ITEM 625  HIGHWAY LIGHTING

625.01   Description
625.02   Materials
625.03   General
625.04   Certified Drawings
625.05   Light Poles and Towers
625.06   Foundations
625.07   Luminaires
625.08   Glare Shields
625.09   Ground Rods
625.10   Pull Boxes
625.11   Trench
625.12   Conduit
625.13   Cable
625.14   unit Type Duct-Cable Systems
625.15   Connections
625.16   Power Service
625.17   Structure Grounds
625.18   Junction Boxes
625.19   Electrical Tests
625.20   Light Pole Identification
625.21   Methods of Measurement
625.22   Basis of Payment

625.01  Description.  This work consists of furnishing and installing electrical materials and equipment complete and ready for service.  This work also includes excavating and backfilling, disposing of surplus materials and restoring disturbed facilities and surfaces to a condition equal to that existing before this Work started, and electrical testing as specified.

625.02  Materials.  Furnish new materials conforming to the Underwriters’ Laboratories, the National Electrical Code, and local codes for the area of installation.  Do not furnish materials containing polychlorinated biphenyls.

Use electrical parts, wire, switches, and other elements of the installations that are of ample capacity to carry the required current without heating or drop of potential.

Ensure that every manufactured item has a nameplate or indelible markings that identify the manufacturer and the manufacturer’s model, serial number, part number, or other means of product identification.

Furnish materials conforming to:

625.03  General.  Use lighting terminology as defined in the American National Standard Practice for Roadway Lighting.  Exceptions are as follows:

A.     A luminaire includes the direct appurtenances such as a reflector, refractor, housing, and supports that are integral with the housing and high intensity discharge (HID) or fluorescent ballasts when applicable.  The luminaire includes the lamp.

B.      A light pole includes the pole, bracket arm if required, transformer base, couplings, slip plates or other break-away device as specified, and integral hardware to support luminaries.

C.     A light tower includes a shaft with base plate, pole head, luminaire ring, integral lowering mechanism, complete lightning protection system, internal power cable, and connecting and associated hardware to support luminaries.

For items of electrical equipment, use components from the same manufacturer, as far as practicable.

Ensure that each system conforms as to voltage, amperage, frequency, and type specified.  Furnish and install all incidentals necessary to provide a complete and practical working unit or system.

Perform installations according to the National Electrical Code, National Electrical Safety Code, and local laws and codes governing such work.

625.04  Certified Drawings.  Submit, to the Engineer before the installation of the item, two copies of the shop drawings and catalog cuts, which identify and describe each manufactured item being incorporated into the construction.  Certify in writing that each manufactured item conforms to all contract requirements for that item.  Ensure that the documents describing each item indicate the project number (including the construction year) and the bid reference number under which the item is being installed.  Ensure that the documentation contains all the information needed to determine that the item supplied meets all applicable requirements along with all information needed to obtain an identical replacement unit from the manufacturer.  If a given item is listed under multiple bid item reference numbers, provide a separate and complete documentation package for each bid item reference number under which the item is to be installed.  If multiple items are incorporated under a single bid reference number, submit all interdependent items together.  The required certified drawings are for documentation and record purposes only and do not require Department acceptance.

625.05  Light Poles and Towers.  Erect light poles and towers upon the completed concrete foundations or other specified type of mounting.  Plumb or align light poles by using metal shims.  Plumb or align towers with leveling nuts.  After erection, adequately ground each light pole as specified in 625.09 or 625.17, and fasten hand hole covers or transformer base doors in place.

After erection, inspect galvanized poles for defects in the galvanized surfaces.  Place two coats of zinc-rich primer over minor scratches.  Do not apply the second coat until after the first coat has adequately dried.  The Department will not accept poles with major scratches or defects in the galvanized surfaces.

625.06  Foundations.  Excavate for foundations to the dimensions shown on the standard construction drawings or plans.  Place cast-in-place concrete, Class C according to Item 511.  Forms are not required for portions of foundations extending more than 6 inches (150 mm) below the ground line, unless the soil does not have sufficient stability to stay in place during the placing of the concrete.  If rock is encountered during excavation and when the Engineer directs, decrease the total depth of the foundation by an amount not exceeding one-half of the depth of the rock excavation required to obtain the foundation depth shown on the plans.  When, in the Engineer’s opinion the bottom of an excavation has an unstable condition, deepen or enlarge the excavation as the Engineer directs.  When a cave-in occurs, excavate using casing, sleeving, or other methods with the Engineer’s approval.  Perform all necessary dewatering of the excavation.

