Article 1 — Description
Construct, furnish, install, or remove Intelligent Transportation System (ITS) ground boxes for fiber optic communication infrastructure complete with lids.
Article 2 — Materials
Provide new materials that comply with the details shown on the plans, the requirements of this Item, and the requirements of the following Items. Item 420, “Concrete Substructures” Item 421, “Hydraulic Cement Concrete” Item 432, “Riprap” Item 44 0, “Reinforcement for Concrete” Item 471, “Frames, Grates, Rings, and Covers” Item 618, “Conduit” Item 620, “Electrical Conductors ” Provide new ITS ground boxes constructed of precast concrete or polymer concrete in accordance with the NEC and in conformance with NEMA standards. Faulty fabrication or poor workmanship in materials, equipment, or installation will be justification for rejection. Provide manufacturer’s warranties or guarantees when offered as a customary trade practice.
2.1 Precast Concrete. Provide precast concrete ground boxes and aprons as shown on the plans and in
accordance with the following . Construct ground boxes with Class A concrete in accordance with Item 421, unless otherwise directed. Provide ASTM A615 Grade 60 reinforcement steel in accordance with Item 440. Provide steel for the frames and covers in accordance with Item 471, unless otherwise approved.
2.1.1 Loading Requirements . Designed to withstand AASHTO H-20 loading. Manufacturer must furnish
certification of conformance with H -20 loading.
2.2 Polymer Concrete. Manufacture ground box and ground box cover from polymer concrete reinforced with
two continuous layers of fiberglass fabric. Provide fabricated precast polymer concrete ground boxes and aprons as shown on the plans and in accordance with ANSI/Society of Cable Telecommunications Engineers (SCTE) 77 . Polymer Concrete. Construct polymer concrete from catalyzed polyester resin, sand, and aggregate. Polymer concrete containing chopped fiberglass or fiberglass -reinforced plastic is prohibited. Ensure a minimum compressive strength of 11,000 psi. Fiberglass Fabric . The base glass on the fiberglass fabric must be alumina-lime borosilicate Type E glass. The reinforcing fabric must line the entire inner and outer surfaces. Obtain approval for the fabric before production.
2.2.1 Loading Requirements . All polymer concrete boxes and covers must meet all test provisions in accordance
with ANSI/SCTE 77 Tier 22 requirements. Al l polymer concret e boxes and covers will be UL-l isted , or manufacturer must provide a certification from a Nationally Recognized Testing Laboratory or documentation of factory testing witnessed and certified by professional engineer licensed in Texas . 869 Ensure ground box withstands 800 lb. per sq. ft. of force applied over the entire sidewall with less than 1/4 -in. deflection per foot length of box. Ensure ground box and ground box cover withstand a test load of 33, 750 lb. over a 10 × 2 0-in. area centered on the cover with less than 1/2 -in. deflection at the design load of 22,500 lb.
Article 3 — Equipment
3.1 Size. Provide ITS g round boxes meeting the configuration types shown in Table 1.
Table 1 Ground Box Inside Dimensions Type Width (in.) Length (in.) Depth (in.) Type 1 ( precast) 24 36 36, 48, or 60 Type 2 ( precast) 36 60 36, 48, or 60 Type 1 ( polymer) 24 36 24, 36, or 48 Type 2 ( polymer) 36 60 24, 36, or 48
3.2 Shape . Provide ITS ground b oxes rectangular in shape.
3.3 Aprons . Provide concrete aprons for ground boxes installed in native ground as shown on the plans. Aprons
will be omitted when the ground boxes are located in riprap, sidewalk, or landscape pavers.
3.4 Bolts . Provide stainless steel penta bolts or special keyed bolts, as required by Department, with associated
hardware as shown on the plans. Provide self -draining bolt holes. Washers must be provided with all bolts .
3.5 Accessories. Include all necessary provisions for knockouts, cable racking, adapters, and terminators for
proper conduit and cable installation.
