639 replacement operation, shall be performed according to Standard Detail TES -04. Concrete shall be allow ed to set for a minimum of 49 hours without being exposed to traffic. At no time shall more than one -half of the roadway be closed for any conduit placement operations. Conduit to be placed beneath railroad tracks shall comply with the following: The co nduit shall be rigid metal type, two ( 2) inches minimum size and shall be placed to a minimum depth of five ( 5) feet below the bottom of the tie. The near side of each conduit jacking pit shall be constructed not less than twelve ( 12) feet from the center line of track. When the jacking pit is to be left overnight it shall be covered with substantial planking.
660.15 Junction Boxes :
Junction boxes shall be installed at the locations shown on the Plans or, in long runs, they shall be spaced at not over 200 feet intervals. The Contractor may, at his own expense and with the approval of the Engineer, install additional junction boxes to facilitate his work The tops of junction boxes installed in the ground or in sidewalk areas shall be flush with the surrounding grade or pavement. Concrete junction boxes shall be poured in place. However, pre -cast junction boxes may be used, when in the opinion of the Engineer, the surrounding subgrade has sufficien t bearing qualities to support the box and cast iron frame. All junction boxes shall be set on at least twelve ( 12) inch bedding of aggregate base material as shown on the Plans. Grouting shall be done prior to the installation of conductors. No junctio n boxes shall be set on uncompacted ground. Concrete work shall be done in accordance with the applicable requirements of subsection 660.8. The Contractor shall be responsible for reconstruction and/or replacement of all damaged junction boxes. Damage junction boxes shall be defined as any junction box more than two (2) inches below grade, or is covered by the area roadway surface. The adjustment of the junction box shall include the complete excavation and shall conform to Specifications, Secti on 660.8 and 660.15. All conduit, cable and attached appurtenances shall be incidental to this junction box. The adjustment of the junction box shall be as per detail and shall conform to Specifications
660.16 Wiring :
Sufficient five -conductor signal light cables shall be provided to perform the functional operation of the signal system and, in addition thereto, one spare conductor of a size equal to the largest signal light conductor in th e run, except neutral, shall be provided throughout the signal light system. No more than two signal heads shall be on the same conductor run. When two signal heads are on the same conductor run, they must be of the same signal color sequence. All signa l light conductors shall be run continuously without splices from the terminal block located in a cabinet, compartment, or signal head, to a similarly located terminal block, unless otherwise specified on the Plans. Signal light conductors shall not run t o a terminal block on a standard unless they are to be connected to a signal head that is mounted. All spare wires shall be placed on a special terminal block mounted in the controller cabinet for this purpose. Five-conductor IMSA cable as specified shal l be provided for all signal light circuits. This cable shall consist of red, orange, green, black and white insulated wires. The insulation color shall correspond as nearly as possible to the associated signal sequence color. 640 Permanent identification l abels shall be attached to all controller and detector cabinet wiring to identify circuit and associated phase. Sequence color need not be identified if clearly indicated by conductor insulation color. Wiring diagrams, detailing on one sheet all wires in the controller cabinet that are external to the controller itself, must be included with all signal systems. The diagrams must be complete and show all connections including switches, terminal block, connectors, relays and all other mechanisms in the cab inet. Other wiring for the controller shall be as required by the wiring diagrams and instructions furnished with the controller by the manufacturer. Connection to each terminal of a pedestrian push button shall be by # 14 AWG single conductor in two -wire IMSA cable as required. The neutral for pedestrian push button circuits shall be separate from the signal light circuit neutral. Pedestrian push button circuits shall be limited to 12 volts AC or DC. Conductors shall be pulled into conduit by hand. Th e use of winches or other power actuated pulling equipment will not be permitted. Powdered soapstone, talc, or other inert lubricants shall be used in placing conductors in conduit. When conductors are to be added to existing conductors in a conduit, all conductors shall be removed; the conduit shall be cleaned as provided in 660.14, and both old and new conductors shall be pulled into the conduit as a unit. Where signal conductors are run in lighting standards containing high -voltage series street lighting conductors, either the signal conductors or the lighting conductors shall be encased in flexible or rigid metal conduit, to a point where the two type of conductors are no longer in the same raceway. Where telephone circuits are installed adjacent to signal and lighting circuits, the telephone conductors shall be encased in UL approved flexible metal conduit. All wiring shall be installed in a neat and workmanlike manner. Conductors within fixtures or cabinets shall be cabled together with self clinch ing nylon cable ties, waxed lacing or other method permitted by the Engineer. Wiring within the controller cabinet shall be firm, neatly arranged and laced, or enclosed in plastic tubing or raceways. The finished wiring shall present a neat, clean appear ance so that individual wires may be easily traced to their terminal points. Unnecessary slack in the conductor wires will not be permitted. Wiring workmanship shall be subject to the approval of the Engineer. The ends of wires which are to be attached to terminal blocks of the barrier screw type shall be provided with solderless terminals that meet the requirements of the National Electrical Code. These terminals shall be the pre -insulated positive grip type. The terminal crimping tool shall produce a transverse crimp on the wire. Wires which insert into a positive wire insert type terminal block will not require terminals. No more than two conductors shall be brought to any one terminal. On all pin and receptacle type connections, the receptacle sh all be on the line side of the circuit. Conductor splices may be permitted only in the following types of circuits at the following locations:
i.Loop conductor and lead -in wire in junction boxes at traffic detectors. ii. In modified traffic signal systems where shown on the Plans (low voltage only). Splices, where permitted, may only be made at points of access in conductor runs or raceways (handholes, junction boxes, etc.) and no splices shall be permitted in controller cabinets. All spli ces, with or without connectors, shall be soldered by the pouring or dipping method, except that soldering of pressure connectors and terminals may be omitted provided the connectors and terminals are applied with the proper type tool as recommended by the manufacturer of the connector or terminal being applied. Finished connections and terminals shall comply with the
Source: West Virginia Standard Specifications for Road and Bridge Construction, 2023 Edition. Pages 659–660 of 1,006.