725
HIGHWAY LIGHTING MATERIALS
725.01 General. Furnish luminaires, conduits,
wire, switch gear and other electrical hardware that are listed with
Underwriters Laboratories.
Ensure
that each item of manufactured electrical apparatus as a unit has a durable
nameplate identifying the manufacturer and manufacturer’s product
identification.
Only
provide samples when required by the Laboratory.
725.02 Wire and Cable. Ensure that each nonshielded wire or cable rated 0-2kV is single conductor,
stranded copper with cross‑linked thermosetting polyethylene insulation, nonjacketed, meets the requirements of ICEA S-95-658/NEMA WC70 and
is of UL Type RHH‑RHW‑USE
except for conductors 10 AWG and smaller for which
those with insulation meeting the requirements of UL Type XHHW
may also be used.
Ensure
that each non-shielded wire or cable rated 5000 volts (2400 volts working under
the 2005 NEC) is single conductor, stranded copper with chemically cross-linked
polyethylene insulation, nonjacketed, meets the
requirements of ICEA S-96-659/NEMA WC71 and
of UL Type MV-90 dry.
Ensure
that each cable’s identification device defining its use is either a tag tied
onto the cable or a band applied around the cable. Ensure that cable tags
are of copper, brass or plastic (except for tags within switch and device
cabinets which shall be nonconducting) 1/32 inch (0.8
mm) minimum in thickness permanently fastened to the cables by means of cable
tying straps. Ensure that cable identifying bands are approximately 1/32
inch (0.8 mm) thick wrap completely around the cable and closed securely.
Ensure that each tag or band is marked using 1/4 inch (6 mm) minimum height
embossed or engraved letters.
Ensure
that conductors shall be marked “CKT” followed by the
circuit designation shown on the plans and that grounding conductors are marked
“GND” and that neutral conductors are marked “NEU” and that hot conductors are marked “Line“ followed by
“1” or “2” for single phase power or “Phase“ followed by “A“ or “B“ or “C“ for
three phase power.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.03
Unit Type Duct-Cable Systems Ensure that
factory made cable-in-duct has conductors as specified, that the duct is high
density polyethylene Type III, Class C, Category 5, Grade 34 conforming to NEMA TC‑7
and that the duct has
the manufacturer’s name and the year of manufacture included in the marking.
Conductors
and neutrals will conform to 725.02.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.04 Rigid Galvanized Steel Conduit and Fittings Ensure
that rigid galvanized steel conduit complies with the requirements of ANSI
C 80.1 and UL 6 Type
I and that each length of conduit bears the UL label. Furnish fittings that
comply with the requirements of ANSI/NEMA FB 1 AND ANSI/UL
514B.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.051
Polyvinyl Chloride Conduits and Fittings. Furnish polyvinyl chloride
conduit EPC-40-PVC conforming with NEMA Standard TC 2 for normal
above ground or below ground installation, either concrete encased or direct
burial. Use fittings conforming to NEMA Standard TC-2 references.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.052
Polyethylene Conduits and Fittings. Furnish polyethylene conduit
EPEC-40-HDPE conforming to NEMA Standard TC 7 for below
ground only installation, whether concrete encased or direct burial. Use
fittings conforming to ASTM
D3350.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.06 Polymer Concrete Pull Boxes. Ensure
that the polymer concrete pull box and cover is of aggregate bound with a
polymer resin. Ensure that the body of the box is of one piece
construction. Ensure that all surfaces of the box and cover are smooth
and that the cover has a molded slip resistant surface. Ensure that the
cover is slip resistant and is labeled in clearly legible block letters 1 to 2
inches (25 to 50 mm) in height integral to the cover with the word “TRAFFIC”,
“LIGHTING”, “ELECTRIC” or “TELEPHONE“ to designate the circuit(s)
contained. Ensure that the cover closely fits the opening and is secured
by stainless steel bolts and hardware and that the threaded holes into which
the cover bolts fasten are of open bottom design. Ensure that the box and
cover meet the structural requirements of Society
of Cable Telecommunications Engineers Tier 15.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.07 Plastic Pull Boxes. Ensure that the
plastic pull box and cover is of high density ultraviolet stabilized molded
polyethylene with a box wall thickness of at least 1/4 inch (6 mm). The box
depth may be obtained through the use of extensions or stacking. Ensure that
the cover is slip resistant and has in clearly legible block letters 1 to 2
inches (25 to 50 mm) in height integral to the cover the word “TRAFFIC”,
“LIGHTING”, “ELECTRIC” or “TELEPHONE” to designate the circuit(s)
contained. Ensure that the cover closely fits the opening and is secured
by stainless steel bolts and hardware and that the threaded holes into which
the cover bolts fasten are of open bottom design. The box shall meet the
structural requirements of Western
Underground Committee Guide 3.6.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.08 Portland Concrete Pull Boxes.
A. Pull Box. Ensure that the Portland concrete pull box is
constructed of reinforced portland
cement concrete. When the box is precast, provide pull boxes from
suppliers certified to Supplement 1073.
Ensure that the pull box cover is constructed according to 725.08.B and as shown on the plans.
B. Pull Box Covers. Furnish metal pull box covers that conform to
the following requirements:
1.
Furnish 1/2-inch (13 mm) thick steel plate for the steel cover conforming to 711.01 with a 1/2-inch (13 mm) minimum flange
around the edge and galvanized to conform to 711.02.
Display on the steel cover or on an attached brass or stainless steel plate
(tag) clearly legible block letters 1 to 2 inches (25 to 50 mm) in height with
the word “TRAFFIC”, “LIGHTING”, “ELECTRIC” or “TELEPHONE” to designate the
circuit(s) contained. Ensure that the word designating the use is in
raised letters that are either integral to the steel cover or integral to a
brass or stainless steel plate 1/16 inch (1.6 mm) in thickness securely
mechanically attached to the steel cover at the four corners of the tag and at
intervals 2 to 3 inches (50 to 75 mm) along the perimeter between corners.