Place reinforcing steel as specified according to Item 509.  Install anchor bolts for light poles and towers in the foundations according to the pole manufacturer’s drawings and anchor bolt setting templates.  Finish the tops of foundations smooth and level.

After removing forms, backfill excavated spaces around the foundations with suitable material placed and tamped in thin layers as the Engineer directs.

625.07  Luminaires.  Adjust light pole luminaires vertically and horizontally to provide the required mounting height and the specified alignment with the roadway.  At pole locations where the profile grade exceeds 4 percent, orient the luminaries so that the vertical axis of the luminaire is perpendicular to the longitudinal centerline of the roadway at that location.  Level tower luminaries by means of the adjustment device provided.

After completing all other work and just before leaving the job, clean refractors with a detergent and clean reflectors with an approved cleaner to provide the maximum lumen output possible.

Ensure that the lamps are compatible with ballasting characteristics of the specified luminaries.

625.08  Glare Shields.  Furnish and install glare shields as designated.  Obtain the shields from the manufacturer of the luminaries with which they are used.

625.09  Ground Rods.  Furnish and install a ground rod of the specified type and size as shown on the plans.  Test each ground rod according to 625.19.  If the earth resistance measurement exceeds 10 ohms for traffic signal controller and tower lightning ground rods and 25 ohms for all other ground rods, install a second ground rod as shown on the standard construction drawings.  Temporarily connect the two rods together with ground cable, and remeasure the earth resistance.  If the measured earth resistance still exceeds the required value after the second rod is driven and interconnected, the Engineer will direct the Contractor to install a grounding grid as shown in the standard construction drawings.  Use the grid to bond light poles and structures in continuous series to some point on a type of terrain that allows obtaining an acceptable earth ground.

If rock is encountered and acceptable earth grounds cannot be accomplished, install a grounding grid as shown in the standard construction drawings.

Connect rods and cable by exothermic welds with two coats of insulating varnish applied over the welds and exposed cable.

625.10  Pull Boxes.  Furnish the types and sizes of pull boxes and covers as specified, and locate them as shown on the plans.  Excavate to the outside dimensions of the pull box.  Furnish a 6-inch (150 mm) gravel base below the pull box.  After setting boxes to proper grades, backfill the excavated spaces around the boxes with suitable material placed and thoroughly tamped in thin layers.

If installing pull boxes in paved areas, remove an adequate area by saw cutting on the sides, or by removal back to an expansion joint.  Adjust the cover surface to be slightly above the surrounding pavement.  Place pavement matching the surrounding area from the pull box rim to the existing pavement, allowing no gaps larger than 1/4 inch (6 mm).

625.11  Trench.  For trenches located adjacent to and parallel with curbs or pavements, do not deviate more than 6 inches (150 mm) from the lines designated.  Construct trenches to a minimum depth of 2 feet (0.6 m) and a maximum width of 12 inches (0.3 m).

Place trench backfill in layers not exceeding 4 inches (100 mm) in thickness and compacted with mechanical tampers or other approved compaction equipment as directed.  Backfill with material consisting of suitable soil or granular material.  For around and in the first 4 inches (100 mm) above the top of unit type duct-cable not encased in concrete, do not backfill with material containing pieces larger than 1/2-inch (13 mm).  For trenches in areas of pavement and stabilized aggregate shoulders, backfill with granular material.

For trenches in paved areas, remove the existing pavement for at least 6 inches (150 mm) beyond the edge of the underlying trench.  For sawcut lines, follow existing joints or grooves where possible, and premark lines and obtain the Engineer’s approval before sawing.  For replacement for flexible pavement, use Class C concrete and placed to within 2 inches (50 mm) of the surface, with a 404 surface course.  For replacement for rigid pavement, use Class C concrete, and place, finish, and texture to the Engineer’s satisfaction.

