14-1 Division 14
LIGHTING 1400 -1 DESCRIPTION Furnish, install, connect and place into satisfactory operating condition lighting at locations shown in the plan s. Perform all work in accordance with the contract and the National Electrical Code. This Division is for methods, materials and equipment to construct and put in working order the proposed lighting; however, every fitting, minor detail, or feature may not be fully shown or described. The Contractor shall be an expert in the trade, capable of understanding the intent of the contract and constr ucting the lighting and electrical system(s) in accordance with the best practice of the trade. The Contractor actually performing the work described in the contract shall comply with NCGS § 87, Article 4, Electrical Contractors and have a license of the p roper classification from the North Carolina State Board of Examiners of Electrical Contractors. Have the licensed Contractor available on the job site as necessary when work is being performed or when requested by the Engineer. Have this Contractor posse ss a set of project plans and s pecifications on the job site and maintain a set of accurate as built plans. This Contractor shall be qualified to responsibly instruct and direct all employees regarding the electrical work. 1400 -2 MATERIALS Refer to Division 10. Item Section Conduit 1091 -3 Ground Rod 1091 -6 Wire 1091 -2
A.General All materials used in the work are to be new materials unless noted elsewhere in the contract. Provide materials that are labeled or listed by an acceptable organization that maintains periodic inspection by a qualified testing laboratory, of the producti on of the materials and verifies, by the labeling or listing procedure , that the materials comply with appropriate standards of performance or are suitable for use in a specified manner. Provide Underwriters' Laboratories (UL) labeled and listed materials when such labeling and listing is available for such materials. Refer to the North Carolina Department of Insurance, Office of State Fire Marshal for other suitable qualified testing laboratories. Make sure that materials are in compliance with requirements for use of domestic products, as specified in other sections of the Standard Specifications .
B.Conduit Use conduit and duct that is either metallic (Rigid Metallic Conduit) or non -metallic (PVC or HDPE ), as noted in the plans.
14-2 (C) Wire
Use wire and cable which conforms to Insulated Cable Engineers Association ( ICEA ) specifications and has marks for identification (manufacturer's name, type insulation and gauge of conductor) and the UL label. Use wire insulation rated at 600 VAC or greater. Use the fo llowing types of wiring unless noted otherwise in the plans: Service Lateral UL Type USE Control System UL Type THW or RHW or THHN Feeder Circuits in Conduit UL Type USE Branch Circuits in Light Standards UL Type SO OW Cable Equipment Grounding Conducto r Solid MHD, Bare or Insulated Grounding Electrode Conductor ASTM B2 Use #6 AWG for the grounding electrode conductor unless noted larger in the plan s.
D.Grounding and Bonding Equipment All grounding and bonding equipment shall conform to UL Standard 467. Use ground rods in accordance with Article 1091 -6.
E.Fuseholders Provide fused overcurrent protection in the base of each light standard and other locations as noted. Use a fuseholder ra ted at least 600 VAC and 30 A approved for wet locations, constructed so t he fuse will be disconnected from the line side power every time the fuseholder is opened. The fuseholder may be made of molded plastic or rubber and have insulating boots. Use ter minals which are specifically rated for the size and number of conductors required. Use fuses which have 5,000 A minimum interrupting capacity at the supply voltage, are rated 10 A or as noted in the plan s and are not glass type unless specified different in the contract. Use the same type fuse in all fuseholders on a project unless specified differently at specified locations. Use fuseholders specifically designed as breakaway devices in fiberglass standards and standards with breakaway bases. Use fuseho lders designed to disconnect line side power without damage to the terminals or conductors every time sufficient pulling force is placed on the line and load side conductors. Fuseholders with plastic locking tabs are prohibited.
F.Hardware Use mounting or a ttachment hardware including bolts, nuts, washers, straps, clamps and hangers which is made of stainless steel, hot dipped galvanized or of equal corrosion resistance. Use bolts, which are minimum length and are not less than one nominal size smaller than the opening being used.
G.Duct and Conduit Sealer Use duct and conduit sealer or mastic which is a putty -like compound and complies with the following :
1.Is permanently non- hardening, non- oxidizing and non- corrosive to metals, rubber, plastic, lacquer and pai nts;
2.Is readily workable for thumbing into openings and forming into seals around wires inside conduits and openings around conduits ;
3.Has a service temperature range of minus 30°F to 200°F ;
14-3 (4) Is clean, non -poisonous and non- injurious to human skin; and
5.Seals against water, dust and air and shall adhere to wood, glass, plastics, metal, rubber and painted surfaces.
