ITEM 632† TRAFFIC SIGNAL EQUIPMENT
632.02† Contractor†Personnel Requirements
632.03† Materials and Equipment
632.04† Certified Drawings
632.06† Vehicular Signal†Head, Conventional
632.07† Vehicular Signal†Head, Optically Programmed
632.08† Pedestrian Signal†Head
632.09† Pedestrian Pushbutton
632.12† Magnetometer Detector unit
632.13† Magnetometer Sensor Probes
632.18† Down Guy Assembly
632.21† Cable†Support Assembly
632.22† Messenger Wire
632.23† Cable†and Wire
632.24† Power Service
632.25† Covering of Vehicular and Pedestrian Signal†Heads
632.26† Removal of Traffic†Signal†Installation
632.27† Reuse of Traffic†Signal†Equipment
632.29† Method of Measurement
632.30† Basis of Payment
632.01† Description.† This work consists of furnishing and installing traffic signal equipment, complete and ready for service.† This work also includes necessary excavation and backfill, disposal of discarded materials, restoration of disturbed facilities, and surfaces to a condition equal to that existing before the Work started, and electrical testing as specified.
Pull boxes, conduits, ground rods, and cable splicing kits required for traffic signal equipment installations are specified in Item 625.
632.03† Materials and Equipment.† Furnish new materials and equipment of first quality, of current design, and free from defects.
Use electrical parts, wire, switches, and other elements of the installations capable of carrying the required current without excessive heating or drop of potential.
Ensure that major items or assemblies of equipment bear a nameplate, indelible marking, or brand that identifies the type, model, catalog number, and manufacturer.
Furnish materials and equipment conforming to:
.... Poles, supports, arms, appurtenances
.... Pedestals............................................................. 732.15
.... Hardware............................................................ 730.08
.... Stainless†steel hardware...................................... 730.10
632.05† General.† Ensure that major items of traffic signal equipment used in combination are compatible, interchangeable, and, whenever feasible, provided by the same manufacturer or supplier.† Furnish electrical materials, equipment, and installations according to the National Electrical Code and the National Electrical Safety Code, and conform to local laws and codes.
Ensure that the traffic control equipment installed in controller cabinets are shop prewired according to a wiring diagram that conforms to plan and specification requirements of the specific project and intersection, and show all wire harness and field connections required, with abbreviations according to Table 632.05-1.† Furnish a neat and legibly drawn wiring diagram, reproduced on durable paper, and place two copies in a plastic envelope fastened to the inside of the controller cabinet.
Identify cable and wire by tags or bands at pull boxes and controller cabinets, with size, material, and method of marking that conform to 725.02, except ensure that the identification on the tags or bands conforms to the wiring diagram with abbreviations according to Table 632.05-1.† The Contractor†may identify field wiring using an indelible pen on a plastic tag instead of embossed letters.
Use spade terminals for wiring connected at signal heads and the wiring connected at terminal blocks within controller cabinets.† However, for incoming power wiring, use either spade terminals or bared conductor wire connected to terminal points utilizing screw or spring applied clamping surfaces compatible with both cooper and aluminum wire and providing a positive grip.† Neatly lash and fasten completed wiring to interiors with clamps and/or ties.
When constructing the traffic control system, cooperate with the agency supplying the electric service.† Supply 120/240 volt, single-phase, three-wire (grounded neutral) power to the disconnect switch.
After completion of the 10-day performance test in compliance with 632.28 and until acceptance, the Contractor†is responsible for the care and maintenance of traffic control equipment installed or reused as part of the Contract.
Upon acceptance of the project, transfer to the Department all manufacturersí guarantees or warranties covering installed electrical or mechanical equipment.† Furnish two copies of wiring diagrams, service manuals, and instructions on installation and maintenance for each different type, model, or system of equipment used on the project.
632.06† Vehicular Signal†Head, Conventional.† Furnish heads in arrangements such that from one to a maximum of five sections assembled with the specified lens size, color, and circular or arrow configuration form a specific signal face.† Mount signal faces alone as a one-way head, or combined with additional faces to form a two-way, three-way, or a maximum of a four-way head.
