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Home My WebLink AboutBUNGALOW ROAD PROJECT DEPT OF TRANSPORTATION . ....\ \ .. DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA r!TV"!'~!TD^ ('IT CONTRACT DO NOT UNSTAPLE THIS BOOKLET.. ..ENTER ALL REQUIRED INFORMATION ---------------------------- EITHER BY HAND OR BY STAMP. DATE OF OPENING PCN S009708CIOOOO NONE CALL ORDER NONE CONTRACT ID C37990-07-000-0 PROJECTS AND CONTRACT NO. COUNTY : RICHMOND PRC10-S009-00(708) C1 CODE: 5AU230 1. CITY OF AUGUSTA , .f dt!?ojo7 L1MIT[ r",'Dl I l'\l II 'rr~T'n~1 ~ t\i IUI~ DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA CONTRACT ID : C37990-07-000-0 , 0.760 MILE OF GRADING, DRAINAGE, BASE, AND PLANT MIX RESURFACING INCULUDING TRAFFIC SIGNAL INSTALLATION ON BUNGALOW ROAD BEGINNING AT RICHMOND HILL ROAD AND ENDING AT SR 121/US 25. . ------------------------------------------------------~--------------- SITE CONTRACT TIME LIQUIDATED DAMAGES ------------------------------------------------------------~--------- 00 COMPLETE CONTRACT NONE . . DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA CONTRACT SCHEDULE DATE PAGE 07/19/07 3 CONTRACT ID: C37990-07-000-0 . PROJECT (S) : S009708C10000 PRC10 -S009- 00 (708) C1 ------------------~-------------------------------------------------------------- LINEI NO I I ITEM DESCRIPTION APPROX. QUANTITY AND UNITS I UNIT PRICE I BID AMOUNT 1----------------1---------------- I DOLLARS I CTS 1 DOLLARS ICTS . --------------------------------------------------------------------------------- SECTION 0001 ROADWAY 400,000.00 --------------------------------------------------------------------------------~ 1001-9998 LIMITED I I 1 00051 PARTICIPATION PROJECT, I 1.000 I 0.00000 I 0.00 1 THE AMOUNT SHALL NOT I * I I I EXCEED - $400,000.00 I 1 I --------------------------------------------------------------------------------- 1207-0203 FOUND BKFILL 1 I I 001olMATL, TP II 1 750.0001 10.910001 8,182.50 I ICY I 1 --------------------------------------------------------------------------------- 1228-1000 GRADING - I 1 I 00151 MODIFIED, INCL HAUL I 0.760 I 13,369.61000 I 10,160.90 1 IMI I 1 --------------------------------------------------------------------------------- 1310-1101 GR AGGR BASE I I I 00201CRS, INCL MATL I 1,800.0001 2.800001 5,040.00 I ITN 1 1 --------------------------------------------------------------------------------- 1318-3000 AGGR SURF CRS I I I 00251 I 600.0001 2.800001 1,680.00 1 jTN I 1 --------------------------------------------------------------------------------- 1402-1812 RECYCLED ASPH I 1 I 0030lcONC LEVELING, INCL 1 3,100.0001 14.720001 45,632.00 1 BITUM MATL & H LIME I TN I 1 --------------------------------------------------------------------------------- 1402-3121 RECYCLED ASPH I I I 00351cONC 25 MM SUPERPAVE, GP I 750.0001 13.910001 10,432.50 11 OR 2, INCL BITUM MATL I TN I I I & H LIME I I 1 --------------------------------------------------------------------------------- 1402-3130 RECYCLED ASPH I I I 0040lcONC 12.5 MM SUPERPAVE, I 1,210.0001 14.650001 17,726.50 I GP 2 ONLY, INCL BITUM I TN I 1 .. I MATL & H LIME I I 1 --------------~------------------------------------------------------------------ 1413-1000 BITUM TACK COAT I 1 I 00451 I 531.0001 0.470001 249.57 I IGL I I . --------------------------------------------------------------------------------- DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA CONTRACT SCHEDULE CONTRACT ID: C37990-07-000-0 DATE PAGE 07/19/07 4 . PROJECT(S) : S009708C10000 PRClO-S009-00(708) Cl --------------------------------------------------------------------------------- I 1 I . --------------------------------------------------------------------------------- I I ISY LINEI NO I I ITEM DESCRIPTION 1441-0104 CONC SIDEWALK, 005014 IN I 1441-0214 REINF CONC I 00551DITCH PAVING, 4 IN, INCL I IREINF STEEL ISY 1441-4020 CONC VALLEY 0060 I GUTTER, 6 IN I I I ISY 1441-6022 CONC CURB & I 0065 I GUTTER, 6 IN X 30 IN, TP I 12 ILF 1500-3101 CLASS A 0070 I CONCRETE I 1500-3200 CLASS B 0075 1 CONCRETE 1 1500-3800 CLASS A 0080 I CONCRETE, INCL REINF I STEEL 1500~9999 CLASS B CONC1 00851BASE OR PVMT WIDENING I 1550-1080 STORM DRAIN 009olpIPE, 8 IN, H 1-10 I << 1550-1100 STORM DRAIN 00951PIPE, 10 IN1 H 1-10 I 1 I ICY 1 I ICY I 1 ICY I 1 ICY I 1 ILF I I ILF APPROX. QUANTITY AND UNITS I UNIT PRICE I BID AMOUNT 1----------------1---------------- I DOLLARS 1 CTS I DOLLARS ICTS I 3,300.0001 I I 150.0001 I I 1,200.0001 1 I 8,400.0001 I I 20.0001 I I 10.000/ I I 19.000/ I I 300.0001 I I 800.0001 I 1 900.0001 I 29,007.00 1,260.00 6,372.00 57,876.00 2,523.00 837.90 2,900.35 13,023.00 8,416.00 9,468.00 -----------------------------~--------------------------------------------------- . DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA CONTRACT SCHEDULE DATE PAGE 07/19/07 5 CONTRACT ID: C37990-07-000-0 . PROJECT(S) : S009708CI0000 PRC10-S009-00(708) C1 I 1 I . --------------------------------------------------------------------------------- I 1 ILF LINEI NO I I ITEM DESCRIPTION 1550-1150 STORM DRAIN 0100IpIPE, 15 IN, H 1-10 I 1550-1180 STORM DRAIN 01051PIPE, 18 IN, H 1-10 I 1550-1240 STORM DRAIN 01I0lpIPE, 24 IN, H 1-10 I 1550-1300 STORM DRAIN 01151PIPE, 30 IN, H 1-10 1 1550-1360 STORM DRAIN 0120lpIPE, 36 IN, H 1-10 1 1550-1420 STORM DRAIN 01251PIPE, 42 IN, H 1-10 I 1550-3318 SAFETY END 0130lsECTION 18 IN, STORM JDRAIN, 4:1 SLOPE 1550-4218 FLARED END 0135 1 SECTION 18 IN, STORM I DRAIN 1603-2018 STN DUMPED RIP 0140lRAP, TP I, 18 IN 1 i 1603-7000 PLASTIC FILTER 0145 I FABRIC 1 . I 1 ILF I I ILF I I ILF I I ILF 1 I ILF I I lEA I I lEA I I ISY I I ISY APPROX. QUANTITY AND UNITS I UNIT PRICE I BID AMOUNT I----------------I---~------------ I DOLLARS I CTS I DOLLARS ICTS I 819.0001 I I 3,125.0001 I 1 700.0001 1 I 400.0001 I I 850.0001 I 1 650.0001 I I 2.0001 I I 1. 000 1 I I 315.0001 I 1 315.0001 I 7,854.21 27,343.75 7,245.00 6,756.00 14,900.50 16,744.00 215.00 149.35 6,363.00 349.65 DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA CONTRACT SCHEDULE DATE PAGE 07/19/07 6 CONTRACT ID: C37990-07-000-0 . PROJECT(S) : S00970SC10000 PRC10-S009-00(708) C1 LINEI NO 1 I ITEM DESCRIPTION --------------------------------------------------------------------------------- I I I . --------------------------------------------------------------------------------- I 1 lEA 1611-3000 RECONSTR CATCH 0150lBASIN, GROUP 1 I 1647-1000 TRAFFIC SIGNAL 015SIINSTALLATION NO - 1 I 1653-0110 THERMOPLASTIC 0160 I PVMT MARKING, ARROW, TP 11 I I LUMP I I I lEA 1653-0210 THERMOPLASTIC I 01651pVMT MARKING, WORD, TP 1 1 j I~ 1653-1501 THERMOPLASTIC 1 0170lsOLID TRAF STRIPE, 5 IN, 1 IWHITE ILF 1653-1502 THERMOPLASTIC I 01751s0LID TRAF STRIPE, 5 IN, I I YELLOW 1 LF 1653-1704 THERMOPLASTIC I 0180ls0LID TRAF STRIPE, 24 IN; I 1 WHITE I LF 1653-1804 THERMOPLASTIC I 0185]SOLID TRAF STRIPE, 8 IN, 1 IWHITE ]LF 1653-6006 THERMOPLASTIC 0190lTRAF STRIPING, YELLOW I , 1654-1001 RAISED PVMT 01951MARKERS TP 1 I I I ISY 1 I lEA APPROX. QUANTITY AND UNITS I UNIT PRICE I BID AMOUNT 1----------------1---------------- I DOLLARS I CTS I DOLLARS ICTS 1 1. 000 I 1 I 1 LUMP 1 I 4.0001 1 I 8.0001 I 1 200.0001 1 I 7,SOO.0001 I I 400.0001 I 1 3,000.0001 I 1 550.0001 I I 200.0001 1 522.97 11,546.06 69.76 119.12 80.00 1,404.00 340.00 1,230.00 412.50 182.00 --------------------------------------------------------------------------------- . DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA CONTRACT SCHEDULE CONTRACT ID: C37990-07-000-0 DATE PAGE ~ PROJECT (S) : S00970SC10000 PRC10-S009-00 (708) C1 07/19/07 7 LINEI NO I I ITEM DESCRIPTION --------------------------------------------------------------------------------- I I I . --------------------------------------------------------------------------------- I I lEA 1654-1003 RAISED PVMT 0200lMARKERS TP 3 I APPROX. QUANTITY AND UNITS I UNIT PRICE I BID AMOUNT 1----------------1---------------- 1 DOLLARS I CTS 1 DOLLARS ICTS 1668-1100 CATCH BASIN, GP 1 020511 I I lEA 1668-1110 CATCH BASIN, GP I 021011, ADDL DEPTH I I ILF 166S-1200 CATCH BASIN, GP I 021512 I I lEA 1668-1205 CATCH BASIN, GP I 022012, SPCL DES I I lEA I I lEA I 519.700001 I I 57.830001 I 1 472.330001 I 1 514.470001 I 1 342.840001 I I 315.450001 I I 1668-1210 CATCH BASIN, GP I 022512, ADDL DEPTH I I I LF 1668-2100 DROP INLET, GP 023011 I 1668-4300 STORM SEWER 0235 I MANHOLE, TP 1 I 1 I lEA /668-7015 DRAIN INLET, 15 I 0240lIN I I lEA AI 1706-1003 TURF 0245 I ESTABLISHMENT, TP C 1 ITOTAL BID I I lAC 4.44 25,985.00 252.95 2,787.76 519.70 57.83 1,416.99 4,115.76 29,141.40 1,104.08 --------------------------------------------------------------------------------- --------------------------------------------------------------------------------- 400,000.00 . THIS AGREEMENT MADE AND ENTERED INTO THIS THE 1.D DAY OF 5rpttm~o 61 BY AND BETWEEN THE DEPARTMENT OF TRANSPORTATION PARTY OF THE FIRST PART (HEREINAFTER CALLED THE DEPARTMENT) AND THE COMMISSION OF THE UNIFIED GOVERNMENT OF AUGUSTA- RICHMOND (HEREINAFTER CALLED THE UNIFIED GOVERNMENT) WHO HAVE BEEN DULY AUTHORIZED TO EXECUTE THIS AGREEMENT. '~HEREAS, THE DEPARTMENT AND THE UNIFIED GOVERNMENT DESIRE THE IMPROVEMENT AND CONSTRUCTION OF A CERTAIN FACILITY AND THE UNIFIED GOVERNMENT DESIRES AND AGREES TO FURNISH AND DELIVER ALL THE MATERIAL AND TO DO AND PERFORM ALL THE WORK AND LABOR FOR SAID PURPOSE. THE PROJECT BEING MORE PARTICULARLY DESCRIBED HEREIN. . NOW THEREFORE IN CONSIDERATION OF THE PREMISES, THE MUTUAL COVENANTS HEREIN CONTAINED AND THE SUM OF ONE DOLLAR ($1.00) BY EACH OF THE PARTIES TO THE OTHER IN HAND PAID, THE RECEIPT WHEREOF IS HEREBY ACKNOWLEDGED, THE PARTIES HERETO AGREE AS FOLLOWS: (I) THE WORK AND MA TERIALS SHALL BE IN STRICT AND ENTIRE CONFORMITY WITH THE PROVISION OF THIS CONTRACT AND THE PLANS AND SPECIFICATIONS PREPARED (OR APPROVED) BY THE CHIEF ENGINEER OR HIS AUTHORIZED REPRESENTATIVE THE ORIGINALS OF WHICH ARE ON FILE IN THE OFFICE OF CHIEF ENGINEER AND WHICH SAID PLANS AND SPECIFICATIONS ARE HEREBY MADE PART OF THIS AGREEMENT AS FULLY AND TO THE SAME EFFECT AS IF THE SAME HAD BEEN SET FORTH AT LENGTH IN THE BODY OF THIS AGREEMENT. THIS CONTRACT WILL BE EXECUTED AND CONSTRUCTED IN ACCORDANCE WITH THE STANDARD SPECIFICATIONS, 1993 EDITION AND THE 1997 SUPPLEMENTAL SPECIFICATION BOOK, AND THE SUPPLEMENTAL SPECIFICATIONS AND SPECIAL PROVISIONS INCLUDED IN AND MADE A PART OF THIS CONTRACT. (2) IT IS UNDERSTOOD THAT MATERIAL PITS ARE TO BE FURNISHED BY THE UNIFIED GOVERNMENT A T NO COST TO THE DEP AR TMENT OF TRANSPORT A TION. (3) IT IS UNDERSTOOD THAT THE DEPARTMENT OF TRANSPORT A TION WILL NOT PARTICIPATE IN THE COST OF ANY UTILITY FACILITY REMOVAL AND RELOCATIONS NECESSARY IN CONNECTION WITH CONSTRUCTION OF THIS PROJECT, UNLESS OTHER WISE SPECIFIED IN THE CONTRACT. THE (COUNTY/CITY) SHALL BE RESPONSIBLE FOR HANDLING THE ARRANGEMENTS WITH THE UTILITY OWNERS FOR ANY REMOVAL AND RELOCATIONS NECESSARY. THE (COUNTY/CITY) SHALL GIVE THE UTILITY OWNERS AMPLE NOTICE, OF THE IMPENDING CONSTRUCTION, TO ALLOW TIME FOR ENGINEERfNG AND MATERIAL ORDERS REQUIRED FOR ANY REMOVAL AND RELOCATIONS NECESSARY. ALSO, THE (COUNTY/CITY) AGREES TO CLEAR RIGHTS-OF-WAY OBSTRUCTIONS WITHOUT EXPENSE TO THE DEPARTMENT OF TRANSPORTATION. FOR PURPOSE OF APPLYING PROVISIONS OF THIS PARAGRAPH, RAILROADS ARE CONSIDERED UTILITIES. IN ADDITION TO THE FOREGOING, THE (COUNTY/CITY) SHALL OBTAIN APPROVAL OF PLANS AND ACQUIRE EASEMENTS OR OTHER PROPERTY RIGHTS FROM THE RAILROAD FOR CONSTRUCTION WITHIN RAILROAD PROPERTY/RIGHT OF WAY AND SHALL PROVIDE FOR THE PROTECTION OF RAILROAD INTERESTS, INCLUDING FLAGGING AND INSPECTION, AS MAY BE REQUIRED BY THE RAILROAD. (4) IT IS UNDERSTOOD THAT THE QUANTITIES SHOWN ARE APPROXIMATE ONLY AND SUBJECT EITHER TO INCREASE OR DECREASE AND ANY INCREASES OR DECREASES ARE TO BE PAID FOR JIl A T THE CONTRACT UNIT PRICE GIVEN. (5) THE WORK SHALL BEGIN WITHIN TEN DAYS AFTER NOTIFICATION TO BEGIN WORK BY THE CHIEF ENGINEER TO THE UNIFIED GOVERNMENT AND SHALL BE CARRIED THROUGH TO COMPLETION · WITHOUT UNREASONABLE DELAY AND WITHOUT SUSPENSION OF WORK UNLESS AUTHORIZED IN WRITING BY THE CHIEF ENGfNEER. rF THERE ARE UNREASONABLE DELAYS OR UNAUTHORIZED SUSPENSIONS OF WORK, THE DEPARTMENT RESERVES THE RIGHT TO CHARGE THE UNIFIED GOYERNMENT, NOT AS A PENALTY BUT AS LIQUIDATED DAMAGES, THE COST TO THE DEPARTMENT OF MAINTAINING rTS ENGINEERfNG AND INSPECTION FORCE ON THE WORK OR TO CANCEL THIS CONTRACT AND COMPLETE THE WORK BY CONTRACT OR OTHERWISE. (6) THE WORK SHALL BE DONE IN ACCORDANCE WITH THE LAWS OF THE STATE OF GEORGIA UNDER THE DIRECT SUPERVISION AND TO THE ENTIRE SATISFACTION OF THE DEPARTMENT OF TRANSPORTATION. THE DECISION OF THE CHIEF ENGINEER UPON ANY QUESTION CONNECTED WITH THE EXECUTION OR FULFILLMENT OF THIS AGREEMENT AND INTERPRETATION OF THE SPECIFICA TIONS OR UPON ANY FAILURE OR DELAY IN THE PROSECUTION OF THE WORK BY THE .. UNlFIED GOVERNMENT SHALL BE FINAL AND CONCLUSIVE. (7) THE UNIFIED GOVERNMENT AGREES TO PERFORM ALL EXTRA WORK THAT MAYBE REQUIRED OF THEM ON THE BASIS OF ACTUAL COST. ... (8) THE FINANCING OF THIS PROJECT SHALL BE AS FOLLOWS: PAYMENTS WILL BE MADE ON MONTHLY STATEMENTS AS THE WORK PROGRESSES. (9) DRUG-FREE WORKPLACE CERTIFICATION: ----------------------------------------------------------------- THE UNDERSIGNED CERTIFIES THAT THE PROVISIONS OF CODE SECTIONS 50-24-1 THROUGH 50-24-6 OF THE OFFICIAL CODE OF THE GEORGIA ANNOTATED, RELATED TO THE **DRUG-FREE WORKPLACE ACT**, HAVE BEEN COMPLIED WITH IN FULL. THE UNDERSIGNED FURTHER CERTIFIES THAT: (I) A DRUG-FREE WORKPLACE WILL BE PROVIDED FOR THE CONTRACTOR'S EMPLOYEES DURING THE PERFORMANCE OF THE CONTRACT; AND (2) EACH CONTRACTOR WHO HIRES A SUBCONTRACTOR TO WORK IN A DRUG-FREE WORKPLACE SHALL SECURE FROM THAT SUBCONTRACTOR THE FOLLOWING WRITTEN CERTIFICATION: 'AS PART OF THE SUBCONTRACTING AGREEMENT WITH (CONTRACTOR'S NAME) (SUBCONTRACTOR'S NAME) --------------------------------------------------------------- ------------------------------------------------------- CERTIFIES TO THE CONTRACTOR THAT A DRUG-FREE WORKPLACE WILL BE PROVIDED FOR THE SUBCONTRACTOR'S EMPLOYEES DURING THE PERFORMANCE OF THIS CONTRACT PURSUANT TO PARAGRAPH (7) OF SUBSECTION (B) OF CODE SECTION 50-24-3.' ALSO THE UNDERSIGNED FURTHER CERTIFIES THAT HE WILL NOT ENGAGE IN THE UNLAWFUL MANUF ACTURE, SALE, DISTRIBUTION, DISPENSATION, POSSESSION, OR USE OF A CONTROLLED SUBSTANCE OR MARIJUANA DURING THE PERFORMANCE OF THE CONTRACT. (10) SERVICE DELIVERY STRATEGY CERTIFlCATION: -------------------------------------------------------------------------- BY EXECUTION OF THlS CONTRACT, I CERTIFY, UNDER PENALTY OF LAW, THAT THE UNIFIED GOVERNMENT IS IN COMPLIANCE WITH THE SERVICE DELIVERY STRATEGY LAW (HOUSE BILL 489) AND IS NOT DEBARRED FROM RECEIVING FINANCIAL ASSISTANCE FROM THE STATE OF GEORGIA. ALSO, l CERTIFY THAT THE FUNDS TO BE USED ON THE PROJECT ARE CONSISTENT WITH THE APPLICABLE SERVICE DELIVERY STRATEGY. ill . IN WITNESS WHEREOF THE DEPARTMENT OF TRANSPORTATION HAS CAUSED THESE PRESENTS TO BE EXECUTED BY THE COMMISSIONER OF SAID DEPARTMENT, WHO HAS BEEN DULY AUTHORIZED, AND BY THE MAYOR OF THE UNIFIED GOVERNMENT, WHO HAS BEEN DULY AUTHORIZED BY THE COMMISSION OF SAID UNIFIED GOVERNMENT, WHO HAVE HERETO SET THEIR HAND THIS DAY AND YEAR AS SHOWN BELOW: -- ****************************************** FED ID NOJIRS NO. -5 2? - ;;:2;;:20lJ-'d7f '"' ****************************************** EXECUTED ON BEHALF OF THE DEPARTMENT OF TRANSPORTATION EXECUTED ON BEHALF OF THE UNIFIED GOVERNMENT OF AUGUSTA-RICHMOND COUNTY THIS THIS THE WDAY~be( BY: ~ ~ COM ISSIONER 20 01 THEZs -LV DA Y OF J4UGt.tS'r DM~ BY: "'. YOR RECOMMENDED: WITNESS FOR UNIFIED GOVERNMENT: ~ 4,.d J W )'\t1\ ~f DATE: 9-lg - 'LOC? 20 0 ., "--" \ WITNESS FOR THE DEPARTMENT OF TRANSPORTATION: THIS CONTRACT APPROVED BY THE MAYOR AND COMMISSION AT A MEETING HELD AT ~flJUJ1?Vjf-W c!Xnfle .. . 20{)/ (Seal) ,""' EXHIBIT . CERTIFICATION OF COMPLIANCE WITH STATE AUDIT REQUIREMENT I hereby certify that I am a principle and duly authorized representative of whose address is . and it is also certified that: The provisions of Section 36-81-7 of the Official Code of Georgia Annotated, relating to the "Requirement of Audits" have been complied with in full such that: (a) Each unit of local government having a population in excess of 1,500 persons or expenditures of $175,000.00 or more shall provide for and cause to be made an annual audit of the financial affairs and transactions orall funds and activities of the local government for each fiscal year of the local government (b) The governing authority of each local unit of government not included above shall provide for and cause to be made the audit required not less often than once every two fiscal years. . (c) The governing authority of each local unit of government having expenditures of less than $175,000.00 in that government's most recently ended fiscal year may elect to provide for and cause to be made, in lieu of the biennial audit. an alUlUal report of agreed upon procedures for that fiscal year. (d) A copy ofthe report and any conunents made by the state auditor shall be maintained as a public record for public inspection during the regular working hours at the principal office of the local government. Those units of local government not having a principal office shall provide a notification to the public as to the location of and times during which the public ma yinspect the report. . , ~ (z'3IcYl J~e 19nature Date ~ CONTRACT I D ... DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA SPECIAL PROVISIONS C37990-07-000-0 0.760 MILE OF GRADING, DRAINAGE, BASE, AND PLANT MIX RESURFACING INCULUDING TRAFFIC SIGNAL INSTALLATION ON BUNGALOW ROAD BEGINNING AT RICHMOND HILL ROAD AND ENDING AT SR l21/US 25. DATE: 07/19/07 PAGE: 1 ------------------------------------------------------------------------------- S.P. CODE SPECIAL PROVISIONS DESCRIPTION .. ------------------------------------------------------------------------------- 107-1-01-SP 108-1-01-SP 109-l-02-SP 152-1-01-SP 400-1-01-SP 402-1-0l-SP 647-1-01-SP 802-1-01-SP 8l9-1-01-SP 328-1-0l-SP 383-1-01-SP 925-1-01-SP !\99-0-00- ... . LEGAL REGULATIONS AND RESPONSIBILITIES TO THE PUBLIC PROSECUTION AND PROGRESS MEASUREMENT & PAYMENT FIELD LABORATORY BUILDING (OFF/SYSTEM 400/402) ASPHALTIC CONCRETE (OFF SYSTEM - 400/402) RECYCLED ASPH CONCRETE (OFF SYSTEM - 400/402) TRAFFIC SIGNAL INSTALLATION - (PI 647-1000) AGGR FOR ASPH CONC (Off System 400/402) FIBER STAB ADDITIVES (Off System 400/402) HOT MIX ASPH CONC MIXTURES (Off System 400/402) MINERAL FILLER (Off System 400/402) TRAFFIC SIGNAL EQUIPMENT (P.I. 647-1000) PLANS (II ) Date: SepteOlber 24, 2002 First Use Date 2001 Specifications: Novcmbec 1,2002 ... DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA . SPECIAL PRoVIsION (For State Aid Contracts Only) Delete Subsection lO7.23.A and substitute the joUowing: 107.23 Environmental Considerations All envitoiUnental Considerations and clearances shall be the responsibility of the County or municipality to.meet. including thereqwremcnts of Section 404 of the Clean Water Act (33 use 1344). After July I, 1991, State funded pto~ccts must comply with the requirements of Chapter 16 of Title 12 of the Official Code of Georgia Annotated, the Georgia Envitonmental Policy Act (GEP A), of 1991. In compliance with OEP A, those projects for which Federal funding.is sought, and NeP A compliance is accomplished, are exempt from the requirements of OEP A 'QEP A requires that environmental documentation be accomplished lor County or City projectS if nJ()re than SO petcent of the total project cost is funded by a grant of a State Agency or a &rant of more that $2S0,ooo.OO is made by the State Agelicy to. the municipality or County. The "responsible official of the goveniment agency shall determine if a proposed governmental action is a proposed governmental action which may significantly adversely affect the quality of the environment" A. The Following Projects Would NotSignifiC8lltly AdverseJyAffect The Quality Of The ~vironment: Non'-Iand disturbing activities and minor land disturbing activities that would not be anticipated to significantly affect the quality of the environment include the following list These types of projects funded with state money would nOt be subject to environmental assessment of any kind. Hearing procedures outline in GEP A would not be applicable. I. Minor roadway and non-historic bridge projects. a. Modernization of an existing highway by resurfacing, J;estoration, rehabilitation. adding shoulders, widening a single lane or less ineacb direction and the addition of a median within preViously disturbed exis,ting right~f. way. . b. Adding auxiliary lanes for localized purposes (weaving, climbing, speed changes, etc.) and correction substandard curves and intersections within previously disturbed existing right-or~way. c. Non-historic bridge replacement prOjects in existing alignment with no detour bridge. 2. Lighting, signing, pavement marking, signalization, freeway surveillance and control systems. and railroad . . protective devices. 3. Safety projects such as grooving, glared screen, safety barriers, energy atteD:uators, median baniCrs, etc. 4. Highway landscaping and ~ing modification, re&t area projects and truck weigh stations within previously .. disturbed existing right-of-way. S. CoDStl1lction of bus shelters and bays within existing right-of-way. 6. Tempomy replacement of a highway facility that is commenced immediately after the occurrence of a natural disaster of catastrophic failure to restore the highway for the health, welfare. and safety of the public. Section 101-Lega, Regulations and Responsibility to the Public ~ Office of State Aid 'l ... .~ ., SectIon 107-LegaI Regulations and Responsibility to the Public B. The Following Projects May Not Significantly Adversely Affect The Quality Of The Environment: Foe projects that will cause land disturbance and for which there is no anticipation that the project may significantly adversely affect the quality of the environment. certain studies will be undertaken. These studies would serve to docutllCllt whether or not the County or municipality should anticipate that a project might significantly adversely affect the quality of the enviroQDlent Documentation of the studies will be accomplished through the use of the ''GEP A Investigation 8,tudiesn checklist ' The types of projects that would fall under the category, would include: 1. Bridge replacement projects on new location or with a detour bridge, where there are no significant adverse impacts to historic or archaeological resources, no involvement with Federally listed threatened and endangered species and no significant adverse impact to wetlands. ' 2. Passing lanes, mecijan additions and widening projects, where there are no significant adverse impacts to historic or archaeological resources, no involvement with Federally listed threatened and endangered species and no significant adverse impact to wetlands. . 3. Safety and intecsection improvements where there are no significant adverse impacts to historic or archaeological resources, no involvement with Federally listed threatened and endangered species and no significant adverse impact to wetlands. 4. Rest area projects and truck weigh stations with no purchase of additiooaI right-of-way. 5. New location projects where there are no significant adverse impacts to histone or arclJaeologicafresources. no involvement with Federally listed threatened and endangered species and no significant.adverSe impact to wetlands. If studies demonstrate that the project will nOt significantly adversely affect the quality of the environment, project files Will be documented. If studies demonstrate that the project may significantly adversely affect the quality of the environment. development of an environmental effects report (EER) will be undertaken along with full GEPA COmpliance. c. The FeUowing Projects May Significantly Adversely Atl'ect The Quality Of The En.vlrCHUltent: This category of projects may include major widening and new location projects. If such projects result in a significant advcrsC effect. an EER shall be prepared. D. EER Procedure: GEPA calls for considerati9n of the "cumulative effect of the proposed gOVernment actions on the environment.....if a series of proposed government actions are related either geographically or as logical parts in a chain of contemplated actions." Therefore, EER's for sections of road ways to be widened or built as new. location facilities will include all projects that are connected geOgraphically or as logical parts in a chain of contemplated actions. 1. Ducii1g preparation of an environmental effect report, the County or Municipality Will consult with and solicit comments from agencies that have jurisdiction by law, special expertise, or other interest with respect to environmental impacts. 2. In compliance with GEP A the follOwing shall be contained in the BER, at a minimum: a. Cover sheet; b. Executive summary; c. Alternatives. including the no-build; d. Relevant environmental setting; Geology, soils, water supply and wetlands, floral fauna, arcbaeologylhistory, econornicenvironment, energy, cultural resources; e. The environmental impact of the proposed action of the relevant setting and mitigation tneasures proposed to avoid or minimize adverse impact; f. Uoavoidable adverse eoviroQDlental effects; g. Value of short-term. uses of the environment and maintenance and enhancement of its long-term value; h. Beneficial aspects, both long term and short term and its economic advantages and disadvantages; i. Comments of agencies whicb have jurisdiction by law, special expertise, or othet'interest with respect to any environmental impact or resource; ~ of State Aid Page 2 SecU0Il107-LegaI Regulations and Responsibility to the Public 3. .At least 45 days prior to making a decision as to whether to proceed with the undertaking, publish in the '1egal organ of each County in which the proposed governmental action or any part thereof is to occur, notice that an environmental effects report has been prepared". .. 4. The County or Municipality shall send a copy of the EER and all other comments to the Oirector, EPD. 5. The County or municipality sbaIl make the document available to the public and agencies, upon request ' , 6. A public bearing will be held in each affected county if at least 100 residents of the State of Georgia request on within 30 days of publication in the legal organ of an affected County. The responsible official or his designee may .. hold a public hearing ifless than 100 requests are received. (The county or municipality is not relieved of otha- State legal tequirements of public hearings, however.) 7. Following the public notice period and/or public hearing, a summary of the document, comments. received and recommendation as to whether to proceed with the action as Originally prepared, to proceed with changes, or not to proceed wiD be ~ (Notice of Decision). 8. This decision document, when signed by the responsible official, will be sent to the director, EPD, and an abbreviated notice of the decision will be published in the legal organ of each County in which the propoSed govcnuneota.J. action or any part thereof is to occur. 9. A copy of the decision document. the EER and public bearing comments (if any) will be sent to the Department Of Traosportation, Office of Envirooment and Location and The Department of Natural ResoW'ccs, Environmental Protection Division for their files. Department Of Transportation OtTace Of Enviromnent And Location 3933 Aviation Circle Atlanta, Georgia 30336 Department Of Natural Resources Environmental Protection I>ivision 205 Butler Street, Be SuIte 1152 Atlanta, Georgia 30334 Any mitigation measures identified in the HER will be incorporated into the final project plans. '" .. OffICe of State Aid Page 3 .. .. ,I. -- , Date: May 29, 2001 FlCSt Use Date 2001 Specifications: November 1.2002 DEPARTMENT OF TRANSPORTA nON STATEOFGEORGIA' SPECIAL PROVISION Section 108-Prosecution and Progress. . Retain Subsection 108.03 except as modified below: , For this Project. the Progress Schedule required by Subsection 108.03 need not be submitted.. .. ... Date: July 3,2001 First Use Date 2001 Specifications: November i, 2002 . DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA SPECIAL PROVISION Section 109-Measurement & Payment (City /CQunty Contracts) Delete the first sentence of Subsection, l09.07.A, paragraph one, and substitute the following: A General: On the tenth day of each calendar month, the total value of Items complete in place will be estimated by the Engi.neerand certified for payment ~ .. . ~ .. Date: August 8,2002 FIrst Use Date 2001 Specifications: November 1, 2002 . DE~ARTMENT OF TRANSPORTATION STATE OF GEORGIA SPECIAL PROVISION Section 152-Reld Laboratory Building Delete Subsection 152.1.02.B and substitute the following: 8.- Retel'elleed Documents GOT 38 ODT83 NFPA-IOA Delete Subsection 152.3.05.D.5.e throuth h. "". Georgia Department of Transportation First Use: Februlll)' 3, 2006 ReviSed: Februlll)' 6, 2006 Revised: May 1,2006 Revised: July 17, 2006 Revised: September 29,2006 State of Georgia . Special Provision Section 400-Hot Mix Asphaltic Concrete Construction Delete Section 400 and Substitute the following: 400.1 General Description This work includes constructing one or more courses of bituminous plant mixture on the prepared foundation or existing roadway surface. The mixture shall conform with lines, grades, thicknesses, and typical cross sections shown on the Plalis or established by the Engineer. This section includes the requirements for all bituminous plant mixtures regardless of the gradation of the aggregates, type and amount of bituminous material, or pavement use. Work will be accepted on a lot-to-lot basis according to the requirements of this Section and Section 106. 400.1.01 Definitions Segregated Mixture: Mixture lacking homogeneity in HMA constituents of such a magnitude that there is a reasonable expectation of accelerated pavement distress or performance problems. May be quantified by measurable changes in temperature, gradation, asphalt content, air voids, or'surface texture. New Construction: A roadway section more than 0.5 mile (800 m) long that is not longitudinally adjacent to the existing roadway. Ifone or more lanes is added longitudinally adjacent to the existing lane, the lane or lanes shall be tested under the criteria for a resurfacing project Trench Widening: Widening no more than 4 ft (L2 m) in width. Comparison sample: Opposite quarter of material sampled by the Contractor. Referee sample: A sample of the material retained during the quartering process which is used for evaluation if a comparison of Contractor and Departmental. test results is outside allowable tolerances. Quality assurance sample: Independent sample taken by the Department to verify quality of mix or acceptance . decision. .. 400.1.02 Related References A. Standard Specifications Section IO&-Control of Materials Section I09-Measurement and Pavment. Section 152~Field Laboratory Building Section 413-Bituminous Tack Coat. Section 424-Bituminous Surface Treatment Section 802-Coarse Aggregate for Asphaltic Concrete Section 828-Hot Mix Asphaltic Concrete Mixtures 1l .. . ~ , B. Referenced Documents AASHTO T 209 AASHTO T 202 AASHTO T 49 Laboratory Standard Operating Procedure (SOP) 27, "Quality Assurance for Hot Mix Asphaltic Concrete Plants in Georgia" Department of Transportation Standard Operating Procedure (SOP) 15 . Georgia Department of Transportation Standard Operation Procedure (SOP) 40 GDT 38 GDT 73 GDT 78 GDT 83 GDT 93 GDT 119 GDT 125 GDT 134 GSP15 GSP 21 OPL 1 OPL2 OPL7 OPL 26 OPL 30 OPL39 OPL 41 OPL 45 OPL 65 OPL 67 OPL 70 OPL 77 400.1.03 Submittals A. Invoices When the Department~equests, furnish formal written invoices from a supplier for aU materials used in production ofHMA. Show the following on the Bill of Lading:. · Date shipped · Quantity in tons (megagrams) · Included with or without additives (for asphalt cement) Purchase asphaltic cement from a supplier who will provide copies of Bill of Lading upon the Department's request. B. Paving Plan Before starting asphaltic concrete construction, submit a written paving plan to the Engineer for approval. Include the following on the paving plan: ... . .. 1l · Proposed starting date · Location ofplant(s) · Rate of production · Average haul distance( s) · Number of haul trucks · Paver speed feet (meter)/minute for each placement operation · Mat width for each placement operation · Number and type o~roUers for each placement operation · Sketch of the typical section showing the paving sequence for each placement operation · Electronic controls used for each placement operation · Temporary pavement marking plan If staged construction is designated in the Plans or contract, provide a paving plan for each construction stage. If segregation is detected, submit a written plan of measures and actions to prevent segregation. Work will not continue until the plan is submitted to and approved by the Depariment C. Job Mix Formula After the Contract has been awarded, submit to the Engineer a written job mix formula proposed for each mixture type to be used based on an approved mix design. Furnish the following information for each mix: · Specific project for which the mixture will be used · Source and description of the materials to be used · Mixture I.D. Number · Proportions ofthe raw materials to be combined in the paving mixture · Single percentage of the combined mineral aggregates passing each specified sieve · Single percentage of asphalt by weight of the total mix to be incorporated in the completed mixture · Single temperature at Which to discharge the mixture from the plant · Theoretical specific gravity of the mixture at the designated asphalt content · Name of the person or agency responsible f?r quality control of the mixture during production Do the following to have the formulas approved in accordance with SOP 40 <<Approval of Contractor Job Mix Formulas" and to ensure their quality: L Submit proposed job mix formulas for review at least two weeks before beginning the mixing operations. 2. Do not start hot mix asphaltic concrete work until the Engineer has approved a job mix formula for the mixture to be used. No mixture will be accepted until the Engineer has given approvaL 3. Provide mix designs for all Superpave and 4.75 mm mixes to be used. The Department wiUprovide mix design results for other mixes to be used. 4. After a job mix formula has been approved, assume res[)onsibility for the quality control of the mixtures supplied to the Department according to Subsection 106.0 I. "Source of SU\Jply and Quantity of Materials. " D. Quality Control Program Submit a Quality Control Plan to the Office of Materials aild Research for approvaL The Quality Control Program will be included as part of the certification in the annual plant inspection report. 400.2 Materials Ensure that materials comply with the specifications listed in Table L Table 1-Materials Specifications Material Subsection Asphalt Cement, Grade Specified 820.2 --,- Coarse Aggregates for Asphaltic Concrete 802.2'<'2 Fine Aggregates for Asphaltic Concrete 802.2.0 I "" . ~ '1< Mineral Filier 883.1 83l.2.04 882.2.03 831.2.05 820.2 828 Heat Stable Anti-Stripping Additive Hydrated Lime Silicone Fluid Bituminous Tack CoaLPG 58-22, PG 64-22, PG 67-22 Hot Mix Asphaltic Concrete Mixtures 400.2.01 Delivery, Storage, and Handling Storage of material is allowed in a properly sealed and insulated system for up to 24 hours except that Stone Matrix Asphalt (SMA), Open-Graded Friction Course (OGFC), or Porous European Mix (PEM) mixtures shall not be stored more than 12 hours. Mixtures other than SMA, OGFC, or PEM may be stored up to 72 hours in a sealed and insulated system, equipped with an auxiliary inert gas system, with the Engineer's approval. Segregation, lumpiness, drain-down, or stiffness of stored mixture is cause for rejection of the mixture. The Engineer will not approve HSing a storage orsurge bin if the mixture segregates, loses excessive heat, or oxidizes during storage. The Engineer may obtain mixture samples or recover asphalt cement according to GDT 119. AASHTO T 202 and T 49 will be used to perform viscosity and penetration tests to determine how much asphalt hardening has occurred. A. Vehicles for Transporting and Delivering Mixtures Ensure that trucks used for hauling bituminous mixtures have tight, clean, smooth beds. Follow these guidelines when preparing vehicles to transport bituminous mixtures: l. ,Use an approved releasing agent from QPL 39 in the transporting vehicle beds, if necessary, to prevent the mixture from sticking to the bed. Ensure that the releasing agent is not detrimental to the mixture. When applying the agent, drain the excess agent from the bed before loading. Remove from the project any transporting vehicles determined to contain unapproved releasing agents. 2. Protect the mixture with a waterproof cover large enough to extend over the sides and .ends of the bed. Securely fasten the waterproof cover before the vehicle begins moving. 3. Insulate the front end and sides of each bed with an insulating material with the following specifications: · Consists of builders insulating board or equivalent · Has a minimum "R" value of 4.0 · Can withstand approximately 400 OF (200 oC) temperatures Install the insulating material so it is protected from loss and contamination. A "Heat Dump Bodi' may be used in lieu of insulation of the bed. "Heat Dump Body" referstQ any approved transport vehicle that is capable of diverting engine exhaust and transmitting heat evenly throughout the dump body to keep asphalt at required temperature. Mark: the "Heat Dump Body" clearly with "OPEN" and "CLOSE" position at the exhaust diverter. Install a padlock and lock it in the "OPEN" positionwhen the "Heat Dump Body" is used to transport bituminous mixturesl 4. Mark each transporting vehicle with a clearly visible identification number. 5. Create a hole in each side of the bed so that the temperature of the loaded mixture can be checked. The placement of these holes shall be located to assure that the thermometer is being placed in the hot mix asphaltic concrete. Ensure that the mixture is delivered to the roadway at a temperature within:f: 20 OP(:f: 11 oC) of the temperature on the job mix formula. . If the Engineer determines that a truck may be hazardous to the Project or adversely affect the quality of the work, remove the truck from the project. .. B. Containers for Transporting, Conveying, and Storing Bituminous Material To transport, convey, and store bituminous material, use containers free offoreign material and equipped with sample valves. Bituminous material will not be accepted from conveying vehicles if material has leaked or spilled from the containers. ... 400.3 Construction Requirements 400.3. 01 Personnel General Provisions 101 through 150. 