In paved areas, the Contractor may utilize a narrow slit type trench with a minimum depth of 2 feet (0.6 m) and a minimum width of 4 inches (100 mm).  Backfill with Class C concrete to full depth.  The Contractor may use tamped soil or granular material for the bottom 4 inches (100 mm) around the conduit.

625.12 Conduit.

A.     General.  Install conduit of the type and size shown on the plans.  Use bends in conduit only when necessary.  Ensure that the total bending between adjacent junction boxes and/or pull boxes does not exceed 180 degrees and that the total bending between adjacent light poles does not exceed 270 degrees.  Ensure that the radius of any field bend is not less than 12 times the internal diameter of the conduit.  When bending metal conduit, do not damage the protective covering or reduce the internal diameter at the bend.

Galvanize all rigid ferrous metal conduit, and fittings and appurtenances thereto.  Use conduit large enough that the wires may be easily drawn into the conduit without excessive pull.  If the plan size of conduit is not sufficient for the specified number of wires, notify the Engineer of the problem.  Ream all cut ends of metallic conduit to remove rough edges.  Paint all conduit threads with zinc rich paint so there are no unprotected surfaces and so the joint is watertight and electrically bonds the jointed sections of conduit.

Check each conduit run by rodding or by pushing a mandrel through the conduit run.  Remove any obstructions that may develop in the conduit.

For conduit that will not have circuit wire or cable pulled into it during construction, install a No. 10 AWG copper-clad, aluminum-clad, or galvanized pull wire in the conduit.  Close the ends with capped bushings, or otherwise seal ends in an approved manner to completely keep all moisture and foreign matter out of the conduit.  Completely seal terminal points of all conduits containing wire or cable by applying heat shrinkable tubing or pre-molded boots.  Furnish equivalent temporary sealing approved by the Engineer immediately after placing conduit where conductors or cables are not installed promptly in the conduit.

B.     Conduit on Structures and in Barriers and Parapets.  Securely fasten conduit to structures when shown on the plans.  When shown on the plans, build conduit into structures, parapets, or barriers, supporting it during concrete placement and slip forming so the final installation is at the elevation shown on the plans.

Properly drain conduit using a T-coupling at the low point of each concrete encased run, unless the conduit is sloped to drain into junction boxes.  If conduit is sloped, provide junction boxes with drains.  Furnish expansion fittings at all expansion joints on structures and with suitable copper jumpers to ensure electrical continuity of the grounding system.

Ensure that all metallic conduits have electrical continuity and are adequately grounded.  Fit the ends with approved bushings.  Design and connect all boxes, fittings, expansion joints, and other appurtenances to the conduit so that adequate electrical continuity from one conduit to another is secured.  If not using boxes or fittings, provide suitable means to accomplish adequate electrical continuity between the several parts.

Where conduit enters a junction box through a slip hole, provide locknuts to fasten the conduit to the junction box.

C.     Underground Conduit.  When the plans show conduit underground, install conduit of the type, size, and locations shown on the plans, at the bottom of trenches.  For underground conduits to be encased in concrete, use Class C concrete for the encasement, and provide a minimum thickness of 3 inches (75 mm).  Use spacers as shown in the standard construction drawings.

D.     Conduit Jacked or Drilled Under Pavement.  If placing conduit under existing pavement or paved shoulder, conform to 725.04.  Install conduit by jacking or drilling, subject to the Engineer’s approval.  If placed by drilling, ensure that the bore does not exceed the conduit diameter by more than 5 percent.  Place the conduit with a minimum amount of disturbance to the roadway.

625.13  Cable.  Install copper wire cables of the types and sizes required as shown on the plans or directed by the Engineer.

Support cable installed in light poles by cable grips attached to J hooks at the tops of the poles.  Do not drag the cable against the openings to the bracket arm.

Identify all cables, except structure grounding system cables, and pole and bracket cable, entering an accessible enclosure (such as a pull box, handhole, transformer base, device housing) for the purpose of being terminated or connected to another cable in such enclosure with tags or bands as specified in 725.18.  Do not make splices between terminations.  Exothermically welded joints in structure grounding systems and taps required for circuit branches are not considered splices.

