626Foundations, Conduit, and Junction Boxes for

626.01 Description This work shall consist of furnishing, installing, modifying, or

removing concrete foundations, conduits, and junction boxes for highway lighting, traffic signals, and highway signing in accordance with these Specifications and in reasonably close conformity with the Contract Documents.

626.02 Materials The materials furnished by the Contractor shall be new. Where an

existing system is to be modified, the existing material shall be removed and abandoned or salvaged as shown in the Contract Documents or as directed by the Resident. All electrical equipment shall conform to NEMA or UL standards, wherever applicable. In addition to these requirements, all materials and workmanship shall conform to the requirements of: NEC, ASTM Standards, the ANSI, the local electrical Utility Company, and any local ordinances that may apply. Materials shall meet the requirements specified in the following Sections of Division 700, Material Details. G r a v e l B o r r o w 703.20 Reinforcing Steel 709.01 Precast Concrete Units 712.06 6-83 Steel Conduit 715.02 Non-metallic Conduit 715.03 A n c h o r B o l t s 720.07 626.021 Miscellaneous Materials Transformer pads shall conform to the requirements of the local electrical Utility Company. If grouting is necessary to correct surface irregularities in the top of the concrete foundations a non-shrink material included on the MaineDOT Qualified Product List (QPL) and satisfactory to the Resident shall be used. All concrete foundations shall be constructed of Class LP concrete in accordance with the applicable requirements of Section 502 – Structural Concrete. All concrete for concrete encasement of conduit shall be Fill Class concrete in accordance with the applicable requirements of Section 502 – Structural Concrete. The above ground portion of concrete foundation surfaces shall receive an application of Type 1c penetrating silane concrete sealer from the MaineDOT QPL. 626.022 Equipment List and Drawings Unless otherwise permitted in writing, the Contractor shall within 30 days following execution of the Contract, submit a list of equipment and materials which are to be installed. The list shall include the name of manufacturer, size, and identifying number of each item. The list shall be supplemented by such other data as may be required, including detailed scale drawings of proposed minor deviations from the Contact Documents. If requested, the Contractor shall submit for review, design data and sample articles of the material proposed for use. All of the above data shall be submitted in duplicate except samples for testing. Following checking, correcting, and reviewing, two complete sets of drawings shall be submitted. The Department will not be liable for material purchased, labor performed, or work delayed before such review. Upon completion of the work, the Contractor shall submit three complete sets of corrected plans showing all construction changes.

