- 928 - SECTION 1073 -- ROADWAY LIGHTING, SIGN LIGHTING, AND TRAFFIC SIGNALS
1073.01 Description
1.This Section describes material requirements for roadway lighting, sign lighting, and traffic signals.
1073.02 Material Characteristics
1.General Requirements:
a.All materials shall be new. Used or reconditioned equipment is not acceptable.
b.Materials scheduled for use on the project must be approved by the Engineer before they can be installed.
c.(1) The Contractor shall be prepared to furnish, upon request, a sample of any item or material t hat he/she proposes to furnish. Unless destructive testing is required, the sample will be returned.
2.All costs related to the furnishing of samples, including all shipping and testing costs, shall be included in the contract bid price.
d.Review of shop drawings by the Engineer is for the purpose of checking for general conformance with the design concept of the project and for general compliance with the contract documents only. Any action taken by the Engineer on submittals and shop drawings will not relieve the Contractor of the responsibility to provide satisfactory materials and equipment meeting the requirement s of the contract documents.
e.If errors in shop drawings are not detected by the Engineer, the Contractor is not relieved of his/her re sponsibility to comply with the contract documents; and the Engineer's review of the shop drawings shall never be construed to allow the Contractor to proceed in error.
f.At the time of each submittal, the Contractor shall, in writing, call the Engineer's attention to any deviations that the shop drawings or samples may have from the require ments of the contract documents.
2.Ground Rods: a. Ground rods shall, with the exception of length and diameter, be in compliance with IMSA Specifications and be installed in accordance with the National Electric Code . Ground rods used in traffic signal installations shall extend through the foundation and at least 7 feet (2.1 m) into the ground with 5 inches (125 mm) extending above the foundation. Ground rods shall have a minimum diam eter of 5/8 inch (13 mm). Ground rods shall be supplied with a ground rod clamp.
b.Ground rods used in roadway lighting installations shall comply with ANSI/UL 467 (ANSI C 33.8 and CSA) and IMSA Specifications and be installed in accordance with the National Electric Code and the contract.
c.Grounding Clamps and connectors shall be UL approved for the material being grounded and the grounding method being used. Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 929 - 3. Electrical Conduit and Duct Systems:
a.Metallic conduits of the various types shall conform to the applicable industry standards as follows:
1.Galvanized rigid steel conduit (GRS) shall meet the requirements of the NEC Article 346 and Underwriters Laboratories UL-6.
2.Intermediate metallic conduit (IMC) shall meet the requirements of the NEC Article 345 and UL-1242.
3.Electrical metallic tubing (EMT) shall meet the requirements of the NEC Article 348 and UL-797.
b.Non-metallic conduits of the various types shall conform to the applicable industry standards as follows:
1.Polyvinyl chloride (PVC) conduit shall be rigid PVC conduit, schedule 40 or 80, and shall meet the requirements of NEC Article 347, NEMA TC-2, and UL-651. Schedule 80 conduit shall be used where the conduit is exposed and may be subject to impact and abuse.
2.Filament reinforced epoxy conduit (FRE) shall be specification grade and shall comp ly with Article 347.1 of the NEC and shall be UL listed.
3.Polyethylene conduit (PE) shall be smooth wall duct of Type III, Grade 34, Class C, Category 5 High Density polye thylene (HDPE) in accordance with the latest edition of ASTM D 1248. The polyethylene conduit shall be manufactured in accordance with ASTM D 3035 and NEMA TC-7.
c.Cable in duct (CID) systems shall be factory assembled in smooth wall HDPE duct of the type specif ied above. Conductors shall be of the type, size, and number called for in the contract. All conductors shall be prelubricated before being inserted in to the duct and the ends of the duct shall be sealed.
d.Fittings used with metallic conduit shall be of a compatible metal. Fittings and cement used with plastic conduit must be compatible with the conduit material.
e.Conduit sizes required are shown in the contract and shall be interpreted to mean the minimum "trade size" allowed for the application. The Contractor may, at his/her option and expense, substitute a larger size.
4.Breakaway Devices:
a.Breakaway devices shall conform to all current AASHTO requirements for energy absorption and structural design.
b.Breakaway devices shall be furnished complete with the necessary hardware to provide a complete installation.
c.Galvanizing requirements for steel breakaway devices shall be in accordance with ASTM A 123.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 930 - 5. Conventional Light Poles [50 Feet or less (15.2 m) Mounting Height]:
a.Light poles, anchor bolts, and all accessory hardware shall be designed in accordance with the current AASHTO Standard Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic Signals . The shaft shall be a single section and shall have only one longitudinal, automatically and electrically welded joint. Shafts for poles of 45 foot (13.7 m) or 50 foot (15. 2 m) mounting height may be two-piece if approved by the Engineer.
1.The pole and mast arm assemblies shall be galvanized in accordance with ASTM A 123 or A 153, as applicable. All burrs, flash, and sharp edges inside the pole and mast arm assemblies shall be removed.
b.All poles shall have an ident ification number stamped into the top of the base plate or into a durable metal tag which is securely attached to the pole shaft. Letter he ight shall be 1/2 inch ( 13 mm). The identification number shall contain the pole length, the mast arm type and size, date of manufacture, and manufacturer's name.
c.Foundation Anchor Bolts (1) Connecting bolts for use with power-install ed foundations shall be carriage bolts supplied by the foundation manufacturer.
2.The bolts shall be galvanized. (3) All other anchor bolts are detailed in the contract. d. Each pole shall be furnished complete with an approved grounding nut or lug. The grounding nut or lug shall be welded inside the shaft opposite the hand hole and accessible through the hand hole.
e.The Contractor shall furnis h a certificate of compliance from the manufacturer stating t hat the poles and associated materials comply with the structural, wind loading, and galv anizing requirements as required.
6.High Mast Lighting Towers (Poles Over 50 Feet (15.2 m) in Mounting Height):
a.High mast towers, anchor bolts, and accessory hardware shall be designed in accordance with the current AASHTO Standard Specifications for Structural Suppor ts For Highway Signs, Luminaires and Traffic Signals . The tower and light ring supports, brackets and locking mechanism shall be designed to support 12 fixtures. The light ring shall be designed to hold the number of fixtures shown in the contract for each particular tower.
1.The high mast tower design drawings and computations must be signed and stamped by a regi stered Professional Engineer, licensed in Nebraska. The Contractor s hall submit 2 sets of computations 30 days prior to installation.
2.Acceptance by the Department of the high mast tower designs will be based upon this seal and signature. By applying the seal and signature to the design drawings and calculations, the Engineer affirms that the high mast towers are of proper design and materials to meet the structural requirements of the contract. Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 931 - b. Unless stated otherwise in the contract, each new high mast tower shall be furnished complete with base plate, hand hole with cover, anchor bolts with nuts and washers, and lowering system with internal motor. All items must be compatible an d work together to provide a reliable and efficient lighting unit. All new towers shall be galvanized.
c.(1) The tower shall be of sectional construction, either round or multi-sided polygon in cross secti on, and shall be fabricated of high strength, low alloy steel.
i.Each individual tower section shall contain no more than 2 longitudinal welds and no transverse or circumferential splices, either mechanical or welded. (ii) Towers shall be constructed with the fewest sections practicable. Towers shall consist of no more than 3 sections with the bottom section greater than or equal in length to the other sections. (iii) Each tower section shall be galvanized after fabrication. (iv) Each section shall be uniformly tapered and shall be joined by slip fit connections. The minimum overlap of the slip fit connections shall be 1 1/2 times the outside di ameter of the male section.
2.The tower shaft shall have a single access door providing access to the winch, cable, cable dr ums, and electrical components. The door opening shall have rounded corners and be reinforced to maintain the original strength of the tower. The door shall be mounted with a stainless steel loose joint butt hinge and a padlock hasp for securing. The hinge shall be heavy duty and of sufficient strength to support the weight of the hand hole door. The door shall be gasketed in a manner which will prevent the entry of water into the tower. The door shall be held closed with stainless steel cover hold downs, deep slot stainless steel screws or hex head stainless steel bolts. The hand hole shall be sized and so arranged to permit removal of the lowering mechanism wi thout excessive dismantling of the equipment.
3.The bottom tower section sh all be furnished complete with two grounding nuts (lugs) welded inside at points 90 degrees and 270 degrees from the hand hole and readily accessible through the hand hole.