625.14  unit Type Duct-Cable Systems.  Install unit type duct-cable (duct-cable) at the bottom of trenches.  When allowed by the Engineer install duct-cable by vibratory-plowing, at a depth of 2 feet (600 mm) or as shown on the plans.  Furnish a method to assure the Engineer that the duct-cable is plowed in to the specified depth.  Do not install duct-cable when the temperature of the duct is below 32 °F (0 °C), except with the Director’s permission.

Before installation, ensure that the duct-cable is “paid-out” from its reel as the reel is moved alongside and parallel to the trench.  Do not pull duct-cable off a reel located in a stationary position.  Furnish duct-cable of sufficient length to ensure there are no splices between terminations in pull boxes, handholes, and junction boxes.  Make allowances for extensions into pull boxes for splicing, and for extension of the conductors through the handholes in light poles.

Install duct-cable as straight as possible to facilitate cable replacement.

Completely seal terminal points and splice locations of duct-cable by applying heat shrinkable tubing or pre-molded boots.  Promptly perform sealing upon completion of the installation.  Identify all conductors or cables as specified in 725.18.

625.15  Connections.  Make cable connections in the handholes or transformer bases of all light poles, or in junction boxes within concrete barrier medians and above pavement elevation, by using approved factory preassembled cable connector kits.  For cable connections below ground line, use permanent water resistant cable splicing kits if connection is directly buried or in accessible enclosure.  Ensure that each kit provides a splice conforming to ANSI C 119.1 when applied according to the manufacturer’s instructions.

For connector kits used in cable connections installed at the last light pole or pull box on a circuit, plug the vacant wire opening according to the manufacturer’s recommendations.

Until completing cable connections, adequately protect all cable connector kits and exposed cable ends by enclosing in plastic bags, taping, or other approved means.

625.16  Power Service.  Furnish and install all equipment necessary to provide complete electrical service to the roadway facilities.  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.

Equipment includes, but is not necessarily limited to, the following items:  wood poles, hardware for dead-ending an overhead line, lightning arrestor, weatherhead, conduit riser, meter base, fused main disconnect switch, magnetically held lighting contactor, HOA switch for control of contactor, photoelectric cell, over-current protection devices for each individual branch circuit fed by the control center, enclosures, conduits, fittings cables, and connectors.

Install the components of the lighting control center in the enclosure with the fused disconnect switch, which is part of the power service.  If using multiple enclosures, label each enclosure with the appropriate designation of the principal component contained therein (such as “SERVICE SWITCH,” “SIGNAL POWER,” “MAIN LIGHTING SWITCH,” “TRANSFORMER,” “LIGHTING CONTACTOR”).  Stencil labels on the outside of the enclosure door or cover in black, weather-resistant paint.

At the time of installation, ensure that the photoelectric cell faces due north unless other orientation is required.  Do not rotate the sensor element more than 45 degrees east or west of due north, tilt the sensor element off of horizontal, or shield the sensor element with auxiliary devices without the Engineer’s approval.

Connect all equipment housings and conduits to a ground rod installed as specified in 625.09.  Connect lightning arrestors on incoming service to equipment ground wire only when grounded neutral service is used and transformation is not required.  Otherwise, separately ground these lightning arrestors to a butt ground or to an additional ground rod installed as specified in 625.09 and located a minimum of 1 foot (0.3 m) from the base of the pole and all other ground rods.  Protect grounding cables installed on a pole using wood or plastic ground wire moldings.

Do not fuse service neutrals.  Do not switch grounded service neutrals; however connect them to a neutral bar in the disconnect enclosure with a screw type pressure connector.  Simultaneously switch all ungrounded neutrals with the associated line conductors.

625.17  Structure Grounds.  Furnish a complete grounding system for each bridge, wall, or other structure having electrical elements contained therein or attached thereto.

To provide continuity in the grounding of conduit at light poles on bridge structures, install ground cable between grounding lugs of each grounding bushing and the ground lug or bolt in the pole base.  If the plans require the use of a raceway employing a junction box, connect the cable between three grounding bushings through a 1 1/2-inch (38 mm) conduit to the pole ground connection.

To minimize potential differences between units of a bridge structure, electrically tie each unit to each adjacent unit both longitudinally and transversely with grounding cable connecting the outside girders or beams together as shown on the plans.  Transverse electrical ties are not necessary when the lateral separation between sections of parallel bridges is 6 feet (1.8 m) or greater.

