be of a heavy duty type and be provided with adjustable settings for varying beam pattern. The ballast shall be 100, 175 or 250 watt high p ower factor constant wattage or constant wattage auto transformer for use with appropriate lamp and system voltage. The lamp shall be 100, 175 or 250 watt deluxe white mercury vapor heavy glass type with rated life of 24,000 hours, equal to ANSI Code H38 -4HT (100), H39 -22KB (175) or H37- 5KB (250). The complete luminaire optical assembly consisting of reflector, refractor, lamp socket position and lamps shall produce a light distribution conforming to the Isofootcandle and Utilization Curves of Guth Vertol Signliter, Hollophane 780 Express lite or eq ual as approved by the Engineer.
659.2.11 -Photoelectric Controls (For Independent Sign Light System Only): WVDOH shall not need or require a photocell at each overhead sign structure containing sign lighting to turn sign lights On and Off if a control station running the sign lights already contains a photocell either by design in the Plans or previously field installed. Photoelectric controls shown on the Plans shall be capable of switching multiple fluorescent luminaires directly. The photo cell shall consist of a light -sensitive element connected directly to a control relay and shall be equipped with circuitry designed to accept a supply voltage of 120 volts, unless otherwise indicated on the Plans. The unit shall be preset to “turn on” be tween one ( 1.0) and 3.5 foot candles. “Turn off” shall be at least two times the “turn on” level; however, “turn off” must be greater than 3.0 and less than fifteen ( 15.0) foot candles. The unit shall meet all relevant NEMA standards and shall be twist -lock type equipped for pole-top mounting using a slip fitter or conduit stem, or where pole -top mounting is impossible, bracket mounting to the side of the pole. The unit shall be north oriented. The unit shall be utility grade locking -type photo controls with a two ( 2) to five ( 5) second time delay.
659.2.12 -Marking: Each overhead sign structure containing sign lighting shall be identified by control station number (as applicable) and circuit number (as applicable) with adhesive labels applied six (6) feet above the grade line normal to the roadway. Adhesive labels shall be designed to be exposed to the weather. Legend shall be three ( 3) inches black on white. Also, each corresponding control station feeding sign lighting shall be identified by “WV DOH” label and control station number (as applicable) and corresponding voltage (as applicable) with adhesive labels on the control station door. The same adhesive label specifications apply as are stated above for the sign lighting labels.
CONSTRUCTION METHODS
659.3 -GENERAL : Existing electrical systems (traffic signal, highway and street lighting, flashing beacon, and sign illumination), or approved temporary replacements thereof, shall be in effective operation for the benefit of the traveling public during the progress of the work, except when shut -down is permitted to allow for alterations or final removal of the systems. All systems shall be complete and in operation to the satisfaction of the Engineer upon comp letion of all the work. This includes field focusing of lamp fixtures.
623 659.3.1 -Excavating and Backfilling: The excavations required for the installation of conduit, foundations, and other appurtenances shall be performed in such a manner as to cause the least possible damage to streets, sidewalks, landscaping, and other improvements. The trenches shall not be excavated wider than necessary for the proper installation of the electrical appurtenances and foundations. Excavation shall not be performed unt il immediately before the installation of conduit and other appurtenances. The material from the excavation shall be placed in a position that will not cause damage or obstruction to vehicular and pedestrian traffic or interfere with surface drainage. All excavations shall be backfilled with suitable random material in horizontal layers not to exceed four ( 4) inches after compaction. Each lift shall be compacted to the satisfaction of the Engineer. Testing is not required. All surplus material shall be removed from the right - of-way and the backfill finished flush with surrounding natural ground, including replacement of any damaged facilities or appurtenances. The Contractor shall restore all areas disturbed by this excavation or other operations to t heir original conditions including grading, seeding, mulching and fertilizing as directed by the Engineer. The Contractor shall employ hand excavation methods in areas where underground facilities exist, in order to avoid damaging these facilities. Any damage caused by the Contractor to existing facilities shall be repaired by the Contractor at his own expense, to the satisfaction of the Engineer. The Contractor will be responsible for all claims and damages for interrupted service and all other damage suits which may result from such interrupted service.