2.
Furnish gray iron or ductile iron with a minimum thickness of 3/8 inch (9 mm)
conforming to 711.14. Certification is
required. Ensure that the word “TRAFFIC,” “LIGHTING”, “ELECTRIC,” or
“TELEPHONE” is cast in the top surface of the cover forming letters 1 to 2
inches (25 to 50 mm) in height.
725.10 Junction Boxes. Ensure that the
junction boxes are iron castings hot‑dip galvanized in accordance with 711.02. Ensure that the junction boxes meet the
requirements of NEMA ICS‑6‑Type 3. When a drilled and
tapped conduit entry is stipulated, ensure that the junction box has adequate
wall thickness and that a boss has been cast into the box if necessary.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
A. Optical System. Furnish a luminaire set to the photometric
distribution stipulated in the plan and that the distribution along with the
settings required to produce it are clearly indicated on a durable label
affixed to the interior of the housing in a position readily apparent and
easily read by a worker lamping the luminaire.
Furnish a luminaire
with a borosilicate glass refractor free of striations and imperfections and
embossed to clearly indicate the street side when the refractor may be
installed in more than one position. Ensure the refractor is held firmly
in the housing, but is easily removed without the use of special tools.
Furnish a luminaire
with an aluminum reflector with a specular polished reflective surface free
from scratches. Ensure the reflector is held firmly in the housing, but
is easily removed without the use of special tools.
Furnish a luminaire
with a socket for mogul base lamps where there is a choice of size for the
application at hand.
Furnish a lamp socket
with a large center contact spring providing a firm contact with the lamp base
and lamp grips to prevent the lamp from loosening. Ensure that the shell
is shrouded in porcelain and that the wiring terminals and contacts are
identified.
Ensure that socket
position adjustments have positive indexing such as holes, lugs or notches and
are not slots with infinite settings.
Ensure that socket
adaptors are not necessary and not used.
B. Lamps. Furnish a luminaire that has been provided with a
lamp of the type and wattage specified and that each lamp has a clear glass
envelope, a date recording feature and does not have any ballasting or starting
components.
Furnish high pressure
sodium lamps that are first line, high quality lamps having heat resistant
clear glass envelopes with a quartz arc tube interior with horizontal initial
lumens and approximate hours of life not be less than the values shown in Table
725.11-1.
ANSI |
WATTS |
Horizontal Lumens |
Economic Life |
S62 |
70 |
5,800 |
14,000 |
S54 |
100 |
9,500 |
14,000 |
S56 |
150 |
16,000 |
16,000 |
S66 |
200 |
22,000 |
16,000 |
S50 |
250 |
27,500 |
16,000 |
S67 |
310 |
37,000 |
16,000 |
S51 |
400 |
50,000 |
16,000 |
S52 |
1,000 |
130,000 |
16,000 |
Furnish high pressure
sodium lamps that produce a minimum of 80 percent of the initial lumen output
at the end of economic life.
Furnish metal halide
lamps that are first line, high quality lamps having heat resistant clear glass
envelopes with a quartz arc tube interior with horizontal initial lumens and
approximate hours of life not less than the values shown in Table 725.11-3.
ANSI |
WATTS |
Horizontal Lumens |
Economic Life |
M57 |
175 |
14,000 |
4,000 |
M58 |
250 |
18,000 |
4,000 |
M59 |
400 |
32,000 |
10,000 |
M47 |
1,000 |
95,000 |
7,500 |
Furnish metal halide
lamps that produce a minimum of 65 percent of the initial lumen output at the
end of economic life.
Furnish low pressure
sodium lamps that are first line, high quality lamps having heat resistant
clear glass envelopes with a quartz arc tube interior with horizontal initial
lumens and approximate hours of life not less than the values shown in Table 725.11-4.
WATTS |
Lumens |
Economic Life |
35 |
4,000 |
16,000 |
55 |
8,000 |
16,000 |
90 |
13,500 |
16,000 |
135 |
22,500 |
16,000 |
180 |
33,000 |
16,000 |
Furnish materials
according to the Department’s Qualified
Products List (QPL).
C. Ballast. Ensure that the ballast is of an integral design
contained within the luminaire housing.
If the ballast is to be
wired line to line or phase to phase, ensure that the ballast has an isolated
primary winding. If the ballast is to be wired line to grounded neutral
or phase to grounded neutral, the ballast may be either the isolated primary
winding design or the auto transformer design.
Furnish a ballast (in conjunction with the starter in the case of
high pressure sodium lamps) capable of starting and operating the lamp at
ambient temperatures as low as ‑20 °F (‑30 °C).
At circuit voltage of
nominal plus or minus 10 percent or the ballast manufacturer’s stated range if
greater, ensure that the ballast can start (in conjunction with the starter in
the case of high pressure sodium lamps) and operate the lamp within the lamp’s
ANSI operating parameters for the full design life of the lamp.
Furnish a ballast capable of operation with the lamp in an open or
short circuit condition for six months without significant loss of ballast
life.
Furnish a starter of
encapsulated solid state design capable of withstanding the temperatures
encountered in the ballast compartment of the luminaire.
Ensure that the
starter provides a timed pulsing with sufficient follow through current to
completely ionize and start all lamps that meet published ANSI standards.
Ensure that the
starter has push‑on type electrical terminations and is field replaceable
with no adjustment necessary for proper operation.
Ensure that there is
a barrier type terminal block for connection of the incoming electrical
circuit.
D. Housing. Furnish a housing of cast aluminum.
Ensure that the
housing has a flat area on the top side on which a level may be placed and read
by a worker leveling a mounted luminaire on an erected support.
Ensure that the
door(s) providing access to the optical and electrical components have hinges
and latches of corrosion resistant materials that remain securely closed during
operation.