4.The bottom tower section shall be provided with an integrally welded base plate using steel that meets or exceeds the specifications of the adjacent tower section.
i.The bottom tower sectio n shaft wall thickness shall be a minimum of 0.375 inches for towers less than 120 feet and 0.4375 inches for towers over 120 feet. (ii) The tower base plate thickness shall be a minimum of the anchor bolt diameter plus 1/4 inch. (iii) The tower base plate shall have drilled anchor bolt holes located outside the bottom tower section. A minimum distance of 3 1/2 inches is required between the outside of the lower tower shaft and the anchor bolt circle.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 932 - (iv) The clear distance between the bottom of the access door or reinforcement flange and the t op of the tower base plate shall be no closer than 18 inches.
v.The surface around each hole (both top and bottom) shall be milled flat and smooth to re ceive the anchor bolt nut and washer. The plate shall be attached to the shaft with 100% penetration circumferential welds. (vi) The base plate shall be designed to be supported solely by nuts.
5.The top of the tower shall be designed to support the head assembly of the lowering system. Drawings shall be provided with the tower which show assembly sequence, lift point and recommended erection procedure. Tower and lowering system shall be compatible. No field welding will be allowed in the assembly of the tower shaft or in attaching the head assembly to the top of the tower.
6.All sections of the shaft shall be match marked to facilitate assembly and to ensure that each shaft is assembled with the proper tapered sections.
d.(1) The tower Contractor shall provide all required anchor bolts. Each anchor bolt shall be provided with seven (7) heavy hex nuts and two hardened steel flat washers.
2.The minimum foundation anchorage design acceptable will be one detailing six 2 inch (50 mm) diameter anchor bolts of AASHTO M 314, Grade 55 Steel. The Contractor’s ac tual design may require a greater number of anchor bolts, anchor bolts of larg er diameter, or both. In all cases, all anchor bolts must meet AASH TO M 314, Grade 55 requirements.
3.The Contractor shall furnish an extra anchor bolt (including one nut and one washer) from each heat of steel used on the project (or multiple projects) to the Department for destructive testing.
4.Anchor bolts shall be straight rods threaded a minimum of 18 inches on the top end and a minimum of 6 inches on the bottom end. The threads of all anchor bolts must be rolled in accordance with standard industry practice. The use of cut thr eads will not be permitted. Galvanizing of the anchor bolts, heavy hex nuts, and flat washers will not be allowed. Prior to shipment, the top 12 inches (305 mm) of the anchor bolt together with its heavy hex nuts and hardened flat washers shall be cleaned and painted with zinc rich paint to a minimum dry film thickness of 4 mils (0.1 mm). The type of zinc rich paint and its method of application shall be approved by the Nebraska Department of Transportation, Materials and Research Division.
5.The heavy hex nuts for the anchor bolts shall meet the requirements of ASTM A-563, Grade C3 or DH3.
6.The plain hardened steel washers shall conform to the requirements of ASTM F 436 Type 3 or ASTM F 436M Type 3. If Type 3 plain hardened steel washers are not available for the specified bolt diameter, mechanically deposited zi nc coated hardened steel washers conforming to the requirements of ASTM F 436 or ASTM F 436M shall be used. Only flat washers shall be used. Lock washers will not be allowed. Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 933 - (7) The manufacturer of the anchor bolts and heavy hex nuts shall furnish certifications, Buy Amer ica Certification, and test reports covering the steel used in each applicatio n. The test reports shall show the following:
i.Chemical analysis of the steel used. (ii) Yield strength in pounds per square inch (MPa). (iii) Tensile strength in pounds per square inch (MPa). (iv) Percent elongation in 2 inches (50 mm) of material.
v.Percent reduction in area. (8) The Contractor shall furnish and install steel anchor bolt containment and alignment template s as detailed in the contract.
i.Anchor bolts shall be caged and retained with steel templates, conforming to the requirements of ASTM A 36/A 36M, and nuts to prevent their movements while the concrete footing is being poured. (ii) Welding on anchor bolts will not be permitted. (iii) The anchor bolt cage shall be centered in the concrete foundation. (iv) Once the concrete has set, no adjustments or realignments shall be made to the anchor bolts. Field straightening of anchor bolts will not be allowed. The anchor bolts shall be truly vertical with no more than 1/8 inch deviation in 12 inches of length permitted.
v.Anchor bolt projection above the base plate shall allow for the thickness of a hardened flat washer, and for the capture of two heavy hex nuts plus 1/2 inch, while allowing no more than two anchor bolt diameters between the top of the conc rete foundation and the bottom of the base plate.
e.High Mast Lowering System
1.(i) High mast lowering systems (head assembly, luminaire ring assembly, terminal block, cable drums, winch assembly, support cables, power cable and electrical components) acceptable for use on state projects will be listed on the Department’s Approved Products List. Only a two-drum bottom tethered lowering system or a single-drum top latching system will be accepted. All to wers on the same contract must be equipped with the same system. (ii) The High Mast lowering system shall be a luminaire hoisting and lowering device consisting of galvanized or stainless steel head assembly, galvanized or stainless steel luminaire ring, winch drums and winch assembly, Internal Power Unit, luminaire ring hoist cables (if applicable), winch cables, power cable, circuit breakers, lightning rod and arrestors, power connections to the power unit assembly and a luminaire ring guide system to protect the tower and luminaire ring assembly during raising and lowering operations. (iii) Luminaire ring hoist cables shall be a minimum 3/16 inch (4.8 mm) stainless steel aircra ft cable of the non-twisting type with the three cable system having a safety fa ctor of 5. The hoist cables shall be manufactured to meet the requ irements of MIL-W834 20C.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 934 - (iv) The winch cable shall be a 1/4 inch (6.3 mm) stainless steel anti-rotational aircraft ca ble with a safety factor of 3. The winch cables shall be manufactured to meet the requirements of MIL- W834 20C.
v.All electrical components of the lowering assembly shall be U.L. approved. (vi) The lowering assembly shall be a system which has been in use for at least five years and proven itself to be a reliable and functional unit. All changes or design modifications to the system during this five-year period shall be noted by the manufacturer. (vii) Any of the design changes considered by the lighting engineer to be critical to the proper operation of the lowering system, and which, in his opinion, have not been in use long enough to establish an acceptable service record, will be sufficient cause for rejection of the entire system.
2.The lowering system shall comply with the current AASHTO Standard Specifications for St ructural Supports For Highway Signs, Luminaires and Traffic Signals . The tower and light ring supports, brackets and locking mechanism shall be designed to support 12 fixtures. The light ring shall be designed to hold the number of fixtures shown in the contract for each particular tower.
3.(i) The masthead assembly shall contain steel sheaves for the support of the hoisting cables and a roller assembly or a large diameter deep groove pulley on which the power cable will ride. (ii) All sheaves shall be precisely sized and formed to fit the cables which they will carry. The cross-section of the groove shall have a radius of 0.005” to 0.009” (0. 13 mm to 0.23 mm) greater than half the nominal cable diameter and a minimu m radius of 6 inches (150 mm), as specified by the Wire Rope Techni cal Board. All sheaves shall have permanently lubricated bearings or oil impregnated bronze bushings mounted on stainless steel shafts. (iii) Hoist Cable sheaves that are not completely enclosed and captured shall have retainers or ke epers to prevent the cables from disengaging the sheaves under slack conditions. The power cable sheave, if provided, shall be a completely enclosed, 14 inch (350 mm) minimum operative diameter, deep groove cable pulley with a close-fitting cover which captures the power cable within the pulley. (iv) The power cable roller assembly, if provided, shall consist of multiple rollers placed between two vertical side plates. The roller assembly shall be of such design as to support the power cord in a 7 inch (175 mm) minimum bending radius. Keep er bars shall be positioned along the assembly to keep the cord in its track during raising and lowering of the light ring.
v.The masthead assembly shall include a galvanized steel or aluminum cover that will effe ctively protect the mechanism from the elements.
4.(i) The luminaire ring assembly shall be fabricated of galvanized or stainless steel and shall contain the required number of 2 inch Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 935 - (50 mm) diameter luminaire mounting arms. A weather tight junction box containing a pre-wired 600 volt terminal block shall be mounted to the ring. The junction box shall be provided with a twist-lock type receptacle capable of receiving the plug of the pigtail lead when testing the luminaries in the lowered position. Pre-wiring shall consist of Type “ST” distribution cable with the insulation suitable for at least 105 degrees Celsius and properly sized to power each luminaire. The terminal block shall contain a sufficient number of terminals to allow connecting all luminaries plus an approved lightning arrestor. The power cord shall be Type “G” or “type SEOOW” with five #8 133-strand copper conductors. Strain relie f shall be provided at both ends of the power cable by using properly sized cable clamps. The use of Kellem- type grips alone will not be allowed. The power cable shall be MSHA approved. (ii) All power cord connections shall be made using weather tight, twist-lock type plugs, connector bodies and receptacles. Connector bodies shall be as small as possible in physical size to prevent hang up inside the tower. (iii) Two 240 volt, 30 amp double pole circuit breakers shall be furnished in the base of each tower. Two 240 volt circuits will be run to each tower. Connect half the luminaries to each circuit in a manner that will provide an alternate feed to the luminaries.
