910HIGHWAY LIGHTING

910.1DESCRIPTION—This work is the furnishing, installation, erection, and wiring of the complete highway

lighting system, including the electrical power supply and distribution system.

910.2MATERIAL—

cost to the Department, catalog cuts, certifications, photometric calculations, drawings, and manufacturer’s specifications for all lighting material including lighting poles, luminaires, junction boxes, conduits, cables, and power supply components proposed for the project. Refer to the Project Office Manual for material information requirements.

• Fine Aggregate, Type A or B. Section 703.1

• Coarse Aggregate, Type A or C. Section 703.2

• Class A Cement Concrete. Section 704

• Expansion Joint Filler. Section 705.1

• Reinforcement Bars. Section 709.1

• Nonshrink Epoxy Grout. Section 1080.2(g)

• Nonshrink Mortar. Section 1001.2(e)

• Caulking Compound. Section 705.7

• Precast Concrete Products. Section 714

and mechanical equipment. Submit these warranties or guarantees to the Department at project completion. Submit material certification, as specified in Section 106.03(b)3. For poles, submit a signed warranty from the manufacturer stating that specifications have been met.

910.3CONSTRUCTION—As shown on the Standard Drawings, as indicated, and as follows:

the electrical regulations of the Department of Labor and Industry; and the construction requirements of the NEC and NESC. Cooperate with the electric utility company or agency furnishing power to the system and meet the necessary service requirements. Acquire permits as specified in Section 107.02. Furnish certificates of approval from appropriate agencies when required. Upon work completion, submit to the Department five copies of “as -built” drawings, as directed, showing the date, all changes from the indicated system made during construction, and all revised circuit diagrams. Upon receipt, “as -built” drawing copies will be supplied to the agency maintaining the system. The acceptance of drawings will not relieve Contractor responsibility for erroneous or inconsistent dimensions, notations, or omissions or for the proper installation and operation of the electrical systems.

for the actual soil conditions encountered. Do not proceed with work until the foundation excavation is accepted.

The foundation design may need to be revised based on the actual conditions encountered as determined by the Representative. Obtain approval of the completed foundation forms before concrete placement. Remove water from the foundation holes before concrete placement.

trenches for conduit runs parallel to the roadway, or as indicated. The preferred location is off of the shoulder. Provide a minimum 18 inch clearance from all underground utilities. Backfill the same day if possible. Remove rock within the excavation unless an alternate layout is authorized. Remove and dispose unsuitable material and excess excavation as directed. Place plastic marking tape within the last layer of backfill material for the entire length of the trench. Provide bedding soil for conduits as specified in Section 206.2(a)1.a. Backfill the remaining portion of the trenches with suitable on -site material to match existing conditions as shown on the Standard Drawings. Do not use coarse aggregate, except within the subbase area or as directed. Compact trench material as specified in Section 601.3(f). Stake trench alignments for inspection and acceptance before excavating when they deviate from the indicated location. Submit the layout for review and acceptance before proceeding if the alignments extend the overall indicated circuit length by more than 5%.

Section 1001.3. Before erection of high mast poles, mix, cure, and test samples of the foundation concrete according to Department procedures. Verify the ground elevation at the foundation location for all high mast pole foundations. Provide and place anchor bolts perpendicular to the top plane of the foundation. Use suitable templates or forms to hold the anchor bolts in position while placing concrete. Clean the exposed portion of anchor bolts and associated hardware. Install the necessary number of conduit sweep elbows and orient them inside the foundation to avoid unnecessary bends in the conduit runs. Fasten elbows securely to prevent movement while concrete is being placed. For high mast pole foundations, install a 1 -inch conduit for the grounding electrode conductor. For all other types of poles, install ground rod in pole foundation. Connect No. 4 AWG copper grounding electrode conductor to the ground rod with an exothermic weld or bronze connector, extend the other end through the center of the foundation, and leave 30 inches coiled above the foundation. Test the resistance to earth ground before placing concrete. Install additional ground rods (a minimum of 6 feet apar t) if the measured resistance between the ground rod and earth is greater than 25 ohms.