Ensure that the
silicone rubber, ethylene propylene terpolymer, dacron felt or other durable gaskets and seals supplied by
the manufacturer either as part of the basic luminaire or as options are in
good condition and properly installed at the socket entry, between the
refractor and reflector and any other location where such gaskets or shields
are part of the luminaire and options.
Ensure that the
exterior finish of the luminaire is a light gray color unless otherwise
specified.
Furnish a glare
shield of aluminum or opaque plastic material when specified. Furnish a shield
supplied by the manufacturer of the luminaire.
E. Conventional Luminaries. Ensure that the luminaire housing doors may be
opened, closed, removed or installed without the use of tools.
Ensure that the clamp
for the slip‑fit mounting accommodates both 1 1/4 inch (32 mm) and 2 inch
(50 mm) nominal pipe mounting bracket. Ensure that a stop is provided as
part of the housing to prevent over insertion of the bracket into the
housing. Ensure that the clamp engages at least 4 1/2 inches (115 mm)
longitudinally along the arm of the bracket arm between the extremes of a
minimum of two clamping points. Ensure that the mounting clamp provides
for leveling of the luminaire to the specified transverse and longitudinal
position with respect to the roadway.
Ensure that the
luminaire is equipped with a device indicating the direction and amount of tilt
over a range of zero to five degrees in any direction with indications at
level, three degree tilt and five degree tilt all accurate to one half
degree. Ensure that the indicating device is clearly readable in daylight
from a distance of 50 feet (15 m) and in no way alters or reduces the amount of
light from the luminaire. Ensure that the indicating device is
constructed of a transparent container having one horizontal surface which is
curvilinear in any vertical cross section for supporting an indicator and a
damping fluid. Ensure that the damping fluid is a liquid which shall be
suitable for operation at ‑40 °F (‑40 °C) and that the transparent
container is fabricated from clear ultraviolet‑inhibited acrylic or
similar material.
Ensure that the glare
shield will cut off the upward component of light and that it does not reduce
the total output of the luminaire more than 3 percent.
Ensure that the
luminaire has a label or decal indicating the type of source and wattage
rating. Ensure that, with the luminaire installed in its normal operating
position, the label or decal is clearly legible in daylight at a distance of 50
feet (15 m). Ensure that the labeling is in accordance with the
provisions of NEMA Publication OD‑150 or EEI
Publication TDJ‑150.
Ensure that the
complete conventional luminaire assembly including the lamp and all options
including, when required, the glare shield does not weigh more than 75 pounds
(34 kg).
Furnish materials
according to the Department’s Qualified
Products List (QPL).
F. Wall Mounted Underpass Luminaires. Ensure that the assembly is weatherproof and sealed
against dust.
Ensure that a wire
entry for the incoming power is provided on both of the vertical side surfaces
of the housing, that each entry is drilled and tapped for 3/4-inch (19 mm)
conduit and that the unused entry is properly closed with the screw type plug
supplied by the manufacturer.
Ensure that the
luminaire housing doors may be opened, closed, removed or installed without the
use of special tools.
Ensure that the
housing can be mounted onto a vertical flat surface by means of cap screws or
bolts through the wall side of the housing.
Ensure that the
luminaire has the option for protecting the glass refractor with a guard or
shield that is integral to the luminaire and does not have to be removed to
gain access to the lamp or ballast.
Furnish materials
according to the Department’s Qualified
Products List (QPL).
G. High Mast / Low Mast Luminaires. Ensure that luminaires with a symmetric distribution
shall have an initial intensity of no more than 100 candela per 1000 lamp
lumens at nadir and no more than 325 candela per 1000 lamp lumens at angles
between 55 and 65 degrees above nadir.
Ensure that luminaires
with an asymmetric distribution or a long and narrow distribution shall have an
initial intensity of no more than 175 candela per 1000 lamp lumens at nadir and
no more than 425 candela per 1000 lamp lumens at angles from 66 through 73
degrees above nadir.
Ensure that the
output efficiency of the luminaire shall be not less than 65 percent of the
bare lamp lumens. The luminaire shall emit at least 25 percent but no
more than 35 percent of the bare lamp lumens at vertical angles of at least 60
degrees above nadir but no more than 90 degrees above nadir.
Ensure that no
portion of the arc tube of the lamp shall be viewable at angles of 70 degrees
or more above nadir.
Ensure that the
photometric distribution is produced by an optical assembly consisting of a
reflector alone or in combination with a refractor which redirects the output
of a lamp mounted in a socket therein and that the reflector and refractor (if
used) are each of a one piece design.
Ensure that the
optical assembly is field rotatable to align the light distribution
horizontally independent of the orientation of the arm supporting the
luminaire.
Ensure that a
luminaire for use with a 1000 watt lamp has an auxiliary lamp support that
engages the outer end of the lamp envelope.
Ensure that the
luminaire is of substantial design adequate to operate at mounting heights up
to and including 150 feet (45 m) and wind velocities up to and including 90 mph
(145 km/h).
Ensure that the
luminaire mounts by means of a slip fit onto a horizontal 2-inch (50 mm) pipe
and that the luminaire’s integral mounting provides adjustment for leveling but
remains secure and does not twist about the mounting pipe of the bracket when
subjected to the vibration and wind loads of the installation.
Ensure that the
maximum weight of the complete luminaire does not exceed 75 pounds (34 kg) and
the maximum projected area does not exceed 3.5 square feet (0.3 m2).
Furnish materials
according to the Department’s Qualified
Products List (QPL).
