617.01 Description
This work is installing or modifying traffic signal(s), lighting, and other electrical systems.
617.02 Materials
Furnish materials in accordance with the following section requirements: Hydraulic Cement Concrete .................................... 551 Lighting and Signal Materials .................................. 703
617.03 Construction Requirements
617.03.1 General
Consult with the Project Manager and affected utility companies about the work prior to commencement of work. Obtain daily, safety circuit clearance from the servicing utility before starting work on existing series street lighting circuits. Pull cut-out plugs and place worker signs at cut-out boxes before work is started. Use rosin core solder in all electrical soldered connections. Pick up Department-furnished material and equipment from the Traffic Engineering Section, 2701 Prospect Avenue, Helena, Montana, and transport to the project as part of the contract unit price. Provide the Traffic Signal Engineer at least 5 business days’ advance notice before arriving to take delivery. The date/time arranged for equipment pickup will be mutually agreed to and be as close as possible to the contractor’s request. Repair or replace all existing improvements and equipment disturbed, damaged, or removed in performing the work at Contractor expense. The locations in the contract for signal and light standards, controller pedestals, conduit runs, pull boxes, illuminated signs, and appurtenances are approximate. The Project Manager will establish the exact field locations and elevations. Furnish and install all incidental parts not specified but necessary to complete or modify the traffic signal, lighting, or other electrical systems at Contractor expense. Make arrangements with the serving utility for providing service to the project. Work with the serving utility to determine the schedule for and exact location of the service. Pay all fees and energy costs used for temporary Contractor operations. The Department will pay the energy costs to operate signals and lighting used by the public. All systems must be complete and operable when the work is completed. Coordinate all construction activities to ensure all interim and/or permanent pavement markings and all associated signs are in place prior to the signal turn-on. Place new traffic signal installations into “flash” for a period of 3 to 5 days immediately prior to the turn-on. The traffic signal will be put into operation upon approval, and at the sole discretion, of the traffic signal engineer from the traffic engineering section. The sole discretion of the traffic signal engineer is based on the whether the project intent has been met, the completeness of the project, and the ability to turn on the traffic signal safely. Inform the Project Manager of the desired turn-on date prior to the time the signals are to become operational. Have the project manager inform the traffic signal engineer of the desired turn-on date at least 2 weeks prior to that date. The date arranged for the signal turn-on will be mutually agreed to and be as close as possible to the contractor’s desired turn-on date. 617 – TRAFFIC SIGNALS AND LIGHTING 2020 EDITION V5.1 617-2
617.03.2 Equipment Lists and Drawings
Submit the following for approval after award:
617.03.3 Maintenance of Signals
Maintain existing traffic signals that are moved or modified once work begins. The responsibility for existing traffic signals continues with the agency normally responsible for the traffic signals until work begins. Be responsible for new or modified traffic signals placed in service until the project is accepted. Provide in writing the names and phone numbers of the persons responsible for the 2020 EDITION V5.1 TRAFFIC SIGNALS AND LIGHTING – 617 617-3 operability and maintenance to the jurisdictional law enforcement agency and the Project Manager in case of signal malfunction.
617.03.4 Excavation and Backfilling
Excavate for conduit, foundations, other equipment, and materials as specified. Excavate trenches to the width necessary to install electrical equipment, materials, and foundations. Saw cut all existing pavements before excavating. Do not start excavation until the conduit, equipment, and materials are on site. Place excavated material without obstructing vehicular or pedestrian traffic or surface drainage. Remove and dispose of surplus excavated material at the end of each work day. Backfill excavations in accordance with Subsection 209.03.6 . Bring excavations up level with the adjacent surface or grade to drain as required until permanent repairs are made. When construction is suspended each day, clear all equipment and material from the roadway for public use as specified in Section 618.
617.03.5 Removing and Replacing Improvements
Replace or re-construct existing sidewalks, curbs, gutters, pavement, bituminous surfacing, base material, landscaping, and other improvements removed, broken, or damaged by the Contractor with equal or better-quality materials. Cut concrete sidewalk and pavement borders to be removed without damaging the adjacent surface. Whenever a part of the existing concrete sidewalk, driveway or pavement is broken or damaged, remove the entire square or slab and replace the concrete as specified. Repair or remove and replace all existing improvements damaged by the Contractor at its expense.