with aluminum bases; and use stainless steel shims with other bases. Place shims under no more than three bolts of any base. Do not use shims on bridges, use leveling nuts. Orient the handhole in the direction of traffic, unless otherwise indicated. Plumb high-mast poles, using the leveling nuts supplied with the anchor bolts. Unless otherwise indicated, install bracket arms at right angles to the pavement edge with arms securely fastened to the pole shafts. Install luminaires according to the manufacturer's instructions or as indicated. Fasten an identification plate and a Lighting Management System (LMS) key plate with stainless steel rivets to the roadway side of the pole 8 feet above the foundation or as directed. Select one or more poles for the static load test, as specified in Section 1101.02 before erecting the remainder of the poles. Use similar pole types and similar materials within the same general area. Field-assemble two-piece pole shafts by overlapping bolted sections. Do not field weld poles or accessories.

in supervising the field assembly and erection of high -mast poles and to instruct Department personnel in the proper procedures for raising and lowering the luminaire ring and in the recommended maintenance care of the poles. Check the pole section mating and alignment before the erection of the pole. Request the electric utility company to be present during erection of poles within 200 feet of their aerial

electric lines.

concrete or while performing other operations. If possible, install conduits under roadways before placing the pavement. If this is not possible, install a 3-inch diameter rigid steel conduit for a sleeve. Jack, auger, or bore under pavements, shoulders, sidewalks, railway tracks, and other indicated areas. Do not water bore. Extend this sleeve under the roadway approximately 24 inches beyond the outside paved edge. Place the lighting conduit through this sleeve. Grind the cut ends of metallic conduit to remove rough edges. Do not use defective conduit. Thread steel conduit for couplings and fittings. Coat the threads as specified in Section 910.3(r). Weld plastic conduit joints with solvent, according to the conduit manufacturer's recommendations. Make conduit bends and offsets, either in the shop or in the field. Do not damage the protective coating when making bends and offsets. Do not reduce the interior diameter of the bend. Form the bend on a radius at least twelve times the conduit diameter, b ut not less than 18 inches. Use manufactured sweep bends whenever possible. Seal the ends of partially installed conduit runs if conduit work is temporarily suspended. If it is necessary to open the ends for cleaning or testing, reseal them upon completion. Seal the conduits in control cabinets. Install conduit expansion and deflection joint fittings at each structure expansion joint as shown on Bridge Standard Drawings. Ground steel conduit and provide electrical continuity on structures, as specified in Section 910.3(q), as soon as possible after installation, and before energizing the system. Connect fittings, junction boxes, and other appurtenances to the conduit on a structure so electrical continuity is maintained. Provide conduit expansion joints with an external bonding jumper. Size the bonding jumper to match the equipment grounding conductor installed in the conduit. Coat underground steel galvanized conduit with asphalt paint or other approved coating if placed in a corrosive area. Use hot-dipped galvanized coating for other areas. Clean conduit runs after installation by pulling a stiff wire brush, the size of the conduit, through the conduit. Then test the conduit by pulling a ball mandrel that has a diameter of at least 85% of the inside diameter of the conduit, through each conduit run. Where the mandrel fails to pass, either clean the conduit without injury to the conduit walls or replace the conduit. Fasten conduits to electrical equipment using code -approved devices. Use watertight conduit fittings to connect to watertight enclosures. Attach conduit to wood poles with 1/8 -inch thick hot-dipped galvanized steel straps and galvanized lag screws. Provide 5 feet maximum spacing between straps. Do not install pull wires in the conduit, unless indicated. Provide a 2-inch minimum direct burial conduit for underground circuits.

or reel. Notify the Representative when cable is to be placed. Do not proceed without the Representative being present. Use cable grips to install the cable in the conduit. Simultaneously pull cables within a single conduit, but do not damage the cable by overpulling. Use a dynamometer if pulling other than by hand. Use pulling lubricant of a type recommended by the cable m anufacturer if necessary. Use extreme care when pulling cable through handholes in pole shafts. Place a pad of firm rubber or other similar material around the bottom edges of the opening to protect the cables. Clearly locate underground conduits with aboveground markers if guide rail or other surface features are to be constructed in the immediate area. Provide enough slack cable in junction boxes and light pole bases to allow exterior splicing. Neatly arrange the spliced cables or coil in junction box or pole base. Prevent the entry of moisture into the cable at all times during installation. Seal the ends of cable until final splices are made. Make splices above grade in pole base or transformer base with pre-molded disconnectable connector kits rated for 600 V. Provide splices with a minimum watertight or splash proof seal using weatherproof boots and tape as required by the manufacturer; and when placed in junction boxes or other potentially wet areas, provide splices that are waterproof and submersible. For in -ground junction boxes use non -fusible splices, unless indicated otherwise. Use only breakaway type connectors for connections where breakaway bases are used. Line splice only at pole bases or junction boxes. Do not splice cables inside conduits.