725.12 Polyethylene, Fiberglass Reinforced, Pull Box with
Polymer Concrete Cover and Support Ring Ensure that the
pull box body is of fiberglass reinforced high density ultraviolet stabilized
molded polyethylene with a polymer concrete cover support ring and polymer
concrete cover. Ensure that the body of the box is of one piece
construction. Ensure that the body of the box has a wall thickness of at
least 1/4 inch (6 mm). Ensure that the cover support ring is permanently
integrated into the box. Ensure that the cover is slip resistant and has
in clearly legible block letters 1 to 2 inches (25 to 50 mm) in height integral
to the cover the word “TRAFFIC”, “LIGHTING”, “ELECTRIC” or “TELEPHONE” to designate
the circuit(s) contained. Ensure that the cover closely fits the opening
and is secured by stainless steel bolts and hardware and that the threaded
holes into which the cover bolts fasten are of open bottom design. Ensure
that the box and cover meet the structural requirements of Society
of Cable Telecommunications Engineers Tier 5.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.15 Circuit Cable Connections and Terminations. Ensure that
each connector or terminator is of the same voltage rating as the wire being
connected or terminated except that 600 volt connectors may be used with 5000
volt (secondary service) cable used in 600 volt service for the highway
lighting circuits.
Ensure
that each connector or terminator is a compression style which fully encloses
the conductor(s) and is of high strength copper alloy not a metal other than
copper which has been plated. Ensure that each connector used for a “butt”
splice is a sleeve type with a “stop” in the center.
A. Termination of Oversize Wire. Ensure that each cable terminal of each device can
properly accommodate the size of the wire being terminated. If a terminal of
adequate size cannot be furnished, ensure that a short length of smaller wire
is connected to the oversize conductor through the use of a proper butt style
crimp connector or a terminal block, that no strands have been cut back in the
oversize conductor to make the connection and that the smaller wire is rated to
carry the full ampacity of the circuit protection
device.
B. Fused Pull-Apart Connection. Ensure that each fused pull-apart cable connector kit
is a molded synthetic rubber housing consisting of a female line side with two
ports and a male load side with one port containing a socket type fuse holder
wherein the fuse also acts as the pin for the load connection which is designed
to break the circuit when the two halves of the connector body are
separated. Ensure that the assembled kit is rated for direct burial and
exposure to sunlight. Ensure that the metal parts of connector are of
copper with a conductivity of 90 percent, have individual compression
connections for each wire on the line side, have a crimp connection for the
wire on the load side and have annular spring on the socket for each end of the
fuse. Ensure that the fuse holder is for a standard midget 13/32 × 1
-1/2-inch (10 × 38 mm) fuse. Ensure that the fuse is rated 600 VAC, 100,000 AIC and does not have a glass body.
Ensure that each cable port is sized for the wire or cable entering the
entering the port and that there is a closure for the second line port if it is
not to be used.
C. Unfused
Pull-Apart Connection. Ensure that
each unfused pull-apart cable connector kit is a
molded synthetic rubber housing consisting of a female line side with two ports
and a male load side with one port containing a line side socket and load side
pin making a connection which is designed to break the circuit when the two
halves of the connector body are separated. Ensure that the assembled kit
is rated for direct burial and exposure to sunlight. Ensure that the
metal parts of connector are of copper with a conductivity of 90 percent, have
an individual compression connection for each wire on the line side, have a
crimp connection for the wire on the load side, and have an annular spring on
the socket for the pin. Ensure that each cable port is sized for the wire
or cable entering the port and that there is a closure for the second line port
if it is not to be used.
D. Unfused
Bolted Connection. Ensure that each unfused re-enterable cable connector kit is a rigid molded
plastic sleeve closed on each end by a molded synthetic rubber female end
housing having one or two ports as needed containing space in which the
connection is made by crimping a lug onto each wire
and then bolting all of the lugs together. Ensure that the assembled kit
is rated for direct burial and exposure to sunlight. Ensure that the metal
parts of connector are of copper with a conductivity of 90 percent and that
each connecting bolt has a self-locking nut. Ensure that each wire enters
through a port sized for the wire and that there is a closure for the port if
it is not to be used.
E. Unfused
Permanent Connection. Ensure that
each cable splicing kit is a rigid transparent molded body having as many as
two ports on each which allows the completed splice to be completely
encapsulated by filling the mold with a resin compound. Ensure that the actual
conductor connections are made using one time use compression connectors and
that each wire or cable enters the mold through its own port.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.16
Ground Rods.
Ensure
that each ground rod is 1 inch (25 mm) in diameter and 10 feet (3 m) in length
with a driving point on the lower end. If of other than circular cross
section, ensure that the periphery of the rod is 3.2 inches (80 mm) or
more. Ensure that the rod is of solid construction and is either
stainless steel jacketed steel, copper clad steel or hot dipped galvanized
steel in accordance with ASTM
A 153, Class B-1.
Ensure
that the rod bears a label denoting that it is UL listed.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.19
Power Service Components. Furnish the materials and equipment
comprising a service pole, including service equipment, that
meets the following requirements.
A. Service Entrance Conduit. Ensure that the service entrance or riser conduit is
rigid galvanized steel with a rain tight galvanized steel service entrance head
(weatherhead) threaded to fit the conduit containing
a composition insert for three conductors.
B. Service Disconnect. Ensure that the service disconnect is a properly
rated fused switch of the ampacity specified and
solid neutral. Ensure that the service fuses are cartridge fuses on the load
side of the switch.
C. Lighting Contactor. Ensure that the lighting contactor is of the open type
electromagnetically held.
Ensure that control of
the contactor is through a photocell connected through a “HAND‑OFF‑AUTOMATIC”
selector switch accessible only with the contactor enclosure open. Ensure
that the control circuit is a separate circuit with its own protection.
D. Lighting Circuit Protection. Ensure that separate protection is provided on the
load side of the lighting contactor for each lighting circuit and that such
protection will open all line or phase conductors of the respective circuit
should a fault occur on any one line or phase conductors.
