drawings indicating the proposed dimensions and material specifications for the control center, enclosure, tran sformer, if required , and navigation light unit shall be submitted for approval purposes within three weeks after the award of the Contract. These drawings will be reviewed by the Division at the earliest possible date and one print will be returned marked "Approved" or "Returned for Revisions as Noted". Eight sets of drawings shall then be submitted for final approval. Resubmission of drawings to obtain final approval by the Division shall not be considered as being just cause for delay in completion of any contract. After the installation is completed, the Contractor shall conduct a continuous 24 -hour operating test for approval. In addition, final acceptance of any installation will not occur until 30 days of operation termed satisfactory by the Engin eer.
662.2.14 .2-Navigation Lighting (Surface): 662.2.14 .2.1-General: Navigation lights shall be securely mounted to the bridge structure or substructure and shall show through a horizontal arc of 360° for green lights and show through a horizontal arc of l80° for red lights as specified or detailed in the Plans. They shall be pivot -swivel mounted or pedestal mounted as specified. The pivot mounted lights shall have a locking mechanism and service -retrieving chain made of corrosion - resistant non -plastic material. The navigation lights shall have one or two lenses with one or two lamps as specified but unless otherwise noted, are to have one lens with one lamp. The lamps shall be 100 -W, 120 -V, rated at 5 -years. The lenses shall be fresnel glass eight (8) inches. The signal housing shall be made of aluminum, silicon bronze or cast bronze and shall be watertight with weather -proof gaskets. The hangar stem shall be 1½ inches minimum galvanized steel pipe or 1½ inches minimum stainless steel pipe. The mo unting bracket and hangar housing shall be cast silicon bronze with stainless steel pivot and shall be watertight. The cable shall be #16 S. O. minimum and all connections shall be watertight. Any other structural connections shall be watertight and of g ood quality non -corrosive construction. The pedestal mounted light shall meet all of the aforenamed light, lamp, lens, signal housing, cable and structural connection requirements. The pedestal mounted stem itself shall be similar to and meet the requirement of the pivot mounted hangar stem requirements. Navigation lights shall be provided with supports constructed of steel meeting ASTM A36. Each fixture shall be individually protected by "in the line" fuses as manufactured by ESNA Corporation, Bussman Manufacturing Division of McGraw - Edison Company, HOMAC, or approved equal. The photoelectric control for navigation lights shall provide automatic switching of circuits. The unit shall be oriented as nearly as possible to face the northern sky. Initial settings shall be thirty -five ( 35) footcandles for "turn on" and fifty-eight ( 58) footcandles for "turn off". The unit shall be housed in a weatherproof enclosure of the twistlock type. The unit shall be "fail safe", i.e., failure of the electronic circuit will "turn on" the navigation lights. The unit shall be suitable for operation in three -wire, 120/240 Volt, 60 Hz. Circuits.
662.2.14 .2.2-Power Service: Power shall be received at a location noted on the Plans or as directed by the Engineer. Power wi ll be 120/240 Volt single phase, 60 Hz., three -
676 wire from the Power Company. Materials to be furnished and installed by the Contractor will be as designated on the Plans or as directed by the Engineer.
662.2.14 .2.3-Cable: Cable shall be single conductor, stranded copper, 600 Volt, Type THW. Cable for the final connection to swivel mounted navigation lights shall be three or four conductor stranded copper, 600 V, TypeS. O. Cable splicing will be permitted in junction bo xes only.
662.2.15 -Electrical Material Documentation and Certification: All work, equipment, and documentation shall conform to 715.43.
CONSTRUCTION METHODS
662.3 -GENERAL : The Plans show, in general, the location of the roadway lighting systems and other incidental work to be performed. They are diagrammatic only, but shall be followed as closely as actual site conditions will permit. Any alternate design or significant departure from the Plans proposed by the Contractor must be prepared by the Contractor in written or plan form, or both, and presented in writing to the Division for approval. The Division will not approve substitution of material or design detail changes which constitute a reduction in q uality, workmanship, or strength of the materials involved.
662.4 -CONCRETE : Concrete shall be mixed and placed in accordance with Section 601 of the Specifications.
662.5 -CONDUIT : Conduits shall be of the size and type noted on the Plans. Conduit shall be installed at a minimum depth of eighteen ( 18) inches and at a distance of at least six (6) inches from any utility line. Conduit runs shall be continuous in size from term inal point to terminal point. No reducing coupling will be permitted. All unused conduits shall be threaded and capped. Unused conduits terminating underground shall also be marked with a concrete marker. The threads on all steel pipe conduit shall be painted with rust preventative paint meeting Military Specification MIL -P-21035 before couplings are made. All couplings shall be tightened until the ends of conduits are brought together. Conduits stubs, caps, exposed threads, or damaged galvanized areas shall be painted with rust preventive paint meeting Military Specification MIL- P- 21035. Expansion deflection fittings shall be installed in metallic conduit runs in bridge structures and in retaining walls at all expansion joints and all stringer (stress) relief joints and all other locations as specified on the Plans. These fittings shall be bonded with approved flexible tinned copper bonding jumpers. Conduit shall be placed under existing pavement by approved jacking or drilling methods. Pavement shall not be disturbed without permission of the Engineer. In the event obstructions are encountered, upon approval of the Engineer, small test holes may be cut in the pavement to locate obstructions. Jacking or drilling pits shall be kept two (2) feet clear of the edge of any type of pavement wherever possible. Water jetting will not be permitted. PVC conduit shall be made water tight by joining with solvent as per the manufacturer ’s recommendations. Ends terminating in junction boxes sha ll be terminated with end bells. Ends
677 joining to metal conduit elbows at foundations shall be connected through expansion couplings and adapters. Approximate lengths of conduit are shown on the Plans. It is the responsibility of the Contractor to determ ine exact lengths of conduit runs in the field. A number 12 AWG (minimum) galvanized 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 te rmination.
