701General Items

701.01DESCRIPTION

This Section describes the requirements for constructing or installing various electrical Items.

701.02MATERIALS

.01 Materials

Provide materials as specified in: Coarse Aggregate (No. 57) ................................ ................................ ................................ ........................... 901.03 Concrete ................................ ................................ ................................ ................................ ...................... 903.03 Grout ................................ ................................ ................................ ................................ ................... 903.08.02.A CLSM ................................ ................................ ................................ ................................ .......................... 903.09 Precast Concrete................................ ................................ ................................ ................................ ........... 904.01 Reinforcement Steel ................................ ................................ ................................ ................................ ..... 905.01 Miscellaneous Hardware ................................ ................................ ................................ ................................ ... 908 Anchor Bolts ................................ ................................ ................................ ................................ ............ 908.01.03 Pipe Bedding................................ ................................ ................................ ................................ ................ 909.01 Junction Box Frames and Covers ................................ ................................ ................................ .................. 909.03 Coal Tar Epoxy Paint ................................ ................................ ................................ ............................... 912.01.03 Conduit and Fittings ................................ ................................ ................................ ................................ ..... 918.01 Cable and Wire ................................ ................................ ................................ ................................ ............ 918.02 Multiple-Lighting and Service Wire................................ ................................ ................................ .......... 918.02.03 Bonding and Grounding Materials ................................ ................................ ................................ ................ 918.03 Resin Splicing Kits ................................ ................................ ................................ ................................ ....... 918.05 Electrical Tape ................................ ................................ ................................ ................................ ............. 918.06 Cable Racks ................................ ................................ ................................ ................................ ................. 918.07 Cast Boxes and Fittings ................................ ................................ ................................ ................................ 918.08 Provide materials as specified in the Contract and in the New Jersey Electrical Materials Specifications that are available on the Department’s website. A listing of pre-qualified materials is also available from the Department’s website. The Department will allow the use of pre-qualified materials provided the materials meet the requirements of the Contract. Submit materials for a pproval on a Materials Questionnaire as specified in 106.04. Include working drawings for certification with the Materials Questionnaire for materials not pre-qualified. Follow the accepted standards of ANSI, NEMA, UL, NEC, ITE, and ASTM for materials not specified in the Contract. Provide nylon cable ties with a tensile strength of 120 pounds. Provide true tape with a tensile strength of 130 pounds.

.02 Equipment

Provide equipment as specified in: Vibrator ................................ ................................ ................................ ................................ ...................... 1005.04 Concrete Batching Plant ................................ ................................ ................................ .............................. 1010.01 Concrete Trucks ................................ ................................ ................................ ................................ .......... 1010.02 328

701.03CONSTRUCTION

.01 Existing Systems

Follow the accepted standards of ANSI, NEMA, UL, NEC, ITE, and ASTM for construction operations not specified in the Contract. Ensure that the work complies with the requirements of the Utilities having jurisdiction at the device location. At least 30 days before starting work on an existing system, submit a plan to the RE for approval that includes the proposed construction methods and describes how the existing sys tems will be maintained, modified, or operated during the performance of the work. Systems are comprised of one or more new or existing Items to provide a fully functional operation. At least 20 days before starting work on an existing system, provide not ification, as specified in 105.07, and arrange a meeting with the Department to verify the operational status of the existing systems and responsibilities for maintenance. Document the findings of the meeting and forward a written summary to the attendees. If work is performed on or damage occurs to an electrical system before the meeting with the Department, the Contractor assumes maintenance responsibility for that electrical system. Do not interfere with the operation of existing systems that are not designated for modification or removal. If removal of existing above ground electrical material is required, deliver salvaged materials to the nearest Department electrical maintenance yard and unload the salvaged materials as directed. Dispose of salvaged materials rejected by the Department from the Project Limits as specified in 201.03.01.H. Provide connections and coordination with utility services as specified in 701.03.15.C.

.02 Rigid Metallic Conduit (Earth)

trenches only for distances to be installed and backfilled during the same day. Prepare the trench bottom to eliminate lumps, ridges, and hollows.

