100 general provisions

631.01 Description

631.02 General

631.03 Materials and Equipment

631.04 Sign Service

631.05 Signs Wired

631.06 Disconnect Switch

631.07 Luminaire

631.08 Controls

631.09 Electrical Signs

631.10 Removal and Storage or Reerection

631.11 Inspection and Testing

631.12 Method of Measurement

631.13 Basis of Payment
631.01 Description. This work consists of furnishing and installing sign lighting or electrical sign equipment, complete, tested, and ready for service.

631.02 General. Perform installations according to the National Electrical Safety Code, the National Electrical Code and local codes for the area of installation. Furnish overhead sign lighting with mercury vapor luminaires, and integrate electric power with roadway lighting circuits.

Furnish certified drawings according to 625.06.

Conform to the requirements of Supplement 1063 for the installation or testing of electrical items installed under 631.08 and 631.09.

Protect wire and cable by installing entirely within support structure interiors, enclosures, junction boxes, and rigid or flexible conduit. Ensure that the methods, materials, and locations of splicing and the methods of connecting and identifying wire and cable conform to Item 625, Item 725, and the plans. Furnish grounding systems according to 625.16.

Power service is furnished under Item 625.

631.03 Materials and Equipment. Furnish materials and equipment that are new, of first quality, of current design, and free from defects.

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

Ensure that each item of equipment bears a nameplate, indelible marking, or brand that identifies the type, model, catalog number, and manufacturer.

Furnish materials conforming to the following:

Ground rod 625.16

Sealing, conduit 625.12

Cable and wire, 600-volt 725.02

Conduit, rigid 725.04

Mercury vapor ballast 725.11

Mercury vapor lamp 725.11

Power service 725.19

Disconnect Switch 725.19

Switch Enclosure 725.19

Mercury vapor luminaire 731.01

Changeable message sign, electric type 731.03

Internally illuminated fixed message sign 731.05

Sign flasher assembly 731.06

School speed limit sign assembly 731.07

Conduit, flexible 731.08

Timer with enclosure 731.10

631.04 Sign Service. Sign service consists of all cable and other equipment to provide a complete electrical service from either an underground or overhead source to the disconnect switch.

Route sign service cable from a pull box to the switch enclosure for overhead supported signs by means of underground conduit, foundation conduit ell, and the interior of the structural member supporting the enclosure.

Route sign service for overpass structure mounted signs through underground and structure attached conduit terminating at a switch enclosure. Attach the conduit by 0.02-inch (0.5 mm) thick by 3/4-inch (19 mm) wide passivated stainless steel straps spaced at intervals of not more than 5 feet (1.5 m).

Route sign service cable from a distribution system direct drop to the switch enclosure by means of a conduit riser with weatherhead. Form a drip loop into the cable. Use either a cast aluminum or galvanized ferrous metal weatherhead of a threaded design. Attach the conduit by straps as described in the previous paragraph.

For sign service, use single conductor stranded copper. When the connection is to highway lighting distribution and circuit cable, use the same cable for sign service. In other applications, use sign service cable rated at 600 volts minimum and not smaller than 4 AWG.

631.05 Signs Wired. Ensure that signs wired complete the electrical system from the disconnect switch to the luminaires.

Furnish continuous wiring from the disconnect switch to a junction box mounted on the sign support or overpass structure. Install junction box in a manner that allows sign removal as a unit by the disconnection of the wires and the removal of sign attachment hardware. Install a junction box for each sign.

Furnish continuous wiring from the junction box to the first luminaire and between additional luminaires.

Use wire rated at 600 volts, single conductor and not smaller than 10 AWG.

Route wire on overhead sign supports from the disconnect switch enclosure through structural member interiors. Support wire hanging within the interior of steel vertical members by looping over the J-hook provided. After wiring in the disconnect switch enclosure, seal the nipple in the enclosure back with self-fusing high-dielectric insulating compound.

Assemble flexible or rigid conduit on the sign structure or lighting support arms with condulets, and attach them to the structure by clamps located within 6 inches (150 mm) of each conduit end and separated by not more than 24 inches (0.6 m).

631.06 Disconnect Switch. Install lighted signs with a disconnect switch within a lockable, weatherproof enclosure. For the switch, use a two-pole (minimum), single-throw, fused safety disconnect type, rated at 600 volts, 30 amperes with the fuse size as specified. Furnish a solid neutral bar.

For the enclosure, use stainless steel NEMA 250, Type 4. Furnish space for a chase nipple in the enclosure back. Field drill a hole through the enclosure and install the nipple. Ensure that enclosures also have a 1/4-inch (6 mm) diameter weep hole located in the bottom surface.

