SECTION 702 – TRAFFIC SIGNALS
702.01 Description
This Section describes the requirements for providing and installing a complete traffic signal system, including temporary and interim traffic signal systems. Terms used are according to NEMA Standard Publication No. TS-1, Section 1, entitled Traffic Control Systems.
702.02 Materials
702.02.01 Materials
Provide materials as specified in: Coal Tar Epoxy Paint ................................ ................................ ................................ ............................... 912.01.03 Loop Detector Lead ................................ ................................ ................................ ................................ .. 918.02.01 Loop Wire................................ ................................ ................................ ................................ ................ 918.02.02 Traffic Signal Cable ................................ ................................ ................................ ................................ . 918.02.04 Cabinets ................................ ................................ ................................ ................................ ........................ 918.09 Panel Boards and Circuit Breakers................................ ................................ ................................ ................. 918.10 Standard and Mast Arms ................................ ................................ ................................ ............................... 918.12 Lamps ................................ ................................ ................................ ................................ ........................... 918.14 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 approval on a Materials Questionnaire as specified in 106.04. Include working drawings for approval 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 When signs are mounted on traffic signal mast arms, use vertical mounted type, high-strength aluminum alloy, swing sign brackets with stainless steel materials; heavy duty stainless steel straps adaptable to any pole diameter; and removable stainless steel damper springs. Use adjustable swing sign brackets for leveling. Use LED modules for all signals. For fittings and mounting hardware not specified, follow the manufacturer’s recommendations.
702.02.02 Equipment
Provide equipment as specified in: Pavement Saw................................ ................................ ................................ ................................ ............. 1008.04 Hot-Air Lance ................................ ................................ ................................ ................................ ............. 1008.06
702.03 Construction
Before working on an existing traffic signal system, meet the requirements of 701.03.01. After placing a new, temporary or interim traffic signal system into operation, inspect the traffic signal system every 2 months. Fill out a Contractor Maintenance Traffic Signal Inspection Report (Form EL -16C) when the traffic signal system becomes operational, when the traffic signal system is modified, and at every 2 month inspection. Maintain as-built drawings of each signal modification. Place copies of the as-built drawings for each traffic signal system modification, Forms EL-16C, and Forms EL-11C in a plastic pocket mounted inside the cabinet door of each controller cabinet. Also provide a copy of all forms and as-built drawings to the RE. If a new, temporary or interim traffic signal system fails or becomes damaged, repair and restore the traffic signal system to normal operation. Begin repair of the traffic signal system within 2 hours of receiving notice of damage or malfunction from the Department, State police, or local authorities. Ensure that workers assigned to such repair work continuously until the traffic signal resumes normal signal operation. For each response to a system failure or damage, fill out a C ontractor Maintena nce Emergency Call Record (Form EL - 11C) and place it in a plastic pocket mounted inside the cabinet door of each controller cabinet. If the Contractor fails to respond to a failure or damage notification and begin work within 2 hours of notification, or does not continue to work until the traffic signal system resumes normal operation, the Department, in the interest of safety, will respond with its own forces to restore normal operation. If the Department mobilizes its forces to effect repairs, the Contractor agrees to pay the Department a sum of $3 ,000 for costs of mobilizing its forces and equipment. In addition, the Contractor must pay the Department the actual cost of material used for the repair and pay the actual costs of police traffic protection.
702.03.01 Controller
Before delivery of a controller to the Project Limits, bench test the controller as a complete unit according to the timing schedule for each location. At least 20 days before the bench testing, notify the Department for approval of the bench testing location. The Department may choose to witness part of the bench test. The Department will approve the controller only after 168 hours of continuous trouble-free operation. If unsatisfactory performance of the controller occurs, correct the problem and repeat the entire bench test. Provide the certified results of bench testing at the time of delivery on forms provided by the Department. Securely bolt the controller cabinet to the foundation in a vertical position using stainless steel hardware. If tempora rily installing a controller cabinet on top of a meter cabinet, fasten it in a vertical position using stainless steel hardware. Seal the joint between the cabinets with a neoprene gasket and seal the wireway with sealing compound.
702.03.02 Standards
Leave the factory wrapping on standards for as long as the manufacturer recommends. Install the standard with the wrapping in place, and maintain the standard and other material in original factory appearance. When erecting the standard and other material, use methods that prevent scratching or abrasion.
1.Traffic Signal Standard. Bolt the standard securely to the foundation, and erect the standard with sufficient rake to assume a vertical position after all attachments and appurtenances are in place. For aluminum standards, the Contractor may install leveling shims to a maximum height of 1/4 inch. Provide and ins tall the standard with ground studs either in the base for aluminum or in the standard for steel. Install a ground wire that extends to the ground rod from the standard.
2.Pedestrian Signal Standard. Bolt the pedestrian signal standard to the foundation securely in a vertical position, using stainless steel hardware. If signs are to be mounted to a standard, provide the necessary mounting hardware.