Use seven-strand No. 10 AWG insulated wire for the line taps from the feeder cable to the ballast or luminaire terminal block for the phase and neutral wires. Provide taps to the feeder cables as specified for line splicing. Do not use wire nuts for cable taps. Provide adequate size connectors for the wire sizes involved. Provide individual fusing for all conventional lighting. F use the tap with a 6A to 10A fuse, midget size, 250 V rating. Fuse the phase wire only. Connect the insulated equipment grounding conductor routed with the circuit conductors to the grounding electrode conductor (from the pole foundation ground rod) with a split bolt connector and then connect to ground lug welded to the pole base. Coat all grounding connections with an approved corrosion inhibitor. Attach the cable to the J hook at the pole top with a cable grip that supports the weight of the cable. Furnish and install circuit-identifying tags on control and distribution circuit cables where they connect to equipment located in service cabinets and vaults and on cables in junction boxes and pole shafts. Use fiber or other acceptable nonconducting tags, not less than 3/4 inch in diameter, and not less than 1/32 inch thick. Legibly stamp identification markings on the tags using small tool dies or permanent, waterproof marker. Securely tie each tag to the proper conductor, using plastic or nylon cord. Use underground cable in direct burial conduit for all underground installations. The minimum underground wire size is No. 8 AWG copper cable.

according to the manufacturer's instructions.

indicated, before placing on the pole top or arms. Uniformly adjust and level luminaires. Install photocontrol or shorting cap according to the manufacturer’s instructions or as indicated. Immediately before the illumination test, and after all dust-generating work has been completed, clean the light control surfaces according to the luminaire manufacturer's recommendations using a cleaner recommended by the manufacturer. Provide luminaires with a weather resistant decal conforming to ANSI C136.15-2011 that shows the lamp wattage. Provide a decal that is visible from the ground.

When required, mount a meter base on the pole according to the utility company's requirements. Coordinate the meter installation with the utility company. Install poles , according to the current specifications and standards of NELA, EEI, and NESC. The minimum depth of holes for setting wood poles 30 feet to 40 feet in length is 6 feet measured from the low side on sloping ground. Dig holes with vertical sides and with a di ameter large enough to allow use of a mechanical tamper around the pole. Ensure that each pole is inspected and accepted before backfilling. Deposit acceptable backfilling material around the poles and mechanically tamp in layers of not over 4 inches. Place backfill material around the pole to drain water away. Guy service poles, if necessary. Install cone anchors 7 feet below ground level. After placing the anchor, backfill the hole with coarse aggregate for a depth of 24 inches above the anchor, then tamp during backfilling. Backfill the remaining hole with the excavated material, then thoroughly tamp. Obtain approval for the guys before the conductors are strung. Install a guy guard if the guy is adjacent to the roadway. Install and tighten anchor bolts as specified in Section 948.

with its detector area facing north.

service disconnect ahead of the control cabinet that is labeled ‘suitable for use as service equipment’. The disconnect can be provided integral to the control cabinet if the cabinet is dead front and labeled as ‘suitable for use as service equipment’. Padlock the enclosures. Key as directed. Provide enclosure ID tags as specified for pole ID tags. Provide the power supply number, the system voltage, and the LMS key number on the tags.