659.3.2 -Removing and Replacing Improvements: Improvements such as sidewalks, curbs, gutters, Portland cement and asphalt concrete pavement, bituminous surfacing, base material, lawn and plants, and any other improvements removed, broken or damaged by the Contractor ’s operations shall be replaced or reconstructed with materials of equal quality. The new work shall be left in a serviceable condition satisfactory to the Engineer. Whenever a part of a square or slab of existing concrete sidewalk or driveway is broken or damaged, the entire square or slab shall be removed and the concrete reconstructed as specified. The outline of all areas to be removed in Portland cement concrete pavements shall be cut to a minimum depth of four ( 4) inches with an abrasive type saw prior to removing the pavement material. The cut for the remainder of the required depth may be made by a method satisfactory to the Engineer. Cuts shall be neat and true with no shatter outside the removal area.
659.3.3 -Conduit Installation: 659.3.3.1 -Type R Conduit: Where pull boxes are installed adjacent to the base of a standard or a sign structure post, conduit installed between pull boxes and base shall not be less than two ( 2) inches in diameter. It shall be the option of the Contractor, at his expense, to use conduit of larger size than specified and where used, the larger size shall be for the entire length of the run from outlet to outlet. No reducing coupling will be permitted. The ends of all conduits, whether shop or field cut, shall be reamed to remove burrs and rough edges. Cuts shall be made square and true so that the ends will butt or come together for the full circumference. Slip joints or running threads will not be permitted for coupling conduit. When a standard coupling cannot be used, an appro ved threaded union coupling shall be used. The treads on all conduit shall be painted with a compound meeting specification MIL -P-21035 before the couplings are made up. All couplings shall be screwed up until the end of the conduits are brought together , providing a good structural
624 connection throughout the entire length of the conduit run. Where the coating on the conduit has been damaged in handling or installation, such damaged places shall be painted with an approved rust preventative paint. So far as practical, all conduit shall be run without traps. Where dips are unavoidable, a pull box or drainage tee shall be placed at each low point to drain any moisture accumulation. Conduit runs shall be made with as few couplings as standard length will permit and the total angle of all bends between any two boxes shall not exceed two quarter bends (180 degrees) unless otherwise approved by the Engineer. Two (2) cubic feet of coarse aggregate (crushed stone or gravel) of a size and grade approved by the En gineer shall be placed at drainage tees for underground conduits. Conduit bends, except factory bends, shall have a radius of not less than six times the inside diameter of the conduit. Where factory bends are not used, the conduit shall be bent without crimping or flattening, using the longest radius practicable. Conduit shall be laid at a depth of not less than eighteen ( 18) inches below the curb grade in the sidewalk area, thirty -six (36) inches below the highway pavement grade in the road are as, and twenty -four ( 24) inches below the finished grade an all other areas. All conduit placed under paved roads shall have a minimum diameter of two ( 2) inches. Conduit shall be placed under existing pavement by jacking or drilling methods. Pavement sh all not be disturbed without the approval of the Engineer. All local subterranean utility maps shall be checked before any jacking or drilling operations begin. The near side of the jacking or drilling pits shall have a four (4) foot horizontal clearance from the edge of any type of pavement wherever possible. Water jetting will not be permitted. Conduit terminating in standards or pedestals shall have a projection above the foundation of four ( 4) inches and shall be sloped towards the handhole opening. Conduit ends shall extend into concrete Junction boxes at least 1½ inches and be equipped with approved bonding bushings. Conduit shall be two ( 2) inches above the bottom, and shall be sloped to facilitate pulling of conductors. Conduit entering through the bottom of a pull box shall be located near the end walls to leave the major portion of the box clear. At all outlets, conduits shall enter from the direction of the run. Expansion or deflection fittings, or both, shall be installed in metallic condui t runs at all joints in the structure to compensate for deflection and expansion. Expansion fittings shall be bonded with approved flexible tinned copper bonding jumpers. Where new pull boxes are placed in existing conduit runs, the conduit shall be fitted with threaded bushings and bonded as shown on the Plans. Conduit run on the surface of bridge structures shall be secured with approved strapping spaced not more than five ( 5) feet apart. Expansion fittings, as detailed on the structure Plans, shall be installed where the conduit crosses an expansion joint in the structure. Each expansion fitting shall be provided with a bonding jumper of at least # 6 AWG copper wire or equal. Conduit leading to soffit, wall or other lights or fixtures below the grade of the pull box shall be sealed by means of an approved sealing fitting and sealing compound. A # 12 AWG copperclad pull wire shall be installed in all conduits which are to receive future conductors. At least two ( 2) feet of pull wire shall be doubled back into the conduit at each termination. After backfilling is completed and prior to the installation of cable, all conduits, existing and new, shall be rodded throughout their entire lengths with a mandrel ¼ inch
625 smaller in diameter than the conduit an d two ( 2) inches in length, and with a cylindrical wire brush the same diameter as the conduit.