400.3.02 Equipment Hot mix asphaltic concrete plants that produce mix for Department use are governed by Quality Assurance for Hot Mix Asphaltic Concrete Plants in Georgia, Laboratory Standard Operating Procedure No. 27. The Engineer will approve the equipment used to transport and construct hot mix asphaltic COncrete. Ensure that the . equipment is in satisfactory mechanical condition and can function properly during production and placement . operations. Place the following equipment at the plant or project site: A. Field Laboratory Provide a field laboratory according to Section 152. B. Plant Equipment 1. Scales Provide scales as follows: a. Furnish (at the Contractor's expense) scales to weigh bituminous plant mixtures, regardless of the measurement method for payment. . b. Ensure that the weight measuring devices that provide documentation comply with Subsection 109.01. '<Measurement and Quantities." c. When not using platform scales, provide weight devices that record the mixture net weights delivered to the truck. A net weight system will include, but is not limited to: · Hopper or batcher-type weight systems that deliver asphaltic mixture directly to the truck · Fully automatic batching equipment with a digital recording device d. Use a net weight printing system only with automatic batching and mixing systems approved by the Engineer. e. Ensure that the net weight scale mechanism or device manufacturer, installation, performance, and operation meets the requirements in Subsection 109.0 1. "Measurement and Quantities" f Provide information on the Project tickets according to Department of Transportation SOP-IS. 2. Time-Locking Devices Furnish batch type asphalt plants with automatic time-locking devices that control the mixing time automatically. Construct these devices so that the operator cannot shorten or eliminate any portion of the mixing cycle. 3. Surge- and Storage-Systems Provide surge and storage bins as follows: a. Ensure that bins for mixture storage are insulated and have a working seaL top and bottom, to prevent outside air infiltration and to maintain an inert atmosphere during storage. Bins not intended as storage bins may be used as surge bins to hold hot mixtures for part of the working daY: However, empty these surge bins completely at the end of the working day. b. Ensure that surge and storage bins can retain a predetermined minimum level of mixture in the bin when the trucks are loaded. c. Ensure that surge and storage systems do not contribute to mix segregation, lumpiness, drain-down, or stiffuess. 4. Controls for Dust Collector Fines Control dust collection as follows: a. When collecting airborne aggregate particles and returning them to the mixture, have the return system meter all or part of the collected dust uniformly into the aggregate mixture and waste the excess. The collected dust percentage returned to the mixture is subject to the Engineer'sapprovaL b. When the coUecteddustis returned directly to the hot aggregate flow, interlock the dust feeder with the hot aggregate flow and meter the flow to maintain a flow that is constant, proportioned; and uniform. ' 5. Hydrated Lime Treatment System .... .. . .... When hydrated lime is required as a mixture ingredient: a. Use a separate bin and feed system to store and proportion the required quantity into the mixture. b. Effiiure that the aggregate is uniformly coated with hydrated lime aggregate before adding the bituminous material to the mixture. Add the hydrated lime so that it will not become entrained in the exhaust system of the drier or plant. c. Control the feeder system with a proportioning device that meets these specifications: · Is accurate to within:l: 10 percent of the amount required · Has a convenient and accurate means of calibration · Interlocks with the aggregate feed or weigh system to maintain the correct proportions for all rates of production and batch sizes and to ensure that mixture produced is properly treated with lime Provide flow indicators or sensing devices for the hydrated lime system and interlock them with the plant controls to interrupt mixture production if hydrated lime introduction fails to meet the required target value after no longer than 60 seconds. 6. Net Weight Weighing Mechanisms Certify the accuracy of the net weight weighing mechanisms by an approved registered scale serviceperson at least once every 6 months. Check the accuracy of net weight weighing mechanisms at the beginning of Project production and thereafter as directed by the Engineer. Check mechanism aCcuracy as follows: a. Weigh a load on a set of certified commercial truck scales. Ensure that the difference between the --- prml:ed lotalfieTwetghrand that obtained from the commercial scales is no greater than 4 Ibs/l,OOO lbs (4 kglMg) ofload. Check the accuracy of the bitumen scales as follows: · Use standard test weights. · If the checks indicate that printed weights are out Of tolerance, have a registered scale serviceperson check the batch scales and certify the accuracy of the printer. · While the printer system is out of tolerance and before its adjustment, continue production only if using a set of certified truck scales to determine the truck weights. b. Have plants that use batch scales maintain ten 50 lb (25 kg) standard test weights at the plant site to check batching scale accuracy. Ensure that plant scales that are used only to proportion mixture ingredients, not to determine pay quantities, are within two percent throughout the range. ... .. C. Equipment at Project Site 1. Cleaning Equipment Provide sufficient hand tools and power equipment to clean the roadway surface before placing the bituminous tack coat. Use power equipment that complies with Subsection 424.3.02.F, "Power Broom and Power Blower." 2. Pressure Distributor To apply the bituminous tack coat, use a pressure distributor that complies with Subsection 424.3.02.8. "Pressure Distributor." 3. Bituminous Pavers To place hot mix asphaltic concrete, use bituminous pavers that can spread and fmish courses that are: · As wide and deep as indicated on the Plans · True to line, grade, and cross section · Smooth · Uniform in density and texture a. Continuous Line and Grade Reference Control. Furnish, place, and maintain the supports, wires, devices, and materials required to provide continuous line and grade reference control to the automatic paver control system. b. Automatic Screed Control System. Equip the bituminous pavers with an automatic screed control system actuated from sensor-directed mechanisms or devices that will maintain the paver screed at a pre-determined transverse slope and elevation to obtain the required surface. -- c~ c. Transverse Slope Controller. Use a transverse slope controller capable of maintaining the screed at the desired slope within:i: 0.1 percent. Do not use continuous paving set-ups that result in unbalanced screed widths or off-center breaks in the main screed cross secti<m unless approved by the Engineer~ d. Screed Control. Equip the paver to permit the following four modes of screed control. The method used shall be approved by the Engineer. · Automatic grade sensing and slope control · Automatic dual grade sensing · Combination automatic and manual control · Total manual control Ensure that the controls are referenced with a taut string or wire set to grade,or with a ski-type device or mobile reference at least 30 ft (9 m) long when using a conventional ski. A non-contacting laser or c sonar-type ski with at least four referencing mobile stations may be used with a reference at least 24 ft. (7.3 m) long. Under limited conditions, a short ski or shoe may be substituted for a long ski on the second paver operating in tandem, or when the reference plane is a newly placed adjacent lane. Automatic screed control is required on aU Projects; however, when the Engineer determines that Project conditions prohibit the use of such controls, the Engineer may waive the grade control, or slope control requirements, or both. e. Paver Screed Extension. When the laydown width requires a paver screed extension., use bolt-on screed extensions to extend thescreeds, or use an approved mechanical screed extension device. When the screed is extended, add auger extensions to assure a length of no more than 18 inches from the auger to the end gate ofthe paver. Auger extensions may be omitted when paving variable widths. Ensure the paver is equipped with tunnel extensions when the screed and augers are extended. f. 30 ~ 45 Degree Wedge. When shown on/required by the plans,' equip the paver to ensure a 30 degree minimum up to a 45 degree maximum wedge along the outside edge of the roadway (measured from the horizontal plane) is in place after final compaction on the fmalsurface course, Use an approved mechanical device that will: · Apply compactive effort to the asphalt mixture to eliminate objectionable voids as the mixture passes through the wedge device · Produce a wedge with a uniform texture, shape, and density while automatically adjusting to varying heights encountered along the roadway shoulder. ., NOTE: Do not use extendible strike-off devices instead of approved screed extensions. Only use a strike-off device in areas that would normally be luted in by hand labor. 4. Compaction Equipment Ensure that the compaction equipment is in good mechanical condition and can compact the mixture to the required density. The compaction equipment number, type, size, operation., and condition is subject to the Engineer's approval. 400.3.03 Preparation A. Prepare Existing Surface Prepare the existing surface as follows: l. Clean the Existing Surface. Before applying hot mix asphaltic concrete pavement, clean the existing surface to the Engineer's satisfaction. '" 2. Patch and Repair Minor Defects Before placing leveling course: a. Correct potholes and broken areas that require patching in the existing surface and base as directed by the Engineer. .. b. Cutout, trim to vertical sides, and remove loose material from the areas to be patched. c. Prime or tack coat the area after it has been cleaned. Compact patches to the Engineer's satisfaction. Material for patches does not require a job mix formula, but shall meet the gradation range shown in Section 828. The Engineer must approve the asphalt content to be used. 3. Apply Bituminous Tack Coat Apply the tack coat according to Section 413. The Engineer will determine the application rate, which must be within the limitations Table 2. Table 2-ApplicationRates for Bituminous Tack, gallyd2 (Um2) Minimum Maximum . All Mixes * 0,04 (0.180) 0.06(0.270) *On thin leveling courses and freshly placed asphaltic concrete mixes, reduce the application rate to 0.02 to 0.04 galfyd2 (0.09 to 0.18 Urn"). . B. Place Patching and Leveling Course 1. . When the existing surface is irregular, bring it to the proper cross section and grade with a leveling course of hot mix asphaltic concrete materials. 2. Place leveling at the locations and in the amounts directed by the Engineer. 3. Use leveling course mixtures that meet the requirements ofthe job mix formulas defined in: · Subsection 400.3.05.A."Observe Composition of Mixtures" · Section 828 4. If the leveling and patching mix type is undesignated, determine the mix type by the thickness or spread rate according to Table 3. Table 3-Leveling and Patching Mix Types Thickness Rate of Spread Type of Mix Up to 0.75 in (19 mm) Up to 851bslyd2 (45 kg/m") 4.75 mm Mix or 9.5 mm Superpave Type I 0.75 to 1.5 in (19 to 38 mm) 85 to 1651bslyd2(45 to 90 kg/m2) 9.5 mm Superpave Type II 1.5 to 2 in (38 to 50 mm) 165 to 220 /bslyd2 (90 to 120 kg/m2) 12.5 mm Superpave * 2 to 2.5 in (50 to 64 mm) 220 to 275/bs/yd2 (120 to 150 kg/m2) 19mm Superpave * Over 2.5 in (64 mm) Over 275 Ibs/yd2 (150 kg/m2) 25 mm Superpave These mixtures may be used for isolated patches no more than 6 in. (150 mm) deep and no more than 4 ft. (1.2 m) in diameter or length. 400.3.04 Fabrication General Provisions 10 I through 150. * 400.3.05 Construction Provide the Engineer at least one day's notice prior to beginning construction, or prior to resuming production if operations have been temporarily suspended. .,. A. Observe Composition of Mixtures I. Calibration of plant equipment If the material changes, or if a component affecting the ingredient proportions has been repaired, replaced, or adjusted, check and recalibrate the proportions. Calibrate as follows: a. Before producing mixture for the Project, calibrate by scale weight the electronic sensors or settings for proportioning mixture ingredients. b. Calibrate ingredient proportioning for aU rates of production. 2. Mixture control ... Compose hot mix asphaltic concrete from a uniform mixture of aggregates, bituminous material, and if required, hydrated lime, mineral filler, or other approved additive. ... Make the constituents proportional to produce mixtures that meet the requirements in Section 828. The general composition limits prescribed are extreme ranges within which the job mix formula must be established. Base mixtures on a design analysis that m,eets the requirements of Section 828. Ensure that the field performance of the in-place mixtures meet the requirements of Section 828.2.B for Permeability, Moisture Susceptibility, Rutting Susceptibility and Fatigue. The in-place mixtures will be subject to testing for compliance with requirements of Section 828.2.B under the following conditions: · Deviates greater than 10 percent on gradation on the mixture control sieves from the approve<!- job mix formula based on acceptance or assurance samples. · Deviates greater than 0.7 percent in asphalt content from the job mix formula based on acceptance or assurance samples. · The calculated mean pavement air voids result in an adjusted pay factor greater than 0.80 or any single sub-lot results in mean pavement air voids exceeding 10.5 %. · Mix produced using an unapproved mix design or job mix formula. Remove and replace (at the Contractor's expense) any areas determined to not meet the requirements of Section 828.2.B If control test results show that the characteristic tested does not conform to the job mix formula control tolerances given in Section 828, take immediate action to ensure that the quality control methods are effective. , . 'J' & Control the materials to ensure that extreme variations do not occur. Maintain the gradation within the composition limits in Section 828. B. Prepare Bituminous Material Uniformly heat the bituminous material to the temperature specified in the job mix formula with a tolerance of :l: 20 OF (::I:: to oc). C. Prepare the Aggregate Prepare the aggregate as follows: l. Heat the aggregate for the mixture, and ensure a mix temperature within the limits of the job mix formula. 2. Do not contaminate the aggregate with fuel during heating. 3. Reduce the absorbed moisture in the aggregate until the asphalt does not separate from the aggregate in the prepared mixture. If this problem occurs, the Engineer will establish a maximum limit for moisture content in the aggregates. When this limit is established, maintain the moisture content below this limit. D. Prepare the Mixture Proportion the mixture ingredients as necessary to meet the required job mix formula. Mix until a hQmogenous mixture is produced, l. Add Hydrated Lime When hydrated lime is included in the mixture, add it at a rate specified in Section 828 and the job mix formula. Use methods and equipment for adding hydrated lime according to Subsection 400.3.02.B.6. "Hydrated Lime Treatment System." Add hydrated lime to the aggregate by using Method A or B as follows: Method A-Dry Form-Add hydrated lime in its dry form to the mixture as follows, according to the type of plant: . a. Batch Type Asphalt Plant: Add hydrated lime to the mixture in the weigh hopper or as approved and directed by the Engineer. b. Continuous Plant Using Pugmill Mixer: Feed hydrated lime into the hot aggregate before it is introduced into the mixer so that dry mixing is complete before the bituminous material is added. c. Continuous Plant Using Drier-Drum Mixer: Add hydrated lime so that the lime will not become entrained into the air stream of the drier and so that thorough dry mixing will be complete before the bituminous material is added. Method B-LimelWater Slurry-Add the required quantity of hydrated lime (based on dry weight) in lime/water slurry form to the aggregate. This solution consists of lime and water in concentrations as directed by the Engineer. ~ ..... . Equip the plant to blend and maintain the hydrated lime in suspension and to mix it with the aggregates uniformly in the proportions specified. . 2. Add Gilsonite Modifier When required, add the Gilsonite modifier to the mixture at a rate such that eight percent by weight of the asphalt cement is replaced by Gilsonite. Use either PG 64-22 or PG 67-22 asphalt cement as specified in Subsection 820.2.0 I. Provide suitable means to caiibrate and check the rate of Gilsonite being added. Introduce Gilsonite modifier by either of the following methods. a. For batch type plants, incorporate Gilsonite into the pu:gmiU at the beginning of the dry mixing cycle. Increase the drymix cycle by a minimum.of 10 seconds after the Gilsonite is added and prior to introduction of the asphalt cement. For this method, supply Gilsonite in plastic bags to protect the material during shipment and handling and store the modifier in a waterproof environment. The bags shall be capable of being completely melted and uniformly blended into the combined mixture. Gilsonite may also be added through a mineral filler supply system as described in Subsection 400.3.02.8.5. "Mineral Filler Supply Svstem." The system shall be capable of injecting the modifier into the weigh hopper near the center of the aggregate batching cycle so the material can be accurately weighed. - - b. For drum drier plants, add Oilsonite through the recycle ring or through an acceptable means which will introduce the Gilsonite prior to the asphalt cement injection point. The modifier shall be proportionately fed into the drum mixer at the required rate by a proportioning device which shall be accurate within :t 10 percent Of the amount required. The entry point shall be away from flames and ensure the Gilsonite will not be caught up in the air stream and exhaust system. . 3. . Materials from Different Sources Do not use mixtures prepared from aggregates from different sources intermittently. This will cause the . color of the finished pavement to vary. E. Observe Weather Limitations Dq not mix and place asphaltic concrete if the existing surface is wet or frozen. Follow the temperature guidelines in the following table: - Table 4-Lift Thickness Table lift Thickness Minimum Temperature 1 in (25 mm) or less 55 OF (13 oc) 1.1 to 2 in (26 mm to 50 mm) 45 OF (8 oc) 2.1 to 3 in (51 mm to 75mm) 40 OF (4 oc) 3.1 to 4 in (76 mm to 100 mm) 35 OF (2 oc) 4.1 to 8 in (101 mm to 200 mm) 32 OF (0 oc) and rising. Base Material must not be frozenl F. Perform Spreading and Finishing Spread and fmish the course as follows: l. Determine the course's maximum compacted layer thickness by the type mix being used according to Table 5. . - Mix Type Minimum Layer Maximum Layer Maximum Total Thickness Thickness Thickness 25 mm Superpave 2 1/2 in (64 mm) 4 in(100 mm) " - 19 mm Superpave 1 3/4 in (44 mm) 3 in (75 mm) " - 12.5 mmSuperpave 1 3/8 in (35 mm) 2 1/2 in (64 mm)* 8 in (200 mm) Table 5-Maximum Layer Thickness Mix Type Minimum Layer Maximum Layer Maximum Total Thickness Thickness Thickness 9.5 mm Superpave Type II 1 1/8in.(28 mm) 1 1/2 in (38 mm) 4 in (100 mm) 9.5mm Superpave Type I 7/8 in (22 mm) 1 1/4 in (32 mm) 4 in (100 mm) .. 4.75 mm Mix 3/4 in (19 mm) 1 1/8in (28 mm) 2in (50 mm) * Allow up to 6 in (150 mm) per lift on trench widening. Place 9.5 mm Superpave and 12.5mm Superpave up to 4 in (100.mm) thick for driveway and side road transition. Unload the mixture into the paver hopper or into a device designed to receive the mixture from delivery vehicles. Except for leveling courses, spread the mixture to the loose depth for the compacted thickness or the spread . rate. Use a mechanical spreader true to the line, grade, and cross section specified. For leveling courses, use a motor grader equipped with a spreader box and smooth tires to spread the material or use a mechanical spreader meetirig the requirements in Subsection 400.3.02.C, "Equi{lment at Proiect Site." Obtain the Engineer's approval for the sequence of paving operations, including paving the adjoining lanes. Minimize tracking tack onto surrounding surfaces. Ensure that the outside edges of the pavement being laid are aligned and parallel to the roadway center line. For New Construction or Resurfacing Contracts that contain multiple lifts or courses, arrange the width of the individual lifts so that the longitudinal joints of each successive lift are offset from the previous lift at least I ft (300 min). This requirement does not apply to the lift immediately over thin lift leveling courses. Ensure that the longitudmaljoint(s) in the surface course and the mix immediately underneath asphaltic concrete OGFC or PEM are at the lane line(s). NOTE: Perform night work with artificial light provided by the Contractor and approved by the Engineer. . 8. Where mechanical equipment cannot be used, spread and rake the mixture by hand. Obtain the Engineer's approval of the operation sequence, including compactive methods, in these areas. . .9. Keep small hand raking tools clean and free from asphalt build up. Do not use fuel oil or other harmful solvents to clean tools during the work. 10. Do not use mixture with any of these characteristics: · Segregated · Nonconforming temperature · Deficient or excessive asphalt cement content · Otherwise unsuitable to place on the roadway in the work II. Remove and replace mixture placed on the roadway that the Engineer determines has unacceptable blemish levels from segregation, streaking, pulling and tearing, or other characteristics. Replace with acceptable mixture at the Contractor's expense. Do not continually place mixtures with deficiencies. Do not place subsequent course lifts over another lift or courses placed on the same day while the temperature of the previously placed mix is 140 OF (60 oc) or greater. 12. Obtain the Engineer's approval of the material compaction equipment. Perform the rolling as fo~lows: a. Begin the rolling as close behind the spreader as possible without causing excessive distortion of the asphaltic concrete surface. b. Continue rolling until roller marks are no longer visible. c. Use pneumatic-tired rollers with breakdown rollers on all courses except asphaltic concrete OGFC, PEM and SMA or other mixes designated by the Engineer. 13. Ifapplicable, taper or "feather" asphaltic concrete from full depth to a depth no greater than 0.5 in (13 mm) along curbs, gutters, raised pavement edges, and areas where drainage characteristics of the road must be retained. The Engineer will determine the location and extent of tapering. G. Maintain Continuity of Operations Coordinate plant production, transportation, and paving operations to maintain a continuous operation. If the spreading operations are intenupted, construct a transverse joint if the mixture immediately behind the paver screed cools to less than 250 of (120 oe). H. Construct the Joints I. Construct Transverse Joints a. Construct transverse joints to facilitate full depth exposure of the course before resuming placement of the affected course. . b. Properly clean and tack the vertical face of the transverse joint before placing additional materiaL .. NOTE: Never burn or heat the joint by applying fuel oil or other volatile materials. c. Straightedge transverse joints immediately after forming the joint. d. Immediately correct any irregularity that exceeds 3/16 in. in 10 ft (5 mm in 3 m). 2. Construct Longitudinal Joints Clean and tack the vertical face of the longitudinal joint before placing adjoining material. Construct longitudinal joints so that the joint is smooth, well sealed, and bonded. I. Protect the Pavement Protect sections of the newly fmished pavement from traffic .until the traffic will not mar the surface or alter the surface texture. If directed by the Engineer, use artificial methods to cool the newly finished pavement to open the pavement to traffic more quickly. .J. Modify the Job Mix Formula If the Engineer determines that undesirable mixture or mat characteristics are being obtained, the job mix formula may require immediate adjustment. ~ 400.3.06 Quality Acceptance A. Acceptance Plans for Gradation and Asphalt Cement Content The Contractor will randomly sample and test mixtures on a lot basis. The Department will monitor the Contractor testing program and perform comparison and quality .assurance testing. 1. Determine Lot Amount A lot consists of the tons (megagrams) of asphaltic concrete produced and placed each produCtion day. If this production is less than 500 tons (500 Mg), or its square yard (meter) equivalent, production may be incorporated into the next working day. The Engineer may terminate a lot when a pay adjustment is imminent if a plant or materials adjustment resulting in a probable correction has been made. Tenninate all open lots at the end of the month, except for materials produced and placed during the adjustment period. If the fmal day's production does not constitute a lot, the production may be included in the lot for the previous day's run; or, the Engineer may treat the production as a separate lot with a corresponding lower number of tests. 2. Determine Lot Acceptance If the Engineer determines that the material is not acceptable to leave in place, the materials shall be removed and replaced at the Contractor's expense. 3. Provide Quality Control Program Provide a Quality Control Program as established in SOP 27 which includes: · Assignment of quality control responsibilities to specifically named individuals who have been certified by the Office of Materials and Research · Provisions for prompt implementation of control and corrective measures · Provisions for communication with Project Manager, Bituminous Technical Services Engineer, and Testing Management Operations Supervisor at all times · Provisions for reporting all test results daily through the Office of Materials and Research computerized Field Data Collection System; other chec~,calibrations and records will be reported on a form developed by the Contractor and will be included as part of the project records · Notification in writing of any change in quality control personnel .. (c) Perform sampling, testing, and inspection duties of GSP 21. (d) Perform extraction or ignition test (GOT 83 or GOT 125) and extraction analysis (GDT 38). If the ignition oven is used, a prinfuut of sample data including weights shall become a part of the project records. For asphalt cement content only, digital printouts of liquid asphalt cement weights may be substituted in lieu of an extraction test for plants with digital recorders. Calculate the asphalt content from the ticket representing the mixture tested for gradation. (e) Save extracted aggregate, opposite quarters, and remaining material (for possible referee testing) of each sample as follows: · Store in properly labeled, suitable containers · Secure in a protected environment · Store for three working days. .If not obtained by the Department, within three days they may be discarded. (t) Add the following information on load tickets from which a sample or temperature check is taken: · Mixture temperature · Signature of the QCT person performing the testing - ' .. (g) Calibrate the lime system when hydrated lime is included in the mixture: · Perform a minimum of twice weekly during production · Post results at the plant for review · Provide records of materials invoices upon request (including asphalt cement, aggregate, hydrated lime, etc.) (h) Take action if acceptance test results are outside Mixture Control Tolerances of Section 828. · One sample out of tolerance (I) Contact Level 2 - QCT to determine if a plant adjustInent is needed (2) Immediately run a process control sample. Make immediate plant adjustments if this sample is also out of tolerance (3) Test additional process control samples as needed to ensure corrective action taken appropriately controls the mixture · Two consecutive acceptance samples of the same mix type out of tolerance regardless of Lot or mix design level, or three consecutive acceptance samples out of tolerance regardless of mix type (I) Stop plant production immediately (2) Reject any mixture already in storage that: · Deviates more than 10 percent in gradation from the job mix formula based on the acceptance sample · Deviates more than 0.7 percent in asphalt content from the job mix formula based on the acceptance sample (3) Make a plant correction to any mix t)'pe out oftolerance prior to resuming production · Do not send any mixture to the project before test results of a process control sample meets Mixture Control Tolerances · Reject any mixture produced at initial restarting that does not meet Mixture Control Tolerances 4) Comparison Testing arid Quality Assurance Program Periodic comparison testing by the Department will be required of each QCT to monitor consistency of equipment and test procedures. The Department will take independent samples to monitor the Contractor's quality control program. a) Comparison Sampling and Testing Retain samples for comparison testing and referee testing if needed as described in Subsection 400.3.06.A.3.b.3. Discard these samples only if the Contractor's acceptance test results meet a LOO pay factor andthe Department does not procure the samples within three working days. . The Department will test comparison samples on a random basis. Results will be compared to the respective contractor acceptance tests and the maximum difference shall be as follows: Table 6-Allowable Percent Difference Between Department and Contractor Acceptance Tests '. SIEVE SIZE SURFACE SUB-SURFACE 1/2 in~(12.5 mm) 4.0% - 3/8 in. (9.5 mm) 3,5% 4.0% No.4 (4.75 mm) 3.5% 3.5% No.8 (2.36 mm) 2.5% 3~0% No. 200 (75 ~m) 2.0% 2.0% A.C. 0.4% 0.5% (1) If test comparisons are within these tolerances: · Continue production · Use the Contractor's tests for acceptance of the lot (2) If test comparisons are not within these tolerances: · Another Departmental technician will test the corresponding referee sample · Results ofthe referee sample will be compared to the respective contractor and Departmental tests using the tolerance for comparison samples given above. (a) lfreferee test results are within the above tolerances when compared to the Contractor acceptance test, use the Contractor's test for acceptance of the effected lot. (b) lfreferee test results are not within the above tolerances when compared to the Contractor acceptance test, the Department will review the Contractor's quality control methods and determine if a thorough investigation is needed. b) Quality Assurance Sampling and Testing (1) Randomly take a minimum of two quality assurance samples from the lesser of five days or five lots of production regardless of mix type or number of projects. (2) Compare test deviation from job mix formula to Mixture Control Tolerances in Section 828. lfresults are outside these tolerances, another sample from the respective mix may be taken. NOTE: For leveling courses less than no Ib/yd1 (60 kg/m1) that have quality assurance test results outside the Mixture Control Tolerances of Section 828, use the Department's test results only. ... If test results of the additional sample are not within Mixture Control Tolerances, the Department will take the following action: · Take random samples from throughout the lot as in Subsection 400.3.06.A.3.b.3 and use these test results for acceptance and in calculations forthe monthly plant rating. Determine if the Contractor's quality control program is satisfactory and require prompt corrective action by the Contractor if specification requirements are not being met. · Determine if the QCT has not followed Departmental procedures or has provided erroneous information. ... .. Take samples of any in-place mixture represented by unacceptable QCT tests and use the additional sample results for acceptance and in calculations for the monthly plant rating. The Contractor QCT tests will not be included in the monthly plant rating. .. B. Compaction Determine the mixture compaction using either GDT 39 or GDT 59. The compaction is accepted in lots defined in Subsection 400.3.06. A "Acceptance Plans for Gradation and Asphalt Cement Content" and is within the sanie lot boundaries as the mixture aCceptance. L Calculate PaNement Mean Air Voids The Department will calculate the pavement air voids placed within each lot as follows: a. One test per sub-lot. . Lots :::: 500 tons of mix should be divided into 5 sub-lots of equal distance. · Lots < 500 tons of mix should be comprised of a sub-lot or sub-lots consisting of up to 100 tons of mix each. There may be less than 5 sub-lots. b. Average the results of aU tests run on randomly selected sites in that lot. c. Select the random sites using GDT 73. Density tests are not requir~d for asphaltic concrete placed at 125 Ibs/yd2 (68 kg/m2) or less, 4.75 mm mix and mixes placed as variable depth or width leveling. Compact these courses to the Engineer's satisfaction. Density tests will not be performed on turn-outs and driveways. The targeted maximum Pavement Mean Air Void content for aU Superpave mixtures is 5 .0 percent. Ensure that the maximum Pavement Mean Air Voids for all Superpave mixtures does not exceed 7.8 percent. The maximum Pavement Mean Air Voids for 2 foot shoulder widening is 9.0 percent. The a.djustment period for density shall be three lots or three. production days, whichever is less, in order for the contractor to ensure maximum compactive effort has been achieved which will yield no more than the specified maximum allowed Mean Air Voids. If the contractor needs to acljust the mixture to improve density results, a change in the job mix formula may be requested for approval during the adjustment period so long as the following values are not exceeded: · Coarse pay sieve :t 4% · No.8 (2.36 mm) sieve :t 2% · No, 200 (75 Jlm) sieve :t l % · Asphalt Content :t 0.2% · All value changes must still be within specification limits If the OffIce of Materials and Research is satisfied that the contractor has exerted the maximum compactive effort and is not able to maintain Pavement Mean Air V oidsat no more than 7.8%, the Engineer may establish a maximum target for Pavement Mean Air Voids. If the Pavement Mean Air Voids within a Lot exceeds 7.8 (or lOO% of the maximum target air voids, if established is not maintained); the Engineer may stop the paving operation until appropriate steps are taken by the Contractor to correct the deficiency. Upon approval of the Engineer, the paving operation may be restarted but will be limited to a 1000 ft (300 m) test section to verify that the corrective action taken will result in satisfactory density. Continued operation may not be permitted if the Pavement Mean Air Voids fail to meet the specified density requirements. 2. Obtain Uniform Compaction For a lot to be accepted for compaction, the air void range cannot exceed 4 percent for new construction or 5 percent for resurfacing projects. The range is the difference between the highest and lowest acceptance test results within the affected lot. e. Surface Tolerance In this Specification, pavement courses to be overlaid with an Open-Graded Friction Course or PEM are considered surface courses. Other asphalt paving is subject to straightedge and visual inspection and irregularity correction as shown below: .. .... ~ I. Visual and Straightedge Inspection Paving is subject to visual and straightedge inspection during and after construction operations until Final Acceptance. Locate surface irregularities as follows: ..,.. - . . a. Keep alOft (3 m) straightedge near the paving operation to measure surface irregularities on courses. Provide the straightedge and the labor for its use. b. Inspect the base, intermediate, and surface course surfaces with the straightedge to detect irregularities. c. Correct irregularities that exceed 3/16 in. in 10 ft (5 nun in 3 m) for base and intermediate courses, and lI8 in. in 10 ft (3 nun in 3 m) for surface courses. Mixture or operating techniques will be stopped if irregularities such as rippling, tearing, or pulling occur and the Engineer suspects a continuing equipment problem. Stop the paving operation and correct the problem. D. Reevaluation of Lots Reevaluation of Lots and acceptance will be based on Department evaluations. The Department will be reimbursed by the Contractor for all costs of these evaluations, Request for reevaluation shall be made within 5 working days of notification of the lot results. E. Segregated Mixture Prevent mixture placement that yields a segregated mat by following production, storage, loading, placing, and handling procedures. Also, make needed plant modifications and provide necessary auxiliary equipment. (See Subsection 400.1.01. "Definitions.") If the mixture is segregated in the fmished mat, the Department will take actions based on the degree of segregation. The actions are described below. l. Unquestionably Unacceptable Segregation When the Engineer determines that the segregation in the finished mat is unquestionably unacceptable, follow these measures: . a. Suspend Work and require the Contractor to take positive corrective action. The Department will evaluate the segregated areas to determine the extent of the corrective work to the in-place mat as follows: · Perform extraction and gradation analysis by taking 6 in (150 nun) cores from typical, visually unacceptable segregated areas. · Determine the corrective work according to Subsection 400.3.06.E.3. h. Require the Contractor to submit a written plan of measures and actions to prevent further segregation. Work will not continue until the plan is submitted to and approved by the Department. c. When workresumes, place a test section not to exceed 500 tons (500 Mg) of the affected mixture for the Department to evaluate. If a few loads show that corrective actions were not adequate, follow the. measures above beginning with step l.a. above. If the problem is solved, Work may continue. 2. Unacceptable Segregation Suspected When the Engineer observes segregation in the fmished mat and suspects that it may be unacceptable, follow these measures: ' a. Allow work to continue at Contractor's risk. b. Require Contractor to immediately and continually adjust operation until the visually apparent segregated areas are eliminated from the finished mat. The Department will immediately investigate to determine the severity of the apparent segregation as follows: · Take 6 in (ISO nun) cores from typical areas of suspect segregation. · Test the cores for compliance with the mixture control tolerances in Section 828. When these tolerances are exceeded, suspend work for corrective action as outlined in Subsection .400.3.06.E.3 . 3. 