617.03.6 Foundations
Construct post, standard, controller cabinet, and pull box concrete encasing pad foundations using Class General or better hydraulic cement concrete in accordance with Section 551 . Place the concrete foundation bottoms on undisturbed ground. Monolithically pour foundations where practical. Form the exposed faces. Ensure forms are rigid and braced true to line and grade. Finish the footing tops for posts and standards, except special foundations, to the curb or sidewalk grade or as directed. Position and hold in place conduit ends and anchor bolts using a template until the concrete has set. Provide the proper anchor bolt circle for all standards. Install luminaire and Type 1 signal foundations to ensure that no portion of the foundation or base that is non-breakaway projects more than 4 inches (100 mm) above the ground line. Leave anchor bolts projecting at least 3 inches (75 mm) from the foundation. Apply an ordinary surface finish to the exposed concrete surfaces in accordance with Subsection 552.03.11(D) . Where obstructions prevent the construction of planned foundations, the Contractor may propose an alternate foundation construction method. Posts, poles, standards, and pedestals may be erected, plumbed, and raked after the foundation concrete has cured at least 72 hours. Concrete quantity increases for foundations to accommodate the standard furnished by the manufacturer are at Contractor expense. Construct foundations to accommodate the conduit and anchor bolts as specified. Do not use pancake grounds. 617 – TRAFFIC SIGNALS AND LIGHTING 2020 EDITION V5.1 617-4 Reinforce foundations with No. 4 (#13) hoops at 1-foot (610 mm) centers and with eight No. 6 (#19) bars equally spaced around the hoops. Form the top 6 inches (150 mm) of the foundation, beveling the exposed concrete edge 2 inches (50 mm). Electrically bond all steel conduits in each foundation to an anchor bolt using an AWG No. 6 copper grounding strap. Connect a bare copper AWG No. 6 solid wire between the grounding lug on the standard and the grounding strap.
617.03.7 Standards
Install signal standards in accordance with Subsections 556.03.8 and 703.04.5 . Field drill other holes for wire entry, mounting pedestrian and vehicle signals, or pedestrian pushbuttons. Treat the holes or threads with a cold galvanizing compound following the manufacturer’s recommendations. Seal unused pipe tenons on mast arms with metal caps. Once the non-breakaway standards, posts, or pedestals are erected and the installation complete, grout the gap between the base and foundation using grout in accordance with Subsection 713.04 . Form or drill a ¾-inch drain hole in the grout at the lowest point. Repair all damage to galvanized pole and standard surfaces by applying one coat of cold galvanizing compound to the damaged area.
617.03.8 Luminaires
Install luminaires in accordance with Subsections 556.03.8 and 703.04.5. Check luminaires on the ground to ensure they provide the specified ANSI/IES light distribution pattern before mounting. Adjust the luminaires at night, as directed, to provide the best roadway light distribution. Notify the Project Manager when the luminaire system is complete. The luminaires may be put into operation when necessary for public use as directed by the Project Manager.
617.03.9 Advanced Flashing Beacons
Furnish mounting hardware to mount the traffic signal and sign as shown in the Detailed Drawings. Furnish a traffic signal as specified in Subsection 703.08 . Payment for the sign and its mounting is covered on the signing plans.
617.03.10 Conductors and Cable
Install wiring in accordance with the NEC requirements. Neatly arrange and lace wiring in cabinets, junction boxes, and the like. Run conductors in conduit except inside poles. Remove all dirt and moisture from the conduit runs before pulling wiring. Use powdered soapstone, talc, or other approved lubricant when placing conductors in conduit. Run signal light conductors without splices from a terminal block located in the cabinet, compartment, or signal head to a similarly located terminal block. Splice conductors only where specified using approved watertight connectors. Locate connectors in pole bases to be easily accessible through the handhole. Furnish watertight connectors with midget ferrule type fuses. Leave 4 feet (1.2 m) of slack for all cables or conductors entering each cabinet. Prepare cables for connection in the cabinet by removing at least 2 feet (610 mm) of the cable sheath. Coil slack cable and conductor neatly inside the cabinet. Furnish spade type connectors for all the conductors in each cable. Supply connectors and fuses shown in the contract and required to complete the work. Include the cost of these items in the bid items for cable or conductor. Leave at least 2 feet (610 mm) of slack for each cable and conductor at each standard and pull box. 2020 EDITION V5.1 TRAFFIC SIGNALS AND LIGHTING – 617 617-5 Use a conductor separate from the signal light circuit for all 24-volt circuits, such as pedestrian push-button circuits. When conductors and cables are pulled through conduit, tape the conductor and cable ends to seal out moisture until the splices are made or terminal appliances attached. Tape the ends of spare conductors. Tag cables at controller cabinets to show routing. Label cable and conductor with the appropriate pole number or as approved by the Project Manager to show individual wire routing.