662.6 -BACKFILL : 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 re store all areas disturbed by this excavation or other operations to their original conditions including grading, seeding, mulching and fertilizing as directed by the Engineer.
662.7 -MANHOLES AND JUNCTION BOXES : Boxes shall be located as shown on the Plans. Manholes and junction boxes shall be set so that the top of cover will be level with the surface without using an excessive amount of mortar for setting the metal frames. Fill material for dra inage shall be laid twelve ( 12) inches minimum depth under the entire manhole or junction box. The aggregate used shall be stone or gravel of a grade approved by the Engineer and shall be by visual inspection a uniformly graded mixture of particles from 3 /8 to 3/4 inch in nominal diameter. The Contractor may, with the approval of the Engineer and at his own expense, install additional manholes or junction boxes to facilitate the work of installing conduit and pulling cable.
662.8-LUMINAIRES : No luminaire shall be installed until the lamp socket position has been inspected and approved by the Engineer for conformance to the manufacturers recommended position for the specified distribution. All luminaires shall be properly adjusted to produce the maximum illumination on the roadway surface, without disrupting the intended light distribution patter. The connection between the luminaire and connector kits shall be made with # 10 wires.
662.9 -CABLES : The Contractor shall provide adequate equipment for installation of cable, and shall pull all wires through conduits in such a manner as not to score, cut, twist or damage the protective covering or insulation. In the pulling of cables into conduits, where the strain on the cables is likely to prove excessive, the Contractor shall use soapstone powder as a lubricant. Where two or more cables are to occupy the same conduit, they shall be drawn in together and kept paral lel to each other by the use of a pulling head. Without exception, cables in manholes, junction boxes and bases shall be provided with an adequate amount of slack for subsequent connects and shall be arranged as ordered by the Engineer. After the cables have been installed and pending permanent connection, the end of each section of cable in manholes, junction boxes, bases and panel boxes shall be carefully sealed, using rubber tape, and painted with a sealing type of waterproof compound. Cables in manho les and
678 junction boxes shall be placed on cable racks while waiting permanent connection. Ends of cable not connected to any device, which are to remain after completion of construction, shall be insulated and sealed in a manner similar to a special splic e. Cables in manholes and junction boxes shall be neatly arranged in a workmanlike manner and laced with nylon cable straps. The Contractor, in connecting sockets, outlets and other similar equipment, shall ground the most accessible bare parts of each piece of equipment. In order 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 ap proved means of testing. All cable in junction boxes and lighting supports shall be tested for circuit connections which shall be in conformity with those indicated on the detail drawings. All cables in junction boxes, manholes and lighting supports/lighting support bases shall be provided with individual non-corrosive metal (minimum 1 ½ inch diameter) tags, die stamped with the control station (as applicable), circuit and phase designation. Similarly designed plastic tags shall be used in control stations. The tags shall be securely attached to the cables with nylon cord of 1/16 inch minimum diameter. Upon completion of each wiring system, and before any connection is made to operating equipment, it shall be the responsibility of the Contractor to perfo rm, in the presence of the Engineer, the following tests of each circuit to determine where the installations are in acceptable working order: • Tests for continuity • Tests for grounds • Tests for 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.
662.10CABLE -IN-DUCT :
At sign bridges where no sign lighting is contemplated under this contract, a sufficient length of cable shall be brought out of the ground or conduit system and extended up to the handhole or junction box of the sign bridge to permit future connections to sign lighting circuits without the need for splicing in additional underground cable. Underground cable shall be installed at a depth of not less than thirty ( 30) inches below finished grade or within the protection of galvanized metal conduit under roadways or in structures. Cable to be placed within the protection of conduit in structures may be installed without the polyethylene duct specified, provided that the duct originating from an underground location is continuous to the first junction box or other terminal connection on the structure. The general location of the cable is shown in the details of the Plans. However, the Contractor shall locate all underground cable in a manner that will preclude damage to cable resulting from subsequent construction operations. The c onductor size indicated in the Plans is the minimum size permitted. Cable placed in continuous conduit raceways shall be terminated with an appropriate splice connection at each junction box provided in the conduit system even though a lighting unit does not exist at that location, unless directed otherwise by the Engineer in the field. A 5/8 inch by eight ( 8) feet copper weld ground rod shall be installed at each ground mounted sign bridge. Installation and connections to units shall be as directed by t he Engineer. The grounding conductor shall be connected to the grounding lug in each lighting support and sign bridge column.