659.3.3.2 -Type P Conduit: Type P conduits shall be installed in accordance with the applicable methods as prescribed for Type R conduits, with regard to parallel conduit installations, coordinated with the existing or newly installed facilities. Type P conduit shall be made wate rtight by joining with solvent in accordance with manufacturer ’s specifications. Ends terminating in junction boxes shall be terminated with expansion couplings and end bells. Ends joining to metal conduit elbows at lighting standard foundations shall be connected through expansion couplings and adapters.
659.3.4 -Luminaires: No luminaire shall be installed until the lamp socket position has been inspected and approved by the Engineer for conformance to the manufacturer ’s recommended position for the specified distribution. The connections between the luminaire and connector kits shall be made with # 10 wires.
659.3.5 -Pull Boxes: Pull boxes shall be installed at the locations shown on the Plans or, in long runs, shall be spaced at not more than 250 feet. It shall be the option of the Contractor, at his expense, to instal l additional pull boxes to facilitate his work. Pull boxes shall be installed so that the covers are flush with the curb or sidewalk or 2 inches above the surrounding ground when no finished grade is established.
659.3.6 -Cables: The Contractor shall provide adequate equipment for installation of cable, shall pull all wires through conduits in such a manner as not to overstress or stretch any wire, and shall use precautions so as not to score, cut, twist or damage the protective covering or insulation. In the pulling of cables in conduits, where the strain on the cables is likely to prove excessive, the Contractor shall use soapstone powder or other approved lubricant. Where two or more cables are to occupy the same conduit, they shall be drawn in tog ether and kept parallel to each other by the use of a pulling head. The Contractor, in connecting sockets, outlets and other similar equipment, shall ground the most accessible bare parts of each piece of equipment. In order to ensure that this has been done, each piece of equipment shall be tested after installation, and under the supervision of the Engineer, with a test lamp, one leg of which has been connected to a definite ground, or by other approved means of testing. All cables in pull boxes and handholes shall be tested for circuit connections which shall be in conformity with those indicated on the detail drawings. All cables in junction boxes (pull boxes), manholes and standard bases shall be provided with individual non -corrosive metal (minim um 1½ inches) tags, die -stamped with control station, circuit and phase designation as applicable. Similarly designed tags shall be used in the switch boxes. The tags shall be securely attached to the cables with nylon cord of 1/16 inch minimum diameter. Splices where necessary to form continuous circuits, complete and ready for operation, shall be made by the Contractor. Cable splices will be permitted only in accessible locations. Cable splices shall be accomplished by the use of manufactured splice k its. Splice design with a final wrap of tape will not be acceptable. Splice kits shall be installed strictly in accordance with the manufacturer ’s instructions. Upon the completion of each wiring system, and before any connection is made to operating equ ipment, it shall be the responsibility of the Contractor to perform, in the presence
626 of the Engineer, the following tests of each circuit to determine whether the installations are in acceptable working order:
ii. Tests for grounds iii. Tests f or insulation resistance between circuit wires and from circuit wires to ground.
Upon completion of the electrical system, with fuses removed and before energizing, the insulation resistance shall be not less than five megohms.
659.3.7 -Grounding: 659.3.7.1 -General: The necessary conduit, conductors, bonding jumpers, clamps, connectors, ground rods, etc. for the grounding system shall be furnished, installed and connected by the Contractor. Conduit systems must be effectively and perm anently grounded with a cross section as required by the National Electrical Code and of capacity sufficient to ensure continuity and continued effectiveness of the ground connections for fault current. Ground conductors shall be as short and straight as possible, protected from mechanical injury and, if practicable, without splice or joint.
