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The work covered by this section shall include furnishing, installing, connecting, and placing into satisfactory operating condition the lighting at locations shown on the plans. All work shall be performed in accordance with the Specifications, the Plans, and the National Electrical Code.
This specification division is for methods, materials and equipment to construct and put in working order the proposed lighting system(s); however, every fitting, minor detail, or feature may not be shown or described. The Contractor is assumed to be an expert in the trade, capable of understanding the intent of the plans and specifications and constructing the lighting and electrical system(s) in accordance with the best practice of the trade.
The Contractor actually performing the work described in the specifications and the plans shall have a license of the proper classification from the North Carolina State Board of Examiners of Electrical Contractors.
The Contractor shall perform the work under the responsible supervision of a person who has passed the N. C. State Board of Examiners of Electrical Contractors test for either limited, intermediate or unlimited classification. This person shall be available on the job site as necessary when work is being performed or when requested by the Engineer. This person shall have a set of project plans and specifications in his possession on the job site and shall maintain accurate "as built" plans and shall be qualified to responsibly instruct and direct all of the Contractor's employees regarding the work.
(A) General:
All materials used in the work are to be new materials unless noted elsewhere in the plans and specifications. References on the plans or in the special provisions to any proprietary device, product, material, fixture, form, type of construction, etc. by make or catalog number, with or without the words "or approved equal", is to be taken as establishing a standard of quality, and is not to be construed as limiting competition. In such case, the Contractor may use any material, equipment or type of construction which has the written approval of the Engineer as being an acceptable equal to that named for the particular use intended by the specifications and plans.
All materials shall be labeled or listed by an organization acceptable to the Engineer. The organization shall maintain periodic inspection of the production of materials and shall, by the labeling or listing procedure, verify that the materials comply with appropriate standards of performance or are suitable for use in a specified manner. Underwriters' Laboratories (UL) labeled and listed materials shall be provided when such labeling and listing is available for such materials.
Materials shall be in compliance with requirements for use of domestic products, as specified in other sections of the specifications.
(B) Conduit:
Conduit and duct shall be either metallic or non-metallic as noted on the plans or in the specifications.
Metallic conduit and duct shall be rigid galvanized steel conduit per UL 6 "Rigid Metallic Conduit" with rigid full weight galvanized threaded fittings. Aluminum conduit bodies shall not be used with steel conduit fittings.
Non-metallic conduit and duct shall be rigid PVC (polyvinyl chloride) heavy wall approved for above ground and underground use without concrete encasement per UL 651 "Rigid Non-Metallic Conduit".
(C) Wire:
All conductors shall be stranded copper unless specifically noted otherwise on the plans or these special provisions. Wire and cable shall conform to IPCEA specifications and shall have marks for identification (manufacturer's name, type insulation, and gauge of conductor) and the UL label.
All wire insulation shall be rated at 600 VAC or greater.
Types of wiring shall be as follows unless noted otherwise on the plans.
Service Lateral - UL Type USE
Control System - UL Type THW or RHW or THHN
Feeder Circuits in Conduit - UL Type USE
Branch Circuits in Light Standards - UL Type NM Cable
Equipment Grounding Conductor - Bare MHD Solid or Insulated
Grounding Electrode Conductor - ASTM B2
Feeder circuits in conduit with conductors #8 and smaller may consist of a cable assembly rated UL Type UF. The grounding electrode conductor shall be #6 AWG unless noted larger on the plans.
(D) Grounding and Bonding Equipment:
Ground Rods shall be 5/8" x 8' copper clad steel. The clamp shall be one piece silicone bronze with a socket or hex head screw. All grounding and bonding equipment shall conform to UL Standard 467, "Electrical Grounding and Bonding Equipment".
(E) Fuseholders:
Fused overcurrent protection shall be provided in the base of each light standard, and other locations as noted. The fuseholder shall be rated 600 VAC, 30 amp minimum and be waterproof. It shall be constructed so that the fuse will be disconnected from the line side power every time the fuseholder is opened. It may be made of molded plastic or rubber and have insulating boots. The terminals shall be specifically rated for the size and number of conductors required.
Fuses shall have 5000 amp minimum interrupting capacity at the supply voltage and be rated 10 amp or as noted on the plans and shall not be glass type unless specified different by the Engineer or elsewhere in the plans and specifications. The same type fuse shall be used in all fuseholders on a project unless specified differently at specified locations.
Fuseholders used in fiberglass standards or standards with breakaway bases shall be specifically designed as a breakaway device. They shall disconnect the fuse from the line side power without damage to the terminals or conductors every time sufficient pulling force is placed on the line and load side conductors.