'Corrective Work a. Remove and replace (at the Contractor's expense) any segregated area where the gradation on the control sieves is found to vary 10 percent or more from the approved job mix formula, the asphalt cement varies 1.0% or more from the approved job mix formula, or if in-place air voids exceed 12.5% based on GDT 39. The control sieves' for each mix type are shown in Subsection 400.5.0l.B "Determine Lot Acceptance." b. Subsurface mixes. For subsurface mixes, limit removal and replacement to the full lane width and no less than 10 ft. (3 m) long and as approved by the Engineer. . Asphaltic concrete base course Intermediate and/or wearing course Thickness Specified :t 0.5 in (:!:13 mm) :to.25 in (:!: 6 mm) Spread Rate Specified +40 Ibs. -50 Ibs (+20 kg, -30 kg) +20 Ibs. -251bs (+10 kg. -15 kg) . c. Surface Mixes. For surface mixes, ensure that removal and replacement is not less than the full width of the affected lane and no less than the length of the affected areas as determined by the Engineer. Surface tolerance requirements apply to the corrected areas for both subsurface and surface mixes. 400.3.07 Contractor Warranty and Maintenance A. Contractor's Record Maintain a dated, written record of the most recent plant calibration. Keep this record available for the Engineer's inspection at all times. Maintain records in the form of: · Graphs . Tables - . Charts · Mechanically prepared data 400.4 Measurement . Thickness and spread rate tolerances for the various mixtures are specified in Subsection 400.4.A.2.b. Table II. Thickness and Spread Rate Tolerance at Anv Given Location. These tolerances are applied as outlined below: A. Hot Mix Asphaltic Concrete Paid for by Weight l. Plans Designate a Spread Rate a. Thickness Determinations. Thickness determinations are not required when the Plans designate a spread rate per square yard (meter). If the spread rate exceeds the upper limits outlined in the Subsection 400.4.A.2.b. Table 11. "Thickness and Spread Rate Tolerance at Any Given Location", the mix in excess will not be paid for. If the rate of spread is less than the lower limit, correct the deficient course by overlaying the entire lot. The mixture used for correcting deficient areas is paid for at the Contract Unit Price of the course being corrected and is subject to the Mixture Acceptance Schedule-Table 9 or 10. b. Recalculate the Total Spread Rate. After the deficient hot mix course has been corrected, the total spread rate for that lot is recalculated, and mix in excess of the upper tolerance limit as outlined in the Subsection 400A.A.2.b. Table 11. "Thickness and Spread Rate Tolerance at Any Given Location" is not paid for: The quantity of material placed on irregular areas such as driveways, turnouts, intersections, feather edge section, etc., is deducted from the fmal spread determination for each lot. 2. Plans Designate Thickness If the average thickness exceeds the tolerances specified in the Subsection 400A.A.2.b. Table 1 L .'Thickness and Spread Rate Tolerance at Any Given Location", the Engineer shall take cores to determine the area of excess thickness. Excess quantity will not be paid for. If the average thickness is deficient by more than the tolerances specified in the Thickness and Spread Rate Tolerance at Any Given Location table below, the Engineer shall take additional cores to determine the area of deficient thickness: Correct areas with thickness deficiencies as follows: a. Overlay the deficient area with the same mixture type being corrected or with an approved surface mixture. The overlay shall extendfor a minimum of300 ft (90 m) for the full width of the course. b. Ensure that the corrected surface course complies with Subsection 400.3.06.C. L "Visual and Straightedge Inspection." The mixture required to correct a deficient area is paid for at the Contract Unit Price of the course being corrected. The quantity of the additional mixture shall not exceed the required calculated quantity used to increase the average thickness of the overlaid section to the maximum tolerance allowed under the following table. ... Table 11-Thickness and Spread Rate Tolerance aiAny Given Location .. Course Tl =T x %AC + +%y Overall of any combination of 1 and 2 :I: 0.5 in (:1:13 mm) +40 lbs, -50 Ibs (+20 kg, -30 kg) Note.1: Thickness and spread rate tolerances are provided to allow nonnal variations within a given lot. 00 not continuously operate at a thickness of spread rate not specified. . - When the Plans specify a thickness, the Engineer may take as many cores as necessary to determine the average thickness of the intermediate or surface course. The Engineer shall take a minimum of one core per 1,000 ft (300 m) per two lanes of roadway. Thickness will be determined by average measurements of each core according to GDT 42. . If the average exceeds the tolerances specified in the Subsection 400A.A.2.b. Table 1 L "Thickness and Spread Rate Tolerance at Any Given Location", additional cores will be taken to determine the area of excess thickness and excess tonnage will not be paid for. B. Hot Mix Asphaltic Concrete Paid for by Square Yard (Meter) I. The thickness of the base course or the intermediate or surface course will be determined by the Department by cutting cores and the thickness will be determined by averaging the measurements of each core. 2. If any measurement is deficient in thickness more than the tolerances given in the table above, additional cores will be taken by the Department to determine the area of thickness deficiency. Correct thickness deficiency areas as follows: a. Overlay the deficient area with the same type mixtures being corrected or with surface mixture. Extend the overlay at least 300 ft (90 m) for the full width of the course. b. Ensure that the corrected surface course complies with Subsection 400.3.06.C.1. Visual and Straightedge Inspection" . c. The mixture is subject to the Mixture Accevtance Schedule-Table 9 or 10. 3. No extra payment is made for mixtures used for correction. 4. No extra payment is made for thickness in excess of that specified. NOTE: Thickness tolerances are provided to allow normal variations within a given lot Do not continuously operate at a thickness not specified. C. Asphaltic Concrete Hot mix asphaltic concrete, complete in place and accepted, is measured in tons (megagrams) or square yards (meters) as indicated in the ProposaL If payment is by the ton (megagram), the actual weight is determined by weighing each loaded vehicle on the required motor truck scale as the material is hauled to the roadway, or by using recorded weights if a digital recording device is used. The weight measured includes all materials. No deductions are made for the weight of the individual ingredients. The actual weight is the pay weight except when the aggregates used have a combined bulk specific gravity greater than 2.75. In this case the pay weight is determined according to the following formula: % Aggregate x 2.75 ... combined bulk Specific Gravity . 100 Where: T1 T= Pay weight, tonnage (Mg) Actual weight %AC= % Aggregate = Combined Bulk Sp. Gr.= Percent asphalt cement by weight of total mixture Percent aggregate by weight of total mixture Calculated combined bulk specific gravity of various mineral aggregates used in the mixture %y= Percent hydrated lime by weight of mineral aggregate . " D. Bituminous Material Bituminous material is not measured for separate payment. E. Hydrated Lime When hydrated lime is used as an anti-stripping additive, it is not measured for separate payment. F. Field Laboratory The field laboratory required in this Specification is not measured for separate payment. G. AsphaltiC Concrete Leveling Payment of hot mix asphaltic concrete leveling, regardless of the type mix, is full compensation for furnishing materials, bituminous materials, and hydrated lime (when required) for patching and repair of minor defects, surface preparation, cleaning, hauling, mixing,. spreading, and rolling. Mixture for leveling courses is subject to the acceptance schedule as stated in Subsection 400.3.06.A and Subsection 400.3.06.8. H. Asphaltic Concrete Patching Hot mix asphaltic concrete patching, regardless of the type mix, is paid for at the Contract Unit Price per ton (Megagram), complete in place and accepted. Payment is full compensation for: · Furnishing materials such as bitunlinous material and hydrated lime (when required) · Preparing surface to be patched · Cutting areas to be patched, trimmed, and cleaned · Hauling, mixing, placing, and compacting the materials 400.4.01 limits When the asphaltic concrete is paid for by the square yard (meter) and multiple lifts are used, the number and thickness of the lifts are subject to the Engineer's approval and are used to prorate the pay factor for the affected roadway section. 400.5 Payment Hot mix asphaltic concrete of the various types are paid for at the Contract Unit Price per ton (megagram) or per square yard (meter), Payment is full compensation for furnishing and placing materials including asphalt cement, hydrated lime when required, approved additives, and for cleaning and repairing, preparing surfaces, hauling, mixing, spreading, rolling, and performing other operations to complete the Contract Item. Payment will be made under: Item No. 400 Asphaltic concrete tiQg Suprpave, Qroup-blend, Induding polymer-modified bituminous materials and hydrated lime Asphaltic concrete tiQg, Superpave, Qroup-blend, induding bituminous materials and hydrated lime Asphaltic concrete tiQg Superpave, Qroup-bIEmd, Induding bituminous materials, Gilsonite modifier, and hydrated lime Per ton (megagram) Item No. 400 Per ton (megagram) .. Item No. 400 Per ton (megagram) w . Item No. 400 Item No, 400 inches asphaltic concrete, tiQg Superpave, Qroup-blend induding bituminous materials, Gilsonite modifier and hydrated lime Asphaltic concrete tiQg Stone Matrix Asphalt, Qroup-blend, induding polymer- Per ton (megagram) Per square yard (meter) Item No. 400 modified bituminous materials and hydrated lime Asphaltic concrete ~ OGFC, Qroup 2 only, induding bituminous materials and hydrated lime Asphaltic concrete ~ OGFC, Qroup 2 only, including polymer-modified bituminous materials and hydrated lime Asphaltic concrete~ Porous European Mix, Qroup 2 only, induding polymer-modified bituminous materials and hydrated lime Per ton {megagram} Item No. 400 Per ton {megagram} ~ Item No. 400 Per ton {megagram} .. 400.5.01 Adjustments A. Determine Lot Acceptance . The control sieves used in the mixture acceptance schedule for the various types of mix are indicated below: Control Sieves Used in the Mixture Acceptance Schedule Asphaltic concrete 25 mm Superpave Asphaltic concrete 19 mm Superpave Asphaltic concrete 12.5 mm Superpave Asphaltic concrete 9.5 mm Superpave Asphaltic cOncrete 4.75 mm Mix 1/2 in., No.8 (12.5 mm, 2.36 mm) sieves and asphalt cement 3/8 in., No.8 {9,5 mm, 2.36 mm} sieves and asphalt cement 3/8 in., NO.8 {9.5 mm, 2.36 mm} sieves and asphalt cement No.4, No.8 {4.75 mm, 2.36 mm} sieves and asphalt cement NO.8 (2.36 mm) sieve and asphalt cement The Department will perform the following tasks: I. Detennine the mean of the deviations from the job mix formula per test results per lot. 2. Determine this mean by averaging the actual numeric value of the individual deviations from the job mix formula; disregard whether the deviations are positive or negatiye amounts. C. Calculate Pavement Mean Air Voids The Department will determine the percent of maximum air voids for each lot by dividing the pavement mean air voids by the maximum pavement mean air voids acceptable. D.'> Asphaltic Concrete For Temporary Detours Hot mix asphaltic concrete placed on temporary detours that will not remain in place as part of the permanent pavement does not require hydrated lime. Hot mix used for this pUrpose is paid for at an adjusted Contract Price. Where the Contract Price of the asphaltic concrete for permanent pavement is let by the ton (megagram), the Contract Price for the asphaltic concrete placed on temporary detours is adjusted by subtracting $0.7 5/ton ($0.85/mg) of mix used. Where the Contract price of the mix in the permanent pavement is based on the square yard (meter), obtain the adjusted price for the same mix used on the temporary detour by subtracting $0.04/yd2 ($0.05/ m2) per I-in (25- mm) plan depth. Further price adjustments required in Subsection 400.3.06. "Quality Acceptance." are based on the appropriate adjusted Contract Price for mix used in the temporary detour work. E. Determine Lot Payment If the Engineer determines that the material is not acceptable to leave in place, remove and replace the materials at the Contractor's expense. .. .. , First Use Date 200 I Specification: November 18, 2005 Revised: August 9, 2006 Off System Revised September 27,2006 DEPARTMENT OF TRANSPORTATION .. STATE OF GEORGIA Special Provision Section 402-Hot Mix Recycled Asphaltic Concrete Delete Subsection 402.5 and Substitute the following: 402.5 Payment The work performed and the materials furnished as described in this Specification will be paid for at the Contract Unit Price per ton (megagrarn). Payment is full compensation forproviding materials, hauling and necessary crushing, processing, placing, rolling and fmishing the recycled mixture, and providing labor, tools, equipment, and incidentals necessary to complete the work, including hauling and stockpiling RAP or RAS materiaL Payment wilfbe made under: .. Item No. Recycled asphaltic concrete ~ Superpave, group-blend, Per ton (megagram) 402 including bituminous materials Item No. Recycled asphaltic concrete ~ Superpave, group-blend, Per ton (megagram) 402 including bituminous materials and hydrated lime Item No. Recycled asphaltic concrete ~ Superpave, group-blend, Per ton (megagram) 402 . including polymer-modified bituminous materials and hydrated lime Item No. Recycled asphaltic concrete mm mix, group-blend, Per ton (megagram) 402. including bituminous materials and hydrated lime Item No. in (mm) recycled asphaltic concrete ~ Superpave, Per square yard 402 group-blend. including bituminous materials (meter) Item No. in (mm) recycled asphaltic concrete ~ Superpave, Per square yard 402 group-blend, including bituminous materials and hydrated lime (meter) Item No. in (mm) recycled asphaltic concrete ~ Superpave, Per square yard . 402 group-blend, including polymer-modified bituminous materials and (meter) hydrated lime Item No. in (mm) recycled asphaltic concrete mm Per square yard 402 mix, group-blend, including bituminous materials and hydrated lime (meter) Item No. Recycled asphaltic concrete patching including. bituminous Per ton (megagram) 402 materials Item No. Recycled asphaltic concrete patching including bituminous Per ton (megagram) 402 materials and hydrated lime Item No. Recycled asphaltic concrete leveling including bituminous materials Per ton (megagram) 402 Item No. Recycled asphaltic concrete leveling including bituminous materials Per ton (megagram) 402 and hydrated lime 4' '.. Asphaltic concrete 25 mm Superpave Asphaltic concrete 19 mm Superpave Asphaltic concrete 12.5 mm Superpave Asphaltic concrete 9.5 mm Superpave Asphaltic concrete 4.75 mm Mix 1/2 in., NO.8 (12.5 mm, 2.36 mm) sieves and asphalt cement 3/8 in., NO.8 (9.5 mm, 2.36 mm) sieves and asphalt cement 3/8 in., NO.8 (9.5 mm, 2.36 mm) sieves and asphalt cement No.4, NO.8 (4.75 mm, 2.36 mm) sieves and asphalt cement NO.8 (2.36 mm) sieve and asphalt cement , 402.5.01 Adjustments A. Determine Lot Acceptance The control sieves used in the mixture acceptance schedule for the various types of mix are indicated below: Control Sieves Used in the Mixture Acceptance Schedule The Department will perform the following tasks: I. Detennine the mean of the deviations from the job mix formula per test results per lot. 2. Determine this mean by averaging the actual numeric value of the individual deviations from the job mix formula; disregard whether the deviations are positive or negative amounts. B. Calculate Pavement Mean Air Voids The Department will determine the percent of maximum air voids for each lot by dividing the pavement mean air voids by the maximum pavement mean air voids acceptable. C. Asphaltic Concrete for Temporary Detours Hot mix asphaltic concrete placed on temporary detours that will not remain in place as part of the permanent pavement does not require hydrated lime. ~ot mix used for this purpose is paid for at an adjusted Contract Price. Where the Contract Price of the asphaltic concrete for permanent pavement is let by the ton (megagram), the Contract Price for the asphaltic concrete placed on temporary detours is adjusted by subtracting $0.7 5/ton ($0.85/mg) of mix used. Where the Contract price of the mix in the permanent pavement is based on the square yard (meter), . obtain the adjusted price for the same mix used on the temporary detour by subtracting $0.04/yd2 ($0.05/ m2) per I-in (25-mm) plan depth. Further price adjustments required in Subsection 400.3.06, "Ouality Acceptance." are based on the appropriate adjusted Contract Price for mix used in the temporary detour work. D. Determine Lot Payment If the Engineer determines that the material is not acceptable to leave in place, remove and replace the materials at the Contractor's expense. . ,. If First Use Date 2001 Specification: May 1, 2005 Revised June 14, 2005 Georgia Department of Transportation SPECIAL PROVISION Project Number: P.I. Number: COUNTIES Section 647- Traffic Signal Installation Delete Section 647 and substitute the following: 647.1 General Description This work consists of furnishing materials and erecting a traffic signal installation including all traffic signal equipment, poles, bases, wires and miscellaneous materials required for completion of the installation. It also includes all test periods, warranties and guarantees as designated in subsequent sections, and response to maintenance and operational issues as described in subsequent sections. Apply for, obtain and pay for all utility services, communications services to, and pole attachment permits that are necessary for the signal installation and operation required in the Plans. Maintain these utility services until fmal acceptance of the signal. Upon final acceptance, make an orderly and uninterrupted transfer of these services and permits to the local government or other jurisdiction that will be responsible for subsequent maintenance and operation. 647.1.01 Definitions General Provisions 101 through ISO. 647.1.02 Related References .. A. Georgia Specifications Section 106-Control of Materials Section 500-Concrete Structures Section 50 t-Steel Structures Section 63I-Changeable Message Signs Section 636 - Highway Signs Section 639-StraiIi Poles for Overhead Sign and Signal Assemblies Section 645-Repair of Galvanized Coatings Section 680-Highway Lighting Section 68 I-Lighting Standards and Luminaires Section 682-Electrical Wire, Cable. and Conduit ~ 1 of 31 ) .. 4' ,4 Section 647- Traffic Signal Installation Section 700----Grassing Section 800~oarse Aggregate Section 80 I-Fine Aggregate Section 832~uring Agents Section 833-Joint Fillers and Sealers Section 850 Aluminum Alloy Materials Section 853-Reinforcement and Tensioning Steel Section 854-Castings and Forgings Section 861---'-Piling and Round Timber Section 870-Paint Section 886-Epoxy Resin Adhesives Section 91 O-Sign Fabrication Section 91 I-Steel Sign Posts Section 912-Sign Blanks and Panels Section 913-Reflectorizing Materials Section 915-Mast Arm Assemblies Section 923-Electrical Conduit Section 925- Traffic Signal EQuipment Section 935-Fiber Optic System Section 936~CTV System Section 937-Video Detection System Section .938-Detection Section 939~ommunications & Electronic Equipment Section 940-Navigator Integration B. Referenced Documents National Electrical Manufacturers Association (NEMA) Traffic Control Systems Standards No. TS I NEMA Traffic Control Systems Standards No. TS 2 AASHTO Roadside Design Guide The Manual on Uniform Traffic Control Devices (MUTCD), current edition National Electrical Code (NEC) National Electrical Safety Code (NESC) GDT7 GDT 24a GDT 24b GDT 67 647.1.03 Submittals Submit to the Engineer, signal material specifications information on all materials proposed for use on the project. Written approval is required from the State Traffic Safety and Design Engineer prior to beginning any work on the traffic signal installation. 2 of 31 )- # .' ,.. Section 647-Traffic Signal Installation A. Review For all submittals, the State Traffic Safety and Design Engineer's review of the material should be completed within thirty (30) days from the date of receipt of the submission unless otherwise specified. The State Traffic Safety and Design Engineer will advise in writing, as to the acceptability of the material submitted. AU material submittals for fiber optic communications equipment and materials used on the project will be reviewed by the Department's Traffic Signal Electrical Facility (TSEF). The material review should be completed within thirty (30) days from the date of receipt of the material submission unless otherwise specified. The State Traffic Signal Engineer will advise in writing as to acceptability of materials to be used on the project. The State Traffic Safety and Design Engineer may determine that the item is approved, in which case no further action is required; or the item may be partially or totally rejected in which case, modify the submittal as required and resubmit within fifteen (15) days. At this time, the review and approval cycle described above begins again. The Department reserves the right to be reimbursed for reviewing any submittals after a second rejection. B. Submittal Costs No separate measurement or payment will be made for submittal costs. C. Steel Strain Pole, Concrete Strain Pole or Steel Pole Certification Instruct the supplier or manufacturer of the strain poles or steel poles with traffic signal mast arms to submit a certification, including mill certificates to: Department of Transportation Office of Materials and Research 15 Kennedy Drive Forest Park, Georgia 30297 Include the following in the certification: . A statement that the items were manufactured according to the Specifications, including the Specification subsection number . Project number and P.L number Instruct the supplier or manufacturer to send copies of the transmittal letter to the Engineer. Refer to Subsection 647.3.03.C. Prepare Shop Drawings and related signal strain pole design calculations. Provide "bending moment at yield" to determine the foundation size according to the signal strain pole foundation drawings. Submit all Shop . Drawings and related signal strain pole design calculations to the Engineer to be forwarded to the State Bridge and Structural Design Engineer for review and approval. Obtain written approval prior to pole fabrication and installation. Show all dimensions and material designations of the designs on the drawings. See Section 50 I for the certification procedure for poles and anchor bolts. D. Signal Item Certification Submit five (5) copies of material catalog product numbers and descriptions to the Engineer. Reference the project number, P.I. number and Specification subsection number for the following traffic signal items: . Signal heads . LED Signal Modules 3 of 31 Section 647- Traffic Signal Installation T . Mounting hardware . Controllers . Cabinet assemblies . Battery Backup System (BBS) . Detectors . . Monitors . Cable . Load switches . Blank-out signs . Lane use signals . Preformed cabinet bases . Other related signal equipment . Modems . Fiber Optic Modems E. Test Results Submittal Submit the results ofthe testing of the following items to the Engineer: . Loop Detector Testing . Signal Cable Testing . Interconnect Cable Testing . Pre-emption Testing . Controller and Cabinet Testing . Any other operational testing required by the Engineer AI/" F. Mast Arm Pole Chart For locations with mast arm pole installations, submit a "Mast Ann Pole Chart" for review and approval by the State Bridge and Structural Design Engineer. The "Mast Arm Pole Chart" shall also include a sketch on an 8 1;2 inch x II in (216 nun x 297 nun) sheet of paper showing the following: . Curb lines . Location of mast arm pole based on utility information and field location verified by contractor. (Final location of mast arm pole must meet the criteria for- setback from the road as specified in the Roadside Design Guide by AASHTO and in the Standard Detail Drawings) . Distance from both adjacent curbs to mast arm pole . Distance along mast arm from pole to curb and from curb to each proposed signal head . Directional arrow . Street names . Position of Luminaries Label the sketched distances. Once this pole chart is approved, the contractor shall use the distances measured to the proposed signal head locations when ordering the mast arm to ensure that the mast arm is fabricated with holes for signal head wiring in the correct locations ... 4 of 31 Section 647-Traffic Signal Installation 647.2 Materials ~ 647.2.01 Delivery, Storage, and Handling .. A. State-supplied Equipment For projects where traffic signal equipment is to be supplied by the Georgia Department of Transportation, obtain State-supplied traffic signal equipment from the Traffic Signal Electrical Facility (TSEF): 1. Contact the Engineer by phone or correspondence within one week after receiving the Notice to Proceed and arrange for a location to pick up the signal equipment. 2. Sign GDOT's Warehouse Issue Request Form 592 to accept delivery of the State-supplied equipment from GDOT's Traffic Signal Equipment Warehouse. Initial Form 592 if equipment is received from a GDOT District Field Office. 3. Inspect the equipment to ensure that it is operating properly and perform any operational tests within ten (10) calendar days after receiving the equipment. 4. Before installation, and within ten (10) calendar days, certify to the Engineer in writing that the State- supplied equipment was received in good condition. 5. Notify the Engineer in writing if the State-supplied equipment is defective. The State Signal Engineer will replace the defective State-supplied equipment. 6. If no written dissent is received after ten (l0) calendar days or if equipment is installed in the field, the Engineer will consider this equipment to be satisfactory and accepted. 7. The Contractor shall supply new equipment to replace State-supplied equipment that is damaged by the Contractor. B. Signal Equipment See Section 925 for signal equipment specifications. The signal equipment, components, supplies, or materials used in traffic signal installation may be sampled and tested if not previously approved by the Department. Test according to the Specifications and the Sampling, Testing, and Inspection Manual using one or more of the following methods: . Have the Department use their own facilities. . Have the supplier or manufacturer use their facilities with an authorized Department representative to witness the testing. · Provide independent laboratory test results indicating compliance with Department Specifications referenced in Subsection 647.1.02, "Related References", of this document. . When testing by the Department is required, supply the item to the Department. Acceptance of materials tested does not waive warranties and guarantees required by the Specifications. C. Cable Use cable conforming to Section 680, Section 925, and the appropriate IMSA, NEMA, or UL Specifications for the wire or cable. Obtain pole attachment permits required by local utility companies or pole owners to allow joint use for signal cable, hardware, or other auxiliary devices. ~ ~ D. Interconnect Communications Cable The interconnect cable (communication cable) links the master controller, the field controllers, and sensors. Follow these guidelines: 1. Use fiber optic interconnect cable for all new interconnected signal systems. See Section 935 for fiber optic cable information, specifications and installation and testing techniques. 5 of 31 Section 647-Traffic Signal Installation 2. Use copper cable only as directed by the Project Engineer or where specifically shown in the Plans. Refer to Section 647.3.05, "Construction", of this document for installation. . E. Messenger Cable Use cable conforming to ASTM A 475 Siemens-Martin grade or better with Class A coating. The messenger is used to support cable indicated in the Plans as overhe!ld cable. Use devices such as wire ties or lashings to attach the cable. . Before erecting the messenger strand, determine the suspension strand length to span the distance between the poles. . Run the messenger strand from structure to structure without splicing. . The maximum allowable sag is two and one-half percent (2.5%) of the longest diagonal distance between the signal poles. . Calculate attachment points for the messenger strand at the signal pole according to the Plan detail sheet. F. Conduit on Structures Use rigid metallic materials for all exposed conduit for cabling. Use metallic conduit on the exterior of signal poles and other structures and to house signal conductors for the entire length from the weatherhead on the pole to the interior of the cabinet (see Subsection 647.3.05X). 647.3 Construction Requirements Refer to Subsection 107.07 ofthe Specifications regarding proper conduct of The Work. 647.3.01 Personnel For the definition of a qualified electrician, see Subsection 755.1.01. 647.3.02 Equipment Use machinery such as trucks, derricks, bucket vehicles, saws, trenchers, and other equipment necessary for the work and approved by the Engineer prior to installation operations. 647.3.03 Preparation Utility Permits A. Application Apply for, obtain, and pay for utility services and pole attachment permits for signal operation required in the Plans. B. Maintenance Maintain these utility services until Final Acceptance of each signal installation. After Final Acceptance, transfer these services and permits to the local government or jurisdiction responsible for maintenance and operation. Ensure that the transfer does not interrupt service. C. Utility Location 1. Adjustment Prior to ordering signal poles, locate utilities and adjust the location of poles, where necessary, to minimize utility conflicts. Obtain approval from the Engineer for any deviation from the Plans. Determine the final length of mast arms based on any field adjusted pole locations, Final location shall be approved by the Engineer. 2. Clearance When installing aerial cable of any type, ensure that overhead clearance and separation requirements conform to local utility company standards the NEC and the NESC. Refer to the Standard Details Drawings for further information on utility clearances. 6 of 31 Section 647-Traffic Signal Installation t D. Signal Controllers Furnish and install approved microprocessor controllers at the locations shown in the Plans or as directed by the Engineer. All equipment furnished shall comply with Section 925."Traffic Signal Equipment"~ 1. Identify the controller and other auxiliary equipment by serial number and model. These numbers shall agree with previously approved catalog submittals. 2. Assemble the controller, cabinet, and auxiliary equipment to provide the operational sequence shown in the Plans and future operations specified. Ensure the Controller functions as a unit with the cabinet assembly. 3. Ensure controller and auxiliary equipment are provided AC power from receptacles marked for controller power. ~. ~ E. Cabinet Assembly 1. Location The cabinet should be located in accordance with the plan location, however if the cabinet location needs to be moved, choose a location that: a. Protects maintenance personnel from vehicles when servicing the equipment b. Allows the front panel door ofthe controller to open away from the intersection for view of signal indications while servicing or performing cabinet work. c. Does not block a sidewalk or passageway and complies with Federal regulations for Americans with Disabilities Act (ADA) clearance requirements. . d. Is located away from the roadway or curb line to prevent vehicular damage to the cabinet. e. Is not located within drainage areas or installed in areas likely to collect and hold surface water. Relocate the cabinet to avoid conflicts from proposed reconstruction projects, commercial driveways, etc. within the right-of-way at the Engineer's discretion. 2. Erection Install and level traffic signal controller cabinets at locations shown in the Plans and/or as directed by the Engineer. a, Install cabinets to conform to the Standard Detail Drawings. Install pole or base-mounted as indicated in the Plans. . b. Seal base-mounted cabinets to their base using silicone based sealer. Pliable sealant used shall not melt or run attemperatures as high as 212 OF (100 oe). c. Use prefabricated bases and work pads d. Install technician pad in front and rear of the controller cabinet door. See standard details for pad information. 3. Field Cabinet Wiring All wiring shall be neat and secured and comply with NEC, NEMA, and Table 647-1, Table 647-2, Table 647-3 and Table 647-4 of this Specification. a. Cut field cabinet wiring to the proper length and organize it in the cabinet. · Use at least No.6 A WG wire on conductors between service terminals and the "AC+" terminals to signal light relays, and buss terminals. · Use at least No.6 A WG wire on terminal connections to light neutral. b. Crimp terminal connections to conductors with a ratchet-type crimping tool that will not release until the crimping operation is completed. c. Do not use splices inside the controller cabinet, base, or conduit. d, Do not use solid wire, except grounding wire. e. Supply the cabinets with cabinet wiring diagrams, schematic drawings, pin assignment charts, and manuals for circuits and components. Store these documents in the cabinet in a resealable, weatherproof container. .. 8 of 31 Section 647-Traffic Signal Installation t' F. Signal Monitors Furnish signal monitor equipment as follows: I. Mount signal monitors in a rack with appropriate connectors to attach to the wiring harness. 2. Program the monitor according to the signal operation indicated in the Signal Plans before placing the installation in flash or stop-and-go operation. Provide any signal monitoring programming tools required to program the monitor to the maintaining agency. 3. Configure and equip the signal monitor to monitor all red signal indications. Ensure that the red output for unused or vacant load oays or output slots is jumpered to 120 V AC+. 4. For ITS Cabinets Configure the CMU and AMU. . G. Power Disconnect Install a power disconnect box at each intersection as shown in the Standard Detail sheets. Ensure the power disconnect is installed at the top of the cabinet pole. Install service cables from disconnect box and terminate as specified on the controller cabinet-wiring diagram. H. Flashing Beacon Furnish and install the flashing beacon controller at the locations shown in the Plans and/or as directed by the Engineer. Install it as a complete unit (solid state flasher and cabinet with time clock, if applicable) and ensure that it conforms to this Specification. . I. Loop Detector Systems Install and test loop detector systems according toNEMA Standards Publication TS 1-1983, Section 15, Inductive Loop Detectors, subsequent revisions (except as shown in the Plans), details, notes, and this Specification. Ensure that loop detectors are complete and fully operational before placing the signal in stop-and-go operation. 1. General Installation Requirements Each loop must consist of at least two turns of conductor, unless otherwise shown in the Plans or this Specification, Do not place a portion of the loop within 3 feet (1 m) ofa conductive material in the pavement such as manhole covers, water valves, grates, etc. a. Install pull boxes, condulets, and conduits before beginning loop installation. b. Ensure that the ambient pavement surface temperature in the shade is at least 40 OF (5 oc) before placing sealant into saw cuts. 2. Loop Saw Cuts a. Outline the loop on the pavement to conform to the specified configuration. b. Install the detector loop in a sawed slot in the roadway surface deep enough to provide at least 2 inches (50 mm) of sealant cover. c. Ensure that the slot is at least 0.25 inches (6 mm) wide for stranded No. 14 A WG loop wire, THHN, THWN, XHHN, or XLPE, and at least 0.31 inches (7 mm) wide for polyethylene or PVC encased No. 14 AWG loop wire. 1) At the intersection of the slots, drill a 1.25 inch (31 mm) diameter hole or make miter saw cuts in the pavement Overlap miter saw cuts at the intersection of saw cuts so that the slots have a full-depth and smooth bottom. 2) Prevent the wire from bending sharply. 3) Do not install detector loop wire unless sawed slots are completely dry and free of debris. Pressure wash the slot to guarantee adhesion of the loop sealant Use compressed air to thoroughly dry the sawed slot. 4) Install the loop wire starting at the nearest pull box or condulet, around the loop for the specified number of turns, and back to the pull box or condulet .. 9 of 31 Section 647- Traffic Signal Installation 5) Quadrupole loops should have a minimum of two (2) turns. Dipole loops require at least three (3) turns. Reference the Standard Details for the correct number of turns. .- NOTE: Loop wire from the street is to be spliced in condulets or pull boxes d .- e. f. g. h. I. Press the wire in the slot without using sharp objects that may damage the jacket. Hold the loop in place every 5 feet (1.5 m) with I inch (25 mm) strips of rubber, neoprene, flexible tubing, or foam backer rod as approved by the Engineer. Leave the hold down strips in place when filling the slot with loop sealant. Where encased loop wire is used, apply a waterproof seal to the ends of the polyethylene tubing that encase the wire to prevent moisture from entering the tube. Where the loop wires cross pavement joints and cracks, protect the loop wires using the method specified in "Miscellaneous Details" in the Plans, Twist Loop Lead-in 3 turns per foot. ~ 3.. Loop Sealing After successfully testing each loop, fill the slots with sealant to fully encase the conductors. a. Ensure that the sealant is at least 2 inches (50 mm) thick above the top conductor in the saw cut. b. Apply the sealant so that subsequent expansion does not extend the sealant material above the pavement surface. c. Before the sealant sets, remove surplus sealant from the adjacent road surfaces without using solvents or epoxy sealants. d. Obtain approval from the Office of Materials and Research to use polyurethane sealants. They shall conform to Subsection 833.2.09. e. When the Engineer determines that the loop sealant can accommodate traffic but the surface is tacky, dust the sealer on the pavement surface with cement dust before opening the roadway to traffic. f. Dispose of the solvents used to clean loop installation equipment according to the manufacturer's specifications and local, State, and Federal regulations, 4. Loop Connections Connect loop conductors to a shielded lead-in cable that runs from the pull box adjacent the pavement edge Or condulet to the detector hook-up panel in the controller cabinet, unless otherwise specified in the Plans. a. Use continuous (no splices) shielded lead-in cable from the pull box or condulet to the cabinet input file terminal. Do not ground the shield in the loop lead-in cable at the cabinet. b. Connect each loop to an individual detector channel as specified in the Plans. c. If the Plans specify that two or more loops will be operated on the same detector channel or detector amplifier unit, wire them in series to their loop lead-in at the pull box or condulet. d. Use series-parallel connections when series connections do not meet the manufacturer's specified operating range for the detector amplifier unit. e. Make weather-tight and waterproof splices as detailed on the plan Standard Detail sheets. Make loop splices to loop lead-in cable only after the detector system has been tested and demonstrated under traffic conditions to the Engineer's satisfaction. 