Do not use disc grinders to cut conduit. Cut conduit square and true and ensure they butt toget her over their full circumference. Ream rigid metallic conduit ends, whether shop or field cut, to remove burrs and rough edges. Thread rigid metallic conduit ends according to NEMA standards, and provide the free ends with grounded -type insulated bushings. For rigid metallic conduit with a diameter less than 1 inch, the Contractor may provide impact-resistant plastic, insulating bushings and bond lock nuts. Thread bonding bushings on the free ends of the conduit and lock bushings in place with set screws. Coat ungalvanized threads on rigid metallic conduit resulting from field cuts and places where the galvanizing on the conduit or fittings has been damaged with a compound that is electrically conductive and prevents oxidation. Construct a conduit run with at least 10 foot sections. The Contractor may use a shorter section to complete a conduit run into a foundation or junction box. Cap conduit that does not terminate in a junction box at the end of the workday. If unable to use a standard coupling, use a UL-approved, concrete-tight compression coupling with a permanent stop. Do not use reducing couplings, except for expansion joints on bridges if necessary, to adapt a service conduit to the meter cabinet. Do not use couplings that use set screws. Do not use slip joints or running threads to couple rigid metallic conduit. Make field bends to rigid metallic conduit with an industry-accepted hydraulic conduit bender. Provide a radius of at least 9 times the inside diameter of the condui t. Do not install more than two 90 degree bends between junction boxes, pull boxes, and foundations. Ensure that bends and elbows used in service conduit conform to the Utility requirements. Ensure that conduit used for fiber optic cables meets the minimum bend and radius requirements as specified in the Contract and as required by the fiber optic cable manufacturer. When installing rigid metallic conduit in structures, rigidly support the conduit before placing concrete. Install expansion joint fittings at structure expansion joints. 329 If installing conduit in existing junction boxes, cut additional holes in the junction boxes to admit the conduit. Grout around conduit installed in junction boxes before installing wire or cables. If unable to install conduit with sufficient grade to provide drainage, install T-drains consisting of standard pipe tee and nipple for conduit at the lowest point of the conduit run. Seal the underground conduit entrance to the meter cabinet and the wire entrance to the controlle r cabinet with a sealing compound. Clean conduit runs, including existing conduit to be used. After cleaning, test each conduit by pulling through a metal ball with a diameter at least 85 percent of the nominal inside diameter of the conduit, to ensure that the conduit is free of any obstruction or foreign material. If the ball fails to pass through the conduit, repair or replace the defective conduit. Install a 130 pound average breaking strength true tape marked in 1 foot increments for the length of th e conduit. Cap and seal the conduit leaving the tape inside. In rigid metallic conduit used exclusively for fiber optic cable, install a tracer wire continuously for the entire run of conduit, including through the junction boxes, mounting it on the wall. Splice the tracer wire only in the junction box. Seal the ends of rigid metallic conduit carrying the tracer wire. If wire or cable is not scheduled to be installed within 6 months of conduit installation, cap and seal the other conduits leaving the true tape inside. Install warning tape in the trench above the conduit.

Backfill with suitable excavated material that is free from rock larger than 2 inches in diameter in lifts not exceeding 6 inches thick, loose measurement. If the excavations do not provide sufficient material of the quality required for backfilling, provide and place the material necessary to make up the deficiency. Compact the backfill using the directed method as specified in 203.03.02.B.3. Restore the disturbed areas to original conditions, the conditions specified in the Contract, or as directed by the RE.