(F) Hardware:
Mounting or attachment hardware including bolts, nuts, washers, straps, clamps, and hangers shall be stainless steel, hot dipped galvanized or of equal corrosion resistance. Bolts shall not be less than 1 nominal size smaller than the opening being utilized and shall be minimum length.
(G) Lamps:
Lamps shall conform to ANSI specifications and shall be the type and wattage indicated on the plans or specifications. They shall be rated for a minimum of 24000 hours life, have a mogul base, and have special coatings for premium efficiency and color rendition. The installation date shall be clearly marked on the base. Lamps shall be provided for all luminaires furnished and installed on the project.
(H) Duct and Conduit Sealer:
Duct and conduit sealer or mastic shall be a putty-like compound which is permanently non-hardening, non-oxidizing, and non-corrosive to metals, rubber, plastic, lacquer and paints. It shall be readily workable for thumbing into openings and forming into seals around wires inside conduits and openings around conduits. The sealer shall have a service temperature range of minus 30F to 200F. It shall be non-oxidizing and shall remain soft and pliable for an indefinite period at 70F. It shall be clean, non-poisonous and non-injurious to human skin. It shall seal against water, dust and air and shall adhere to wood, glass, plastics, metal, rubber, and painted surfaces.
(A) Catalog Cuts:
The Contractor shall submit for the Engineer's approval catalog cuts and/or shop drawings for materials he proposes to use on the project. Forty days shall be allowed for the Engineer's review of each submittal. Materials which have not been approved shall not be delivered to the project. Eight copies of each catalog cut and/or drawing shall be submitted and each shall show the material description, brand name, stock-number, size, rating, manufacturing specification and the use for which it is intended.
All components of each contract item shall be represented with a catalog cut or drawing. The submittals shall be neatly presented and arranged in the same order as the contract bid items.
(B) Certifications:
In accordance with Article 1063 the Contractor shall furnish either Type 3 "Manufacturer's Certifications" or Type 5 - "Supplier's Certifications" for certain material used on the project. Type 3 - "Manufacturer's Certifications" shall be submitted for light standards, high mounts and lowering devices. Type 5 - "Supplier's Certifications" shall be submitted for conductors. Certifications shall be submitted to the Engineer when the above materials are delivered to the project.
Type 3 or Type 5 Certifications may be requested by the Engineer for any or all of the other material which does not have a name plate showing sufficient information to verify that the material was manufactured to the requirements of these specifications.
(C) Samples:
The Engineer will take random samples of the various items for the purpose of verifying conformance with specifications. The selection of the items to be sampled and the taking of the samples will be done by the Engineer.
Failure to meet specification requirements by 2 samples of any material shall be sufficient reason for rejection of all materials from the same lot.
The Contractor, upon request, will be reimbursed for the actual verified cost of such material taken by the Engineer as samples, including any handling charges less any discount allowed on the invoice, but with no percentage added, and such material will thereafter become the property of the Department.
(D) As-Built Plans:
The Contractor shall submit two complete sets of "as-built" plans upon completion of the work showing all buried cable locations with pavement crossings dimensioned from fixed objects or from survey stations.
These as-built plans shall include the title (No. 1), index (No. 1A), summary of quantities (No. 3), and all of the layout and detail (E) sheets of the project with all changes indicated. After review by the Engineer, one set of these as-built plans shall be placed in a waterproof envelope and filed by the Contractor in each Control Panel.
One set of as-built plans shall be submitted to the Design Services Unit.
The light standard foundations that are relocated by permission of the Engineer shall be shown on the as-built plans in their final locations.
The Contractor shall keep a daily record of the location of all items in order to ensure the accuracy of the as-built plans.
(E) Warranties:
Warranties from each manufacturer of electrical materials and equipment pertinent to the complete and satisfactory operation of the system shall be turned over to the Engineer prior to the acceptance of the project. Each warranty so furnished shall indicate its expiration date and shall not be less than those provided as a customary trade practice.
(F) Computations and Welding Procedures:
Submittals of structural design computations and drawings showing material and welding specifications as required in other sections of the specifications, such as High Mount Standards, may require ten (10) weeks for review by the Engineer.
(A) Location Surveys:
The Engineer will locate all light standards, high mount foundations, and electrical duct unless indicated differently elsewhere in the specifications. The Contractor shall mark the proposed location of circuits, circuit markers, control systems, service poles, junction boxes, luminaires, and all other components for the Engineer's approval prior to installation. The Engineer will provide the top of foundation elevations unless indicated differently.