H.Pull Lines Place pull lines specifically designed for pulling a rope in all empty conduits and electrical duct so that electrical circuits can be installed in the future. Use pull lines which are 2 ply with a tensile strength of at least 240 lb. and resistant to tangling, rot and mildew. 1400 -3 SUBMITTALS
A.Catalog Cuts and Working Drawings Electronically s ubmit catalog cuts and/or shop drawings for materials proposed for use on the project per Sections 105 and 106. Do not deliver materials which have not been approved to the project. E ach material catalog cut and/or shop drawing shall show the description, brand name, stock- number, size, rating, manufacturing specification and the intended use. The approved submittals will be returned to the Contractor by the Engineer . Present a catalog cut or shop drawin g for all components of each contract item. Electronic submittals shall be legible with the intended item clearly marked, and arranged in the same order as the contract bid items.
B.Certifications Furnish a Type 3 material certification in accordance with A rticle 106-3 for light standards, high mounts and lowering devices and a Type 6 material certification for conductors. Submit certifications when the above materials are delivered to the project. Type 3 or Type 6 material certifications in accordance with Article 106-3 may be requested for any or all of the other material which does not have a name plate showing sufficient information to verify that the material was manufactured to the requirements of this section.
C.Samples Random samples may be taken of the various items for the purpose of verifying conformance with the plans and s pecifications. The selection of the items to be sampled and the taking of the samples will be done by the Engineer. Failure to meet specification requirements by two samples of a ny material will be sufficient reason for rejection of all materials from the same lot. Upon request, there will be reimbursement for the actual verified cost of such material taken as samples, including any handling charges less any discount allowed on the invoice, but with no percentage added, and such material will thereafter become the property of the Department.
D.As-Built Plans Submit one complete set of electronic as-built plans to the Engineer for review upon completion of the work, showing the locati on of all buried electrical circuits, with pavement crossings dimensioned from fixed objects or from survey stations. Include in the as -built plans the title (No. 1), index (No. 1A), summary of quantities (No. 3) and all of the lighting layout and detail ( E) sheets of the project with all changes indicated. After review and approval, place one set of these as -built plans in a waterproof envelope and file in each control panel and submit an electronic copy to the Engineer .
14-4 Show the light standard foundations that are relocated on the as -built plans in their final
locations. Keep a daily record of the location of all items in order to ensure the accuracy of the as-built plans.
E.Warranties Turn over warranties to the Engineer from each manufacturer of electrical materials and equipment pertinent to the complete and satisfactory operation of the system before the acceptance of the project. Indicate the expiration date on each warranty furnished. The warranty shall not be less than those provided as a c ustomary trade practice. 1400 -4 CONSTRUCTION METHODS
A.Location Surveys All light standards, high mount foundations and electrical duct will be located unless indicated different ly elsewhere in the contract. Mark the proposed location of circuits, circuit markers, control systems, service poles, junction boxes, luminaires and all other components for approval before installation. The plan locations of the light standards and high mounts may be adjusted to be behind guardrail, to avoid obstructions or to avoid undesirable foundation conditions. Light standards can be moved no more than 10 f eet longitudinally and 2 f eet laterally unless approved by the Engineer. High mast light standards can be moved no more than 25 f eet radially but no closer than 50 feet to the edge of travel unless approved by the Engineer. Ensure location changes are approved by the Engineer before construction. Verify project dimensions on the site with ever y part of the work fitted to actual conditions at the site. Actual measurement always tak es precedence over scaled plan dimensions .
B.Damage to Facilities Take all precautions necessary to avoid damage to existing underdrains and other buried facilities. Hand trenching may be required to avoid damage to the underdrains, storm sewer systems and other facilities. Construct light pole foundations with a minimum horizontal clearance of 10 f eet to storm sewers or other underground installations. If closer than 10 feet, submit light pole foundation design sealed by an engineer licensed by the State of North Carolina to the Engineer. Make lateral and longitudinal changes in pole locations in the field to provide the required clearance, as directed by the Engineer . Trenching and construction operations may require the removal of, or result in damage to, existing shoulders and paved ditches. Restore all disturbed portions of the project to their original condition or as approved by the Engineer . Installation of conductors may require trenching through existing guardrail locations. Trenching may be done beneath the guardrail in a manner that will not disturb the guardrail installation or the Contractor may remove short sections of guardrail to facilitate mechanical trenching. Reinstall all removed guardrail by the end of the day's work. Permission is required from the Engineer before removal of any guardrail. Repair any damage to the guardrail installation or to the galvanizing of the material as di rected by the Engineer . Repair all trenched, excavated, or otherwise damaged earth surface areas by shaping, smoothing, seeding and mulching the damaged areas as required by the s pecifications and as directed by the Engineer .
C.Existing Utilities Water, sewer, telephone, fire alarm, traffic signal and power lines may be located in the same area that light standards and circuits are to be installed.
14-5 Prior to beginning operations, l ocate existing utilities . Field changes approved by the
Engineer may be made to provide clearance required by the NESC. Foundations or other construction which is installed in conflict with existing utilities will not be acceptable. Remove unacceptable conflicting construction and repair damage to utilities at no cost to the Departm ent. When the work involves replacing or renovating existing lighting, make all reasonable efforts to prevent dark spots in the lighting system. Phase lighting construction to allow existing lighting to remain in operation as long as possible.
D.Operation o f Equipment Use a bucket truck to raise workers into position to install and/or adjust luminaires after the initial setting of the light standards. Dismounting and lowering the light standard to check or make adjustments at the top is not allowed. Insta ll all bore pits outside the clear zone.
E.Conduit Installation Install conduit continuous, watertight, free of kinks and make all runs with as few couplings as standard lengths will permit. Do not exceed a total angle of 270° between outlets unless otherwi se approved by the Engineer . Conduit bodies with covers and neoprene gaskets may be used to facilitate the installation of the wires at locations indicated in the plan s. Provide protection at all times against the entrance of water or other foreign matter into the conduit. Plug or cap conduit when work is temporarily suspended, including nightly stoppage of work. Clean all conduits before installation and upon completion of the system. Snake an approved cleaner with a diameter not less than 85% of the nominal diameter of the conduit through each conduit before installing the wire. Install the conduit in such a manner that temperature changes will not cause elongation or contraction that might damage the system. Provide expansion fittings where conduit crosses structure expansion j oints and at other locations shown in the plans. Avoid short radius bends in non- metallic conduit to prevent burn- through of the pulling cable or conductors during pulling operations. Install caps or plugs on stub- outs for future use. Caps and plugs shall be made of the same material as the conduit. Where non -metallic conduit is joined to metallic conduit, use a transition adapter. Install bushings on all conduit ends projecting into panels, boxes, or other enclosures. Provide pull lines in all conduits for future installation of circuitry. Coat field cut threads and other uncoated metal or damaged galvanizing with organic zinc repair paint in accordance with Section 1076 . Securely fasten conduit. Space conduit fasteners per NEC spacing requirements . Use fasteners that are hot dipped galvanized or stainless steel. Provide backs with all conduit straps installed on flat surfaces. Rotary - impact drills may be used for installing expansion anchors in concrete. Do not use powder explosion type units. Do n ot install underground conduit until the area has been brought to final earth grade. Give careful attention to the vertical and horizontal alignment of the conduit to provide the smoothest installation.
F.Wiring Methods Do not pull wire through a conduit system until the system is complete and has been cleaned. Use lubricant that will not physically or chemically harm cable jacket, wire insulation or conduit . Pull conductors by hand, or use motorized cable -pulling equipment
14-6 designed for pulling multiple ca bles into conduit. Use sheaves or rollers, as required to
prevent damage to conductor insulation. Use a dynamometer (clutch device) so as not to exceed maximum allowable pulling tension if conductor is pulled by mechanical means. Do not use a motorized vehicle or heavy equipment to generate pulling forces. Color code all conductors per the NEC (grounded neutral is white, grounding is bare or green) and use phase conductors which are black and red. Approved marking tape, paint, or sleeves may be used in stead of continuous colored conductors for No. 8 AWG and larger . Red or black conductor may be stripped at all accessible points and used as a bare equipment grounding conductor. Joints, taps and splices will only be permitted at locations indicated in the plans and by the following method. Install UL Listed manufactured set screw type connectors, suitable for connecting multiple wires for all phase conductor splices. These precise fit connectors are insulated with high –strength dielectric material and hav e removable access plugs over the set screws. Direct buried and/or submersible versions of these connectors (UL486D) , equipped with factory made waterproof insulating boots, are required for splicing inside junction boxes. Non- direct buried and/or non- submersible connectors (UL486A and UL486B ) may be used for phase conductor splicing in normally dry areas such as inside poles and transformer bases. After tightening set screw, tape down the access plugs to keep them securely in place. Split -bolt connecto rs may be used for ground wire splicing. Wire nut and compression type connectors will not be allowed. Breakaway fuseholders are not an acceptable means of splicing in junction boxes and are not permitted for this purpose. Cut conductor so that 3 feet of spare conductor is available for splicing from the end of each respective conduit. Neatly coil extra conductor in junction box. Position splices near the top of the junction box. All splices inside light standards shall be easily accessible through handholes unless standard is mounted on breakaway transformer base.