3.5.1 Knockouts . Provide knockouts at the factory to accommodate the appropriate number and size of condui ts
entering the ground box as shown on the plans. Within the factory, score or provide indention on each outside wall identifying additional conduit entry points for future expansion that does not impact the rebar structure. Place a bell fitting on the end of each conduit to ensure a flush fit inside the ground box. Place concrete grout in the knockout (inside and out), around the conduit and bell fitting, to ensure a neat and watertight fit. Ensure that the grout does not enter the inside of the conduit.
3.5.2 Cable Racking . Provide steel (in accordance with ASTM A153), non- metallic glass reinforced nylon, or
equivalent cable rack assemblies as shown on the plans .
3.5.3 Terminators . Terminators must be appropriately sized for the conduits shown on the plans and must be an
airtight and watertight connection. Terminators for the polyvinyl chloride (PVC) conduits should be placed symmetrically about the centerline of the box at the depth shown on the plans. Terminators that do not have conduits attached must be capped and sealed as shown on the plans . Install the quantity , size, and location of terminators as shown on the plans .
3.6 Cover Requirements. Provide the following types of cover s based on the type of ground box .
3.6.1 Precast C oncrete Ground Box. Provide a one-piece or two -piece galvanized steel or cast- iron cover
depending on the ground box type. Provide a torsion assisted cover for Type 2 ground box with lids that can open freely a minimum 90º each and lock in place with locking latches or a pin- lock inserted in the hinge. Covers must be grounded in accordance with the requirements of the NEC . Provide the cover with drop handles . 870 3.6.2. Polymer Concrete Ground Box. Provide a one- piece or two -piece cover depending on the ground box type, bolted to the ground box . Cover must have at least two lifting eyes .
3.7 Label . Permanently mark all ground boxes and covers with the manufacturer’s name or logo and model
number. Legibly imprint each cover with a permanently marked logo in letters at least 1 in. high as follows : “DANGER —HIGH VOLTAGE TRAFFIC MANAGEMENT,” unless otherwise directed. Glue -in logos are prohibited.
3.8 Security. Equip all ground box cover s with a stainless steel penta head or keyed bolting system that will
securely hold the cover in place. Provide an appropriate means to secure or lock the cover in place as sh own on the plans.
3.9 Skid Resistance. All ground box covers must be skid resistant and should have a minimum coefficient of
friction of 0.50 on the top surface of the cover . Provide certification that minimum coefficient of friction value is met as part of material documentation.
3.10 Strength Requirements . The following ground box strengths are required based on the following two
applications .
3.10.1 Deliberate Roadway Traffic. Precast concrete ground boxes with steel covers must be used in location s
that may experience deliberate, continuous vehicular traffic , such as near the shoulder or an auxiliary lane, or immediately adjacent to the unprotected edge of pavement. Do not place ground boxes in the paved travel lanes or shoulder of highways, frontage roads, streets, bridges, or driveways . Ground boxes and covers located in these areas must be r ated for heavy -duty traffic loading and meet an AASHTO H-20 design loading. Precast concrete ground boxes and covers located in non- deliberate heavy vehicular traffic must still m eet AASHTO H -20 design loading.
3.10.2 Non-Deliberate Heavy Vehicular Traffic. Polymer concrete ground boxes and cover s may be used in
off-roadway applications subject to occasional non- deliberate heavy vehicular traffic, such as driveways, along sidewalks, parking lots, and behind non- mountable curb. Polymer ground boxes and cover s located in these areas must meet ANSI /SCTE Tier 22 loading requirements.
Article 4 — Construction
Perform work as shown on the plans and in accordance with this Item. Use established industry and utility safety practices when installing or removing ground boxes located near underground utilities. Consult with the appropriate utility company before beginning work.
4.1 Installation . Install ground boxes as shown on the plans. Maintain spacing as shown on the plans.
Ground box locations may be revised to fit existing field conditions or to better facilitate the installation of the conduit system with approval. Field -locate ground boxes to avoid steep slopes and low -lying locations with poor drainage. Construct ground box cover to fit properly on ground box . When installing ground boxes in surfaced areas, make the tops of the ground boxes flush with the finished surface.
4.1.1 Gravel at Base of Ground Box. Install all ground boxes on a bed of crushed rock at the base of the
excavation as shown on the plans. Place 12 in. of washed, crushed stone (1.5 in. nominal ) that extends 6 in. 871 in all directions from the perimeter of the box. Lightly tamp the gravel immediately before the placement of the ground box to reduce settlement. Crushed gravel will not be paid for directly, but will be subsidiary to this Item.