Furnish multi-way heads with top and bottom brackets for mounting purposes.† Fit faces of lesser height in multi-way heads with pipe spacers.† Close openings unused for mounting purposes with weatherproof caps.
Install signals in a plumb condition, using a balance adjustor only if necessary.† Fit heads mounted on mast arms, except those intended to be rigidly mounted, with a universal hanger allowing the head to swing in both longitudinal and transverse directions.† Use drop pipes of suitable length only when necessary to bring the bottom of the signal heads to a proper roadway clearance.† Use disconnect hangers for suspended heads when specified.
Install incandescent lamps of the proper wattage and light center distance or, when specified, LED lamps in each section.† Rotate lamp sockets positioning the open portion of the incandescent lamp filament in an upward position.
632.07† Vehicular Signal†Head, Optically Programmed.† Furnish heads of this type consisting totally of optically programmed sections unless an intermix of optically programmed and conventional sections is specified.† Install lamps in each optically programmed section.
Program each signal section according to the plan requirements.† For 8-inch (200 mm) sections, use an extender tool as recommended by the manufacturer to program each section.† Upon completion of the project, deliver one extender tool per project to the maintaining agency.
632.08† Pedestrian Signal†Head.† Furnish heads with the type of light source and symbol height specified.† Orient each signal head to its crosswalk, and lock heads in place by the serrated or other type device incorporated in signal housing and support hardware.† Close openings unused for mounting purposes with weatherproof caps.
632.09† Pedestrian Pushbutton.† Properly orient and install pushbuttons on poles or pedestals.† Service pushbuttons mounted on steel poles by wiring inside the poles.† Furnish 3/4-inch (19 mm) diameter holes through the back of the housing and the pole wall, install a rubber grommet, and route wiring through until no external wiring is visible.† Plug any unused conduit attachment holes.† Attach the housing by machine or self-tapping screws in the housing back wall.† Service pushbutton mounted on wooden poles through conduit.† Furnish pedestrian pushbutton signs of the legend and size required.
632.10† Loop Detector unit.† Install and tune detector units to their loops with the sensitivity set for optimum operation and any interference or cross talk eliminated between other detector units in the cabinet.† Perform a field check to ensure that no extraneous detections are occurring by observing each detector unitís operation to determine that a signal occurs only when a vehicle enters its associated loop.† If actuations are observed when there is no vehicle in the loop, eliminate the extraneous detections.
632.11† Detector Loop.† Saw slots in the pavement for installation of vehicle detector loop wire in the configuration, dimensions, and combinations required.† Cut an extension from the loop to the pavement edge to allow wire routing to an adjacent pull box.
Furnish slots 1/16 to 1/8-inch (1.6 to 3 mm) wider than the outside diameter of the loop wire or tubing.† Ensure that the slot depth provides a covering of not less than 3/4-inch (19 mm) above the uppermost detector wire tubing after the loop installation is completed.† Before installing loop detector wire, brush and blow all slots clean of loose material and completely dry.† Install loop detector wire according to 632.23.
For loop detector wire installations in new asphalt, the Contractor†may saw slots and embed sealant in a subsurface course with subsequent covering by the surface course, subject to the Engineerís approval.
632.13† Magnetometer Sensor Probes.† Properly locate and install probes in holes in pavement or bridge slabs.† Form probe holes during concrete placement by pouring around a vertical piece of capped PVC or other non-metallic conduit.† Drill probe holes in existing pavement.† Center probe positions on bridge slabs in the steel reinforcing grid square nearest to the plan location using a metal locator, such as a Pachometer.† Install sensor probe leads in non-metallic conduit, in sawed pavement slots, or by other design methods.† Embed probes, and leads if installed in slots, with flexible sealant according to 632.11.
632.14† Foundations. †Locate support foundations, and stake with the proper elevation.† If underground or overhead obstacles are encountered during stakeout, or to correct slope and subsurface difficulties, change foundation location and orientation with the approval of the Engineer.† Ensure that the approved location provides a safe clearance from overhead power lines for construction operations, in compliance with the National Electric Safety Code.† The Contractor†is responsible for the correct location, elevation, and orientation for all poles and pedestals installed on the foundations.