626.03 General All work shall conform to NEC and NESC standards as set forth in the

NIST Handbook H-32, except when otherwise noted in the Contract Documents or in the Special Provisions. The Contractor shall be responsible for and shall repair all damage caused to underground drainage structures, utilities or lighting conduit, which are encountered during construction. 6-84 The Contractor is responsible for final design of the above-grade components of the highway lighting, traffic signals, and highway signing structure(s) in accordance with Standard Specification Sections 634, 643 and 645, respectively. 626.0301 Electrical Supply Lines and Service Connections The following requirements shall apply to Electric Supply Lines and Service Connections feeding traffic signalization equipment control boxes and lighting breaker boxes. Whenever possible, the meter and breaker panel feeding traffic signal control boxes or lighting control boxes shall be constructed within 30 feet of the service drop pole. All underground service connections that are constructed in trenches and carrying Secondary Utility Power to a MaineDOT meter and breaker panel, or, directly to MaineDOT traffic signalization control cabinets or lighting breaker boxes shall be in Rigid Metal Conduit or concrete encased PVC conduit. Where trenchless technologies are employed to install the service connection conduit, Schedule 120 PVC conduit shall be used for the trenchless bore section of conduit. In addition, concrete encasement shall be used for any PVC conduit placed in trench sections and carrying Secondary Utility Power more than 10 feet before or after the limits of the trenchless bore conduit. The construction practices described above shall be used for service connections up to a maximum of 600 feet. There may be rare exceptional cases where the service connection must exceed 600 feet. In these cases, the power companies may require primary power be run over 600 feet for the purpose of power consumption and dependable service. These cases will be evaluated on a case-by-case basis for alternate power feed methods and/or the need for steel or concrete encased conduit. 626.031 Conduit If the trench for conduit is located in wet, spongy or otherwise unsuitable ground, as determined by the Resident, the trench shall be further excavated to a depth sufficient to overcome this condition, as determined by the Resident, and shall be backfilled with approved gravel. The gravel shall be compacted in layers not exceeding 8 inches, loose measure. The grade of the bottom of the trench shall be parallel to the proposed grade of the conduit. Trenches for conduits shall be excavated to a width that will permit proper installation of the conduit and to a minimum depth of 3 feet below finish grade as measured from the top of the conduit. If deeper depths are required, the conduit shall be installed at the depth shown in the Contract Documents or as directed by the Resident. Conduit shall not interfere with poles, guardrail posts, foundations or other objects. All junction or pull boxes shall be vehicle rated (22,000 lbs) and concrete junction boxes shall be Class LP concrete, in accordance with the applicable requirements of Section 502 – Structural Concrete and installed as shown in the Contract Documents 6-85 Where conduits enter exposed junction boxes, they shall be sloped to drain towards the conduit entrance holes, unless otherwise directed by the Resident. Weep holes of ¼ inch diameter shall be placed in all pull boxes, junction boxes, and fuse boxes. After the trench has been excavated as specified, the bottom of the trench shall be prepared with a 6-inch thick (minimum) sand bedding material. After placing the conduit, sand shall be placed around the sides and over the top of the conduit, when shown in the Special Details. The entire trench shall then be backfilled with approved material, placed in layers not exceeding 8 inches, and thoroughly tamped. Where concrete encasement is required around the conduit, backfilling with approved material may begin adjacent to and above the encased conduit no sooner than 24 hours after concrete placement. All conduit ends shall be capped with conduit caps until wiring has begun. All conduit shall be sealed to prevent rodent ingress after cables have been installed. Any blocking material shall be removable without use of tools. The size and type of conduit required will be noted in the Contract Documents, except that the minimum size of conduit risers required for traffic signal installations shall be determined by percentage fill in a single conduit, as specified in the latest revision of the NEC. Where more than one conduit is required to be installed in the same location, the conduits may be placed in the same trench. The weather head on conduit risers on Utility Company poles shall not be less than 1 foot from any utility wires. Conduit risers on Utility Company poles shall be located as required by the Utility Company. Within 10 days after completion of each section of conduit, the Contractor, in the presence of the Resident, shall rod and pull through each duct a mandrel and brush of a pattern satisfactory to the Resident, but which shall not be more than ⅛ inch smaller than the bore of the ducts. Where obstructions in the ducts prevent passage of the mandrel, the Contractor shall, at their own expense, remove and relay those portions of the ducts necessary to clear the obstruction. The Contractor shall install a suitable nylon pulling string with a rated 210 lb. tensile strength in all unused conduits. The ends of the string shall be secured in such manner as to prevent accidental withdrawal of the string. 