Apply two coats of insulating varnish over all exothermic welds and exposed cable.

625.18  Junction Boxes.  Furnish and install junction boxes of the size and types specified as required.  For junction boxes embedded in concrete, provide drains.

625.19  Electrical Tests.

A.     General.  Furnish all personnel and equipment required to perform the following tests, and furnish two certified copies of complete test records to the Engineer on test reporting forms supplied by the Engineer or alternate certification approved by the Engineer.

B.     Ground Test.  Measure each ground rod, structure ground, and ground grid for earth resistance immediately after being installed and before the ground wire is attached.  If the earth resistance measurement exceeds 10 ohms for traffic signal controller and tower lightning ground rods or 25 ohms for all other ground rods, proceed as specified in 625.09.  For reporting purposes, express the units of measurement in ohms.

C.     Cable Continuity Test.  Before performing any cable insulation tests, high voltage tests, or performance tests on primary feeder cable, secondary feeder cable, distribution cable, or other special circuits, perform a continuity test with a volt-ohmmeter or other approved instrument.  Conduct continuity tests with electrical loads, power sources, and grounds, including earth grounds, disconnected.

Measure each conductor against every other conductor and ground, including earth ground, to ensure that no short circuits, cross circuits, or other improper connections exist.  No voltage shall exist between any conductor and another conductor including ground.  One at a time, temporarily short each circuit branch at its termination, and measure 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.

D.     Cable Insulation Test.  Measure the insulation resistance for each insulated cable, except pole and bracket cable, located in each primary feeder, secondary feeder, and distribution circuit, including duct-cable used in distribution circuits.  Perform the test on each cable of each circuit with all ballasts disconnected and all connections to earth grounds, including ground rods and grounding connections to light poles, disconnected.  For reporting purposed, express the units of measurements in megohms.  Ensure that the cable insulation resistance exceeds 10 megohms.  The above testing requirements are waived for those circuits on which a high voltage direct current test is to be performed.

E.      High Voltage Test.  If shown on the plans and before the 10-day performance test begins, perform a high voltage test according to Supplement 1003 on all insulated cables and connections installed.  Do not perform the test until after all new construction (such as guardrail, fence, delineator posts, and sign supports) in the immediate vicinity of the location of the cable run being tested has been completed.

For operation of the test equipment, furnish a source of electrical energy, preferably the power line that will ultimately supply the electrical system.  Ensure that the supply voltage is well regulated (±5 percent) and free of transient variations.  If the voltage is not steady, or if it is necessary to use portable generating equipment, insert a voltage regulator with adequate power capacity in the supply line.  Ensure that the test equipment has an adequate milampere capacity capable of supplying a variable, metered direct current voltage from 0 to 6000 volts to the circuit, and a meter to read the system leakage current.

F.      Performance Test.  Before acceptance, operate the lighting system, including automatic control equipment and other specified apparatus, from sunset to sunrise for 10 consecutive days without interruption or failure.  If a lamp or ballast should fail, immediately replace it; such a failure will not require a restart of the test.  Record each fault, the method and date of correction of each, and the beginning and end of the 10-day test.  Notify the Engineer at least 3 days before the commencement of this performance test.

If the performance test is conducted before all other tests, energize and manually operate the entire roadway lighting system, including control equipment for a minimum period of 1 hour to ensure that all connections disturbed by later tests are completely restored.

Arrange with the supplying agency to purchase electrical power necessary to conduct the performance test.  The Department does not consider portable generating plants a suitable source of power for the performance test.

G.     Luminaire Lowering Device Test.  Before acceptance, demonstrate to the Engineer the workability of the luminaire lowering devices by lowering and raising the luminaire assembly on each tower on two separate occasions during the 10-day performance test.  Record the cause of and the method and date of correction for each malfunction.

625.20  Light Pole Identification.  Identify each light pole and light tower by a number that indicates both the circuit number and the pole number.  Ensure that the identifying numbers are as shown on the circuit drawings and on the plans, or as specified by the maintaining agency shown on the plans.  Locate the identification approximately 7 feet (2.1 m) above the ground line, on the quadrant of the surface of the pole that faces oncoming traffic, and apply identification when the ambient temperature is above 40 °F (4 °C).