Excavate for foundations using an earth auger to specified dimensions according to 503.04.† Exercise caution when excavating in areas of underground installations to avoid their disturbance or damage.† When a cave-in occurs, excavate using casing, sleeving, or other methods, with the Engineerís approval.† If subsurface obstructions are encountered, remove the obstructions, or replace the excavated material and relocate the foundation, with the Engineerís approval.† If bedrock is encountered, the Contractor†may reduce that portion of the specified foundation depth within the bedrock up to 50 percent.† Perform all necessary dewatering of the excavation.
Perform foundation concrete work according to Item 511, except that the loading restrictions in 511.17 are modified by this subsection.† Place the concrete against undisturbed soil or compacted embankment.† Form the top of the foundations to a nominal depth of 6 inches (150 mm) below the groundline.† Place† the concrete foundation, including formed top, in one continuous concrete pour.
Before placing foundation concrete for embedded supports, position and brace the supports with any necessary rake to ensure that the supports, after tensioning, assume an essentially vertical position.† For foundations for anchor base type supports, provide the required reinforcing rods, and have anchor bolts and conduit ells accurately held by a template.
Remove forms and templates once the concrete has hardened sufficiently so as not to be susceptible to damage.† Remove bracing for embedded supports after 7 days.† After 14 days, load embedded supports, and erect and load supports on anchor base foundations.† The Contractor†may erect and load supports after 7 days if the tests of two beam specimens of concrete yield an average modulus of rupture of not less than 650 pounds per square inch (4.5 MPa).
Furnish individual anchor bolt covers or cover bases for poles erected in sidewalks, traffic islands, curbed areas, and seeded areas of urban character as specified in 659.09, or when directed by the Engineer.† Do not use concrete grouting in the space between the foundation surface and support base.
632.17† Wood†Pole.† Set wood poles in holes excavated by an earth auger to a minimum depth of 6 feet (1.8 m).† Use an auger with a diameter approximately 4 inches (100 mm) greater than the pole butt.† Hold poles with initial rake, up to a maximum of 12 inches (0.3 m), while tamping backfill into place, so that under messenger wire tensioning conforming to 632.22, the poles assume an essentially vertical position.† Furnish backfill material no greater than 1 inch (25 mm) in size, and thoroughly tamp material in lifts not exceeding 6 inches (150 mm), to the satisfaction of the Engineer.† If concrete embedment is specified, brace the poles until the concrete has set.
Liberally coat field holes bored for the attachment of messenger or guy wire with approved creosote base paint and fitted with 5/8-inch (16 mm) thimble-eye through-bolts and 3-inch (75 mm) washers.† Securely attach and protect ground wire furnished as part of another work item with a wood or plastic molding for a minimum distance of 10 feet (3 m) above groundline.
632.20† Conduit†Riser.† Attach risers to poles to provide a wiring raceway and include a weatherhead, conduit, necessary fittings, and pole attached clamps.† Attach risers to poles by clamps spaced at intervals not exceeding 5 feet (1.5 m).† Paint†conduit risers mounted on painted poles to match the poles.
632.21† Cable†Support Assembly.† Use cable support assemblies to eliminate strain on cables, or groups of cables up to a maximum of four, entering the interior of poles through a weatherhead or mast arm.† If required, include a length of messenger wire forming a sling with ends formed of lapped wire, thimbles, and clamps as part of the assembly.
632.22† Messenger Wire.† Arrange messenger wire with accessories between two or more poles to provide support and attachment for traffic control equipment.† Accessories used with messenger wire include bullrings, thimbles, preformed guy grip dead ends, and three bolt clamps.† Furnish bullrings at messenger wire network corners.† Use thimbles to attach messenger wire to the shackles of strain pole clamps and bullrings.
Adjust the length of the messenger wire under the load of traffic control equipment so the sag at the lowest point is not greater than 5 percent or less than 3 percent of the span.† Attach signal cable to messenger wire with lengths of preformed helical lashing rod that are of a proper internal diameter to tightly secure the cable to the messenger wire.† Attach interconnect cable with preformed lashing rod or spinning wire.