617.03.11 Service and Control Assembly
Equip and locate service and control assemblies as shown in the contract. Meet all applicable Codes and local utility company requirements. Furnish lock and 3 keys to the lock. Service pole locations shown in the contract are approximate. The Contractor, Project Manager and serving utility will jointly determine the exact locations. The utility must specify the riser location when the Contractor is to install the lower section of a riser on a utility pole. Include the cost of the 6 x 6-inch (150 x 150 mm) wood post, if necessary, as part of the service assembly bid item. Pressure-treat all S4S timber posts and poles in accordance with Subsection 706.04 . Seat, backfill, and compact around the poles. Compact backfill in 8-inch (200 mm) lifts. Plumb and rake the pole as directed. Treat injuries, cuts, and holes in poles after treatment with 3 applications of Ammoniacal Copper Zinc Arsenate (ACZA) or copper naphthenate (CuN) solution containing a minimum 2% copper metal in accordance with AWPA M4. 617 – TRAFFIC SIGNALS AND LIGHTING 2020 EDITION V5.1 617-6 Furnish all steel conduit, ground wire, insulated clevis, service wire, all mounting hardware and fittings required to complete this item of work. Include the cost of these items, if necessary, as part of the service assembly bid item. Run a bare AWG No.6 solid copper ground wire from the cabinet to a ⅝-inch by 8-foot (16 mm x 2.4 m) copperweld ground rod and clamp, as shown in the contract.
617.03.12 Photoelectric Controls
Wire photoelectric controls to meet the contract requirements. Mount the control at the top of the standard with the photocell oriented toward the north sky or as directed. Use a 3 AWG No. 14 signal cable in accordance with Subsection 703.05.1 between the photoelectric controller and the electrical service. Include the cost of the photoelectric control, if necessary, as part of the service assembly bid item.
617.03.13 Control Cabinet Pedestals
Locate the pedestal as specified or directed. Construct the pedestal, including the concrete work, as specified. Furnish a bare solid copper AWG No. 6 ground wire, ground rod clamp, and ⅝-inch x 8 feet (16 mm x 2.4 m) copperweld ground rod for the controller cabinet as part of this item.
617.03.14 Traffic and Pedestrian Signals
617.03.15 Loops
Repair saw cuts through existing pavement markings as directed. Clean the saw cut slot before placing the loop. Make loop wire connections in pull boxes or signal standards using soldered, waterproof splices. Excess make-up wire, lead-in or loop wire coils are not permitted. Ensure a minimum of 3 feet (1 m) of insulated conductor is coiled neatly in the bottom of the pull box for each loop. Tag loop wire in the pull box, or signal standard if spliced there, with a permanent wire marker indicating the approach, loop number, and “input” or “output”. The Department will verify the following loop characteristics prior to accepting the loop. • A resistance to ground of less than 100 Megohms indicates a faulty loop. • An Inductance of less than 100 microhenries indicates a faulty loop. • A resistance of more than 5 ohms indicates a faulty loop. Repair faulty loops at Contractor expense.
617.03.16 Radio Antennas
Furnish and install suitable brackets for mounting the antenna as illustrated in the contract. Be responsible for providing proper fit of the antenna and associated assembly components. Furnish and install a broadband (125 MHz to 1,000 MHz) flange-mounted surge suppressor utilizing a UL497B listed gas tube. Furnish an arrester that is multi-strike capable and has a maximum turn on time of 2.5 ns for a 2 kV/ns surge. Furnish an arrester with an operating temperature range of −50 to 120 °F. Install the surge suppressor in the lower right-hand side of the controller cabinet below the incoming power panel or as directed by the Project Manager. Ensure the surge arrestor is grounded to the cabinet ground bar.