Excavate, then construct or install the box. Set each junction box on minimum 8 -inch base of AASHTO No. 57 or equivalent. Backfill with suitable material and compact in lifts as specified in Section 206.3(b)4 around the junction box. Dispose of excess or unsuitable material. Top of junction boxes must be flush with

surrounding surface. If using precast junction boxes with knockouts, remove the knockouts, then tightly grout the conduit or conduit sleeves in place with non-shrink mortar. Ground exposed metal parts of junction boxes with a minimum No. 4 AWG grounding electrode conductor and a minimum 5/8-inch by 8-foot ground rod with no more than 24 inches of exposed rod in each junction box. Connect the grounding electrode conductor to the ground rod with either an exothermic weld or with a bronze connector clamp. Connection to an adjacent system ground rod is allowable.

required if the measured resistance to earth is greater than 25 ohms. At the service entrance, install the first rod electrode (ground rod) inside a cast-in-place or precast junction box with lid and attach the ground rod to the grounding electrode conductor with an exothermic weld or a bronze connector. Coat the connection(s) with approved corrosion inhibitor. Provide an equipment grounding conductor with all circuits. Do not connect the neutral to ground except at the service location. Provide an insulated equipment grounding conductor with the same insulation and size as specified for the circuit conductors.

on structures by the following methods:

• By connecting to the embedded or surface structure mounted steel conduit.

• By use of a continuous insulated equipment grounding conductor routed with the circuit conductors inside the conduit and connected to ground lugs installed inside the junction boxes.

If using embedded or surface structure mounted non -metallic conduit, use a continuous insulated equipment grounding conductor routed with the circuit conductors in the non-metallic conduit as the sole equipment grounding conductor for those portions of the circuit. Provide one ground rod for structures up to 500 feet in length. Provide one ground rod at each end of structures over 500 feet in length. Provide a No. 4 AWG uninsulated copper grounding electrode conductor from the ground rod to the nearest structure -mounted junction box and attach to the ground lug inside the box. Attach the ground rod to the grounding electrode conductor with an exothermic weld or a bronze connector. Provide a separate insulated continuous equipment grounding conductor of the same size and material as routed with the circuit conductors for structures using either steel or non-metallic conduit.

the lighting system. Furnish and install the specified number of wooden poles for the power supplies with the necessary auxiliary equipment (crossarms, brackets, meter base, transformers, cutouts, lightning arresters, conduit, insulators, switches, fuses, circuit breakers, lighting contactors, photoelectric controls, enclosures, weather heads, service wire, guywire, and grounding) to provide complete electrical service for the entire lighting system.

trench. Place the marker directly under the guide rail when trench and guide rail cross.

that bear a certification of calibration with the past year from a recognized testing laboratory. Provide the electrical energy and furnish personnel and equipment to complete the tests. Correct any defects disclosed by the tests and then retest the corrections. Perform the tests in the presence of the Representative.

Form Title CS-4225A Ground Rod Test CS-4225B Conductor Insulation Resistance Test CS-4225C Circuit Performance Test CS-4225D Highway Illumination Test (Conventional) CS-4225E Sign Illumination Test CS-4225F High Mast Lighting Test CS-4225G Static Load Test (Conventional)

Satisfactorily demonstrate that circuits are continuous and free from short circuits and from unspecified grounds. Provide a resistance to earth -ground, for each ground rod location, of not more than 25 ohms. Supply and install additional ground rods , connected by a common grounding electrode conductor and installed a minimum of 6 feet apart, until this requirement is met or as directed. The resistance to ground of conductors for underground cable is to be as shown in Table A at 60F, when measured with a 1000 V megger:

TABLE A Insulation Resistance (Megohms- minimum, based on 1,000 feet) Wire Size (AWG) Cable Type 10-6 4-1 1/0-2/0 Cross-Linked Polyethylene RHW, RHH, USE 2,000 1,500 1,300 Cross-Linked Polyethylene XHHW 1,600 1,100 900 Rubber-Neoprene RHW 500 350 300 PVC THW 140 120 100

Take voltage readings, with load and without load, at the power supply side of the control cabinet main breaker. The readings with load must be within ±5% of nominal voltage (typically either 120 V or 240 V). Take voltage readings at the last light of each circuit. A voltage reading is acceptable if it is within 5% of the reading with load at the supply point. Take current (ampere) readings with a full lighting load on the load side of each distribution breaker in the control cabinet. A current reading is acceptable if it does not exceed 75% of the breaker rating. Energize and operate the lighting system, including automatic control(s), for 168 consecutive hours. At each control cabinet, supply a service voltage graphic record covering the test period, with the installed electrical equipment in normal operation (lights on at night and off in daytime). After the lights have been energized for at least 100 hours burning time, and after dark, take horizontal footcandle readings at road level with the light meter leveled. Use a light meter conforming to the following:

• Lowest full scale not exceeding 2.0 footcandles or equivalent sensitivity.