E. Photoelectric Cell. Ensure that the photoelectric control is a twist‑lock
plug-in, utility grade, solid state, cadmium sulfide type of the proper
voltage, rated for 1000 watts maximum load, with integral surge protection, a
fail‑safe mode in which the lighting circuits will remain energized, and
a hermetically sealed case. Ensure that the nominal “turn on” level is 1 footcandle (10 lux) vertical and that the nominal “turn‑off”
level is 6 footcandles (65 lux) vertical with
tolerances of 20 percent for the specified values. Ensure that the
photocell has a time delayed response that will not respond to flashes of light
from lightning, headlights of passing vehicles or emergency vehicle strobes and
beacons. Ensure that the photoelectric control mounting bracket has a EEI‑NEMA locking‑type
receptacle.
F. Switchgear Enclosure. Ensure that components are mounted on a removable
back panel of 14 gage or heavier enameled steel rather than directly on the
back wall of the enclosure and that the back panel mountings do not penetrate
the walls of the enclosure.
Ensure that a neutral
terminal bar of adequate ampere rating and with holes in number and of size to
terminate each conductor separately is provided in each enclosure where neutral
conductors are to be terminated. Ensure that an equipment grounding
conductor terminal bar of adequate ampere rating and with holes in number and
of size to terminate each conductor separately is provided in each enclosure
where grounding conductors are to be terminated. When there is no code or
utility company prohibition, a combination neutral and equipment grounding
conductor bar may be furnished.
Ensure that an
enclosure containing a disconnect switch with an external operating handle
allows that handle to be padlocked in either the “OFF” or the “ON” position.
Ensure that the
enclosure containing the service disconnect switch has an interlock to prevent
the door from being opened when the switch is in the “ON” position
Ensure that the
enclosure provides for padlocking the door.
Ensure that each
switchgear enclosure is a NEMA ICS‑1‑110.15 Type 4 fabricated from
No. 16 gage or heavier AISI Type 302 or 303 annealed stainless steel with fully welded seams and a brushed
finish.
All fasteners used in
assembly of the enclosures shall conform to ASTM A
320/A 320M (AISI‑300 series).
G. Wiring Schematic, Wiring Diagram, Placards. Furnish both a schematic diagram and a wiring diagram
of the entire power service from the power company service transformer
secondary connection through the lighting branch circuit connections in
triplicate with two copies delivered to the project and the third copy placed
in the service disconnect enclosure. The Engineer will ensure that one of
the two copies delivered to the project is filed with the project records and
the other is delivered to the maintaining agency .
Ensure that each
placard to be attached to an apparatus enclosure is of multiple layers of
plastic thermally bonded together to provide a plate of at least 1/8 inch (3
mm) in thickness with engraved plain block letters at least 1/2 inch
(12 mm) in height. Ensure that placards designating the function of
the apparatus contained in an enclosure or other such information are of white
letters on a black placard. Ensure that placards warning of high voltage
possibly present in an enclosure or other such warning are of white letters on
a red placard.
H. Customer Service Pole. Furnish a wood pole that complies with Supplement 1072.
Ensure that the pole and any cross arms or pole key is Southern Pine or Western
Red Cedar, full length, pressure treated in compliance with specifications of
the American Wood Preservers Association
using either creosote or pentachlorophenol. Ensure that the retention of
preservative in Southern Pine is 7.5 pounds (120 kg) of creosote by assay or
0.38 pounds (6 kg) of pentachlorophenol by lime‑ignition assay per cubic
foot (cubic meter) of wood. Ensure that the retention of preservative in
Western Red Cedar is 16 pounds (256 kg) of creosote by assay or 0.8 pounds (13
kg) of pentachlorophenol by lime‑ignition assay per cubic foot (cubic
meter) of wood. Ensure that the pole is 35 feet (10.5 m) minimum in
length and Class 4 or heavier and conforming to ANSI 05.1
Specifications and Dimensions for wood poles. Ensure that the pole is
reasonably straight without pronounced sweep or short crooks.
Ensure that all pole
hardware, including racks, braces, straps, guy anchors, guy wire, clamps, bolts,
nuts, washers, screws, nails, etc. is hot dip galvanized in accordance with 711.02.
Ensure that the
grounding conductor is fastened to the pole with copper clad, rolled point
staples of adequate size.
Ensure that the
grounding conductor molding is either wood or plastic, in sections not less
than 8 feet (2.4 m) long, of sufficient width and groove depth to completely
enclose the grounding conductor.
Ensure that each pole
anchor is of malleable iron or galvanized steel, 6 inch (150 mm) minimum
diameter, two‑way or four‑way expanding type. Ensure that each
anchor rod is 5/8 inch (16 mm) minimum diameter, 8 feet (2.4 m) minimum length
galvanized steel with thimble eye. Ensure that each guy wire is 3/8 inch (10
mm) minimum diameter, conforming to ASTM A
475, galvanized steel.
725.20 Multiple Cell Polyvinyl Chloride Conduit and Fittings. Ensure that the
multiple cell conduit consists of inner ducts
conforming to NEMA TC-8 type DB in an outer conduit conforming to NEMA TC-2 (type EPC-40 or EPC-80 as specified except
that size shall be the true inside diameter) in a factory preassembled
unit. Ensure that fittings are factory made couplings that couple inner
ducts and the outer conduit simultaneously, maintain the continuity and
indexing of the inner ducts and are of a push fit design mechanically locked in
place.
Furnish
materials according to the Department’s Qualified
Products List (QPL).
725.21 Luminaire Supports. Ensure that
the complete luminaire support from the luminaire(s) down through the
connection to the foundation or other structure to which the luminaire support
is attached conforms to the requirements of AASHTO’s Standard Specifications for Structural Supports
for Highway Signs, Luminaires and Traffic Signals. Ensure that
the combined stress ratio above the first field joint is greater than the
combined stress ratio at the base of the pole.
The
design wind speed for all areas of the State shall be 90 mph (145 km/h).
The
Department may require various tests including destructive tests at either the
factory or on site prior to acceptance of a support in which case the
Department’s representative will supervise the Contractor and/or manufacturer
as the appropriate entity performs the tests on supports selected at random by
the Department from the lot produced for the project. Ensure that any
support damaged by the testing is replaced at no additional cost to the
Department.