5. Loop Maintenance Locate all existing loops, determine the operatipnal status of all loop assemblies, and notify the Engineer prior to commencing loop construction activities at the intersection. Maintain all existing, operational loops, unless otherwise notified by the Engineer. Repair of an existing loop that is non-operational prior to beginning work will be considered as extra work. Locate points of conflict, between new loops and existing loops, and install all new loops and saw cuts so as not to cut existing loop lead-ins and loop wires that are to be retained. ~ 10 of 31 Section 647-Traffic Signal Installation ,.. If an existing operational loop . that is not scheduled for rep lacement fails during the construction time frame, notify the Engineer and complete the replacement of the damaged loops immediately. The Engineer may grant a twenty-four (24) hour period to repair the loops iftheir operation is not critical. All costs associated with the replacement of the loops damaged during construction shall be charged and paid for by the Contractor. .. .T. Pedestrian Push Button Install the push button with a pedestrian instruction sign as illustrated on the Department's standard detail sheets and according to the Plans. I. Place the pedestrian buttons as shown on the signal plan sheet and within easy access of the pedestrian crosswalk. 2. Position the pedestrian button to correspond to the appropriate signal phase. Locate pedestrian buttons perpendicular to the appropriate signal indication and signal phase, and as field conditions require. 3. Place the buttons approximately 3.5 feet (I.05 m) above the sidewalk or ground level. K. Cable Install and connect electrical cable to the proper equipment to produce an operating traffic signal system. Use stranded copper cable conforming to Section 925. Install wiring in accordance with ISMA, NEMA, UL, and the Department's Traffic Signal Wiring Standards, shown in Tables 647-1, 647-2, 647-3,.and 647-4 of this Specification. In addition to the information provided below, see Section 682, Section 922, and Section 925 for cable equipment and installation specifications. Table 647-1 Vehicular Signals Georqia DOT Wiring Standards 3-Section Signal Heads 5~Section Signal Heads Signal Indications Seven Conductor Cable Seven Conductor Cable Phases 2, 4, 6, and 8 Phases 1, 3, 5, and 7 Phases 1/6, 2/5, 3/8 & 4/7 Red Red Wire Red Wire Yellow Orange Wire Orange Wire Green Green Wire Green Wire Red Arrow White Wire with Black . Tracker Yellow Arrow Black Wire Black Wire Green Arrow Blue Wire Blue Wire Neutral White Wire White Wire . White Wire Detectors Table 647-2 Vehicular Loop Detectors . Geor ia DOT Wirin Standards Phases 3, 4, 7, and 8 Presence Loops Phases 2 and 6 Setback Pulse Loops and Phases 1 and 5 Presence Loops -(' 4 Loop Wires Right Curb Lane Red Wire Shielded Loop Lead- in Cable, 3 Pair Red/Black Pair (1) Loop Wires Red Wire Shielded Loop Lead- in Cable, 3 Pair Red/Black Pair (1) 11 of 31 Section 647-Traffic Signal Installation Second Lane Green Wire Green Black Pair (1) Green Wire Green Black Pair (1) Third Lane White Wire White/Black Pair (1) White Wire White/Black Pair (1) *' Fourth Lane Red Wire Red/Black Pair (3) Red/Black Pair (3) Red Wire Fifth Lane Green Wire Green/Black Pair (3) Green Wire Green/Black Pair (3) Sixth Lane White Wire White/Black Pair (3) ... First Left-Turn Lane Red Wire Red/Black Pair (4) Second Left-Turn Lane Green Wire Green/Black Pair (4) Table 647-3 Pedestrian Signals Georgia DOT Wiring Standards Signal Indications 2-Section Signal Heads Seven Conductor Cable Phases 2 and 6 Phases 4 and 8 Don't Wall< Red Wire White Wire with Black Tracker Walk Green Wire Blue Wire Neutral White Wire White Wire Table 647-4 Pedestrian Detectors Georgia DOT Wiring Standards 3 Pair Shielded Cable Push Buttons Phase 2 and 6 Phase 4 and 8 Call Green and Black Pair Red and Black Pair NOTE: Do not use aluminum cable. L. Signal Cable for Vehicular Signal Headsan~ Pedestrian Heads Install cable for signal heads and pedestrian heads as follows: 1. For vehicle signal heads, install one 7-conductor signal cable for each intersection approach from the controller cabinet to the leftmost through-signal head on each approach. From this leftmost signal head, install a 4-conductor signal cable to each of the other signal heads on the same approach in sequence. 2. For pedestrian signal heads, install one 7-conductor signal cable from the controller cabinet to each pedestrian head installation location to operate either one or two pedestrian heads. 3. Make a minimum I foot (300 mm) diameter weather drip loop as shown in the Standard Detail Drawings in (" the Plans at the entrance to each pole, overhead conduit, and weatherhead. 4. Neatly tie signal cables leaving a structure or weatherhead to enter a signal fixture. Tie the cables to the messenger cable as illustrated in the Standard Detail Drawings. 5. Provide anS inch diameter service loop at each signal head. . M. Interconnect Communications Cable Use fiber optic interconnect cable for all new interconnected signal systems. See Section 935 for fiber optic cable information, specifications and installation and testing techniques. Install and test interconnect communications cable as follows: 12 of 31 Section 647- Traffic Signal Installation .' 1. Installation a. Provide support for the interconnect cable on new or existing utility poles or signal poles; install underground in conduit. Use fiber optic standoff brackets as needed to prevent damage from poles, trees and other structures. b. Pull cables with a cable grip that firmly holds the exterior covering of the cable. c. Pull the cables without dragging them on the ground, pavement or over or around obstructions. The Engineer will inspect and approve the cable prior to installation. Use powdered soapstone, talc, or other approved inert lubricants to pull the cable through the conduit. d. When using a separate messenger cable, spirally wrap the communications cable with a lashing . machine according to the IMSA-20-2 Specifications. e. Do not splice outside the signal cabinet except at the end of full reels of 5,000 feet (1500 m). f. Ensure that splice points are near support poles and accessible without closing traffic lanes. g. Unless drop cable assemblies for communications are used, loop the cable in and out of the control cabinets. Coil and tie 10 feet (3 m) of cable in the controller cabinet foundation. Tape the cable ends to keep moisture out until the terminals are attached. h. Prevent damage to the cable during storage and installation. NOTE: Do not allow anyone to step on or run over any cable with vehicles or equipment. 2. . Field Test Conduct a test for continuity and isolation with the Engineer according to Section 935. a. Perform the attenuation test for each fiber. Test for all events above 0.10 dB and total attenuation of the cable. Submit both printed and electronic (diskette) OTDR testing results as referenced in Subsection 935.1.03. b. Perform the isolation test for testing insulation resistance for each conductor and cable shield in the system. 1) Fiber optic cable testing is to be conducted according to the requirements of Section 935.3.06.B, of the Specifications. 2) Record the fiber cable test results for each on the Interconnect Cable Data Sheet and include it as project documentation. c. If the conductors fail the continuity or isolation test, remove the installed cable, instaU new cable, and repeat the tests. Table 647-5 Interconnect Cable Data Sheet Project Number: Date: Weather: ~ Temperature: Contractor: Controller Cabinet: ~ City or County: Intersection Name(s) Route Number(s) 13 of 31 Section 647-Traffic Signal Installation .. Type: Manufacturer: Number of Conductors: - Splice Point: Total Length of Cable: Conductor Tube Color Description Continuity Attenuation 1. 2. 3. 4, 5. 6, 7. 8. 9. 10. 11, 12. Shield Inspector's Name and Title: 1# N. Loop Detector Lead-in Cable Use 3-pair shielded lead-in cable in compliance with Section 925 and manufacturer's recommendations for Detector loop lead-in installed for loop detectors. Use a shielded lead-in cable connecting the loop to the detector hook-up panel in the controller cabinet, unless otherwise specified in the Plans. · Splice the loop detector wire to a shielded loop detector lead-in cable in a pull box adjacent to the loop detector installation. · Use continuous (no splices) shielded lead-in cable from the pull box or condulet to the cabinet input file terminal. Do not ground the shield in the loop lead-in cable at the cabinet. · Connect each loop to an individual detector channel as specified in the Plans. · Make weather tight and waterproof splices between lead-in and loop wire. Loop installation may be approved only after the detector system has been tested and demonstrated under traffic conditions to the Engineer's satisfaction, during the Operational Test Period. ~ 14 of 31 'Section 647-Traffic Signal Installation ~ O. Pedestrian Push Button Lead-in Use 3-pair shielded lead-in cable compliant with Section 925 for pedestrian push buttons. Install one 3-pair shielded lead-in cable to each corner of the intersection, to operate either one or two push buttons. Do not ground the shield for the push button lead-in cable at the controller cabinet. Do not use the same 3 pair cable for loop and pedestrian detectors. .. P. Messenger Cable, Stranded-Steel Set messenger strands so that the height of the installed traffic signal heads conforms to the clearances on the Standard Detail Drawings. Lash cables to messenger cable or use aluminum wrap spaced at 6 inch (150 mm) increments. 1. Drill wood poles to receive the eye bolts so that the span wire and eyebolt at each connection form a straight angle. Never pull or strain the messenger on the eye bolt to an angle of variance greater than ten degrees (l00). 2. Attach down guy wires to guy hooks. Never attach them directly to the eyebolt. 3. Ensure that messenger strand clearances conform with local utility company standards. 4. Make stranded messenger cable attachment points with the appropriate size strand vises or 3 bolt clamps. Stranded steel messenger cable is not paid for separately under this Specification. NOTE: Never splice messenger cable between structures or stand off brackets. ,# Q. Underground Cable for Signal Circuits Underground cable for signal circuits includes cable, with conduit, as shown in the Plans. Install cable under existing pavement or surfaced shoulder, according to Subsection 680.3.05. 1. Cable in Conduit Pull cable into conduits as follows: a. Pull cables into conduits without electrical or mechanical damage. Pull cables by hand only. The use of trucks or other equipment is not permitted, unless approved by the Engineer. If mechanical pulling is approved, do not exceed the manufacturer's tension rating for the cable. b. Pull cables with acable grip that firmly holds the exterior covering of the cable. c. Use powdered soapstone, talc, or other inert lubricants to place conductors in conduit according to manufacturer's recommendations. d. Handle and install the conductors to prevent kinks, bends, or other distortion that may damage the conductor or outer covering. e. Pull aU cables in a single conduit at the same time. When pulling cables through hand holes, pole shafts, etc., use a pad of firm rubber or other material between the cable and the opening edges to prevent cable damage. f. When installing cable in conduit with existing signal cable circuits remove all existing cables and pull them back into the conduit with the new cables. g. The distance between pull boxes in a run of conduit shall not be greater than 250 feet (75 m), unless otherwise shown in the Plans or approved by the Engineer, with the exception of fiber optic cable. The distance between pull boxes in a run of conduit for fiber optic cable shall not exceed 750 feet (225 m). Identification tape and or tone detection wire shall be used for fiber optic cable in conduit. All unused conduit shall have a continuous pull cable installed between pull boxes. All buried conduit shall be marked using sentinel marker posts identifying buried conduit, approved by the project engineer. See Section 682 for additional requirements. 2. Splices Required signal conductor splicing shall be performed according to the National Electric Code; use materials compatible with the sheath and insulation of the cable. Make splices at the first opportunity for items such as electrical communication boxes, pull boxes, controller cabinets, or pole bases unless otherwise shown in the Plans. ,# 15 of 31 Section 647-Traffic Signal Installation .. NOTE: Do not splice signal conductor cables for vehicle signal heads or pedestrian heads between the controller cabinet and the first signal or pedestrian signal head attachment. Do not splice the pedestrian push button lead-in cable between the controller cabinet and the first pedestrian push button on each corner. Do not splice fiber optic cable or copper cable between intersections unless otherwise approved by the Engineer. If approved, splice only in above ground enclosures or aerial splice boxes. Do not splice fiber optic or copper cable in pull boxes. ... Make signal conductor line splices with copper-clad pressed sleeves or an approved equivalent~ See "Pull Box Splices" in the miscellaneous construction details in the Plans. a. Insulate required splices with plastic, pressure sensitive, all-weather 1.5 mil (0.038 mm) electrical tape b. Apply the tape half-lap to a thickness 1.5 times thicker than the factory-applied insulation and sheath. Taper it off over the sheath neatly to approximately 3 inches (75 mm) from the conductor splice. c. For cable splicing injunction boxes, use a heat-shrinkable, self-sealing splice instead of the above. d. Pad the sharp points and edges of the connector and fill voids with extra wraps of plastic tape. Do not stretch the tape excessively or cause creeping. e. Make the spliced joints watertight. Note: Splice detector wires to shielded loop detector lead-in at pull boxes located immediately after the loop wire leaves the roadway. No splices will be permitted in shielded loop detector lead-in cable from this point to the controller cabinet. R. Aerial Cable for Signal Circuits Aerial cable for signal circuits consist of one or all of the following cables: · Loop lead-in (sensor and detector) · Signal wiring (controller) · Interconnect cable (communications) Support these cables on existing or newly installed signal or utility poles as detailed in Subsection 647.2.01.F. .~ S. Conduit and Fittings Install conduit by type (rigid, HDPE, PVC) as shown in the Plans and the Standard Detail Drawings. Refer to the NEe, for conduit full percentages. Separate signal conductors from vehicle detector and communications interconnect cables, except inside of poles. Separate the power cable to the controller cabinet from all other cables in its own lin (25 mm) galvanized rigid steel conduit except inside poles. Ensure that conduit conforms to Section 682, Section 923 and Section 925 with the following addition: · Use flexible conduit only where shown in the Details or as directed to do so in writing by the District Signal Engineer. Use the conduit size specified in the Plans, unless otherwise directed by the Engineer. Obtain written approval from the Engineer prior to installing conduit other than the size specified in the Plans. All 2 inch (50 mm) conduit elbows shall be "sweep" type. The minimum radius for the elbow is 18 inches (450 mm), unless otherwise approved by the Engineer. ... NOTE: Do not use multi-cell conduit. Install conduit and fittings as follows: 16 of 31 .... .... "" .. Section 647-Traffic Signal Installation 1. Ensure that exposed conduit on poles are rigid, galvanized metal conduit. 2. Ream the ends of metallic conduit after cutting the threads. Ream other conduit as necessary. 3. Cut the ends square, and butt them solidly in the joints to form a smooth raceway for cables. 4. Make conduit joints to form a watertight seaL 5. Coat metallic conduit threads with red- or white-lead pipe compound, thermoplastic or Teflon seal. Ensure that they are securely connected. 6. Make plastic conduit joints with materials recommended by the conduit manufacturer. 7. Install bushings in the conduit to protect the conductors. When conduit is installed for future use, properly thread and cap the ends of the metallic conduit runs. a. Plug the ends of nonmetallic conduit runs to prevent water or other foreign matter from entering the conduit system. b. Seal the exposed conduit ends with a permanently malleable materiaL c. Ensure that empty conduit installed for future wire or cable has a nylon pull string or cord inside that is impervious to moisture and rot and can withstand a load of 50 pounds (23 kg) without breaking. Secure this pull cord at each open end and at each pull box. 8. Ensure that conduit on pole exteriors are mounted with galvanized, two-hole straps or clamps. Place the clamps not more than 3 feet (I m) from junction boxes, condulets, or weatherheads. Place it at 5 foot (1.5 m) intervals elsewhere. a. Fasten the clamps to wood poles with galvanized screws or lag bolts. b. Do not install conduit risers on concrete, steel, or mast arm poles unless approved by the Engineer. 9. Install a weatherhead at the end of exterior conduit runs on a pole or other structure to prevent moisture of other matter from entering the conduit. 10. After installation, ensure that the conduit or fitting placement has not warped or distorted any condulet, terminal, or control or junction box. II. Ensure Conduit that is terminated at poles is grounded at the pull box. T. Underground Conduit Underground conduit includes encased or direct burial conduit. 1. Install the conduit in a trench excavated to the dimensions and lines specified in the Plans. a. Provide at least 18 inches (450 nun) fmished cover, unless otherwise specified. b. Under pavement, excavate at least 36 inches (900 mm) below the bottom of the pavement. 2. Before excavation, contractor is responsible for determining the location of electrical lines, drainage, or utility facilities in the area to prevent damage. a. Place the conduit where it will not conflict with proposed guardrail, sign posts, etc. b. Change locations of conduit runs, pull boxes, etc., if obstructions are encountered during excavation. Changes are subject to the Engineer's approvaL c. Where possible, provide at least 12 inches (300 nun) between the finished lines of the conduit runs and utility facilities such as gas lines, water mains, and other underground facilities not associated with the electrical system. 3. When the conduit run is adjacent to concrete walls, piers, footings, etc., maintain at least 4 inches (100 nun) of undisturbed earth or fmnly compacted soil between the conduit and the adjacent concrete or, when the conduit is encased, between the encasement and the adjacent concrete. Unless specified in the Plans, do not excavate trenches in existing pavement or surfaced shoulders to install conduit 4. When placing conduit under an existing pavement, install the conduit by jacking and boring, or other approved means. See Section 615 for jacking and boring pipe specifications. Obtain the Engineer's approval prior to installing conduit by means of boring-method. 5. When the Plans allow trench excavation through an existing pavement or surfaced shoulder, restore the pavement shoulder surface, base, and subgrade according to the Specification. 17 of 31 Section 647- Traffic Signal Installation .. 6. Cut trenches for conduit on a slight grade (0.25 percent minimum) for drainage, unless otherwise specified. When the grade can not be maintained all one way, grade the duct lines from the center, both directions, down to the ends. 7. A void moisture pockets or traps. Excavate vertical trench walls. 8. Tamp the bottom of the trench to produce a firm foundation for the conduit. 9. When necessary to prevent damage, sheet and brace the trenches and support pipe and other structures exposed in the trenches. 10. Conduit installed for fiber optic cable installation shall have detectable tone wire installed for detection as specified and detailed in the Project Standard Detail Sheets. "" U. Encased Conduit Place encased conduit in the locations shown in the Plans unless otherwise specified. Construct as follows: 1. Construct the encasement using Class A concrete that meets requirements in Section 500 . 2. Extend the encasement or conduit under roadway pavements or surfaces 6 inches (150 nun) past the outer edge of paved shoulders or sidewalks, or past curbs if no shoulder or sidewalk is present. 3. Extend the conduit at least 3 inches (75 nun) beyond the encasement. 4. Place 3 inches (75 nun) of concrete in the bottom of the trench and place the conduit on top of it. 5. Temporarily plug the ends of the conduit to prevent concrete or foreign materials from entering. 6. Cover the conduit with at least 3 inches (75 nun) of concrete. Wait to encase the conduit with concrete until the Engineer inspects and approves the conduit. 7. Cure the concrete encasement according to Subsection 500.3.05.Z, except curing may be reduced to twenty-four (24) hours. Use a precast encasement if approved by the Engineer. V. Direct Burial Conduit Install direct burial conduit as shown in the Plans. Use rigid galvanized steel, polyvinyl chloride, or polyethylene conduit. Excavate at least 36 inches (900 nun) below the top of the finished ground or 36 inches (900 nun) below the bottom of the pavement. When rock is in the bottom of the trench, install the conduit on a bed of compacted, fme;-grain soil at least 4 inches (100 nun) thick. Conduit installed for fiber optic cable installation shall have detectable tone wire installed for detection as specified in Section 935 and detailed in Standard Detail Sheets. W. Backfilling Immediately backfill the conduit after the Engineer's inspection and approval, except for encased conduit, which must complete a twenty-four (24) hour cure period. l. Backfill with approved material free of rocks or other foreign matter. 2. Backfill in layers no greater than 6 inches (150 nun) loose depth, up to the original ground level. 3 Compact each layer to one hundred percent (100%) of the maximum dry density as determined by GDT 7. GDT 24a, or GDT 24b, GDT 67. . X. Conduit on Structures Install conduits, condulets, hangers, expansion fittings, and accessories on structures according to the Plans and, unless otherwise specified, the following: I. Run the conduit parallel to beams, trusses, supports, pier caps, etc. ... 2. Install horizontal runs on a slight grade without forming low spots so they may drain properly. 3. Run conduits with smooth, easy bends. Hold the conduit ends in boxes with locknuts and bushings to protect the conductors. 18 of 31 Section 647-TrafficSignallnstallation .. 4. When not specified in the Plans or Special Provisions, submit the type and method for attachment to structures to the Engineer for submission to the District Traffic Operations Engineer for approval. 5. Ground galvanized rigid steel conduit in pull boxes. All exposed conduit shall be galvanized, rigid conduit unless otherwise specified. Y. Testing Conduit After installing the conduit, test it in the presence of the Engineer. l. Test conduit using a mandrel 2 inches (50 mm) long and 0.25 inches (6 mm) smaller in diameter than the conduit. 2. Repair conduit to the Engineer's satisfaction if the mandrel can not pass through. If repairs are ineffective, remove and replace the conduit at no additional cost to the Department. 3. Thoroughly clean the conduits. When installing conduit but wiring at a later date: a. Perform the mandrel test. b. Ream the duct opening to remove burrs or foreign matter. c. Thoroughly clean the duct. d. Provide and install a weatherproof cap at each open end. e. All installed conduit not used or containing cable shall have a continuous nylon pull string installed between junction boxes. ... Z. Grounding Ground the cabinets, controller, poles, pull boxes, and conduit to reduce extraneous voltage to protect personnel or equipment. See Section 639 and Section 924 for grounding requirements. l. 2. 3. 4. 5. 6. 7. 8. t:' 9. NOTE: Grounding shall meet the minimum requirements of the NEe. Provide permanent and continuous grounding circuits with a current-canying capacity high enough and an impedance low enough to limit the potential above the ground to a safe level. Perform grounding as follows: Bond the grounding circuits to nonferrous metal driven electrodes. Use electrodes that are at least 0.625 inches (15 mm) in diameter, 8 feet (2.4 m) long, and are driven straight into the ground. Use the shortest possible ground lead that leads directly to a grounding source. Ensure that the maximum resistance between the ground electrode and the cabinet ground buss or other point in the grounding system is no greater than five (5) ohms. Connect the ground electrodes and the ground wire with an exothermic weld. Connect neutral conductors to the cabinet buss-bar and ground them at each terminal point. Ground the cabinet with a No.6 A WG solid copper wire between the buss-bar to the ground electrode. Bends shall not exceed 4 inch (l00 mm) radius bends. Permanently ground the poles by bonding the No.6 A WG solid copper wire to a separate ground rod. Ground pole-mounted accessories to the pole. Underground metallic conduit or down guys are not acceptable ground electrodes. Do not use Snap-On connections. AA. Ground Rod Install copper clad ground rods in or adjacent to the traffic signal pole bases, controller cabinet bases, and pull boxes to shield and protect the grounding system. When ground rods are not protected, bury them at least 2 inches (50 mm) below the finished ground level. See Section 924 for information pertaining to ground rod composition. ..- 19 of 31 Section 64 7 -Traffic Signal Installation .. L Use 0.625 inch (15 mm) diameter ground rods at least 8 feet (2.4 m) long. Use copper clad ground rods. 2. Drive single ground rods vertically until the top of the rod is no more than 2 inches (50 mm) above the fmished ground. 3; Attach a length of No. 6 A WG solid copper wire to the top of the ground rod using an exothermic weld. 4. When controller cabinets are mounted on timber poles, ground them with No.6 A WG solid copper wire attached to the ground rod. Run the wire inside a minimum 0.75 inch (19 mm) rigid conduit attached to the timber pole and to the chassis ground in the controller cabinet. 5. When ground penetration is not obtained: a. Place a horizontal ground rod system of three (3) or more parallel ground rods at least 6 feet (L8 m) center-to-center and no more than 2 inches (50 mm) above the finished ground. b. Ensure that this grounding system produces a resistance of 5 ohms or less. c. Join the ground rods and connect them to the grounding nut of the traffic signal base with No.6 A WG solid copper wire. 6. Install a ground wire on wood poles. a. Use at least No.6 A WG solid copper wire bonded to the grounding electrode and extending upward to a point perpendicular to the uppermost span. b. Place wire staples no greater than 2 feet (0.6 m) apart to secure the ground wire to the pole. c. Connect the span wire to the pole ground using copper split bolt connectors. Use the pole ground for a pole mount cabinet. 7. Ensure that grounding for signal strain poles conforms to the grounding assembly typical erection detail sheet in the Plans. 8. Permanently ground cabinet and cabinet conduits to a multi-terminal main ground buss. a. Use a No.6 A WG solid copper wire bonded between the buss and grounding electrode. b. Connect the power company neutral, conduit ground, and grounds of equipment housed in the cabinet to the buss-bar. c. Do not ground to a permanent water system instead of the driven ground rod. Ensure that grounding devices conform to the requirements of the NEC and NEMA. 9. When testing for resistance ensure the ground is dry. . " Bn. Signal Poles See Section 50 I for signal pole materials certification and Subsection 925.2.27 and Subsection 925.2.28 for traffic signal equipment. Refer to the Plans for pole locations. Where necessary, adjust pole location to avoid utility conflicts. Provide minimum clearance distances between the signal pole and the roadway as specified in the Plans and on the Standard Detail Drawings. L Strain Poles Provide signal strain poles that conform to Section 639. Provide caissons or foundations that conform to the "Construction Detail for Strain Pole and Mast Arm Pole Foundations" in the Plans. Determine the required foundation size based on the manufacturer's specified "bending moment at yield" for the each pole. Provide strain poles with manufacturer-installed holes for pedestrian heads and push buttons. Seal unused holes with water tight plugs and/or rubber gaskets provided by the manufacturer of the pole. Rake the poles during installation to provide a pole that is plumb once the load is applied. 2. Metal Poles Install metal poles as follows: a. Ensure that anchor bolts, reinforcing bars, and ground rods conform to Section 639 and Section 852 and are placed in the excavation. ~ 20 of 31 Section 647- Traffic Signal Installation .. b. Support the anchor bolts with a template to provide the proper bolt circle for the pedestal or pole to be installed. c. Wire the reinforcing bars together or to the anchor bolts. . d. Wire the conduits in the base to the reinforcing bars for support. Ensure that they are accessible above and beyond the foundation. e. Before pouring the foundation concrete, determine that the anchor bolt orientation is correct so that the tensile load is divided between at least two anchor bolts, Pour and vibrate the concrete with the Engineer present. f Ensure that the pole foundations and pedestals with the anchor-type base conform to Section 500 and Section 639. Do not install or locate poles without the Engineer's approval. The Engineer may take a concrete test cylinder as it is being poured. I ) Cure the cylinder and submit it for testing to the Office of Materials and Research. 2) If the concrete foundation fails to meet the requirements of the Specifications and is not accepted, replace the foundation upon notification of failure. g. After installing poles and applying the load of the signal span, inspect them for plumb and for the proper horizontal position of the mast arm, when applicable. Make sure all threads of the nut are threaded onto the anchor bolt. Correct deficiencies by using the leveling nuts on the anchor bolts or be adjusting the mast arm. h. The Engineer will examine the pedestals and poles for damaged paint or galvanizing. Restore the fmish coating where necessary. L After the Engineer approves the pole installation, fmish the area between the pole base and the top of the foundation with grounding material. If the finish or galvanized steel materials is scratched, chipped, or damaged, the material will be rejected. The fmish may be replaced as specified under Section 645, with the Engineer's approval. .. NOTE: Never add holes or openings to the metal pole or mast arm without approval from the Office of Bridge and Structural Design. " J. For poles or arms that need galvanization, thoroughly clean the steel poles and arms and touch up non- galvanized parts with i-d red or original-type primer. Apply the remaining coats according to the System V (Heavy Exposure) Section 535, unless otherwise indicated in the Plans. The entire pole shall be the same color. k. Install a service bracket on one pole at each intersection to attach power service wire as specified in the Plan details. Install a disconnect box on the cabinet pole at each intersection to attach power service where the power service is provided overhead. I. Install poles to which controller cabinets are attached with mounting plates, bolts, nipples, and at least two, 2 inch (50 rum) threaded openings at the top and bottom of the pole. m. Attach the fittings to the poles as specified by the manufacturer in the Plans or as the Engineerdirects. The fittings may include: · Cast aluminum cap · Weatherhead with chase nipples and couplings · Galvanized elbow with bushing installed by cutting the pole and welding in place around the entire circumference · Copper-clad ground rod that is 0.5 inches (12 mm) or 0.625 inches (IS rum) diameter by 8 feet (2.4 m) long attached to the pole by a tap screw or weld fitting of No. 6 A WG semi-hard drawn solid copper wire and a standard copper clad ground clamp n. Use a strandvise to attach spanwire to a clevis device or another strandvise. The Office of Materials and Research will inspect the anchor bolts. If approved, the Office of Materials and Research will display the inspector's hammer stamp mark on the top of the bolt. . 21 of 31 Section 647-Traffic Signal Installation '" 3. Concrete Strain Poles a. Ensure that concrete strain poles meet the requirements of Section 639. Use concrete poles that have threaded couplings to accept weatherheads, pedestrian head mounting hardware, or utility service points shown in the construction details. b. Install concrete strain poles so that the angle of variance between the eye bolt on the pole and the span wire is less than ten degrees (100). c. Verity pole hole orientations for pedestrian heads, pedestrian push button stations, luminaries arms, etc., with the Engineer prior to proceeding with traffic signal installation. 4. Mast Arms Install mast arms that can accommodate traffic signal mounting hardware and that adhere to the manufacturer's recommended procedures and Section 925 and Section 915. Do not add holes. a. Seal the openings in the mast arms to prevent pests from entering. b. Align the mast arm to allow the signal heads to hang plumb at the correct height without using extensions. c. All Mast arms are to be galvanized unless indicated otherwise in the plans. ~ NOTE: The contractor shall submit a "Mast Arm Pole Chart" to the Engineer" and the Office of Bridge and Structural Design for review and approval as described in Subsection 647.1.03.F of this Specification. . Verity pole hole orientations for pedestrian heads, pedestrian push button stations, luminaries arms, etc., with the Engineer prior to proceeding with traffic signal installation. 5. Aluminum Pedestrian Pedestals Poles Install aluminum pedestal poles, which adhere to Section 850 on breakaway aluminum bases that meet the requirements for breakaway construction. See Section 925 for breakaway base requirements. See the Standard Detail Drawings for Pole and Foundation Details. a. Secure at least four anchor bolts in a concrete foundation as shown in the construction detail. b. Contain the wiring inside the pole. Do not allow conduit outside the pole except to wire the pedestrian push button. c. Position the pedestal pole plumb and high enough to clear the pedestrian's head as shown in the Plans- usually 10 feet (3 m) from the ground line. d. Instruct the supplier to furnish a mill certificate that shows the alloy and physical properties of the steel used in fabricating the anchor bolts. The bolts may be subjected to a tensile and shear strength test. 6. Timber Poles Timber poles do not require the use of concrete for filling the cavity around the pole base. Use timber poles that meet the requirements of Section 861. Use Class II for all signal support poles. Use Class IV for aerial loop lead-in or communicationcable if approved by the Engineer. Poles shall be inspected and include A WW stamp. Drill wood poles to receive the eye bolt so that the angle of variance between the eye bolt and span wire at each connection is less than ten degrees (l00). See the Standard Detail Drawings for additional information. Guy timber poles use single or double guy wires as shown in the Plans and as directed by the Engineer. Guy helper cables with separate guy wires when helper signal span cables are indicated in the Plans. ~ NOTE: Never attach down guy wires to eye b~lts. Attach down guy wires to angle guy attachment only and install insulating rods on all down guy installations as detailed on Standard Detail Sheets. 22 of 31 Section 647- Traffic Signal Installation . cc. Pull Boxes Ensure that pull boxes conform to Subsection 680.3.05.B and the Standard Detail Drawings or Plan Detail Sheet. Install pull boxes as required by the Specifications arid Plans. I. Include provisions for drains in pull box excavations as specified. 2. Do not place the aggregate for the drain until the Engineer approves the excavation. 3. Set the precast pull boxes in place, level, and install conduits at required (conduit shall penetrate at least 3 inches (75 mm) into the pull boxes). Adjust the location of the pull box if necessary to avoid obstacles. · Do not locate pull boxes on the curb side of the signal pole in the intersection radius return · Install pull boxes so that the long dimension is parallel to the adjacent roadway · Install the pull box at a location that is level with the surrounding ground or pavement. Do not place a pull box ina ditch or depression. Unless otherwise shown in the Plans, when installed either in a sidewalk or in the ground, the top of the pull box shall be level with the sidewalk or ground surface 4. Obtain the Engineer's approval, and begin backfilling and installing the frame and cover. Ground metal lids or covers. DD. Span Wire and Span Wire Assemblies Use span wire to support signal heads, cable, and other hardware only. Use messenger .cable to support the aerial cable plant. Install span wire and messenger wire where specified in the Plans and in accordance with the Standard Detail Drawings. See Section 92-5 for information on span wire and messenger cable. I. Install signal span wire not to exceed the sag specified in the Standard Detail Drawings. 2. Use helper cables where specified in the plans and on the Standard Detail Drawings. 3. See Subsection 639.3.05.F except, when erecting cable on a timber pole, in which case locate the attachment point a minimum of 18 inches (450 mm) from the top of the pole, to determine the required attachment point. 4. For construction of a box or modified box span, use either bullrings or interlocking strandvises. Be consistent throughout the intersection in use of bull rings or strandvises. 5. Install 8 inch (200 mm) diameter drip loop wrapped two times at the cable entrance to signal heads. Arrange cable so that it enters the structure from the bottom of the drip loop. Use a 24 inch (600 mm) diameter drip loop where cables enter a weatherhead and use 24 inch (600 mm) sag at comers of a span. 6. Lash cables to span wire or use cable ties spaced at 6 inch (150 mm) increments. 