659.3.7.2 -Codes and Approvals: All grounding work shall be done in accordance with the latest edition and revisions of the National Electrical Code and the regulati ons of State and local codes. All connections in ground network shall be those of a type approved by NEC, Article 250.
659.3.7.3 -Metal Conduits: All metal conduit ends shall be bonded and grounded by means of a # 4 bare copper cable. The grounding shall be accomplished by driving ground rods as detailed on the Plans and connecting it through a # 4 copper conductor in the foundation as shown on t he Plans; or by driving ground rods through the junction box drainhole, and connecting it through a # 4 copper connector attached to a grounding stud on the sign lighting standard junction box frame, etc. The connection of the bonding cable to the junctio n box frames and to the shafts of the metallic sign lighting standard shall be done by means of a grounding stud, Burndy ’s Type K2C, Dossert Type DCM, or approved equal. Where the supply voltage is greater than 120/140, the neutral conductor shall be groun ded at the service panels only with the neutrals of dry transformers. At each service point, a ground electrode shall be furnished and installed. Ground electrodes shall be one -piece lengths of copperclad rod, diameter and length as shown on the Plans. Ground electrodes shall be installed in accordance with the provisions of the Code and as indicated on the Plans.
659.3.8 -Service: Service points shown on the Plans are approximate only. The Contractor shall determine the exact locations from the serving utility. Poles shall be placed in the ground to a depth of at least five ( 5) feet. The Contractor shall furnish conduit, cond uctors and all other necessary material to complete the installation of the service riser. Service riser conduit shall terminate with a weather head to prevent the entrance of water, as approved by the serving utility. Where a meter is required, a meter base, furnished by the serving utility, shall be installed by the Contractor.
627 Each multiple service installation shall be grounded in accordance with the provisions in the Code. Where an approximate service point is shown on the Plans, installation an d materials for the connection between the actual service point, as established by the serving utility, and the nearest pull box of the electrical system shown on the Plans, shall be paid for by the Contractor. Where a service point is omitted from the P lans, installation and materials for the connection between the service point, as established by the serving utility, and the nearest pull box of the electrical system shown on the Plans, shall be paid per section 109.4 and 104.3. Upon request of the Con tractor, the Engineer will arrange with the serving utility to complete the service connections and the Contractor shall pay all costs and fees required. Upon request of the Contractor, the Engineer will arrange for furnishing electrical energy. Energy used prior to the completion of the contract will be charged to the Contractor, except that the cost of energy used for the public benefit, when such operation is ordered by the Engineer, will be borne by the Division. When the power service is within a roadway lighting system, it shall be necessary only to provide the connections as shown on the Plans.
659.3.9 -Field Tests: Prior to the completion of the work, the Contractor shall cause the following tests to be made on all lighting circuits, in the p resence of the Engineer.
ii. Each circuit shall be tested for unspecified grounds. iii. A megger test shall be made on each circuit between the circuit and the ground. The insulation resistance shall not be less than th e values specified in the provisions of the Code. iv. A functional test shall be made in which it is demonstrated that each and every part of the system functions as specified or intended.
After the installation is completed, the Contractor shall conduct a continuous 24 -hour operating test for approval. In addition, final acceptance of an installation will not occur until 30 days of operation termed satisfactory by the Engineer. During the 30 days of operation, the Contractor shall be responsibl e for repairing or replacing any defective equipment within 24 hours after being notified by the Engineer. After any malfunctioning equipment has been repaired or replaced, the 30 -day test shall begin anew. Where the sign lighting installation is a part of, and connected to, a roadway lighting installation, the functional test shall be the same as the functional test for the roadway lighting system.
659.3.10 -Ballasts and Isolating Transformers: Splices at ballasts and transformers shall conform to th e Code. Where more than one conductor enters a ballast or transformer sleeve, the insulation and taping shall be applied between the conductors in such a manner as to provide a watertight joint. The splice installation shall be capable of satisfactory op eration under continuous submersion in water.
659.4 -METHOD OF MEASUREMENT : Measurement for payment for sign lighting will be based on each individual lighting system (normally one per overhead sign structure) complete in place, which will include power service, service poles, meter bases, switch box, pole mounted enclosure, transformers, photoelectric controls, disconnects, junction boxes, cable, conduit, luminaires, lamps, ballasts, impact -proof