Ensure
that the support identification labels are adhesive labels with silver white
reflective characters on a reflective green background meeting the requirements
of 730.18.
Furnish
certified luminaire supports according to Supplement 1091
A. Light Poles. Ensure that the deflection of the pole from vertical
when placed under the load of the bracket arm, and a weight of 75 pounds (35
kg) in place of each luminaire does not exceed an angle of 1 degree 10 minutes
when tested in accordance with Supplement 1025
and that certified copies of the results obtained from the deflection tests are
furnished the Laboratory.
A pole and arm
constructed from either aluminum or steel but not a combination of the two may
be furnished.
Ensure that each
bracket arm is made from straight or tapered stock round or ovaliptic
in cross section not less in size than 2 inch (50 mm) nominal pipe.
Ensure that the
luminaire end of each bracket arm has an outside diameter equal to 2 inch (50
mm) pipe, is straight for a distance of eight inches (203 mm), with the
longitudinal axis canted not less than 1 degree and not more than 4 degrees
above horizontal.
Ensure that the
bracket has an internal raceway with a minimum internal diameter of 1 3/32
inches (28 mm) free of projections and obstructions, which, when assembled to
the shaft, will permit installation of luminaire supply conductors without
insulation damage and which will not require bending the conductors to a radius
less than 3 inches (75 mm).
Ensure that the pole
does not have more than two sections, that the shorter section of a sectional is
at the top and that the shorter section of a sectional pole is not less than 10
feet (3 m) in length. Ensure that the pole sections are joined by
telescoping the bottom of the upper section over the top of the lower section
for a minimum length of 1 1/2 times the external diameter of the bottom of the
upper section, driving the joint tight, and securing by through bolting with a
stainless steel hex head bolt of a minimum diameter of 5/8 inch (16 mm).
Ensure that a pole
section does not have more than one longitudinal, automatically electrically
welded seam and no transverse seams. Ensure that the longitudinal welded
seam is neat and uniform in appearance, that the weld is not less than the
thickness of the base material and that the bead height does not exceed 1/16
inch (2 mm). Ensure that the wall thickness is uniform throughout, except
at the weld bead. Ensure that the cross section of the pole is circular, or
multi-sided with no less than eight sides and that the difference between the
major and minor diameters of poles of circular cross section or the difference
between the maximum and minimum distances across corners for poles of
multi-sided cross section, measured at any point along the longitudinal axis,
does not exceed 3/16 inch (5 mm).
Ensure that steel
poles are tapered tubes with a true continuous taper not less than 0.06 inches
per foot (1.5 mm per 300 mm) and not more than 0.16 inches per foot (4.0 mm per
300 mm).
Ensure that aluminum
poles, either spun or cold rolled, are a true continuous taper except for the
top and bottom sections which may be straight, that no more than 40 percent of
the total shaft length is straight, and that the average rate of shaft taper
including straight portions of the shaft is not less than 0.06 inches per foot
(1.5 mm per 300 mm) and not more than 0.16 inches per foot (4.0 mm per 300 mm).
Ensure that the full
design strength of the pole shaft section in bending can be transmitted through
the base plate into the transformer base or the anchor bolts without permanent
bending of the base plate or failure of the pole shaft to base plate
connection.
Ensure that there is
a “J” hook inside the pole just below the top on which to hang the pole and
bracket cable support assembly.
Ensure that
nonstructural castings for aluminum poles, including the pole cap are of ASTM B 26/B 26M or B 108, Alloy S 5 A, Condition
F.
Ensure that steel
poles and bracket arms are hot dipped galvanized after fabrication in
accordance with the requirements of 711.02.
Furnish aluminum
poles and bracket arms in natural aluminum with a satin brushed surface.
Ensure that each light
pole is identified by a raised or engraved marking applied to the edge of the
base plate which identifies the manufacturer and the year that the pole was
manufactured and that such marking remains legible
after the pole has been galvanized.
Ensure that bolts,
nuts, washers and other fasteners used to assemble the light pole are of
galvanized steel conforming to 711.02, stainless
steel conforming to ASTM A 320/A 320M (AISI‑300 series) or silicon bronze
conforming to ASTM B 98M (B
98).
Ensure that each
non-frangible steel transformer base is capable of transmitting the design
dead, live, ice and wind loads of the light pole to be mounted on it to the
foundation without failure or permanent deformation, has a flush door
permanently attached by means of a top‑mounted continuous stainless steel
hinge, and is made from steel conforming to ASTM A36/A 36M hot dip
galvanized after fabrication.
Ensure that each
frangible aluminum transformer base is capable of transmitting the design dead,
live, ice and wind loads of the light pole to be mounted on it to the foundation
without failure or permanent deformation, has a flush aluminum door permanently
attached by means of a top‑mounted continuous stainless steel hinge, and
bears easily found and read durable labeling as to which AASHTO
frangibility criteria the base meets. Ensure that the base has been tested and
accepted by the FHWA as complying with the 1985 AASHTO frangibility requirements .
Ensure that the bolts
and nuts used to fasten the base plate of the pole to the transformer base are
heavy hex conforming to ASTM A 307 and galvanized in accordance with 711.02. When either the top or the bottom of
an aluminum transformer bases is to be fastened against non‑galvanized
steel, ensure that both the steel and the aluminum mating surfaces have been
coated with a heavy film of zinc rich paint.
Ensure that the
anchor bolts are steel with 55,000 psi (380 Mpa)
minimum yield strength, that the threaded ends of the bolts and nuts are
galvanized in accordance with 711.02 for at
least 2 inches (50 mm) beyond the threads and that the nuts are capable of
developing the full strength of the anchor bolt and are galvanized in
accordance with 711.02.
B. Light Towers. Ensure that
the structural design of the light tower is based on a load of six luminaires
or the actual number of luminaires to be installed whichever is greater.