7. Ground all span wire and down guy assemblies as shown on Standard Detail Sheets.. Bond all span wire together and bond to ground at every pole. . EE. Traffic Signal Heads Place traffic signal heads according to the signal design and Plan detail drawings. Deviation from the Plans must be according to the MUTeD, current edition and at the Engineer's approvaL l. Install traffic signal heads at least 17 feet (5.1 m), but no greater than 19 feet (5.7 m) over the roadway. 2. Adjust signal heads on the same approach to have the same vertical clearance. a. Measure the clearance from the pavement to the lowest part of the assembly, including brackets and back plates. b. Mount traffic signals on the side of wood or metallic poles with a clearance of at least 12 feet (3.6 m) above the sidewalk or pavement grade of the center of the highway, whichever grade is higher. 3. Connect the signal cable to the wire in each signal head to provide the correct signal indication when the cables are connected to the controller cabinet back panels. Do not splice cables. 4. Install optically programmable (OP) or Electronically Steerable Beam LED (ESBLED) signal heads as shown in the Plans and standard detail sheet and as directed by the manufacturer. 5. Mount OP or ESBLED heads securely or tether them to limit movement. 6. Mask the OP lamp for directing visibility under the Engineer's supervision. r 23 of 31 ~ " ..- Section 647-Traffic Si9nallnstallation .. 7. Program the ESBLED signal heads for visibility coverage. Provide for reprogramming the ESBLED visibility coverage for 90 days after final acceptance. 8. Tether signal heads that have tunnel visors longer than 12 inches (300 mm), at the discretion of the Engineer. 9. Attach signal heads to mast arms using rigid mounting brackets. See Section 925 for equipment information. Adjust signal heads on mast arms so that all red indications on the same mast arm are at the same elevation. 10. Install lane control heads for reversible lane systems and ramp metering heads as shown in the Plans and the Standard Detail Drawings. Center each signal over the lane or lanes under signal control. Leave a vertical clearance for blank-out signs as shown on the Standard Detail Drawings. Use a spirit level to ensure that the bottom edge of each sign is horizontal. FF. Pedestrian Signal Heads Install pedestrian signal heads on wood, concrete, steel strain poles, wood or steel auxiliary poles, or metal pedestal poles. Do not mix pole mount methods at the same intersection installation. Install the pedestrian signall heads as shown on the Standard Detail Drawings and the intersection plan sheets and drawings. Leave a vertical clearance liom the bottom of the head to the ground level ofleastlO feet (3 m) unless specified by the Engineer. 1. Pedestal Mounts Make pedestal mounts with a lower supporting assembly consisting of: a. A 4 inch (100 mm) slip-fitter bracket b. Hollow aluminum arms with a minimum inside cross-sectional area equal to a 1.5 inch (38 mm) pipe Use serrated locking devices that firmly hold the signal heads in the required alignment. 2. Pole Mounts (Side of Pole) For Metal poles, use side hinge "clamshell" mounting hardware or hardware as described in Wood Pole or Metal Pole alternate. . a. Side Hinge "Clamshell" See the Standard Detail Drawings. b. Wood Pole or Metal Pole alternate: Make pole mounts with the upper and lower assembly consisting of: · A post arm with a minimum cross-sectional area equal to a 1.5 inch (38 mm) pipe · A post hub plate that matches the outside pole contour · Secure the hubs to metal or concrete poles using 0.75 inch (19 mm) wide stainless steel bands. Secure the hubs to wood poles using lag bolts Space the junctions so that each pedestrian signal head can be directed toward approaching traffic as needed. Use serrated locking devices that hold the pedestrian signal heads in alignment. GG. Blank-out Signs Install blank-out signs as follows: 1. Securely fasten the signs to a stationary structure or to a messenger strand support system. 2. Center each sign over the lane or lanes under sign control, where applicable. 3. Leave a vertical clearance for blank-out signs as shown in the Plans or in Subsection 647.3.05.EE. "Traffic Signal Heads." Use a spirit level to ensure that the bottom edge of each sign is horizontal. 4. Use terminal strips to connect each sign electrically to the external control box or cabinet. 24 of 31 Section 647-Traffic SignallnstaUation ~ HH. Battery Backup System (BBS) Install Battery Backup System (BBS) if indicated on the plans. Only install Battery Backup Systems at locations using LED Signal Heads. Install in accordance with the option (either Internal or External) as indicated on the plans. If the internal option is specified ensure that the battery backup system can be mounted in the 332A cabinet without interfering with access to other equipment. Mount the equipment in accordance with section 925 and ensure all wiring is done in accordance with cabinet assembly specifications. Ensure the external cabinet option cabinet assembly is installed in accordance with the cabinet assembly specification with regards to location and erection. .. If the external option is specified ensure that the external cabinet supplied meets the section 925 specifications and is mounted to the 332A cabinet as specified. The external cabinet option allows for 2 separate configurations. Ensure that the correct configuration is installed in accordance with the plans. Ensure the BBS functions as required by the specifications. Ensure the "ON BATTERY" relay provides an input into the controller Alarm 2. II. Wireless Communications Install, and integrate the spread spectrum wireless radio system with all necessary hardware in accordance with the Special Provisions. Prior to installing any equipment perform a radio path Site Survey test. Ensure the test evaluates the Signal Strength (dBm), Fade Margin (dB), Signal-to-Noise Ratio, Data Integrity (poll test), and a complete frequency spectrum scan. Ensure the radio path site survey test is performed using the supplied brand of radio equipment to be deployed. Duringthe initial radio path signal strength test it may be determined that a repeater station may be necessary to complete the intended link. Provide the test results to the Engineer for review and approval. Submit copies of the test results and colored copies of the frequency spectrum scan along with an electronic copy of this information. Final locations of antennas and any necessary repeater stations are to be approved by the Engineer. Install the antenna in such a manner that avoids conflicts with other utilities (separation distances in accordance with the guidelines of the National Electrical Safety Code) and as specified in the antenna manufacturer's recommendations. Secure the antenna mounting hardware to the pole and route the coaxial cable such that no strain is placed on the coaxial connectors. On wood pole installations, bond the antenna mounting hardware to the pole ground using # 6 A WG bare copper wire using split bolt or compression type fitting. Do not exceed the I inch (25.4 mm) bend radius of the coaxial cable as it transverses from the cabinet to the antenna assembly. Connect the lightning arrestor to the coaxial cable in the equipment cabinet. Properly ground and secure the arrestor in the cabinet. Permanently label all cables entering the cabinet. Ensure that the power supply for the radio system is NOT connected to the GFCI receptacle circuitry located in the cabinet. Place a copy of all manufacturer equipment specifications and instruction and maintenance manuals in the equipment cabinet. At certain locations it may be necessary to integrate the radio system with an existing communications system. Follow the details shown in plans. 647.3.06 Quality Acceptance '\ A. Testing Loop Detector Installation Test each loop after installing the conductors in the slots cut in the pavement and before sealing. · Perform a test where the loop wire is spliced to the shielded lead-in wire and where the shielded lead-in wire enters the controller cabinet · If there are no splice points, such as in direct entry to the controller cabinet, only perform the tests at the controller · Record the test results on the Loop Installation Data Sheet in Table 647-7, as shown in this section. Make copies of the data sheet as needed . 25 of 31 Section 647- Traffic Signal Installation '" · Include the data sheets in the records, and place a copy in the controller cabinet Conduct the following five (5) tests to evaluate each loop installation for acceptance before sealing the loop in the pavement: 1. Induced AC Voltage Test Read 0.05 V AC or less on a digital voltmeter or no deflection on the pointer of an analog meter. 2. Inductance Inductance (I) is measured in microhenries (mH), and the total inductance is equal to the inductance ofloop plus inductance ofthe loop lead-in. Acceptable inductance is within 10 percent (10%) of the calculated value for a single loop with the design criteria listed in Table 647-5 and Table 647-6: .. 6 ft x 6 ft (3 turns) [1.8 m x 1.8 m (3 turns)] 6 ft x 18 ft (2 turns) [1.8 m x 5.4 m (2 turns)] 6 ft x 30 ft (2 turns) [1.8 m x 9 m (2 turns)] 6 ft x 40 ft (2 turns) [1.8 m x 12 m(2 turns)] 6 ft x 50 ft (2 turns) [1.8 m x 15 m (2 turns)] 6 ft x 70 ft (2 turns) [1.8 m x 21 m (2 turns)] Table 647-5 Standard (Bi-Pole) Loops I = 76 mH per 100 feet of loop lead-in cable I = 76 mH per 30 m of loop lead-in cable I = 80 mH per 100 feet of loop lead-in cable I = 80 mH per 30 m of loop lead-in cable I = 126 mH per 100 feet of loop lead-in cable I = 126 mH per 30 m of loop lead-in cable I = 165 mH per 100 feet of loop lead-in cable I = 165 mH per 30 m of loop lead-in cable I = 205 mH per 100 feet of loop lead-in cable I = 205 mH per 30 m of loop lead-in cable 1= 285 mH per 100 feet of loop lead-in cable I = 285 mH per 30 m of loop lead-in cable Table 647-6 Quadrupole (QP) Loops .. 4. 6 ft x 30 ft (2, 4, 2 turns) [1.8 m x 9 m (2, 4, 2, turns)] 6 ft x 40 ft (2, 4, 2 turns) {1.8 m x 12 m (2, 4, 2 turns)] 6 ft x 50 ft (2, 4, 4 turns) {1.8 m x 15 m (2, 4, 4, turns)] 6 ft x 60 ft (2, 4, 2 turns) {1.8 m x 18 m (2, 4, 2, turns)] 6 ft x 70 ft (2, 4, 2 turns) [1.8 m x 21 m (2, 4, 2, turns)] 3. Leakage Resistance to Ground The resistance to ground shall be 1 Mohm or more. Loop Resistance The resistance reading on an ohmmeter is approximately within ten percent (10%) of the calculated value: · Acceptable Resistance @ (dc @68 OF (20 OC]):ohmS(fl) I = 269 mH + 23 mH per 100 feet of loop lead-in cable I = 269 mH + 23 mH per 30 m of loop lead-in cable I = 349 mH + 23 mH per 100 feet of loop lead-in cable I = 349 mH + 23 mH per 30 m of loop lead-in cable I = 429 mH + 23 mH per 100 feet of loop lead-in cable I = 429 mH + 23 mH per 30 m of loop lead-in cable I = 509 mH + 23 mH per 100 feet of loop lead-in cable I = 509 mH + 23 mH per 30 m of loop lead-in cable I = 589 mH + 23 mH per 100 feet of loop lead-in cable I = 589 mH + 23 mH per 30 m of loop lead-in cable .. 26 of 31 Section 647-TrafficSignallnstallation ... · No. 14 A WG wire: R = 13.32Jllmile (or) R = 2.523 x 1O-3Jllft. Approximately 2.52 ohms per 1,000 feet of No. 14 A WG wire)[R = 8.3Jl/km (or) R=8.3 x 1O-3Jllm] · No. 12 A WG wire: R = 5.2Jllmile (or) R = 9.85 x IO-4Jl/ft. Approximately 0.98 ohms per 1,000 feet of No. 12 A WG wire [R = 3.24Jl/km (or) R = 3.24 x 1O-3Jl/IJl] 5. Loop Q Q at 50 kHz is greater than 5. Report to the Engineer an out-of-range reading on any ofthe above tests. If a test is found unacceptable, remove the loop, install new wire, and repeat the test procedure. Include in the test results: · Type and model number of the equipment used (must be ohmmeter having a high resistance scale of R x 10 KW or greater) · The last calibration date of the equipment and the scale used Check the loop using an impedance tester to determine the natural operating frequency and impedance. Ensure that the completed units detect all motor vehicles. If the loop detection system does not meet the above test requirements, payment will not be made for work on the signal installation until corrections are completed. .. Table 647-7 Loop Installation Data Sheet Project Number: Date: Contractor: Weather: Temperature: Pavement Condition - Wet ( ) or Dry ( ) City or County: Intersection Name or Number: Phase: Route Number(s) or Name (s): Installation or Plan Sheet Number: Size and Type of Loop: Distance from Stop Bar: Distance Lead-in Cable: Function: Lane Location: No. of Turns: Downstream/Upstream: Down ( ) Up () Distance E.O.P/Curb to Lead-in: . .. Loop Wire Color/Insulation Type/Gauge: Loop Lead-In Wire Color/Insulation Type/Gauge: Splice Point: Conduit Length from Curb/E.O.P. to Splice Point: Conduit Length from Splice Point to Cabinet: Sealant Type and Part Number: "" 27 of 31 Section 647-Traffic Signa! Installation Sealant Manufacturer and Lot No.: Interconnect Wire Type and Length: .. 1. Induced Voltage _ 2, Inductance microhenries 3. Leakage Resistance to Ground _ megohoms 4. Loop Resistance _ ohms 5. Loop Q (Quality) -'-- Q .. Inspector's Name, and Title B. Field Tests In addition to performing tests during installation and before turning on the equipment, perform the following tests on traffic signal circuits in the presence of the Engineer: · Test each circuit for continuity · Test each circuit for grounds If a test fails, repair the circuit immediately. New signals shall operate in the flash mode for three (3) days prior to beginning stop-and-go operation unless otherwise directed by the Engineer. ~ C. Operational Tests After the equipment is installed and the system checkout is complete: I. The Engineer will notify the District Traffic Operations Engineer in writing to request final inspection. 2. The District Signal Technicians will conduct an in-depth inspection and will give the Engineer a written punch list of items that the Contractor needs to correct within ten weekdays ofthe notification. 3. When defects are resolved, the District Traffic Operations Engineer will begin the contractors operational test period to demonstrate that every part of the system functions as specified. a. The operational test for the traffic signal system shall be at least thirty (30) days of continuous, satisfactory operation. b. If a component or system fails or shows unsatisfactory performance, the condition must be corrected and the test repeated until thirty (30) days of continuous satisfactory operation is obtained. c. The District Traffic Operations Engineer will send the Engineer and Construction Office a letter showing the start, termination, suspension, or successful completion of the operational test period. 4. The District Traffic Operations Engineer may recommend payment only after the successful completion of the test period. 5. The Contractor shall obtain written acceptance of the signal installation from the District Traffic Operations Engineer before Final Acceptance. Costs incurred during operational tests, including power consumption, shall be at the Contractor's expense and included in the price bid for Contract Items. ... 28 of 31 Section 647-Traffic Signal Installation 647.3.07 Contractor Warranty and Maintenance .... A. Traffic Signal Equipment Maintenance "- Perform an inspection with the Engineer to determine the operational status of existing field equipment and fmalize materials and equipment is to be removed due to the project. Prepare written directions identifying what equipment was operational and non-operational and responsibility for repair. Functional responsibility for new traffic signal equipment installed will become the responsibility of the contractor until successful completion of a 30 day Acceptance Test Period. Contractor responsibility for operation and maintenance for newly installed signal matetial at the intersection begins from the first day of construction activity at the intersection, including modification of existing equipment due to construction activity, until Final Acceptance of the traffic signal. ~ Measure and document existing vertical signal head clearance during the inspection. Maintain existing vertical clearances until Final Acceptance. Failure to measure and document vertical clearances as part of the inspection will require that all signals be maintained with a vertical clearance of 17 feet (5.1 m) until Final Acceptance. Maintain newly installed signals continuously as detailed in following sections, until Final Acceptance. Provide a telephone number where the Worksite Traffic Control Supervisor (WTCS) responsible representative of the contractor can be reached twenty four (24) hours a day seven (7) days a week in the event of an emergency. If a signal is not functioning properly: I. Non-Emergency Commence work on this signal within one (I) day of the written notice from the Engineer requesting per calendar day charged against monies due or that may become due until the maintenance work is started. Liquidated damages are in addition to those specified in Subsection 108.08. "Failure or Delay in Completing Work on Time." for delay or failure in completing the Work within the specified time and to the satisfaction of the Engineer. The contractor shall be responsible for all materials and equipment necessary to correct signal malfunction or repaIr. 2. Emergency If the District Traffic Operations Engineer determines that the signal malfunction or failure is an operational hazard, the contractor is to take corrective action within three (3) hours of notification. Failure to respond within three (3) hours will result in a non-refundable deduction of money of $1 ,000.00 with an additional charge of$500.00 per hour after the first three (3) hours until a work crew arrives on site and begins corrective action. In addition, the cost of labor and material will be charged if the Department takes corrective action using its own forces or local municipality forces. Total charges will not exceed $5,000.00 (per emergency call) in addition to the material cost and labor incurred to make repairs by the Department or local municipality forces. The Department will not be held responsible or liable for any alleged damage to the signal or as a result of the signal malfunction due to problems that may occur after Department or local municipality forces make emergency repairs. The contractor shall be responsible for all materials and equipment necessary to correct signal malfunction or repair. In the event of failure to replace or repair to original condition any equipment or material within seven (7) calendar days from the Engineer's notice, the Engineer may have the work done by others and charge the cost of money due from the contract work. Final Acceptance will not be given until payment for such work is received. '" 29 of 31 Section 647- Traffic Signal Installation ).. B. Warranties Provide manufacturer's warranties or guarantees on electrical, electronic, or mechanical equipment furnished, except state-supplied equipment. Ensure that warranties and/or guarantees are consistent with those provided as customary trade and industry standard practices; or as otherwise specified in the Plans, Standard Specifications, or Special Provisions. Upon Final Acceptance, transfer the manufacturer and Contractor warranties or guarantees to the Engineer. Ensure that warranties are continuous and state that they are subject to transfer. Acceptance or approval of the Work does not waiver warranties or guarantees where required by the Specifications. Final Acceptance will not be granted until all warranties and guarantees are received. .. C. Guaranties Repair and/or replace all equipment and material supplied under these Contract Documents which has been determined by the Engineer to not meet Specifications. The Engineer reserves the sole right to determine suitability or unsuitability ofthe supplied equipment and material. The contractor shall bear the total cost of delivery and transportation relatedto the repair and replacement of equipment and material throughout the duration of the Contract unless otherwise approved by the Engineer. Transfer to the Engineer any warranties and guaranties remaining on all items after Final Acceptance. Perform transfer at 12:01 AM of the day following Final Acceptance. 647.4 Measurement Traffic signal items complete, in place, and accepted of the kind, size, and type specified are measured as follows: A. Traffic Signal Installation Signal installation will be paid for by lump sum, including furnishing labor, materials, tools, equipment, and incidentals required to complete the work unless otherwise specified in this Subsection. B. Communications Wire, Fiber Optic Cable The number of feet (meters) of communications cable, wire or fiber optic cable, is the actual number of/inear feet (meters) of the size installed and accepted. Communications cable shall be paid for under Section 935. C. Strain Poles, Traffic Signs Highway signs are measured and paid for under Section 636. Strain poles are measured and paid for under Section 639. D. Type 4, 4S and 5, 5S Pull Boxes The number of pull boxes will be the actual number of pull boxes installed and accepted. 647.4.02 Limits General Provisions 101 through 150. 647.5 Payment " ..' The lump price bid for Traffic Signal Installation covers all Items of work in this Specification including furnishing labor, materials, tools, equipment, and incidentals required to complete the work. Costs for installation, operation, maintenance, and removal of the traffic signal equipment are included under this Item. Include payment for removal; disposal of existing pavement, shoulder surface, base and sub-grade; and restoration to original condition in the Contract Price for th.e items to which they pertain. They will not be paid for separately. 30 of 31 Section 647- Traffic Signal Installation ,". Furnishing, installing, and removing sheeting, bracing, and supports will not be paid for separately, but is included in the Contract Prices for other items. No additional payment will be made for testing and storing State-supplied or contractor-furnished traffic signal equipment. No payment will be made for individual items unless a pay item is included ~ the plans for the specific item. Type 4, 4S, 5 and 5S pull boxes will be paid for per each. Payment will be made under: . Item No. 647-Traffic signal installation no- Item No. 647- Pull Box PB4 Item No. 647- Pull Box PB4S Item No. 647-Pull Box PB5 Item No. 647-Pull Box PB5S Per lump sum Per each Per each Per each Per each Payment for various elements of traffic signals will be as shown on the plans. A. Partial Payment The Contractor may initiate a partial payment process for the lump sum traffic signal Items by submitting a written request to the Engineer. If the Engineer approves this request, payment will be made as follows: Underground (loops, pull boxes, and conduits) Overhead (span, heads, poles, push buttons) Cabinet, contents, and base Successful completion of operational test 20% 30% 30% 20% B. Additional Items Payment Items related to Section 647 are described in the following sections: Strain Poles Section 639 Section 680 Section 681 Section 682 Section 700 Section 639 and Subsection 861.2.02 Section 912 Section 913 Section 925 ~ Highway Lighting Lighting Standards and Luminaries Electrical Wire, Cable, and Conduit* Grassing Timber Poles Sign Blanks Refledorization Materials Traffic Signal Equipment * Payment for conduit installation shall be as described in Section 682 unless conduit installation is performed as part of a traffic signal installation, in which case measurement and payment is a part of the complete traffic signal installation. Payment is Lump Sum, unless listed as a separate pay item. 647.5.02 Adjustments oV General Provisions 101 through 150. Office of Traffic Safety and Design 31 of 31 ~ .. iIV Date: August 8, 2002 First Use Date 2001 Specifications: November 1. 2002 :) DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA SPECIAL PROVISION Section 8OO-Aggregates for Asphaltic Concrete Delete Subsection 802.2.01.A.5. fk' ~: Date August 8. 2002 First Use Date 2001 Specifications: November 1.2002 GEORGIA DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA SPECIAL PROVISION Section 819-Fiber,Stabilizing Additives Delete Section 819: ~ . Page 1 First Use: February 03, 2006 Revised February 24, 2006 '"' DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA ,. Special Provision Section 828-Hot Mix Asphaltic Concrete Mixtures Delete Section 828 and substitute the following: 828.1 General Description This specification includes the requirements for hot mix asphaltic concrete mixtures, including: · Open-graded surface mixtures (OGFC and PEM) · Stone Matrix Asphalt mixtures (SMA) · Superpave mixtures · Fine-graded (4.75 rum) mixtures 828.1.01 Definitions The Nominal Maximum Sieve Size is one standard sieve size larger than the first sieve to retain more than ten percent of the aggregate, per AASHTO PP28. Mixture types in this section are identified according to Nominal Maximum Sieve Size. 828.1.02 Related References A. Standard Specifications Section 400-Hot Mix Asphaltic Concrete Construction Section 800-Coarse Aggregate Section 802-Aggregates for Asphaltic Concrete Section 819-Fiber Stabilizing Additives Section 820-Asphalt Cement Section 83 I-Admixtures Section 882-Lime Section 883-Mineral Filler B. Referenced Documents \' PP 2 PP28 TP 8-94 T 112 T209 T305 T312 T-245 PS-129 ., ~ SOP-36 SOP-2 SP GDT 56 GDT 66 GDT 114 GDT U5 GDT 123 QPL 1 QPL2 QPL7 QPL 26 QPL 41 QPL 77 QPL 81 828.2 Materials .. A. Requirements Use approved hot mi,x asphalt concrete mixtures that meet the following requiJ:ements: 1. Produce each asphalt mixture according to a Job Mix Formula and Asphalt Mix Design approved by the Department. For submittal aud approval of Job Mix Formulas, see Subsection 400.1. 2. Ensure that individual acceptance test results meet the Mixture Control Tolerances specified in the appropriate table below, Subsections 828.2.01 through 828.2.04. 3. Ensure thatthe Engineer approves aU materials used to prepare and place the mixtures before incorporating them into the Work. Use only the ingredients lis~ed in the approved Asphalt Mix Design and Job Mix Formula. For virgin aggregates use sources which meet the requirements of Section 802 and are listed in QPL 1 or QPL 2; for mixes in which local sand is permitted, use the approved sand source identified in the mix design. For mixtures containing Reclaimed Asphalt Pavement (RAP), use only RAP from the approved stockpile identified in the mix design. Use asphalt cement meeting the requirements of Section 820, from a source listed in QPL 7. 4. Obtain approved Superpave mix designs and 4.75 mmmix designs from a mix design laboratory certified by theDepartment. Obtain approved mix designs for types PEM, OGFC, and SMA mixtures from the Department's Office of Materials and Research, which produces and furnishes these.mix designs. 5. Ensure that Superpave and 4.75 mm mix designs are designed in accordance with SOP-2SP ("Control of ~ Superpave Bituminous Mixture Designs") and are approved by the Department as provided therein. Ensure that these mixes are designed by a laboratory and technician certified in accordance with SOP-36, ("Certification of Laboratories and Personnel for Design of Sl!perpave Asphalt Mixtures"). 6. Use only mixtures composed of the aggregate groups and blends indicated in the Proposal and Plans by their pay item designations, defmed as follows: " Pay Item Designation Group I or II Group II only Blend I Allowable Aggregate Groups Group I, Group II, or Blend I Group II only Either 100% Group II material or a blend of Group I and Group II. Do not use Group I material for more than 60%, by weight, of the total aggregate nor more than 50%, by weight, of the coarse aggregate fraction. JIY 7. For patching or leveling use Group I, Group II, or Blend L Mix types for patching and leveling are specified in Subsection 400.3.03.B. ~ ... 8. Include lime (hydrated lime) from an approved source and meeting the requirements of Subsection 882.2.03 in all paving courses except as otherwise provided in the Contract. For a list of approved sources oflime, see OPL 41. a. Add lime to each mixture at the rate prescribed in the approved mix design. b. Mix designs using only virgin aggregate shall include lime at a minimum rate of 1.00 % of the total dry aggregate weight. Mix designs using RAP shall include lime at a minimum rate equal to 1.00 % of the virgin aggregate fraction plus 0.50 % of the aggregate in the RAP fraction. c. If necessary to meet requirements for mixture properties, and pursuant to an approved mix design, add more lime or add lime plus an approved Heat-Stable Anti-Stripping Additive that meets the requirements of Subsection 831.2.04. However, the Departmentwill not make additional payment for these materials. For a list of sources of Heat-Stable Anti-Stripping Additives, see OPL 26. d. Where specifically allowed in the contract on LARP, airport, and parking lot projects, an approved Heat-Stable Anti-Stripping Additive that meets the requirements of Subsection 831.2.04 may be substituted for hydrated lime. In this case the mix gradation shall be adjusted as necessary to replace the lime with an equivalent volume offmes passing the 0;075 mm sieve. Add Heat-Stable Anti- stripping Additive at a minimum rate of 0.5 percent of the asphalt cement portion. 9. Use performance grade PG67-22 asphalt cement in all mix designs and mixtures except as follows: a. For mixtures containing 25% or greater RAP, the Engineer will determine the performance grade to be used. b. On PR, LARP, airport, and parking lot projects, PG 64-22 may be substituted for PG 67-22, with approval of the Office of Materials and Research, on roads having current ADT less than 2,000. c. Use only grade PG 76-22 in the following mixes: SMA, 12.5 mm PEM, 12.5 mm and 9.5 mm OGFC, 12.5 mm Superpave, excluding shoulder construction, on projects with ADT greater than 25,000; and in all mixtures for which polymer-modified asphalt is specified in the pay item 10. Use oflocal sand is restricted as follows: a. Do not place mixtures containing local sand on the traveled way of the mainline or ramps of the Interstate System Mixtures with local sand may be used for shoulder construction on these facilities. b. Local sand shall not constitute more than 20 % of the total aggregate weight of any mix design or production mix. c. Subject to the above limits, 19 mm, 12.5 mm, and 9.5 mm Superpave mix designs and 4.75 mm mix designs containing local sand may be used on projects with a currentADT not exceeding 2,000. d. 25 mm Superpave mix designs containing not more than 20 % local sand may be used on all facilities except the main line and ramps of the Interstate System e. Obtain local sand for use in asphalt mixtures from a source approved by the Department. f. Approval of local sand sources: The Department will sample, test, and approve sources of local sand. Local sand shall not contain more than 7.0 % clay by weight and shall be free of foreign substances, roots, twigs, and other organic matter. It shall be free of clay lumps, as determined by AASHTO T 112, and shall have a sand equivalent value exceeding 25%, as determined by GDT63. 't B. Design requirements and limits - aU mix types 1. Design procedures: For all Superpave and 4.75 mm mixes, designers shall adhere to the Superpave System for Volumetric Design (AASHTO T 312 and AASHTO PP 2), as adapted in SOP-2SP. The Department will design open-graded mixes and Stone Matrix Asphalt (SMA) mixes according to GDT 114 and GDT 123, respectively. In all cases, the procedure for measuring Maximum Specific Gravity (Gmm) shall be AASHTOT 209. In addition to gradation and volumetric analysis, mix designs shall include the following performance tests, as applicable. . 9.5 mm Superpave 9.5mmSuperpave mixes should specify "Type I" or "Type II" mix design in the plans or contract documents. If "Mix Design Level A" is specified, ensure the Asphaltic Concrete meets the requirements of a "Type I" mix. If a "Mix Design Level B, C or D" is specified, ensure the Asphaltic Concrete meets the requirements of a "Type II" mix. . . Other Superpave mixes ~ p ~ .. ! No "Type" is required for other Supetpave Asphaltic Concrete mixes (12.5 rom, 19 rom, or 25 mm). Any "Mix Design Levels A, B, C or D" specified in the plans or contract documents do not affect the current asphalt mix designs. 2. Permeability test: Supetpave and Stone Matrix mix designs shall include testing according to ASTM PS- 129. Specimen air voids for this test shall be 6.0 :i:1.0 %. The average permeability of three specimens may not exceed 3.60 ft Per day (125 xl 0-5 cm per sec). 3. Moisture susceptibility test: Mix designs of all types except open-graded surface mixes shall include testing for moisture susceptibility according to GDT 66. Specimen air voids for this test shall be 7.0 :i:1.0%. The minimum tensile splitting ratio is 0.80, except that a tensile splitting ratio of no less than 0.70 maybe acceptable if all individual strength values exceed 100 psi (690 kPa). Average splitting strength of the three conditioned and three controlled samples shall be not less than 60 psi (415 kPa) for eithergroup. Retention of coating as determined by GDT 56 shall be not less than 95%. 4. Rutting susceptibility test. Mix designs of all types except Open-graded Surface Mixes (OGFC and PEM), and mixtures designed exclusively for trench widening shall include testing according to GDT 115. Design limits for this test are as follows: Specimen air voids for this test shall be 5.0:i: 1.0% for all mix types. Testing temperature shall be 640C (1470F) for all mix types except 25 mm Supetpave mixes, which shall be tested at 490C (1200F). Maximum deformation shall be 5.0mm for all mixes except 4.75 mm mix and 9.5 mm Type I Supetpave mix. Maximum deformation for these mix types shall be 8.0 mm at 640C. 5. Fatigue testing: The Department may verify Supetpave designs by fatigue testing according to AASHTO TP 8-94 or other procedure approved by the Department. 828.2.01 Open-Graded Surface Mixtures A. Requirements Use approved mixtures that meet the following mixture control tolerances and design criteria: Mixture Design Gradation Limits, % Passing Sieve Size Control 9.5 mm OGFC 12.5 mm OGFC 12.5 mm PEM Tolerance, % 3/4 in (19 mm) sieve :to.O 100 100 1/2 in (12.5 mm) sieve I6.1 100* 85-100 80-100 3/8 in (9.5 mm) si~ve :t5.6 85-100 55-75 35-60 NO.4 (4.75 mm) sieve IS.7 20-40 15-25 10-25 NO.8 (2.36 mm) sieve :t4.6 5-10 5-10 5-10 No. 200 (75 ~m) sieve 12.0 2-4 2-4 1-4 Range for % AC :tOA 6.0-7.25 5.75-7.25 5.5-7.0 Class of stone (Section 800) "A" only "Aft only . "A" only Drain-down (MSHTO T305), % <0.3 <0.3 <0.3 * Mixture control tolerance is not applicable to this sieve for this mix. 1. In 12.5 mm and 9.5 mm OGFC and 12.5 mm PEM mixes, use only PG 76-22 asphalt cement (specified in Section 820). 2. All OGFC and PEM mixes shall include a stabilizing fiber of the type (cellulose or mineral) specified in the mix design and meeting the requirements of Section 819. The dosage rate shall be as specified in the mix design and shall be sufficient to prevent drain-down exceeding the above tolerance. ... Mixture Design Gradation limits, Percent Passing Sieve Size Control 9.5mm 9.5mm 12.5 mm 19mm 25mm Tolerance Superpave Superpave Superpave Superpave Superpave Type I Type II Note 1 1-1/2 in (37.5 100 mm) sieve 1- in (25.0 :l:8.0 100* 100* 90-100 mm) sieve 3/4 in (19.0 :l:8.0** 100* 100* 98-100**** 90-100 55-89** mm) sieve 1/2 in (12.5 :t6.0*** 98-100**** 98-100**** 90-100 60-89 50-70 mm) sieve 3/8 in (9.5 :l:5.6 90-100 90-100 70-89 55-75 mm) sieve No.4 (4.75 . :l:5.6 65-85 55-75 mm) sieve No.8 (2.36 :l:4.6 48-55 42-47 38-46 32-36 30-36 mm) sieve No. 200 (75 :l:2.0 5.0-7.0 5.0-7.0 4.5-7.0 4.0-6.0 3.5-6.0 11m) sieve .. * Mixture control tolerance is not applicable to this sieve for this mix. ** Mixture control tolerance shall be :!:: 10.0% for this sieve for 25 rum Superpave. ***Mixture control tolerance shall be:!:: 8.0% for this sieve for 19 rum Superpave. ****Mixture control tqlefllnce shall be:!:: 2.0% for this sieve for 12.5 rum and 95 rum mixes. Note 1: Use PG 76-22 in 12.5 rum Superpave, excluding shoulder construction, on all projects with ADT greater than 25,000. 3. The Mixture Control Tolerance for asphalt cement shall be :!:: 0.4% for all mix types. 4. Volumetric limits are as follows: Design Parameter Mix Type limits % of Maximum Specific Gravity (Gmm) @ design gyrations, AU 96% Ndesl % Gmm at the initial number of gyrations, Nj All 91.5% maximum % voids filled with asphalt (VFA) at Ndes 9.5 mm Type I Min. 72; Max. 80 all other types Min 72; Max. 76 Fines to effective asphalt binder ratio (F/Pbe) 9.5 mm Type I 0.6 to 1.4 all other types 0.8 to 1.6 Minimum % Voids in Mineral Aggregate (VMA)* 25mm 13.0 19mm 14.0 12.5 mm 15.0 9.5 Type I 16.0 9.5 Type II 16.0 It ... * VMA shall be calculated using the effective specific gravity of the aggregate (Gse). See SOP-2SP. 828,2.04 Fine-Graded Mixtures A. Requirements Design gyrations (Ndes) for fine-graded mixes shall be 50 gyrations. Ensure that fine-graded mixtures meet the following mixture control tolerances and design limits: " ASPHALTIC CONCRETE - 4.75 mm Mix Sieve Size Mixture Control Tolerance Design Gradation Limits, % passing 1/2 in (12.5 mm) sieve' :to.0 100' .... 3/8 in (9.5 mm) sieve :t5.6 90-100 NO.4 (4.75 mm) sieve :t5.7 75-95 No.8 (2.36 mm) sieve . :t4.6 60-65 . No. 50 (300 11m) sieve :t3;8 20-50 . No. 200 (75 Jim) sieve :t2.0 4-12 Range for % AC :tOA 6.00 -7.50 . Design optimum air voids (%) 4.0 - 7.0 . % Aggregate voids filled with AC 60-80 * Mixture control tolerance is not applicable to this sieve for this mix. ~ B. Fabrication See Section 400. C. Acceptance See Subsection 106.03 and Section 400. Ensure that individual test results meet the Mixture Control Tolerances listed in Subsections 828.2.01, 828.2.02,828.2.03, or 828.04, whichever applies. D. Materials Warranty See General Provisions 101 through 150. , .. " If' )( It' Delete Section 883. Date: August 8. 2002 FIrst Use Date 2001 Specificatio~ November 1.2002 DEPARTMENT OF TRANSPORTATION STATE OF GEORGIA SPECIAL PROVISION Section 883-Mineral Filler First Use Date 2001 Specification: May 1,2005 Georgia Department of Transportation ... SPECIAL PROVISION Project Number: ,. P.I. Number: County Section 925- Traffic Signal Equipment Delete Section 925 and substitute the following: 925.1 General Description This-section provides specifications for a variety of traffic signal equipment. 