Furnish each enclosure with at least one padlock. Use padlocks with a bronze or brass lock body and a corrosion protected steel shackle. Key all padlocks for a project alike, and obtain the appropriate master key number from the maintaining agency.

When specified, furnish and install bracket assemblies on existing overhead sign supports or on concrete structures. Use bracket assemblies made of steel, galvanized according to 711.02, or aluminum.

631.07 Luminaire. Include a lamp of the wattage specified.

Locate ballasts integral with the luminaire. Furnish weatherproof ballast housings made from corrosion resistant materials.

631.08 Controls. When specified, furnish photoelectric controls when sign lighting is fed by uncontrolled circuits.

When specified, furnish and install the timer with enclosure to provide automatic school speed limit sign operation.

631.09 Electrical Signs. Furnish changeable message signs that conform to the Contract Documents. The pay item will specify if the display capabilities are limited message or unlimited message. The Contractor may use line units of these types as inserts in a panel sign, singly or grouped to provide a multiline sign. Hardware and software shall be complete to operate and maintain the sign.

Furnish internally illuminated signs consisting of the single or double face type. The sign support is furnished under another pay item. Furnish suspended signs that hang plumb, are properly oriented, and locked in place.

Furnish sign flasher assemblies consisting of a pair of flashing beacons. The sign, support, and foundation are furnished under other pay items.

Furnish school speed limit sign assemblies that conform to the Contract Documents. School speed limit sign assemblies consist of a reflectorized SCHOOL SPEED LIMIT 20 DURING RESTRICTED HOURS (S5-H3) sign fitted with a pair of flashing beacons arranged above and below the sign.

631.10 Removal and Storage or Reerection. Carefully remove sign lighting equipment (such as luminaires, disconnect switches, or ballasts) and electrical signs, and either store on the project for salvage by the Department or reerect elsewhere on the project. Clean and restore luminaires to be reerected to an operating condition, fitted with new lamp boots, relamped with the proper type and size lamp, and provided with new hardware.

631.11 Inspection and Testing. Ensure that the sign lighting systems and electrical signs meet all requirements of the ground, cable insulation, and performance tests specified in 625.19. Correct lamps, ballasts, and transformers that failed during the performance test by replacing the faulty component; the entire test period will not require restarting.

During the performance test, make final adjustments to sign lateral position and aiming angles of luminaires to eliminate excessive brightness and glare, and to obtain optimum sign face reflected brightness, uniformity of illumination, visibility, and legibility, to the satisfaction of the Engineer.

631.12 Method of Measurement. All of the following methods of measurement include all hardware necessary to securely mount the associated item including angles, plates, tubes and channels.

The Department will measure Sign Service by the number of complete units for each support, and will include conduit, conduit riser, weatherhead, fittings, cables, trenching, and backfilling.

The Department will measure Sign Wired and Sign Wired, Overpass Structure by the number of complete units of wiring for each individual sign, and will include junction boxes, rigid or flexible conduit, condulets, clamps, wires, and connectors.

The Department will measure Disconnect Switch with Enclosure by the number of each, and will include field drilling and padlocks.

The Department will measure Switch Enclosure Mounting Bracket Assembly by the number of each, and will include two brackets and field drilling.

The Department will measure Ballast and Photoelectric Control by the number of each separate item.

The Department will measure Mercury Vapor Luminaire by the number of each, and will include lamps and luminaire attachment hardware.

The Department will measure Changeable Message Sign by the number of each, and will include cabinet, external enclosures, conduit, electrical, electronic and auxiliary components, and remote control units to provide a fully functional unit.

The Department will measure Internally Illuminated Fixed Message Sign by the number of each, and will include lamps and ballasts.

The Department will measure Sign Flasher Assembly by the number of each, and will include beacons, flasher control unit with enclosure, and lamps.

The Department will measure School Speed Limit Sign Assembly by the number of each, and will include sign, beacons, flasher control unit with enclosure, and lamps.

The Department will measure Timer with Enclosure by the number of each, and will include field drilling and padlocks.

The Department will measure Removal and Storage or Removal and Reerection of sign lighting equipment or electrical signs by the number of each like items removed and stored or reerected.

631.13 Basis of Payment. The Department will pay for grounding systems under Item 625.

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

Item Unit Description

631 Each Sign Service

631 Each Sign Wired

631 Each Sign Wired, Overpass Structure

631 Each Disconnect Switch with Enclosure, Type ___

631 Each Switch Enclosure Mounting Bracket Assembly

631 Each Ballast, Type ___

631 Each Photoelectric Control

631 Each Mercury Vapor Luminaire,
Type ___, with ___-watt Lamp

631 Each Changeable Message Sign,

(Limited, Unlimited) Message

631 Each Internally Illuminated Fixed

Message Sign, Type ___

631 Each Sign Flasher Assembly

631 Each School Speed Limit Sign Assembly,
___ inches  ___ inches
(___ mm  ___ mm)

631 Each Timer with Enclosure

631 Each Removal of (Luminaire, Disconnect Switch,
Ballast, etc.) and (Storage or Reerection)

ITEM 632 TRAFFIC SIGNAL EQUIPMENT

632.01 Description

632.02 Contractor Personnel Requirements

632.03 Materials and Equipment

632.04 Certified Drawings

632.05 General

632.06 Vehicular Signal Head, Conventional

632.07 Vehicular Signal Head, Optically Programmed

632.08 Pedestrian Signal Head

632.09 Pedestrian Pushbutton

632.10 Loop Detector Unit

632.11 Detector Loop

632.12 Magnetometer Detector Unit

632.13 Magnetometer Sensor Probes

632.14 Foundations

632.15 Signal Support

632.16 Strain Pole

632.17 Wood Pole

632.18 Down Guy Assembly

632.19 Pedestal

632.20 Conduit Riser

632.21 Cable Support Assembly

632.22 Messenger Wire

632.23 Cable and Wire

632.24 Power Service

632.25 Covering of Vehicular and Pedestrian Signal Heads

632.26 Removal of Traffic Signal Installation

632.27 Reuse of Traffic Signal Equipment

632.28 Testing

632.29 Method of Measurement

632.30 Basis of Payment
632.01 Description. This work consists of furnishing and installing traffic signal equipment, complete and ready for service. This work also includes necessary excavation and backfill, disposal of discarded materials, restoration of disturbed facilities, and surfaces to a condition equal to that existing before the Work started, and electrical testing as specified.

Pull boxes, conduits, ground rods, and cable splicing kits required for traffic signal equipment installations are specified in Item 625.

632.02 Contractor Personnel Requirements. Conform to the requirements of Supplement 1063 for the installation or testing of traffic signal equipment.

632.03 Materials and Equipment. Furnish new materials and equipment of first quality, of current design, and free from defects.

Use electrical parts, wire, switches, and other elements of the installations capable of carrying the required current without excessive heating or drop of potential.

Ensure that major items or assemblies of equipment bear a nameplate, indelible marking, or brand that identifies the type, model, catalog number, and manufacturer.

Furnish materials and equipment conforming to:

Concrete, Class C 499, 511

Steel*:

Poles, supports, arms, appurtenances

and anchor bases 730.02, 730.03, 730.04,

730.05, 730.06, 730.07,

732.12, 732.11

Pedestals 732.15

Backplates…………………………………….. 732.22

Hardware 730.08

Stainless steel hardware 730.10

Other Items:

Conduit, rigid 725.04, 725. 05

Ground rod 725.16

Pull boxes 725.06, 725.07, 725.08, 725.12

Identifying tags or bands 725.02

Signal heads 732.01, 732.02, 732.03, 732.05

Lamps 732.04

Pushbuttons 732.06

Detectors 732.07, 732.08, 732.09

Probes 732.10

Wood poles 732.13

Down guys 732.14

Conduit risers 732.16

Cable supports 732.17

Messenger wire 732.18

Cable and wire 732.19

Power service 732.20

Disconnect Switch with enclosure 732.21

Backplates………………………………………732.22

* Acceptance of materials and products is based on certified test data, furnished in triplicate, or on test results of samples according 106.04, as required by the Laboratory.

632.04 Certified Drawings. Furnish certified drawings according to 625.06.

632.05 General. Ensure that major items of traffic signal equipment used in combination are compatible, interchangeable, and, whenever feasible, provided by the same manufacturer or supplier. Furnish electrical materials, equipment, and installations according to the National Electrical Code and the National Electrical Safety Code, and conform to local laws and codes.

Ensure that the traffic control equipment installed in controller cabinets are shop prewired according to a wiring diagram that conforms to plan and specification requirements of the specific project and intersection, and show all wire harness and field connections required, with abbreviations according to Table 632.05-1. Furnish a neat and legibly drawn wiring diagram, reproduced on durable paper, and place two copies in a plastic envelope fastened to the inside of the controller cabinet.

Identify cable and wire by tags or bands at pull boxes and controller cabinets, with size, material, and method of marking that conform to 725.02, except ensure that the identification on the tags or bands conforms to the wiring diagram with abbreviations according to Table 632.05-1. The Contractor may identify field wiring using an indelible pen on a plastic tag instead of embossed letters.

Use spade terminals for wiring connected at signal heads and the wiring connected at terminal blocks within controller cabinets. However, for incoming power wiring, use either spade terminals or bared conductor wire connected to terminal points utilizing screw or spring applied clamping surfaces compatible with both cooper and aluminum wire and providing a positive grip. Neatly lash and fasten completed wiring to interiors with clamps and/or ties.

Table 632.05-1 Table and Wire Identification

Cable	Tag
Ground	GND
Power (2 wire)1 120 volt	AC +AC- or ACN
Power (3 wire) 1 120/240 volt Neutral wire	AC + 1, AC + 2 AC- or ACN
Phase A Phase 1 Phase 1 northbound left turn lanes	 A  1  1 NBLT
Phase A, pedestrian signal	 A PD
Overlap, phase A + C Overlap, phase 1 + 6	 A + C  1 + 6
Detector lead-in, phase A Detector lead-in, phase 1 Detector lead-in, phase 1 northbound left turn lanes	DET A DET 1 DET 1 NBLT
Detector lead-in, phase A (call type) Detector lead-in, phase 1 (call type) northbound thru lanes	DET A CALL DET 1 CALL NB-THRU
Detector harness^[1]	DET A
Interconnect	IC
Pre-emption, fire	PE FIRE
Pre-emption, railroad	PE RR
[1] Place the tag next to the MS plug at the detector amplifier.

When constructing the traffic control system, cooperate with the agency supplying the electric service. Supply 120/240 volt, single-phase, three-wire (grounded neutral) power to the disconnect switch.

After completion of the 10-day performance test in compliance with 632.28 and until acceptance, the Contractor is responsible for the care and maintenance of traffic control equipment installed or reused as part of the Contract.

Upon acceptance of the project, transfer to the Department all manufacturers’ guarantees or warranties covering installed electrical or mechanical equipment. Furnish two copies of wiring diagrams, service manuals, and instructions on installation and maintenance for each different type, model, or system of equipment used on the project.

632.06 Vehicular Signal Head, Conventional. Furnish heads in arrangements such that from one to a maximum of five sections assembled with the specified lens size, color, and circular or arrow configuration form a specific signal face. Mount signal faces alone as a one-way head, or combined with additional faces to form a two-way, three-way, or a maximum of a four-way head.

Furnish multi-way heads with top and bottom brackets for mounting purposes. Fit faces of lesser height in multi-way heads with pipe spacers. Close openings unused for mounting purposes with weatherproof caps.

Install signals in a plumb condition, using a balance adjuster only if necessary. Fit heads mounted on mast arms, except those intended to be rigidly mounted, with a universal hanger allowing the head to swing in both longitudinal and transverse directions. Use drop pipes of suitable length only when necessary to bring the bottom of the signal heads to a proper roadway clearance. Use disconnect hangers for suspended heads when specified.

Orient each signal face to its traffic approach, and lock faces in place by the serrated or other type device incorporated in signal housing and support hardware.

Install incandescent lamps of the proper wattage and light center distance or, when specified, LED lamps in each section. Rotate lamp sockets positioning the open portion of the incandescent lamp filament in an upward position.

When specified, furnish backplates.

632.07 Vehicular Signal Head, Optically Programmed. Furnish heads of this type consisting totally of optically programmed sections unless an intermix of optically programmed and conventional sections is specified. Install lamps in each optically programmed section.

Program each signal section according to the plan requirements. For 8-inch (200 mm) sections, use an extender tool as recommended by the manufacturer to program each section. Upon completion of the project, deliver one extender tool per project to the maintaining agency.

When specified, furnish backplates.

632.08 Pedestrian Signal Head. Furnish heads with the type of light source and symbol height specified. Orient each signal head to its crosswalk, and lock heads in place by the serrated or other type device incorporated in signal housing and support hardware. Close openings unused for mounting purposes with weatherproof caps.

632.09 Pedestrian Pushbutton. Properly orient and install pushbuttons on poles or pedestals. Service pushbuttons mounted on steel poles by wiring inside the poles. Furnish 3/4-inch (19 mm) diameter holes through the back of the housing and the pole wall, install a rubber grommet, and route wiring through until no external wiring is visible. Plug any unused conduit attachment holes. Attach the housing by machine or self-tapping screws in the housing back wall. Service pushbutton mounted on wooden poles through conduit. Furnish pedestrian pushbutton signs of the legend and size required.

632.10 Loop Detector Unit. Install and tune detector units to their loops with the sensitivity set for optimum operation and any interference or cross talk eliminated between other detector units in the cabinet. Perform a field check to ensure that no extraneous detections are occurring by observing each detector unit’s operation to determine that a signal occurs only when a vehicle enters its associated loop. If actuations are observed when there is no vehicle in the loop, eliminate the extraneous detections.