702.03.03 Traffic Signal Mast Arm
Leave the factory installed wrapping on the arm for as long as the manufacturer recommends. Install the arm with the wrapping in place, and maintain it in original factory appearance. Erect mast arms with methods that prevent scratching or abrasions. Install a traffic signal arm on a traffic signal standard with a pole clamp (as required), mast arm hanger, grommet, safety chains, swing sign brackets (as required), and miscellaneous fi ttings and hardware. Provide for all modifications or adjustments that may be required for staged construction.
702.03.04 Traffic Signal Cable
Install multi-conductor cable and cable identification tags. Individually wire each push button, traffic signal face and pedestrian signal face using the specified colors for each with an insulated locking spade terminal. Perform splices at the bottom of the standard. Attach the terminations in meter cabinets or controller cabinets to barrier type terminal blocks. Ensure that the terminal blocks are clearly identified. Terminate and clearly identify spare wires. Provide slack cable in standards, mast arms, and cabinets as specified in Table 701.03.15-1. Color code traffic signal circuits and wire as follows: Table 702.03.04-1 Conductor Cable Assignments Function Color Number Two-Conductor Cable Pedestrian Push Button Black 1 Neutral White 2 Five-Conductor Cable (Traffic Signal) Spare Black 1 Neutral White 2 Red Red 3 Green Green 4 Yellow Orange 5 Five Conductor Cable (One Pedestrian Signal) Spare Black 1 Neutral White 2 Don’t Walk Red 3 Walk Green 4 Spare Orange 5 Five Conductor Cable (Two Pedestrian Signal) Walk (2) Black 1 Neutral White 2 Don’t Walk Red 3 Walk Green 4 Don’t Walk (2) Orange 5 Ten-Conductor Cable (Traffic Signal) Green Arrow (spare) Black 1 Neutral (1) White 2 Red (1) Red 3 Green (1) Green 4 Yellow (1) or Yellow Arrow Orange 5 Arrow Neutral (spare) Blue 6 Neutral (2) White-Black 7 Red (2) Red-Black 8 Green (2) Green-Black 9 Yellow (2) Orange-Black 10 If splices are required above ground, use a compression solderless connector, and mechanically and electrically secure them with the proper tool. Clean the conductors with a minimum of the insulation removed. Insulate splices located in standards using insulating tape to provide 1 1/2 times the insulation rating of the original conductor. Coat the taped splices with an electrical grade sealant and bonding compound. If splices are required below ground in junction boxes or junction box foundations, use a compression solderless connector, and mechanically and electrically secure them with the proper tool. Before splicing, clean the conductors with a minimum of the insulation removed. Complete splice with a resin splicing kit.
702.03.05 Traffic Signal Head
Assemble traffic signal faces using a wrench designed for that purpose. Use mounting fittings designed to function with the unit and that provide the proper clearance to aim and adjust the traffic signal head. If directed by the Department, install dull black louvers of the specified cutoff angle inside the signal visor using stainless steel sheet metal screws. When attaching the visors, backplates, or adaptors, ensure that they conform and readily fasten to existing mounting surfaces without affecting the water and light integrity of the traffic signal head. Make field adjustments of louvers and optically programmed traffic signal heads as directed by the Department. Install cable from the traffic signal head to the foundation and make connections. If replacing an existing traffic signal head, remove the existing head and cable and dispo se of as specified in 201.03.01.H.
702.03.06 Pedestrian Signal Head
Install a pedestrian signal head with pole clamp mounting, miscellaneous fittings and hardware, and grommet including drilling the standard as required. Install cable from the pedestrian signal head to the foundation and make connections. If replacing an existing pedestrian signal head, remove the existing head and cable and dispose of as specified in 201.03.01.H.
702.03.07 Push Button
Install a push button that operates on logic ground including its housing, and instruction signage. Install cable from the push button to the foundation and make connections. Install the instruction sign and ensure that it conforms to the MUTCD. If replacing an existing push button, remove the existing head and cable and dispose of as specified in 201.03.01.H.
702.03.08 Image Detector
Install a camera mounted to a mast arm, with an automatic control unit, a pointing device, and all materials needed to provide accurate vehicle detection at the specifie d location. Mount and install according to the manufacturer’s recommendation, including all cable and cable connections from the camera to the control unit without splices.