5.The latch barrels, for a top latching system, shall be cast, high strength, and copper-free aluminum. Latching shall be accomplished by the alternate raising and lowering of the luminaire ring assembly using the winch and hoisting assembly. There shall be no moving latch parts or springs attached to the head frame assembly. The latch mechanism shall not be impaired by the formation of ic e and shall not require adjustment after the original installation. Indicator flags shall be used to show if the luminaire support ring is in a latched or unlatched position.
6.(i) The winch assembly shall consist of worm gear speed reducer with either one or two output shafts with cable drum attached. The winch shall be securely anchored and capable of supporting five (5) times the maximum lifted load. The winch shall include an integral drag brake to prevent unwinding, slipping or free-sp ooling of the winch cable. The drums shall be provided with keepers to ensure that the cable will properly wrap onto the drum. The winch, when powered by the Internal Power Unit, shall raise the luminaire ring at a minimum rate of 12 ft/min. (ii) Single drum units wi ll require the use of a transition device (clevis assembly) to properly attach the winch cable to the hoisting cables. The clevis shall not allow either the winch cable or any of the hoist cables to independently rotate. No bearings of any type will be allowed in the clevis. The clevis shall be beveled or tapered on the bottom of the plate to ensure that the transition device will not hang up on the inside of the tower.
7.(i) Means shall be provided to accurately position, stabilize and hold the luminaire ring in place when in the raised position. (ii) The luminaire ring shall be held in its raised position by either a top-latching or bottom tether ed system. If a top-latching system is supplied, each latch must be capable of supporting three (3) times the weight of the luminaire ring with its full complement of luminaires attached.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 936 - Rotation of the luminaire ring to achieve positive latching with this system will not be allowed. (iii) With the bottom tethered system, compression springs shall keep the luminaire ring assembly securely in place against the masthead while the load of the luminair e ring assembly is transferred from the winch assembly to chain or turnbuckle tension latches at the bottom of the tower. (iv) Latching or unlatching with either system shall impart no more than one “G” acceleration in any direction on the luminaires and lamps.
8.An Internal Power Unit shall be supplied with each lowering system supplied under this contract. The power unit shall be a heavy duty, reversing gear, single-phase motor, rated 1.8 peak HP or greater. The motor shall be operated by a push-button or lever control mounted at the end of a 20 ft. (min.) Type “SO” power cord.
9.The pigtail lead used to power the lowered light ring and internal motor when servicing shall be a minimum of 12 ft. in length. The female pigtail end shall be supplied with a weather-tight rubber cap. The cap shall protect the pigtail end when not in use and stored in the tower base. The rubber cap shall be loosely attached to the pigtail lead with a cord or other restraint to prevent its becoming lost.
10.Centering Arms or a rubber bumper ring shall be mounted to the inside of the luminaire ring to protect the tower, luminaire ring and luminaires from damage during raising and lowering. If Centering Arms are employed, they must be interconnected or of a design that precludes any possibility of the tower shaft slipping behind the arms and causing a “hang- up.”
11.(i) The manufacturer shall supply all drawings, installation instructions, maintena nce manuals and technical information required for the proper installation an d maintenance of a complete operating assembly. (ii) The entire assembly shall meet all applicable local, county, state and national codes.
12.The manufacturer shall guarantee all equipment from failure due to defects in material or workmanship for two (2) full years from date of shipment and shall warrant to repair or replace any equipment that fails within that time. In addition, the manufacturer shall provide a “Pass- Through Warranty” for use by the Electric al Contractor or Utility assigned by the State as maintaining authority (“P ass-Through Warranty” means that the manufacturer, manufacturer’s represent ative and distributor shall accept defective warranted material directly fr om the State’s appointed maintainer, on behalf of the State wi thout State personnel having to coordinate the return).
7.Roadway Lighting Luminaires: (Conventional and High Mast): a. Roadway lighting luminaires and lamps acceptable for use on State projects will be shown in the contract.
b.Luminaire type, wattage, and ballast ratings shall be as shown in the contract. Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 937 - c. Luminaires shall be supplied with lamps.
d.Luminaires must meet the design parameters shown in the contract.
8.Lighting Control Center : a. The lighting control center and components shall conform to the requirements shown in the contract.
9.Photoelectric Control:
a.Photoelectric controls shal l conform to the requirements shown in the contract.
10.Roadway and Sign Lighting Structures: a. All roadway and sign lightin g structures requiring galvanizing shall be galvanized in compliance with ASTM A 123 after fabrication and welding has been completed.
b.All hardware shall be galvanized in compliance with ASTM A 153.
11.Sign Lighting Luminaires: a. Sign lighting luminaires and lamps acceptable for use on State projects will be listed on the Department’s Approved Products List.
b.Luminaire, ballast, lamp dimensions, and ratings shall be as described in the contract.
c.The luminaire shall be furnished completely assembled and ready for mounting, connecting, and lamp installation.
d.Luminaires shall be U.L. label ed and listed as "Suitable for Wet Locations."
12.Electrical Items: All electrical items for roadway and sign lighting, such as wire, circuit breakers, relays, conduit, cable, mounting hardware, wood poles, pipe clamps, and related electrical material, shall conform to the appropriate National Electric Code requirements.
13.Traffic Signal Cable:
a.The traffic signal cable shall be as shown in the contract and shall comply in all respects with the IMSA specification as follows: Specification Reference Use 19-1 or 20-1 General Use 19-3 or 20-3 Aerial Cable 19-5 or 20-5 Direct Burial Cable
b.(1) Acceptable alternat ives to the above cable may be furnished providing the specific cabl e has been approved in writing by the office of the Department Traffic Engineer before its installation.
2.IMSA conductor color coding shall be used and will be provided by the use of base colored insulation.
3.This coloring shall penetrate the full thickness of all the conductor insulation.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 938 - (4) "Color" coding by the use of words or numerals printed on the insulation will not be accepted.
14.Electrical Wire and Cable:
a.Conductors and cables used for the electrical service shall conform to the applicable portions of Articles 230, 310, and 338 of the National Electrical Code (NEC) as well as to the requirements of the contract, and shall bear the U-L label.
b.The word "wire," when used in conjunction with roadway lighting, sign lighting, and traffic signal s, shall be taken to mean a single electrical conductor, either bare or insulated.
c.The word "cable," when used in conjunction with roadway lighting, sign lighting, and traffic signals, shall be taken to mean single electrical conductors, insulated from eac h other but laid up together by being twisted around a central core.
d.The word "conductor," when used in conjunction with roadway lighting, sign lighting, and traffic signals, shall be taken to mean either a single conductor (wire) or assembly of individual conductors (cable) capable of transmitting electricity.
15.Aerial Cable: Aerial cable (ACSR) shall meet or exceed the applicable sections of the following specifications:
a.ASTM B-232 Aluminum Conduc tors, Concentric-Lay-Stranded, Coated Steel Reinforced (ACSR)
b.ANSI/CEA S-76-474 16. Detector Lead-in Cable: The detector lead-in cable shall be polyethylene insulated, polyethylene jacketed cable conforming to the la test edition of IMSA Specification No. 50-2.
17.Loop Detector Wire: The loop detector wire shall be st randed, insulated wire rated at 600 volts for use in an inductance loop detector or as a lead-in wire. The wire shall comply with IMSA Specification 51-5.
18.Traffic Signals: a. Traffic signals shall be designed in die cast aluminum or polycarbonate sections. All sections shall be interchangeable and fit so they can be combined in a tier.
b.The mounting device, lens in dications, and other modifications shall be as shown in the contract.
c.The reflector shall be parabolic in design. d. Other parts of the optical system, including the lens lamp socket, reflector, and reflector holder, shall be designed as a whole system so as to eliminate the return of outside light rays which enter the unit.
e.All parts of the vehicle signals shall be in compliance with the ITE Standard “Vehicle Traffic Control Sign al Heads” Part 1 and Part 2, and Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 939 - all parts of the pedestrian signals shall be in compliance with the ITE Standard “Pedestrian Traffic Control Signal Indications”.
f.(1) The body, doors, visors, and backplates of the signals and all mounting accessories shall be colored flat black.