925.1.01 Related References A. Georgia Specifications Section 500"-'-concrete Structures Section 639-Strain Poles for Overhead Sign and Signal Assemblies Section 647- Traffic Signal Installation Section 682-Electrical Wire. Cable and Conduit Section 833-Joint Fillers and Sealers Section 861-Piling and Round Timber Section 870--'-Paints (Field Painting) Section 915-Mast Arm Assemblies Section 922-Electrical Wire and Cable Section 923-Electrical Conduit Section 935-Fiber Optic System Section 938-Detection Section 939"-'-communications and Electronic Equipment B. Referenced Documents NEMA TS-IITE Traffic Signal Lamps f IMSA #20-1-1984 IMSA #20-4-1984 IMSA #20-6-1984 ~ IMSA #50-2-1984 IMSA #51-5-1984 UL #493 Carol #C6047 or Belden #9773 Traffic Signal Control Equipment Specifications, current edition and addenda, State of California Business, Transportation & Housing Agency 1 of 72 Section 925--Traffic Signal Equipment CALTRANS Qualified Products List, QPL, "Polyurethane Sealant for Inductive Loops" and QPL-XX, "Model 2070 traffic Controllers", Transportation Electrical Equipment Specifications (TEES). QPL 75 '", 925.2 Materials A. Requirements Ensure that the traffic signal equipment and materials meet the Plans and Specifications. ". All equipment furnished shall be new and meet the requirements of the following: · Underwriter's Laboratory Incorporated (UL) · Electronic Industries Association (EIA) · National Electric Code (NEe) · American Society of Testing and Materials (ASTM) · American National Standards Institute (ANSI) · International Municipal Signal Association (IMSA) · National Electrical Manufacturers Association (NEMA) · Applicable Standards, Specifications, and Regulations of the: Georgia Department of Transportation Traffic Signal Electrical Facility & NaviGAtor Support (TSEF) 935 E. Confederate Avenue, Building 5 Atlanta, GA 30316 B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty · Provide all manufacturers' warranties and guarantees for all signal equipment items listed in this document as well as any signal equipment listed in the plans, except for state supplied equipment. · Ensure that warranties and guarantees are consistent with those provided as customary trade practices; or as otherwise specified in the plans, Standard Specifications, Supplemental Specifications or Special Provisions. · Ensure that manufacturer's and supplier's warranties and guarantees are transferable to the agency or user that is responsible for traffic signal maintenance, are continuous throughout their duration and state that they are subject to such transfer. · Ensure equipment provided Wlder this specification shall be warranted by the manufacturer to be free from defects in materials and workmanship for a period of two years from date of receipt or one year from date of acceptance of installation. · Ensure the manufacturer will repair any faulty equipment during this period at no charge to the Department for parts, labor or shipping to and from the factory. y" 925.2.01 Type 2070 Controller Assemblies A. Requirements For 2070 controller cabinet assemblies, use 2070 controller units that meet the requirements of the following or are previously approved by TSEF: Ir . Traffic Electrical Equipment Specifications (TEES) published by the State of California Business, Transportation, and Housing Agency; Department of Transportation, current edition and current addenda · CALTRANS Qualified Products List (QPL) · Ensure the unit supplied is compatible with current GDOT licensed firmware. 2 of 72 tc y lo' Section 925- Traffic Signal Equipment " The following specifications augment the CAL TRANS specific;ations and take precedence over conflicting CAL TRANS Specifications. 1: Input/output (I/O) and Configuration: The 2070 Controller shall be supplied in one of the following configurations, as specified in the Plans (all modules are specified in TEES, but these configurations supersede the defmed configurations in TEES): 2070L: Provide Chassis, 2070-lB Single-Board CPU, 2070-2A Field I/O Module, 2070-3B Front Panel (8x40 display), 2070-4B 3.5-amp Power Supply, and a 2070-7 A Module. This unit shall provide the default input and output configuration as shown in Tables 925 -6, 925-8 and 925-9 for ITS cabinets. 2070LlTS: Provide Chassis, 2070-1B Single-Board CPU, 2070-2B Field I/O Module, 2070-3B Front Panel (8x40 display), 2070-4B 3.5-amp Power Supply, and a 2070-7 A Module. This unit shall provide the default input and output configuration as shown in Tables 925 -6, 925-8 and 925-9 for ITS cabinets. 2070 LB: Provide Chassis, 2070-lB Single -Board CPU, 2070-2A Field I/O Module, 2070-3C Front Panel, 2070- 4B 3.5-amp Power Supply, and a 2070--7 A Module. This unit shall provide the default input and output configuration as shown in Tables 925 -6, 925-8 and 925-9 for ITS cabinets. 2070 LCNl: Provide Chassis, 2070-lB Single-Board CPU, 2070-2B Field I/O Module, 2070-3B Front Panel (8x40 display), 2070-4NB 3.5-amp Power Supply, 2070-8 NEMA Interface Module, and a 2070-7A Module. 2070 LCN2: Provide Chassis, 2070-lB Single-Board CPU, 2070-2N Field I/O Module, 2070-3B Front Panel (8x40 display), 2070-4NB 3.5-amp Power Supply, 2. Power Supply Modules: Either the 2070-4A, 2070-4B, 2070-4NA or 2070-4NB module shall be provided as required in the configuration requirements in the preceding Item. In addition to all requirements of the TEES, the power supplies shall be clearly marked as a "2070-4A", "2070-4B","2070-4NA", or "2070-4NB". . The Vendor may supply a 2070-4A or 4NA power supply module in lieu of a 2070-4B or 4NB, as long as it is so marked and adds no additional cost to GDOT. 3. Documentation: Include with each controller, manuals that document the programming, operation, and maintenance of the unit. Include schematic drawings and pin assignment charts in the manuals for maintenance. Documentation shall include all components, including communications modules. 4. Testing: Provide for complete testing of unit before it is shipped. If unit is shipped with applications software installed. It must be tested with the application (e.g. Traffic Signal Control). If a random sample of greater than 10 percent of the units tested are rejected then the total shipment shall be rejected and vendor will be responsible for all costs to test and repair all units provided. B. Fabrication General Provisions 101 through 150. C. Acceptance (See Subsection 925.2.01 for compliance with CALTRANS QPL also see 4. Testing in Section A above.). D. Materials Warranty: (See Subsection 925.2.D for Materials Warranties). 925.2.02 Type 2070 Controller Subassemblies A. Requirements For 2070 controller subassemblies, use 2070 controller subassembly units that meet the requirements of the following or are previously approved by TSEF: · Traffic Electrical Equipment Specifications (TEES) published by the State of California Business, Transportation, and Housing Agency; Department of Transportation, current edition and current addenda · CALTRANS Qualified Products List (QPL) The following specifications augment the CALTRANS specifications and take precedence over conflictingCALTRANS Specifications. 1. 2070 IB Module: 3 of 72 Section 925- Traffic Signal Equipment The 2070 1B module may be supplied as a separate item to be used in all versions of the 2070 controller. The 2070 1B module shall be supplied complete with the operating software. Ensure it contains the required files to be compatible with the current GDOT applications software. " 2. 2070 2A Field I/O Module The 2070 2A Field I/O module may be supplied as a separate item. The 2070 2A Field I/O module shall consist of the Field Controller Unit; Parallel Input/Output Ports; other Module Circuit Functions (includes muzzle jumper); Serial Communication Circuitry; Module Connectors CIS, CIIS and Cl2S mounted on the module front plate; VDC Power Supply (+ 12VDC to + 5VDC) and required software. Ensure it contains any configuration jumpers to be compatible with current GDOT Applications software. Ensure the 2070 2Afield I/O Module functions with a Model 2070 Lor 2070LB Controller Assembly and is compatible with current GDOT applications software. . 3. 2070 2B Field I/O Module: The 2070 2B Field I/O module may be supplied as a separate item and consist of the Serial Communication Circuitry, DC powerSupply, and Module Connector 12S mounted on the module front plate only. Ensure it contains a.ny configuration jumpers to be compatible with current GDOT Applications software. Ensure the 2070 2B field I/O Module functions with a Model 2070 LC or 2070LCNI Controller Assembly and is compatible with current GDOT applications software. 4. 2070 2N Field I/O Module: The 2070 2N Field I/O module maybe supplied as a separate item and provides a NEMA TS2-lcompatible SDLC interface via Serial Port 3. AC power to the 2070 Unit and Fault Monitor Logic Output via 2070 Serial Port 5 and Output Frame Byte 9 Bit 6 to the NEMA TS2 Cabinet Monitor Unit (CMU). . Ensure it contains any configuration jumpers to be compatible with current GDOT Applications software. Ensure the 2070 2N field I/O Module functions with a Model 2070 LCN2 Controller Assembly and is compatible with current GDOT applications software. 5. 2070 3B Front Panel Display Module: The 2070 3B Display Module may be supplied as a separate item and provides a Front Panel Assembly controller, two keyboards, AUX switch alarm bell and an 8 line by 40 character display. This assembly shall also include a panel with latch assembly and two TSD #1 hinge attaching devices, assembly PCB, external serial port connectors, CPU active LED indicator, contrast adjustment knob, and Front Panel Harness. Ensure it contains any configuration jumpers to be compatible with current GDOT Applications software. Ensure the 2070 3B Front Panel Assembly Module functions with Models 2070 L, 2070 LC, 2070 LCNI and 2070 LCN2 Controller Assemblies and is compatible with current GDOT applications software. Ensure the hardware hinge attaching devices mate with existing 2070 assemblies. Ensure the Front Panel Harness is connected to the front panel via a removable connector. Ensure the front panel connector supports the aux switch. 1" 6. 2070 3C Front Panel Display Module: The 2070 3C Display Module may be supplied as a separate item and provides a System Serial Port 6Lines, Isolated and vectored to Connector C60S. This assembly shall also include a panel with latch assembly and two TSD #1 hinge attaching devices, , assembly PCB, external serial port connectors, CPU active LED indicator, and Front Panel Harness. Ensure it contains any configuration jumpers to be compatible with current GDOT Applications software. Ensure the 2070 3B Front Panel Assembly Module functions with Model 2070 LB Controller Assembly and is compatible with current GDOT applications software. Ensure the hardware hinge attaching devices mate with existing 2070 assemblies. Ensure the Front Panel Harness is connected to the front panel via a removable connector. Ensure the front panel connector supports the aux switch. t< 7. 2070 4B Power Supply Module: The 2070 4B Power Supply Module may be supplied as a separate item and is an independent, self contained module. Ensure that it is vented and cooled by convection only. Provide module that slides into power supply compartment from the back of the chassis and is attached to the Backplane mounting surface by its four TSD #3 Devices. Ensure the module supplies at least 3.5 amperes of +5VDC. Ensure the 2070 4B Power Supply Module 4 of 72 Section 925- Traffic Signal Equipment ... is compatible with Models 2070 L, 2070 LB, and 2070 LC Controller Assemblies and is compatible with current GDOT applications software. Ensure the connection harness PS 2 on existing units can be mated with the 4B module supplied A 2070 4A Power Supply Module may be provided in place of a 4B module as long as it is labeled as such and there is no additional cost to GDOT. Ensure the module supplied is appropriately marked as a 4B or 4A module. 8. 20704NB Power Supply Module: The 2070 4NB Power Supply Module may be supplied as a separate item and is an independent self contained .. module. Ensure that it is vented and cooled by convection only. Provide module that slides into power supply compartment from the back of the chassis and is attached to the Backplane mounting surface by its four TSD #3 Devices. Ensure the module supplies at least 3.5 amperes of +5VDC. Ensure the 2070 4B Power Supply Module is compatible with Models 2070 LCNI, and 2070 LCN2 Controller Assemblies and is compatible with current GDOT applications software. Ensure the connection harness PS 2 on existing units can be mated with the 4B module supplied. Ensure the 4NB power supply module supports the NEMA TSl and TS2 Standards. A 2070 4A Power Supply Module may be provided in place of a 4B module as long as it is labeled as such and there is no additional cost to GDOT. Ensure the module supplied is appropriately marked as a 4NA or 4NB module. 9. 20706B Communications Module: The 2070 6B Communications Module is supplied as a separate item. The 6B communications module is a dual Ci3}J:ic!illodeill 5eriat illudute. Eusurc the ii:i.oaule 1;upports bom Seriai and modem FSK communications on both of two separate ports. Ensure the Modem data bud rate supports 0 to 9600. Ensure the module is configured to support FSK communications on the C2S connection. Ensure it contains any configuration jumpers to be compatible with current GDOT Applications software. 10. 2070 7 A Communications Module: The 2070 7 A Communications Module may be supplied as a separate item. The 7 A communications module is a dual async serial communications module. Ensure the module supports serial communications on both ports. Ensure it contains any configuration jumpers to be compatible with current GDOT Applications software. II. 2070 8 Field I/O Module: The 2070 8 Field I/O Module may be supplied as a separate item. The 8 Field I/O Module consists of the module chassis, module power supply, Field Control Unit Controller, parallel input/output ports, serial communications circuits and module connectors. Ensure the EXl connector is provided with appropriate mating connections to interface with either6B or 7 A communications modules. Ensure the 2070 8 Field I/O module is provided with the appropriate mating connector to mate with the Cl2S connector on the 2070 2B Field I/O module. Ensure the 2070 8 Field I/O module functions as part of a Model 2070 LCNl controller. 12. 2070 D Panel: The 2070 D panel is supplied as a separate item. The 2070 D panel supports the inputs and outputs of the "D" connector.provided on a 2070-8 module which is also part of a Model 2070 LCNl. Ensure the "D" Connector panel supports all 61 pins with a connecting MS "D" connector and terminal blocks. Ensure the 2070 D Panel provides adequate cable length to allow attachment in an existing NEMA Cabinet. Ensure that the terminal blocks allow for two connections. .,r B. Fabrication General Provisions 101 through 150. C. Acceptance ~ (See Subsection 925.2.01 for compliance with CALTRANS QPL). 5 of 72 Section 925-Traffic Signal Equipment D. Materials Warranty: (See Subsection 925.2.D for Materials Warranties). .. " 925.2.03 Type 170E Cabinet Assemblies A. Requirements Ensure that the cabinet assembly meets the requirements of the CAL TRANS Specifications as described in this document In addition to the CAL TRANS Specifications, ensure that the cabinet assembly conforms to the requirements listed below, which take precedence over conflicting CAL TRANS Specifications. 1. Cabinet configuration: Supply cabinets in accordance with these specifications. Equip the cabinets with auxiliary equipment as follows: a. Model 332A Cabinet: Lower input field termination panel 1 - Model 242 DC Isolator in Slot 14 of Upper Input File 4 - Flash Transfer Relays 2 - Model 204 Flashers 1- Auxiliary Cabinet Shelf to support Communication Devices 1- 4 Position Power Strip b. Model 336 Cabinet: I-Model 242 DC Isolator in Slot 14 ofInput File 4- Flash Transfer Relays 2-Model 204 Flashers 1- Auxiliary Cabinet Shelf to support Communication Devices 1- 4 Position Power Strip l-"M" Base Adapter installed (Base Mount Cabinets Only) I-Aluminum Cover Plate for Cabinet Bottom (Pole Mount Cabinets Only) c. Model 337 Cabinet 3-Flash Transfer Relays I-Model 204 Flasher Note: Include above components in cabinet at time of delivery. Other auxiliary cabinet components such as controllers, monitors, load switches, etc. will be ordered as separate items. 2. Finish Use cabinets that have a bare aluminum fmish (see Subsection 925.2.06.A.I for controller-cabinet minimum fabrication specifications). 3. Locks EquIp the main cabinet door with locks that accept No.2 Corbin keys. Provide two sets of keys with each cabinet. One set of keys is defmed as one - No.2 key and one - police panel key. ~ 4. Power Equip the cabinet assemblies with a power distribution assembly to generate AC and DC power for the electronic components, except the DC power for the controller units. Provide the Model 332 and 336 cabinets with a DC isolator for stop timelflash sense, located in slot 14 of the input file. .. 5. Mounting Equip the cabinets for pole or base mounting, as specified in the Plans. a. Base Mount Supply Model 336 cabinets, when specified as base mount, with a "M" base-mounting adapter installed. 6 of 72 .. . ;cr- ~ Section 925- Traffic Signal Equipment b. Pole Mount Supply Model 336 or 337 cabinets, when specified as pole mount, with two exterior pole mounting brackets that allow for mounting on steel, concrete, and timber poles. Ensure that the bracket mounting holes are properly reinforced with metal plates of adequate size and strength, welded longitudinally across the inside depth of the cabinet Ensure that the exterior-mounting bracket is shipped installed on the cabinet housing. Additionally, provide an aluminum plate, which covers the bottom cabinet opening. 6. Unused Phase Monitoring Provide odd-phase reds with ballast resistor dummy loads. Do not wire the cabinet to monitor pedestrian yellow indications. Neatly lace and bundle the wiring from the signal monitor for pedestrian yellow monitoring on the back panel. 7. Red Monitoring Provide a connector and terminal assembly designated as P20 (Magnum PIN 722120 or equivalent) for monitoring the absence of red as an integral part of the output file. Terminate the connector and ensure compatible with the cable and C connector of a Type 2010 conflict monitor unit capable of monitoring the absence of red. Provide the pin assignments of the P20 connector and terminal assemble with the cabinet plans. Ensure that the P20 connector is physically alike to the cable and connector of a Type 2010 conflict monitor unit to prevent the absence of red cable connector from being inserted into the P20 connector 180 degrees out ofalignment Submit details for programming of the unused red channels for approval. 8. Cabinet Light Include in each cabinet one fluorescent lighting fixture mounted inside the top front portion of the cabinet The fixture includes a cool white lamp, covered, and operated by a normal power factor, UL listed ballast Install a door-actuated switch to turn on the cabinet light when either door is opened. 9. Cabinet Interlock Do not install the interlock circuit, as detailed in the CAL TRANS Specifications. 10. Cabinet Drawer Equip each Model 332A, and 336 cabinet with an aluminum storage compartment mounted in the rack assembly with the approximate following dimensions: 16 inches (400 mm) wide, 14 inches (350 mm) long, and 1.75 inches (44 mm) deep. Mount this compartment directly under the Type 2070 controller. Provide a drawer with telescoping drawer guides to allow full extension from the rack assembly. When extended, the storage compartment opens to provide storage space for cabinet documentation and other miscellaneous items. Ensure that the storage compartment be of adequate construction to support a weight of25 pounds (12 kg) when extended. Provide a top for the storage compartment that has a non-slip plastic laminate attached, which covers a minimum of 90% of the surface area of the top. II. Auxiliary Equipment Shelf Provide a "shelf' in each cabinet that provides a location to mount Fiber modem, dialup modem and/or Field hardened switch. Provide shelf in location that allows easy access to ACpower outlets and communications links (telephone, interconnect). Locate shelf so as not block access to other equipment or modules including Battery Backup System. 12. Power Strip Equip each cabinet with a power strip (minimum of 4 outlets) to support AC power for external communications devices in cabinet Ensure that power strip may be used by block power supplies such that the block power supply does not block other outlets. Attach power strip to a permanent location that is easily accessible to devices in the rear of the cabinet. Do not plug power strip into GFI outlet. 7 of 72 Section 925- Traffic Signal Equipment .. 13. Surge Protection Equip each cabinet with devices to protect the control equipment from surges and over voltages. Design the surge protector panels to allow for adequate space for a wire connection and surge protector replacement without the removal ofterminal blocks or panels. Provide surge protectors for the input sections as detailed below and as shown in the Input Terminal and Surge Arrestor Detail. Supply surge protectors that meet the following specifications. a. AC Service Input Include a surge protection unit for each cabinet on the AC service input that meets or exceeds the following requirements: · Provide a hybrid type power line surge protection device on a separate service panel that is external to the PDA.. . Install the protector between the applied line voltage and earth ground. Use a surge protector capable of reducing the effect of lightning transient voltages applied to the AC line that conforms to the following: Peak surge current for an 8 x 20 Jls waveform: Clamp voltage @ 20,000A: Maximum continuous operating current: Series Inductance: Response time: Spike suppression for +/- 700 V spike: 20,OOOA for 20 occurrences 280V max @ 120V I 60 Hz lOA AC Line/AC Neutral- 200 micro henries Voltage never exceeds 280V during surge +/- 40 V deviation from sine wave at all phases angles between 0 and 180 degrees. · Provide a protector that is modular and uses a 12 pin Beau connector with the following terminals: Main Line (AC line first stage terminal) Main Neutral (AC neutral input terminal) Equipment Line In (AC line second stage input terminal, lOA) Equipment Line Out (AC line second stage output terminal, lOA) Equipment neutral out (neutral terminal to protected equipment) GND (Earth connection) · Supply a protector that is epoxy encapsulated in a flame-retardant material. · Configure the Equipment Line Out to provide power to the Type 2070 and to the 24 V power supply. b. AC+ Interconnect Cable Inputs Use a surge protection device to protect each AC interconnect line as it enters the cabinet with a surge protection device that meets or exceeds the following requirements: · 3-electrode gas tube type of surge arrestor · Striking voltage of 300-500 V DC with a minimum holder over voltage of 155V DC · A three terminal device, one of which is connected to ground, the other tWo are connected across each input respectively · The units must meet the following minimum requirements: Impulse breakdown: Impulse breakdown balance: Energy application: Less than 100V in less than l.l JlS at 10 kV/Jls 0.01 microsecond (or less) difference at 10 kV/Jls impulse Withstands 20A AC for one (1) second applied ten (10) times at three (3) minute intervals on either section IO,OOOA (8 x 20 Jls impulse) 6 pF, line to ground ~ Current rating: Capacitance: . c. Inductive Loop Detector Inputs Protect each inductive loop detector channel input by an external surge protection device that meets or exceeds the following requirements: · A three-terminal device, two (2) of which are connected across the signal inputs of the detector with the third connected to the chassis ground to protect against common mode damage. · Instantly clamps differential mode surges (induced voltage across the loop detector input terminals) via a semiconductor array. The array appears as a low capacitance to the detector. 8 of 72 Section 925-Traffic Signal Equipment .. · Clamps common mode surges (induced voltage between the loop leads and ground) via solid state clamping devices. · Withstand 25-1 OOA surge current occurrences of a lOx 700 f.1s waveform. · Have the following clamp characteristics: Maximum break over voltage: 170 V Maximum on-stage clamping voltage: 3V Response Time: <5 ns Off-stage leakage current: <10 f.1A Capacitance: less than 220 pf · Ensure that the unit also meets the following minimum requirements: Peak surge current: 6 times Differential mode: 400 A (8x 20 ms) Common mode: 1,000 A (8 x 20 ms) Estimated occurrences: 500 @ 200 A Response time: 40 ns Input capacitance: 35 pF typical Temperature: _400 F to +1850 F (-400 C to 850 C) Mounting: No. lO-32 x 3/8-inch (No.5 x 10 mm) bolt Clamp voltage @400 A diff. Mode: @1,000 A comm. Mode: 30 V max. 30 V max. fI" d. Signal Load Switches (Switchpacks) Provide the output of the switchpack in the output file with metal oxide varistors (MOV) tied from the AC positive field terminal to the chassis ground to protect switchpacks from surges on the AC output lines. Ensure that these MOVs meet or exceed these requirements: · Steady state sinusoidal voltage (RMS) rating at 50 to 60 Hz of at least 150 Vat 77 OF (25 oc) · Steady state applied DC voltage rating of at least 200 V at 77 OF (25 oc) · Transient energy rating is of at least 80 J for a single impulse of 10/1,000 J..i.s current waveform at 77 OF (25 oc) · Peak current rating of 6,500 A for a single impulse of 8/20 f.1s waveform with the ratyd continuous voltage applied · Varistor voltage of at least 212 V at 1.0mA of DC current applied for the duration of20 f.1s to 5s · Clamping voltage of at least 395 V with an applied 8/20 f.1s impulse of 100 A · Typical capacitance at a frequency of 0.1 to 1.0 MHz of 1600 pF · Two-terminal device, one of which is connected to the AC output of the signal load switch on the output file terminals (backside of the field terminals) with the other connected to AC neutral e. Communication Inputs Protect low voltage communications input as it enters the cabinet with a solid-state surge protection unit that meets or exceeds these requirements: ~ · Dual pair (4-wire) module with a printed circuit board connector, double sided and gold plated for reliability · Ability to mate with and be installed in a lO-circuit Buchanan connector PNPCBffi or equivalent · Usable as two independent signal pairs · The data circuits pass through the protection in a serial fashion · C2 connector of the 2070 controller that terminates on the line side of the unit · Communication field wires for this local side that terminate on the line side of the unit · Ground terminals connected to power ground · Ensure that the unit meets the following minimum requirements: .. Peak surge current: 10 leA (8 x 20 f.1s wave shape) 500A (10 x 700 f.1S wave shape) 50 typical <Ins 8V line to line Occurrences @ peak: Response time: Voltage Clamp: 9 of 72 Section 925- Traffic Signal Equipment ,. Series Resistance: Temperature Primary protector: tube 5IcA, (8 x 20/!s wave shape), per side Secondary protector: Silicon avalance, 1.5 kW minimum 24 n total -40 of (-40 oc) to +185 of (85 OF) 3 element gas . f. Low Voltage DC Inputs Provide an external surge protection device for each low voltage DC input channel which meets the same requirements as the communication inputs with the followlng exception of the Voltage clamp, which shall be 30 V line-to-line. 14. Type 2010 Signal Monitors: a. Introduction This Specification sets forth the minimum requirements for a rack-mountable, sixteen channel, solid-state 2010 Signal Monitor fora Type 170E Traffic Cabinet Assembly. Ensure that as a minimum, the Signal Monitor complies with all Specifications outlined in Chapter 3 Section 6 of the California TEES, August 2002 Where differences occur, this Specification governs. Ensure that the manufacturer of the unit is listed on the current California Department of Transportation (Caltrans) Qualified Products List (QPL) for signal monitors. Provide a Signal Monitor that is capable of monitoring sixteen channels consisting of a Green input, a Yellow input, and a Red input for each channel. Ensure that the unit also includes the enhanced monitoring functions described in Subsection 925.2.03.A.14.b, diagnostic display functions described in Subsection 925.2.03.A.14.c, event logging functions described in Subsection 925.2.03.A.14.d, communications functions described in Subsection 925.2.03.A.14.e, and hardware functions described in Subsection 925.2.03.A.14.f.. b. Monitor Functions Except for Conflict faults, compute all fault timing for each channel individually. 1) Conflict Monitoring Ensure that the Signal Monitor is able to detect the presence of conflicting green or yellow signal voltages on the AC field terminals between two or more non-compatible channels. A Conflict fault (CONFLICT) shall be a latching fault. 2) Conflict Recognition Time Ensure the Signal Monitor shall trigger when voltages on any conflicting channels are present for more than 500 illS. Ensure that the Signal Monitor does not trigger when voltages on any conflicting channels are present for less than 200 illS. COIiflicting signals sensed for more than 200 illS and less than 500 illS mayor may not trigger the unit. 3) 24VDC Monitoring VDC Ensure that the Signal Monitor is able to detect that the cabinet +24 Vdc supply has fallen below 18 Vdc. A 24 VDC failure (VDC FAIL) shall be a latching fault. 4) 24VDC Recognition Time Ensure that the Signal Monitor shall trigger when the voltage on the +24V input is below 18 Vdc for more than 500 illS. Ensure that the Signal Monitor does not trigger when the voltage on the + 24V input is below 18 V dc for less than 200 illS. A voltage level of +22 V dc will be required to prevent the unit from triggering. 5) Controller Watchdog Monitoring Ensure that the Signal Monitor triggers when the Watchdog input does not toggle within the programmed time period (WDT ERROR). Ensure that the unit remains latched in the fault state until reset by the Reset button, an External Reset input command, or AC Line voltage restoring from a AC Line Brownout event (see 2.4). Ensure that a reset resulting from an AC Line Brownout event does not clear the WDT ERROR LED. 6) Controller Watchdog Latch Option Ensure a programming option sets the Watchdog monitoring function to a latching mode and that only a reset from the Reset button or External Reset input can clear a Watchdog fault. An AC Line brownout condition will not reset the fault. "# ;. 10 of 72 Section 925- Traffic Signal Equipment ... 7) Controller Watchdog Recognition Time Ensure a programming option sets the maximum Watchdog recognition time to: 1000 + or - 100 illS; or 1500 + or - 100 illS. 8) Controller Watchdog Enable Switch Provide an internal switch to disable the Watchdog monitoring function. Mount the switch on the PCB and be clearly label"WD ENABLE - ONu.OFF". Ensure that placement of the switch in the OFF position causes monitoring of the Watchdog to be inhibited. 9) WDT ERROR LED Control Ensure that the WDT ERROR LED illuminates when the unit has been triggered by a Watchdog fault. Ensure that it can only be cleared by a reset command from the front panel Reset switch or External Reset input. If the Watchdog monitoring function is inhibited due to the Watchdog Enable switch, the WDT ERROR LED shall flash at a 0.5 Hz rate. II' .. 10) AC Line Monitoring a) AC Line Brownout Recognition Ensure that the Signal Monitor is able to detect that the AC Line has fallen below 98 + or - 2 Vac for greater than 400 + or - 50 illS. This shall force the output Relay to the de-energized "fault" state, enable the Stop-Time output, and cause the AC POWER LED to flash at a 2 Hz rate. Ensure that the unit maintains this state until the AC Line voltage rises above 103 + or - 2 Vac for greater than 40050 illS. Provide a jumper option which will change the AC Brownout dropout level to 92 + or - 2 Vac and the restore level to 98 + or - 2 Vac. b) AC Line Power-up and Brownout Delay Time When the AC Line is greater than 103 + or - 2 volts after power-up or Brownout restore, ensure that the Signal Monitor holds the Output Relay in the de-energized "fault" state and enable the Stop-Time output, for a period of not less than 6.0 + or - 0.5 seconds and not greater than 10.0 + or - 0.5 seconds. Ensure thatthis flash interval is terminated after at least 6.0 + or - 0.5 seconds if the Signal Monitor has detected at least five transitions of the Watchdog input. If the Signal Monitor does not detect five transitions of the Watchdog input before 10.0 + or - 0.5 seconds, ensure that the Signal Monitor goes to the fault state. During this interval, ensure that the AC POWER LED flashes at a 4 Hz rate. c) Red Fail Monitoring Ensure that the Signal Monitor is able to detect the absence of an active voltage on the green and yellow and red field signal inputs of a channel. Red Fail fault (RED FAIL) shall be a latching fault. Ensure that the Red Fail monitoring function is enabled for all channels except when the Red Enable input is not active, or pin #EE is active, or Special Function #1 input is active, or Special Function #2 input is active. d) Red Fail Recognition Time Ensure the Signal Monitor triggers when an active voltage on one of the three inputs of a channel are absent for more than 1500 illS. Ensure that the Signal Monitor does not trigger when an active voltage on one of the three inputs of a channel are absent for less than 1200 illS. Channels without proper voltages sensed for more than 1200 illS and less than 1500 illS mayor may not trigger the unit. Provide an option switch (RF 2010) which will change the fault recognition time to between 700 illS and 1000 IllS. e) Red Interface Cable Fault Ensure a programming option is provided such that operating without the Red Interface cable installed shall cause the Signal Monitor to enter the fault mode causing the Output relay contacts to close and enabling the Stop-Time output to the controller. To indicate this fault mode, ensure that the Red Fail indicator is illuminated with all fault channel indicators Off. Ensure that any Red Fail preemption control to the monitor uses the Special Function inputs #1 or #2. t) Dual Indication Monitoring Ensure that the Signal Monitor is able to detect the presence of active voltage on the green and yellow, green and red, or yellow and red field signal inputs of a channel. GYR Dual Indication fault (DUAL IND) shall be a latching fault. Ensure this function is enabled on a per channel basis using dip switches . 11 of 72 Section 925- Traffic Signal Equipment ... mounted on the PCB labeled "CHI" through "CHI6". Ensure that the GYR Dual Indication monitoring function is enabled for all selected channels except when the Red Enable input is not active or pin #EE is active. g) GY Dual Indication Monitoring Ensure that the Signal Monitor is able to detect the presence of active voltage on the green and yellow field signal inputs of a channel. GY Dual Indication fault (DUAL IND) shall be a latching fault. Enable this function with a dip switch on the PCB labeled "GY ENABLE". When the switch is in the ON position, monitor all channels for simultaneous active green and yellow inputs on a channel. When selected by the GY ENABLE switch, ensure that the GY Dual Indication monitoring function is disabled when pin #EE is active. h) Dual Indication Recognition Time Ensure that the Signal Monitor triggers when multiple inputs are active on a channel for more than 500 illS. Ensure that the Signal Monitor does not trigger when multiple inputs are active on a channel for less than 250 illS. Channels with multiple voltages active for more than 250 illS and less than 500 illS mayor may not trigger the unit. i) Sequence (Short or Absent Yellow) Monitoring Ensure that the Signal Monitor is able to detect that a channel has not provided an adequate Yellow Clearance interval during a green to yellow to red sequence. A Sequence failure (SEQUENCE) shall be a latching fault. Ensure that this function is enabled on a per channel basis using dip switches mounted on the PCB labeled "CHI" through "CHI6". Ensure that the Sequence monitoring function is enabled for all selected channels except when the Red Enable input is not active or pin #EE is active. j) Sequence Recognition Time The minimum Yellow Clearance interval maybe modified by switches mounted on the PCB labeled "YEL TIME I", "VEL TIME 2", and ''YEL TIME 3". Ensure that the Yellow Clearance interval is 2.7 seconds plus 0.2 seconds times the binary sum of the three switches. The minimum Yellow Clearance intervaJ shall therefore have a range of 2. 7 seconds to 4.1 seconds, 0.1 seconds. k) Recurrent Pulse Detection (RPDetect) Ensure that the Signal Monitor detects Conflict, Red Fail, and Dual Indication faults that result from intermittent or flickering field signal inputs. These recurring pulses shall result in a latching fault with the RP DETECT indicator illuminated along with the resulting Conflict, Red Fail, or Dual Indication indicator. Provide an option switch to disable the RP detect function. 1) Configuration Change Monitoring On power-up, reset, and periodically during operation, ensure that the Signal Monitor compares the current configuration settings with the previously stored value and if the settings have changed, the Signal Monitor automatically logs the new setting. Ensure that these settings include the pennissive diode matrix, all switches, alljumpers, and the Watchdog Enable switch. Provide a programming option such that any change in the configuration parameters will cause the Signal Monitor to enter the fault mode causing the Output relay contacts to close and enabling the Stop-Time output to the controller. To indicate this fault mode ensure that the PCA indicator will flash at a 4 Hz rate. Depressing the Reset button for 5 full seconds is required to clear this fault and log the new configuration parameters. If the programming option is not selected, ensure that the unit does not set the fault mode but will still log the configuration change. m) Program Card Ajar Ensure that when the Programming Card is removed or not seated properly, the Signal Monitor forces the Output Relay to the de-energized "fault" state, enable the Stop-Time output, and illuminate the PCA LED. A reset command from the front panel Reset switch or External Reset input is required once the Program Card is in place. n) Exit Flash When the Signal Monitor exits the flash state (Output relay de-energized) as a result of a Reset command or AC Line brownout restore, ensure that the Stop Time output goes to the inactive state 250 + OR - 50 illS before the Output relay transfers to the energized state. This transition will provide an early indication to the Controller Unit that the cabinet will transfer from flash to signal operation. .. .:" .\ 12 of 72 Section 925- Traffic Signal Equipment ~ c. Display Functions Ensure that it is possible to view the active channels for each individual color (GYR) during operation and when latched in a fault state. When the Signal Monitor is latched in a fault state ensure that it is also be possible to view the active channels for ea<:;h individual color and fault status for each channel for the current fault and the two previous faults. 