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ALABAMA DEPARTMENT OF TRANSPORTATION DATE: April 1, 2014 Special Provision No. 12-0268(2) EFFECTIVE DATE: August 1, 2014 SUBJECT: Roadway Lighting. Alabama Standard Specifications, 2012 Edition, shall be amended by replacing SECTION 750 and SECTION 889 as follows: SECTION 750 ROADWAY LIGHTING 750.01 Description. This work shall consist of furnishing
  ALABAMA DEPARTMENT OF TRANSPORTATION DATE: April 1, 2014 Special Provision No. 12-0268(2) EFFECTIVE DATE: August 1, 2014 SUBJECT: Roadway Lighting. Alabama Standard Specifications, 2012 Edition, shall be amended by replacing SECTION 750 and SECTION 889 as follows: SECTION 750 ROADWAY LIGHTING 750.01 Description. This work shall consist of furnishing and installing roadway lighting systems, or the modification of roadway lighting. The structural requirements (design and materials) for roadway lighting are addressed in Section 718. 750.02 Materials. Materials shall meet the requirements given in Section 889. Prior to purchasing materials, and within 30 days after the issuance of the Notice to Proceed , the Contractor shall submit five copies of a complete descriptive list of all materials to the Design Bureau’s Traffic Design Section for approval. (The requirement for the submittal of structural designs and details is given in Section 718.) This information shall be submitted on the Department’s Material Submittal Form furnished to the Contractor for this purpose. The submittal shall have each item sequentially numbered, a reference to the Specification Section and/or plan sheet, and a description of the material. The description shall include the type, model number, catalog number, and manufacturer, and shall include a legible manufacturer’s catalog cut sheet with each item being submitted clearly identified. All roadway lighting components (wiring, conduits, boxes, mounting hardware, power control devices, luminaires, luminaire poles, etc.) shall be itemized on the submittal form. Submittals shall be clear and complete. Pay Items are not to be referenced on the form. Incomplete or inaccurate submittals will be returned to the Contractor for revision and resubmittal. Partial lists may be considered if prior approval for the submittal of a partial list is approved in writing by the Engineer. Materials shall not be installed prior to approval. The Department will not be liable for materials purchased, work performed, or any delay incurred due to the failure of the Contractor to secure prior approval. Failure of the Engineer to note unsatisfactory material as received at the job site will not relieve the Contractor of the responsibility of furnishing the required material. 750.03 Construction Requirements. (a) CODE. All work shall be done in accordance with the requirements given in the current edition of the National Fire Protection Association NFPA 70, National Electrical Code (NEC) and the regulations and standards of the power company providing service. (b) LICENSE. The Contractor responsible for the performance of the work shall be licensed as a General Contractor authorized to perform electrical work by the Alabama State Licensing Board for General Contractors At least one out of every three persons in each work crew shall be a Journeyman licensed by the Alabama Electrical Contractors Board. Journeymen shall be present and shall have direct  Special Provision No. 12-0268(3) Page 2  of 16  involvement with all work required for the installation and operational testing of electrical materials and equipment. The Journeymen shall also possess an IMSA (International Municipal Signal Association) Roadway Lighting Level 1 Certification. The Contractor shall submit copies of the General Contractor license, Journeyman licenses and IMSA certifications to the Engineer as a part of the submittal of the list of materials proposed for installation. Work shall not begin on the installation of electrical materials or equipment until copies of the licenses and certifications have been approved by the Engineer. (c) ELECTRICAL POWER. The entity (City, County, State, etc.) that will be responsible for the eventual operation and maintenance of the roadway lighting system will make application for electrical service upon notification that power service will be required. The Contractor shall inform the Engineer when power service is required at least 30 calendar days prior to the need of the power service. This same entity will be responsible for the cost of the service connection and the monthly service billings thereafter. Electrical power shall be the power system shown on the plans which will usually be a single phase, 3-wire, 480 Volt-AC system. Power shall be provided by a transformer that does not provide power to any other equipment. (d) GENERAL CONDUIT SYSTEM INSTALLATION REQUIREMENTS. Conduit shall be installed in accordance with the details shown on the plans or as directed by the Engineer. Rigid Nonmetallic Conduit (RNC) may be installed as a substitute for Nonmetallic Underground Conduit and Cable (NUCC) if it is the same size and schedule as the NUCC. Conduit routing shown on the plans is diagrammatic only. Actual routing shall be in the most prudent manner as approved by the Engineer. Underground conduit depth shall be   24 inches {600 mm}, minimum, unless shown otherwise on the plans. All conduit ends (except NUCC and HDPE) shall be put together in couplings to form a smooth raceway for cables. Bushings and duct sealant shall be installed at all conduit terminations to protect the insulation of the conductors and to prevent debris from entering the conduit. Conduits shall be joined by approved methods   prescribed by the manufacturer of the conduit. When conduit is installed for future use, the ends of the conduit shall be   capped with a fitting listed for this purpose to prevent water and other foreign matter from entering the conduit system. The Contractor shall seed and mulch disturbed areas as directed by the Engineer. The seeding and mulching of disturbed areas shall be a subsidiary obligation of the conduit installation. Before beginning excavation, the Contractor shall determine the location of all utilities in the vicinity. Utilities shall not be damaged during construction. Conduit shall be located to avoid potential conflict with the future installation of guardrail, signposts, and other equipment and devices. A minimum of 12 inches {300 mm} clearance shall be provided between the finished lines of conduit runs and existing underground utilities. Where the underground conduit run is adjacent to concrete walls, piers, footings, etc., a minimum of 4 inches {100 mm} of undisturbed earth or firmly compacted soil shall be maintained between the conduit and the adjacent concrete. Unless shown otherwise on the plans, trenches shall not be excavated in existing pavement or paved shoulders to install conduit. When it is necessary to place conduit under an existing pavement, the conduit shall be installed in accordance with the requirements given in Section 756. Unless approved otherwise by the Engineer, trenches shall not remain open after normal work hours each day.   Liquid Tight Flexible Metal Conduit (LFMC) or Liquid Tight Flexible Non-metallic Conduit (LFNC) as shown on the plans or directed by the Engineer shall be installed where conduits cross an expansion or open joint on bridges, barrier rails or structure. The LFMC or LFNC shall be 36 inches {900 mm} in length and shall have a sag of not   more than 3 inches {75 mm} between the fixed ends of the rigid conduit.  Special Provision No. 12-0268(3) Page 3  of 16   (e) JUNCTION BOXES. The types of junction box shall be: TYPE INSTALLATION LOCATION BOX MATERIAL Type 1 Installed flush with grade. Non-Metallic Type 2 Installed on the surface of a structure. Metal Type 3 Installed flush with surface of a structure. Non-Metallic Type 4 As Shown on the Plans As Shown on the Plans (f) NONMETALLIC UNDERGROUND CONDUIT AND CABLE. Nonmetallic Underground Conduit and Cable (NUCC) shall be installed in accordance with the manufacturer's recommendations. If plowing is proposed for the installation of the NUCC, the manufacturer’s recommended installation practices shall be submitted to the Engineer prior to beginning the installation. If the Engineer is not satisfied with the Contractor’s performance and knowledge once installation begins, the Contractor shall arrange for a manufacturer’s representative experienced in plowing methods to be at the jobsite until the Engineer determines that the Contractor is capable of properly installing the NUCC. If rock or other obstructions hinder plowing operations, the Engineer may require that conductor routes be pre-ripped to locate rock or hidden obstructions. Obstructions may be removed or the conductors routed around them as approved by the Engineer. If the Plow Pulling method is used, the plow operator shall have an acceptable method to insure that the manufacturer’s recommended maximum tensile force on the NUCC is not exceeded. If at any time the Engineer determines the installation is not in full compliance with the intent of the manufacturer’s recommended practices, the operation shall stop until a manufacturer’s representative can further instruct the Contractor’s personnel in the deficient areas. If the Chute Plowing method is used, special attention shall be given to the conductor feed chute dimensions. (g) CONDUCTOR INSTALLATION. 1. SPLICES AND TAPS IN CONDUCTORS. Splices and taps in conductors shall only be made in junction boxes and pole bases. They shall be made with solderless split bolt connectors. Splices and taps shall be protected in sealed in silicone gel filled enclosures to provide a waterproof connection and to ensure the required electrical insulation. Silicone gel filled enclosures shall be re-enterable; shall be UV resistant, listed for temperatures from -40 ° C to 90 ° C; and shall be impact and abrasion resistant. The enclosure shall be sized as shown in the following table: Conductor Size Gel Enclosure Size #4 AWG and smaller #2 #2 AWG #2.5 or Miniwedge Larger than #2 AWG #3 2. PULLING CONDUCTORS INTO CONDUIT. Conductors shall not be pulled into a conduit until the installation of the conduit is complete. Conductors in conduits shall be carefully pulled into place using approved methods so that the conductors will not be damaged. Powdered soapstone, talc, or other inert lubricant specifically designed for the purpose shall be used when pulling conductors through the conduit. All conductors within a single conduit shall be pulled at the same time and shall be handled and installed in such a manner as to prevent kinks, bends or other distortion which could damage the conductor and outer covering. When conductors are pulled through hand holes, pole shafts, etc., a pad of firm rubber or other suitable materials shall be placed between the conductors and the edges of the opening to prevent damage to the conductors.   (h) GROUNDING. All metal poles and metal enclosures containing electric wires and/or equipment shall be grounded.   Exothermic welds or other approved connectors shall be used to connect the grounding conductor to the ground rods.  Special Provision No. 12-0268(3) Page 4  of 16  A continuous grounding conductor, either bare or having a green colored insulation, shall be extended from the service ground to all equipment and shall be used for grounding purposes only. (i) LIGHTNING PROTECTION. Lightning protection shall be installed as shown on the plans at all poles greater than or equal to 75 feet {22.8 m} in height. (j) FOUNDATIONS. For bidding purposes, the size and configuration of reinforced concrete foundations will be shown on the plans for the designated ranges of pole heights The Engineer will inform the Contractor if changes are required to the depth of concrete foundation required at each pole. Changes in the depth of foundations may be made based on a review the Contractor's design submittal. The Contractor will be notified of any such changes upon completion of this review. If no changes are required, the Contractor shall install the as-bid sizes of foundations. Care shall be taken to properly orient the anchor bolts of concrete foundations so that the luminaire assembly will be in proper alignment with the roadway. Conduits shall be accurately placed, oriented in the proper direction to accommodate future extension, and securely held in place to prevent movement. Concrete shall then be placed in the excavated area against undisturbed earth   below the finished ground line. The concrete shall be placed in an approved form above ground line to the top of the foundation. All exposed edges of the concrete shall have a 3/4 inch {19 mm} chamfer. The top of the foundation shall be level and shall be placed to properly orient the luminaire assembly with the roadway. For breakaway poles, the finished foundation shall have a maximum 4 inch {100 mm} Breakaway Support Stub Height Measurement as defined in the AASHTO Roadside Design Guide, Chapter 4.2. (k) INSTALLATION OF LUMINAIRE POLES. Luminaire poles   shall be installed in a vertical position. Erection shall be accomplished carefully to prevent marring the finish or otherwise damaging the pole. When lighting is to be installed on a bridge, the Contractor shall, before ordering the poles, examine the bridge plans or the completed bridge, whichever is applicable, to determine the exact nature of the proposed or existing details which will accommodate the luminaire poles. Any discrepancies between the plans and an existing bridge structure   shall be immediately reported to the Engineer. The Contractor shall verify that the pole anchor bolts, base plate bolt pattern, and pole assembly (including tenon mounting holes, multiple pole sections, and hand-hole orientation) are coordinated for proper orientation of lowering devices and luminaires to the roadway as shown on the plans. A screen made from 1/4 inch {6.4 mm} mesh galvanized wire cloth shall be fabricated and inserted in the pole base to prevent rodents, etc. from entering the pole. Backfill for direct burial fiberglass poles shall be as recommended by the pole manufacturer. Care shall be taken to assure the bracket arm is properly aligned. (l) INSTALLATION OF LUMINAIRES. The light control surfaces and glassware shall be cleaned after installation. Cleaning shall be performed in accordance with the luminaire manufacturer’s recommendations. Luminaires shall be leveled, plumbed, and installed as per the manufacturer’s recommendations to achieve the most suitable light pattern. The Contractor shall verify that the lamp socket is in the proper position to produce the optimum lighting pattern for each luminaire not to just meet minimum. Each luminaire shall be adjusted to provide the most effective light pattern as directed by the Engineer after installation. (m) TESTING INSULATION. The insulation of all lighting circuits will be tested by the Engineer at   the load side of the contactors or circuit breakers. These tests shall be made with a 500-volt DC Megger Tester. Any reading of 250,000 ohms to ground or higher is satisfactory. Any reading of less than 250,000 ohms to ground is unacceptable and shall be corrected. The Engineer may   conduct additional insulation testing after the completion of the operational testing.
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