2.Die cast aluminum sectio ns shall be given 1 prime coat of metal primer and 2 coats of high quality flat black enamel.
3.Dipping will not be allowed for any part of the enameling process
4.The color shall be completely impregnated in polycarbonate material, and scratches shall not expose uncolored material.
g.Visors shall be attached with attaching screws and designed in a manner such that the visor may be easily installed or removed from the signal head.
h.A terminal block shall be mounted in the back of the second section of the signal head. The terminal block for a standard 3-section face shall be a 4-position, 8-terminal, barrier-type strip.
i.Hardware hinges shall be enclosed and have solid non- corrosive metallic hinge pins. Doors sh all be secured against gaskets with wing nut clamps.
j.All signals at each intersection shall be from one manufacturer unless otherwise approved by the Engineer.
19.Vehicle Signals: a. All lenses for incandescent signal lamps shall be prismatic and long range. The lenses shall have a nomin al diameter of 8 inch (200 mm) or 12 inch (300 mm) as indicated in the c ontract. All lenses shall be made of glass meeting the light transitivity and chromaticity standards established by ITE Standard “Vehicle Traffic Control Signal Heads”, Part 1 and Part 2.
b.Each signal lens, with the exception of lenses for optically programmed sections, shall have a visor of a type normally described as a tunnel visor which encloses 75% of t he lens circumference for the entire length of the visor.
c.Cutaway type visors shall be provided for each lens of optically programmed sections.
d.Vehicle signal heads shall be equipped with a one-piece, vacuum formed backplate. The backplate shall provide a black field border, 5 inches (125 mm) wide, around the assembly. Backplates are not required on single section heads, on 3 or 4 way heads, or on pole mounted heads.
e.Vacuum formed backplates are not required for signal heads with T51A, T51B, T52A, and T52B signal faces.
f.All vehicle signal indications, except optically programmed signal heads, shall be of the LED type, unless noted otherwise in the contract.
g.All LED signals shall be limited to those on the Department’s Approved Products List.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 940 - 20. Pedestrian Signals:
a.Pedestrian signals shall be a single section housing with a 12” (300 mm) high rectangular lens, with sun visor and mounting hardware.
b.The lens shall be made of vandal-resistant, polycarbonate or acrylic plastic.
c.The “DON’T WALK” symbol shall be displayed on the left side of the lens, and the “WALK” symbol on the right side of the lens.
d.The “DON’T WALK” symbol shall be orange and the “WALK” symbol shall be white. The background or field around the symbols shall be black. The “WALK” and “DON’T WALK” symbols shall conform to the MUTCD.
e.All pedestrian indications shall be of the LED type, unless noted otherwise in the contract.
f.All LED signals shall be limited to those on the Department’s Approved Products List.
21.Optically Programmed Traffic Signal: Optically programmed tra ffic signals shall be li mited to those on the Department’s Approved Products List.
22.Traffic Signal Lamps: The traffic signal lamps shall be clear and operate at 120 volts with an 8000 hour minimum rated life. All lamps shall have brass bases. All lamps shall be 150 watt for the 12 inch (300 mm) signal sections and 116 watt for the 8 inch (200 mm) signal sections. All lamps for pedestr ian signal heads shall be 116 watt.
23.Traffic Signal Controllers and Cabinets: a. Traffic Signal Controllers sha ll be either solid state pre-timed, NEMA vehicle actuated, or Type 170/ 2070 as indicated in the contract.
b.Solid state pre-timed controllers shall comply with all applicable sections of NEMA specification TS -1, including environmental and design standards. The controllers shall fulfill all functional requirements of electro- mechanical pre-timed controllers with the following additional features:
1.4 cycles.
2.3 offsets per cycle.
3.3 splits per cycle. (4) 24 intervals per split. (5) 24 signal circuits, minimum. (6) 4 signal plans. (7) 3 preemption sequences. (8) 2 detector inputs minimum.
c.All interval timing shall be operator settable from the front panel of the unit. A conflict monitor shal l be provided, either internal to the timer unit or shelf mounted. The controller cabinet shall be furnished with the number of load switches required to provide the sequence shown in the Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 941 - contract, but shall be capable of expansion to 24 signal circuits by the insertion of additional load switches.
d.Type 170 traffic signal controllers shall comply with FHWA Publication IP-78-16 except for the system memory module. The system memory module shall be a model 412B2 with one 256k, 200 ns, Nonvolatile SRAM.
e.Type 2070 traffic signal controllers shall comply with the State of California Department of Trans portation, Transportation Electrical Equipment Specificati ons (TEES) dated November 19, 1999 and all addendum publications to present date. The 2070 shall include one each of the following modules:
1.Model 2070-1B One Board CPU with removable data key and OS-9 operating system loaded
2.Model 2070-2A Field I/O for 170 Cabinet
3.Model 2070-3B Front Panel-Display B (8x40)
4.Model 2070-4 Power Supply (5) Model 2070-7A Serial Communications This configuration is often referred to as a 2070L. f. Cabinets for Type 170/2070 traffic signal controllers shall comply with FHWA Publication IP-78-16 with the following exceptions:
1.The standard gas tube arrestor shall not be used in the cabinet.
2.A 120 VAC, 60 amp Radio Interference Suppressor (RIS) shall be furnished between the service terminal block and the main circuit breaker. The RIS shall provide 50 decibel minimum attenuation over a frequency range of 200 kHz to 75 MHz. Two 130 VRMS MOV, having a transient energy dissipation of a minimum of 37 ft-lb (50j), shall be furnished between the load terminal and ground and between the neutral terminal and ground.
3.The Power Distribution Assembly shall be a PDA-2.
4.The AC Power to the controller receptacle, to the 24 Volt Power Supply, to the I/O files, and to the conflict monitor unit, shall be protected with an EDCO SHA1210 Series Parallel Protection Device, or approved equal. The device shall be located in the PDA-2 assembly.
5.Enclosure shall be unpainted aluminum. (6) Flash programming plugs shall be furnished for all vehicle phases.
7.Door locks shall be number two Corbin locks. (8) The conflict monitor unit shall be a Model 210, with one second delay on the Watchdog Timer, and a start-up timer compatible with 2070 controller boot-up.
9.The cabinets shall be furnished with a full complement of Flash Relays and Model 240 Flashers.
10.The cabinets shall have a ventilation fan baffle.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 942 - g. NEMA vehicle actuated controllers shall comply with NEMA Standards Publication TS-1 with the foll owing exceptions: Controllers shall be furnished in 4-phase and 8-phase cha ssis only. If the controller is phase modular, the unit shall be furnished with a full complement of phase modules. Conflict monitors for 4-ph ase controllers shall be 6 channel. Monitors for 8-phase controllers shall be 12 channel. Cabinets shall be wired for the maximum number of phases plus 2 overlap phases, but shall be furnished with only those load switc hes required to provide the sequence shown in the contract.
h.The controller and all auxiliar y equipment shall be housed in a weatherproof cabinet. The cabinet shall be of sufficient size to encase all control equipment and shall conform to the contract and the following requirements:
1.The cabinet size shall be as stated in the contract. The manufacturer shall insure that not more than 60% of the internal cabinet volume is occupied by the required traffic control equipment.
2.The cabinet shall be fabricated of high-grade aluminum alloy, sheet aluminum alloy, or rust -resistant copper bearing sheet steel.
3.Cabinets shall be primed and finished with 2 coats of resin base paint. The finishing coats of paint shall be aluminum or silver in color unless otherwise specified. Brushed al uminum cabinets need not be painted.
4.The cabinet shall contain a minimum of 2 metal shelves securely fastened to the side walls. The height and position of the shelves shall be easily changed or removed and replaced.
5.The cabinet shall employ a roof design that extends over the main door.
6.The main door of the cabinet shall substantially cover the full area of the front of the cabinet. This door shall be right hand hinged and allow complete access to the cabinet interior. A weatherproof and dustproof seal shall be provided between the door and cabinet using neoprene sponge or other approved gasket material.
7.A door stop shall be provided for base mounted cabinets, which securely holds the door at open positions of 90 and 135 degrees.