The plan locations of the light standards and high mounts may be adjusted in order to be behind guardrail, to avoid obstructions, or to avoid undesirable foundation conditions. Location changes shall have been approved by the Engineer prior to construction. Longitudinal relocations of luminaires of more than 10 feet or lateral relocations of more than 2 feet shall have been approved by the Design Services Unit.
All project dimensions shall be verified on the site, actual measurement always taking precedence over scaled plan dimensions, with every part of the work fitted to actual conditions at the site.
(B) Damage to Facilities:
The Contractor shall take all precautions necessary to avoid damage to existing underdrains and other buried facilities located in certain areas. Hand trenching by the Contractor may be required to avoid damage to the underdrains, storm sewer systems and other facilities. Light pole foundations shall have a minimum horizontal clearance of 10 feet to storm sewers or other underground installations which might affect the foundation stability. Lateral and longitudinal changes in pole locations shall be made in the field to provide the required clearance, as directed by the Engineer.
The Contractor's trenching and construction operations may require the removal of or result in damage to existing shoulders and paved ditches. All portions of the project that are disturbed by the Contractor's operations shall be restored by the Contractor to their original condition or as otherwise approved by the Engineer.
Installation of conductors may require trenching through existing guardrail locations. The Contractor may trench beneath the guardrail in a manner that will not disturb the guardrail installation or he may remove short sections of guardrail to facilitate mechanical trenching. All guardrail removed shall be reinstalled by the end of the day's work. Permission from the Engineer is required prior to removal of any guardrail, and any damage to the guardrail installation or to the galvanizing of the material shall be repaired as directed by the Engineer.
All trenched, excavated, or otherwise damaged earth surface areas shall be repaired by the Contractor by shaping, smoothing, seeding, and mulching the damaged areas as required by the Specifications and as directed by the Engineer.
(C) Existing Utilities:
Water, sewer, telephone, fire alarm, traffic signal, and power lines may be located in the same area that lighting standards and circuits are to be installed.
The Contractor shall locate these lines before operations are begun. Field changes approved by the Engineer may be made to provide clearance required by the National Electrical Safety Code.
Foundations or other construction which is installed in conflict with existing utilities will not be acceptable. They shall be removed and damage to utilities repaired at no cost to the Department.
(D) Operation of Equipment:
The Contractor shall not store equipment or materials in the median or on the roadway shoulders unless otherwise permitted by the Engineer.
The Contractor shall not cross the median with any equipment except at designated interchanges unless otherwise permitted by the Engineer.
A bucket truck shall be used to raise workmen into position to install and/or adjust luminaires and lamps after the initial setting of the standards. The Contractor will not be allowed to take down the light standard to check or make adjustments at the top.
(E) Conduit Installation:
Conduit shall be installed continuous, watertight, free of kinks, and all runs shall be made with as few couplings as standard lengths will permit. The total angle of all bends between outlets shall not exceed 270 (3-90° bends) unless approved otherwise by the Engineer. Conduit bodies with covers and neoprene gaskets may be used to facilitate the installation of the wires at locations indicated on the plans.
Protection shall be provided at all times against the entrance of water or other foreign matter into the conduit.
Conduit shall be plugged or capped when work is temporarily suspended, including nightly stoppage of work.
All conduit shall be clean before installation, and upon completion of the system an approved cleaner with a diameter not less than 85% of the nominal diameter of the conduit shall be snaked through each conduit prior to installing the wire.
The conduit shall be installed in such a manner that temperature changes will not cause elongation or contraction which might damage the system. Expansion fittings shall be provided where conduit crosses structure expansion joints.
Short radius bends in non-metallic conduit shall be avoided to prevent "burn-through" of the pulling cable or conductors during pulling operations.
Stub-outs for future use shall have caps or plugs of the same material as the conduit. Where non-metallic conduit is joined to metallic conduit, a non-metallic female threaded adapter shall be used. All conduit ends projecting into panels, boxes, or other enclosures shall have bushings. Pull lines shall be provided in all conduits for future installation of circuitry.
Field cut threads and other uncoated metal or damaged galvanizing shall be coated with zinc rich paint.
Conduit shall be securely fastened. The spacing of fasteners shall not exceed 4' for 1 1/2" conduit and larger or 6' for 1 1/4" conduit and smaller. All fasteners shall be hot dipped galvanized or stainless steel. Backs shall be provided with all conduit straps installed on flat surfaces. Rotary-impact drills may be used for installing expansion anchors in concrete. Powder explosion type units shall not be used.