G.Grounding Electrodes Install grounding electrodes at each light standard, high mast light standard and control system as shown in the plan s. The rod shall be driven vertically unt il the top is 4 inches below the ground surface. The grounding conductor must be connected to the grounding electrode by an irreversible compression ground connector . Permanently bond grounding conductor to ground rod using an irreversible compression ground connector . Unless the irreversible compression connectors are designed for use with more than one conductor, only one conductor shall be placed under each irreversible compression ground connector. Ensure all connections are made using a hydraulic, power or ratcheting type crimper with appropriate dies. Use of handheld pliers for crimping is prohibited. For ease of inspection, the t op of ground rods shall be no more than 4 inches below finished grade and shall remain exposed until electrical inspection is complete.
H.Equipment Mounting Mount equipment securely at locations shown in the plans in conformance with the dimensions shown and m ake vertically plumb and level. Install fasteners as recommended by the manufacturer and space evenly. U se all mounting holes and attachment points for attaching enclosures to structures.
I.Base Protection For median mounted light standards, use a protective metal shroud installed underneath the light standard base plate to protect the exposed anchor bolts and lighting circuitry
14-7 segments between the base plate and the top of the concrete median barrier. The metal
shroud shall be fabricated of either galvaniz ed steel, minimum gauge 22, or aluminum, minimum gauge 18, to match the material type of the light standard. The metal shroud shall be composed of two overlapping pieces, and attached with two self -tapping stainless steel or galvanized machine screws at each overlap point. For high mount standard, use galvanized steel welded wire reinforcement between the top of foundation and bottom of mounting base. Attach welded wire reinforcement to anchor bolts with size AWG 14 copper wire or small gauge galvanized w ire.
J.Galvanizing Repair Repair any damaged galvanized components in accordance with Article 1076- 7.
K.Foundations Form foundations with prefabricated cardboard forms down to 12 inches minimum below top of ground. To avoid vehicle undercarriage snagging of any substantial remains of a breakaway support (when it is broken away), the edge of the foundation or top of anchor bolt should not extend more than 4 inches above a 60 inch chord aligned radially to the centerline of the highway, and connecting any poi nt within the length of the chord on the ground surface on one side of the foundation to a point on the ground surface on the other side. If this cannot be achieved due to site conditions, the Contractor shall notify the Engineer. 1400 -5 ELECTRICAL INSPECTIONS AND TESTING Comply with all local ordinances and regulations. Apply for and obtain all permits and/or licenses required by local regulation. Provide a calibrated MegOhm Meter, with certification that calibration was done within one year of use. Provide a meter manufactured by Fluke, Amprobe, Biddle or Engineer approved equal. Present the meter for inspection, at the Pre- Lighting -Work meeting described in
Article 1400 — 11.
During project construction perform an insulation resistance test on each feeder circuit conductor. The insulation resistance for each conductor shall exceed 5 megaohms after charging for 30 seconds at 500 VAC or 1000 VDC. T he Contractor Meg Circuit Data Form is available on the Department website. Submit the data form to the Engineer for review before final inspection. If the insulation resistance test of any conductor indicates a value of less than 5 megaohms, locate the fault. If the fault is in a conductor between terminal connections, replace the conductor. If the fault is at a terminal connection, repair or replace the terminal device. Removing water from the conduit of a faulty circuit is not considered a repair. If a circuit fails the insulation resistance test and removing water allows the circuit to pass, replace the conductors and re -test the new circuit. The following electrical inspections and tests are required:
1.Inspection of the control panel by the authority having jurisdiction After all control system cabinet wiring has been installed and connected in the proposed permanent manner the Contractor will contact the North Carolina Department of Insurance, Office of State Fire Marshal or local authority having jurisdiction, to perform an electrical inspection of the lighting system. Upon satisfactory testing, the Contractor will be issued a Certificate of Inspection for the lighting system. The Contractor may then arrange with the power company to provide the necessary power service. The Certificate of Inspection will be turned over to the Engineer before project acceptance.
14-8 Inspection by local authorities will neither eliminate nor supersede the final inspection by
the Engineer to ensure compliance with the contract.
2.Inspections by the Engineer Have all work inspected and approved by the Engineer before concealment. An inspection will be made during the progress and after the work has been completed. It will also include an inspection made at night to determine the optical qualities of each luminaire. Adjust all luminaires having unsatisfactory qualities as directed by the Engineer . Provide the necessary personnel and equipment for aiming luminaires during nighttime inspections by the Engineer.