8.The door hinge pins shall be made of stainless steel. (9) A hinged auxiliary door of weatherproof design shall be provided on the front of the main door and shall be secured with a standard police lock furnished with 2 keys. The door shall house the switches described in the electrical design port ion of this cabinet specification.
10.All cabinets shall be secured using a Corbin No. 2 lock, or approved equal, and shall be provided with 2 keys.
11.Pad mounted cabinets shall be provided with a 3-point door latch mechanism with a handle in addition to the Corbin No. 2 lock, or approved equal. This handle shall be designed to accept a padlock.
i.(1) A thermostatically c ontrolled, ducted fan unit with a minimum rating of 100 ft³/min (2.83 m 3/min) in free air shall be installed in the cabinet to provide forced air ventilation through the cabinet. The fan unit shall be mounted to the inside top of the cabinet and shall be easily removed Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 943 - and replaced without having to dismantle any part of the cabinet or exhaust duct system.
2.The fan shall intake air th rough filtered vents located near the bottom of the cabinet or cabinet d oor and exhausts it through a screened duct located near the top of the cabi net. Fiberglass type dry filters shall be used to cover the cabinet's air intakes. These filters shall be easily removed and replaced and be of standard dimensions commercially available.
j.A heavy-duty clear plastic envelope, securely attached to the inside wall of the cabinet or cabinet door, shall be provided for stowing the cabinet electrical prints. Minimum dimensions shall be 7 inches (175 mm) wide x 7/16 inch (11 mm) deep.
k.The cabinets shall be furn ished with all of the hardware necessary for assembly and installation. The hardware shall include anchor bolts, anchor bolt template, pole mounti ng attachments, and all nuts, bolts, and washers necessary to assemble and install the cabinet as specified in the contract.
l.(1) The controller and all au xiliary equipment housed within the cabinet shall be designed to oper ate from 117 VAC 60 Hertz, single- phase, alternating current supply. Distrib ution of the 117 VAC throughout the cabinet shall not occur until the AC power has first passed through the power protection devices specified herein.
2.The power protection devices shall include the main AC power circuit breakers, radio interference suppressors, and lightning and surge protectors. These devices sha ll be in addition to any protection devices furnished with the controller and auxiliary equipment housed within the cabinet. The protection devices sh all be mounted to a panel that is securely fastened to an interior wall of the cabinet.
3.The AC power field service shall be connected directly to a circuit breaker. This circuit breaker shall be a single pole, nonadjustable, magnetic breaker rated for 117 VAC operations with a minimum rating of 50 amperes. It shall be equipped with a solder less connector suitable for terminating 6 gauge [0.184 inch (4.67 mm)] in diameter AWG wire. The circuit breaker shall be capable of manual operation and shall be clearly marked to indicate the "ON" and "OFF" positions.
4.Radio interference suppressors (RIS), adequate in number to handle the power requirements for the cabinet, shall be wired in series with and after the main AC power circuit breaker. The RIS shall be designed to minimize interference in all broadcast, transmission, and aircraft frequency bands.
m.As a minimum requirement, the lightning and voltage surge protectors shall be a combination of gas -type thyristors rated for 350 volts operation and metal oxide varistors rated for 150 volts. The combination shall be wired in advance of the main circuit breaker and shall provide a direct path to ground. Additional protection shall be provided on all loop detector input terminals.
n.(1) All cabinet wiring shall be neatly trained throughout the cabinet and attached to the interior panels using non-conductive clamps or tie-wraps. Bundles of cables shall be laced or tied every 4 inches (100 mm) or enclosed in a sheathing material. The cabinet wiring shall not interfere
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 944 - with the entrance, training, or connec tion of the incoming or outgoing field conductors.
2.Except where terminated by direct soldering, all wires shall be provided with terminal lugs for attachment to terminal blocks using screws. All wires shall be identified and labeled in accordance with the cabinet wiring prints.
3.All wire insulation shall have a minimum rating of 600 volts.
o.The outgoing signal indication conductors shall be of the same polarity as the line (+) side of the AC field service to the cabinet. The incoming signal indication conductors shall be common and of the same polarity as the neutral (-) side of the AC field service. The neutral (-) side of the AC field shall be connected to the cabinet in an approved manner, usually to the copper ground bus. The c abinet shall, in turn, be connected to an earth ground through a ground rod.
p.The flashing operating switch shall control the power and flash transfer relays. It shall be labeled "AUTO-FLASH". In the "AUTO" position, normal controller operation prevails. When placed in the "FLASH" position, AC power is transferred from the load switches to the solid state flasher which, in turn, flashes the signal in dications as specified. The vehicle detectors shall remain operational, but the AC power to the controller is interrupted.
q.The signal indication switch shall control AC power for the signal indications and shall not affect normal controller cycling. This switch shall be either a multipole toggle sw itch bussed together to obtain the required load rating or a circuit breaker. The minimum rating for the switch shall be 30 amperes and shall be labeled "SIGNALS-ON-OFF".
r.On the inside of the main door and accessible only when the main door is open shall be mounted a maintenance panel containing the test switches defined herein:
1.The controller test switch shall allow the controller to be turned on for test purposes when the "AUTO-FLASH" switch on the Police Panel has been placed in the "FLASH" position. The switch shall be labeled "CONTROLLER", "TEST", "NORMAL".
2.Detector test switches shall be used to manually place calls into the controller during actuat ed operation. These switches, one for each vehicle and pedestrian phase, shall be in parallel with the vehicle detector relay closure and pedestrian pushbutton circuits.
3.A 3-wire ground fault type receptacle shall be provided and be easily accessible. This receptac le and the incandescent lamp shall be separately fused from and wired in advance of the main AC power circuit breaker.
4.This assembly shall contain electromechanical relays used to transfer AC power and operation from the controller and load switches to the solid state flasher. This transfer relay assembly shall be controlled by either the "AUTO-FLASH" mode switch located on the Police Panel or the conflict monitor. The flasher shall re main operational with the controller removed from the cabinet. Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 945 - (5) The cabinet shall be wired to flash amber for the main street and red for the cros s streets. The red-yellow-flash indications shall be easily changed.
6.The plug-in transfer relays shall be rated at a minimum of 20 amps per pole and shall be enclosed in a transparent case for protection against dust and for visual observance of operation.
s.The cabinet shall be furnished with an incandescent lamp mounted near the top of the cabinet inte rior. This lamp shall be controlled by either a manual switch mounted on the maintenance panel or by the main door using a pushbutton, refrigerator-type switch.
t.The cabinet fan (solid state controller only) shall be separately fused and wired after the main AC power circuit breaker.
u.(1) Molded composition barri er type terminal blocks shall be used for termination of the incoming and outgoing signals within the cabinet assembly. Each terminal block shall be one-piece construction with a minimum of 12 terminals. Each terminal shall have a threaded contact plate with a binderhead screw. The terminal blocks shall have minimum rating of 600 volts.
2.All terminals shall be identified and labeled in accordance with the cabinet wiring diagram.
3.The terminal block facilities shall be arranged in functional groupings and mounted to either panels or brackets fastened to the interior walls of the cabinet. Each terminal block shall be retained using either machine or self-tapping screws and shall be easily removed and replaced.
v.Outgoing signal conductor terminals shall be provided for the vehicle and pedestrian signal circuits for each phase. The terminal blocks shall be of the barrier type using 6 gauge [0.184 inch (4.67 mm)] in diameter or larger binderhead screw s. These terminal blocks sh all be located near the bottom of the cabinet, a minimum of 6 inches (150 mm) above the bottom surface for base mounted cabinets and 2 inches (50 mm) for pole mounted cabinets. A minimum number of 2 a dditional terminal blocks shall be provided for future expanded operation.
w.Controller input/output circuit terminals shall be provided and connected for all of the controller inpu t and output circuits including those circuits which are not to be used on the project. The terminal blocks shall utilize 6 gauge [0.184 inch (4.67 mm)] in diameter or larger binderhead screws.
x.(1) A special panel shall be provided with terminal blocks for terminating all circuitry associated with vehicle detectors and pedestrian pushbuttons. These circuits shall be wired to their respective termination points within the cabinet and shall be operational. The terminal blocks shall use binderhead screws.