.03 Rigid Metallic Conduit (Roadway)

Comply with the requirements specified in 701.03.01. Submit working drawings for approval, detailing the proposed method of jacking or directional drilling. Ensure that jacking or drilling and receiving pits are not within 2 feet from the edge of the pavement. Excavate the pits as specified in 202.03.02. Ensure that the force of the jacks is transmitted uniformly to the end face of the end pipe. Replace end sections of pipe that are damaged during jacking. If obstructions are encountered during conduit installation, submit a new working drawing for approval detailing an alternate method of installation. This may include moving the location (horizontally and vertically). If the alternate method is unsuccessful, the RE may allow the Contractor to use the open-cut method to excavate as specified in 701.03.02.A except sawcut the pavement full depth and no wider than 2 inches greater than the proposed conduit diameter. Excavate the trench, place and maintain the conduit in the center of the trench and fill the trench with CLSM to the bottom of the pavement structure. Replace the existing pavement structure in kind. Remove unsuccessful conduit and grout any voids left by the jacking or drilling operations as directed by the RE. The Contractor may leave the unsuccessful conduit in place if approved by the RE. Note these sections of conduit on the as -builts as abandoned. Restore disturbed areas to original conditions, the conditions specified in the Contract, or as directed by the RE. Ensure that jacking or drilling and receiving pits are not within 2 feet from the edge of the pavement. In rigid metallic conduit used exclusively for fiber optic cable, install a tracer wire continuously for the entire run of conduit, including through the junction boxes, mounting it on th e wall. Splice the tracer wire only in the junction box. Seal the ends of rigid metallic conduit carrying the tracer wire. If wire or cable is not sch eduled to be installed within 6 months of conduit installation, cap and seal the other conduits leaving the true tape inside. Install warning tape i n the trench above the conduit.

.04 Rigid Metallic Conduit (Exposed)

Comply with the requirements specified in 701.03.01. Install rigid metallic conduit as specified in 701.03.02.B. Also, install expansion joint fittings at structure expansion joints and provide necessary mounting hardware and fittings for the conduit run. Install and support exposed rigid metallic conduit parallel with or at right angles to the lines of the structure. Install and rigidly support concealed rigid metallic conduit in as direct a line as possible. 330 Ensure the following:

stainless steel couplings.

.05 Rigid Nonmetallic Conduit

trenches only for distances to be installed and backfilled during the same day. Prepare the trench bottom to eliminate lumps, ridges, and hollows.

Do not use disc grinders to cut conduit. Cut rigid nonmetallic conduit square and true and ensure they butt together over their full circumference. Construct rigid nonmetallic with at least 10 foot sections. The Contractor may use a shorter section to complete a conduit run into a foundation and junction box. Cap conduit that does not terminate in a junction box at the end of the workday. Make rigid nonmetallic conduit connections according to the manufacturer’s directions using manufacturer-recommended solvents. If connecting nonmetallic conduit to metallic conduit or other existing conduit, use a manufacturer’s recommended adapter. When installing rigid nonmetallic conduit in concrete, use a UL-approved, concrete-tight compression coupling with a permanent stop. Do not use reducing couplings, except for expansion joints on bridges if necessary, to adapt a service conduit to the meter cabinet. Make field bends to rigid nonmetallic with an industry-accepted flameless heater designed to distribute heat evenly over the section of conduit being bent. Provid e internal supports to prevent deformation of the conduit during bending. The Contractor may also use manufactured bends and elbows of material identical to the conduit. Do not install more than two 90 degree bends between junction boxes, pull boxes, and foundations. Ensure that bends and elbows used in service conduit conform to the Utility’s requirements. Ensure that conduit used for fiber optic cables meets the minimum bend and radius requirements as specified in the Contract and as required by the fiber optic cable manufacturer. The Contractor may cut off damaged ends of rigid nonmetallic conduit, and use the remainder of the undamaged conduit on the Project, provided at least a 9 foot length remains. The RE will not allow other repairs to rigid nonmetallic conduit. Do not repair rigid nonmetallic fittings. Remove broken, chipped, cracked, or impaired fittings, and replace with new fittings. If installing 2 or more rigid nonmetallic, use impact-resistant plastic spacers. Install the spacers a maximum of 8 feet on center to provide a separation between conduit equal to at least 65 percent of the diameter of the conduit. If installing conduit in existing junction boxes, cut additional holes in the junction boxes to admit the conduit. Grout around conduit installed in junction boxes before installing wire or cables. If unable to install rigid nonmetallic conduit with sufficient grade to provide drainage, install T-drains consisting of standard pipe tee and nipple for conduit at the lowest point of the conduit run. Seal the underground rigid nonmetallic entrance to the meter cabinet and the wire entrance to the controller cabinet with a sealing compound. Clean rigid nonmetallic conduit runs, including existing conduit to be used. After cleaning, test each rigid nonmetallic conduit by pulling through a metal ball with a diameter at least 85 percent of the nominal inside diameter of the rigid nonmetallic conduit, to ensure that the conduit is free of any obstruction or foreign material. If the ball fails to pass through the conduit, repair or replace the defective conduit. 331 Install true tape marked in 1 foot increments for the length of the rigid non-metallic conduit. Install a tracer wire continuously for the entire run of conduit, including through the junction boxes, mounting it on the wall. Splice the tracer wire only in the junction box. Seal the ends of rigid nonmetallic conduit carrying the tracer wire. If wire or cable is not scheduled to be installed within 6 months of conduit installation, cap and seal the other conduits leaving the true tape inside. Install warning tape in the trench above the conduit.