3.Final Inspection Contact the Department to schedule a final inspection of lighting systems at least 2 weeks before the requested inspection date. The Lighting and Electrical personnel will perform an insulation resistance test as described above, inspect the system for adheren ce to contract requirements and prepare a lighting inspection memo based on the Lighting System Inspection Checklist . The inspection checklist is available on the Department’s website. As -built plans are required to be submitted to the Engineer prior to the final inspection . If there is a change to the as -built plans after the final inspection, as -built plans are required to be resubmitted to the Engineer. P rovide the personnel and equipment necessary for removing and replacing fuseholders and/or operat ing circuit breakers to facilitate the insulation resistance test performed by the Lighting and Electrical personnel . 1400 -6 BURN- IN TEST After all the issues mentioned in the lighting inspection punchlist are addressed to the satisfaction of the Engineer, the lighting system will undergo a 2 week burn- in test. The burn - in test consists of normal dusk to dawn operation of all lighting system control equipment and apparatus, wit hout interruption or failure attributable to poor workmanship or defective material. All burn -in testing shall be performed using power from the local utility and not from mechanical generators unless approved by the Engineer. At the end of the burn- in test, all lights and equipment will be inspected for normal operation. The Contractor will make any necessary repairs or replacements at no cost to the Department. Conduct the burn -in test at the same time for all lights which are energized from the same utility company service point. Burn -in tests of individual circuits or groups of lights will not be acceptable. The Contractor is responsible for all maintenance of the lighting system(s) installed or renovated as part of the contract until project final ac ceptance or in accordance with Article 36 105-17. 1400 -7 IDENTIFICATION Identify each component of the lighting/electrical system as indicated in the plan s. Use a method of ident ification which includes an approved paint, adhesive label, heat shrink label or embossed concrete. Label conductors on components requiring identification at each terminal, circuit breaker, light standard, high mount standard, control system, junction box and underpass panel. Identify each circuit conductor using a one piece nylon cable tie with a label at each terminal and access point . Use permanent marker to label the circuit conductor with the circuit number indicated in the plan s. Identify light sta ndards and high mount standards by the control system and location number indicated in the plan s. Put the identification on the front side of the standard facing the traffic
14-9 at a height of 6 f eet above ground level. Identify control systems and underpass panels on the
exterior of the front panel. 1400 -8 LOCKS AND KEYS Supply all access doors to control cabinet enclosures and high mount poles with locks that meet the Engineer's approval. Key all locks alike and furnish eight keys to the Engineer. 1400 -9 ELECTRICAL SERVICE Coordinate all work to ensure that electri cal power of the proper voltage, phase, frequency and ampacity is available to complete the project. Contact the utility company, make application, pay all deposits and other costs to provide necessary electrical service. The Contractor will be reimburse d for the actual verified cost of any utility company charges. The Engineer will provide authorization to the Contractor for electrical service to be obtained in the name of the Department and for the monthly power bills to be sent directly from the utility company to the Department. The Department will be responsible for direct payment of monthly power bills received from the utility company. 1400 -10 TERMINOLOGY The term s “High Mast” and “High Mount” are used synonymously in the contract. The term “By Others” means work to be accomplished and paid under contract items other than those clearly pertaining to the work specified or shown. Work by others may be included in this contract for the Contractor to provide, or it may be provided under another contract or by someone other than the Contractor. Abandon means that the materials will not be used in the final completed form of the work. Remove all abandoned materials from the project or terminate at least 18 inches below subgrade so they will not be in conflict with the finished project. 1400 -11 CONSTRUCTION PHASING Schedule a Pre- Lighting Work meeting with the Engineer before beginning work on the lighting system. Include staff members from the prime contractor and electrical sub - contractor . Accomplish lighting work along with other roadway construction in the appropriate phases as indicated in the Transportation Management Plans and these Standard Specifications . 1400 -12 COORDINATION OF EXISTING LIGHTING WORK Maintain operation of the existing lighting systems unti l such time that they become in conflict with the actual construction work, or they become a hazard to traffic as determined by the Engineer. Use care in working around the lights and circuitry and phase operations so that the disruption of existing lighting systems will be minimized. Make repairs or replacements in conformance with the contract. Should the Contractor fail to make such repairs within the time allowed, the Department will cause the necessary repairs to be made by others. The costs of such repairs will be deducted from any monies due the Contractor on the next subsequent monthly or final payment. 1400 -13 MEASUREMENT AND PAYMENT There will be no direct payment, except where specifically noted in Subarticle 1400 -3(C) and
Article 1400 — 9 for the work required in the preceding sections of this D ivision. Payment of
the contract unit prices for the various items in the contract will be full compensation for all work required.
Source: North Carolina Standard Specifications for Roads and Structures, 2024 Edition. Pages 701–709 of 857.