2.Terminals shall be provided for each vehicle detector including AC neutral, relay common, re lay closure, and the loops or probes from the field. Solid state lightning pr otection devices shall be provided for each loop input from the field. A minimum number of 2 additional terminal blocks shall be provided for future expanded detection.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 946 - (3) Terminals shall be provided for each pedestrian pushbutton circuit from the field.
y.Unfused terminals shall be provided for the neutral side of the AC field service and all common conductors within the cabinet assembly. This terminal strip shall be made of copper and use 6 gauge [0.184 inch (4.67 mm)] in diameter or larger screw s. The ground bus shall be located on the panel with the main AC power circuit breaker and provide a minimum of 18 terminals.
z.The cabinet shall be wired for the maximum operation of the control unit including overlap and pedestrian phases. It shall only be necessary to add plug-in cabinet accessories (i.e., load switches, flash transfer relays, etc.) to obtain future operation. aa. All load switches shall conf orm to the triple-signal solid state type load switch as specified in the NEMA Standard Publication No. TS-1. Dual-signal type load switches shall not be allowed.
24.Vehicle Detector Amplifier: a. Integrated circuits and/or discrete semiconductor devices and resistors, capacitors, transformers, etc. shall be used throughout the detector amplifier instead of vacuum or gaseous tubes and electromechanical devices except for the indicator lights and detector amplifier output replay. Logic design shall be such as to insure maximum noise immunity.
b.All solid state components sh all be amply derated with respect to heat dissipating capacity and rated voltage. Shortening of component life or shift in values shall not occur at maximum operating temperature and voltage. The design life under continu ous duty operation shall not be less than 5 years.
c.(1) All solid state components shall be individually replaceable and shall be readily available from any industrial electronics supply house.
2.The solid state compone nts used in the design of the amplifier shall be mounted on printed circuit (PC) boards. The PC boards shall be fabricated from glass-epoxy laminate, NEMA grade G-10, with a minimum thickness of 1/16 inch (1.5 mm). Intercomponent circuit traces shall be copper track, with a minimu m weight of 2 oz/ft² (605 g/m
2.and shall be of adequate cross-sectional area to carry the designed current. All holes in the PC board utilizing intercomponent circuit traces on 2 sides shall be plated through.
3.All solid state components mounted and soldered to the PC board shall be easily removed and replaced without causing damage to the board or tracks.
4.All solid state components contained on the PC board shall either have their circuit reference symbol clearly marked on the board or be easily identifiable by referring to pictorial assembly drawings.
5.The vehicle detector amplifier defined in these Specifications shall maintain normal operation over all combinations of temperature and voltage ranging from 105 to 136 VAC and -30°F to +165°F (-34C to +74 C) ambient. The use of auxiliary heating and cooling devices Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 947 - which would reduce the operational temperature range in order to achieve satisfactory performance shall not be allowed.
6.The amplifier shall have a light for each detection channel to indicate vehicle detection. All indicator lights shall have a minimum design life of 20,000 hours at rated voltage a nd shall be easily replaceable. All indicator lights, when illuminated, shall be visible in bright sunlight.
7.All tuning and/or sensitiv ity adjustment shall be made from the front of the enclosure without the use of tools. The connector and the tuning and detection indicators s hall be mounted on the front of the enclosure.
8.Service personnel shall have complete access to any part of the detector amplifier assembly for test and/or maintenance without affecting the warranty.
25.Loop, Vehicle Detector Amplifiers: a. Loop, vehicle detector, ampl ifiers shall be of Type 170 or NEMA shelf mounted type as required by the controller with which it will be used.
b.Type 170 loop amplifiers shall be model 222 and shall comply in all respects with FHWA publication IP-78-16.
c.NEMA Type loop amplifiers shall conform to the following requirements:
1.Sensitivity shall be selective for a minimum of 3 positions in regular increments.
2.All electrical connections and adjustments shall be made on the front panel without the use of special tools. Connection shall be made using an MS 3102 A18-1P connector.
3.No burn-in or warm up ti me shall be required before the detector amplifier is fully operational.
4.The loop detector amplifier shall operate properly despite resistive leakage or total grounding of the loop.
5.Loop detector amplifiers with more than one detection channel shall have lightning protecti on on each channel separately with complete immunity to crosstalk between channels. Each detection channel shall be electrically connected through a separate MS 3102 A18-1P connector. Mode of operation and sensitivity adjustments shall be independent between channels. Multiple channel detection amplifiers shall also comply with all other cond itions of these Specifications.
6.The loop detector amplifier shall provide a minimum of 2 modes of operation. The pulse or pr esence mode shall be switch selective on the front panel.
7.The loop detector amplifier shall produce an output pulse of 100 milliseconds duration for each vehicle entering the detection zone. Any vehicle stopped on the loop for 2 seconds or more shall be automatically tuned into the resonant circuit so that any unused portion of the loop may detect passing vehicles.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 948 - (8) The unit shall provide a det ection output for as long as the vehicle remains in the detection area or for at least 10 minutes after which it shall be incorporated in the backgro und inductance so that any unused portion of the loop may detect passing vehicles.
9.The loop detection amplifier shall employ a digital self- tuning system which is activated aut omatically with each application of power. That is, it shall self-tune duri ng the process of connecting the mating connector and immediately following any power failure. The unit shall automatically return to the correct tuning level after a vehicle which has been incorporated into the background inductance moves away. Automatic and continuous fine tuning shall be featured to correct for the environmental drift of the loop impedance.
10.The output relay shall be a failsafe relay (SPDT) with a contact rating of at least one ampere at 117 VAC. If specifically stated, the output shall be failsafe solid state sw itch, zener protected for 40VDC at 0.25 amp.
11.Each vehicle detector amplifier shall be enclosed in a sheet aluminum case with a durable protective finish. This enclosure shall be easily removed allowing convenient access to the solid state circuitry. All electrical connections to the device shall be made using type MS multipin threaded shell connectors. The mating MS plug receptacle shall be attached to one end of a connecting cable at least 30 inches (750 mm) long.
26.Magnetic Vehicle Detector Amplifiers, Type 170: a. Magnetic vehicle detector amp lifiers shall be either a Type 170 card rack mounted or NEMA shelf mounted as required by the type of controller with which they are to be used.
b.Type 170 magnetic detector amplifiers shall be model 232 and shall comply with FHWA publication IP-78-16.
c.Magnetic amplifiers for use with NEMA controllers shall conform to the following requirements:
1.Detection is achieved by monitoring the earth's magnetic field. The earth's magnetic field is momentarily disturbed where a vehicle passes within close proximity of the det ector. This disturbance will induce a signal voltage in the coil which is applied to the amplifier input.
2.The unit shall be designed to provide amplification of the signals produced by all vehicles ranging in size from a motorcycle to a tractor-trailer traveling at speeds of 5 MPH (8 km/h) or greater over the magnetic detector.
3.The unit shall be designed to operate satisfactorily with the magnetic detector supplied.
4.The amplifier shall be provided with an indicator light that is visible from the front of the case and will light momentarily to indicate an actuation. It shall be provided with a knob on the front of the case for adjusting the degree of amplification of the electrical energy from the detector. On the front of the unit adja cent to the adjustment dial and MS connector, there shall be mounted 2 test jacks labeled J101 and J102 for the purpose of checking the proper adj ustment of the s ensitivity knob. Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 949 - (5) The registration of over lapping impulses from 2 detector relay units shall be ensured by the use of normally open and normally closed contacts provided on the out put relay. Any contact t hat opens or closes in response to vehicle actuations shall be capable of making, breaking, and carrying 3 amperes at 120 Volts AC.
6.The amplifier circuits shall be designed using semiconductor devices and shall o perate with maximum stability and reliability under conditions of line vo ltage fluctuation up to 5%. Circuits employing printed circuits shall be of the highest quality with extra-heavy [2 oz/ft² (605 g/m2) or better] copper.
7.The amplifier shall be de signed for operation at 120 volts, 60 cycle, single phase. Maximum power consumption shall not exceed 5 watts and shall be suitably enclosed in a durable, protective case. It shall be supplied for plug connection.
8.All circuits shall be designed to provide stable operation within an ambient temperature range of -30°F to +180°F (-34 C to +82 C).
9.(i) The unit shall be housed in a durably finished fabricated sheet aluminum case. (ii) Removal of the unit from its case shall require the use of simple tools. The removal of 2 screws shall allow access to the printed circuit panel and components. (iii) Electrical connections of both the incoming and outgoing circuits shall be made by means of an 8 terminal MS type plug. The unit shall be replaceable with a similar unit without the necessity of disconnecting or reconnecting individual wires leading from the unit. The type MS plug shall be a protected male plug and shall be rigidly fixed to the front of the unit. (iv) The mating MS plug receptacle shall be attached to one end of the connecting cable and be at least 2 feet (600 mm) long. The other end of the connecting cable shal l have tagged leads, each of which shall be fitted with a spade type lug for easy attachment to the terminal blocks.