Ensure that the structural design of the light tower is based on each luminaire
weighing 75 pounds (34 kg) and having an effective projected area of 3.5 square
feet (0.3 m2) or the actual weight and effective projected area of
each luminaire whichever is greater. Ensure that the structural design of
the light tower is based on the head frame assembly with lowering device
weighing 340 pounds (154 kg) and having a projected area of 5.3 square feet
(0.5 m2) or the actual weight and effective projected area of the
head frame and lowering device whichever is greater.
Ensure that the
luminaire lowering device (consisting of the luminaire ring, the head frame,
the winch, the power cables and all miscellaneous mechanical and electrical
equipment mounted in or on the pole) and the pole are compatible with each
other.
1.
Luminaire Ring. Ensure that the
luminaire ring assembly is fabricated from steel which conforms to ASTM A 36/A 36M and that the
ring is fitted with a separate 2 inch (50 mm) nominal steel pipe mounting arm
directly attached to the ring for each luminaire.
Ensure that the
luminaire ring is supported by three wire ropes equally spaced around the
ring. Ensure that the three wire ropes are of the same material and
construction. Ensure that the wire rope for this purposed is 3/16 inch (5
mm) minimum diameter and either galvanized steel hoisting cable or aircraft
grade stainless steel control cable composed of 7 strands of 19 wires each.
Ensure that each wire rope support cable is connected to the ring by a
corrosion resistant device that will allow the connection to develop the full
breaking strength of the wire rope while permitting ready adjustment of the
length of the wire rope to level the ring. Ensure that the ring is
equipped with a minimum of three spring loaded roller tipped centering arms
equally spaced around the ring that are in continuous contact with the pole
shaft and that the guide arm rollers are of a nonabrasive, water resistant
material.
Ensure that the
luminaire ring is equipped with three positive latching devices equally spaced
around the ring that latch to the head frame supporting the ring in the raised
position allowing tension to be removed from the lifting cables. Ensure that
all moving parts of each latching device are part of the ring portion of the
latch assembly and that each latch assembly incorporates a reflectorized flag
that is clearly discernible from the ground when the ring is latched to the
head frame. Ensure that the latching sequence shall not exert a
horizontal force sufficient to cause an excess of 4 g’s acceleration upon the
luminaires.
Ensure that the
luminaire ring is equipped with a NEMA 4 corrosion resistant junction box for the
connections between the main power cord bringing power to the ring and the
separate power cords for each luminaire. Ensure that each power cord has
copper conductors of adequate size and insulation, that each power cord is of
suitable construction, and that each power cord enters the junction box through
a weather tight cord connector. Ensure that there is a cord support capable of
withstanding a load of 1 1/2 times the weight of the main power cord without
damage to the cord transmitting the weight of the main power cord directly to
the ring. Ensure that there is a weather tight power inlet on the
luminaire ring which allows the main power cord in the base of the tower to
connect to the ring when the ring is in the lowered position. Ensure that
the junction box is equipped with a 600 volt class terminal block for the
connections between the main power cord, the luminaire power cords and the
power inlet cord. Ensure that each luminaire ring is identified by a
raised or engraved marking applied in a prominent location which identifies the
manufacturer and the year that the ring was manufactured and that such marking
remains legible after the ring has been galvanized
2.
Head Frame Assembly. Ensure that the
head frame is fabricated from steel which conforms to the requirements of ASTM A
36/A 36M. Ensure that the head frame assembly is equipped with pulleys for
the wire ropes hoisting cables and rollers for the main power cord to the
luminaire ring. Ensure that each hoisting cable sheave has a tread
diameter of at least 20 times the cable diameter for galvanized cable and 25
times the cable diameter for stainless steel cable, that the groove for the
hoisting cable has a semi‑circular in cross section with a radius of one‑half
the cable diameter plus 1/64 inch (0.4 mm), that the sheave has an oil‑impregnated
bronze bushing and that the shaft on which the sheave turns is of stainless
steel. Ensure that the rollers for power cord run on AISI
304 stainless steel shafts between cold‑rolled steel plates. Ensure that
bending radius of the power cord is not less than 7 inches (180 mm).
Ensure that keeper bars have been provided over the power cord and ring support
cables to keep them in their respective tracks. Ensure that a guide is
provided to separate the individual cables as they pass between the head frame
and the top of the pole. Ensure that the head frame mechanism is
protected from the weather by a domed cover of either copper free spun aluminum
or fiberglass. Ensure that each head frame is identified by a raised or
engraved marking applied in a prominent location which identifies the
manufacturer and the year that the head frame was manufactured and that such marking remains legible after the head frame has
been galvanized.
3.
Transition Plate. Ensure that there
is a transition plate between the ring support cables and the main hoisting
cable. Ensure that the luminaire ring support cables are secured to the
transition plate by shop applied, swage‑type fittings designed to develop
a connection strength equal to the breaking strength
of the cable and prevent abrasion of the cable by the transition plate.
Ensure that there is a cord support capable of withstanding a load of the
weight of the main power cord plus a wind load on the cord equal that of a 30
mph (48 km/h) wind perpendicular to the full length of the cord without damage
to the cord connecting the main power cord to the transition plate.
4.
Hoisting Winch. Ensure that the winch
is of cast iron and steel construction with an integral enclosed lubricant
bathed worm and gear drive having a reduction great enough to be self‑locking.
Ensure that the winch has a pulling capacity at least five times greater than
that required to lift the load. Ensure that the winch drum diameter is
not less than 4 inches (100 mm), that the drum flange
diameter is at least 3 inches (75 mm) greater than the diameter of the drum.
Ensure that there is a cable guide or follower to prevent cable buildup at the
ends of the winch drum. Ensure that the support plate for the winch bears a
durable tag which identifies the manufacturer, manufacturer’s model and year of
manufacture for the lowering device.
5.
Winch Drive Unit (Portable Power Unit).