1) Previous Fault GYR Display When the Signal Monitor has been triggered by a fault the channel status display will alternate between the channels which were involved in the fault (fault status) for 2 seconds, and the field signals active at the time of the fault for 6 seconds. The channels involved in the fault will flash their respective Green, Yellow, and Red indicators simultaneously at a 4 Hz rate for the 2 second interval. The two previous faults may also be displayed individually. This status is not reset by an AC Line power interruption. To enter this display mode remove the Program Card. The sequence is as follows: . Reset Event PCA LED Fault Status LEOs Channel Status LEOs -- #1 Single flash Current Fault Status (newest) Current Field status #1 #2 Double flash Event #2 Fault Status Event #2 Field status #2 #3 Triple flash Event #3 Fault Status (oldest) Event #3 Field status (repea~s back to top) .- d. Event Logging Functions Ensure that the Signal Monitor is capable of storing in non-volatile memory a minimum of 100 events. Mark each event with the time and date of the event. These events consist of fault events, AC Line events, reset events, and configuration change events. Provide a graphical means of displaying the signal states of all field inputs for 30 seconds prior to a fault trigger event. Provide the capability to assign a four-digit identification number to the unit shall be provided. Upload the event logs to a PC using the serial port of the Signal Monitor and software provided by the manufacturer. Ensure each event log report contains the following information: · Monitor 10#: a four digit (0000-9999) 10 number assigned to the monitor. · Time and Date: time and date of occurrence. · Event Number: identifies the record number in the log. Event #1 is the most recent event. I) Monitor Status Report (CS) Ensure the Current Status report contains the following information: a) Fault Type: the fault type description. b) Field Status: the current GYR field status and field RMS voltages if the monitor is not in the fault state, or the latched field status and field RMS voltages and fault channel status at the time of the fault. c) Cabinet Temperature: the current temperature if the monitor is not in the fault state, or the latched temperature at the time of the fault. d) AC Line Voltage: the current AC Line voltage if the monitor is not in the fault state, or the AC Line voltage at the time of the fault e) Control Input Status: the current state and RMS voltages of the Red Enable input, EE input, and Special Function #1 and #2 inputs if the monitor is not in the fault state, or the status latched at the time of the fault. 2) Previous Fault Log (PF) Ensure the Previous Fault log contains the following information: a) Fault Type: the fault type description. b) Field Status: the latched field status with RMS voltages, and fault cha.nnel status at the time of the fault. c) Cabinet Temperature: the latched temperature at the time of the fault. d) AC Line Voltage: the AC Line voltage at the time of the fault. e) Control Input Status: the latched state of the Red Enable input, EE input, and Special Function #1 and #2 inputs at the time of the fault. , 13 of 72 . ~ . ~ Section 925-Traffic Signal Equipment 3) AC Line Event Log (Ae) The AC Line log shall contain the following information: a) Event Tvpe: describes the type of AC Line event that occurred. Power-up--AC on, monitor performed a cold start Interrupt-AC Line < Brownout level Restore-AC restored from brown-out or interruption (AC Oft), no cold start b) AC Line Voltage: the AC Line voltage at the time of the event. 4) Monitor Reset Log (MR) Ensure the Monitor Reset log contains the following information: a) The monitor was reset from a fault by the front panel Reset button or Extemal Reset input. 5) Configuration Change Log (CF) Ensure the Configuration Change log contains the following information: a) Program Card Matrix: the pennissive programming for each channel. b) Yellow Disable Jumpers: the YeHow Disable programming for each channel. c) Dual/Sequence Switches: the switch programming for each channel. d) Option Switches: RF 2010, RP Disable, GY Enable, SFI Polarity, Sequence Timing, Minimum Flash Enable, Configuration Fault Enable, Red Cable Fault enable, AC Brownout timing. e) Watchdog Programming: Watchdog Enable, Watchdog Latch, and Watchdog timing. t) Configuration CRC: A unique CRC value which is based on the configuration of items #a though #e above. Indicate on the log, which items have been changed since the last log entry. 6) Signal Sequence Log Provide a log that graphically displays all field signal states for up to 30 seconds prior to the current fault trigger event. Ensure that the resolution of the display is at least 50 milliseconds. e. Communications Functions 1) Controller Unit Communications Ensure that the Signal Monitor is compatible with the Command/Response protocol of BI Tran Systems Inc. Model 233 Software. Ensure the unit supports command types 02 and 07. 2) Personal Computer Communications Have the manufacturer provide software to access the Signal Monitor status and event logs described in Subsection 925.2.0l.A.14.d. Ensure this software operates with Microsoft Windows 2000™ or Windows xp™ f. Hardware 1) Red Monitoring a) Red Field Inputs Ensure that the Signal Monitor is capable of monitoring sixteen Red field signals. Ensure that a Red input is sensed active when the input voltage exceeds 70 Vnns. Ensure that a Red input is sensed not active when the input voltage is less than 50 Vnns. A Red input mayor may not be sensed active when the input voltage is between 50 Vnns and 70 Vrms. b) Red EnableInput Ensure that the Red Enable input provides an AC input to the unit which enables Red Monitoring, Dual Indication Monitoring, and Sequence monitoring when the input is sensed active. Ensure that the Red Enable input is sensed active when the input voltage exceeds 70 Vnns. Ensure that the Red Enable input is sensed not active when the input voltage is less than 50 Vnns. The Red Enable input mayor may not be sensed active when the input voltage is between 50 Vnns and 70 Vrms. 'c) Special Function Preemption Inputs Ensure that the Special Function Preemption inputs #1 and #2 provide an AC input to the unit which disables only Red Fail Monitoring (Lack of Output) when either input is sensed active. 14 of 72 Section 925-Traffic Signal Equipment .. Ensure that a Special Function input is sensed active when the input voltage exceeds 70 Vnns. Ensure that a Special Function input is sensed not active when the input voltage is less than 50 Vrms. A Special Function input mayor may not be sensed active when the input voltage is between 50 Vrrns and 70 Vnns. Use a PCB mounted switch to provide the option to invert the active status of the Special Function #1 input. When the switch is in the ON position, ensure that the Special Function #1 input is sensed not active when the input voltage exceeds 70 Vnns. Ensure that the Special Function #1 input is sensed active when the input voltage is less than 50 Vrms. The Special Function #1 input mayor may not be sensed active when the input voltage is between 50 Vnns and 70 Vnns. d) Red Interface Connector This connector provides the required inputs for the unit to monitor the Red field signal outputs. Ensure the connector is a 3M #3428-5302 type or equivalent and be polarized to insure proper mating with the cable. Ensure Ejector latches are included to facilitate removal and prevent the ca,ble from inadvertently disconnecting. Ensure the unit shall function as a standard 210 Signal Monitor when the cable is disconnected. Use the pin assignments shown in Table 1. Table 1 J Pin Function Pin Function 1 Channel 15 Red 11 Channel 9 Red 2 Channel 16 Red 12 Channel 8 Red 3 Channel14 Red 13 Channel 7 Red 4 Chassis Ground* 14 Channel 6 Red 5 Channel 13 Red 15 Channel 5 Red 6 Special Function #2 16 Channel 4 Red 7 Channel 12 Red 17 Channel 3 Red 8 Special Function #1 18 Channel 2 Red 9 Channel 10 Red 19 Channel 1 Red 10 Channel 11 Red 20 Red Enable * A jumper option shall be provided to allow the connection of Pin #4 to be made with Chassis Ground. 2) Front Panel Ensure the front panel is constructed of sheet aluminum with a minimum thickness of 0.090 in.. (2.286 mm), and finished with an anodized coating. Ensure the model information shall be permanently displayed on the front surface. a) Indicators Ensure that all display indicators are mounted on the front panel of the Signal Monitor and are water clear, T-l package, Super Bright type LEDs. Ensure that all fault LEDs are red except the AC POWER indicator which is green. Provide a separate Red, Yellow, and Green indicator for each channel. Label the indicators and provide the information as follows: ,.; >" (1) AC POWER Ensure the AC Power indicator flashes at a rate of 2 Hz when the unit has detected a low voltage condition as described in Subsection 925.2.03.A.14.b.l0).a. Ensure the AC POWER indicator flashes at a rate of 4 Hz during the minimum flash interval as described in Subsection 925.2.03.A.14.b.lO).b. Ensure that the indicator illuminates when the AC Line voltage level is restored above the brownout level. Ensure the indicator extinguishes when the AC Line voltage is less than 80 Vac. 15 of 72 Section 925- Traffic Signal Equipment .. c) Serial Communications Connector Use this connector to provide EIA-232 serial communications. Ensure that it is an AMP 972lA or equivalent 9 pin metal shell D subminiature type with female contacts. Refer to Table 2 for Pin assignments. Table 2 Pin Function J DCD* 2 TXDATA 3 RX DATA 4 DTR (Data Terminal Ready) 5 SIGNAL GROUND 6 DSR 7 DSR* 8 CTS* 9 NC ... * Provide Jumper options to allow the connection of Pin #4 to be made with Pin #7, and the connection of Pin #8 to be made with Pin #1. 3) Electronics a) RMS Voltage Sampling Use high speed sampling techniques to determine the true RMS value of the AC field inputs. Sample each AC input at least 32 times per cycle. Ensure that the RMS voltage measurement is insensitive to phase, frequency, and waveform distortion. b) Internal MPU Watchdog Use a microprocessor for all timing and control functions. Verify continuing operation of the microprocessor by an independent monitor circuit, that forces the Output Relay to the de-energized "fault" state, enable the Stop-Time output, and illuminate the DIAGNOSTIC indicator if a pulse is not received from the microprocessor within 300 UlS. If the microprocessor should resume operation, ensure the Signal Monitor continues to operate. Ensure that this monitoring circuit is also configurable to latch in the fault state. Ensure the unit requires a power-up cycle to reset the circuit once it is triggered. c) Sockets In the interest of reliability, ensure that only the PROM memory device for the microprocessor firmware is socket mounted. Ensure that the PROM memory socket is a precision screw machine type socket with a gold contact finish providing a reliable gas tight seal. Low insertion force sockets or sockets with "wiper" type contacts are not acceptable. d) Internal Power Supply Use a built-in, high-efficiency switching power supply to generate all required internal voltages. Ensure that all supply voltages regulated. Failure of the internal power supply to provide proper operating voltages shall force the output Relay to the de-energized "fault" state, enable the Stop-Time output, and illuminate the DIAGNOSTIC indicator. Provide auser replaceable slow blow fuse for the AC Line input. Ensure the unit is operational over the AC Line voltage range of75 Vac to 135 Vac. e) EIA-232 Interface Ensure the EIA-232 port interface electronics is electrically isolated from all monitor electronics except chassis ground. f) Configuration Parameters Select user-programmed configuration settings using PCB mounted switches or jumpers. Designs requiring a Personal Computer (PC) to program or verify the configuration parameters are not . 17 of 72 t . . Section 925- Traffic Signal Equipment ~ Supply Model 332A (lower input panel) cabinets, with housing Type IB, and all components as described in these specifications. Supply cabinets having two input files which conform to the CAL TRANS Specifications and configured to accept two 2070 controllers in the top portion of the cabinet. Configure the cabinet for dial up communications. Mount a two (2) circuit Buchanan connector on the right side panel (from rear door). Mount a phone jack with a RJll connector above or to the right of the Buchanan terminal block. Wire the phone jack to the Buchanan and to the Terminal Block (1'80) in accordance with Figure 925-1. A manual jack shall be installed on the police paneL The jack shall intennate with a three circuit l/4inch (6.35 mm) diameter phone plug. The tip and ring (middle) circuits of the jack shall-be connected to the logic ground and the interval advance inputs of controller unit. When the manual hand cord is plugged into the jack and the pushbutton is pressed, logic ground shall be connected to the interval advance input of the controller unit. A manual pushbutton with cord shall be provided. The cord shall have a minimum length of 3 feet (0.9 m). It shall have a l/4 inch (6.35 mm) diameter, three circuit plug connected to one end and a manual pushbutton enclosed in a hand held enclosure at the other end. A complete cycle (push-release) of the manual pushbutton shalf terminate the controller unit interval which is active except the vehicular yellow and all red clearance intervals. Cycling the push- button during the vehicular yellow or all red clearance intervals shall not terminate the timing of those intervals. 20. Cabinet Model 332A with Auxiliary Output File) Ensure that this unit meets the requirements of Subsection 925.2.03.A.19 above, except that the cabinet is configured with an Auxiliary Output File. Additionally, the field wiring terminals may be mounted on the rear of the input file. 21. Cabinet Model 336S (Base Mount) This unit meets the CAL TRANS Specification with the addition of approximately 6 additional inches (150 mm) of cabinet height exclusive of the "M" base adapter. Configure the internal component layout so that the additional space is available in the bottom area of the cabinet cage. Ensure that the field wiring input panels and surge protection conform to Table 925-3 Model 336 Default Input File Assignment Detail and Table 925-4 Required Surge Arrestors for Model 336 Cabinet. Ensure that the C 1 connector harness is provided with pins for all 1 04 inputs and outputs from the controller. A manual jack shall be installed on the police paneL The jack shall intennate with a three circuit l/4 inch (6.35 mm) diameter phone plug. The tip and ring (middle) circuits of the jack shall-be connected to the logic ground and the interval advance inputs of controller unit. When the manual hand cord is plugged into the jack and the pushbutton is pressed, logic ground shall be connected to the interval advance input of the controller unit. A manual pushbutton with cord shall be provided. The cord shall have a minimum length on feet (0.9 m). It shall have a 1/4 inch (6.35 mm) diameter, three circuit plug connected to one end and a manual pushbutton enclosed in a hand held enclosure at the other end. A complete cycle (push-release) of the manual pushbutton shall terminate the controller unit interval which is active except the vehicular yellow and all red clearance intervals. Cycling the push- button during the vehicular yellow or all red clearance intervals shall not terminate the timing of those intervals. 22. Cabinet Model 336 (Pole Mount) Ensure that this unit meets the requirements of Subsection 925.2.03.A.21 above, except that the cabinet is configured for pole mounting as specified in the General Requirements for Type 170 Cabinet Assemblies. 23. Cabinet Model 336S (Base Mount with AuxiliaryOutput File) Ensure that this unit meets the requirements of Subsection 925.2.03.A.21 above, except that the cabinet is configured with an Auxiliary Output File. Additionally, the field wiring terminals may be mounted on the rear of the input file. 23. Cabinet Model 337 The Model 337 cabinet is a compact cabinet with an output capacity off our vehicle phases plus two pedestrian phases; the dimensions not to exceed 17 inches (425 mm) deep x 20 inches (500 mm) wide x 35 inches (875 mm) high and its shipping weight not to exceed 175 pounds (80 kg). Supply the cabinet assembly with capacity for 11, two-channel slots in the input file. 19 of 72 " ~ c Q) E a.. :::J 0- W m c .Ql en u ~ ~ ~ 1.0 ('\J 0) c o +:; u Q) en """ \..) ~ -... Q 00 "'" \..) 00 -... Q \0 <"\l \..) t'- -... Q \0 -... -... c::, -... - .; .... ~ ~ ..... ..... <Il 0 ~, Q \0 .... I:: ~ e I:: bJl .~ '" ~ ..... 00 <Il 0\ Q '<l'" t'-.. ~ tn Q \0 '" ~ ~ .... ::I e. 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CJ <"'l ~ ~ ~ l::I 6 p..1Ll o;;;g ~f- u Z 000 .e.\I.l p.. "'f" , 00 III . f-<'- ~fil p.. 1''''f" III . f-'" o > \I.l V) N cb--: f-::: u > ILl V) , 00 III . f-<'- t:r: ~ V) cb~ f-'" 00 .e. 0\ . 00 III . f-r-- 0\ . "'f" III . f-<<1 'D .e. 00 N cOo-: f-::: ..-l 'D..-l .e.<l; U 00 ~~ "'f" .e. 00 , '1' III . f-'" ..-l '1'..-l .e.<l; U r--'" ~2 N .e. <'- . 00 III . f-r-- ..-l N..-l .e.<l; U r-- ''1' III . f-<<1 ::: .~ .... <..l ::: ci: il ~ k;~ ~ ~ u u 0 0 ~ ~ c; c; Q 1=1 'g og ... <I) <I) ~ E-< E-< = m m :E .... .-< .-< (II ~ m m u u U \0 Il.. Il.. ("l ,S .S ("l ~ qJ ~ <Il <Il ~ .... .... '0 ~ 0 s 0 .!:: .... <Il <Il 0 ~ ~ <I) <I) 1:: 1:: ~ J". ~ '" '" u 0 ~ Q Q ..9 .... '" .~ o~ m J". c; 0 ... l5. P. Q '" 'g ~ 0 0 J". J". M M 0 0 <I) <: U U E-< ~ ~ N N m 'D J". '1' '1' .-< ~ = 'D 'D m rJ) u u U '0 Il.. Il.. p.. rJ) ~ 0 0 0 0 J". .~ U U U U Q Q Q Q ~ ~ ~ ~ ~ ~ '1' .J::l I l::! t() N .5 Q\ ~ ~ N N N :c ~ .-< '1' .-< .-< I I . . (II .-< .-< tr) .-< E-< ..::c OJ .s 0\ !:q . - m l::! E-< .5 oo~ ~ . ~ ~ ~ '1' tr) tr) t-~ . . . . ~ m m m ~ ~ E-< E-< E-< ~ ..... o C") C\t .... , .. .A . ~ Section 925- Traffic Signal Equipment 2. b. Model 342 Cabinet: I-Model 242 DC Isolator 6- Flash Transfer Relays 2-Model 204 Flashers c. Model 346 Cabinet I-Model 242 DC Isolator 6-Flash Transfer Relays 2-Model 204 Flasher I-"M" Base Adapter installed (Base Mount Cabinets Only) I-Aluminum Cover Plate for Cabinet Bottom (Pole Mount Cabinets Only) d. Model 354 Cabinet: Specific Equipment Layout and additional cabinet equipment determined on a project specific basis. e. Model 356 Cabinet Specific Equipment Layout and additional cabinet equipment determined on a project specific basis. I_"M" Base Adapter installed (Base Mount Cabinets Only) I-Aluminum Cover Plate for Cabinet Bottom (pole Mount Cabinets Only) Note: Include above components in cabinet at time of delivery. Other auxiliary cabinet components such as controllers, load switches, etc. will be ordered as separate items. Finish Use cabinets that have a bare aluminum fmish (see Subsection 925.2.06.A.l for controller-cabinet minimum fabrication specifications). Locks Equip the main cabinet door with locks that accept No.2 Corbin keys. Provide two sets of keys with each cabinet. One set of keys is defined as one - No.2 key and one - police panel key. Power 3. 4. Equip the cabinet assemblies with an ITS power distribution assembly to generate AC and DC power for the electronic components, except the DC power for the controller units. 5. Mounting Equip the cabinets for pole or base mounting, as specified in the Plans. a. Base Mount Supply Model 346and 356 cabinets, when specified as base mount, with a "M" base-mounting adapter installed. b. Pole Mount Supply Model 346 and 356 cabinets, when specified as pole mount, with two exterior pole mounting brackets that allow for mounting on steel, concrete, and timber poles. Ensure that the bracket mounting holes are properly reinforced with metal plates of adequate size and strength, welded longitudinally across the inside depth of the cabinet. Ensure that the exterior-mounting bracket is shipped installed on the cabinet housing. Additionally, provide an aluminum plate, which covers the bottom cabinet opening. 6. Cabinet Light Include in each cabinet one fluorescent lighting fixture mounted inside the top front portion of the cabinet. The fixture includes a cool white lamp, covered, and operated by a normal power factor, UL listed ballast. Install a door-actuated switch to turn on the cabinet light when either door is opened. 7. Cabinet Interlock Do not install the interlock circuit, as detailed in the CALTRANS Specifications. 25 of 72 Section 925-Traffic Signal Equipment '" · A three-terminal device, two (2) of which are connected across the signal inputs of the detector with the third connected to the chassis ground to protect against common mode damage. · Instantly clamps differential mode surges (induced voltage across the loop detector input terminals) via a semiconductor array. The array appears as a low capacitance to the detector. · Clamps common mode surges (induced voltage between the loop leads and ground) via solid state clamping devices. · Withstand 25-100A surge current occurrences of a 10 x 700 /is wavefonn . Have the following clamp characteristics: Maximum break over voltage: 170 V Maximum on-stage clamping voltage: 3V Response Time: <5 ns Off-stage leakage current: <10 IlA Capacitance: less than 220 pf · Ensure that the unit also meets tht? following minimum requirements: Peak surge current: 6 times Differential mode: 400 A (8 x 20 ms) Common mode: 1,000 A (8 x 20 rns) Estimated occurrences: 500 @ 200 A Response time: 40 ns Input capacitance: 35 pF typical Temperature: -400 F to +1850 F (_400 C to 850 C) Mounting: No. 10-32 x 3/8-inch (No.5 x 10 mm) bolt Clamp voltage @400 A difE Mode: 30 V max. @1,000 A comm. Mode: 30 V max. c. Signal Load Switches (Switchpacks) Provide the output of the switchpack in the output file with transient protection via the nine position transient protection device in the output file. Protect switchpacks from surges on the AC output lines. Ensure that the transient protectors meet or exceed these requirements: · Steady state sinusoidal voltage (RMS) rating at 50 to 60 Hz of at least 150 Vat 77 OF (25 oc) · Steady state applied DC voltage rating of at least 200 V at 77 QP (25 oc) · Transient energy rating is of at least 80 J for a single impulse of 10/1,000 Ils current waveform at 77 QF (25 oc) · Peak current rating of 6,500 A for a single impulse of 8/20 Ils waveform with the rated continuous voltage applied · Varistor voltage of at least 212 Vat l.OmA of DC current applied for the duration of20 Ils to 5s · Clamping voltage of at least 395 V with an applied 8/20 IlS impulse of 100 A · Typical capacitance ata frequency of 0.1 to l.0 MHz of 1600 pF · Two-terminal device, one of which is connected to the AC output of the signal load switch on the output file terminals (backside of the field terminals) with the other connected to AC neutral d. Communication Inputs Protect low voltage communications input as it enters the cabinet with a solid-state surge protection unit that meets or exceeds these requirements: · Dual pair (4-wire) module with a printed circuit board connector, double sided and gold plated for reliability · Ability to mate with and be installed in a 10-circuit Buchanan connector PNPCBlB or equivalent · Usable as two independent signal pairs · The data circuits pass through the protection in a serial fashion · C2 connector of the 2070 controller that terminates on the line side of the unit · Communication field wires for this local side that terminate on the line side of the unit · Ground terminals connected to power ground · Ensure that the unit meets the following minimum requirements: ... t\. ). 27 of 72 Section 925- Traffic Signal Equipment . Supplies,; Conflicting Channel Monitor, Serial Bus 1 and 3 Error; Message 62; Diagnostic Error; Multiple Channel Inputs; Lack of Signal Inputs; Yellow Clearance; Yellow plus Red Clearance; Police and Power Distribution Switch Monitor; door Switches and Main Contactor Status; Circuit Breakers; Flash Unit Output Status; and AC Line Level Sense. Ensure the Unit supplied is listed on the most recent California Department of Transportation Qualified Products List (QPL). The Type 214 AMU shall provide the field signal sensing. b. Current Moilitoring Supply Type 214 AMU capable of operating in a 14 channel mode or a 6 channel mode. Ensure the address select is correct for the output assembly in which the Model 214 AMU is installed. c. Diagnostics Ensure the Type 214 AMU has self diagnostic tests that execute continuously to provide for correct operation to properly monitor the current for use with LED signal heads. A 13. Type 218 ITS Serial Interface Unit a. Introduction Supply each input and output assembly with a Type 218 ITS Serial Interface Unit (SID). Ensure the Type 218 ITS SIU supplied meets the Caltrans TEES specifications. Ensure the Unit supplied is listed on the most recent California Department of Transportation Qualified Products List (QPL). The Type 218 ITS SID shall provide the interface between the 2070 controller and the input and output files. b. Configuration Supply Type 218 SID capable of operating in all input and output modes. Provide a Model 218 SID that is configured correctly for the input or output file for which it is supplied. c. Programming Ensure programming of the Type 218 SID is programmed by assembly mounted addressjumpers and that no other setup is required. d. Diagnostics Ensure the Type 218 SID supplied has a complete set of internal diagnostics self-tests run continuously to monitor critical components of the unit. Provide unit with a front panel LED indicator that can be used to report the current Input/Output assembly address assignment of the unit for cabinet configuration verification. Ensure unite has a diagnostic EIA-232 port on the front panel to interface with the SID 218 functions. 14 Model 242 DC Isolator Provide Model 242 DC Isolators that are in accordance with the latest version of CAL TRANS Specifications as referenced earlier in this section. Ensure that the 242 isolator input signal polarity may easily be inverted. Provide isolators that: · Output is OFF for input voltages greater than 12 volts; · Output is ON for voltages ofless than 8 volts that have a duration of at least 5 to 25 ms (optional 2-7 ms); · Minimum output pulse width is 100 mswith a valid input (can be disabled); · Output is optically isolated open collector NPN transistor; · Capable of sinking 50 ma when on; · Can register a new input within 25 ms of the old signal going away; and " · Output clamped on power up and down 15. Model 200 Switchpack Provide Model 200 Switchpacks that are in accordance with the latest version of CAL TRANS Specifications as referenced earlier in this section. .. 16. Model 204 Flasher Unit Provide Model 204 Flasher Units that are in accordance with the latest version of CAL TRANS Specifications as referenced earlier in this section. 29 of 72 ~ .... c Q) E Q. :J 0- W <tl c .2> (J) u lE ~ ~ l.O N 0> C o +=- u Q) (J) 10<0 <00'> C'l <0 .... 0'> 00 t- ~ I()- <0 to 0 0> ~ Q a5 ~ ;;: to N <') .0 E 0> m to <') <') I() E 0> o..~ o..~ N ...- ...- ~ ~~~~~g~~:6re~ 0> o..~ Q....OI()N...- ~ ;;: I() N <') I() Qi 0<0 N"I:t~,-<o"'=t(W) "OOalION<').o C])~ a.. <')<0<') "<I: 0) ;;: ..t N ;n t- ";U ... Gl C ... C Gl E c "~ III III '0 ~<ii ~:! u:u:: ... ~ c: NV~t.O CO ;;: ....- N N ..... T""" N 0> M ..q- ;;: ....- ...- .... cD 00t- t-: <O:(~T"""<OT""" ~ :::s CU - Gl C ... Gl c: ..0 CU () (f) t: C'l ~ M Gl 1:J o ~ CD 10 C'l en ~ ..0 CU I- IO~~~~~ ~~~~OO~ C") !;( ~ C'l ~~O>O T"""<X)~ ...-N.... 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"'0 (!) -S en c .Q ro ,Q c ::J E E o () a. ::J I (tj o '- .E ~ ...... o C') C') ,!Q E (1J '- OJ ro (5 OJ C "C 1 N I lO N 0> (!) '- :J OJ u:: Q) .~ ..a (1J o N """ ('t) (j) "'0 o ~ (!) .s::::. +-' c- o :;::; E1 (tj (;) .~ (tj C 0> "00 (tj .Q a. .c ro '- o u.. i1i o z Section 925- Traffic Signal Equipment 925.2.05 Battery Backup System A. Requirements This specification is for establishing the minimum requirements for a complete emergency battery backup system for use with Light Emitting Diode Traffic Signal Modules at intersections with 332 cabinets. The Battery Backup System (BBS) shall include, but not be limited to the following: Inverter/Charger, Power Transfer Relay, Batteries, a separate manually operated nonkelectric Bypass Switch and all necessaryhardware and interconnect wiring. The BBS shall be capable of providing power for full run-time operation for an "LED -{}nly" intersection (all colors: red, yellow, green and pedestrian heads) or flashing mode operation and intersection Red LED's. The BBS shall be designed for outdoor applications, in accordance with the Caltrans TEES. ., A ," NOTE: Transfer Relay may be internal to the Inverter. Utility Line Power Figure 925-3 Battery Backup Block Diagram. Battery Back Up System (BBS) Block Diagram Inverter/Charger Batteries Transfer Relay SPOT NOINC contact closures - Energized whenever system is running on batteries connect to Controller Alarm Input 2 SPOT NOINC contact closures - Energized whenever system is running on batteries and there is less than 40% battery SPOT NOINC contact closures - Energized whenever system has run on batteries for more th~n two hOIlT~ Manual Bypass Switch Model 332A Cabinet AC Line Power to Cabinet NOTE: Manual Bypass Switch will be external to Inverter/Charger. If Transfer Relay is external to Inverter, then the Manual Bypass Switch and Transfer Switch may be incorporated together. 1. Operation: a, The BBS shall provide a minimum two (2) hours of full run-time operation for an "LED-only" intersection (minimum 700W/lOOOV A active output capacity, with 80% minimum inverter efficiency). .. b. The maximum transfer time allowed, from disruption of normal utility line voltage to stabilized inverter line voltage from batteries, shall be 65 milliseconds. The same maximum allowable transfer time shall also apply when switching from inverter line voltage to utility line voltage. 35 of 72 Section 925- Traffic Signal Equipment . h. 1. . J. k. I. g. The BBS shall use a temperature-compensated battery charging system The charging system shall compensate over a range of2.5 - 4.0 mVI oC per cell. The. temperature sensor shall be external to the inverter/charger unit. The temperature sensor shall come with 3 meters (9' 10") of wire. . Batteries shall not be recharged when battery temperature exceeds 50 oC :I: 3 oC. BBS shall bypass the utility line power whenever the utility line voltage is outside of the following voltage range: 100VACto 130VAC(:l:2VAC). When utilizing battery power, the BBS output voltage shall be between 110 V AC and 125 V AC, pure sine wave output, ::3% THD, 60Hz :I: 3Hz. BBS shall be compatible with Caltrans Model 332A Cabinets, Model 170E Controllers, Model 2070 Controllers and cabinet components for full time operation. In cases oflow (below 98V AC) or absent utility line power, when the utility line power has been restored at above 105 V AC:I: 2 VAC for more than 30 seconds, the BBS shall transfer from battery backed inverter mode back to utility line mode. m In cases of high utility line power (above 132V AC), when the utility line power has been restored at below 125V AC:I: 2 V AC for more than 30 seconds, the BBS shall transfer from battery backed inverter mode back to utility line mode n. BBS shall be equipped to prevent a malfunction feedback to the cabinet or from feeding back to the utility servIce. o. In the event of inverter/charger failure, battery failure or complete battery discharge, the power transfer relay shall revert to the NC (and de-energized) state, where utility line power is connected to the cabinet. p. Recharge time for the battery, from "protective low-cutoff' to 80% or more of full battery charge capacity, shall not exceed twenty (20) hours. 2. Mounting/Configuration NOTE: All references made to EIA rail or EIA 19" (482.6mm) rack shall conform to Electronic Industries Standards EIA-310-B, Racks, Panels, and Associated Equipment, with 10-32 "Universal Spacing" threaded holes. . J. a. General 1) Inverter/Charger Unit shall be shelf-mounted or rack-mounted on a standard EIA 19" rack. If designed to be shelf mounted inside the 332A Cabinet, the shelf shall be provided. 2) Power Transfer Relay and Manual Bypass Switch shall be mounted on EIA rail. 3) All interconnect wiring shall be provided between Power Transfer Relay, Bypass Switch and Cabinet Terminal Service Block and shall be no less than 3 meters (9'10") ofUL Style 1015 CSA TEW with the following characteristics: . AWG Rating: 10 AWG . Stranding: 105 strands of 30 A WG tinned copper . Rating: 600 V, 105 oC, PVC Insulation 4) Relay contact wiring provided for each set of NO/NC relay contact closure terminals shall be 3 meters (9'10") ofUL Style 1015 CSA TEW 18 AWG wire, same ratings as above, except 16 strands of30 AWG tinned copper. 5) Figure 925-6 provides clarification as to how BBS Power Transfer Relay and Manual Bypass Switch are interconnected with Model 332A Cabinets in order to ensure interchangeability between all BBS manufacturers. 37 of 72 Section 925- Traffic Signal Equipment Figure 925- 7 BBS Mounting Diagram FOl a typical Model. 3321\ Cabinet o cl.38 ~17.78---j ~ r---- --j EIA 19< Ra.cl< unting Rail r 6.00 t- 5.75 L 17.76 r-Ma Model 170/2070 Controller Unit Input fU" r Input File J 55.5 PDA #2 Output File Reserved SpIKe 49.00 Controll..... Mountlng Shel f . L l.ooT Openlng Reser-veal Spa.ce Frant View ErA 19' Ro.ck Notes: Hounting Ra.il Area Inside of do.shed lines represents o.voila.ble Mounting locations for ll11S. Prescribed a.va.ila.ble Mountinll o.reasar" o.ppraxiMa te. AU diMensions shawna.re in Incn~s. Reor View 3) Batteries mounted below the controller shelf shall be swing-tray mounted. Batteries may be shelf mounted in area behind controller so long as shelf and batteries do not interfere with controller unit and Cl plug. 4) Battery swing-tray hinge bracket shall mount on right hand side ofEIA rack in rear of cabinet. c. External Cabinet Option I) The External Cabinet shall be used for housing batteries and/or BBS, which includes inverterlcharger unit, power transfer relay, manually operated bypass switch, any other control panels, and all wiring and harnesses. 2) The same Inverter/Charger, Power Transfer Relay and manually operated Bypass Switch that fits inside a typical fully equipped Caltrans Model 332A Cabinet shall also be able to fit inside the externally mounted cabinet. 3) The ExternalCabinet shall be a NEMA 3R rated cabinet mounted to the side of the Model 332 Cabinet(see Figure 925- 8 for details). This external cabinet shall conform to TEES. August 16. 2002 Chapter 7. Section 2-Housings for the construction and finish of the cabinet. The specific fmish of the external cabinet shall be anodic as per TEES 7.2.2.3.1. Anti-Graffiti paint shall not be used. .. ). 39 of 72 Section 925-Traffic Signal Equipment Figure 925 - 9 External BBS Cabinet Details .... DETAIL. A CiIIJIIUt..J!knU:IIIC..1IIcIp --.G...hlI:r opaaIIq ~.. 45 i.q . DlNUW IBIB" s~ J/01H EN/!S 1rI1II. S'/!JOOIE IIIEl/J/OSWctIIflII(JI. _ PINEl <<1 TOP VIE.... A-'1 I DflIltA 1l&JIll'.t _ f"<<iwo ar oe<<o: B f.-tO..l!l R/fJ~/1JA;:_MlNlW6ftf ...., w ~ (J~ lO~lI8 TImo..J04 PJCI(. fto.!.o PIa .1'EU..-{JJ2-10 (",~ llfW C .m 55.88 IhndiB en. Rt S;~ of lloor\ 1 (;l)RSIN P mwar (-I.) 1:==-==1 .!;6.(J{J M2S ~fp ~ DPfNINiI utJO :;t~ IZ()(} ~1fIiJuo/itJg :'=~p..) ~;~-:~ C==lI,..~c:::;::::J, c:=::3--c:=:::3;~ -~-~.c::::::=:::30 ~-~-~ c=::::::ll-c:::::=:3I-~ 23'8:,~ J. ==>~= c:::::3Io'.c::::::::li,'.c::::::Jo ~-~-~ c:::::::::3P ~'c==:l c:::::::II c::::I-.c:::::;=:::t c::::=:::::.,'c::::::J.-c:::::=;,; ~-g--g Bt.tl"", She tl-{}/} t2.00 fI/r;/( fl.7UI ~J.tIlO-I RIGHT SIDE ~Zf,IJ(} FRONT VIEW D.5O 01'f/(fI/C FRONT VIEW Ol'EN DOOR . 12) Fasteners shall meet the following requirements: · (Total of 8 bolts per cabinet with 2 flat washers per bolt and I K-lock nut per bolt) · Cabinet mounting bolts shall be: · 18-8 Stainless Steel Hex Head (Fully Threaded) · 3/8"-16Xl" · Washers shall be: · Designed for 3/8" bolt · 18-8 Stainless Steel 1 " OD round flat type · K-lock washer shall be: · 18-8 Stainless Steel, Hex Nut Assembled with Free-Spinning Tooth Washer · 3/8" - 16 Screw size 13) External Cabinet to 332A Cabinet couplings shall provide a conduit for power connections between the 332A Cabinet and External Cabinet. The couplings shall consist of three parts and meet the following requirements: · 2" Nylon Insulated, Steel Chase Nipple, T & B 1947 or equivalent · 2" Sealing, Steel Locknut, T & B 146SL or equivalent · 2" Nylon Insulated, Steel Bushing, T & B 1227 or equivalent 14) Two EIA angle rails, per Detail C, Figure 925 - 10, along with all necessary mounting hardware (4 sets of 10-32 bolts and nuts with captive washers) shall be provided with the external cabinet (not installed). Rails shall be symmetric to allow for installation on either right or left sides of the cabinet. Mounting holes and bracket shall allow for EIA rail installation at any location in the external cabinet. The EIA mounting angle nominal thickness shall be either 0.1345 inch (3.4 I 63mm) plated steel or 0.105 inch (2.667mm) stainless steel. .J 41 of 72 . . J Section 925- Traffic Signal Equipment t e. The BBS shall include a front-panel event counter display to indicate the number of times the BBS was activated and a front-panel hour meter to display the total number of hours the unit has operated on battery power. Both meters shall have push button resets. f. Manufacturer shall include a set of equipment lists, operation and maintenance manuals, and board-level schematic and wiring diagrams of the BBS, and the battery data sheets. Manual shall conform to TEES August 16,2002, Chapter 1, Section 1.2.4.2. 4. Battery System a. .Individual batteries shall be: · Voltage rating: 12V type · Amp-hour rating: 80 amp-hour maximum · Group size: 24 maximum · Batteries shall be easily replaced and commercially available off the shelf. b. Batteries used for BBS shall consist of 4 to 8 batteries with a cumulative minimum rated capacity of 240 amp- hours. c. Batteries shall be deep cycle, sealed prismatic lead-calcium based AGMlVRLA (Absorbed Glass Mat/ Valve Regulated Lead Acid). d. Batteries shall be certified by the manufacturer to operate over a temperature range of - 25 oC to +74 oC. e. The batteries shall be provided with appropriate interconnect wiring and corrosion-resistant mounting trays and/or brackets appropriate for the cabinet into which they will be installed. f_ Batteries shall indicate maximum recharge data and recharging cycles. g. Battery Harness 1) Battery interconnect wiring shall be via two-part modular harness. 2) Part I shall be equipped with red (+) and black (-) 30.48 cm (12") cabling that can be permanently connected to the positive and negative posts of each battery. Each red and black pair shall be terminated into an Anderson style Power Pole connector or equivalent. 3) Part II shall be equipped with the mating Power Pole style connector for the batteries and a single, insulated Power Pole style connection to the inverter/charger unit. Harness shall be fully insulated and constructed to allow batteries to be quickly and easily connected in any order to ensure proper polarity and circuit configuration. 