Underground conduit shall not be installed until the area has been brought to final earth grade. Careful attention shall be given to the vertical and horizontal alignment of the conduit to provide the smoothest installation.
(F) Wiring Methods:
No wire shall be pulled through a conduit system until the system is complete and has been cleaned. Approved wire pulling lubricants shall be used. Wires shall be pulled into conduit at a slow steady pace and careful attention given to assure that no wire is damaged.
All conductors shall be color coded per the NEC (grounded neutral- WHITE; grounding - BARE or GREEN) and phase conductors shall be BLACK and RED. Approved marking tape, paint, or sleeves may be used in lieu of continuous colored conductors for No. 8 AWG and larger. A white conductor in a cable assembly shall not be marked any other color. However, a white, red, or black conductor may be stripped at all accessible points and used as a bare equipment grounding conductor.
Joints, taps, and splices will only be permitted at locations indicated on the plans and by the following methods.
Locations in junction boxes and bases of standards:
(1) Cut and remove the insulation only as far as necessary to make a secure mechanical and electrical connection. The connector shall be a removable type (split-bolt, set screw, wire nut, etc.) and shall be covered with self-vulcanizing rubber tape applied in half-lap layers, to give a smooth covering of not less than 2 times the thickness of the original insulation. Over the rubber tape, at least two layers of vinyl plastic tape shall be applied half-lap. The rubber tape shall be a self-fusing type putty in tape form that can be wrapped, stretched, or molded around irregular shapes for smooth insulation build-up. The vinyl plastic tape shall be 7 mil (0-220F) ultraviolet, abrasion, moisture, alkali, acid and corrosion resistant.
(2) Install a manufactured mechanical or compression connector with factory made waterproof insulating boots in accordance with procedures and using tools as specified by the manufacturer.
(G) Grounding Electrodes:
Grounding electrodes shall be installed at each light standard, junction box, and control system as shown on the plans. They may be encased in light standard and high mount concrete foundations if they are securely bonded with tie wires to the reinforcing steel. Where installed in earth, they shall be driven flush with the ground after installation of the clamp and conductor.
(H) Equipment Mounting:
Equipment shall be mounted securely at locations shown on the plans in conformance with the dimensions shown and shall be vertically plumb and level. Fasteners shall be installed as recommended by the manufacturer and shall be evenly spaced. All mounting holes and attachment points shall be utilized for attaching enclosures to structures.
(I) Concrete Foundations:
Concrete foundations shall have dimensions verified by the Engineer in accordance with the details shown on the plans or approved drawings. Construction shall be in accordance with Section 825 of the Standard Specifications. Concrete shall be Class "A", meeting the requirements of Section 1000 of the Standard Specifications. Reinforcing steel shall conform to the requirements of Section 1070 of the Standard Specifications.
Foundation excavation shall conform to the applicable provisions of Section 410 of the Standard Specifications. The sides of the excavation shall conform as nearly as practicable to the required dimensions. Concrete shall be placed against undisturbed soil unless otherwise permitted by the Engineer. If, in the judgment of the Engineer, large discontinuities in the required configuration of the excavation are created by the removal of boulders or due to any other causes, the excavation shall be backfilled and compacted as provided for in Section 410 of the Standard Specifications. The foundation shall then be re-excavated to the proper dimensions.
Foundations shall be formed with prefabricated cardboard forms down to 6" min. below top of ground. Shoring, if used to stabilize the sides of the excavation, shall have been approved by the Engineer prior to its use.
Top of foundation elevation shall be set relative to the surrounding ground surface as shown on the plans. Corners at the top of foundation shall be chamfered. Exposed vertical concrete surfaces shall be given an ordinary surface finish. Exposed horizontal concrete surfaces shall be given a float finish. Non-shrinking grout approved by the Engineer prior to its use, shall be used between the top of foundation and bottom of mounting base if indicated on the plans or other sections of the specifications. Drainage ("weep") holes shall be provided through the grout so that water will not accumulate on top of the foundation or inside the standard.
Standards shall not be erected before test cylinders representing the foundation concrete have attained a minimum compressive strength of 3000 psi. Forms shall not be removed until the concrete has properly cured, and in no case less than 24 hours after the concrete has been placed.
Anchor bolts shall be arranged symmetrically about the center of the foundations. Anchor bolts shall be securely braced and held in proper position and alignment. Electrical conduits of the size and number required by the circuits shall be installed in the concrete as shown on the plans. The number of conduits shown on the plans is a guide only, with the actual number required being based on the number of circuits to be installed at the foundation being constructed; however, in no case should less than 2 conduits be installed.