• Cosine correction, filtered or adjusted to match the CIE response curve and calibrated for the light source.

• Accuracy: ±3% reading ±0.5% full-scale (< 929 footcandles)

• Resolution: 0.001 footcandles

• Calibrated within the last 12 months by an independent testing company.

Take footcandle readings, where directed. Give particular attention to points where low illumination is most likely to occur, usually midway between luminaires. Complete the static load tests specified in Section 1101.02(a)1. Lower and raise the ring assembly of all high mast poles to ensure proper operation.

assets within the contract limits. Enter the data electronically in the Highway Lighting Asset Numbering spreadsheet and provide the updated spreadsheet electronically to the Bureau of Operations – Maintenance Technical Leadership Division (BOO-MTLD) Highway Lighting group.

components of the entire lighting system including lamps, for a period of 180 days. The guarantee begins the day after the lighting system is fully operational, as determined by the Representative, after completion of all lighting system related work and completion of the 168-hour performance test specified in Section 910.3(u). The energizing cost during the guarantee period will be borne by the owner, under the terms of the agreement (where agreements are applicable). Perform the following at the onset of and during the guarantee period:

• Execute the in-service guarantee notification Form CS-4225H, provided by the Department.

• Commence repairs within one calendar day following notification to the person designated on Form CS-4225H.

• Guarantee all repairs and material replacements for the balance of the guarantee period, or 30 days, whichever is the longer period.

• Repair work not performed within the guarantee period, or any extension periods, will be considered latent defects as specified in Section 107.16(b).

Repairs that are the direct result of external causes will be performed by others. Examples of external causes are lightning strikes, vehicular impact, objects driven through the underground circuit, trenching through installed circuits, etc. Issuance of certificate of acceptance or final settlement of the contract is not consequential to the in-service guarantee period described herein. The guarantee period is not a part of the contract time.

910.4MEASUREMENT AND PAYMENT—

The price includes the ground wire, ground rod, ground clamp, bedding, and necessary excavation and backfill.

The price includes either frangible or breakaway base (when indicated) and arm.

The price includes the lowering device and wiring from the line splice to the luminaire ring. The winch drive unit is incidental to the total number of poles constructed.

The price includes complete installation.

The price includes integral ballast or driver and complete wiring from luminaire ballast or driver to line splice.

The price includes integral ballast or driver and complete wiring from the luminaire-ring terminal board to the luminaire ballast or driver.

The price includes integral ballast or driver and complete wiring, conduit, and necessary mounting provisions from the line splice at the junction box to the luminaire.

The price includes mounting and wiring, as directed.

The price includes excavation, concrete, anchor bolt assemblies, reinforcement bars, conduit, ground rod(s), ground rod clamp(s), grounding electrode conductor, backfilling, and satisfactory disposal of surplus material.

The price includes excavation, concrete, backfilling, and satisfactory disposal of surplus material.

The price includes fittings, expansion/deflection fittings, joints, bends, grounds, protective coatings, and appurtenances. Does not include conduit in pole foundations. Unless otherwise authorized, no allowance will be made for additional conduit lengths as a result of deviation from the indicated conduit location.

No allowance will be made for coiling or looping cable slack lengths inside pole bases or junction boxes, when additional lengths of cable are necessary for splicing. An allowance will be made for cable entry into each pole base from the trench to the handhole. Unless otherwise authorized, no allowance will be made for additional cable lengths, or cable size, as a result of deviation from the indicated cable location. The ground rods specified for structures are incidental to the circuit cables. Splices and fuses are incidental to the circuit cables.

The price includes excavation, backfilling, temporary and permanent plastic trench markers, and surplus material disposal. No allowance will be made for rock excavation or for any other subsurface condition encountered. Unless otherwise authorized, no allowance will be made for additional trench lengths as a result of deviation from the indicated trench locations.

The price includes service pole and all necessary power supply equipment.

The price includes furnishing personnel, equipment, and electrical energy necessary for tests.

The price includes all work necessary to install the conduit sleeve as specified in Section 910.3(g). The price does not include circuit conduit passing through the sleeve.

The price includes furnishing personnel and equipment necessary to gather accurate information and to provide updated documentation in electronic spreadsheet format.