4) Power Pole connectors may be either one-piece or two-piece. If a two-piece connector is used, a locking pin shall be used to prevent the connectors from separating. 5) The length of the battery interconnect harness (Part II) shall be a minimum of 152.4 cm (60") from the Inverter/Charger plug to the first battery in the string. The lateral length of the harness between battery connectors shall be a minimum of 30.48 cm (12"). 6) All battery interconnect harness wiring shall be UL Style 1015 CSA TEW or Welding Style Cable or equivalent, all of proper gauge with respect to design current and with sufficient strand count for flexibility and ease of handling. 7) Battery terminals shall be covered and insulated with molded boots so as to prevent accidental shorting. B. Fabrication Refer to Subsection 925.2.06.A.l for controller cabinet minimum fabrication specifications. C. Acceptance General Provisions 101 through 150. Each BBS shall be manufactured in accordance with a manufacturer Quality Assurance (QA) program. The QA program shall include two Quality Assurance procedures: (1) Design QA and (2) Production QA. The Production QA shall include statistically controlled routine tests to ensure minimum performance levels ofBBS units built to meet this specification and a documented process of how problems are to be resolved. The manufacturer, or an independent testing lab hired by the manufacturer, shall perform Design Qualification Testing on new BBS system(s) offered, and when any major design change has been implemented on an existing design. A major design change is defmed as any modification, either material, electrical, physical or theoretical, that changes any performance characteristics of the system, or results in a different circuit configuration. Where a dispute arises in determining if a system is a new design or if the system has had a major design change, the State will make the fmal determination if Design Qualification Testing is required prior to production consideration. 43 of 72 .- ~ . J Section 925- Traffic Signal Equipment 1. Cabinet Supply a NEMA Type 3R cabinet assembly, manufactured of aluminum with a minimum thickness of 0.125 inches (3 mm). Ensure that the cabinet exterior has a smooth, uniform "bare" aluminum fInish with all joints between adjoining cabinet components (sides and bottom) continuously welded on the outside to prevent the intrusion of moisture and dust. Ensure that all welds are free of cracks, blow holes and other irregularities. Supply a cabinet with the following exterior dimensions: Minimum Maximum Height 14 inches (350 rum) 18 inches (450 mm) Width 10 inches (250 mm) 14 inches (350 mm) Depth 7 inches (175 mm) 10 inches (250 mm) Use a cabinet door that is double flanged on all four sides to prevent the entry of dirt and liquids when the door is open. Install a one-piece gasket formed around the door opening to insure a weather tight seal when the door is secured. Attach the door to the cabinet housing by a continuous tamper proof hinge. Equip each cabinet with a Corbin #2 lock and one key. Police panel type locks are not acceptable. Install an aluminum back panel in the cabinet, mounted on standoffs, to facilitate mounting of internal components. Install exterior aluminum mounting brackets, which extend a minimum of 1.75 inches (44 mm) and a maximum of 2.5 inches (63 mm) from the top and bottom of the cabinet. Use brackets that extend across the full width of the cabinet back on the top and bottom. Provide these brackets with holes for mounting to a flat surface with screws and vertical slots for banding to steel, concrete or wooden signal poles. 2. Flasher Unit Supply a standard plug in two circuits NEMA flasher. Ensure that the flasher is of all solid state construction, meets the requirements of the NEMA standards and is rated at a minimum of 10 A per circuit. Ensure that the flasher utilizes zero voltage turn-on and turn-,off current and is capable of dimming outputs. 3. Surge Arrestor Supply a flasher cabinet that incorporates an AC surge arrestor (EDCO SPA-IOO or equivalent) to protect the internal components from lighting and over voltages on the AC service input The requirements for the surge arrestor are: Peak Surge Current 15000 A Peak Surge Voltage @ 10KA 680 V Energy Handling 220 J Power Dissipation Rate 1.5 W maximum Continuous AC Voltage 130 V AC RMS Initial Breakdown (1mA) 212 V Typical Capacitance 4000 pF Operating Temp. -40 OF to 185 OF (-40 oC to 85 0c) 4. Circuit Breaker Include a 15 A circuit breaker in the cabinet. (Square D QOU 115 Series or equivalent). 5. Terminal Block Include a four position terminal block in the cabinet for making field connections. Properly label all field terminal connections. 6. Construction Assemble the flasher assembly, terminal block, surge arrestor and circuit breaker in the cabinet as shown on the attached drawing. 45 of 72 Section 925- Traffic Signal Equipment 0 .. 0 0 0 0 I! TIME CLOCK AC BRKR NEMA FLASHER @@@ @ TB @@@ @ I I C ~ 0 0 0 0 0 Note: Front view of cabinet Door Assembly not shown No scale Figure 925-13-Typical Flashing Cabinet with Time Clock Cabinet Layout . 2. Flasher Unit Supply a standard plug in, two circuits NEMA flasher. Ensure that the flasher is of aU solid state construction, meets the requirements of the NEMA standards and is rated at a minimum of 10 A per circuit. Ensure that the flasher utilizes zero voltage turn-on and turn-off current and be capable of dimming outputs. 3. Time Switch Supply a time switch that meets the requirements of Subsection 925.2.08 of this specification. 4. Surge Arrestor Supply flasher cabinets that incorporate an AC surge arrestor (EDCO SPA -100 or equivalent) to protect the internal components from lighting and over voltages on the AC service input. The requirements of the surge arrestor are as follows: .) Peak Surge Current Peak Surge Voltage @ 10KA Energy Handling Power Dissipation Rate 15000 A 680V 220J 1.5 W maximum 47 of 72 Section 925- Traffic Signal Equipment 1. General Requirements a. Mounting Ensure that the unit is configured for rack mount insertion into a NEMA (TS I or TS 2) card rack and/or .. CAL TRANS Type 2070 cabinet input file. b. Environmental Ensure that the unit is in full compliance with the environmental tests, transient tests and size requirements of NEMA standard TS-l Section 15, TS-2 Section 6.5 and the Califomia Type 2070 specifications. . Provide documentation from an independent laboratory, which certifies that the unit is in compliance with the . above specifications. c. LED Indicator Ensure that each channel includes two high visibility LED indicators; one for the detect state and the second to indicate the status ofthe fault monitor. d. Phase Indicator Ensure that each channel has an erasable write-on pad to aid in identification of the associated phase or function. 2. Operational Requirements a. Tuning Supply units that are fully digital and self-tuning. Ensure that each channel of the unit can automatically tune to any loop and lead in combination within two (2) seconds of application of power or when a reset signal is received. Ensure that the tuning circuit is designed so that drift, caused by environmental changes or changes in applied power, does not cause false actuations. b. Scanning Supply units that sequentially scan each channel (only one channel energized at any given time) to eliminate crosstalk from multiple loops in adjacent lanes and/or allow overlapped loops for directional control and/or allow use of multi-conductor homerun cable when connected to the same detector unit. c. Sensitivity Setting Ensure that each channel is equipped with front panel selectable sensitivity settings in presence and pulse modes. d. Frequency Supply units that have a minimum of three switch selectable operating frequencies. e. Inductance Range Ensure that each channel can tune to an inductive load from 50 to 2000 microhenries with a Q factor> 5. f. Grounded Loops Ensure that each channel can continue to operate with poor quality loop systems (Q>2) including those that have a single point short to ground. g. Fault Monitoring Supply units that constantly monitor the operation of each channel. Ensure that the unit detects shorted loops, open circuit loops or sudden changes in inductance (>25% of nominal). 6 Ensure that each type of fault is indicated on a fault LED by a unique sequence of flashes until the fault is rectified. Ensure that while the channel is in the fault condition, the channel output remains in the detect state. When the fault is rectified, the fault LED continues to emit the sequence signifying the last fault detected, but ; the detect LED and output returns to normal operation. h. Failsafe Output Ensure that each channel output generates a continuous solid state output to the controller when power to the detector is removed. 49 of 72 Section 925- Traffic Signal Equipment ~ b. Option 2 - Advanced Features When the option for advanced features is specified, supply units that incorporate the following advanced features: · Serial Port Interface When the serial port interface is specified, equip the detector with a front and rear panel RS 232 port for the transmission of data. Provide Windows 95 compatible software for interfacing with the detector. . PC Interface Ensure that PC software, when connected directly to the unit through the front panel RS 232 port, provides a screen to display the following loop system operating characteristics, on a per channel basis, for system setup, data collection and diagnostics. * Loop Status * Loop Inductance (IlH) * Loop Frequency (kHz) * Inductance Change (nH) * Last Fault: Open, Shorted, >25% f1L * Fault Occurrence: Date & Time * Vehicle Count · Speed, Volume & Occupancy The software, when connected directly to the unit, is capable of collecting and storing speed, volume and occupancy data from each detector channel. The software allows assignment of loop- to-loop distances to enable accurate speed and vehicle length rneasurements. The speed volume and occupancy information is uploaded and stored in the vendor-supplied software. Upon request, supply the necessary information/protocols to allow the Department to write custom software to retrieve speed, volume and occupancy data. B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty R~fer to Subsection 925.2.D for Materials Warranties. . 925.2.10 Loop Sealant A. Requirements Furnish and instaUloop sealant according to Subsection 833.2.09. "Polyurethane Sealant for Inductive Loops". For a list of sources, see QPL 75. B. Fabrication General Provisions 101 through 150. C. Acceptance . General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. j 925.2.11 Vehicle Signal Heads A. Requirements Supply vehicle signal heads that are 12 inches (300 mm) in diameter. 51 of 72 Section 925-Traffic Signal Equipment . 925.2.13 Optically Programmed or High Visibility Signal Head A. Requirements Supply signal heads that permit the visibility zone of the indication to be determined optically and require no hoods or louvers. The projected indication may be selectively visible or veiled anywhere within 15 degrees of the optical axis. Ensure that no indication results from external illumination and that one light unit does not illuminate a second. The components of the optical system include the lamp, lamp collar, opticallirniter-diffuser, and objective lens. Ensure that the optical system accommodates projection of diverse, selected indications to separate portions of the roadway such that only one indication will be simultaneously apparent to any viewer. Ensure that the projected indication conforms to ITE transmittance and chromaticity standards. . 1. Construction a. Ensure that the lamp is nominal 150 W, 120 V AC, three prongs, and sealed beam having an integral reflector with stippled cover and an average rated life of at least 6,000 hours. Couple the lamp to the diffusing element with a collar including a specular inner surface. The diffusing element may be discrete or integral with the convex surface of the optical limiter. b. Supply an optical limiter with an accessible imaging surface at focus on the optical axis for objects 900 to 1,200 feet (270 to 360 m) distance and permit an effective veiling mask to be variously applied as determined by the desired visibility zone_ Ensure that the optical limiter is provided with positive indexing means and is composed of heat-resistant glass. c. Ensure that the objective lens is a high-resolution planar incremental lens hermetically sealed within a flat laminate of weather resistant acrylic or approved equaL Supply a lens that is symmetrical in outline and that may be rotated to any 90-degree orientation about the optical axis without displacing the primary image. 2. Mounting a. Supply signals that mount to standard 1.5 inch (38 mm) fittings as a single section, as a multiple section face, or in combination with other signals. Provide signal sections with an adjustable connection that permits incremental tilting from 0 to 10 degrees above or below the horizontal while maintaining a common vertical axis through couplers and mounting. Ensure that terminal connections permit external adjustment about the mounting axis in 5-degree increments. b. Ensure that the signal is mountable with ordinary tools and capable of being serviced with no tools. Supply attachments such as back plates or adapters that conform and readily fasten to existing mounting surfaces without affecting water and light integrity of the signaL Supply heads with tri-studs for mounting. 3. Electrical Supply lamp fixtures that comprise a separately accessible housing and integral lamp support indexed ceramic socket and self-aligning, quick release lamp retamer. Ensure that electrical connection between case and lamp housing can be accomplished with an interlock assembly, which disconnects lamp holder when opened. Include a covered terminal block for clip or screw attachment of lead wires for each signal section. Use concealed No. 18 A WG, stranded and coded wires to interconnect all sections to permit field connection within . any section. 4. Photo Controls Ensure that each signal includes integral means for regulating its intensity between limits as a function of the individual background illumination. ).. Ensure that lamp intensity is not less than 97% of uncontrolled intensity at 10 750 lux, and reduces to 15 + 2% of maximum at less than 10.75 lux. Ensure that response is proportional and essentially instantaneous to any detectable increase of illumination from darkness to 10 750 lux, and damped for any decrease from 10 750 lux. 53 of 72 Section 925- Traffic Signal Equipment . b. Housing The housing shall be a minimum of .090 inch thick, and may have a 4-inch square opening in the rear. The opening shall accommodate a thermal transfer device that shall vent to the outside of the housing and physically connect to the LED's within the housing. . c. Visors: Ensure that tunnel visors (unless otherwise indicated) are supplied with each section and are manufactured from Ultra-Violet stabilized polycarbonate resin (glass fill not required). Visors shall have 4 (four) integral screw tab slots to provide secure attachment to the door assembly. Visors shall provide a downward tilt of three and one half (3 Yz) degrees and 12-inch section visors shall be a minimum of nine and one half (9Yz) inches in length. d. Optics, Lens 1) Ensure the Red, Yellow, and Green projected indication conforma to ITE Vehicle Traffic Control Signal Head (VTCSH) Part II Chromaticity standards and maintains the Luminous Intensity levels for total light output, over time and temperature during the warranty period of 20 years. 2) Ensure the integrated outer lens shall be clear, circular, convex, scratch resistant, hard coated and UV stabilized. 3) The inner lens shall diffuse the light emanating from the LED's to provide a uIiiform light disbursement across the outer lens. Ensure that individual LED's be visible when the signal section is energized. 4) Ensure the lens is designed to allow the light output through the lens to be directed or steered into a specific viewing zone. Steering shall be accomplished electronically. 2. Electrical Ensure all wiring and terminal blocks meet the requirements of the ITE VTSCH specification and applicable portions of section 925.2.11 Vehicle Signal Heads. Ensure the ESBLEDSH operates from a 60::!:: 3 cycle ac line power over a voltage range from 80 V AC RMS to 135 V AC RMS. The current draw shall be sufficient to ensure compatibility and proper triggering and operation of load switches and conflict monitors in signal controller units: NEMA (TS-I or later), Model 170 (1989 or later) and model 2070 (all). The nominal operating voltage shall be 120 + 3 volts rms. Fluctuations in line voltage over the range of 80 V AC to 135 V AC shall not affect luminous intensity by more than i: lOpercent. The LED-ESBSH circuitry shall prevent flicker at less than 100 Hz over the voltage range of 80 V AC RMS to 135 V AC RMS. a. Transient Voltage Protection The LED-ESBSH shall include voltage surge protection to withstand high repetition noise transients and low- repetition, High-Energy Transients as stated in section 2.1.6,and Non Destruct Transient Immunity 2.1.8 NEMA Standard TS-2, 1998. . b. Ambient Light Adjust Ensure that Ambient Light Adjust shall be provided and shall be designed to adjust the intensity of the light output in response to ambient light levels. Adjustments shall be accomplished in a smooth manner in response to ambient light levels and corresponding to three internal levels described as (Day, Night and Bright). ! c. Electronic Noise: Ensure that the LED signal and associated onboard circuitry shall meet Federal Communications Commission (FCC) Title 47, Sub Part B, Section 15 regulations concerning the emission of electronic noise. ~ d. Predictive Failure Circuitry Circuitry shall be provided within each section of the traffic signal that will continuously monitor the LED's in each traffic signal section. It shall be possible to communicate with each traffic signal section and be capable of obtaining a report showing the LED color, ID number of the LED module, operational hours on the LED's, operating temperature of the LED's, and generate a report indicating when the LED's will go below specifications for light output. 55 of 72 Section 925- Traffic Signal Equipment The failure of a single LED in a string causes loss of light from only that LED, not the entire string or indication. Provide control circuitry that prevents the current flow through the LEDs in the "off' state to avoid any false indications as may be perceived by the human eye during daytime and nighttime hours. Ensure that the LED signal module is operationally compatible with existing or new supplied conflict monitors (NEMA TS-, NEMA TS-2, Model 210, Model 2010, ITS CabinetCMU andAMU.. Ensure that the LED Signal Module is operationally compatible with existing or new supplied load switches. Ensure that the intensity of the LED signal module does not vary by more than 10% over the allowable voltage range as specified in the electrical section below. Ensure that the LED signal modules maintain not less than 90% of the required intensity, as defmed by the ITE intensity standards for LED traffic signal modules. Ensure this over the temperature range of -40 OF to 165 OF (-40 oc to + 74 OC) at 120 V AC, when new and after four (4) years of field installation. 3. Electrical All Modules Supply LED signal modules that operate over the temperature range of -40 OF to 165 OF (-40 oC to 74 0C). Ensure that the power factor is 90% or greater, at nominal rated voltage, at 77 OF (25 oC), after 60 minutes of operation. Ensure that the total harmonic distortion (THD) is less than 20% at rated voltage, at 77 OF (25 oC) and that all LED traffic signal modules are in compliance with FCC noise regulations. Ensure that the LED signal modules operate on line voltage, 120 V AC nominal, and are able to operate over the voltage range of 80 V AC to 135 V AC. Provide transient voltage suppression rated at 1,500 W for 1 millisecond and fusing with a maximurn rating of 2 A to minimize the effect and repair cost of an extreme over voltage situation or other failure mode. Ensure the lens of the modules that are polymeric and are not frosted have a surface coating to provide front surface abrasion resistance. Ensure the modules allow a reduction of the intensity of the light output in response to an input from the traffic signal controller. Ensure the minimum light output when dimmed is not less than 30% of the minimum maintained luminous intensity as defined in the applicable ITE Signal Head Module. Supply only modules that are on the Caltrans QPL list. 4. Circular Signal Modules Supply LED Circular Signal Modules that fit in standard incandescent vehicle traffic signal housings and meet the ITE Vehicle Traffic Control Signal Head LED Circular Signal Supplement specification. Supply lenses for that are made of ultraviolet stabilized polycarbonate or glass, and incorporate facets to enhance the optical efficiency of the LED traffic signal module. Ensure that the external lens surface is smooth, with no raised features, to, minimize the collection of dirt, diesel smoke, and other particulate contaminates, and to facilitate periodic cleaning. . Ensure that Circular Signal Modules have prominent and permanent markings to designate the proper orientation of the signal module in the traffic signal housing. This marking should bean up arrow or the word "UP" or "TOP". Ensure Circular Signal Module meets the photometric requirements as indicated and described in the ITE VTCSH LED Circular Signal Supplement. Supply Red andYellow LEDs that utilize AllnGap technology, either AS (Absorbing Substrate or TS (Transparent Sub~lIatc an\! UQ UQ! ~~~\' · . . Section 925- Traffic Signal Equipment B. Fabrication Gene,ral Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2.41 Cable Ties A. Requirements Ensure that all cable ties are nylon, ultraviolet resistant black and consist of the following as a minimum: Nominal Length 8 inches (200 mm) Width 0.30 inches (7 mm) Tensile Strength 120 pounds (55 kg) B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 10 1 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2.42 Guide Insulators A. Requirements Ensure that all guide insulators are Empire fiberglass strain insulators Series 500-24EE or equivalent. B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2.43 Universal Closure Kit A. Requirements Supply a Universal Signal Closure Kit to seal the signal head at either the top or bottom Ensure that the kit will fit any manufacturer's signal head (top or bottom) without the use of special tools or modification. L Ensure that the Signal Closure Kit is a Pelco SE-3054 or equivalent. 2. Ensure that the gasket is 60-70 durometer neoprene. 3. Ensure that Closure Cap is injection molded ABSplastic. The plastic is to be loaded with UVstabilizers. 4. Ensure that Adapter Bar is made so that it will secure the closure cap and compensate for varying thickness of signal heads. 5. Provide two # 10 (9mm) screws to fit any manufacturer's signal head. Ensure that one screw is 0.75 inches (19 mm) in length and the second screw is 1 inch (25 mm) in length: 6. Pack each assembly in a clear plastic bag. Mark the bag with the manufacturer's name and part number. Include the Universal Signal Closure Kit in a package containing the span wire clamp and Tri-Stud wire entrance fitting. 7. Ensure that the Closure Cap is molded to closely match the color of the signal head (Federal Yellow). The adapter bar and screws are to be zinc plated steeL 70 of 72 Section 925-Traffic Signal Equipment 925.2.33 Prefabricated Controller Cabinet Base A. Requirements Ensure that prefab controller cabinet bases are designed to withstand wind loading of 100 mph (160 km/h) with a 332A cabinet mounted. Refer to Standard Detail Drawings for further information. B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925 .2.D. for Materials Warranties. 925.2.34 Loop Lead-In Cable A. Requirements Ensure that loop detector lead-in cable is No. 18 A WG, 3-pair shielded cable meets IMSA specification #50-2-1997. Ensure that identification markings. are stamped on the jacket. B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2.35 Encased Loop Detector Wire A. Requirements Ensure that encased loop detector wire, meets IMSA specification #51-1-1997 and is 14 A WG. B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2.36 Aerial (Lashed) & Duct Signal Cable A. Requirements Ensure that aerial (lashed) or duct (conduit) No. 14 A WG, stranded, 7-conductor, with black polyethylene (PE) jacket and 600 V AC rating meets IMSA specification #20-1-1997. Use conductors that are straight, not twisted pairs. B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 68 of 72 Section 925- Traffic Signal Equipment · Contains ultra-violet inhibitors and stabilizers for protection against UV degradation · Is injection molded with a smooth front fmish · Has flat and straight surfaces without blisters, buckling or warping; have reinforcing ribs · Contains two (2) injection molded lugs on the bottom of the door with slots of the proper width and depth to fit the base door opening. 9. Supply the base with a set offour (4) anchor bolts, 0.75 inch (19 mm) diameter by 18 inches (450 mm) in length, material per ASTM A 572A 572M, Galvanized per ASTM A 153/A 153M. Supply (1) hex nut and (1) flat washer with each bolt. B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. .D. Materials Warranty General Provisions 101 through 150. 925.2.29 Timber Poles A. Requirements Ensure that aU timber poles meet the requirements of Section 861. Poles must be inspected and tested by the GDOT Office of Materials and Research and hammer stamped by the inspector. Ensure that aU poles have a brand or stamp 10 feet (3 m) from the butt that notes the type wood, date of manufacture, manufacturer, class and length. Ensure that all timber poles that have guy attachments or supportspanwire or arms that suspend signal heads over the roadway or sidewalk are Class II. Poles that support loop lead-in, messenger or communications cable that does not have guy attachments may be Class IV SIZe. Ensure that aU poles meet the requirements in the table below unless otherwise noted on the traffic signal plans or list of materials. Class II II II II II IV IV IV IV Nominal Length, ft (m) 30 (9) 35 (10.5) 40 (12) 45 (13.5) 50 (15) 30 (9) 35 (10.5) 40 (12) 45 (13.5) Minimum Circumference At 6 feet (2.4 m) from butt, in. (mm) 34.0 (850) 36.5 (913) 38.5 (963) 40.5 (1013) 42.0 (1050) 29.5 (738) 31.5 (788) 335(838) 35.0 (875) B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 66 of 72 Section 925- Traffic Signal Equipment B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2.24 Hardware For Signal Head Pole Mounting A. Requirements General Provisions 101 through 150. B. Fabrication General Provisions 101 through 150. C. Acceptance Ensure that this item consists ofPelco 1.5 inch (38 mm) hardware or approved equal as shown in the standard details. This item will be approved upon submittal of catalog cuts. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2.25 Balance Adjuster A. Requirements General Provisions 10 I through 150. B. Fabrication General Provisions 101 through 150. C. Acceptance Ensure this item consists of Pelco or equivalent hardware. This item will be approved upon submittal of catalog cuts. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2.26 Hardware For Mounting 12 Inch (300 mm) Pedestrian Head A. Requirements General Provisions 101 through 150. B. Fabrication General Provisions 101 through 150. C. Acceptance Ensure this item consists of Pelco or equivalent hardware. This item will be approved upon submittal of catalog cuts. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2.27 Pedestal Pole A. Requirements The Pedestal poles support vehicle signal heads, Pedestrian signal heads, and push button. Furnish Pedestal poles according to type and overall length. 1. Ensure that aU poles are made of one continuous piece of bare finish aluminum from top to base connection for the entire height of the pole. 64 of 72 Section 925- Traffic Signal Equipment 1. Sun -phantom screen Provide each signal face with a screen, which substantially counteracts sun phantom effect. 2. Signal Display Ensure that the symbols, which are on an opaque blackor dark gray background, meet ITE requirements and are blacked out when not illuminated. 3. LED Optical System a. Ensure that the LEDs supplied for the lane use control signal meet the specifications for a type module as required in section 925.2.14. Ensure that each separate color indication in a sign face is illuminated by independent LEDs . b. Ensure that the green arrow indication does not utilize the same termination points as any "X" indication. c. Ensure that total power required for any single indication does not exceed 250 W. d. Ensure that all modules are contained behind a water tight signal face or lens assembly. e. Ensure that the entire optical system is weatherproof and is not vulnerable to extremes in temperature or moisture. B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2~19 Pedestrian Push Button Station A. Requirements Ensure that Pedestrian push buttons are of tamperproof construction and consist of a direct push type button and single momentary contact switch in a cast metal housing. Finish the housing with baked enamel and paint the push button housing and Pedestrian heads highway yellow (unless otherwise specified by the Engineer). Ensure that any screws or bolts are stainless steeL Provide the unit with a 0.5 inch (13 mm) threaded opening with plug. Ensure that the assembly is weatherproof and so constructed that when properly installed, it will be impossible to receive an electrical shock under any wea~er condition. Ensure this item consists ofPelco hardware or approved equaL Ensure that Pedestrian Pushbuttons are integrated with a sign as shown in the standard details. Ensure the proper size sign is used as indicated on the plans. B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.Dfor Materials Warranties. 925.2.20 Signal Head Back Plate A. Requirements Ensure that each back plate is designed to properly shield a traffic signal head from background distractions for better visibility. Design the back plates to extend beyond the signal head to a minimum of 6 inches (150 mm) on all sides and have all corners rounded with minimum 2 inch (50 mm) radii. Construct the back plates from aluminum, sheet metaL UV stabilized polycarbonate or, ABS plastic material with a finished color of flat black. 62 of 72 Section 925-Traffic Signal Equipment D. Materials Warranty Ensure that LED traffic signal modules and LED Pedestrian modules are performance warranted to be in compliance with the latest ITE and Caltrans minimum intensity standards for LED traffic signal modules, measured at 120 V AC and 165 of (74 oc), for a period of five (5) years. Ensure that the manufacturer's name, part number, date code, and electrical characteristics of the LED signal module is visible on the assembly, and that each LED signal module is identified for warranty purposes. 925.2.17 Blank-Out Signs A. Requirements Ensure that each sign provides a clearly visible and definable legend for 500 feet with ample safety factors. Provide hardware to mount the sign on standard 1.5 inch (38 mm) pipe brackets or to mount directly to signal mast arms or span wue. Supply blank-out signs faces 30 inches x 36 inches (750 mm x 900 mm) that are capable of displaying one message at a time in one direction. 1. Case Use a case formed from aluminum extrusion F 1-6-E and a special aluminum door frame angle. For Alloy 6063- T5, ensure that the wall is at least 0.075 inches thick and the corners and joints are at least 0.080 inches (2 mm) thick. Use filler arc for all welding. Use a BR-type take-apart door hinge and draw bolt. Furnish one P-15 1.5 inch (38 mm) hub on the top surface. Prime the entire case with zinc chromate, bake the inside with two coats of non-yellowing white, and paint the outside with two coats of highway yellow. 2. Electrical Ensure that all blankout signs are LED and conform to current ITE standards. Supply all signs with the necessary mounting hardware to provide for mounting as shown on the plans. Provide mounting for one way or two way configurations. Obtain approval for messages and letter dimensions from the Engineer. 3. Sun Phantom Screen Attach to each sign a heavy-duty aluminum louver-type sun phantom screen covering the entire sign face. Slant the louvers down enough to eliminate the sun glare without obstructing the view of the sign face. 4. Painting Paint the signal surfaces, inside and out, with two coats of oven-baked enamel in addition to the primer coat. Paint the non-illuminated portions of the signal face black. Paint the housings, brackets, fittings, and etc. highway yellow. 5. LenS Use a fabricated, three-section Plexiglas lens clear face, with or without legend, which can accept a silk~screened legend on the fIrst surface. Provide a thickness of at least 0.31 inches (8 mm). 6. Legend Acceptable legends are as follows: NO LEFT TURN NO RIGHT TURN SIGNAL AHEAD NO TURNS B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. 60 of 72 Section 925- Traffic Signal Equipment Ensure Arrow Signal Module meets the photometric requirements as indicated and described in the ITE VTCSH LED Vehicle Arrow Traffic Signal Module Specification. Ensure that these measurements are done with the arrow orientation in the direction of its intended use, Supply Red and Yellow LEDs that utilize AllnGap technology, eitherAS (Absorbing Substrate or TS (Transparent Substrate) and do not exhibit degradation of more than 30% of their initial light intensity following accelerated life testing (operating at 185 F (85 C) and 85% humidity, for 1000 hours). AIGaAs technology is not acceptable. Supply Green LEDs that utilize gallium nitride technology. Supply red arrow LED Traffic signals modules that are temperature compensated so as to maintain intensity at elevated temperatures. Ensure the Red arrow LED Traffic Signal modules are tested and documented as being in compliance with Caltrans intensity standards for red arrows at elevated temperatures. 6. Pedestrian Signal Modules Supply LED Pedestrian Traffic Signal Modules that fit in standard pedestrian one section signal head manufactured in accordance with the ITE Pedestrian Traffic Control Signal Indications (PTCSI) housings and meet the ITE Pedestrian Traffic Signal Modules specification. Ensure that the Pedestrian Indications for the "Hand" and "Man" are filled in so as to provide a solid indication. Do not supply Pedestrian Indications for the Hand and Man that are "outlines". Ensure that Pedestrian Signal Modules have prominent and permanent markings to designate the proper orientation of the signal module in the pedestrian signal housing. This marking should be an up arrow or the word "UP" or "TOP". Ensure Pedestrian Signal Module meets the photometric requirements as indicated and described in the ITE PTCSI LED Pedestrian Traffic Signal Module Specification. Supply Portland Orange LEDs that utilize AllnGap technology, either AS (Absorbing Substrate or TS (Transparent Substrate) and do not exhibit degradation of more than 30% of their initial light intensity following accelerated life testing (operating at 185 F (85 C) and 85% humidity, for 1000 hours). AlGaAs technology is not acceptable. Supply White LEDs that utilize InGaN technology. B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Ensure that LED traffic signal modules and LED Pedestrian modules are performance warranted to be in compliance with the latest ITE and Caltrans minimum intensity standards for LED traffic signal modules, measured at 120 V AC and 165 OF (74 0c), for a period of three (5) years. Ensure that the manufacturer's name, part number, date code, and electrical characteristics of the LED signal module is visible on the assembly, and that each LED signal module is identified for warranty purposes. 925.2.16LED Pedestrian and Countdown Signal Module A. Requirements This specification covers LED traffic signal module designed as a retrofit replacement for the message bearing surface of nominal 16" x 18" traffic signal housing built to the PTSCI Standard. The message bearing surface of the module consists of an overlapping "Hand" and "Man" Symbols with a numerical display of numbers from 00 to 99. 1. General Requirements Ensure that the unit supplied meets the applicable portions of section 925.15 of this specification. Ensure that the message numbers "00" to "99" are a minimum of 7 inches in height. EnsUre the module fits in the Pedestrian Signal Housing without modification to the housing and requires no special tools for installation. 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N 0 ~ l"- e e ~ 0 (") -... v c Ol "0 ~ (J) Ol 06 0 06 c Q) -0 ] 0 Q) (J) a. :>. ~ 0 0 ~ Section 925- Traffic Signal Equipment ALUMINUM ALLOY No. 713 YIELD STRENGTH, ksi (MPa) 25 (172) TENSILE STRENGTH, ksi (MPa) 35 (240) BRINELL HARDNESS 75 ELONGATION (% in 2 inches (50 mm)] 3 L Ensure that the Tri-Stud Span Wire Entrance fitting has a mounting support at the top of the wire entrance 0.69 inches (17 mm) thick (+/- 0.07 inches (L5 mm)]. 2. Ensure that theTri-Stud Span Wire Entrance fitting weight is not less than L 75 pounds (0.8 kg) with hardware. 3. Ensure that the mounting support has at least six (6) clevis openings for adjustment with suspension bracing between every two (2) openings. 4. Ensure that the Tri-Stud Span Wire Entrance has a minimum of 0.5 inch (13 mm) diameter throughout for wire access and that wire access is free of burrs and casting webs. 5. Ensure that the Wire Entrance opening is recessed and has a neoprene grommet with sealed membrane sections. 6. Ensure that the signal head attachment end is serrated and has a minimum of3-signal head centering bosses extending 0.19 inches (5 mm) from the serrations. 7. Ensure that the serrations have a 72-tooth design to match the signal head. 8. Ensure that three (3) stainless steel studs are cast into the wire entrance fitting. Ensure that the studs are 0.31 inches (7 rmi1) and extend 1.5 inches (38 mm) [+/- 0.13 inches (4 mm)] beyond the serrations. Provide each Tri-Stud span wire entrance fitting with a Tri-Stud hardware kit. 9. Ensure that the Tri-Stud Span Wire Entrance Fitting has an alodine conversion coating to provide a proper base for paint adhesion. Ensure that the assembly is painted federal yellow and baked in a drying oven after painting. 10. Ensure that the all Hardware is galvanized or stainless steeL B. Fabrication General Provisions 101 through 150. C. Acceptance General Provisions 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. 925.2.46 Bull Rings A. Requirements Provide bull rings that are galvanized weldless steel 0.63 inch (16 mm) diameter. Submit catalog cuts for approvaL B. Fabrication General Provisions 101 through 150. C. Acceptance General ProvisionS 101 through 150. D. Materials Warranty Refer to Subsection 925.2.D for Materials Warranties. Office of Traffic Safety and Design 72 of 72