626.032 Metallic Conduit Installation Conduits shall be of the sizes noted in the Contract Documents, which are indicated as the nominal inside diameter. All conduits shall be joined with threaded couplings using approved thread sealant. Conduit shall be installed so that it is continuous and watertight between boxes or equipment. Running threads will not be permitted. When necessary, the Contractor shall use an approved electrical union-type coupling. Conduits shall be protected at all times from the entrance of water or other foreign matter. Conduit runs shall be made with as few couplings as standard lengths will permit. The total angle of all bends in one run and the radius of conduit bends shall conform to the 6-86 NEC requirements. All field bends and offsets shall be made with approved hickey or conduit benders. Pull boxes shall be used wherever necessary to facilitate the installation of the wires. In making up a run of conduits, all cut ends shall be reamed to remove rough edges and cut threads shall be painted with an approved thread sealant in such a manner that there will be no unprotected surfaces and joints will be watertight. All conduits shall have electrical continuity and shall be adequately grounded. Conduits to be placed in the superstructure of bridges and similar structures shall be securely supported and fastened, in order to maintain the conduits' position within the superstructure, as shown in the Contract Documents. Pull boxes shall be located as shown in the Contract Documents. Clearance between conduit runs shall preferably be 2 inches, but at no time shall be less than the maximum size of the aggregate used in the embedding concrete. At all joints where relative movement between adjacent parts of a structure can occur, a double "O"-ring expansion coupling, or other approved expansion device shall be installed. Exposed conduit shall be rigidly and securely fastened with acceptable fasteners or supports, as indicated in the Contract Documents or approved. Fasteners or supports shall not be placed more than 6 feet apart on centers, except as otherwise authorized. Conduits shall generally be supported by an approved spacer at the point of support, so that there is an air space between the conduit and the supporting surface. Ends of conduit runs terminating in a metallic box without a threaded hub shall be provided with a metallic locknut on the outside of the box, and a metallic locknut and insulated bushings on the inside. A lock washer and a galvanized steel flat washer shall be installed between the outside locknut and face of the box. 626.033 Polyvinylchloride Conduit Installation Polyvinylchloride conduit and High Density Polyethylene, hereafter called PVC conduit, shall be installed in accordance with the applicable methods as specified in Section 626.032 for metallic conduits. In addition, PVC conduit used for Electrical Supply Lines and Services constructed as underground service connections in trenches and carrying Secondary Utility Power to a MaineDOT meter and breaker panel, or, directly to MaineDOT traffic signalization control cabinets or lighting breaker boxes shall be concrete encased. When trenchless technologies are used to install PVC conduit, concrete encasement shall not be required. Concrete encasement shall consist of a minimum of 4 inches of concrete above, below and on both sides of the conduit that shall have a minimum compressive strength of 3000 psi and a maximum aggregate size of 1-inch (Fill Class concrete). The concrete encasement may be backfilled no sooner than 24 hours after placement. Non-Metallic Under Pavement Conduit Installation Where noted in the Contract Documents, non-metallic under pavement conduit of schedule 80 or greater rating shall be provided to facilitate conduit crossing of the existing highway and ramps without disruption to the existing highway and ramp pavement surface. The non-metallic under pavement 6-87 conduit shall be hydraulically jacked or directional bored below the highway and ramp at a depth of not less than (36 inches). Under pavement conduit shall extend for a distance of (10 feet) beyond the highway or ramp edge at each side. PVC conduit shall be made watertight by joining with solvent or in accordance with the manufacturer's specifications. Conduit shall be bent carefully to avoid damage and without the use of an open flame. Bends sharper than 45º [⅛ bend] will not be permitted in PVC conduit. The total angle of all bends in one run and the radius of bends shall conform to the NEC requirements. Conduits to be placed in the superstructure of bridges and similar structures shall be securely supported and fastened, in order to maintain the conduits' position within the superstructure, as shown in the Contract Documents. Pull boxes shall be located as shown in the Contract Documents. Clearance between conduit runs shall preferably be 2 inches, but at no time shall be less than the maximum size of the aggregate used in the embedding concrete. At all joints where relative movement between adjacent parts of a structure can occur, a double "O"-ring expansion coupling, or other approved expansion device shall be installed. To allow for expansion and contraction of PVC conduit during installation of long runs, one end shall be left unconnected or a double "O"-ring expansion coupling shall be inserted near one end of the run until final covering of the conduit is in progress. Where PVC conduit runs are placed parallel to other conduit runs or cross one over another, they shall be separated by a minimum of 3 inches of sand or soil cushion. The bottom of trenches for PVC conduit shall be lined with a 6-inch minimum bedding of tamped sand or soil before laying the conduit. Backfill to a compacted depth of 6 inches above the top of the conduit shall be sand or soil, free from rocks or hard lumps. No aluminum wire shall be allowed underground. No pre-wired conduit shall be allowed. Conduit and wire sizes shall be as shown in the Contract Documents. 