27.Vehicle Detector-Magnetic, Type TD-3: a. This Specification defines the minimum detailed requirements applicable to the magnetic vehicle dete ctor. The detector will operate on the principal that all vehicles create thei r own magnetic fields as they move through the earth's magnetic field. This causes an induced voltage in the coil of the detector. The volta ge is amplified by a device and actuates a relay to operate the controller.
b.Operational Features: (1) The magnetic detector shall be designed for installation in or near the roadway, capable of being actuated by the magnetic or electrical disturbance caused by the passage of a vehicle.
2.The operation of the det ector shall not be affected by parked cars or other stationary meta llic objects in or upon the roadway.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 950 - (3) The detector, when used with the proper amplifying device, shall be capable of actuation by any vehi cle passing the detector at the distance and speeds indicated below:
i.At a speed of 12 MPH to 80 MPH (20 km/h to 130 km/h)--within 15 feet (4.6 m) of the detector. (ii) At a speed of 7 MPH to 80 MPH (12 km/h to 130 km/h)--within 10 feet (3 m) of the detector. (iii) At a speed of 3 MPH to 80 MPH (5 km/h to 130 km/h)--within 5 feet (1.5 m) of the detector.
c.Mechanical Requirements: (1) The detector shall have sufficient mechanical strength to withstand normal handling and the transmitted shock of vehicular loads when installed in accordance with the manufacturer's instructions.
2.The detector shall have a moisture-proof housing designed for underground operation. T he detector's operation shall not be affected by temperature, humidity, or soil conditions.
3.The detector shall be provided with means for making a waterproof connection to the cable or closed conduit system and shall be provided with insulated leads at least 50 feet (15 m) long.
4.The detector shall be designed for use with one or more types of devices for amplifying, rectif ying, or otherwise intensifying the electrical energy produced by the detector.
28.Pedestrian Pushbuttons:
a.Pedestrian pushbuttons shall be of the type and style specifically intended for the application shown in the contract. They shall be housed in a durable casting and be weather tight. The button and mechanism shall be of sufficient size and rugged design to withstand some abuse and discourage vandalism. The internal switching device shall be closed by physical contact with the button.
b.Signs shall be provided for mounting directly above the pedestrian pushbuttons indicating which pedestrian signal is associated with that particular button. These signs s hall be of the size, type, and style specifically intended for that purpose and shall be provided by the manufacturer of the pedestrian pushbuttons. Each sign shall include an arrow to indicate the direction of t he crossing to which the button applies.
29.Hardware: a. All ferrous bolts, nuts, clamps, miscellaneous hardware, and fittings shall be galvanized according to ASTM A 153.
b.All other material or fittings necessary to complete the work shall be approved by the Engineer.
c.Saw cuts and holes made in the roadway for installation of vehicle detectors shall be sealed with a sealant that is on the Department’s Approved Products List.
d.Chemical and physical proper ties of sealants are similar, but the potting and hardening time varies with temperature and composition of the particular mix. The Contractor shal l assume responsibility for the type of Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 951 - sealant used on a particular project under the prevailing environmental conditions.
e.Approval of other seal ants will be determined from the manufacturer's technical information and actual samples taken and tested by the Department before installation.
30.Traffic Signal Poles: a. This Specification sha ll be intended as the minimum requirements for furnishing mast arm and span wire signal poles of various sizes with and without lighting. Each signal pole supplied for installation shall conform to the contract and these Specifications.
b.(1) Each pole shaft, luminaire extension, luminaire mast arm, and signal mast arm shall be formed of proper steel to a tapered shaft and shall have only one longitudinal automatic electric weld. Each steel shaft shall be treated after forming and welding to flatten the weld.
2.Each pole shaft, lumina ire extension, signal arm, and luminaire arm shall be furnished with all miscellaneous hardware necessary to complete the signal po le assembly. Miscellaneous hardware shall include pole caps, hand hole covers, anchor bolt covers, anchor bolts, and all bolts, nuts, and washers necessary to complete the signal pole assembly and installation.
3.A one-piece steel anchor base of adequate strength, shape, and size shall be secured to the lower end of the shaft by 2 continuous electric arc welds. The bas e shall telescope the shaft. One weld shall be on the inside of the base at t he end of the shaft, while the other weld shall be on the outside at the top of the base.
4.A grounding nut for accommodating a 6 gauge [0.184 inch (4.67 mm)] diameter bare copper wire sh all be provided on the inside of the shaft 8 inches (200 mm) above the bottom weld joining the shaft to the anchor base. The grounding nut shall be mounted directly opposite the hand hole opening and shall not be allowed on the hand hole frame.
5.When specifically required by the contract, a transformer base shall be provided. In such case, the hand hole in the pole shaft is not required and the grounding nut shall be located in the transformer base.
c.Anchor Bolts: (1) Anchor bolts shall be supplied by the pole manufacturer. The manufacturer shall certify that th e bolts are of adequate strength to resist the loading required in these S pecifications and the Nebraska Signal Pole Standard.
2.All anchor "J" bolts shall comply with the “Traffic Signal Pole Details” Standard Plan and be 1.65 inch (42 mm) diameter by 4.5 feet (1.37 m) long with a 6 inch (150 mm) hook. Each anchor bolt shall be threaded and galvanized to a length that will insure that all parts of the bolt exposed after installation are galvanized. Threads shall be rolled. Each anchor bolt shall be furnished with 2 hexagon nuts and 2 flat washers.
d.A removable pole top shall be furnished with pole shafts and luminaire extensions complete with a positioning cap screw.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 952 - e. A plate shall be welded interior to the top of each pole shaft for mounting a luminaire extension. The bol t circle shall be 5.5 inches (140 mm) in diameter. 4 holes shall be drill ed and tapped to accommodate 1 inch (25 mm) bolts. A 3 inch (75 mm) diameter hole shall be prov ided in the middle of the plate for passage of electrical cable.
f.Signal mast arm and luminaire arms shall be furnished with a clamp-on mounting device suitable for attaching the arm to its respective shaft at the height specified. The cl amp-on mount shall be structurally sound and neat in appearance. The signal arm mount shall provide a minimum 2% rise and a maximum 4% rise for each loaded signal arm or shall be adjustable in the field.
g.Hand holes:
1.All hand holes shall be reinforced to maintain full strength of the steel shaft. Hand holes shall have a minimum opening of 4 inches x 6 inches (100 mm x 150 mm). Hand hole covers of a weatherproof design shall be supplied by the pole manufacturer.
2.Mounting of the grounding nut on the hand hole frame shall not be allowed.
3.The bottom of the hand hole opening shall be at least 3 inches (75 mm) above the top of the base.
h.Signal arms, luminaire arms, luminaire extensions, and pole shafts shall be supplied with 1 inch (25 mm) I.D. rubber grommets as shown on the pole standard plan. Signal arms shall also be supplied with 1 inch (25 mm) I.D. rubber grommets for the number of signals specified in the loading chart in the contract. Cable inlet holes shall be drilled in the field by the Contractor.
i.(1) Each pole shaft, luminaire extension, luminaire arm, and signal arm shall be galvanized to comply with ASTM A 123.
2.All miscellaneous hardware shall be galvanized in accordance with ASTM A 153.
j.Loads:
1.The pole shall be designed to support the signal load shown in the contract plus one additional signal head per span and shall withstand wind velocities up to 100 mph (160 km/h). The design weight of the signal head shall be 75 pounds (34 kg) with a surface area of 7 square feet (0.65 m 2).
2.The poles shall be designed to support the required signal and luminaire load, mast arms with 10 p ounds of ice per linear foot (15 kg of ice per linear meter), and signal and lighting cables while withstanding winds with velocities up to 100 MPH (160 km/h).
3.The pole shaft and signal mast arm shall be designed to support either a 2 or 3 signal head load as indicated in the contract with 12 feet (3.65 m) of separation.
k.The manufacturer shall stat e the necessary amount of pole- rake necessary for the pole to set plumb under the required signal and lighting load in the contract. Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 953 - l. A certificate of compliance ve rifying the adequacy of the signal poles and their conformity to these Specifications shall be submitted to the Department Traffic Engineer. The certificate shall state that the pole and anchor bolts shall not fail under the loading requirements of these Specifications.