632.23† Cable†and Wire.† Fashion cable at traffic signal equipment weatherhead entrance fittings into a drip loop that extends at least 6 inches (150 mm) below the entrance.† Do not allow the cable to chafe on the equipment.† Support cables installed in strain poles and signal supports with cable support assemblies according to 632.21.
For splices allowed in aerial installations, accomplish splicing in weather tight splice enclosures.† For splices allowed in underground installations, accomplish splicing in pull boxes or poles where the splice is encapsulated with poured waterproof epoxy insulation according to 725.15.
Install signal cable between signal heads and controller cabinets, and install interconnect cable between controller cabinets of different intersections.† Route signal and interconnect cable by aerial installation supported by messenger wire or within underground conduit.† If specified, use aerial self-supporting integral messenger type interconnect cable with a figure ď8Ē cross-section and include pole clamps and splice enclosures.† Ground the supporting messenger wire of interconnect cable.
Provide loop detector wire consisting of detector wire inserted into flexible plastic tubing.† Ensure that the tubing encases the wire continuously from the splice at the lead-in cable, through the entire loop turns, and back to the splice.† Install loop detector wire in sawn roadway slots forming loops according to 632.11.† Furnish the required number of turns of wire installed for each loop, and push the wire carefully into the slots with a blunt tool to avoid damaging the tubing.† Run the wire continuously around the loop perimeter and through a slot leading to the pavement edge and by underground conduit to a roadside pull box or pole with 5 feet (1.5 m) at each end for slack and splice.† uniformly twist wires and tubing installed in the conduit to the splice with lead-in cable at 3 to 5 turns per foot (10 to 16 turns per meter).† Splice the loop ends to lead-in cable, which are connected to the controller cabinet.† Join the wires by a mutually twisted in-line splice, rosin core soldered, and wrapped in vinyl or equivalent electrical tape, and encapsulate wires with an approved poured waterproof epoxy insulated splice according to 725.15.† Extend and seal the tubing ends into the poured epoxy splice.† Also, solder crimped terminals to the conductors and the shield for connections inside the cabinet.
For magnetometer sensor probe installations, splice the leads from the probes to the specified lead-in cable by the same method.† Route lead-in cable within underground conduit or by aerial installation supported by messenger wire.
Install service cable aerially from a remote power source to the vicinity of the controller cabinet with the support cable functioning as the electrical neutral.† Furnish connections used with aluminum power or service cable of an approved type for aluminum to aluminum or aluminum to copper connections, and insulate connections with an approved vinyl mastic pad.
632.24† Power Service.† Furnish and install all equipment necessary to provide complete electrical service to each signal installation as shown on the plans.† Make all necessary arrangements with the local electrical power company for connections to establish electrical service.† The Department will reimburse the Contractor†by Supplemental Agreement for power company fees for establishment of service and electricity.† This compensation is for invoiced cost without mark up.
Power service†consists of equipment to provide a pole attached wiring raceway and disconnect switch for use with power cable routed from the service entrance to the controller cabinet.† The power service installation includes a weatherhead, conduit and fittings, a disconnect switch with enclosure, meter base and attachment clamps.
Terminate the conduit riser at an electric meter base or at the disconnect switch enclosure.† Bend the conduit away from the pole at the top and bottom of the riser to allow the conduit to enter straight into the enclosure or meter base hub, and to provide space for the weatherhead when the riser is pulled tight against the pole.† Furnish watertight conduit connections between the meter base and enclosure by using conduit hubs listed on the enclosure UL label.
From the switch enclosure, make a connection to either a controller cabinet, a pull box, an underground conduit, or a conduit riser.† Ground the switch enclosure neutral bar directly to the pole grounding lug.
632.25† Covering of Vehicular and Pedestrian Signal†Heads.† Cover vehicular signal heads if erected at intersections where traffic is maintained before energizing the signals.† Cover pedestrian signal heads when specified in the plans.† Use a sturdy opaque covering material and method of covering and cover attachment as approved by the Engineer.† Maintain covers, and remove and dispose of them when directed by the Engineer.