626.034 Concrete Foundations The Department has completed an appropriate test boring program to characterize the subsurface conditions in the general vicinity of proposed foundations for highway lighting, traffic signals, and highway signing foundations. The associated boring log(s), as well as foundation type and size and any other foundation- specific details and information, as designed by the Department, are provided in the Contract Documents. The Contractor shall construct the foundation(s) as shown in the Contract Documents and in accordance with these Specifications, unless otherwise directed by the Resident. Alternate foundations to those designed by the Department and shown in the Contract Documents will not be permitted unless directed by the Department. Foundations shall consist of cast-in-place, reinforced concrete, drilled shafts in soil or bedrock unless another foundation type (i.e., grouted, rock-anchored foundations; spread footings; or Special Foundations) is specified in the Contract Documents. Reinforcing shall 6-88 be as specified in the Contract Documents. Precast foundations shall not be allowed except as specified in Section 626.037. Special Foundations shall only be permitted if designated by the Department. Design computations for the Contractor’s design of the above-grade components of the highway lighting, traffic signals, and highway signing structure(s) shall be submitted to the Department and shall include the actual loads (bending moment, shear force, torsion and axial load) at the top of each foundation. These actual loads at the top of each foundation will be used by the Department to check the efficacy of the foundation design shown in the Contract Documents. The Contractor shall not commence foundation construction prior to receiving approval from the Department. All unsuitable material (including but not limited to peat, organic material, and material that has been disturbed and/or dumped) within the limits of a foundation shall be removed to the minimum limits directed by the Resident. Foundation depths shall be increased as directed by the Department to account for the unsuitable material. Unsuitable material removed from below subgrade for spread footing foundations shall be replaced with compacted material as set forth below for foundation backfill. In areas where bedrock is encountered above the proposed bottom of the foundation, the Contractor shall notify the Resident and the Department will determine whether: 1.) the bedrock should be removed and the foundation should be constructed at the design depth shown in the Contract Documents, or 2.) the foundation should be constructed using a grouted, rock-anchored foundation system or spread footing. If an alternative grouted, rock- anchored foundation system or spread footing foundation design is required due to shallow bedrock it will be provided by the Department. Drilled shaft foundation holes, except in bedrock, shall be excavated by auger method to the neat line of the outside dimensions of the shaft without disturbing the soil around or below the proposed shaft. Drilled shafts in bedrock shall be excavated by standard rock drilling method. Drilled shafts shall not be permanently cased except for the top 3.0 feet or as otherwise shown in the Contract Documents. Concrete shall be tremie poured directly against the surrounding soil and/or bedrock. Spread footings shall be founded at least 5.0 feet below the lowest surrounding proposed finished grade for frost protection. The 5.0-foot embedment for spread footings constructed on cleaned bedrock is waived. If soil conditions differ materially from those described on the boring logs, the Contractor shall stop work on that foundation and contact the Resident. Concrete for drilled shafts shall be placed (via tremie methods) as soon after excavation as practicable to prevent debris from collecting in the excavated area. The Contractor shall provide temporary dewatering of excavations for foundations such that concrete is placed in the dry. Concrete for drilled shafts shall be placed in accordance with Section 502.10 as temporary casing is withdrawn to prevent debris from contaminating the foundation and to ensure concrete is cast against the surrounding soil. At all times, the level of the concrete inside the temporary casing shall be above the bottom of the casing. 