Fill the trench sides around the conduit with Class C bedding material to the top of the conduit. If more than 1 conduit is in the trench, then also center fill. Place additional bedding material over the conduit to a depth of 6 inches and compact using a vibratory pad -type compactor. Above this depth, backfill with suitable excavated material that is free from rock larger than 2 inches in diameter in lifts not exceeding 6 inches thick, loose measurement, with a flat faced mechanical tamper. If the excavations do not provide sufficient material of the quality required for backfilling, provide and place the material necessary to make up the deficiency. Restore disturbed areas to original conditions, the conditions specified in the Contract, or as directed by the RE.

.06 Flexible Metallic Conduit

Install liquidtight flexible metallic conduit according to NEC requirements. Cut liquidtight flexible metallic conduit according to manufacturer’s recommendations. Ensure that conduit used for fiber optic cables meets the minimum bend and radius requir ements as specified in the Contract and according to the fiber optic cable manufacturer. Utilize NEMA-4X weather-tight hubs for conduit connections to ITS and electrical enclosures.

.07 Flexible Nonmetallic Conduit

trenches only for distances to be installed and backfilled during the same day. Prepare the trench bottom to eliminate lumps, ridges, and hollows.

Construct flexible nonmetallic conduit runs so that there are no joints or splices in the conduit between adjacent junction boxes. Ensure flexible nonmetallic conduit runs are terminated in the junction boxes according to manufacturer’s recommendations. Ensure that conduit used for fiber optic cables meets the minimum bend and radius requirements as specified in the Contract and as required by the fiber optic cable manufacturer. If installing flexible nonmetallic conduit in existing junction boxes, cut additional holes in the junction boxes to admit the conduit. Grout around conduit installed in junction boxes before installing wire or cables. Seal the underground conduit entrance to the meter cabinet and the wire entrance to the controller cabinet with a sealing compound. Clean flexible nonmetallic conduit runs, including existing conduit to b e used. After cleaning, test each flexible nonmetallic conduit by pulling through a metal ball with a diameter at least 85 percent of the nominal inside diameter of the flexible nonmetallic conduit, to ensure that the conduit is free of any obstruction or foreign material. If the ball fails to pass through the flexible nonmetallic conduit, repair or replace the defective conduit. Install true tape marked in 1 foot increments for the length of the flexible non-metallic conduit. Install a tracer wire continuously for the entire run of conduit, including through the junction boxes, mounting it on the wall. Splice the tracer wire only in the junction box. Seal t he ends of flexible nonmetallic conduit carrying the tracer wire. If wire or cable is not scheduled to be installed within 6 months of conduit installation, cap and seal the other conduits leaving the true tape inside. Install warning tape in the trench above the conduit.

.08 Junction Box

Comply with the requirements specified in 701.03.01. Excavate as specified in 202.03.02. Place precast junction boxes on 6 inches of coarse aggregate No. 57. With each junction box, provide 4 cable racks, inserts and fasteners, and a ground rod and clamp. Do not provide the cable racks with the circular 20 inch junction boxes. 332

working drawings for approval for those locations approved.