Tops of foundations which will have breakaway devices attached shall be recessed below normal grade. To avoid vehicle undercarriage snagging of any substantial remains of a breakaway support (when it is broken away), the edge of the foundation or top of anchor bolt should not extend more than four inches (4") above a sixty inch (60") chord aligned radially to the centerline of the highway and connecting any point, within the length of the chord, on the ground surface on one side of the foundation to a point on the ground surface on the other side.
The Contractor shall be responsible for having each electrical system inspected and approved by the electrical inspector having jurisdiction in the area in which the systems are located. The Contractor shall furnish written verification to the Engineer that the electrical systems have been approved by the local inspector. This verification shall be provided prior to the final acceptance of the project. Inspection by local authorities shall neither eliminate nor supersede, the inspection by the Engineer to ensure compliance with the plans and specifications.
The Contractor shall comply with all local ordinances and regulations. He shall apply for and obtain all permits and/or licenses required by local regulation.
All work shall have been inspected and approved by the Engineer before concealment. An inspection will be made during the progress and after the work has been completed. It will also include an inspection made at night to determine the optical qualities of each luminaire. All luminaires having unsatisfactory qualities shall be adjusted as directed by the Engineer.
The Contractor shall provide the necessary personnel and equipment for aiming luminaires during nighttime inspections by the Engineer.
Prior to acceptance the Contractor shall operate the lighting system, including automatic control equipment and all other apparatus, without interruption or failure attributable to poor workmanship or defective material for 2 consecutive weeks. All lights and equipment will be inspected by the Engineer for normal operation. The Contractor shall make all necessary repairs or replacements.
The performance test shall be conducted at the same time for all lights which are energized from the same utility company service point.
Performance tests of individual circuits or groups of lights will not be acceptable.
The Contractor shall arrange with the power company to provide the electric power necessary. Separate payment will not be made for labor, materials, equipment, and incidentals required for performing the tests.
After all wiring has been installed and connected in the proposed permanent manner, but prior to the above operation period, each feeder circuit conductor shall be given an insulation resistance test by the Engineer. The insulation resistance for each conductor shall exceed 5 megohms after charging for 30 seconds at 500 VAC or 1000 VDC.
If the insulation resistance test of any conductor indicates a value of less than 5 megohms, the Contractor shall locate the fault. If the fault is in a conductor between terminal connections, the conductor shall be replaced. If the fault is at a terminal connection, the terminal device shall be replaced or repaired as directed by the Engineer. All wiring shall have satisfactory insulation resistance prior to beginning the 2 week operation test.
Each component of the lighting/electrical system shall be identified as indicated on the plans. The method of identification shall be by an approved paint, adhesive label, or embossed concrete. Components requiring identification shall include conductors at each terminal, circuit breakers, light standards, high mount standards, control systems, junction boxes, and underpass panels.
Each circuit conductor shall be labeled at each terminal and access point with the circuit number indicated on the plans.
Light standards and high mount standards shall be identified by the control system and location number indicated on the plans. The identification shall be on the front side of the standard facing the traffic at a height of 6 feet above ground level. Control systems and underpass panels shall be identified on the exterior of the front panel.
All access doors to control cabinet enclosures shall be supplied with locks meeting the Engineer's approval. All locks shall be keyed alike and the Contractor shall furnish to the Engineer 8 keys.
The Contractor shall coordinate all work to ensure that electrical power of the proper voltage, phase, frequency, and ampacity is available to complete the project.
When electrical service is required, the Contractor shall contact the utility company, make application and pay all costs, including the monthly power usage bill, to assure that all work can be completed. The Contractor, upon request, will be reimbursed for the actual verified cost of any utility company charges, including the monthly power usage bills. The Contractor will be responsible for payment of utility company charges incurred until the date of acceptance of the work by the Department.
The terms "high mast" and "high mount" are used synonymously in this specifications and the plans.
The term "by others" means work to be accomplished and paid for under contract items other than those clearly pertaining to the work specified or shown. Work "by others" may be included in this contract for the Contractor to provide with other work or it may be provided under another contract or by someone other than the Contractor.
Abandon means that the materials will not be used in the final completed form of the work. All abandoned materials shall be removed from the project or terminated at least 18" below subgrade by the Contractor so that they will not be in conflict with the finished project.
Lighting work shall be accomplished along with other roadway construction in the appropriate phases as indicated in the Traffic Control Plans and these specifications.
There will be no direct payment, except where specifically noted
in the sections titled "Samples" and "Electrical
Service", for the work required in the preceding sections
of this division. Payment of the contract unit prices for the
various items in the contract will be full compensation for all
work required.