6-89 Grout used for rock-anchored foundations shall be non-shrink grout included on the MaineDOT Qualified Product List (QPL) and approved by the Resident. Backfill for spread footing foundations shall be Gravel Borrow meeting the requirements of Section 703.20 - Gravel Borrow. Gravel Borrow shall be placed in layers not exceeding 8 inches in depth before compaction (i.e., loose lifts). Each layer of backfill shall be thoroughly compacted to at least 95% of the material’s maximum dry density as measured in the field by an approved method using a calibrated nuclear device. All backfilling and compacting shall be in accordance with the applicable provisions of Section 206 – Structural Excavation. Before placing concrete, the required elbows of entrance conduits, reinforcing steel and anchor bolts shall be carefully positioned in accordance with Standard Specification 633. The anchor bolt size and the bolt circle diameter shall be determined from data furnished by the supplier of the above-grade components of the highway lighting, traffic signals, and highway signing structure(s) or as shown in the Contract Documents. Anchor bolts for use with breakaway couplings, longitudinally grooved-type, shall be 1-inch diameter and shall project between 2½ and 3 inches above the top of the foundation. All other anchor bolts shall be a minimum of 1-inch diameter and shall project sufficiently to accommodate the thickness of the base plus all nuts and washers. The bolt length shall also be sufficient to allow clearances of approximately ½ inch below the leveling nut and ¼ inch above the top nut. At least two threads on each anchor bolt shall project beyond the outside of the nuts holding the plumbed pole. All foundations shall be warrantied against leaning and corrosion for two (2) years after the project is completed. If the lean is greater than 2 degrees from normal or the foundation is spalling within the first two (2) years, the Contractor shall replace the foundation at no extra cost. The finished ground at each foundation shall be graded flush with the top of the foundation except at locations where the foundation is protected by guardrail, by curb, or is outside the clear zone in which case the foundation shall have a 3-inch reveal. If required, approved backfill material shall be added to grade the slopes as specified. There will be no additional compensation for furnishing, placing and compacting material flush around the foundation. In all cases, the surface area around the foundations shall be graded to drain away from the foundation and loamed and seeded in accordance with the requirements of Section 615 and Section 618. The concrete portion of the foundations exposed to view shall have a troweled finish. A drainage groove shall be formed in the horizontal surface of the foundation. The top of the concrete foundation shall be horizontal. The above ground portion of concrete foundation surfaces shall receive an application of Type 1c penetrating silane concrete sealer from the MaineDOT QPL. The application rate and method of application shall be in accordance with the manufacturer’s published recommendations. On surfaces to be treated, all voids shall be filled with mortar and the 6-90 entire surface shall be dressed by dry rubbing to remove marks and blemishes to present a neat appearance. The silane application shall not be done until a minimum of 14 days after casting and the surfaces shall be free of laitance, oil, grease, dirt, dust, curing compound or any other deleterious material. The temperature of the concrete shall be above 40oF and below 90oF at the time of application, or per the manufacturer’s published recommendations. When the anchor bolt template is removed, the threads of the anchor bolts shall be greased and protected with a metal sleeve, held in position with nuts and washers to be furnished with the bolts. This thread protection shall remain in place until the pole or other equipment is installed. A copper-clad steel ground rod shall be installed when shown in the Contract Documents. 626.035 Foundations to be Modified or Removed Concrete foundations designated to be modified or removed shall be modified or removed as shown in the Contract Documents. Debris resulting from the modification or removal shall be removed from the project. Once removal has been completed, the area shall be brought to grade by addition of granular material and loam, or by loam only, depending on the extent of modification or removal as directed by the Resident. The area shall then be seeded in accordance with Section 618. 626.036 Precast Foundations In the absence of foundation type and size and any other foundation-specific details and information, as designed by the Department, provided in the Contract Documents, precast foundations will be permitted for 18- and 24-inch diameter foundations for structures less than 30-feet tall with no projecting arms. No foundation design will be required for precast 18- and 24-inch diameter foundations for structures less than 30-feet tall with no projecting arms. A foundation design prepared by a Professional Engineer licensed in the State of Maine will be required for all other foundations. Where precast foundations are permitted flowable concrete fill shall be used as backfill in the annular space and placed from the bottom up. Construction of precast foundations shall conform to the Standard Details and all requirements of Section 712.061 except that the concrete shall have a minimum permeability of 17 kOhm-cm and the use of calcium nitrite will not be required. The construction requirements of Section 626.034 apply to precast foundations used by the Contractor and their Subcontractor(s).

626.04 Method of Measurement Precast Concrete Junction Box, and Remove or

Modify Concrete Foundation will be measured by each unit. All conduit will be measured by the number of linear feet. Drilled shaft foundations in soil, bedrock, or anchored to bedrock will be measured by Linear Foot. Spread footing foundations will be measured by Cubic Yard. Grouted, rock- anchored foundations will be measured by Cubic Yard. Modified or removed concrete 6-91 foundations will be measured by Each unit. Special Foundations will be measured by Each unit. The quantity of structural earth excavation to be measured for payment below grade will be the amount actually excavated from 1 foot below the bottom of the foundation to the required foundation bottom elevation, provided the maximum allowable horizontal dimensions do not exceed those bounded by vertical surfaces 9 inches each side of the installation, as shown in the Contract Documents. The quantity of structural rock excavation to be measured for payment will be the number of cubic yards actually removed, provided the maximum allowable horizontal dimensions do not exceed those bounded by vertical surfaces specified herein.

626.05 Basis of Payment The accepted quantity and/or volume of foundations will be

paid for at the Contract Unit Price for each type of foundation. This payment shall include: all excavation, bedrock removal, unsuitable soil excavation, concrete, anchor bolts, reinforcing steel, conduit within the foundation and extending 12 inches from the foundation, backfill, loam, seeding, mulching and all labor, equipment, and materials, necessary to complete the work. If a design is required by the Contractor, payment shall include the test boring(s), structural, and geotechnical design. The accepted quantity of junction boxes will be paid for at the Contract Unit Price Each. Payment for junction boxes shall include furnishing and installing precast concrete or bituminized fiber boxes as designated, including that portion of conduit extending 12 inches outside the box. Excavating and backfilling for junction boxes, foundations, and excavating, backfilling and sand bedding for conduit ducts will be considered incidental in the respective Contract Unit Prices and no separate payment will be made, except as hereafter provided. Excavating and backfilling as shown in the Contract Documents, or as required to overcome soft or otherwise unsuitable material, or for excavating rock will be paid for as provided in Section 206. Required backfill material, except sand bedding as shown on the detail Plan, will be paid for as provided in Section 304. Payment will be made for the total number of linear feet of prewired conduit actually furnished, installed, and accepted at the Contract Price per Linear Foot. This price shall include the cost of hand digging, trenching, or plowing; furnishing and installing the prewired conduit; and all labor, equipment and incidentals necessary to complete the work. The accepted quantity of ground mounted cabinet foundations will be paid for at the Contract Unit Price Each, which payment shall include conduit within the foundation and extending 12 inches from the foundation and for loam, seeding, mulching and all incidentals necessary to complete the work. The accepted quantity of Remove or Modify Concrete Foundations will be paid for at the Contract Unit Price Each. Such price shall include disposing of concrete removed, 6-92 backfilling with granular material, loaming, seeding, and all incidentals necessary to complete the work. Payment for restoration of roadway pavement, sidewalks, grass areas and resetting curbing removed in conjunction with this work shall be considered incidental to the respective Contract Unit Prices for each related item except as otherwise provided. Payment will be made for the total number of linear feet of under pavement conduit actually furnished, installed and accepted at the Contract Price per Linear Foot. This price shall include the cost of: furnishing and installing the conduit; excavating; furnishing special backfilling materials, pull wire, fittings, grounding and bonding; test cleaning interiors of conduits and all materials, labor, equipment and incidentals necessary to complete the work. P a y I t e m P a y U n i t

626.11 Precast Concrete Junction Box E a c h

626.21 Metallic Conduit L i n e a r F o o t

626.22 Non-metallic Conduit L i n e a r F o o t

626.221 Non-metallic Conduit, Concrete Encased Linear Foot 626.251 Non-Metallic Under Pavement Conduit Linear Foot (Schedule 80 or greater rating)

626.35 Controller Cabinet Foundation E a c h

626.36 Remove or Modify Concrete Foundation Each

626.37 Special Foundation E a c h

626.38 Ground Mounted Cabinet Foundation Each

626.411 18-inch Diameter Foundation L i n e a r F o o t 626.421 24-inch Diameter Foundation L i n e a r F o o t

626.43 30-inch Diameter Foundation L i n e a r F o o t

626.44 36-inch Diameter Foundation L i n e a r F o o t

626.451 42-inch Diameter Foundation L i n e a r F o o t

626.46 48-inch Diameter Foundation L i n e a r F o o t

626.47 54-inch Diameter Foundation L i n e a r F o o t

626.48 60-inch Diameter Foundation L i n e a r F o o t

626.501 Spread Footing Foundation C u b i c Y a r d

626.60 Grouted, Rock-Anchored Foundation C u b i c Y a r d