617.03.17 Pedestrian Push Buttons
Install the push button and sign on the crosswalk side of the pole with the arrow pointing in the direction of the crosswalk. Use ¼-inch (M6) coarse thread stainless steel bolts to mount pedestrian push buttons to the side of signal poles.
617.03.18 Span Wire-mounted Signals
Install span wire suspended signals on overhead guys providing a sag of 5% of the total span distance. Raise overhead guys with the signals attached to the specified sag. Adjust the guy mounting height at either or both poles, or the sag, or the rake of steel poles so that the signals are at the specified height with the proper sag and the poles are plumb when completed. Do not pull guys beyond the specified sag.
617.03.19 Bonding and Grounding
Make metallic cable sheaths, conduit, and metal poles and pedestals mechanically and electrically secure to form a continuous grounded system. Use copper wire or strap of equal cross-sectional area to an AWG No. 6 conductor for bonding and grounding jumpers. Use a No. 6 copper bonding strap, to bond standards and pedestals, attaching it to an anchor bolt and all conduit. Use a bare copper AWG No. 6 solid wire connected between the grounding lug on the standard or pedestal and the bonding strap. Ground one side of the secondary circuit of series- multiple transformers. Ground conduit and neutrals at service points in accordance with the NEC or this Section; except use AWG No. 6 conductor or equal for grounding. Furnish and install nonferrous ground rods or approved equals of at least ⅝-inch x 8 feet (16 mm x 2.4 m) at each service point. Install ground rods in accordance with the contract and Code requirements. Bond the service equipment to the ground rod using a ground clamp and a bare AWG metal No. 6 solid copper wire or equal enclosed in a ¾-inch (19 mm) diameter schedule 80 plastic conduit.
617.03.20 Conduit and Pull Boxes
Refer to Section 616 .
617.03.21 Field Test
Conduct the following tests on traffic signal and lighting circuits with the Project Manager present before completing the work:
617.03.22 Salvaging and Reinstalling Electrical Equipment
617.03.23 Road Closure Gate Assemblies
Furnish and install road closure gates as shown in the contract. Include all necessary items and work required to erect the road closure gates as shown in the contract as part of this bid item. The cost of foundations, pull boxes, luminaire assemblies, service assemblies, conduit, and cables/conductors from the service assemblies to the road closure gate(s) are included under separate bid items. Include the Type 3R cabinet mounted on the road closure gate and internal components thereof as part of this bid item. Furnish a dry type core and coil transformer with 120 volt primary / 12 volt secondary in accordance with UL standard 506. Size of the transformer is a nominal 2.79ʺ(H) x 3.29ʺ(W) x 3.97ʺ(D). Furnish and install gate arm lights that utilize red LEDs and have an operating range of 8.5 to 12 VAC (input voltage). Furnish vehicular traffic signal heads in accordance with Subsection 703.08 .
617.03.24 Overheight Detectors
Install and adjust the detectors on the poles following the manufacturer’s recommendations. Furnish the transmitter, receiver, 2 poles, anchor bolts, nuts, washers, all necessary wiring, and connectors for this item.
617.04 Method of Measurement
617.04.1 Lump Sum Basis
When a traffic signal and lighting system or portion thereof is specified in the contract on a lump sum basis, the system is measured by the lump sum.
617.04.2 Traffic Signals and Lighting
Measurement for traffic signals and lighting is made as follows:
617.05 Basis of Payment
Payment for the completed and accepted quantities is made under the following: Pay Item Pay Unit Cables Foot (m) Concrete Cubic Yard (m3) Conductors Foot (m) Conduit and Pull Boxes See 616.05 Controllers Each Controller Cabinet Pedestals Each Detector Loops Each Detector Loop Amplifiers Each Emergency Pre-emption Systems Each Luminaire Assemblies Each Overheight Detector Each Pedestrian Signals Each Pedestrian Push Buttons Each Photoelectric Controls Each Pull Boxes Each Radar Detector, & Advanced Each Road Closure Gate Assembly Each Remove and Reset Existing Pole Each Standards Each Service and Control Assemblies Each Signal Standards Each Traffic Signals Each Traffic Signal and Lighting System Lump Sum 2020 EDITION V5.1 TRAFFIC SIGNALS AND LIGHTING – 617 617-11 Treated Timber Poles Foot (m) Other Components as specified in the contract Each
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