702.03.09 Loop Detector
Sawcut the pavement as shown on the Plans. After sawcutting, immediately collect the slurry from the sawcut cavity and surrounding pavement surface and dispose of as specified 201.03.01.H. Clean sawcuts with a 150 pounds per square inch water blast to remove remaining debris in the sawcut cavity, and then blow sawcuts with a hot -air lance to provide a dry surface. If not immediately installing the loop wire, install a filler to prevent the sawcut from collapsing. Place a continuous length wire in the sawcut. Install wire by laying turns of the wire in the sawcut so there are no kinks or curls. Do not strain or stretch the wire insulation around the corners of the sawcut or in the junction box. When seating the wire in the bottom of the sawcut, do not damage the wire. Do not splice the wire. Twist the 2 wires that form the lead-in wires together in the trench and in the conduit to the nearest junction box. Extend the wire from the sawcut to the nearest junction box. Connect the loop wire to the loop detector cable using a compression solderless connector, and mechanically and electrically secure them with the proper tool. Clean the conductors with a minimum of insulation removed. Insulate the joints and splices using a resin splicing kit. After placing the wire, recheck the wire for slack, raised portions, or tightness. Correct slack, raised portions, and tightness in the wire. After testing the loop for continuity, seal the sawcut with a joint sealant applied according to the manufacturer’s recommendation. If installing a loop on a grade steeper than 3 percent, use Type 1 joint sealant. Do not place the joint sealant in the sawcut at temperatures below 45 °F or during precipitation. Completely fill the sawcut with the joint sealant so there are no air bubbles below the surface. Prevent joint sealant from running out of the trench and on to the roadway. Remove joint sealant applied to the roadway. Allow the joint sealant to harden before allowing opening to traffic. When the roadway in the area of the loop detector is to be resurfaced, or when constructing a new section of roadway, install the loop detector immediately below the top layer of pavement. Ensure that the joint sealant is hardened before the installation of the pavement.
702.03.10 Loop Detector Cable
Install loop detector cable continuously from the controller to the junction box nearest to the loop. Do not splice the loop detector cable.
702.03.11 Temporary and Interim Traffic Signal Systems
Perform requirements that are specific to temporary or interim traffic signal systems as follows:
1.Temporary Traffic Signal System. A temporary traffic signal system includes, but is not limited to, temporary wiring, span and tether wire, signal heads, relamping, mast arms, poles, traffic signal cables, junction boxes, foundations, conduit, detectors, controllers and timing sequences, cabinets, associated lighting units, providing and maintaining electric services, and necessary hardware. If the Plans do not specify the design, at least 30 days before starting the installation, submit working drawings for approval. Prepare and design the system according to the Department design manuals. Include complete structural design calculations signed and sealed by a Professional Engineer. Before energizing the temporary traffic si gnal system, provide the RE with the contact information of the Contractor’s personnel should a failure occur. Provide only individuals who are familiar with traffic signal construction and operation.
2.Interim Traffic Signal System. Install a modification to an existing traffic signal system to provide the timing and operation as shown on the Plans. An interim traffic signal system includes, but is not limited to, temporary wiring, span and tether wire, signal heads, relamping, mast arms, poles, traffi c signal cables, junction boxes, foundations, conduit, detectors, controllers and timing sequences, cabinets, associated lighting units, obtaining electric services, and necessary hardware. The Contractor may use above-ground traffic signal materials designated for removal in interim traffic signal systems with the RE’s approval. Maintain an interim traffic signal system from the first alteration of the existing traffic signal installations until the work of revising the existing traffic signal installations is fully operational, inspected, and partially accepted by the Department. Before modifying the existing traffic signal system, provide the RE with the contact information of the Contractor’s personnel should a failure occur. Provide only individuals wh o are familiar with traffic signal construction and operation. Upon removal of the interim traffic signal system, salvage existing above-ground material for Department use. Salvaged material becomes property of the Department. Store salvaged material nea r or within the Project Limits. As directed, deliver salvaged material to the nearest Department electrical maintenance yard and unload the material as directed.
702.03.12 Controller Turn-On
Controller turn-on consists of supplying a technician authorized by the controller manufacturer at the work site when each controller is placed into flash mode and into final operation. Provide the RE a letter, from the controller manufacturer, stating the technician is authorized and qualified to perform the work. Ensure that the technician is available at all times during flash mode testing. Ensure that traffic signals complete a successful flash period for 3 consecutive days as part of the required testing.
702.04 Measurement and Payment
The Department will measure and make payment for Items as follows: Item Pay Unit CONTROLLER, ___ PHASE UNIT TRAFFIC SIGNAL STANDARD, ALUMINUM UNIT TRAFFIC SIGNAL STANDARD, STEEL UNIT PEDESTRIAN SIGNAL STANDARD UNIT TRAFFIC SIGNAL MAST ARM, ALUMINUM UNIT TRAFFIC SIGNAL MAST ARM, STEEL UNIT TRAFFIC SIGNAL CABLE, ___ CONDUCTOR LINEAR FOOT TRAFFIC SIGNAL HEAD UNIT PEDESTRIAN SIGNAL HEAD UNIT PUSH BUTTON UNIT IMAGE DETECTOR UNIT LOOP DETECTOR LINEAR FOOT LOOP DETECTOR CABLE LINEAR FOOT TEMPORARY TRAFFIC SIGNAL SYSTEM, LOCATION NO. ___ LUMP SUM INTERIM TRAFFIC SIGNAL SYSTEM, LOCATION NO. ___ LUMP SUM CONTROLLER TURN-ON UNIT The Department will measure a unit of CONTROLLER TURN-ON for each controller that the technician turns on unless the controller does not function as specified.
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Traffic Signals in other states
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Source: Standard Specifications for Road and Bridge Construction, 2019 (rev. 2022-12-21) Edition. Pages 369–374 of 651. View official source ↗