Ensure that the winch drive unit is powered by a heavy duty reversing drill
motor, minimum 560 W (3/4 horsepower) rating, 120 volt. Ensure that there
is a mechanical slip clutch torque limiter incorporated into the output shaft
and that there is a placard on the portable winch drive unit giving the
settings and instructions for care of the torque limiter. Ensure
that there is a separately packaged dry type isolated winding transformer
included to permit operation of the drill motor from the lighting circuit by
plugging into the luminaire power cord outlet in the base of the tower.
Ensure that the cord outlet and plug for connecting the motor to the
transformer are NEMA L5-15 devices. Ensure that he hoisting
rate is between 15 and 25 feet per minute (4 and 8 m/min). Ensure that
the hand control switch incorporates 20 feet (6 m) of cable to allow operation
of the lowering device from a position away from the pole and not beneath the
ring and luminaires. Ensure that each winch drive unit frame is identified by a
raised or engraved marking applied in a prominent location which identifies the
manufacturer and the year that the portable power winch drive unit was
manufactured and that such marking remains legible
after final finish has been applied to the frame.
6.
Connection of Tower to Lighting Circuit. Ensure that there is a separate terminal block for each conductor of
the supply circuit in the base of the tower, and that there are enough spaces
on the blocks to allow the incoming circuit to split into three outgoing
directions in addition to the feed to the tower itself. Ensure that the
terminal block has set screw style terminations, sized for 4 AWG - 1/0 AWG for the incoming
and outgoing lighting circuit and 12 AWG - 10 AWG for the tower wiring. Ensure that there is a
circuit breaker in a NEMA 4 enclosure located electrically after the
terminal blocks for the lighting circuit and before the power cord leading up
the tower to the luminaires. Ensure that the breaker enclosure is
internally mounted and that the breaker is readily accessible through the tower
hand hole. Ensure that the circuit breaker is a bolt on design, sized at
15 amperes with a minimum interrupting capacity of 14,000 amperes for 480 volt
circuits or sized at 20 amperes with a minimum interrupting capacity of 10,000 amperes
for 240 volt circuits and is of a single handle rather than a tied handle
design with one pole for each line or phase conductor. Ensure that cord
connector, plug and inlet on the ring for electrical power to the luminaires
are NEMA L8-20 devices for 480 volt systems or are NEMA L6-30 devices for 240 volt systems.
7.
Operating Manual. Furnish a complete
manual including instructions on installation, operation and maintenance for each
type of the following: lowering device, winch assembly and portable power winch
drive unit.
8.
Shaft. Ensure that shaft of the tower
is of not more than four round or multi-sided tapered steel sections for towers
up to and including 100 feet (30 m), five sections for towers over 100 feet (30
m) up to and including 120 feet (37 m), and six sections for towers over 120
feet (37 m). Ensure that the shaft is of steel having a
minimum yield strength of 55,000 psi (379 MPa).
Ensure that the shaft sections are joined by telescoping the bottom of the
upper section over the top of the lower section for a minimum length of 1 1/2
times the external diameter of the bottom of the upper section or two feet (0.6
m) whichever is greater and driving the joint tight. Ensure that the
sections have been pre‑fitted and match‑marked at the factory.
Ensure that the inside surface of the shaft is relatively smooth and that there
are no more than two longitudinal welds which shall be made by automatic
electric arc welding. Ensure that the longitudinal seam welds have
complete penetration, are of uniform density, are no
thinner than the shaft material and not more than 20 percent thicker than the
shaft material. Ensure that the base plate is fabricated from steel which
conforms to the requirements of ASTM
A 36/A 36M and that the shaft is joined to the base plate using the American Welding
Society prequalified joint TC‑U4a‑S or TC‑U4c‑GF.
Ensure that the hand hole in the shaft is properly reinforced to avoid stress
risers and that the reinforcements are welded to the shaft using a joint and
techniques designed to insure total penetration plus an outside fillet equal to
the thickness of the shaft material. Ensure that all welds in the shaft
satisfy AWS
D 1.1 Structural Welding Code Article 9.25.3 for tensile stress when tested
either by the ultrasonic method or by an approved alternate method, and that
certified results are furnished to the Laboratory. Ensure that the door
is fabricated from the same type steel as the shaft, is attached with a
continuous stainless steel hinge having non-removable stainless steel hinge
pins, fits the opening closely, and is securely held shut. Ensure that
there are provisions for padlocking the handhole door
closed and that each tower has been furnished with a vandal resistant padlock
having a bronze or brass lock body and a corrosion‑protected steel
shackle keyed to the key number specified by the maintaining agency.
Ensure that there are two holes, tapped 1/2-13, 180 degrees apart provided at
the base of the tower for the grounding conductors. Ensure that the shaft
shall be hot dipped galvanized after fabrication in accordance with the
requirements of 711.02. Ensure that each
shaft is identified by a raised or engraved marking applied to the edge of the
base plate which identifies the manufacturer and the year that the shaft was
manufactured and that such marking remains legible
after the pole has been galvanized.
9.
Anchor Bolts and Nuts. Ensure that
each anchor bolt is steel conforming to ASTM F1554, Grade 55, and
galvanized in accordance with 711.02. at least 2 inches (50 mm) beyond the threads. In lieu
of a bent end, an anchor bolt with the lower end threaded and inserted into a
steel plate of approved size and thickness which has been drilled and tapped to
receive the anchor bolt may be furnished. Ensure that the nuts used with
each anchor bolt are capable of developing the full strength of the anchor
bolt.
725.22
Plastic Caution Tape. Furnish tape that is an inert material,
approximately 6 inches (150 mm) wide composed of polyethylene plastic, highly
resistant to alkalis, acids or other chemical components likely to be
encountered in soils. Furnish tape that is bright red with identifying
printing “ELECTRIC” in black letters on one side only. Furnish tape in
continuous rolls with the identifying lettering repeated continuously the full
length of the tape.