632.26† Removal of Traffic†Signal†Installation.† Remove signal heads, cable, messenger wire, strain poles, cabinet, controller, or other incidental items required by the Engineer.† Remove support foundations to at least 1-foot (0.3 m) below subgrade or finished groundline.† Backfill, restore surfaces, and dispose of surplus material according to 603.09.† Store removed items on the project for salvage by the maintaining agency, or reuse removed items as part of a new installation on the project under another item of work.† Dispose of all items not designated for salvage or reuse.† As specified in 614.03, do not remove signals until a new signal system or a temporary traffic control method approved by the Engineer is in operation.† Suitably protect stored equipment.
632.27† Reuse of Traffic†Signal†Equipment.† Reinstall or re-erect specified traffic equipment, removed from existing signal installations within the project.† Clean and restore reused equipment to an operating condition, and relamp signals with the proper type and size lamp.† Furnish all additional hardware and incidentals necessary to allow reuse of the equipment.
A.††††† General.† Furnish all personnel and equipment required to successfully perform the following tests, and furnish to the Engineer†six certified copies of complete test records, test reporting forms supplied by the Engineer, or alternate certification approved by the Engineer.
C.††††† Short-Circuit Test.† Before performing any cable insulation tests or performance test, perform a short-circuit test with a volt-ohmmeter or other approved instrument.† Conduct short-circuit tests with electrical loads, power sources, equipment grounds, and earth grounds disconnected.† Test signal cable routed to signal heads with connections made to lamp sockets without lamps installed.† Measure each conductor against every other conductor and ground to ensure that no short-circuits, cross-circuits, or other improper connections exist.† Ensure that continuity does not exist between any conductor and another conductor including ground.
D.††††† Circuit Continuity Test.† Temporarily jumper each circuit branch at its termination and the temporarily looped circuit measured for continuity to ensure that no open circuits exist, that the circuit branch is according to plan, that no high resistance connections exist, and that each circuit is properly identified.† Test the lead-in cable for loop detector wire before and after splicing the cable to the loop wire.† As an alternative, perform the circuit continuity testing of signal head cable by applying 120 volts to each outgoing circuit and observing that only the proper lamps are lighted.
E.††††† Cable†Insulation Test.† Ensure that the insulation resistance measured to ground is not less than 10 megohms for each conductor of cable or wire terminating at the controller cabinet.† Perform insulation testing with all conductors disconnected from their points on the terminal blocks.† Measure insulation resistance for the wire of roadway loops after the embedding of the wire with sealant in slots.† Include a list of the resistance readings for each conductor in the test results.† After completing the cable insulation test, connect all cabinet wiring according to the wiring diagram.† Demonstrate to the satisfaction of the Engineer†that all circuits are continuous and operating correctly with freedom from shorts, crosses, and unintentional grounds.
F.††††† Functional Test.† Before the 10-day performance test begins, make the following checks and demonstrate to the Engineer†that the system is ready for the performance test.† Ensure that the incoming AC voltage is a nominal 120 volts.† If the supplied voltage under load is less than 100 or more than 130 VAC, contact the power company to arrange correction.† Ensure that the cabinet ventilating fan, fan thermostat, and convenience outlet with lamp is operational.† Correct timing settings on the controller as shown on the plans.† Check all cabinet switches including the power on/off switch and flash switch.† Check all controller functions to verify correct operation.† Check the detector units to determine which pavement loop is associated with which detector unit.† Check the visual indication of detector units to determine that each vehicle class (truck, car, or motorcycle) entering sensor areas is detected on the associated detector unit and that no extraneous calls occur when the sensor area is vacant.† Check the flash switch to verify transfer of signal operation to flash and return to stop-and-go.† Check the conflict monitor to verify that it is not activated by normal signal operations or by the manipulation of cabinet switches.† If the monitor is activated, determine the cause of the problem and make appropriate changes and adjustments before beginning the performance test.† Test the conflict monitor by artificially causing a number of different conflicting indications, and verify that at each test the monitor causes the signals to begin flashing and places the controller in a ďstop timingĒ mode.† Obtain artificial causation either by touching a jumper wire between two conflicting load switch outputs or by other methods approved by the Engineer.† Ensure that the signal flashes when the monitor is disconnected.