Keep forms in place for at least 24 hours after placing concrete. Neatly finish exposed portions of junction boxes with a wood float followed by brushing with a wet, soft-haired brush. Set junction box covers to grade with the surrounding area.

where the slope is less than 22H:1V. Backfill and compact using the directed method as specified in 203.03.02.B.3. Restore disturbed areas to original conditions, the conditions specified in the Contract, or as directed by the RE.

.09 Metal Junction Boxes

Comply with the requirements specified in 701.03.01. Install on structures with mounting attachments according to the manufacturer’s recommendations.

.10 Junction Box Foundation

Comply with the requirements specified in 701.03.01. Excavate as specified in 202.03.02. Place cast-in-place junction box foundations on 6 inches of coa rse aggregate. With each junction box foundation, provide 4 cable racks, inserts and fasteners, and a ground rod and clamp.

Submit working drawings for approval for those locations approved.

for at least 24 hours after placing concrete. Neatly finish exposed portions of junction box foundations with a wood float followed by br ushing with a wet, soft -haired brush. Set junction box covers to grade with the surrounding area. Backfill and compact using the directed method as specified in 203.03.02.B.3. Restore disturbed areas to original conditions, the conditions specified in the Contract, or as directed by the RE.

.11 Junction Box Frame and Cover

Remove the existing junction box frame and cover, and the damaged portion of the wall as directed by the RE. Reuse concrete as specified in 202.03.03.C.1. Dispose of other material as specified in 201.03.01.H. Obtain RE approval to reuse the cover. Reconstruct the walls to the elevation shown on the Plans. Ensure that the junction box frame is set to the correct elevation and held firmly in place. Place concrete, as specified in 504.03.02.D, and in accordance with the limitations specified in

504.03.02.C. Set the cover on the junction box frame. If the cover wobbles, grind to obtain a tighter fit

.12 Foundations

Comply with the requirements specified in 701.03.01. Excavate as specified in 202.03.02. Set or finish the top of foundations to a level elevation 1 inch above curb or sidewalk. Where curbs or sidewalks are not constructed or do not exist, finish the top of foundations to an elevation 2 inches above the surrounding lawn or earth. For foundations used with lighting, finish the top of foundations to grade when installed with curb or sidewalk. Where curbs or sidewalks are not constructed or do not exist, finish the top of foundations to an elevation 1 inch above the surrounding lawn or earth.

areas where the slope is less than 22H:1V. Submit working drawings for approval for those locations approved.

Terminate conduit with a coupling flush with the surface of structural concrete, and provide the conduit with a close nipple. Provide pipe caps for the conduit during concrete placement. When the foundation finishing is 333 complete, remove the pipe caps and install insulated grounding bushings. If not immediately installing wiring, install the bushings with push-penny plugs. Ensure that foundations are completely formed. Pour foundations monolithically on firm ground. Place conduit and anchor bolts in proper and plumb position and hold in place using a template until the concrete sets. Keep forms in place for at least 24 hours after placing concrete. Neatly finish exposed portions of foundations with a wood float followed by brushing with a wet, soft-haired brush. Allow foundations to cure for at least 3 days before installing poles, standards, or other equipment. Place backfill as specified in 203.03.02.B.3. Restore disturbed areas to original conditions, the conditions specified in the Contract, or as directed by the RE.

.13 Cable Rack

A cable rack consists of a cable rack, including inserts or fasteners. When pulling cable and wire through existing junction boxes not equipped with cable racks, install cable racks as directed by the RE. In addition, provide bonding bushings and bonding wire on metallic conduit ends within these junction boxes.

.14 Meter Cabinet

Install cabinets, meters, control and distribution systems, including the grounding of all materials, the photoelectric control, and internal wire and wiring. Install the metering systems as required by the Utility.