31.Pedestal Traffic Signal Pole: a. Pedestal traffic signal poles shall consist of a threaded aluminum or steel shaft and an appropriate threaded base, together with anchor bolts to provide the mounting he ight and accept the traffic signal hardware as shown in the contract.
b.The pedestal pole assembly shall have the characteristic of yielding under impact when struck by a motor vehicle to cause a minimum deceleration effect upon the vehicle so as to reduce vehicle damage and personal injury potential. This yielding characteristic shall be provided by a breakaway base constructed of cast al uminum which shall be of such design that adequate static strength is maintained to support the pole, traffic signal, and mounting hardware along with ice and wind loadings.
c.The base shall be approximately 18 inches (450 mm) high and not more than 17 inches (425 mm) in diameter at the bottom.
d.The base shall have an opening on the side of not less than 40 square inches (25,800 mm
2.which is covered by a door secured with a stainless steel screw.
e.There shall be a grounding nut located inside the base directly across from the opening and sized to accommodate a 6 gauge [0.184 inch (4.67 mm)] diameter bare copper conductor.
f.If the Contractor elects to fu rnish and install aluminum pedestal poles, they shall be fabricated from spun seamless tubing conforming to ASTM B 210M, Aluminum Alloy 6063-T6.
g.If the Contractor elects to furnish and install steel pedestal poles, they shall be fabricated in accordance with the applicable requirements of Paragraphs 5. and 6. of this Subsection.
32.Wood Poles: a. Poles shall be Southern Yellow Pine or Douglas Fir of the Coast Region. Poles shall conform to American Standard 05.1 and shall be the length and class shown in the contract.
b.The preservative treatment shall be by the Empty-cell (Rueping) or Full-cell (Bethell) Process, whichever applies, and shall conform to the requirements specifie d in Standard C4 of the American Wood-Preservers' Association, with the exception that creosote is excluded.
c.Southern Yellow Pine poles [ up to 45 feet (13.7 m)] shall be treated with not less than 0.38 pound (6 .0 kg) of pentachlorophenol or 0.60 pound (9.6 kg) of ammoniacal copper arsenate (ACA), or chromated copper arsenate (CCA) per cubic foot (meter) of timber.
d.Southern Yellow Pine poles [45 feet (13.7 m) and larger] shall be treated with not less than 0.45 pound (7.2 kg) of pentachlorophenol or 0.60 pound (9.6 kg) of ammoniacal copper arsenate (ACA) or chromated copper arsenate (CCA) per cubic foot (meter) of timber.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 954 - e. Douglas Fir poles shall be treated with not less than 0.60 pound (9.6 kg) of pentachlorop henol, ammoniacal copper arsenate (ACA), or chromated copper arsenate (CCA) per cubic foot (meter) of timber.
f.The pentachlorophenol, ammoniacal copper arsenate, and chromated copper arsenate shall meet the requirements of Section 1076.
g.Poles to be treated with ammoniacal copper arsenate or chromated copper arsenate shall be dried to the fiber saturation point required to put the timber into satisfactory condition to accept the preservative and attain the required pr eservative retention and penetration. After treatment, the poles shall be re-dried and have a moisture content of not more than 30% at the time of shipment to the job site.
h.Each pole shall be marked in accordance with requirements of American Standard 05.1. The marking on the face of the pole shall be located approximately 10 feet (3 m) above the butt of the pole.
i.Poles shall be carefully selected for straightness.
j.Poles in line shall not have sweeps and short crooks exceeding 50% of the maximum sweeps and short crooks allowed in the American Standard and shall present a neat appearance after installation.
k.The number of poles containing the maximum sweeps and short crooks allowed in the American St andard shall be kept to a minimum. These poles shall be installed in locations where they will not detract from the general appearance of the line of poles.
l.Poles that are to be given a full-length preservation treatment shall be roofed, gained, and bored before treatment.
m.Gains shall be cut on the face (concave side) or side of greatest curvature in poles having reverse or double sweep between the ground line and the top of the pole, a nd the gained surfaces shall be in approximately parallel planes.
n.Poles stored for any reason more than 2 weeks shall be stacked on creosoted or decay-resisting skids of such dimensions and so arranged as to support the poles without producing noticeable distortion in any of them.
o.Poles shall be stored to allo w free circulation of air, and the bottom poles of a pile shall be at least 1 foot (300 mm) above the ground level or any vegetation.
p.No decayed or decaying wood shall be allowed to remain underneath stored poles.
q.Treated poles shall not be dragged along the ground. r. Pole tongs, cant hooks, and other pointed tools capable of producing indentations more than 1 inch (25 mm) in depth shall not be used in handling the poles.
s.No tools shall be applied to the groundline section of any pole. The groundline section is that por tion between 1 foot (300 mm) above and 2 feet (600 mm) below the groundline.
t.The basis of acceptance of wood poles shall be as described in Section 1075. Roadway Lighting, Sign Lighting, and Traffic Signals 1073.02 - 955 - 33. Anchors for Guy Wires:
a.Anchors for guy wires shall have a 8 inch (200 mm) minimum diameter and shall be a type approp riate for the soil conditions.
b.Anchor rods shall be 5/8 inch (16 mm) galvanized steel rods 8 feet (2.4 m) in length with a thimble eye end.
c.Guy guards shall be half-ro und galvanized metal guards 8 feet (2.4 m) in length.
d.Bonding clamps shall be galvanized clamps providing a continuous column of metal wedged solidly between the anchor rod and the guy strand. Bonding clamp expansion shall be accomplished by tightening a set screw.
34.Span and Tie Wire: Span wire and tie wire shall conform to the requirements of Section 1062.
35.Coaxial Cable:
a.Coaxial cable shall be 75 ohm RG 59/U Type or RG 11/U Type.
b.The conductor shall be solid or stranded copper. Minimum conductor size shall be 22 AWG for installations where the distance between the controller cabinet and the video ca mera is less than 200 feet (60 m); 20 AWG for distances less than 2000 feet (610 m); and 14 AWG for distances less than 3000 feet (910 m).
c.The insulation shall be polyethylene. d. The shield shall be braided bare copper.
e.The jacket shall be black polyethylene or black polyvinylchloride.
f.The finished outside diameter of the cable shall not exceed 0.405 inch (10 mm).
g.The contractor shall furn ish and install a BNC connector on each end of the cable.
36.Optical Detector Cable
a.Optical Detector Cable shall meet the requirements of IPCEA-S-61-402/NEMA WC 5, Section 7.4, 600 volt control cable, 75 degrees Celsius, Type B.
b.The cable shall contain 3 conductors, each of which shall be #20 AWG (7x28) stranded, tinned copper with 25 mil (630 m) minimum average thickness low-density polyethylene insulation. Insulation shall be color-coded: 1-yellow, 1-blue, 1-orange.
c.The shield shall be aluminized polyester film with a nominal 20% overlap. A #20AWG (7x28) stranded, tinned, bare drain wire shall be placed between the insulated conductors and the shield and in contact with the conductive surface of the shield.
d.The jacket shall be black PVC with minimum ratings of 600 volts and 175 F (80C) and a minimum thickness of 45 mils (1100 um). The jacket shall be marked as required by IPCEA/NEMA.
1073.02 Roadway Lighting, Sign Lighting, and Traffic Signals
- 956 - e. The finished outside diameter of the cable shall not exceed 0.35 inch (9 mm).
f.The capacitance as measured between any conductor and the other conductors and the shield shall no t exceed 40 pico farads per foot at 1000 Hz.
1073.03 Acceptance Requirements
1.All items described in this Se ction are accepted as described or as indicated in the Department’s Materials Sampling Guide . - 957 - SECTION 1074 -- GABIONS AND REVET MATTRESSES
1074.01 Description
1.Gabions and revet mattresses are generally used for erosion and earth control.
1074.02 Material Characteristics
1.Wire coatings shall be as described in the contract.
2.The size of the stone for gabions shall be 4 inches to 8 inches (100 mm to 200 mm) in diameter. The size of the stone for revet mattresses shall be 3 inches to 6 inches (75 mm to 150 mm) in diameter. The maximum length of stone shall not exceed 16 inches (400 mm). The maximum weight for any one stone shall not exceed 6.0 pounds (2.7 kg).
3.Approved stone is defined as that meeting the requirements of Paragraphs 1., 3., and 4. of Subsection 905.02.
1074.03 Acceptance Requirements
1.Acceptable gabions and revet mattresses are shown on the Department’s Approved Products List.
Source: Nebraska Standard Specifications for Highway Construction, 2017 Edition. Pages 962–990 of 1,048.