G. Performance Test.† At least 7 days before the performance test begins, notify the Engineer†of the starting date.† The Engineer will notify the maintaining agency.† Before acceptance, operate the traffic control system continuously for 10 consecutive days without major malfunction or failure.† Immediately replace or repair minor failures (such as lamps, a single detector unit, or an individual signal head, etc.) that do not cause restart of the test.† Major malfunctions or failures (such as a master or local controller, interconnect equipment, etc.) will cause termination of the test and, after replacement or repair, the beginning of a new 10-day test.† Monitor items that have been repaired or that are replacements for a 10-day period to provide assurance of their reliability.† Record, for inclusion in the test result, the method and date of correction of each fault, and the beginning and end of the test.
632.29† Method of Measurement.† The Department will measure Vehicular Signal†Head and Pedestrian Signal Head by the number of complete units, and will include all support or mounting hardware, disconnect hangers, closure caps, dimmers, and lamps as required.† Optically programmed heads shall include programming.† For programming purposes, 8-inch (200 mm) programmed heads shall include one extender tool per project.
The Department will measure Loop Detector unit and Magnetometer Detector unit by the number of individual units, adjusted and tuned, and will include a wiring harness.† If multi-channel detector units are used, the Department will consider each channel as an individual detector unit up to the number of units specified.
The Department will measure Detector Loop by the number of††††††††††††† complete detector loops installed in the pavement, and will include pavement cutting, loop detector wire with tubing in place, application of sealant, conduit, trenching, backfilling, and surface restoration from the edge of pavement to the pull box.
The Department will measure Strain†Pole Foundation, Signal†Support Foundation, and Pedestal Foundation by the number of complete units, and will include excavation, dewatering, sleeving, casing, reinforcing steel, concrete, backfilling, disposal of surplus excavation, and installation only of anchor bolts and conduit ells.
The Department will measure Signal†Support, Combination Signal Support, Strain†Pole, Combination Strain Pole, Strain Pole Embedded, Combination Strain Pole Embedded, Wood†Pole, and Pedestal by the number of complete units of each, and will include pole arms, weather-heads and blind half couplings, anchor bolts and conduit ells furnished for foundations, and required individual anchor bolt covers or cover bases.
The Department will measure Messenger Wire†by the number of feet (meters) in place, and will include all necessary accessories such as, grips, thimbles, clamps, bullrings, and lashing rod.† The Department will measure from pole center to pole center, or pole center to bullring, or bullring to bullring.† The Department will not measure any length of messenger wire for attachment to poles, or bullrings by bending, lapping, or wrapping.
The Department will measure Signal†Cable, Interconnect Cable, Loop Detector Lead-In Cable, Magnetometer Lead-In Cable, Power Cable, and Service Cable by the number of feet (meters) in place.† Cable inside of poles shall include cable support assemblies.† Aerial cable shall include pole attachment hardware, splices, splice enclosures, and ground connection.† Lead-in cable shall include poured epoxy insulated splices.† The Department will measure:† (1) horizontally from center-to-center of pull boxes, poles, cabinets, power sources, and signal heads with an additional allowance of 5 feet (1.5 m) at each pull box and terminating points for slack and connections; and (2) vertically between pole or conduit outlets.† If single-conductor power cable is substituted for multi-conductor cable, the Department will measure required length of multi-conductor cable.
The Department will measure Power Service by the number of complete units, and will include weatherhead, conduit, fittings, clamps and other necessary hardware, installation of meter base, ground wire connection, and disconnect switch with enclosure.
The Department will measure Covering of Vehicular Signal†Head and Covering of Pedestrian Signal Head by the number of individual signal heads covered, and will include materials and labor to erect, maintain, and remove the covering.
The Department will measure Removal of (Item) and (Storage or Reerection) by the number of specific traffic signal installation parts (such as a signal head, controller unit, or pole) removed, and will include storage when required.
632†††††††††††† Each††††††††††††††††††††††††††††††† Vehicular Signal†Head,
†††††††††††††††††††††††††††††††††††††††††††††††††††††††††††††† Optically Programmed,
†††††††††††††††††††††††††††††††††††††††††††††††††††††††††††††† ___-Section, ___ inch
†††††††††††††††††††††††††††††††††††††††††††††††††††††††††††††† (___ mm) Lens, ___-Way