4.1.2 Cable Racking Installation . Provide and locate cable rack assemblies designed to support up to 25 ft. of
slack for each fiber optic cable inside each Type 1 ground box , 100 ft. of slack for each fiber optic cable inside each Type 2 ground box , slack associated with other communication cabling, and any splice enclosure as shown on the plans or as directed. Cable racks may be installed at the factory or in the field. Place the racks in a manner so as not to impede access in and out of the ground box . Ground metallic cable rack assemblies to grounding system inside ground box in accordance with the NEC. Use fasteners with an ultimate pull out strength of at least 2, 500 lb. and ultimate shear strength of at least 3,000 lb. When securing cable racks to si dewalls of ground box in the field, seal all penetrations to the sidewall to prevent moisture and contaminant penetration. Enough cable supports must be provided for the particular conductors or cables coiled or passing through the ground as shown on the plans or directed by the Engineer.
4.1.3 Buried Installation . When shown on the plans or identified in the General Notes, bury ground boxes for
security measures. When burying ground boxes, provide polymer concrete ground boxes meeting ANSI/SCTE Tier 22 loading r equirements. Provide 12 in. cover between ground surface and top of ground box lid. Before backfilling, provide 30- lb. felt paper over the entire ground box extending at least 2 in. from either side to prevent backfill materials from entering ground box.
4.2 Excavation and Backfill . Ensure excavation and backfill for ground boxes are in accordance with Item 400,
“Excavation and Backf ill for Structures.” For buried ground boxes, compact backfill material to prevent depressions in ground surface from occurring ov er the ground box.
4.3 Testing . Ground box and cover must be tested by a laboratory independent of the manufacturer to meet
loading requirements. Certificate of such tests must be submitted to the Engineer for approval .
4.4 Documentation Requirements . Submit docum entation for this Item consisting of the following for Engineer
approval before installation or as specified below: recorded Global Positioning System (GPS) coordinates using North American Datum of 1983 (NAD83) for all ground boxes before backfill , with c oordinates identif ied by location on drawing detail ; shop drawings; concrete mix design; material specifications for ground box, lid, cable racks, bolts, and skid resistance for cover; and testing certification for loading requirements. Shop drawings should clearly detail the following for g round boxes , at minimum : dimensions, knockouts, cable racks, terminators, adapters, bolts, cover, load rating, and cover lock. 872 4.5. Removal . Remove existing ground boxes and concrete aprons to at least 6 in. below the conduit level. Uncover conduit enough distance so that 90º bends can be removed and conduit reconnected. Clean the conduit in accordance with Item 618. Replace conduit within 5 ft. of the ground box. Remove old conductors and install new conductors as shown on the plans. Backfill area with material equal in composition and density to the surrounding area. Replace surfacing material with similar material to an equivalent condition.
Article 5 — Measurement
This Item will be measured by each ground box installed or removed.
Article 6 — Payment
The work performed and materials furnished in accordance with this Item and measured as provided under “Measurement” will be paid for at the unit price bid for “ITS Ground Box (Precast Concrete)” of the various types and sizes specified or “ITS Ground Box (Polymer Concrete)” of the various types and sizes specified, and for “Remove ITS Ground Box.”
6.1 Furnish and Install. This price is full compensation for excavating and backfilling; constructing, furnishing,
and installing the ITS ground boxes and concrete aprons, when required; and all labor, tools, equipment, materials, transportation, accessories, documentation, testing, and incidentals. Conduit will be paid for under Item 618 and Item 619, “Intelligent Transportation System ( ITS) Multi -Duct Conduit.” Electrical conductors will be paid for under Item 620.
6.2 Remov e. This price is full compensation for removing and disassembling ground boxes and concrete aprons;
excavation, backfilling, and surface placement; removing old conductors; disposal of unsalvageable materials; and materials, equipment, labor, tools, and incidentals. Cleaning of conduit will be subsidiary to this Item. Conduit replaced within 5 ft. of the ground box will be subsidiary to this Item.