625.21  Method of Measurement.  The Department will measure Light Pole, Light Tower, Light Tower Maintenance Platform, Luminaire, Glare Shield, Pull Box, Connector Kit, Cable Splicing Kit, Structure Grounding System, Light Pole Anchor Bolts on Structure, and Portable Power unit by the number of each furnished and installed, complete in place.  The Department will include furnishing and placing light pole identification under Light Pole and Light Tower.  The Department will include bracket arms under Light Pole; however, if separate bracket arms are required, the Department will measure Bracket Arm by the number of each, complete in place.

The Department will measure Light Pole Foundation and Light Tower Foundation by the number of each furnished and installed including any necessary dewatering and use of any necessary sleeving and casing, complete and in place, and will include reinforcing steel, anchor bolts, and conduit ells as shown on the plans.

The Department will measure Ground Rod by the number of each 10-foot (3 m) section of rod furnished and installed, complete in place, and will include grounding cable and all specified tubing, fittings, and connections.

The Department will measure Trench by the number of feet (meters) of trench completed, measured from center-to-center of foundations, pull boxes, etc., and will include excavating, backfilling with granular and other backfill material, compacting, disposing of surplus materials, and restoring disturbed facilities and surfaces.  When vibratory-plowing is allowed in lieu of trenching, the Department will measure it the same as Trench and pay for it at the bid price for Trench and will include the cost of installation depth verification.

The Department will measure Trench in Paved Areas by the number of feet (meters) of trench completed, measured from center-to-center of foundations, pull boxes, etc., and will include excavating, sawing and removing of pavement, backfilling with granular and other backfill material, compacting, disposing of surplus materials, and restoring disturbed facilities and surfaces.  The Department will measure trench in pavements or sidewalks less than 6 inches (150 mm) thick as Type A and in pavements 6 inches (150 mm) or greater as Type B.

The Department will measure Conduit by the number of feet (meters) of conduit furnished and installed, measured from center-to-center of pull boxes, foundations, etc., and will include all fittings and appurtenances, joints, bends, grounds, and concrete encasement where specified.

The Department will measure Conduit Jacked or Drilled Under Pavement by the number of feet (meters) installed, measured in place, as accepted by the Engineer, and will include excavating, furnishing conduit, jacking or drilling, and restoring the jacking pits, pavements, sod, and other disturbed areas to their original condition.

The Department will measure Distribution Cable by the number of feet (meters) of distribution cable furnished and installed, measured as the sum of the distances from center-to-center of foundations, pull boxes, etc., plus 10 feet (3 m) per each spacing to allow for slack and splicing leads multiplied by one of the following, as applicable:

A.     By two for two-wire distribution circuits.
B.      By three for three-wire distribution circuits.

The Department will measure Pole and Bracket Cable by the number of feet (meters) of pole and bracket cable furnished and installed, measured as twice the light pole mounting height plus twice the designated arm length or lengths.

The Department will measure Duct-Cable by the number of feet (meters) of duct cable furnished and installed, measured from center-to-center of pull boxes, foundations, etc., plus 10 feet (3 m) per each spacing to allow for slack and splicing leads.

The Department will measure Power Service by the number of each, complete in place, determined as one unit for each of the installations specified.

The Department will measure Junction Box by the number of each furnished and installed, complete in place, and will include the junction box drain and the conduit section between the junction box and the adjacent light pole base.

The Department will measure High Voltage Test on a lump sum basis.

625.22  Basis of Payment.  The Department will not pay for obtaining required permits.

If, in the Engineer’s opinion, unstable conditions at the bottom of the excavation exist, the Department will pay for additional quantities of excavation and foundation concrete required by the Engineer by Supplemental Agreement.

If necessary because rock is encountered and acceptable earth grounds cannot be accomplished, the Department will pay for a grounding grid by Supplemental Agreement.

The Department will include all costs of labor, materials, equipment, and incidentals required to perform electrical tests, except for high voltage tests, in the contract unit prices for the respective items tested.

The Department will pay for accepted quantities at the contract price as follows: