extension adaptor for circuit breakers, duplex receptacles, lights, transformers, contactors, fuses, and other control equipment. Provide a cabinet with all wiring and components approved by the manufacturer as an assembly or stamped and certified by a Professional Engineer licensed in the Commonwealth of Kentucky. Provide documentation from the manufacturer confirming that the cabinet, wiri ng, and all components are fabricated in compliance with the NEC. Manufacturer shall provide a warranty that the product furnished will perform in accordance with the requirements of the specifications and be warranted against defects in materials and/or workmanship for a period of 2 years. Warranty shall include shipping both ways.

834.22.01 Weatherproof Enclosure. Provide aluminum weatherproof enclosure with

NEMA 3R rating and UL listed with an 18 inch extension adaptor. Fabricate enclosures and adaptor from 0.125 inch or thicker natural finished 5052 aluminum. Equip the enclosure with two adjustable "c" mounting channels on both of the side walls and the back wall of the enclosure. Provide a cabinet that ha s sufficient size to gain easy access to each component. Provide a rear aluminum panel that is a minimum of 27 inches wide by 42 inches high. The integrity of the cabinet walls should not be compromised except for where the conduit enters (preferably on the bottom) or for a weatherproof vent. The enclosure 834-14 door frame shall be double flanged out on all four sides. Provide exterior seams that are continuously welded and ground smooth. Provide welds that are neatly formed and free of cracks, blowholes, and other irregularities. Provide inside and outside edges of cabinet that are free of burrs. Provide a door restraint to prevent door movement in windy conditions. Provide the door with a gasket which forms a weather tight seal between the cabinet and door. Provide the door with a stainless steel co ntinuous hinge. All exterior hardware shall be stainless steel. Provide interior hardware that is stainless steel or cadmium plated, type II, class I or equal. Provide a cabinet that is vented. Provide a cabinet door with a louvered air vent, filter-retaining brackets, and an easy to clean metal filter. Provide a cabinet door that is keyed with a factory installed standard no. 2 Corbin traffic control key. Welding shall conform to the latest edition of ANSI/AWS D1.2, Structural Welding Code-Aluminum (2014). Workmanship requirement of Class I structures shall be specified for tubular support structures. Class II workmanship requirements may be specified where more rigid controls are desired.

834.22.02 Mounting for Base Mounted . The mounting anchors to the concrete shall

be galvanized steel per ASTM A153 or ASTM F2329 and be appropriate to secure the cabinet adaptor to the concrete. These anchors shall be isolated from the aluminum and steel connections to prevent corrosion. The adaptor connection shall use appropriate aluminum washers, lock washers, and bolts to secure the adaptor to the main lighting enclosure.

834.22.03 Mounting for Pole Mounted. Provide two aluminum brackets that are

appropriate for the overall weight of the cabinet. The attachments bolts shall be appropriate aluminum washers, lock washers, and bolts to secure the both brackets on a wood pole or any other structure.

834.22.04 Light Fixture. Provide a light fixture with switch and bulb. Use a 120 volt

fixture and utilize an LED bulb (equivalent to 60 watts minimum). Fixture shall be situated at or near the top of the cabinet and illuminate the contents of the cabinet.

834.22.05 Receptacle. Provide a 120 VAC GFI duplex receptacle in the enclosure

with a separate 20 AMP breaker.

834.22.06 Magnetic Contactor. Provide magnetic contactors that are electrically

held, 2 pole, sized as specified in the Contract, and that have a 120 volt coil. Protect each contactor coil by a 15 AMP fuse. Equip contactors with control switches for both automatic and manual actuation. Provide photoelectric switches for automatic actuation. Ensure that each switch has minimum rating of 125 volts, 15 amperes. Provide two pole, double throw switches that manually actuate. Solid state contactors may be used.

834.22.07 Control Transformers. Use control transformers that are one KVA, single

phase, 240/480 volt primary, 120 volt secondary, dry type, 60 Hz, with primary winding isolated from secondary winding. Use transfor mers that are capable of indoor or outdoor installation. There shall be two in line fuses on the primary side (480 volt).

834.22.08 Photoelectric Control. Use photoelectric controls that are solid state

cadmium sulfide type designed for use in 120 volt, 60 Hz circuits and rated for a resistive load of 1,000 watts. Use photoelectric controls with built-in surge protection and that are designed to provide an output circuit closure when photoelectric control components fail. Provide photoelectric controls and mounting bases that are twist-lock type. All mounting shall be weather resistant and provide protection from any water entering the cabinet. If the 834-15 photoelectric control is for an LED fixture, the contacts shall be made robust to allow the increase of in-rush current from the fixture. The photocell shall be mounted on top of the lighting control cabinet.

834.22.09 Secondary Lightning Arresters. Provide only secondary lightning

arresters designed for use with the specified voltage and rated at 0-650 volts RMS.

834.22.10 Fuses. Conform to Subsection 834.12. Use 15 AMP fuses on light fixture

and receptacle in the cabinet. Use a 6 AMP fuse between the main circuit breaker and the 480/120 volt control transformer.

834.22.11 Breakers. Branch breakers shall have lugs that can accept a maximum of

#2 AWG Wire. Main Breakers shall have lugs that can accept a maximum of #2/0 AWG Wire. Circuit breaker shall be rated for 600 volts, be a molded case, and be panel-mounted. No din rail is allowed.

834.22.12 ARC Warning Sticker. Install a 4 inch by 6 inch Arc Flash Warning

sticker 3 inches above each door handle. The sticker shall be a Metalcraft PLY695 Premium STYLEMARK label (or approved equal) with 0.007 inch thickness, with UV white polycarbonate material, and with MC53FL pressure sensitive adhesive. The sticker shall have two colors of black and custom color orange.

834.22.13 One Way/Three Way Switches.

The three-way switch shall be black, three position, 45 degree throw, and non-illumi nated. The cover for the three-way switch shall have a “man-off-auto” legend. The one-w ay switch shall have “on/off” functionality and can be either a standard light switch or a door switch. Each switch shall be placed in a standard enclosure and shall have a front plate. Both switches shall be UL rated and rated for 120 volts.

834.23 WOOD POLES. Provide a class 5 pole that conforms to Section 820.

834.24 METER SOCKET. Provide a meter socket that has copper-aluminum line and

load lugs. Socket shall be ring-less type with horn bypass. Provide a meter socket with a 1 inch bolt on hub, that is NEMA 3R UL rated for commercial use, and that accommodates overhead and underground feeds. The enclosure sha ll be stainless steel. Meter socket shall be certified by UL or third party that it meets North American Standards. Install a 2 inch by 4 inch Arc Flash Warning sticker on the front of the meter base. The sticker shall be a Metalcraft PLY695 Prem ium STYLEMARK label (or approved equal) with 0.007 inch thickness, with UV white polycarbonate material, and with MC53FL pressure sensitive adhesive. The sticker shall have two colors of black and custom color orange. The wording on the arc flash sticker shall be: “WARNING. Arc Flash Hazard. Appropriate PPE required. Failure to comply can result in death or injury. Refer to NFPA 70E.” 834.25 SAFETY SWITCH. Provide a safety switch disconnect that is 3-wire, 600 volt, 2-pole, and 2-fuse in a NEMA 3R stainless steel enclosure. Provide an enclosure that has a 1 inch size bolt on hub. Provide a bolt pattern on the hub that aligns with predrilled holes on the enclosure. Provide a line cover shield. Provide a safety switch that is UL approved for commercial use and that is manufactured in th e United States of America. Safety switch shall be marked in accordance with the National Electrical Code Article 230.66. The utility may require a safety switch before the meter socket on 480 volt installation. 834-16 Install a Maximum Available Fault sticker on the disconnect with the symmetrical RMS amperes and the date that this fault current is calculated. The sticker shall be 4 inches long and 4 inches wide and be a metalcraft PLY425 Premium Stylemark label (or approved equal) with 0.007 inch thickness, with UV white polycarbonate material, and with MC778 pressure sensitive adhesive or approved equal. Install a 2 inch by 4 inch Arc Flash Warning sticker on the disconnect. The sticker shall be a Metalcraft PLY695 Premium STYLEMARK label (or approved equal) with 0.007 inch thickness, with UV white polycarbonate material, and with MC53FL pressure sensitive adhesive. The sticker shall have two colors of black and custom color orange. The wording on the arc flash sticker shall be: “WARNI NG. Arc Flash Hazard. Appropriate PPE required. Failure to comply can result in death or injury. Refer to NFPA 70E.”

834.26 PADLOCKS. Provide a 1 3/4 inch wide, laminated steel body with 5/16 inch

case hardened steel shackle, 4 pin tumbler, Master Lock No. 1KA, with 2.5 inch shackle. Provide locks that are keyed to series 2577. Provide two keys with each lock.

834.27 GROUNDING LUGS. Grounding lug shall be of bronze construction. Lug shall

be UL listed. For conventional lighting, it shall be able to accommodate 5/8 inch ground rod and #4 AWG solid bare copper wire. For high mast lighting, it shall be able to accommodate 3/4 inch ground and #4 AWG solid bare copper wire. For high-mast lighting, an alternative grounding clamp may be used. The alternative grounding clamp shall be cast bronze or copper alloy construction with a clamp opening to accommodate 1 inch RS conduit. The wire terminal shall accommodate the required #4 AWG bare copper wire required for grounding. Clamp shall be UL listed. 834.28 BANDING. Banding shall be 3/4 inch, type 201 stainless steel. Banding shall be BAND-IT C206 or approved equal. Banding tape buckles shall be type 201 stainless steel and be sized for 3/4 inch banding. Banding tape buckles shall be BAND-IT C256 or approved equal. 834.29 ANCHORS. Anchors shall be expanding type, made of steel, and be galvanized per ASTM A123.

834.29.01 30 Inch Long Rock Anchor. Anchors shall be 1.75 inches in diameter,

triple eye, with 0.75 inch diameter rod having a minimum tensile strength of 23,000 pounds. Shall be a Maclean J3437 or approved equal.

834.29.02 53 Inch Long Rock Anchor. Anchors shall have a hole size of 1 7/8 inches,

anchor closed size of 1 3/4 inches, anchor expo sed size of 2 3/8 inches; rod diameter size of 3/4 inch; triple eye style; and have an ultimate strength rating of 23,000 pounds. Shall be a Joslyn J3438 or approved equal.

834.29.03 8-Way 135 Inch Anchor Rod. Anchors shall have an 8 inch hole with a

5/8 inch rod. Shall be a Chance #88135 or approved equal.

834.29.04 Rod. Rods shall be 5/8 inches in diameter, 7 feet long, with twin eye, and

rated at 16,000 LBF ultimate. Shall be a Joslyn J7517 or approved equal.

834.30 Messenger/Guy/Tether Cable and Hardware.

834.30.01 Messenger, Guy, and Tether Cable. Conform to Subsection 835.16.01.

834-17

834.30.02 Strandvise. Conform to Subsection 835.16.02.

834.30.03 Strandlink. Conform to Subsection 835.16.03.

834.30.04 Cable Rings. Conform to Subsection 835.16.04.

834.30.05 Bull Rings. Conform to Subsection 835.16.05.

834.30.06 Guy Guard. Conform to Subsection 835.16.06.

834.31 NAVIGATION LIGHTS. Navigation lights shall meet all requirements of the

United States Coast Guard 33 CFR 322 and other regulatory agencies. Dual lamp housing, mounting, and swivels shall be cast silicon bron ze. Stems and pull chains shall be stainless steel. All connections shall be sealed with waterproof gaskets and the assembly shall be rain tight. Lens shall be of permanent, rigid, heat resistant glass, 8 inch nominal outside diameter, standard marine Fresnel type 180° or 360°, and red or green as specified. Pivoting fixtures shall be suspended from the swivel on a stem made of 1 1/2 inch (i.d.) schedule 40 stainless steel pipe of required length to meet USCG requirements as noted in the plans. Stems over 5 feet long shall require a 60% counterweight. Swivel and pipe stem shall provide for all wiring to be completely contained inside the light assembly. Gaskets and o-rings shall be used to provide a weather tight assembly. Spindle shall be of stainless steel. An automatic latch shall hold the light securely in normal operating and service positions. A firm pull on the stainless steel pull chain shall automatically release the latch, allowing the fixture to pivot. As the light is raised, latch shall automatically engage to hold light in service position. Fixture shall be designed so that light may be pulled from either side. Assembly mounting shall be accomplished by us ing 1/2 inch diameter stainless steel bolts, nuts, and locking washers. All attachments to bridge steel members shall be separated from direct contact with steel members by a minimum 1/8 inch neoprene or mylar gasketing material to prevent corrosion caused by contact between dissimilar metals. This includes navigation fixtures, control cabinets, and all mounting brackets. This system can be 120 volt or 12 volt (solar).

834.31.01 Solar Powered. System shall utilize solar electric modules with storage

batteries as the power source to provide continuous power for navigation lights at the specified locations on each bridge as well as sufficient power to operate the wireless monitoring system (approximately 10 watts per monitoring control panel location). The system shall operate at an average monthly insolation on a horizontal surface, insolation at tilt, and average monthly temperatures at each site.

834.31.03 Mounting brackets and arms shal l be fabricated from stainless steel

materials sufficient to provide necessary stability for the panel arrays. Panel orientation shall be adjustable to facilitate maximum solar input. All mounting hardware for attachment to the bridge shall be stainless steel.

834.31.02 Solar Battery Backup for 120 Volt Installation. System shall utilize

existing electric service as the power source to provide continuous power for navigation lights at the specified locations as well as the wireless monitoring system. The system shall use a 12-volt solar powered battery backup to provide continuous power for navigation lights at the specified locations in the event of a power outage. The system shall operate at an average monthly insolation on a horizontal surface, insolation at tilt, and average monthly temperatures at each site. This system shall be able to power a DC LED bulb when the AC bulb has a power failure. The system shall be able to power the DC bulb up to 10 days without power. The system shall use a circuit to sense the 120 volt power failure and switch the navigation fixture to the battery backup state. The system shall have a monitoring system that is separate from the monitoring system for the 120 volt navigation lights. This system shall be able to turn on navigation fixtures just like using a photocell. Use K&K Systems or approved equal.

834.31.03 Wireless monitoring. A system shall monitor the status of the individual

navigation lighting units. The purpose of the monitoring system is to provide a complete, programmable, intelligent, networkable, and expandable low voltage monitoring system for the navigational lighting as described herein and as shown on the schematic drawings and schedules. The monitoring system shall be a microproc essor based, addressable, networkable, intelligent, and low voltage lighting communication system for centralized monitoring. System shall include, but not be limited to: relays, controllers, light level sensors, radio frequency transceivers, low voltage control power and data line wiring, software, programming, custom graphical screens, and miscellaneous components as required for a complete, operable navigational monitoring system. All system components shall arrive at the job site completely factory pre-wired and ready for field installation. All connections shall be clearly and permanently labeled to facilitate correct and easy identification and installation of equipment. Each monitoring system shall be wireless and will be powered by the 120 volt or 12 volt (if solar) feed inside the navigation control cabinet. The monitoring system shall be capable of sensing current flow, voltage, and fault conditions for the navigation lighting units. The central processing unit cabinet shall have the necessary communications equipment to relay information to the appropriate District Office by a wireless modem that is compatible with the Verizon network. The external wireless router shall be Sierra Wireless Airlink GX450 with ethernet add- on or approved equal and shall support Verizon 3G/4G/LTE services for the camera installation. The antenna should be Laird Lp-800-2500-9NF sku393969, or approved equal, and include a DH wireless solutions AP- CCG-Q-S222-BL, or approved equal, for GPS locating. An internal wireless card can be utilized in lieu of the external wireless router. All system components shall arrive at the job site completely factory pre-wired and ready for field installation. All connections shall be clearly and permanently labeled to facilitate correct and easy termination of equipment. The monitoring system shall have a two year warranty on all parts and materials. The warranty shall start on the date of the acceptance of the installation by the Department. System shall be capable of wireless monitoring within 1/2 mile line of sight distance in an urban environment or with wireless repeaters. Fully programmable circuit diagnostic capability and alarming via Personal Computer (PC) shall be possible for all fixtures. Radio network shall operate within an unlicensed FCC band, utilizing spread spectrum and frequency hopping technology. Radio network shall be transparent across Ethernet (LAN) platform. All of the data accumulation transferred over the wireless RF network shall be automatically error checked. Systems that do not provide two-way error checking are not acceptable. Password protected access via the modem shall be possible for interoperable connection from an off-site based PC for factory programming and support and owner access. System communications shall include the modem and bridge to the monitoring system. Factory programming and troubleshoot ing assistance shall be available via the 834-21 wireless modem. The system shall be capable of accepting any number of commands or command sequences while allowing programs to run continuously. The monitoring system shall be able to email alerts regarding values for each node and alerts regarding connectivity issues. System sh all be able to email alerts to a minimum of 30 email addresses at a minimum of one minute in crements. The alerts shall be labelled for each node including minimum thresholds, maximum thresholds, actual current reading, and location of system. The monitoring system shall include web-based (internet browser) control. The web-based control application shall reside within the owner's secure server network and provide the capability to reset the alert/notification system (via the internet) to a user-defined default condition. This web-based control application shall not have any recurring maintenance costs by the cabinet. The enclosure shall be fabricated from Grade 316 Stainless Steel with a minimum thickness of 0.125 inch and be NEMA 3R rated. The cabinet shall provide screened louvered vents on each side of each compartment. The louver screening shall be Grade 316 stainless steel. An integral rain lip shall also be provided at the top of the main cabinet body to minimize entry of rain. The maintenance entrance shall be hinged and double- locking. The entrance shall be lined with a neoprene gasket around the entire edge. The entrance shall be secured with a Corbin #2 lock. The keyhole for this lock shall have a cover attached to the door with a single rivet. The battery component shall provide a minimum of 1/2 inch of insulating sheeting around the battery to minimize heat transfer between the battery and the enclosure wall. The cabinet shall be of sufficient size to house the battery and all control components (including monitoring system) and allow sufficient room for routine maintenance. Maximum size is 20 inches high by 15 inches wide by 6 inches deep. Central control unit shall support up to 64,000 controllers networked on wireless systems. Programmed data being stored in static RAM shall be protected from loss during power failure. The CPU based real time clock shal l be protected by a rechargeable NiCad or lithium battery capable of withstanding up to a thirty day power loss. Provide wireless linking expandability with a wireless card slot in communication hub. Wireless link shall provide full function zone control and data accumulation, diagnostics, and include current sensing and voltage sensing. Wireless communications shall be bidirectional. RF transceiver shall operate in an unlicensed FCC ISM band, FCC/IC certified. RF range shall be a minimum 1/2 mile line of sight. Surge Protection shall be a minimum 2,500 Volts to ground. Equipment shall operate at a voltage of 120 VDC. Equipment shall be capable of operating at temperatures ranging from -40 °C to 65 °C, at 95% relative humidity, and at a relative humidity ranging from 0-95%, non-condensing. Provide Redundant RF link where specified, one for each transceiver used. Provide custom graphical site screens using CAD drawings of the site provided by the Department to serve as backgrounds for the site zoom screens. Provide a custom graphical screen for each monitoring system, from which the user shall be able to access each fixture individually, view fixture status, diagnostic files, and data logs. The monitoring system software shall allow data from the system to be logged and archived. Data shall be accessible via spreadsheet or database, and contain the following for both navigation and aviation obstruction lighting:

834.32.01 Solar Powered. Conform to Subsection 834.31.01.

834.32.02 Solar Battery Backup. Conform to Subsection 834.31.02.

834.32.03 Wireless Monitoring. Conform to Subsection 834.31.03.

834.33 WARNING TAPE. Provide tape that is 6 inches wide and 7.0 mils (nominal)

thick. Provide tape that has a minimum tensile strength of 600 pounds per 6 inch width and that is color-coded and impregnated with alkali and acid stable, lead-free, organic pigments that are suitable for direct burial. Use tape that is ultraviolet colorfast and non-distorting with no elongation. Use tape that includes black lettering and symbols on a gray background that conforms to the APWA-ULCC national color code for DOT. Provide tape that continuously reads, "CAUTION: ELECTRIC LINE BURIED BELOW" alternating with a “No Digging” symbol.

834.34 WARRANTIES. Materials shall be warrantied as stated under individual

material specifications. If not specifically addressed in other sections, warranty materials for a period of one year or provide the manuf acturer’s standard warranty, whichever is greater. Warranty shall include shipping both ways. The warranty shall begin the date that materials are received by the Department and shall be transferable. 834-23

834.35 DOCUMENTATION. With each unit purchased under this section, include one

documentation package consisting of:

835.01 GENERAL. This section covers the material requirements for electrical traffic

control device components (including traffic signals, flashing beacons, and school flashers) that are supplied by the Contractor. Materials commonly provided by the Department are listed on the Project Install Items List (available on the Division of Traffic Operation’s webpage) and are not addressed in these specifications. Certain materials for electrical traffic control devices are included on the Department’s List of Approved Materials. Materials shall comply with the Manual on Uniform Traffic Control Devices (MUTCD) and the Division of Traffic Operation’s Traffic Signal Standard Detail Sheets. Materials shall be approved by the Engineer prior to utilization on a project. Once approval is given for a product, substitutions will only be permitted with written permission from the Engineer. If materials provided by the Contractor are not addressed in these specifications, contact the Division of Traffic Operations for approval before using on a project.

835.02 CONCRETE. Conform to Subsection 834.02.

835.03 STEEL REINFORCEMENT. Conform to Subsection 834.03.

835.04 GROUND RODS. Conform to Subsection 834.04. Use rods with a minimum

diameter of 5/8 inch and a minimum length of 8 feet. 835.05 CONDUIT. Ensure the conduit is the size specified on the plans and detail sheets.

835.05.01 Rigid Steel and Fittings. Conform to Subsection 834.05.01.

835.05.02 Schedule 40/80 PVC and Fittings. Conform to Subsection 834.05.02.

835.05.03 Stainless Steel and Fittings. Conform to Subsection 834.05.03.

835.05.04 Aluminum and Fittings. Conform to Subsection 834.05.04.

835.05.05 Condulent. Conform to Subsection 834.05.05.

835.05.06 Conduit Straps. Conform to Subsection 834.05.06.

835.05.07 Test/Pipe Plugs. Conform to Subsection 834.05.07.

835.06 ELECTRICAL JUNCTION BOX. Conform to Subsection 834.07. Provide a

junction box marked "Signal". If junction box has signal and main service wires, the box shall be marked as “Signal/Electric”. 835.07 MAST ARM POLES. Pole diameter and wall thickness shall be calculated in accordance with AASHTO’s Standard Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals, 2013-6th Edition with current interims. For mast arm poles, provide fatigue classification that is Category II, in accordance with Table 11.6-1 from the AASHTO Standard Specifications with galloping and natural wind gusts, and with a 25 year design life in accordance with Table 3.8.3-2. Provide poles and arms that conform to: 835-1