.15 Cable and Wire

and connection to cabinets, standards, mast arms, and other Items. Identify the circuit number of the cables and wires by attaching cable identification tags to each of the cables or wires in all junction boxes and in the cabinets of the load centers or controller. Secure tags to the cable or wire using nylon cable ties. When pulling wires and cables through conduit, do not overstress or stretch, and take precautions not to score, twist, or damage the protective covering or insulation. Ensure wire lubricant is used or an industry approved wire pulling machine. Except for ground wire, provide all wires and cables in junction boxes, pull boxes and enclosures with adequate slack placed on the cable racks. Include a minimum length of slack as follows: Table 701.03.15-1 Minimum Length of Slack Item Length of Slack Rectangular Junction Box Rigid Metallic Conduit 7 feet Rigid Nonmetallic Conduit 9 feet 20 inch Junction Box (Circular) 5 feet1 Standard Base and Cabinet 3 feet

After installing cables and pending permanent splicing, seal the end of each section of cable jacket in junction boxes and service panels or cabinets with rubber tape, and then paint the ends with a waterproof sealing compound. Secure conductors to the cable racks using nylon cable ties. Group and identify new and existing conductors in standard bases, junction boxes, meter cabinets, and controller cabinets using cable identification tags. Test the existing tracer wire in the conduit for continuity. If there is no existing tracer wire in any of the conduits in the same trench, then install a continuous tracer wire between the adjacent junction boxes without any splice when installing the cable and wire as directed by the RE. 334

foundations, above-ground material, and all other materials as specified in the NEC and as required by the Utility. Ensure bare ground wire is used when installing a bonding wire in junction boxes and ITS Items. Secure it to the conduit bushings and to the ground rod. For traffic signal systems, install an insulated, color-coded green, ground wire continuously throughout. Secure the ground wire to all ground rods and all materials requiring grounding. For lighting systems, use either an insulated or bare ground wire.

extend from a meter cabinet or junction box to a point on the service pole or manhole, and supply a sufficient length of conductors to extend to the overhead utility service as required by the Utility and subject to its approval. Ensure the Utility completes the extensions of the conductors from this point on the pole and connections to overhead utility service, or the connection inside a service manhole. Service points shown on the Plans are approximate only. Contact the serving Utility to determine the exact locations. Install the service conduit as required by the Utility. Notify the Utility and complete the required applications for inspection. Provide permits, fees, and access for inspections. If the meter socket is not provided by the Utility, obtain the meter socket as required by the Utility’s regulations. Verify the dimensions of the socket and meter to ensure proper installation in the cabinet and conformance with Utility’s requirements. Provide temporary services if required for testing and operation of the electrical systems until Substantial Completion or as directed by the RE. Coordinate temporary services with the Utility Company.

following tests on each circuit using suitable equipment in the presence of the RE:

resistance is at least 150 megaohms between conductors, or between conductor and ground for circ uits with a total single conductor length of 1,500 feet or more, and at least 175 megaohms for circuits with a total single conductor length of less than 1,500 feet. Complete the electrical system, including connections, and repeat continuity, ground, and insulation resistance testing starting from the control cabinet. Record the observed readings with their respective circuits. Submit 4 copies of the wiring test results to the RE. Record on the test results the Project title, the date of the test, and t he atmospheric conditions. Energize each electrical system, with the exception of traffic signals, for a minimum of 10 consecutive periods of normal operation. In addition, test traffic signal and system loop detectors by checking the complete loop wire an d detector lead for continuity using a suitable tester. Before placing the sealant, perform an insulation resistance test on the loop and lead wire to ensure that the resistance to ground is 10 megaohms or greater. If the resistance to ground is less than 10 megaohms, perform corrective measures, as necessary, to obtain the desired readings. Perform an inductance test on the loop using a loop inductance meter. Provide a tabulation of the results for the loops. Replace defective material discovered during testing and retest as required.

701.04MEASUREMENT AND PAYMENT

The Department will measure and make payment for Items as follows: Item Pay Unit ___" RIGID METALLIC CONDUIT LINEAR FOOT